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FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Operation Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
TURBOCHARGER EN08-001
STARTER EN12-001
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE PTO
(POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROL
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
OTHERS
GENERAL INTRODUCTION (ENGINE) GN01–1
Some recommended and standard maintenance services for your engine are included in this section. When per-
forming maintenance on your engine, be careful not to get injured by using improper work procedures. Improper
or incomplete work can cause a malfunction of the engine, which may result in personal injury and/or property
damage. If you have any question about performing maintenance, please consult your Hino dealer.
CAUTION
When working on your engine, observe the following general precautions to prevent personal injury and/or prop-
erty damage, in addition to the particular NOTICES or CAUTIONS in each chapter.
TOWING
• When being towed, always place the gear shift lever in "Neutral"
and release the parking brake completely. In order to protect the
bumper, fit a protection bar against the lower edge of the bumper
and put a wood block under the frame near the No. 1 crossmem-
ber when attaching the towing chain. Never lift or tow the vehicle if
the chain is in direct contact with the bumper.
1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is
removed. When the differential gear or rear axle shaft is defective,
remove both right and left rear axle shafts, then cover the hub
opening to prevent loss of axle lubricant and entry of dirt or for-
eign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten
the cable securely to the towing hook on the frame. The hook
should be used only if the towed vehicle is not loaded.
(3) The angle of pulling direction of the cable fastened to the towing
hook must not exceed 15 in horizontal and vertical directions from
the straight ahead, level direction. Avoid using the hook in a way
that subjects it to jerk, as in towing a vehicle trapped in a gutter.
GENERAL INTRODUCTION (ENGINE) GN01–3
• REPAIR PROCEDURES
Repair procedures when self-explanatory, such as simple installa-
tion and removal of parts, have been omitted. Illustrations, such
as the one below, have been provided to make such simple proce-
dures clear. Only essential procedures requiring specific direc-
tions have been dealt with explicitly.
GN01–4 GENERAL INTRODUCTION (ENGINE)
OVERHAUL
3 5 A
12
13 5 B
4
12
C
5 13
2 6
1 7 12
5
13
8
11
5
10
9
M00010100002
IDENTIFICATION INFORMATION
M000101BEC1003
M00010100003
Class 7T 9T
Representation
7 q
Diameter x Pitch
Class 4T 7T 9T
Representation
7 q
M14 x 1.5 83 {850, 61.5} 147 {1,500, 108.5} 186 {1,900, 137.4}
Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
8 {0.315} 13 {130, 9}
Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
10 {0.394} 11 {110, 8}
NOTICE:
• Before installing the joints, ensure that is no dirt or burrs
adhering to the various seat faces (pipe joints, gasket, etc.)
• Because the pipes can move relatively freely during installa-
tion and the seat faces are liable to tilt, first temporarily
tighten the pipes, then tighten them to the specified torque
and ensure that there is no leakage from them.
• When tightening two pipes together, be very careful that they
do not rotate together.
• After installing the pipes, apply the correct pressure to each
pipe joint and ensure that there is no leakage.
• Ensure that the various tightening torques conform to the
above table.
*If a soft washer #4840 FR–N (aluminum + rubber and carbon
press fit part) is loosened or removed subsequent to being
installed, be sure and replace it with a new one.
There is no need to replace it, however, for normal retightening.
ENGINE INTRODUCTION (J08C) EN01–1
ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
M01010101BEI2001
Model J08C-UJ
Compression pressure 3.4-3.7 MPa {35-38 kgf/cm2, 495-540 lbf/in.2} at 280 r/min
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Model J08C-UK
Compression pressure 3.4-3.7 MPa {35-38 kgf/cm2, 495-540 lbf/in.2} at 280 r/min
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
TROUBLESHOOTING
M01010101BEF3001
Engine overheating
Symptom Possible cause Remedy/Prevention
Engine overheating (Coolant) Insufficient coolant Add coolant.
Defective thermostat Replace thermostat.
Coolant overflow due to leakage of Repair.
exhaust into cooling system
Coolant leakage from cylinder head Replace gasket.
gasket
Defective coolant pump Repair or replace.
Engine overheating (Radiator) Clogged with rust or scale Clean radiator.
Clogged with iron oxide due to leakage Clean coolant passage and correct
of exhaust into cooling system exhaust leakage.
Clogged radiator core due to mud or Clean radiator.
other debris
Defective radiator cap pressure valve Replace radiator cap.
Engine overheating (Abnormal Incorrect injection timing Adjust injection timing.
combustion) Reduced injection pressure Adjust injection pressure.
Poor fuel Use good quality fuel.
Poor nozzle spray Adjust or replace nozzle.
Unsatisfactory automatic timer Repair or replace timer.
advance angle
Engine overheating (Other prob- Defective or deteriorated engine oil Change engine oil.
lems) Unsatisfactory operation of oil pump Replace or repair.
Insufficient oil Add oil.
Brake drag Repair or adjust.
Piston seizure
Symptom Possible cause Remedy/Prevention
Piston seizure (Operation) Abrupt stoppage of engine after run- Operate engine properly.
ning at high speed
Hill climbing using unsuitable gear Select suitable gear.
Piston seizure (Oil) Insufficient oil Add oil.
Dirty oil Change oil.
Poor quality oil Replace with proper engine oil.
High oil temperature Repair.
Low oil pressure Repair.
Defective oil pump Repair oil pump.
Reduced performance due to worn oil Replace oil pump.
pump
Suction strainer sucking air Add oil and/or repair strainer.
Piston seizure Abnormal combustion See Symptom: "Engine overheating".
Piston seizure Coolant See Symptom: "Engine overheating".
Lack of power
Symptom Possible cause Remedy/Prevention
Lack of power Injection pump Refer to CHAPTER FUEL CONTROL.
Lack of power (Intake) Clogged air cleaner Clean element or replace element.
Lack of power Overheating See Symptom: "Engine overheating".
Lack of power (Fuel and nozzle) Poor nozzle spray Adjust or replace injection nozzle.
Clogged nozzle with carbon Clean nozzle.
Wear or seizure of nozzle Replace nozzle.
Air in fuel system Repair and bleed air from fuel system.
Clogged fuel filter Replace element.
Use of poor fuel Use good quality fuel.
Lack of power Abnormal combustion See Symptom: "Engine overheating".
Lack of power Wear of cylinder liners, and piston See Symptom: "Engine overheating".
rings
EN01–6 ENGINE INTRODUCTION (J08C)
Rough idling
Symptom Possible cause Remedy/Prevention
Rough idling Injection pump Refer to CHAPTER FUEL CONTROL.
Rough idling (Nozzles) Uneven injection pressure Adjust.
Poor nozzle spray Adjust or replace nozzle.
Carbon deposit on nozzle tip Remove carbon.
Seized needle valve Replace nozzle.
Rough idling (Engine proper) Improper valve clearance Adjust valve clearance.
Improper contact of valve seat Replace or repair valve and valve seat.
Idling speed too low Warm up engine.
Compression pressure of cylinders Overhaul engine.
markedly different from one another
ENGINE INTRODUCTION (J08C) EN01–7
Leakage of exhaust
Symptom Possible cause Remedy/Prevention
Leakage of exhaust (Cylinder head Fatigued gasket (aging) Replace gasket.
gasket) Damage Replace gasket.
Improper installation Replace gasket.
Leakage of exhaust (Cylinder head Loose bolts Tighten bolt.
bolts) Elongated bolts Replace bolt.
Improper tightening torque or tighten- Tighten properly.
ing sequence
Leakage of exhaust (Cylinder block) Cracking Replace cylinder block.
Surface distortion Repair or replace.
Fretting of cylinder liner insertion por- Replace cylinder liner or cylinder
tion (insufficient projection of cylinder block.
liner)
Leakage of exhaust (Cylinder head) Cracking Replace cylinder head.
Surface distortion Repair or replace.
Leakage of exhaust (Cylinder liners) Cracking Replace cylinder liner.
Corrosion Replace cylinder liner.
Insufficient projection of cylinder liner Replace cylinder liner.
Leakage of exhaust (Other prob- Incorrect injection timing Adjust injection timing.
lems)
ENGINE TUNEUP
M01010101BEH3001
• Among three drill holes on the camshaft gear, when two drill holes
are on horizontal position, and the rest of the drill hole is visible,
the No.1 piston is at the Top Dead Center of the compression
stroke .
NOTICE:
If the rest of drill hole is invisible by camshaft housing, the No.6
piston is at the Top Dead Center of the compression stroke.
DRILL HOLE
M01010100046
(2) Make sure that the valve stem is correctly inserted in the cross
head.
NOTICE:
Click Move the cross head with fingers right and left to confirm the
valve stem is correctly inserted in the cross head by listening to
the clicking sound.
Good
(3) Confirm that there is no foreign particles or dust between the
cross head and the valve stem.
Cylinder 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
(2) Before checking the valve clearance, make sure that the roller is
on the base circle of the camshaft.
M01010100005
M01010100006
3. VALVE CLEARANCE ADJUSTMENT
CAUTION:
Valve clearance adjustment is performed only when the checking
result is outside the specified value.
NOTICE:
• Before beginning the adjustment you must perform "PREPA-
RATION OF CHECKING AND ADJUSTMENT" described on
page EN01-7.
• As for the valve which can adjust the valve clearance refer to
the chart on page EN01-8.
• Make sure that the cylinder head bolt, rocker arm support
bolt, nozzle clamp bolt, cam housing bolt and cam bearing
cap bolt are tightened to the specified torque.
(1) Loosen the adjusting screw lock nut A, D of the rocker arm and
A B cross head fully.
ROCKER ARM (2) The cross head adjusting screw must protrude 10 mm {0.394 in.}
or more from the cross head upper face.
10mm or more NOTICE:
C Unless the adjusting screw is completely loose to the valve stem
D head, the following adjustments may be adversely affected.
"Zero" Need
clearance clearance
CROSS HEAD
M01010100007
(4) After completion of the adjustment, tighten the lock nut A securely
with the specified tightening torque.
Tightening Torque:
M01010100008
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
EN01–10 ENGINE INTRODUCTION (J08C)
(5) The condition of inserted feeler gauge, loosen the adjusting screw
of the cross head, make sure that the feeler gauge does not feel
LOOSEN
loose.
C
NOTICE:
If the feeling of the feeler gauge becomes loose, repeat steps from
(1).
D
Need
clearance
M01010100009
(6) Tighten the adjusting screw C of the cross head until the feeler
ROCKER ARM gauge does not move.
TIGHTEN
NOTICE:
C In this situation, clearance between adjusting screw C and valve
stem head is zero.
"ZERO"
"ZERO" clearance
clearance
M01010100010
(7) While loosening the adjusting screw C of the cross head gradu-
ally, adjust the valve clearance. Tighten the lock nut D of the cross
head securely with the specified tightening torque when the feeler
C gauge feels correct.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
D
M01010100011
NOTICE:
• Do not over loosen the adjusting screw.
Not over loosen
• Over loosening of the adjusting screw C will cause the same
C
condition as in step (3) again. The feeler gauge may feel cor-
rect, but there may be excessive clearance between the
adjusting screw C of the cross head and the valve stem head
E E. This does not allow for correct adjustment.
"ZERO" (8) Positioning each piston at Top Dead Center of compression stroke
clearance by turning the crankshaft counterclockwise view from flywheel
side. Then adjust the valve clearance for each cylinder in the firing
M01010100012
order.
(3) Turn the automatic timer to the left (counterclockwise viewed from
the drive shaft) to align the automatic timer mark with the pointer
of the pump.
(4) Tighten the adjusting bolt to the specified torque.
M01010100014
SST: Injection pump coupling wrench (09511-2500: BOSCH)
Tightening Torque:
88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}
NOTICE:
• No clearance is allowed between thin plates.
• No deformation of the flange is allowed due to distortion of a
thin plate.
1. PREPARATION
(1) Supply engine oil.
M01010100015
M01010100016
M01010100017
EN01–12 ENGINE INTRODUCTION (J08C)
LUBRICATION
M01010100018
SPECIAL TOOL
M01010101BEK1001
COMPRESSION GAUGE
09552-1090 For Overhaul criteria
ADAPTER (A)
OVERHAUL CRITERIA
M01010101BEH3002
(2) Measurement
a. Insert the gauge adaptor into the nozzle holder hole.
SST:
Compression gauge adaptor(A) (09552-1090)
Compression gauge adaptor(B) (09552-1030)
Compression gauge adaptor(B) (09552-1060)
b. Run the engine with the starter and measure the compression
pressure.
