Engine J05D-TI J05E-TI Service
Engine J05D-TI J05E-TI Service
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1 MENU
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
(14'914&HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧡㧡ಽ
EN08-001 EN08-002
TURBOCHARGER (VARIABLE NOZZLE (WASTE GATE VALVE
TURBINE TYPE) TYPE)
EN12-001 EN12-002
STARTER
(24V, 4.5 kW) (24V, 5.0 kW)
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE P.T.O.
(POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROL
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
OTHERS
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GENERAL INTRODUCTION
GN01
GENERAL INTRODUCTION.....................GN01-2
WARNING .......................................................GN01-2
HOW TO USE THIS MANUAL.........................GN01-3
PRECAUTIONS FOR WORK ..........................GN01-8
TIGHTENING OF BOLTS
AND NUTS FOR ENGINE .............................GN01-13
TIGHTENING OF BOLTS
AND NUTS FOR CHASSIS ...........................GN01-15
TIGHTENING OF FLARE NUTS
AND HOSES..................................................GN01-17
SEALANT ON THE TAPERED SCREW
FOR PIPING ..................................................GN01-18
NYLON TUBE ................................................GN01-19
ASSEMBLY OF JOINT/GASKET
FOR PIPING ..................................................GN01-23
HANDLING OF LIQUID GASKET..................GN01-25
TROUBLESHOOTING
USING THE TROUBLE LIST.........................GN01-26
TROUBLESHOOTING
USING A DIAGNOSIS MONITOR .................GN01-27
DIAGNOSIS USING THE PC
(PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE.........GN01-31
CHASSIS SERIAL NUMBER,
VEHICLE IDENTIFICATION NUMBER
AND ENGINE SERIAL NUMBER ..................GN01-34
RECOMMENDED LUBRICANTS ..................GN01-35
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GENERAL INTRODUCTION
WARNING
EN00Z0101C100001
In order to ensure safety in work and avoid possible damage to vehicle, strictly observe the following precautions:
Audience of this manual is a qualified service engineer who has acquired expertise. In case an unqualified service engi-
neer or a service engineer without appropriate training has performed maintenance, or in case maintenance is performed
without using appropriate tools and units or in accordance with the method described in this manual, the vehicle under
maintenance could be damaged as well as do harm to the service engineer and the people in the maintenance site.
• Appropriate maintenance and repairs are a must for assurance of safety of the service engineer as well as the safety
and reliability of the vehicle. Replace parts of the vehicle with HINO genuine parts. Avoid using degraded parts.
• This manual contains the procedures to follow in performing maintenance and repairs. When performing mainte-
nance and repairs in accordance with the procedures, use special tools designed to meet specific needs in a proper
way.
• Never use a non-recommended work method or tool; this could impair the safety of the service engineer as well as
the safety and reliability of your vehicle.
• This manual contains various items classified into DANGERS, WARNINGS, CAUTIONS and NOTICES in order to
avoid accidents during maintenance and repairs or damage to the vehicle resulting in impairment of its safety and
reliability.
Note that these instructions described as DANGERS, WARNINGS, CAUTIONS and NOTICES are not the minimum
requirements to observe in order to avoid possible dangers.
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1. REPAIR WORK
(1) The repair work is roughly classified into the three processes: "diagnosis", "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work" and "final inspection".
(2) This manual describes the first process "diagnosis" and the second process "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work". Description on the third process "final inspection" is omitted.
(3) While this manual does not describe the following element work, the work is to be performed in practical cases:
a. Jack work and lift work
b. Cleaning of removed parts as required
c. Visual inspection
Check for the trouble after the trouble is removed. In case the
(6) Checkup test "Step 4" trouble is hardly replicated, conduct a checkup test under the con-
ditions and environment for the trouble.
(2) Pre-inspection
SHTS00Z010100001
✩: This is the ID number of an item to be prepared for creating electronic data and is not necessary for repair work.
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SHTS00Z010100002
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4. DEFINITION OF TERMS
This manual defines the terms used herein as follows:
(1) Direction
a. Chassis
• To-and-fro direction
The direction of forward travel of the vehicle while mounted on the vehicle is forward direction; the direction of back-
ward travel of the vehicle while mounted on the vehicle is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the vehicle is clockwise direction; the counterclockwise direction as
seen from the rear of the vehicle is counterclockwise direction. (In case of engine, the clockwise direction as seen
from the flywheel side is clockwise direction; the counterclockwise direction as seen from the flywheel side is coun-
terclockwise direction.)
• Upward/Downward direction
The upward direction while mounted on the vehicle is upward, and downward direction while mounted on the vehicle
is downward.
• Right/Left direction
The right direction as seen from the rear of the vehicle while mounted on the vehicle is right direction; the left direc-
tion as seen from the rear of the vehicle while mounted on the vehicle is left direction. (In case of engine, the right
direction as seen from the flywheel side is right direction; the left direction as seen from the flywheel side is left direc-
tion.)
b. Standalone unit
• To-and-fro direction
The direction of input of power is forward direction; the direction of output of power is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the unit is clockwise direction; the counterclockwise direction as
seen from the rear of the unit is counterclockwise direction.
• Upward/Downward direction
The upward direction while the unit is mounted on the vehicle (chassis) is upward, and downward direction while the
unit is mounted on the vehicle (chassis) is downward.
• Right/Left direction
The right direction as seen from the rear of the unit is right direction; the left direction as seen from the rear of the unit
is left direction.
(2) Standard value (Assembly standard):
Indicates a basic dimension or including the tolerance and the clearance generated by the clearance of a combina-
tion of two parts
(3) Limit (Service limit):
Indicates a numeric value which requires correction or replacement.
Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.
6. UNIT
(1) This manual uses the SI unit system. The SI unit is an international unit which is based on one unit per quantity unlike
the conventional unit system which differs from country to country, in order to facilitate technology exchange.
(2) This manual writes the SI unit and a conventional unit side by side, the conventional unit enclosed in parentheses { }.
*1: X is a value obtained by converting 1 [conventional unit] to an SI unit and is used as a conversion factor of the
conventional unit and SI unit.
*2: The torque conversion value may depend on the unit. Follow the specific value described for each unit.
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GENERAL PRECAUTIONS
To assure safety in work and prevent possible danger, observe the following:
2. SAFETY WORK
(1) To prevent burns, never touch a radiator, muffler, exhaust pipe, and tail pipe just after the engine is turned off.
(2) While the engine is rotating, keep your clothes and tools off the rotating sections, in particular the cooling fan and V-
belt.
(3) Remove the starter key except when starting the engine.
(4) Provide good ventilation to avoid excessive CO when starting the engine.
(5) The fuel/battery gas is flammable. Never make a spark or light a cigarette.
(6) Take utmost care when working on the battery. It contains corrosive sulfuric acid.
(7) Large electric current flows through the battery cable and starter cable. Be careful not to cause a short, which can
result in personal injury and/or property damage.
(8) Leaving a tool or waste in the engine room causes the tool or waste to touch the rotating section of the engine and
pop out, which could result in an injury.
3. TOWING
• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order
to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame
near the No.1 crossmember when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct con-
tact with the bumper.
(1) Towing procedures
a. Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle
shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle
lubricant and entry of dirt or foreign matter.
b. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame. The hook should be used only if the towed vehicle is not loaded.
c. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-
tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in
towing a vehicle trapped in a gutter.
d. Keep the gear shift lever in "Neutral".
e. Make sure that the starter switch is kept in the "ON" position.
f. Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum
will be available for the brake. This is dangerous, as the brake system does not function if the engine is not run-
ning.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually
hard to turn, making it impossible to control the vehicle.
g. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
h. Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.
(2) If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed for
that purpose.
a. Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect
the transmission and differential gears from being damaged. The hub openings should be covered to prevent the
loss of axle lubricant or the entry of dirt or foreign matter.
The above-mentioned precautions should be observed for vehicles equipped with either automatic or manual
transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with
lubricant if necessary.
b. Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight
ahead position.
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PRECAUTIONS ON MAINTENANCE
Observe following before maintenance:
6. ASSEMBLY
(1) Observe the specified values (tightening torque, adjustment value) to assemble conforming parts in a correct proce-
dure.
(2) Use genuine parts for replacement.
(3) Use new packing, gasket, O-ring and cotter pin.
(4) Use a seal gasket depending on the location of gasket. Apply specified oil or grease to a sliding section where indi-
cated. Apply specified grease to the lip of the oil seal.
SHTS00Z010100008
SHTS00Z010100009
SHTS00Z010100010
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4. HANDLING OF CONNECTOR
(1) To remove a connector, hold the connector (indicated by an arrow
in the figure) to pull it out. Never pull the harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the
connector.
(5) In case it is difficult to insert a test lead from behind the connector,
prepare a harness for inspection and perform inspection.
SHTS00Z010100011
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SHTS00Z010100012
(2) In order to prevent damage to ancillary equipment components
from sparks during welding, take steps such as putting fire-resis-
tant covers over things like the engine, meters, steering wheel,
hoses, leaf spring and tires.
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NOTICE
8T bolt conforms to the standard of 7T bolt.
(2) With washer
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Screw diameter x pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6 {60, 4.3} 10 {100, 7.2} 13 {130, 9.4}
M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}
M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}
M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}
M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1,200, 87}
M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1,100, 80}
M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1,500, 108} 186 {1,900, 137}
M14 x 2 (Coarse thread) 74 {750, 54} 132 {1,350, 98} 172 {1,750, 127}
Bolt with the numeral "4"
Bolt with the numeral "7"
on its head
on its head Bolt with the numeral "9"
Remarks Projection bolt
Stud with chamfered free on its head
Stud with rounded free
end face
end face
NOTICE
8T bolt conforms to the standard of 7T bolt.
2. PRE-COATED BOLT
A pre-coated bolt is a bolt having a thread coated with seal-
ant.
(1) Cases where sealant must be applied again
a. Pre-coated bolt is removed
b. Pre-coated bolt has moved during tightening torque inspec-
tion
(Loosened or tightened)
HINT
Torque check is to be made using the lower limit value. In case the
bolt has moved, retighten it in the following procedure:
SHTS00Z010100014 (2) How to reuse pre-coated bolt
a. Clean the bolt and the tapped hole (clean the tapped hole
also when the bolt is to be replaced).
b. Blow air to dry up the bolt.
c. Apply a specified sealant to the thread of the bolt.
