SK480 8

HINO DIESEL ENGINE
WORKSHOP MANUAL
P11C-UP
(Shovel)
KSS-SHP1-E001E
2007.3
GENERAL 1
STANDARD VALUE 2
PARTS TO BE PREPARED 3
ENGINE ASSEMBLY/DISASSEMBLY 4
FUEL SYSTEM 5
EMISSION CONTROL 6
ELECTRICAL 7
INTAKE 8
ENGINE MECHANICAL 9
EXHAUST 10
COOLING 11
LUBRICATION 12
STARTING AND CHARGING 13
TURBOCHARGER 14
AIR COMPRESSOR 15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16
ENGINE DIAGNOSIS CODE 17
For your information:
This documentation does not contain any descriptions in

regard to the hatched part
"15. Air Compressors".

GENERAL 1–1
ENGINE
1
1 GENERAL
General information
Outline
Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts ...................... 1-11
Tightening of chassis bolts and nuts..................... 1-13
Tightening of flare nuts and hoses........................ 1-15
Taper thread sealant for piping ............................. 1-16
Assembly of joints and gaskets for piping ............. 1-17
Handling of liquid gasket....................................... 1-19
Failure diagnosis table for each problem .............. 1-20
Failure diagnosis procedures ................................ 1-21
Failure diagnosis using HinoDX ............................ 1-23
Connection method of HinoDX ............................. 1-26
Chassis number and engine number ................... 1-26
1–2 GENERAL
Warning
JP30001010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical experts. Those who are not
qualified, who are not appropriately trained, who perform service without appropriate tools or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows "Warning" and "Caution" for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with "Warning" or
"Caution" are not absolute for safety.
GENERAL 1–3
How to read this manual

JP30001010102002
1. Scope of repair work

(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement, assembly⋅disassembly and
inspection⋅adjustment" in the second process. Explanation of "Final inspection" in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually equipped
in general service shop are omitted.
4. How to read sections and titles

(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)
! CAUTION The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in February, 2007. (Some areas do not show exploded view.
They will be additionally issued when the parts catalog CD is revised.) Be sure to use the
parts catalog for confirmation of illustrations and part numbers and for ordering parts.
5. How to read troubleshooting

(1) Failure diagnosis in this manual describes Step 2 and Step 3 below:
Hear from customers for conditions and environments of

(1) Question "Step 1"
failures and check the fact.
Perform diagnosis inspection, status inspection, function

(2) Pre-inspection inspection and basic inspection. Check the failure status.
"Step 2"
(3) Reproduction method If it is difficult to reproduce the problem with status
inspection, use the reproduction method.
(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each troubleshooting procedures for each diagnosis code or
failure status failure status.
Check if failure occurs again after repair. If it is difficult to

(6) Confirmation test "Step 4" reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.
1–4 GENERAL
(2) Pre-inspection
• Pre-inspection is performed in the following steps:

Diagnosis inspection → Diagnosis deletion → Failure status check (Use the reproduction
method if not reproduced.) → Diagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
Pre- estimated cause of a failure.
inspection • An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
• Failure status check
If failure is reproduced,perform Step 2 → Step 3 → Step 4.
If failure is not reproduced,use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
GENERAL 1–5
6. How to read explanation details

(1) Part layout
Example
ENGINE MECHANICAL [J08E] 9–17
Timing Gear Cover and Flywheel Housing

Part layout
JP04117090402003
Part name code
Part catalog Fig. No.
SAPH041170900182
11308 Flywheel housing 11390 End plate

Description of
11309 Oil seal retainer 9828A Front oil seal* part name code
11357 Gasket* 9828B Rear oil seal*
11357A Gasket*
*Parts not to be reused.

Left: Part name code (nut)
Tightening torque
9069H M14 : 171.5 N.m{1, 750 kgf.cm, 126 lbf.ft} 9419A M16 : 196 N.m{2, 000 kgf. cm, 145 lbf.ft}
9069J M12 : 97 N.m{990 kgf.cm, 71 lbf.ft} 9419B M16 : 196 N.m{2, 000 kgf. cm, 145 lbf.ft}
Service procedure
Overhaul item
SAPH300010100001
✩ It is the ID number for parts to prepare electronic data. It is not required for repair work.
1–6 GENERAL
7. Definition of terms
Terms in this manual are defined as follows:
(1) Direction
a. Individual unit
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
Vertical direction
With the unit installed on the upper frame, the upward direction shall be the upper side and the
downward direction the lower side.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ⋅⋅⋅⋅⋅⋅⋅Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined
(3) Repair limit⋅⋅⋅It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
the standard value.
(4) Operation limit⋅⋅⋅It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that may result in risk of human life or serious injury by incorrect handling.
(6) Caution⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
(7) Reference⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is supplementary explanation in work.
8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Conventional Conversion value*1(1[Conventional unit] = X

SI unit
unit [SI unit])
Force N kgf 1kgf=9.80665N
Torque*2 N⋅m kgf⋅cm 1kgf⋅cm=0.0980665N⋅m
kgf/cm2 1kgf/cm2=98.0665kPa=0.0980665MPa
Pressure Pa
mmHg 1mmHg=0.133322kPa
r/min 1rpm=1r/min
Rotational speed rpm
min-1 1rpm=1min-1
Spring constant N/mm kgf/mm 1kgf/mm=980665N/mm
Volume L cc 1cc=1mL
Efficiency W PS 1PS=0.735499kW
Calorific value W⋅h cal 1kcal=1.13279W⋅h
Fuel consumption rate g/W⋅h g/PS⋅h 1g/PS⋅h=1.3596g/kW⋅h
*1:X
means the value when 1 [Conventional unit] is converted to the SI unit. It is used as the
conversion factor from the conventional unit to the SI unit.
*2:The
conversion value of the torque may vary depending on the unit. Observe the standard
values described for each unit.
GENERAL 1–7
Safety information
Precautions for work

JP30001010101001
1. General precautions
To ensure safety in work and to prevent accidents, observe the following items:
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V-belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
f. Since the battery fluid is poisonous and corrosive sulfuric acid, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
2. Precautions for service work

Pay attention to the following points before service work
(1) Preparation before disassembly
a. Prepare general tools, special tools and gauges before work.
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
c. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
(3) Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
(4) Washing of disassembled parts
Clean and wash parts to be reused well.
(5) Inspection and measurement
Inspect and measure parts to be reused as required.
(6) Assembly
a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct parts
in the correct order.
b. Be sure to use genuine parts for parts to be replaced.
c. Use new packings, gaskets, O-rings and cotter pins.
d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
(7) Check of adjustment
Make adjustments to the service standard values using a gauge or tester.
1–8 GENERAL
3. Precautions for electric system

(1) Removal of battery cable
a. In an electric system, remove the cable from the battery

minus (-) terminal to prevent burnout due to short-
circuit.
b. When the battery cable is removed, the battery terminal
Loosen
may be damaged. Loosen the nut completely and never
pry it for removal.
SAPH300010100002
(2) Handling of electronic parts
a. Do not give impact on electronic parts such as

computer and relay.
b. Do not place electronic parts at a high temperature and
humidity area.
c. Do not expose electronic parts to water in washing of a
vehicle.
SAPH300010100003
(3) Handling of wire harness
a. Mark clamps and clips to prevent interference of a wire

harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch a
wire harness.
SAPH300010100004
GENERAL 1–9
(4) Handling of connector
a. When a connector is removed, hold the connector (as

shown by the arrow in the left figure) and pull it out. Do
not pull the wire harness.
b. Unlock the locking connector before pulling.
c. Insert the locking connector completely until it clicks.
d. To insert a test lead into the connector, insert it from the
back of the connector.
e. If it is difficult to insert a test lead from the back of the
connector, prepare a harness for inspection.
SAPH300010100005
1–10 GENERAL
4. Precautions for electric welding

Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
(1) Turn "OFF" the starter switch.
(2) Make sure that switches are "OFF".
(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(5) Remove all fuses. (For locations of fuses, refer to "manual".)
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
(7) Other precautions
a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they may
not be exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
(9) After reassembly, check the function if it operates correctly.
General information
GENERAL 1–11
Tightening of engine bolts and nuts

JP30001010102003
1. Tightening torque of general standard bolts

(1) For bolts with seatings
Unit:N⋅m{kgf⋅cm}
Screw diameter x Pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5{290} 36{370}
M10 x 1.25 (Fine thread) 60{610} 74.5{760}
M10 x 1.5 (Coarse thread) 55{560} 68.5{700}
M12 x 1.25 (Fine thread) 108{1,100} 136{1,390}
M12 x 1.75 (Coarse thread) 97{990} 125{1,280}
M14 x 1.5 (Fine thread) 171.5{1,750} 216{2,210}

M14 x 2 (Coarse thread) 154{1,570} 199{2,030}
Remark Bolt with number "7"on the head Bolt with number "9"on the head
! CAUTION • 8T bolt is in accordance with 7T bolt.
(2) For bolts with washers

Screw diameter x Pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6{60} 10{100} 13{130}
M8 x 1.25 (Coarse
14{140} 25{250} 31{320}
thread)
M10 x 1.25 (Fine thread) 29{300} 51{520} 64{650}
M10 x 1.5 (Coarse

26{270} 47{480} 59{600}
thread)
M12 x 1.25 (Fine thread) 54{550} 93{950} 118{1,200}
M12 x 1.75 (Coarse

49{500} 83{850} 108{1,100}
thread)
M14 x 1.5 (Fine thread) 83{850} 147{1,500} 186{1,900}
M14 x 2 (Coarse thread) 74{750} 132{1,350} 172{1,750}

Bolt with number "4" on
Bolt with number "7" on
the head Bolt with number "9" on
Remark the head Stud with C
Projection bolt Stud with the head
surface at free end
R surface at free end
! CAUTION • 8T bolt is in accordance with 7T bolt.
R surface (4T) C surface (7T)
SAPH300010100006
1–12 GENERAL
2. Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.
(1) When re-application of lock agent is required

a. When precoated bolts are removed
b. When precoated bolts are moved due to tightening
Seal lock agent check (for loosening or tightening)
NOTICE • Check torque with the lower limit of the

SAPH300010100007 tightening torque allowable value. If
movement is found, tighten the bolt according
to the procedure below.
(2) Re-use method of precoated bolt lock

a. Clean bolt and screw holes. (Clean screw holes for
replacement.)
b. Dry completely by blowing air.
c. Apply the specified seal lock agent to the thread of the
bolt.
3. Plastic region tightening method (angle method)

One turn by 90°
(1) Precautions
Some engines are tightened with the plastic region
Tighten it 90°
tightening method.
Since it is different from the conventional method, tighten
it according to the instruction in the text.
SAPH300010100008
(2) Parts tightened

One turn by 90° Tighten it 45°
One turn by 45° (Second time) Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc.
Tighten it 90°
(First time)
! CAUTION • Measure the overall length of the bolt before
assembly and replace the bolt if the length
exceeds the operation limit.
Apply engine oil to bolt seating and bolt
thread in assembly.
SAPH300010100009
(3) Tightening method after tightening to seating torque

Two turns by 90° Tighten it 90°
(Second time) Tightening of 90°, 135°(90°once and 45°once) and
Tighten it 90° 180°(90°twice) is available.
(First time)
SAPH300010100010
GENERAL 1–13
Tightening of chassis bolts and nuts

JP30001010102004
1. Tightening torque of general standard bolts and nuts

(1) Selection method of tightening torque
a. Find the applicable strength zone from the table below and select the bolt tightening torque from the
table described later.
b. Select the nut tightening torque from the mating bolt as described above.
(2) Identification method of bolt strength zone
a. Identification method with product
Hexagonal bolt
Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression and
upset on the head with the symbol in the table.
Strength zone 6T 7T 8T 9T 10T 11T 12T

Identification symbol for part 6 7 8 q*1 10 11 12
(*1): 9 may be misread with 6. It is expressed in q.
Depression Relief Base depression Upset
SAPH300010100011
Hexagonal nut
Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below:
Formula
(3) Types of general standard bolts and nuts
Standard seating Seating A with flange Seating B with flange

1–14 GENERAL
(4) Standard tightening torque table of general standard bolts and nuts
(Representative standard seating is described.)
Strength
zone
Bolt 4T 7T 9T
diameter
(mm)
4.5±1.8{50±20}
(Cab)
M6 9.0±1.8{90±20} 11.5±2.0{117±23}
5.5±1.1{60±10}
(Chassis)
14.0±3.5{140±40}
(Cab)
M8 22.0±4.0{220±40} *2 29.0±5.5{300±60} *2
17.0±3.0{170±30}
(Chassis)
43.0±8.5{440±90} *2 57.0±11.0{580±110} *2
(Cab) (Cab)
M10 27.0±5.0{276±55}
51.5±10.0{530±100} 68.5±13.5{700±140}
(Chassis) (Chassis)
76.0±15.0{776±150} *2 100.0±20.0{1,020±200} *2
(Cab) (Cab)
M12 48.0±9.5{490±98}
91.0±18.0{930±180} 120.0±24.0{1,220±240}
(Chassis) (Chassis)
M14 77.0±15.0{786±157} 120.0±24.0{1,220±240} 160.0±32.0{1,630±326}
M16 120.0±24.0{1,220±244} 190.0±38.0{1,940±390} 250.0±50.0{2,550±510}
M18 165.0±33.0{1,680±336} 260.0±52.0{2,650±530} 345.0±69.0{3,520±704}
M20 235.0±47.0{2,400±480} 370.0±74.0{3,770±750} 490.0±98.0{5,000±1,000}
M22 320.0±64.0{3,270±654} 505.0±100.0{5,150±1,030} 670.0±130.0{6,840±1,370}

M24 405.0±81.0{4,130±826} 640.0±125.0{6,530±1,310} 845.0±165.0{8,620±1,720}
! CAUTION • Use the tightening torque value for seating A with flange except for *2 in the table larger by
10% than the tightening torque value in the table.
• Use the tightening torque value for seating B with flange of *2 in the table larger by 20%
than the tightening torque value in the table.
The tightening torque value of M8 for seating B with flange remains unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in
pairs. Use the standard seating for the tightening torque value.
GENERAL 1–15
Tightening of flare nuts and hoses

JP30001010102005
1. Tightening torque of pipe flare nut

Pipe outer
diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15
Material
Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}
2. Tightening torque of hoses

Hose outer diameter

Hose outer diameter Hose outer diameter
φ13,φ20,φ22, fitting at
φ10.5 fitting PF3/8 fitting
packing
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
3. Lock nut tightening torque of brass joint

Screw nominal
M12 M16 M20 M27
size
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
1–16 GENERAL
Taper thread sealant for piping

JP30001010102006
The taper thread of the air pipe joint has application of sealant
[Loctite #575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.
1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant (#Loctite 575) has strong sealing feature. The
Frame Air pipe (Flare joint) return torque of the taper joint is increased about 1.5
(No application of sealant)
times the initial tightening torque. When the joint is
Since sealant is disconnected, use a long wrench for disconnection.
applied to this area,
remove accessories
(2) When a joint at a poorly accessible area is replaced,
with the joint remove accessories first and disconnect the joint.
attached and remove
Air hose
SAPH300010100016
2. For connection
1/4 turn (1) For application of sealant (#Loctite 575), wipe the sealing
Amount of application: 0.1 g/piece
area completely with a rag or thinner. Apply sealant
directly to about three ridges for quarter round with offset
3 threads
1 thread
of one ridge from the end. Tighten it according to the
tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.
SAPH300010100017 ! CAUTION • If your eye or skin comes in contact with

sealant, wash it off immediately with water.
Tightening torque of taper joint Unit:N⋅m{kgf⋅cm}
Screw
diameter 1/4 3/8 1/2
Material
49±10{500±
Steel 64±15{650±150}
100}
Aluminum,
25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
(2) When a sealing tape is replaced with sealant, remove the

tape completely first as in (1).
! CAUTION • Be careful to prevent entry of dirt or foreign

matter in the pipe.
(3) If air leak is found after assembly with application of

sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
(2).
GENERAL 1–17
Assembly of joints and gaskets for piping

JP30001010102007
1. Tightening torque of joints

Metal sealing method
Sealing method
Gasket sealing method (Flare pipe type, nipple connector type)
Tightening screw (Aluminum + Rubber or Copper)

Type A Type B
size
M8 13{130}
M10 20{200} 11{110}

M12 25{250} 20{200}
M14 25{250} 31{320}
M16 29{300} 39{400}

M18 39{400} 59{600}
M20 *39{400} 64{650} 20{200}
M24 69{700}
M28 *127{1300}
2. Joint assembly procedure and subsequent inspection

(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4) Observe the values above for each tightening torque.
*When assembled soft washer #4840FR-N (aluminum and rubber carbon pressure bonding) is loosened or
removed, be sure to replace it with a new part. This is not necessary for normal retightening.
1–18 GENERAL
3. Examples of joint methods in various pipes
Metal sealing method

Gasket sealing method Type A Type B
(Flare pipe type) (Nipple connector type)
Joint bolt Sealing surface: 3 places

Flare pipe
Gasket Connector
Flare nut Nut
Joint bolt Connector nipple
Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint Gasket
with sleeve Gasket Sealing surface
Sealing surface: 5 places
Gasket : 5 places
Joint bolt Nut

Lock washer Bracket
Nut
Sealing surface
: 8 places Connector nipple
Sealing surface: 1 place

Sealing surface: 1 place
Flare connector
Nut Lock washer

Box nut
3-way joint
Sealing surface
: 8 places
Joint pipe
Bracket
Sealing surface
: 3 places
One piece eye joint without sleeve
Joint bolt
Joint bolt
Joint pipe

GENERAL 1–19
Handling of liquid gasket

JP30001010102008
1. Application of liquid gasket and part assembly procedure

(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
Be sure to overlap parts at the beginning and at the end of application.
(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
liquid gasket again if offset occurs.
(3) Assemble parts within 20 minutes after application of the liquid gasket.
If 20 minutes has passed, remove the liquid gasket and apply it again.
(4) Start the engine at least 15 minutes or more after assembly of parts.
2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.
3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.
Winding tool
Application gun
Tube: 150 g
Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
1:Approx. 2 mm at the 1st section cut

2:Approx. 5 mm at the 2nd section cut
Nozzle of tube
General information
Description of function
1–20 GENERAL
Failure diagnosis table for each problem

JP30001010301001
The cause and action for each item are described.

Engine mechanical
JP03Z01020601001
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression Non-synchronous injection timing Adjust injection timing.
pressure) Faulty fuel injection pressure Adjust injection pressure
Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of vavle guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
SAPH300010100031
GENERAL 1–21
Failure diagnosis procedures

JP30001010301002
1. Display of failure code

(1) If the system has an error, the failure code is displayed on the multiple display of gauge cluster.
SAPH300010100032
2. Deletion method of past failure

(1) To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX manual".)
SAPH300010100033
3. Deletion of cluster gauge past failure

(1) Turn "ON" the starter switch.
(2) When the buzzer stop switch is pressed consecutively 5

times in 10 seconds, the failure history mode is displayed.
(3) Press work mode selecting switch and the buzzer stop
switch at the same time for 10 seconds or more.
(4) When the display shows "No error", deletion is completed.
SAPH300010100034
1–22 GENERAL
4. How to read troubleshooting for each diagnosis monitor code

(1) "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives
output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be
started from the code list.
ENGINE DIAGNOSIS CODE [Engine Common] 3–15
Failure of main speed sensor (DTC code P0335/diagnosis monitor code 13)
JP03Z01030601004
1 Measurement of resistance between terminals
1. Set the starter key to "LOCK" and connect the signal check
B6 B B7 harness.
2. Remove the ECU side connector of the signal check harness

and meausre the resistance between terminal B6 and terminal
B7. Details of work
Standard value : Approx. 125.5 17 (20 dC)
NG [3] Go to measurement of resistance between sensor terminals.

SAPH03Z010300010
OK
2 Check of diagnosis code
1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, output the diagnosis code again.
Standard : Normal
NG Contact failure of ECU connector, ECU failure,

short-circuit of harness
SAPH03Z010300011
OK
Normal
1. Remove the connector of the main engine speed sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.
Standard value : Approx. 125.5 17 (20 dC)
NG Failure of main engine speed sensor
Indicates replacement of the main

SAPH03Z010300012
engine revolution sensor.
OK
Check the harness of the relevant circuit and repair the faulty area.
Harness disconnection or connector failure
SAPH300010100035
GENERAL 1–23
Failure diagnosis using HinoDX

JP30001010301003
! CAUTION HinoDX is used for inspection and adjustment

of the system in addition to failure diagnosis.
1. HinoDX
(1) With HinoDX, failure of the common rail fuel injection

system can be diagnosed. The interface box (Hino-Bowie)
and the special cable are required for connection to the
unit.
Special tool : 09121-1040 Hino-Bowie
SAPH300010100036
09042-1220 Cable between unit and
Hino-Bowie
CD-ROM HinoDX
! CAUTION • Install the software of the Hino Diagnostic

eXplorer (Hino DX) in the PC. For the
installation method, refer to the instruction
manual accompanying the CD.
2. List of failure diagnosis tools
Part name Part No. External shape General description and function
PC • Operating system (OS): Windows 95,

(DOS/V standard) Windows 98 (IE5.0 or later), Windows
2000 (SP3, IE5.0 or later), Windows XP
(SP1a, IE6.0 or later)
—
• CPU and memory: Conditions that
assure operation of the above operating
system
• Display: 800 x 600, 256 colors or more
Hino-Bowie 09121 - 1040 • PC interface

(Interface box) Cable between unit • The cable for connection between PC
and Hino-Bowie and Hino-Bowie is enclosed with Hino-
(09042 - 1220) Bowie.
Signal check 09049 - 1080 Interrupting installation between unit

harness (for common rail fuel harness and ECU allows inspection with a
injection system) tester rod while the power is supplied.
1–24 GENERAL
3. Connection of signal check harness
(1) To prevent damage to the ECU connector and to improve

accessibility, connect the signal check harness and put a
testing rod on the signal check connector of the signal
check harness for measurement.
a. Disconnect the connector from the ECU.
Unit harness ! CAUTION • Do not break the locking tab of the connector.
Signal check harness
b. Connect the signal check harness to the machine
harness and the ECU.
Test lead
(for common rail fuel injection system)
Part No.
09049-1080
Signal check connector
SAPH300010100040
GENERAL 1–25
(2) Terminal No.

For the signal check harness connector, the ECU terminal number in the text is treated as follows:
ECU unit
Signal check
harness
ECU side Unit side
SAPH300010100041
1–26 GENERAL
Connection method of HinoDX

JP30001010301004
1. Removal of the maintenance cover

(1) Remove the maintenance cover (A) on the rear cover
Maintenance Cover (A)
behind the operator seat by pushing down the tab at the
top (at one location).
NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.
SAPH300010100042
2. Connection of HinoDX
Engine ECU (1) Connect the engine failure diagnosis connector to the PC
which installed HinoDX through the interface box.
Special tool : 09121-1040 Hino-Bowie (Interface box)

09042-1220 Connecting cable
Engine failure
diagnosis CD-ROM HinoDX
connector
(2) Set the starter key to "ON" and start HinoDX.
SAPH300010100043
Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH300010100044
Setup layout
Layout
Chassis number and engine number

JP30001010401001
1. Engine type and engine number

Engine type and engine number are
stamped on the left side

of the cylinder block.
When ordering parts, report this number for smooth
processing.
Stamp position Example: P11C TB10001
SAPH300010100045
STANDARD VALUE 2–1
ENGINE
2 STANDARD VALUE 2
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Engine Body................................................................ 2-2

Standard value........................................................ 2-2
Fuel System ................................................................ 2-2
Tightening torque .................................................... 2-2
Emission control ........................................................ 2-2
Electrical...................................................................... 2-3
Standard value........................................................ 2-3
Intake ........................................................................... 2-3
Engine Mechanical ..................................................... 2-4
Standard value........................................................ 2-4
Tightening torque .................................................. 2-12
Exhaust...................................................................... 2-13
Cooling ...................................................................... 2-13
Standard value...................................................... 2-13
Lubrication ................................................................ 2-14
Standard value...................................................... 2-14
Starting and Charging.............................................. 2-16
Standard value (alternator 60A)............................ 2-16
Tightening torque (alternator 60A)........................ 2-16
Standard value (starter) ........................................ 2-17
Tightening torque (starter) .................................... 2-18
Turbocharger............................................................. 2-18
Standard value...................................................... 2-18
2–2 STANDARD VALUE
Engine Body
Standard value
JP30109020205001
Unit: MPa {kgf/cm2, lbf/in.2}
Operation
Inspection item Standard value Repair limit Action
limit
Compression pressure
2.9{30, 720} — 2.5{26, 362} Overhaul
(Engine revolution per cylinder: 200 r/min)
Fuel System
Tightening torque
JP30109020205002
Unit:N⋅m{kgf⋅cm,lbf⋅ft}
Tightening area Tightening torque Remark
Injector clamp mounting bolt 26{270, 19}
Injector union bolt 20{200, 15}
Leakage pipe - cylinder head

20{200, 15}
(Union bolt)
Injection pipe (M14) 44{450, 32}
Injection pipe (M16) 54{550, 40}
Supply pump cotter bolt 91{930, 67}
Supply pump coupling bolt 61{620, 45}
Supply pump mounting bolt 28{290, 20}
Supply pump drive gear mounting nut 245{2,500, 180}
Emission control
Tightening torque
JP04118010701002
EGR cooler mounting bolt 55{560,40}
EGR valve mounting bolt 72{730,53}
EGR pipe mounting bolt and nut 72{730,53}

Electrical
Standard value
JP31199020205003
Inspection item item item Standard value Remark

14 - 16mm {0.5512 - 0.6299in.} Compression
Deflection (Reference push force 98N gauge (09444-
{10kgf, 22lbf}) 1210) is used.
When installing Belt tension
a new belt gauge (95506-
600 - 690N
Tension 00090 Denso
{65 - 70kgf,135 - 155lbf}
part No.) is
V–belt tension used.
adjustment 15 - 17mm {0.5906 - 0.6693in.} Compression
Deflection (Reference push force 98N gauge (09444-
{10kgf, 22lbf}) 1210) is used.
At the time of Belt tension
inspection gauge (95506-
590 - 640N
Tension 00090 Denso
{60 - 65kgf,133 - 144lbf}
part No.) is
used.
Intake
Tightening torque
JP30109020205003
Intake manifold mounting bolt 55{560, 40}
Intake air heater mounting nut and intake pipe

55{560, 40}
mounting nut
Engine Mechanical
Standard value
JP30109020205004
Unit:mm{in.}
Standard Operation
Inspection item Repair limit Action
value limit
Cylinder liner protrusion 0.04 - 0.10

{0.0016 - — —
0.0039}
Cylinder liner flange width 8{0.315} — —
Cylinder block flange width 8{0.315} — 7.97{0.3138} Replacement
Cylinder block inner A 127 -

diameter 127.0085
— —
{5.000 -
5.003}
B 127.0085 -
127.0165
— —
{5.003 -
5.0007}
C 127.0165 -
127.0250
— —
{5.0007 -
5.0010}
Cylinder liner outer A 126.9795 -

diameter 126.9875
— —
{4.9992 -
4.9995}
B 126.9875 -
126.9960
— —
{4.9995 -
4.9998}
C 126.9960 -
127.0045
— —
{4.9998 -
5.0002}
Standard Operation
value limit
Clearance between A 0.0120 -

cylinder liner and 0.029
— —
cylinder block {0.0005 -
0.0011}
B 0.0120 -
0.029
— —
{0.0005 -
0.0011}
C 0.0125 -
0.029
— —
{0.0005 -
0.0011}
Cylinder liner inner diameter 122.15 Replacement

122{4.803} —
{4.8090}
Piston outer diameter (Pin hole 25 mm

121.95
above the lower end of the skirt square — —
{4.8012}
direction)
Piston clearance 0.060 - 0.080 Replace liner or
{0.0024 - — 0.15{0.0059} piston.
0.0031}
Standard Operation
value limit
Piston Free joint Top Approx. 12.7 — —

ring clearance Second Approx. 14.6 — —
Third Approx. 15 — —
Oil Approx. 11 — —
Cylinder Top 0.30 - 0.50 Replace piston ring.
liner Joint {0.0118 - — 1.5{0.0590}
for assembly 0.0196}
Clearance Second 0.50 - 0.70
{0.0197 - — 1.2{0.0472}
0.0275}
Third 0.35 - 0.50

{0.0138 - — 1.2{0.0472}
0.0196}
Oil 0.30 - 0.50

{0.0118 - — 1.0{0.0393}
0.00196}
Piston ring Top 3.312
— (Taper)
thickness {0.1304}
Second 2.306
— (Taper)
{0.0908}
Third 2.0{0.0787} — 1.80{0.0708}

Oil 4.0{0.1575} — 3.90{0.1535}
Piston Piston ring Top (Taper) — — Replace piston.

ring and groove
Second (Taper) — —
ring
Third 2.0{0.0787} — —
groove
Oil 4.0{0.1575} — —
Clearance Top — — — Replace piston ring

between Second — — — or piston.
piston ring
Third 0.065 - 0.105
and ring
{0.0026 - — 0.20{0.0078}
groove
0.0041}
Oil 0.025 - 0.065

{0.0010 - — 0.10{0.0039}
0.0025}
Piston pin Piston pin outer diameter 47{1.850} — — Replace piston pin.
Piston boss inner diameter 47{1.850} — —
Clearance between piston 0.041 - 0.059 Replace piston or

pin and piston boss {0.0017 - — 0.05{0.019} piston pin.
0.0023}
Standard Operation
value limit
Connecti Small end bushing inner

47{1.850} — —
ng rod diameter
Small end bushing oil 0.025 - 0.043 Replace piston pin or
clearance {0.0394 - — 0.10{0.0039} connecting rod.
0.0016}
Large end width 42.85

— —
{1.6800}
End play 0.15 - 0.32 Replace connecting

{0.0059 - — 0.6{0.0236} rod or crankshaft.
0.0125}
Connecting rod bolt length 102.5 Replacement

— 105.0{4.1338}
{4.0354}
Cranksha Journal outer diameter 90{3.543} — 88.8{3.4960} Replace crankshaft

ft journal bearing or
Journal bearing thickness 3{0.118} — —
crankshaft.
Journal crankshaft oil 0.044 - 0.097
clearance {0.0018 - — 0.3{0.0118}
0.0038}
Pin outer diameter 80{3.150} 79.8{3.1417} 78.8{3.1023}
Journal bearing thickness 2.5{0.0984} — —
Pin connecting rod oil 0.025 - 0.084

clearance {0.0010 - — 0.30{0.0118}
0.0033}
Thickness of thrust bearing 3{0.118} — —
Crankshaft end play 0.110 - 0.240 Replace thrust

{0.0044 - — 0.5{0.0196} bearing.
0.0094}
Crankshaft runout — — 0.07{0.0027} Replace crankshaft.
Crank pin width 43{1.693} — —

Standard Operation
value limit
Camshaft Camshaft No.1 65.0{2.5590} — — Replace camshaft.

journal outer No.2 64.6{2.5433} — —
diameter
No.3 64.2{2.5275} — —
No.4 63.8{2.5118} — —
No.5 63.4{2.4960} — —
No.6 63.0{2.4803} — —
No.7 62.6{2.4645} — —
Bearing oil clearance 0.030 - 0.120 Replace camshaft or

{0.0012 - — 0.3{0.0118} bearing.
0.0047}
Cam height IN 56.03 55.23 Replace camshaft.
—
{2.2059} {2.1744}
EX 53.72 52.92
—
{2.1150} {2.0835}
Cam lift IN 6.63{0.2610} — 6.48{0.2551}
EX 8.72{0.3433} — 8.57{0.3374}
Thrust plate thickness 8{0.315} — —
End play 0.10 - 0.23 Replace thrust plate.

{0.0039 - — 0.3{0.0118}
0.0091}
Camshaft runout — — 0.05{0.0019} Replace camshaft.
Valve Tappet Tappet outer

28{1.102} — —
system diameter
Tappet guide
inner 28{1.102} — —
diameter
Oil clearance 0.020 - 0.066 Replace tappet.
{0.0008 - — 0.10{0.0039}
0.0260}
Rocker arm Shaft outer 27.92 Replace shaft.

28{1.102} —
diameter {1.0992}
Bushing Replace bushing.

