Engine J08 PDF

FOREWORD.
fm 1 ページ２０１４年８月２５日　月曜日　午前９時４４分
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for J08E engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
FOREWORD.fm 2 ページ２０１４年８月２５日　月曜日　午前９時４４分
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL No. S5-MJ08E07A

CHAPTER
MODEL J08E
GENERAL INTRODUCTION 1-001
ENGINE INTRODUCTION 2-001
ENGINE MECHANICAL 3-001
AIR INTAKE SYSTEM 4-001
EXHAUST SYSTEM 5-001
LUBRICATING SYSTEM 6-001
COOLING SYSTEM 7-001
FUEL SYSTEM 8-001
TURBOCHARGER 9-001
FUEL INJECTION PUMP 10-001
ALTERNATOR 12-001
STARTER 13-001
14-003
14-001 14-002
AIR COMPRESSOR (80 x 54 x 2 CYLIN-
(85 x 40) (85 x 60)
DERS)
ENGINE PTO (POWER TAKE-OFF) 15-001
ENGINE CONTROL 17-001

INDEX.fm 1 ページ２０１４年８月２５日　月曜日　午前９時４５分
INDEX: ENGINE GROUP 1/1
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.fm 2 ページ２０１４年８月２５日　月曜日　午前９時４５分
230_Engine.book 1 ページ２０１４年８月２５日　月曜日　午前９時２２分
GENERAL INTRODUCTION 1–1
1
1-001
GENERAL INTRODUCTION ....................................... 1-2

WARNING............................................................... 1-2
HOW TO USE THIS MANUAL ................................ 1-3
PRECAUTIONS FOR WORK ................................. 1-8
TIGHTENING OF BOLTS AND NUTS
FOR ENGINE ....................................................... 1-13
TIGHTENING OF BOLTS AND NUTS .................. 1-15
TIGHTENING OF FLARE NUTS AND HOSES .... 1-21
SEALANT ON THE TAPERED SCREW
FOR PIPING ......................................................... 1-23
NYLON TUBE....................................................... 1-24
ASSEMBLY OF JOINT/GASKET FOR PIPING .... 1-30
HANDLING OF LIQUID GASKET......................... 1-32
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER AND ENGINE SERIAL
NUMBER .............................................................. 1-33
GLOSSARY .......................................................... 1-34
RECOMMENDED LUBRICANTS ......................... 1-37
1–2 GENERAL INTRODUCTION
General Safety information
WARNING
EN01F00ZZZ010A01001001
In order to ensure safety in work and avoid possible damage to vehicle, strictly observe the following precautions:
Audience of this manual is a qualified service engineer who has acquired expertise. In case an unqualified service engi-
neer or a service engineer without appropriate training has performed maintenance, or in case maintenance is performed
without using appropriate tools and units or in accordance with the method described in this manual, the vehicle under
maintenance could be damaged as well as do harm to the service engineer and the people in the maintenance site.
• Appropriate maintenance and repairs are a must for assurance of safety of the service engineer as well as the safety
and reliability of the vehicle. Replace parts of the vehicle with HINO genuine parts. Avoid using degraded parts.
• This manual contains the procedures to follow in performing maintenance and repairs. When performing maintenance
and repairs in accordance with the procedures, use special tools designed to meet specific needs in a proper way.
• Never use a non-recommended work method or tool; this could impair the safety of the service engineer as well as the
safety and reliability of your vehicle.
• This manual contains various items classified into "DANGERS", "WARNINGS", "CAUTIONS" and "NOTICES" in order to
avoid accidents during maintenance and repairs or damage to the vehicle resulting in impairment of its safety and reli-
ability.
Note that these instructions described as "DANGERS", "WARNINGS", "CAUTIONS" and "NOTICES" are not the mini-
mum requirements to observe in order to avoid possible dangers.
1
General information
HOW TO USE THIS MANUAL

EN01F00ZZZ010A02001001
1. REPAIR WORK
(1) The repair work is roughly classified into the three processes: "diagnosis", "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work" and "final inspection".
(2) This manual describes the first process "diagnosis" and the second process "mounting/dismounting, replace-
ment, assembly/disassembly and inspection/adjustment work". Description on the third process "final inspec-
tion" is omitted.
(3) While this manual does not describe the following element work, the work is to be performed in practical cases:
a. Jack work and lift work
b. Cleaning of removed parts as required
c. Visual inspection
2. TROUBLESHOOTING IN THIS MANUAL

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

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

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

(4) Troubleshooting by diagnosis code
"Step 3" perform inspection accordance with the troubleshooting proce-
(5) Troubleshooting by trouble
dure by diagnosis code or trouble.
Check for the trouble after the trouble is removed. In case the
(6) Checkup test "Step 4" trouble is hardly replicated, conduct a checkup test under the con-
ditions and environment for the trouble.
(2) Pre-inspection
• Execute the following steps to perform pre-inspection.

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

(1) Component locator
5–54 CLUTCH/CLUTCH MECHANICAL
Example
CLUTCH COVER ASSEMBLY
COMPONENT LOCATOR
EN01E05307050401001001
Alphabetical mark indicating the

tightening torque in the following
6
tightening torque table
A
7 11
12
13
1 14
2
6
3
15
4
13
5
16
8
9
Numerical order indicating 10

the part name in the
following part name table
Numerical order Part name table SHTS053070500020
1 Clutch facing 9 Pivot ring

2 Clutch disc hub Part name 10 Clutch cover
3 Rivet 11 Washer
4 Pressure plate 12 Strap plate bolt
5 Stopper pin 13 Friction spring
6 Retainer ring 14 Release lever support plate
7 Release lever support 15 Release bearing
8 Diaphragm spring 16 Release bearing hub
Tightening torque Tightening torque table Unit: N.m {kgf.cm, lbf.ft}

A 58.8-78.5 {600-800, 44-57}
Alphabetical mark Tightening torque
SHTS00ZZZ0100001
☆ : The ID number is given to required items for the purpose of preparing electronic data and is not needed in
repair work.
(2) Work steps
BRAKE/BRAKE CONTROL 9–49
Example
Indicating the work sequence OVERHAUL

EN01E09ZZZ150703003001
REMOVING THE AUTO SLACK ADJUSTER
1. REMOVING THE AUTO SLACK ADJUSTER

(1) Remove the auto slack adjuster from the wheel brake.
DISASSEMBLING THE AUTO SLACK ADJUSTER
2. DISASSEMBLING THE RACK AND SPRING SECTION

(1) Remove the 6 torx screws with the special tool.
NOTICE
When the 6 torx screws have been tightened strongly, using the
special impact screwdriver and hammer.
SST: S0963-02350
Special parts assembly
Indicating the part number of

special tool required for work
(2) Remove the holder and gasket.
SHTS09ZZZ1500028
(3) Remove the rack using the screwdriver.
Descriptive text:
Indicating the work method which is gone
into detail
SHTS09ZZZ1500029
(4) Push and shrink the spring with screwdriver and bring the tapping
rod into contact with plug.
(5) Remove the plug using the tapping rod and hammer.
(6) Remove the spring.
SHTS09ZZZ1500030
SHTS00ZZZ0100002
4. DEFINITION OF TERM
This manual defines the terms used herein as follows:
(1) Direction
a. Chassis
• To-and-fro direction
The direction of forward travel of the vehicle while mounted on the vehicle is forward direction; the direction
of backward travel of the vehicle while mounted on the vehicle is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the vehicle is clockwise direction; the counterclockwise
direction as seen from the rear of the vehicle is counterclockwise direction. (In case of engine, the clockwise
direction as seen from the flywheel side is clockwise direction; the counterclockwise direction as seen from
the flywheel side is counterclockwise direction.)
• Upward/Downward direction
The upward direction while mounted on the vehicle is upward, and downward direction while mounted on
the vehicle is downward.
• Right/Left direction
The right direction as seen from the rear of the vehicle while mounted on the vehicle is right direction; the
left direction as seen from the rear of the vehicle while mounted on the vehicle is left direction. (In case of
engine, the right direction as seen from the flywheel side is right direction; the left direction as seen from the
flywheel side is left direction.)
b. Standalone unit
• To-and-fro direction
The direction of input of power is forward direction; the direction of output of power is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the unit is clockwise direction; the counterclockwise direc-
tion as seen from the rear of the unit is counterclockwise direction.
• Upward/Downward direction
The upward direction while the unit is mounted on the vehicle (chassis) is upward, and downward direction
while the unit is mounted on the vehicle (chassis) is downward.
• Right/Left direction
The right direction as seen from the rear of the unit is right direction; the left direction as seen from the rear
of the unit is left direction.
(2) Standard value (Assembly standard):
Indicates a basic dimension or including the tolerance and the clearance generated by the clearance of a combi-
nation of two parts
(3) Limit (Service limit):
Indicates a numeric value which requires correction or replacement.
5. DEFINITION OF SAFETY TERMS
Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.
Provides additional information to help you to perform the repair efficiently.

6. UNIT
(1) This manual uses the SI unit system. The SI unit is an international unit which is based on one unit per quantity
unlike the conventional unit system which differs from country to country, in order to facilitate technology
exchange.
(2) This manual writes the SI unit and a conventional unit side by side, the conventional unit enclosed in parenthe-
ses { }.
Item SI unit Traditional unit Conversion*1 (1 [traditional unit] = X [SI unit])
Force N kgf 1 kgf=9.80665 N
Torque*2 Nm kgfcm 1 kgfcm=0.0980665 Nm
kgf/cm2 1 kgf/cm2=98.0665 kPa=0.0980665 MPa

Pressure Pa
mmHg 1 mmHg=0.133322 kPa
r/min. 1 rpm=1 r/min.

Revolving speed rpm
-1
min. 1 rpm=1 min.-1
Spring constant N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm
Volume L cc 1 cc = 1 mL
Efficiency W PS 1 PS = 0.735499 kW
Calorie Wh cal 1 kcal = 1.13279 Wh
Fuel
g/Wh g/PSh 1 g/PSh = 1.3596 g/kWh
consumption rate
*1: X is a value converted from 1 [traditional unit] into the SI unit and is also used as a conversion rate between
the traditional unit and a SI unit.
*2: The torque conversion may vary depending on the device. In proceeding with work, use the standard value
defined for each device.
1
General information
PRECAUTIONS FOR WORK

EN01F00ZZZ010A02001002
GENERAL PRECAUTIONS
To assure safety in work and prevent possible danger, observe the following:
1. CLOTHES AND APPEARANCE

(1) Use safety glasses.
(2) To prevent injury, remove a watch, necktie, ring, bracelet and necklace.
(3) Bind long hair behind.
(4) Wear a cap and safety boots.
2. SAFETY WORK
(1) To prevent burns, never touch a radiator, muffler, exhaust pipe, and tail pipe just after the engine is turned off.
(2) While the engine is rotating, keep your clothes and tools off the rotating sections, in particular the cooling fan and
V-belt.
(3) Remove the starter key except when starting the engine.
(4) Provide good ventilation to avoid excessive CO when starting the engine.
(5) The fuel/battery gas is flammable. Never make a spark or light a cigarette.
(6) Take utmost care when working on the battery. It contains corrosive sulfuric acid.
(7) Large electric current flows through the battery cable and starter cable. Be careful not to cause a short, which
can result in personal injury and/or property damage.
(8) Leaving a tool or waste in the engine room causes the tool or waste to touch the rotating section of the engine
and pop out, which could result in an injury.
3. TOWING
• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order
to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the
frame near the No.1 crossmember when attaching the towing chain. Never lift or tow the vehicle if the chain is in
direct contact with the bumper.
(1) Towing procedures
a. Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear
axle shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss
of axle lubricant and entry of dirt or foreign matter.
b. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame. The hook should be used only if the towed vehicle is not loaded.
c. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15 in horizontal and
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.　
d. Keep the gear shift lever in "Neutral". In case of ZF transmission, keep the gear shift lever in the high range
"Neutral" position.
e. Make sure that the starter switch is kept in the "ON" position.
f. Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vac-
uum will be available for the brake. This is dangerous, as the brake system does not function if the engine is
not running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually
hard to turn, making it impossible to control the vehicle.
g. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
h. Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}. In case of ZF
transmission, towing speed should be less than 10 km/h {6 mile/h}.
i. In case of ZF transmission, towing distance maximum 100 km {60 miles}.
(2) If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed
for that purpose.
a. Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to pro-
tect the transmission and differential gears from being damaged. The hub openings should be covered to pre-
vent the loss of axle lubricant or the entry of dirt or foreign matter.
The above-mentioned precautions should be observed for vehicles equipped with either automatic or manual
transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with
lubricant if necessary.
b. Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a
straight ahead position.
PRECAUTIONS ON MAINTENANCE
Observe following before maintenance:
1. PREPARATIONS FOR DISASSEMBLY

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

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

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

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

(1) Inspect and measure the parts to be reused as required.
6. ASSEMBLY
(1) Observe the specified values (tightening torque, adjustment value) to assemble conforming parts in a correct
procedure.
(2) Use genuine parts for replacement.
(3) Use new packing, gasket, O-ring and cotter pin.
(4) Use a seal gasket depending on the location of gasket. Apply specified oil or grease to a sliding section where
indicated. Apply specified grease to the lip of the oil seal.
7. ADJUSTMENT WORK CHECK

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

(1) Before electrical system work, disconnect the cable from the negative (minus) terminal of the battery in order to
avoid burning caused by short-circuiting.
(2) To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the termi-
nal.
LOOSEN
SHTS00ZZZ0100008
2. HANDLING OF ELECTRONIC PARTS

(1) Never give an impact to electronic parts of a computer or relay.
(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.
INCORRECT
SHTS00ZZZ0100009
3. HANDLING OF WIRE HARNESS

(1) Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not inter-
fere with the end and acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.
INCORRECT
INCORRECT
INCORRECT
SHTS00ZZZ0100010
4. HANDLING OF CONNECTOR
(1) To disconnect a connector, hold the connector (indicated by an arrow in the figure) to pull it out. Never pull the
harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the connector.
(5) In case it is difficult to insert a test lead from behind the connector, prepare a harness for inspection and perform
inspection.
INCORRECT INCORRECT
CORRECT
SHTS00ZZZ0100011
PRECAUTION FOR ELECTRIC WELDING
1. PRECAUTION FOR ELECTRIC WELDING

Electrical components such as the alternator and tachograph are directly connected to the battery and one
end is grounded to the chassis frame. Under these conditions, welding current will flow back along the
ground circuit if electric welding is carried out and damage may be caused to the alternator, tachograph, elec-
trical components, etc. Consequently, the following precautions are always to be taken during welding.
(1) Disconnect the ground terminal of the battery at the frame fitment and ground the welding equipment securely to
the frame itself. (Do not fit the welding equipment ground to such things as the tire rims, brake pipes or fuel pipes
and leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the battery's negative terminal of the battery.
c. Ground welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the function of all instruments.
SHTS00ZZZ0100012
(2) In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as
putting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.
1
General information
TIGHTENING OF BOLTS AND NUTS FOR ENGINE

EN01F00ZZZ010A02001003
1. TIGHTENING TORQUE OF GENERAL STANDARD

(1) Washer based bolt
Unit: Nm {kgfcm, lbfft}
Screw diameter x pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}
M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}
M10 x 1.5 (Coarse thread) 55 {560, 40} 68.5 {700, 51}
M12 x 1.25 (Fine thread) 108 {1,100, 80} 136 {1,390, 101}
M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1,280, 93}
M14 x 1.5 (Fine thread) 171.5 {1,750, 127} 216 {2,210, 160}
M14 x 2 (Coarse thread) 154 {1,570, 114} 199 {2,030, 147}
Remarks Bolt with the numeral "7" on its head Bolt with the numeral "9" on its head
NOTICE
8T bolt conforms to the standard of 7T bolt.
(2) With washer
Screw diameter x pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6 {60, 4.3} 10 {100, 7.2} 13 {130, 9.4}
M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}
M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}
M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}
M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1,200, 87}
M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1,100, 80}
M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1,500, 108} 186 {1,900, 137}
M14 x 2 (Coarse thread) 74 {750, 54} 132 {1,350, 98} 172 {1,750, 127}
Bolt with the numeral "4" Bolt with the numeral "7" Bolt with the numeral "9"
on its head on its head on its head
Remarks Projection bolt Stud with chamfered free
Stud with rounded free end face
end face
NOTICE
8T bolt conforms to the standard of 7T bolt.
R FACE (4T) C FACE (7T)

2. PRECOATED BOLT
A precoated bolt is a bolt having a thread coated with seal lock agent.
(1) Cases where seal lock agent must be applied again
a. A precoated bolt has been removed, or
b. A precoated bolt has been turned during a tightening check or other activities. (loosened or tightened)
HINT
• A precoat bolt is a bolt of which threads are applied with seal lock agent.
• Conduct a torque check with the lower limit of a permissible tightening torque range. If a bolt has been turned
or rotated, follow the procedures below to retighten a bolt.
(2) How to reuse precoated bolt
a. Clean the bolt and the screw hole (clean the tapped hole also when the bolt is to be replaced).
b. Blow air to dry up the bolt.
c. Apply a specified seal lock agent to the thread of the bolt.
SHTS00ZZZ0100014
3. TENSION CONTROL WITH ANGULAR TORQUING METHOD IN PLASTIC REGION OF MATERIAL

(1) Precautions
Part of an engine uses the tension control with angular torquing method in plastic region of material.
This is different from the conventional tightening method. Follow the instructions in each chapter.
SHTS00ZZZ0100015
(2) Target region

Cylinder head bolt, crankshaft main bearing cap bolt, connecting rod bearing, cap bolt and so on.
! CAUTION
Before assembly, measure the entire length of the bolt and if the use limit is exceeded, replace the bolt with new
one.
Apply engine oil to the bolt seat face and bolt thread.
SHTS00ZZZ0100016
(3) Tightening after tightening at the pre-set seating torque.

Further tighten by 90 or 135 (a turn by 90 and another by 45) or 180 (two turns by 90).
SHTS00ZZZ0100017
1
General information
TIGHTENING OF BOLTS AND NUTS

EN01F00ZZZ010A02001004
BOLTS AND NUTS

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

Predefined tightening torque must be applied to ensure sufficient tightening by threads.
It also has purposes to prevent the adverse events below due to excessive or insufficient tightening.
Conditions Adverse events
• Stretch or fracture of bolt

• Depression of seat surface and looseness
Excessive tightening • Gasket damage
• Rounding and damage of hexagon part
• Opening of spring washer
• Looseness
• Gas and liquid Leakages
Insufficient tightening
• Continuity malfunction
• Damage by fretting wear
NOTICE
Unique tightening torque may be specified for some parts.
Tighten with the tightening torque specified in the service manual.
HINT
Check the tightening torque list for general torques.
CAUTIONS TO PREVENT LOOSENESS.

When tightening, pay attention to the followings to prevent looseness after tightening.
• Insufficient tightening torque
• Inclusion of foreign matters (burrs and coatings) in the tightening surface.
• Sagging of coat
• Sinking into the seat surface hole by omitting installing a plain washer.
• Defective seat surface flatness (wear-out during use)
TYPES AND IDENTIFICATION

There are 3 types of bolts and nuts.
1. STANDARD (W/O FLANGE)

(1) Bolt/Nut without flange
SHTS00ZZZ0100018
2. WITH OLD FLANGE (W/GROOVE)

(1) Flange is small and has grooves on its back.
GROOVE
GROOVE
FLANGE OUTER DIAMETER
SHTS00ZZZ0100019
3. WITH NEW FLANGE (W/O GROOVE)

(1) Flange is big and does not have grooves on its back.
FLANGE OUTER DIAMETER
SHTS00ZZZ0100020
Comparison of flange outer diameters
Bolt Nut
With old flange With new flange With old flange With new flange
(w/grooves) (w/o grooves) (w/grooves) (w/o grooves)
Thread diameter
Flange Flange Flange Flange
Strength Strength Strength Strength
outer outer outer outer
class class class class
diameter diameter diameter diameter
M8 7T, 9T 15.5 8.8, 10.9 17 7N 15.5 8 17
8.8 20
M10 7T, 9T 18.5 7N 18.5 8 21.5
10.9 21.5
8.8 24
M12 7T, 9T 21.5 7N 21.5 8 26
10.9 26
M14 - - 10.9 30.5 - - 12 30
COMPATIBILITY (NO COMPATIBILITY IN BOLT AND NUT)
BOLT/NUT WITH OLD FLANGE (W/GROOVE)
SEAT SURFACE WITH OLD FLANGE SEAT SURFACE WITH OLD FLANGE
NO COMPATIBILITY
BOLT/NUT WITH NEW FLANGE (W/O GROOVE)
SEAT SURFACE WITH NEW FLANGE SEAT SURFACE WITH NEW FLANGE
SHTS00ZZZ0100021
NOTICE
[Bolt/Nut with new flange (w/o groove)] can not be used on the place where [Bolt/Nut with old flange (w/groove)]
were used. In addition, use care to avoid misassembly because even when nominal sizes and pitches are same,
there is no compatibility in strength if types are different.
STRENGTH CLASSES AND SYMBOLS
Bolt Nut
Symbols
Strength class Strength class Symbols
Carbon steel Boron steel
4T -
7T 7N
9T
2. WITH NEW FLANGE (W/GROOVE)
Bolt Nut
Symbols
Strength class Strength class Symbols
Carbon steel Boron steel
8.8 8
10.9 12
PART No.
Bolt Nut
Thread
diameter Strength Surface Strength Surface
Part No. Part No.
class treatment class treatment
7T SH111-**** Plating
M8 8N SL113-00807 Plating
M14 9T SH112-**** Plating 8N SL113-01411 Plating
Bolt Nut
Thread
Part No. Part No.
7T SH562-**** Torquer
Bolt Nut
Thread
Part No. Part No.
8.8 91551-808** Plating

M8 8 94151-80800 Plating
10.9 91551-008** Plating
8.8 91552-E10** Neotorquer

M10 8 94151-81001 Neotorquer
10.9 91552-F10** Neotorquer
8.8 91552-E12** Neotorquer

M12 8 94151-81201 Neotorquer
10.9 91552-F12** Neotorquer
M14 10.9 91552-F14** Neotorquer 12 94151-21401 Neotorquer
NOTICE
Some bolts/nuts are applied friction stabilizer on thread surface. Note that their tightening torques are different
from those of plated-only bolts/nuts even if the strength class is same. (Threads with Neotorquer are colored in
light red.)
HINT
The * below the hyphen of a part number shows a thread diameter and length under head, so the numbers vary
depending on type.
LIST OF TIGHTENING TORQUE

Apply a tightening torque specified in the strength class of the bolt/nut used.
NOTICE
Refer to the service manual because tightening torques of some parts do not conform to it due to their tightening
conditions, strength classes, and surface treatments.

Thread diameter Strength classes Tightening Torque
7T 18.0-26.0 {184-265, 14-19}

M8
9T 23.5-34.5 {240-351, 18-25}
7T 34.5-51.5 {352-525, 26-37}

M10
9T 46.0-68.0 {470-693, 34-50}
7T 61.0-91.0 {623-927, 45-67}

M12
9T 80.0-120.0 {816-1,223, 59-88}
M14 9T 128-192 {1,306-1,957, 95-141}

7T 18.0-26.0 {184-265, 14-19}

M8
9T 23.5-34.5 {240-351, 18-25}
7T 41.5-61.5 {424-627, 31-45}

M10
9T 55.0-82.0 {561-836, 41-60}
7T 73.0-109.0 {745-1,111, 54-80}

M12
9T 96.0-144.0 {979-1,468, 71-106}

8.8 21.7-40.3 {222-410, 16-29}

M8
10.9 27.3-50.7 {279-516, 21-37}
M10 10.9 24.5-45.5 {250-463, 19-33}
8.8 44.1-81.9 {450-835, 33-60}

M12
10.9 57.4-106.6 {586-1,087, 43-78}
M14 10.9 91-169 {928-1,723, 68-124}

1
General information
TIGHTENING OF FLARE NUTS AND HOSES

EN01F00ZZZ010A02001005
1. TIGHTENING TORQUE OF PIPE FLARE NUT

Outer diameter of pipe
4.76 6.35 10 12 15
Material
Steel pipe and 10-20 20-30 45-59 60-74 80-96
copper pipe {102-203, 8-14} {204-305, 15-22} {459-601, 34-43} {612-754, 45-54} {816-978, 59-70}
2. TIGHTENING TORQUE OF AIR HOSE JOINT

Nominal designation
M20 M22 M28
of thread
Tightening torque 39-44 {398-448, 29-32} 39-44 {398-448, 29-32} 39-44 {398-448, 29-32}
3. TIGHTENING TORQUE OF HOSE

Outer diameter of hose Outer diameter of hose 22 Outer diameter of hose PF
10.5, 12 fittings packing fittings 3/8 fittings
Air hose 20-23 {204-234, 15-16} 39-44 {398-448, 29-32} —
Brake hose — 39-44 {398-448, 29-32} —
PS fluid hose — — 39-49 {398-499, 29-36}
4. TIGHTENING TORQUE OF COPPER-PACKING FITTING FOR BRAKE HOSE

Tightening torque 27-35 {275-357, 20-26}
5. TIGHTENING TORQUE OF THE NYLON TUBE CONNECTOR

Nominal designation
PT1/8 PT1/4 PT3/8 PT1/2
of thread
15-25 20-30 29-39 39-49
Tightening torque
{153-254, 12-18} {204-305, 15-22} {296-397, 22-28} {398-499, 29-36}
Nominal designation
NPTF1/8 NPTF1/4 NPTF3/8 NPTF1/2
of thread
15-25 20-30 29-39 39-49
Tightening torque
{153-254, 12-18} {204-305, 15-22} {296-397, 22-28} {398-499, 29-36}
6. TIGHTENING TORQUE OF THE SLEEVE NUT FOR THE RE-TIGHTENING TYPE NYLON TUBE CONNECTOR
Diameter 6 8 10 12
12.3-18.3 13.9-21.9 18.0-28.0 23.0-33.0
Tightening torque
{126-186, 10-13} {142-223, 11-16} {184-285, 14-20} {235-336, 17-24}
Diameter 1/4 — 3/8 1/2

20-26 35-45 50-60
Tightening torque —
{203-266, 14-20} {356-459, 25-34} {509-612, 36-45}
7. TIGHTENING TORQUE OF THE FLARE TYPE NYLON TUBE CONNECTOR

Nominal designation
M12 M16 M20
of thread
Tightening torque 12.7-16.7 {130-170, 9-12} 24.4-34.4 {249-351, 18-25} 46.9-56.9 {478-580, 35-42}
8. TIGHTENING TORQUE OF THE LOCK NUT FOR THE BRASS CONNECTOR

Nominal designation
M12 M14 M16 M20 M27
of thread
88-106 190-228
13-17 18-22 60-72
Tightening torque {897-1,081, {1,937-2,325,
{133-173, 10-13} {183-225, 13-17} {612-734, 44-53}
65-78} 140-168}
9. TIGHTENING TORQUE OF THE LOCK NUT FOR THE THROUGH CONNECTOR

Nominal designation
M12 M14 M20 M22 M24 M25
of thread
55-75 62-92 84-156 102-162 120-180 124-186
Tightening torque {560-765, {632-939, {856-1,591, {1,041-1,651, {1,224-1,835, {1,264-1,897,
41-55} 45-68} 61-116} 76-119} 89-132} 91-138}
10. TIGHTENING TORQUE OF FLARE NUTS FOR THE COPPER PIPE

Outer diameter of pipe
4.76 6.35 8 10 12 15
Material
15-16 16-17 19.5-24.5 32-40 37-55 53-59
Torque for copper pipe {152-164, {163-174, {198-250, {326-408, {377-561, {540-602,
11-12} 11-13} 14-19} 23-30} 27-41} 39-44}
1
General information
SEALANT ON THE TAPERED SCREW FOR

PIPING
EN01F00ZZZ010A02001006
To the tapered thread of the air pipe joint is applied the sealant (LOC-
TITE No.575, No. 572 or equivalent). Follow the procedure below to
remove/attach the piping.
1. TO REMOVE
(1) The sealant (LOCTITE No.575, No. 572 or equivalent) has a
high sealing capability. The return torque of taper joint is
about 1.5 times as high as the initial tightening torque. To
remove the joint, use a longer wrench.
(2) For replacement of joint in a place with poor workability,
remove the auxiliaries with the joint attached then remove the
joint.
SHTS00ZZZ0100035
2. TO INSTALL
(1) To apply sealant (LOCTITE No.575, No. 572 or equivalent),
use waste and thinner to wipe the dirt off the sealing section,
directly apply the sealant by a quarter turn (3 ridges) starting
from the second ridge from the tip, then assemble in accor-
dance with the tightening torque table below.
Wipe dirt off the mating part (female threads) before tighten-
ing it.
! WARNING
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.
SHTS00ZZZ0100036
TIGHTENING TORQUE FOR TAPER JOINTS

Thread diameter
Material
1/8 1/4 3/8 1/2
15-25 39-59 49-79

Steel
{153-254, 12-18} {398-601, 29-43} {500-805, 37-58}
15-25 20-30 29-39 39-49

Aluminum, brass
{153-254, 12-18} {204-305, 15-22} {296-397, 22-28} {398-499, 29-36}
(2) If tape seal is replaced with sealant, take the similar step as
in the step (1) above after removing all tape seal.
NOTICE
Use particular care to avoid entry of dirt or contaminant into a
pipe.
(3) If air leak is found after applying sealant and assembling,
repeat the steps (1) and (2). Retightening will not remedy air
leak.
1
General information
NYLON TUBE
EN01F00ZZZ010A02001007
1. TYPES OF JOINT
(1) Nylon tube joints have 2 types: one-touch connector joint and
sleeve nut joint.
! CAUTION
Function and quality of a nylon tube and each joint are guaranteed
as a set. Use HINO genuine parts. Otherwise a burst or break may
result.
Structure of joint and components
One-touch connector joint Sleeve nut joint Sleeve nut joint
RETAINER HOOK SLEEVE NUT SLEEVE O-RING O-RING

CONNECTOR/
O-RING RETAINER INSERT CONNECTOR
UNION
NYLON TUBE
COUPLING O-RING NYLON TUBE

CONNECTOR
NYLON TUBE
2. ONE-TOUCH CONNECTOR JOINT

(1) Remove the one-touch connector joint.
SHTS00ZZZ0100040
a. Check that there is no dust or dirt in the proximity of the

connector end. If any, use air blow to remove dust or dirt
before removal.
SHTS00ZZZ0100041
b. To remove the connector, pull out the nylon tube at a stroke

in the axial direction while holding down the retainer of the
connector. Use a dedicated special tool to hold down the
retainer of the connector.
Size of special tool
Tube outer diame-
Part No. Name
ter
6 S0942-11510
8 S0942-11520
10 S0942-11530 Release tool
SHTS00ZZZ0100042 12 S0942-11540
15 S0942-11550
Set in above 5
S0942-11560 Release tool set
sizes
c. To connect the connector joint, give a mark such as taping

at the tube insertion length and insert the tube to the posi-
tion of the mark.
! CAUTION
Fully insert the nylon tube to the position although shock is felt 2
times as the nylon tube passes through the retainer hook and O-
ring.
Tube outer diameter Tube insertion length (mm

{in.})
6 21.5-22.5 {0.847-0.885}
SHTS00ZZZ0100043
8, 10 22.0-23.0 {0.867-0.905}
12 22.5-23.5 {0.886-0.925}
15 24.0-25.0 {0.945-0.984}
d. After connection, pull the tube and check that the distance
from the connector end (retainer) to the taping at the inser-
tion length position is 5 mm {0.197 in.} or less.
3. SLEEVE NUT JOINT

(1) Connection of sleeve nut
a. Thread the sleeve nut and sleeve in this order into the
tube. Then push in the insert at the tip.
! CAUTION
Take care of the assembling direction.
b. For connection, push the insert until its end strikes the con-
nector/union while taking care not to let the sleeve nut,
INSERT sleeve and insert drop. In this state, fully tighten the sleeve
nut with hand. The position of sleeve nut is referred to as
the "hand-tightening position".
TUBE
CONNECTOR/UNION c. Hold down the tube so that it will not move (come loose)
and tighten the sleeve nut in accordance with the torque in
SLEEVE
the table below.
Tightening torque of sleeve nut Unit: Nm {kgfcm, lbfft}
SLEEVE NUT Nominal diameter of
Tightening torque
screw x pitch
SHTS00ZZZ0100044
M12 x 1 (6) 12.3-18.3 {126-186, 10-13}
M14 x 1.5 (8) 13.9-21.9 {142-223, 11-16}
M16 x 1.5 (10) 18.0-28.0 {184-285, 14-20}
M18 x 1.5 (12) 23.0-33.0 {235-336, 17-24}
(2) Assembly of sleeve nut (removing the tube from the joint and
reinstalling it in the same position)
ALIGNMENT MARK a. Give a match mark between the connector/union and the
sleeve nut before loosening the sleeve nut so as to memo-
rize the position.
b. For reassembly, tighten the sleeve nut up to the previous
position (alignment mark position). After that, retighten by
60.
c. After reassembly, check for air leakage, if any, retighten
until the leakage stops.
d. If the leakage persists, replace the tube, sleeve and insert
SHTS00ZZZ0100045
with new ones. If this does not stop the leakage, replace
the sleeve nut and connector/union as well.
4. QUICK CONNECTOR JOINT

(1) Press-fit of nylon tube
NOTICE
• Before press-fitting, make sure that there are no adherents such
as a flaw, crushing, stain and dirt in the press-fit area of the con-
nector.
• Before press-fitting, make sure that there are no adherents such
as crushing, stain and dirt in the press-fit area of the nylon tube.
a. When press-fitting using the hand tool
CLAMP AREA OF NYLON TUBE Pull out the nylon tube from the fixing clamp by at least
"a+2 mm {0.0787 in.}" as shown in the illustration, and
ADAPTER securely fix it so that it does not move. Use an appropriate
mating adapter for the connector shown in the table
depending on the type of the connector to be press-fitted,
insert the connector with the dust-proof cap fitted straight
into the nylon tube, and move the lever to press-fit. Press-
fit the connector until the clearance between the nylon tube
end and the connector becomes 2 mm {0.0787 in.} or less.
Hand tool exclusive for press fit (VOSS made)

L a+2 mm {0.0787 in.}
(For 6, 8, 10, 12, 15: S0911-E0010)
a
CLAMP AREA OF ADAPTER
NYLON TUBE
SHTS00ZZZ0100046
Adapter
Nylon tube a (mm {in.}) Elbow with test
Straight Elbow
connection
6 16 {0.630} —
NG8 (M16) S0911-E0040 S0911-E0060
8 16 {0.630} —
6 16 {0.630} —
S0911-E0070
8 16 {0.630} —
10 22 {0.866} —
NG12 (M22) S0911-E0050 S0911-E0080
12 22 {0.866} S0911-E0110
S0911-E0090
15 25 {0.984} —
S0911-E0110 (135)
b. When press-fitting by striking with a plastic hammer In the

case of a brass connector, pull out the nylon tube from the
fixing tool clamp by approx. 2 mm {0.0787 in.} as shown in
the illustration and fix the fixing tool in the vise so that it
does not move. Insert the connector with the dust-proof
cap fitted straight into the nylon tube and strike it with a
plastic hammer to press-fit.
Pull out the nylon tube from the fixing clamp by at least
"a+2 mm {0.0787 in.}" as shown in the illustration, and
securely fix it so that it does not move. Use an appropriate
mating adapter for the connector shown in the table
depending on the type of the connector to be press-fitted,
insert the connector with the dust-proof cap fitted straight
into the nylon tube, and move the lever to press-fit. Press-
fit the connector until the clearance between the nylon tube
end and the connector becomes 2 mm {0.0787 in.} or less.
Special tool for fixing nylon tube (VOSS made)

Approx. 2 mm
{0.0787 in.}
(For 6, 8, 10, 12: S0911-E0020)
SHTS00ZZZ0100047
(2) Assembly procedures

a. Method of assembling the connector and coupling
Assemble the coupling to the mating part to the tightening
torque of 10 to 17 Nm {102 to 173 kgfcm, 7.4 to 12.5 lbfft}
PLUG
STICKER (M16, M22).
NOTICE
• Peel off the plug sticker of the coupling immediately before
inserting the connector.
• Remove the dust-proof cap of the connector also immediately
before inserting the connector.
Make sure that there are no adherents such as dirt in the
SHTS00ZZZ0100048
O-ring and the mating press-fitting area, and insert the
connector until the O-ring on the tree side of the connector
is concealed in the coupling.
NOTICE
INSERT THE CONNECTOR • At this time, do not touch the insertion area with fibrous cloth
UNTIL THE O-RING IS such as cotton work gloves.
CONCEALED
• After insertion, pull the connector to make sure that it is
securely connected.
SHTS00ZZZ0100049
b. When re-assembling the coupling with the connector

inserted When any flaw or crack is recognized, replace the
O-ring with a new one.
Fix the nylon tube near the press-fit area so that it does not
turn together and is twisted, turn only the coupling at the
base with a tool, and assemble it to the tightening torque of
10 to 17 Nm {102 to 173 kgfcm, 7.4 to 12.5 lbfft} (M16,
M22).
Insert the coupling until the O-ring is concealed.
(3)Removal procedures
a.
When removing the whole coupling with the nylon tube
press-fitted into the connector
Make sure that there are no adherents such as dirt and
stains around.
If adherents are recognized, remove all of them with air
blow.
Fix the nylon tube near the press-fitting area so that it does
not turn together and is twisted, and turn only the coupling
at the base with a tool to remove.
b. When removing the connector from the coupling
Tilt the tool with the special tool for removal fitted into the
groove of the fixing ring of the coupling as shown in the
illustration, and remove the resin ring. Or break the fixing
ring with nippers to remove.
Pull out 2 clips using the hook area of the special tool as
GROOVE OF FIXING RING shown in the illustration, remove the clip holding ring, and
then remove the connector. It is not permissible to reuse a
coupling from which a fixing ring is removed.
Special tool for disassembling coupling (VOSS made)
(S0911-E0030)
NOTICE
• In the case of both a. and b., store them so that no dirt, stain
and flaw adhere to either inner or outer surface of the connec-
tor.
• It is not permissible to remove the press-fitted nylon tube from
SHTS00ZZZ0100050
the connector and to reuse the connector because it cannot be
guaranteed against air leak.
5. HANDLING OF NYLON TUBE