SHTS00Z010100015
SHTS00Z010100016
SHTS00Z010100017
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HEXAGON BOLT
On the hexagon bolt, the strength category is generally indicated on the head of the bolt by way of depression,
embossment, hollow and upset in accordance with the symbol in the table below.
HEXAGON NUT
The following tables shows examples of symbols to identify the strength category of hexagon nut on the nut itself.
(4) Table of tightening torque of general standard bolt and nut (Standard seat face is shown as a typical case)
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Strength category
4T 7T 9T
Bolt diameter
4.5±1.8 {50±20, 3.6±1.4}
(Cab)
M6 9.0±1.8 {90±20, 6.5±1.4} 11.5±2.0 {117±23, 8.5±1.6}
5.5±1.1 {60±10, 4.4±0.7}
(Chassis)
14.0±3.5
{140±40, 10.1±2.8} (Cab)
22.0±4.0 29.0±5.5
M8 17.0±3.0
{220±40, 15.9±2.8}*2 {300±60, 21.7±4.3}*2
{170±30, 12.3±2.1}
(Chassis)
57.0±11.0
43.0±8.5
{580±110, 41.9±7.9}*2
{440±90, 31.8±6.5}*2 (Cab)
27.0±5.0 (Cab)
M10 51.5±10.0
{276±55, 20.0±3.9} 68.5±13.5
{530±100, 38.3±7.2}
{700±140, 51±10}
(Chassis)
(Chassis)
76.0±15.0 100.0±20.0
{776±150, 56±10}*2 (Cab) {1,020±200, 74±14}*2 (Cab)
48.0±9.5
M12 91.0±18.0 120.0±24.0
{490±98, 35.4±7.0}
{930±180, 67±13} {1,220±240, 88±17}
(Chassis) (Chassis)
77.0±15.0 120.0±24.0 160.0±32.0
M14
{786±157, 57±11} {1,220±240, 88±17} {1,630±326, 118±23}
120.0±24.0 190.0±38.0 250.0±50.0
M16
{1,220±244, 88±17} {1,940±390, 140±28} {2,550±510, 184±37}
165.0±33.0 260.0±52.0 345.0±69.0
M18
{1,680±336, 121±24} {2,650±530, 192±38} {3,520±704, 255±50}
235.0±47.0 370.0±74.0 490.0±98.0
M20
{2,400±480, 174±34} {3,770±750, 273±54} {5,000±1,000, 362±72}
320.0±64.0 505.0±100.0 670.0±130.0
M22
{3,270±654, 236±47} {5,150±1,030, 372±74} {6,840±1,370, 495±99}
405.0±81.0 640.0±125.0 845.0±165.0
M24
{4,130±826, 299±59} {6,530±1,310, 472±94} {8,620±1,720, 623±124}
! CAUTION
• In case of tightening the bolt/nut with the flanged seat face A, the tightening torque value except *2 in the
table is to be increased by 10% from the indicated tightening torque value.
• In case of tightening the bolt/nut with the flanged seat face B, the tightening torque value *2 in the table is to
be increased by 20% from the indicated tightening torque value.
Note that for M8 the tightening torque value is constant for the flanged seat face B also.
• The bolt/nut with flanged seat B which is marked *2 in the table is compatible with a standard seat face as a
pair. Its tightening torque is the same as that of the standard seat face.
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To the tapered thread of the air pipe joint is applied the sealant "LOC-
TITE #575". Follow the procedure below to remove/attach the piping.
1. REMOVAL
(1) The sealant (LOCTITE #575) has a high sealing capability. The
return torque of taper joint is about 1.5 times as high as the initial
tightening torque. To remove the joint, use a longer wrench.
(2) For replacement of joint in a place with poor workability, remove
the auxiliaries with the joint attached then remove the joint.
SHTS00Z010100023
2. ATTACHING
(1) To apply sealant (LOCTITE #575), use waste and thinner to wipe
the dirt off the sealing section, directly apply the sealant by a
quarter turn (three ridges) starting from the second ridge from the
tip, then assemble in accordance with the tightening torque table
below.
Wipe dirt off the mating part (female screw) before tightening it.
! WARNING
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.
SHTS00Z010100024
Tightening torque of tapered joint Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Screw diameter
1/4 3/8 1/2
Material
49±10
Steel {500±100, 64±15 {650±150, 47±10}
36.2±7.2}
25±5 34±5 44±5
Aluminum, brass {250±50, {350±50, {450±50,
18.1±3.6} 25.3±3.6} 32.5±3.6}
(2) To replace vulcanized tape with sealant, remove the tape before-
hand, same as (1).
NOTICE
Take special care not to let dirt and foreign matters enter the pip-
ing.
(3) In the event of air leakage after sealant is applied and piping
attached, retightening cannot check the air leakage. Follow the
steps (1) and (2) to reassemble the piping.
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NYLON TUBE
EN00Z0101C100008
1. TYPES OF JOINT
(1) Nylon tube joints have two types: one-touch connector joint and
sleeve nut joint.
! CAUTION
Function and quality of a nylon tube and each joint are guaranteed
as a set. Use HINO genuine parts. Otherwise a burst or break may
result.
SHTS00Z010100027
SHTS00Z010100028
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d. After connection, pull the tube and check that the distance
from the connector end (retainer) to the taping at the insertion
length position is 5 mm {0.197 in.} or less.
(2) Assembly of sleeve nut (removing the tube from the joint and re-
attaching it in the same position)
MATCH MARK a. Give a match mark between the connector/union and the
sleeve nut before loosening the sleeve nut so as to memorize
the position.
b. For reassembly, tighten the sleeve nut up to the previous
position (match mark position). After that, retighten by 60°.
c. After reassembly, check for air leakage, if any, retighten until
the leakage stops.
d. If the leakage persists, replace the tube, sleeve and insert
with new ones. If this does not stop the leakage, replace the
SHTS00Z010100032 sleeve nut and connector/union as well.
-40-90°C
DIN tube φ6, φ10, φ12
{-40-194°F}
! CAUTION
• Cut a tube only when there is extra length or when using a
new tube.
• When cutting a nylon tube, set the squareness of the tube
end with respect to the axis core within 90±5°.
SHTS00Z010100034
5 OR LESS
SHTS00Z010100035
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! CAUTION
• Never repair a nylon tube under high temperatures exceeding
the operating temperature range, in particular when drying
the coating.
• For punching, welding and sanding, protect a nylon tube
from tools, cutting, heat source or spark or remove the nylon
tube.
• Never attach the clamp of the welder near the tube.
• Never splash acidic liquid such as battery liquid onto the
tube.
• Never exceed the minimum bending radius R of the nylon
tube listed in the table below. Avoid using a tube with trace of
bending line.
! CAUTION
SHTS00Z010100036
• Set the tool clamping force to "3" on the dial.
• If the nylon tube is fixed with nonconforming clamping force,
the nylon tube may be damaged.
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2. REMOVING PARTS
(1) To remove each part, never twist a single section but twist the part in alternate directions at the collar or clearance on
the flange. When removing gasket, take care not to let the refuse of gasket enter the engine.
3. OTHER
(1) When the liquid gasket comes in a tube, use the supplied winding tool. When the gasket comes in a cartridge, use a
spray gun.
Note that the cutting position of the nozzle of the tube provides necessary width of application.
SHTS00Z010100050
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1. DIAGNOSIS MONITOR
(1) When connected to the diagnosis connector dedicated to each
system, the diagnosis monitor indicates a faulty section with
sound and light.
SST: Diagnosis Monitor (S0963-01370)
SHTS00Z010100051
SHTS00Z010100052
! CAUTION
The central diagnosis connectors are normally connected to the
(RIGHT-HAND DRIVE)
fixing dummy connectors. Remove the central diagnosis connec-
FIXING DUMMY tors from the dummy connectors before using them. When the
CONNECTOR central diagnosis connectors are not used, they should be
engaged into the fixing dummy connectors.
HINT
• Turning "ON" the starter switch with the diagnosis monitor
BLACK CONNECTOR connected causes the diagnosis monitor to keep sounding
without outputting diagnosis monitor codes. First turn "ON"
the starter switch, wait at least ten seconds, and connect the
WHITE CONNECTOR
diagnosis monitor.
SHTS00Z010100053
• The method for outputting diagnosis monitor codes differs
from system to system. Follow the instruction in the chapter
for each system.
SHTS00Z010100054
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
4 3
10 6 5
8 7
12 11 9
SHTS00Z010100055
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
LIGHT ON
LIGHT OFF
4.3 SECONDS
0.3 SECONDS
LIGHT ON
LIGHT OFF
SHTS00Z010100056
! CAUTION
• If the starter key is placed in "LOCK" position, the past faults
are not erased. Keep the starter key "ON".
• Erase the malfunction code memory using the PC DIAGNO-
SIS TOOL (Hino DX).
(3) Wait at least 5 seconds. Connect the diagnosis monitor to output
SHTS00Z010100057 the current fault information.
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
SHTS00Z010100058
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC diagnosis tool.
By connection to the diagnosis connector, the trouble location is
indicated.
SST:
Communication interface assembly (09993-E9070)
Cable communication (S0904-21220)
Diagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager
SHTS00Z010100059 NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.
P P
INTERFACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS00Z010100060
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
SHTS00Z010100061
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
SHTS00Z010100062
.
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
(EXAMPLE)
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER AND ENGINE
SERIAL NUMBER
ENGRAVED EN00Z0101C100011
POSITION
1. VEHICLE MODEL AND CHASSIS SERIAL NUMBER OR VEHI-
CLE IDENTIFICATION NUMBER
(1) Vehicle model and chassis serial number or vehicle identification
number are engraved near the front wheel of the right or left frame
SHTS00Z010100063
of the vehicle. When ordering parts, notify us of these numbers for
quick support.
(2) At the step inside the right door of the cab is attached an identifi-
(RIGHT-HAND DRIVE) cation plate stamped the vehicle model and chassis serial number
or vehicle identification number.