28.08
inner 28{1.102} —
{1.1055}
diameter
Oil clearance 0.044 - 0.120 Replace shaft or

{0.0018 - — — bushing.
0.0393}
Standard Operation
value limit
Valve Valve stem IN 8{0.315} — 7.88{0.3102} Replace valve.

system outer EX
8{0.315} — 7.88{0.3102}
diameter
Valve guide IN 8{0.315} — Refer to the

inner diameter Replace valve guide.
EX 8{0.315} — main text.
Oil clearance IN 0.040 - 0.077 Replace valve or

between {0.0016 - — 0.12{0.0047} valve guide
valve system 0.0030}
and valve
EX 0.057 - 0.094
guide
{0.0023 - — 0.14{0.0055}
0.0037}
Valve sink IN -0.05 - 0.35 Replace valve or

{-0.0020 - — 0.7{0.0275} valve seat.
0.0137}
EX 0.55 - 0.95
{0.0217 - — 1.3{0.0511}
0.0374}
Valve seat IN 30° 30° - 30°35’ — Correction

angle EX 45° 45° - 45°30’ —
Valve spring Set length

54.1{2.130} — —
inner (IN)

54.7{2.1535} — —
inner (EX)
Valve spring Set load 166.7N 153.0N Replacement

inner (IN) {17.0kgf, — {15.6kgf,34.4
37.5lbf} lbf}
Valve spring Set load 160.8N 147.1N

inner (EX) {16.4kgf, — {15.0kgf,
36.2lbf} 33.0lbf}
Valve spring Free length

72.0{2.8346} — 70.0{2.7559}
inner
58.1{2.2874} — —
outer (IN)

58.7{2.3110} — —
outer (EX)
Standard Operation
value limit
Valve Valve spring Set load 389.3N 357.9N Replacement

system outer (IN) {39.7kgf, — {36.5kgf,
87.5lbf} 80.5lbf}
Valve spring Set load 351.1N

382.5N{39.0k
outer (EX) — {35.8kgf,78.9
gf86.0lbf}
lbf}
Valve spring Free length

93.0{3.6614} — 91.0{3.5826}
outer
Push rod bend — — 0.5{0.0197}
Timing Supply pump drive gear - 0.05 - 0.19 Replace each gear.
gear Main idle gear(No.2) {0.0020- — 0.30{0.0118}
backlash 0.0075}
Camshaft gear - Main idle 0.07 - 0.19

gear(No.2) {0.0028 - — 0.30{0.0118}
0.0074}
Main idle gear(NO.1) - 0.07 - 0.19

Crankshaft gear {0.0028 - — 0.30{0.0118}
0.0074}
Oil pump drive gear and oil 0.06 - 0.30

pump driven gear {0.0024 - — 0.40{0.0157}
0.0118}
Camshaft gear - Idle gear 0.06 - 0.19
{0.024 - — 0.30{0.0118}
0.0074}
Main idle Shaft outer diameter 64{2.520} — —
Bushing inner diameter 64{2.520} — —

{0.0012 - — 0.20{0.0028} bushing.
0.0035}
End play 0.065 - 0.149

{0.0026 - — 0.30{0.0118}
0.0058}
Idle gear Shaft outer diameter 52{2.047} — —

{0.0012 - — 0.20{0.0028} bushing.
0.0035}
End play 0.070 - 0.125

{0.0028 - — 0.30{0.0118}
0.0049}
Head bolt length (long) 250{9.843} — 252{9.921} Replacement

Standard Operation
value limit
Head bolt length (short) 158{6.220} — 161{6.338} Replacement
Injector protrusion 2.9{0.1142} — —
Flatness under cylinder head 0.05{0.0019} Grind for correction

0.15{0.0059} —
or less
Flatness above cylinder block 0.05{0.0019} Grind for correction

0.15{0.0059} —
or less
Clearance between engine speed 1.0 - 1.5

sensor and flywheel ring gear {0.0394- — — Adjustment
0.0591}
Flywheel Plane run- Correction

out 0.2{0.0078}
— —
or less
Axial run-out Replacement
Valve clearance IN 0.45{0.0177} — — Adjustment

(Cold engine) EX 0.60{0.0236} — —
Valve Exhaust valve open

59° — —
timing (before BDC)
Exhaust valve close

13° — —
(after TDC)
Intake valve open

11° — —
(before TDC)
Intake valve close

22° — —
(after BDC)
Supply pump drive bearing rolling 0.39 - Shim adjustment

torque 1.17N⋅m
{4 -
— —
12kgf⋅cm,
3.5 -
10.4lbf⋅in.}
Tightening torque
JP30109020205005
Head cover mounting bolt (upper) 25{250, 18}
Head cover mounting bolt (lower) 54{550, 40}

Head bolt 118{1,200, 87}+90°+90° Angle method
Additional head bolt 69{700, 51}
Rocker support bolt 52{530, 38}

Rocker arm adjusting screw lock nut
44{450, 32}
(M10)
Rocker arm adjusting screw lock nut Exhaust side

(M12) 69{700, 51} with engine
retarder
Cross head adjusting screw lock nut

28{290, 20}
(M10)
Cross head adjusting screw lock nut

28{290, 20}
(M12)
Idle gear shaft mounting bolt 108{1,100, 80}
Idle gear shaft mounting bolt

44{450, 32}
(main idle)
Supply pump drive gear mounting nut 245{2,500, 180}
Supply pump drive bearing case retainer mounting

25{250, 18}
bolt
Flywheel mounting bolt 270{2,750, 200}
Flywheel housing mounting bolt (M8) 25{250, 18}
Flywheel housing mounting bolt (M14) 113{1,150, 83}
Flywheel housing stay mounting bolt (M14) 113{1,150, 83}
Flywheel housing stay mounting bolt (M16) 211{2,150, 156}
Connecting rod mounting nut 69{700, 51}+90°+90° Angle method
Cooling jet mounting bolt 23{230, 17}

Main bearing cap mounting bolt 274{2,800, 200}
Camshaft gear mounting bolt 137{1,400, 100} Warm fitting
Crankshaft damper - crank pulley mounting bolt 108{1,100, 80}

Crank pulley - crankshaft 245{2,500, 180}
Timing gear case cover mounting bolt 44{450, 32}
Engine mounting bracket mounting bolt 76{770, 56}

Engine speed sensor (B) At the unit side
49±4.9{500±50, 36±4} Engine speed
sensor
Exhaust
Tightening torque
JP30109020205006
Exhaust manifold mounting nut 59{600, 44}
Exhaust manifold mounting stud bolt 30{300, 22}

Exhaust manifold bracket mounting bolt 68.5{700, 51}
Cooling
Standard value
JP30109020205007
Unit:mm{in.}
Standard Operation
value limit
Thermostat valve open temperature 74.5 - 78.5°C Replacement

— —
{176 - 183°F}
Thermostat valve lift 10{0.394} Replacement

— —
(Set temperature 90 °C{194 °F}) or more
Inspection item item Belt position Standard value Remark

9 - 11mm
Compression
{0.3543 - 0.4331in.}
Deflection gauge (09444-
(Reference push force 98N
1210) is used.
{10kgf, 22lbf})
When installing
Belt tension
a new belt
gauge (95506-
520 - 610N
Tension 00090 Denso
{53 - 62kgf,117 - 137lbf}
part No.) is
Fan belt tension used.
adjustment 12 - 14mm
Compression
{0.4724 - 0.5512in.}
Deflection gauge (09444-
(Reference push force 98N
1210) is used.
{10kgf, 22lbf})
At the time of
Belt tension
inspection
gauge (95506-
340 - 440N
Tension 00090 Denso
{35 - 45kgf,76 - 99lbf}
part No.) is
used.
Tightening torque
JP30109020205008
Tension pulley bracket - timing gear case cover 55{560, 40} M10
211{2,150, 156} M16

Fan drive ASSY - timing gear case cover 47{480, 35}
Tension pulley fixing nut 108{1,100, 80}
Fan drive pulley - fan spacer 60{610, 44}

Cooling fan - fan spacer 47{480, 35}
Thermostat case mounting bolt 55{560, 40}
Cooling fan mounting nut 66±7{673±71,487±5}
Lubrication
Standard value
JP30109020205009
Unit:mm{in.}
Standard Operation
value limit
Oil pump End play 0.045 - 0.105 Replacement

drive gear {0.0018 - — 0.15{0.0059}
0.0041}
Tip clearance 0.038 - 0.115 Replacement

{0.0015 - — 0.17{0.0066}
0.0045}
Shaft outer diameter 20{0.787} — —
Case cover inner diameter 20{0.787} — —
Oil clearance 0.040 - 0.074 Replacement

{0.0016 - — 0.17{0.0066}
0.0029}
Oil pump Shaft outer diameter 20{0.787} — —
driven
gear
Oil clearance 0.040 - 0.074 Replacement
{0.0016 - — 0.17{0.0066}
0.0029}
Drive gear and driven gear backlash 0.072 - 0.208 Replacement
{0.0029 - — 0.4{0.0157}
0.0081}
Tightening torque
JP30109020205010
Oil pan mounting bolt 31{320, 23} M8
51{520, 38} M10

Oil pan drain cock 69{703, 51}
Oil pump mounting bolt (M10) 47{480, 35}
Oil pump mounting bolt (M14) 113{1,150, 83}
Oil pump feed pipe mounting bolt (M8) 21{210, 15}
Oil pump feed pipe mounting bolt (M10) 23{230, 17}
Oil strainer mounting bolt 23{230, 17}
Oil pump case assembly bolt A 22.6±2.9{230±30,17±2}

Oil pump case assembly bolt B 44.0±4.9{449±50,32±3.6}
Oil cooler element mounting nut 19.6±4.9{200±50,14±4}
Oil cooler with oil filter mounting bolt (M8) 25{250, 18}
Oil cooler with oil filter mounting bolt (M10) 47{480, 35}
Oil pressure switch 19{190, 14}
Oil filter warning switch 29.4±4.9{300±50,22±4}

Starting and Charging

Standard value (alternator 60A)
JP30002020205012
Standard Operation
value limit
Resistance between stator coil

0.15 - 0.17 Ω — — Replacement
terminals (U—V, V—W, W—U)
Resistance between stator coil core and Replacement

1MΩ or more — —
coil
Resistance of field coil 6.4 - 7.0 Ω — — Replacement
Resistance between field coil core and Replacement

1MΩ or more — —
coil
Ball bearing Replacement

25mm{0.984i 24.98mm{0.9
insertion —
n.} 834in.}
area
Shaft outer diameter of
Roller
rotor assembly
bearing 17mm{0.669i 16.98mm{0.6
—
insertion n.} 685in.}
area
Resistance between diode and Forward Replacement

Approx. 10 Ω — —
rectifier holder resistance value
Reverse
Infinite — —
resistance value
Resistance between Forward Replacement

Approx. 10 Ω — —
regulator terminals F -E resistance value
Reverse
Infinite — —
resistance value
Tightening torque (alternator 60A)

JP30002020205013
Unit:N⋅m{kgf⋅cm, lbf⋅ft}
Bearing cover mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}

Pulley mounting nut 127 - 157{1,300 - 1,600, 94 - 115}
Field coil - Rear bracket 2.9 - 3.9{30 - 39, 2.1 -2.5}
Heat sink mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}

Regulator mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}
Inside B terminal mounting nut 4.9 - 5.9{50 - 60, 3.7 - 4.3}
Front side - Rear side mounting bolt 7.8 - 9.8{80 - 99, 6 - 7}
Coupler holder mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}
Cover mounting bolt 3.3 - 4.4{34 - 44, 2.5 - 3.2}

Standard value (starter)

JP30109020205013
Unit:mm{in.}
Standard Operation
value limit
Yoke Resistance between coil Replace yoke

— — 1 kΩ or less
assembly lead wire and yoke assembly.
Brush length 13{0.512} Replace brush.

18{0.709} —
or less
Armature Resistance between 1 MΩ or Replace armature
— 1 kΩ or less
assembly commutator and core more assembly.
Commutator outer diameter 34{1.339}

36{1.417} —
or less
Shaft outer diameter A 11.98

12{0.472} — {0.4717}
or less
Shaft outer diameter B 8.98

9{0.354} — {0.3535}
or less
Undercut depth 0.5 - 0.8 Correction

0.2{0.0079}
{0.0197 - —
or less
0.0314}
Holder Resistance between holder Replace holder

— — 1 kΩ or less
assembly and plate assembly.
Brush length 13{0.512} or Replace brush.

18{0.709} —
less
Shaft A 25.90
assembly 26{1.024} — {1.0197}
outer or less Replace shaft
diameter assembly.
B 14.04
14.1{0.5552} — {0.55258}
or less
Clutch assembly inner sleeve outer 27.90
diameter 28{1.102} — {1.0984} Replacement
or less
Metal bushing inner diameter of pinion 28.2 Replace pinion

case 28{1.102} — {1.1102} case.
or more
Metal bushing inner diameter of center Replace center

26{1.024} — 26.2{1.0315}
bracket bracket.
Metal bushing inner diameter of shaft Replace shaft
9{0.354} — 9.2{0.3622}
assembly assembly.
Bearing housing inner diameter of rear 28.1{1.1062} Replace rear

28{1.102} —
bracket or more bracket.
Standard Operation
value limit
Start Between C terminal and M Replace start

0.12 - 0.14 Ω — —
magnet terminal (P coil) magnet switch
switch Between C terminal and assembly.
assembly 1.13 - 1.25 Ω — —
body (H coil)
Tightening torque (starter)

JP30109020205014

Starter mounting nut 127{1,300, 114}
M lead wire mounting nut 12.3 - 15.2{126 - 154, 9.1 - 11.0}
Rear bracket mounting through bolt 15.7 - 17.6{160 - 179, 11.6 - 12.9}
Brush holder fixing bolt of rear bracket 3.6 - 4.9{37 - 49, 2.6 - 3.6}
Start magnet switch assembly mounting bolt at

3.6 - 4.9{37 - 49, 2.6 - 3.6}
pinion case
Battery cable mounting nut 16 - 22{165 - 225, 12 - 16}
Turbocharger
Standard value
JP30109020205015
Unit:mm{in.}
Inspection item Standard value Operation limit Action
Shaft axial play 0.06 - 0.09 Replacement

{0.0023 - 0.110{0.0043}
0.0035}
Shaft radial play 0.10 - 0.17 Replacement
{0.0039 - 0.205{0.0081}
0.0067}
Tightening torque
JP30109020205016
Turbocharger mounting nut 59{600, 44}

PARTS TO BE PREPARED 3–1
ENGINE
3 PARTS TO BE PREPARED
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3
Engine Body................................................................ 3-2
Special tools ........................................................... 3-2
Fuel System ................................................................ 3-2
Special tools ........................................................... 3-2
Electrical...................................................................... 3-3
Special tools ........................................................... 3-3
Engine Mechanical ..................................................... 3-3
Special tools ........................................................... 3-3
Instruments ............................................................. 3-5
Lubricant, etc. ........................................................ 3-6
Cooling ........................................................................ 3-6
Special tools ........................................................... 3-6
Lubrication .................................................................. 3-6
Instruments ............................................................. 3-6
Starting and Charging................................................ 3-7
Jig(reference dimensionaldrawing
for manufacture)...................................................... 3-7
Common tools......................................................... 3-7
Instruments ............................................................. 3-7
Lubricant, etc. ........................................................ 3-8
Turbocharger............................................................... 3-8
Special tools ........................................................... 3-8
Instruments ............................................................. 3-8
3–2 PARTS TO BE PREPARED
Engine Body
Special tools
JP30109030901001
Shape Part No. Name Remark

09552–1030 Compression gauge adapter
09405–1190 Engine lift
Fuel System
Special tools
JP30109030901002
09420-2010 Puller For injector removal
For assembly/disassembly
09819-1707 Supply pump coupling wrench
of supply pump coupling
For supply pump drive oil

09482-2330 Press
seal press-fit
09553-1010 Fuel filter wrench

Electrical
Special tools
JP30109030901003
For V–belt Deflection

09444-1210 Compression gauge
adjustment
95506-00090 For V–belt tension

Belt tension gauge
(Denso part No.) adjustment
Engine Mechanical
Special tools
JP30109030901004
For crankshaft front oil seal

09420-1980 Puller
removal
09470-1120 Valve spring press
of valve spring retainer
09431-1010 Valve lapping tool For valve adjustment
For valve stem seal

09472-1870 Valve stem seal press
mounting
09442-1230 Piston ring expander
of piston ring
For cooling jet inspection

9001-24262 Check bolt
and adjustment
For cooling jet inspection

09470-1180 Test kit
and adjustment
For use with idle gear shaft

09481-1660 Guide press-fitting tool 13572-
1021
09420-1750 Cylinder liner puller For cylinder liner removal
09441-1330 Piston ring holder For piston mounting

09407-1180 Press
mounting
For crankshaft rear oil seal

09420-1850 Puller
removal

09407-1110 Press
mounting
09433-1030 Eye bolt For cylinder head lifting
09472-1210 Bar For nozzle seat press
9800-06100 Nozzle seat press (steel ball) For nozzle seat clamping
09451-1040 Stopper For tappet fixing (lifting)
Used together with 09462-

09420-1442 Sliding hammer
1410.
09480-1190 Liner insertion guide For cylinder liner mounting
For camshaft gear and

09420-1111 Timing gear puller supply pump drive gear
removal
09462-1410 Idle gear shaft puller adapter For idle gear shaft removal
For use with idle gear shaft

13572-1021 Plate press-fitting tool 09481-
1660
Instruments
JP30109030901005
Name Remark
Micrometer For measurement of parts

Cylinder gauge For measurement of parts
Thickness gauge For measurement of parts
Dial gauge For measurement of parts

Square For measurement of valve spring squareness
Calipers For measurement of parts
Straight edge Valve sink

Spring tester For measurement of valve spring set load
Lubricant, etc.
JP30109030901006
Name Remark
Liquid gasket (Threebond TB1207C or equivalent : Red) Push rod cover and flywheel housing
Liquid gasket (Threebond TB1211 or equivalent : White) Lower part of nozzle seat and oil pan
Red lead For inspection of valve contact

Lapping compound For valve adjustment
Dye penetrant For inspection of crack and damage
Cooling
Special tools
JP30109030901007
09420-1820 Puller For vane removal
09420-1810 Puller For pulley center removal
For mechanical seal

09482-2340 Press
mounting
09482-1700 Press For vane press-fit
Lubrication
Instruments
JP30109030901008
Name Remark
Micrometer For measurement of part outer diameter
Cylinder gauge For measurement of part inner diameter
Thickness gauge For measurement of each clearance

Starting and Charging

Jig (reference dimensional drawing for manufacture)
JP30109030901009
Alternator
This is used for assembly of bearing. Reference dimensions are shown in the figures below:
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}
35{1.378}
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}
Jig C Jig D
φ34{1.339} φ41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
φ54{2.126} φ64{2.520}
φ60{2.362} φ70{2.756}
SAPH301090300036
Common tools
JP30109030901010
Alternator
Name Remark
Soldering bit 80 - 100 W
Instruments
JP30109030901011
Alternator
Name Remark
Circuit tester For measurement of parts
Megger tester For inspection of insulation
Micrometer For measurement of parts
Regulator checker (G&M Machinery ICD-101D or

For inspection of regulator
equivalent)
Starter
Name Remark
Circuit tester For measurement of parts
Micrometer For measurement of part outer diameter
Growler tester For inspection of armature

Cylinder gauge For measurement of part inner diameter
For measurement of brush length and commutator

Calipers
outer diameter
Dial gauge For measurement of shaft runout
Magnet stand For measurement of shaft runout
Lubricant, etc.
JP30109030901012
Starter
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
Nisseki Mitsubishi Pyroknock #2 For lubrication of parts

For pouring grease into the metal (center bearing)
Grease syringe
grease reservoir
Turbocharger
Special tools
JP30109030901013
09407-1290 Tool assembly
Instruments
JP30109030901014
Name Remark
Dial gauge For measurement of turbine shaft bend
ENGINE ASSEMBLY/DISASSEMBLY 4–1
ENGINE
4 ENGINE ASSEMBLY/DISASSEMBLY
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Inspection Before Service ......................................... 4-2

Measurement of compression pressure ................. 4-2 4
Engine Body................................................................ 4-3
Removal .................................................................. 4-3
Installation............................................................... 4-5
Work after installation ............................................. 4-5
4–2 ENGINE ASSEMBLY/DISASSEMBLY
Inspection Before Service

Measurement of compression pressure
JP30109040702001
NOTICE • Measure the compression pressure before

disassembly of the engine and record the
result. Regular measurement of the
compression pressure can tell the engine
status.
1. Preparation before measurement

(1) Charge the battery completely.
(2) Check the valve clearance and adjust it when exceeding
the standard value.
(3) Warm the engine and set the water temperature to 80
°C{176 °F}.
(4) Remove the air cleaner.
(5) Remove the head cover.
(6) Remove all injectors.
(7) To prevent spread of engine oil, attach a jig which cuts a
head cover in half. (Cut it so that the camshaft may be
covered.
2. Measurement
(1) Attach a special tool to the nozzle sheet of the cylinder

where the compression pressure is measured.
Special tool : 09952-1080, 09552-1060, 09552-1030
Compression gauge adapter
(2) Turn the starter and measure the compression pressure.
! CAUTION • Do not operate the starter for 15 seconds or

SAPH301090400001
more.
• Since the air cleaner is removed, prevent
entry of dirt.
(3) Measure the compression pressure of each cylinder

continuously.
Engine revolution 200r/min {rpm}

Unit : MPa {kgf/cm2,lbf/in.2}
Compression pressure
Standard value 2.9 {30, 421}
Operation limit 2.5 {26, 362}
(4) If the compression pressure is below the operation limit,

overhaul the engine.
(5) After measurement, reassemble the removed parts.
Engine Body
Removal
JP30109040702002
1. Preliminary work before removal of engine

(1) Place the vehicle on a level ground.
(2) Block tires with scotch.
(3) Remove the battery cable from the battery minus terminal.
2. Drain of coolant and engine oil

Right side of engine
(1) Drain coolant from the radiator drain cock and the oil
cooler drain plug.
NOTICE • Removal of the filler cap facilitates quick

drain.
• Connection of an appropriate hose to the oil
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH301090400002
! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• To dispose coolant, observe the specified
method (waste disposal) or the method with
attention to the environment.
(2) Drain engine oil from the oil pan drain plug as required.
! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• Dispose coolant according to the specified
method (waste treatment) or with a method
considering the environment.
Drain cock
SAPH301090400003
3. Removal of intake hose, intercooler hose and exhaust pipe
(1) Loosen the clamp and remove the intake hose.

(2) Remove nuts and remove the exhaust pipe.
Intake manifold
! CAUTION • Close the opening of the intake manifold with
a packing tape to prevent entry of dirt inside
the engine.
Cylinder head
cover
SAPH301090400004
4–4 ENGINE ASSEMBLY/DISASSEMBLY
4. Disconnection of fuel hose

Feed
(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
Return
upward to prevent spill of fuel.
! CAUTION • Wipe spilled fuel with a rag.
SAPH301090400005
5. Disconnection of water, engine oil pipes, etc.

(1) Disconnect the hose between the radiator and the engine.
(2) Disconnect the car heater pipe.
(3) Disconnect the oil filter pipe.
! CAUTION • Wipe off spilled water and engine oil with a

rag.
6. Engine lifting
(1) Place a hook on the hole in the engine hanger.

(2) Keep a little slack of the wire rope.
(3) When the wire is completely tense, make sure that the
wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.
Reference: "Lubrication, oil filter"
! CAUTION • Work carefully so that the engine may not

come in contact with the frame and others.
SAPH301090400006
Installation
JP30109040702003
1. Connection of fuel hose

(1) Insert a fuel hose and fix it with a hose band.
Work after installation

JP30109040702004
1. Inspection of engine oil
(1) Make sure that the drain cock is closed.

(2) Pour engine oil.
Engine oil amount (L{us gal})
Oil pan Oil filter and Remote hose
Approx. 35{9.25} Approx. 7.5{1.98}
Filler cap
! CAUTION • Please use Hino genuine engine oil
SAPH301090400007
• Check the amount of oil with an oil level
gauge.
Multi grade SAE #10W-30
Single grade SAE #30
2. Air bleeding of fuel system
(1) Prepare a rag to receive fuel at the end of the drain hose.
(2) Loosen the air bleeding bolt of the fuel filter.
(3) Turn the knob of the priming pump to the left to let it float
up, and then operate it.
(4) Move the knob until fuel without bubble comes out from
the drain hose.
(5) Tighten the air bleeding plug.
Tighening torque : 7N⋅m{70kgf⋅cm,7 lbf⋅ft}
SAPH301090400008
! CAUTION • Do not tighten the air venting plug while

operating the knob of the priming pump.
(6) Turn the knob of the priming pump again five or six turns.
(7) Press the priming pump and tighten it fully to the right.
! CAUTION • After work, wipe off spilled fuel. After start of

the engine, make sure that there is no fuel
leak.
FUEL SYSTEM 5–1
ENGINE
5 FUEL SYSTEM
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Fuel System ................................................................ 5-2

Fuel system diagram............................................... 5-2
Part layout (typical example)................................... 5-3
Replacement of the fuel filter .................................. 5-7
Replacement of supply pump ................................. 5-9
5
Replacement of injector ........................................ 5-11
Inspection of injector ............................................. 5-15
Inspection of common rail function parts
(evaluation) ........................................................... 5-16
Overhaul of
supply pump drive bearing case ........................... 5-17
5–2 FUEL SYSTEM
Fuel System
Fuel system diagram
JP30109050402001
Injection pipe
Common rail
Feed pump
Overflow Overflow pipe

valve Flow damper
Injector
Leakage pipe
Pressure limiter
Return Through feed pipe
pipe
Fuel
Filter
Priming pump
Supply pump
Feed pipe Fuel tank

Feed pipe
Feed pipe
Feed pump
Through feed valve
SAPH301090500001
FUEL SYSTEM 5–3
Part layout (typical example)

JP30109050402002
Fuel pipe
SAPH301090500002
23081 Leakage pipe 23811 Feed pipe

23300 Fuel filter 23811A Feed pipe
23391 Leakage pipe 23812 Feed pipe
23701 Injection pipe 23815 Feed pipe
23702 Injection pipe 23816 Overflow pipe
23703 Injection pipe 23816A Through feed pipe
23704 Injection pipe 23871 Pressure feed pipe
23705 Injection pipe 9655-10100 Gasket*
23706 Injection pipe 9655-14140 Gasket*
23766A Fuel pipe SZ209 Gasket*
23766B Overflow pipe
Tightening torque
23081 20N⋅m{200kgf⋅cm,15 lbf⋅ft} 23705 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
23701 44N⋅m{450kgf⋅cm,32 lbf⋅ft} 23706 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
23702 44N⋅m{450kgf⋅cm,32 lbf⋅ft} 23871 Common rail side:54N⋅m{550kgf⋅cm,40
lbf⋅ft}
23703 44N⋅m{450kgf⋅cm,32 lbf⋅ft} 23871 Supply pump side:44N⋅m{450kgf⋅cm,32
lbf⋅ft}
23704 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
5–4 FUEL SYSTEM
Supply pump,Common rail,Injector
SAPH301090500003
11195 Injector clamp 22760 Common rail assembly

11491B Common rail bracket 29611 Oil pipe
13610 Supply pump drive case assembly 9645A O-ring*
13611 Supply pump drive shaft 9655-12100 Gasket*
13691 Bearing holder case 9655-15104 Oil seal*
13693 Bearing retainer 9851A O-ring*
15773 Oil pipe 9851B O-ring*
15774 Fuel pipe 900111 Shim
22730 Supply pump 993-302080 Bearing
23670 Injector 993-322070 Bearing

Tightening torque
22730 Cotter bolt:91N⋅m{930kgf⋅cm,67 lbf⋅ft} 9181-08400 25N⋅m{250kgf⋅cm,18 lbf⋅ft}
22730 Coupling bolt:61N⋅m{620kgf⋅cm,45 lbf⋅ft} 9191-08901 28N⋅m{290kgf⋅cm,21 lbf⋅ft}
900124 26N⋅m{270kgf⋅cm,19 lbf⋅ft} 9219A 245N⋅m{2,500kgf⋅cm,181 lbf⋅ft}
FUEL SYSTEM 5–5
Fuel filter
SAPH301090500004
23300 Fuel filter assembly 23401 Fuel filter

23316 Air bleeding plug
Tightening torque
23316 7N⋅m{70kgf⋅cm,5 lbf⋅ft}
5–6 FUEL SYSTEM
Priming pump
SAPH301090500005
22509 Knob 22570 Priming pump assembly

FUEL SYSTEM 5–7
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Replacement of the fuel filter

JP30109050704001
1. Fuel filter removal

(1) Use the special tool and remove the fuel filter.
Special tool : 09553-1010 Fuel filter wrench
! CAUTION • Prepare a tray because the filter contains

diesel fuel
• Do not use a commercial chain-type filter
wrench or similar to remove the filter. This
SAPH301090500006
can cause scratches or deformation for the
outer circumference, which can lead to fuel
leakage and fire.
• For disposal of fuel, observe the local
disposal procedure.
2. Fuel filter installation

(1) Remove dirt and foreign matter from the installation
surface.
(2) Apply a thin coating of diesel oil to the gasket of the new
fuel filter.
(3) Turn the fuel filter clockwise by hand until the gasket
comes into contact with the body seal face.
! CAUTION • Confirm that the gasket is in positive contact

with the seal surface.
Element
Gasket
Scale
Element
SAPH301090500007
5–8 FUEL SYSTEM
(4) Use the special tool and tighten for approximately another
2/3 turns.
! CAUTION • At the time of installation, take care that the

gasket is not damaged by twisting.
• Replace the gasket by the new one in the
element kit.
• Do not reuse an element.
• After work, wipe off spilled fuel. After start of
leak.
• Do not use a commercial chain-type filter
wrench or similar to install the filter. This can
cause scratches or deformation for the outer
circumference, which can lead to fuel leakage
and fire.
NOTICE • The scale markings are in the order of

1→2→3→4→5→6→1→2..., and one gradation
corresponds to 60°.
• The above 2/3 turns corresponds to 4
gradations (240°), and element and body
should be marked before turning.
3. Fuel system air venting
(1) Prepare a shop towel or similar at the time of the drain

hose to receive fuel.
(2) Loosen the fuel filter air venting plug.
(3) Turn the knob of the priming pump to the left to let it float
up, and then operate it.
(4) Operate the knob until fuel without air bubbles flows from
the hose.
(5) Tighten the air venting plug.
SAPH301090500008
Tightening torque: 7 N⋅m {70 kgf⋅cm,5 lbf⋅ft}
! CAUTION • Do not tighten the air venting plug while

operating the knob of the priming pump.
(6) Turn the knob of the priming pump again five or six turns.
(7) Press the priming pump and tighten it fully to the right.
! CAUTION • After work, wipe off spilled fuel. After start of

leak.
FUEL SYSTEM 5–9
Replacement of supply pump

JP30109050704004
1. Removal of supply pump
NOTICE • The supply pump does not have to be

adjusted.
• If insufficient discharge rate or a faulty sub-
engine speed sensor occurs, contact the
Denso service shop.
(1) Remove the fuel pipe and oil pipe connected to the supply
Supply pump
pump.
SAPH301090500009
(2) Align the No. 1 cylinder to the compression top dead

center and align the stamp lines of the supply pump.
stamp lines.
Align
Coupling (3) Remove the coupling bolt.
Special tool : 09819-1707 Supply pump coupling
wrench
SAPH301090500010
(4) Remove four bolts and remove the supply pump.
(5) Loosen the cotter bolt and ensure shaft play for
reinstallation.
Loosen the cotter bolt.

SAPH301090500011
2. Installation of supply pump

(1) Turn the crankshaft in the engine rotating direction
Flywheel housing (clockwise as viewed from the cooling fan side), align the
Inspection window
"16" stamp line of the crankshaft damper with the pointer,
and align the No. 1 cylinder to the compression top dead
center.
16
! CAUTION • If the pointer is matched with "16", but the
supply pump bearing case shaft key or cotter
bolt faces down, No. 6 is at the compression
SAPH301090500012
top dead center. Turn the crankshaft one turn
and set the No. 1 cylinder at the compression
top dead center.
5–10 FUEL SYSTEM
(2) Make sure that the cotter bolt is loose and install the
supply pump on the bracket.
Tightening torque : 28 N⋅m {290 kgf⋅cm, 20 lbf⋅ft}

Install the supply
pump with a loose
cotter bolt.
SAPH301090500013
(3) Install two bolts at the coupling and tighten the coupling
Stamp line bolt by aligning the stamp line of the supply pump.
Coupling bolt
Special tool : 09819-1707 Supply pump coupling
wrench
! CAUTION • Make sure that there is no clearance between

laminate plates. Make sure that there is no
Cotter bolt
SAPH301090500014
flange deformation due to crashing of
laminate plates.
(4) Tighten the cotter bolt.

! CAUTION • Make sure that laminate plates are not

deformed or there is no undue force on them.
(5) Replace the gasket with a new one and connect the fuel
Injector pipe and oil pipe to the supply pump.
Common rail Tightening torque :

44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft} (Fuel pipe M14)
54 N⋅m {550 kgf⋅cm, 40 lbf⋅ft} (Fuel pipe M16)
㧹
㧹
Supply
Pump
SAPH301090500015
FUEL SYSTEM 5–11
Replacement of injector
JP30109050704005
1. Removal of injector harness

Injector harness (1) Remove each connector and bolt and remove the injector
harness.
! CAUTION • Since the injector harness bracket is

susceptible to distortion, be careful for
handling.
NOTICE • Refer to the following for installation of the

engine retarder. "Reference: Engine
SAPH301090500016
mechanical, Engine retarder, Removal"
2. Removal of leakage pipe
(1) Remove the injector and cylinder head union bolts.

(2) Remove bolts and remove the leakage pipe.
! CAUTION • Since the leakage pipe is susceptible to

distortion, be careful for handling.
SAPH301090500017
3. Removal of injector
(1) Remove the injection pipe seal.
(2) Remove the injector clamp mounting bolt and remove the
injector and injector clamp.
Special tools
NOTICE • If it is difficult to pull it out, pull it out with a

special tool.
Special tool : 09420-2010 Puller
(3) Remove the O-ring from the cylinder head.