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

Tube indication
diameter perature range
-40-90C
DIN tube 6, 8, 10, 12, 15
{-40-194F}
(2) Cut the nylon tube.

a. To cut a nylon tube in a predetermined length, use a dedi-
cated special tool.
SST: Nylon Tube Cutter
S0946-01020
! CAUTION
• Cut a tube only when there is extra length or when using the
new tube.
• When cutting a nylon tube, set the squareness of the tube end
with respect to the axis core within 905.
SHTS00ZZZ0100052
5 OR LESS
SHTS00ZZZ0100053
! CAUTION
• Never repair a nylon tube under high temperatures exceeding
the operating temperature range, in particular when drying the
coating.
• For punching, welding and sanding, protect a nylon tube from
tools, cutting, heat source or spark or remove the nylon tube.
• Never install the clamp of the welder near the tube.
• Never splash acidic liquid such as battery liquid onto the tube.
• Never exceed the minimum bending radius R of the nylon tube
listed in the table below. Avoid using the tube with trace of
bending line.
Tube outer diameter Minimum bending radius in use:

mm inch R (mm {in.})
6 1/4 30 {1.181}
8 — 50 {1.969}
10 3/8 65 {2.559}
12 1/2 70 {2.756}
15 5/8 90 {3.543}
(3) Fixing the nylon tube

a. To fix the nylon tube to a vehicle, use a dedicated clamp
and a dedicated special tool or clamping tool available on
the market.
SST: S4783-71230
Clamp
S0962-01010
Nylon Tube Tensioning Tool Assembly
Tool available on the market: Clamping tool (Tyton
MK6)
Clamping torque (reference): 166.6 N {17 kgf, 37.5 lbf}
SHTS00ZZZ0100054 ! CAUTION
• Set the tool clamping force to "3" on the dial.
• If the nylon tube is fixed with nonconforming clamping force,
the nylon tube may be damaged.
1
General information
ASSEMBLY OF JOINT/GASKET FOR PIPING

EN01F00ZZZ010A02001008
1. TIGHTENING TORQUE OF JOINT

Types of sealing
Size of tightening Metal sealing type

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

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

Gasket seal system
Type A (Flare pipe system) Type B (Nipple connector system)
1
General information
HANDLING OF LIQUID GASKET

EN01F00ZZZ010A02001009
1. APPLICATION OF LIQUID GASKET AND ASSEMBLY OF PARTS

(1) Thoroughly remove the old liquid gasket on each part and mating part and clean the parts by using waste to
wipe off oil, water and dust.
Overlap the coating at the beginning and end of coating.
(2) To assemble coated part, beware of any dislocation from the mating part. If any dislocation is found, coat the
part again.
(3) Finish assembly within 20 minutes of completion of liquid gasket application.
If 20 minutes is exceeded, remove the liquid gasket and apply it again.
(4) Wait at least 15 minutes after assembly of parts before starting the engine.
2. REMOVING PARTS
(1) To remove each part, never twist a single section but twist the part in alternate directions at the collar or clear-
ance on the flange. When removing gasket, take care not to let the refuse of gasket enter the engine.
3. OTHER
(1) When the liquid gasket comes in a tube, use the supplied winding tool. When the gasket comes in a cartridge,
use a spray gun.
WINDING TOOL SPRAY GUN
TUBE CARTRIDGE TYPE
SHTS00ZZZ0100065
Note that the cutting position of the nozzle of the tube provides necessary width of application.
1: Approx. 2 mm {0.079 in.} when cut at the first segment

2: Approx. 5 mm {0.197 in.} when cut at the second segment
1
General information
CHASSIS SERIAL NUMBER, VEHICLE IDEN-

TIFICATION NUMBER AND ENGINE SERIAL
NUMBER
EN01F00ZZZ010A02001010
1. VEHICLE MODEL AND CHASSIS SERIAL NUMBER OR VEHI-

(EXAMPLE) CLE IDENTIFICATION NUMBER
(1) Vehicle model and chassis serial number or vehicle identifi-
cation number are engraved near the front wheel of the right
or left frame of the vehicle. When ordering parts, notify us of
these numbers for quick support.
ENGRAVED
POSITION
SHTS00ZZZ0100067
2. VEHICLE IDENTIFICATION NUMBER PLATE

(1) At the step inside the right door of the cab is attached an
identification plate stamped the vehicle model and chassis
serial number or vehicle identification number.
IDENTIFICATION
PLATE
SHTS00ZZZ0100068
3. ENGINE MODEL AND ENGINE SERIAL NUMBER

ENGRAVED (1) Engine model and engine serial number are engraved on the
POSITION right side of the cylinder block.
When ordering parts, notify us of these numbers for quick
support.
SHTS00ZZZ0100069
1
General information
GLOSSARY
EN01F00ZZZ010A02001011
LIST OF ABBREVIATION
Abbreviations Meaning, or Official Name
A/C Air Conditioner
ABS Anti-lock Brake System
ACC Accessory
ACU Auto Clutch Unit
AMT Automated Manual Transmission
AT Automatic Transmission
ATC After Turbo Catalyst
ATF Automatic Transmission Fluid
CA Crank Angle
CAN Controller Area Network
CD-ROM Compact Disc Read Only Memory
CPU Central Processing Unit
dB Decibel
DC Direct Current
D-CAT Diesel-Clean Advanced Technology System
DC motor Direct Current Motor
DCU Dosing Control Unit
DEF Diesel Exhaust Fluid
DPR Diesel Particulate active Reduction system
DSS Driving Support System
ECU Electronic Control Unit
EEPROM Electronically Erasable and Programmable Read Only Memory
EGR Exhaust Gas Recirculation
ELR Emergency Locking Retractor
ENG Engine
ES START Easy and Smooth start system
F/A Front Axle
FCCB Fuel Control Cylinder Balance
FCV Fuel Cutoff Valve
FF shift Feather touch & Finger shift
FL Fusible link
Fr Front
FRP Fiber Reinforced Plastic
FUP Front Underrun Protector

GND Ground
GVW Gross Vehicle Weight
Hi High
HINO DX Ⅱ HINO Diagnostic eXplorer Ⅱ
HSC HINO Signal Converter
HV Hybrid Vehicle
HVAC Heating, Ventilating and Air-Conditioning unit
I.S.C. Idle Speed Control
IC Integrated Circuits
ID Identification
IPD Intelligent Power Device
IS Idle Stop
ISO International Organization for Standardization
JIS Japanese Industrial Standards
LED Light Emitting Diode
LEV Low Emission Vehicle
LH Left Hand
LLC Long Life Coolant
Lo Low
MAX Maximum
MIN Minimum
MS evaporator Multi-tank and Super slim structure evaporator
MT Manual Transmission
No. Number
NOx Nitrogen Oxide
NMR No load Maximum Revolution
OHC Over Head Camshaft
PC Personal Computer
PCD Pitch Circle Diameter
PCS Pre-Crash Safety
PCV Pump Control Valve
PCV valve Positive Crankcase Ventilation valve
PM Particulate Matter
PPG Glass-fiber-reinforced Polypropylene
ppm Parts Per Million
PS Power Steering
PTO Power Take-Off
PVD Physical Vapor Deposit

PWR Power
QR code Quick Response Code
R/A Rear Axle
RH Right Hand
SCR Selective Catalytic Reduction
SCV Suction Control Valve
SST Special Service Tool
SW Switch
T/M Transmission
VCS Vehicle Control System
VNT Variable Nozzle Turbo
VSS Vehicle Speed control System

1
General information
RECOMMENDED LUBRICANTS
EN01F00ZZZ010A02001012
No. LUBRICANTS POSITION VISCOSITY RECOMENDATIONS (SAE)
Engine oil Cylinder block

(API: CD, CE, CF, CH-4, CI-4,
CI-4 PLUS)
(JASO: DH-1)
(ACEA: E-4, E-7)
Gear oil Transmission:

API: GL-5 MX06, M009
API: GL-4 (SAE 90)
2
SAE 90
SAE 80W-90
Hypoid gear oil Differential (Rear):

3 (API: GL-5) SH16, SH17, SH18, THD17
Gear oil Steering SAE 90

(API: GL-4)
SAE 80W-90
4
SAE 140
No. LUBRICANTS POSITIONS
5 Power steering fluid (ATF DEXRON) Integral power steering gear
6 Brake fluid (DOT-3) or (DOT-4) Brake
7 Clutch fluid (DOT-3) or (DOT-4) Clutch
Wheel bearing grease Wheel hub

8 Lithium base wheel bearing grease NLGI No.2 LITH-
IUM-SOAP
Chassis grease Steering, suspension, etc.

9
Lithium base multipurpose grease NLGI No.2
ENGINE INTRODUCTION (J08E) 2–1
ENGINE INTRODUCTION (J08E)

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

DATA AND SPECIFICATIONS ................................ 2-2
ENGINE TUNEUP .................................................. 2-4
OVERHAUL CRITERIA......................................... 2-12
DISMOUNTING AND MOUNTING ....................... 2-14
LIQUID GASKET AND APPLICATION POINTS ... 2-18
2–2 ENGINE INTRODUCTION (J08E)
Mechanical Specifications
ENGINE ASSEMBLY
DATA AND SPECIFICATIONS

EN01F01103010I02001001
ENGINE SERIES: J08E-NB (J08E-UF, UG, UH)
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,

Type
water-cooled, direct injection
Aspiration Turbocharged with intercooler
Bore and stroke 112 x 130 mm {4.41 x 5.11 in.}
Piston displacement 7.684 L {468.9 cu.in.}
Compression ratio 18: 1
1-4-2-6-3-5 (The cylinder numbers are counted in order from

Firing order
the crankshaft pulley side)
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 150 r/min.
Maximum revolution (at full load) 2,900 r/min.
Idling revolution 550 r/min.
Dry weight Approximately 600 kg {1,323 lb.}
Intake 30
Valve seat angle
Exhaust 45
Intake 30
Valve face angle
Exhaust 45
Intake opens 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 1st: 17.7 MPa {180 kgf/cm2, 2,570 lbf/in.2}
Type
2nd: 24.5 MPa {250 kgf/cm2, 3,550 lbf/in.2}
Type Forced circulation by volute pump

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

Injection timing (flywheel travel)
sion stroke
ENGINE SERIES: J08E-CR (J08E-WM, WL, WK)
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,

Type
water-cooled, direct injection
Aspiration Turbocharged with intercooler
Bore and stroke 112 x 130 mm {4.41 x 5.11 in.}
Piston displacement 7.684 L {468.9 cu.in.}
Compression ratio 18: 1
1-4-2-6-3-5 (The cylinder numbers are counted in order from

Firing order
the crankshaft pulley side)
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 150 r/min.
Maximum revolution (at full load) 2,900 r/min.
Idling revolution 550 r/min.
Dry weight Approximately 600 kg {1,323 lb.}
Intake 30
Valve seat angle
Exhaust 45
Intake 30
Valve face angle
Exhaust 45
Intake opens 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
Injector Type Multi-hole nozzle type
Type Forced circulation by volute pump

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

Injection timing (flywheel travel)
sion stroke
2
Cleaning, Inspection and Adjustment
ENGINE ASSEMBLY
ENGINE TUNEUP
EN01F01103010H03001001
VALVE CLEARANCE CHECKING AND ADJUSTING

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

(REPRESENTATIVE TYPE) (1) Turn the crankshaft counterclockwise (viewed from the fly-
wheel side) to align mark "16" on the outer periphery of the
flywheel with the pointer of the flywheel housing.
FLYWHEEL
NOTICE
16 • Always turn the crankshaft counterclockwise (viewed from the
FLYWHEEL flywheel side).
HOUSING • In this position the No.1 or No.6 piston is at the Top Dead Center
of the compression stroke.
SHTS011030100001
(2) (J08E-NB) Confirm whether No.1 or No.6 piston is at the Top

Dead Center of the compression stroke by the following two
steps.
• If the timer timing mark is nearly aligned with the pointer,
the No.1 piston is at the Top Dead Center of the compres-
sion stroke.
• 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

SHTS011030100002
(3) 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
SHTS011030100003
(4) Make sure that the valve stem is correctly inserted in the
cross head.
NOTICE
Move the cross head with fingers right and left to confirm the
CLICK valve stem is correctly inserted in the cross head by listening to
the clicking sound.
GOOD
(5) Confirm that there are no foreign particles or dust between
the cross head and the valve stem.
NO GOOD
SHTS011030100004
2. VALVE CLEARANCE CHECKING

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

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

• Mark: Possible to check valve clearance
• Firing order: 1-4-2-6-3-5
• T.D.C.: Top Dead Center
(2) Before checking the valve clearance, make sure that the
roller is on the base circle of the camshaft.
SHTS011030100007
(3) Insert a feeler gauge of the specified thickness as below

between the rocker arm and the cross head to check the
ROCKER ARM valve clearance.
FEELER GAUGE
VALVE CLEARANCE (when cold)
Intake valve 0.30 mm {0.0118 in.}

CROSS HEAD
Exhaust valve 0.45 mm {0.0177 in.}
! CAUTION
SHTS011030100008
result is outside the specified value.
3. VALVE CLEARANCE ADJUSTMENT

! CAUTION
result is outside the specified value.
NOTICE
• Before beginning the adjustment you must perform "PREPARA-
TION OF CHECKING AND ADJUSTMENT" described on page 2-
3.
• As for the valve which can adjust the valve clearance refer to the
chart on page 2-4.
• 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
A B and cross head fully.
ROCKER ARM (2) The cross head adjusting screw must protrude 10 mm {0.394
10 mm in.} or more from the cross head upper face.
{0.394 in.}
or more NOTICE
Unless the adjusting screw is completely loose to the valve stem
C head, the following adjustments may be adversely affected.
D
"Zero" Need
clearance clearance
CROSS HEAD
SHTS011030100009
(3) Insert a feeler gauge of the specified thickness shown below

between the rocker arm and the cross head, and adjust the
valve clearance with the adjust screw of the rocker arm.
FEELER GAUGE
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

SHTS011030100010
securely with the specified tightening torque.
Tightening Torque:
25 N·m {250 kgf·cm, 18 lbf·ft}
(5) The condition of inserted feeler gauge, loosen the adjusting

screw of the cross head, make sure that the feeler gauge
LOOSEN does not feel loose.
C
NOTICE
If the feeling of the feeler gauge becomes loose, repeat steps from
(1).
D
Need
clearance
SHTS011030100011
(6) Tighten the adjusting screw C of the cross head until the
ROCKER ARM feeler 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
CROSS HEAD
SHTS011030100012
(7) While loosening the adjusting screw C of the cross head

gradually, adjust the valve clearance. Tighten the lock nut D
LOOSEN of the cross head securely with the specified tightening
C
torque when the feeler gauge feels correct.
Tightening Torque:
D
SHTS011030100013
NOTICE
• Do not over loosen the adjusting screw.
Not over loosen
C • Over loosening of the adjusting screw C will cause the same
condition as in step (3) again. The feeler gauge may feel correct,
but there may be excessive clearance between the adjusting
screw C of the cross head and the valve stem head E. This does
E
not allow for correct adjustment.
Need (8) Position each piston at Top Dead Center of compression

clearance stroke by turning the crankshaft counterclockwise viewed
from flywheel side. Then adjust the valve clearance for each
SHTS011030100014
cylinder in the firing order.
INJECTION TIMING INSPECTION PROCEDURES
1. INSPECT THE INJECTION TIMING. (J08E-CR)

(REPRESENTATIVE TYPE) (1) Turn the crankshaft counterclockwise (viewed from the fly-
wheel side) to align mark "16" on the outer periphery of the
flywheel with the pointer of the flywheel housing.
FLYWHEEL
NOTICE
Always turn the crankshaft counterclockwise (viewed from the fly-
16 wheel side).
FLYWHEEL
HOUSING
SHTS011030100015
(2) Taking off the inspection hole plug, located at bearing holder
BEARING HOLDER CASE case of supply pump and tightening slightly the special tool
therein, check that the seat face of tool is seated with the
SEATED bearing holder.
CORRECT SST: SZ105-08067
Guide bolt
SST
NOTICE
NOT When it is not seated, it means it is contacting with other parts
SEATED
than the turning stopper hole of coupling flange. Therefore, do not
tighten in too much. In this case, the timing is not fit. So, perform
INCORRECT again the setting for Top Dead Center of No.1 cylinder compres-
SHTS011030100016
sion stroke in above (1).
2. INSPECT THE INJECTION TIMING. (J08E-NB)

(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 the section “DATA AND
SPECIFICATIONS”
(2) Check that the timing mark on the automatic timer is aligned
with the pointer of the pump.
If not, adjust the injection timing as on the following page.
SHTS011030100017
3. ADJUST THE INJECTION TIMING. (J08E-NB)

(1) Make sure that the timing mark on the outer periphery of the
flywheel is aligned with the timing pointer.
(2) Loosen two adjusting bolts of the injection pump coupling. Do
not remove the bolts.
SST: S0981-91707
Injection pump coupling wrench
(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.
SST: S0981-91707
SHTS011030100018 Injection pump coupling wrench
Tightening Torque:
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

! WARNING
Do not leave tools on or around the engine. Contact of tools with
moving parts may result in personal injury or damage to equip-
ment.
1. PREPARATION
(J08E-CR) (1) Supply engine oil.
(2) Supply cooling water and bleed air from it.
PRIMING
(3) Bleed air from the fuel system.
PUMP (4) Check connection to the alternator.
NOTICE
AIR
BLEEDING
Starting the engine without wiring in place may burn out the alter-
PLUG nator.
(5) Check the engine stopping performance.
SHTS011030100019
(J08E-NB) BLEEDER
PLUG
SHTS011030100020
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 follow-
ing locations of all rocker arms within approximately 10 sec-
onds.
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.
2
All Special Tools and Equipment
ENGINE ASSEMBLY
SHTS011030100021
SPECIAL TOOL
EN01F01103010K01001001
Prior to starting an engine overhaul, it is necessary to have these special tools.
Illustration Part No. Name Remarks
J08E-CR
SZ105-08067 GUIDE BOLT
For "ENGINE TUNEUP"
INJECTION PUMP J08E-NB

S0981-91707
COUPLING WRENCH For "ENGINE TUNEUP"
J08E-NB
S0955-21090 For
COMPRESSION GAUGE "OVERHAUL CRITERIA"
ADAPTER (A) J08E-CR
S0955-21110 For
"OVERHAUL CRITERIA"
For 3/4-
COMPRESSION GAUGE Select
S0955-21030 16UNF
ADAPTER (B) according to
thread size
the thread
For W16 size of air
COMPRESSION GAUGE
S0955-21060 threads 18 gauge.
ADAPTER (B)
threads size
2
ENGINE ASSEMBLY
OVERHAUL CRITERIA
EN01F01103010H03001002
FACTORS TO DETERMINE THE ENGINE OVERHAUL
1. LOW COMPRESSION PRESSURE

(1) Before measurement
a. Charge the battery completely.
b. Set the valve clearance to the correct value.
c. Idle the engine (Coolant temperature at 80C {176F}).
d. Remove the air cleaner.
e. Remove all injectors.
(2) Measurement
a. Insert the gauge adaptor into the nozzles.
SST: S0955-21090 (J08E-NB)
Compression gauge adaptor (A)
S0955-21110 (J08E-CR)
Compression gauge adaptor (A)
S0955-21030
Compression gauge adaptor (B)
S0955-21060
Compression gauge adaptor (B)
b. Run the engine with the starter and measure the compres-
SHTS011030100026
sion pressure.
Difference
Standard Limit between each
cylinder
3.4-3.6 MPa
J08E-
{35-36 kgf/cm2,
NB
494-522 lbf/in.2} 2.3 MPa 0.3 MPa
{24 kgf/cm2, {3 kgf/cm2,
J08E-
2.9-3.1 MPa 334 lbf/in.2} 43 lbf/in.2}
{30-31 kgf/cm2,
CR
421-449 lbf/in.2}
Engine revolution 150 r/min.
NOTICE
Do not operate the starter for more than 15 seconds.
c. Measure the compression pressure of each cylinder.
NOTICE
Do not allow gas leakage from the seal face.
(3) Reassemble the removed parts.
2. ENGINE OIL PRESSURE

(1) Check the oil pressure warning light when the oil and coolant
temperature is hot [about 80C {176F}].
a. If the warning light 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.
SHTS011030100027
d. Measure the oil pressure at a coolant temperature of 80C

VISCOSITY RECOMMENDATIONS (SAE) {176F} or more.
Oil pressure
Standard Limit
SAE 5W-30
49-490 kPa Less than 49 kPa
SAE 10W-30 {0.5-5.0 kgf/cm2, {0.5 kgf/cm2,
7.11-71.10 lbf/in.2} 7.11 lbf/in.2}
SAE 15W-40
SHTS011030100028
3. OTHER FACTORS
(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
2
Removal, Replacement and Instructions
ENGINE ASSEMBLY
DISMOUNTING AND MOUNTING

EN01F01103010H01001001
IMPORTANT POINT - DISMOUNTING
1. DISMOUNT THE ENGINE ASSEMBLY.

(1) Park the vehicle on level ground and then block the wheels.
(2) Tilt the cab.
(3) Drain coolant from the radiator and cylinder block, and
engine oil from the oil pan.
! WARNING
To avoid the danger of burns, do not drain the coolant and engine
oil while the engine and radiator are still hot.
(4)
Disconnect the power steering piping and hose.
(5)
(J08E-NB) 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 "LOCK" position.
(6) Disconnect the electric lines, fuel lines and air lines.
NOTICE
• Disconnect the battery cable from the negative terminal (-) of
the battery and disconnect the electric lines.
• Cover open ends of the pipes, hoses and pumps to prevent
entry of dirt.
SHTS011030100029 (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.

(EXAMPLE) (9) Disconnect the propeller shaft.
(10) Disconnect the transmission control and transmission with
FRONT
clutch housing from the flywheel housing.
(11) Remove the cab mounting member from the frame.
(12) Connect a cable from an engine hanger to the generator
brace (1 point) on the front of the engine, and to the hanger
bracket (1 point) on the flywheel housing at the rear of the
engine. Using a hoist, raise the hanger until there is a bit of
slack in the cables.
Engine weight: Refer to the section "DATA AND SPECIFI-
CATIONS".
(13) Remove the engine mounting fitting nuts (front and rear, both
sides).
HANGER BOLT (14) Lift the engine hanger so that the cables are fully tightened,
REAR 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.
SHTS011030100030
IMPORTANT POINTS - MOUNTING
1. MOUNT THE ENGINE ASSEMBLY.

(1) Mount the engine assembly in the reverse order of dismount-
ing.
Tightening Torque:
A: 118 N·m {1200 kgf·cm, 87 lbf·ft}
B: 63 N·m {642 kgf·cm, 46 lbf·ft}
NOTICE
Check to see that there are no oil leaks, fuel leaks, coolant leaks,
or air leaks.
(Front side) (Rear side)
A A
B B
B
A: Engine mounting fitting nut (Engine side)

B: Engine mounting fitting nut (Frame side)
SHTS011030100031
2. CONNECT THE ENGINE STOP CABLE. (J08E-NB)

(1) Set the starter switch to the "ON" position.
NOTICE
Do not start the engine.
(2) Connect the connectors of the engine stop motor harness.
! CAUTION
Do not connect the electric harness to the engine stop motor
while the engine starter switch is at the "LOCK" or "ACC" posi-
tions as this operates the engine stop motor instantaneously and
the link lever of the engine stop motor and the engine stop lever of
the injection pump move, resulting in your fingers being caught
by the lever.
(3) Connect and adjust the engine stop cable with adjusting nut
so that clearance "A" between the clevis and cable stopper is
1-3 mm {0.04-0.11 in.}.
(4) Set the starter switch to the "LOCK" position.
NOTICE
After adjustment, confirm correct execution of engine start and
stop.
SHTS011030100032
2
Overhaul and Repair Instructions
ENGINE ASSEMBLY
LIQUID GASKET AND APPLICATION POINTS

EN01F01103010H02001001
• Liquid gasket is used at the following positions for the J08E series
engine.
Liquid gasket specification
ThreeBond TB1207B or equivalent: Black
ThreeBond TB1207D or equivalent: Silver
ThreeBond TB1211 or equivalent: 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
gasket. 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 liquid 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
location only. Use the tool at various locations such as a
flange step or gap for removal. When removing the gasket,
be careful that gasket residue does not enter the engine.
3. OTHERS
(1) For tube-type liquid gasket, use the winding tool that comes
with the liquid gasket.
SHTS011030100033
(2) For cartridge-type gasket, use an application gun.
SHTS011030100034
(3) For tube-type liquid gasket, required width of application can

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

2: Approximately 5 mm {0.197 in.} wide when cut at the 2nd step
SHTS011030100035
4. PARTS AND POSITIONS FOR LIQUID GASKET

(1) Apply liquid gasket to positions and types of gasket accord-
ing to the table shown below.
Follow the application pattern at each position shown in the
figures.
Unit: mm {in.}
Application Gasket to
No. Part name Application position and pattern Remarks
width be used
Matching flange face with the block
1.5-2.5
1 Oil seal retainer {0.0591- Black
0.0984}
LIQUID GASKET
1.5-2.5
2 Coolant pump {0.0591- Black
0.0984}
LIQUID GASKET
1.5-2.5
3 Oil cooler {0.0591- Silver
0.0984}
Matching flange face with the flywheel housing
LIQUID GASKET
1.5-2.5
Dust cover
4 FLYWHEEL {0.0591- Silver
(J08E-NB)
HOUSING 0.0984}
OPENING
width be used
Matching flange face with the cylinder head
LIQUID GASKET
1.5-2.5
5 Thermostat case {0.0591- Black
0.0984}
Matching face with the rear edge
1.5-2.5
6 Flange {0.0591- Silver
0.0984}
Matching face with the intake manifold
LIQUID GASKET
1.5-2.5
7 Intake pipe {0.0591- Black
J08E-CR 0.0984}
LIQUID GASKET
J08E-NB
width be used
Matching parts of block upper face rear end,

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

ends of upper/
8
lower faces of
block
NOTICE
Cut the rear end plate gasket with a craft knife
flush with the block upper face.
Matching face of rear end plate
LIQUID GASKET
LIQUID
GASKET 1.5-2.5
Flywheel hous-
9 {0.0591- Silver
ing
0.0984}
width be used
1. Matching faces with cam housing and plug

2. Matching parts of cam housing, plug, cylinder
head cover and gasket
NOTICE
• Application area of liquid gasket is half circle
of cam housing. Never apply it to the upper
half circle of the plug. 2 loca-
1.5-2.5
tions at
10 Cam housing • Remove the excessive gasket completely. {0.0591- Black
front and
0.0984}
rear ends
• When the cylinder head cover is assembled,

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 (J08E) 3–1
ENGINE MECHANICAL (J08E)

3
3-001
CYLINDER HEAD ........................................................ 3-2

COMPONENT LOCATOR....................................... 3-2
SPECIAL TOOL ...................................................... 3-8
OVERHAUL ............................................................ 3-9
INSPECTION AND REPAIR ................................. 3-20
CRANKSHAFT FRONT END..................................... 3-24
COMPONENT LOCATOR..................................... 3-24
SPECIAL TOOL .................................................... 3-25
OVERHAUL .......................................................... 3-26
FLYWHEEL AND FLYWHEEL HOUSING ................. 3-28
SPECIAL TOOL .................................................... 3-29
OVERHAUL .......................................................... 3-30
TIMING GEAR............................................................ 3-35
SPECIAL TOOL .................................................... 3-37
OVERHAUL .......................................................... 3-38
MAIN MOVING PARTS AND CYLINDER BLOCK .... 3-45
SPECIAL TOOL .................................................... 3-48
OVERHAUL .......................................................... 3-50
3–2 ENGINE MECHANICAL (J08E)
All Description and Operation
CYLINDER HEAD
COMPONENT LOCATOR
EN01F01103020C01001001
J08E-CR (J08E-WM, WL, WK)
2
1
A
4
C
20
21
B
K
19
5
29 6
7 E
8 10
F
11
D
9 11
I
16 12 14
25
J 26
G
18 15
30
13
23 17
22
24
27
28
31
32
SHTS011030200001
1 Oil filler cap 17 Collar

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

A 28.5 {290, 20} G 23 {230, 16}
B 31 {320, 23} H 59 {600, 43}+90+90#
C 59 {600, 43}+90# I 25 {250, 18}
D 25 {250, 18} J 6 {61, 4.4}
E 59 {600, 43} K 28 {286, 21}
F 12.3 {125, 9}
#=Apply oil to the threads and seat surfaces before tightening.
4
1
5
A
6 2
7
8
9 15
10
16
11
12
17
13
14
SHTS011030200002
1 Flange 10 Valve stem seal

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

A 108 {1,100, 79}#
J08E-NB (J08E-UF, UG, UH)
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
SHTS011030200003
1 Oil filler cap 17 Bushing

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

A 28.5 {290, 20} F 12.25 {125, 9}
B 31 {320, 23} G 23 {230, 16}
C 59 {600, 43}+90# H 59 {600, 43}+90+90#
D 25 {250, 18} I 25 {250, 18}
E 59 {600, 43}
4
1
5
A
6 2
7
8
9 15
10
16
11
12
17
13
14
SHTS011030200004
1 Flange 10 Valve stem seal

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

A 108 {1,100, 79}#
3

CYLINDER HEAD
SPECIAL TOOL
EN01F01103020K01001001
S0943-31070 EYE BOLT
S0949-11010 WIRE
S0947-01170 VALVE SPRING PRESS
S0943-11020 VALVE LAPPING TOOL
S0947-22100 VALVE STEM SEAL PRESS
S0947-21210 BAR For Nozzle sleeve
SN441-00610 STEEL BALL Used with S0947-21210
S0947-11520 GUIDE
3

CYLINDER HEAD
OVERHAUL
EN01F01103020H02001001
IMPORTANT POINTS - DISASSEMBLY
1. DISASSEMBLE THE CYLINDER HEAD.

(1) Clean parts around the injector and fuel system connections.
NOTICE
Entry of foreign particles into the combustion chamber may result
in engine trouble.
(2) (J08E-CR) Remove the injector harness assembly.
a. Disconnect the connector of injector.
b. Remove the 7 nuts, disconnect the injector harness
assembly with plate.
(3) (J08E-CR) Remove the injector assembly.
NOTICE
Refer to the section "INJECTOR" in the chapter "FUEL SYSTEM
(J08E)".
(4) (J08E-NB) Remove the nozzle holder assembly.
NOTICE
Refer to the chapter "FUEL SYSTEM (J08E)".
SHTS011030200013
(5) Remove the rocker arm assembly.

a. Loosen the lock nut at the end of the rocker arm and turn
ADJUSTING the adjusting screw counterclockwise completely.
SCREW
NOTICE
Not loosening the adjusting screw may result in a bent rocker
LOCK NUT
shaft.
b. Loosen the injector clamp bolt.
SHTS011030200014
c. Loosen the rocker arm support bolt as shown in the figure.

(EXAMPLE) NOTICE
If the cross head is removed from the valve during disassembly of
the rocker arm assembly, reassemble the cross head as it was.
ROCKER ARM SUPPORT
7 5 3 1 2 4 6
SHTS011030200015
(6) Remove the cylinder head bolts.

a. Gradually loosen bolts three times in the order shown in
the figure.
SHTS011030200016
(7) Lift and remove the cylinder head using the special tool and
hoist.
SST: S0943-31070
Eye bolt
S0949-11010
Wire
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.
SHTS011030200017
2. DISASSEMBLE THE VALVE SYSTEM.

(1) Remove the valve spring retainer using the special tool.
SST: S0947-01170
Valve spring press
SHTS011030200018
(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.
SHTS011030200019
3. CLEAN THE CYLINDER HEAD.

(1) Clean the cylinder head and remove carbon deposits or for-
eign particles.
NOTICE
Be careful not to damage the cylinder head lower surface when
removing carbon deposits or foreign particles.
SHTS011030200020
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 ham-
mer.
! WARNING
Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.
(3) When installing a new valve guide, do not twist the end.
Press fit the valve guide using the special tool.
SST: S0947-11520
SHTS011030200021
Guide
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.
VALVE SEAT (1) When replacing the valve seat, cut three places on the cir-
BACK PLATE cumference 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
VALVE WELDING (2) Place a (brass) back plate at the top of the valve system and
CUT THREE strike it with a hammer to remove the valve seat.
PLACES HERE
! WARNING
SHTS011030200022 Striking the valve guide during removal may cause metal chips to
(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}
SHTS011030200023
Intake Exhaust
41.085-41.1 39.12-39.135
C
Valve seat {1.6176-1.6181} {1.5402-1.5407}
side 7-7.2 6-6.2
D
{0.2756-0.2834} {0.2363-0.2440}
(4) Heat the cylinder head to 80 - 100C {176 - 212F} in hot

water.
After cooling the valve seat, insert it into the cylinder head.
! WARNING
Striking the valve guide during removal may cause metal chips to
SHTS011030200024
(5) Apply a small amount of lapping compound to the contact

surfaces of the valve and valve seat. Turn the valve using the
special tool and tap it lightly to lap.
SST: S0943-11020
Valve lapping tool
SHTS011030200025
3. REPLACE THE VALVE STEM SEAL.

STEM SEAL (1) After removing the valve stem seal, assemble the spring
SPECIAL TOOL lower seat and apply engine oil to the stem seal lip. Punch it
SPRING
LOWER SEAT into the valve guide using the special tool.
SST: S0947-22100
Valve stem seal press
! WARNING
Punching the valve stem seal during installation may cause metal
chips to fly up. Be sure to wear protective goggles.
NOTICE
After assembly of the stem seal, check for deformation or cracking
of the rubber or incline.
APPLICATION OF OIL
RUBBER
SHTS011030200026
(2) After punching the valve stem seal, measure the height A.
VALVE STEM
SEAL SPRING Height A: 22.5-23.0 mm {0.886-0.906 in.}
VALVE SPRING
LOWER SEAT
SHTS011030200027
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
hammer to remove the nozzle seat from the cylinder head.
! WARNING
Punching the nozzle seat during removal may cause metal chips
to fly up. Be sure to wear protective goggles.
NOTICE
After removing the nozzle seat, remove the rest of liquid gasket or
the adhesion such as dust completely.
SHTS011030200028
(2) After inserting the O-ring into the nozzle seat insertion hole
of the cylinder head, apply liquid gasket (ThreeBond 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.
SHTS011030200029
(3) Caulk the nozzle seat with the special tools.

SST: S0947-21210
Bar
SN441-00610
Steel ball
SHTS011030200030
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: S0947-01170
Valve spring press
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.
• When the valve spring is compressed, be careful of damage to
the stem seal due to contact of the upper seat.
SHTS011030200031 • 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 cylin-
der 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 damaged.
• Since silicon material is used for the gear case print seal, make
sure that there is no peeling before assembly.
SHTS011030200032
(1) Install the cylinder head gasket on the cylinder block and fly-
wheel 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.
SHTS011030200033
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.}
SHTS011030200034
4. INSTALL THE CYLINDER HEAD.

(1) Using the special tool and hoist, put the cylinder head.
SST: S0943-31070
Release tool set
S0949-11010
Wire
NOTICE
When put the cylinder head, attention to cam idle gear and sub
idle gear engagement.
SHTS011030200035
(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
surface.
(4) Tighten No.1-No.26 (M12 bolts) in the order shown in the fig-
ure to the specified torque.
Tightening Torque:
SHTS011030200036
(5) Mark the M12 bolts with paint to indicate the same directions
(EXAMPLE) as shown in the figure.
(6) Turn No.1-No.26 (M12 bolts) 90° (1/4 turn) in the same order
as in (4).
PAINT MARK
(7) Retighten them 90° (1/4 turn) as step (6).
90 (8) Make sure that all paint marks face the same direction.
90
NOTICE
When adding torque, never untighten the bolts, even if they have
been overtightened.
SHTS011030200037
(9) Tighten No.27-No.29 (M10 bolts) in the order shown in the

figure to the specified torque below.
Tightening Torque:
SHTS011030200038
5. INSTALL THE CAM IDLE GEAR.