IDENTIFICATION
PLATE
SHTS00Z010100064
(LEFT-HAND DRIVE)
IDENTIFICATION
PLATE
SHTS00Z010100065
ENGRAVED
POSITION
SHTS00Z010100066
2A)0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦ೨㧝㧜ᤨ㧜ಽ
RECOMMENDED LUBRICANTS
EN00Z0101C100012
EN01-001
ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
EN01Z0101I200001
Compression pressure 2.9-3.1 MPa {30-31 kgf/cm2, 421-449 lbf/in.2} at 150 r/min.
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 280 r/min.
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Compression pressure 3.4-3.6 MPa {35-36 kgf/cm2, 494-522 lbf/in.2} at 280 r/min.
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
TROUBLESHOOTING
EN01Z0101F300001
Engine overheating
Symptom Possible cause Remedy/Prevention
Engine overheating (Coolant) Insufficient coolant Add coolant.
Defective thermostat Replace thermostat.
Overflow of coolant due to leakage of Repair.
exhaust into cooling system
Damaged rubber hose Replace rubber hose.
Coolant leakage due to deteriorated Replace rubber hose.
rubber hose
Coolant leakage from coolant pump Replace the coolant pump.
Coolant leakage from rubber hose Retighten or replace clamp.
connection
Coolant leakage from cylinder head Replace gasket.
gasket
Engine overheating (Coolant pump) Bearing seizure Replace.
Damaged (corroded) vane Replace vane.
Engine overheating (Radiator) Clogged with rust or scale Clean radiator.
Clogged with iron oxide due to leakage Clean coolant passage and correct
of exhaust into cooling system exhaust leakage.
Coolant leakage Repair or replace radiator.
Damaged cooling fan Replace cooling fan.
Clogged radiator core due to mud or Clean radiator.
other debris
Defective radiator cap pressure valve Replace radiator cap.
Engine overheating Poor fuel Use good quality fuel.
(Abnormal combustion) Breakdown of injector Replace the injector.
(Except J05E-TE)
Incorrect injection timing Adjust injection timing.
(J05E-TE)
Poor nozzle spray (J05E-TE) Adjust or replace nozzle.
Unsatisfactory automatic timer Repair or replace timer.
advance angle (J05E-TE)
Reduced injection pressure Adjust injection pressure.
Engine overheating Defective or deteriorated engine oil Change engine oil.
(Other problems) Unsatisfactory operation of oil pump Replace or repair.
Insufficient oil Add oil.
Brake drag Repair or adjust.
Break coolant temperature sensor Replace it.
Engine overheating Lugging the engine Operate engine properly.
(Severe operating condition)
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NOTICE
If oil consumption is excessive, the problems above will occur. Complaints from the customer are often related to
such problems.
1. White smoke is emitted continuously when the engine is run at high speed.
2. White smoke is emitted only immediately after the engine speed is abruptly raised when idling.
3. The tail pipe is blackened with oil.
4. Oil leaks from the flanges of the exhaust manifold.
5. Lack of power.
6. Excessive blow-by gas.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧠ಽ
Piston seizure
Symptom Possible cause Remedy/Prevention
Piston seizure Incorrect clearance between piston Replace piston, piston rings and cylin-
(Pistons, cylinder liners and piston and cylinder liner der liner.
rings) Unsatisfactory installation of piston pin Replace piston, piston rings, cylinder
liner and piston pin as required.
Broken piston ring Replace piston, piston rings and cylin-
der liner.
Difference in expansion due to use of Replace piston, piston rings and cylin-
wrong piston der liner.
Piston seizure (Coolant) Reduction in capacity of coolant pump Replace the coolant pump.
(due to vane corrosion)
Leakage of coolant Repair.
Insufficient coolant Add coolant.
Dirty coolant Clean and replace coolant.
Defective radiator (coolant leakage, Repair or replace the radiator.
clogging)
Defective rubber hose (leakage) Replace rubber hose.
Defective thermostat Replace the thermostat.
Leakage of exhaust into cooling sys- Repair.
tem
Piston seizure (Operation) Abrupt stoppage of engine after run- Operate engine properly.
ning at high speed
Hill climbing using unsuitable gear Select suitable gear.
Piston seizure (Oil) Insufficient oil Add oil.
Dirty oil Change oil.
Poor quality oil Replace with proper engine oil.
High oil temperature Repair.
Low oil pressure Repair.
Defective oil pump Repair oil pump.
Reduced performance due to worn oil Replace oil pump.
pump
Suction strainer sucking air Add oil and/or repair strainer.
Piston seizure (Abnormal combus- Use of defective fuel Change fuel.
tion) Engine overheating See Symptom: "Engine overheat-
ing".
Breakdown of injector Replace the injector.
NOTICE
If piston seizure occurs, the problems above will occur. Complaints from the customer are often related to these
problems.
1. White smoke is emitted.
2. Lack of power
3. Excessive blow-by gas
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Lack of power
Symptom Possible cause Remedy/Prevention
Lack of power (Supply pump) Damaged suction control valve Replace the supply pump.
(Except J05E-TE)
Lack of power (Injection pump) Injection pump Refer to the chapter "FUEL INJEC-
(J05E-TE) TION PUMP".
Lack of power (Intake) Clogged air cleaner Clean element or replace element.
Lack of power (Overheating) See Symptom: "Engine overheating".
Lack of power [Fuel and injector Air in fuel system Repair and bleed air from fuel system
(or injection nozzle)] Clogged fuel filter Replace element
Use of poor fuel Use good quality fuel.
Breakdown of injector Replace the injector.
(Except J05E-TE)
Poor nozzle spray (J05E-TE) Adjust or replace injection nozzle.
Clogged nozzle with carbon Clean nozzle.
(J05E-TE)
Wear or seizure of nozzle Replace nozzle.
(J05E-TE)
Lack of power Seized or wear of piston Replace the piston, piston rings and
(Pistons, cylinder liners and piston liner.
rings) Worn or broken piston rings, piston Replace piston rings, piston and liner.
and cylinder liner
Lack of power (Other problems) Exhaust brake butterfly valve stuck in Replace or repair exhaust brake.
half-open position
Connecting rod bent Replace or repair connecting rod.
Exhaust pipe or muffler crushed Replace exhaust pipe or muffler.
(increased back-pressure)
Breakage of turbine or blower Replace turbocharger.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧠ಽ
Leakage of exhaust
Symptom Possible cause Remedy/Prevention
Leakage of exhaust (Head gasket) Fatigued gasket (aging) Replace gasket.
Damage Replace gasket.
Improper installation Replace gasket.
Leakage of exhaust (Head bolts) Loose bolts Tighten bolts.
Elongated bolts Replace bolts.
Improper tightening torque or tighten- Tighten properly.
ing sequence
Leakage of exhaust (Cylinder block) Cracking Replace cylinder block.
Surface distortion Repair or replace.
Fretting of cylinder liner insertion por- Replace cylinder block.
tion (insufficient projection of cylinder
liner)
Leakage of exhaust (Cylinder head) Cracking Replace cylinder head.
Surface distortion Repair or replace.
Leakage of exhaust (Cylinder liners) Cracking Replace cylinder liner.
Corrosion Replace cylinder liner.
Insufficient projection of cylinder liner Replace cylinder liner.
Leakage of exhaust Incorrect injection timing Adjust injection timing.
(Other problems) (J05E-TE)
NOTICE
If leakage of the exhaust occurs, the problems above will occur. Complaints from the customer are often related to
these problems.
1. Lack of power.
2. The engine overheats.
3. The coolant is discolored.
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Rough idling
Symptom Possible cause Remedy/Prevention
Rough idling (Supply pump) Damaged suction control valve Replace the supply pump.
(Except J05E-TE)
Rough idling Injection pump Refer to the chapter "FUEL INJEC-
(Injection pump) (J05E-TE) TION PUMP".
Rough idling (Injector) Breakdown of injector Replace the injector.
(Except J05E-TE)
Rough idling (Nozzles) Uneven injection pressure Adjust.
(J05E-TE) Poor nozzle spray Adjust or replace nozzle.
Carbon deposit on nozzle tip Remove carbon.
Seized needle valve Replace nozzle.
Rough idling (Engine proper) Improper valve clearance Adjust valve clearance.
Improper contact of valve seat Replace or repair valve and valve seat.
Idling speed too low Adjust idling speed.
Coolant temperature too low Warm up engine.
Compression pressure of cylinders Overhaul engine.
markedly different from one another
Rough idling (Other problems) Clogged high pressure injection line Replace line.
Leakage due to improper tightening of Tighten sleeve nut.
high pressure fuel line
Engine seizure Replace pistons, piston rings and lin-
ers.
Incorrect valve timing Replace camshaft.
Diesel knock
Symptom Possible cause Remedy/Prevention
Diesel knock (Supply pump) Damaged suction control valve Replace the supply pump.
(Except J05E-TE)
Diesel knock (Injector) Breakdown of injector Replace the injector.
(Except J05E-TE)
Diesel knock (Injection nozzle) Bad fuel nozzle spray pattern after- Check and correct it.
(J05E-TE) dribble
High nozzle opening pressure Adjust the opening pressure.
Diesel knock (Fuel system) Use of poor fuel Use good quality fuel.
Incorrect fuel deliveries to some noz- Readjust the fuel deliveries
zles (J05E-TE)
Diesel knock (Other problems) Excessively cooled or heated engine Warm up or cool engine.
Insufficient air intake Correct.
Insufficient compression pressure Repair.
Compression pressure leaks at cylin- Replace head gasket.
der head gasket
Improper valve clearance or valve Adjust or repair.
sticking
Tappet sticking Replace tappet and camshaft.
Improper injection timing Correct it.
(J05E-TE)
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NOTICE
The items on this page concern unusual engine noise which is due to causes other than those given for diesel
knock.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧠ಽ
Excessive smoke
Symptom Possible cause Remedy/Prevention
Excessive smoke (Black smoke) Defective sensors or circuits Refer to the chapter "FUEL CON-
TROL".
Defective injector Replace the injector.
Excessive smoke (White smoke) Water in fuel Check and clean fuel lines.