Injector
SAPH301090500018
5–12 FUEL SYSTEM
4. Installation of injector
O-ring
(1) Install a new O-ring on the cylinder head groove and
insert the injector.
! CAUTION • Apply engine oil to the O-ring and be careful

to prevent pinching of the O-ring.
SAPH301090500019
(2) Put a new injection pipe oil seal on the injector and install
it with bolts and nuts.
! CAUTION • Do not fix the injector clamp until the injection

pipe is tack welded temporarily.
• Install the injection pipe seal to prevent undue
force to the injector. (Offset position between
the injection pipe oil seal and the injector may
cause oil leak or poor assembly of the
SAPH301090500020 injection pipe.)
(3) Replace the gasket with a new one and tack weld the
leakage pipe to the injector and cylinder head temporarily.
! CAUTION • Install the gasket in a direction in which it

does not interfere with the valve spring.
• Since the injector top union bolt and the
cylinder head joint union bolt are different in
screw thread pitch, be careful for handling.
Injector top union bolt (M10 x 1.0)

SAPH301090500017
Cylinder head joint union bolt (M10 x 1.5)
(4) Tack weld the injection pipe through the injection pipe seal
Injection pipe seal until it comes in contact with the seat.
Injection pipe
! CAUTION • Tack weld it by adjusting so that the injector is

aligned with the injection pipe.
• Make sure that the seal spring is installed
correctly.
Seal spring
SAPH301090500021
FUEL SYSTEM 5–13
(5) Tighten the injector clamp mounting bolts to fix the

Injector clamp injector.
! CAUTION • After tightening, make sure that the rocker

arm moves smoothly.
Make sure that there is no undue force on the
injection pipe oil seal. (Otherwise, oil leak or
Injection pipe
poor assembly of injection pipe may occur.)
SAPH301090500022
(6) Tighten the injection pipe.
(7) Tighten the leakage pipe.
! CAUTION • Assemble so that the gasket connection may

not come in contact with the rocker arm.
SAPH301090500017
5. Installation of injector harness

Injector harness (1) Connect each connector and install the injector harness.
SAPH301090500023
5–14 FUEL SYSTEM
6. Entry of injector correction value to the engine ECU (entry

using HinoDX and QR code reader)
! CAUTION • When the injector is replaced, it is necessary

to enter the injector correction value (QR
code) described on the new injector to the
engine ECU. Incorrect entry of the correction
value may result in faulty engine.
NOTICE • Available entry methods of the injector

SAPH301090500024
correction value are the PC tool and the QR
code reader.
• The work flow is described below. For detailed
procedures, refer to the operation manual of
the HinoDX.
(1) Read the injector QR code with the scanner of the QR

code reader and prepare the correction data file.
(2) Enter the injector correction value directly from the
HinoDX to the engine ECU.
PC
QR code reader
Hino-Bowie
(Special interface)
Connector
New injector
ECU
SAPH301090500025
FUEL SYSTEM 5–15
Inspection of injector
JP30109050704006
1. Inspection of injector insulation

(1) Remove the injector plastic terminal cap (upper).
<Cross-section view of injector head>
(2) Measure the insulation resistance between the injector
upper body and one terminal (no polarity) of two terminals
for the injector harness.
Terminal (harness Terminal cap (upper)
tightening area) Standard value
Terminal cap 1000 MΩ or more
(normal temperature)
(lower)
(3) Measure the resistance value between two terminals

above.
Injector harness
and rubber seal
Standard value
0.45 Ω ± 0.1
(at 20 °C{68 °F})
(4) If the resistance value in (2) and (3) exceeds the standard
value, replace the injector assembly.
Upper body
2. Cleaning of injector
(1) Remove sludge at or around the terminal, if any.
SAPH301090500026
! CAUTION • In removing sludge, do not use a cleaning
agent. Wipe it off with a rag. Use of a cleaning
agent may result in electric failure due to
penetration of the agent.
nomatch
5–16 FUEL SYSTEM
Inspection of common rail function parts

(evaluation)
JP30109059999001
1. Inspection of pressure sensor

(1) If the check engine lamp illuminates and it applies to
"Pressure sensor disconnection", "Pressure sensor short-
circuit" or "Pressure sensor output does not change" in
inspection of failure diagnosis system, replace the
pressure sensor.
2. Inspection of pressure limiter
(1) Remove the hollow screw of the pressure limiter.

(2) Install a blank plug on the pipe side using a bolt to prevent
Install a blank plug
on the pipe. fuel discharge.
Remove the hollow screw
SAPH301090500027
(3) Install the union on the pressure limiter and connect the
plastic hose to the tip of the union.
(4) Prepare a fuel container at the tip of the plastic hose.

(5) If the engine is started and fuel discharge is recognized
Union continuously, replace the pressure limiter.
Plastic hose
Container
SAPH301090500028
3. Inspection of flow damper

(1) Start the engine, run it from idling to full throttle and check
the diagnosis code of "flow damper operation".
(2) If the diagnosis code of "flow damper operation" is
detected, replace the applicable injector and inspect
again.
(3) If the failure is reproduced after the injector is replaced,
replace the flow damper with the common rail assembly.
êÆî óvóÃ
FUEL SYSTEM 5–17
Overhaul of supply pump drive bearing case

JP30109050702001
1. Removal of timing gear case cover

"Reference: Engine mechanical, timing gear cover and
flywheel housing, timing gear case cover replacement"
2. Removal of supply pump drive gear
(1) Remove the drive gear mounting nut.

(2) Remove the oil pipe connected to the supply pump drive
bearing case.
SAPH301090500029
(3) Pull out the gear using a special tool or install a box nut on
the shaft, hit the shaft with a copper hammer, loosen and
Box nut
remove the gear with impact.
Special tool : 09420-1111 Timing gear puller
(4) Remove the supply pump drive bearing case.
SAPH301090500030
3. Disassembly of supply pump drive bearing case

(1) Remove the bolt and disassemble the supply pump drive
bearing case.
SAPH301090500031
5–18 FUEL SYSTEM
4. Assembly and adjustment of supply pump drive bearing

case
(1) Insert the bearing and shaft applied with engine oil into
the case, replace the O-ring with a new one applied with
engine oil and assemble the supply pump bearing case as
shown in the figure.
! CAUTION • Adjust temporarily with a shim so that the

SAPH301090500032 drive shaft is turned manually and there is no
axial backlash.
• Assemble so that the bearing retainer
protrusion (oil return groove) is lower.
SAPH301090500033
(2) Measure the rolling torque using a torque wrench and

adjust it so that it satisfies the standard value.
Standard value (N⋅m 0.39 - 1.17

{kgf⋅cm, lbf⋅in.}) {4 - 12, 3.5 - 10.4}
(3) Apply engine oil to the lip of a new oil seal.
SAPH301090500034
(4) Press fit the oil seal using a special tool so that the oil seal
is flush with the bearing retainer.
Special tool : 09482-2330 Press
SAPH301090500035
FUEL SYSTEM 5–19
5. Installation of supply pump drive bearing case
(1) Replace the O-ring with a new one and install the supply
pump bearing case with adjusted preload from the back.
(2) Fix the drive shaft, align the gear stamp, install the drive
gear and tighten the nut.
Tightening torque : 245 N⋅m {2,500 kgf⋅cm, 180 lbf⋅ft}
6. Installation of timing gear cover

"Reference: Engine mechanical, timing gear cover and
SAPH301090500036
flywheel housing, timing gear case cover replacement"
EMISSION CONTROL 6–1
ENGINE
6 EMISSION CONTROL
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Emission control ........................................................ 6-2

Parts layout diagram ............................................... 6-2
Overhaul of EGR cooler and EGR valve................. 6-3
6
6–2 EMISSION CONTROL
Emission control
Parts layout diagram
JP04109060402001
SAPH301090600001
16302 Coolant pipe 17308 EGR pipe1

16305A Coolant pipe 25601 EGR pipe2
16306 Coolant pipe 25608 EGR cooler assembly
17104A Gasket* 25620 EGR valve assembly
17104B Gasket* 900234 Coolant hose
17104C Gasket* 900234A Coolant hose
17113D Intake pipe
*: Parts which cannot be reused

Tightening torque
9029A 72N⋅m{734kgf⋅cm,53 lbf⋅ft} 900125 55N⋅m{560kgf⋅cm,40 lbf⋅ft}
9068-10500 55N⋅m{560kgf⋅cm,40 lbf⋅ft} SZ105 55N⋅m{560kgf⋅cm,40 lbf⋅ft}
9069B 55N⋅m{560kgf⋅cm,40 lbf⋅ft}
êÆî óvóÃ
ÉIÅ[ÉoÅ[ÉzÅ[Éã
Overhaul of EGR cooler and EGR valve

JP04109060702001
1. EGR pipe removal

(1) Remove the nuts and remove EGR pipe 1.
(2) Remove the gaskets.
EGR pipe 1
SAPH301090600002
(3) Remove the bolts and nuts and remove EGR pipe 2.
EGR pipe 2
SAPH301090600003
2. Removal of EGR valve and EGR cooler

(1) Drain the coolant.
(2) Remove the clips and shift the engine harness running at
the upper side of the EGR cooler to a position where it
does not impair the work.
(3) Remove the wiring connected to EGR valve and EGR
cooler.
(4) Disconnect the coolant hose connected to the EGR

cooler.
Connector
Coolant hose
SAPH301090600004
(5) Loosen the bolts connecting EGR valve and EGR cooler
in advance.
SAPH301090600005
(6) Remove the mounting volts of EGR valve and EGR cooler
and remove them from the engine.
SAPH301090600006
(8) Remove the four bolts connecting EGR valve and EGR
Gasket cooler and separate EGR valve and EGR cooler.
(9) Remove the gasket.
Bolt
SAPH301090600007
3. EGR valve inspection (inspection by HinoDX)

(1) Use HinoDX to inspect the operation of the EGR valve
while mounted on the machine.
(Refer to the "HinoDX Instruction Manual".)
! CAUTION • Do not step onto the EGR valve at the time of

engine servicing.
• Do not loosen or remove bolts or nuts of the
EGR valve component parts.
• Defective performance may result in case of
loosening or removal.
• If bolts or nuts have been removed and
disassembly has been made, do no
reassemble, but replace by a new unit.
SAPH301090600008
4. EGR cooler inspection

(1) Inspect the EGR cooler visually for cracks and clogging. In
case of abnormalities, replace the EGR cooler body.
5. Installation of EGR valve and EGR cooler

(1) Replace the gaskets by new ones and temporarily
assemble EGR valve, EGR cooler, and EGR pipe 2.
EGR cooler
EGR valve ! CAUTION • As this part is tightened at a right angle, final
tightening without temporary tightening may
cause gas leakage from the gasket parts.
EGR pipe 2
SAPH301090600009
(2) When installing the above temporary assembly to the

Bracket
engine, loosen the bracket bolts slightly for play
adjustment.
SAPH301090600010
(3) Set a new gasket with the positioning claw pointing down
between EGR valve and intake pipe and tighten the bolts
temporarily.
Bolt
! CAUTION • As this part is tightened at a right angle, final
tightening without temporary tightening may
cause gas leakage from the gasket parts.
Claw
Gasket
SAPH301090600011
(4) Install to the engine with secure tightening of the

temporarily tightened bolts and nuts in the order shown in
Ԝ the figure.
Ԟ Tightening torque
:55N⋅m{560kgf⋅cm,40 lbf⋅ft}(Bolt)
ԝ :72N⋅m{734kgf⋅cm,53 lbf⋅ft}(Nut)
ԛ
Ԛ
Ԙ
ԙ
SAPH301090600012
(5) Connect the coolant hose to be connected to the EGR

cooler.
(6) Connect the wiring to be connected to EGR valve and

EGR cooler.
Connector
Coolant hose
SAPH301090600004
(7) Return the shifted engine harness to its original position.

(8) Fill up coolant.
6. EGR pipe installation
(1) Replace the gaskets by new ones and install EGR pipe 1.
Tightening torque:72N⋅m{734kgf⋅cm,53 lbf⋅ft}(Nut)
EGR pipe 1
SAPH301090600002
ELECTRICAL 7–1
ENGINE
7 ELECTRICAL
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ç\ê¨îzíuê}
Electrical System........................................................ 7-2

Layout of components............................................. 7-5
Inspection of components ....................................... 7-7
Installation of components ...................................... 7-9
Installation of starter ............................................... 7-9
Installation of alternator ........................................ 7-10
7
7–2 ELECTRICAL
Electrical System
JP30109070402001
SAPH301090700001
22790 Fuel temperature sensor 89390 Boost pressure sensor

82030 Injector harness 89410 Engine speed sensor
82121 Engine harness 89441 Engine main revolution sensor
83420 Water temperature sender gauge 9659A Soft washer*
83420 EGR water temperature sensor 9655-12100 Soft washer*
83530 Oil pressure warning switch 9655-14140 Soft washer*

ELECTRICAL 7–3
SAPH301090700002
17171A Gasket* 19201 Intake air heater

7–4 ELECTRICAL
SAPH301090700003
12281 Engine hanger 28100 Stator assembly

12509 Alternator brace 900149 V-belt
27060 Alternator assembly
Tightening torque
9189A 6N⋅m{60kgf⋅cm,4 lbf⋅ft} 9201-10080 47N⋅m{480kgf⋅cm,35 lbf⋅ft}
9201-14110 Starter: 9402-12000 83N⋅m{846kgf⋅cm,61 lbf⋅ft}
127N⋅m{1,300kgf⋅cm,94 lbf⋅ft}
Alternator through bolt:
132N⋅m{1,350kgf⋅cm,97 lbf⋅ft}
ELECTRICAL 7–5
Layout of components
JP30109070402002
Pressure control valve Common rail pressure sensor

Boost pressure sensor Fuel temperature sensor
Engine
main revolution sensor
EGR gas temperature sensor
Engine auxiliary rotation sensor
Left side view

SAPH301090700004
7–6 ELECTRICAL
EGR water temperature sensor
Coolant temperature sender gauge
Engine
speed sensor
Main revolution sensor Oil pressure warning switch
Right side view
SAPH301090700005
êÆî óvóÃ
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ELECTRICAL 7–7
Inspection of components
JP30109070703001
1. Inspection of fuel temperature sensor

Fuel temperature sensor
(1) Heat the fuel temperature sensor using hot water.
(2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the sensor.
Temperat
ure -20{-4} 20{68} 80{176} 110{230}
(°C{°F})
Resistanc
SAPH301090700006 13.84 - 2.32 - 0.31 - 0.1399 -
e value
16.33 2.59 0.326 0.1435
(Ω)
2. Inspection of oil pressure warning switch
(1) Install the oil pressure warning switch on the air tank, etc.
SAPH301090700007
(2) Increase or decrease air tank pressure, check continuity

Oil pressure warning switch between the terminal and switch main unit using a circuit
tester. If it is faulty, replace it.
39.2 - 58.8kPa
2 2
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in. } ON Operation standard
2
2.9kPa{0.03kgf/ cm , When 39.2 - 58.8 kPa {0.4 - 0.6kgf/cm2,
ON →
2
4.7lbf/in. }
Within 5.7 - 8.5 lbf/in.2} is exceeded during
OFF
OFF Toward pressure increase pressurization
The pressure that changes the switch from OFF to
SAPH301090700008 ON during pressure reduction is different from the
pressure that changes the switch from ON to OFF
during pressurization by within 2.9 kPa {0.03 kgf/
cm2, 4.6936 lbf/in.2}.
3. Inspection of oil filter warning switch

Oil filter warning switch (1) Check continuity between the tip of the switch and the
Tip of the switch coupler using a circuit tester.
(2) If there is no electric continuity, replace the switch.
Coupler
SAPH301090700009
7–8 ELECTRICAL
4. Inspection of water temperature sender gauge

Water temperature sender gauge
(1) Heat the water temperature sender gauge using hot water.
Connector color: Darkgray (2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the gauge.
㧭 Between A and C
Temperature 110
-20{-4} 20{68} 80{176}
㧯 (°C{°F}) {230}
㧮
Resistance 13.84 - 2.32 - 0.31 - 0.1399 -
SAPH301090700010 value (Ω) 16.33 2.59 0.326 0.1435
Between B and body
Temperature
75{167} 100{212}
(°C{°F})
Resistance 35.5 -
79 - 92
value (Ω) 42.5
5. Inspection of intake air heater

Intake air heater
(1) Measure continuity between terminals and the body and
the terminal using a circuit tester. If it is faulty, replace the
heater.
Between terminals With continuity
Between the terminal and the Without

body continuity
SAPH301090700011
6. Inspection and replacement of pressure control valve

Pressure control valve (PCV)
(PCV) and engine speed sensor (sub)
(1) If the pressure control valve (PCV) and the engine speed
sensor are faulty, remove them from the engine in the
supply pump assembly and request for reinspection at the
Denso service shop.
Engine speed sensor (sub)

SAPH301090700012
ELECTRICAL 7–9
Installation of components
JP30109070702001
1. Pressure control valve (PCV) wire

"Front"
! CAUTION • Wire the main harness with the "Front" label
to the pressure control valve.
SAPH301090700013
2. Installation of engine speed sensor (main)

(1) Make sure that the sensor has an O-ring. Install the
sensor on the upper surface of the flywheel.
NOTICE • Since this sensor is a flange type, gap does

not have to be adjusted.
SAPH301090700014
Installation of starter
JP30109070702002
1. Installation of starter
(1) Install the starter with bolts and nuts.
Nut
Starter
SAPH301090700015
7–10 ELECTRICAL
Installation of alternator
JP30109070702003
1. Installation of alternator
Adjusting bolt
Alternator brace Fixing bolt at brace (1) Hand-tighten the brace mounting bolt to temporarily
secure the alternator brace.
(2) Hand-tighten the through-bolt to temporarily secure the
alternator.
(3) Hand-tighten the mounting bolt and nut on the brace side
Brace fixing bolt
Through bolt to temporarily secure the alternator and brace.
(4) Thread the adjusting bolt into the mounting bolt on the
Alternator brace side.
SAPH301090700016
(5) Fully tighten the brace mounting bolt.
(6) Tighten the belt by turning the adjusting bolt with a
wrench.
(7) Fully tighten the alternator through-bolt.
(8) Fully tighten the mounting bolt and nut on the brace side.
(9) Tighten the adjusting bolt and make sure it is locked in
place.
Tightening torque : 6 N⋅m {60 kgf⋅cm, 4.4 lbf⋅ft}
2. V–belt tension adjustment

㧭 Alternator (1) Loosen the fixing bolt and through bolt on the alternator
pulley
brace side and adjust the tension of the V–belt
(measurement position: A) using the adjusting bolt and
the special tool.
Water
pump pulley When installing At the time of
Item
Crankshaft pulley a new belt inspection
14 - 16 15 - 17
Deflection
SAPH301090700017 {0.5512 - {0.5906 -
(mm{in.})
0.6299} 0.6693}
640 - 690 590 - 640
Tension
{65 - 70, {60 - 65,
(N{kgf,lbf})
144 - 155} 133- 144}
Special tool : 09444-1210 Compression gauge (used

at the time of measuring the deflection
amount) [ Reference push force 98N
{10kgf, 22lbf} ]
95506-00090 (Denso part No.) Belt
tension gauge (used at the time of
measuring the tension force)
ELECTRICAL 7–11
! CAUTION • If the V–belt is replaced with a new one, it

becomes loose due to initial fitting. Run the
engine for three to five minutes and adjust the
tension of the belt again.
NOTICE • At the time of inspection, the new V-belt has

reached the value after complete initial
stretching. A new V-belt completes initial
stretching after running the engine for
approximately two hours.
INTAKE 8–1
ENGINE
8 INTAKE
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ç\ê¨îzíuê}
Intake Manifold ........................................................... 8-2

Replacement........................................................... 8-3
8
8–2 INTAKE
Intake Manifold
JP30109080402001
SAPH301090800001
17031 Intake pipe 17171 Gasket*

17101 Intake manifold 17171A Gasket*
17113A Intake pipe 17171B Gasket*
17113B Intake pipe 900239 Hose
17113C Intake pipe 9769A Clamp
17138 Bracket

Tightening torque
9068-10450 55N⋅m {560 kgf⋅cm,40 lbf⋅ft} 9241-10107 55N⋅m {560 kgf⋅cm,40 lbf⋅ft}
9068-60050 55N⋅m {560 kgf⋅cm,40 lbf⋅ft}
êÆî óvóÃ
INTAKE 8–3
Replacement
JP30109080704001
1. Removal of wiring harness

(1) Remove each connector and remove the wiring harness.
2. Removal of injection pipe

(1) Remove the injection pipe in front of the intake manifold.
3. Removal of intake manifold
(1) Remove the injection pipe.
SAPH301090800002
(2) Remove the intake manifold.
! CAUTION • Close the opening for installation of the

engine with a packing tape, etc. to prevent
entry of dust.
SAPH301090800003
4. Installation of intake manifold

(1) Clean inside of the intake manifold and the cylinder head.
(2) Replace the gasket with a new one and install the intake
manifold.
5. Installation of injection pipe

(1) Install the injection pipe using the part layout of the fuel
system.
SAPH301090800004
8–4 INTAKE
6. Installation of intake pipe

(1) Replace the gasket with a new one and install the intake
pipe.
SAPH301090800002
ENGINE MECHANICAL 9–1
ENGINE
9 ENGINE MECHANICAL
ç\ê¨ê}
ç\ê¨îzíuê}
Cylinder Head ............................................................. 9-2

Replacement........................................................... 9-5
Overhaul ............................................................... 9-10
Cylinder Block .......................................................... 9-14
Part layout ............................................................. 9-14
Overhaul ............................................................... 9-15
Timing Gear Cover and Flywheel Housing............. 9-18
Part layout ............................................................. 9-18
Replacement of flywheel housing ......................... 9-19
Replacement of crankshaft front oil seal............... 9-20
Replacement of crankshaft rear oil seal................ 9-21
Replacement of timing gear case cover................ 9-23
9
Main Moving Parts.................................................... 9-24
Part layout ............................................................. 9-24
Replacement of piston and connecting rod .......... 9-25
Inspection of piston and connecting rod ............... 9-29
Replacement of crankshaft ................................... 9-33
Inspection of crankshaft ........................................ 9-34
Replacement of crankshaft pulley ......................... 9-35
Replacement of flywheel....................................... 9-36
Inspection of flywheel ........................................... 9-39
Camshaft and Idle Gear ........................................... 9-41
Part layout ............................................................. 9-41
Gear train layout ................................................... 9-42
Removal of camshaft ............................................ 9-43
Disassembly of camshaft ...................................... 9-43
Inspection of camshaft .......................................... 9-44
Assembly of camshaft........................................... 9-45
Installation of camshaft ......................................... 9-46
Removal of timing gear ......................................... 9-47
Inspection of timing gear....................................... 9-48
Installation of timing gear ...................................... 9-48
Inspection of installation status for each gear....... 9-50
Valve System............................................................. 9-51
Part layout ............................................................. 9-51
Overhaul of valve system...................................... 9-52
Adjustment of valve clearance .............................. 9-59
9–2 ENGINE MECHANICAL
Cylinder Head
JP30109090402001
SAPH301090900001
11101 Cylinder head assembly 12210A Ventilator

11115 Head gasket* 12203 Ventilation pipe
11185 Head bolt (additional) 12261 Ventilator hose
11185A Head bolt 12261A Oil hose
11185B Head bolt 12505 Silent block
11201 Head cover (lower) 13719 Valve stem oil seal*
11211 Head cover (upper) 18109 Terminal
11213 Gasket* 23745 Injection pipe oil seal
11213A Gasket 9349A Stud bolt (for exhaust manifold
installation)
11455 Plate 9851A O-ring*
12108 Oil filler cap 9851C O-ring*
12210 Ventilator

Tightening torque
11185 69N⋅m{700kgf⋅cm,51 lbf⋅ft} 9191-08401 25N⋅m{250kgf⋅cm,18 lbf⋅ft}
11185A 118N⋅m{1,200kgf⋅cm,87 lbf⋅ft}+90°+90° 9349A 30N⋅m{300kgf⋅cm,22 lbf⋅ft}
11185B 118N⋅m{1,200kgf⋅cm,87 lbf⋅ft}+90°+90° 9412-10301 54N⋅m{550kgf⋅cm,40 lbf⋅ft}
9068-10250 68.5N⋅m{700kgf⋅cm,51 lbf⋅ft} 9412-10551 54N⋅m{550kgf⋅cm,40 lbf⋅ft}
9068-10350 68.5N⋅m{700kgf⋅cm,51 lbf⋅ft} 9412-10851 54N⋅m{550kgf⋅cm,40 lbf⋅ft}
9068-10600 68.5N⋅m{700kgf⋅cm,51 lbf⋅ft} SZ109 25N⋅m{250kgf⋅cm,18 lbf⋅ft}
SAPH301090900002
11101 Cylinder head 11135 Valve seat

11122 Valve guide 11176 Nozzle seat
11131 Valve seat
êÆî óvóÃ
Replacement
JP30109090704001
1. Removal of head cover (upper)

Bolt Head cover (1) Remove the ventilator hose and the bolt and remove the
(upper)
head cover (upper).
! CAUTION • Be careful for fall of the silent block.
Silent block Ventilator hose
SAPH301090900003
2. Removal of injector
Reference: "Replacement of fuel system, injector"
3. Removal of rocker arm assembly

Referenc:" Engine mechanical, Overhaul of valve system"
4. Removal of head cover (lower)
(1) Pull out the push rod.
! CAUTION • Do not pull out the tappet together with the

push rod.
SAPH301090900004
(2) Remove one fuel pipe at the rear of the head cover
(lower).
! CAUTION • Wipe off spilled fuel.
SAPH301090900005
(3) Remove bolts and remove the head cover (lower).
SAPH301090900006
5. Removal of cylinder head

(1) Loosen the head bolts from outside to inside gradually (1/
4 turn for each) as shown in the order of the figure and
remove them.

SAPH301090900007
(2) Remove the cylinder head using a special tool and hoist.
Special tool : 09433-1030 Eye bolt
NOTICE • If it is difficult to remove the cylinder head,

insert a chisel between the cylinder head and
the cylinder block, and move the chisel
vertically so that the contact surface may not
be damaged. Then, separate the cylinder
head.
SAPH301090900008
6. Inspection of head bolt length
(1) Measure the under head length of the head bolt using a
vernier calipers. If it is out of the operation limit, replace it
with a new one.
Standard value Operation limit

(mm{in.}) (mm{in.})
Long 250{9.843} 252{9.921}
SAPH301090900009 Short 158{6.220} 161{6.338}

7. Compression upper dead center setting of No.1 cylinder

Key
(1) Turn the crankshaft in the engine rotating direction
Flywheel housing
inspection window (clockwise as viewed from the cooling fan side), align the
"16" stamp line of the crankshaft damper with the pointer,
and set the No. 1 cylinder to the compression top dead
center.
! CAUTION • If the pointer is matched with "16", but the

supply pump bearing case shaft key or the
SAPH301090900010 coupling cotter bolt faces down, No. 6 is at
the compression top dead center. Turn the
crankshaft one turn and set the No. 1 cylinder
at the compression top dead center.
Coupling bolt
Stamp line
Cotter bolt
SAPH301090900011
8. Installation of head gasket
(1) Place a new head gasket on the cylinder block.
! CAUTION • Remove dirt, water or oil from the mounting

surfaces of the cylinder head and the cylinder
block before work.
• Never reuse the gasket. Otherwise, it may
damage the engine.
• Before installation of the head gasket, make sure
SAPH301090900012
that there is no fall of or damage to the seal ring.
• Do not apply liquid gasket to each seal.
9. Installation of cylinder head
(1) Clean the head bolt seating at the cylinder head upper
surface and the cylinder head lower surface.
(2) Align the dowel pins of the cylinder block using a special
tool and hoist and mount the cylinder head.
! CAUTION • Before mounting the cylinder head, make sure

that there is no foreign matter in the cylinder.
Special tool : 09433-1030 Eye bolt

SAPH301090900008
(3) Apply engine oil to the bolt seating and thread and tighten
19 head bolts in the order shown in the figure.
Seating torque : 118 N⋅m {1,200 kgf⋅cm, 87 lbf⋅ft}
SAPH301090900013
(4) Install the armature assembly.

(5) Install 7 rocker support bolts (head bolts) in the order
Seating torque : 118 N⋅m {1,200 kgf⋅cm, 87 lbf⋅ft}
SAPH301090900014
(6) Make sure the 26 head bolts are tightened to a torque

value of 118N⋅m {1,200kgf⋅cm, 87lbf⋅ft} and finally tighten
the additional bolt.
Additional bolt
SAPH301090900015
(7) Mark the heads of the 26 head bolts in the above figure in
Paint
the same direction using paint.
q q
(8) Tighten 26 head bolts at rotation angle 90° in the same
order as above using a special tool and make sure that all
paint marks are in the same direction. Tighten them
further at rotation angle 90° and make sure that all paint
marks are in the same direction.
Paint ! CAUTION • If a bolt is turned excessively in retightening,

SAPH301090900016 do not loosen it.
SAPH301090900017
10. Installation of head cover (lower)
(1) Replace the gasket with a new one and install the head
cover (lower).
SAPH301090900018
(2) Replace the gasket with a new one and install one fuel
pipe.
SAPH301090900019
11. Installation of injector

Reference: "Fuel system, Replacement of injector"
12. Installation of head cover (upper)

Bolt Head cover
(upper) (1) Wipe dirt and oil on the joint surfaces of the head cover
(upper) and head cover (lower) and on the groove of the
gasket and install the head cover (upper) and gasket.
! CAUTION • Since the head covers are floating mount, do

not overtighten the bolts.
Silent block Ventilator hose
(2) Connect the ventilator hose.
SAPH301090900003
Overhaul
JP30109090702001
1. Cleaning of cylinder head
(1) Remove carbon or other deposit using a scraper.

(2) Clean the cylinder head.
! CAUTION • To remove carbon or other deposit, do not

damage the lower surface of the cylinder
head.
SAPH301090900020
2. Replacement of valve guide

Valve guide
(1) Remove the valve stem seal.
(2) Remove the valve guide using a brass bar or press.
(3) If a new valve guide is assembled, press-fit carefully,
being careful not to pry the end.
! CAUTION • In press fit, be careful not to damage the valve

stem at the upper/lower ends of the guide.
• In press fit, be sure to apply engine oil to the
SAPH301090900021 circumference of the valve guide.
3. Replacement of valve seat
Backing Valve seat ! CAUTION • The valve seat replacement procedure below
metal may damage the cylinder head depending on
the case. It is recommended that a request for
replacement be made to a machining vendor.
Electric
Valve welding
(1) If the valve seat is replaced, use an out-of-use valve. After
Cut these 3 parts.
cutting three pieces from the valve circumference, weld
them to the valve seat.
SAPH301090900022
! CAUTION • Apply grease to protect the cylinder head

lower surface from welding spatter before
work.
(2) Put a backup metal (e.g. brass bar) at the valve stem
head and pull out the valve seat using a press.
(3) Remove welding spatter or dirt on the valve seat surface.
ࠑ ࠑ
ࠑ ࠑ
Intake Exhaust
SAPH301090900023
(4) Heat the cylinder head to approx. 80 °C{176 °F} to 100 °C

{212 °F} and strike the cooled valve seat into the mounting
area of the cylinder head.
! CAUTION • Be careful not to break it because it is a

sintered part.
SAPH301090900024
(5) Apply small amount of lapping compound to the contact

surface between the valve and the valve seat.
(6) Strike gently while turning the valve using a special tool
for adjustment.
Special tool : 09431-1010 Valve lapping tool
SAPH301090900025
4. Replacement of nozzle seat
(1) Tap the nozzle seat from the cylinder head lower part.
Then, put a bolt in the nozzle seat tap.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.
! CAUTION • After pulling out the nozzle seat, be sure to

remove deposit such as remaining liquid
SAPH301090900026 gasket or dirt.
(4) After attaching a new O-ring applied with engine oil into
Nozzle seat O-ring the nozzle seat hole in the cylinder head, apply the liquid
gasket [Threebond TB1211 (white) or equivalent] to the
lower part of a new nozzle seat and assemble it on the
cylinder head.
! CAUTION • Be sure to replace the O-ring with a new part.

Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
SAPH301090900027
head.
• Install it within 20 minutes after application of
the liquid gasket.
(5) Clamp the nozzle seat using a special tool and a

Push rod pneumatic hammer.
Pressing tool
Special tool : 09472-1210 Bar
Nozzle seat
9800-06100 Steel ball
! CAUTION • Do not strike out with a normal hammer.

㧭 Conical surface A must be in close contact on
Steel ball
the circumference after clamping.
SAPH301090900028
5. Inspection of cylinder head
(1) Check for crack or damage using dye penetrant. If a faulty

condition is found, replace the cylinder head.
SAPH301090900029
(2) Measure distortion of cylinder head lower surface using a

ruler. If the measurement value is beyond the repair limit,
grind and correct it.
Standard value (mm{in.}) Repair limit (mm{in.})

0.05{0.0019} 0.15{0.0059}
SAPH301090900030
Cylinder Block
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Part layout
JP30109090402002
SAPH301090900031
11408 Cooling jet 11841 Camshaft bearing

11467 Cylinder liner 11851 Camshaft bearing
11811 Camshaft bearing 11861 Camshaft bearing
11821 Camshaft bearing 11871 Camshaft bearing
11831 Camshaft bearing 15605 Bolt
Tightening torque
11521 274N⋅m{2,800kgf⋅cm,203lbf⋅ft} 15605 23N⋅m{230kgf⋅cm,17lbf⋅ft}
êÆî óvóÃ
Overhaul
JP30109090702002
1. Removal of cylinder liner
(1) Put match marks on the flange surfaces of the cylinder

block and the cylinder liner using a oil based marker.
! CAUTION • Store removed cylinder liners for each

cylinder number.
• Never provide match marks with a punch.
SAPH301090900032
(2) Pull out the cylinder liner toward the cylinder block upper
part using a special tool.
Special tool : 09420-1750 Cylinder liner puller
! CAUTION • Be careful for handling of the cylinder liner.