Difference between
Standard Limit
each cylinder
M01010100021 3.4-3.7 MPa 2.7 MPa 0.3 MPa
{35-38 kgf⋅cm2, {28 kgf⋅cm2, {3 kgf⋅cm2,
497-540 lbf/in2} 398 lbf/in2} 43 lbf/in2} or less
Engine revolution 280r/min
NOTICE:
Do not operate the starter for more than 15 seconds.
c. Measure the compression pressure of each cylinder.
NOTICE:
Do not allow gas leakage from the seal face.
(3) Reassemble the removed parts.
CAUTION:
When the starter switch is at ON position, do not connect the
engine stop motor connector. Connection operates the engine
stop motor (motor link is at OFF position) and the lever may catch
your finger.
M01010100060
3. OTHER FACTORS
M01010100023 (1) Increase of blowby gas
(2) Defective engine start
(3) Decrease of engine output
(4) Increase of fuel consumption
(5) Increase of engine noise
(6) Increase of oil consumption
EN01–14 ENGINE INTRODUCTION (J08C)
NOTICE:
Check to see that there are no oil leaks, fuel leaks, coolant leaks,
M01010100025 or air leaks.
M01010100026
EN01–16 ENGINE INTRODUCTION (J08C)
• Liquid gasket is used at the following positions for the J08C series
engine.
2. REMOVE PARTS.
(1) When removing parts, do not use a tool for removal at one loca-
tion only. Use the tool at various locations such as a flange step or
gap for removal. When removing the gasket, be careful that gas-
ket residue does not enter the engine.
3. OTHERS.
(1) For tube-type liquid gasket, use the winding tool that comes with
the liquid gasket.
M01010100027
M01010100028
1: Approxi-
2 mm wide when cut at the first step
mately
2: Approxi-
5 mm wide when cut at the second step
mately
M01010100029
ENGINE INTRODUCTION (J08C) EN01–17
Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1.5-2.5
1 Oil seal retainer {0.0591- Black
0.0984}
1.5-2.5
2 Coolant pump {0.0591- Black
0.0984}
1.5-2.5
3 Oil cooler {0.0591- Silver
0.0984}
1.5-2.5
5 Thermostat case {0.0591- Silver
0.0984}
1.5-2.5
6 Flange {0.0591- Silver
0.0984}
EN01–18 ENGINE INTRODUCTION (J08C)
Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
NOTICE:
Cut the rear end plate gasket with a craft knife
flush with the block upper face.
ENGINE INTRODUCTION (J08C) EN01–19
Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1.5-2.5
Flywheel hous-
9 {0.0591- Silver
ing
0.0984}
NOTICE:
• Application area of liquid gasket is half cir-
cle of cam housing. Never apply it to the
10 Cam housing upper half circle of the plug.
• Remove the excessive gasket completely.
NOTICE:
Figure on the right shows application "pattern" of the liquid gasket.
Apply the liquid gasket to the center of seal flange inside whenever pos-
sible.
ENGINE MECHANICAL (J08C) EN02–1
EN02-001
FLYWHEEL AND
FLYWHEEL HOUSING............................ EN02-22
COMPONENT LOCATOR.............................. EN02-22
SPECIAL TOOL ............................................. EN02-23
OVERHAUL ................................................... EN02-23
INSPECTION AND REPAIR .......................... EN02-26
CYLINDER HEAD
COMPONENT LOCATOR
M01020101BED1001
A 5
2
3
C
20
19
21
29
D
6
9
7 E
F 8 10
11
11
I
25 12 14
G 17
26
15
30 18
23 13
22 16
24
27
28
31
32
M01020100089
ENGINE MECHANICAL (J08C) EN02–3
4
5
1
6 A
2
7
3
8
9
10 16
11
17
12
13
18
14
15
M01020100090
SPECIAL TOOL
M01020101BEK1001
09491-1010 WIRE
09471-1520 GUIDE
EN02–6 ENGINE MECHANICAL (J08C)
OVERHAUL
M01020101BEH2001
M01020100010
7 5 3 1 2 4 6
M01020100094
M01020100091
ENGINE MECHANICAL (J08C) EN02–7
(5) Lift and remove the cylinder head using the special tool and hoist.
SST:
Eye bolt (09433-1070)
Wire (09491-1010)
NOTICE:
• Do not damage the cylinder head lower surface or cylinder
block upper surface during removal of the cylinder head.
• If it is difficult to lift off the cylinder head, pry with a chisel
between the cylinder head and cylinder block.
M01020100013
M01020100014
M01020100015
M01020100016
EN02–8 ENGINE MECHANICAL (J08C)
IMPORTANT POINTS-REPLACEMENT
(3) When installing a new valve guide, do not twist the end. Press fit
the valve guide using the special tool.
M01020100017 SST: Guide (09471-1520)
NOTICE:
• Be careful not to damage the valve stem at the upper or lower
end of the guide during press-fitting.
• Be sure to apply engine oil around the valve guide during
press-fitting.
ELECTRIC (2) Place a (brass) back plate at the top of the valve system and
VALVE WELDING strike it with a hammer to remove the valve seat.
CUT THREE CAUTION:
PLACES HERE Striking the valve seat for removal may cause metal chips to fly
up. Be sure to wear protective goggles.
M01020100018
(4) Heat the cylinder head to 80 - 100°C {176 - 212°F} in hot water.
After cooling the valve seat, insert it into the cylinder head.
CAUTION:
Striking the valve seat during installation may cause metal chips
to fly up. Be sure to wear protective goggles.
M01020100020
ENGINE MECHANICAL (J08C) EN02–9
M01020100021
CAUTION:
Punching the valve stem seal during installation may cause metal
chips to fly up. Be sure to wear protective goggles.
NOTICE:
After assembly of the stem seal, check for deformation or cracking
of the rubber or incline.
APPLICATION OF OIL
RUBBER
M01020100022
M01020100023
EN02–10 ENGINE MECHANICAL (J08C)
(2) After inserting the O-ring into the nozzle seat insertion hole of the
cylinder head, apply liquid packing (Three Bond No. 1211 or
equivalent) to the lower part of the new nozzle seat and assemble
it onto the cylinder head.
NOTICE:
Be sure to replace the O-ring with a new one. Reuse of the O-ring
may cause water or gas leakage, resulting in overheating or crack-
ing of the cylinder head.
M01020100024
M01020100025
NOTICE:
• Be sure to apply engine oil to the contact surface of each
part before assembly.
• Be sure to place each valve in its original position.
M01020100014 • When the valve spring is compressed, be careful of damage
to the stem seal due to contact of the upper seat.
• Since this valve spring is evenly pitched, it can be installed
either end up.
(1) Install the cylinder head gasket on the cylinder block and flywheel
housing.
(2) Fill the hole at the back of the cylinder head gasket with liquid
gasket.
NOTICE:
Make sure that the liquid gasket surface is flush with the cylinder
head gasket upper surface.
M01020100027
M01020100028
M01020100013
EN02–12 ENGINE MECHANICAL (J08C)
(2) Apply clean engine oil to the bolt surface and bolt threads of the
M10 and M12 bolts.
(3) Clean the bolt seats completely on the cylinder head upper sur-
face.
(4) Tighten No. 1 - No. 26 (M12 bolts) in the order shown in the figure
to the specified torque.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100092
(5) Mark the M12 bolts with paint to indicate the same directions as
shown in the figure.
(6) Turn No. 1 - No. 26 (M12 bolts) 90° (1/4 turn) in the same order as
in (4) .
(7) Retighten them 90° (1/4 turn) as step (6).
(8) Make sure that all paint marks face the same direction.
NOTICE:
When adding torque, never untighten the bolts, even if they have
been overtightened.
M01020100031
(9) Tighten No. 27 - No. 29 (M10 bolts) in the order shown in the fig-
ure to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100093
LUBRICATION
CYLINDER HEAD HOLE
M01020100033
ENGINE MECHANICAL (J08C) EN02–13
M01020100034
(2) Make sure that there is neither damage to the camshaft gear or
camshaft nor dirt on them.
(3) Apply clean engine oil to the bolt surface and bolt threads and
tighten them to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100035
M01020100036
(3) Install the camshaft bearing cap, and tighten the bolts.
EN02–14 ENGINE MECHANICAL (J08C)
M01020100038
M01020100039
(3) Install the camshaft housing plug to camshaft housing with torx
bolt.
NOTICE:
Make sure that the camshaft housing plug installed with no tilt.
M01020100040
(4) Apply liquid gasket to the front and rear half circles of the cam-
shaft housing.
NOTICE:
Wipe out excess liquid gasket completely.
M01020100041
ENGINE MECHANICAL (J08C) EN02–15
(5) Install the head cover gasket into the gasket groove at the head
cover lower surface.
NOTICE:
Make sure that there are no foreign particles (including liquid gas-
ket), or oil on the gasket grooves of the head cover, gasket or cam
housing upper surface nor damage to them.
CYLINDER PLUG
(6) Apply liquid gasket to plug corner at the front and rear ends of the
cam housing before installing the head cover.
CAM HOUSING
M01020100042
(7) Insert the silent block (No.1) from the head cover lower surface.
(8) Tighten the bolt through the silent block (No.2) to the specified
torque below and fix the head cover on the cam housing.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
M01020100043
Unit: mm {in.}
Measure
0.100-0.178
Camshaft end play — Replace camshaft.
(0.0040-0.0070)
49.987 Measure
IN 50.067{1.9711}
{1.9680}
Measure
Stem out-
side diame- 7 {0.2756} 6.85 {0.2697} Replace the valve.
ter
Exhaust Guide inside Replace the valve
valve 7 {0.2756} 7.04 {0.2772}
diameter guide.
Valve sink
1.05-1.35 Replace the valve
EX 1.6 {0.0630}
{0.0414-0.0531} and valve seat.
IN 30° 29°30°-30'
Resurface the
valve and/or valve
Valve face seat.
angle EX 45° 44°30°-45''
ENGINE MECHANICAL (J08C) EN02–17
2.6 {0.1023}
Squareness — Replace.
(2.0°)
129 N 119.5 N
Setting load {13.2 kgf, 29.1 lbf} {12.2 kgf, Replace.
at 44.8 {1.764} 26.9 lbf}
Free length
(reference 64.6 {2.543} 61.6 {2.425} Replace.
value)
Inner valve
spring
2.3 {0.0905}
Squareness — Replace.
(2.0°)
Visual check
Wear and damage of valve
spring seat upper and — — Replace.
lower
Measure
Replace.
Cylinder head lower sur-
0.20 {0.0078} NOTICE: Do not
face flatness 0.03 or less grind for repair.
{0.0012 or less}
for lateral
direction
EN02–18 ENGINE MECHANICAL (J08C)
Visual check
Visual check
M01020200017
SPECIAL TOOL
M01020201BEK1001
OVERHAUL
M01020201BEH2001
(1) Place the plate at the crankshaft end using the crankshaft pulley
bolts.
PLATE
M01020200003
(2) Engage the hook with the oil seal notch and install the hook using
REMOVE THIS AFTER INSTALLING THE HOOK the bolt supplied.
(3) Remove the installed bolt in step (1).
NOTCH
HOOK
M01020200004
(4) Install the center bolt and tighten it to remove the oil seal.
CENTER BOLT
M01020200005
ENGINE MECHANICAL (J08C) EN02–21
(1) Clean the edges and surface of the crankshaft and the special
tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal press.
OIL SEAL
M01020200006
NOTICE:
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
M01020200007
(3) Apply a little engine oil to the seal portion of the crankshaft oil
seal.
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
GUIDE BOLT
M01020200008
(5) Insert the oil seal press by adjusting the oil seal press hole to the
PRESS guide bolt.
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
CENTER BOLT
M01020200009
EN02–22 ENGINE MECHANICAL (J08C)
M01020300022
SPECIAL TOOL
M01020301BEK1001
OVERHAUL
M01020301BEH2001
(1) Place the plate at the crankshaft end using the flywheel bolts.
NOTICE:
Match the plate hole to the crankshaft collar knock part.
M01020300002
(2) Engage the hook with the oil seal notch and install the hook using
HOOK the bolt supplied.
NOTCH (3) Remove the installed flywheel bolts in step (1).
M01020300003
EN02–24 ENGINE MECHANICAL (J08C)
(4) Install the center bolt and tighten it to remove the oil seal.
CENTER
BOLT
M01020300004
(1) Clean the edges and surface of the crankshaft and the special
tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal press.
M01020300005
NOTICE:
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
M01020300006
(3) Apply a little engine oil to the seal portion of the crankshaft oil
seal.
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
GUIDE BOLT
M01020300007
(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
PRESS
CENTER BOLT
M01020300008
ENGINE MECHANICAL (J08C) EN02–25
M01020300009
(2) Heat the ring gear evenly to about 200°C {392°F} with a torch.