Glow plug not operating Check glow plug circuit.
ENGINE TUNEUP
EN01Z0101H300001
(2) Among three drill holes on the camshaft gear, when two drill holes
are on horizontal position, and the rest of the drill hole is visible,
the No.1 piston is at the Top Dead Center of the compression
stroke.
NOTICE
If the rest of drill hole is invisible by camshaft housing, the No.6
piston is at the Top Dead Center of the compression stroke.
DRILL HOLE
SHTS01Z010100003
(3) Make sure that the valve stem is correctly inserted in the cross
head.
NOTICE
Click Move the cross head with fingers right and left to confirm the
valve stem is correctly inserted in the cross head by listening to
the clicking sound.
Good
(4) Confirm that there are no foreign particles or dust between the
cross head and the valve stem.
No Good
SHTS01Z010100004
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Cylinder 1 2 3 4
Valve IN EX IN EX IN EX IN EX
SHTS01Z010100007
SHTS01Z010100008
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"Zero" Need
clearance clearance
CROSS HEAD
SHTS01Z010100009
(4) After completion of the adjustment, tighten the lock nut A securely
with the specified tightening torque.
Tightening Torque:
SHTS01Z010100010 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
(5) The condition of inserted feeler gauge, loosen the adjusting screw
of the cross head, make sure that the feeler gauge does not feel
LOOSEN
loose.
C
NOTICE
If the feeling of the feeler gauge becomes loose, repeat steps from
(1).
D
Need
clearance
SHTS01Z010100011
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(6) Tighten the adjusting screw C of the cross head until the feeler
gauge does not move.
ROCKER ARM
TIGHTEN NOTICE
C In this situation, clearance between adjusting screw C and valve
stem head is zero.
Need
"ZERO" clearance
clearance
SHTS01Z010100012
(7) While loosening the adjusting screw C of the cross head gradu-
ally, adjust the valve clearance. Tighten the lock nut D of the cross
head securely with the specified tightening torque when the feeler
C gauge feels correct.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
D
SHTS01Z010100013
NOTICE
• Do not over loosen the adjusting screw.
Not over loosen
C • Over loosening of the adjusting screw C will cause the same
condition as in step (3) again. The feeler gauge may feel cor-
rect, but there may be excessive clearance between the
E adjusting screw C of the cross head and the valve stem head
E. This does not allow for correct adjustment.
Need (8) Positioning each piston at Top Dead Center of compression stroke
clearance
by turning the crankshaft counterclockwise view from flywheel
side. Then adjust the valve clearance for each cylinder in the firing
SHTS01Z010100014 order.
SHTS01Z010100015
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(2) Taking off the inspection hole plug, located at bearing holder case
BEARING HOLDER CASE of supply pump and tightening slightly the special tool therein,
check that the seat face of tool is fitting snugly with the bearing
holder.
FITTING
SNUGLY SST: Guide bolt (SZ105-08067)
NOTICE
When it is not well seated, it means it is contacting with other
parts than the turning stopper hole of coupling flange. Therefore,
NOT WELL do not tighten in too much. In this case, the timing is not fit. So,
INSPECTION SEATED perform again the setting for Top Dead Center of No.1 cylinder
HOLE PLUG compression stroke in above (1).
SHTS01Z010100016
SHTS01Z010100017
(3) Turn the automatic timer to the left (counterclockwise viewed from
the drive shaft) to align the automatic timer mark with the pointer
of the pump.
(4) Tighten the adjusting bolt to the specified torque.
SST: Injection pump coupling wrench (S0981-91707)
SHTS01Z010100018
Tightening Torque:
64 N⋅m {650 kgf⋅cm, 47 lbf⋅ft}
NOTICE
• No clearance is allowed between thin plates.
• No deformation of the flange is allowed due to distortion of a
thin plate.
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1. PREPARATION
(1) Supply engine oil.
(2) Supply cooling water and bleed air from it.
(3) Bleed air from the fuel system.
(EXCEPT J05E-TE) BLEEDER PLUG (4) Check connection to the alternator.
NOTICE
Starting the engine without wiring in place may burn out the alter-
nator.
(5) Check the engine stopping performance.
PRIMING PUMP
SHTS01Z010100019
(J05E-TE) BLEEDER
PLUG
SHTS01Z010100020
LUBRICATION
SHTS01Z010100021
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SPECIAL TOOL
EN01Z0101K100001
Except J05E-TE
SZ105-08067 GUIDE BOLT
For "ENGINE TUNEUP"
J05E-TE
S0955-21090
COMPRESSION GAUGE For "OVERHAUL CRITERIA"
ADAPTER (A) Except J05E-TE
S0955-21110
For "OVERHAUL CRITERIA"
OVERHAUL CRITERIA
EN01Z0101H300002
SHTS01Z010100026
J05D-TI
Difference
Standard Limit between each
cylinder
2.9-3.1 MPa 2.3 MPa 0.3 MPa
{30-31 kgf/cm2, {24 kgf/cm2, {3 kgf/cm2,
421-449 lbf/in.2} 334 lbf/in.2} 43 lbf/in.2} or less
Engine revolution 150 r/min.
J05E-TI
Difference
Standard Limit between each
cylinder
3.4-3.6 MPa 2.3 MPa 0.3 MPa
{35-36 kgf/cm2, {24 kgf/cm2, {3 kgf/cm2,
494-522 lbf/in.2} 334 lbf/in.2} 43 lbf/in.2} or less
Engine revolution 280 r/min.
NOTICE
Do not operate the starter for more than 15 seconds.
c. Measure the compression pressure of each cylinder.
NOTICE
Do not allow gas leakage from the seal face.
(3) Reassemble the removed parts.
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SHTS01Z010100027
SHTS01Z010100028
3. OTHER FACTORS
(1) Increase of blowby gas
(2) Defective engine start
(3) Decrease of engine output
(4) Increase of fuel consumption
(5) Increase of engine noise
(6) Increase of oil consumption
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SHTS01Z010100030
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧠ಽ
NOTICE
Check to see that there are no oil leaks, fuel leaks, coolant leaks,
or air leaks.
SHTS01Z010100031
• Liquid gasket is used at the following positions for the J05D, J05E
series engine.
2. REMOVE PARTS
(1) When removing parts, do not use a tool for removal at one loca-
tion only. Use the tool at various locations such as a flange step or
gap for removal. When removing the gasket, be careful that gas-
ket residue does not enter the engine.
3. OTHERS
(1) For tube-type liquid gasket, use the winding tool that comes with
the liquid gasket.
SHTS01Z010100032
SHTS01Z010100033
SHTS01Z010100034
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Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1.5-2.5
1 Oil seal retainer {0.0591- Black
0.0984}
1.5-2.5
2 Coolant pump {0.0591- Black
0.0984}
1.5-2.5
3 Oil cooler {0.0591- Silver
0.0984}
1.5-2.5
4 Thermostat case {0.0591- Black
0.0984}
1.5-2.5
5 Flange {0.0591- Silver
0.0984}
1.5-2.5
6 Intake pipe {0.0591- Black
0.0984}
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Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1.5-2.5
Matching parts of oil seal retainer and block
{0.0591- Black
lower face front end
0.0984}
1.5-2.5
Matching parts of block lower front end, gasket,
{0.0591- Silver
rear end plate and flywheel housing
0.0984}
LIQUID GASKET
LIQUID GASKET
Front and rear
ends of upper/
7
lower faces of
block
NOTICE
Cut the rear end plate gasket with a craft knife
flush with the block upper face.
LIQUID
GASKET 1.5-2.5
Flywheel hous-
8 {0.0591- Silver
ing
0.0984}
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Gasket
Application
No. Part name Application position and pattern to be Remarks
width
used
1. Matching faces with cam housing and plug 1.5-2.5 Black 2 locations
{0.0591- at front and
2. Matching parts of cam housing, plug, cylin-
0.0984} rear ends
der head cover and gasket
NOTICE
• Application area of liquid gasket is half cir-
cle of cam housing. Never apply it to the
9 Cam housing upper half circle of the plug.
• Remove the excessive gasket completely.
NOTICE
Figure on the right shows application "pattern" of the liquid gasket.
Apply the liquid gasket to the center of seal flange inside whenever pos-
sible.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
EN02-001
FLYWHEEL AND
FLYWHEEL HOUSING............................ EN02-24
COMPONENT LOCATOR ............................. EN02-24
SPECIAL TOOL ............................................. EN02-25
OVERHAUL ................................................... EN02-26
INSPECTION AND REPAIR .......................... EN02-30
CYLINDER HEAD
COMPONENT LOCATOR
EN01Z0102D100001
A
1
3
2
5
28
12
14
B
13
C 11
8
F
22
E
23
15
9
16
4
17
18
4
19
21 10
20
27
24
26
25
SHTS01Z010200001
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SPECIAL TOOL
EN01Z0102K100001
S0949-11010 WIRE
S0947-11520 GUIDE
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
OVERHAUL
EN01Z0102H200001
SHTS01Z010200011
5 3 1 2 4
SHTS01Z010200012
3
2
SHTS01Z010200013
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
10 18 17 9
6 14 21 13 5
7 15 20 12 4
11 19 16 8
SHTS01Z010200014
(7) Lift and remove the cylinder head from the cylinder block.
SST: Eye bolt (S0943-31070)
NOTICE
• Place a piece of wood between the cylinder head and table.
• When removing the cylinder head together with the injection
nozzle, avoid contact between the injection nozzle and piece
of wood.
Check that there is no oil, water or gas leakage in the cylin-
der head gasket if overheated or not.
SHTS01Z010200015
SST
SHTS01Z010200016
SHTS01Z010200017
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200018
SHTS01Z010200019
(3) When installing a new valve guide, do not twist the end. Press fit
the valve guide using the special tool.
SHTS01Z010200020 SST: Guide (S0947-11520)
NOTICE
• Be careful not to damage the valve stem at the upper or lower
end of the guide during press-fitting.
• Be sure to apply engine oil around the valve guide during
press-fitting.
ELECTRIC
(2) Place a (brass) back plate at the top of the valve system and
VALVE WELDING strike it with a hammer to remove the valve seat.