NOTICE
IDLE GEAR
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
SHTS011030200039
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.
SHTS011030200040
(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:
SHTS011030200041
(4) Turn bolts an additional 90° (1/4 turn).

(EXAMPLE) NOTICE
MARKING
• When adding torque, never untighten the bolt, even if it has
been overtightened.
90
SHTS011030200042
7. INSTALL THE CAMSHAFT.

(1) Align the mark on the damper or the flywheel with the fly-
wheel housing pointer to set the No.1 piston to top dead cen-
ter of the compression stroke.
NOTICE
Engine adjustment - Refer to "PREPARATION OF CHECKING AND
ADJUSTMENT" in the section "ENGINE TUNEUP" in the chapter
"ENGINE INTRODUCTION (J08E)".
(2) Install the camshaft into the cam housing.
NOTICE
Two drill holes on the camshaft gear should be located at left side
SHTS011030200043 and lower drill hole should match with the camshaft housing
upper surface.
(3) Install camshaft bearing caps by fitting the position, in the

FRONT stamped order of 1, 2, 3, 4 and 5, with each engraved mark
headed toward engine front.
1
SHTS011030200044
8. INSTALL THE ROCKER ARM ASSEMBLY.

(1) Make sure that the cross head is on each valve.
ROCKER ARM SUPPORT NOTICE
If the cross head is assembled whilst off the valve, the upper seat
will be pressed, resulting in a loose valve.
(2) Make sure that the adjusting screw at the end of the rocker
arm is completely screwed in.
(3) Tighten the rocker arm support bolt as shown in the figure to
7 5 3 1 2 4 6 the specified torque.
Tightening Torque:
SHTS011030200045
(4) (J08E-NB) Tighten the nozzle clamp bolt to the specified-

torque.
Tightening Torque:
(5) Make sure that the rocker arm moves smoothly.

HINT
(J08E-NB) When assembling the rocker arm assembly, fix the arm
and nozzle clamp with an O-ring as shown in the figure to facilitate
installation.
SHTS011030200046
NOTICE
Make sure the oil hole is placed below.
SHTS011030200047
9. INSTALL THE HEAD COVER.

(1) Remove the camshaft housing plugs at the front and rear
ends of the camshaft housing.
NOTICE
If there is no oil leakage from plug, do not remove the plug.
(2) Remove the liquid gasket from camshaft housing plugs and
camshaft housing completely.
(3) Apply liquid gasket to the front and rear half circles of the
camshaft housing.
SHTS011030200048
(4) Install the camshaft housing plug to camshaft housing with

torx bolt.
Tightening Torque:
6 N·m {62 kgf·cm, 4.4 lbf·ft}
NOTICE
• Wipe out excess liquid gasket completely.
• Make sure that the camshaft housing plug installed with no tilt.
SHTS011030200049
SHTS011030200050
(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
SHTS011030200051
(7) Insert the silent block from the head cover lower surface.
(8) Tighten the bolt through the silent block to the specified
torque below and fix the head cover on the cam housing.
Tightening Torque:
SHTS011030200052
3
CYLINDER HEAD
INSPECTION AND REPAIR

EN01F01103020H03001001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Camshaft journal outside 40 39.85 Replace Measure

diameter {1.5748} {1.5689} camshaft.
Replace
Camshaft bearing inside 40 40.15
camshaft
diameter {1.5748} {1.5807}
bearing.
Replace
Clearance between camshaft 0.020-0.063 camshaft and/
—
journal and camshaft bearing {0.0008-0.0024} or cam
bearing.
Measure
0.100-0.178 Replace
Camshaft end play —
{0.0040-0.0070} camshaft.
IN 50.046 {1.9703} 49.966 {1.9672} Measure
Cam Replace
height EX 52.739 {2.0763} 52.659 {2.0732} camshaft.
Measure
0.1 Replace
Camshaft deflection 0.04 {0.0016}
{0.0039} camshaft.
Rocker arm bushing inside Replace rocker Measure

22 {0.866} 22.08 {0.8693}
diameter arm bushing.
Rocker shaft outside diame- Replace rocker

22 {0.866} 21.92 {0.8630}
ter shaft.
Replace rocker
Clearance between rocker 0.030-0.101 arm bushing
0.15 {0.0059}
shaft and rocker arm bushing {0.0012-0.0039} and/or rocker
shaft.
Stem Replace the Measure

7 {0.2756} —
outside diameter valve.
Guide inside Replace the

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

7 {0.2756} —
outside diameter valve.
Guide inside Replace the

7 {0.2756} —
Exhaust diameter valve guide.
valve J08E- 0.050-0.083
CR {0.0020-0.0032} Replace the
Clear-
— valve and/or
ance J08E- 0.037-0.067 valve guide.
NB {0.0015-0.0026}
Replace the Measure

0.55-0.85 1.1
IN valve and valve
{0.0217-0.0334} {0.0433} VALVE SINK
seat.
J08E- 1.15-1.45 1.7

Valve sink
CR {0.0453-0.0570} {0.0669} Replace the
EX valve and valve
J08E- 1.05-1.35 1.6 seat.
NB {0.0414-0.0531} {0.0630}
Measure
IN 30° 30°-30°35'
Valve seat
angle
EX 45° 45-4530'
Resurface the
valve and/or
IN 30° 29°30'-30° valve seat.
Valve face
angle
EX 45° 44°30'-45°
314 N Measure
{32.0 kgf,
Setting load — Replace.
70.5 lbf}
at 46.8 {1.843}
Outer Free length 72.7
valve 75.7 {2.980} Replace.
(reference value) {2.862}
spring
J08E-
2.0 {0.0787}
Square CR
— Replace.
ness J08E- 2.3
NB {0.0787}
129 N
{13.2 kgf,
Setting load — Replace.
29.1 lbf}
at 44.8 {1.764}
Free length 61.6

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

— — Replace.
spring seat upper and lower
Measure
J08E- 2.45-2.95
CR {0.0965-0.1161}
Replace
Nozzle protrusion —
nozzle seat.
J08E- 2.25-2.75
NB {0.0886-0.1083}
0.06 {0.0024} or Measure

less for longitu-
dinal direction
Replace.
Cylinder head lower surface
0.20 {0.0078} NOTICE: Do not
flatness 0.03 {0.0012} or grind for repair.
less for lateral
direction
Visual check
Cracks of damage to cylinder

head — — Replace.
(Dye penetrant check)
Visual check
Entire periph-
Contact of valve
ery of valve
(Use of Red lead marking — Matches valve.
head evenly in
compound)
contact
Cam idle gear shaft outside Measure

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

34 {1.3386} — —
inside diameter
Replace idle
Clearance between cam idle
0.025-0.075 0.2 gear shaft
gear shaft and cam idle gear
{0.0010-0.0029} {0.0078} bushing and/or
bushing
idle gear.
3
All Component Locator
CRANKSHAFT FRONT END
COMPONENT LOCATOR
EN01F01103020D01002001
A
4
SHTS011030200068
1 Crankshaft pulley 3 Oil seal retainer

2 Torsional damper 4 Crankshaft oil seal

A 118 {1,200, 86} # B 108 {1,100, 80} #
3
SPECIAL TOOL
EN01F01103020K01002001
S0942-01731 OIL SEAL PULLER
S0940-71030 OIL SEAL PRESS

3
OVERHAUL
EN01F01103020H02002001
1. REMOVE THE CRANKSHAFT FRONT OIL SEAL.

SST: S0942-01731
Oil seal puller
(1) Place the plate at the crankshaft end using the crankshaft
pulley bolts.
PLATE
SHTS011030200071
(2) Engage the hook with the oil seal notch and install the hook
REMOVE THIS AFTER INSTALLING THE HOOK using the bolt supplied.
(3) Remove the installed bolt in step (1).
NOTCH
HOOK
SHTS011030200072
(4) Install the center bolt and tighten it to remove the oil seal.
CENTER BOLT
SHTS011030200073
2. INSTALL THE CRANKSHAFT FRONT OIL SEAL.

GUIDE SST: S0940-71030
Oil seal press
(1) Clean the edges and surface of the crankshaft and the spe-
cial tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal
press.
OIL SEAL
SHTS011030200074
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
SHTS011030200075
(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
SHTS011030200076
(5) Insert the oil seal press by adjusting the oil seal press hole to
the guide bolt.
PRESS
(6) Press the crankshaft oil seal inside by attaching the accom-
panying center bolt onto the oil seal press and tightening it
until it stops.
CENTER BOLT
SHTS011030200077
3
FLYWHEEL AND FLYWHEEL HOUSING
COMPONENT LOCATOR
EN01F01103020D01003001
(REPRESENTATIVE TYPE)
B
5
A 6 A 2
C
X A A
W
X
W
4
3
SHTS011030200078
1 Flywheel housing 4 Flywheel

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

A M8: 28.5 {290, 21} B 186 {1,900, 137}#
M10: 55 {560, 40.5} C 36 {367, 27}
M16: 196 {2,000, 145}
#=Apply oil to the threads and seat surface before tightening.
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
3
SPECIAL TOOL
EN01F01103020K01003001
S0942-01742 REAR OIL SEAL PULLER
S0948-11340 GUIDE BAR

3
OVERHAUL
EN01F01103020H02003001
1. REMOVE THE FLYWHEEL.

O-RING (1) (J08E-CR) Remove the main engine speed sensor from the
flywheel housing.
MAIN ENGINE
SPEED SENSOR
SHTS011030200082
NOTICE
MAIN ENGINE SPEED SENSOR (J08E-CR) When dismounting and remounting the flywheel.
Remove the main engine speed sensor. If not removed, it will
result in damage of the sensor.
FLYWHEEL
1 mm
{0.394 in.}
SHTS011030200083
(2) Install the special tool, remove the flywheel.

SST: S0948-11340
Guide bar
! WARNING
The flywheel is heavy when removing, be careful not to drop it on
SST
your feet.
SHTS011030200084
1. REMOVE THE CRANKSHAFT REAR OIL SEAL.

PLATE SST: S0942-01742
Rear oil seal puller
(1) Place the plate at the crankshaft end using the flywheel bolts.
NOTICE
Match the plate hole to the crankshaft collar knock part.
SHTS011030200085
(2) Engage the hook with the oil seal notch and install the hook
NOTCH using the bolt supplied.
(3) Remove the installed flywheel bolts in step (1).
HOOK
SHTS011030200086
(4) Install the center bolt and tighten it to remove the oil seal.
SHTS011030200087
2. INSTALL THE CRANKSHAFT REAR OIL SEAL.

SST: S0940-71040
Oil seal press
GUIDE
(1) Clean the edges and surface of the crankshaft and the spe-
cial tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal
press.
OIL SEAL
SHTS011030200088
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
SHTS011030200089
(3) Apply a little engine oil to the seal portion of the crankshaft oil
OIL SEAL seal.
(4) Attach the oil seal press guide with the new crankshaft oil
seal onto the crankshaft using the attached guide bolt.
GUIDE
GUIDE BOLT
SHTS011030200090
(5) Insert the oil seal press by adjusting the oil seal press hole to
the guide bolt.
OIL SEAL
PRESS
SHTS011030200091
(6) Press the crankshaft oil seal inside by attaching the accom-
panying center bolt onto the oil seal press and tightening it
until it stops.
SHTS011030200092
3. REPLACE THE FLYWHEEL RING GEAR.

(1) Heat the ring gear evenly to about 200C {392F} with a
torch. Tap the ring gear periphery lightly using a cushion bar
to remove the gear.
! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
SHTS011030200093
(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 cham-
fered side is upward.
! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
SHTS011030200094
IMPORTANT POINT - ASSEMBLY
1. INSTALL THE FLYWHEEL.

(1) Make sure that there are no burns or dirt on the contact sur-
face or in the threaded holes of the crankshaft or flywheel.
Install the special tool onto the crankshaft.
SST: S0948-11340
Guide bar
SST
NOTICE
Place one guide bar at the collar knock and another at the oppo-
site side of the collar knock.
SHTS011030200095
(2) Insert the flywheel slowly until it contacts the collar knock to
prevent impact on the guide bar. Adjust the position, then
insert the flywheel completely.
! WARNING
The flywheel is too heavy. When installing, be careful not to drop it
on your feet.
(3) Apply clean engine oil to the threads of the flywheel bolt and
the flywheel bolt seat. Be sure to tighten the flywheel bolts (6
pieces) with a low-torque impact wrench.
(4) Pull out the guide bar and tighten the remaining two flywheel
SHTS011030200096
bolts provisionally as in step (3).
(5) Tighten the flywheel in the order shown in the figure to the
specified 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.
SHTS011030200097
3

EN01F01103020H03003001
Unit: mm {in.}
Measure
Flywheel surface deflection — 0.15 {0.0059} Repair.
Flywheel flange depth Measure

48 {1.890} — —
(Dimension A)
Flywheel thickness
23 {0.906} 22 {0.866} Replace.
(Dimension B)
Flywheel surface crank on Visual check

— — Repair.
heat spot
3
TIMING GEAR
COMPONENT LOCATOR
EN01F01103020D01008001
14 A
3
13
4
2 14 B
13
1 5
6 14
13
7
5 A
8 12 14
11
10
9
5
C
SHTS011030200100
1 Gasket 8 Main idle gear

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

A 108 {1,100, 80}# C 55 {560, 41} Application of lock sealant
B 172 {1,750, 127}#
SHTS011030200101
1 Gasket 7 Oil pump gear

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

A 108 {1,100, 80}# C 172 {1,750, 127}#
B 108 {1,100, 80}# D 55 {560, 41} Application of lock sealant
3
TIMING GEAR
SPECIAL TOOL
EN01F01103020K01008001
S0942-01100 SLIDING HAMMER For Main idle gear
S0942-01442 SLIDING HAMMER For Sub and cam idle gear
S0941-11300 SOCKET WRENCH For Torx bolt

3
TIMING GEAR
OVERHAUL
EN01F01103020H02008001
IMPORTANT POINT - DISASSEMBLY
1. REMOVE THE IDLE GEAR SHAFT.

(1) Remove the idle gear shaft using the special tool.
SST: S0942-01100
Sliding hammer (for main idle gear)
S0942-01442
Sliding hammer (for sub and cam idle gear)
SHTS011030200105
SHTS011030200106
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 fit-
ting (2 places) and tighten to the specified torque using the
special tool.
SST: S0941-11300
TORX BOLTS Socket wrench
Tightening Torque:
REAR END 55 N·m {560 kgf·cm, 41 lbf·ft}
PLATE
SHTS011030200107
2. INSTALL THE CRANKSHAFT GEAR.

(1) Heat the crankshaft gear in oil heated to 100C -150C
{212F-302F}.
! WARNING
Never touch the heated gear with your bare hand. This can result
in personal injury.
(2) Align the crankshaft gear groove with crankshaft pin.
(3) Install the crankshaft gear onto the crankshaft as shown in
the figure.
Dimension A: 22 mm {0.866 in.}
SHTS011030200108
3. INSTALL THE IDLER GEAR SHAFT AND GEAR.

• J08E-CR
SHTS011030200109
• J08E-NB
SHTS011030200110
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 com-
pressor gear as shown in the figure.
4. MEASUREMENT OF GEAR BACKLASH

(1) Measure the backlash between the gears with a dial gauge.
(Refer to the table of "INSPECTION AND REPAIR")
NOTICE
After measurement of the backlash, apply engine oil to each gear
surface.
SHTS011030200111
3
TIMING GEAR

EN01F01103020H03008001
J08E-CR
Unit: mm {in.}
Crankshaft-
0.030-0.167
Main idle 0.30 {0.0118}
{0.0012-0.0065}
(without PTO)
Crankshaft-
0.030-0.132
Main idle 0.30 {0.0118}
{0.0012-0.0052}
(with PTO)
Main idle-Air Measure

0.032-0.096
compressor 0.10 {0.0039}
{0.0013-0.0038}
idle
Air compres-
0.020-0.083
sor idle-Air 0.10 {0.0039}
{0.0008-0.0033}
compressor
Timing gear
Replace gear.
backlash Air compres-
sor-Power 0.030-0.134
0.30 {0.0118}
steering {0.0012-0.0052}
pump
Main idle-Sub 0.030-0.113

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

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

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

0.30 {0.0118}
Camshaft {0.0012-0.0099}
Shaft outside
57 {2.244} — —
diameter
Bushing
inside 57 {2.244} — —
diameter
Main idle 0.030-0.090 Replace bush-
shaft Clearance 0.20 {0.0079}
{0.0012-0.0035} ing and/or shaft.
Gear width 44 {1.732} — —
Shaft length 44 {1.732} — —
0.114-0.160 Replace gear

End play 0.30 {0.0118} Measure
{0.0045-0.0062} and/or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside 50 {1.969} — —
diameter
Sub idle shaft Clearance 0.025-0.075 Replace bush-

0.20 {0.0079}
{0.0010-0.0029} ing and/or shaft.
Gear width 22 {0.866} — —

End play 0.30 {0.0118}
{0.0016-0.0047} and/or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
inside 34 {1.339} — —
diameter
Cam idle 0.025-0.075 Replace bush-

Clearance 0.20 {0.0079}
shaft {0.0010-0.0029} ing and/or shaft.
Gear width 22 {0.866} — —
Replace gear
0.040-0.120
End play 0.30 {0.0118} and/or thrust
{0.0016-0.0047}
plate.
Shaft outside
34 {1.339} — —
diameter
Bushing
inside 34 {1.339} — —
diameter
Air
compressor 0.025-0.057 Replace bush-
Clearance 0.10 {0.0039}
idle {0.0010-0.0022} ing and/or shaft.
Gear width 28.5 {1.1220} — —
Shaft length 28.5 {1.1220} — —
0.160-0.220
End play — —
{0.0063-0.0086}
J08E-UF, UG
Unit: mm {in.}
Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}
Main idle-Air 0.030-0.218 Measure

0.30 {0.0118}
compressor {0.0012-0.0085}
Air compres-
sor-Power 0.030-0.183
0.30 {0.0118}
steering {0.0012-0.0072}
pump
Timing gear
Replace gear.
backlash Main idle-Sub 0.030-0.162
0.30 {0.0118}
idle {0.0012-0.0063}
Sub idle-Oil 0.030-0.131

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

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

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

End play 0.30 {0.0118}
{0.0045-0.0062} and/or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside 50 {1.969} — —
diameter
Sub idle shaft Clearance 0.025-0.075 Replace gear

0.20 {0.0079}
{0.0010-0.0029} and/or shaft.
Gear width 22 {0.866} — —

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

End play 0.30 {0.0118}
{0.0016-0.0037} and/or shaft.
3
MAIN MOVING PARTS AND CYLINDER BLOCK
COMPONENT LOCATOR
EN01F01103020D01005001
SHTS011030200116
1 Cylinder liner 7 Retainer ring 13 Crankshaft main bearing

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

A 22 {220, 15.5} C 69 {700, 50}+90+45#
B 69 {700, 50}+90+45#
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
2 3
A
4
B
SHTS011030200117
1 Gasket 3 Soft washer

2 Oil pan 4 Drain plug

A 41 {420, 30} B 30 {300, 21}
SHTS011030200118
1 Injection pump bracket (J08E-NB only)

3
SPECIAL TOOL
EN01F01103020K01005001
S0944-21011 PISTON RING EXPANDER For Piston ring
S0942-02100 PULLER For Cylinder liner
SZ910-24098 CONNECTOR BOLT For Piston cooling jet
S0947-21620 ADJUSTING BAR
S0947-11490 GUIDE
S0940-21540 SPINDLE
S0948-11540 GUIDE
SH691-20825 BOLT
S0948-11130 GUIDE For Connecting rod bushing
S0940-21530 PRESS SUB-ASSEMBLY
SL271-01036 WING NUT
S0944-11370 PISTON RING HOLDER
S0947-01280 TOOL ASSEMBLY

3
OVERHAUL
EN01F01103020H02005001
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 cir-
cular direction.
SHTS011030200132
• Arrange the removed pistons and connecting rod caps in the

order of cylinder numbers. Be careful not to change the combi-
nation of the connecting rod and cap.
SHTS011030200133
2. REMOVE THE PISTON RINGS.

(1) Remove the piston ring using the special tool.
SST: S0944-21011
Piston ring expander
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.
SHTS011030200134
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.
SHTS011030200135
(2) Pull the cylinder liner from the cylinder block using the spe-
cial tool.
SST: S0942-02100
Puller
NOTICE
• Carefully set the special tool to prevent touching to the piston
cooling jet.
• After removing the cylinder liners, arrange them in sequence.
SHTS011030200136
1. INSPECT AND ADJUST THE PISTON COOLING JET.

(1) Install the piston cooling jet on the cylinder block using the
special tool.
SST: SZ910-24098
Connector bolt
SHTS011030200137
(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.
SHTS011030200138
(3) Set the special tool on the cylinder block upper surface
against the dowel pin.
SST: S0947-01280
Tool assembly
(4) Test jet oil flow from the piston cooling jet nozzle at a hydrau-
lic pressure of 196 kPa {2 kgf/cm2, 28 lbf/in.2}.
SHTS011030200139
(5) If the center of the jet flow is within the target circle (7 mm
{0.2756 in} diameter: Red), the test is acceptable.
NOTICE
Fire may occur due to splattered oil during the jet flow test. Do not
use naked lights near the test area.
! WARNING
Engine oil is flammable. Carry out this test in a well ventilated
room and do not use naked lights in the room.
SHTS011030200140
(6) If the center of the jet flow is out of the target circle, realign
the nozzle using the special tool.
SST: S0947-21620
Adjusting bar
SHTS011030200141
2. INSTALL THE CYLINDER LINER.

NOTICE
ENGINE TYPE STAMP
• 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.
SHTS011030200142
SHTS011030200143
(1) Apply engine oil to the inner surface of the block bore and
insert the cylinder liner using the special tool.
SST: S0947-11490
Guide
NOTICE
Handle the cylinder liner carefully because it is thin.
(If it falls on the floor, it cannot be used.)
SHTS011030200144
3. MEASURE THE PROTRUSION AT THE CYLINDER LINER

FLANGE.
SST: S0942-02100
Puller
Tightening Torque:
9.8 N·m {100 kgf·cm, 7 lbf·ft}
Standard: 0.01-0.08 mm {0.0004-0.0031 in.}
SHTS011030200145
4. MEASURE THE CRANKSHAFT.

(1) If necessary, grind the crankshaft and use an under size
bearing.
Outside diameter
Bearing size
Crank pin Journal
64.94-64.96 mm 79.94-79.96 mm
Standard
{2.5567-2.5574 in.} {3.1473-3.1480 in.}
64.69-64.71 mm 79.69-79.71 mm
0.25US
{2.5469-2.5476 in.} {3.1375-3.1381 in.}
64.44-64.46 mm 79.44-79.46 mm
0.50US
{2.5371-2.5377 in.} {3.1276-3.1283 in.}
(2) Dimension of fillet "R"
Crank pin 2.5-3.0 mm {0.0985-0.1181 in.}

NOT "R" SMALL "R"
STEPPED STEPPED Journal 2.5-3.0 mm {0.0985-0.1181 in.}
R
GOOD NOT GOOD
SHTS011030200146
5. INSTALL THE CRANKSHAFT.

(1) Install the main bearing onto the bearing caps and the cylin-
der 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.
SHTS011030200147
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
APPLICATION and replace any bolts not meeting the limit with new ones.
POSITION OF
A
Dimension A: 108 mm {4.252 in.}
ENGINE OIL
SHTS011030200148
(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
FRONT specified torque.
Tightening Torque:
2 4 6 8 10 12 14 (5) Loosen all bolts, tap the front and back ends of the crank-
1 2 3 4 5 6 7 shaft 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.
SHTS011030200149
(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.
SHTS011030200150
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: S0948-11130
Guide
S0940-21530
Press sub-assembly
SL271-01036
Wing nut
NOTICE
• Bring lever "H" punched on the guide above the pin.
SHTS011030200151
• 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.
SHTS011030200152
b. Install the spindle into the bushing.

SST: S0940-21540
Spindle
NOTICE
Align the groove of the spindle with the groove of the press sub
assembly.
SHTS011030200153
c. Using a hydraulic press, remove the bushing.

NOTICE
Always operate the press slowly and smoothly.
SHTS011030200154
(3) Chamfer one edge of the bushing hole at the small end of the
connecting rod uniformly by 0.5-1.0 mm {0.0197-0.0393 in.}.
NOTICE
• Irregular chamfering can cause out-of-roundness of the pressed
bushing, which may result in jamming during insertion.
• Remove dust from the inner surface of the small-end hole.
SHTS011030200155
(4) Mount the bushing on the spindle.

a. Set the bushing and guide on the spindle as shown in the
figure, then secure them with the bolt.
SST: S0940-21540
Spindle
S0948-11540
Guide
SH691-20825
Bolt
Tightening Torque:
5.0-6.8 N·m {50-70 kgf·cm, 3.62-5.06 lbf·ft}
(Bolt)
SHTS011030200156
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 con-
necting rod.
NOTICE
• Put the connecting rod to the press sub assembly that chamfer
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.
SHTS011030200157
(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.
SHTS011030200158
8. ASSEMBLE THE PISTON AND CONNECTING ROD.

(1) Heat the piston to 50C {122F}.
(2) Assemble the piston 0-mark to be opposite to the connecting
rod match mark.
NOTICE
Replace the retainer ring with a new one.
SHTS011030200159
9. ASSEMBLE THE PISTON RING.

(1) Install in the order of oil ring, 2nd ring and top ring using the
special tool.
SST: S0944-21011
NOTICE
Install the 2nd ring that turn the identification print on the piston
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 opposite to the matching point.
SHTS011030200160
(3) Position the matching points of the piston ring at a even dis-
tance as shown in the figure.
2ND RING
OIL RING
TOP RING
SHTS011030200161
10. INSTALL THE PISTON.

COOLING JET (1) Apply engine oil to the piston, cylinder liner and connecting
rod bearing, then compress the piston ring using the special
tool.
SST: S0944-11370
Piston ring holder
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.
SHTS011030200162
(2) Insert the piston into the cylinder liner.
SHTS011030200163
SHTS011030200164
11. TIGHTEN THE CONNECTING ROD BOLT.

(1) Measure the length of the bolts, if the length is A or more,
replace with new bolts.
(2) Apply clean engine oil to the bolt thread and the bolt seat sur-
face of the connecting rod cap.
SHTS011030200165
(3) Tighten the connecting rod bolt to the specified torque.

Tightening Torque:
(4) Mark the bolt heads in the same direction with paint.
(5) Tighten the connecting rod bolt 90 (1/4 turn).
(6) Tighten the connecting rod bolt 45 (1/8 turn).
(7) Make sure that the paint marks face the same direction.
NOTICE
• When adding torque, never untighten the nuts, even if they have
been overtightened.
SHTS011030200166 • If the angle of bolts is adjusted to the specified angle by turning
counterclockwise, the axial force of the bolts might fall short
and it is feared that this could reduce the engine reliability. Also
there is a possibility that this could reduce the number of times
a bolt can be reused.
12. INSTALL THE OIL PAN.

(EXAMPLE) BOLT TIGHTENING (1) Make sure that there is no deformation, impact marks or for-
DIRECTION eign particles on the cylinder block, oil pan or flange surface.
Apply liquid gasket to the front and back ends of the cylinder
block lower surface.
NOTICE
Refer to "PARTS AND POSITIONS FOR LIQUID GASKET" in the
section "LIQUID GASKET AND APPLICATION POINTS" in the
chapter "ENGINE INTRODUCTION (J08E)".
REAR (2) Install the gasket so that the protrusion is at the flywheel
housing side and the intake side. (the print seal surface is at
the cylinder block side)
FRONT (3) Place a guide pin of 70 mm {2.76 in.} or more in the cylinder
block and assemble the oil pan against the guide.
(4) Tighten oil pan fitting bolts according to the arrows with an
PROTRUSION
impact wrench.
OIL STRANER Tightening Torque:
19.7-24.5 N·m {200-250 kgf·cm, 15-18 lbf·ft}
(5) Finish tightening the bolts with a torque wrench to the speci-
fied torque. Tighten the bolts according to the arrows in the
figure.
LIQUID GASKET NOTICE
SHTS011030200167
Make sure that the washer is not on the flange.
13. INSTALLING THE OIL PAN COVER

(1) Install the oil pan cover to the oil pan with 4 nuts.
Tightening Torque:
Oil pan cover
Nut
SHTS011030200168
3

EN01F01103020H03005001
Unit: mm {in.}
Cylinder block flange depth 3 {0.1181} — — Measure
Cylinder liner thickness 3 {0.1181} — —
0.01-0.08
Cylinder liner protrusion — —
{0.0004-0.0031}
117-117.008 Reference only

A
{4.6063-4.6066}
Block inside 117.008-117.014

B — —
diameter {4.6067-4.6068}
117.014-117.022
C
{4.6069-4.6071}
116.982-116.990 Reference only

A
{4.6056-4.6058}
Liner outside 116.990-116.996

B — —
diameter {4.6059-4.6061}
116.996-117.004
C
{4.6062-4.6064}
0.010-0.026 Reference only

A
{0.0004-0.0010}
Clearance between 0.012-0.024

B — —
block and liner {0.0005-0.0009}
0.010-0.026
C
{0.0004-0.0010}
Piston outside diameter at A: 111.892-111.908 Measure

—
23 {0.9055} {4.4052-4.4058}
Liner inside diameter

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

—
and cylinder liner {0.0036-0.0042}
Top 2.5 {0.0984} 2.4 {0.0945} Measure
2nd 2.0 {0.0787} 1.9 {0.0748}

Piston
Replace ring.
ring width
Oil 4.0 {0.1575} 3.9 {0.1535}
Top 2.5 {0.0984} 2.7 {0.1062} Measure
2nd 2.0 {0.0787} 2.2 {0.0866}

Piston ring groove
Replace piston.
width
Oil 4.0 {0.1575} 4.1 {0.1614}
0.09-0.13
Top
{0.0036-0.0051}
Clearance between
Replace piston
piston ring 0.04-0.08
2nd — ring and/or pis- —
and piston ring {0.0016-0.0031}
ton.
groove
0.02-0.06
Oil
{0.0008-0.0023}
0.30-0.40 Measure
Top 1.5 {0.0591}
{0.0119-0.0157}
Cylinder liner
0.75-0.90
2nd 1.2 {0.0472}
Gap between ends {0.0296-0.0354} Replace piston
of piston ring ring.
0.15-0.30 Piston ring

Oil 1.2 {0.0472}
{0.0059-0.0118}
Replace piston Measure

Piston pin outside diameter 37 {1.4567} 36.96 {1.4551}
pin.
Piston pin bore inside

37 {1.4567} 37.05 {1.4586} Replace piston.
diameter
Clearance between piston pin Replace piston

-0.002-0.025
and 0.05 {0.0020} and/or piston
{-0.0008-0.00098}
piston pin bore pin.
Measure
Replace con-
Connecting rod bushing
37 {1.4567} 37.1 {1.4606} necting rod
inside diameter
bushing.
Replace piston
Clearance between piston pin 0.035-0.056 pin and/or con-
0.08 {0.0031} —
and connecting rod bushing {0.0014-0.0022} necting rod
bushing
Visual check
Wear or damage of connect-

ing rod
— — Replace.
*Dye penetrant check
(Color check)
Visual check
Clogging of connecting rod

— — Replace.
oil hole
More than Measure

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

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

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

0.2 {0.0079}
journal and main bearing {0.0021-0.0040} bearing.
Measure
Replace crank-
Center journal width 36 {1.417} 37 {1.456}
shaft.
Thrust bearing thickness 2.5 {0.0984} — — Measure
More than Replace over

0.5 {0.0197} size thrust
0.050-0.270 (Repair) bearing.
Crankshaft end play
{0.0020-0.0106}
1.270 {0.0499} Replace
(Service) crankshaft.
Measure
Regrind under
Crankshaft deflection — 0.15 {0.0059}
size.
Visual check
Clogging of crankshaft oil

— — Clean.
hole
Visual check
Crack and wear of crankshaft

*Dye penetrant check — — Replace.
(Color check)
Measure
Longitudinal
direction:
Replace.
0.06 {0.0024}
Cylinder block upper surface NOTICE:
Right angle 0.20 {0.0080}
flatness Do not grind for
direction:
repair.
0.03 {0.0012}
or less
AIR INTAKE SYSTEM (J08E) 4–1
AIR INTAKE SYSTEM (J08E)

4
4-001
AIR INTAKE MANIFOLD AND PIPE ........................... 4-2

DISMOUNTING AND MOUNTING ......................... 4-3
AIR INTAKE ................................................................. 4-4
OVERHAUL ............................................................ 4-6
AIR CLEANER ............................................................. 4-7
OVERHAUL ............................................................ 4-8
4–2 AIR INTAKE SYSTEM (J08E)
AIR INTAKE MANIFOLD AND PIPE
COMPONENT LOCATOR
EN01F01103030D01001001
(Example)
A
6
SHTS011030300001
1 Intake manifold 4 Intake pipe gasket

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

A 28.5 {291, 21}
SHTS011030300002
1 Intake manifold gasket 3 Intake pipe

2 Intake manifold 4 Intake pipe gasket

A 28.5 {291, 21}
4
AIR INTAKE MANIFOLD AND PIPE

EN01F01103030H01001001
IMPORTANT POINT - MOUNTING
1. INSTALL THE INTAKE MANIFOLD GASKET.

(1) Install the intake manifold gasket so that the protrusion is
positioned at the stud bolt side of the cylinder head rear end.
SHTS011030300003
4
AIR INTAKE
COMPONENT LOCATOR
EN01F01103030D01002001
B Z
2
5
1 6
7
4
A
5
5
Z
A
9
5
8
SHTS011030300004
1 Air cleaner 6 Air hose (Inter cooler)

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

A 5.4-6.6 {56-67, 4.0-4.8} B 4.5-5.5 {46-56, 3.4-4.0}
STACK DUCT
1
2
X
4
5
1
SHTS011030300005
1 Air intake bracket 5 Air hose

2 Intake pipe 6 Air guide plate
3 Pre-cleaner 7 Spring guide
4 Clamp
4
AIR INTAKE
OVERHAUL
EN01F01103030H02002001
1. INSTALL THE AIR HOSES.

(1) Install the air hoses as shown in the figure.
(2) Tighten the clamp.
Tightening Torque:
Clamp A: 5.4-6.6 N·m {56-67 kgf·cm, 4.0-4.8 lbf·ft}
Clamp B: 4.5-5.5 N·m {46-56 kgf·cm, 3.4-4.0 lbf·ft}
Air cleaner
Align the arrow mark

with the stopper's center.
Air hose
(Air cleaner)
Vehicle A
Front
B B
Air hose
(Inter cooler) Align the
arrow marks.
Intake pipe
(Mechanical pump)
Air hose
(Inter cooler)
Intake pipe
A Align the arrow mark

with the stopper's center.
(Common rail)
Air hose
(Inter cooler)
SHTS011030300006
AIR CLEANER
COMPONENT LOCATOR
EN01F01103030D01003001
1 2
SHTS011030300007
1 Body 4 Cover
2 Filter element 5 Clamp
3 Filter element (for dual element, if equipped) 6 Dust unloader valve
4
AIR CLEANER
OVERHAUL
EN01F01103030H02003001
IMPORTANT POINT - INSPECTION
1. INSPECTING
(1) If on inspection the dust indicator is red, clean or replace the
filter element.
(2) If the cover, body or dust unloader valve are damaged,
replace the parts.
(3) Check the filter element to see if it is flattened or deformed,
or whether the filter paper of the element is torn.
(4) Check to see if the sealing of the packing is complete.
! CAUTION
If an abnormality is found during the above inspection, replace the
element with a new one. If dust is taken into the engine, the engine
will wear and its performance will deteriorate.
EXHAUST SYSTEM (J08E) 5–1
EXHAUST SYSTEM (J08E)

5
5-001
EXHAUST MANIFOLD AND PIPE............................... 5-2

DISMOUNTING AND MOUNTING ......................... 5-3
EXHAUST PIPE AND MUFFLER ................................ 5-4
OVERHAUL ............................................................ 5-5
5–2 EXHAUST SYSTEM (J08E)
EXHAUST MANIFOLD AND PIPE
COMPONENT LOCATOR
EN01F01103040D01001001
SHTS011030400001
1 Heat insulator 7 Clamp

2 Exhaust connector 8 Hose
3 Coolant pipe 9 Intake pipe
4 Oil pipe 10 Exhaust manifold
5 Turbocharger 11 Exhaust manifold gasket *
6 Gasket 12 Spacer
*: Nonreusable part

A 53 {540, 39} B 61 {620, 44}
5

EXHAUST MANIFOLD AND PIPE

EN01F01103040H01001001
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.
SHTS011030400002
2. INSTALL THE EXHAUST MANIFOLD.