Insert the ring gear into the flywheel so that the chamfered side is
upward.
CAUTION:
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
M01020300010
NOTICE:
Place one guide bar at the collar knock and another at the oppo-
site side of the collar knock.
M01020300011
(2) Insert the flywheel slowly until it contacts the collar knock to pre-
vent impact on the guide bar. Adjust the position, then insert the
flywheel completely.
CAUTION:
The flywheel is too heavy. When installing, be careful not to drop it
on your feet.
(3) Apply clean engine oil to the threads of the flywheel bolt and the
flywheel bolt seat. Be sure to tighten the flywheel bolts (6 pieces)
with a low-torque impact wrench.
(4) Pull out the guide bar and tighten the remaining two flywheel bolts
provisionally as in step (3).
(5) Tighten the flywheel in the order shown in the figure to the speci-
fied torque below.
Tightening Torque:
186 N⋅m {1,900 kgf⋅cm, 137 lbf⋅ft}
(6) Loosen all bolts and tighten them again to the specified torque.
M01020300012
EN02–26 ENGINE MECHANICAL (J08C)
Unit: mm {in.}
Measure
Flywheel surface
— 0.15 {0.0059} Repair.
deflection
Flywheel Measure
flange
depth CS350 43 {1.693} 43 {1.693} Repair.
(Dimen- series
sion A) (Diameter
Flywheel 350 mm
thickness {14 in.})
21 {0.827} 20 {0.787} Repair.
(Dimen-
sion B)
Flywheel
flange
depth 48 {1.890} 48 {1.890} Repair.
(Dimen- CS380
sion A) series
(Diameter
Flywheel 380 mm
thickness {15 in.})
23 {0.906} 22 {0.866} Repair.
(Dimen-
sion B)
TIMING GEAR
COMPONENT LOCATOR
M01020401BED1001
M01020400001
SPECIAL TOOL
M01020401BEK1001
OVERHAUL
M01020401BEH2001
M01020400005
M01020400006
ENGINE MECHANICAL (J08C) EN02–29
Tightening Torque:
55 N⋅m {560 kgf⋅cm, 41 lbf⋅ft}
M01020400007
M01020300024
3. INSTALL THE IDLER GEAR SHAFT AND GEAR.
M01020400008
NOTICE:
• Install each idle gear shaft through the thrust plate as shown
in the figure so that the lubrication hole is downward.
• Adjust the timing of the main idle gear to align with the air
compressor gear as shown in the figure.
EN02–30 ENGINE MECHANICAL (J08C)
M01020400009
Unit: mm {in.}
Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}
Air compres-
sor-Power 0.030-0.183
0.30 {0.0118}
steering {0.0012-0.0072}
Timing pump
gear back- Replace gear.
Main idle-Sub 0.030-0.162
lash 0.30 {0.0118}
idle {0.0012-0.0063}
Shaft outside
57 {2.244} — —
diameter
Bushing
inside diame- 57 {2.244} — —
ter
Measure
Main idle 0.030-0.090 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0012-0.0035} or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside diame- 50 {1.969} — —
ter
Sub idle 0.025-0.075 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
34 {1.339}
inside diame- — —
ter
Cam idle 0.025-0.075 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.
M01020500093
ENGINE MECHANICAL (J08C) EN02–33
M01020500094
M01020500095
SPECIAL TOOL
M01020501BEK1001
09471-1490 GUIDE
09402-1540 SPINDLE
09481-1540 GUIDE
9191-08252 BOLT
09444-1630 GAUGE
OVERHAUL
M01020501BEH2001
M01020500017
M01020500018
ENGINE MECHANICAL (J08C) EN02–37
NOTICE:
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• Keep the piston rings for each cylinder separately.
M01020500019
M01020500020
(2) Pull the cylinder liner from the cylinder block using the special
tool.
SST: Puller (09420-1720)
NOTICE:
• Carefully set the special tool to prevent touching to the pis-
ton cooling jet.
• After removing the cylinder liners, arrange them in sequence.
M01020500021
M01020500022
EN02–38 ENGINE MECHANICAL (J08C)
(2) For the jet test, connect the oil hose to the connector bolt from the
cylinder block lower side.
NOTICE:
Use clean engine oil for jet flow.
M01020500023
(3) Set the special tool on the cylinder block upper surface against
the dowel pin.
SST: Gauge (09444-1630)
(4) Test jet oil flow from the piston cooling jet nozzle at a hydraulic
pressure of 196 kPa {2 kgf/cm2, 28 lbf/in2}.
M01020500096
(5) If the center of the jet flow is within the target circle (7mm {0.2756
in} diameter: Red), the test is acceptable.
NOTICE:
• Fire may occur due to splattered oil during the jet flow test.
Do not use naked lights near the test area.
CAUTION:
• Engine oil is flammable. Carry out this test in a well venti-
lated room and do not use naked lights in the room.
M01020500025
(6) If the center of the jet flow is out of the target circle, realign the
nozzle using the special tool.
SST: Adjusting bar (09472-1620)
M01020500026
M01020500027
ENGINE MECHANICAL (J08C) EN02–39
M01020500028
(1) Apply engine oil to the inner surface of the block bore and insert
the cylinder liner using the special tool.
SST: Guide (09471-1490)
NOTICE:
Handle the cylinder liner carefully because it is thin.
(If it falls on the floor, it cannot be used.)
M01020500029
Tightening Torque:
9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}
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.}
M01020500031
EN02–40 ENGINE MECHANICAL (J08C)
M01020500032
M01020500033
(3) Apply clean engine oil to the bolt seat and bolt threads.
(4) Tighten the bolts in the order as shown in the figure to the speci-
FRONT fied torque.
Tightening Torque:
69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
2 4 6 8 10 12 14 (5) Loosen all bolts, tap the front and back ends of the crankshaft
1 2 3 4 5 6 7
using a plastic hammer.
1 3 5 7 9 11 13
(6) Tighten the bolts as in step (4).
(7) Mark the bolt heads with paint.
M01020500097
(8) Tighten the bolts 90° (1/4 turn) in the same order as in step (4).
(9) Retighten the bolts 45° (1/8 turn) as in step (8).
(10) Make sure that all paint marks face the same direction.
NOTICE:
When adding torque, never untighten the bolt, even if they have
been overtightened.
(11) After tightening, tap the front and back ends of the crankshaft
using a plastic hammer to allow complete fit.
M01020500035
ENGINE MECHANICAL (J08C) EN02–41
NOTICE:
• Bring lever "H" punched on the guide above the pin.
M01020500036
• Making sure to align both supporting surfaces of the guide
and press sub-assembly flush on a flat plane.
M01020500037
NOTICE:
Align the groove of the spindle with the groove of the press sub
assembly.
M01020500038
M01020500039
(3) Chamfer one edge of the bushing hole at the small end of the con-
necting rod uniformly by 0.5-1.0 mm {0.0197-0.0393 in.}.
NOTICE:
• Irregular chamfering can cause out-of-roundness of the
pressed bushing, which may result in jamming during inser-
tion.
• Remove dust from the inner surface of the small-end hole.
M01020500040
EN02–42 ENGINE MECHANICAL (J08C)
Tightening Torque:
5.0-6.8 N⋅m {50-70 kgf⋅cm, 3.62-5.06 lbf⋅ft} (Bolt)
M01020500041
NOTICE:
• Align the groove of the spindle with the groove of the press
sub assembly.
• Make sure that the contact surfaces of the bushing seats
firmly against the contact surfaces of the spindle and guide.
b. Apply the fresh engine oil around the bushing and guide.
(5) Align the oil hole of the bushing with the oil hole of the connecting
rod.
NOTICE:
• Put the connecting rod to the press sub assembly that cham-
fer side of the small end to the bushing side.
• Apply the fresh engine oil to the bore of the connecting rod.
M01020500042
M01020500043
M01020500018
ENGINE MECHANICAL (J08C) EN02–43
NOTICE:
Install the second ring that turn the identification print on the pis-
ton ring to upper surface.
(2) Connect the joint of the coil expander for the oil ring and install it
inside the piston ring. Assemble the ring with the joint 180° oppo-
site to the matching point.
M01020500044
(3) Position the matching points of the piston ring at a even distance
as shown in the figure.
M01020500045
NOTICE:
• When installing the piston, be careful that the cooling jet is
not struck by the connecting rod.
• Make sure that the 0-mark on the piston is at the exhaust
side.
M01020500046
M01020500047
EN02–44 ENGINE MECHANICAL (J08C)
(2) Apply clean engine oil to the bolt thread and the nut seat surface
of the connecting rod cap.
M01020500050
(4) Mark the nut heads in the same direction with paint.
(5) Tighten the connecting rod nut 90° (1/4 turn).
(6) Tighten the connecting rod nut 45° (1/8 turn) .
(7) Make sure that the paint marks face the same direction.
NOTICE:
When adding torque, never untighten the nuts, even if they have
been overtightened.
M01020500048
M01020500049
ENGINE MECHANICAL (J08C) EN02–45
Unit: mm {in.}
2.5 Measure
Top 2.4 {0.0945}
{0.0984}
Piston 2.0
Second 1.9 {0.0748} Replace ring.
ring width {0.0787}
4.0
Oil 3.9 {0.1535}
{0.1575}
EN02–46 ENGINE MECHANICAL (J08C)
2.5 Measure
Top 2.7 {0.1062}
{0.0984}
Piston
2.0
groove Second 2.2 {0.0866} Replace piston.
{0.0787}
width
4.0
Oil 4.1 {0.1614}
{0.1575}
Clearance 0.09-0.13
Top
between {0.0036-0.0051}
piston
0.04-0.08
ring and Second — — —
{0.0016-0.0031}
piston
ring 0.02-0.06
groove Oil
{0.0008-0.0023}
0.30-0.40 Measure
Top 1.5 {0.0591}
{0.0119-0.0157}
Cylinder liner
Gap
between 0.30-0.45
Second 1.2 {0.0472}
ends of {0.0119-0.0177} Replace piston ring.
piston
ring 0.30-0.45 Piston ring
Oil 1.2 {0.0472}
{0.0119-0.0177}
Measure
Visual check
Wear or damage of con-
necting rod
— — Replace.
*Dye penetrant check
(Color check)
ENGINE MECHANICAL (J08C) EN02–47
Visual check
Clogging of connecting
— — Replace.
rod oil hole
34
Crankpin width 34.8 {1.371} Replace crankshaft.
{1.339}
Replace connecting
Connecting rod end 0.20-0.52
1.0 {0.0394} rod and/or crank-
play {0.0079-0.0204}
shaft.
Clearance between
0.051-0.102 Replace main bear-
crank journal and main 0.2 {0.0079}
{0.0021-0.0040} ing.
bearing
More than
Replace over size
0.5 {0.0197}
0.050-0.219 thrust bearing.
Crankshaft end play (Repair)
{0.0020-0.0086}
1.0 {0.0393}
Replace crankshaft.
(Service)
Measure
Visual check
Clogging of crankshaft
— — Clean.
oil hole
Visual check
Measure
Replace.
Cylinder block upper 0.05 {0.0019}
0.20 {0.0080} NOTICE: Do not
surface flatness or less
grind for repair.
AIR INTAKE SYSTEM (J08C) EN03–1
EN03-001
M01030100003
M01030100002
EXHAUST SYSTEM (J08C) EN04–1
EN04-001
M01040100004
M01040100002
NOTICE:
Be sure to hold the inner nut when tightening the outer nut.
M01040100005
LUBRICATING SYSTEM (J08C) EN05–1
EN05-001
LUBRICATING SYSTEM
DIAGRAM
M01050101BEJ1001
M01050100003
LUBRICATING SYSTEM (J08C) EN05–3
M01050200001
OVERHAUL
M01050201BEH2001
Unit: mm {in.}
Block side
bushing
18 {0.709} — —
inside
Drive gear diameter
0.040-0.099
Clearance — —
{0.0016-0.0038}
Block hole
18 {0.709} — —
diameter
0.030-0.075
Clearance — —
Driven {0.0012-0.0029}
gear
Gear bush-
ing inside 18 {0.709} — —
diameter
0.040-0.083
Clearance 0.15 {0.0059} Replace gear.
{0.0016-0.0032}
Measure
0.073-0.207
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0081}
EN05–6 LUBRICATING SYSTEM (J08C)
M01050300001
SPECIAL TOOL
M01050301BEK1001
M01050300003
NOTICE:
Make sure that O-rings are not on the oil cooler case side.
M01050300004
EN05–8 LUBRICATING SYSTEM (J08C)
NOTICE:
M01050300005 • Do not reuse the O-ring.