Do not reuse the cylinder liner which has
been dropped.
• Do not touch the cooling jet during work.
SAPH301090900033
2. Installation of cylinder liner

(1) Apply engine oil to the inner bore of the cylinder block.
(2) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
Special tool : 09480-1190 Liner insertion guide
! CAUTION • When a new cylinder liner is installed, install

the cylinder liner with the same identification
mark (A, B, C) stamped on the cylinder block.
SAPH301090900034
3. Inspection of protrusion at cylinder liner flange
(1) Measure protrusion of the flange using a dial gauge.
0.04 - 0.10
Standard value (mm{in.})
{0.0016 - 0.0039}
SAPH301090900035
4. Inspection of cooling jet
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
Special tool : 9001-24262 Check bolt
Check bolt
SAPH301090900036
(2) Connect the injection test oil hose from the lower part of
the cylinder block to the special tool check bolt.
! CAUTION • Use new engine oil for injection of oil.
Check bolt
Oil hose
SAPH301090900037
(3) Set a special tool on the cylinder block.
Special tool : 09470-1180 Test kit

Special tool
test kit
(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Cylinder
pressure of 196 kPa{2 kgf/cm2, 28 psi}.
Liner
Cooling jet NOTICE • Refer to the drawing for the oil injection unit.
SAPH301090900038
Oil injection unit (example)

Pressure
regulator
Oil hose
Air tank
(oil tank)
Air
Air gauge compression
Air hose
To cooling jet
Valve
SAPH301090900039
(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.
Faulty Faulty Normal Normal (6) Make sure that the jet position check gauge hole at the
tool assembly end may not interfere with the cooling jet
pipe.
SAPH301090900040
(7) If injection does not hit the target circle, correct it with a
special tool.
! CAUTION • If the injection position of the cooling jet is

incorrect, replace parts with new ones instead
of correction.
(8) Remove the check bolt and install the cooling jet on the
cylinder block using the genuine oil check valve.
(9) After assembly of the piston, make sure that the cooling
jet does not interfere with the piston at the piston bottom
dead center.
5. Inspection of cylinder block
(1) Check for crack or damage using dye penetrant. If a faulty

condition is found, replace the crankshaft.
(2) Measure distortion on the cylinder block using a ruler. If
the measurement value is beyond the operation limit,
replace it.
0.05{0.0019} 0.15{0.0059}
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SAPH301090900041
Timing Gear Cover and Flywheel Housing

Part layout
JP30109090402003
SAPH301090900042
11306 Dust cover 11356 Flywheel housing stay

11311 Timing gear case assembly 11356A Flywheel housing stay
11321 Timing gear case cover assembly 12281 Engine hanger
11351 Flywheel housing assembly 9828A Crankshaft rear oil seal*
11328 Gasket* 9828B Crankshaft front oil seal*
11329 Gasket*

Tightening torque
11185 211N⋅m{2,150kgf⋅cm,156 lbf⋅ft} 9411-10502 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
900125 211N⋅m{2,150kgf⋅cm,156 lbf⋅ft} 9411-10602 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
9409A 172N⋅m{1,750kgf⋅cm,127 lbf⋅ft} 9411-10952 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
9411-10252 44N⋅m{450kgf⋅cm,32 lbf⋅ft} 9412-14652 113N⋅m{1,150kgf⋅cm,83 lbf⋅ft}
9411-10352 44N⋅m{450kgf⋅cm,32 lbf⋅ft}
êÆî óvóÃ
Replacement of flywheel housing

JP30109090702003
1. Removal of flywheel housing
(1) Remove the housing stay.

Flywheel (2) Remove 8 M8 bolts and then remove the flywheel
housing housing.
stay
Flywheel
housing
stay
SAPH301090900043
2. Installation of flywheel housing

Application width
3.5 - 4.5mm (1) Remove contamination from the joint surfaces of the
{0.1378 - 0.1771in.}
flywheel housing and the cylinder block using a scraper.
(2) Apply the liquid gasket [Threebond TB1207D (red) or
equivalent] to the flywheel housing as shown in the figure.
(3) Install the guide bolts at several mounting threads and
align the flywheel housing with the cylinder block without
shifting the liquid gasket.
SAPH301090900044 ! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of
4±0.5mm{0.1575 ± 0.0197in.}.
the liquid gasket.
(4) Tighten the flywheel housing stay and flywheel housing

bolts.
Flywheel Tightening torque :

housing Flywheel housing: M14
stay
113 N⋅m{1,150 kgf⋅cm, 83 lbf⋅ft}
Flywheel housing stay: M16
211 N⋅m{2,150 kgf⋅cm, 156 lbf⋅ft}
Flywheel åšä²óvóÃçÄñ⁄
housing
stay
SAPH301090900043
Replacement of crankshaft front oil seal

JP30109090704002
1. Removal of crankshaft front oil seal

(1) Align the special tool with the convex in the crankshaft
rear oil seal, insert the special tool sleeve and fix it.
! CAUTION • Install the special tool so that the dowel pin of

the crankshaft may not come in contact with
it.
SAPH301090900045
(2) Tighten the center bolt of the special tool gradually and
pull out the crankshaft front oil seal.
! CAUTION • Check the engagement of the special tool and

oil seal during work and pull it out so that the
special tool is not removed.
SAPH301090900046
2. Installation of crankshaft front oil seal
(1) Make sure that there is no impact mark or dirt on the oil
seal insertion of the timing gear case cover and
crankshaft.
(2) Remove contamination from the special tool press.
(3) Apply a small amount of engine oil to the lip of a new oil
seal.
(4) Insert the oil seal into the crankshaft manually until it
stops paying attention to the direction of the oil seal.
SAPH301090900047
! CAUTION • Install the oil seal so that the felt surface is

outside and the slinger (steel plate) surface is
inside.
• Install the oil seal so that it is not tilted.
(5) Install the plate on the end of the crankshaft with 2 bolts.
SAPH301090900048
(6) Align the press with the guide bolt, tighten the center bolt
and press-fit the oil seal.
! CAUTION • Press-fit uniformly on the circumference.
(7) Tighten until the press hits and make sure the oil seal is
press-fit uniformly on the circumference.
SAPH301090900049
Replacement of crankshaft rear oil seal

JP30109090704003
1. Removal of crankshaft rear oil seal

(1) Align the special tool with the convex in the crankshaft
rear oil seal, insert the special tool sleeve and fix it.
SAPH301090900050
! CAUTION • Since the special tool can be used for K13C

and P11C, align "K" and "P" with the
positions shown in the figure and install it on
the oil seal.
SAPH301090900051
(2) Tighten the center bolt of the special tool gradually and
pull out the crankshaft rear oil seal.
! CAUTION • Check the engagement of the special tool and

oil seal during work and pull it out so that the
special tool is not removed.
SAPH301090900052
2. Installation of crankshaft rear oil seal

Oil seal guide
(1) Make sure that there is no impact mark or dirt on the oil
seal insertion of the flywheel housing and crankshaft.
Oil seal
(2) Remove contamination from the special tool press.
(3) Apply a small amount of engine oil to the lip of a new oil
seal.
(4) Insert it into the oil seal guide of the special tool press,
paying attention to the direction of the new oil seal.
SAPH301090900053
! CAUTION • Install the oil seal so that the felt surface is

outside and the slinger (steel plate) surface is
inside of the engine.
• Install the oil seal so that it is not tilted.
(5) Install the oil seal guide assembled with the oil seal on the
end surface of the crankshaft with 2 bolts.
! CAUTION • Make sure that the step of the crankshaft and

the oil seal guide is uniform on the
circumference after tightening the guide bolt.
SAPH301090900054
(6) Align the press with the oil seal guide and tighten it with
the center bolt.
! CAUTION • Press-fit uniformly on the circumference.
(7) Tighten until the press hits and make sure that the oil seal
is press-fit uniformly on the circumference.
SAPH301090900055
Replacement of timing gear case cover

JP30109090704004
1. Removal of crankshaft front oil seal

Reference: "Engine mechanical, Timing gear cover and
flywheel housing, Replacement of crankshaft front oil
seal"
2. Removal of timing gear case cover

(1) Remove bolts and remove the timing gear cover.
3. Installation of timing gear cover

(1) Replace the gasket and O–ring with new ones and install
the timing gear cover.
(2) Cut the gasket projecting to the engine lower surface so
that it becomes a flat surface.
4. Installation of crankshaft front oil seal

Reference: "Engine mechanical, Timing gear cover and
flywheel housing, Replacement of crankshaft front oil"
Main Moving Parts

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Part layout
JP30109090402004
SAPH301090900056
04132 Piston pin 13453 Ring gear

11011 Thrust bearing 13470 Crankshaft pulley assembly
11701 Crankshaft bearing 13471 Crankshaft pulley
13201 Connecting rod bearing 13521 Crankshaft gear
13260 Connecting rod assembly 13531 Oil pump drive gear
13265 Connecting rod bolt 9532-07220 Key
13272 Connecting rod bushing 9819A Retainer ring*
13400 Crankshaft assembly S1304 Piston ring
13407 Crankshaft damper S130B Piston assembly

Tightening torque
13266 69N⋅m{700kgf⋅cm,51 lbf⋅ft}+90°+90° 900124 108N⋅m{1,100kgf⋅cm,80 lbf⋅ft}
13455 270N⋅m{2,750kgf⋅cm,200 lbf⋅ft}(Standard) 900124A 245N⋅m{2,500kgf⋅cm,180 lbf⋅ft}
13455 225N⋅m{2,290kgf⋅cm,166 lbf⋅ft}(Vehicle 9068-10300 55N⋅m{560kgf⋅cm,41 lbf⋅ft}
with PTO)
êÆî óvóÃ
Replacement of piston and connecting rod

JP30109090704005
1. Removal of piston
(1) Remove nuts and remove the connecting rod cap.
! CAUTION • Fix the cylinder liner on the block.

• Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.
• Store removed connecting rod cap for each
SAPH301090900057
cylinder number so that combinations of the
connecting rod and the connecting rod cap
may not be changed.
(2) Remove carbon on the cylinder liner inner surface with a

scraper or a sand paper (No. 150 or so) in the
circumferential direction.
! CAUTION • Do not damage parts lower than the carbon

deposit area.
(3) Fix the cylinder liner with bolts and a plate.
SAPH301090900058
(4) Hit the connecting rod from underneath the engine using
the handle of a hammer. Remove the piston together with
the connecting rod.
SAPH301090900059
NOTICE • In removing the piston, rotate the connecting

Cooling jet
rod as shown in the figure. Do not bend the
cooling jet.
! CAUTION • Store removed pistons and connecting rods

for each cylinder number.
• Be careful not to touch the cooling jet.

SAPH301090900060
2. Disassembly of piston and connecting rod
(1) Remove the retainer ring using snap ring pliers.

(2) Warm the piston to 50 °C{122 °F} or more.
(3) Remove the piston pin using the brass bar and disconnect
the piston from the connecting rod.
SAPH301090900061
(4) Remove the piston ring using a special tool.
Special tool : 09442-1230 Piston ring expander
! CAUTION • Since the piston ring is susceptible to

damage, be careful for handling.
• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and
lower surfaces may be identified.
SAPH301090900062
3. Assembly of piston and connecting rod

Piston "0" mark position
(1) Warm the piston to 50 °C{122 °F} or more.
(2) Install the piston on the connecting rod so that the "0"
Ex-haust side In-take side
mark on the piston may be opposite to the match mark
stamp on the connecting rod.
Oil hole
! CAUTION • Make sure that the oil hole offset is as shown
Match mark stamp
in the figure.
(3) Install a new retainer ring using snap ring pliers.

SAPH301090900063
! CAUTION • Make sure that there is no backlash in the

retainer ring.
(4) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a special tool.
Special tool : 09442-1230 Piston ring expander
Upper surface (5) Connect the joint of the coil expander and fit the oil ring
Oil
Top Second Third
inside the ring. Offset the coil expander joint with the ring
joint by 180 deg for installation.
Lower surface Oil ring (6) Allocate the joints of the piston ring with uniform intervals
Clearance as shown in the figure.
Joint
Coil expander Second
Oil Third
Top
SAPH301090900064
4. Installation of piston and connecting rod

Second ring (1) Apply engine oil to the inner diameter surface of the
connecting rod.
(2) Allocate the joints of the piston ring with uniform intervals
Oil ring Third ring as shown in the figure.
Top ring
SAPH301090900065
(3) Measure the overall length of the connecting rod bolt

using a vernier calipers. If it is out of the operation limit,
replace it with a new one.
Overall length
of the bolt
Standard value (mm{in.}) Operation limit (mm{in.})
102.5{4.0354} 105.0{4.1338}
(4) Apply engine oil to the connecting rod bolt thread and the
nut seat and install the piston on the connecting rod.
SAPH301090900066
(5) Install the connecting rod bearing to suit concave shape of
the connecting rod.
! CAUTION • Make sure that the oil hole of the connecting

rod bearing is aligned with the oil hole of the
connecting rod.
(6) Apply engine oil to the piston, cylinder liner and

connecting rod bearing and compress the piston ring
using a special tool.
Special tool : 09441-1330 Piston ring holder
! CAUTION • Make sure that there is no deformation or

damage to the special tool piston ring holder.
(7) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.
! CAUTION • Face the "0" mark on the piston toward the

exhaust side for insertion.
• Set the crankshaft of the cylinder as the top
Cooling jet dead center for assembly.
• Do not damage the cylinder liner, crankshaft
and cooling jet during work.
SAPH301090900067
• After assembly, make sure that the oil hole of
the connecting rod is at the air intake side.
(8) Install the connecting rod bearing to suit concave shape of

the connecting rod cap.
Match mark
stamp (9) Apply engine oil to the bolt thread and seating, align the
connecting rod cap and connecting rod match mark
directions and numbers and tighten nuts temporarily.

• Do not change the combination between the

! CAUTION
connecting rod and the connecting rod cap.
SAPH301090900068
(10) Tighten the connecting rod nut and mark the nut head in
Paint mark the same direction with paint.
Seating torque : 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}

ࠑ

(11) 90Retighten the 90 deg connecting rod nut.

(12) Retighten the 90 deg connecting rod nut.
(13) Make sure that all marks are in the same direction.
! CAUTION • If a bolt is turned excessively in retightening,

Paint mark
do not loosen it.
SAPH301090900069
(14) Make sure that the end play is the standard value after
installation.

0.15 - 0.32
0.6{0.0236}
{0.0059 - 0.0125}
Inspection of piston and connecting rod

JP30109090703001
1. Inspection of piston clearance
(1) Measure the inner diameter of the cylinder liner sliding

surface using a cylinder gauge.
122{4.803} 122.15{4.8090}
SAPH301090900070
(2) Measure the piston outer diameter using a micrometer.
! CAUTION • The measuring position is 25 mm{0.984 in.}

above the piston lower end and square to the pin
hole.
Standard value (mm{in.}) 121.95{4.8012}
(3) Calculate the difference between the inner diameter of the
SAPH301090900071
cylinder liner and the outer diameter of the piston. If it is beyond
the standard value, replace the cylinder liner and the piston.
0.060 - 0.080
0.15{0.0059}
{0.0024 - 0.0031}
2. Inspection of clearance between piston ring and ring groove
(1) Measure the piston ring width using a micrometer. If it is

beyond the operation limit, replace the piston ring.

(mm{in.}) (mm{in.})
Top ring 3.312{0.1304} (Taper)
Second
2.306{0.0908} (Taper)
SAPH301090900072 ring
Third ring 2.0{0.0787} 1.80{0.0708}
Oil ring 4.0{0.1575} 3.90{0.1535}

(2) Measure the piston ring groove using a thickness gauge.

If it is out of the operation limit, replace the piston.

Top ring groove (Taper)
Second ring groove (Taper)
Third ring groove 2.0{0.0787}

Oil ring groove 4.0{0.1575}
SAPH301090900073
(3) Calculate the difference between the piston ring thickness

and ring groove. If it is beyond the operation limit, replace
the piston ring or the piston.
Standard value Operation

(mm{in.}) limit (mm{in.})
Top ring clearance — —
Second ring clearance — —
0.065 - 0.105
Third ring clearance 0.20{0.0078}
{0.0026 - 0.0041}
0.025 - 0.065
Oil ring clearance 0.10{0.0039}
{0.0010 - 0.0025}
3. Inspection of piston ring joint clearance

Cylinder liner
(1) Insert the piston ring into the cylinder liner by
80mm{3.150in.} horizontally using piston.
(2) Measure the piston ring joint clearance using a thickness
gauge. If it is out of the operation limit, replace the piston ring.
Piston ring
Operation limit
(mm{ni.})
Top ring 0.30 - 0.50{0.0118 - 0.0196} 1.5{0.0590}

SAPH301090900074
Second ring 0.50 - 0.70{0.0197 - 0.0275} 1.2{0.0472}
Third ring 0.35 - 0.50{0.0138 - 0.0196} 1.2{0.0472}
Oil ring 0.30 - 0.50{0.0118 - 0.0196} 1.0{0.0393}
4. Inspection of piston pin
(1) Measure the outer diameter of the contact area of the

piston pin with the piston boss using a micrometer.
Standard value (mm{in.}) 47{1.850}
SAPH301090900075
(2) Measure the piston boss inner diameter using a cylinder

gauge.
(3) Calculate the difference between the outer diameter of the piston
pin contact area with the piston boss and the inner diameter of the
piston boss. If it is out of the operation limit, replace the piston pin.
SAPH301090900076
0.041 - 0.059{0.0017 - 0.0023} 0.05{0.0019}
5. Inspection of connecting rod bushing oil clearance
(1) Measure the outer diameter of the center of the piston pin
using a micrometer.
SAPH301090900077
(2) Measure the connecting rod bushing inner diameter using

a cylinder gauge.
(3) Calculate the difference between the outer diameter of the

center of the piston pin and the inner diameter of the
connecting rod bushing. If it is beyond the operation limit,
replace the piston pin and connecting rod.
SAPH301090900078
0.025 - 0.043{0.0394 - 0.0016} 0.10{0.0039}
6. Inspection of connecting rod
(1) Check for crack or damage to the connecting rod using

dye penetrant. If a faulty condition is found, replace the
crankshaft.
SAPH301090900079
(2) Insert a rod with the diameter of 6 mm{0.236 in.} from the
oil hole at the connecting rod large end and make sure
that it goes through the oil hole at the small end. If the rod
with the diameter of 6 mm{0.236 in.} does not through due
to clogging of the oil hole, replace the connecting rod.
SAPH301090900080
7. Inspection of connecting rod oil clearance
(1) Measure the outer diameter of the crankshaft crank pin

using a micrometer.
Measure 2 parts.
Standard value Repair limit Operation limit

(mm{in.}) (mm{in.}) (mm{in.})
80{3.150} 79.8{3.1417} 78.8{3.1023}
SAPH301090900081
(2) Assemble the bearing on the connecting rod large end,

install the cap and tighten the nut of the connecting rod
bolt.
(3) Measure the bearing inner diameter of the connecting rod

large end using a cylinder gauge.
crank pin of the crankshaft and the inner diameter of the
connecting rod bearing. If it is beyond the operation limit,
replace the connecting rod bearing and the crankshaft.
SAPH301090900082
NOTICE • The crankshaft can be ground and corrected.
0.025 - 0.084
0.30{0.0118}
{0.0010 - 0.0033}
Replacement of crankshaft
JP30109090704006
1. Removal of crankshaft
(1) Remove the main bearing cap and the crankshaft bearing.
Remove the crankshaft using a hoist.
! CAUTION • Since the part is heavy, be careful for

handling.
• Store removed main bearing caps and
crankshaft bearings for each cylinder number.
SAPH301090900083
2. Installation of crankshaft
(1) Place the bearing with oil hole on the cylinder block and
apply engine oil.
(2) Place the crankshaft.
(3) Align the bearing with no hole with the bearing cap and
apply engine oil.
(4) Insert the thrust bearing applied with engine oil between
the crankshaft and the cylinder block so that the dented
surface faces outside.
(5) Apply engine oil to the thrust bearing at the cap side in the
same way and install the cap with the dented surface
facing outside.
Dent
SAPH301090900084
(6) Install it so that the triangular mark on the main bearing

Front of engine
cap faces the front of the engine.
Stamp number
! CAUTION • Check the stamp number of each main

bearing cap with the stamp number of the

cylinder block.
(7) Apply engine oil to the bolt seating and the bolt thread of
the main bearing cap bolt and tighten the bolts three times
Stamp number
from the center to outside.
SAPH301090900085
! CAUTION • Loosen the No. 4 cap bolt, tap the front/rear ends of
the crankshaft with a plastic hammer for initial fit and
tighten it while sometimes turning the crankshaft.
Tightening order : 4—3—5—2—6—1—7

(8) Make sure that the crankshaft turns smoothly.
Inspection of crankshaft
JP30109090703002
1. Inspection of end play

(1) Measure the end play of the crankshaft using a dial
gauge. If it is beyond the operation limit, replace the thrust
bearing.

0.110 - 0.240
0.5{0.0196}
{0.0044 - 0.0094}
2. Inspection of rotation runout
(1) Hold the No. 1 and No. 7 journals with the V–block,
measure the rotation runout of the crankshaft, and if it
exceeds the operation limit, replace the crankshaft.
Operation limit (mm{in.}) 0.07{0.0027}
SAPH301090900086
3. Inspection of crankshaft oil clearance
(1) Measure the outer diameter of the crankshaft journal

Measure 2 using a micrometer.
parts.
ࠑ
90{3.543} 88.8{3.4960}
SAPH301090900087
(2) Do not install the crankshaft. Install the crankshaft bearing

and the main bearing cap on the cylinder block.
(3) Measure the crankshaft bearing inner diameter using a

cylinder gauge.
crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the standard value,
replace the crankshaft or crankshaft bearing.
SAPH301090900088
0.044 - 0.097
0.30{0.0118}
{0.0018 - 0.0038}
4. Inspection of crack and damage to crankshaft and of oil

hole
(1) Check for crack or damage to the crankshaft using dye

penetrant. If a faulty condition is found, replace the
crankshaft.
SAPH301090900089
(2) Check for clogging of the crankshaft oil hole. If faulty

condition is found, replace the crankshaft.
SAPH301090900090
Replacement of crankshaft pulley

JP30109090704007
1. Removal of crankshaft pulley
(1) Remove the 1 crankshaft pulley mounting bolt and install

the guide bolt to prevent fall.
(2) Remove the remaining bolts while supporting the
crankshaft pulley, and remove the crankshaft pulley
assembly.
! CAUTION • When the bolt is removed, the crankshaft

pulley may fall. It must be firmly supported
SAPH301090900091 during removal.
NOTICE • Insert a large flat tip screwdriver into the

crankshaft.
2. Installation of crankshaft pulley

(1) Assemble the crankshaft pulley and crankshaft damper.
(2) Apply engine oil to the bolt seat and the bolt thread of the
crankshaft pulley mounting bolt.
(3) Install the crankshaft pulley on the crankshaft and tighten

it according to the figure.

NOTICE • Insert a large flat tip screwdriver into the

SAPH301090900092 crankshaft.
Replacement of flywheel
JP30109090704008
1. Removal of flywheel
㧔㧭㧕
(1) Remove the engine revolution sensor on the flywheel
housing.
Engine ! CAUTION • If the engine revolution sensor is not removed

revolution before removing the flywheel, the engine
sensor
revolution sensor is damaged.
㧔㧮㧕
SAPH301090900093
(2) Remove the 2 flywheel mounting bolts and install the

guide bolt to prevent fall.
(3) Remove the remaining bolts while supporting the

flywheel, and remove the flywheel.
! CAUTION • Since the part is heavy, be careful for

handling.
SAPH301090900094
2. Removal of ring gear

(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C{392 °F}.
! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.
SAPH301090900095
(2) Hit the circumference of the ring gear gently using a

backing rod to remove the ring gear from the flywheel.

SAPH301090900096
3. Installation of ring gear
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C{392 °F}.

SAPH301090900097
(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.

SAPH301090900098
4. Installation of flywheel
(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Align the flywheel with the crankshaft with 2 guide bolts,
apply engine oil to the bolt seating and thread and install
the bolts.
Tightening torque :
Standard
270 N⋅m{2,750 kgf⋅cm, 200 lbf⋅ft}
Vehicle with PTO
225 N⋅m{2,290 kgf⋅cm, 166 lbf⋅ft}
SAPH301090900094 ! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Since the bolts for vehicles with PTO cannot
be reused, replace them with new ones.
(3) Install the engine revolution sensor on the flywheel

housing.
5. Installation of the engine rotation sensor

(1) Install engine revolution sensor (A).
㧔㧭㧕
(2) Screw in engine revolution sensor (B) by hand, until its tip
comes into contact with the ring gear, and then turn it one
turn back.
Engine
revolution ! CAUTION • When a tool is used to screw in the engine
sensor
rotation sensor, the sensor may become
damaged.
㧔㧮㧕
SAPH301090900093
(3) Match the gap between engine revolution sensor (B) and
ring gear to the reference value and secure with the lock
}
91
-0 m
Engine revolution sensor(B)

94 1.5 m
.05
nut.
{0. 1.0 -
Tightening torque: 49 ± 4.9 N⋅m {500 ± 50 kgf⋅cm,36±4

03
lbf⋅ft}
Ring gear
Standard value (mm{in.}) 1.0 - 1.5{0.0394 - 0.0591}
SAPH301090900099
Inspection of flywheel
JP30109090703003
! CAUTION • When flywheel plane run-out and axial run-out

are not within the standard values, troubles
like coupling damage or shaft damage may be
caused at the time of connection with the
machine.
1. Inspection of flywheel plane run-out and axial run-out

(1) Hoist the flywheel side of the engine, so that no load acts
onto the flywheel housing.
Raise (2) Push the crankshaft to the front of the engine and stabilize
it.
! CAUTION • Take care not to include the end play of the

crankshaft in the measurement.
SAPH301090900100
(3) Use a dial gauge to measure plane run-out (A) and axial
run-out (B) of the flywheel.
Repair limit (mm{in.}) 0.2{0.0078}
! CAUTION • Measure in engine rotation direction

(counterclockwise as seen from the flywheel)
at eight positions in intervals of 45°.
SAPH301090900101
SAPH301090900102
(4) If the plane run-out of the flywheel is outside the reference

values, clean the mounting surface for the flywheel on the
crankshaft and reassemble after using an oil stone to
remove burr.
If the value is still outside the reference values, replace
the flywheel.
(5) If the axial run-out of the flywheel is outside the reference
values, replace the flywheel.
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Camshaft and Idle Gear

Part layout
JP30109090402005
SAPH301090900103
13505 Idle gear assembly 13580 Idle gear shaft assembly

13505A Main idle gear assembly 13581 Idle gear shaft
13511 Camshaft 13613 Supply pump drive gear
13523 Camshaft gear 900116 Spacer
13571 Thrust plate 900116Ç` Spacer
13572 Thrust plate 9532-07150 Key
13572A Thrust plate 9851A O-ring*
13572B Thrust plate

Tightening torque
900124A 44N⋅m{450kgf⋅cm,32 lbf⋅ft} 9019A 137N⋅m{1,400kgf⋅cm,100 lbf⋅ft}
900124 108N⋅m{1,100kgf⋅cm,80 lbf⋅ft}
Gear train layout

JP30109090402006
Air compressor idle gear

Main idle gear (No.1)
Main idle gear (No.2)
Supply pump drive gear
Camshaft gear
Oil pump drive gear

Crankshaft gear
Oil pump driven gear
Details of parts A, B and C

SAPH301090900104
êÆî óvóÃ
Removal of camshaft
JP30109090702004
1. Removal of push rod cover
(1) Remove the push rod cover on the side of the engine.
(2) Hold the roller tappet so that it does not fall using a special
tool.
Special tool : 09451-1040 Stopper
SAPH301090900105
2. Removal of camshaft
(1) Turn the camshaft gear, align the camshaft gear hole with
the thrust plate mounting bolt position, remove the bolt
and remove the shaft.
! CAUTION • Pull out the cam bearing so that it is not

damaged.
NOTICE • Refer to the following for installation of the

camshaft.
SAPH301090900106
Reference: "Engine mechanical, Camshaft
and idle gear, Installation of camshaft"
Disassembly of camshaft
JP30109090702005
1. Removal of camshaft
(1) Fix the camshaft through an aluminum plate, etc. with a

vice and remove the camshaft gear bolt.
! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.
(2) Pull out the main bearing from the crankshaft using a
special tool.
Special tool : 09420-1111 Timing gear puller
SAPH301090900107
NOTICE • Refer to the following for inspection and

disassembly of the camshaft.
and idle gear, Inspection of camshaft"
and idle gear, Assembly of camshaft"
Inspection of camshaft
JP30109090703004
1. Inspection of cam height on camshaft
(1) Measure the cam height using a micrometer. If it is

beyond the operation limit, replace the camshaft.

(mm{in.}) (mm{in.})
Cam IN 56.03{2.2059} 55.23{2.1744}

height EX 53.72{2.1150} 52.92{2.0835}
SAPH301090900108
Cam IN 6.63{0.2610} 6.48{0.2551}
lift EX 8.72{0.3433} 8.57{0.3374}
2. Inspection of camshaft bearing oil clearance
(1) Measure the outer diameter of the camshaft journal using

a micrometer.
Journal No. 1 65.0{2.5590}
Journal No. 2 64.6{2.5433}
Journal No. 3 64.2{2.5275}

SAPH301090900109
Journal No. 4 63.8{2.5118}
Journal No. 5 63.4{2.4960}
Journal No. 6 63.0{2.4803}
Journal No. 7 62.6{2.4645}
(2) Measure the camshaft bearing inner diameter using a

cylinder gauge.
camshaft journal and the inner diameter of the camshaft
bearing. If it is beyond the operation limit, replace the
camshaft or camshaft bearing.

0.030 - 0.120{0.0012 - 0.0047} 0.30{0.0118}
3. Inspection of camshaft runout
(1) Hold the camshaft with the V–block, measure the rotation
runout of the camshaft using a dial gauge. If it is beyond
the operation limit, replace the camshaft.
SAPH301090900110
Assembly of camshaft
JP30109090702006
1. Installation of ring gear

(1) Insert the spacer and thrust plate into the camshaft.
(2) Warm the cam gear to approx. 180 °C{356 °F} using a
heater (piston heater, etc.).
! CAUTION • Do not touch parts with bare hand because

they are hot.
(3) Apply engine oil to the bolt seating and thread, fix the cam
gear using a vice with the part number stamp surface
facing outside, and tighten the bolt.
! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.
(4) Tighten the bolt again to the specified torque after the
cam gear decreases to room temperature.
SAPH301090900111
2. Inspection of camshaft end play
Thrust plate thickness (1) Measure the camshaft end play using a thickness gauge
and measure the thrust plate thickness using calipers. If it
is beyond the operation limit, replace the thrust plate.

(mm{in.}) (mm{in.})
End play
0.10 - 0.23
End play 0.3{0.0118}
{0.0040 - 0.0090}
SAPH301090900112
Thrust plate
8{0.315} —
thickness
End play
SAPH301090900113
Installation of camshaft
JP30109090702007
1. Tappet installation
(1) Insert the tappet coated with engine oil.
! CAUTION • Check the tappet visually for absence of

eccentric wear, cracks, scratches, etc.
(2) Use the special tool and secure the tappet.

Special tool : 09451-1040 Stopper
SAPH301090900114
2. Installation of camshaft
(1) Apply engine oil to the camshaft journal and insert it into
the cylinder block while turning the camshaft.
! CAUTION • Do not damage the camshaft bearing.
(2) Install the camshaft using 4 bolts.

(3) Make sure that the camshaft end play is the standard
value.
SAPH301090900106 Standard value (mm{in.}) 0.10 - 0.23

{0.0040 - 0.0090}
(4) Apply the liquid gasket [Threebond TB1207C (red) or

equivalent] and install the push rod cover.
! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 - 0.0984 in.}.
the liquid gasket.
SAPH301090900105
Removal of timing gear

JP30109090702008
1. Removal of supply pump drive gear

Reference: "Fuel system, Overhaul of supply pump drive
bearing case"
2. Removal of idle gear and main idle gear
(1) Remove the idle gear shaft mounting bolts of the idle gear
and main idle gear.
(2) Remove the thrust plate and main idle gear at the main
idle gear side.
SAPH301090900115
3. Removal of idle gear shaft

Example of use of special tool
! CAUTION • Do not remove the idle gear shaft unless
necessary.
(1) Pull out each idle gear shaft using the special tool.
Special tool : 09420-1442 Sliding hammer
09462-1410 Idle gear shaft puller
adapter
SAPH301090900116 ! CAUTION • Refer to the following for installation of the

timing gear.
and idle gear, Assembly of timing gear"
Inspection of timing gear

JP30109090703005
1. Inspection of idle gear oil clearance
(1) Measure the idle gear shaft outer diameter using a

micrometer and measure the idle gear bushing inner
diameter using a cylinder gauge.
Standard value
(mm{in.})
Main Shaft outer diameter 64{2.520}

idle gear Bushing inner diameter 64{2.520}
Shaft outer diameter 52{2.047}
Idle gear
Bushing inner diameter 52{2.047}
(2) Calculate the difference between the idle gear shaft outer
diameter and the idle gear bushing inner diameter. If it is
beyond the operation limit, replace the idle gear shaft and
the idle gear bushing.

SAPH301090900117 (mm{in.}) (mm{in.})
0.030 - 0.090
Main idle gear 0.20{0.0078}
{0.0012 - 0.0035}
0.030 - 0.090
Idle gear 0.20{0.0078}
{0.0012 - 0.0035}
Installation of timing gear

JP30109090702009
1. Temporary tightening of air compressor idle gear shaft
(1) Apply engine oil to the idle gear shaft.

(2) Direct the identification hole of the idle gear shaft to the
lower part of the engine and fix the idle gear shaft, gear
and thrust plate temporarily.
Special tool : 13572-1021 Plate
09481-1660 Guide
Identification hole
! CAUTION • Press-fit vertically so that the idle gear shaft

SAPH301090900118
does not hit the timing gear case.
(3) Remove the special tool, apply engine oil to the bolt
seating and the bolt thread and fix it temporarily.
2. Installation of idle gear
(1) Align the gear mark and install each idle gear.
Tightening torque :
Main idle gear
44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft}
Idle gear
108 N⋅m {1,100 kgf⋅cm, 80 lbf⋅ft}
(2) Make sure that each backlash and end play are within the
standard value after installation.
"Reference: Engine mechanical, Camshaft and idle gear,
Inspection of timing gear installation status"
SAPH301090900119
Inspection of installation status for each

gear
JP30109090703006
1. Inspection of backlash
(1) Measure backlash between gears using a dial gauge. If it
is beyond the operation limit, replace the gear.
Standard
Operation
value
limit (mm{in.})
(mm{in.})
Between supply
SAPH301090900120
0.05 - 0.19
pump drive gear
{0.0020 - 0.30{0.0118}
and main idle
0.0074}
gear(No.2)
Between camshaft 0.07 - 0.19

gear and main idle {0.0028 - 0.30{0.0118}
gear(No.2) 0.0074}
0.06 - 0.19
Between camshaft
{0.0024 - 0.30{0.0118}
gear and idle gear
0.0074}
Between main idle 0.07 - 0.19

gear(NO.2) and {0.0028 - 0.30{0.0118}
crankshaft gear 0.0074}
Between oil pump 0.06 - 0.30

drive gear and oil {0.0024 - 0.40{0.0157}
pump driven gear 0.0118}
2. Inspection of idle gear end play
(1) Measure the end play of the main idle gear and idle gear
using a thickness gauge. If it is beyond the operation limit,
replace the gear and shaft.
Standard value Operation

(mm{in.}) limit (mm{in.})
0.065 - 0.149
Main idle gear 0.30{0.0118}
{0.0028 -0.0049}
SAPH301090900121
0.070 - 0.125
Idle gear 0.30{0.0118}
{0.0026 -0.0058}
ç\ê¨ê}
ç\ê¨îzíuê}
Valve System
Part layout
JP30109090402007
SAPH301090900122
13706 Crosshead 13840 Rocker arm assembly

13707 Tappet 13901 Rocker shaft
13711 Intake valve 13951 Rocker arm support
13715 Exhaust valve 13951B Rocker arm support
13731 Outer valve spring 13951C Rocker arm support
13732 Inner valve spring 900126 Valve spring retainer
13734 Lower spring seat 900129 Collar
13735 Upper spring seat S1306 Push rod
13830 Rocker arm assembly
Tightening torque
900125 52N⋅m{530kgf⋅cm,38 lbf⋅ft} 9219A Rocker arm:44N⋅m{450kgf⋅cm, 32lbf⋅ft}
9219A Crosshead:28N⋅m{290kgf⋅cm,20 lbf⋅ft}
êÆî óvóÃ
Overhaul of valve system

JP30109090702010
1. Removal of rocker arm assembly
(1) Loosen the lock nut and turn the adjusting screw
completely.
! CAUTION • Removal without turning the adjusting screw

may bend the rocker shaft.
SAPH301090900123
(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm shaft.