(1) Install the exhaust manifold onto the cylinder head and
TIGHTENING ORDER .... NEW MANIFOLD
tighten the mounting nut in the order shown in the figure to
18 17 16 15 14 13 12 11 10 9 8 7 the specified torque.
Tightening Torque:
1 2 5 6 (2) Retighten the same nuts according to the same procedure

3 4 again.
NOTICE
TIGHTENING ORDER .... REUSED MANIFOLD Be sure to carry out the procedure.
14 15 8 9 2 3 5 6 11 12 17 18
13 7 10 16
1 4
SPACER
SHTS011030400003
5–4 EXHAUST SYSTEM (J08E)
5
EXHAUST PIPE AND MUFFLER
COMPONENT LOCATOR
EN01F01103040D01002001
A
3
9 X Y
Vehicle Front
2 H H
3
4 5
F F
E E
7
7 8
8
6 6
D D
B C
View X View Y
Tightening order: D→B Tightening order: D→C
SHTS011030400004
1 Insulator 6 Clamp
2 Exhaust pipe 7 Exhaust pipe support
3 Gasket 8 Cushion
4 Muffler 9 Exhaust brake
5 Tail pipe

A 20-24 {204-244, 15-17} E 35 {357, 26} New flange (w/o grooves)
B 21-27 {215-275, 16-19} F 130 {1,326, 96}
C 29.5-37.5 {301-382, 22-27} G 56-84 {572-856, 42-61}
D 46-56 {470-571, 34-41} Old flange (w/grooves)
NOTICE
Unspecified tightening torque shall be as follows.
M14: T= 130 Nm {1,326 kgfcm, 96 lbfft}
5
EXHAUST PIPE AND MUFFLER
OVERHAUL
EN01F01103040H02002001

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

NOTICE
• Be particularly careful of rust holes and dents caused by flying
stones.
• If there are holes or cracks in the exhaust muffler and pipe, the
exhaust noise will increase. In addition, hot gas may blow out,
resulting in the risk of fire.
• If the exhaust muffler and pipe is severely dented by flying
stones, etc., the exhaust resistance will increase, causing out-
put decrease and resulting in an increase of fuel consumption.
SHTS011030400005
1. INSTALL THE EXHAUST MUFFLER AND PIPES.

NOTICE
• Replace the gasket with a new one.
• The mounting portion of the exhaust manifold is subjected to
heat and is likely to come loose, so special nuts are employed.
Be sure to use the correct nuts.
• When tightening the clamp, first tighten the upper bolt then the
lower bolt.
• Removal and installation should be done completely.
• Fit the clamp to the muffler as shown in the figure.
Slit • Caution when handling and assembling the catalytic muffler.

The ceramic part, which is easily broken, is contained inside the
muffler. Be careful not to apply shocks to it. Excessive loads,
hitting of hard things such as tools etc., onto the edges could
cause it to shatter and drop off.
! WARNING
If the position on the tail pipe is incorrect, exhaust fumes may
0 - 6mm blow onto passers by and burns may also result.
Clamp
SHTS011030400006
LUBRICATING SYSTEM (J08E) 6–1
LUBRICATING SYSTEM (J08E)

6
6-001
LUBRICATING SYSTEM ............................................. 6-2

DIAGRAM ............................................................... 6-2
OIL PUMP AND OIL STRAINER ................................. 6-4
OVERHAUL ............................................................ 6-6
INSPECTION AND REPAIR ................................... 6-7
OIL FILTER AND OIL COOLER .................................. 6-8
SPECIAL TOOL .................................................... 6-10
DISMOUNTING AND MOUNTING ....................... 6-10
6–2 LUBRICATING SYSTEM (J08E)
Mechanical Diagrams and Drive Belt/Chain Routing Schematic Diagrams
LUBRICATING SYSTEM
DIAGRAM
EN01F01103050J01001001
ROLLER
PIN
CAM ROLLER
CROSS ADJUST ROCKER ROCKER ARM

VALVE
HEAD SCREW ARM SHAFT
O CAM
I SHAFT
L
P
A CAM
N IDLE GEAR SHAFT
SUB
IDLE GEAR SHAFT
TURBO
CHARGER
S
T
R
A OIL OIL OIL MAIN
I PUMP COOLER FILTER OIL HOLE
N
E
R PISTON CONNECTING CRANK
PIN ROD SHAFT
AIR COMPRESSOR AIR

IDLE GEAR SHAFT COMPRESSOR
PISTON COOLING JET SUB

(CHECK VALVE) OIL HOLE
MAIN IDLE
GEAR SHAFT
: LUBRICATION
: RETURN
SHTS011030500001
ROLLER
PIN
CAM ROLLER
CROSS ADJUST ROCKER ROCKER ARM

VALVE
HEAD SCREW ARM SHAFT
O CAM
I SHAFT
L
P
A CAM
N IDLE GEAR
SHAFT
SUB
IDLE GEAR
SHAFT
TURBO
CHARGER
S
T
R
A OIL OIL OIL MAIN
I PUMP COOLER FILTER OIL HOLE
N
E
R
CONNECTING CRANK
ROD SHAFT
INJECTION
PUMP
AIR
COMPRESSOR
PISTON COOLING JET SUB

(CHECK VALVE) OIL HOLE
MAIN IDLE
GEAR SHAFT
: LUBRICATION
: RETURN
SHTS011030500002
6
OIL PUMP AND OIL STRAINER
COMPONENT LOCATOR
EN01F01103050D01002001
J08E-CR
1 A
8 9
SHTS011030500003
1 Gasket 6 Safety valve

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

A 28.5 {290, 21} B 30 {306, 22}
J08E-NB
SHTS011030500004
1 Gasket 6 Safety valve

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

A 28.5 {290, 21} B 30 {306, 22}
6
OVERHAUL
EN01F01103050H02002001
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 shown in the figure. Tighten them to the specified torque.
SHTS011030500005
6

EN01F01103050H03002001
Unit: mm {in.}
Gear outside diameter 54 {2.126} — — Measure
Block side pump body inside

54 {2.126} — —
diameter
0.093-0.252
Tip clearance 0.30 {0.0118} Replace pump.
{0.0037-0.0099}
Type A 37.5 {1.476} — —

Gear width
Type B 43.0 {1.692} — —
Measure
Block side Type A 37.5 {1.476} — —
pump body
inside depth Type B 43.0 {1.692} — —
0.047-0.150
With gasket 0.15 {0.0059} Replace pump.
{0.0019-0.0059}
End play
Without -0.013-0.050
— —
gasket {-0.0006-0.0019}
Shaft outside Measure

18 {0.709} — —
diameter
Block side
bushing
18 {0.709} — —
inside diame-
Drive gear ter
0.040-0.099 Replace pump or

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

18 {0.709} — —
diameter
Block hole
18 {0.709} — —
diameter
0.030-0.075
Clearance — Replace pump.
{0.0012-0.0029}
Driven gear
Gear bush-
ing inside 18 {0.709} — —
diameter
0.040-0.083 Replace pump or

Clearance 0.15 {0.0059}
{0.0016-0.0032} gear.
Measure
0.073-0.207
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0081}
6
OIL FILTER AND OIL COOLER
COMPONENT LOCATOR
EN01F01103050D01003001
SHTS011030500011
1 Oil cooler with filter assembly 6 Regulator valve

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

A 24.5-34.3 {250-349, 19-25} D 19.6-29.4 {200-300, 15-21}
B 24.5-34.3 {250-350, 19-25} E 28.5 {291, 21}
C 8-12 {82-122, 6-8} F 24.5-32.3 {250-329, 19-23}
SPECIAL TOOL
EN01F01103050K01003001
Prior to starting an engine overhaul, it is necessary to have this special tool.
S0950-31110 OIL FILTER WRENCH
6

EN01F01103050H01003001
1. REMOVE THE OIL FILTER.

(1) Remove the drain plug from bottom of the oil filter and drain
the engine oil.
SHTS011030500013
(2) Using the special tool, remove the oil filter.

SST: S0950-31110
Oil filter wrench
NOTICE
Make sure that O-rings are not on the oil cooler case side.
SHTS011030500014
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: S0950-31110
Oil filter wrench
NOTICE
• Do not reuse the O-ring.
SHTS011030500015
• 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.
• Do not reuse the O-ring and gasket.
• Attention the O-ring to damage.
(2) Apply liquid gasket to the oil cooler case and install it onto the
cylinder block, then tighten the bolt to the specified torque.
Tightening Torque:
28.5 N·m {291 kgf·cm, 21 lbf·ft}
SHTS011030500016
6

EN01F01103050H03003001
Oil cooler air leakage Air Visual check

Replace
pressure: 588 kPa {6 kgf/cm2, 0 mL —
if necessary.
85 lbf/in.2}
1. Damage to sliding
Wear or damage to valve
Replace face of valve
spring of oil cooler and oil fil- — —
if necessary. 2. Valve movement
ter
(smoothness)
COOLING SYSTEM (J08E) 7–1
COOLING SYSTEM (J08E)

7
7-001
COOLING SYSTEM ..................................................... 7-2

DIAGRAM ............................................................... 7-2
COOLANT PUMP ........................................................ 7-3
SPECIAL TOOL ...................................................... 7-4
OVERHAUL ............................................................ 7-5
INSPECTION AND REPAIR ................................... 7-8
THERMOSTAT ............................................................. 7-9
OVERHAUL .......................................................... 7-10
RADIATOR ................................................................. 7-12
SPECIAL TOOL .................................................... 7-13
OVERHAUL .......................................................... 7-13
COOLING FAN........................................................... 7-18
7–2 COOLING SYSTEM (J08E)
COOLING SYSTEM
DIAGRAM
EN01F01103060J01001001
FOR COOLING ENGINE

1 FOR COOLING AUXILIARY UNITS
4
2
5
10
3 11
9
8
7 12
13 13
SHTS011030600001
1 Reservoir tank 8 Air compressor

2 Radiator cap 9 Turbocharger
3 Radiator 10 Cylinder head
4 Coolant temperature gauge 11 Cylinder block
5 Thermostat case 12 Oil cooler
6 Thermostat 13 Drain plug
7 Coolant pump
230_Engine7.fm 3 ページ２０１４年８月２５日　月曜日　午後８時１分
7
COOLANT PUMP
COMPONENT LOCATOR
EN01F01103060D01002001
11
10
7
6
5
4
SHTS011030600002
1 Fan pulley 6 Coolant shaft

2 O-ring 7 Pump case
3 Coolant pump assembly 8 Coolant seal
4 Pulley center 9 Vane
5 Retainer ring
7
COOLANT PUMP
SPECIAL TOOL
EN01F01103060K01002001
For coolant pump pulley

S0942-01810 PULLER
center
S0942-01820 PULLER For coolant pump vane
S0948-22060 PRESS For coolant pump seal

7
COOLANT PUMP
OVERHAUL
EN01F01103060H02002001
1. DISASSEMBLE THE COOLANT PUMP.

(1) Remove the vane from the shaft using the special tool.
SST: S0942-01820
Puller
SHTS011030600006
(2) Remove the pulley center from the shaft using the special
tool.
SST: S0942-01810
Puller
SHTS011030600007
(3) Remove the retainer ring from the pump case using snap ring
pliers.
SHTS011030600008
(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.
SHTS011030600009
(5) Remove the coolant seal from the pump case using a ham-
mer and brass bar.
! WARNING
Impact due to punching may cause metal chips to fly up. Be sure
to wear protective goggles.
NOTICE
Replace the removed coolant seal with a new one. Never reuse it.
SHTS011030600010
1. ASSEMBLE THE COOLANT PUMP.

(1) Install the coolant shaft onto the pump case using a hydraulic
press.
Assembly standard (A): 4.9-5.1 mm {0.193-0.2007 in.}
NOTICE
Press until the bearing upper end surface comes into contact with
the retainer ring groove lower end surface.
SHTS011030600011
(2) Install the retainer ring onto the pump case using snap ring
pliers.
SHTS011030600012
(3) Install the pulley center onto the shaft using a hydraulic
press.
Standard: 149.7-150.5 mm {5.894-5.925 in.} from the pulley
center mounting surface to the pump case end
surface
SHTS011030600013
(4) Install the new coolant seal.

a. Apply liquid gasket (ThreeBond #1104 or equivalent) to the
seal outer circumference and case bore.
b. Install the slinger and seal to the case using a press.
SST: S0948-22060
Press
SHTS011030600014
c. Install the seal to the vane.

APPLY LIQUID GASKET NOTICE
Replace the coolant seal with new one.
CASE
SLINGER
SEAL
VANE
SHAFT
SEAL
SHTS011030600015
(5) Install the vane onto the shaft using a hydraulic press.
Assembly standard (B): 0.7-1.3 mm {0.0275-0.0511 in.}
NOTICE
Press until the vane end face comes into contact with the shaft
end surface.
(6) After assembly, turn the shaft by hand and make sure that
there is no noise, catching or rough movement in the shaft
direction and that it rotates smoothly.
SHTS011030600016
7
COOLANT PUMP

EN01F01103060H03002001
Unit: mm {in.}
Visual check
Wear, damage and corrosion — — Replace parts.
Measure
0.015-0.048 Replace shaft

Tightness of shaft and vane —
{0.0006-0.0018} and/or vane.
Measure
Replace shaft
Tightness of shaft and pulley 0.029-0.063
— and/or pulley
center {0.0012-0.0024}
center.
NOTICE
• Tightness = Outside diameter - Inside diameter
• Prevent a reassembly more than three times even if it is within
the standard value.
7
THERMOSTAT
COMPONENT LOCATOR
EN01F01103060D01003001
2
3
1
4
5
6
2
SHTS011030600020
1 Thermostat case assembly 4 Thermostat case

2 Thermostat case cover 5 Thermostat
3 O-ring 6 Gasket
7
THERMOSTAT
OVERHAUL
EN01F01103060H02003001
IMPORTANT POINT - INSPECTION AND REPAIR
1. INSPECT THE THERMOSTAT FUNCTION.

T1 : Valve opening temperature (1) Place the thermostat in hot water and check the valve open-
T2 : Valve opened temperature ing temperature and the valve lift.
13 mm
{0.512 in.} Thermostat valve opening temperature:
Thermostat valve opening

Service standard
temperature. (T1)
82C {180F} 80-84C {176-183F}
NOTICE
SHTS011030600021
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
Thermostat valve lift:
Thermostat valve Measuring temp.

Valve lift (L2-L1)
opening temp. (T1) (T2)
13 mm {0.512 in.}
L 1: When cold 82C {180F} 95C {203F}
or more
L 2: When (T2 ) C
L 2-L1: Valve lift
(2) Immerse the opened thermostat in water at normal tempera-
ture. If it completely closes within 5 minutes, it is satisfactory.
If it remains slightly open, it is defective and must be
replaced.
SHTS011030600022
1. ASSEMBLE THE THERMOSTAT CASE.

(REPRESENTATIVE TYPE) NOTICE
JIGGLE • Remove water or dirt adhering to the thermostat case.
VALVE
• Be sure to replace the gasket if it is corroded, damaged or flat-
tened.
• 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.
• Be sure that the jiggle valve faces upward when installing it.
SHTS011030600023
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.
(3) Temporarily tighten the bolts "1" and bolts "2" in that order,
and securely contact the fitting surface.
(4) Tighten the bolts in numeral order.
SHTS011030600024
"2"
"1"
SHTS011030600025
RADIATOR
COMPONENT LOCATOR
EN01F01103060D01004001
12
B
1
7
10
11 A
B
12
9
4
8
7
6
5
14
13
13
In case of vehicle without under cover In case of vehicle with under cover
SHTS011030600026
1 Radiator cap 8 Distance piece

2 Upper tank 9 Radiator fitting cushion
3 Radiator core 10 Right support
4 Left support 11 Coolant level switch
5 Drain plug 12 Hose
6 Lower tank 13 Baffle plate
7 O-ring 14 Intercooler

A 6-7 {62-71, 4.5-5.1} B 14-20 {143-203, 11-14}
7
RADIATOR
SPECIAL TOOL
EN01F01103060K01004001
Prior to starting a radiator overhaul, it is necessary to have these special tools.
S0976-01030 RADIATOR TOOL For uncaulking
For caulking
S0976-01040 RADIATOR TOOL
(Used with S0976-01030)
7
RADIATOR
OVERHAUL
EN01F01103060H02004001
1. DISMOUNT THE RADIATOR.

! WARNING
• Never remove the radiator cap when the coolant temperature is
high.
• To avoid the danger of burns and scalds, do not drain the cool-
ant while the engine and radiator are still hot.
NOTICE
When dismounting and mounting the radiator, do not damage the
radiator core.

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

ATOR CORE.
(1) Remove the left support and right support.
SHTS011030600029
(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: S0976-01030
Radiator tool
NOTICE
Be sure to adjust the dimension to prevent damage of the crow.
SHTS011030600030
(3) Using a special tool, lift the staked part.

NOTICE
Do not lift up tangs more than 90.
SHTS011030600031
(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.
SHTS011030600032
1. ASSEMBLE THE UPPER TANK, LOWER TANK AND RADIA-

TOR CORE.
(1) Exchange the crow of the radiator tool (S0976-01030) for the
radiator tool (S0976-01040) as shown in the figure.
SST: S0976-01030
Radiator tool
S0976-01040
Radiator tool
SHTS011030600033
230_Engine7.fm 15 ページ２０１４年８月２６日　火曜日　午後２時１１分
(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: 10 mm {0.394 in.}
SHTS011030600034
(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
radiator core.
SHTS011030600035
(5) Flap the tangs to obtain a tight contact with the upper tank
and lower tank.
SHTS011030600036
(6) Press the radiator tool (caulking tool) against the side por-
tion. 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.
SHTS011030600037
230_Engine7.fm 16 ページ２０１４年８月２６日　火曜日　午後２時１１分
NOTICE
Perform the caulking according to the sequence as shown in the
figure.
SHTS011030600038
(7) Check the dimension C.

TANK Assembly standard: 8.12-8.7 mm {0.3197-0.3425 in.}
If the dimension is out of the standard value, adjust the stop-
per bolt of the handle once again and perform the caulking
again.
CORE PLATE
SHTS011030600039
7
RADIATOR

EN01F01103060H03004001
Unit: kPa {kgf/cm2, lbf/in.2}
Air leakage (When the air Visual check

pressure of 177 {1.8, 25.67} is — — Replace radiator.
applied.)
Clogging of the Fines — — Clean.
Measure
Radiator cap
39-59
valve
Mark 0.5 {0.4-0.6, 5.66- — Replace.
opening
8.55}
pressure
Intercooler
Replace the
• Air leakage test 0 mL —
intercooler.
(when the air pressure of
177{1.8, 25.67} is applied.)
• Clogging of the fins
— — Clean.
NOTICE
• The coolant filler cap valve opening pressure is indicated on the
cap and it should be confirmed. If the cap pressure is incorrect,
there is a risk of abnormally high pressure being generated in
the cooling system, which may cause the hose to drop off or
burst and may result in the damage of the engine.
• When carrying out high pressure washing to remove fin clog-
ging, do not apply excessive pressure to the fins which may
cause deformation and consequent performance deterioration.
230_Engine7.fm 18 ページ２０１４年８月２６日　火曜日　午前９時３９分
7
COOLING FAN
COMPONENT LOCATOR
EN01F01103060D01006001
SHTS011030600043
1 Cooling fan 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 dam-
aged 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 per-
formance will be erratic, and may result in overheating or overcooling. In such case, carefully remove mud and
dust adhering to the surface of the bimetal, using a wire brush, or the like.
Take particular care not to apply excessive force.
Do not paint the fan or fan clutch. Do not place any paint or other reagents which are likely to dissolve plastic in
contact with the fan.
7

COOLING FAN

EN01F01103060H03006001
Visual check
Cooling fan and fan clutch Replace

— —
deformation and damage if necessary.
230_Engine8.fm 1 ページ２０１４年８月２７日　水曜日　午前１１時３７分
FUEL SYSTEM (J08E) 8–1
FUEL SYSTEM (J08E)

8
8-001
FUEL SYSTEM (J08E-WM, WL, WK) ......................... 8-2

DIAGRAM ............................................................... 8-2
FUEL SYSTEM (J08E-UF, UG, UH) ............................ 8-3
DIAGRAM ............................................................... 8-3
FUEL SYSTEM (J08E-UF, UG, UH) ............................ 8-5
SPECIAL TOOL ...................................................... 8-5
OVERHAUL ............................................................ 8-5
SUPPLY PUMP (J08E-WM, WL, WK) ......................... 8-8
SPECIAL TOOL .................................................... 8-10
OVERHAUL .......................................................... 8-11
INJECTOR (J08E-WM, WL, WK)............................... 8-19
OVERHAUL .......................................................... 8-21
INJECTION NOZZLE (TWO-SPRING TYPE)
[J08E-UF, UG, UH]..................................................... 8-28
DESCRIPTION ..................................................... 8-28
SPECIAL TOOL .................................................... 8-30
OVERHAUL .......................................................... 8-31
COMMON RAIL (J08E-WM, WL, WK) ...................... 8-37
DESCRIPTION ..................................................... 8-37
INSPECTION........................................................ 8-39
REPLACEMENT ................................................... 8-40
MAIN FUEL FILTER (ENGINE MOUNT)
[J08E-WM, WL, WK].................................................. 8-45
DESCRIPTION ..................................................... 8-45
OVERHAUL .......................................................... 8-47
MAIN FUEL FILTER (CHASSIS MOUNT)
[J08E-WM, WL, WK].................................................. 8-51
PRE FUEL FILTER .................................................... 8-52
FUEL TANK ............................................................... 8-53
OVERHAUL .......................................................... 8-56
8–2 FUEL SYSTEM (J08E)
FUEL SYSTEM (J08E-WM, WL, WK)
DIAGRAM
EN01F01103070J01017001
COMMON RAIL SYSTEM
Final fuel filter Pressure

(Engine mount) limiter
Common rail
Injector
Pre fuel filter

(Chassis mount)
Supply pump
Main fuel filter

(Chassis mount)
: Suction line
: Positive pressure line
: High pressure line
: Return line
Fuel tank
SHTS011030700001
8
FUEL SYSTEM (J08E-UF, UG, UH)
DIAGRAM
EN01F01103070J01018001
INJECTION PUMP SYSTEM
SHTS011030700002
1 Return pipe 5 Feed pump

2 Injection nozzle 6 Fuel filter
3 Through feed pipe 7 Injection pipe
4 Fuel tank
8
COMPONENT LOCATOR
EN01F01103070D01018001
SHTS011030700003
1 Injection nozzle 3 Fuel injection pump

2 Fuel filter

A 12.3 {125, 9} C 25 {250, 18}
B 34 {350, 25}
8
SPECIAL TOOL
EN01F01103070K01018001
S0950-31040 FUEL FILTER WRENCH
INJECTION PUMP
S0981-91707
COUPLING WRENCH
8
OVERHAUL
EN01F01103070H02018001
IMPORTANT POINT - DISASSEMBLING
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: S0981-91707
(3) Remove the injection pump installing bolt and remove the
pump.
SST: S0981-91707
SHTS011030700006 NOTICE
After removing the pump, cover the pump and high pressure pipe
to prevent entry of dirt.
IMPORTANT POINT - INSTALLING
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 hous-
ing to injection timing before top dead center for No.1 cylinder
compression stroke.
SHTS011030700007
(2) Turn the timer counterclockwise slowly viewed from the cou-
pling (normal direction of engine) and align the mark on the
timer with the mark on the injection pump pointer.
SHTS011030700008
(3) Tighten the injection pump installing bolt evenly to the torque
below.
SST: S0981-91707
Tightening Torque:
SHTS011030700009
(4) Tighten the adjusting bolt using the special tool.

SST: S0981-91707
Tightening Torque:
61.3 N·m {625 kgf·cm, 45 lbf·ft}
(5) Tighten the through bolt at the flange.

Tightening Torque:
90.7 N·m {925 kgf·cm, 67 lbf·ft}
(6) Install pipes and engine control cables.

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

(1) Remove the fuel filter using the special tool.
SST: S0950-31040
Fuel filter wrench
SHTS011030700011
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
288 (8/10 turn).
SST: S0950-31040
Fuel filter wrench
NOTICE
• Do not reuse the element.
SHTS011030700012 • Be careful not to damage the gasket.
AIR BLEEDING FROM FUEL SYSTEM
1. BLEED AIR FROM THE FUEL FILTER.

BLEEDER PLUG (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}
NOTICE
The bleeder plug should be tightened while the priming pump
SHTS011030700013
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.
8
SUPPLY PUMP (J08E-WM, WL, WK)
COMPONENT LOCATOR
EN01F01103070D01019001
2 A
SHTS011030700014
1 Return pipe No.1 3 Supply pump assembly

2 Pressure feeding pipe *
*: Nonreusable part

A 44 {449, 32}
SHTS011030700015
1 Supply pump assembly

1 A
SHTS011030700016
1 Supply pump assembly 5 Bearing holder case

2 O-ring * 6 Coupling assembly
*: Nonreusable part

A 28.5 {290, 21}
8
SPECIAL TOOL
EN01F01103070K01019001
Prior to starting an engine overhaul, it is necessary to have the special tool.
SZ105-08067 GUIDE BOLT

8
OVERHAUL
EN01F01103070H02019001
REMOVING THE SUPPLY PUMP

NOTICE
While working, be careful not to make dirt and water enter parts.
1. TURNING THE STARTER SWITCH TO THE LOCK POSITION

! WARNING
Perform the following work after the engine cools off to avoid fire
or burning. The fuel in the common rail could have a high temper-
ature (approximately 100C {212F}) immediately after driving.
SHTS011030700018
2. DRAINING THE FUEL

AIR BLEEDING (1) Prepare reservoir under the drain pipe to receive the drained
PLUG fuel.
(2) Loosen the drain plug and then the air bleeding plug of the
main fuel filter (engine mount), and drain fuel from the drain
pipe. Check that no fuel is drained from the drain pipe before
tightening the drain plug.
Tightening Torque:
DRAIN
DRAIN 4.9-8.9 N·m {50-90 kgf·cm, 3.7-6.5 lbf·ft}
PLUG
PIPE
NOTICE
SHTS011030700019
Dispose of the drained fuel in accordance with the regulation of
disposal specified in each region.
3. REMOVING THE MAIN FUEL FILTER CASE

(1) Remove the main fuel filter case and the fuel pipe.
4. REMOVING THE INTAKE PIPE

(1) Remove the intake pipe.
Reference: AIR INTAKE SYSTEM (J08E)
5. DISCONNECTING THE HARNESS

SUCTION (1) Disconnect the connector connected to each of the suction
CONTROL VALVE control valve of the supply pump.
SHTS011030700020
6. REMOVING THE FUEL PIPE

(EXAMPLE) (1) Remove the 2 nuts to remove the 2 clips.
(2) Remove the union 3 bolts securing return pipe No.1 to the
pressure limiter, the inlet manifold, and the supply pump, and
disconnect the return pipe No.1.
RETURN PIPE No.1
HINT
Prepare a reservoir and waste cloths because fuel spills when dis-
connecting the fuel pipe.
SUPPLY PUMP
SHTS011030700021
7. REMOVING THE PRESSURE FEEDING PIPE

(EXAMPLE) (1) Remove the 2 nuts securing the clips, and remove the 2 clips.
(2) Loosen the nut, and remove the pressure feeding pipe.
HINT
PRESSURE
FEEDING PIPE Prepare a reservoir and waste cloths because fuel spills when
removing the pressure feeding pipe.
SHTS011030700022
8. SETTING THE COMPRESSION STROKE TOP DEAD CENTER

OF No.1 CYLINDER
(1) Remove the 2 bolts securing the flywheel housing cover, and
remove the flywheel housing cover from the flywheel hous-
ing.
FLYWHEEL
HOUSING
COVER
SHTS011030700023
(2) Turn the crankshaft in the direction of engine revolution

(counterclockwise viewed from the flywheel side) to align the
timing mark ruling on the flywheel periphery to "16" (vehicle
FLYWHEEL equipped with manual transmission).
FLYWHEEL
HOUSING
SHTS011030700024
(3) Remove the timing check window plug from the bearing
BEARING HOLDER CASE holder case of the supply pump.
(4) Install the special tool specified below to the timing check
SEATED window of the bearing holder case to see that the bearing
CORRECT surface of the special tool is seated on the supply pump.
SST: SZ105-08067
SST Guide bolt
NOT NOTICE
SEATED
• If the special tool is not seated, it is in contact with a part other
than the detent of the coupling flange. Do not forcibly tighten
INCORRECT
the special tool.
SHTS011030700025 • If the special tool is not seated, the No.1 cylinder is not set at
the compression stroke top dead center. In this case, remove
the special tool, turn the crankshaft, and install the special tool
again to see if it is seated.
• Before turning the crankshaft, do not fail to pull out the special
tool.
• Do not perform cranking with the special tool inserted.
9. REMOVING THE SUPPLY PUMP

NOTICE
DO NOT REMOVE PIPE B
• While working, be careful not to make dirt and water enter parts.
• Do not remove pipe A and pipe B.
• Be careful not to apply excessive load on pipe A and pipe B.
(Pipe twist will cause fuel leakage.)
• Do not hold pipe A or pipe B when carrying the pump.
DO NOT
REMOVE PIPE A
SHTS011030700026
INCORRECT CORRECT
DO NOT GRIP PIPES AND JOINT BOLTS WHEN HOLDING THE SUPPLY PUMP HOLD IN YOUR ARMS
SHTS011030700027
(1) Remove the 4 bolts securing the supply pump, and remove
COUPLING AIR COMPRESSOR the supply pump, the coupling, and the O-ring from the air
compressor.
BEARING HOLDER
CASE NOTICE
Remove the supply pump and the bearing holder case together.
SUPPLY PUMP O-RING

SHTS011030700028
(2) Remove the nut with the coupling flange locked with a vise,
BEARING HOLDER CASE and remove the coupling flange.
SHAFT
NUT
COUPLING FLANGE
SHTS011030700029
(3) Remove the 3 bolts to remove the bearing holder case and
BEARING the O-ring from the supply pump.
HOLDER CASE
SUPPLY PUMP
O-RING
BOLT
SHTS011030700030
INSPECTING THE COMPONENT PARTS
1. INSPECTING THE SUCTION CONTROL VALVE AND THE FUEL

SUCTION CONTROL TEMPERATURE SENSOR
VALVE (1) Using the HINO DX Ⅱ , inspect the suction control valve. If
some abnormalities are found, replace the supply pump.
SHTS011030700031
2. INSPECTING THE RESISTANCE OF THE SUCTION CONTROL

VALVE
SUCTION CONTROL (1) Using the circuit tester, measure the resistance between the
VALVE terminals. If the measured value is in excess of the standard
value, replace the supply pump.
Standard value (at a temperature of 20C {68F}): 7.65-
8.15 
NOTICE
If SCV and fuel temperature sensor need replacement, they should
be serviced by DENSO Service Dealer.
SHTS011030700032
INSTALLING THE SUPPLY PUMP

NOTICE
• Before installing parts, make sure that there is no dirt on the
connection between them.
• If air enters the fuel pipe in the process of installing the pre fuel
filter case, after installing is completed, thoroughly purge air
from the fuel pipe.
1. SETTING THE COMPRESSION STROKE TOP DEAD CENTER

OF No.1 CYLINDER
(1) Turn the crankshaft in the direction of engine revolution
(counterclockwise viewed from the flywheel side) to align the
FLYWHEEL timing mark ruling on the flywheel periphery to "16" (vehicle
equipped with manual transmission).
FLYWHEEL
HOUSING
SHTS011030700033
2. ADJUSTING THE TOP OF THE AIR COMPRESSOR

(1) Align the cast mark on the air compressor with the "" mark
STAMP "0" MARK put on the front face of the coupling.
ON FRONT FACE
CAST MARK
SHTS011030700034
3. INSTALLING THE SUPPLY PUMP

BEARING HOLDER CASE (1) Replace the O-ring with a new one, and install the bearing
holder case to the supply pump with the 3 bolts.
SUPPLY PUMP
Tightening Torque:
28.5 N·m {291 kgf·cm, 21 lbf·ft}
O-RING
BOLT
SHTS011030700035
(2) Install the coupling flange to the shaft.

BEARING HOLDER CASE
(3) Fix the supply pump and tighten the nuts while preventing the
coupling flange from rotating with the vise.
SHAFT Tightening Torque:
63.7 N·m {650 kgf·cm, 47 lbf·ft}
NOTICE
NUT
Do not use an special tool to lock the shaft.
COUPLING FLANGE
SHTS011030700036
(4) Insert the special tool specified below into the bearing holder
BEARING HOLDER CASE case and bring it into close contact with the detent of the cou-
pling flange.
SST: SZ105-08067
Guide bolt
COUPLING NOTICE
FLANGE • Do not tighten the special tool by applying it to a part other than
SST
the detent of the coupling, or do not use a tool other than the
special tool for locking.
• The special tool is not designed to allow its tip to come into
DETENT HOLE
contact with the end of the detent hole. (The clearance at the tip
SHTS011030700037
is 2 mm {0.079 in.}.)
(5) Replace with a new O-ring, and install the coupling and the
COUPLING AIR COMPRESSOR supply pump to the air compressor using the 4 bolts.
BEARING HOLDER Tightening Torque:
CASE 28.5 N·m {291 kgf·cm, 21 lbf·ft}
NOTICE
Install the coupling and the supply pump to the air compressor
with the No.1 cylinder set at the compression stroke top dead cen-
ter and the cast mark on the air compressor and the "" mark on
the front face of the coupling aligned with each other.
SUPPLY PUMP O-RING
SHTS011030700038
(6) Make sure that the No.1 cylinder is set at the compression
stroke top dead center, and then remove the special tool and
BEARING HOLDER CASE
install the timing checking window plug.
NOTICE
• After all parts are assembled, do not fail to remove the special
tool and install the timing checking window plug.
• Before turning the crankshaft, do not fail to pull out the special
SST tool.
• Do not perform cranking with the special tool inserted.
(7) Tighten the two bolts on the bracket.
SHTS011030700039 Tightening Torque:
68.5 N·m {700 kgf·cm, 50.6 lbf·ft}
NOTICE
Once the bolts have been tightened to a point where the bracket is
in contact with both the surface of the cylinder block and the sur-
face of the bearing holder case tighten fully by alternating
between the bolts on either surface.
(8) Remove the SST and install the plug.
(9) Install the flywheel housing cover to the flywheel housing with
the 2 bolts.
Tightening Torque:
5 N·m {51 kgf·cm, 3.7 lbf·ft}
FLYWHEEL
HOUSING
COVER
SHTS011030700040
4. INSTALLING THE PRESSURE FEEDING PIPE

(EXAMPLE) (1) Install the pressure feeding pipe.
Tightening Torque:
44 N·m {449 kgf·cm, 32.5 lbf·ft}
PRESSURE
FEEDING PIPE
(2) Install the 2 clips with the 2 nuts and fix the pressure feeding
pipe.
! CAUTION
Always replace the pressure feeding pipe by a new one because
the pipe is subjected to high pressure; reusing the same pipe
result in a fuel leak.
SHTS011030700041
5. INSTALLING THE FUEL PIPE

(EXAMPLE) (1) Replace the gasket with a new one, and install return pipe
No.1 on the supply pump, the inlet manifold, and the pressure
limiter with the 3 union bolts that secured the return pipe.
Tightening Torque:
(Supply pump side)
RETURN PIPE No.1 7.9-12.7 N·m {81-129 kgf·cm, 6-9 lbf·ft}
(Intake manifold side)
SUPPLY PUMP (Pressure limiter side)
SHTS011030700042
(2) Install the 2 clips with the 2 nuts and fix the return pipe.
6. CONNECTING THE HARNESS

SUCTION CONTROL (1) Connect the connector to the suction control valve of the sup-
VALVE ply pump.
NOTICE
Before connecting the connectors, make sure that the terminals
are free of a spark mark.
SHTS011030700043
7. INSTALLING THE INTAKE PIPE

(1) Install the intake pipe.
Reference: AIR INTAKE SYSTEM (J08E)
8. INSTALLING THE MAIN FUEL FILTER CASE

(1) Install the main fuel filter case and the fuel pipe.
9. AIR BLEEDING OF FUEL SYSTEM

(1) Operate the priming pump to purge air from the fuel system.
8
INJECTOR (J08E-WM, WL, WK)
COMPONENT LOCATOR
EN01F01103070D01020001
SHTS011030700044
1 Injector harness
5 3
C
4
2
SHTS011030700045
1 Injection pipe * 4 Clamp

2 Injector 5 Clamp bolt
3 Connector 6 O-ring *
*: Nonreusable part

A 44 {449, 32} C 12.3 {125, 9}
B 25 {255, 18}
8
INJECTOR (J08E-WM, WL, WK)
OVERHAUL
EN01F01103070H02020001
REMOVING THE INJECTOR

NOTICE
• Clean off surrounding area of the injectors and fuel line connec-
tors.
1. REMOVING THE HEAD COVER

(1) Remove the head cover.
Reference: ENGINE MECHANICAL (J08E)
2. REMOVING THE LEAKAGE PIPE

UNION BOLT (1) Remove the 7 union bolts to remove the leakage pipe and the
UNION BOLT
7 gaskets.
NOTICE
The leakage pipe can be twisted easily. Take care in handling.
LEAKAGE PIPE
SHTS011030700046
3. REMOVING THE INJECTOR HARNESS

INJECTOR HARNESS CONNECTOR (1) Disconnect each connector connected to the injector.
BRACKET (2) Remove the 7 nuts securing the injector harness, and
remove the injector harness together with the injector har-
ness bracket.
INJECTOR
HARNESS NOTICE
The injector harness bracket can be twisted easily. Take care in
handling.
NUT
SHTS011030700047
HINT
CONNECTOR It is easy to disconnect the connectors by last disconnecting the
one connected to the camshaft housing.
INJECTOR CAMSHAFT
HARNESS HOUSING
SHTS011030700048
4. REMOVING THE INJECTION PIPE

(1) Remove the 6 nuts securing the clips, and remove the clips.
SHTS011030700049
(2) Loosen the nuts securing the 6 injection pipes to remove

them from the injector and the common rail.
NOTICE
Do not reuse the injection pipes.
HINT
Prepare a reservoir and waste cloths because fuel spills when
removing the injection pipes.
SHTS011030700050
5. REMOVING THE INJECTOR

(1) Remove the 2 bolts to remove the 6 injection pipe oil seals
PLATE and 6 plates from the cylinder head.
INJECTION PIPE
OIL SEAL
BOLT
SHTS011030700051
(2) Remove the injector clamp installing bolts to remove the

INJECTOR injector and injector clamp.
BOLT
(3) Remove the O-ring.
INJECTOR
CLAMP NOTICE
Replace the O-ring with a new one.
O-RING
SHTS011030700052
SINGLE UNIT INSPECTION
1. INSPECTING THE RESISTANCE

(1) Using the 1,000V megohmmeter, measure the insulation
MEGOHMMETER
resistance between either of the 2 terminals (no polarity) to
which the injector harness is connected and the upper body
of the injector.
UPPER BODY
NOTICE
Never measure between the terminals, or the injector will be dam-
aged.
Standard value (Room temperature):
10 M or more (Use a 1,000V megohmmeter.)
SHTS011030700053
(2) Using the circuit tester, measure the resistance between ter-
minals.
Standard value (at a temperature of 20C {68F}): 0.37-
0.57 
UPPER BODY (3) The resistance values of (1) and (2) exceed the standard
value, replace the injector.
2. CLEANING THE INJECTOR

(1) Use clean cloths to remove sludge adhered to the terminal
part and its perimeter.
NOTICE
SHTS011030700054 • Use clean cloths to wipe off sludge without using any detergent.
• Use of detergent causes it to penetrate, which may lead to elec-
tric failure.
3. CLEANING THE INSIDE OF THE NOZZLE SEAT

CYLINDER HEAD (1) If sludge sticks to the inside of the nozzle seat, spray a deter-
gent over it, wipe it off with a waste cloth, and wash it out with
the detergent.
HINT
• If sludge sticks hard to the inside of the nozzle seat, remove it
NOZZLE SEAT with brush and a detergent.
• It is advisable to perform a contact check using red lead primer.
(2) Make sure that the inside of the nozzle seat is free of sludge
or foreign matters.
SHTS011030700055
INSTALLING THE INJECTOR

NOTICE
• If air enters the fuel pipe in the process of installing the pre fuel
filter case, after installing is completed, thoroughly purge air
from the fuel pipe.
1. INSTALLING THE INJECTOR AND THE INJECTION PIPE

(1) Apply engine oil to a new O-ring and properly install it to the
groove on the head side. Install the injector. Then temporarily
fit the injector clamp and injector at the same time.
BOLT INJECTOR NOTICE
• Apply engine oil to the O-ring. Take care not to get the O-ring
INJECTION jammed when inserting it.
PIPE
• Note that if the O-ring is caught or damaged, fuel will enter,
which will result in oil burning and eventually the inability to
install/remove the nozzle holder.
• Do not fix the injector clamp until the injection pipe is fit tempo-
rarily.
(2) Install a new injection pipe oil seal on the injector, and install
BOLT the plate with the 2 bolts that secured it.
INJECTOR PLATE NOTICE
CLAMP Install the injection pipe oil seal so that excessive force will not be
INJECTION PIPE applied to the injection nozzle. (If the injection pipe oil seal and
OIL SEAL the injection nozzle are out of position, oil leakage or improper
O-RING
assembly of the injection pipe will result.)
SHTS011030700056
(3) Temporarily install 6 new injection pipes on the injector and

the common rail.
! CAUTION
• Do not fail to replace the injection pipes with new ones because
they are subjected to high pressure and may cause fuel leak-
age.
• Fuel will leak out if the injection pipes are not properly con-
nected. Follow the procedure.
• Fuel leakage will cause damage to the engine.
NOTICE
SHTS011030700057 Arrange the injector and the injection pipes in a straight line.
INJECTOR CLAMP INJECTION PIPE
INJECTOR
SHTS011030700058
(4) Tighten the injector clamp installing bolt.