• Attention the O-ring to damage.
(2) Apply liquid gasket to the oil cooler case and install it onto the cyl-
inder block, then tighten the bolt to the specified torque.
Tightening Torque:
28.4 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
M01050300006
1. Damage to sliding
Wear or damage to
Replace, if neces- face of valve
valve spring of oil — —
sary. 2. Valve movement
cooler and oil filter
(smoothness)
COOLING SYSTEM (J08C) EN06–1
EN06-001
COOLING SYSTEM
DIAGRAM
M01060101BEJ1001
1
4
2
5
11
3 12
10
7 9
8 13
14 14
M01060100001
COOLANT PUMP
COMPONENT LOCATOR
M01060201BED1001
M01060200028
SPECIAL TOOL
M01060201BEK1001
09420-1810 PULLER
09420-1820 PULLER
OVERHAUL
M01060201BEH2001
M01060200002
(2) Remove the pulley center from the shaft using the special tool.
SST: Puller (09420 - 1810)
M01060200003
(3) Remove the retainer ring from the pump case using snap ring pli-
ers.
M01060200004
COOLING SYSTEM (J08C) EN06–5
(4) Push the shaft from the vane side using a hydraulic press, and
remove the coolant shaft from the pump case.
NOTICE:
Before pressing, recheck that the retainer ring is removed com-
pletely.
M01060200005
(5) Remove the coolant seal from the pump case using a hammer
and brass bar.
CAUTION:
Impact due to punching may cause metal chips to fly up. Be sure
to wear protective goggles.
NOTICE:
Replace the removed coolant seal with a new one. Never reuse it.
M01060200006
M01060200007
(2) Install the retainer ring onto the pump case using snap ring pliers.
M01060200004
(3) Install the pulley center onto the shaft using a hydraulic press.
Standard: 129.0 - 129.8 mm {5.079 - 5.110 in.} from the
pulley center mounting surface to the pump
case end surface
M01060200008
EN06–6 COOLING SYSTEM (J08C)
M01060200009
M01060200010
(5) Install the vane onto the shaft using a hydraulic press.
Assembly standard (B): 0.6-1.2 mm {0.0237-0.0472 in}
NOTICE:
Press until the vane end face comes into contact with the shaft
end surface.
(6) After assembly, turn the shaft by hand and make sure that there is
no noise, catching or rough movement in the shaft direction and
that it rotates smoothly.
M01060200011
COOLING SYSTEM (J08C) EN06–7
Unit: mm {in.}
Visual check
Measure
Measure
NOTICE:
• Tightness= Outside diameter - Inside diameter
• Prevent a reassembly more than three times even if it is
within the standard value.
EN06–8 COOLING SYSTEM (J08C)
THERMOSTAT
COMPONENT LOCATOR
M01060301BED1001
M01060300010
OVERHAUL
M01060301BEH2001
M01060300002
NOTICE:
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
COOLING SYSTEM (J08C) EN06–9
M01060300003
JIGGLE VALVE
1. ASSEMBLE THE THERMOSTAT CASE.
NOTICE:
• Remove water or dirt adhering to the thermostat case.
• Be sure to replace the gasket if it is corroded, damaged or
flattened.
• Before installing the hose, apply liquid gasket to the hose
installation part of the thermostat case cover.
• To prevent clogging of the radiator, do not use a large
amount of liquid gasket.
M01060300004
• Be sure that the jiggle valve faces upward when installing it.
M01060300005
(3) Temporarily tighten the bolts "1" and bolts "2" in that order, and
securely contact the fitting surface.
"2"
(4) Tighten the bolts in numeral order.
"1"
M01060300006
EN06–10 COOLING SYSTEM (J08C)
RADIATOR
COMPONENT LOCATOR
M01060401BED1001
M01060400018
SPECIAL TOOL
M01060401BEK10001
OVERHAUL
M010604BEH2001
M01060400002
(2) Grip the handle until it hits to the stopper bolt, then adjust the
dimensions A with stopper bolt.
Dimension A: 0.2-0.3 mm {0.0079-0.0118 in.}
SST: Radiator (09760-1030)
NOTICE:
Be sure to adjust the dimension to prevent damage of the crow.
M01060400003
EN06–12 COOLING SYSTEM (J08C)
M01060400004
(4) Remove the upper tank and lower tank from the radiator core by
tapping lightly with plastic hammer.
NOTICE:
Do not remove the tank by forcing or prying.
M01060400005
M01060400006
(2) Grip the handle of the radiator tool until it hits to the stopper bolt,
then adjust the dimensions B with stopper bolt.
Dimension B: 8.4 mm {0.3307 in.}
M01060400007
(3) Install the new O-ring into the groove of the radiator core (upper
and lower) in such away that it will not be twisted.
NOTICE:
Be sure to clean the fitting portion before installing. When clean-
ing, lightly rub the inside portion of the groove with the emery
paper.
(4) Install the upper tank and lower tank into the groove of the radia-
tor core.
M01060400008
COOLING SYSTEM (J08C) EN06–13
(5) Frap the tangs to obtain a tight contact with the upper tank and
lower tank.
M01060400009
(6) Press the radiator tool (caulking tool) against the side portion.
Temporarily caulk the tangs several times, then proceed to the
final caulking by gripping the handle until it hits the stopper bolt.
NOTICE:
For the positions where the radiator tool is not usable, perform the
caulking with pliers.
M01060400010
NOTICE:
Perform the caulking according to the sequence as shown in the
figure.
M01060400011
M01060400012
EN06–14 COOLING SYSTEM (J08C)
NOTICE:
• The coolant filler cap valve opening pressure is indicated on the cap and it should be confirmed. If the cap
pressure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system,
which may cause the hose to drop off or burst and may result in the damage of the engine.
• When carrying out high pressure washing to remove fin clogging, do not apply excessive pressure to the
fins which may cause deformation and consequent performance deterioration.
COOLING SYSTEM (J08C) EN06–15
COOLING FAN
COMPONENT LOCATOR
M01060601BED1001
M01060600006
Unit: mm {in.}
Visual check
EN07-001
INJECTION NOZZLE
(TWO-SPRING TYPE - BOSCH MAKE)... EN07-7
DESCRIPTION ................................................ EN07-7
COMPONENT LOCATOR................................ EN07-8
SPECIAL TOOL ............................................... EN07-9
OVERHAUL ................................................... EN07-10
EN07–2 FUEL SYSTEM (J08C)
FUEL SYSTEM
DIAGRAM
M01070101BEJ1001
M01070100001
DESCRIPTION
M01070101BEC1001
M01070100019
SPECIAL TOOL
M01070101BEK1001
09515-2470 WRENCH
NOTICE:
BOSCH: BOSCH AUTOMOTIVE SYSTEMS CORPORATION
OVERHAUL
M01070101BEH2001
M01070100007
FUEL SYSTEM (J08C) EN07–5
(2) Turn the timer counterclockwise slowly viewed from the coupling
(normal direction of engine) and align the mark on the timer with
the mark on the injection pump pointer.
M01070100008
(3) Tighten the injection pump mounting bolt evenly to the torque
below.
SST: Wrench (09515-2470)
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
M01070100009
M01070100015
EN07–6 FUEL SYSTEM (J08C)
NOTICE:
• Do not reuse the element.
• Be careful not to damage the gasket.
M01070100016
M01070200026
COMPONENT LOCATOR
M01070201BED1002
M01070200027
SPECIAL TOOL
M01070201BEK1002
Length (L)
157892-4620 157892-4200: 160 mm {6.300
NOTICE: It is BOSCH TOOL SET in}
product number that NOTICE: BOSCH product tool 157892-4300: 110 mm {4.331
mentioned part num- set in}
ber.
EN07–10 FUEL SYSTEM (J08C)
OVERHAUL
M01070201BEH2002
M01070200008
M01070200009
FUEL SYSTEM (J08C) EN07–11
(2) Operate the lever at the rate of 50 to 60 strokes per minute. If the
injection pressure is not within specified value, adjust the injection
pressure with adjusting screw.
First opening pressure
With new parts : 18.1-18.9 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts : 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
M01070200010
M01070200011
M01070200012
M01070200013
EN07–12 FUEL SYSTEM (J08C)
Work steps
1. Adjustment of first opening pressure Adjust first opening pressure with the adjusting screw.
5. Adjusting of second opening pressure Adjust second opening pressure with adjusting shim.
M01070200031
FUEL SYSTEM (J08C) EN07–13
(3) Put the gasket (special tool) onto the nozzle, then use the adjust-
able retaining nut (special tool) to holder the nozzle in place on
the nozzle holder.
SST:
Gasket (157892-1500)
Adjustable retaining nut (157892-4000)
Tightening Torque:
68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
NOTICE:
• Make sure that the pin is all the way in the nozzle and then
M01070200032 tighten adjustable retaining nut.
• Finger-tighten the adjustable retaining nut until it no longer
turns and tighten the nut to specified torque.
(4) Install the push rod, first pressure spring and first pressure adjust-
ing screw into the nozzle holder.
(5) Install the gasket and cap nut onto the first pressure adjusting
screw.
M01070200033
M01070200034
(7) Adjusting the first opening pressure to the specified value with the
first pressure adjusting screw.
First opening pressure
With new parts : 18.1-18.9 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts : 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
M01070200035
(8) Holder the nozzle holder body using a adjustable wrench, then
tighten the cap nut to the specified torque.
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 33 lbf⋅ft}
M01070200036
EN07–14 FUEL SYSTEM (J08C)
M01070200037
(2) Turn the nozzle holder body so that the cap side facing upward.
(3) Attach the holder (special tool) to the cap nut.
SST: Holder (157892-4400)
(4) Temporarily tighten the attachment nut (special tool) onto the
holder.
SST: Nut (157892-1000)
M01070200038
(5) Screw the pin (special tool) into the dial gauge.
SST: Pin (157892-4200 or 157892-4300)
M01070200039
FUEL SYSTEM (J08C) EN07–15
(6) Tighten the nut so that it holds the dial gauge in place in the noz-
zle holder assembly and so that the pin is in contact with the push
rod upper surface.
NOTICE:
• Attach the dial gauge into place so that it can measure a
stroke of approx. 2 mm {0.079 in.}.
• Do not tighten the nut too much, or the dial gauge shaft will
be stuck.
M01070200040
(7) Attach the nozzle holder assembly to the nozzle tester and adjust
the dial gauge to zero.
(8) Operate the nozzle tester to bleed air in the adjustable retaining
nut. Make sure that there are no fuel leaks.
M01070200041
M01070200042
M01070200043
EN07–16 FUEL SYSTEM (J08C)
(2) When the second pressure spring stop to action and the needle
valve drop ends (the needle valve lift dimension "L'" ) read the dial
gauge indication, make sure it is within specified values.
M01070200044
M01070200045
(3) If pre-lift is not within the specified value, replace the pins, the lift
piece, the spacer and the nozzle assembly with the nozzle service
kit.
M01070200046
M01070200047
FUEL SYSTEM (J08C) EN07–17
(3) Read the value indicated on the pressure gauge at the instant the
dial gauge needle indicates the specified needle valve lift value
(pre-lift " L' " + 0.05 mm {0.0020 in.}).
Second opening pressure
With new parts : 22.1-23.1 MPa {225-235 kgf/cm2,
3,200-3,341 lbf/in.2}
With reused parts : 21.6-22.6 MPa {220-230 kgf/cm2,
3,129-3,270 lbf/in.2}
M01070200048
(2) If the first opening pressure has been readjusted and the second
opening pressure still deviates from the specified value, disas-
semble the nozzle side of the nozzle holder and remove the
adjusting shim.
(3) If the second opening pressure is higher than the specified value,
replace the adjusting shim with a thinner one.
(4) After replacing the adjusting shim, remeasure the second opening
pressure, and adjust the pressure until it comes to the specified
value.
M01070200051
M01070200009
(2) To replace the nozzle, the lift piece, and the spacer, which are all
in one set, with the nozzle service kit.
NOTICE:
Replacing only the nozzle will cause the amount of pre-lift deviate
from the specified value.
M01070200052
FUEL SYSTEM (J08C) EN07–19
NOTICE:
After tightening the bolt, make sure that the rocker arm moves
M01070200025
smoothly.