CUT THREE ! WARNING
PLACES HERE Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.
SHTS01Z010200021
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(4) Heat the cylinder head to 80 - 100°C {176 - 212°F} in hot water.
After cooling the valve seat, insert it into the cylinder head.
BRASS ROD DIAMETER A: A
INTAKE 41 mm {1.61 in.}
EXHAUST 39 mm {1.541 in.} ! WARNING
Striking the valve guide during removal may cause metal chips to
fly up. Be sure to wear protective goggles.
SHTS01Z010200023
SHTS01Z010200024
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
! WARNING
Punching the valve stem seal during installation may cause metal
chips to fly up. Be sure to wear protective goggles.
NOTICE
After assembly of the stem seal, check for deformation or cracking
of the rubber or incline.
APPLICATION OF OIL
RUBBER
SHTS01Z010200025
SHTS01Z010200026
(2) After inserting the O-ring into the nozzle seat insertion hole of the
cylinder head, apply liquid packing (Three Bond No.1211 or
equivalent) to the lower part of the new nozzle seat and assemble
it onto the cylinder head.
NOTICE
Be sure to replace the O-ring with a new one. Reuse of the O-ring
may cause water or gas leakage, resulting in overheating or crack-
ing of the cylinder head.
SHTS01Z010200027
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200028
(1) Install the cylinder head gasket on the cylinder block and flywheel
housing.
(2) Fill the hole at the back of the cylinder head gasket with liquid
gasket.
NOTICE
Make sure that the liquid gasket surface is flush with the cylinder
head gasket upper surface.
SHTS01Z010200031
SHTS01Z010200032
(2) Apply clean engine oil to the bolt surface and bolt threads.
(3) Clean the bolt seats completely on the cylinder head upper sur-
19 face.
20
12 4 5 13 (4) Tighten the cylinder head bolt.
16 8 1 9 17 21
The total tightening toque and angles are shown in the table
15 7 2 10 18 below. The tightening methods are shown in the steps below.
11 3 6 14
Head bolt number Total tightening angle
M12: No.1-18 1, 2, 7, 8, 9, 10, 15, 16, 17 59 N⋅m +90°+90°
M10: No.19-21
4, 5, 12, 13 59 N⋅m +90°+135°
SHTS01Z010200033
3, 6, 11, 14, 18 59 N⋅m +90°+180°
19, 20, 21 59 N⋅m
b. After tightening bolt No.18, check the torque again through all
PAINT the bolts from No.1 to No.18.
c. Mark the bolts with paint to indicate the same directions as
shown in the figure.
d. Turn No.1-No.18 bolts 90° (1/4 turn).
e. Make sure that all paint marks face the same direction.
SHTS01Z010200034
f. Tighten the head bolts again (M12 bolts only) in the same
sequence and to their respective tightening angles
NOTICE
When adding torque, never untighten the nuts, even if they have
been overtightened.
SHTS01Z010200035
15 7 2 10 18
11 3 6 14
SHTS01Z010200036
SHTS01Z010200037
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200038
SHTS01Z010200039
(2) Make sure that there is neither damage to the camshaft gear or
camshaft nor dirt on them.
(3) Apply clean engine oil to the bolt surface and bolt threads and
tighten them to the specified torque below.
Tightening Torque:
59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
SHTS01Z010200040
SHTS01Z010200041
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(3) Install the camshaft bearing cap, and tighten the bolts.
(4) (J05E-TE) Tighten the nozzle clamp bolt to the specified torque.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
SHTS01Z010200044
NOTICE
Make sure the oil hole is placed below.
SHTS01Z010200045
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
CYLINDER
HEAD
SHTS01Z010200046
(2) Install the head cover gasket into the gasket groove at the head
cover lower surface.
NOTICE
Make sure that there are no foreign particles (including liquid gas-
ket), or oil on the gasket grooves of the head cover, gasket or cam
housing upper surface nor damage to them.
(3) Apply liquid gasket to plug corner at the front and rear half circles
of the cam housing before installing the head cover.
SHTS01Z010200047
(4) Insert the silent block from the head cover upper surface.
(5) Tighten the bolt through the silent block to the specified torque
below and fix the head cover on the cam housing.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
SHTS01Z010200048
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Unit: mm {in.}
Measure
0.110-0.296
J05D
{0.0043-0.0116}
0.100-0.178
J05E
{0.0040-0.0070}
Measure
Replace
Camshaft deflection 0.04 {0.0016} 0.1 {0.0039}
camshaft.
Measure
IN 30° 30°-30°35'
Valve seat
angle
EX 45° 45°-45°30'
Resurface the
valve and/or
IN 30° 29°30'-30° valve seat.
Valve face
angle
EX 45° 44°30'-45°
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
2.6 {0.1023}
Squareness — Replace.
(2.0°)
129 N 119.5 N
Setting load {13.2 kgf, 29.1 lbf} {12.2 kgf, Replace.
at 44.8 {1.764} 26.9 lbf}
Free length
(reference 64.6 {2.543} 61.6 {2.425} Replace.
value)
Inner valve
spring
2.3 {0.0905}
Squareness — Replace.
(2.0°)
Visual check
Measure
0.06 or less
Cylinder head {0.0023 or less} Replace.
lower sur- J05E 0.20 {0.0078} NOTICE: Do not
for longitudinal
face flatness direction grind for repair.
0.03 or less
{0.0012 or less}
for lateral
direction
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Visual check
Visual check
Entire periphery
Contact of valve (Use of Red
of valve head — Matches valve.
lead marking compound)
evenly in contact
SHTS01Z010200064
SPECIAL TOOL
EN01Z0102K100002
OVERHAUL
EN01Z0102H200002
(1) Place the plate at the crankshaft end using the crankshaft pulley
bolts.
PLATE
SHTS01Z010200067
(2) Engage the hook with the oil seal notch and install the hook using
REMOVE THIS AFTER INSTALLING THE HOOK the bolt supplied.
(3) Remove the installed bolt in step (1).
NOTCH
HOOK
SHTS01Z010200068
(4) Install the center bolt and tighten it to remove the oil seal.
CENTER BOLT
SHTS01Z010200069
(1) Clean the edges and surface of the crankshaft and the special
tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal press.
OIL SEAL
SHTS01Z010200070
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
SHTS01Z010200071
(3) Apply a little engine oil to the seal portion of the crankshaft oil
seal.
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
GUIDE BOLT
SHTS01Z010200072
(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
PRESS
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
CENTER BOLT
SHTS01Z010200073
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
B
5
A 6 A 2
C
X A A
W
X
W
4
3
SHTS01Z010200074
SPECIAL TOOL
EN01Z0102K100003
OVERHAUL
EN01Z0102H200003
MAIN ENGINE
SPEED SENSOR
SHTS01Z010200078
NOTICE
MAIN ENGINE SPEED SENSOR
(Except J05E-TE) When dismounting and remounting the flywheel.
Remove the main engine speed sensor. If not removed, it will
result in damage of the sensor.
FLYWHEEL
1 mm
{0.394 in.}
SHTS01Z010200079
! WARNING
The flywheel is heavy when removing, be careful not to drop it on
SST
your feet.
SHTS01Z010200080
(1) Place the plate at the crankshaft end using the flywheel bolts.
NOTICE
Match the plate hole to the crankshaft collar knock part.
SHTS01Z010200081
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(2) Engage the hook with the oil seal notch and install the hook using
NOTCH the bolt supplied.
(3) Remove the installed flywheel bolts in step (1).
HOOK
SHTS01Z010200082
(4) Install the center bolt and tighten it to remove the oil seal.
SHTS01Z010200083
OIL SEAL
SHTS01Z010200084
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
SHTS01Z010200085
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(3) Apply a little engine oil to the seal portion of the crankshaft oil
OIL SEAL seal.
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
GUIDE
GUIDE BOLT
SHTS01Z010200086
(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
OIL SEAL
PRESS
SHTS01Z010200087
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
SHTS01Z010200088
SHTS01Z010200089
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(2) Heat the ring gear evenly to about 200°C {392°F} with a torch.
Insert the ring gear into the flywheel so that the chamfered side is
upward.
! WARNING
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
SHTS01Z010200090
NOTICE
Place one guide bar at the collar knock and another at the oppo-
site side of the collar knock.
SHTS01Z010200091
(2) Insert the flywheel slowly until it contacts the collar knock to pre-
vent impact on the guide bar. Adjust the position, then insert the
flywheel completely.
! WARNING
The flywheel is too heavy. When installing, be careful not to drop it
on your feet.
(3) Apply clean engine oil to the threads of the flywheel bolt and the
flywheel bolt seat. Be sure to tighten the flywheel bolts (6 pieces)
with a low-torque impact wrench.
(4) Pull out the guide bar and tighten the remaining two flywheel bolts
SHTS01Z010200092 provisionally as in step (3).
(5) Tighten the flywheel in the order shown in the figure to the speci-
fied torque below.
Tightening Torque:
186 N⋅m {1,900 kgf⋅cm, 137 lbf⋅ft}
(6) Loosen all bolts and tighten them again to the specified torque.
SHTS01Z010200093
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Unit: mm {in.}
Measure
Flywheel thickness
21 {0.827} 20 {0.787} Replace.
(Dimension B)
TIMING GEAR
COMPONENT LOCATOR
EN01Z0102D100004
14 A
3
13
4
2 14 B
13
1 5
6 14
13
7
5 A
8 12 14
11
10
9
5
C
SHTS01Z010200096
SPECIAL TOOL
EN01Z0102K100004
OVERHAUL
EN01Z0102H200004
SHTS01Z010200099
SHTS01Z010200100
SHTS01Z010200101
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200102
3. INSTALL THE IDLER GEAR SHAFT AND GEAR.
SHTS01Z010200103
NOTICE
• Install each idle gear shaft through the thrust plate as shown
in the figure so that the lubrication hole is downward.
• Adjust the timing of the main idle gear to align with the air
compressor gear as shown in the figure.