INJECTOR Tightening Torque:
BOLT
NOTICE
• Insufficient tightening will cause gas leakage, which will result
in the seizure of the nozzle.
INJECTOR • Before reusing the injector clamp bolt, be sure to apply oil to the
CLAMP washer and thread part.
• Tighten the bolt by using the torque wrench, tighten with the
specified torque.
SHTS011030700059
(5) Tighten the injection pipe to the specified torque.

Tightening Torque:
SHTS011030700060
(6) Install the clips with the 6 nuts, and fix the injection pipes.
SHTS011030700061
2. INSTALLING THE INJECTOR HARNESS

INJECTOR HARNESS CONNECTOR (1) Install the injector harness together with the injector bracket
BRACKET with the 7 bolts that secured them.
(2) Connect each connector of the injector harness.
INJECTOR NOTICE
HARNESS Before connecting the connectors, make sure that the terminals
NUT
SHTS011030700062
HINT
CONNECTOR It is easy to connect the connectors by first connecting the one to
the camshaft housing.
INJECTOR
HARNESS
CAMSHAFT HOUSING
SHTS011030700063
3. INSTALLING THE LEAKAGE PIPE

UNION BOLT UNION BOLT (1) Remove dirt or foreign matters from the gasket installing sur-
face.
(2) Replace the gasket with a new one, and install the leakage
pipe on the injector and the camshaft housing with the 7
union bolts that tightened them.
Tightening Torque:
9.8-14.7 N·m {100-149 kgf·cm, 7.3-10.8 lbf·ft}
NOTICE
LEAKAGE PIPE
• Do not reuse the old gasket.
SHTS011030700064 • The leakage pipe can be twisted easily. Use care in handling.
• Note that the thread pitch is different between the 6 union bolts
A : INJECTOR (M8 x 1.0) for the injector and the union bolt for the camshaft housing.
B : CAMSHAFT HOUSING (M8 x 1.25)
A
B
A
A
LEAKAGE PIPE
SHTS011030700065
• An "X" mark is put on the union bolt for the camshaft housing.
CAMSHAFT HOUSING
UNION BOLT
SHTS011030700066
4. INSTALLING THE HEAD COVER

(1) Install the head cover.
Reference: ENGINE MECHANICAL (J08E)

8
INJECTION NOZZLE (TWO-SPRING TYPE) [J08E-UF, UG, UH]
DESCRIPTION
EN01F01103070C01021001
Detail of C
SHTS011030700067
1 Joint bolt 9 Second pressure adjusting shim

2 Gasket 10 Second pressure spring
3 Cap nut 11 Second pressure spring seat
4 Gasket 12 Pre-lift adjusting shim
5 Adjusting screw 13 Distance piece
6 First pressure spring 14 Nozzle assembly
7 Push rod 15 Retaining nut
8 Nozzle holder 16 Pre-lift
8
COMPONENT LOCATOR
EN01F01103070D01021001
SHTS011030700068
1 Joint bolt 9 Second pressure adjusting shim

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

A 12.3 {125, 9} C 63.7 {650, 47}
B 53.9 {550, 40}
8
SPECIAL TOOL
EN01F01103070K01021001
Prior to starting an engine overhaul, it is necessary to have the special tool.
S0942-01442 SLIDING HAMMER
NOZZLE HOLDER
S0946-21130 Used with S0942-01442
ADAPTER
95991-10150 SOCKET WRENCH
S0946-21420 BASE, TWO-SPRING

8
OVERHAUL
EN01F01103070H02021001
IMPORTANT POINTS - REMOVING
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.
(3) Remove the bolt of the injection pipe seal and pull it with the
injection pipe from the camshaft housing.
SHTS011030700073
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
special tool.
SST: S0942-01442
Sliding hammer
S0946-21130
Nozzle holder adapter
(3) Remove the O-ring.
NOTICE
Replace the O-ring with a new one.
SHTS011030700074
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 prevent
scattering of fuel.
SHTS011030700075
(2) Operate the lever at the rate of 15 to 60 strokes per minute. If

the injection pressure is not within specified value, adjust the
injection pressure with adjusting screw.
First opening pressure

With new parts: 18.14-18.92 MPa
{185-193 kgf/cm2, 2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa
{180-188 kgf/cm2, 2,561-2,673 lbf/in.2}
SHTS011030700076
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
incorrect, replace or clean the nozzle.
CORRECT INCORRECT
INCORRECT INCORRECT
SHTS011030700077
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 noz-
zle using a nozzle tester.
If incorrect, replace or clean the nozzle.
CORRECT INCORRECT
SHTS011030700078
1. REMOVE THE RETAINING NUT

NOTICE
To prevent dropping parts, face the nozzle holder toward the
retaining nut side.
SST: 95991-10150
Socket wrench
SHTS011030700079
IMPORTANT POINT - INSPECTION AFTER DISAS-

SEMBLY
1. TEST THE NOZZLE SINKING.

(1) Wash the nozzle proper with diesel fuel oil, them immerse it
in diesel fuel oil.
(2) Next slide the needle inside the nozzle proper and ensure
that it moves smoothly. The needle valve should fall under its
own weight when withdrawn vertically about 1/3 its length
and released. If its motion is sluggish, replace the nozzle with
a new one.
NOTICE
When assembling, you must reinstall the same parts in the same
nozzle holder. Do not mix them up.
SHTS011030700080
IMPORTANT POINTS - ADJUSTMENT
1. CHECK AND ADJUST PRE-LIFT.

SPRING SEAT (1) The nozzle assembly, distance piece, and spring seat are
DISTANCE PIECE attached in order to the special tool.
NOTICE
NOZZLE ASSEMBLY Each part must be washed carefully to eliminate any debris.
SST: S0946-21420
SPECIAL TOOL Base, two-spring
SHTS011030700081
(2) The hole in the special tool and the pin on the distance piece
NOZZLE NEEDLE are lined up and the dial gauge is pushed down until it con-
SPRING SEAT tacts the distance piece. Next, set the dial gauge to "0".
SHTS011030700082
(3) Install the pre-lift adjusting shim.

(4) Measurement the pre-lift.
PRE-LIFT
PRE-LIFT: 0.085-0.105 mm {0.0034-0.0041 in.}
SHIM (5) If the pre-lift out of the assembly standard, suitable shims are
then used to adjust this pre-lift value to a standard value.
NOTICE
• Thick shims=increase the pre-lift
PRE-LIFT
• Thin shims=decrease the pre-lift
Pre-lift adjusting shim line-up Unit: mm {in.}
Parts number Shim thickness

SHTS011030700083
S2288-56820– 1.30-1.42 {0.052-0.055}

S2288-56880 (jump at 0.02 {0.0008})
S2288-56900– 1.44-1.70 {0.057-0.066}

S2288-57030 (jump at 0.02 {0.0008})
2. ADJUSTMENT OF THE FIRST OPENING PRESSURE

SECOND PRESSURE NOZZLE HOLDER (1) Attach the second opening pressure adjusting shim, second
ADJUSTING SHIM SECOND PRESSURE pressure spring and adjusted parts to the bottom of the noz-
SPRING zle holder.
SPRING SEAT
DISTANCE PIECE
(2) Using a wrench, tighten the retaining nut.
PRE-LIFT ADJUSTING
Tightening Torque:
SHIM
NOZZLE ASSEMBLY 63.7 N·m {650 kgf·cm, 47 lbf·ft}
NOTICE
RETAINING NUT
• Adjust the first opening pressure. Then the second opening
pressure is adjusted at the same time.
SHTS011030700084 • Exchange parts is nozzle assembly and opening pressure
adjusting shim. Do not exchange other parts.
(3) Insert the push rod and first pressure spring to the nozzle
CAP NUT holder body. Tighten the adjusting screw.
GASKET (4) Assemble the new gasket, tighten temporarily the cap nut.
ADJUSTING SCREW
FIRST PRESSURE
SPRING
PUSH ROD
NOZZLE HOLDER
SHTS011030700085
(5) Install the above stated nozzle holder on the nozzle hand tes-
ter to determine the pressure at the start of injection.
This value is used as the first opening pressure. The adjust-
ing screw is tightened or loosened to keep this value within a
set range.

{185-193 kgf/cm2, 2,632-2,745 lbf/in.2}
{180-188 kgf/cm2, 2,561-2,673 lbf/in.2}
SHTS011030700086
NOTICE
• Tightening the adjusting screw  increases pressure
• Loosening the adjusting screw  decreases pressure
(6) After adjustment, a gasket is installed and the cap nut is tight-
ened down to anchor the adjusting screw.
Tightening Torque:
53.9 N·m {550 kgf·cm, 40 lbf·ft}
NOTICE
Make sure that the adjusting screw does not turn at the same time.
SHTS011030700087
3. ADJUSTMENT OF SECOND OPENING PRESSURE

NOTICE
NOZZLE HOLDER
SECOND PRESSURE This operation is necessary only when changing the second pres-
ADJUSTING SHIM SECOND PRESSURE sure adjusting shim, second pressure spring, spring seat, and
SPRING distance piece. This procedure is not required in other cases.
SPRING SEAT
DISTANCE PIECE
NOZZLE ASSEMBLY (1) Preparation
After adjusting the first opening pressure, dismantle the bot-
tom of the nozzle and remove the pre-lift shim. Then assem-
RETAINING NUT
ble the second pressure adjusting shim (generally 1.4 mm
{0.055 in.}), second pressure spring, spring seat, distance
piece, and nozzle assembly. Then attach and tighten the
SHTS011030700088 retaining nut.
NOTICE
Do not install the pre-lift shim.
Tightening Torque:
63.7 N·m {650 kgf·cm, 47 lbf·ft}
SST: 95991-10150
Socket wrench
(2) Adjustment
The nozzle holder is installed on a nozzle hand tester to
determine the pressure at the start of injection. This value is
used as the second valve opening pressure. Suitable shims
are used to keep this value within a standard range.
Second opening pressure

{319-329 kgf/cm2, 4,537-4,678 lbf/in.2}
{314-324 kgf/cm2, 4,467-4,608 lbf/in.2}
SHTS011030700089
NOTICE
• Thick shims  increases pressure
• Thin shims  decreases pressure
• About 88.26 kPa {0.9 kgf/cm2, 12.8 lbf/in.2} of change is obtained
for every 0.01 mm {0.0004 in.} of shim thickness.
Second opening pressure adjusting shim line-up
Parts number Shim thickness
S2288-57670– 1.0-1.375 {0.0394-0.0541}

S2288-57820 (jump at 0.025 {0.001})
S2288-57040– 1.4-1.7 {0.0551-0.0669}

S2288-57160 jump at 0.025 {0.001})
S2288-57180– 1.725-2.1 {0.0679-0.0827}

S2288-57330 (jump at 0.025 {0.001})
(3) Confirm the first opening pressure

a.
Preparation
After adjusting the second opening pressure, the bottom of
the nozzle is dismantled. Then, the same pre-lift adjusting
SPRING SEAT shim is installed between the spring seat and distance
DISTANCE PIECE piece.The unit is then reassembled.
PRE-LIFT ADJUSTING Tightening Torque:
SHIM
63.7 N·m {650 kgf·cm, 47 lbf·ft}
SST: 95991-10150
Socket wrench
SHTS011030700090
b. Measurement
The nozzle holder is installed on the nozzle hand tester
and a check is made to determine if the pressure at the
start of injection (first opening pressure) is within the stan-
dard range.If not within the specified pressure, readjust
with the adjusting screw.

{185-193 kgf/cm2, 2,632-2,745 lbf/in.2}
SHTS011030700091
{180-188 kgf/cm2, 2,561-2,673 lbf/in.2}
IMPORTANT POINT - INSTALLING
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 seal-
ing 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 injec-
tion 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
smoothly.
(7) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
SHTS011030700092 34.3 N·m {350 kgf·cm, 25.3 lbf·ft}
(8) Install the return pipe.

8
COMMON RAIL (J08E-WM, WL, WK)
DESCRIPTION
EN01F01103070D01022001
SHTS011030700093
1 Common rail 3 Common rail pressure sensor

2 Pressure limiter
COMPONENT LOCATOR
EN01F01103070D01022002
B
1
SHTS011030700094
1 Injection pipe * 3 Common rail

2 Bracket
*: Nonreusable part

A 44 {450, 32} B 28.5 {291, 21}
8
INSPECTION
EN01F01103070H03022001
INSPECTING THE COMMON RAIL
1. INSPECTING THE PRESSURE LIMITER

STOP THE (1) Remove the union bolt securing the pressure limiter.
RETURN PIPE No.1
SIDE WITH A (2) Stop the return pipe No.1 side with a blank cap to prevent the
BLANK CAP outflow of fuel.
! CAUTION
While working, be careful not to make dirt and water enter parts.
PRESSURE LIMITER
UNION BOLT
SHTS011030700095
(3) Install the union to the pressure limiter, and connect a vinyl
hose to the end of the union.
UNION
(4) Place a fuel reservoir under the free end of the vinyl hose.
(5) Start the engine. If the fuel continuously flows out, replace
VINYL HOSE the pressure limiter of a common rail assembly.
PRESSURE LIMITER ! WARNING
When the pressure limiter is working, fuel flow out at a high tem-
perature and pressure, serious injury like scalding could result
from this hot fuel being blown under pressure.
RESERVOIR
SHTS011030700096
2. INSPECTING THE COMMON RAIL PRESSURE SENSOR

(1) Using the circuit tester, measure the resistance between the
terminals. If the measured value is in excess of the standard
value, replace the common rail assembly.
Standard value (k)

1 2 3 Terminal to be measured At 20C {68F} with the
engine turned off
12 0.5-3.0
23 6.5-18.5
SHTS011030700097
8
REPLACEMENT
EN01F01103070H02022001
REMOVING THE COMMON RAIL

NOTICE
• Clean off surrounding area of the injectors and fuel line connec-
tors.
1. DISCONNECTING THE HARNESS

(1) Disconnect the connector connected to the common rail
pressure sensor.
SHTS011030700098
1 2 3
SHTS011030700099
2. DISCONNECTING THE FUEL PIPE

(1) Remove the union bolt securing return pipe No.1, and dis-
connect the return pipe No.1 from the pressure limiter.
HINT
Prepare a reservoir and waste cloths because fuel spills when dis-
connecting the fuel pipe.
Pressure limiter
SHTS011030700100
3. REMOVING THE INJECTION PIPE

(1) Remove the injection pipe from the common rail.
4. REMOVING THE PRESSURE FEEDING PIPE

(1) Remove the pressure feeding pipe from the common rail and
the supply pump.
5. REMOVING THE COMMON RAIL

(1) Remove the 2 bolts securing the common rail, and remove
the common rail and the bracket from the intake manifold.
BRACKET
NOTICE
• Protect with clean vinyl to avoid entry of dirt into the common
rail.
• Remove dirt from around each part, and detach the common
rail.
• Remove the common rail together with the flow damper, the
PRESSURE common rail pressure sensor, and the pressure limiter.
LIMITER
COMMON RAIL HINT
PRESSURE SENSOR Prepare a reservoir and waste cloths because fuel spills when
removing the common rail.
BOLT
COMMON RAIL
SHTS011030700101
INSTALLING THE COMMON RAIL

NOTICE
• Air enters the fuel pipe while working. After working, be sure to
purge air.
1. INSTALLING THE COMMON RAIL

(1) Install the common rail and the bracket on the intake manifold
with the 2 bolts that secured them.
BRACKET
Tightening Torque:
28.5 N·m {291 kgf·cm, 21 lbf·ft}
PRESSURE
LIMITER
COMMON RAIL
PRESSURE SENSOR
BOLT
COMMON RAIL
SHTS011030700102
2. INSTALLING THE PRESSURE FEEDING PIPE

(1) Install the pressure feeding pipe.
3. INSTALLING THE INJECTION PIPE

(1) Install 6 new injection pipes on the injector and the common
rail.
Tightening Torque:
! CAUTION
• Do not fail to replace the injection pipes with new ones because
they are subjected to high pressure and may cause fuel leak-
age.
• Fuel leakage will cause damage to the engine.
SHTS011030700103
(2) Install the clips, and fix the injection pipes.
SHTS011030700104
4. INSTALLING THE FUEL PIPE

(1) Replace the gasket with a new one, and connect return pipe
No.1 to the pressure limiter with the union bolt that secured
the return pipe No.1.
Tightening Torque:
(Supply pump side)
7.9-12.7 N·m {81-129 kgf·cm, 6-9 lbf·ft}
(Intake manifold side)
Pressure limiter (Pressure limiter side)
SHTS011030700105
5. CONNECTING THE HARNESS

(1) Connect the connector to the common rail pressure sensor.
SHTS011030700106
NOTICE
Before connecting the connectors, make sure that the terminals
1 2 3
SHTS011030700107

8
MAIN FUEL FILTER (ENGINE MOUNT) [J08E-WM, WL, WK]
DESCRIPTION
EN01F01103070C01023001
6
IN
8
5
2
7
3
OUT
SHTS011030700108
1 Hand priming pump 5 Air bleeding plug

2 Element 6 Center bolt
3 Drain plug 7 Body
4 Water level sensor 8 Cap
8

COMPONENT LOCATOR
EN01F01103070D01023001
15
1 A
8
2 3 B
14
9
4
13 12
10
11
SHTS011030700109
1 Center bolt 9 Body

2 O-ring 10 Hand priming pump
3 Air bleeding plug 11 Water level sensor
4 Cap 12 Drain plug
5 Spring 13 Drain pipe
6 Holder 14 Air bleeding pipe
7 Element 15 Main fuel filter (engine mount)
8 Gasket

A 24.5-34.3 {250-350, 18.1-25.3} B 4.9-8.9 {50-91, 3.6-6.5}
8
OVERHAUL
EN01F01103070H02023001
DRAINING WATER FROM THE FUEL FILTER CASE

NOTICE
• Air enters the fuel pipe in the process of installing the pre fuel
filter case. After installing is completed, thoroughly purge air
from the fuel pipe.
1. WATER DRAINING OF THE FUEL FILTER

AIR BLEEDING PIPE AIR BLEEDING (1) Prepare a reservoir under the drain pipe to receive water.
PLUG
(2) Loosen the drain plug and then the air bleeding plug, and
drain the water trapped at the bottom of the fuel filter case.
NOTICE
• The drained water contains fuel. Dispose the drained water in
accordance with the regulation of disposal specified in each
DRAIN region.
DRAIN
PLUG
PIPE • Do not fail to drain water because the ingress of water into the
fuel causes not only poor driving but also damage to the
engine.
SHTS011030700110
(3) Tighten the drain plug of the fuel filter.
Tightening Torque:
4.9-8.9 N·m {50-90 kgf·cm, 3.7-6.5 lbf·ft}
(4) Connect the hose to the air bleeding pipe.

(5) Turn the priming pump to the left to lift it up and then move it
front-to-back.
(6) Operate the priming pump front-to-back and continue pres-
sure feed until the pump discharges all the fuel including air
from the air bleeding pipe.
SHTS011030700111
NOTICE
AIR BLEEDING • Check that the air bleeding plug of the fuel filter is loosened.
PLUG
• Check that the air bleeding plug of the pre fuel filter is tightened.
DRAIN
PLUG
SHTS011030700112
(7) Disconnect the hose and tighten the air bleeding plug of the
AIR BLEEDING fuel filter.
PLUG
Tightening Torque:
4.9-8.9 N·m {50-90 kgf·cm, 3.7-6.5 lbf·ft}
NOTICE
After operation, wipe out leaked water or fuel and check again for
fuel leakage after the engine is started.
SHTS011030700113
AIR BLEEDING OF FUEL SYSTEM

NOTICE
• Make sure that the fuel cock of the pre fuel filter is open.

(1) Connect the hose to the air bleeding pipe and prepare a res-
AIR BLEEDING PIPE AIR BLEEDING ervoir under the air bleeding pipe to receive the drained fuel.
PLUG NOTICE
Drain the fuel in accordance with the regulation of disposal speci-
fied in each region.
(2) Remove air bleeding plug of the fuel filter.
SHTS011030700114
(3) Turn the priming pump to the left to lift it up and then move it
front-to-back.
SHTS011030700115
(4) Operate the priming pump front-to-back and continue pres-

AIR BLEEDING sure feed until the pump discharges all the fuel including air
PLUG from the air bleeding pipe.
NOTICE
• Check that the air bleeding plug of the fuel filter is loosened.
• Check that the air bleeding plug of the pre fuel filter is tightened.
DRAIN
PLUG
SHTS011030700116
(5) Disconnect the hose and tighten the air bleeding plug of the
AIR BLEEDING fuel filter.
PLUG
Tightening Torque:
4.9-8.9 N·m {50-90 kgf·cm, 3.7-6.5 lbf·ft}
(6) Tighten the plug fully clockwise with the priming pump
pressed down.
NOTICE
• Note that squeezing the priming pump forcibly for stowing may
cause jamming.
• Check that the priming pump is securely tightened.
SHTS011030700117
• After operation, wipe out leaked water or fuel and check again
for fuel leakage after the engine is started.
REPLACING THE ELEMENT

NOTICE
• Use Hino's genuine fuel filter element.
• Air enters the fuel pipe in the process of installing the pre fuel
filter case. After installing is completed, thoroughly purge air
from the fuel pipe.
1. FUEL DISCHARGE
AIR BLEEDING (1) Prepare reservoir under the drain pipe to receive the drained
PLUG fuel.
(2) Loosen the drain plug and then the air bleeding plug of the
fuel filter, and drain fuel from the drain pipe.
(3) Check that no fuel is discharged from the drain pipe before
tightening the drain plug.
Tightening Torque:
DRAIN
DRAIN 4.9-8.9 N·m {50-90 kgf·cm, 3.7-6.5 lbf·ft}
PLUG
PIPE
NOTICE
SHTS011030700118 • Drain the fuel in accordance with the regulation of disposal
specified in each region.
• Make sure that the drain plug is free of damage or corrosion.
2. REMOVING THE ELEMENT

(1) Remove the center bolt securing the cap, and remove the 2
CENTER O-rings and the cap from the fuel filter case.
BOLT
(2) Remove the element.
NOTICE
O-RING
• When draining fuel, drain all the fuel in the filter. If the element is
replaced without draining all the fuel, unfiltered fuel may remain
CAP
inside the filter and flow into the engine side.
• Fuel is in the fuel filter case. Prepare a tray not to spill the fuel
adhered to the element.
ELEMENT
O-RING
FUEL FILTER
CASE
SHTS011030700119
3. INSTALLING THE ELEMENT

(1) Clean the element setting face inside the fuel filter case and
CENTER inside the cap.
BOLT
(2) Insert a new element into the fuel filter case.
NOTICE
O-RING
If the element is replaced with the fuel remained in the fuel filter
case, unfiltered fuel will remain in the fuel filter case. Check for
CAP residual fuel.
(3) Apply fuel to new O-rings, and set one in the groove of the
fuel filter case and the other on the seating face of the center
bolt.
ELEMENT
NOTICE
• Do not reuse the element.
• Replace the O-rings with the new ones supplied with the ele-
O-RING ment kit.
FUEL FILTER (4) Set the cap on the fuel filter case with the alignment marks
CASE aligned with each other, and tighten the center bolt.
SHTS011030700120
Tightening Torque:
24.5-34.3 N·m {250-349 kgf·cm, 19-25 lbf·ft}
NOTICE
• Be careful not to damage the O-ring by twisting it.
• Make sure that the O-rings are in close contact with the sealing
surface.
• Align the alignment mark on the cap with that on the fuel filter
case.

SHTS011030700121 (1) Operate the priming pump to purge air from the fuel system.
8
MAIN FUEL FILTER (CHASSIS MOUNT) [J08E-WM, WL, WK]
COMPONENT LOCATOR
EN01F01103070D01024001
IN OUT
A
3 4
A Section A-A
SHTS011030700122
1 Main fuel filter (chassis mount) 4 Head

2 Element 5 Gasket
3 Air bleeding plug
HINT
Install the new fuel filter element on the duel filter body by turning it slightly clockwise by hand until the new fuel
filter element comes in contact with the sealing face of the fuel filter body. From this position turn the fuel filter
element between 3/4 turn.
8
PRE FUEL FILTER
COMPONENT LOCATOR
EN01F01103070D01009001
6
A
7
4
1
8
B 3
C
SHTS011030700123
1 O-ring 6 Pre fuel filter

2 Pre fuel filter case 7 Air bleeding plug
3 Drain plug 8 Cover
4 Float 9 Element
5 Gasket

A 24.1-33.9 {246-345, 18-24} C 1.2-1.8 {13-18, 0.9-1.3} *
B 17.1-22.1 {175-225, 13-16}
*: If tightening torque can not be confirmed, tighten the drain plug by hand until the clearance between the seating
face of the drain plug and mating surface will be vanished.
8
FUEL TANK
COMPONENT LOCATOR
EN01F01103070D01006001
200L (900 x 415 x 652)
D
7
2
6 3
4 B
E 5
SHTS011030700124
1 Fuel tank 5 Fuel drain plug

2 Fuel tank band 6 Gasket *
3 Fuel tank cap 7 Fuel sender gauge
4 Fuel tank support
*: Nonreusable part

A 151-203 {1540-2070, 112-149} D 1.5-2.5 {16-25, 1.2-1.8}
B 7.7-11.5 {79-117, 5.7-8.4} E 25-34 {255-346, 19-25}
C 14-20 {143-203, 11-14}
200L (750 x 505 x 609)
2 D
A 6
3
4 B
6
5
E
SHTS011030700125

4 Fuel tank support
*: Nonreusable part

A 151-203 {1540-2070, 112-149} D 1.5-2.5 {16-25, 1.2-1.8}
B 7.7-11.5 {79-117, 5.7-8.4} E 25-34 {255-346, 19-25}
C 14-20 {143-203, 11-14}
390L (1050 x 605 x 695)
2 7
3
A 6
F
8
1
4 B
E 5
SHTS011030700126

4 Fuel tank support 8 Fuel tank stopper
*: Nonreusable part

A 151-203 {1540-2070, 112-149} D 1.5-2.5 {16-25, 1.2-1.8}
B 7.7-11.5 {79-117, 5.7-8.4} E 25-34 {255-346, 19-25}
C 14-20 {143-203, 11-14} F 22-40 {222-410, 16-29}
230_Engine8.fm 56 ページ２０１４年８月２６日　火曜日　午前９時４８分
OVERHAUL
EN01F01103070D01006002
CLEANING THE FUEL TANK CAP BREATHER
1. CLEAN THE FUEL TANK CAP BREATHER

(Representative type) (1) Wipe the dirt on the fuel tank cap breather with a wetting
cloth.
Fuel tank cap

! CAUTION
• Never use a high-pressure washing machine.
• If using the high-pressure washing machine, water may enter
the fuel tank from the cap.
NOTICE
Fuel tank • If it left unattained the dirt sitting on the cap breather, it may
SHTS011030700127
cause the cap breather clogging and no air flows.
• By this, if no air flows, the engine may not be started.
• And if the pressure of fuel tank decreases, it may result of dam-
age to the fuel tank.
Air flow
Air flow
WITHOUT KEY TYPE
Air flow
Fuel tank
WITH KEY TYPE Fuel tank

cap
SHTS011030700128
230_Engine9.fm 1 ページ２０１４年８月２７日　水曜日　午前１１時４４分
TURBOCHARGER (J08E: WASTE GATE VALVE TYPE) 9–1
TURBOCHARGER
(J08E: WASTE GATE VALVE TYPE)
9
9-001
TURBOCHARGER....................................................... 9-2
DESCRIPTION ....................................................... 9-2
SPECIAL TOOL ...................................................... 9-4
OVERHAUL CRITERIA........................................... 9-4
9–2 TURBOCHARGER (J08E: WASTE GATE VALVE TYPE)
TURBOCHARGER
DESCRIPTION
EN01F01103080C01001001
J08E-NB 8
J08E-CR (Low) 10
9
13 11 12
7 6
20
22 17
19 18 3 16 15 24 14 23 1
2 21
5 4
SHTS011030800001
1 Turbine housing 13 Hexagon nut

2 Compressor housing 14 Piston ring
3 Center bearing 15 Journal bearing
4 Clamp 16 Spacer
5 Bolt 17 Thrust bearing
6 Actuator bracket 18 Thrust collar
7 Actuator assembly 19 Seal ring
8 Hexagon nut 20 Back plate
9 Hose 21 Compressor wheel
10 Hose clamp 22 O-ring
11 Rod end 23 Turbine wheel assembly
12 Retaining nut 24 Wheel shroud
J08E-CR (Hi) 8
10
9
13 11 12
7 6
20
22
17
19 18 3 16 15 24 14 23 1
2 21
5 4
SHTS011030800002
1 Turbine housing 13 Hexagon nut

2 Compressor housing 14 Piston ring
3 Center bearing 15 Journal bearing
4 Clamp 16 Spacer
5 Bolt 17 Thrust bearing
6 Actuator bracket 18 Thrust collar
7 Actuator assembly 19 Seal ring
8 Hexagon nut 20 Back plate
9 Hose 21 Compressor wheel
10 Hose clamp 22 O-ring
11 Rod end 23 Turbine wheel assembly
12 Retaining nut 24 Wheel shroud
9
TURBOCHARGER
SPECIAL TOOL
EN01F01103080K01001001
Prior to starting a turbocharger overhaul, it is necessary to have this special tool.
For measuring the turbine

S0944-41130 END PLAY GAUGE shaft end play with a dial
gauge.
9
TURBOCHARGER
OVERHAUL CRITERIA
EN01F01103080H03001001
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.
! WARNING
Do not work on the turbocharger while it is still hot. This can
result personal injury.
Visually check for:

• Missing or loose nuts and bolts.
• Loose or damaged intake and exhaust pipe.
• Damaged oil supply and drain lines.
• Cracked or deteriorating turbocharger housings.
• External oil or coolant leakage.
Correct any installation problems. If turbocharger parts are
damaged, the unit should be overhauled after completion of
the remainder of this troubleshooting procedure.
! WARNING
Operation of the turbocharger without the intake pipe and air
cleaner connected can result in personal injury and damage to
equipment from foreign objects entering the turbocharger.
3. INSPECTION TURBINE WHEEL AND HOUSING.

Remove the duct from the turbine outlet. Using a flash-light,
check the turbine for wheel to housing rub, evidence of oil
leakage or foreign object damage. Foreign object damage to
the turbine is not usually 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
SHTS011030800004
a. If oil deposits are found, determine whether the oil has
come from the engine exhaust or from the turbocharger
center housing.
b. If the oil has come from the engine, consult the 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.
4. EXAMINE COMPRESSOR WHEEL AND HOUSING.

Remove the ducting from the compressor inlet. Using a flash-
light, check the compressor for wheel to housing rub, evi-
dence 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.
SHTS011030800005
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
compressor 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.
SHTS011030800006
6. CHECK AXIAL BEARING CLEARENCES.

(1) Check the turbine rotor (exhaust side) for axial play using the
special tool and dial gauge.
SST: S0944-41130
End play gauge
Service limit: 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.
SHTS011030800007
7. CHECK WASTE GATE PERFORMANCE.