(7) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
34.3 N⋅m {350 kgf⋅cm, 25.3 lbf⋅ft}
TURBOCHARGER (J08C)
EN08
EN08-001
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING ..................................... EN08-3
SPECIAL TOOL ............................................. EN08-11
OVERHAUL CRITERIA.................................. EN08-12
COMPONENT LOCATOR.............................. EN08-14
EN08–2 TURBOCHARGER (J08C)
TURBOCHARGER
DESCRIPTION
M01080101BEC1001
M01080100001
TROUBLESHOOTING
M01080101BEF3001
1. Table 1-1. Troubleshooting -Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
M01080100002
M01080100003
M01080100004
EN08–6 TURBOCHARGER (J08C)
M01080100005
M01080100006
M01080100007
TURBOCHARGER (J08C) EN08–9
M01080100008
EN08–10 TURBOCHARGER (J08C)
M01080100009
a. Refer to engine manufacturer's service manual for inspection requirements and replacement specifications.
b. With engine stopped, check duct clamping devices for tightness.
c. With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connections will be indi-
cated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the
engine combustion chambers.
d. With engine running at idle speed, check duct connections for leaks by applying lightweight oil or liquid soap to areas
of possible leakage and checking for bubbles. Exhaust gas leakage between the engine block and the turbocharger
inlet will also create a noise level change.
e. With engine running at idle speed, check for unusual noise and vibration. If either condition is noted, shut down the
engine immediately to protect the turbocharger and engine from further damage. With the engine stopped, check the
turbocharger shaft wheel assembly for damage as outlined Note I, below.
f. With engine running, a change in the noise level to a higher pitch can indicate air leakage between the air cleaner
and the engine or a gas leak between the engine block and the turbocharger inlet.
g. Exhaust gas leakage may be indicated by hat discoloration in the area of the leak.
h. With the engine running, noise level cycling from one level to another can indicate a plugged air cleaner, a restriction
in the air-cleaner to compressor duct, or a heavy build-up of dirt in the compressor housing or on the compressor
wheel.
i. Internal inspection of the center housing can be accomplished by removing the oil drain line and looking through the
oil drain opening. When a slugged or coked condition exists, a heavy sludge build-up will be seen on the shaft
between the bearing journals and in the center housing from the oil drain opening back to the turbine end.
j. Thorough cleaning of the air intake system is essential following compressor wheel damage due to foreign object
impact. in many cases, metal pieces from the wheel become imbedded in the air cleaner element. If the element is
not changed, these metal pieces can be drawn into the replacement turbocharger and cause it to fail in the same
manner as the original unit.
k. With the air inlet and exhaust gas ducting removed from the turbocharger, examine both the compressor and turbine
wheels for blade damage. Examine the outer blade tip edges for evidence of rubbing on housing surfaces.
• Turn the rotating assembly by hand and feel for dragging or binding. Push the rotating assembly side-ways while
rotating to feel for wheel rub. If there is any indication of rubbing, perform the bearing clearance inspection proce-
dure. If the rotating assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that
the turbocharger is serviceable.
SPECIAL TOOL
M01080101BEK1001
OVERHAUL CRITERIA
M01080101BEH3001
M01080100013
M01080100014
(5) Release the air pressure at the sensing port. Note that the dial
gauge pointer returns exactly to zero.
(6) Repeat steps (4) through (5) several times to make sure that
wastegate valve or rod movement has been accurately measured.
(7) If the specified value or rod movement cannot be obtained within
the specified air pressure range.The turbine housing assembly or
actuator assembly must be replaced.
NOTICE:
Operation of the engine with the wastegate calibrated to some
value other than that specified can result in reduced performance
or severe engine damage.
(8) If wastegate performance is within specification, install the hose
onto the wastegate sensing port.
ALTERNATOR (J08C: 24V-50A) EN11–1
EN11-001
ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS ......................... EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING ..................................... EN11-4
COMPONENT LOCATOR................................ EN11-5
SPECIAL TOOL ............................................... EN11-7
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-14
EN11–2 ALTERNATOR (J08C: 24V-50A)
ALTERNATOR
DATA AND SPECIFICATIONS
M01110101BEI2001
Regulator Mount-on
DESCRIPTION
M01110101BEC1001
M01110100001
CIRCUIT
3 8
B
10
L
7
R
P
9
5
6 11
M01110100002
TROUBLESHOOTING
M01110101BEF3001
COMPONENT LOCATOR
M01110101BED1001
M01110100040
1 Brace 4 Bracket
2 Harness 5 V-bolt
3 Alternator 6 Strap band
M01110100003
SPECIAL TOOL
M01110101BEK1001
OVERHAUL
M01110101BEH2001
M01110100004
M01110100005
EN11–8 ALTERNATOR (J08C: 24V-50A)
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
M01110100006
M01110100007
(3) Remove the rotor from drive end frame, using a press.
NOTICE:
Hold rotor by hand so that it will not fall off.
M01110100008
M01110100009
M01110100010
ALTERNATOR (J08C: 24V-50A) EN11–9
M01110100011
M01110100012
M01110100013
M01110100015
M01110100014
EN11–10 ALTERNATOR (J08C: 24V-50A)
M01110100016
M01110100017
M01110100018
M01110100009
ALTERNATOR (J08C: 24V-50A) EN11–11
M01110100019
(4) Install the space collar, fan and pulley, tighten the lock nut.
NOTICE:
Wind V-belt around pulley groove and grip it securely in a vice so
that pulley is held with V-belt as a cushion.
M01110100020
M01110100021
M01110100022
EN11–12 ALTERNATOR (J08C: 24V-50A)
(2) Refer to " COMPONENT LOCATOR ", then install the each parts.
M01110100023
M01110100024
(4) Using a solder ring iron, solder the lead wire connecting the regu-
lator and field coil as well as the stator coil and diode.
(5) Install the condenser.
M01110100025
M01110100026
M01110100027
ALTERNATOR (J08C: 24V-50A) EN11–13
M01110100028
PERFORMANCE TEST
NOTICE:
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1MΩ 0.5MΩ or less Replace.
field coil
Measure
Resistance of stator
0.247-0.273Ω — Replace.
coil [at 20°C (68°F)]
Measure
Insulation resistance of
1MΩ or more 0.5MΩ or less Replace.
stator
Measure
Normal direction
7-10Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Measure
Measure
Measure
Visual check
EN11-002
ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS ......................... EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING ..................................... EN11-4
COMPONENT LOCATOR................................ EN11-5
SPECIAL TOOL ............................................... EN11-6
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-15
EN11–2 ALTERNATOR (J08C: 24V-80A)
ALTERNATOR
DATA AND SPECIFICATIONS
M01110101BEI2001
Regulator Mount-on
DESCRIPTION
M01110101BEC1001
M01110100047
CIRCUIT
3 8
B
10
L
7
R
P
9
5
N
6 11
M01110100048
TROUBLESHOOTING
M01110101BEF3001
COMPONENT LOCATOR
M01110101BED1001
M01110100049
M01110100050
1 Cover 12 Regulator
2 Rectifier 13 Field coil
3 Holder 14 Stator coil
4 Rectifier 15 Rotor assembly
5 Terminal insulator 16 Retainer plate
6 Connector 17 Shim
7 Holder insulator 18 Ball bearing
8 Condenser 19 Cover
9 Lead wire connector 20 Drive end frame
10 Rectifier end frame 21 Fan with pulley
11 Roller bearing 22 Lock nut
SPECIAL TOOL
M01110101BEK1001
OVERHAUL
M01110101BEH2001
FIXING BOLT
IMPORTANT POINTS - MOUNTING
A COOLANT
PUMP 1. ADJUST THE ALTERNATOR V-BELT DEFLECTION.
PULLEY (1) Loosen the through bolt and the fixing bolt.
ADJUSTING (2) Apply a load of about 98N {10 kgf} by pressing the measuring
BOLT point A.
CRANK (3) Turn the adjusting bolt, and adjust the deflection of the belt at
SHAFT
ALTERNATOR PULLEY measuring point A, so that it comes within the standard value.
PULLE Y SST: Compression gauge (09444-1210)
THROUGH BOLT
Standard: 8-10 mm {0.314-0.394 in.}
M01110100051
NOTICE:
• When installing a new V-belt, be sure to repeat the adjust-
ment two or three times, after running the engine.
• When adjusting the V-belt, do not apply the lever directly
against the alternator.
(4) After adjusting the deflection, tighten the through bolt and then
securely tighten the fixing bolt.
(5) Retighten the adjusting bolt.
(6) Connecting the harness.
M01110100052
(2) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
M01110100053
EN11–8 ALTERNATOR (J08C: 24V-80A)
M01110100054
(3) Remove the rotor from drive end frame, using a press.
NOTICE:
Hold rotor by hand so that it will not fall off.
M01110100008
M01110100055
M01110100010
M01110100056
ALTERNATOR (J08C: 24V-80A) EN11–9
(2) Unsolder the stator coil lead wires from the diode.
NOTICE:
Raise the positive diode terminal upward, then unsolder the stator
lead wires form the negative diode terminal.
M01110100057
(3) Unsolder the field coil lead wires and condenser lead wire from
the connector.
NOTICE:
After opening the crimped section, remove the soldered portion.
M01110100058
(4) Unsolder the lead wire P and stator coil lead wire from the con-
nector.
NOTICE:
After opening the crimped section, remove the soldered portion.
M01110100059
(5) Unsolder the lead wires from the regulator. (connector lead wire L,
lead wire N, lead wire R, field coil lead wire, stator coil lead wire
N)
M01110100060
M01110100061
EN11–10 ALTERNATOR (J08C: 24V-80A)
(7) Remove the regulator fixing bolt, then remove the terminal insula-
tor.
M01110100062
M01110100063
(9) Remove the bolts, then remove the connector with lead wire,
clamp, connector and regulator.
M01110100064
M01110100065
M01110100066
ALTERNATOR (J08C: 24V-80A) EN11–11
M01110100067
M01110100068
M01110100018
M01110100069
EN11–12 ALTERNATOR (J08C: 24V-80A)
M01110100019
(4) Install the fan with pulley, tighten the lock nut.
NOTICE:
Wind V-belt around pulley groove and grip it securely in a vice so
that pulley is held with V-belt as a cushion.
M01110100020
M01110100021
M01110100070
ALTERNATOR (J08C: 24V-80A) EN11–13
M01110100071
M01110100072
M01110100073
(4) Using a soldering iron, solder the lead wires to the regulator. (con-
nector lead wire L, lead wire N, lead wire R, field coil lead wire,
stator coil lead wire N)
M01110100074
(5) Using a soldering iron, solder the lead wire P to the connector.
M01110100075
EN11–14 ALTERNATOR (J08C: 24V-80A)
(6) Using s soldering iron, solder the stator coil lead wire, diode lead
wire and connector.
M01110100076
(7) Using a soldering iron, solder the stator coil lead wires to the
diode.
M01110100077
M01110100078
M01110100079
M01110100080
ALTERNATOR (J08C: 24V-80A) EN11–15
PERFORMANCE TEST
NOTICE:
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1 MΩ or more 0.5MΩ or less Replace.
field coil
Measure
Resistance of stator
0.152-0.168 Ω — Replace.
coil [at 20°C (68°F)]
EN11–16 ALTERNATOR (J08C: 24V-80A)
Measure
Insulation resistance of
1MΩ or more 0.5MΩ or less Replace.
stator
Measure
Normal direction
7-10Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Measure
Measure
Measure
Visual check
STARTER (J08C)
EN 12
EN12-001
STARTER
DATA AND SPECIFICATIONS
M01120101BEI2001
Module 3
DESCRIPTION
M01120101BEC1001
M01120100001
TROUBLESHOOTING
M01120101BEF3001
COMPONENT LOCATOR
M01120101BED1001
M01120100002
STARTER (J08C) EN12–5
OVERHAUL
M01120101BEH2001
M01120100003
M TERMINAL LEAD
1. REMOVE THE TERMINAL LEAD.
CAP
(1) Remove the bolt, disconnect the "C" terminal lead.
(2) Remove the nut, disconnect the "M" terminal lead.
CAP
C TERMINAL LEAD
M01120100004
EN12–6 STARTER (J08C)
M01120100005
(2) Remove the bolt and O-ring, remove the commutator end frame.
COMMUTATOR
END FRAME
M01120100006
M01120100007
M01120100008
STARTER (J08C) EN12–7
M01120100009
M01120100010
M01120100011
M01120100012
(4) Remove the lever and drive shaft assembly from the drive hous-
ing.
HOLDER
PIN
LEVER
SHAFT ASSEMBLY
M01120100013
EN12–8 STARTER (J08C)
RESERVOIR
M01120100014
G1
M01120100015
M01120100016
M01120100017
STARTER (J08C) EN12–9
M01120100046
M01120100009
M01120100018
M01120100019
EN12–10 STARTER (J08C)
M01120100020
(3) Apply grease (G1: Multemp AC-N) to the portion as shown in the
LOCATION G1 figure.
GIDE (4) Install the commutator end frame aligning the location guide of the
commutator end frame (convexity) with notches of the holder
assembly (concavity).