SHTS01Z010200104
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Unit: mm {in.}
Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}
Main idle-Air
0.032-0.096
compressor 0.10 {0.0039}
{0.0013-0.0038}
idle
Measure
Air compres-
0.020-0.083
sor idle-Air 0.10 {0.0039}
{0.0008-0.0033}
compressor
Air compres-
Timing gear sor-Power 0.030-0.134
0.30 {0.0118} Replace gear.
backlash steering {0.0012-0.0052}
pump
Shaft outside
57 {2.244} — —
diameter
Bushing
inside 57 {2.244} — —
diameter
Main idle 0.030-0.090 Replace bushing
shaft Clearance 0.20 {0.0079}
{0.0012-0.0035} and/or shaft.
Shaft outside
50 {1.969} — —
diameter
Bushing
inside 50 {1.969} — —
diameter
Sub idle 0.025-0.075 Replace bushing
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} and/or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
inside 34 {1.339} — —
diameter
Cam idle 0.025-0.075 Replace bushing
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} and/or shaft.
Shaft outside
34 {1.339} — —
diameter
Bushing
inside 34 {1.339} — —
diameter
Air
compressor 0.025-0.057 Replace bushing
Clearance 0.10 {0.0039}
idle {0.0010-0.0022} and/or shaft.
0.160-0.220
End play — —
{0.0063-0.0086}
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
2 A
3
5
6
7
9
8 13
10 12
B 15
14
16
11
SHTS01Z010200107
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
4
3
A
SHTS01Z010200108
SPECIAL TOOL
EN01Z0102K100005
S0947-11490 GUIDE
S0940-21540 SPINDLE
S0948-11540 GUIDE
SH691-20825 BOLT
OVERHAUL
EN01Z0102H200005
SHTS01Z010200122
SHTS01Z010200123
NOTICE
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• Keep the piston rings for each cylinder separately.
SHTS01Z010200124
SHTS01Z010200125
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(2) Pull the cylinder liner from the cylinder block using the special
tool.
SST: Puller (S0942-02100)
NOTICE
• Carefully set the special tool to prevent touching to the pis-
ton cooling jet.
• After removing the cylinder liners, arrange them in sequence.
SHTS01Z010200126
SHTS01Z010200127
(2) For the jet test, connect the oil hose to the connector bolt from the
cylinder block lower side.
NOTICE
Use clean engine oil for jet flow.
SHTS01Z010200128
(3) Set the special tool on the cylinder block upper surface against
the dowel pin.
SST: Tool assembly (S0947-01280)
(4) Test jet oil flow from the piston cooling jet nozzle at a hydraulic
pressure of 196 kPa {2 kgf/cm2, 28 lbf/in.2}.
SHTS01Z010200129
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧟㧡ಽ
(5) If the center of the jet flow is within the target circle (7 mm {0.2756
in.} diameter: Red), the test is acceptable.
NOTICE
Fire may occur due to splattered oil during the jet flow test. Do not
use naked lights near the test area.
! CAUTION
Engine oil is flammable. Carry out this test in a well ventilated
room and do not use naked lights in the room.
SHTS01Z010200130
(6) If the center of the jet flow is out of the target circle, realign the
nozzle using the special tool.
SST: Adjusting bar (S0947-21620)
SHTS01Z010200131
SHTS01Z010200132
SHTS01Z010200133
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(1) Apply engine oil to the inner surface of the block bore and insert
the cylinder liner using the special tool.
SST: Guide (S0947-11490)
NOTICE
Handle the cylinder liner carefully because it is thin.
(If it falls on the floor, it cannot be used.)
SHTS01Z010200134
Tightening Torque:
9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}
SHTS01Z010200135
4. MEASURE THE CRANKSHAFT.
(1) If necessary, grind the crankshaft and use an under size bearing.
Outside diameter
Bearing size
Crank pin Journal
64.94-64.96 mm 79.94-79.96 mm
Standard
{2.5567-2.5574 in.} {3.1473-3.1480 in.}
64.69-64.71 mm 79.69-79.71 mm
0.25US
{2.5469-2.5476 in.} {3.1375-3.1381 in.}
64.44-64.46 mm 79.44-79.46 mm
0.50US
{2.5371-2.5377 in.} {3.1276-3.1283 in.}
SHTS01Z010200136
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200137
SHTS01Z010200138
(3) Apply clean engine oil to the bolt seat and bolt threads.
(4) Tighten the bolts in the order as shown in the figure to the speci-
fied torque.
Tightening Torque:
69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
(5) Loosen all bolts, tap the front and back ends of the crankshaft
using a plastic hammer.
(6) Tighten the bolts as in step (4).
(7) Mark the bolt heads with paint.
SHTS01Z010200139
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(8) Tighten the bolts 90° (1/4 turn) in the same order as in step (4).
(9) Retighten the bolts 45° (1/8 turn) as in step (8).
PAINT MARK
(10) Make sure that all paint marks face the same direction.
NOTICE
When adding torque, never untighten the bolt, even if they have
been overtightened.
45 (11) After tightening, tap the front and back ends of the crankshaft
90
using a plastic hammer to allow complete fit.
SHTS01Z010200140
NOTICE
• Bring lever "H" punched on the guide above the pin.
SHTS01Z010200141
• Making sure to align both supporting surfaces of the guide
and press sub-assembly flush on a flat plane.
SHTS01Z010200142
NOTICE
Align the groove of the spindle with the groove of the press sub
assembly.
SHTS01Z010200143
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200144
(3) Chamfer one edge of the bushing hole at the small end of the con-
necting rod uniformly by 0.5-1.0 mm {0.0197-0.0393 in.}.
NOTICE
• Irregular chamfering can cause out-of-roundness of the
pressed bushing, which may result in jamming during inser-
tion.
• Remove dust from the inner surface of the small-end hole.
SHTS01Z010200145
Tightening Torque:
5.0-6.8 N⋅m {50-70 kgf⋅cm, 3.62-5.06 lbf⋅ft} (Bolt)
NOTICE
SHTS01Z010200146
• Align the groove of the spindle with the groove of the press
sub assembly.
• Make sure that the contact surfaces of the bushing seats
firmly against the contact surfaces of the spindle and guide.
b. Apply the fresh engine oil around the bushing and guide.
(5) Align the oil hole of the bushing with the oil hole of the connecting
rod.
NOTICE
• Put the connecting rod to the press sub assembly that cham-
fer side of the small end to the bushing side.
• Apply the fresh engine oil to the bore of the connecting rod.
SHTS01Z010200147
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
SHTS01Z010200148
SHTS01Z010200123
NOTICE
Install the second ring that turn the identification print on the pis-
ton ring to upper surface.
(2) Connect the joint of the coil expander for the oil ring and install it
inside the piston ring. Assemble the ring with the joint 180° oppo-
site to the matching point.
SHTS01Z010200149
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(3) Position the matching points of the piston ring at a even distance
as shown in the figure.
SECOND RING
OIL RING
TOP RING
SHTS01Z010200150
NOTICE
• When installing the piston, be careful that the cooling jet is
not struck by the connecting rod.
• Make sure that the 0-mark on the piston is at the exhaust
side.
SHTS01Z010200151
SHTS01Z010200152
(2) Apply clean engine oil to the bolt thread and the nut seat surface
of the connecting rod cap.
SHTS01Z010200153
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
(4) Mark the nut heads in the same direction with paint.
(5) Tighten the connecting rod nut 90° (1/4 turn).
(6) Tighten the connecting rod nut 45° (1/8 turn).
(7) Make sure that the paint marks face the same direction.
NOTICE
When adding torque, never untighten the nuts, even if they have
been overtightened.
If the angle of bolts is adjusted to the specified angle by turning
SHTS01Z010200154
counterclockwise, the axial force of the bolts might fall short and
it is feared that this could reduce the engine reliability. Also there
is a possibility that this could reduce the number of times a bolt
can be reused.
REAR
(2) Install the gasket so that the protrusion is at the flywheel housing
side and the intake side. (the print seal surface is at the cylinder
block side)
FRONT (3) Place a guide pin of 70 mm {2.76 in.} or more in the cylinder block
and assemble the oil pan against the guide.
(4) Tighten oil pan fitting bolts according to the arrows with an impact
PROTRUSION wrench.
OIL STRANER Tightening Torque:
19.7-24.5 N⋅m {200-250 kgf⋅cm, 15-18 lbf⋅ft}
(5) Finish tightening the bolts with a torque wrench to the specified
torque. Tighten the bolts according to the arrows in the figure.
Tightening Torque:
30 N⋅m {300 kgf⋅cm, 22 lbf⋅ft}
LIQUID GASKET
NOTICE
SHTS01Z010200155
Make sure that the washer is not on the flange.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Unit: mm {in.}
117.014-117.022
C
{4.6069-4.6071}
Clearance 0.115-0.131
J05D
between {0.0046-0.0051}
—
piston and 0.092-0.108
cylinder liner J05E
{0.0036-0.0042}
0.09-0.13
Top
Clearance {0.0036-0.0051}
between
0.04-0.08 Replace piston ring
piston ring Second — —
{0.0016-0.0031} and/or piston.
and piston
ring groove 0.02-0.06
Oil
{0.0008-0.0023}
0.30-0.40 Measure
Top 1.5 {0.0591}
{0.0119-0.0157}
Cylinder liner
-0.013-0.014
J05D
Clearance {-0.00005-0.0006}
between
Replace piston and/
piston pin 0.05 {0.0020}
or piston pin.
and piston
pin bore -0.002-0.025
J05E
{-0.00008-0.00098}
Measure
Connecting rod
Replace connecting
bushing inside 37 {1.4567} 37.1 {1.4606}
rod bushing.
diameter
Visual check
Wear or damage of
connecting rod
— — Replace.
*Dye penetrant check
(Color check)
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Visual check
Clogging of connecting
— — Replace.
rod oil hole
Clearance between
0.031-0.082 Replace connecting
connecting rod bearing 0.2 {0.0079}
{0.0013-0.0032} rod bearing.
and crank pin
Replace connecting
Connecting rod end 0.20-0.52
1.0 {0.0394} rod and/or
play {0.0079-0.0204}
crankshaft.
Clearance between
0.051-0.102 Replace main
crank journal and main 0.2 {0.0079}
{0.0021-0.0040} bearing.
bearing
Measure
More than
Replace over size
0.5 {0.0197}
0.050-0.219 thrust bearing.