SAPH301090900124
(3) Pull out the push rod.
! CAUTION • Do not pull out the tappet together with the

push rod.
SAPH301090900125
2. Inspection of rocker arm oil clearance
(1) Measure the outer diameter of the rocker shaft using a

micrometer.
28{1.102} 27.92{1.0992}
SAPH301090900126
(2) Measure the rocker arm bushing inner diameter using a

cylinder gauge.
28{1.102} 28.08{1.1055}

rocker shaft and the inner diameter of the rocker arm
bushing. If it is beyond the standard value, replace the
SAPH301090900127 rocker shaft or the rocker arm bushing.
0.044 - 0.120
{0.0018 - 0.0393}
3. Removal of valve spring
(1) Compress the valve spring from the cylinder head using a
special tool and remove the valve spring retainer.
Special tool : 09470-1120 Valve spring press
SAPH301090900128
(2) Remove the intake and exhaust valves.
! CAUTION • Attach a tag with the applicable cylinder

number to the valve so that combinations of
the valve and the cylinder head may not be
mixed.
SAPH301090900129
4. Replacement of valve stem seal

Stem seal
Special tools
(1) After removing the valve stem seal, assemble the valve
Valve spring
spring lower seat. Apply engine oil to the lip and the inner
lower seat
surface of the stem seal. Strike the valve stem seal using
a special tool until the special tool comes in contact with
the valve spring lower seat.
Special tool : 09472-1870 Valve stem seal press
! CAUTION • After assembly of the stem seal, make sure

that there is no deformation, crack or
Spring inclination of the rubber, or disconnection of
Oil application
Rubber the spring.
Stem seal
SAPH301090900130
5. Inspection of valve spring

Clearance A
(1) Measure squareness of the valve spring using a square or
a thickness gauge. If it is beyond the operation limit
(clearance A), replace the valve spring.
Clearance A (mm{in.}) 2.0{0.0787}
SAPH301090900131
(2) Measure the set load of the valve spring using a spring
tester. If it is out of the operation limit, replace the valve
spring.

(mm{in.}) (mm{in.})
Set length Intake 54.1{2.1299} —

(mm{in.}) Exhaust 54.7{2.1535} —
Inner
SAPH301090900132
Set load Intake 166.7{17, 37.5} 153{15.6, 34.4}
(N{kgf,lbf}) Exhaust 160.8{16.4, 36.2} 147.1{15.0, 33.0}
Set length Intake 58.1{2.2874} —

(mm{in.}) Exhaust 58.7{2.3110} —
Outer
Set load Intake 389.3{39.7, 87.5} 357.9{36.5, 80.5}
(N{kgf,lbf}) Exhaust 382.5{39.0, 86.0} 351.1{35.8, 78.9}
(3) Measure the free length of the valve spring using a vernier
calipers. If it is out of the operation limit, replace the valve
spring.

(mm{in.}) (mm{in.})
Inner valve spring 72.0{2.8346} 70.0{2.7559}
Outer valve spring 93.0{3.6614} 91.0{3.5826}

SAPH301090900133
6. Inspection of spring seat
(1) Check for wear and damage of the spring seats (upper
and lower). If a faulty condition is found, replace the seats.
SAPH301090900134
7. Inspection of oil clearance between valve guide and valve

stem
(1) Measure the outer diameter of the valve stem using a

micrometer.
Standard
Operation
value
limit (mm{in.})
(mm{in.})
Intake valve stem 8{0.315} 7.88{0.3102}
SAPH301090900135
Exhaust valve stem 8{0.315} 7.88{0.3102}
(2) Measure the valve guide inner diameter using a cylinder

gauge.
Standard value
(mm{in.})
Intake valve guide 8{0.315}

Exhaust valve guide 8{0.315}
SAPH301090900136
(3) Calculate the difference between the valve stem outer

diameter and the valve guide inner diameter. If it is beyond
the operation limit, replace the valve stem or the valve

guide.

#

$ Standard Standard Operation
value clearance limit
(mm{ni.}) (mm{in.}) (mm{in.})
%
Stem outer 0.12
SAPH301090900137 8{0.315} 0.040 - 0.077
diameter {0.0047}
Intake {0.0016 -
Guide inner
8{0.315} 0.0030} Following
diameter
Stem outer 0.14

8{0.315} 0.057 - 0.094
diameter {0.0055}
Exhaust {0.0023 -
Guide inner
8{0.315} 0.0037} Following
diameter
Guide inner Part A Part B Part C

diameter (mm{in.}) (mm{in.}) (mm{in.})
Intake 7.88{0.3102} 7.88{0.3102} 7.82{0.3079}
Exhaust 7.86{0.3094} 7.86{0.3094} 7.80{0.3071}
8. Inspection of valve sink

Valve sink
(1) Measure valve sink using a straight edge, thickness
gauge or dial gauge. If it is beyond the operation limit,
replace the valve or the valve seat.

(mm{in.}) (mm{in.})
Intake -0.05 - 0.35

0.7{0.0275}
valve sink {-0.0020 - 0.0137}
SAPH301090900138
Exhaust 0.55 - 0.95

1.3{0.0511}
valve sink {0.0217 - 0.0374}
9. Inspection of tappet oil clearance
(1) Measure the tappet guide inner diameter using a

micrometer and measure the tappet guide inner diameter
using a cylinder gauge.
Standard value
(mm{in.})
Tappet outer diameter 28{1.102}
SAPH301090900139 Tappet guide inner

28{1.102}
diameter
(2) Calculate the difference between the tappet outer

diameter and the tappet guide inner diameter. If it is
beyond the operation limit, replace each part.
0.020 - 0.066
0.10{0.0039}
{0.0008 - 0.0260}
SAPH301090900140
10. Installation of valve and valve spring
(1) Place the lower seat, valve spring and upper seat on the
cylinder head in the order listed.
(2) Compress the valve spring using a special tool and install
the valve spring retainer.
Special tool : 09470-1120 Valve spring press
! CAUTION • Apply engine oil to the contact surface of

each part before assembly.
SAPH301090900128
• Be sure to assemble each valve at the original
cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for
assembly.
• Check for scratch on the valve stem seal
when the valve is reused.
11. Installation of rocker arm assembly
(1) Apply engine oil to both ends of the push rod and insert it
into the cylinder block.
SAPH301090900141
(2) Apply engine oil to the valve stem head.
(3) Apply engine oil to the crosshead mounting area.

(4) Attach the crosshead.
! CAUTION • Make sure that the crosshead is correctly

placed on the valve.
Correct Wrong
SAPH301090900142
(5) Place the rocker arm assembly on the cylinder head and
temporarily tighten the 12 support bolts until it comes in
contact with the cylinder head upper surface in the order
! CAUTION • If an engine retarder is equipped, long bolts

for tightening the engine retarder are used for
the 4, 6, 10, 12 areas in the figure. Use
substitute bolts (9001-24352). (Remove this
SAPH301090900143
bolt when installing the engine retarder.)
• Turn all adjusting screws and place the rocker
arm assembly.
(6) Tighten 12 support bolts in the order shown in the figure.

(7) If an engine retarder is equipped, remove the substitute
bolts 4, 6, 10, 12 that tighten the rocker arm support.
NOTICE • Install the engine retarder on the area where

the substitute bolt is used.
ëïíÖóvóÃçÄñ⁄
Adjustment of valve clearance

JP30109090706001
! CAUTION • Make sure that the bolts around head bolts

are tightened to the specified tightening
torque before adjustment.
• When an engine retarder is installed, remove
the engine retarder, use substitute bolts to
tighten the rocker arm support to the
specified tightening torque, and then adjust
the valve clearance.
• Make sure that there is no dirt on the
crosshead, the valve stem and the push rod.
1. Adjustment of valve clearance

Coupling bolt
(1) Turn the crankshaft and check that the timing mark at the
Stamp line Flywheel housing flywheel inspection window is at "1/6" and that the key on
inspection window
the shaft of the supply pump bearing case is pointing up
to confirm that the No. 1 cylinder is at the compression top
16 dead center.
! CAUTION • If the timing mark is at "1/6", but the shaft key

Half coupling bolt Pointer
is pointing down, the No. 6 cylinder is at the
SAPH301090900144
compression top dead center. In this case,
turn the crankshaft another turn to set the No.
1 cylinder to the compression top dead
center.
(2) When the No. 1 cylinder is at the compression top dead

center, the valves marked by { in the following table can
be adjusted, and when the No. 6 cylinder is at the
compression top dead center, the valves marked by ●
can be adjusted.
At the time of No. 1 At the time of No. 6

Cylinder Valve cylinder at the cylinder at the
No. layout compression top compression top
dead center dead center
Suction {
1
Exhaust {
Suction ●
2
Exhaust {
Suction {
3
Exhaust ●
Suction ●
4
Exhaust {
Suction {
5
Exhaust ●
Suction ●
6
Exhaust ●
(3) Loosen the adjusting screw and the lock nut of the
crosshead completely.
14 mm{0.5512in.}
or more • Provide the adjusting screw protrusion of 14
! CAUTION
mm{0.5512 in.} or more from the top surface
of the crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
SAPH301090900145
(4) Insert a thickness gauge between the rocker arm and the
Thickness gauge
crosshead and adjust the clearance with the adjusting
Adjustment screw of the rocker arm. Tighten the lock nut.
Standard value IN 0.45{0.0177}

There is a (cold engine)
clearance. (mm{in.}) EX 0.60{0.0236}
Contact

SAPH301090900146
(5) Loosen the adjusting screw of the crosshead with the

Start thickness gauge inserted. Make sure that feel on the
Feel of thickness gauge
thickness gauge is not lighter.

(Do not move.) Nut fixing position
! CAUTION • If it becomes lighter, make adjustments again

(Correct contact) from the beginning.
Feel does not change.

Adjusting screen loosening amount Large
SAPH301090900147
(6) Tighten the adjusting screw of the crosshead until the

Thickness gauge thickness gauge does not move.
Adjustment
Contact Contact
SAPH301090900148
(7) While loosening the adjusting screw of the crosshead

Start gradually, tighten the lock nut of the crosshead at the
Feel of thickness gauge
position where feel on the thickness gauge is appropriate.

(Do not move.) Nut fixing position
(Correct contact)
! CAUTION • Do not over-loosen the adjusting screw. Over-
loosening of the adjusting screw reproduces
Feel does not change. the original status. Although feel on the
Adjusting screen loosening amount Large thickness gauge is appropriate, there is a
SAPH301090900149 clearance between the adjusting screw and
the valve of the crosshead. Correct
adjustment is not allowed.
EXHAUST 10–1
ENGINE
10 EXHAUST
Setup layout
Layout
Exhaust Manifold...................................................... 10-2

Part layout (typical example)................................. 10-2
Replacement......................................................... 10-3
10
10–2 EXHAUST
Exhaust Manifold
JP30109100402001
SAPH301091000001
17044 Insulator 17105 Exhaust manifold

17044A Insulator 17118 Exhaust manifold bracket
17104 Gasket* 17271 Insulator
17104D Gasket*

Tightening torque
9209A 59⋅m{600kgf⋅cm, 44 lbf⋅ft} 9029B 68.5⋅m{700kgf⋅cm, 50 lbf⋅ft}
9068-10700 68.5⋅m{700kgf⋅cm, 50 lbf⋅ft}
Service procedure
Replacement procedure item
EXHAUST 10–3
Replacement
JP30109100704001
1. Removal of exhaust manifold
(1) Remove the turbocharger.

(2) Remove the insulator.
(3) Remove the exhaust manifold bracket.
(4) Remove the exhaust manifold.
2. Replacement of stud bolt

(1) Remove dirt (e.g. sealant) at the female thread of the
cylinder head and clean the thread again with tap (M10 x
SAPH301091000002
1.5).
(2) Tighten the new stud bolt.
! CAUTION • Excessive tightening with overtorque may

cause crack in the cylinder head.
3. Installation of exhaust manifold

(1) Install a new gasket and align the exhaust manifold with
the cylinder head.
22 20 18 16 14 12 10 8 6 4 2 (2) Tighten the nuts from the top to the bottom and from the
1 right to the left.
23 21 19 17 15 13 11 9 7 5 3 Tightening torque : 44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft}
SAPH301091000003
(3) Tighten the nuts again from the top to the bottom and from
the right to the left.

1 3 5 7 9 11 13 15 17 19 21
23 ! CAUTION • Be sure to retighten it.
2 4 6 8 10 12 14 16 18 20 22
SAPH301091000004
10–4 EXHAUST
(4) For the exhaust manifold bracket, fix the eight bolts
Exhaust
manifold temporarily, push the bracket against the cylinder block,
Bracket center tighten the bolt at the manifold side and then tighten the
Spacer
bolt at the cylinder block side.
Bolt Cylinder head
Tightening torque : 68.5 N⋅m {700 kgf⋅cm, 50 lbf⋅ft}
Cylinder block
Bolt
(5) Connect the insulator.
Fix bracket and (8) bolts temporarily. (6) Install the turbocharger.
Push the
bracket.
Tighten bolt.
(Manifold side)
Tighten bolt.
(Block side)
SAPH301091000005
COOLING 11–1
ENGINE
11 COOLING
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Cooling System ........................................................ 11-2

Cooling system drawing........................................ 11-2
Part layout ............................................................. 11-3
Replacement of coolant pump .............................. 11-5
Replacement of thermostat case .......................... 11-5
Inspection of thermostat ....................................... 11-6
Replacement of fan drive, tension pulley .............. 11-7
Replacement of cooling fan, fan spacer................ 11-9
11
11–2 COOLING
Cooling System
Cooling system drawing
jp30109110804001
Reservoir
Coolant temperature gauge
Radiator cap
Thermostat case
Cylinder head
Thermostat
Radiator
Cylinder block
Car heater
Coolant pump Oil cooler
Drain cock
Drain cock
SAPH301091100001
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COOLING 11–3
Part layout
jp30109110402001
Water pump, Thermostat
SAPH301091100002
16100 Coolant pump 16332 Coolant pump outlet pipe

16173 Coolant pump pulley 900234 Coolant hose
16303 Thermostat case 9644A O-ring*
16308 Coolant pump pulley 9645A O-ring*
16323 Thermostat case cover 9655-14140 O-ring*
16325 Gasket* 9778-04620 Clamp
16325A Gasket* 9851A O-ring*

Tightening torque
9068-10800 55N⋅m {560 kgf⋅cm.40 lbf⋅ft} 9068-10950 55N⋅m {560 kgf⋅cm,40 lbf⋅ft}
11–4 COOLING
Fan drive system
SAPH301091100003
16365 Fan spacer 9201-14110 Pulley lock nut

16371 Fan drive pulley 9644C O-ring*
16384 Tension pulley 9645B O-ring*
16390 Fan drive assembly 9851C O-ring*
16630 Tension pulley assembly 9851D O-ring*
88444 Tension pulley bracket S1637 Fan drive
9189A Adjusting bolt SZ910 Fan belt

Tightening torque
9068-10750 55 N⋅m {560 kgf⋅cm,40 lbf⋅ft} 9201-14110 108 N⋅m {1,100 kgf⋅cm,80 lbf⋅ft}
9201-10080 60 N⋅m {610 kgf⋅cm,44 lbf⋅ft} 9419A 47 N⋅m {480 kgf⋅cm,35 lbf⋅ft}
êÆî óvóÃ
COOLING 11–5
Replacement of coolant pump

jp30109110704004
1. Removal of coolant pump

Coolant
pump Hose (1) Loosen the coolant hose clamp, remove bolts and remove
the coolant pump.
2. Installation of coolant pump

(1) Insert the coolant hose into the coolant pump and install
the coolant pump on the timing gear case.
(2) Tighten the coolant hose clamp.
SAPH301091100004
Replacement of thermostat case

jp30109110704003
1. Removal of thermostat case

Hose Thermostat case
(1) Remove the coolant pump.
(2) Remove the coolant hose clamp, remove bolts and
remove the thermostat case.
2. Installation of thermostat case

(1) Insert the coolant hose into the thermostat case, replace
the gasket with a new one and install the thermostat case
on the cylinder head.
SAPH301091100005
(2) Tighten the coolant hose clamp.
(3) Replace the gasket with a new one and install the coolant
pipe.
(4) Replace the coolant pump.
11–6 COOLING
Inspection of thermostat
jp30109110703001
1. Individual inspection of thermostat

Wire Thermometer (1) Put the thermostat in water as shown in the figure and
heat it.
! CAUTION • Support the thermostat in the center to

prevent approach to the heat source.
Thermostat Valve lift • Stir the water well so that water temperature
in the container may be uniform.
Heat source
SAPH301091100006
(2) Measure the temperature (valve opening temperature)

T1 : Valve opening temperature (start of valve opening) that opens the thermostat valve.
T2: Full open lift inspection temperature
10mm Thermostat valve

{0.394in.}
opening temperature
74.5 - 78.5{166.1 - 173.3}
Valve lift
standard value :
T1(°C{°F})
0°C{32°F} 10°C Temperature
T1°C{°F} T2°C{°F}
{50°F} • The thermostat valve opening temperature
NOTICE
SAPH301091100007
(T1) is stamped on the thermostat seat.
(3) Increase the water temperature to 90 °C and measure the

lift of the thermostat valve.
Thermostat valve full

open lift inspection Valve lift : L (mm{in.})
L1 At cold open
L2 : (T2) °C {°F} temperature : T2 (°C{°F})
L : Valve lift
L 90{194} 10{0.394} or more
L 1
L 2
(4) Put the full open thermostat valve in water at normal
SAPH301091100008
temperature. Make sure that the thermostat valve closes
completely within 5 minutes.
(5) If faulty item is found with the inspection above, replace
the thermostat.
COOLING 11–7
Replacement of fan drive, tension pulley

jp30109110704001
1. Removal of fan drive, tension pulley

(1) Remove the cooling fan.
(2) The pulley fixing nut of the tension pulley, loosen the
adjusting bolt and remove the V belt.
V belt
Fixing nut
Tension pulley
Adjusting bolt
SAPH301091100009
(3) Loosen the four fan drive mounting bolts and remove the
(a) fan drive(a) from the timing gear case cover.
(4) Remove the tension pulley(b).
View A (b)
SAPH301091100010
2. Installation of fan drive, tension pulley

(1) Install the tension pulley assembly on the timing gear
case cover with the tension pulley bracket.
Install the pulley fixing nut temporarily.
Tension pulley
SAPH301091100011
(2) Install two new O–rings on the O–ring groove at the timing
case cover side and install the fan drive assembly on the
timing gear case cover.
O-ring
SAPH301091100012
11–8 COOLING
(3) Fix the V belt temporarily.

(4) Install the cooling fan.
Tightening torque : 66±7 N⋅m {673±71 kgf⋅cm, 487±
5lbf⋅ft}
3. Adjustment of fan belt

(1) Loosen the tension pulley fixing nut to the degree that the
pulley moves freely.
(2) Adjust it with adjusting bolt B so that the fan belt tension
between the tension pulley and the fan drive pulley is the
standard value.
Tension pulley
fixing nut When a new belt
Fan drive Item In inspection
pulley is installed
9 - 11mm 12 - 14mm
Deflection {0.3543 - {0.4724 -
Tension pulley
Adjusting bolt 0.4331in.} 0.5512in.}
SAPH301091100013 520 - 610 N 340 - 440 N
Tension {53 - 62 kgf, 117 {35 - 45 kgf,76 -
- 137 lbf} 90 lbf}
Special tool : 09444-1210 Compression gauge (used

at the time of measuring the deflection
amount) [ Reference push force 98N
{10kgf, 22lbf} ]
95506-00090 (Denso part No.) Belt
tension gauge (used at the time of
measuring the tension force)
Special tool : 09444-1210 Compression gauge

[ Reference push force 98N {10kgf,
22lbf} ]
! CAUTION • If the fan belt is replaced with a new one, it

becomes loose due to initial fitting. Run the
engine for three to five minutes and adjust the
tension of the belt again.
NOTICE • At the time of inspection, the new fan belt has

reached the value after complete initial
stretching. A new fan belt completes initial
stretching after running the engine for
approximately two hours.
(3) After adjustment, tighten the tension pulley fixing nut and
fix the pulley.
COOLING 11–9
Replacement of cooling fan, fan spacer

jp30109110704002
1. Removal of cooling fan

(1) Remove the cooling fan from fan spacer.
Fan spacer
Cooling fan
SAPH301091100014
(2) Remove nuts and remove the fan spacer from the fan
drive pulley.
Fan spacer Fan drive pulley
SAPH301091100015
2. Installation of fan spacer

(1) Install the fan spacer on the fan drive pulley.
3. Installation of cooling fan

(1) Install the fan spacer on the cooling fan.
Tightening torque : 66±7 N⋅m {673±71 kgf⋅cm,49±5
lbf⋅ft}
(2) Fix the fan belt temporarily.
LUBRICATION 12–1
ENGINE
12 LUBRICATION
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Lubrication System .................................................. 12-2

System drawing .................................................... 12-2
Oil Pump.................................................................... 12-3
Part layout ............................................................. 12-3
Replacement......................................................... 12-5
Overhaul ............................................................... 12-7
Oil Filter ................................................................... 12-10
Part layout ........................................................... 12-10
Replacement....................................................... 12-12
Oil cooler ................................................................. 12-16
Part layout ........................................................... 12-16
Replacement....................................................... 12-20
Overhaul ............................................................. 12-23
Oil pan ..................................................................... 12-26
Part layout ........................................................... 12-26
Replacement....................................................... 12-27
12
12–2 LUBRICATION
Lubrication System
System drawing
JP30109120804001
Rocker arm
Sub oil hole Crosshead

Liner circumference cooling
Check valve
To oil pan
Cam bearing circumference groove
Main oil hole

Sub oil hole for liner cooling
Piston
Cooling jet Bushing rod
Check valve (each cylinder)
Crankshaft Check Tappet

valve
Main oil hole
Camshaft
To idle gear No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Camshaft
Air compressor
To idle shaft
To valve system
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Supply pump
Filter warning switch To supply pump drive unit
Safety valve
Oil cooler Safety valve Pressure gauge

Air compressor
Relief valve
Oil filter
To oil pan
To oil pan
Bypass
Oil pump
Safety valve
Oil strainer To oil pan Turbocharger
Turbocharger check valve
Air compressor idle gear
SAPH301091200001
LUBRICATION 12–3
Oil Pump
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Part layout
JP30109120402001
SAPH301091200002
15110 Oil pump 9644E O-ring*

15104 Oil strainer 9851A O-ring*
15431 Oil feed pipe

Tightening torque
9181-08200 21N⋅m{210kgf⋅cm,15 lbf⋅ft} 9411-10451 47N⋅m{480kgf⋅cm,35 lbf⋅ft}
9181-08500 23N⋅m{230kgf⋅cm,17 lbf⋅ft} 9411-14902 113N⋅m{1,150kgf⋅cm,83 lbf⋅ft}
9181-08550 21N⋅m{210kgf⋅cm,15 lbf⋅ft}
12–4 LUBRICATION
SAPH301091200003
15101 Oil pump body assembly 15132 Relief valve spring

15107 Driven gear 15133 Plug
15110 Oil pump 900700 Bolt A
15115 Cover 9061-10350 Bolt B
15131 Relief valve
Tightening torque
15133 83.4±4.9N⋅m{850±50kgf⋅cm,62±4lbf⋅ft} 9061-10350 44.0±4.9N⋅m{449±50kgf⋅cm,32±4lbf⋅ft}
900700 22.6±2.9N⋅m{230±30kgf⋅cm,17±2lbf⋅ft}
LUBRICATION 12–5
êÆî óvóÃ
Replacement
JP30109120704002
1. Removal of oil pump

(1) Remove bolts and remove the oil pan.
SAPH301091200004
(2) Remove bolts and remove the oil strainer.
SAPH301091200005
(3) Remove bolts and remove the oil feed pipe and the oil
pump.
SAPH301091200006
2. Installation of oil pump

(1) Replace the O-ring with a new one and install the oil pump
and oil feed pipe.
Tightening torque :
47 N⋅m {480 kgf⋅cm, 35 lbf⋅ft} (Oil pump: M10)
113 N⋅m {1,150 kgf⋅cm, 83 lbf⋅ft} (Oil pump: M14)
21 N⋅m {210 kgf⋅cm, 15 lbf⋅ft} (Oil feed pipe: M8)
! CAUTION • In installation, be careful that the O-ring may

not be caught.
SAPH301091200006
12–6 LUBRICATION
(2) Replace the O-ring with a new one and install the oil
strainer.

not be caught.
SAPH301091200005
3. Installation of oil pan

"Reference: Lubrication, Oil pan, Replacement"
LUBRICATION 12–7
êÆî óvóÃ
Overhaul
JP30109120702001
1. Disassembly of oil pump

Plug
(1) Remove the plug and remove the spring and relief valve.
Spring
Relief valve ! CAUTION • When the plug is removed, the spring and the
relief valve may eject out.
SAPH301091200007
(2) Remove bolts and remove the oil pump case cover.
(3) Remove the driven gear.
! CAUTION • Do not damage the joint surface during work.
Driven gear
SAPH301091200008
2. Inspection of oil pump

(1) Inspection of clearance between drive gear and oil pump
case (tip clearance)
a. Measure the clearance between the drive gear and the

oil pump case using a thickness gauge. If it is beyond
the operation limit, replace the oil pump assembly.

Drive gear
0.038 - 0.115
0.17{0.0066}
SAPH301091200009 {0.0015 - 0.0045}
(2) Inspection of side clearance between drive gear and oil

pump case (end play)
Drive gear
a. Place the straight edge on the case and measure the
drive gear width and the oil pump case depth using a
depth gauge.
b. Calculate the difference between the width of the drive
gear and the oil pump case depth. If it is beyond the
operation limit, replace the oil pump assembly.
SAPH301091200010 Standard value (mm{in.}) Operation limit (mm{in.})

0.045 - 0.105
0.15{0.0059}
{0.0018 - 0.0041}
12–8 LUBRICATION
(3) Inspection of clearance of drive gear shaft outer diameter

and drive gear side hole inner diameter of oil pump case
cover
a. Measure the outer diameter of the drive gear shaft

using a micrometer and measure the drive gear side
hole inner diameter of the oil pump case cover using a
micrometer.
Drive gear shaft Standard value

Measuring area
SAPH301091200011 (mm{in.})
Outer diameter of drive gear shaft 20{0.787}
Drive gear side hole inner
20{0.787}
diameter of oil pump case cover
b. Calculate the difference between the outer diameter of

the drive gear shaft and the drive gear side hole inner
Oil pump
case cover diameter of the oil pump case cover. If it is beyond the
operation limit, replace the oil pump case cover.

0.040 - 0.074
0.17{0.0066}
{0.0016 - 0.0029}
SAPH301091200012
(4) Inspection of oil clearance between outer diameter of

driven gear shaft and inner diameter of driven gear
bushing
a. Measure the outer diameter of the driven gear shaft

using a micrometer and measure the inner diameter of
Driven gear shaft
the driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
SAPH301091200013 Outer diameter of driven gear
20{0.787}
shaft
Inner diameter of driven gear
20{0.787}
bushing
b. Calculate the difference between the outer diameter of

the driven gear shaft and the inner diameter of the
driven gear bushing. If it is beyond the operation limit,
replace the oil pump or the driven gear.

0.040 - 0.074
0.17{0.0066}
{0.0016 - 0.0029}
SAPH301091200014
LUBRICATION 12–9
(5) Inspection of drive gear backlash
a. Fix the oil pump with a vice.

b. Measure backlash between the drive gear and the
driven gear using a dial gauge. If it is beyond the
operation limit, replace the oil pump.

0.072 - 0.208
Drive gear 0.4{0.0157}
{0.0029 - 0.0081}
SAPH301091200015
Plug
3. Assembly of oil pump
(1) Install the relief valve, spring and plug on the oil pump
Spring
case cover.
Relief valve
Tightening torque : 83.4 ± 4.9 N⋅m {850 ± 50 kgf⋅cm, 62
± 48 lbf⋅ft}
SAPH301091200016
(2) Apply engine oil to the gear inner surface and the shaft,
align the oil pump body dowel pin and assemble the oil
pump.
Tightening torque :
22.6 ± 2.9 N⋅m {230 ± 30 kgf⋅cm, 17 ± 2 lbf⋅ft}(Bolt A)
44.0 ± 4.9 N⋅m {449 ± 50 kgf⋅cm, 32 ± 4 lbf⋅ft}(Bolt B)
ç\ê¨ê}
ç\ê¨îzíuê}
#
$
SAPH301091200017
12–10 LUBRICATION
Oil Filter
Part layout
JP30109120402003
SAPH301091200018
15600 Oil filter assembly 9655-12100 Gasket*

15671 Oil filter bracket 9644A O-ring*
23201 Oil hose(Bypass) 9644B O-ring*
23201A Oil hose 9739A Joint
23201B Oil hose

Tightening torque
23301A 196N⋅m{2,000kgf⋅cm,145 lbf⋅ft} 9411A-10002 47N⋅m{480kgf⋅cm,35 lbf⋅ft}
23301B 196N⋅m{2,000kgf⋅cm,145 lbf⋅ft} 9419A 47N⋅m{480kgf⋅cm,35 lbf⋅ft}
9019A 25N⋅m{255kgf⋅cm,18 lbf⋅ft}
LUBRICATION 12–11
SAPH301091200019
15600 Oil filter assembly 15643 Drain plug

15604 Safety valve 15651 Center bolt
15607 Oil filter element 15651A Center bolt
15607A Oil filter element 15660 Oil filter warning switch
15612 Oil filter element cover 15691 O-ring*
15614 Cover 15691A O-ring*
15614A Cover 9851C O-ring*
15615 Spring 9851D O-ring*
15629 Gasket* 9851E O-ring*
15629A Gasket*

Tightening torque
15643 17.2±2.5N⋅m{175±25kgf⋅cm,13±2lbf⋅ft} 15651A 44±4.9N⋅m{450±50kgf⋅cm,32±4lbf⋅ft}
15651 44±4.9N⋅m{450±50kgf⋅cm,32±4lbf⋅ft}
12–12 LUBRICATION
êÆî óvóÃ
Replacement
JP30109120704001
NOTICE • The shape of brackets and hose joints in the

illustrations and the hose routing differ
according to the model.
1. Engine oil draining
(1) Prepare a tray or another container to receive engine oil,

loosen the drain plug at the lower end of the oil filter, and
drain the engine oil.
! CAUTION • When draining the engine oil, follow the

Center
bolt specified method (waste processing) or an
environment-friendly method.
Center
bolt Drain plug
SAPH301091200020
2. Removal of oil filter element
(1) Loosen the center bolt and remove the cover.
SAPH301091200021
(2) Remove the oil filter element.

O-ring
O-ring Cover
! CAUTION • Make sure that there is no O-ring left at the oil
Cover cooler case.
Oil filter element
Center bolt Center bolt

SAPH301091200043
3. Disconnecting the oil hose

Union bolt
! CAUTION • When disconnecting the oil hose, receive the

Joint oil remaining in the hose in a container and
(Fix) plug the end of the hose with a shop towel or
similar.
(1) Secure the joint securely with a hand vise or similar,

loosen the nut of the oil hose, and disconnect the oil hose
Oil hose
from the oil filter assembly. (Inlet and outlet)
SAPH301091200022
LUBRICATION 12–13
! CAUTION • When working with two spanners, use

spanners with the same length for the
moment arm to make spanner control easier.
NOTICE • Install the joint on the oil filter bracket.
(2) Loosen the union bolt and disconnect the oil hose
(bypass) from the oil filter assembly. Remove the two
gaskets.
4. Removal of the oil filter element cover (when required)

Bolt (two)
Oil filter element cover (1) Disconnect the oil filter warning (clogging alarm)
connector.
(2) Loosen the bolt and remove the oil filter element cover
from the oil filter bracket.
(3) Remove the three O-rings from the oil filter element cover
or the oil filter bracket.
Bolt
Oil filter warning switch
SAPH301091200023
5. Removal of the oil filter bracket (when required)
(1) Loosen the bolt and remove the oil filter bracket.
Bolt
Oil filter bracket.

SAPH301091200024
6. Installation of the oil filter bracket (when it has been

removed)
(1) Install the oil filter bracket with a bolt on the oil filter
bracket.
Bolt
Oil filter bracket.