NOTCH
HOLDER
ASSEMBLY
M LEAD WIRE
M01120100021
M TERMINAL LEAD
(5) Secure the brush holder with the bolt and a new O-ring.
CAP
(6) Secure the drive housing assembly and commutator end frame
with the through bolt.
CAP (7) Connect the terminal lead, install the cap.
C TERMINAL LEAD
M01120100004
M01120100022
(4) If the above condition, push pinion back to measure the gap.
Standard: 0.5-0.3 mm {0.020-0.118 in.}
NOTICE:
Perform the inspection work for an instance (within 15 seconds).
PUSH BACK THE
PINION SLIGHTLY.
GAP
0.5-3.0 mm
{0.020-0.118 in.}
M01120100023
STARTER (J08C) EN12–11
M01120100024
M01120100025
M01120100026
EN12–12 STARTER (J08C)
No-load test
• With the starter securely clamped in a vise.
• Using a battery and suitable ammeter.
• Connect the positive lead to the ammeter, "B" and "C" terminal.
• Connect the negative lead to the starter body.
(2) The starter should show smooth and steady rotation immediately
after jumping out of the pinion and should draw less than the
specified current.
M01120100027
Unit: mm {in.}
Measure
Measure
Less than
Armature insulation More than 1 MΩ Replace.
0.5 MΩ
Measure
Measure
Measure
Depth between the mica
0.5-0.8 0.2 {0.0078} or
and the commutator Replace or repair.
{0.0197-0.0314} less
(Under cut depth)
Measure
Measure
A: 11.98 Measure
Outside diameter of the A: 12.0 {0.472} {0.471}
Replace. B
armature assembly B: 15.0 {0.591} B: 14.98 A
{0.589}
Measure
Measure
Measure
A: 25.88 B A
Outside diameter of the A: 26.0 {1.024}
{1.018} Replace.
drive shaft assembly B: 12.1 {0.476}
B: 12.0 {0.472}
Measure
Measure
Measure
Visual check
NEEDLE
ROLLER
Rotating of needle roller
— — Replace. BEARING
bearing
Visual check
Measure
Measure
EN13-001
AIR COMPRESSOR
DATA AND SPECIFICATIONS
M01130101BEI2001
DESCRIPTION
M01130101BEC1001
M01130100001
1 O-ring 8 Crankshaft
2 Cylinder head assembly 9 Crankcase
3 Gasket 10 Piston pin
4 Valve seat 11 Piston ring
5 Piston A Suction
6 Connecting rod B Delivery
7 Bearing
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–3
TROUBLESHOOTING
M01130101BEF3001
COMPONENT LOCATOR
M01130101BED1001
M01130100043
1 Air compressor
M01130100002
SPECIAL TOOL
M01130101BEK1001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
09420-1830 PULLER
OVERHAUL
M01130101BEH2001
1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.
M01130100003
(2) Align the aligning mark (two drill hole) on the side of gear teeth
with protrusion on the compressor housing.
M01130100004
(3) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(4) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
M01130100005
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
M01130100006
EN13–8 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
NOTICE:
When installing the injection pump, make sure that the coupling
phase adjusting bolt is at the center of the slot.
M01130100007
M01130100008
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Puller (09420-1830)
M01130100009
M01130100010
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–9
M01130100011
NOTICE:
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.
M01130100012
M01130100013
EN13–10 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
M01130100014
M01130100015
M01130100016
M01130100017
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–11
M01130100018
M01130100019
M01130100020
M01130100021
M01130100022
EN13–12 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
M01130100023
NOTICE:
Install the piston rings with the identification mark at the top of the
ring facing up.
M01130100024
NOTICE:
Apply oil to the threads and seat surface before tightening.
M01130100026
EN13–14 AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
Unit: mm {in.}
Visual check
Replace con-
0.2-0.4
Connecting rod end play 0.5 {0.0197} necting rod or
{0.0079-0.0157}
crankshaft.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) EN13–15
Visual check
A:79.79-79.82 Measure
{3.1414-3.1425}
Outside diameter of the piston —
B:79.90-79.93
{3.1457-3.1468}
Replace.
Outer diameter of the piston
16 {0.630} —
pin
Compression Measure
Piston ring 3.0 {0.1181} —
ring
thickness
Oil ring 4.0 {0.1575} —
Compression
Piston ring 3.0 {0.1181} —
ring
groove
Oil ring 4.0 {0.1575} — Replace.
Visual check
Visual check
Visual check
79.996 Measure
Cylinder block 80 {3.1496}
{3.1494}
Inside diame-
ter of the
Replace.
bearing Bearing 71.996
holder 72.0 {2.8346}
holder {2.8345}
Measure
Replace crank
Crankshaft end play 0-0.3 {0-0.012} 0.4 {0.06}
shaft bearing
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–1
EN13-002
AIR COMPRESSOR
DATA AND SPECIFICATIONS
M01130101BEI2001
DESCRIPTION
M01130101BEC1001
M01130100081
TROUBLESHOOTING
M01130101BEF3001
COMPONENT LOCATOR
M01130101BED1001
M01130100123
1 Air compressor
M01130100122
SPECIAL TOOL
M01130101BEK1001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
09420-1830 PULLER
OVERHAUL
M01130101BEH2001
1. INSTALLATION PROCEDURES.
(1) Fit the No.1 cylinder to the Top Dead Center.
M01130100124
(2) Align the aligning mark (two drill hole) on the side of gear teeth
with protrusion on the compressor housing.
M01130100004
(3) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(4) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
M01130100125
(5) Make sure that the compressor crankshaft key is aligned with
aligning mark (J) on the bearing holder.
M01130100006
EN13–8 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
NOTICE:
When installing the injection pump, make sure that the coupling
phase adjusting bolt is at the center of the slot.
M01130100007
M01130100126
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Puller (09420-1830)
M01130100009
M01130100083
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–9
M01130100084
M01130100085
M01130100087
EN13–10 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
(2) Press the crankshaft end face and remove the crankshaft with the
bearing holder.
M01130100088
M01130100089
M01130100090
M01130100016
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–11
M01130100091
M01130100092
M01130100093
(2) Remove the retainer ring and disassemble the unloader valve.
M01130100127
M01130100095
EN13–12 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
M01130100096
M01130100097
(2) Before completely tightening the suction valve holder, push in the
suction valve with a finger or bar from the upper side of cylinder
head (unloader valve side), and check that the suction valve and
valve spring moves smoothly.
M01130100059
(3) Tighten the suction valve holder to the specified torque using a
special tool.
SST: Adapter (09481-1090)
(4) Make sure that the suction valve stroke is approximately 2.5 mm
{0.0984 in.}.
M01130100098
(5) Caulk three places on the outer periphery of the suction valve
holder.
NOTICE:
In this case, be sure that the lower face of the valve holder is not
protruding from the head lower face. (The faces should be flush or
the lower face of the valve holder should be recessed from the
head lower face.)
M01130100099
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–13
M01130100100
M01130100063
M01130100101
M01130100102
EN13–14 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
M01130100120
M01130100109
M01130100103
M01130100087
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–15
M01130100105
M01130100106
M01130100107
M01130100110
NOTICE:
Install the piston rings with the identification mark at the top of the
ring facing up.
M01130100069
EN13–16 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
M01130100111
M01130100113
M01130100083
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) EN13–17
M01130100128
Unit:mm{in.}
Visual check
16 Measure
Outside diameter of piston pin —
{0.630}
Replace.
Clearance between the piston 0.02-0.04 0.07
pin and connecting rod {0.0008-0.0016} {0.0027}
EN13–18 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
Measure
Replace con-
0.2-0.4 0.5
Connecting rod end play necting rod or
{0.0079-0.0157} {0.0197}
crankshaft.
Visual check
80 Measure
Outside diameter of the piston —
{3.150}
A: 0.25-0.30 0.33
{0.0099-0.0118} {0.0130] Replace.
Replace.
Outside diameter of the piston 16
—
pin {0.630}
Compression Measure
0.3-0.5
ring
{0.0119-0.0196}
(Top, Second)
Piston Compression 0.1-0.3
ring gap: ring (Third) {0.0040-0.0118} 1.0
Replace.
compression {0.0394}
ring, oil ring
0.2-0.8
Oil ring
{0.0079-0.0314}
Compression 3.0
—
Piston ring ring {0.1181}
Replace.
groove 4.0
Oil ring —
{0.1575}
Visual check
Visual check
Replace
Worn or damaged delivery
— — delivery valve
valve and valve seat
assembly.
Visual check
Replace
Worn or damaged suction
— — suction valve
valve and valve seat
assembly.
EN13–20 AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
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
4.41 N
{0.45 kgf, 3.63 N Measure
Suction valve spring setting
0.992 lbf} {0.36 kgf, Replace.
load
at 7.0mm 0.794 lbf}
{0.276 in.}
4.5 N
{0.46 kgf, 3.6 N
Delivery valve spring 1.019 lbf} {0.37 kgf, Replace.
at 9.5 mm 0.816 lbf}
{0.374 in.}
Visual check
Wear or damage of the suc-
tion valve spring and delivery — — Replace.
valve spring
ENGINE P.T.O. (POWER TAKE-OFF) EN14–1
EN14-001
M01140100028
COMPONENT LOCATOR
M01140102BED1001
M01140100029
OVERHAUL
M01040102BEH2001
M01140100030
M01140100031
(4) Using a suitable sliding hammer, remove the driven shaft with ball
bearing.
(5) Remove the drive gear.
M01140100032
(6) Using a press, remove the ball bearing from the driven shaft.
M01140100033
ENGINE P.T.O. (POWER TAKE-OFF) EN14–5
(7) Using a press, press the driven shaft into the ball bearing.
M01140100034
(8) Using a suitable sliding hammer, remove the ball bearing with
driven shaft.
M01140100035
(9) Using a press, remove the ball bearing from the driven shaft.
M01140100036
(10) Using a flathead screwdriver, pay off the oil seal evenly until the oil
seal comes off.
M01140100037
M01140100038
EN14–6 ENGINE P.T.O. (POWER TAKE-OFF)
NOTICE:
• Apply lithium based grease between the main lip and sub-lip
of the oil seal and to the back of the main lip.
• Do not use too much grease. Also, apply grease evenly
around entire circumference.
M01140100039
(2) Using a press, press the driven shaft into the ball bearing.
M01140100040
(3) Using the suitable tool and a press, press the ball bearing into the
gear case.
M01140100041
(4) Set the drive gear in position, then press the driven shaft with ball
bearing into the ball bearing.
M01140100042
(5) Apply liquid gasket to the gear cover, then install the gear cover.
NOTICE:
Align the threaded hole of the gear case and the bolt hole of the
gear cover.
(6) Tighten the bolts evenly.
M01140100043
ENGINE P.T.O. (POWER TAKE-OFF) EN14–7
(7) Install the output flange, then tighten the lock nut.
M01140100044
M01140100045
(2) Apply liquid gasket to the gear case and the flywheel housing.
(3) Install the power take-off and case cover with 4 bolts.
M01140100046
EN14–8 ENGINE P.T.O. (POWER TAKE-OFF)
M01140100047
ENGINE P.T.O. (POWER TAKE-OFF) EN14–9
Unit:mm{in.}
FUEL CONTROLDN02
DN02-001
TE SYSTEM ..............................................DN02-2
OUTLINE OF THE TE SYSTEM...................... DN02-2
OUTLINE OF THE PRE-STROKE
PUMP SYSTEM............................................... DN02-2
COMPONENT LOCATOR................................ DN02-3
DIAGRAM ........................................................ DN02-9
PRECAUTIONS ............................................. DN02-11
INSPECTION ................................................. DN02-12
DIAGNOSIS USING
THE DIAGNOSIS MONITOR ......................... DN02-14
ENGINE SPEED SENSOR NO PULSE
(MALFUNCTION CODE:2-1) ......................... DN02-16
ABNORMALITY OF ENGINE SPEED SENSOR
(MALFUNCTION CODE:3-1) ......................... DN02-17
ABNORMALITY OF COOLANT TEMPERATURE
SENSOR (MALFUNCTION CODE:4-1)......... DN02-18
ABNORMALITY OF STARTER SWITCH
(MALFUNCTION CODE:6-1) ......................... DN02-19
ABNORMALITY OF RACK SENSOR
(MALFUNCTION CODE:14-1) ....................... DN02-20
ABNORMALITY OF PRE-STROKE SENSOR
(MALFUNCTION CODE:16-1) ....................... DN02-21
ABNORMALITY OF PRE-STROKE F/B
(MALFUNCTION CODE:16-2) ....................... DN02-22
ABNORMALITY OF PRE-STROKE LEARNING
(MALFUNCTION CODE:16-3) ....................... DN02-23
ABNORMALITY OF PRE-STROKE POWER SUPPLY
(MALFUNCTION CODE:16-4) ....................... DN02-24
ABNORMALITY OF PRE-STROKE POWER SUPPLY
RELAY (POWER SUPPLY CUT RELAY) CONTROL
CIRCUIT (MALFUNCTION CODE:16-6) ....... DN02-25
ABNORMALITY OF ECU
(MALFUNCTION CODE:22-1) ....................... DN02-27
ENGINE OVERRUN
(MALFUNCTION CODE:23-1) ....................... DN02-27
ENGINE OVERHEAT
(MALFUNCTION CODE:24-1) ....................... DN02-27
ECU CHASSIS SIDE CONNECTOR PIN
ASSIGNMENT ............................................... DN02-28
DISMOUNTING AND MOUTING................... DN02-30
DN02–2 FUEL CONTROL (J08C: PRE-STROKE PUMP)
TE SYSTEM
OUTLINE OF THE TE SYSTEM
M16020101BEF2001
The TE (Total Electronics) system uses electronic control to regulate every aspect of the engine's running condition. It is a
comprehensive electronic control system developed to extract maximum power and low-pollution of the engine.