Crankshaft end play (Repair)
{0.0020-0.0862}
1.219 {0.0479}
Replace crankshaft.
(Service)
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧡ಽ
Measure
Visual check
Clogging of crankshaft
— — Clean.
oil hole
Visual check
Measure
0.05 {0.0019}
J05D
or less
Cylinder Replace.
block upper NOTICE:
0.20 {0.0080}
surface flat- Do not grind for
ness Longitudinal direc- repair.
tion: 0.06 {0.0024}
J05E Right angle direc-
tion: 0.03 {0.0012}
or less
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧤ಽ
EN03-001
1 2
3
A
SHTS01Z010300001
SHTS01Z010300002
PROTRUSION
SHTS01Z010300003
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧤ಽ
AIR INTAKE
COMPONENT LOCATOR
EN01Z0103D100002
5 10
7
2 Z
3
4
7
1 5
5
6
6
9
SHTS01Z010300004
MODELS FOR CHILE, THAILAND, PHILIPPINES AND VIETNAM (J05E-TC, TD, TE)
4
6
3
2
W
V
1 7 6
5
X W
X Y 9
6
Y
V 10 8
6
Z
6
10
12
11
SHTS01Z010300005
1
2
5
1
SHTS01Z010300006
OVERHAUL
EN01Z0103H100002
VEHICLE
FRONT
A B AIR HOSE
(AIR CLEANER)
A
AIR HOSE
(INTER COOLER)
AIR HOSE
AIR HOSE
(INTER COOLER)
A
ALIGN THE ARROW MARK
A WITH THE STOPPER.
SHTS01Z010300007
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧤ಽ
VEHICLE
FRONT
AIR HOSE
(AIR CLEANER)
AIR HOSE
(INTER COOLER)
AIR HOSE
(INTER COOLER)
A
TURN THE ARROW MARKS UPWARD.
A
SHTS01Z010300008
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧤ಽ
AIR CLEANER
COMPONENT LOCATOR
EN01Z0103D100003
SHTS01Z010300009
1 Body 4 Clamp
2 Filter element 5 Dust unloader valve
3 Cover
OVERHAUL
EN01Z0103H100003
1. INSPECTING
(1) If on inspection the dust indicator is red, replace it.
(2) If the cover, body or dust unloader valve is damaged, replace the
part.
(3) Check the element to see if it is flattened or deformed, or whether
the filter paper of the element is torn.
(4) Check to see if the sealing of the gasket is complete.
! CAUTION
If an abnormality is found during the above inspection, replace the
element with a new one. If dust is taken into the engine, the engine
will wear and its performance will deteriorate.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧤ಽ
1
3
6
5
9
7
8 2
6
7
B
4
1
10
A
11
SHTS01Z010400001
MODELS FOR CHILE, THAILAND, PHILIPPINES AND VIETNAM (J05E-TC, TD, TE)
SHTS01Z010400002
SHTS01Z010400003
1 2 3 4 (2) Tighten the same nuts according to the same procedure again.
NOTICE
Be sure to carry out the procedure.
TIGHTENING ORDER .... REUSED MANIFOLD
8 9 2 3 5 6 11 12
7 1 4 10
NUT
SPACER
SHTS01Z010400004
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧤ಽ
(REPRESENTATIVE TYPE)
b
10
c 5
6 9
7 a 10 7
Y
c
8 6
A
A 6
X A
6
6 7
10
6
B
10
7 6 4
1
11 3
3 6 8
A b
D
3 13 10
D 12
6 X
C 7
Z
7 2
7 6
10 D
6 5
a
C 6 6
Z 8
Y 8
SHTS01Z010400005
OVERHAUL
EN01Z0104H200001
! WARNING
If the position on the tail pipe is incorrect, exhaust fumes may
1-3 mm {0.04-0.12 in.} blow onto passers by and burns may also result.
CLAMP
SHTS01Z010400007
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧥ಽ
EN05-001
LUBRICATING SYSTEM
DIAGRAM
EN01Z0105J100001
ROLLER
PIN
CAM ROLLER
O CAM
I SHAFT
L
P
A CAM
N IDLE SHAFT
SUB
IDLE SHAFT
TURBO
CHARGER
S
T
R
A OIL OIL OIL MAIN
I PUMP COOLER FILTER OIL HOLE
N
E
R PISTON CONNECTING CRANK
PIN ROD SHAFT
AIR
COMPRESSOR
MAIN IDLE
GEAR SHAFT
AIR COMPRESSOR
IDLE GEAR SHAFT
: LUBRICATION
: RETURN
SHTS01Z010500001
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧥ಽ
2
1 A
SHTS01Z010500002
OVERHAUL
EN01Z0105H200001
Unit: mm {in.}
Block side
bushing inside 18 {0.709} — —
diameter
Drive gear
0.040-0.099
Clearance — —
{0.0016-0.0038}
Block hole
18 {0.709} — —
diameter
0.030-0.075
Clearance — —
{0.0012-0.0029}
Driven
gear Gear bushing
18 {0.709} — —
inside diameter
0.040-0.083
Clearance 0.15 {0.0059} Replace gear.
{0.0016-0.0032}
Measure
0.072-0.277
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0109}
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧥ಽ
4
5 A
6
3
C
K
I
J 9
D
11
H
G M F
8
10
E
L
1
2
SHTS01Z010500009
SPECIAL TOOL
EN01Z0105K100001
SHTS01Z010500011
NOTICE
Make sure that O-rings are not on the oil cooler case side.
SHTS01Z010500012
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧥ಽ
NOTICE
SHTS01Z010500013 • Do not reuse the O-ring.
• Attention to damage of O-ring.
(2) Apply liquid gasket to the oil cooler case and install it onto the cyl-
inder block, then tighten the bolt to the specified torque.
Tightening Torque:
19.6-29.4 N⋅m {200-300 kgf⋅cm, 15-21 lbf⋅ft}
SHTS01Z010500014
1. Damage to sliding
Wear or damage to valve
Replace, face of valve
spring of oil cooler and — —
if necessary. 2. Valve movement
oil filter
(smoothness)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
EN06-001
COOLING SYSTEM
DIAGRAM
EN01Z0106J100001
1
4
2
12
5
13
10
6
3 14
11
7 9
8 15
14 16
SHTS01Z010600001
MODELS FOR CHILE, THAILAND, PHILIPPINES AND VIETNAM (J05E-TC, TD, TE)
1
4
2
5
11
3 12
10
7 9
8 13
14 14
SHTS01Z010600002
COOLANT PUMP
COMPONENT LOCATOR
EN01Z0106D100001
(REPRESENTATIVE TYPE)
9
6
5
8
4
SHTS01Z010600003
SPECIAL TOOL
EN01Z0106K100001
Prior to starting a coolant pump overhaul, it is necessary to have these special tools.
OVERHAUL
EN01Z0106H200001
SHTS01Z010600007
(2) Remove the pulley center from the shaft using the special tool.
SST: Puller (S0942-01810)
SHTS01Z010600008
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
(3) Remove the retainer ring from the pump case using snap ring pli-
ers.
SHTS01Z010600009
(4) Push the shaft from the vane side using a hydraulic press, and
remove the coolant shaft from the pump case.
NOTICE
Before pressing, recheck that the retainer ring is removed com-
pletely.
SHTS01Z010600010
(5) Remove the coolant seal from the pump case using a hammer
and brass bar.
! WARNING
Impact due to punching may cause metal chips to fly up. Be sure
to wear protective goggles.
NOTICE
Replace the removed coolant seal with a new one. Never reuse it.
SHTS01Z010600011
SHTS01Z010600012
NOTICE
Press until the bearing upper end surface comes into contact with
the retainer ring groove lower end surface.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
(2) Install the retainer ring onto the pump case using snap ring pliers.
SHTS01Z010600013
(3) Install the pulley center onto the shaft using a hydraulic press.
Standard:
Engine From the pulley center mounting surface
series to the pump case end surface
J05D 113.6-114.4 mm {4.472-4.504 in.}
J05E 129.0-129.8 mm {5.079-5.110 in.}
SHTS01Z010600014
SHTS01Z010600015
SHTS01Z010600016
(5) Install the vane onto the shaft using a hydraulic press.
Assembly standard (B): 0.7-1.3 mm {0.0276-0.0510 in.}
NOTICE
Press until the vane end face comes into contact with the shaft
end surface.
(6) After assembly, turn the shaft by hand and make sure that there is
no noise, catching or rough movement in the shaft direction and
that it rotates smoothly.
SHTS01Z010600017
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
Unit: mm {in.}
Visual check
Measure
Measure
NOTICE
• Tightness= Outside diameter - Inside diameter
• Prevent a reassembly more than three times even if it is
within the standard value.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
THERMOSTAT
COMPONENT LOCATOR
EN01Z0106D100002
SHTS01Z010600021
MODELS FOR CHILE, THAILAND, PHILIPPINES AND VIETNAM (J05E-TC, TD, TE)
SHTS01Z010600022
OVERHAUL
EN01Z0106H200002
NOTICE
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
(REPRESENTATIVE TYPE)
IMPORTANT POINT - ASSEMBLY
SHTS01Z010600026
(3) Temporarily tighten the bolts "1" and bolts "2" in that order, and
(J05D-TG) securely contact the fitting surface.
"2"
(4) Tighten the bolts in numeral order.
"1"
SHTS01Z010600027
"1"
SHTS01Z010600028
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
RADIATOR
COMPONENT LOCATOR
EN01Z0106D100003
11
7
10
9 3
8
7
6
5
4
SHTS01Z010600029
SPECIAL TOOL
EN01Z0106K100002
For caulking
S0976-01040 RADIATOR TOOL
(Used with S0976-01030)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
OVERHAUL
EN01Z0106H200003
SHTS01Z010600032
(2) Grip the handle until it hits to the stopper bolt, then adjust the
dimensions A with stopper bolt.
Dimension A: 0.2-0.3 mm {0.0079-0.0118 in.}
SST: Radiator tool (S0976-01030)
NOTICE
Be sure to adjust the dimension to prevent damage of the crow.