SAPH301091200024
12–14 LUBRICATION
7. Installation of the oil filter element cover (when it has been

Bolt (two)
Oil filter element cover
removed)
(1) Replace the O-ring by a new one and install the oil filter
element cover with a bolt on the oil filter bracket.
(2) Connect the oil filter warning (clogging alarm) connector.
Bolt
SAPH301091200023
8. Connecting the oil hose

Union bolt
tighten the nut of the oil hose, and connect the oil hose to
Joint
(Fix) the oil filter assembly. (Inlet and outlet)
(PF1)

Oil hose spanners with the same length for the
SAPH301091200025 moment arm to make spanner control easier.
• If the joint part has been loosened, replace
the O-ring by a new one.
(2) Replace the gasket by a new one and connect the oil
hose(bypass) with a union bolt to the oil filter assembly.
Tightening torque : 26.5 N⋅m {270 kgf⋅cm, 20 lbf⋅ft}
9. Installation of oil filter element

O-ring
(1) Remove contamination or foreign matter on the mounting
O-ring Cover
surface of the oil filter element cover.
Cover
(2) Apply engine oil thinly to the O-ring (large⋅small) of a new
oil filter element.
(3) Install the oil filter element.
Oil filter element
(4) Tighten the center bolt.
Tightening
Center bolt Center bolt
torque:44±4.9N⋅m{450±50kgf⋅cm,32±4lbf⋅ft}
SAPH301091200026
LUBRICATION 12–15
(5) Replace the O–ring of the drain plug with a new one for
installation.
Tightening
torque:17.2±2.5N⋅m{175±25kgf⋅cm,13±2lbf⋅ft}

not be damaged by distortion.
• Do not reuse the O-ring.
NOTICE • Assemble the full flow side oil filter element

so that the top and the bottom are identified
correctly.
• The oil filter element on the bypass side can

be installed in either orientation, as it has the
Bypass side Full flow side same shape at top and bottom.
SAPH301091200027
10. Engine oil filling

(1) Confirm that the drain plug at the lower end of the oil filter
has been tightened, and then fill in engine oil while looking
at the oil level gauge.
Reference: "Engine removal/installation, work after
installation, engine oil inspection"
12–16 LUBRICATION
Oil cooler
ç\ê¨ê}
ç\ê¨îzíuê}
Part layout
JP30109120402005
SAPH301091200028
15431A Coolant pipe 9644E O-ring*

15710 Oil cooler assembly 9659A Gasket*
9644A O-ring* 9659B Gasket*
9644D O-ring*

Tightening torque
900124A 39N⋅m{400kgf⋅cm,29 lbf⋅ft} 9411-10501 55N⋅m{560kgf⋅cm,40 lbf⋅ft}
9191-08002 25N⋅m{250kgf⋅cm,18 lbf⋅ft} 9419A 47N⋅m{480kgf⋅cm,35 lbf⋅ft}
LUBRICATION 12–17
SAPH301091200029
23201 Oil hose(Bypass) 9644A O-ring*

23201A Oil hose 9655-12100 Gasket*
23201B Oil hose 9739A Joint
90404A Joint

Tightening torque
23301A 196N⋅m{2,000kgf⋅cm,145 lbf⋅ft} 9019A 25N⋅m{255kgf⋅cm,18 lbf⋅ft}
23301B 196N⋅m{2,000kgf⋅cm,145 lbf⋅ft}
12–18 LUBRICATION
SAPH301091200030
24106 Oil pipe 9655-14140 Gasket*

Tightening torque
9019D 25N⋅m{255kgf⋅cm,18 lbf⋅ft} 9068-10180 55N⋅m{560kgf⋅cm,40 lbf⋅ft}
LUBRICATION 12–19
SAPH301091200031
15612 Oil cooler cap 9851B O-ring*

15621 Gasket* 9851C O-ring*
15643 Drain plug 9851D O-ring*
15662 Valve cap 9851E O-ring*
15675 Relief valve 9851F O-ring*
15710 Oil cooler assembly 9851G O-ring*
15712 Oil cooler element 9851H O-ring*
15714 Safety valve 9851J O-ring*
15715 Gasket* 9851K O-ring*
15716 Valve cap 9851L O-ring*
15717 Gasket* 9851M O-ring*
15717A Gasket* 9851N O-ring*
15721 Cover 9851P O-ring*
15726 Valve cap 9851Q O-ring*
15726A Valve cap S1148 Drain plug
15726B Plug S1565 Center bolt
15726C Plug S1571 Plug
23314 Plug S1572 Plug
23322 Plug S1572A Oil cooler cover
9851A O-ring* S1572B Oil cooler cover
Tightening torque
9191-08301 19.6±4.9N⋅m{200±50kgf⋅cm,14±4lbf⋅ft} 9191-08401 19.6±4.9N⋅m{200±50kgf⋅cm,14±4lbf⋅ft}
12–20 LUBRICATION
êÆî óvóÃ
Replacement
JP30109120702003
NOTICE • The shape of brackets and hose joints in the

illustrations and the hose routing differ
according to the model.
1. Removal of pipes
(1) Disconnect all pipes connected to the oil cooler.
! CAUTION • Loosen the bolts after preparing containers to

receive cooling water or engine oil
respectively.
(2) Remove O-rings and gaskets.
SAPH301091200032
2. Disconnecting the oil hoses
! CAUTION • When disconnecting the oil hose, receive the

oil remaining in the hose in a container and
plug the end of the hose with a shop towel or
similar.

loosen the nut of the oil hose, and disconnect the oil hose
from the oil filter assembly. (Inlet and outlet)
Oil hose
(Bypass)
moment arm to make spanner control easier.
NOTICE • Install the joint on the oil filter bracket.
(2) Loosen the union bolt and disconnect the oil hose
(Bypass) from the oil filter assembly.Remove two gaskets.
Lock 3. Oil cooler removal

(1) Remove the bolts and take off the oil cooler.
SAPH301091200033
LUBRICATION 12–21
4. Installation of oil cooler
(1) Use a scraper to remove any dirt from the connection

surfaces of oil cooler and cylinder block.
(2) Install new O-rings in the O-ring installation grooves of the
oil cooler.
! CAUTION • At the time of installation, take care that the

O-ring is not damaged by twisting.
• Install O-rings on the oil cooler side.
SAPH301091200034
(3) Insert positioning stud bolts in the cylinder block mounting

holes and install the oil cooler.
(4) After temporary tightening of the bolts, remove the

positioning stud bolts and tighten the bolts securely.
Tightening torque
: 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}(M8)
: 47 N⋅m {480 kgf⋅cm, 35 lbf⋅ft}(M10)
SAPH301091200035
12–22 LUBRICATION
5. Connecting the oil hoses

tighten the nut of the oil hose, and connect the oil hose to
the oil filter assembly. (Inlet and outlet)
Tightening torque : 196 N⋅m
{2,000 kgf⋅cm, 145 lbf⋅ft}(PF1)

Oil hose moment arm to make spanner control easier.
(Bypass)
• If the joint part has been loosened, replace
the O-ring by a new one.
(2) Replace the gasket by a new one and connect the oil
hose(Bypass) with a union bolt to the oil filter assembly.
6. Pipe installation
Lock (1) Replace O-rings and gaskets by new ones and connect
the pipes to the oil cooler.
SAPH301091200033 Unit : N⋅m{kgf⋅cm,lbf⋅ft}
Tighten-
Position M radius Quantity ing
torque
55
Coolant pipe IN M10 2
{560,40}
39
M24 1
{400,29}
Union
25
Oil pipe M14 1
{250,18}
55
Clip M10 1
{560,40}
LUBRICATION 12–23
êÆî óvóÃ
Overhaul
JP30109120702002
1. Removal of oil cooler element
Bolt (1) Remove the bolts and take off the cover of the oil cooler.
(2) Remove the nuts and remove the oil cooler element from
Cover the oil cooler.
Gasket
Oil cooler element
O-ring
Gasket
O-ring
Gasket
Nut
SAPH301091200036
2. Disassembly oil cooler cap.
! CAUTION • Do not remove the plug unless necessary.
(1) Remove the safety valve.

Safety valve (2) Remove the relief valve.
(3) Remove the oil filter warning switch.
Relief valve
SAPH301091200037
12–24 LUBRICATION
3. Safety valve wear and tear inspection
(1) Inspect the safety valve visually and replace it in case of

wear or damage.
Safety valve
SAPH301091200038
4. Relief valve wear and tear inspection
(1) Inspect the relief valve visually and replace it in case of

wear or damage.
Relief valve
SAPH301091200039
5. Assembly of oil cooler case
(1) Replace the O-ring with a new one and install each valve.
Tightening torque :
19 N⋅m {190 kgf⋅cm, 141 lbf⋅ft}(Oil pressure warning
switch)
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft}(Valve cap:
M14)
M26)
M20)
SAPH301091200040
LUBRICATION 12–25
6. Installation of oil cooler element
Bolt (1) Replace the gasket and O-ring with new ones and install
the oil cooler element.
Cover Tightening torque :
19.6±4.9N⋅m{200±50kgf⋅cm,14±4lbf⋅ft}
(2) Replace the gasket of the cover with a new one and install
it.
Gasket
Oil cooler element
O-ring
Gasket
O-ring
Gasket
Nut
SAPH301091200036
12–26 LUBRICATION
Oil pan
ç\ê¨ê}
ç\ê¨îzíuê}
Part layout
JP30109120402004
SAPH301091200041
12111 Oil pan 12151 Gasket*

12149 Drain cock 9659C Gasket*
Tightening torque
9191-08452 31N⋅m{320kgf⋅cm, 23 lbf⋅ft}
LUBRICATION 12–27
êÆî óvóÃ
Replacement
JP30109120704004
1. Removal of oil pan

(1) Remove bolts and remove the oil pan.
! CAUTION • If the gasket is sticking, remove it using a

scraper, etc.
2. Installation of oil pan

Liquid gasket
applying position (1) Apply a small amount of liquid gasket [Threebond TB1211
(white)] to the step of the joint surface between the timing
gear case and the cylinder block and between the
flywheel housing and the cylinder block.
(2) Replace the gasket with a new one and install the oil pan.
! CAUTION • Wipe off oil on the oil pan and cylinder block
SAPH301091200042 before installation.
STARTING AND CHARGING 13–1
ENGINE
13 STARTING AND CHARGING

ç\ê¨ê}
ç\ê¨îzíuê}
Starter ........................................................................ 13-2

Part layout (typical example)................................. 13-2
Disassembly.......................................................... 13-3
Inspection of components ..................................... 13-9
Assembly ............................................................ 13-14
Alternator (60A) ...................................................... 13-16
Part layout (typical example of 60A) ................... 13-16
Circuit drawing (60A) .......................................... 13-17
Disassembly (60A).............................................. 13-18
Inspection of components (60A) ......................... 13-21
Assembly (60A)................................................... 13-24
Inspection after assembly (60A) ......................... 13-28
13
13–2 STARTING AND CHARGING
Starter
JP30109130402001
SAPH301091300001
28011 Clutch subassembly 28138 Packing*

28100 Starter assembly 28140 Brush holder assembly
28111 Bushing 28142 Brush
28113 Lever assembly 28142A Brush
28115 Pinion case 28143 Spring
28117 Packing* 28150 Center bracket
28117A Packing* 28160 Armature assembly
28118 Plate 28168 Retainer clip*
28118A Plate 28199 Dust protector
28118B Plate 28251 Pinion
28118C Plate 28252 Bearing
28118D Cover 28255 Shaft assembly
28120 Yoke assembly 28253 Planetary gear
28133 Rear bracket 28253A Internal gear

Tightening torque
28112 14 - 16N⋅m{140 - 160kgf⋅cm,10 -12lbf⋅ft} 28112E 15.7 - 17.6N⋅m{160 - 179kgf⋅cm,12 -
13lbf⋅ft}
28112A 3.6 - 4.9N⋅m{37 - 49kgf⋅cm,3 - 4lbf⋅ft}
êÆî óvóÃ
Disassembly
JP30109130702001
M lead wire NOTICE • Fix the starter on the working table to ease
accessibility.
M terminal
1. Removal of M lead wire

(1) Remove the cap of the M terminal.
(2) Remove nuts and remove the M lead wire.
SAPH301091300002
2. Removal of rear bracket

Through bolt (1) Loosen and remove two through bolts.
Rear bracket
SAPH301091300003
(2) Remove two set bolts and remove the rear bracket.
Set bolt ! CAUTION • Hold the M lead wire and remove the rear
bracket by lifting.
SAPH301091300004
3. Removal of brush holder assembly

Brush holder
assembly (1) Lift the spring using a flat tip screwdriver, long-nose pliers
or pliers. Remove four brushes from the brush holder
assembly.
! CAUTION • Do not cut the brush lead fixing clamp.
(2) Remove the brush holder assembly from the armature

Spring
assembly.
Brush
Brush lead
Clamp
SAPH301091300005
4. Removal of yoke assembly

M lead wire (1) Remove the yoke assembly from the center bracket
Yoke assembly
assembly.
! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.
Center bracket
assembly
SAPH301091300006
5. Removal of packing
Yoke assembly
(1) Remove the packing from the centering parts at both ends
of the yoke assembly.
! CAUTION • The packing must not be reused. Replace it

with a new one.
Packing Packing
SAPH301091300007
6. Removal of armature assembly

(1) Remove the armature assembly by lifting.
Armature
assembly
! CAUTION • When the armature assembly is removed, the
washer at the end of the gear may be dropped
Center and lost. Be careful for handling.
bracket
assembly
SAPH301091300008
7. Removal of rear bearing

(1) Pull out the bearing of the armature assembly using a
Rear bearing puller or press.
! CAUTION • Removed bearing must not be reused.

Replace it with a new one.
Puller
SAPH301091300009
8. Removal of cover
Packing Cover
(1) Remove the cover from the center bracket assembly.
(2) Remove the packing.
! CAUTION • Damaged packing must not be reused.

Replace it with a new part.
SAPH301091300010
9. Removal of planetary gear

(1) Remove the planetary gear from the carrier pin.
Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin
SAPH301091300011
10. Removal of internal gear

(1) Remove the internal gear from the center bracket.
! CAUTION • Make sure that the gear is not damaged or

chipped.
Internal gear
Center case
SAPH301091300012
11. Removal of shim washer

(1) Remove the internal gear from the center bracket.
Shim
SAPH301091300013
12. Removal of pinion

(1) Remove the retainer clip using a tool such as snap ring
pliers.
Retainer clip ! CAUTION • Retainer clip must not be reused. Replace it

with a new one.
Pinion stopper
NOTICE • Push upward or pull out the chipped part of
the clip mouth.
Pinion
SAPH301091300014
(2) Remove the pinion stopper.

(3) Remove the pinion.
Pinion stopper
! CAUTION • Make sure that the gear is not damaged or
chipped.
Pinion
SAPH301091300015
13. Removal of pinion case

Pinion case
(1) Remove two set bolts at the switch using a box
screwdriver or offset wrench.
(2) Lift and remove the pinion case.
Clutch
assembly
SAPH301091300017
14. Removal of lever

(1) Hold the lever holder and press the entire lever to the
Plunger clutch. Remove the link with the plunger.
Holder
Lever assembly
SAPH301091300018
(2) Turn and pull out the lever assembly using the clutch as
the axis.
Lever assembly
SAPH301091300019
15. Removal of brake plate

(1) Hold the clutch case outer diameter and slide the clutch
assembly upward. Pinch the clip end fixing the brake plate
with pliers and remove it by bending.
SAPH301091300020
(2) Remove the brake plate.
Brake plate
SAPH301091300021
16. Removal of clutch assembly

(1) While pressing the clutch assembly to the center bracket
Clutch assembly
assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
Center bracket position and remove it.
assembly
SAPH301091300022
17. Removal of shaft assembly

Washer (1) Turn the center bracket assembly upside down. Hold the
carrier plate and pull out the shaft assembly.
! CAUTION • Washers are available at the upper and lower

parts of the carrier plate. Be careful for loss of
the washers.
Shaft assembly
SAPH301091300023
18. Removal of packing

(1) Turn the center bracket assembly upside down again and
remove the packing.
! CAUTION • Packing must not be reused.
Packing
SAPH301091300024
Inspection of components
JP30109130703001
1. Inspection of yoke assembly

(1) Make sure that the coil lead wire has electric continuity
using a circuit tester.
SAPH301091300025
(2) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation. When the
value is below the operation limit, replace it.
Field coil
Operation limit 1 kΩ or less
! CAUTION • After cleaning and drying, take

Yoke assembly
measurements.
SAPH301091300026
(3) Measure the brush length using vernier calipers.
18{0.709} 13{0.512} or less
SAPH301091300027
2. Inspection of armature assembly

(1) Turn the armature assembly using a commercially
available growler tester and put a piece of steel on the
armature assembly. Make sure that the steel piece is not
vibrating on the core circumference.
SAPH301091300028
(2) Make sure that adjacent segments of the commutator

have electric continuity using a circuit tester.
(3) Make sure that there is no discoloration at the coil.
SAPH301091300029
(4) Measure the resistance between the commutator and the

core using a circuit tester and check insulation.
1 MΩ or more 1 kΩ or less

measurements.
SAPH301091300030
(5) Measure the commutator outer diameter using vernier

calipers.
! CAUTION • After removing roughness on the surface

(after polishing), take measurements.
Commutator outer diameter
36{1.417} 34{1.338} or less

SAPH301091300031
(6) Measure the undercut depth between segments. If the

undercut depth is beyond the operation limit, repair it.
0.5 - 0.8{0.0197 - 0.0314} 0.2{0.0078} or less
! CAUTION • In repair, do not leave insulation material at

the end of the segment.
SAPH301091300032
(7) Measure the shaft outer diameter using a micrometer. If it

is beyond the operation limit, replace the armature
assembly.
㧭
Measuring area
㧮 (mm{in.}) (mm{in.})
11.98{0.4717}
Part A 12{0.472}
or less
SAPH301091300033 8.98{0.3535}
Part B 9{0.354}
or less
3. Inspection of brush holder assembly

(1) Measure the resistance between the holder (plus) and the
plate using a circuit tester and check insulation. When the
value is below the operation limit, replace it.
Operation limit 1 kΩ or less

measurements.
SAPH301091300034
(2) Measure the brush length using vernier calipers.
18{0.709} 13{0.512} or less
(3) Make sure that the spring has pressure.
SAPH301091300035
4. Inspection of shaft assembly

(1) Measure the outer diameter of the shaft using a
micrometer
If it is beyond the operation limit, replace the shaft.
㧮㧭
Measuring area
(mm{in.}) (mm{in.})
25.90{1.0197}
Part A 26{1.024}
or less
SAPH301091300036
14.04{0.5528}
Part B 14.1{0.5552}
or less
5. Inspection of clutch assembly

(1) Measure the outer diameter of the inner sleeve using a
micrometer.

28{1.102} 27.90{1.0984} or less
SAPH301091300037
6. Inspection of bearing
(1) Measure the inner diameter (1 in the figure) of the pinion
case bearing metal part using a cylinder gauge.
28{1.102} 28.2{1.1102} or more
SAPH301091300038
(2) Measure the inner diameter (2 in the figure) of the center

bracket bearing metal part using a cylinder gauge.
26{1.024} 26.2{1.0315}

SAPH301091300039
(3) Measure the inner diameter (3 in the figure) of the shaft

assembly bearing metal part using a cylinder gauge.
9{0.354} 9.2{0.3622}
(4) Measure the inner diameter (4 in the figure) of the rear

bracket bearing housing using a cylinder gauge.
SAPH301091300040 Standard value (mm{in.}) Operation limit (mm{in.})
28{1.1024} 28.1{1.1062} or more

7. Inspection of start magnet switch assembly (resistance of

C terminal
P coil)
M terminal
(1) Measure the P coil resistance between the C terminal and
the M terminal using a circuit tester.
Standard value (Ω) 0.12 - 0.14
SAPH301091300041
8. Inspection of start magnet switch assembly (resistance of

H coil)
(1) Measure the H coil resistance between the C terminal and
C terminal the body using a circuit tester.
Standard value(Ω) 1.13 - 1.25

Body
SAPH301091300042
9. Inspection of start magnet switch assembly (electric

continuity inspection)
M terminal (1) Check electric continuity between the B terminal and the
M terminal using a circuit tester, and make sure that there
is no electric continuity.
B terminal
SAPH301091300043
(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.
SAPH301091300044
Assembly
JP30109130702002
1. Assembly procedure
Perform assembly procedure in the reverse order
disassembly.
2. Tightening torque
For the bolt tightening torque, refer to the parts layout.
3. Lubrication
Refer to the following figure and table for lubricant to be
applied.
! CAUTION • There shall be no lubricant on the

commutator surface, brush and contact.
SAPH301091300045
Table of lubricant
Lubricant Lubricant
Code Lubricating point Amount (g{oz}) Remark
used manufacturer
Pinion case metal 0.8 - 1.5{0.0282 -
1 Multemp AC-N Kyodo Yushi
and grease reservoir 0.0529}
Bracket center metal 0.8 - 1.5{0.0282 -

and grease reservoir 0.0529}
0.2 - 0.5{0.0070 - Applied to both sides

3 Shim washer Multemp AC-N Kyodo Yushi
0.0176} of washer.
0.5 - 1{0.0176 -
4 Armature front metal Multemp AC-N Kyodo Yushi
0.035}
0.2 - 0.5{0.0070 - Applied to both sides

5 Shim washer Multemp AC-N Kyodo Yushi
0.0176} of washer.
Internal gear
7 - 11{0.247 -
6 Armature gear Multemp AC-N Kyodo Yushi
0.388}
Planetary gear
Pinion straight 0.5 - 1{0.0176 -

Spline 0.035}
0.3 - 0.6{0.0106 -
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
0.0211}
0.5 - 1{0.0176 -
9 Helical spline Multemp AC-N Kyodo Yushi
0.035}
Clutch case lever Pyroknock 1 - 2{0.0070 - Nisseki

10
shifter No.2 0.0176} Mitsubishi
Bracket rear bearing Pyroknock 0.2 - 0.5{0.0070 - Nisseki

11
housing No.2 0.0176} Mitsubishi
1 - 2{0.0070 -
12 Planetary gear metal Multemp AC-N Kyodo Yushi
0.0176}
0.4 - 0.8{0.0141 -
13 Lever holder Multemp AC-N Kyodo Yushi
0.0282}
Assemble the roller

after application of
Pyroknock 0.2 - 0.5{0.0070 -
14 Lever roller rod grease to prevent fall Kyodo Yushi
No.2 0.0176}
of the roller in
assembly.
Alternator (60A)
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Part layout (typical example of 60A)

JP30002130402002
SAPH301091300046
27017 Field coil 27392 Cover

27060 Armature assembly 27410 Stator coil
27311 Front bracket 27412 Collar
27312 Bearing cover 27431 Pulley
27330 Rotor assembly 27441 Fan
27353 Heat sink minus 27445A Coupler holder
27356 Heat sink plus 27700 Regulator
27359 Rear bracket 28252 Ball bearing
27364 B terminal 28252A Roller bearing
Tightening torque
27317 7.8 - 9.8N⋅m{80 - 99kgf⋅cm,6 - 7lbf⋅ft} 27317C 1.9 - 2.5N⋅m{20 - 25kgf⋅cm,1.4 - 1.8lbf⋅ft}
27317A 1.9 - 2.5N⋅m{20 - 25kgf⋅cm,1.4 - 1.8lbf⋅ft} 27391 127 - 157N⋅m{1,300 - 1,600kgf⋅cm,94 -
115lbf⋅ft}
27317B 2.9 - 3.9N⋅m{30 - 39kgf⋅cm,2.1 - 2.5lbf⋅ft} 27391A Internal nut :
4.9 - 5.9N⋅m{50 - 60kgf⋅cm,3.7 - 4.3lbf⋅ft}
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Circuit drawing (60A)

JP30002130803001
Capacitor
Diode
Fuse Load
. Lamp (1.4 to 3W)
4
Starter switch
2
Field coil
0
Regulator
Stator coil Battery 24V
'
Alternator
SAPH301091300047
êÆî óvóÃ
Disassembly (60A)
JP30002130702003
! CAUTION • Place a rubber mat and perform work on the

mat.
1. Disconnection of front from rear
(1) Remove fixing bolts and remove the cover.
! CAUTION • Press the tabs of the cover for removal. Be

careful not to break the tabs with excessive
force.
SAPH301091300048
(2) Remove bolts with a screwdriver and remove the coupler

holder.
SAPH301091300049
(3) Remove three through bolts and disconnect the front from
the rear.
SAPH301091300050
2. Disassembly of front
(1) Remove nuts and remove the pulley, fan and collar.
! CAUTION • Tie around a general V–belt in the pulley

groove and fix the pulley with a vice.
SAPH301091300051
(2) Remove the rotor assembly using a press.
! CAUTION • Do not damage the end of the thread.

• Support the rotor assembly to prevent fall of
the rotor assembly.
SAPH301091300052
(3) Remove three bolts with a screwdriver and remove the

bearing cover.
SAPH301091300053
(4) Remove the ball bearing from the front bracket using a
press and jig C.
! CAUTION • Place jig C at the inner race of the front

bearing.
• Removed bearing must not be reused.
SAPH301091300054
3. Disassembly of rear
(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device
! CAUTION • At solder of the stator coil and the diode, the

end of the diode is clamped. Do not damage
the diode by prying. Deformed diode must not
be reused.
SAPH301091300055 • Perform soldering in a short time (within 5
seconds).
(2) Remove the stator coil from the rear bracket.
! CAUTION • Do not damage the stator coil.
SAPH301091300056
(3) Remove solder of the lead wire connecting the regulator

and the field coil using a soldering bit.
! CAUTION • Remove the lead wire of the field coil by

raising the terminal of the regulator.
• Perform soldering in a short time (within 5
seconds).
SAPH301091300057
Terminal
Lead wire
Regulator assembly
SAPH301091300058
(4) Loosen the nut at the B terminal.
! CAUTION • Loosen the nut to some extent and do not

remove it from the B terminal.
SAPH301091300059
(5) Remove five bolts using a screwdriver and remove the

heat sink assembly (plus), heat sink assembly (minus)
and regulator all together.
! CAUTION • Screw lock is used. Since torque is high until

bolt is removed, be careful not to damage the
groove of the bolt head.
• When the rear bracket is reused, clean the
screw hole.
SAPH301091300060
(6) Remove the capacitor.

(7) Remove three bolts with a screwdriver and remove the
field coil from the rear bracket.
SAPH301091300061
(8) Remove the roller bearing from the rear bracket using a
press, jig A and jig B.
! CAUTION • Removed bearing must not be reused.
SAPH301091300062
Inspection of components (60A)

JP30002130703002

mat.
1. Inspection of stator coil and field coil
(1) Measure the resistance between U-V, V-W and W-U

terminals of the stator coil using a circuit tester.
SAPH301091300063
(2) Measure the resistance between the stator coil core and
each terminal using a megger tester.
Standard value (MΩ) 1 or more
SAPH301091300064
(3) Measure the resistance of the field coil using a circuit

tester.
! CAUTION • Do not damage the circumferential surface of

the coil.
• Damaged coil circumference must not be
reused.
SAPH301091300065
(4) Measure the resistance between the core and the coil
using a megger tester.
Standard value (MΩ) 1 or more
SAPH301091300066
2. Inspection of rotor assembly
(1) Measure the outer diameter of the shaft at the ball bearing
insertion area of the rotor assembly using a micrometer.
SAPH301091300067
(2) Measure the outer diameter of the shaft at the roller

bearing insertion area of the rotor assembly using a
micrometer.

SAPH301091300068
3. Inspection of diode and regulator
(1) Measure the resistance between the minus diode and the
heat sink holder using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
SAPH301091300069
(2) Measure the resistance between the capacitor terminal

and the body using a circuit tester. Make sure that it
indicates 800 kΩ and then immediately indicates infinite
value.
SAPH301091300070
(3) Inspection of regulator

Measure the resistance between regulator terminals F
and E using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
SAPH301091300071
Assembly (60A)
JP30002130702004

mat.
1. Assembly of front
(1) Press fit a new ball bearing into the front bracket using a
press and jig C.
! CAUTION • Place jig C at the outer race of the ball

bearing.
SAPH301091300072 • Removed bearing must not be reused.
(2) Install the bearing cover with bolts.

Tightening torque : 1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1.4 -
1.8 lbf⋅ft}
SAPH301091300073
(3) Install the rotor assembly using a press.
! CAUTION • Be sure to support the inner race of the

bearing for press fit of the rotor.
• Do not damage the shaft.
SAPH301091300074
(4) Install the space collar, fan and pulley on the shaft of the
rotor assembly.
Tightening torque : 127 - 157 N⋅m {1,300 - 1,600

kgf⋅cm, 94 - 115 lbf⋅ft}
! CAUTION • Tie around a general V–belt in the pulley

groove and fix the pulley with a vice.
SAPH301091300075
2. Assembly of rear
(1) Press fit a new roller bearing into the rear bracket using a
press, jig A and jig B.
! CAUTION • Press fit until jig A comes in contact with the

rear bracket.
SAPH301091300076
(2) Install the field coil on the rear bracket.
Tightening torque : 2.9 - 3.9 N⋅m {30 -39 kgf⋅cm, 2.1 -

2.5 lbf⋅ft}
! CAUTION • Tighten bolts finally after temporary

tightening. Tighten them evenly.
SAPH301091300077
(3) Assemble the stator coil on the rear bracket temporarily.
! CAUTION • Do not damage the stator coil.
SAPH301091300078
(4) Install parts referring to the part layout.

1.8 lbf⋅ft}
! CAUTION • Apply screw lock to the ends of the heat sink

mounting bolt and the regulator mounting
bolt.
SAPH301091300079
(5) Solder the lead wire connecting the regulator and the field
coil, and connecting the stator coil and the diode using a
soldering bit.
! CAUTION • Perform soldering after tightening of bolts.

• Bend and fix the regulator terminal before
soldering the lead wire of the field coil.
• Clamp the end of the diode of the stator coil
before soldering.
SAPH301091300080 • Perform soldering in a short time (within 5
seconds).
terminal
Lead wire
Regulator assembly
SAPH301091300081
(6) Tighten the nut inside the B terminal.

4.3 lbf⋅ft}
NOTICE • After installation of the alternator, connect the

wire and tighten the outside nut
SAPH301091300082
3. Joint of front and rear

(1) Joint the front with the rear with bolts.
Tightening torque : 7.8 - 9.8 N⋅m {80 - 99 kgf⋅cm, 6 - 7
lbf⋅ft}
! CAUTION • Tighten bolts evenly.
SAPH301091300083
(2) Install the coupler holder and tighten bolts.

1.8 lbf⋅ft}
SAPH301091300084
(3) Align the tab and install the cover. Fix it with bolts.

3.2 lbf⋅ft}
! CAUTION • Do not hit the cover because the tab may be

broken.
SAPH301091300085
Inspection after assembly (60A)

JP30002130703003

mat.
1. Inspection of rotation
(1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is smooth.
SAPH301091300086
(2) Measure the resistance between B and E terminals and

between P and E terminals using a circuit tester. If it is
beyond the standard value (e.g. 0 Ω), disassemble it again
and reassemble the unit correctly.
Circuit tester lead

Standard value
(+) (–)
B E Approx. 20 Ω
SAPH301091300087
E B Infinite
P E Approx. 7 Ω
E P Infinite
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Connector details
SAPH301091300088
TURBOCHARGER 14–1
ENGINE
14 TURBOCHARGER
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Turbocharger Assembly........................................... 14-2

Assembly/disassembly layout ............................... 14-2
Inspection ............................................................. 14-3
Inspection procedure with special tool .................. 14-3
Removal ................................................................ 14-7
Installation............................................................. 14-8
14
14–2 TURBOCHARGER
Turbocharger Assembly
Assembly/disassembly layout
JP30109140402001
SAPH301091400001
15474 Oil outlet pipe 24135 Gasket*

17159 Exhaust manifold connector 9655-12100 Gasket*
24106 Oil inlet pipe 9655-14140 Gasket*
24109 Gasket* 9851A O-ring*
24109A Gasket* S1760 Turbocharger assembly

Tightening torque
9209A 59N⋅m{600kgf⋅cm,44lbf⋅ft}
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êÆî óvóÃ
TURBOCHARGER 14–3
Inspection
JP30109140706001
1. Hold the lock nut at the end of the blower impeller, turn the
turbine shaft gently by hand and inspect rotation.
2. Hold the lock nut at the end of the blower impeller and
inspect the radial play of the turbine shaft by hand. (To
compare degrees of play, use the metal wear limit sample
turbocharger.)
3. If the turbine shaft does not turn, rotation sticks, the radial
play is large, or the blower impeller comes in contact with
the blower case, it is considered the metal area has a
failure.
Overhaul or replace the turbocharger.
4. If it is difficult to judge the amount of play, judge the play

using a special tool shown below and determine if the
turbocharger needs to be replaced or overhauled.
5. If the turbocharger is overhauled or the assembly is

replaced, inspections after this item are not necessary.
Part No. Part name Remark
Turbocharger Limit sample for recognizing

24100–
assembly the backlash of the turbine
2360
shaft by the feel of hand.
Inspection procedure with special tool

JP30109140706002
1. Inspection of radial play

(1) Put the stopper on the thread protruding to the lock nut at
the end of the blower impeller. (The stopper is left-hand
thread.)
SAPH301091400002
(2) Insert the guide at the air inlet of the blower case and
tighten bolts and fix it.
SAPH301091400003
14–4 TURBOCHARGER
(3) Put a bar on the stopper and lock it.
SAPH301091400004
(4) Insert a dial gauge into the plate and fix it with bolts.
SAPH301091400005
(5) Attach a bar to the hook at the tip of the bar, set the dial
gauge to 0 while pull the bar down with a force of 4.9 - 5.9
N{0.5 - 0.6 kgf, 1.1 - 1.3 lbf}.
SAPH301091400006
(6) Pull the bar up with a force of 4.9 - 5.9 N{0.5 - 0.6 kgf, 1.1
- 1.3 lbf} and measure radial motion with a dial gauge.
SAPH301091400007
(7) Take three measurements and take an average. If it is

beyond the operation limit, overhaul or replace it with a
new one.
Radial play
! CAUTION • If the turbocharger is overhauled or the

assembly is replaced, inspections after this
item are not necessary.
TURBOCHARGER 14–5
2. Inspection of axial (thrust) play

(1) Remove the dial gauge, loosen the guide bolt and turn the
guide 90°. Put the dial gauge into the plate that is
inspected for axial play, and tighten the bolt for fixing.
SAPH301091400008
SAPH301091400009
(2) Insert the guide to prevent horizontal movement of the

measuring instrument.
SAPH301091400010
(3) When the guide is fixed, move the bar vertically and fix the
guide with a stopper so that the dial gauge pointer is at
the center.
SAPH301091400011
14–6 TURBOCHARGER
(4) Hold the puller and press it toward the turbine in the axial
direction. Set the dial gauge reading to 0.
SAPH301091400012
(5) Pull it to the opposite side and measure movement in the

axial direction.
(6) Take three measurements and take an average. If it is

beyond the operation limit, overhaul or replace it with a
new one.
Radial play
êÆî óvóÃ
SAPH301091400013
TURBOCHARGER 14–7
Removal
JP30109140702001
1. Disconnect the boost pipe and the air pipe.
2. Remove the insulator.