There are 4 types of the TE system, detail at below, this engine employ the "Pre-stroke" type.
The Pre-stroke Pump System has a lot of control functions than the conventional injection pump system, These functions
are controlled by the ECU (Electronic Control Unit).
Function of Tachometer
Driver
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–3
COMPONENT LOCATOR
M16020101BEF2003
M16020100060
M16020100061
M16020100122
M16020100040
M16020100123
M16020100042
DIAGRAM
M16020101BEJ1001
FUEL SYSTEM
M16020100035
DN02–10 FUEL CONTROL (J08C: PRE-STROKE PUMP)
ELECTRICAL SYSTEM
+24V
CONTROL UNIT
ACTUATOR POWER
ENGINE SPEED SUPPLY RELAY
SENSOR (N.C)
PRE-STROKE
COOLANT
ACTUATOR
TEMPERATURE
SENSOR
RACK SENSOR
PRE-STROKE
SENSOR
EXHAUST BRAKE
ECU
TACHOMETER SWITCH
CHECK ENGINE
ECU LAMP
MAIN RELAY
(N.O)
PRECAUTIONS
M16020101BEC1011
2. PRE-STROKE ACTUATOR.
• Never apply electricity to the pre-stroke actuator except through
the control unit. Never connect the actuator connectors directly to
a power source. Doing so could burn out the actuator coil.
• Also, note that the mounting position of the actuator is carefully
adjusted. Never do anything that could change the actuator's
mounting position.
• To have the actuator or sensor replaced, contact an establishment
specializing in BOSCH (ZEXEL).
• Do not let water, oil or dust get on the connector when it is discon-
nected, as this could cause poor contacts when the connector is
reconnected.
• Do not open the control unit cover. It could malfunction if dust or
water get inside.
• Take care to ensure that water, oil or dust do not get on or inside
parts.
• When connecting in connectors, push them in all the way and
make sure that the lock engages.
8. RADIO INSTALLATION
• There is a danger that the control unit might malfunction if a high
output radio transmitter (over 50W) is installed in the vehicle.
12. OTHER
• Make sure to check the fellow of connectors before connecting
them in to prevent incorrect connections.
• Be careful not to allow the connectors to become soiled with dust,
water, fuel or oil when performing inspections or removing and
replacing parts.
INSPECTION
M16020101BEH3001
M16020100033
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–13
ON Major
BLINKING OFF
0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec
Degree
ON of
trouble
ON (1)
OFF
ON
Minor
ON (2) OFF
The lamp ON/OFF status and illumination pattern as well as the corre-
sponding conditions they indicate and the measures to be taken-are
shown in the following table.
Lamp ON/OFF
STATUS
This indicates that the engine has stopped or it will not start.
Turn the starter switch to the [LOCK] position and wait few seconds.
Blinking
If the engine does not start and the lamp lights in continuously or blinking after the starter
switch is turned to the [START] position, and move the vehicle to a safe location by traction.
This indicates that the engine has insufficient force and irregular idling occurred due to a sys-
ON (1) tem damage.
This condition must be inspected at a Hino service dealer as soon as possible.
NOTICE:
Trouble diagnosis also can be performed using the diagnosis
monitor. The malfunction codes are indicated by sound and light.
(1) Turn the starter switch to the "ON".
M16020100001
M16020100002
M16020100003
M16020100004
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–15
(2) Check engine lamp and exhaust brake indicator lamp flashes on
and off to inform the malfunction codes.
(3) Read out the malfunction codes and write down the malfunction
codes that are displayed.
NOTICE:
Malfunction codes are displayed, starting from the lowest and pro-
gressing upward, with no distinction between present and past
malfunction codes.
M16020100005
Malfunction Code 9 - 2
Turn ON
Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Lamp
Turn ON
Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2
Exhaust Brake
2s 2s Indicator Lamp
2-1 Engine speed sensor no pulse Excessive air gap or abnormality of sensor
3-1 Abnormality of engine speed sensor Harness disconnection, short circuit or abnormality of sensor
14-1 Abnormality of rack sensor Harness disconnection, short circuit or abnormality of sensor
16-2 Abnormality of pre-stroke F/B Harness disconnection, short circuit or abnormality of sensor
NE1-
M16020100008
.
NG
Proceed to 3
OK
NG
• Bad contact of ECU connectors
• Abnormality of ECU
OK • Abnormality of ECU connectors
Normal
DN02–18 FUEL CONTROL (J08C: PRE-STROKE PUMP)
M16020100009
.
NG
Abnormality of sensor
OK
Standard:
THW- APPROX. 2.4 kΩ at 20°C {68°F}
APPROX. 1.5 kΩ at 40°C {104°F}
M16020100022 APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–19
Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023
NG
Abnormality of coolant temperature sensor
OK
CAUTION:
Make sure that transmission is in neutral position.
MGD1
M16020100036
.
NG
Abnormality of harness
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
.
DN02–20 FUEL CONTROL (J08C: PRE-STROKE PUMP)
MDL
1 2
3 4
GND
OSC
M16020100011
.
NG
Abnormality of harness and connectors
OK
.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–21
PMDL
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
PGND
POSC
M16020100012
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
DN02–22 FUEL CONTROL (J08C: PRE-STROKE PUMP)
POSC
M16020100013
.
NG
Abnormality of pre-stroke sensor
(Injection pump)
OK
PS-
M16020100014
.
NG
Proceed to 2
OK
M16020100015
.
NG
Abnormality of pre-stroke actuator
(Injection pump)
OK
M16020100016
.
NG
Abnormal adjustment of pre-stroke sensor
(Injection pump)
OK
.
DN02–24 FUEL CONTROL (J08C: PRE-STROKE PUMP)
M16020100017
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
NC
S+
M16020100018
.
NG
Abnormality of pre-stroke power supply relay
OK
.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–25
M16020100019
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
S+
M16020100020
.
NG
Abnormality of pre-stroke power relay
OK
DN02–26 FUEL CONTROL (J08C: PRE-STROKE PUMP)
S-
PSRY
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
M16020100021
.
NG
• Harness disconnection
• Abnormality of connectors
OK
.
FUEL CONTROL (J08C: PRE-STROKE PUMP) DN02–27
M16020100016
.
NG
The same code is being shown up: Malfunction
of ECU.
OK
Normal
(Temporary malfunction because of radio interference noise)
Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023
DN02–28 FUEL CONTROL (J08C: PRE-STROKE PUMP)
NG
Abnormality of coolant temperature sensor
OK
HINT:
This code will be displayed when the coolant temperature sensor
operates normally and coolant temperature ascends over 115°C
{239°F}. Also, while the malfunction code is being detected, Max.
volume of fuel injection will be limited and will return back to nor-
mal control volume when it descends less than 105°C {221°F}.
.
26 PIN CONNECTORS
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
1 — 14 —
2 — 15 —
3 — 16 —
9 — 22 —
22 PIN CONNECTORS
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
1 — 12 —
5 — 16 —
8 — 19 —
11 — 22 —
16 PIN CONNECTORS
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 — 9 —
2 — 10 —
3 — 11 —
4 — 12 —
5 — 13 —
7 — 15 —
8 CGD1 Ground 16 —
DN02–30 FUEL CONTROL (J08C: PRE-STROKE PUMP)
12 PIN CONNECTORS
1 2 3 4 5 6
7 8 9 10 11 12
1 — 7 —
2 — 8 —
3 — 9 —
4 — 10 —
6 TACH Tachometer 12 —
(3) Screw in the sensor by hand until the leading edge of the sensor
lightly contacts to the protrusion.
(4) After contacting the sensor to the protrusion, unscrew the sensor
1.0-1.5 turns (to create a gap of 1.0-1.5 mm {0.0394-0.0590 in.}).
(5) Tighten the lock nut while the hexagonal part on the sensor is
held to prevent the gap from changing.
Tightening Torque:
45-54 N⋅m {450-550 kgf⋅cm, 33-39 lbf⋅ft}
M16020100067
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–1
DN02-002
TE SYSTEM
OVERVIEW
M16020101BEC1001
TE SYSTEM
The TE (Total Electronics) system uses electronic control to regulate
every aspect of the engine's running condition. It is a comprehensive
electronic control system developed to extract maximum power and
low-pollution of the engine.
There are 4 types of the TE system, detail at below, this engine employ
the "Pre-stroke" and "Electronic Governor" type.
COMPONENT LOCATOR
M16020101BED1001
M16020100107
M16020100069
M16020100125
M16020100070
M16020100071
M16020100042
DIAGRAM
M16020101BEJ1001
FUEL SYSTEM
ELECTRICAL WIRING
CHECK ENGINE
LAMP ACCELERATOR SENSOR
CONTROL
UNIT
POWER
SUPPLY
COOLANT TEMPERATURE
SENSOR PRE-STROKE
ACTUATOR
MAIN ENGINE
SUB ENGINE SPEED SENSOR, SPEED SENSOR
RACK SENSOR AND ELECTRONIC
GOVERNOR ACTUATOR
INJECTION PUMP
M16020100072
DN02–10 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ELECTRICAL SYSTEM
+24 V
CONTROL UNIT
ACTUATOR POWER
MAIN ENGINE SUPPLY RELAY
SPEED SENSOR (N.C)
COOLANT GOVERNOR
TEMPERATURE ACTUATOR
SENSOR
RACK SENSOR
VEHICLE
SPEED SENSOR
TACHOMETER
STARTER DIAG
SWITCH
PRECAUTIONS
M16020101BEC1011
2. PRE-STROKE ACTUATOR.
• Never apply electricity to the pre-stroke actuator except through
the control unit. Never connect the actuator connectors directly to
a power source. Doing so could burn out the actuator coil.
• Also, note that the mounting position of the actuator is carefully
adjusted. Never do anything that could change the actuator's
mounting position.
• To have the actuator or sensor replaced, contact an establishment
specializing in BOSCH (ZEXEL).
M16020100032
• Do not let water, oil or dust get on the connector when it is discon-
nected, as this could cause poor contacts when the connector is
reconnected.
• Do not open the control unit cover. It could malfunction if dust or
water get inside.
• Take care to ensure that water, oil or dust do not get on or inside
parts.
• When connecting in connectors, push them in all the way and
make sure that the lock engages.
8. RADIO INSTALLATION
• There is a danger that the control unit might malfunction if a high
output radio transmitter (over 50W) is installed in the vehicle.
12. OTHER
• Make sure to check the fellow of connectors before connecting
them in to prevent incorrect connections.
• Be careful not to allow the connectors to become soiled with dust,
water, fuel or oil when performing inspections or removing and
replacing parts.
INSPECTION
M16020101BEH3001
M16020100033
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–13
ON Major
BLINKING OFF
0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec
Degree
ON of
trouble
ON (1)
OFF
ON
Minor
ON (2) OFF
M16020100034
The lamp ON/OFF status and illumination pattern as well as the corre-
sponding conditions they indicate and the measures to be taken-are
shown in the following table.
Lamp ON/OFF
STATUS
This indicates that the engine has stopped or it will not start.
Turn the starter switch to the [LOCK] position and wait few seconds.
Blinking
If the engine does not start and the lamp lights in continuously or blinking after the starter
switch is turned to the [START] position, and move the vehicle to a safe location by traction.
This indicates that the engine has insufficient force and irregular idling occurred due to a sys-
ON (1) tem damage.
This condition must be inspected at a Hino service dealer as soon as possible.