(1) Remove hose clamps and hose from waste gate 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.
SHTS011030800008
Specified air pressure:
Parts No. Air pressure: kPa {mmHg, inHg}
17201-EW040 130-136 {975-1,025, 39-40}
17201-EW050 154.6-161.2 {1.159-1,209, 46-48}
(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
waste gate valve or rod movement has been accurately mea-
sured.
(7) If the specified value or rod movement cannot be obtained
within the specified air pressure range.The turbine housing
assembly or actuator assembly must be replaced.
! CAUTION
Operation of the engine with the waste gate calibrated to some
value other than that specified can result in reduced performance
or severe engine damage.
(8) If waste gate performance is within specification, install the
hose onto the waste gate sensing port.
IMPORTANT POINTS - AFTER INSTALLING
1. DRIVING PROCEDURE
(1) After installing the turbocharger on the engine, start the
engine to check any leakage of air, oil, cooling water, or
exhaust gas from related parts.
NOTICE
• Do not put the engine in high-speed rotation immediately after
starting the engine. If the turbocharger is driven in insufficient
lubricated condition, which is inevitable immediately after start-
ing the engine, failure such as bearing seizing may be caused.
• Before stopping the engine, idle the engine approximately for 5
minutes. If the engine is stopped suddenly without idling, the
turbocharger is forced to rotate without oil pressure. This may
eliminate the necessary oil film and cause the bearing wear.
FUEL INJECTION PUMP (J08E) 10–1
FUEL INJECTION PUMP (J08E)

10
10-001
FUEL INJECTION PUMP........................................... 10-2

DATA AND SPECIFICATIONS .............................. 10-2
DESCRIPTION (NB-TYPE) ................................ 10-10
COMPONENT LOCATOR (NB-TYPE)................ 10-11
SPECIAL TOOL .................................................. 10-13
OVERHAUL ........................................................ 10-15
INSPECTION AND REPAIR ............................... 10-26
ADJUSTMENT (NB-TYPE)................................. 10-27
TIMER (SA2 TYPE).................................................. 10-31
COMPONENT LOCATOR................................... 10-31
SPECIAL TOOL .................................................. 10-32
OVERHAUL ........................................................ 10-33
FUEL FEED PUMP (KD TYPE) ............................... 10-37
OVERHAUL ........................................................ 10-38
GOVERNOR (R901)................................................. 10-40
DESCRIPTION ................................................... 10-40
SPECIAL TOOL .................................................. 10-43
OVERHAUL ........................................................ 10-44
ADJUSTMENT.................................................... 10-48
BOOST COMPENSATOR........................................ 10-54
ADJUSTMENT.................................................... 10-55
10–2 FUEL INJECTION PUMP (J08E)
FUEL INJECTION PUMP

EN01F01103090I02001001
ENGINE MODEL: J08E-UF

INJECTION PUMP NUMBER: 22010-EW020
Engine model J08E-UF
Injection pump part number 22010-EW020

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

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

Calibration
Fuel temperature 40-45 C {104-113 F}
Fuel feed pressure 196 kPa {2.0 kgf/cm2, 28.4 lbf/in.2}
Overflow valve opening pressure 241-269 kPa {2.5-2.7 kgf/cm2, 34.95-39.00 lbf/in.2}
Rotation Counterclockwise viewed from drive side
Injection order 1-4-2-6-3-5

INJECTION
Injection interval 6015'
TIMING
No.1 cylinder 3.07-3.13 mm {0.121-0.123 in.}
Pre-stroke
No.2-No.6 cylinder 3.05-3.15 mm {0.120-0.124 in.}
Pump
Rack position Measuring Injection volume Variation limit
revolution
mm {in.} stroke mm3 {cu.in.} mm3 {cu.in.}
r/min
INJECTION
VOLUME 8.75 {0.345}
500 4.0-5.0 {0.244-0.305} 1.5 {0.092} or less
ADJUSTMENT =Rw1
500
13.25 {0.520} 750 73.25-74.75 {4.470-4.562} 4.0 {0.244} or less
15.9 {0.626} 1,250 88.25-91.25 {5.385-5.568} 4.0 {0.244} or less
Adjuster lever position Pump speed r/min Advance angle

TIMER
750 0.3 or less
ADVANCE Full load
1,250 3.4-4.0
Adjusting position
Stopper bolt
Idle set bolt
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
100 11.7-12.1 {0.461-0.476}
185 11.7 {0.461} or more
Idling speed Idling 205 0 11.4 {0.449} or less

control 12.55 275 {0} 8.65-8.85 {0.340-0.348}
400 7.65-8.05 {0.301-0.317}
900 4.7-5.3 {0.185-0.209}
300 12.25-12.65 {0.482-0.498}
12.35-12.75 {0.486-0.502}
500
=Rw3
Full load
Medium speed 93.3
403 750 13.05-13.45 {2.514-0.530}
control {700, 27.6}
Between idling and full load
1,000 14.2-14.6 {0.559-0.575}
15.7-16.1 {0.618-0.634}
1,250
=Rw4
1,430 15.35-15.75 {0.604-0.620}

Full load
Maximum speed 93.3
403 1,535 (9.3)
control {700, 27.6}
1,700 6.5 {0.256} or less
BOOST COMPENSATOR ADJUSTMENT
Pump speed Boost pressure Control rack position

Adjusting lever position
r/min kPa {mmHg, inHg} mm {in.}
100 0 {0, 0} 13.35-13.95 {0.526-0.549}

Full load
403 300 0 {0, 0} 10.8 {0.425}=Rw2
Between idling and full 300 21.6 {162, 6.4} 10.9-11.1 {0.429-0.437}
load
500 93.3 {700, 27.6} 12.35-12.75 {0.486-0.502}=Rw3
MEASURE THE INJECTION VOLUME
Pump speed Boost pressure Measuring Injection volume

r/min kPa {mmHg, inHg} stroke mm3 {cu.in.}
Full load 750 73.25-74.75 {4.470-4.562}

403 93.3 {700, 27.6}
Between idling and full load 1,250 88.25-91.25 {5.385-5.568}
Full load 100 500 66.5 {4.058}

(Boost compensator control)
0 {0, 0}
403 300 30.0-32.0 {1.831-1.953}
CONTROL RACK POSITION ADJUSTMENT

Idling
275 0 {0, 0} 8.65-8.85 {0.341-0.348}
12.55
LEVER ANGLE
Adjusting lever angle Stop lever angle
Vertical position Vertical position
FULL ROAD 15.75

12.5 STOP 15.75
40 3
IDLING RUN
GOVERNOR CHARACTERISTIC DIAGRAM
Rw4
Rw (mm)
Np (r/min) x102
REMARKS
• Stop lever operation check: When the adjusting lever at "IDLING" position and pump speed is 0 r/min, control
rack should be 5.0 mm {0.197 in.} or less.
• Boost compensator inside seal: When pump speed at 1,250 r/min and boost pressure is 93.3 kPa {700 mmHg,
27.6 inHg}, set the boost compensator stopper for control rack position to (A+0.7)0.3 mm {(A+0.028)0.012
in.}. If turn back the full load stopper to end, then turn back to A with bolt.
NOTICE
A = 14.75-15.15 mm {0.581-0.596 in.}
• Set adjusting lever from idle to full load position when boost pressure and pump speed is 0, measure the
starting injection volume at pump speed at 100 r/min.
• Boost compensator air seal: Air pressure drop from 133 kPa {1,000 mmHg, 39.4 inHg} to 131 kPa {980 mmHg,
38.6 inHg} should be taken more than 10 seconds.
BOOST COMPENSATOR CHARACTERISTIC DIAGRAM
Rw (mm) Boost compensator’s set (Np=300 r/min)

14
(10.8)=Rw2
13 Q=62 2
12
Rw3
11 (Np=500 r/min)
(Rw2+0.2) 0.1
10
21.6
93.3
0 20 40 60 80 100 120 140 Pb (kPa)

ENGINE MODEL: J08E-UG

INJECTION PUMP NUMBER: 22010-EW010
Engine model J08E-UG
Injection pump part number 22010-EW010

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

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

Calibration
Fuel temperature 40-45 C {104-113 F}
Fuel feed pressure 196 kPa {2.0 kgf/cm2, 28.4 lbf/in.2}
Overflow valve opening pressure 241-269 kPa {2.5-2.7 kgf/cm2, 34.95-39.00 lbf/in.2}
Rotation Counterclockwise viewed from drive side
Injection order 1-4-2-6-3-5

INJECTION
Injection interval 6015'
TIMING
No.1 cylinder 3.07-3.13 mm {0.121-0.123 in.}
Pre-stroke
No.2-No.6 cylinder 3.05-3.15 mm {0.120-0.124 in.}
Pump
Rack position Measuring Injection volume Variation limit
revolution
mm {in.} stroke mm3 {cu.in.} mm3 {cu.in.}
r/min
INJECTION
VOLUME 9.15 {0.360}
500 4.0-5.0 {0.244-0.305} 1.5 {0.092} or less
ADJUSTMENT =Rw1
500
13.4 {0.528} 750 70.5-72.0 {4.302-4.394} 4.0 {0.244} or less
15.3 {0.602} 1,250 78.5-81.5 {4.790-4.973} 4.0 {0.244} or less
Adjuster lever position Pump speed r/min Advance angle

TIMER
750 0.3 or less
ADVANCE Full load
1,250 3.4-4.0
Adjusting position
Stopper bolt
Idle set bolt
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
100 12.0-12.4 {0.473-0.488}
185 12.05 {0.474}
Idling speed Idling 205 0 11.75 {0.463}

control 13.55 275 {0} 9.05-9.25 {0.357-0.364}
400 7.65-8.05 {0.302-0.316}
900 4.15-4.75 {0.164-0.187}
300 12.45-12.85 {0.491-0.505}}
12.55-12.95 {0.500-0.509}
500
=Rw3
Full load 750 13.2-13.6 {0.520-0.535}
Medium speed 93.3
383
control 1,000 {700, 27.6} 13.95-14.35 {0.550-0.560}
15.1-15.5 {0.595-0.610}
1,250
=Rw4
1,350 14.7-15.1 {0.579-0.594}
Full load 1,550 8.5-8.9 {0.335-0.350}

Maximum speed 93.3
383
control 1,800 {700, 27.6} 5.15 {0.203} or less
BOOST COMPENSATOR ADJUSTMENT

100 0 {0, 0} 14.05-14.65 {0.553-0.577}

Full load
383 300 0 {0, 0} 11.05 {0.435}=Rw2
Between idling and full 300 25.7 {193, 7.6} 11.15-11.35 {0.439-0.447}
load
500 93.3 {700, 27.6} 12.55-12.95 {0.494-0.510}=Rw3
MEASURE THE INJECTION VOLUME
Pump speed Boost pressure Measuring Injection volume

r/min kPa {mmHg, inHg} stroke mm3 {cu.in.}
Full load 750 70.5-72.0 {4.302-4.394}

383 93.3 {700, 27.6}
Between idling and full load 1,250 78.5-81.5 {4.790-4.973}
Full load 100 500 73.5 {4.485}

(Boost compensator control)
0 {0, 0}
383 300 31.0-33.0 {1.892-2.014}
CONTROL RACK POSITION ADJUSTMENT

Idling
275 0 {0, 0} 9.05-9.25 {0.356-0.364}
13.55
LEVER ANGLE
Adjusting lever angle Stop lever angle
Vertical position Vertical position
FULL ROAD 15.75

13.5 STOP 15.75
38 3
IDLING RUN
GOVERNOR CHARACTERISTIC DIAGRAM
Rw4
Rw (mm)
Np (r/min) x 102
REMARKS
• Stop lever operation check: When the adjusting lever at "IDLING" position and pump speed is 0 r/min, control
rack should be 5.0 mm {0.197 in.} or less.
• Boost compensator inside seal: When pump speed at 1,250 r/min and boost pressure is 93.3 kPa {700 mmHg,
27.6 inHg}, set the boost compensator stopper for control rack position to (A+0.7)0.3 mm {(A+0.028)0.012
in.}. If turn back the full load stopper to end, then turn back to A with bolt.
NOTICE
A = 14.75-15.15 mm {0.581-0.596 in.}
• Set adjusting lever from idle to full load position when boost pressure and pump speed is 0, measure the
starting injection volume at pump speed at 100 r/min.
• Boost compensator air seal: Air pressure drop from 133 kPa {1,000 mmHg, 39.4 inHg} to 131 kPa {980 mmHg,
38.6 inHg} should be taken more than 10 seconds.
BOOST COMPENSATOR CHARACTERISTIC DIAGRAM
Boost compensator’s set (Np=300r/min)

Rw3
Rw (mm) (11.05)=Rw2 (Np=500r/min)
Q=64 2
12
11 (Rw2 0.2) 0.1

93.3
25.7
10
0 20 40 60 80 100 Pb (kPa)
10

FUEL INJECTION PUMP
DESCRIPTION (NB-TYPE)
EN01F01103090C01001001
SHTS011030900011
1 Delivery valve holder 7 Control sleeve

2 Delivery valve 8 Plunger spring
3 Shim 9 Lower spring seat
4 Injection pump element (Cylinder plunger) 10 Camshaft
5 Upper spring seat 11 Tappet
6 Control rack 12 Pump housing
10
FUEL INJECTION PUMP
COMPONENT LOCATOR (NB-TYPE)

EN01F01103090D01001001
SHTS011030900012
1 Delivery valve holder 16 Camshaft adjustment ring

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

A 88.3 {900, 65} C 7.8 {80, 6}
B 19.1 {195, 14} D 14.8-19.6 {151-199, 11-14}
10
FUEL INJECTION PUMP
SPECIAL TOOL
EN01F01103090K01001001
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
S0951-21790 BOX WRENCH
DELIVERY VALVE
S0951-22380
HOLDER REMOVER
CONTROL SLEEVE
S0951-22400
REMOVER
SPRING COMPRESSION
S0951-22410
TOOL
S0951-21620 TWEEZERS
S0951-22370 CIRCLIP PLIERS
S0951-22390 SETTING SUPPORT
S0951-22330 OUTER RACE PULLER

S0951-22350 BEARING DRIVING TOOL
CAMSHAFT PROTRU-
S0951-22340
DANCE GUIDE RAIL
CAMSHAFT END PLAY

S0951-01150
GAUGE
S0951-01130 PUMP STAND
S0951-01160 BEARING REMOVER
RACK POSITION MEA-

95091-00170 DENSO part No.
SURING ASSEMBLY
10
FUEL INJECTION PUMP
OVERHAUL
EN01F01103090H02001001

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

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

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

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

(1) Using a special tool, remove the nut that secures the cylin-
der.
SST: S0951-21790
Box wrench
SHTS011030900026
(2) Fix the special tool on the stud bolts, turn the guide until the
clearance between the washer and the handle is approxi-
mately 1-2 mm {0.0394-0.0787 in.}, to set the special tool.
NOTICE
The guide of the special tool is left-hand threaded.
SST: S0951-22380
Delivery valve holder remover
SHTS011030900027
(3) Turn the handle clockwise into the delivery valve holder. Con-
tinue until the O-ring in the cylinder comes off the pump body.
SHTS011030900028
(4) Pull the special tool upward to remove the delivery valve
group.
SHTS011030900029
5. REMOVE THE RACK GUIDE BOLT.
SHTS011030900030
6. REMOVE THE CONTROL SLEEVE.

(1) Pull the control rack to the left (viewed from the feed pump)
as far as it goes.
(2) Hook the end of the control sleeve remover onto the groove
of the control sleeve and remove it.
SST: S0951-22400
Control sleeve remover
NOTICE
Set the camshaft at bottom dead center before removing the con-
trol sleeve.
SHTS011030900031
7. REMOVE THE CONTROL RACK.
8. REMOVE THE PLUNGER.

(1) Bring the camshaft of the cylinder to top dead center.
NOTICE
• Do not mix up the plungers since they must be put back into the
same cylinders.
• Handle the plunger very difficulty, in order not to damage it.
• Keep the removed plungers in a pan containing clean diesel
fuel.
SHTS011030900032
9. REMOVE THE UPPER SPRING SEAT.

(1) Pushing the handle down to push in the plunger spring, turn
the guide lever 90 (in either direction) to remove the upper
spring seat from the stopper pin.
SST: S0951-22410
Spring compression tool
NOTICE
First bring the cam of the cylinder to bottom dead center.
SHTS011030900033
10. REMOVE THE UPPER SEAT AND THE PLUNGER SPRING.
11. REMOVE THE LOWER SPRING SEAT.

(1) Use a special tool to pull out the lower spring seat.
SST: S0951-21620
Tweezers
SHTS011030900034
12. REMOVE THE TAPPET.

(1) Use a special tool to pull out the tappet.
SST: S0951-22370
Circlip pliers
NOTICE
The tappet can be removed more easily when the cam of the cylin-
der is at top dead center.
SHTS011030900035
13. REMOVE THE CAMSHAFT FROM THE PUMP HOUSING.

(1) Remove the center bearing set screws.
(2) Loosen the bearing cover set screws.
(3) Lightly tap the camshaft with a plastic hammer from the gov-
ernor side, and remove the camshaft and bearing cover
together.
NOTICE
Put the round nut of governor to the camshaft at the governor side
to protect the threads.
SHTS011030900036
14. DISASSEMBLE THE DELIVERY VALVE GROUP.

(1) Mount the delivery valve group in the special tool, and
remove the delivery valve holder.
SST: S0951-22390
Setting support
SHTS011030900037
15. REMOVE THE TAPER ROLLER BEARING FROM THE CAM-

SHAFT.
(1) Remove the taper roller bearing from the drive end of the
camshaft using the special tool.
SST: S0951-01160
Bearing remover
SHTS011030900038
(2) Use the special tool to remove the taper roller bearing at the
governor side.
SST: S0951-01160
Bearing remover
SHTS011030900039
(3) Use the special tool to tap out the outer race in the bearing
cover.
SST: S0951-22330
Outer race puller
SHTS011030900040

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

(1) Put the special tool on the bearing outer race, and press-fit it
into the bearing cover using a hand press.
SST: S0951-22350
Bearing driving tool
SHTS011030900041
(2) Install the camshaft adjusting ring, shim and taper roller bear-
ing, in that order, on the camshaft.
NOTICE
Put a round nut on the other end of the camshaft to protect the
threads.
SHTS011030900042
2. INSTALL THE CAMSHAFT.

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

Tightening Torque:
Bearing cover
7.8 N·m {80 kgf·cm, 6 lbf·ft}
Governor housing
11.7-13.7 N·m {120-139 kgf·cm, 9-10 lbf·ft}
SHTS011030900043
4. MEASURE THE PROTRUDING LENGTH OF THE CAMSHAFT.

(1) Measure the distance from the surface of the end of the
pump housing to the surface of the end of the special tool
(where the tapered section of the camshaft starts).
SST: S0951-22340
Camshaft protrudance guide rail
Standard length: 16-17 mm {0.63-0.66 in.}
SHTS011030900044
(2) If the specification is not met, use appropriate shim at the

governor end of camshaft until the specification is met.
SHTS011030900045
5. MEASURE THE CAMSHAFT END PLAY.

(1) Attach the special tool onto the camshaft drive end and mea-
sure the thrust clearance of the camshaft with a dial gauge.
SST: S0951-01150
Camshaft end play gauge
Standard end play: 0.03-0.05 mm {0.0012-0.0020 in.}
SHTS011030900046
(2) If the specification is not met, use, appropriate shim at the

drive end of camshaft until the specification is met.
SHTS011030900047
6. INSTALL THE TAPPETS.

(1) Install the tappet using the special tool.
SST: S0951-22370
Circlip pliers
NOTICE
Position the groove provided in the tappet in the axial direction of
the camshaft, and position it accurately so that the tappet is
retained in position by the tappet retainer pin which is driven
inside the pump housing.
SHTS011030900048
7. INSTALL THE LOWER SPRING SEATS.

(1) Install the lower spring seat, using the special tool.
SST: S0951-21620
Tweezers
NOTICE
Be sure that the flange of the lower spring seat is accurately
seated in the groove of the tappet.
This is very important since an inaccurately positioned seat may
cause damage to the pump.
SHTS011030900049
8. INSTALL THE PLUNGER SPRINGS.
9. INSTALL THE UPPER SPRING SEATS.

(1) Insert the upper spring seat with the projected part of the
seat facing at the drive end of the housing.
SST: S0951-21620
Tweezers
SHTS011030900050
(2) Attach the upper spring extractor, and fit the guide groove on
the extractor to the projected part of the upper spring seat.
SST: S0951-22410
Spring compression tool
SHTS011030900051
(3) Push the handle down to compress the plunger spring, turn
the guide lever 90 toward you, and installing the upper
spring seat underneath the stopper pin which is driven inside
the pump housing.
SHTS011030900052
NOTICE
• First bring the cam of the cylinder to bottom dead center.
• Check that the spring is accurately retained by the stopper pin.
• Check that the projected part of the upper spring seat faces
away from the rack.
SHTS011030900053
10. INSTALL THE PLUNGER.

(1) Put the flange of the plunger foot through the hole provided in
the lower spring seat, with the part number marking facing
the spill side (away from the feed pump), then turn it clock-
wise 90.
NOTICE
• The plunger can be installed more easily if the cam of the cylin-
der is at top dead center.
• Grip the plunger at the top, and pull up to check that it does not
come out.
SHTS011030900054
11. INSTALL THE CONTROL RACK AND CONTROL SLEEVE.

(1) Insert the control rack.
(2) Install the control sleeve.
SST: S0951-21620
Tweezers
SHTS011030900055
NOTICE
Position the flanges of the control sleeve and the plunger, and the
projected part of the upper spring seat correctly before inserting
the control sleeve.
SHTS011030900056
(3) Move the control rack until the ball in the control sleeve is
accurately inside the groove provided in the control rack.
NOTICE
• The plunger may slip out of its position during installation.
Check the following for a second time.
• The vertical groove of the plunger must face the spill side.
• The plunger must not come out when it is pulled up.
SHTS011030900057
12. ASSEMBLE THE DELIVERY VALVE GROUP.

(1) Install the valve gasket, delivery valve, valve spring, shim,
and the valve holder in that order inside the cylinder.
NOTICE
• Apply grease to each O-ring first to protect it from damage.
Install O-ring (a) and (b) in that order.
• Use new valve gaskets and O-rings. Never reuse them.
SHTS011030900058
(2) Put the delivery valve group in the support, and tighten the
delivery valve holder on the delivery valve group.
SST: S0951-22390
Setting support
Tightening Torque:
88.2 N·m {900 kgf·cm, 65 lbf·ft}
SHTS011030900059
13. INSTALL THE DELIVERY VALVE GROUP.

(1) Apply a small amount of grease to the O-rings and the out-
side of the cylinder, position the cylinder with the marked line
on its flange facing the spill side of the feed pump, slip the
cylinder over the plunger, moving the control rack in and out,
and insert the delivery valve group inside the pump housing.
NOTICE
• Install the cylinder in the correct position. This is very important
since, otherwise, the relative position of the feed hole and the
spill port will be reversed and the characteristics of the injection
volume will be different.
SHTS011030900060 • Each time a cylinder is inserted, move the control rack to check
that it slides smoothly.
(2) Put a pair of shims under the flange of the cylinder.
NOTICE
• Use a pair of shims of the same thickness at the sides of each
cylinder.
• Install the shims with the thickness marking facing up. (They
cannot be installed upside down since the delivery valve holder
cover will be in the way).
• Push each shim completely in until it touches the cylinder.
SHTS011030900061
SHTS011030900062
(3) Tighten the nuts finger tight. Then, tighten the nuts alter-
nately to their specified torque.
SST: S0951-21790
Box wrench
Tightening Torque:
19.1 N·m {195 kgf·cm, 14 lbf·ft}
SHTS011030900063
14. MEASURE THE SLIDING RESISTANCE OF THE CONTROL

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

Round nut tightening torque:
127-147 Nm {1,296-1,498 kgfcm, 94-108 lbfft}
16. INSTALL THE GOVERNOR

SHTS011030900064
(1) Refer to the section "GOVERNOR (R901)".
10
FUEL INJECTION PUMP

EN01F01103090H03001001
Unit: mm {in.}
Plunger spring Measure

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

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

— —
wear, any other damage if necessary.
10

FUEL INJECTION PUMP
ADJUSTMENT (NB-TYPE)
EN01F01103090H03001002
PREPARATION
1. PREPARATION
(1) Mount the injection pump correctly on the pump tester.
SHTS011030900071
(2) Attach a rack position measuring device to the control rack

and set to "0".
SST: 95091-00170
Rack position measuring assembly
(3) Install calibration nozzles and lines.
Nozzle and lines: Refer to "DATA AND SPECIFICA-
TIONS".
SHTS011030900072
(4) Fill the pump camshaft chamber with engine oil.
SHTS011030900073
ADJUSTING THE INJECTION TIMING
1. PREPARATION OF THE PRE-STROKE

(1) Remove the screw plug from the pre-stroke measuring hole
of the first cylinder.
(2) Remove the overflow valve, attach the inlet adaptor and con-
nect the fuel hose of the pump tester. Close the fuel port of
the injection pump with a blind plug.
(3) Install a pre-stroke measuring instrument. Bring the tappet of
the first cylinder to its bottom dead center, and set the pointer
tip on the tappet.
SHTS011030900074
2. MEASURE THE PRE-STROKE. (No.1 PLUNGER)

(1) Set the control rack at full-load position.
(2) Loosen the overflow screw of each nozzle holder.
(3) Operate the high-pressure pump of the pump tester and let
fuel run out of the overflow line.
SHTS011030900075
(4) Move the angle dial to set the first cylinder of the pump to
bottom dead center and adjust the pre-stroke gauge to zero.
NOTICE
Bottom dead center is the point at which the pointer of the dial
gauge does not move even when the angle dial is rotated while
fuel is flowing from the overflow line.
SHTS011030900076
(5) Turn the camshaft clockwise the angle dial and read the dial
gauge when the fuel stops running out of the overflow line.
This reading is the pre-stroke value of the pump.
Pre-stroke: Refer to "DATA AND SPECIFICATIONS".
(6) If the pre-stroke value is not within specification, change the
shims between the cylinder flange and the pump housing.
SHTS011030900077
3. ADJUST THE PRE-STROKE.

(1) Use the delivery valve remover to lift the cylinder and install
the proper shim.
SST: S0951-22380
Delivery valve holder remover
NOTICE
• Insert a pair of shims of same thickness to the cylinder. (If dif-
ferent thickness shims are used the rack will not move smoothly
and hunting and other trouble will result.)
• Use only one shim on each side.
• Always install the shims with the thickness marking facing up.
SHTS011030900078
SHTS011030900079
4. ADJUST THE INJECTION INTERVAL.

(1) Using the No.1 cylinder injection starting point as a base,
inspect and adjust the injection interval in the order of injec-
tion.
Injection interval: 5945'-6015'
Injection order: 1-4-2-6-3-5
SHTS011030900080
(2) If the injection intervals are not within specification, adjust by

using the same procedure as for pre-stroke adjustment.
(3) After adjustment, make sure the injection timing is correct.
SHTS011030900081
5. MEASURING AND ADJUSTING THE INJECTION VOLUME.

(1) Connect the fuel line and the overflow valve in their correct
positions.
(2) Measure the injection volume for each control rack position
and pump revolution.
Injection volume: Refer to "DATA AND SPECIFICA-
TIONS".
SHTS011030900082
a. To adjust the injection volume, loosen the delivery valve

holder tightening nut and rotate the delivery valve holder.
b. After adjustment has been completed, tighten the nuts
alternately to the specified torque.
Tightening Torque:
19.1 N·m {195 kgf·cm, 14 lbf·ft}
SHTS011030900083
10
TIMER (SA2 TYPE)
COMPONENT LOCATOR
EN01F01103090D01006001
SHTS011030900084
1 Oil seal 9 Timer spring

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

A 13.7 {140, 10}
10
TIMER (SA2 TYPE)
SPECIAL TOOL
EN01F01103090K01006001
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
S0951-22430 TIMER EXTRACTOR
S0951-22200 TIMER HOLDER
S0951-22210 TIMER WRENCH
S0951-22310 WEIGHT SPRING PRESS

10
TIMER (SA2 TYPE)
OVERHAUL
EN01F01103090H02006001
1. REMOVE THE TIMER FROM THE INJECTION PUMP.

(1) Remove the timer round nut from the timer.
(2) Remove the timer from the injection pump.
SST: S0951-22430
Timer extractor
SHTS011030900090
1. REMOVE THE TIMER COVER.

(1) Fix the special tool on a vise.
SST: S0951-22200
Timer holder
(2) Set the timer on the special tool.
NOTICE
Face the cover side upward.
(3) Remove the two screws.
SHTS011030900091
(4) Install the special tool on the cover, and fix with the nut.
NOTICE
Do not tighten the nut but leave loosened.
SST: S0951-22210
Timer wrench
SHTS011030900092
(5) Set the extension bar on the timer wrench, then loosen and
remove the timer cover.
SHTS011030900093
2. REMOVE THE TIMER WEIGHT.

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

NOTICE
Remember the position of timer cams.
SHTS011030900094
4. REMOVE THE TIMER SPRING.

(1) Using the special tool, compress the timer spring, then
remove the spring seat retainer.
SST: S0951-22310
Weight spring press
SHTS011030900095
5. REMOVE THE OIL SEAL.

(1) Using a screwdriver, remove the oil seals from the timer
cover and driving flange.
SHTS011030900096
1. INSTALL THE OIL SEAL.

(1) Using the special tool, push the oil seals into the timer cover
and driving flange.
NOTICE
The oil seals must be replaced with new ones.
SST: S0951-22420
Oil seal press
SHTS011030900097
2. INSTALL THE TIMER HUB AND TIMER CAMS.

(1) Fix the special tool on a vise.
SST: S0951-22200
Timer holder
(2) Set the driving flange to the special tool.
(3) Install the timer hub and timer cams to the driving flange as
shown in the figure.
SHTS011030900098
3. INSTALL THE TIMER SPRING TO TIMER WEIGHT.

NOTICE
Take care of the spring seat direction.
SST: S0951-22310
Weight spring press
SHTS011030900099
4. INSTALL THE TIMER COVER.

NOTICE
O-ring must be replaced with new one.
(1) Install the special tool on the cover and fix with the nut.
NOTICE
Do not tighten the nut but leave loosened.
SST: S0951-22210
Timer wrench
SHTS011030900100
(2) Hook a spring balancer between the two socket bolts at the
end of the extension bar, then pull the spring balancer until it
shows 213 N {22 kgf, 49 lbf} to tighten up the timer cover.
Tightening Torque:
319 N·m {3,250 kgf·cm, 235 lbf·ft}
SHTS011030900101
5. FILL THE PUMP TIMER OIL INTO THE TIMER THEN TIGHTEN-
ING THE SCREWS.
Oil grade: SAE 90
Oil Volume: 140-160 cm3 {8.54-9.76 cu.in.}
Tightening torque for timer hub screw:
13.7 Nm {140 kgfcm, 10 lbfft}
SHTS011030900102
ADJUSTMENT OF THE TIMER
1. INSPECT THE TIMER ADVANCE.

(1) Set a stroboscope on a pump tester.
(2) Check the timer advance.
Advance angle: Refer to "DATA AND SPECIFICATIONS".
(3) If the angle is not within specification, adjust with an appro-
priate shim.
10
FUEL FEED PUMP (KD TYPE)
COMPONENT LOCATOR
EN01F01103090D01007001
SHTS011030900103
1 Plug 11 Push rod

2 Gasket 12 Feed pump housing
3 Spring 13 Tappet
4 Check valve 14 Sliding block
5 Joint bolt 15 Roller
6 Special washer 16 Pin
7 Screw plug 17 Retainer ring
8 Priming pump 18 Filter
9 Piston spring 19 Oil seal
10 Piston
10

FUEL FEED PUMP (KD TYPE)
OVERHAUL
EN01F01103090H02007001
1. REMOVE THE PRIMING PUMP AND CHECK VALVES.

(1) Remove the priming pump.
(2) Remove the outlet check valve and spring.
SHTS011030900104
2. REMOVE THE TAPPET.

(1) Remove the retainer ring and pull out the tappet.
SHTS011030900105
3. REMOVE THE FILTER FROM INLET PIPE JOINT.

(1) Clean the filter with clean diesel fuel.
SHTS011030900106
1. INSTALL THE TAPPET.
2. INSTALL THE RETAINER RING.
3. INSTALL THE PISTON.

(1) Insert the piston and spring in the housing and install the
plug with a new gasket.
SHTS011030900107
4. INSTALL THE PRIMING PUMP AND CHECK VALVES.
SHTS011030900108
10
GOVERNOR (R901)
DESCRIPTION
EN01F01103090C01008001
14
15 16
32
SHTS011030900109
1 Diaphragm plate 17 Inner lever

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

GOVERNOR (R901)
COMPONENT LOCATOR
EN01F01103090D01008001
SHTS011030900110
1 Bracket 23 Spring seat

2 Return spring 24 Idling inner spring
3 End cover 25 Idling outer spring
4 Gasket 26 Bushing
5 Adapter 27 Flyweight sub-assembly
6 Oil seal 28 Timer weight rod
7 Guide lever 29 Flyweight assembly
8 Key 30 Governor cover
9 Cam plate 31 Governor housing
10 Speed control lever 32 Screw plug
11 Floating lever sub-assembly 33 Shim
12 Floating lever 34 Stopper
13 Control lever 35 Rack limiter cap
14 Tension shaft 36 Rack limiter
15 Sliding lever 37 Boost compensator
16 Straight pin 38 Stopper screw
17 Inner lever 39 Cap nut
18 Guide lever 40 Idling spring
19 Nut 41 Shaft
20 Adapter 42 Collar
21 Plain washer 43 Diaphragm plate
22 Governor spring 44 Connector pin
10
GOVERNOR (R901)
SPECIAL TOOL
EN01F01103090K01008001
Prior to starting a governor overhaul, it is necessary to have these special tools.
S0951-21320 ROUND NUT WRENCH
S0951-21670 SPRING NUT WRENCH
S0951-21770 WRENCH
CAMSHAFT BUSHING
EXTRACTOR
S0951-22260
(DAMPER WEIGHT
MODEL)
S0951-22510 BIT
S0951-22520 DRIVER CHUCK

10
GOVERNOR (R901)
OVERHAUL
EN01F01103090H02008001

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

(1) With the adjusting lever hold in its "idling" position, detach the
governor cover by lifting it up in such as way that the sliding
block can slide out of the slit in the floating lever.
SHTS011030900117
NOTICE
Before lifting the governor cover, be sure to pull up the supporting
lever as shown by dotted lines in the figure, so that its lower end
may not obstruct the lifting of the governor cover.
SHTS011030900118
2. REMOVE THE FLYWEIGHT ROUND NUT.

NOTICE
Use the holding spanner to keep the camshaft from rotating.
SST: S0951-21320
Round nut wrench
SHTS011030900119
3. REMOVE THE FLYWEIGHT SUB-ASSEMBLY.

(1) Remove the flywheel sub-assembly using a screwdriver to
pull it out slowly.
SHTS011030900120
(2) Remove the bushing.

SST: S0951-22260
Camshaft bushing extractor
SHTS011030900121
(3) Remove the adapter from the flyweight sub-assembly.
SHTS011030900122
4. DISASSEMBLE THE FLYWHEEL SUB-ASSEMBLY.

(1) Remove the adjusting nut with special tool, and disassemble
the inner parts of the flyweight sub-assembly.
SST: S0951-21670
Spring nut wrench
SHTS011030900123

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

(1) Install the stopper as shown.
(2) Measure the thrust clearance of the guide lever.
Thrust clearance: 0.05-0.10 mm {0.002-0.004 in.}
NOTICE
The O-ring should be coated with grease before being fitted.
SHTS011030900124
2. ASSEMBLE THE FLYWEIGHT.

NOTICE
Be sure to install the spring inner seat correctly; its "LAPPED"
surface should face downwards.
(1) Tighten the adjusting nut with the special tools.
SST: S0951-21670
Spring nut wrench
Protrusion of adjusting nut A:
-0.4 to 0.2 mm {-0.015 to 0.007 in.}
SHTS011030900125
3. IF EQUIPPED WITH ADAPTER, ADJUST THE ADAPTER

THRUST CLEARANCE.
This provides a clearance between the flyweight and the
bushing.
(1) Temporarily install the bushing on the camshaft.
(2) Install the flyweight without the adapter.
(3) Temporarily fit the governor round nut.
SHTS011030900126
(4) Apply a dial gauge to the end face of the flyweight, and mea-
sure the thrust clearance.
Thrust clearance: 0.02-0.10 mm {0.0008-0.0039 in.}
(5) If not within specification, adjust the clearance by inserting
shims between the bushing and the governor round nut.
SHTS011030900127
4. INSTALL THE TENSION SHAFT.

(1) Measure the free play of the jointing bolt along its axis.
Standard free play: 1.5-2.0 mm {0.0591-0.0787 in.}
NOTICE
Make sure the bearing bolt can be moved smoothly thought the
bushing.
SHTS011030900128
(2) Measure the fitting dimension of the tension shaft.

a. While pulling on the tension shaft, measure the dimension
"L" with calipers.
Fitting dimension: 49.7-50.1 mm {1.957-1.972 in.}
SHTS011030900129
5. ASSEMBLE THE GOVERNOR COVER.

(1) Install the cam plate on the governor cover and shim with E-
ring.
NOTICE
Shim A about of 0.5 mm {0.02 in.} in thickness should be installed
with the E-ring.
(2) Measure the cam plate thrust clearance B.
Thrust clearance B: 0.08-0.12 mm {0.0032-0.0047 in.}
SHTS011030900130
10
GOVERNOR (R901)
ADJUSTMENT
EN01F01103090H03008001
PREPARATION
1. PREPARATION
(1) Connect the rack measuring device to the control rack and
set to "0".
(2) Connect the fuel line.
(3) Refill the camshaft chamber with engine oil.
(4) Install the angle gauge on the speed control lever.
(5) Remove the rack limiter cover.
(6) Connect the boost line to the compensator port from the vac-
uum pump on a test bench via a "T" connection to a pressure
gauge.
SHTS011030900131
2. STEP IN GOVERNOR ADJUSTMENT.

(1) Perform governor testing and adjustment in the following
sequence:
a. Preliminary adjustment of the cam plate
b. Adjustment of idling speed control
c. Preliminary adjustment of maximum speed control
d. Adjustment of medium speed control
e. Adjustment of maximum speed control
f. Adjustment of fuel injection volume under full-load
g. Inspection of stopper operation
SHTS011030900132
(2) Preliminary adjustment of cam plate.

L1= L2= About 25.5 mm {1.004 in.}
SHTS011030900133
(3) Adjustment of idling speed control.