Insulator
SAPH301091400014
3. Disconnect all pipes connected to the turbocharger.

Turbocharger
! CAUTION • Loosen the union bolt of the coolant pipe,
remove it after water draining, separate in the
same way also at the bottom, and then
remove the oil pipe.
• After removal of each pipe, seal the water hole
and the holes on the cylinder block side to
Oil pipe prevent entry of dirt etc.
SAPH301091400015
4. Remove the nuts and take off the turbocharger.

Turbocharger
! CAUTION • After removal, seal the opening on the
exhaust manifold side and on the exhaust
pipe side to prevent entry of foreign objects.
• If the stud bolts should be difficult to remove,
use a commercial stud remover to remove
them and then replace them.
Nut
SAPH301091400016
14–8 TURBOCHARGER
Installation
JP30109140702002
1. Before installation on the engine, pour new engine oil from

the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing.
2. Replace the gasket by a new one, install exhaust pipe and

Turbocharger
turbocharger, and install the turbocharger to the engine.

(Turbocharger to exhaust manifold)
! CAUTION • Make sure that there is no dirt or foreign

matter in the exhaust piping system.
• Since heat resistant steel is used for bolts and
Nut nuts, do not mix them with normal bolts for
SAPH301091400016 installation.
3. Replace the gasket with a new one and connect the

Turbocharger coolant pipe and oil pipe to the turbocharger.
! CAUTION • Clean the pipe and make sure that there is no

pipe deformation or no dirt or foreign matter
in the pipe.
• Do not use sealant at the installation surface
of the oil pipe and the coolant pipe or joint
Oil pipe between the coolant hose and the coolant
SAPH301091400015 pipe to prevent failures such as damage due
to clogging or loosening of tightened areas.
4. Install the insulator on the turbocharger.

Insulator
SAPH301091400014
5. Install the boost pipe and U-turn pipe.
! CAUTION • Make sure that there is no dirt or foreign

matter in the air intake system. Do not use
sealant at the inlet/outlet of air to prevent
failures such as damage due to clogging or
loosening of tightened areas.
• Be sure to install the air feed pipe and the air
hose correctly to prevent air leak from
connections.
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–1
ENGINE
16 FAILURE DIAGNOSIS FOR EACH ENGINE

STATUS
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Engine mechanical ............................................... 16-2

Alternator .............................................................. 16-5
Starter ................................................................... 16-6
Turbocharger......................................................... 16-7
16
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Engine mechanical
JP03Z01020601001
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Water leak from EGR cooler Replace EGR cooler.
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Clogging of flyscreen (vehicle with Cleaning of flyscreen
flyscreen)
Clogging of intercooler core front Cleaning of intercooler core
part
Engine overheat (compression Non-synchronous injection timing Inspection of supply pump timing
pressure) Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of valve guide Replace valve guide.
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Faulty ventilator Replace ventilator.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Status Cause Action

Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
Insufficient engine power (air Clogging of air cleaner element Clean or replace air cleaner
cleaner) element
Insufficient engine power Overheat Refer to overheat section.
Insufficient engine power (fuel Faulty injection of injector Replace injector
unit) Faulty injector due to deposit of Replace injector
carbon
Entry of air into fuel system Air bleeding of fuel system
Faulty fuel filter Replace element
Faulty fuel Replace with correct fuel
Insufficient engine power Abnormal compression pressure Refer to overheat section.
Insufficient engine power Piston, cylinder liner and piston ring Refer to overheat section.
Faulty engine start (electric unit) Faulty battery Check battery
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection
or replace cable
Faulty operation of starter Replace starter assembly
Faulty start assist unit Replace start assist unit
Faulty engine start (air cleaner) Clogging of air cleaner element Clean or replace air cleaner
element
Faulty engine start (fuel unit) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air intake from connection of fuel Tighten connections
system
Clogging of fuel filter Replace fuel filter
Loose connection of injection pipe Tighten connecting nut of injection
pump
Faulty engine start (injector) Injector seizure Replace injector
Faulty engine start (lubrication Excessive viscosity of engine oil Replace with engine oil with correct
unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and
cylinder liner
Bearing seizure Replace bearing and crankshaft
Low compression pressure Overhaul engine
Damage to ring gear Replace ring gear and replace
starter pinion gear.
Status Cause Action

Faulty idling (injector) Faulty injection pressure Adjust injection pressure.
Faulty injection status Adjust or replace injector.
Faulty idling (nozzle) Faulty injection pressure Adjust injection pressure.
Faulty spray status Adjust or replace nozzle
Carbon deposit at nozzle end Remove carbon
Seizure of needle valve Replace nozzle
Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance
Faulty contact of valve seat Adjust or replace valve and valve
seat.
Low coolant temperature Perform warm-up.
Large variation of compression Overhaul engine
pressure between cylinders
Gas leak (head gasket) Reuse Replace gasket.
Damage Replace gasket.
Poor assembly Replace gasket.
Gas leak (head bolt) Loose head bolt Tighten bolt.
Incorrect tightening sequence or Tighten bolt to correct torque
incorrect tightening torque according to the correct tightening
sequence.
Gas leak (cylinder block) Crack Replace cylinder block.
Distortion of cylinder block upper Repair or replace cylinder block.
surface
Depression of cylinder liner Replace cylinder liner or block.
insertion (insufficient protrusion of
cylinder liner)
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Distortion of cylinder head lower Repair or replace cylinder head.
surface
Gas leak (cylinder liner) Crack of cylinder liner Replace cylinder liner.
Corrosion of cylinder liner Replace cylinder liner.
Insufficient protrusion of cylinder Replace cylinder liner or block.
liner
Gas leak (others) Incorrect injection timing Adjust injection timing.
Alternator
JP03Z01020601002
Status Cause Action

Lamp is ON. → Charge current Faulty regulator (open PTr) Replace regulator.
does not run (alternator). Faulty stator coil (disconnection, Replace stator coil.
rare shorting)
Fault feed coil (disconnection, rare Replace feed coil.
shorting)
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is ON. → Charge current Disconnection of wire (fuse) Replace wire (fuse).
does not run (wiring).
Lamp is ON. → Voltmeter Faulty regulator (shorting of PTr) Replace regulator.
indicates 29V or more Faulty tightening of voltage Repair, replace voltage detection
(alternator). detection circuit (e.g. support) circuit or replace regulator.
Lamp is ON. → Charge current is Faulty regulator (open Tr) Replace regulator.
correctly running (alternator).
Lamp is OFF. → Charge current Faulty stator coil (disconnection of 1 Replace stator coil.
is always limited. → Battery goes phase, rare shorting)
flat (alternator). Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is OFF. → Charge current Operation load is large (Load Reduce load
is always limited. → Battery goes balance is poor).
flat (operation load).
Lamp is OFF. → Charge current Faulty regulator (shorting of PTr) Replace regulator.
is always large. → Battery fluid Faulty tightening of voltage Repair or replace voltage detection
runs short in a short period of detection circuit (e.g. support) circuit.
time (alternator).
Lamp is OFF. → Charge current Battery is close to the service life. Replace battery.
is always large. → Battery fluid
runs short in a short period of
time (battery).
Others → Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Contact of inner surface (faulty Repair or replace bearing.
bearing, wear of bracket)
Others → Abnormal noise (V Faulty tension of V belt (belt slip) Correction
belt)
Starter
JP03Z01020601003
Status Cause Action

Starter does not turn. Turning is Faulty connection of starter key Repair connecting area.
low. Flat battery Charge or replace.
Disconnection, loosening or After cleaning, tighten.
corrosion of battery terminal
Grounding wire is disconnected. Be sure to connect it.
Use of incorrect engine oil Replace with correct oil.
Faulty contact of start magnet Replace start magnet switch
switch assembly. assembly.
Faulty contact or failure of starter Replace starter relay.
relay
Wear of starter brush Replace brush.
Seizure of commutator Repair commutator.
Wear of commutator Undercut
Shorting of armature Replace armature assembly.
Insufficient tension of brush spring Replace brush spring.
Faulty operation of clutch Clean or replace.
Turbocharger
JP03Z01020601005
Status Cause Action

Exhaust smoke is black Clogging of air cleaner element Clean or replace air cleaner
(insufficient intake air). element.
Air intake inlet is closed. Recover normal status.
Leak from connection of air intake Check and repair.
system
Revolution of blower impeller and Replacement
turbine shaft is heavy
Defective waste gate operation Check and replace.
Exhaust smoke is black Oil impurities are deposited at the Replace engine oil and
(Turbocharger is not operating). sealing part of the turbine and disassemble the turbocharger for
revolution of the turbine shaft is cleaning.
heavy.
Seizure of bearing Replace turbocharger.
Seizure of bearing (insufficient Check the oil system of the engine
lubrication or clogging of oil pipe) and repair faulty areas. Also,
replace engine oil.
Seizure of bearing (Oil temperature Check the oil system of the engine
is too high.) and repair faulty areas. Also,
replace engine oil.
Seizure of bearing (Balance of Replace turbocharger.
revolving body is poor.)
Seizure of bearing (insufficient Observe the precautions strictly in
warm-up or sudden stop from the operation manual.
loaded operation: Unloaded
operation)
Contact of or damage to turbine Check and repair engine parts.
shaft and blower impeller
(excessive operation)
Contact of or damage to turbine Check and repair engine parts.
shaft and blower impeller
(excessive increase of exhaust gas
temperature)
Contact of or damage to turbine Inspect the air cleaner and the
shaft and blower impeller (entry of engine parts and repair or replace
foreign matter) the turbocharger.
Contact of or damage to turbine Replace turbocharger.
shaft and blower impeller (wear of
bearing)
Contact of or damage to turbine Replacement
shaft and blower impeller (faulty
assembly)
Status Cause Action

Exhaust smoke is black (due to Exhaust gas is leaking before the Check and repair mounting area.
exhaust gas resistance). turbocharger. Revolution is not
increased.
Since pipe of the exhaust system is Recover normal status.
deformed or clogged, revolution of
the turbocharger is not increased.
Exhaust smoke is white. Engine oil runs out to the blower or Repair or replace pipe.
the turbine due to clogging or
deformation of the oil return pipe.
Negative pressure at the back of Check and replace the pipe.
the blower impeller is increased and Replace or clean the air cleaner
engine oil runs out to the blower. element.
Seal ring is excessively worn or Replace turbocharger.
damaged due to excessive wear of
the bearing.
Water leakage from the EGR cooler EGR cooler replacement.
to the intake system.
Oil is quickly reduced. Seal ring is excessively worn or Replace turbocharger.
damaged due to excessive wear of
the bearing.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Low engine output Gas leak from exhaust system Check and repair faulty areas.
parts
Air leak from blower outlet Check and repair faulty areas.
Clogging of air cleaner element Clean or replace air cleaner
element
Contamination of or damage to Replace turbocharger.
turbocharger
Faulty operation of turbocharger Check and replace.
Acceleration (follow-up of Carbon deposit at the turbine (disc Replace the engine oil and the
turbocharger) is poor (slow). sealing area) makes revolution of turbocharger.
the turbine heavy.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Combustion is faulty. Check the engine fuel system and
recover correct combustion status.
Faulty operation of turbocharger Replace turbocharger.
Status Cause Action

Abnormal noise If the gas passage is extremely Replace turbocharger.
narrowed due to clogging at the
turbine case nozzle or if
acceleration is performed, reverse
flow (usually called surging) occurs
due to clogging of blower discharge
air.
Revolving part is in contact. Replace turbocharger.
Faulty operation of turbocharger Check and replace.
system
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Vibration Loosening between turbocharger Check the turbocharger mounting
and intake/exhaust pipe and status and repair faulty areas.
between oil pipe and mounting area
Failure of metal, contact between Replace turbocharger.
revolving part and peripheral parts,
or damage to the blower impeller of
the turbine rotor due to entry of
foreign matter is found.
Balance of revolving body is poor. Replace turbocharger.
ENGINE DIAGNOSIS CODE 17–1
ENGINE
17 ENGINE DIAGNOSIS CODE

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Engine ECU ............................................................... 17-3 Accelerator sensor 1 and 2 malfunction

Precautions ........................................................... 17-3 (DTC code P2120) .............................................. 17-41
System block diagram........................................... 17-4 Emergency accelerator sensor malfunction
Inspection ............................................................. 17-5 (DTC code P1133) ............................................. 17-42
Connection method of HinoDX ............................. 17-6 Atmospheric pressure sensor malfunction
Table of failure code .............................................. 17-7 (DTC code P2228, P2229)................................. 17-44
Signal check harness.......................................... 17-11 Injector common 1 short to GND
Computer pin arrangement ................................. 17-13 (DTC code P1211),
Check the ECU power supply voltage................. 17-14 Injector common 2 short to GND
Check the ground................................................ 17-14 (DTC code P1214) .............................................. 17-45
Engine speed main sensor circuit malfunction Injector common 1 short to BATT
(DTC code P0335) .............................................. 17-15 (DTC code P1212),
Abnormal engine main rotation sensor pulse count Injector common 2 short to BATT
(DTC code P0336) .............................................. 17-16 (DTC code P1215) .............................................. 17-47
Engine speed sub sensor circuit malfunction Injector circuit malfunction
(DTC code P0340) .............................................. 17-18 (DTC code P0201 to P0206)............................... 17-49
Abnormal engine auxiliary rotation sensor pulse count Cylinder contribution/balance fault
(DTC code P0341) .............................................. 17-20 (DTC codes P0263, P0266, P0269, P0272, P0275,
Engine speed main and sub sensor circuit malfunction P0278) ................................................................ 17-52
(DTC code P0335) .............................................. 17-22 PCV1 malfunction
Coolant temperature sensor malfunction (DTC code P0628) .............................................. 17-54
(DTC code P0117, P0118) ................................. 17-23 PCV1 malfunction
Engine overheat (DTC code P0628) .............................................. 17-57
(DTC code P0217) .............................................. 17-24 PCV1 out put short to GND
Engine overrun (DTC code P0629) .............................................. 17-58
(DTC code P0219) .............................................. 17-25 PCV1 malfunction
Fuel temperature sensor malfunction (DTC code P0629) .............................................. 17-60
(DTC code P0187, P0188) ................................. 17-26 PCV2 malfunction
Boost pressure sensor malfunction (DTC code P2633) .............................................. 17-61
(DTC code P0108, P0237) ................................ 17-27 PCV2 out put short to GND
Turbocharger over boost (DTC code P2634) .............................................. 17-64
(DTC code P0234) .............................................. 17-29 Supply pump over-feed
EGR cooler coolant temperature sensor malfunction (DTC code P1229) .............................................. 17-66 17
(DTC code P1417, P1418) ................................. 17-30 Supply pump over-feed
Excessive common rail pressure (DTC code P1266) .............................................. 17-67
(DTC code P0088) .............................................. 17-31 EGR actuator fault
Excessive common rail pressure, supply pump excess (DTC code P1458,P1459)................................... 17-68
forced feed EGR valve sticking 1
Common rail pressure sensor malfunction EGR cooler overheat
Common rail pressure sensor failure Preheat circuit malfunction
(DTC code P0192, P0193) ................................. 17-34 (DTC code P0540) .............................................. 17-71
Fuel leakage Injector correction data conformily error
(DTC code P0093) .............................................. 17-36 (DTC code P1601) ............................................. 17-72
Accelerator sensor 1 malfunction ECU internal error
(DTC code P2122, P2123) ................................. 17-37 (DTC code P0605, P0606, P0607) ..................... 17-73
Accelerator sensor 1 malfunction ECU charge circuit malfunction
(DTC code P2127, P2128) ................................. 17-39 (DTC code P0200, P0611).................................. 17-74
17–2 ENGINE DIAGNOSIS CODE
Main relay malfunction

(DTC code P0686) ..............................................17-75
Starter signal malfunction
(DTC code P0617) ..............................................17-76
CAN communication loss EGR actuator
(DTC code U1122) ..............................................17-77
CAN1 communication error (Engine)
(DTC code U0073)
CAN2 communication error (Unit)
(DTC code U1001) ..............................................17-78
17
Engine ECU
Precautions
JP31Z01170102001
! CAUTION • Make sure that each connector is connected

before inspection.
• Do not place a tester rod on the connecting
surface of the connector. Otherwise,
terminals are damaged or short-circuited.
• Delete the past failure memory after
recording. Perform failure diagnosis again to
check current failure.
• After failure analysis, delete the past failure
memory. If the past failure memory is not
deleted, the failure indicator lamp remains
ON.
• All connector drawings are viewed from the
connecting surface. Place the tester rod from
SAPH31Z011700001
the back.
NOTICE • The mounting position of each sensor is

described in HinoDX with illustrations.
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SAPH31Z011700002
System block diagram

JP31Z01170803001
PCV relay
Fuse 20A
main relay
PCV power Fuse 15A
supply
- +
Battery
Shovel controller
Main relay number Failure diagnosis tool
Accelerator signal 1, 2
KWP2000 Hino-Bowie PC failure
Neutral switch diagnosis
CAN signal
Key switch signal

OUTPUT
Starter signal
INPUT
Air heater relay

Emergency accelerator
sensor
Neutral switch Injector drive signal

Supply pump
(Normal input)
Supply pump control valve drive signal
CAN communication
Others
Main engine speed sensor
Sub-engine speed sensor
Fuel temperature sensor (leakage)

Boost pressure sensor
PC sensor 1
PC sensor 2
Water temperature
sensor
EGR gas temperature sensor
Coolant temperature
EGR cooler exit
sensor
P
P Common rail T T T T
G
Engine
N
EGR
Turbo charger
DC motor
Waste gate
SAPH31Z011700003
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Inspection
JP31Z01170703001
1. Pre-inspection
(1) If the system has an error, the failure code(DTC code) is
displayed on the multiple display of gauge cluster.
SAPH31Z011700004
2. Deletion method of past failure
(1) To delete past failures of the engine ECU, use HinoDX on

the PC. (Refer to "HinoDX operation manual".)
SAPH31Z011700005
3. Deletion of cluster gauge past failure

(1) Turn "ON" the starter switch.
(2) When the buzzer stop switch is pressed consecutively 5

times in 10 seconds, the failure history mode is displayed.
(3) Press work mode selecting switch and the buzzer stop
switch at the same time for 10 seconds or more.
(4) When the display shows "No error", deletion is completed.
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SAPH31Z011700006
Connection method of HinoDX

JP31Z01170301001
1. Removal of the maintenance cover

Maintenance Cover (A)
(1) Remove the maintenance cover (A) on the rear cover
behind the operator seat by pushing down the tab at the
top (at one location).
NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.
SAPH31Z011700007
2. Connection of HinoDX
Engine ECU (1) Connect the system to the engine failure diagnosis
connector through the interface box.
Special tool : 09121-1040 Hino-Bowie (Interface box)

09042-1220 Connecting cable
Engine failure
diagnosis CD-ROM HinoDX
connector
(2) Set the starter key to "ON" and start HinoDX.
SAPH31Z011700008
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Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH31Z011700009
Table of failure code

JP31Z01170601001
NOTICE • For the system status by check engine lamp ON in the table, refer to "Inspection - Pre-
inspection".
"Reference: Engine diagnosis code, Inspection"
[a] Failure diagnosis and

DTC code Estimated failure cause Page
[b] Alarm display (alarm status)
a. Engine does not start. P0606 CPU malfunction (Hard detection) 17-73
Engine stopped. P0335 Engine speed main sensor circuit 17-15
malfunction
b. DTC code display on the (Failure of both NE & G sensors)
multiple display of the P0628 PCV1 malfunction 17-57
gauge cluster. (Failure of both PCV1 & 2)
P0629 PCV1 malfunction 17-60

(Both PCV1 & 2 failure)
P0093 Fuel leakage 17-36
a. Low output (limp form) P2120 Accelerator sensor 1 and 2 malfunction 17-41
b. DTC code display on the

multiple display of the
gauge cluster.
a. Low output P0217 Engine overheat 17-24
P0234 Turbocharger over boost 17-29

b. DTC code display on the P0605 Flash ROM error 17-73
multiple display of the
P0607 Monitoring IC malfunction in CPU 17-73
gauge cluster.
U0073 CAN1 communication error 17-78
(Engine)
U1001 CAN2 communication error 17-78

(Unit)
U1122 CAN communication loss 17-77

(EGR actuator)
P0108 Boost pressure sensor circuit high input 17-27
P0237 Boost pressure sensor circuit low input 17-27
P0201 Injector circuit malfunction -cylinder 1 17-49




a. Low output P1211 Injector common 1 short to GND 17-45

(GND short-circuit)
b. DTC code display on the P1212 Injector common 1 short to BATT 17-47
multiple display of the (VB short-circuit)
gauge cluster. P1212 Injector common 1 short to BATT (Open) 17-47
P1214 Injector common 2 short to GND 17-45

(GND short-circuit)
P1215 Injector common 2 short to BATT 17-47

(VB short-circuit)
P1215 Injector common 2 short to BATT (Open) 17-47
P0200 ECU charge circuit high input 17-74
P0611 ECU charge circuit malfunction 17-74
P0191 Common rail pressure sensor malfunction 17-33
P0192 Common rail pressure sensor circuit low 17-34

input
P0193 Common rail pressure sensor circuit high 17-34

input
P0088 Excessive common rail pressure 17-31

(1st step)
P0088 Excessive common rail pressure 17-31

(2nd step)

(GND short-circuit)
P0629 PCV1 out put short to GND 17-60
(VB short-circuit)
P2634 PCV2 out put short to GND 17-64
P0088 Excessive common rail pressure, supply 17-32

pump excess forced feed
P1229 Supply pump over-feed 17-66
P1266 Supply pump over-feed 17-67

P1458 EGR actuator fault 17-68
P1459 EGR actuator fault 17-68
P0404 EGR valve sticking 1 17-69


a. Other problems P1601 Injector correction data conformity error 17-72
P0686 Main relay malfunction 17-75

b. DTC code display on the P0117 Coolant temperature sensor circuit low 17-23
multiple display of the input
gauge cluster.
P0118 Coolant temperature sensor circuit high 17-23
input
P0340 Engine speed sub sensor circuit 17-18

malfunction
P0335 Engine speed main sensor circuit 17-22
malfunction
P0187 Fuel temperature sensor circuit low input 17-26
P0188 Fuel temperature sensor circuit high input 17-26

P2228 Atmospheric pressure sensor circuit low 17-44
input
P2229 Atmospheric pressure sensor circuit high 17-44

input
P0336 Abnormal engine main rotation sensor 17-16

pulse count
P0341 Abnormal engine auxiliary rotation sensor 17-20

pulse count
P2122 Accelerator sensor circuit 1 low voltage 17-37
P2123 Accelerator sensor circuit 1 high voltage 17-37
P2127 Accelerator sensor circuit 2 low voltage 17-39
P2128 Accelerator sensor circuit 2 high voltage 17-39
P1133 Emergency accelerator sensor malfunction 17-42

high input
P0540 Preheat circuit malfunction 17-71

(Open/ground short-circuit)
P0540 Preheat circuit malfunction 17-71

(VB short-circuit)

a. Other problems P0219 Engine over-run 17-25
P1417 EGR cooler coolant temperature sensor 17-30

b. DTC code display on the malfunction
multiple display of the P1418 EGR cooler coolant temperature sensor 17-30
gauge cluster. malfunction
P0617 Starter signal malfunction 17-76
P0263 Cylinder 1 contribution/balance fault 17-52

P1416 EGR cooler overheat 17-70

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JP31Z01170301002
1. Signal check harness
! CAUTION • When measuring terminal of the engine ECU,

connect the signal check harness to prevent
damage to the connector. Place the tester rod
on the contact box of the signal check
harness for measurement.
NOTICE • Terminal numbers in the text and the

illustrations correspond as shown below in
the "Computer pin arrangement".
ECU terminal name
[Example] For terminal A8 ECU terminal number

(Contact box)
SAPH31Z011700010
2. Connection of signal check harness

(1) Set the starter key to "OFF" and disconnect the connector
from the engine ECU.
(2) Connect the signal check harness to the engine ECU and
the unit harness.
Signal check harness : 09049-1080
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unit harness
Test lead
Signal check connector
SAPH31Z011700011
Computer pin arrangement

JP31Z01170201001
SAPH31Z011700012
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Check the ECU power supply voltage

JP31Z01170601002
1 Measurement of voltage between terminals
1. Set the starter key to "OFF" and connect the signal check
A5 㧭 A6 D1 㧰 E4 㧱 E5 harness
A7
2. Turn the starter key "ON" and measure voltage between
terminals A5, A6, A7 and terminals D1, E4, E5.
Standard value : 20 V or more
NG • 0V: Blown fuse, harness failure, ground failure, etc.

• 20V or less: Battery deterioration, ground failure,
SAPH31Z011700013
etc.
OK
Normal
Check the ground

JP31Z01170601003
D1 㧰 E4 㧱 E5 harness.
2. Disconnect the ECU side connector of the signal check

Frame
harness and measure the resistance between terminals D1,
E4, E5 and the terminal (-) of the battery.
Standard value : 1 Ω or less
NG Disconnection of ground harness, contact failure,

SAPH31Z011700014 etc.
OK
Normal
Engine speed main sensor circuit malfunction

(DTC code P0335)
JP31Z01170601004
B6 B B7 harness.

harness and measure the resistance between terminal B6 and
terminal B7.
Standard value : Approx. 125.5 ± 17 Ω (20 °C{68 °F})
NG [3] Go to measurement of resistance between sensor

SAPH31Z011700015 terminals.
OK
1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, Start the engine and confirm that
START no diagnostic code is put out.
Standard : No diagnostic code
OFF NG Contact failure of ECU connector, ECU failure, short-

circuit of harness
SAPH31Z011700016
OK
Normal
1. Disconnect the connector of the main engine speed sensor and

the sensor.
Standard value : Approx. 125.5 ± 17 Ω (20 °C{68 °F})
NG Failure of main engine speed sensor
SAPH31Z011700017
OK
Harness disconnection or connector failure

Abnormal engine main rotation sensor pulse count

(DTC code P0336)
JP31Z01170601013
1 Measuring the input waveform on the engine ECU side
B6 㧮 B7
harness.
2. Start the engine.
3. Measure the waveform between terminals B6 and B7 of the

signal check harness.
Standard : 56 pulses from missing tooth to missing

tooth
SAPH31Z011700018
4. Stop the engine after measuring.
NG Go to [2] Measuring the resistance between

terminals.
OK
Defective ECU, defective ECU connector
2 Measuring the resistance between terminals
1. Leave the connector of the engine main rotation sensor

connected.
B7
2. Measure the resistance between terminal No. 1 of the engine

main rotation sensor connector (unit harness side) and
terminal B7 of the signal check harness.
! CAUTION • The connector of the engine main rotation

sensor is shown from the engagement side.
SAPH31Z011700019
3. Measure the resistance between terminal No. 2 of the engine

B6
terminal B6 of the signal check harness.

Standard value : 2Ω or less
NG Defective harness
SAPH31Z011700020
OK
Go to [3] Measuring the output waveform on the sensor side

3 Measuring the output waveform on the sensor side
1. Leave the connector of the engine main rotation sensor

connected.
3. Measure the waveform between terminal No. 1 of the engine

terminal No. 2.

SAPH31Z011700021
Standard : 56 pulses from missing tooth to missing

tooth
NG Defective engine main rotary sensor or defective

flywheel pulser
OK
Defective connector contact

Engine speed sub sensor circuit malfunction

(DTC code P0340)
JP31Z01170601005
1 Measurement of voltage between sensor terminals
harness.
GND +5V
2. Disconnect the connector of the sub-speed sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the sub-speed sensor
connector (at unit harness side).
Standard value : 5.0 ± 0.5 V

SAPH31Z011700022
NG [2] Go to measurement of voltage between terminals.
OK
[3] Go to measurement of voltage between terminals.
1. Measure voltage between terminal D32 and terminal D30 of

D the signal check harness.
D32 D30
Standard value : 5.0 ± 0.5V
NG Engine ECU failure, connector failure
SAPH31Z011700023
OK
Harness failure
1. Set the starter key to "OFF" and connect the connector of the
D D19
sub-speed sensor.
D30
2. Start the engine and keep idling status.
3. Measure voltage between terminal D19 and terminal D30 of

the signal check harness.
4. After measurement, stop the engine.
SAPH31Z011700024 Standard : Pulse waveform of 0 ↔ 5 V
NG [4] Go to measurement of resistance between

terminals.
OK
Engine ECU failure, ECU connector failure
1. Leave the connector of the sub-speed sensor connected.

SIG
D19 2. Measure resistance between the No. 1 terminal at the unit
harness of the sub-speed sensor connector and terminal D19
of the signal check harness.
! CAUTION • The connector of the sub-speed sensor in the

figure is viewed from the fitting surface.
SAPH31Z011700025
NG Harness failure
OK
Failure of sub-speed sensor

Abnormal engine auxiliary rotation sensor pulse count

(DTC code P0341)
JP31Z01170601039
1 Measuring the voltage between the sensor terminals
harness.
GND +5V
2. Disconnect the connector of the engine auxiliary rotation
sensor.
3. Set the starter key to "ON" and measure the voltage between
the +5 V terminal of the engine auxiliary sensor connector (unit
harness side) and the GND terminal.
SAPH31Z011700026 Standard value : 5.0 ± 0.5 V
NG Go to [2] Resistance between terminals.
OK
Go to [3] Measuring the input waveform on the engine ECU side.
2 Measuring the resistance between terminals
SIG engine auxiliary rotation sensor.
D19
2. Measure the resistance between terminal SIG of the engine
auxiliary rotation sensor connector (unit harness side) and
terminal D19 of the signal check harness.
! CAUTION • The connector of the engine auxiliary rotation

SAPH31Z011700027 Standard value : 2 Ω or less
NG Defective harness
OK
Go to [3] Measuring the input waveform on the engine ECU side.

3 Measuring the input waveform on the engine ECU side
D19 2. Measure the waveform between terminals D19 and D30 of the
D30
signal check harness.
Standard : Seven pulses from excess tooth to excess

tooth
SAPH31Z011700028 NG Go to [4] Measuring the output waveform on the

sensor side.
OK
Defective engine ECU, defective ECU connector
4 Measuring the output waveform on the sensor side.
1. Leave the connector of the engine auxiliary rotation sensor

SIG GND
connected.
3. Measure the waveform between terminal SIG of the engine

auxiliary rotation sensor connector (unit harness side) and
terminal GND.
! CAUTION • The connector of the engine auxiliary rotation

SAPH31Z011700029
Standard : Seven pulses from excess tooth to excess

tooth
NG Defective engine auxiliary rotations sensor or

defective pulser
OK
Defective connector contact

Engine speed main and sub sensor circuit malfunction

(DTC code P0335)
JP31Z01170601006
1 Inspection item
1. Take actions of (DTC code P0335) and (DTC code P0340).

"Reference : Engine speed main sensor circuit malfunction
(DTC code P0335), Engine ECU, Engine diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction
(DTC code P0340), Engine ECU, Engine diagnosis code"
Coolant temperature sensor malfunction

(DTC code P0117, P0118)
JP31Z01170601007
DTC P0117 Coolant temperature sensor circuit low input
DTC P0118 Coolant temperature sensor circuit high input
1. Set the starter key to "OFF" and connect the signal check harness.
D E
E19 2. Disconnect the ECU side connector of the signal check
D34 harness and measure the resistance between terminal E19
and terminal D34.
Standard value (Measure either one point of the following.)

Characteristics table of temperature—resistance value
20 °C{68 °F} 2.45 kΩ

SAPH31Z011700030
40 °C{104 °F} 1.15 kΩ
60 °C{140 °F} 0.584 kΩ
80 °C{176 °F} 0.318 kΩ
NG [2] Go to measurement of resistance between sensor

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
1. Disconnect the connector of the coolant temperature sensor

and measure the resistance between No. 1 and No. 2 terminals
at the sensor.

20 °C{68 °F} 2.45 kΩ
40 °C{104 °F} 1.15 kΩ
SAPH31Z011700031 60 °C{140 °F} 0.584 kΩ
80 °C{176 °F} 0.318 kΩ
NG Failure of coolant temperature sensor
OK
Harness disconnection, connector failure

Engine overheat
(DTC code P0217)
JP31Z01170601008
1. Set the starter key to "OFF", disconnect the connector of the

coolant temperature sensor and measure the resistance
between No. 1 and No. 2 terminals at the sensor.