NOTICE:
Trouble diagnosis also can be performed using the diagnosis
monitor. The malfunction codes are indicated by sound and light.
(1) Turn the starter switch to the "ON" (Do not start the engine).
M16020100001
M16020100002
M16020100003
M16020100004
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–15
(2) Check engine lamp and exhaust brake indicator lamp flashes on
and off to inform the malfunction codes.
(3) Read out the malfunction codes and write down the malfunction
codes that are displayed.
NOTICE:
Malfunction codes are displayed, starting from the lowest and pro-
gressing upward, with no distinction between present and past
malfunction codes.
M16020100005
Malfunction Code 9 - 2
Turn ON
Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Lamp
Turn ON
Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2
Exhaust Brake
2s 2s Indicator Lamp
M16020100127
NOTICE:
Trouble diagnosis also can be performed using the diagnosis
monitor. The malfunction codes are indicated by sound and light.
(1) Turn the starter switch to the "ON" (Do not start the engine).
M16020100001
M16020100002
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–17
M16020100003
M16020100004
(2) Check engine lamp and exhaust brake indicator lamp flashed on
and off to inform the malfunction codes.
(3) Read out the malfunction codes and write down the malfunction
codes that are displayed.
NOTICE:
Malfunction codes are displayed, starting from the lowest and pro-
gressing upward, with to distinction between present and past
malfunction codes.
M16020100005
DN02–18 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
Malfunction Code 9 - 2
Turn ON
Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Lamp
Turn ON
Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2
Exhaust Brake
2s 2s Indicator Lamp
M16020100128
9-2 Abnormality of idle set controller Short-circuit or abnormality of idle set controller
25 26 27 2829 30 31 32
NE1-
M16020100074
.
NG
Proceed to 3
OK
NG
• Bad contact of ECU connectors
• Abnormality of ECU
OK • Abnormality of ECU connectors
Normal
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–21
M16020100075
.
NG
Abnormality of sensor
(Injection pump)
OK
25 26 27 2829 30 31 32
NE2-
M16020100076
.
NG
Proceed to 3
OK
DN02–22 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
NG
• Bad contact of ECU connectors
• Abnormality of ECU
OK • Abnormality of ECU connectors
Normal
M16020100129
.
NG
Abnormality of sensor
(Injection pump)
OK
Standard:
APPROX. 2.4 kΩ at 20°C {68°F}
THW-
APPROX. 1.5 kΩ at 40°C {104°F}
M16020100077 APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023
NG
Abnormality of coolant temperature sensor
OK
.
DN02–24 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
CAUTION:
Make sure that transmission is in neutral position.
1. CHECK THE VOLTAGE BETWEEN TERMINALS.
(1) Set the starter switch to "LOCK" and disconnect the 25 pin con-
ST nectors of ECU.
(2) Measure the voltage between ST and MGD1 terminals of 25 pin
1 2 3 4 5 6 7 8 connectors. (Chassis harness side)
9 10 11 12 13 14 15 16 17 18 + - Standard:
Starter switch "LOCK" : 0V
19 2021 22 23 24 25
Starter switch "START" : 24V
MGD1
M16020100078
.
NG
Abnormality of harness
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
PIM-
ECU VIEW
M16020100145
.
NG
Proceed to (3)
OK
• Abnormality of ECU
• Abnormality of ECU connectors
• Bad contact of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–25
(3) Set the starter switch to "LOCK" and disconnect the connector of
GND VCC
boost pressure sensor.
(4) Set the starter switch to"ON" and measure the voltage between
VCC and GND Terminals (Chassis harness side).
Standard: 4.5V or more
M16020100053
.
NG
Proceed to 2 - (4)
OK
25 26 27 2829 30 31 32
pressure sensor.
(3) Measure the resistance between PIM terminal of 32 pin connec-
SIG tors and SIG connector of boost pressure sensor (Chassis har-
ness side).
Standard: 2Ω or less
M16020100146
.
NG
Abnormality of harness
OK
25 26 27 2829 30 31 32
(6) Measure the resistance between PIM+ terminal of 32 pin connec-
tors and VCC terminal of boost pressure sensor (Chassis harness
VCC side), PIM- terminal of 32 pin connectors and GND terminal of
boost pressure sensor (Chassis harness side).
Standard: 2Ω or less
M16020100147
PIM-
1 2 3 4 5 6 7 8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24
25 26 27 2829 30 31 32
GND
M16020100148
.
NG
Abnormality of harness
OK
• Abnormality of ECU
• Bad contact of connectors
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–27
VCC1
M16020100130
.
NG
Proceed to (4)
OK
Proceed to (5)
222120191817161514131211
+ -
313029 282726 252423
AGD1
ECU VIEW
M16020100079
.
NG
• Abnormality of ECU
• Abnormality of ECU connectors
OK
Abnormality of harness
DN02–28 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ECU VIEW
M16020100080
.
NG
Proceed to (9)
OK
• Abnormality of ECU
• Abnormality of ECU connectors
(9) Measure the voltage between SIG1 and GND1 terminals of accel-
GND1 erator sensor. (Chassis harness side).
Standard:
0.7-1.0 V: Release the accelerator pedal.
1 2 3 + - 3.55-4.0 V: Depress the accelerator pedal fully.
4 5 6
SIG1
VIEW
CHASISS HARNESS SIDE
M16020100083
.
NG
Abnormality of accelerator sensor
OK
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–29
M16020100110
.
NG
Proceed to (4)
OK
Proceed to (5)
222120191817161514131211
+ -
313029 282726 252423
AGD2
ECU VIEW
M16020100085
.
NG
• Abnormality of ECU
• Abnormality of ECU connectors
OK
Abnormality of harness
DN02–30 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ECU VIEW
M16020100086
.
NG
Proceed to (9)
OK
• Abnormality of ECU
• Abnormality of ECU connectors
(9) Measure the voltage between SIG2 and GND2 terminals of accel-
GND2 erator sensor. (Chassis harness side).
Standard:
0.7-1.0 V: Release the accelerator pedal.
1 2 3 3.55-4.0 V: Depress the accelerator pedal fully.
4 5 6
+ -
SIG2
VIEW
CHASISS HARNESS SIDE
M16020100087
.
NG
Abnormality of accelerator sensor
OK
AGD1
ECU VIEW
M16020100080
NG
Abnormality of accelerator sensor
OK
AGD1
ECU VIEW
M16020100080
.
NG
Abnormality of accelerator sensor
OK
Abnormality of harness
.
DN02–32 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
AGD2
ECU VIEW
M16020100086
NG
Abnormality of accelerator sensor
OK
AGD2
ECU VIEW
M16020100086
.
NG
Abnormality of accelerator sensor
OK
Abnormality of harness
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–33
ECU VIEW
M16020100090
.
NG
Proceed to 2
OK
Abnormality of ECU
M16020100111
.
NG
Abnormality of accelerator switch
OK
Abnormality of harness
.
DN02–34 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
NG
No resistance of Q-adjustment resistor:
Install the register No.4 of Q-adjustment resis-
tor as listed below.
OK
NG
Proceed to (3)
OK
• Abnormality of ECU
• Abnormality of ECU connector
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–35
NG
Abnormality of Q-adjustment resistor
OK
M16020100113
.
NG
Proceed to (4)
OK
Proceed to (5)
DN02–36 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
(4) Measure the voltage between IV+ and IVG terminals of 26 pin
IV+ connectors.
Standard: 4.5-5.5 V
13 12 11 10 9 8 7 6 5 4 3 2 1 + -
26 25 24 23 22 21 20 19 18 17 16 15 14
IVG
ECU VIEW
M16020100093
.
NG
• Abnormality of ECU
• Abnormality of ECU connectors
OK
Harness disconnection
M16020100094
.
NG
Proceed to (9)
OK
• Abnormality of ECU
• Abnormality of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–37
(9) Measure the voltage between SIG and GND terminals of Idle set
controller connectors (Chassis harness side).
Standard:
APPROX. 0 V: Turn idle control knob to left fully
APPROX. 0.7 V: Turn idle control knob to left.
APPROX. 4.3 V: Turn idle control knob to right fully
M16020100114
.
NG
Abnormality of idle set controller
OK
.
DN02–38 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
NG
Proceed to
OK
• Abnormality of ECU
• Bad contact of harness connector
M16020100089
NG
Harness disconnection of vehicle speed sen-
sor circuit
OK
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–39
10 9 8 7 6 5 4 3 2 1
GROUND
222120191817161514131211
VS
ECU VIEW
M16020100131
.
NG
Short circuit of vehicle speed sensor circuit
OK
.
DN02–40 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
M16020100098
.
NG
Abnormality of harness and connectors
OK
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–41
POSC
PMDL
1 2 3 4 5 6 7 8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24
25 26 27 2829 30 31 32
PGND
M16020100099
.
NG
Proceed to 2
OK
POSC
M16020100013
.
NG
Abnormality of pre-stroke sensor
(Injection pump)
OK
25 26 27 2829 30 31 32
PS+
M16020100100
.
NG
Proceed to 2
OK
M16020100015
.
NG
Abnormality of pre-stroke actuator
(Injection pump)
OK
M16020100016
.
NG
Abnormal adjustment of pre-stroke sensor
(Replace the injection pump)
OK
.
DN02–44 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
PSGD
M16020100088
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
NC
S+
M16020100018
.
NG
Abnormality of pre-stroke power supply relay
OK
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–45
CASE
M16020100092
.
NG
Proceed to 2
OK
• Abnormality of ECU
• Abnormality of ECU connectors
S+
M16020100020
.
NG
Abnormality of pre-stroke power supply relay
OK
DN02–46 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
S-
1 2 3 4 5 6 7 8 9 10
111213141516171819202122
PSRY
M16020100101
.
NG
• Harness disconnection
• Abnormality of connectors
OK
M16020100098
.
NG
Abnormality of harness and connectors
OK
NG
Return the emergency engine stop knob and
stop lever to the engine start (drive) position
OK
Combination of terminals
Terminal Terminal
Terminal No. Terminal No.
name name
1 GVB 2 7 GVB 2
1 2 3 4 5 6 7 8
1 2
2 GND 1 17 GND 1
9 10 11 12 13 14 15 16 17 18
3 4 5
6 7 19 2021 22 23 24 25
3 SOL 1 6 SOL 1
4 +5V 1 5 +5V 1
M16020100095
DN02–48 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
Terminal Terminal
Terminal No. Terminal No.
name name
1 GVB 1 8 GVB 1
2 GND 2 24 GND 2
3 SOL 2 15 SOL 2
4 +5V 2 14 +5V 2
1 2 3 4 5 6 7 8
1 2 3 4 9 10 11 12 13 14 15 16 17 18 Standard: 1 Ω or less
5 6 7 8
19 2021 22 23 24 25
M16020100096
.
NG
Abnormality of harness and connectors
OK
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–49
M16020100016
.
NG
The same code is being shown up: Malfunction
of ECU.
OK
Normal
(Temporary malfunction because of radio interference noise)
Standard:
APPROX. 2.4 KΩ at 20°C {68°F}
APPROX. 1.5 KΩ at 40°C {104°F}
APPROX. 870 Ω at 60°C {140°F}
APPROX. 530 Ω at 80°C {176°F}
M16020100023
NG
Abnormality of coolant temperature sensor
OK
HINT:
This code will be displayed when the coolant temperature sensor
operates normally and coolant temperature ascends over 115°C
{239°F}. Also, while the malfunction code is being detected, Max.
volume of fuel injection will be limited and will return back to nor-
mal control volume when it descends less than 105°C {221°F}.
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) DN02–51
32 PIN CONNECTORS
1 2 3 4 5 6 7 8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24
25 26 27 2829 30 31 32
25 PIN CONNECTORS
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
19 2021 22 23 24 25
7 GVB2 Governor actuator power supply 20 BSW2 Brake switch (with ATM)
31 PIN CONNECTORS
1 2 3 4 5 6 7 8 9 10
111213141516171819202122
M16020100104
7 — 23 —
8 — 24 CASE Ground
9 — 25 —
10 — 26 —
16 PIN CONNECTORS
1 2 3 4 5
6 7 8 9 101112
13 141516
M16020100105
4 — 12 —
26 PIN CONNECTORS
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 1617181920212223 24 25 26
M16020100106
1 — 14 —
2 — 15 —
5 AT Ground 18 —
6 — 19 —
7 — 20 —
8 — 21 —
9 — 22 —
10 — 23 —
11 — 24 —
13 — 26 —
M16020100068
DN02–56 FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
M16020100067
1-1, HINODAI 3-CHOME, HINO-SHI, TOKYO 191-8660 JAPAN
PRINTED IN JAPAN