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

position Ra mm.
Na and Ra: Refer to "DATA AND SPECIFICATIONS".
If there are not within specifications, adjust with the idle
adjusting screw.
SHTS011030900134
NOTICE
The idle adjusting screw will change the governor characteristics
as show on the left.
SHTS011030900135
b. At a pump speed of Nb r/min, measure the control rack

position Rb mm.
Nb and Rb: Refer to "DATA AND SPECIFICATIONS".
SHTS011030900136
c. At a pump speed of Nc r/min, measure the control rack

position Rc mm.
Nc and Rc: Refer to "DATA AND SPECIFICATIONS".
If not within specification, replace the idle outer spring.
NOTICE
Protrusion of the adjusting nut (A) should be within -0.4 mm {-
0.0158 in.} - 0.2 mm {0.0078 in.}.
SHTS011030900137
d. At a pump speed of Nd r/min, measure the control rack

position Rd mm.
Nd and Rd: Refer to "DATA AND SPECIFICATIONS".
If not within specification, replace the washer (A).
SHTS011030900138
e. At a pump speed of Ne r/min, measure the control rack

position Re mm.
Ne and Re: Refer to "DATA AND SPECIFICATIONS".
If not within specification, replace the washer (B).
SHTS011030900139
(4) Preliminary adjustment of maximum speed control.

a. Apply a P mmHg boost pressure to the boost compensa-
tor.
P: Refer to "DATA AND SPECIFICATIONS".
b. The speed control lever should be in the "FULL-LOAD"
position.
c. At a pump speed of Nj r/min, measure the control rack
position Rj mm.
Nj and Rj: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the idle adjusting
screw.
SHTS011030900140
(5) Adjusting of medium speed control.

NOTICE
• The speed control lever should always be in the "FULL-LOAD"
position during adjustment of the medium speed control.
• Apply a 13.3 kPa {100 mmHg} boost pressure to the boost com-
pensator.
SHTS011030900141
a. At a pump speed of Nf r/min, measure the control rack

position Rf mm.
Nf and Rf: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the stopper screw.
SHTS011030900142
b. At a pump speed of Ng r/min, measure the control rack

position Rg mm.
Ng and Rg: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the adapter screw
(A).
SHTS011030900143
c. At a pump speed of Nh r/min, measure the control rack

position Rh mm.
Nh and Rh: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the adapter screw (A)
and (B).
SHTS011030900144
d. Confirm the rack position Ri mm with at a pump speed of

Ni r/min.
Ni and Ri: Refer to "DATA AND SPECIFICATIONS".
SHTS011030900145
(6) Adjustment of maximum speed control.

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

position Rj mm.
Nj and Rj: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust with the stroke adjusting
screw.
SHTS011030900146 b. Confirm the rack position Rm and Rn mm, with at a pump
speed Nm and Nn r/min.
Each speed and rack position: Refer to "DATA AND
SPECIFICATIONS".
(7) Adjustment of the boost compensator.
NOTICE
The speed control lever should be in the "FULL-LOAD" position
during adjustment of the boost compensator.
SHTS011030900147
a. Without boost pressure, N1 r/min measure the injection

volume and read the rack position.
TIONS".
Rack position: Refer to "DATA AND SPECIFICATIONS".
If not within specification, adjust the volume with the stop
screw.
SHTS011030900148
b. Apply boost pressure of P1 kPa to the boost compensator.

At a pump speed of N1 r/min, adjust with the guide bushing
to adjust the rack position.
Boost pressure: Refer to "DATA AND SPECIFICA-
TIONS".
c. Apply boost pressure of P2 kPa to the boost compensator.
At a pump speed of N2 r/min, confirm the rack position.
Boost pressure: Refer to "DATA AND SPECIFICA-
TIONS".
SHTS011030900149
(8) Adjusting of fuel injection volume under "FULL-LOAD". Mea-

sure the injection volume in the "FULL-LOAD" position. Apply
a P mmHg boost pressure to the boost compensator.
P: Refer to "DATA AND SPECIFICATIONS".
If the average injection volume is not at standard value,
adjust with the stopper screw.
TIONS".
SHTS011030900150
(9) Inspection of stopper operation.

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

GOVERNOR HOUSING WITH SPECIAL BOLTS USING THE
SPECIAL TOOL.
SST: S0951-22510
SHTS011030900151 Bit
S0951-22520
Driver chuck
NOTICE
All adjusting devices on the fuel injection pump governor, except
the low idle adjustment screw, are secured with the special bolts
and crimp caps as a protection for the customer. This is to prevent
unauthorized readjustment which may cause engine malfunction
and/or engine failure. Periodically check to insure that special
bolts and crimp caps are not removed as this will void the war-
ranty.
10
BOOST COMPENSATOR
COMPONENT LOCATOR
EN01F01103090D01005001
SHTS011030900152
1 Housing 9 Cover
2 Plate washer 10 Thrust washer
3 Screw plug 11 Diaphragm
4 Push rod 12 Spring upper seat
5 Screw 13 Spring
6 Cap 14 Clamp plate
7 Lock nut 15 Guide bushing
8 Stop screw
10
BOOST COMPENSATOR
ADJUSTMENT
EN01F01103090H03005001
PRE-ADJUSTMENT OF BOOST COMPENSATOR
1. PRE-ADJUSTMENT OF BOOST COMPENSATOR.

(1) Before installing the boost compensator on the full-load stop-
per housing, should be done pre-adjustment the boost com-
pensator as follows.
SHTS011030900153
(2) Turn the guide bushing with a screw driver inserted through
the screw plug hole and set the "A" clearance to zero.
SHTS011030900154
(3) Tighten the stop screw until it comes in contact with the push
rod end, then further tighten the stop screw by 1/2 turn.
SHTS011030900155
(4) Set length "B", by means of the adjust with screw indicated in
figure.
Length "B": 13.5 mm {0.531 in.}
SHTS011030900156
(5) Check screw traveling length, "E" while apply 133.3 kPa
{1,000 mmHg} boost pressure to port "D".
Traveling length "E": 4-5 mm {0.157-0.196 in.}
(6) Check the boost compensator air seal. While applied 133.3
kPa {1,000 mmHg} boost pressure to port "D", the time
required for pressure to drop to 130.7 kPa {980 mmHg}
should be more than 10 seconds.
SHTS011030900157
ALTERNATOR (J08E: 24 V-60 A) 12–1
ALTERNATOR (J08E: 24 V-60 A)

12
12-001
ALTERNATOR............................................................ 12-2
DIAGAM................................................................ 12-3
SPECIAL TOOL .................................................... 12-5
OVERHAUL .......................................................... 12-5
12–2 ALTERNATOR (J08E: 24 V-60 A)
ALTERNATOR
Nominal voltage 24 V
Nominal output 24 V-60 A
Max. output 60 A (at 28 V, 5,000 r/min.)
Initial output starting speed 1,000 r/min. or less (at 27 V, 0A, 25 C)
Max. rotating 8,178 r/min.
Rotating direction Right (seen from pulley side)
Regulator Mount-on
12
ALTERNATOR
DIAGAM
27060-EW040
3
7 10
B
6
L L
8
R R
4
5 C
P P
N
2 9
SHTS011031100001
1 Alternator 6 Light (1.4-3.0 W)

2 Stator coil 7 Fuse
3 Diode 8 Starter switch
4 Field coil 9 Battery
5 Regulator 10 Load
12
ALTERNATOR
COMPONENT LOCATOR
27060-EW040
A
B
7
6
9
H H F E
G 8
11 12
10
5 4 3
2
H I
C
17 18 19
13 14 15 16
SHTS011031100002
1 Alternator 11 Field coil

2 Cover 12 Stator coil
3 Rectifier 13 Rotor assembly
4 Plate 14 Bearing cover
5 Clamp 15 Front bearing
6 Connector 16 Drive end frame
7 Insulator 17 Collar
8 Regulator 18 Fan
9 Rear bearing 19 Pulley
10 End frame

A 3.3-4.4 {34-44, 2.5-3.2} F 1.6-2.3 {17-23, 1.2-1.6}
B 4.9-5.9 {50-60, 3.7-4.3} G 1.0-14 {11-14, 0.8-1.0}
C 127-157 {1,296-1,600, 94-115} H 1.9-2.5 {20-25, 1.5-1.8}
D 2.9-4.9 {30-49, 2.2-3.6} I 7.8-9.8 {80-99, 5.8-7.2}
E 3.9-4.9 {40-49, 2.9-3.6}
12
ALTERNATOR
SPECIAL TOOL
Prior to starting a alternator overhaul, it is necessary to have this special tool.
S0944-41210 COMPRESSION GAUGE
12
ALTERNATOR
OVERHAUL
DISASSEMBLING THE ALTERNATOR
1. REMOVE THE DRIVE END FRAME SIDE FROM THE END

FRAME SIDE.
NOTICE
Perform work on a rubber mat.
(1) Remove the 2 bolts to remove the cover from the drive end
frame.
Bolt
NOTICE
• When press the tab on the cover, take care not to break the tab
with excessive force.
• Do not press the tab with the driver.
Cover
SHTS011031100004
(2) Remove the 3 through bolts and remove the drive end frame
Drive end frame side side from the end frame side.
End frame side
SHTS011031100005
2. DISASSEMBLE THE DRIVE END FRAME SIDE.

Fan (1) Remove the nut to remove the pulley, fan and collar.
NOTICE
Pulley
• Wind a common V-ribbed belt around the pulley groove to fix
V-ribbed belt
the pulley by using the vice.
• Damaged pulley threads are not reusable.
SHTS011031100006
(2) Using the press, remove the rotor assembly from the drive
end frame.
Rotor assembly
NOTICE
• Do not damage the screw tip.
• Support the rotor assembly not to drop the rotor assembly.
SHTS011031100007
(3) Remove the 2 bolts to remove the bearing cover from the
drive end frame.
Bearing cover
SHTS011031100008
(4) Using the press and jig C, remove the front bearing from the
drive end frame.
Front bearing Jig C
NOTICE
• Press the jig C against the inner race of the front bearing.
• Removed bearings are not reusable.
SHTS011031100009
230_Engine11.fm 7 ページ２０１４年８月２６日　火曜日　午前１０時０分
3. DISASSEMBLE THE END FRAME SIDE.

(1) Using the soldering iron and solder sucking line or solder
sucker, remove the lead wire solder between the stator coil
and rectifier.
NOTICE
• For the solder between the stator coil and rectifier, the rectifier
tip is staked. Take care not to break the rectifier tip.
• Soldering must be done in a short period of time (within 10 sec-
onds).
SHTS011031100010
(2) Remove the stator coil from the end frame.

NOTICE
End frame Do not damage the stator coil.
Stator coil
SHTS011031100011
(3) Remove the 3 regulator connecting bolts and 2 regulator fix-

ing bolts to remove the regulator.
Regulator
NOTICE
As the 2 regulator fixing bolts are provided with a lock agent, high
torque is required to remove the bolts. Take care not to break the
bolt head groove.
SHTS011031100012
(4) Loosen the nut of the B terminal.

NOTICE
Loosen the nut to some extent, but do not remove it from the B
terminal.
SHTS011031100013
(5) Remove the 4 rectifier fixing bolts and 2 plate fixing bolts to
remove the rectifier and plate.
Rectifier
NOTICE
As the 4 rectifier fixing bolts are provided with a lock agent, high
torque is required to remove the bolts. Take care not to break the
bolt head groove.
Plate
SHTS011031100014
(6) Remove the 3 bolts to remove the field coil from the end
End frame frame.
Field coil
SHTS011031100015
(7) Using the press and jig A, remove the rear bearing from the
end frame.
Jig A NOTICE
• If the bearing hole inner surface of the end frame is damaged
when removing the bearing, the end frame is not reusable.
• Removed bearings are not reusable.
SHTS011031100016
INSPECTING THE COMPONENT PARTS
1. INSPECT THE STATOR COIL AND FIELD COIL.

NOTICE
(1) Using the circuit tester, measure the resistance between U-V,
V-W and W-U terminals of the stator coil. If a measurement
W reading exceeds the standard value, replace stator coil.
Standard value: 0.18-0.20 
U ! CAUTION
V
• If the coil is damaged, it is not reusable.
• Take care not to damage the coil circumference.
• If damage is found with the coil circumference, the coil is not
Stator coil
reusable.
• Do not use organic solvent to clean the coil, or the grease will
SHTS011031100017 deteriorate.
(2) Using the 500V megohmmeter, measure the resistance

Megohmmeter between the stator coil core and each terminal. If it exceeds
the standard value, replace the stator coil.
Stator coil Standard value: 1 M or more
(using 500 V megohmmeter)
! CAUTION
Never measure between the terminal, or the stator coil will be
damaged.
SHTS011031100018
(3) Using the circuit tester, measure the resistance of the field
coil. If a measurement reading exceeds the standard value,
replace the field coil.
Standard value: 6.4-7.0 M
! CAUTION
• If the coil is damaged, it is not reusable.
• Take care not to damage the coil circumference.
• If damage is found with the coil circumference, the coil is not
Field coil
reusable.
• Do not use organic solvent to clean the coil, or the grease will
SHTS011031100019 deteriorate.
(4) Using the 500V megohmmeter, measure the resistance

Megohmmeter between the field coil core and coil. If it exceeds the standard
value, replace the stator coil.
Standard value: 1 M or more
(using 500 V megohmmeter)
! CAUTION
Never measure between the coil, or the stator coil will be dam-
aged.
Field coill
SHTS011031100020
2. INSPECT THE ROTOR ASSEMBLY.

(1) Using the micrometer, measure the outer diameter of shaft at
the front bearing insertion area of the rotor assembly. If it
exceeds the service limit, replace the rotor assembly.
Standard Value (mm) Service limit (mm)
25.0 24.98
SHTS011031100021
(2) Using the micrometer, measure the outer diameter of shaft at

the rear bearing insertion area of the rotor assembly. If it
exceeds the service limit, replace the rotor assembly.
Standard Value (mm) Service limit (mm)
17.0 16.98
SHTS011031100022
3. INSPECT THE DIODE AND REGULATOR

(1) Using the circuit tester, measure the resistance between the
positive and negative rectifier holder and the rectifier connec-
tor. If it exceeds the standard value, replace the diode.
Measurement direction Standard Value ()
Forward direction
Approximately10
resistance value
Rectifier
Reverse direction

resistance value
SHTS011031100023
NOTICE
The digital tester is not reusable.
(2) Using the circuit tester, measure the resistance between F
terminal and E terminal of the regulator. If it exceeds the
standard value, replace the regulator.
Measurement direction Standard Value ()
Forward direction
Approximately10
F resistance value
Reverse
E Reverse direction
side 
resistance value
The digital tester is not reusable.
ASSEMBLING THE ALTERNATOR
1. ASSEMBLE THE DRIVE END FRAME SIDE.

NOTICE
(1) Using the press and jig, press-fit the new front bearing to the
drive end frame.
Front bearing Jig C
NOTICE
Press the jig C against the outer race of the front bearing.
SHTS011031100025
(2) Install the bearing cover to the drive end frame with 3 bolts.
Tightening Torque:
2.9-4.9 N·m {30-49 kgf·cm, 2.2-3.6 lbf·ft}
Bolt
Bearing cover
Drive end frame
SHTS011031100026
(3) Using the press, press-fit the rotor assembly to the drive end
frame.
Bearing
Rotor NOTICE
assembly
• When press-fitting, make sure to receive the bearing inner race
part.
• Take care not to damage the shaft.
SHTS011031100027
(4) Wind a common V-belt around the pulley groove and fix the
pulley by using the vice.
(5) Install the collar, fan and pulley to the rotor assembly shaft.
Tightening Torque:
127-157 N·m {1,296-1,600 kgf·cm, 94-115 lbf·ft}
NOTICE
Damaged the pulley threads are not reusable.
SHTS011031100028
2. ASSEMBLING THE END FRAME SIDE

(1) Using the press, jig A and jig B, press-fit a new rear bearing
to the end frame.
Jig A
! CAUTION
Striking
face • Press-fit until the jig A touches the end frame.
Bearing
• If the bearing case is deformed or damaged during press-fitting,
the bearing case must not be reused.
Jig B
SHTS011031100029
(2) Install the field coil to the end frame.

End frame
Tightening Torque:
3.9-4.9 N·m {40-49 kgf·cm, 2.9-3.6 lbf·ft}
NOTICE
After tightening the bolts temporarily, tighten them fully and
evenly.
Field coil
SHTS011031100030
(3) Installing the stator coil to the end frame.
End frame
NOTICE
Take care not to damage the stator coil.
Stator coil
SHTS011031100031
(4) Temporarily assemble the rectifier, regulator and connector,

Rectifier and install them to the end frame and then apply the lock
agent (ThreeBond TB1344 or equivalent) to the tips of the
Connector
regulator to install the regulator to the end frame with bolt.
Tightening Torque:
1.6-2.3 N·m {17-23 kgf·cm, 1.2-1.6 lbf·ft}
NOTICE
After tightening the inner nut of the B terminal temporarily, tighten
them fully and evenly.
Regulator
SHTS011031100032
(5) Apply the lock agent (ThreeBond TB1344 or equivalent) to

the tips of rectifier mounting bolts, and install the rectifier to
Rectifier
the end frame with the bolt. And install the plate and connec-
tor to the rectifier and end frame with the bolts.
Connector
Tightening Torque:
Rectifier fixed
1.9-2.5 N·m {20-25 kgf·cm, 1.5-1.8 lbf·ft}
Plate Plate fixed
1.9-2.5 N·m {20-25 kgf·cm, 1.5-1.8 lbf·ft}
Connector fixed
1.9-2.5 N·m {20-25 kgf·cm, 1.5-1.8 lbf·ft}
SHTS011031100033
Coil lead connection
1.0-1.4 N·m {11-14 kgf·cm, 0.8-1.0 lbf·ft}
Regulator connection
1.0-1.4 N·m {11-14 kgf·cm, 0.8-1.0 lbf·ft}
(6) Using the solder and soldering iron, solder the lead wires
between the stator coil and rectifier.
NOTICE
• Perform soldering after tightening the bolts.
• Insert the lead wire of the stator coil to the rectifier support tip,
and then staked the support tip to solder the stator coil.
• Soldering must be done in a short period of time (within 10 min-
utes)
SHTS011031100034
(7) Tighten the inner nut of the B terminal.

Tightening Torque:
4.9-5.9 N·m {50-60 kgf·cm, 3.7-4.3 lbf·ft}
HINT
Tighten the outer nut with the wiring connected after installing the
alternator.
SHTS011031100035
3. JOIN THE DRIVE END FRAME SIDE TO THE END FRAME

SIDE.
(1) Join the drive end frame side to the end frame side with the 3
through bolts.
Tightening Torque:
7.8-9.8 N·m {80-99 kgf·cm, 5.8-7.2 lbf·ft}
NOTICE
Tighten the bolt evenly.
SHTS011031100036
(2) Align the tab position to install the cover to drive end frame
and fix it with 2 bolts.
Bolt
Tightening Torque:
1.9-2.5 N·m {20-25 kgf·cm, 1.5-1.8 lbf·ft}
! CAUTION
Do not tap the cover, or the tab will be broken.
Cover
SHTS011031100037
INSPECTING AFTER ASSEMBLING
1. INSPECT FOR THE ROTATION.

NOTICE
(1) Rotate the pulley manually and check that it rotates smoothly
without interference with internal parts.
Pulley
SHTS011031100038
(2) Using the circuit tester, measure the resistance between B

terminal and E terminal, P terminal and E terminal, and N ter-
minal and E terminal.
If it exceeds the standard value (or the value is 0 ), disas-
semble the pulley again and then assemble it.
Circuit tester lead

Standard value ()
(+) (–)
B E Approximately 20
SHTS011031100039
E B 
P E Approximately 7
E P 
C E Approximately 7
E C 
A
L
VIEW OF A
E
SHTS011031100040
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 circuit
and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring harness.
• 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 tes-
ter.
• In operation, never disconnect the battery.
1. ALTERNATOR PERFORMANCE TEST

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

(1) Turn switch SW1 on and SW2 off to increase the revolution of
the rotor to 5,000 r/min.
Standard value: 28.0-29.0 V
SHTS011031100041
12
ALTERNATOR

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

6.4-7.0  — Replace.
[at 20C (68F)]
Measure
Insulation resistance of
1 M or more — Replace.
field coil
Measure
Resistance of stator
0.18-0.20  — Replace. V U
coil [at 20C (68F)]
WIRING
Measure
Insulation resistance of
1 M or more — Replace.
stator
Measure
Normal direction
Approximately 10 
Resistance of diode — Replace.
Reverse direction

Measure
Normal direction
Approximately 10 
Resistance of regulator — Replace.
Reverse direction

Measure
Rotor shaft outside

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

diameter (Rear bearing 17 {0.669} 16.98 {0.6685} Replace.
portion)
STARTER (J08E: 24 V, 5.0 kW) 13–1
STARTER (J08E: 24 V, 5.0 kW)

13
13-001
STARTER ................................................................... 13-2

DESCRIPTION ..................................................... 13-3
OVERHAUL .......................................................... 13-5
13–2 STARTER (J08E: 24 V, 5.0 kW)
STARTER

EN01F01103120I02001001
Type Reduction gear type

Rated output 24 V, 5.0 kW
Number of teeth of pinion 11
Module 3
Rotating direction Clockwise (Seen from pinion side)
STARTER (J08E: 24 V, 5.0 kW) 13–3
13
STARTER
DESCRIPTION
EN01F01103120C01001001
24 23 22
SHTS011031200001
1 Pinion stopper (C-ring) 13 Brush holder assembly

2 Pinion gear 14 Bearing
3 Dust protector 15 Through bolt
4 Brush 16 Packing
5 Clutch assembly 17 Armature assembly
6 Holder assembly 18 Yoke assembly
7 Plunger 19 Cover
8 Lever assembly 20 Internal gear
9 Plate 21 Planetary gear
10 Magnetic switch assembly 22 E-clip
11 Terminal cover 23 Drive shaft assembly
12 Commutator end frame 24 Drive housing assembly
230_Engine12.fm 4 ページ２０１４年８月２６日　火曜日　午前１０時３３分
13–4 STARTER (J08E: 24 V, 5.0 kW)
13
STARTER
COMPONENT LOCATOR
EN01F01103120D01001001
2
B
8 11
4
6 7
1 C
9
A D
5
3
10 1
19
4
18
4 22
21 1
20
4
4
16
A
13
15 17
14
12
DETAIL D
SHTS011031200002
1 Packing 12 Pinion stopper (C-ring)

2 Magnet switch assembly 13 Pinion gear
3 Cover 14 Dust protector
4 Plate 15 Bushing
5 Armature assembly 16 Drive housing assembly
6 Yoke assembly 17 Clutch sub assembly
7 Brush 18 Drive shaft assembly
8 Brush holder assembly 19 Planetary gear
9 Brush spring 20 Internal gear
10 Bearing 21 Lever gear
11 Commutator end frame 22 Spring

A 10.5-14.5 {108-147, 8-10} C 13.7-15.7 {140-160, 11-12}
B 3.6-4.9 {37-49, 2.7-3.6}
13
STARTER (J08E: 24 V, 5.0 kW) 13–5

STARTER
OVERHAUL
EN01F01103120H02001001

When disassembling the starter, prepare a work stand as shown in the
figure.
D
D: Diameter = 125 mm {4.921 in.}
T T: Thickness = 10 mm {0.394 in.}
H
H: Height = 120 mm {4.724 in.}
SHTS011031200003
1. REMOVE THE TERMINAL LEAD.

(1) Remove the nut, disconnect the "M" terminal lead.
LEAD
TERMINAL
SHTS011031200004
2. REMOVE THE COMMUTATOR END FRAME.

(1) Remove the through bolt.
THROUGH BOLT
COMMUTATOR
END FRAME
SHTS011031200005
(2) Remove the bolt, remove the commutator end frame.

BOLT
SHTS011031200006
13–6 STARTER (J08E: 24 V, 5.0 kW)
3. REMOVE THE HOLDER ASSEMBLY.

(EXAMPLE) (1) Using a long nose plier, remove the brush of the yoke from
the holder.
SHTS011031200007
(2) Remove the holder assembly from the armature.

NOTICE
Do not cut the fixed clamp of brush lead.
SHTS011031200008
4. REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEM-

BLY.
YOKE (1) Remove the yoke assembly and armature assembly from the
ASSEMBLY
pinion case.
SHTS011031200009
ARMATURE
ASSEMBLY
SHTS011031200010
STARTER (J08E: 24 V, 5.0 kW) 13–7
5. REMOVE THE BEARING.

(1) Using a puller or a press, remove the bearing.
BEARING
PULLER
SHTS011031200011
6. REMOVE THE PINION GEAR AND INTERNAL GEAR.

(1) Remove the cover and packing.
PLANETARY (2) Remove the planetary gear.
GEAR
SHTS011031200012
7. REMOVE THE PINION.

C-ring (1) Using the vise, fix the pinion gear with the C-ring opening fac-
ing directry above to prevent the gear from rotating.
Pinion gear
SHTS011031200013
(2) Use a hammer to tap the end of the screwdriver to shift the
C-ring
C-ring slightly while applying two flat blade screwdrivers to
the both sides of the C-ring opening.
! WARNING
While working, wear safety glasses because the C-ring may come
out.
SHTS011031200014
13–8 STARTER (J08E: 24 V, 5.0 kW)
(3) Insert the flat blade screwdriver into the gap with the pinion
stopper for removal.
Clutch assembly
(4) Remove the pinion from the clutch assembly.
C-ring
SHTS011031200015
8. REMOVE THE ENGAGE SWITCH.

(1) Remove the 2 engage setting bolts.
(2) Remove the coupller setting plate.
BOLT
SHTS011031200016
(3) Tilt the engage switch and remove it from the lever.
SHTS011031200017
9. REMOVE THE PACKING.

PACKING
SHTS011031200018
STARTER (J08E: 24 V, 5.0 kW) 13–9
10. REMOVE THE LEVER ASSEMBLY AND THE SHAFT ASSEM-

LEVER BLY ( * )
(1) Remove the lever assembly and the shaft assembly from the
pinion case.
SHAFT ASSY (*Shaft assembly: Shaft, clutch assembly and internal gear)
SHTS011031200019
11. REMOVE THE E-CLIP.

(1) Attaching the end of 2 flat blade screwdrivers to the both
sides of the E-clip opening, press the 2 screwdrivers to
remove the E-clip.
! WARNING
While working, wear safety glasses because the E-clip may come
out.
NOTICE
Removed E-clip should not be reused.
SHTS011031200020
(2) Push the clutch assembly until the clutch assembly contacts
to internal gear, then turn the one tooth (D) of the clutch
assembly to align the tooth (D) of the shaft assembly and the
groove (E) of the clutch assembly.
SHTS011031200021
13–10 STARTER (J08E: 24 V, 5.0 kW)
(3) Remove the clutch assembly.
SHTS011031200022
12. REMOVE THE SHAFT ASSEMBLY.
SHTS011031200023
1. INSTALL THE SHAFT ASSEMBLY TO THE INTERNAL GEAR.

G1
G1 (1) Apply the grease (G1: Multemp AC-N) to both surfaces of the
PLATE plate, then install it on the internal gear.
(2) Install the shaft assembly into the internal gear.
SHAFT
ASSEMBLY
SHTS011031200024
2. INSTALL THE CLUTCH ASSEMBLY ONTO THE SHAFT

ASSEMBLY.
G1
G1 (1) Apply the grease (G1: Multemp AC-N) to the portion as
shown in the figure.
(2) Install the clutch assembly onto the shaft assembly until the
clutch assembly contacts to the internal gear, then turn one
tooth of the clutch assembly
(3) Pull the clutch assembly until clutch assembly contacts to
portion A.
A
SHTS011031200025
STARTER (J08E: 24 V, 5.0 kW) 13–11
3. INSTALL THE E-CLIP.

(1) Using the jig, install the E-clip to the internal gear.
SHTS011031200026
4. INSTALL THE PINION DRIVE LEVER.

(1) Apply the grease (G1: Multemp AC-N, G2: Pyronoc No.2) to
G1
the portion as shown in the figure.
G2
SHTS011031200027
5. INSTALL THE DRIVE HOUSING TO THE CENTER BRACKET.

(1) Fill up grease (Multemp AC-N) to the reservoir from bushing
DRIVE HOUSING
hole until it overflows from other hole.
DUST PROTECTOR BUSHING
HOLE
RESERVOIR
SHTS011031200028
6. INSTALL THE LEVER ASSEMBLY AND THE SHAFT ASSEM-

BLY ( * )
(1) Install the lever assembly and the shaft assembly to the pin-
ion case.
(*Shaft assembly: Shaft, clutch assembly and internal gear)
SHTS011031200029
13–12 STARTER (J08E: 24 V, 5.0 kW)
7. INSTALL THE PACKING.

(1) Install the packing to the drive housing.
PACKING
NOTICE
Be careful not to forget installation of the spring.
HINT
Replace with a new packing if crack or deformation is found.
SHTS011031200030
8. INSTALL THE ENGAGE SWITCH.

(1) Hook the engage switch to the lever and install the engage
switch to the drive housing.
SHTS011031200031
(2) Tighten the new 2 setting bolts.

HINT
Tighten the 2 bolts evenly.
BOLT
SHTS011031200032
9. INSTALL THE PLATE AND PLANETARY GEAR ON THE INTER-

G1 G1 NAL GEAR.
G1
(1) Apply the grease (G1: Multemp AC-N) to both surface of
plate, gear teeth and armature bushing.
G1
SHTS011031200033
STARTER (J08E: 24 V, 5.0 kW) 13–13
(2) Install the plate.
PLATE
SHTS011031200034
(3) Install the internal gear and planetary gears.
PLANETARY
GEAR
SHTS011031200035
(4) Install the packing and cover.
SHTS011031200036
10. INSTALL THE ARMATURE ASSEMBLY INTO THE PINION

CASE.
ARMATURE
(1) Install the bearing onto the armature assembly using a press.
ASSEMBLY
(2) Apply the grease (G1: Multemp AC-N) to the armature gear,
then install the armature assembly.
SHTS011031200037
13–14 STARTER (J08E: 24 V, 5.0 kW)
11. INSTALL THE YOKE ASSEMBLY ON THE PINION CASE.

(1) Install the packing to the end of the yoke assembly (Grommet
YOKE side).
ASSEMBLY
(2) Install the yoke assembly on the pinion case.
PACKING
SHTS011031200038
12. INSTALL THE BRUSH HOLDER ASSEMBLY AND COMMUTA-

TOR END FRAME.
(1) Install the brush holder assembly.
SHTS011031200039
(2) Install the commutator end frame and tighten the brush
holder attaching bolts.
BOLT
SHTS011031200040
(3) Install the through bolts.
THROUGH BOLT
COMMUTATOR
END FRAME
SHTS011031200041
STARTER (J08E: 24 V, 5.0 kW) 13–15
13. INSTALL THE TERMINAL LEAD.

(1) Connect the "M" terminal lead, install the nut.
LEAD
(2) Connect the "C" terminal lead, install the bolt.
TERMINAL
SHTS011031200042
14. INSTALL THE PINION.

(1) Install the pinion into the inner sleeve.
(2) Using long nose pliers, hold a new C-ring and the shaft and
press in the C-ring.
! WARNING
While working, wear safety glasses because the C-ring may come
out.
C-ring
SHTS011031200043
13–16 STARTER (J08E: 24 V, 5.0 kW)
13
STARTER

EN01F01103120H03001001
Unit: mm {in.}
Measure
If the iron rod does

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

segments of the com- Continuity — Replace.
mutator
Measure
Outside diameter of the

36 {1.417} 34 {1.339} Replace.
commutator
Measure
Depth between the mica
0.5-0.8 0.2 {0.0078} or
and the commutator Replace or repair.
{0.0197-0.0314} less
(Under cut depth)
Measure

brush and the "M" ter- Continuity — Replace.
minal
STARTER (J08E: 24 V, 5.0 kW) 13–17
Measure
Insulation between the

Less than
brush and the yoke More than 1 M Replace.
1 k
body
Measure
A: 11.98
Outside diameter of the A: 12 {0.472} {0.4717}
Replace. 㧭
armature assembly B: 9 {0.354} B: 8.98
㧮
{0.3535}
Measure
Insulation between the Less than

More than 1 M Replace.
brush and brush holder 1 k
Measure
Brush length 18 {0.709} 13 {0.5112} Replace.
Measure
A: 25.90
Outside diameter of the A: 26.0 {1.024} {1.018}
Replace.
drive shaft assembly B: 14.0 {0.551} B: 13.94 㧮㧭
{0.549}
Measure
Inside diameter of the

26.0 {1.024} 26.2 {1.031} Replace the metal.
drive housing assembly
Measure

clutch assembly inner 28 {1.102} 27.90 {1.0984} Replace.
sleeve
13–18 STARTER (J08E: 24 V, 5.0 kW)
Measure
Inside diameter of the

28 {1.102} 28.2 {1.1102} Replace.
drive housing
Visual check
Inside diameter of com-

28 {1.102} 28.1 {1.1063} Replace.
muter end frame
Visual check
Inside diameter of shaft

9 {0.354} 9.2 {0.362} Replace.
assembly
Measure
Replace, if both side

Rotating of clutch
— — turn or does not turn
assembly
at all.
Measure
M
Resistance between the
C terminal and M termi- 0.10-0.12  — Replace.
nal (Pulling coil)
Measure
Resistance between the

C terminal and the body 1.23-1.35  — Replace.
(Holding coil)
C
BODY
STARTER (J08E: 24 V, 5.0 kW) 13–19
Measure

Free: No Continuity
M terminal and B termi- — Replace. FREE
Push: Continuity
nal M
PUSH
B
AIR COMPRESSOR (J08E: 85 x 40) 14–1
AIR COMPRESSOR (J08E: 85 x 40)

14
14-001
AIR COMPRESSOR .................................................. 14-2

DESCRIPTION ..................................................... 14-2
SPECIAL TOOL .................................................... 14-5
OVERHAUL .......................................................... 14-6
14–2 AIR COMPRESSOR (J08E: 85 x 40)
AIR COMPRESSOR

EN01F01103130I02001001
Type Reciprocating, single cylinder
Discharge amount 227 cm3 {13.9 cu.in.}
Bore x stroke 85 mm x 40 mm {3.35 in. x 1.57 in.}
Lubrication system Forced feed lubrication
Cooling system Forced water-circulated
14
AIR COMPRESSOR
DESCRIPTION
EN01F01103130C01001001
SHTS011031300001
1 O-ring 9 Crankcase
2 Cylinder head 10 Piston pin
3 Gasket 11 Piston ring
4 Valve seat 12 Suction valve
5 Piston 13 Delivery valve
6 Connecting rod A Suction
7 Bearing B Delivery
8 Crankshaft
14
AIR COMPRESSOR
COMPONENT LOCATOR
EN01F01103130D01001001
b 4
7
6
Z
a
3 6
a a
a c
8 b 5
Z 10
2
B Z
6
c 1
6
3 11 6
Z
A 6
SHTS011031300002
1 Air compressor idle gear 7 Hose

2 O-ring 8 Coolant pipe B
3 Clip 9 Oil pipe C
4 Clamp 10 Coolant pipe C
5 Delivery air pipe 11 Air compressor
6 Gasket

A 28.5 {291, 21} B 353 {3,600, 260}#
#=Apply oil to the threads and seat surface before tightening.
1
6
12
2 7
11
3 B
8 D
4 10
9
5 17
A
14
18
4
14
16
9
13
8
C
15
SHTS011031300003
1 Cylinder head 10 Lock washer

2 Gasket 11 Piston pin
3 Valve seat 12 Retainer ring
4 O-ring 13 Coupling
5 Cylinder liner 14 Ball bearing
6 Piston ring 15 Crank case
7 Piston 16 Crankshaft
8 Connecting rod 17 Woodruff key
9 Connecting rod bearing 18 Bearing holder

A 25-30 {255-305, 19-22} D 6-7.5 {61-76, 4.4-5.5}
B 23-26 {235-265, 17-19} E 29-34 {296-346, 22-25}
C 30-36 {305-367, 22-26}
14
AIR COMPRESSOR
SPECIAL TOOL
EN01F01103130K01001001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
S0965-01310 PULLER ASSEMBLY
S0944-01060 PISTON RING EXPANDER
S0965-01101 BEARING PULLER

14
AIR COMPRESSOR
OVERHAUL
EN01F01103130H02001001
IMPORTANT POINTS - DISMOUNTING
1. REMOVE THE SUPPLY PUMP.

(1) Refer to the chapter "FUEL SYSTEM (J08E)".
2. REMOVE THE AIR COMPRESSOR.