20 °C{68 °F} 2.45 kΩ
40 °C{104 °F} 1.15 kΩ
SAPH31Z011700031 60 °C{140 °F} 0.584 kΩ
80 °C{176 °F} 0.318 kΩ
NG Failure of coolant temperature sensor
OK
Failure of engine cooling system
NOTICE • This code is displayed when the coolant temperature sensor is normal and the coolant
temperature is 105 °C{221 °F} or more.
• While this failure code is detected, the maximum injection volume is restricted. When the
coolant temperature is 80 °C{176°F} or less, normal control is resumed.
Engine overrun
(DTC code P0219)
JP31Z01170601009
1 This failure code is displayed when the engine speed of 2,560 r/min or more is detected. While this
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,460 r/min,
fuel injection is resumed.
NOTICE • The objective of this failure code is not to

detect overrun due to failure of this system,
but to memorize high revolution of the engine.
• Engine speed may be incorrectly recognized
with noise on the speed sensor signal due to
harness failure or modification, resulting in
detection of overrun.
Fuel temperature sensor malfunction (DTC code P0187, P0188)

JP31Z01170601010
DTC P0187 Fuel temperature sensor circuit low input

DTC P0188 Fuel temperature sensor circuit high input
D E harness.
D34 E26
harness and measure the resistance between terminal E26
and terminal D34.

SAPH31Z011700032 20 °C{68 °F} 2.45 kΩ
40 °C{104 °F} 1.15 kΩ

60 °C{140 °F} 0.584 kΩ
80 °C{176 °F} 0.318 kΩ

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
2 Measurement of sensor resistance
1. Disconnect the connector of the fuel temperature sensor and

the sensor.

20 °C{68 °F} 2.45 kΩ
40 °C{104 °F} 1.15 kΩ
SAPH31Z011700033 60 °C{140 °F} 0.584 kΩ
80 °C{176 °F} 0.318 kΩ
NG Failure of fuel temperature sensor
OK
Harness disconnection, connector failure

Boost pressure sensor malfunction

(DTC code P0108, P0237)
JP31Z01170601011
DTC P0108 Boost pressure sensor circuit high input

DTC P0237 Boost pressure sensor circuit low input
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
+5V terminal and the GND terminal of the boost pressure
sensor connector (at unit harness side).
Standard value : 5 ± 0.5 V

SAPH31Z011700034
OK
1. Measure the voltage between terminal D25 and terminal D33

D D25
of the signal check harness.
D33 NG Engine ECU failure, ECU connector failure
SAPH31Z011700035
OK
Harness failure
D D27
boost pressure sensor.
terminal D27 and terminal D33 of the signal check harness.
D33
Standard value : 0.2 to 4.8 V
SAPH31Z011700036
OK
1. Leave the connector of the boost pressure sensor connected.

GND SIG
2. Measure the voltage between the SIG terminal and the GND
terminal of the boost pressure sensor connector (at unit
harness side).
NG Boost pressure sensor failure
SAPH31Z011700037
OK
Harness failure
Turbocharger over boost

(DTC code P0234)
JP31Z01170601012
1 Inspection with failure diagnosis tool
1. After failure, perform failure diagnosis with a failure diagnosis

tool (HinoDX) using PC.
㪦㪥 2. Connect the failure diagnosis tool (HinoDX) using PC and set

the starter key to "ON".
㪦㪝㪝
SAPH31Z011700083
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
EGR cooler coolant temperature sensor malfunction

(DTC code P1417, P1418)
JP31Z01170601014
1. Disconnect all ECU connectors and measure the resistance

A D between terminal A34 and terminal D34 of the check harness.

A34 D34
20 °C{68 °F} 2.45 kΩ
40 °C{104 °F} 1.15 kΩ
60 °C{140 °F} 0.584 kΩ

SAPH31Z011700038
80 °C{176 °F} 0.318 kΩ
NG [2] Measurement of sensor resistance
OK
ECU, ECU connector failure, harness failure (short-circuit)
2 Measurement of sensor resistance
1. Disconnect the sensor connector and measure the resistance

of the sensor.

20 °C{68 °F} 2.45 kΩ
40 °C{104 °F} 1.15 kΩ
60 °C{140 °F} 0.584 kΩ

SAPH31Z011700039
80 °C{176 °F} 0.318 kΩ
NG Sensor failure
OK
Harness failure (disconnection), connector failure

Excessive common rail pressure

(DTC code P0088)
JP31Z01170601015
DTC P0088 Excessive common rail pressure (1st step)
DTC P0088 Excessive common rail pressure (2nd step)
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
NG Engine ECU failure or harness/connector contact

SAPH31Z011700040 failure
OK
Failure of common rail pressure sensor

Excessive common rail pressure, supply pump excess forced feed

(DTC code P0088)
JP31Z01170601016
D D20 harness.
D31 2. Start and warm-up the engine until the coolant gauge moves
D33 (failure code P0088 or 76 is displayed).
3. Set the engine speed to idling. PFIN = Approx. 25 MPa

(approx. 1.5 V)
4. Measure the voltage between terminal D20/D31 and terminal

SAPH31Z011700041
D33 of the signal check harness.
Standard value:1.56 V or less
NG Common rail pressure sensor failure or engine ECU

failure
OK
2 Check of failure code
1. Make sure that other failure code is not output.

If other failure code is output, repair the failure code and make
sure again that failure code P0088 or 76 is output. In particular,
if a failure code of the main and sub-engine speed sensor
systems is output, make necessary repairs to prevent output of
the code.
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with HinoDX.
SAPH31Z011700042
Common rail pressure sensor malfunction

(DTC code P0191)
JP31Z01170601017
D D20 harness.
D33 terminals D20/D31 and terminal D33.
NG Engine ECU failure or harness/connector contact

failure
SAPH31Z011700043
OK

㧰 D20
2. While measuring the voltage between terminals D20/D31 and
D31 terminal D33 of the signal check harness, repeat full opening/
D33 closing of the accelerator.
Standard : Voltage must change. (1.0 to 3.2 V)
NG Common rail pressure sensor failure or harness/

connector contact failure
SAPH31Z011700044
OK
Engine ECU failure, connector contact failure

Common rail pressure sensor failure

(DTC code P0192, P0193)
JP31Z01170601018
DTC P0192 Common rail pressure sensor circuit low input
DTC P0193 Common rail pressure sensor circuit high input
D33 D D20
harness.
terminals D20/D31 and terminal D33 of the signal check
harness.

SAPH31Z011700045
OK
1. Set the starter key to "OFF" and disconnect the connector of

the common rail pressure sensor.
GND +5V
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at unit harness side).

SAPH31Z011700046 terminals.
OK
Go to [3] measurement of resistance between terminals

1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
SIG
NG Harness failure
SAPH31Z011700047
OK
Connector contact failure
1. Set the starter key to "OFF" and disconnect the ECU side
2. Measure the resistance between terminals D23/D33 of the

㧮 +5V
B23 signal check harness and the +5 V terminal of the common rail
Standard value:2 Ω or less

B33
NG Harness failure
SAPH31Z011700048
OK

Fuel leakage
(DTC code P0093)
JP31Z01170601019
1 Inspection item
1. For evaluation conditions for this failure diagnosis, if there is no

failure of failure code P0628, P0629, P2633, P2634, P0191,
P192, P0193 or 77, engine revolution is 400 r/min or more and
engine coolant temperature is 60 °C{140°F} or more, and the
following status (a, b or c) is detected, it is diagnosed as an
error.
a. If the common rail actual pressure (NPC) is 5MPa {51kgf/
cm2, 725lbf/in.2} lower than the target pressure (PFIN) for a
certain time although the supply pump is the maximum
discharge status (failure code P1266 or 77 is detected).
b. If the discharge amount of the supply pump is greater than
during normal idling for a certain period of time when it is
within 5 MPa{51 kgf/cm2, 725 lbf/in.2}, the deviation of NPC
and PFIN during idling control.
c. If the discharge amount of the supply pump is large for a
certain period of time when it is within 5 MPa{51 kgf/cm2,
725 lbf/in.2}, the deviation of NPC and PFIN when the
injection volume is zero.
Since the injection volume and injection pressure are limited
during detection of this failure, the engine output is reduced.
Check clogging of fuel supply system. If the high pressure pipe
does not have a failure, the supply pump may have a failure.
2. Perform more detailed diagnosis with HinoDX.
SAPH31Z011700042
Accelerator sensor 1 malfunction

(DTC code P2122, P2123)
JP31Z01170601020
DTC P2122 Accelerator sensor circuit 1 low voltage
DTC P2123 Accelerator sensor circuit 1 high voltage
harness.
terminal A21 and terminal B20 of the signal check harness.
B20
A21 Standard value : 1.0 - 1.5V (idle status)
NG [3] Voltage measuring at the output port of the

mechatronic controller
SAPH31Z011700049
OK
1. While increasing the throttle, measure the voltage between

Standard value
B20 Engine
A21 Measuring item Voltage(V)
revolution(r/min)
Low idle 800 Approx. 1.0
High idle 1,850 Approx. 2.9
SAPH31Z011700049
NG Defective mechatronic controller
OK
Harness failure
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronic controller and B20 of the signal check
harness.
When an abnormal value is detected, the mechatronic
controller becomes defective.
Abnormal value
: 0.6 V or less
: 4.85 V or more
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller

Accelerator sensor 1 malfunction

(DTC code P2127, P2128)
JP31Z01170601021
DTC P2127 Accelerator sensor circuit 2 low voltage
DTC P2128 Accelerator sensor circuit 2 high voltage
㧭㧮 harness.
A22
B21
Standard value : 1.0 - 1.5V (idle status)
NG [3] Voltage measuring at the output port of the

mechatronic controller
SAPH31Z011700050
OK
1. While increasing the throttle, measure the voltage between

㧭㧮 terminal A22 and terminal B21 of the signal check harness.
A22
B21
Standard value
Engine
Measuring item Voltage(V)
revolution(r/min)
Low idle 800 Approx. 1.0
High idle 1,850 Approx. 2.9
SAPH31Z011700050
NG Defective mechatronic controller
OK
Harness failure
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 27 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.6 V or less
: 4.85 V or more
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller

Accelerator sensor 1 and 2 malfunction

(DTC code P2120)
JP31Z01170601022
1 Inspection item
1. Take action of failure code P2120 or 22.

"Reference: Accelerator sensor 1 malfunction (DTC code
P2121)
"Reference: Accelerator sensor 2 malfunction (DTC code
P2126)"
Emergency accelerator sensor malfunction

(DTC code P1133)
JP31Z01170601023
1 Power supply voltage measuring
1. With the ECU connector connected, disconnect the sensor

connector and measure the voltage between the power
+5V terminal (+5 V) and the GND terminal.
! CAUTION • The connector in the figure is seen from the

fitting surface.
GND Standard value : 5.0 ± 0.5 V

SAPH31Z011700051
OK
1. Measure the voltage between terminals B20 and B23 of the

㧮 signal check harness.
B23 B20
Standard value : 5.0 ± 0.5 V
NG Engine ECU, engine ECU connector failure
SAPH31Z011700052
OK
Harness failure
1. Connect the sensor connector and measure the voltage

between terminals A23 and B20 of the signal check harness.
Standard value : Approx. 0.0 to 2.6±0.3 V (at the time

of 1,700 - 1,850 r/min)
B20
A23 NG [4] Go to measurement of voltage between terminals.
SAPH31Z011700053
OK
Engine ECU failure, engine ECU connector failure
1. Leave the emergency accelerator sensor connected.
2. Connect the sensor connector and measure the voltage

GND between the terminals SIG and GND of the sensor.
! CAUTION • The connector in the figure is seen from the

SIG
fitting surface.
Standard value : Approx. 0.0 to 2.6±0.3 V (at the time

of 1,700 - 1,850 r/min)
SAPH31Z011700054
NG Emergency accelerator sensor failure
OK
Harness failure
Atmospheric pressure sensor malfunction

(DTC code P2228, P2229)
JP31Z01170601024
DTC P2228 Atmospheric pressure sensor circuit low input
DTC P2229 Atmospheric pressure sensor circuit high input
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output.
㪪㪫㪘㪩㪫㪦㪥
Standard : Normal
NG Engine ECU failure

㪦㪝㪝
SAPH31Z011700084
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
Injector common 1 short to GND

(DTC code P1211),
Injector common 2 short to GND
(DTC code P1214)
JP31Z01170601025
harness.

harness.
3. Measure the resistance between each terminal of the signal
D5 D D6 check harness and the ECU case ground.
ECU case ground
(ECU mounting bolt)
DTC code Terminal to measure resistance
ECU case
E6 E E7 P1211 D5, D6
ground
ECU case
P1214 E6, E7
ground
SAPH31Z011700055 Standard value: ∞ Ω

injector terminals.
OK
1. Set the starter key to "OFF" and connect the ECU side
START 2. Start the engine and delete the past failure.
3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
OFF
temporary error has occurred.
SAPH31Z011700016
3 Measurement of resistance between injector terminals
1. Set the starter key to "OFF".
2. Tilt the cab and disconnect the injector clustered connector at

the front of the cam housing.
1 2 3 4
5 6 7 8 3. Measure the resistance between terminals of the injector
9 10 11 12 clustered connector (at unit harness side).
Terminal to measure voltage

DTC code
SAPH31Z011700056
+ side – side
1, 2
ECU case
P1211 9, 10
ground
8, 6
5, 7
ECU case
P1214 12, 11
ground
4, 3
Standard value: ∞ Ω
NG Harness failure (failure including pinching of harness

which has not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
Injector common 1 short to BATT

(DTC code P1212),
Injector common 2 short to BATT
(DTC code P1215)
JP31Z01170601026
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
! CAUTION • Never start the engine because it may cause

SAPH31Z011700057
failure of the unit or electric shock.

DTC code
+ side – side
ECU case
P1212 D5, D6
ground
ECU case
P1215 E6, E7
ground
Standard value: 14V or less
NG [3] Go to measurement of voltage between injector

terminals.
OK
START 2. Start the engine and delete the past failure.
3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
OFF
SAPH31Z011700016
3 Measurement of voltage between injector terminals
2. Tilt the cab and disconnect the injector clustered connector at

the front of the cam housing. Set the starter key to "ON".
1 2 3 4
5 6 7 8 3. Measure the voltage between terminals of the injector
9 10 11 12 clustered connector (at unit harness side).
! CAUTION • Never start the engine because it may cause

failure of the unit or electric shock.
SAPH31Z011700056

DTC code
+ side – side
1
ECU case
P1212 9
ground
8
5
ECU case
P1215 12
ground
4
Standard value: 14V or less
NG Harness failure (harness failure of terminal that has

not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
Injector circuit malfunction

(DTC code P0201 to P0206)
JP31Z01170601027
DTC P0201 Injector circuit malfunction -cylinder 1


harness.
D3
D2 D6
harness and measure the resistance between terminals.
D4 D5
Terminal to
Failure area
DTC code measure
(injector)
resistance
P0201 #1 D2 ↔ D5
P0202 #2 D3 ↔ D5
E3 E6
P0203 #3 D4 ↔ D6
E2 P0204 #4 E1 ↔ E6
E7
E1
P0205 #5 E3 ↔ E6
P0206 #6 E2 ↔ E7

injector terminals.
SAPH31Z011700058
OK
START 2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
3. If the same failure code is output again, replace the common

OFF
rail ECU. If the normal code is output, it is considered that a
SAPH31Z011700016
1. Disconnect the injector clustered connector at the front of the

cam housing.
2. Measure the resistance between terminals of the injector

clustered connector (male) at the cam housing.
Terminal to measure
DTC code
resistance
P0201 1↔2
SAPH31Z011700059 P0202 9 ↔ 10
P0203 8↔6
P0204 5↔7
P0205 12 ↔ 11
P0206 4↔3

injector terminals.
OK
Unit harness disconnection (Check the harness between the ECU and the injector clustered connector.)
1. Remove the head cover and disconnect the injector connector

(injector side) of the cylinder indicated by the failure code.
Measure the resistance between the No. 1 terminal and the No.
2 terminal.
Standard value : 0.45 ± 0.1 Ω

injector terminals.
SAPH31Z011700060
OK
Contact failure of harness or connector inside the head cover

1. Remove the terminal cap of the injector of the cylinder

indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.
Standard value : 1, 000 MΩ or more
NG Injector TWV coil disconnection (Replace the injector

assembly.)
SAPH31Z011700061
OK
Injector harness disconnection (Replace the injector harness.)

Cylinder contribution/balance fault

(DTC codes P0263, P0266, P0269, P0272, P0275, P0278)
JP31Z01170601028
DTC P0263 Cylinder 1 contribution/balance fault

1 Inspection of flow damper
1. Set the starter key to "OFF" and stop the engine.
2. Wait for approx. 30 seconds and start the engine.

START
3. Warm up the engine until coolant is 60 °C{140 °F} or more and
delete the past failure.
OFF
SAPH31Z011700016
4. If the same failure code is displayed as the current failure after

deleting the past failure, check the flow damper of the cylinder
indicated by the failure code.
Failure area
DTC code
(Flow damper)
P0263 #1
P0266 #2
P0269 #3
SAPH31Z011700062
P0272 #4
P0275 #5
P0278 #6
Inspection details
: Remove the flow damper from the common rail and
run air from one side of the flow damper. Check if the
damper is not blocked by release of air to the
opposite side.
! CAUTION • When air is run, be careful so that dirt, water,

etc. may not enter the flow damper.
The flow damper is activated (air is not run).

: Replace the flow damper.
The flow damper is not activated (air is run).
: [2] Go to check of failure code.
1. Make sure that other failure code is not output. If other failure
code is output, repair the failure first and delete the past failure
with the failure diagnosis tool (HinoDX) using PC. Then, if this
failure code is output again, the following failures may be
estimated.
• Excessive fuel flow due to leak from broken pipe, crack in
pipe or pipe connection between the flow damper and the
injector pipe
→ Check for leak
• Too large or too small fuel flow due to increase of leak inside
the injector
→ Check for leak on the individual injector with a nozzle
tester
• Excessive fuel flow due to failure of injection nozzle and seat
→ Check for seat failure on the individual injector with a
nozzle tester
• Too large or too small fuel flow due to malfunction of the
injector
→ Check with replacement of injector
• Too small fuel flow due to clogging in the fuel supply system
→ Inspection of fuel filter
2. Check the compensation between cylinders and stop an

injector with HinoDX. Then, perform diagnosis while viewing
the engine data.
SAPH31Z011700042
PCV1 malfunction
(DTC code P0628)
JP31Z01170601029
E5 E16
D1 D E4 E E17
harness.

3. Measure voltage between terminal E16/E17 and terminal D1/

E4/E5.
Standard value: 19 V or more

SAPH31Z011700063
NG [3] Go to measurement of resistance of the supply

pump solenoid valve.
OK
connector of the signal check harness. After deleting the past
failure, output the diagnosis code again.
START
Standard: Normal

OFF
SAPH31Z011700016
OK
Normal
3 Measurement of resistance of supply pump solenoid valve 1
1. Set the starter key to "OFF" and remove the harness

connected to supply pump solenoid valve 1.
NOTICE • Supply pump solenoid valve 2 has an

identification tag (rear) on the harness
connected to the supply pump identification
tag.
2. Measure resistance between the No.1 terminal and No.2

terminal of the connector (at parts side) of supply pump
SAPH31Z011700064
solenoid valve 1.
Standard value: 3.2 ± 0.3 Ω
NG Failure of supply pump solenoid valve 1 (Replace the

supply pump.)
OK
4 Measurement of voltage between terminals of supply pump solenoid valve 1
1. Turn "ON" the starter key.

Engine ground,
chassis ground, etc. 2. Measure the voltage between the No. 1 terminal and the GND
terminal of the connector (at unit harness side) of supply pump
solenoid valve 1.
Standard value: 19 V or more
NG [7] Go to measurement of relay power.
SAPH31Z011700065
OK

Supply pump solenoid valve 1 E16
E E17 2. Measure the resistance between terminals E16/E17 of the
signal check harness and the supply pump solenoid valve 1
solenoid valve 1.
Standard value: 2 Ω or less
NG Failure of harness between supply pump solenoid 1

and ECU
SAPH31Z011700066
OK
[6] Go to check of failure code.

1. Connect all connectors, delete the past failure and output the
failure code again.
START NOTICE • If the past failure is deleted and the same

code is displayed again, check it again from
the beginning since it may be a connector
contact failure.
OFF
• Measure resistance between the battery
minus terminal and the same part, such as
SAPH31Z011700016 supply pump solenoid valve 1 and engine
ground, and make sure that it is insulated.
7 Inspection of supply pump solenoid valve relay
1. Set the starter key to "OFF", remove the supply pump solenoid
valve relay and measure the resistance between terminals.
Standard value
: 282 to 369 Ω between terminals in Fig. "1"
: ∞ Ω between terminals in Fig. "2"
NG Failure of supply pump solenoid valve relay
1 2
SAPH31Z011700067
OK
Power circuit harness failure or blown PCV1 fuse

PCV1 malfunction
(DTC code P0628)
JP31Z01170601030
1 Inspection item
1. Take action of failure code P0628 or 71 and P2633 or 72.

"Reference: PCV1 malfunction (DTC code P0628)"
"Reference: PCV2 malfunction (DTC code P2633)"
PCV1 out put short to GND

(DTC code P0629)
JP31Z01170601031
harness.
2. Remove the harness connected to supply pump solenoid valve

1 of the supply pump.

connected to the supply pump, and supply
pump solenoid valve 1 does not have an
SAPH31Z011700064
identification tag.
3. Measure resistance between the No. 1 terminal and No. 2

solenoid valve 1.

supply pump.)
OK

E4, E5 E E16, E17 D harness.
D1 2. Turn the starter key "ON" and measure voltage between

terminals E16, E17 and terminals D1, E4, E5.
Standard value: Approx. 1.0 V or less
NG Failure of harness between supply pump solenoid

valve 1 and ECU (Check short-circuit of supply pump
SAPH31Z011700068 solenoid valve 1 harness and +24 V system.)
OK
Go to [3] Check of failure code

1. Set the starter key to "OFF" and connect all connectors. After
deleting the past failure, output the diagnosis code again.
Standard: Normal
START
OFF
SAPH31Z011700016
OK
Normal
PCV1 malfunction
(DTC code P0629)
JP31Z01170601032
1 Inspection item
1. Take action of failure code P0629 and P2634 or 72.

"Reference: PCV1 out put short to GND (DTC code P0629)"
"Reference: PCV2 out put short to GND (DTC code P2634)"
PCV2 malfunction
(DTC code P2633)
JP31Z01170601033
E5
D1 D E4 E harness.

E14
E15
3. Measure voltage between terminal E14/E15 and terminal E4/
E5/D1.
Standard value: 19V or more

SAPH31Z011700069
NG [3] Go to supply pump solenoid valve 2.
OK
connector of the signal check harness. After deleting the past
failure, output the diagnosis code again.
START
Standard: Normal
NG ECU failure
OFF
SAPH31Z011700016
OK
Normal
1. Set the starter key to "OFF" and remove the harness

connected to supply pump solenoid valve 2 of the supply pump.

connected to the supply pump solenoid valve,
and supply pump solenoid valve 1 does not
have an identification tag.
SAPH31Z011700064 2. Measure resistance between the No. 1 terminal and No. 2

solenoid valve 2.

supply pump.)
OK
4 Measurement of voltage between terminals of supply pump solenoid valve 2
1. Turn "ON" the starter key.

Engine ground,
chassis ground, etc. 2. Measure the voltage between the No. 1 terminal and the GND
solenoid valve 2.
Standard value: 19V or more
NG [7] Go to measurement of relay power.
SAPH31Z011700065
OK

Supply pump
solenoid valve 2 E14 E E15 2. Measure the resistance between terminals E14/E15 of the
signal check harness and the supply pump solenoid valve 2
solenoid valve 2.
Standard value: 2 Ω or less

SAPH31Z011700070 valve 2 and ECU
OK
[6] Go to check of failure code.

1. Connect all connectors, delete the past failure and output the
failure code again.
START NOTICE • If the past failure is deleted and the same

code is displayed again, check it again from
the beginning since it may be a connector
contact failure.
OFF
• Measure resistance between the battery
minus terminal and the same part, such as
SAPH31Z011700016 supply pump solenoid valve 1 and engine
ground, and make sure that it is insulated.
7 Inspection of supply pump solenoid valve relay
1. Set the starter key to "OFF", remove the supply pump solenoid
valve relay and measure the resistance between terminals.
Standard value
: 282 to 369 Ω between terminals in Fig. "1"
: ∞ Ω between terminals in Fig. "2"
NG Failure of supply pump solenoid valve relay
1 2
SAPH31Z011700067
OK
Power circuit harness failure or blown PCV2 fuse

PCV2 out put short to GND

(DTC code P2634)
JP31Z01170601034
harness.

connected to the supply pump solenoid valve,
and supply pump solenoid valve 1 does not
have an identification tag.
2. Measure resistance between the No. 1 terminal and No. 2

SAPH31Z011700064
solenoid valve 2.

supply pump.)
OK

E5
D1 D E4 E harness.
2. Turn the starter key "ON" and measure voltage between

terminals E14, E15 and terminals D1, E4, E5.
E14
E15
Standard value: Approx. 1.0V or less

valve 2 and ECU (Check short-circuit of supply pump
SAPH31Z011700071 solenoid valve 2 harness and +24 V system.)
OK
Go to [3] check of failure code.

1. Set the starter key to "OFF" and connect all connectors. After
deleting the past failure, output the diagnosis code again.
Standard: Normal
START
OFF
SAPH31Z011700016
OK
Normal
Supply pump over-feed

(DTC code P1229)
JP31Z01170601035
1 Inspection item
For evaluation conditions for this failure diagnosis, if the supply

pump discharge volume is the maximum for a certain period of time,
it is diagnosed as an error.
If this failure is output, replace the pressure limiter. If the system
does not recover normal operation, the supply pump may have a
failure.
Perform more detailed diagnosis with HinoDX.
SAPH31Z011700042
Supply pump over-feed

(DTC code P1266)
JP31Z01170601036
1 Inspection item
1. For evaluation conditions for this failure diagnosis, if there is no

failure of failure code P0628, P0629, P2633, P2634, P0191,
P0192, P0193 or 73, 71, 72, 76, engine revolution is 400 r/min
or more and engine coolant temperature is 60°C{140°F} or
more, and the supply pump discharge volume is the maximum
for a certain period of time, it is diagnosed as an error.
If this failure is output, replace the pressure limiter. If the
system does not recover normal operation, the supply pump
may have a failure.
SAPH31Z011700042
2. Perform more detailed diagnosis with HinoDX.

EGR actuator fault

(DTC code P1458,P1459)
JP31Z01170601037
1 EGR inspection
1. Perform warm-up until the engine water temperature becomes

60° or more.
2. Check EGR with the failure diagnosis tool (HinoDX) using PC.
SAPH31Z011700072
EGR valve sticking 1

(DTC code P0404)
JP31Z01170601038
1 EGR inspection
1. Perform warm-up until the engine water temperature becomes

60° or more.
2. Inspect the EGR with a fault diagnosis tool (HinoDX) using a

personal computer.
3. Check that the EGR actuator is operating when the engine is

stopped. (Wiping operation)
SAPH31Z011700073
EGR cooler overheat

(DTC code P1416)
JP31Z01170601041
1 Make sure that P0217 is not displayed.
1. Make sure that there is no P0217 or 6 coolant temperature

overheat.
Standard value: Approx. Water temperature overheat,

no defect
NG Overheat due to cooling system error

Check cooling system (Is there coolant, Coolant
leak)
SAPH31Z011700042
OK
Replace the EGR cooler.

Preheat circuit malfunction

(DTC code P0540)
JP31Z01170601042
C2
C1 C D1 D E4 E E5
harness.

harness and measure the resistance between terminals HRY1,
HRY2 and terminals PGD1, PGD2, PGD3.
Standard value: 25 ± 2.5 Ω
NG [2] Go to measurement of relay resistance.

SAPH31Z011700074
OK
2 Measurement of relay resistance
1. Remove the heater relay and measure the resistance between

terminals.
NG Heater relay failure
SAPH31Z011700075
OK
Harness failure, connector failure

Injector correction data conformily error

(DTC code P1601)
JP31Z01170601043
1 Inspection of QR code
1. Read QR code data with the failure diagnosis tool (HinoDX)

using PC.
Standard value: The code shall conform to the QR

code registered in the service server.
NG Write the QR code again.
SAPH31Z011700042
OK
Replace ECU.
ECU internal error

(DTC code P0605, P0606, P0607)
JP31Z01170601044
DTC P0605 Flash ROM error
DTC P0606 CPU malfunction (Hard detection)
DTC P0607 Monitoring IC malfunction in CPU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check if the same code (DTC
㪪㪫㪘㪩㪫㪦㪥 code P0605, P0606, P0607) is output again.
Standard: Normal
㪦㪝㪝 NG Engine ECU failure
SAPH31Z011700076
OK
normal operation.
ECU charge circuit malfunction

(DTC code P0200, P0611)
JP31Z01170601045
DTC P0200 ECU charge circuit high input
DTC P0611 ECU charge circuit malfunction
1 Check of ECU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check again if the same code
㪪㪫㪘㪩㪫㪦㪥 (P0611, P0200 or 59) is output.
Standard: Normal
㪦㪝㪝 NG Engine ECU failure
SAPH31Z011700076
OK
normal operation.
Main relay malfunction

(DTC code P0686)
JP31Z01170601046
A6
A5 A A7 harness.
2. Disconnect the ECU side connector of the signal check side

Frame harness and set the starter key to "ON".
3. Measure the voltage between terminals A5, A6, A7 and the

chassis GND.
Standard value: 0 V
SAPH31Z011700077
terminals.
OK
ECU failure, ECU connector failure
2 Measurement of resistance between relay terminals
1. Set the starter key to "OFF", remove the battery relay and
measure the resistance between terminals.
NG Faulty battery relay
OK
Harness failure
Starter signal malfunction

(DTC code P0617)
JP31Z01170601047
B B14 C C4
harness.
C3 2. Disconnect the ECU side connector of the signal check

3. Measure voltage between terminal B14 and terminals C3/C4.
! CAUTION • Pay attention to the gear position and

periphery.
SAPH31Z011700078
Standard value
: 0 V (when starter key is at "OFF")
: 24 V (when starter key is at "START")
NG Harness failure
OK

CAN communication loss EGR actuator

(DTC code U1122)
JP31Z01170601048
1 Measurement of the EGR actuator voltage
1. Set the starter key to "OFF" and disconnect the connector of

No.3 the EGR actuator.
No.6 terminals 3 and 6 of the connector of the EGR actuator (on the
side of the unit harness).
Standard:19 V or more
NG Harness defective
SAPH31Z011700079
OK
2 Measurement of the voltage between the CAN communication terminals
harness with the connector of the EGR actuator.
terminals E21 and E22 of the signal check harness.
E21 E22
Standard:Pulse waveform between 0 and 5 V
NG • Wire break, short-circuit (GND short-circuit, 24 V

short-circuit)
SAPH31Z011700080
• Bad harness and/or connector contact
OK
EGR actuator fault

CAN1 Communication error (Engine)

(DTC code U0073)
CAN2 Communication error (Unit)
(DTC code U1001)
JP31Z01170601049
1 Measurement of conductivity of the CANH terminal
No.1 harness.
2. Disconnect the connector of the EGR actuator.
E21
3. Disconnect the connector of the signal check harness on the
ECU side and measure for conductivity between terminal E21
and terminal 1 of the connector of the EGR actuator (on the
side of the unit harness).
SAPH31Z011700081 Standard:Conductivity
OK
2 Measurement of conductivity of the CANL terminal
1. Measure the conductivity between terminal E22 of the signal

check harness and terminal 4 of the connector of the EGR
No.4 actuator (on the side of the unit harness).
Standard:Conductivity
E22
SAPH31Z011700082
OK
Replace the engine ECU

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HINO DIESEL ENGINE

For your information:

This documentation does not contain any descriptions in

"15. Air Compressors".

How to read this manual

1. Scope of repair work

4. How to read sections and titles

5. How to read troubleshooting

Hear from customers for conditions and environments of

Perform diagnosis inspection, status inspection, function

Check if failure occurs again after repair. If it is difficult to

• Pre-inspection is performed in the following steps:

6. How to read explanation details

ENGINE MECHANICAL [J08E] 9–17

Timing Gear Cover and Flywheel Housing

Part name code

Part catalog Fig. No.

11308 Flywheel housing 11390 End plate

*Parts not to be reused.

Conventional Conversion value*1(1[Conventional unit] = X

Precautions for work

2. Precautions for service work

3. Precautions for electric system

a. In an electric system, remove the cable from the battery

(2) Handling of electronic parts

a. Do not give impact on electronic parts such as

(3) Handling of wire harness

a. Mark clamps and clips to prevent interference of a wire

(4) Handling of connector

a. When a connector is removed, hold the connector (as

4. Precautions for electric welding

Tightening of engine bolts and nuts

1. Tightening torque of general standard bolts

Screw diameter x Pitch 7T 9T

M8 x 1.25 (Coarse thread) 28.5{290} 36{370}

M10 x 1.25 (Fine thread) 60{610} 74.5{760}

M10 x 1.5 (Coarse thread) 55{560} 68.5{700}

M12 x 1.25 (Fine thread) 108{1,100} 136{1,390}

M12 x 1.75 (Coarse thread) 97{990} 125{1,280}

M14 x 1.5 (Fine thread) 171.5{1,750} 216{2,210}

! CAUTION • 8T bolt is in accordance with 7T bolt.

(2) For bolts with washers

M6 x 1 (Coarse thread) 6{60} 10{100} 13{130}

M10 x 1.5 (Coarse

M12 x 1.25 (Fine thread) 54{550} 93{950} 118{1,200}

M12 x 1.75 (Coarse

M14 x 1.5 (Fine thread) 83{850} 147{1,500} 186{1,900}

M14 x 2 (Coarse thread) 74{750} 132{1,350} 172{1,750}

! CAUTION • 8T bolt is in accordance with 7T bolt.

R surface (4T) C surface (7T)

(1) When re-application of lock agent is required

NOTICE • Check torque with the lower limit of the

(2) Re-use method of precoated bolt lock

3. Plastic region tightening method (angle method)

(2) Parts tightened

(3) Tightening method after tightening to seating torque

Tightening of chassis bolts and nuts

1. Tightening torque of general standard bolts and nuts

Strength zone 6T 7T 8T 9T 10T 11T 12T

(*1): 9 may be misread with 6. It is expressed in q.

Depression Relief Base depression Upset

(3) Types of general standard bolts and nuts

Standard seating Seating A with flange Seating B with flange