(1) Remove the six air compressor mounting bolts and remove
the air compressor without applying excessive force.
NOTICE
Excessive force to the air compressor may damage the mounting
spigot or may cause oil leakage due to flaking of liquid gasket
between the flywheel housing and plate.
1. INSTALLATION PROCEDURES
(REPRESENTATIVE TYPE) (1) Fit the No.1 cylinder to the Top Dead Center.
NOTICE
FLYWHEEL
Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
INTRODUCTION (J08E)".
16
FLYWHEEL
HOUSING
SHTS011031300007
(2) Align the aligning mark "0" on the top of coupling flange with
protrusion on the compressor housing.
(3) Insert the O-ring into the O-ring groove of the air compressor
of bearing holder side.
"0" MARK
COUPLING FLANGE PROTRUSION

SHTS011031300008
(4) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.}
or more) in the flywheel housing as shown in the figure and
insert the compressor onto the stud bolt.
(5) Tighten the mounting bolts (other than the stud bolt) then
remove the stud bolt. Insert a bolt in the place of the stud
bolt.
Tightening Torque:
28.5 N·m {290 kgf·cm, 20 lbf·ft}
SHTS011031300009
(6) Make sure that the aligning mark "0" on the top of the cou-
pling flange is aligning with protrusion on the compressor
"0" MARK
housing.
2. INSTALL THE SUPPLY PUMP.

COUPLING FLANGE PROTRUSION

SHTS011031300010
1. REMOVE THE DRIVE GEAR.

(1) Remove the lock nut from the compressor drive gear.
DRIVE GEAR
NOTICE
If the spread is insufficient, the drive gear will be damaged when
loosening the nut.
LOCK THE GEAR

BY VISE
SHTS011031300011
(2) Pull the drive gear from the crankshaft, then remove the
woodruff key.
SST: S0965-01101
Bearing puller
SHTS011031300012
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.
VALVE SEAT
• Do not disassemble the valve seat.
MARKING
SHTS011031300013
3. REMOVE THE CONNECTING ROD WITH THE PISTON.

(1) Rotate the crankshaft to the top dead center position.
(2) Spread the staking of the nut completely with a chisel, then
loosen the nut.
ALIGNING NOTICE
MARKS
Put the aligning marks to the connecting rod and the cap.
(3) Remove the connecting rod with piston.
SHTS011031300014

(1) Remove the piston rings.
SST: S0944-01060
SST
NOTICE
• When reusing the piston rings, first arrange them face up and in
the correct installation sequence in order to prevent installing
them incorrectly.
SHTS011031300015
5. REMOVE THE PISTON.

RETAINER RING (1) Remove the retainer rings installed on both ends of the pis-
ton, using retainer ring pliers.
! WARNING
Wear a pair of safety goggles, because the retainer rings may
spring out the groove at the time of removal.
(2) Strike out the piston pin.
NOTICE
Warm up the piston first in hot water, 80-90C {176-194F}, for
PISTON PIN approximately 5 minutes before removing the piston pin.
SHTS011031300016
6. REMOVE THE CRANKSHAFT.

(1) Remove the coupling.
(2) Remove the bearing holder fitting bolts.
(3) Using a press, remove the crankshaft with bearing holder.
SHTS011031300017
7. REMOVE THE BEARING HOLDER.

(1) Strike the circumference of the holder lightly with a plastic
hammer or a mallet and remove the holder.
NOTICE
Be careful not to damage the bearing holder.
SHTS011031300018
8. REMOVE THE BALL BEARING.

(1) Using the special tool, remove the ball bearing from the end
of the crankshaft.
SST: S0965-01101, for supply pump side
Bearing puller
S0965-01310, for drive gear side
Puller assembly
SHTS011031300019
1. INSTALL THE BALL BEARING.

(1) Install the ball bearing.
STRIKING
TOOL
SHTS011031300020

(1) Using a copper hammer, install the crankshaft to the bearing
holder.
STRIKING
TOOL
SHTS011031300021
(2) Install the crankshaft and bearing holder in the crankcase.

(3) Tighten the bearing holder fitting bolt.
SHTS011031300022
3. INSTALL THE COUPLING.

(1) Install the coupling.
SHTS011031300023
4. INSTALL THE CONNECTING ROD AND MEASURE THE END

PLAY.
NOTICE
ALIGNING
• Be sure to align the aligning mark.
MARKS • Apply engine oil to the bearing.
(1) Apply engine oil to the thread before installing the connecting
rod bolt.
SHTS011031300024
(2) Measure the connecting rod end play.

Assembly standard: 0.2-0.4 mm {0.008-0.015 in.}
Limit: 0.5 mm {0.02 in.}
SHTS011031300025
(3) Lock the nut with a lock washer.
BENT SURFACE FITS

CLOSE TO THE NUT
AND CONNECTING ROD
SHTS011031300026
5. MEASURE THE END PLAY OF THE CRANKSHAFT.

Assembly standard: 0-0.6 mm {0-0.023 in.}
Limit: 1.0 mm {0.039 in.}
SHTS011031300027
END PLAY
SHTS011031300028
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
piston skirt is at the bottom, and use the special tool.
SST: S0944-01060
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011031300029

NOTICE
Warm up the piston first in hot water, to 80-90C {176-194F}, for
approximately 5 minutes.
(1) Install the retainer ring at one end of the piston holes.
(2) Apply engine oil to the piston pin.
(3) Fix the piston and connecting rod by inserting the pin.
(4) Fit the new retainer ring at the other end.
! WARNING
The retainer ring may spring out of the groove during assembly.
Wear a pair of safety goggles during assembly.
SHTS011031300030
8. INSTALL THE CYLINDER LINER AND CYLINDER HEAD.

3RD TOP (2) Arrange the piston rings so that their gaps are equally
RING RING spaced.
45 45
OIL
RING
2ND
RING PIN HOLE
SHTS011031300031
(3) Install the cylinder liner.

O-RING NOTICE
• Align the aligning marks.
• Do not twist the O-ring when installing.
ALIGNING MARK
SHTS011031300032
(4) Install the cylinder head.

NOTICE
• Align the aligning marks.
• Do not twist the O-ring when installing.
O-RING
ALIGNING MARK
SHTS011031300033
9. INSTALL THE DRIVE GEAR.

(1) Install the key to the crankshaft.
DRIVE (2) Insert the drive gear.
GEAR (3) Insert the collar and lock nut.
Tightening Torque:
353 N·m {3,600 kgf·cm, 260 lbf·ft}
NOTICE
LOCK THE Apply oil to the threads and seat surface before tightening.
GEAR
BY VISE
SHTS011031300034
14
AIR COMPRESSOR

EN01F01103130H03001001
Unit: mm {in.}
Visual check
Cracks or defects of the

— — Replace.
connecting rod
Visual check
Damage and scratches of the

— — Replace.
cylinder liner
Visual check
Worn or damaged delivery Replace valve

— —
valve seat.
Visual check
Worn or damaged suction Replace valve

— —
valve seat.
Outside diameter of piston pin 18.0 {0.709} — Measure
Replace pis-
Clearance between the piston 0.016-0.044 ton pin or con-
0.07 {0.0028} necting rod.
pin and connecting rod {0.0007-0.0017}
Inside diameter of the con-

necting rod (with bearings): A
34 {1.339} —
#Tighten the bearing cap to
the specified torque
Outside diameter of the crank

34 {1.339} —
pin: B
Replace con-
necting rod
bearing.
Oil clearance between the
connecting rod and the crank
0.017-0.083
pin: C 0.1 {0.0039}
{0.0007-0.0032}
# Oil clearance
C= A-B
Outside diameter of the piston Measure

85 {3.346} —
(Measure at A and B)
Inside diameter of the cylinder

85 {3.346} —
liner (Measure at A and B)
A: 0.18-0.245
0.285 {0.0112} Replace pis-
{0.0071-0.0096}
ton or cylinder
liner.
Clearance between the piston
and the cylinder liner B: 0.09-0.155
0.195 {0.0076}
{0.0036-0.0061}
Inside diameter of the piston Measure

18.0 {0.709} —
pin hole: A
Outer diameter of the piston

18.0 {0.709} —
pin: B
Replace pis-
ton or piston
Clearance between the piston pin.
pin hole and the piston pin: C 0-0.028
0.08 {0.0031}
# Clearance {0-0.0011}
C= A-B
0.025-0.060 Measure
Top ring 0.1 {0.0039}
{0.0010-0.0023}
Clearance
between the Replace pis-
ring groove ton or piston
and the pis- 0.005-0.040 ring.
2nd, 3rd ring 0.08 {0.0031}
ton ring {0.0002-0.0016}
Measure
Piston ring gap: 0.1-0.3

1.0 {0.0394} Replace.
compression ring {0.0040-0.0118}
A: 40.002-40.013 Measure
39.995 {1.575}
{1.5749-1.5753}

Replace.
crankshaft journal B: 50.002-50.011
49.995 {1.968}
{1.9686-1.9689}
Cylinder block 80 {3.1496} 80.04 {3.151} Measure
Inside
diameter of
Bearing Replace.
the bearing 90 {3.543} 90.04 {3.545}
holder holder
Visual check
Worn or damaged bearing — — Replace.
Measure
Replace
END PLAY
0.2-0.4 connecting
Connecting rod end play 0.5 {0.0197}
{0.0079-0.0157} rod or
crankshaft.
Measure
Replace
Crankshaft end play 0-0.6 {0-0.023} 1.0 {0.039} crankshaft
bearing.
230_Engine14.fm 1 ページ２０１４年８月２５日　月曜日　午前１１時４５分
AIR COMPRESSOR (J08E: 85 x 60)

14
14-002
AIR COMPRESSOR .................................................. 14-2

DESCRIPTION ..................................................... 14-3
SPECIAL TOOL .................................................... 14-5
OVERHAUL .......................................................... 14-6
AIR COMPRESSOR
Type Reciprocating, single cylinder
Discharge amount 340 cm3 {20.7 cu.in.}
Bore x stroke 85 mm x 60 mm {3.35 in. x 2.36 in.}

14
AIR COMPRESSOR
DESCRIPTION
A
B
3 2
4 1
12 5
6
11
8
7
9 10
SHTS011031300001
1 O-ring * 8 Crankshaft
2 Cylinder head assembly 9 Bearing holder
3 Gasket * 10 Crankcase
4 Suction valve * 11 Piston pin
5 Piston 12 Piston ring
6 Connecting rod A Suction
7 Bearing B Delivery
* Nonreusable part
230_Engine14.fm 4 ページ２０１４年８月２６日　火曜日　午前１１時０分
14
AIR COMPRESSOR
COMPONENT LOCATOR
E A
24
1
2
9 6
15
3
16
2
14
4
11 C
13 5
7 B
12 20
8
17
16
23 17 7
19
12
11
21 18
22
25
D
F
SHTS011031300002
1 Head cover 14 Piston pin

2 Gasket * 15 Retainer ring *
3 Cylinder head 16 Bearing holder
4 Valve seat 17 Ball bearing
5 Suction valve * 18 Crankcase
6 Unloader valve 19 Crankshaft
7 O-ring * 20 Woodruff key
8 Cylinder liner 21 Coupling
9 Piston ring 22 Coupling bolt
10 Piston 23 Pin
11 Connecting rod 24 Air compressor assembly
12 Connecting rod bearing 25 Screw
13 Lock washer *
* Nonreusable part

A 29-34 {296-347, 22-25} D 30-36 {305-367, 22-27}
B 25-29 {255-295, 19-21} E 23-26 {235-265, 17-19}
C 23-26 {235-265, 17-19} F 2.5-3.9 {26-39, 1.9-2.8}
14
AIR COMPRESSOR
SPECIAL TOOL

14
AIR COMPRESSOR
OVERHAUL
1. REMOVE THE SUPPLY PUMP.

(1) Remove The supply pump.

(1) Remove the 6 air compressor mounting bolts and remove the
air compressor without applying excessive force.
NOTICE
1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.
POINTER
NOTICE
Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
1/6 MARK INTRODUCTION".
DAMPER
SHTS011031300005
(2) Align the aligning mark "0" on the top of coupling flange with
protrusion on the compressor housing.
(3) Insert the O-ring in to the O-ring groove of the air compressor
of bearing holder side.
PROTRUSION
"0" -MARK
COUPLING FLANGE
SHTS011031300006
bolt.
Tightening Torque:
28.5 N·m {290 kgf·cm, 20 lbf·ft}
SHTS011031300007
(6) Make sure that the aligning mark "0" on the top of coupling
flange is aligned with protrusion on the compressor housing.
2. INSTALL THE SUPPLY PUMP AND AIR COMPRESSOR.

PROTRUSION
"0" -MARK
COUPLING FLANGE
BODY
SHTS011031300008

NOTICE
loosing the nut.
SHTS011031300009
230_Engine14.fm 8 ページ２０１４年８月２６日　火曜日　午前１１時１５分
woodruff key.
SST: S0965-01101
Bearing puller
SHTS011031300010
2. REMOVE THE CYLINDER HEAD ASSEMBLY AND O-RING.

(1) Remove the cylinder head assembly and o-ring.
A
NOTICE
• Put the marking through the cylinder head to the cylinder liner.
• Do not loosen the bolt A (Disassemble parts).
SHTS011031300011
3. REMOVE THE CONNECTING ROD WITH THE PISTON.

loosen the nut.
(3) Remove the connecting rod with piston.
SHTS011031300012

SST: S0944-01060
NOTICE
them incorrectly.
SHTS011031300013

(1) Remove the retainer rings installed on both ends of the pis-
! WARNING
(2) Strike out the piston pin.
NOTICE
approximately 5 minutes before removing the piston pin.
SHTS011031300014

(1) Remove the bearing holder fitting bolts.
(2) Using a press, remove the crankshaft with bearing holder.
BEARING NOTICE
HOLDER Be careful not to damage the bearing holder.
CRANKSHAFT
SHTS011031300015

(1) Using the press, remove the bearing holder.
BEARING HOLDER
NOTICE
CRANKSHAFT
SHTS011031300016

of the crankshaft.
SST: S0965-01101
Bearing puller
SHTS011031300017

(1) Install the ball bearing onto the both ends of the crankshaft.
SHTS011031300018

(1) Using the press, install the crankshaft to the bearing holder.
(2) Install the crankshaft and bearing holder into the crankcase.
(3) Tighten the bearing holder fitting screw.
SHTS011031300019

PLAY.
NOTICE
• Apply engine oil to the connecting rod and cap.
rod bolt.
SHTS011031300020

Limit: 0.5 mm {0.02 in.}
SHTS011031300021
SHTS011031300022

Limit: 1.0 mm {0.0394 in.}
SHTS011031300023

NOTICE
parts.
SST: S0944-01060
NOTICE
Install the piston rings in order shown in the figure.
TOP RING
SECOND RING
OIL RING
SHTS011031300024

NOTICE
! WARNING
SHTS011031300025
7. INSTALL THE CYLINDER LINER.

NOTICE
Piston Piston ring gap Do not twist the O-ring when installing it on the cylinder liner and
㧯 cylinder head.
(2) Arrange the piston rings so that their gaps are equally
㧮㧭 spaced.
A: Top ring gap
B: Second ring gap
Piston ring gap C: Oil ring gap
SHTS011031300026
(3) Replace with a new O-ring and align the alignment marks,
install the cylinder liner to the crank case with bolts.
Bolt NOTICE
Be careful not to twist the O-ring when installing the cylinder liner.
Cylinder
liner
Crank case Alignment mark
SHTS011031300027
8. INSTALL THE CYLINDER HEAD.

Bolt
Alignment (1) Replace with a new gasket and O-ring, align the alignment
mark marks and then install the valve seat and cylinder head to the
Gasket crank case.
NOTICE
Alignment • Be careful not to twist the O-ring when installing it.
mark
• Do not put an alignment mark on the engine mounting surface.
O-ring
Alignment mark
SHTS011031300028

Air compressor drive Air
compressor
(1) Assemble the key to the crankshaft and insert the drive gear
gear securely.Fix the drive gear with a vise with aluminum plates
set between its jaws and tighten it with a nut.
NOTICE
Vise
Take care not to deform or damage the drive gear.
Aluminum plate Nut

SHTS011031300029
IMPORTANT POINT-INSTALLING
1. INSTALL THE BEARING CASE ASSEMBLY.

(1) Install the bearing case assembly to the flywheel housing.
2. SETTING THE COMPRESSION STROKE TOP DEAD CENTRE

OF NO. 1 CYLINDER
(1) Set the No. 1 cylinder at the compression stroke top dead
center.
3. ALIGN THE MARKS.

(1) Align the cast mark on the air compressor with the "O" mark
put on the front face of the coupling.
O-mark
Cast mark
SHTS011031300030
4. INSTALL THE AIR COMPRESSOR.

Air
compressor (1) Align a new O-ring with the O-ring groove of the air compres-
sor.
NOTICE
Check the O-ring groove and contact surface for dirt before
mounting the O-ring.
Clean if dirty.
O-ring
SHTS011031300031
(2) Install the air compressor to the flywheel housing bearing

Air compressor
case with 6 bolts.
O-ring NOTICE
• Adjust the gear in a way not to change the alignment of the No.1
cylinder with the compression stroke top dead center.
• Be careful not to drop the O-ring.
SHTS011031300032
14
AIR COMPRESSOR

Unit: mm {in.}
Visual check
Cracks or defects of the con-

— — Replace.
necting rod
Outside diameter of piston pin 18.0 {0.709} — 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- Measure

necting rod
34 {1.339} —
(Tighten the bearing cap to
the specified torque.)
Outside diameter of the crank

34 {1.339} —
pin
Replace.

0.025-0.075
connecting rod and the crank 0.1 {0.0039}
{0.0010-0.0029}
pin
Measure
Replace con-
0.2-0.4
Connecting rod end play 0.5 {0.0197} necting rod or
{0.0079-0.0157}
crankshaft.
Visual check

— — Replace.
cylinder liner
Outside diameter of the piston 85 {3.346} — Measure
Inside diameter of the cylinder

85 {3.346} —
liner
A: 0.23-0.295
0.33 {0.0130}
{0.0091-0.0116}
Replace.

and the cylinder liner B: 0.09-0.155
0.195 {0.0077}
{0.0036-0.0061}
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
18 {0.709} —
pin
Compression Measure
Piston ring 2.0 {0.0787} —
ring
thickness
Oil ring 4.0 {0.1575} —
Compression
Piston ring 2.0 {0.0787} —
ring
groove
Oil ring 4.0 {0.1575} — Replace.
Clearance between the ring

0.01-0.045
groove and the compression 0.08 {0.0031}
{0.0004-0.0017}
ring
0.1-0.3 Measure
Top 1.0 {0.0394}
{0.0040-0.0118}
Gap between
ends of pis- Replace.
ton ring 0.1-0.3
2nd 1.0 {0.0394}
{0.0040-0.0118}
Visual check
Visual check
Replace cylin-
Worn or damaged valve seat — — der head
assembly.
Visual check
Worn or damaged suction Replace valve

— —
valve seat.
Drive gear Measure

45 {1.7716} 44.995 {1.7714}
side
Outside
diameter of
Opposite Replace.
the crank-
shaft journal drive gear 55 {2.1654} 54.995 {2.1651}
side
100.04 Measure
Cylinder block 100 {3.9370}
{3.9385}
Inside diame-
ter of the
Replace.
bearing Bearing 100.04
holder 100 {3.9370}
holder {3.9385}
Measure
Replace
crankshaft
Crankshaft end play 0-0.6 {0-0.0236} 1.0 {0.0394}
and/or ball
bearing.
Visual check
Worn or damaged unloader

— — Replace.
valve piston
230_Engine15.fm 1 ページ２０１４年８月２７日　水曜日　午前１１時４９分
AIR COMPRESSOR (J08E: 80 x 54 x 2 CYLINDERS) 14–1
AIR COMPRESSOR
(J08E: 80 x 54 x 2 CYLINDERS)
14
14-003
AIR COMPRESSOR .................................................. 14-2

DESCRIPTION ..................................................... 14-2
SPECIAL TOOL .................................................... 14-5
OVERHAUL .......................................................... 14-6
14–2 AIR COMPRESSOR (J08E: 80 x 54 x 2 CYLINDERS)
AIR COMPRESSOR

EN01F01103130I02001001
Type Reciprocating, two cylinder
Discharge amount 271 cm3 {16.5 cu.in.} x 2 cylinders
Bore x stroke 80 mm x 54 mm {3.15 in. x 2.13 pin.}
14
AIR COMPRESSOR
DESCRIPTION
EN01F01103130C01001001
SHTS011031300001
1 Unloader valve 8 Cylinder liner

2 Inlet valve 9 Connecting rod
3 Piston ring 10 Bearing
4 Piston pin 11 Crankshaft
5 Delivery valve A From pressure regulator
6 Cylinder head B To tank
7 Piston C Air suction
14

AIR COMPRESSOR
COMPONENT LOCATOR
EN01F01103130D01001001
5
3
6
4 6
7 5
4 7 6
4 6 13
6
10
6
1
6 6 2
13
3
11
6
8
12
6
9
6
6
SHTS011031300002
1 Air compressor idle gear 8 Pipe

2 O-ring 9 Oil pipe C
3 Clip 10 Coolant pipe C
4 Clamp 11 Air compressor
5 Delivery air pipe 12 Oil pipe
6 Gasket 13 Unloader airpipe
7 Hose

A 353 {3,600, 260}#
#=Apply oil the threads and seat surface before tightening
SHTS011031300003
1 Cylinder block 19 Retainer ring

2 Crankshaft 20 Straight pin
3 Oil seal sleeve 21 Cylinder liner gasket
4 O-ring 22 Cylinder liner
5 Suction valve assembly 23 Cylinder liner gasket
6 Bearing holder assembly 24 Cylinder head assembly
7 Bearing holder 25 Cylinder head
8 Oil seal 26 Delivery valve assembly
9 Bearing retainer 27 Delivery valve holder
10 Bolt 28 Through bolt
11 Woodruff key 29 Lock washer
12 Connecting rod assembly 30 Bearing
13 Connecting rod bearing 31 Piston ring set
14 Connecting rod bolt 32 Unloader valve assembly
15 Connecting rod nut 33 Unloader valve holder
16 Connecting rod washer 34 Unloader valve spring
17 Piston 35 Unloader valve
18 Piston pin 36 Spacer

A 98.1-117.7 {1,000-1,200, 73-86} D 24.5-29.4 {250-300, 19-21}
B 39.2-49.0 {400-500, 29-36} E 13.7-17.6 {140-180, 11-13}
C 22.6-25.5 {230-260, 17-18}
14

AIR COMPRESSOR
SPECIAL TOOL
EN01F01103130K01001001
S0942-01830 PULLER
S0942-01670 PULLER ASSEMBLY
S0948-22220 SLEEVE PRESS
INLET VALVE HOLDER

S0948-11090
ADAPTER
14

AIR COMPRESSOR
OVERHAUL
EN01F01103130H02001001

(1) Remove the five air compressor mounting bolts and remove
the air compressor without applying excessive force.
NOTICE
1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.
SHTS011031300011
(2) Align the aligning mark (two drill hole) on the side of gear
teeth with protrusion on the compressor housing.
SHTS011031300012
bolt.
SHTS011031300013
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
SHTS011031300014
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.
SHTS011031300015

NOTICE
loosing the nut.
SHTS011031300016
woodruff key.
SST: S0942-01830
Puller
SHTS011031300017
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.
SHTS011031300018

(1) Remove the retainer rings installed on both ends of the pis-
! WARNING
(2) Strike out the piston pin, using a tapping rod and a hammer.
NOTICE
approximately 5 minutes before removing the piston pin.
SHTS011031300019
4. REMOVE THE CONNECTING ROD.

loosen the nut.
(3) Remove the connecting rod.
SHTS011031300020

SST: S0944-01060
NOTICE
them incorrectly.
SHTS011031300021

(1) Remove the bearing retainer.
SHTS011031300022
(2) Press the crankshaft end face and remove the crankshaft
with the bearing holder.
SHTS011031300023

(1) Strike the circumference of the holder lightly with a plastic
hammer or a mallet and remove the holder.
NOTICE
SHTS011031300024
8. REMOVE THE OIL SEAL SLEEVE.

(1) Using the special tool, remove the oil seal sleeve.
SST: S0942-01670
Puller assembly
SHTS011031300025

of the crankshaft.
SST: S0965-01101
Bearing puller
SHTS011031300026
10. REMOVE THE SUCTION VALVE ASSEMBLY.

(1) Using the special tool, remove the suction valve holder.
SST: S0948-11090
Inlet valve holder adapter
SHTS011031300027
(2) Disassemble the suction valve.
SHTS011031300028
11. REMOVE THE UNLOADER VALVE ASSEMBLY.

(1) Loosen the unloader valve guide and take it out together with
the unloader valve.
SHTS011031300029
(2) Remove the retainer ring and disassemble the unloader

valve.
SHTS011031300030
12. REMOVE THE DELIVERY VALVE ASSEMBLY.

(1) Remove the delivery valve holder.
SHTS011031300031
(2) Disassemble the delivery valve.
SHTS011031300032
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.
SHTS011031300033
(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 suc-
tion valve and valve spring moves smoothly.
SHTS011031300034
(3) Tighten the suction valve holder to the specified torque using
a special tool.
SST: S0948-11090
Inlet valve holder adapter
(4) Make sure that the suction valve stroke is approximately 2.5
mm {0.0984 in.}.
SHTS011031300035
(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.)
SHTS011031300036
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.
SHTS011031300037
(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.}.
SHTS011031300038
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
specified torque.
SHTS011031300039

(1) Install the ball bearing on the both end of the crankshaft.
SHTS011031300040
5. INSTALL THE OIL SEAL SLEEVE.

(1) Using the special tool, install the oil seal sleeve onto the
crankshaft.
SST: S0948-22220
Sleeve press
SHTS011031300041
6. INSTALL THE OIL SEAL.

(1) Using the special tool, install the oil seal into the bearing
holder.
SST: S0948-22230
Oil seal press
SHTS011031300042

(1) Using a copper hammer, install the crankshaft to the bearing
holder.
SHTS011031300043
(2) Install the crankshaft and bearing holder in the crankcase.

(3) Tighten the bearing holder fitting bolt.
SHTS011031300044

PLAY.
NOTICE
• Apply engine oil to the bearing.
rod bolt.
SHTS011031300045

Limit: 0.5 mm {0.0197 in.}
SHTS011031300046
SHTS011031300047

Limit: 0.4 mm {0.0157 in.}
SHTS011031300048

NOTICE
parts.
SST: S0944-01060
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011031300049
SHTS011031300050

NOTICE
! CAUTION
SHTS011031300051
12. INSTALL THE CYLINDER LINER AND CYLINDER HEAD.

(1) Arrange the piston rings so that their gaps are equally
spaced.
SHTS011031300052
(2) Install the cylinder liner and cylinder head.
SHTS011031300053

(1) Install the woodruff key to the crankshaft.
(2) Install the drive gear.
(3) Install the collar and lock nut.
SHTS011031300054
14
AIR COMPRESSOR

EN01F01103130H03001001
Unit: mm {in.}
Visual check
Cracks or defects of the con-

— — Replace.
necting rod
16 Measure
Outside diameter of piston pin —
{0.630}
Replace.
Clearance between the piston 0.02-0.04 0.07
pin and connecting rod {0.0008-0.0016} {0.0027}
Inside diameter of the con- Measure

necting rod (without bear- 37
—
ings): A #Tighten the bearing {1.457}
cap to the specified torque
Thickness of the connecting 1.5

—
rod bearing: B, C {0.0594}
Outside diameter of the crank 34

—
pin: D {1.339}
Replace.

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
0-0.3 0.4 connecting
Connecting rod end play
{0-0.0118} {0.0157} rod or
crankshaft.
Visual check

— — Replace.
cylinder liner
80 Measure
Outside diameter of the piston —
{3.150}
Inside diameter of the cylinder 80

—
liner {3.150}
A: 0.23-0.30 0.33
{0.0091-0.0118} {0.0130}
Replace.

and the cylinder liner B: 0.07-0.13 0.18
{0.0028-0.0051} {0.0071}
Clearance between the piston 0-0.028 0.08 Measure

pin hole and the piston pin {0-0.0011} {0.0031}
Replace.
Outside diameter of the piston 16
—
pin {0.630}
Compression Measure
0.3-0.5
ring
{0.0119-0.0196}
(Top, 2nd)
Piston Compression 0.1-0.3
ring gap: ring (3rd) {0.0040-0.0118} 1.0
Replace.
compression {0.0394}
ring, oil ring
0.2-0.8
Oil ring
{0.0079-0.0314}
Compression 3.0 Measure

—
Piston ring ring {0.1181}
thickness 4.0
Oil ring —
{0.1575}
Compression 3.0
—
Piston ring ring {0.1181}
Replace.
groove 4.0
Oil ring —
{0.1575}
Clearance between the ring

0.02-0.055 0.08
groove and the compression
{0.0008-0.0021} {0.0031}
ring
Visual check
Visual check
Replace
Worn or damaged delivery
— — delivery valve
valve and valve seat
assembly.
Visual check
Replace
Worn or damaged suction
— — suction valve
valve and valve seat
assembly.
34.99-35.0 34.985 Measure

Drive side (A)
{1.3776-1.3779} {1.3774}
Outside
diameter of
Replace.
the crank- Opposite 35.002-35.013 34.997
shaft journal drive side (B) {1.3781-1.3784} {1.3778}
80 79.996 Measure
Cylinder block
{3.1496} {3.1494}
Inside
diameter
Replace.
of the bearing Bearing 72 71.996
holder holder {2.8346} {2.8345}
Measure
Replace
0-0.3 0.4
Crankshaft end play crankshaft
{0-0.0118} {0.0157}
bearing.
4.41 N Measure
{0.45 kgf, 3.63 N
Suction valve spring setting
0.992 lbf} {0.36 kgf, Replace.
load
at 7.0 mm 0.794 lbf}
{0.276 in.}
4.5 N
{0.46 kgf, 3.6 N
Delivery valve spring 1.019 lbf} {0.37 kgf, Replace.
at 9.5 mm 0.816 lbf}
{0.374 in.}
Visual check
Wear or damage of the suc-
tion valve spring and delivery — — Replace.
valve spring
ENGINE PTO (POWER TAKE-OFF) (J08E) 15–1
ENGINE PTO (POWER TAKE-OFF) (J08E)

15
15-001
POWER TAKE-OFF ASSEMBLY............................... 15-2

DESCRIPTION ..................................................... 15-2
OVERHAUL .......................................................... 15-4
15–2 ENGINE PTO (POWER TAKE-OFF) (J08E)
POWER TAKE-OFF ASSEMBLY
DESCRIPTION
EN01F01106160C01002001
SHTS011031400001
1 Case cover 5 Crankshaft gear

2 Power take off assembly 6 Drive gear
3 Output coupling 7 Ball bearing
4 Main idle gear 8 Oil seal
COMPONENT LOCATOR
EN01F01106160C01002002
SHTS011031400002
1 Case cover 6 Driven shaft

2 Gear case 7 Gear cover
3 Knock pin 8 Oil seal
4 Ball bearing 9 Output coupling
5 Drive gear

A 226 {2,300, 160} B 28.4 {290, 21}
15
OVERHAUL
EN01F01106160H03002001

! WARNING
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.
SHTS011031400003
(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.
SHTS011031400004
(4) Using a suitable sliding hammer, remove the driven shaft with
ball bearing.
(5) Remove the drive gear.
SHTS011031400005
(6) Using a press, remove the ball bearing from the driven shaft.
SHTS011031400006
(7) Using a press, press the driven shaft into the ball bearing.
SHTS011031400007
(8) Using a suitable sliding hammer, remove the ball bearing with
driven shaft.
SHTS011031400008
(9) Using a press, remove the ball bearing from the driven shaft.
SHTS011031400009
(10) Using a flathead screwdriver, pay off the oil seal evenly until
the oil seal comes off.
SHTS011031400010
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.
SHTS011031400011
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.
SHTS011031400012
(2) Using a press, press the driven shaft into the ball bearing.
SHTS011031400013
(3) Using the suitable tool and a press, press the ball bearing
into the gear case.
SHTS011031400014
(4) Set the drive gear in position, then press the driven shaft with
ball bearing into the ball bearing.
SHTS011031400015
(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.
SHTS011031400016
(7) Install the output flange, then tighten the lock nut.
SHTS011031400017
1. INSTALL THE POWER TAKE-OFF

(1) Insert two knock pins.
SHTS011031400018
(2) Apply liquid gasket to the gear case and the flywheel hous-
ing.
(3) Install the power take-off and case cover with 4 bolts.
SHTS011031400019
2. CHECK THE GEAR BACKLASH.

(1) Using a dial gauge, measure the backlash between gears at
the bolt hole of the output flange.
Standard: 0.035-0.657 mm {0.0014-0.0259 in.}
15
SHTS011031400020
230_Engine16.fm 9 ページ２０１４年８月２５日　月曜日　午前１１時５５分


EN01F01103120H03001001
Unit: mm {in.}
Visual check
Shaft and gear: Replace,

— —
Wear and damage if necessary.
Visual check
Oil seal lip: Replace,

— —
Wear and damage if necessary.
Visual check
Bearing improper Replace,

— —
rotation if necessary.
Measure
Drive gear backlash

(Measure at bolt of out- 0.035-0.657
— Replace.
put coupling P.C.D: 100 {0.0014-0.0259}
mm {3.937 in.})
ENGINE CONTROL (J08E) 17–1
ENGINE CONTROL (J08E)

17
17-001
ACCELERATOR PEDAL............................................ 17-2

DESCRIPTION ..................................................... 17-2
ADJUSTMENT...................................................... 17-2
230_Engine17.fm 2 ページ２０１４年８月２５日　月曜日　午後１２時０分
17–2 ENGINE CONTROL (J08E)
ACCELERATOR PEDAL
DESCRIPTION
EN01F01103160C01003001
SHTS011031600001
1 Accelerator pedal assembly

17
ACCELERATOR PEDAL
ADJUSTMENT
EN01F01103160H03002001
1. ADJUSTMENT FOR OUTPUT VOLTAGE OF THE ACCELERA-

TOR STROKE SENSOR.
(1) Check the output voltage with use of HINO DX Ⅱ .
(2) When the output voltage does not match with the standard,
adjust (Sensor long hole) by moving the installation position
of accelerator stroke sensor toward its rotation direction or
replace accelerator stroke sensor with a new one.
ACCELERATO Item Standard value (V)

STROKE
SENSOR Pedal idle 0.70-1.00
Pedal full stroke 3.55-4.4
Exhaust brake switch "ON" 0.70-1.00

SHTS011031600002
COLOPHON.fm 1 ページ２０１４年８月２５日　月曜日　午前９時４２分
Pub. No. S5-MJ08E07A ’14-8

COLOPHON.fm 2 ページ２０１４年８月２５日　月曜日　午前９時４２分

Engine J08 PDF

Загружено:

Сведения о документе

Исходное описание:

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Engine J08 PDF

Загружено:

Авторское право:

Доступные форматы

FOREWORD.

Applicable for J08E engine

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MANUAL No. S5-MJ08E07A

GENERAL INTRODUCTION 1-001

ENGINE INTRODUCTION 2-001

ENGINE MECHANICAL 3-001

AIR INTAKE SYSTEM 4-001

EXHAUST SYSTEM 5-001

LUBRICATING SYSTEM 6-001

COOLING SYSTEM 7-001

FUEL SYSTEM 8-001

FUEL INJECTION PUMP 10-001

ENGINE PTO (POWER TAKE-OFF) 15-001

ENGINE CONTROL 17-001

INDEX: ENGINE GROUP 1/1

WORKSHOP AIR INTAKE SYSTEM

MANUAL EXHAUST SYSTEM

FUEL INJECTION PUMP

ENGINE PTO (POWER TAKE-OFF)

All rights reserved. This manual may not be

GENERAL INTRODUCTION 1–1

GENERAL INTRODUCTION ....................................... 1-2

1–2 GENERAL INTRODUCTION

General Safety information

GENERAL INTRODUCTION 1–3

HOW TO USE THIS MANUAL

2. TROUBLESHOOTING IN THIS MANUAL

Thoroughly listen to the conditions and environment for the trou-

Perform diagnostic inspection, checkup of the symptom, function

Classify the inspection results obtained in step 2 to systematically

• Execute the following steps to perform pre-inspection.

1–4 GENERAL INTRODUCTION

3. DESCRIPTION IN THIS MANUAL

5–54 CLUTCH/CLUTCH MECHANICAL

Alphabetical mark indicating the

Numerical order indicating 10

1 Clutch facing 9 Pivot ring

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

Alphabetical mark Tightening torque

GENERAL INTRODUCTION 1–5

(2) Work steps

BRAKE/BRAKE CONTROL 9–49

Indicating the work sequence OVERHAUL

REMOVING THE AUTO SLACK ADJUSTER

1. REMOVING THE AUTO SLACK ADJUSTER

DISASSEMBLING THE AUTO SLACK ADJUSTER

2. DISASSEMBLING THE RACK AND SPRING SECTION

Indicating the part number of

(3) Remove the rack using the screwdriver.

1–6 GENERAL INTRODUCTION

5. DEFINITION OF SAFETY TERMS

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

GENERAL INTRODUCTION 1–7

Item SI unit Traditional unit Conversion*1 (1 [traditional unit] = X [SI unit])

Force N kgf 1 kgf=9.80665 N

Torque*2 Nm kgfcm 1 kgfcm=0.0980665 Nm

kgf/cm2 1 kgf/cm2=98.0665 kPa=0.0980665 MPa

r/min. 1 rpm=1 r/min.

Spring constant N/mm kgf/mm 1 kgf/mm = 9.80665 N/mm

Calorie Wh cal 1 kcal = 1.13279 Wh

1–8 GENERAL INTRODUCTION