SHTS01Z010600033
SHTS01Z010600034
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
(4) Remove the upper tank and lower tank from the radiator core by
tapping lightly with plastic hammer.
NOTICE
Do not remove the tank by forcing or prying.
SHTS01Z010600035
SHTS01Z010600036
(2) Grip the handle of the radiator tool until it hits to the stopper bolt,
then adjust the dimensions B with stopper bolt.
Dimension B: 8.4 mm {0.3307 in.}
SHTS01Z010600037
(3) Install the new O-ring into the groove of the radiator core (upper
and lower) in such away that it will not be twisted.
NOTICE
Be sure to clean the fitting portion before installing. When clean-
ing, lightly rub the inside portion of the groove with the emery
paper.
(4) Install the upper tank and lower tank into the groove of the radia-
tor core.
SHTS01Z010600038
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
(5) Frap the tangs to obtain a tight contact with the upper tank and
lower tank.
SHTS01Z010600039
(6) Press the radiator tool (caulking tool) against the side portion.
Temporarily caulk the tangs several times, then proceed to the
final caulking by gripping the handle until it hits the stopper bolt.
NOTICE
For the positions where the radiator tool is not usable, perform the
caulking with pliers.
SHTS01Z010600040
NOTICE
Perform the caulking according to the sequence as shown in the
figure.
SHTS01Z010600041
SHTS01Z010600042
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧟㧣ಽ
Measure
Radiator cap
40-58
valve open- Mark 0.5 — Replace.
{0.4-0.6, 5.7-8.5}
ing pressure
Intercooler
• Air leakage test
(when the air pres- 0 mL —
Replace the inter-
sure of 490 {5.0, 71} is
cooler.
applied.)
• Clogging of the fins
— —
NOTICE
• The coolant filler cap valve opening pressure is indicated on the cap and it should be confirmed. If the cap
pressure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system,
which may cause the hose to drop off or burst and may result in the damage of the engine.
• When carrying out high pressure washing to remove fin clogging, do not apply excessive pressure to the
fins which may cause deformation and consequent performance deterioration.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧜ಽ
COOLING FAN
COMPONENT LOCATOR
EN01Z0106D100004
3
3
1
1
SHTS01Z010600046
Visual check
INJECTION NOZZLE
(TWO-SPRING TYPE - DENSO MAKE)
(J05E-TE) ................................................ EN07-24
DESCRIPTION .............................................. EN07-24
COMPONENT LOCATOR ............................. EN07-25
SPECIAL TOOL ............................................. EN07-26
OVERHAUL ................................................... EN07-26
5 4 3 2
13
6 12
11
7
9
10
8
SHTS01Z010700001
COMPONENT LOCATOR
EN01Z0107C100001
(REPRESENTATIVE TYPE)
B C
3
A
W
Y
4
X
SHTS01Z010700002
SHTS01Z010700003
DESCRIPTION
EN01Z0107C100002
SHTS01Z010700004
SPECIAL TOOL
EN01Z0107K100001
OVERHAUL
EN01Z0107H200001
SHTS01Z010700008
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
(2) Turn the timer counterclockwise slowly viewed from the coupling
(normal direction of engine) and align the mark on the timer with
the mark on the injection pump pointer.
SHTS01Z010700009
(3) Tighten the injection pump mounting bolt evenly to the torque
below.
Tightening Torque:
25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
SHTS01Z010700010
Tightening Torque:
61.3 N⋅m {625 kgf⋅cm, 45 lbf⋅ft}
(5) Tighten the through bolt at the flange.
Tightening Torque:
90.7 N⋅m {925 kgf⋅cm, 67 lbf⋅ft}
SHTS01Z010700012
NOTICE
• Do not reuse the element.
• Be careful not to damage the gasket.
SHTS01Z010700013
SHTS01Z010700014 NOTICE
The bleeder plug should be tightened while the priming pump
knob is operated.
(5) Once again, operate the priming pump knob several times.
(6) Push back the priming pump knob and tighten it.
NOTICE
Wipe up any splashed fuel.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
SHTS01Z010700015
COMPONENT LOCATOR
EN01Z0107C100003
3
B
4
2
1
SHTS01Z010700016
SPECIAL TOOL
EN01Z0107K100002
OVERHAUL
EN01Z0107H200002
! WARNING
Perform the following work after the engine cools off to avoid fire
or burning. The fuel in the common rail could have a high temper-
ature (approx. 100°C {212°F}) immediately after driving.
SHTS01Z010700018
SHTS01Z010700019
(2) Taking off the inspection hole plug, located at bearing holder case
BEARING HOLDER CASE of supply pump and inserting the special tool therein, check that
the seat face of tool is fitting snugly with the bearing holder.
SST: Guide pin (S0904-81040)
FITTING
SNUGLY NOTICE
When it is not well seated, it means it is contacting with other
SST
parts than the turning stopper hole of coupling flange. Therefore,
NOT WELL do not insert in too much. In this case, the timing is not fit. So,
SEATED perform again the setting for Top Dead Center of No.1 cylinder
INSPECTION compression stroke in above (1).
HOLE PLUG
SHTS01Z010700020
(2) Remove the six bolts for mounting the air compressor and dis-
AIR COMPRESSOR mounting the supply pump with the air compressor.
O-RING
SUPPLY
PUMP
SHTS01Z010700022
(3) Remove the bolts, and then the supply pump with the bearing
SUPPLY PUMP AIR COMPRESSOR holder case from the air compressor.
BEARING
HOLDER CASE
COUPLING
O-RING
SHTS01Z010700023
(4) Remove the nut, and then the coupling flange from the bearing
BEARING HOLDER CASE holder case.
(5) Remove the bolts, and then the bearing holder from the supply
SHAFT
pump.
NOTICE
After dismounting the pump, cover the pump and high pressure
NUT pipe to prevent entry of dirt.
COUPLING FLANGE
SHTS01Z010700024
BEARING
HOLDER CASE
SHTS01Z010700025
P_EN07_Mokuji kai.fm 13 ページ 2008年7月21日 月曜日 午前9時36分
SST COUPLING
FLANGE
(5) Align the aligning mark "0" on the top of coupling flange with pro-
trusion on the compressor housing.
"0" MARK
PROTRUTION
SHTS01Z010700027
(6) The special tool should be fit snugly with the turning stopper hole
BEARING HOLDER CASE of coupling flange through bearing holder case.
SST: Guide pin (S0904-81040)
NOTICE
• Make sure not to insert the tool, fitting with other parts than
SST
the turning stopper hole of the coupling and not to stop its
COUPLING inserting with use of other than the special tool.
FLANGE
• The specified tool is designed so that the tip of special tool
TURNING STOPPER HOLE might not touch deeply with its turning stopper hole (Clear-
SHTS01Z010700028
ance of the tip is 2 mm {0.079 in.}).
(7) Replace the O-ring with a new one and install it to the air com-
SUPPLY PUMP AIR COMPRESSOR pressor.
BEARING (8) Install the supply pump to the air compressor.
HOLDER CASE
COUPLING
O-RING
SHTS01Z010700029
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧟㧤ಽ
(9) Replace the O-ring with a new one and install the air compressor
AIR COMPRESSOR with the supply pump to the flywheel housing.
O-RING NOTICE
SUPPLY • Without moving the piston position fit to the top dead center
PUMP of compression stroke in No.1 cylinder, put the gears (timing
gear side and air compressor one) in engagement.
• When cranking engine, make sure to remove off the special
tool.
• After completing the installation, make sure to remove the
special tool and to install inspection window plug.
SHTS01Z010700030
2. RESETTING FOR THE VALUES OF SUPPLY PUMP.
(1) Reset the values memorized in engine ECU by re-programing
when replacing supply pump.
NOTICE
Unless the same values are not reset, correct control of common
rail will not be done, which will cause engine stall or abnormality
in high common rail pressure. Therefore, make sure to reset the
same values when replacing supply pump.
Standard:
SCV 7.65-8.15 Ω at 20°C {68°F}
1 3 2
4
SHTS01Z010700032
OVERHAUL
EN01Z0107H200003
SHTS01Z010700033
SHTS01Z010700034
SHTS01Z010700035
SHTS01Z010700036
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
SHTS01Z010700037
SHTS01Z010700038
GASKET
PRESSURE SENSOR
SHTS01Z010700040
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
SHTS01Z010700041
SHTS01Z010700043
(4) Tighten the force feed pipe nuts to the specified torque.
(EXAMPLE)
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft}
NOTICE
• If the tightening torque of the nuts is less than the specified
value, it may cause a fuel leak. If the tightening torque of the
nuts is greater than the specified value it may have a nega-
tive influence on the engine function. As a result, always per-
form torque management.
• After the operation is completed, wipe off the fuel which
SHTS01Z010700044
leaked and start the engine. Make sure that the fuel does not
leak again.
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
1 2 3
SHTS01Z010700045
SHTS01Z010700046
SHTS01Z010700047
SHTS01Z010700048
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
6
1
2
7
3 8
4 9
10
11
12
13
14
15
SHTS01Z010700049
OVERHAUL
EN01Z0107H200004
INJECTION PIPE
CLAMP
INJECTION PIPE
OIL SEAL
O-RING
SHTS01Z010700051
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧟㧥ಽ
(5) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 32 lbf⋅ft}
(6) Install the leakage pipe with the 5 new gasket and 5 joint bolts.
Tightening Torque:
12.3 N⋅m {125 kgf⋅cm, 91 lbf⋅ft}
SHTS01Z010700053
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
SHTS01Z010700054
SHTS01Z010700056
COMPONENT LOCATOR
EN01Z0107D100001
SHTS01Z010700057
SPECIAL TOOL
EN01Z0107K100003
OVERHAUL
EN01Z0107H200005
SHTS01Z010700063
(2) Operate the lever at the rate of 15 to 60 strokes per minute. If the
injection pressure is not within specified value, adjust the injection
pressure with adjusting screw.
First opening pressure
With new parts: 18.14-18.92 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
SHTS01Z010700065
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
SHTS01Z010700066
SHTS01Z010700067
SHTS01Z010700068
SHTS01Z010700070
(2) The hole in the special tool and the pin on the distance piece are
NOZZLE NEEDLE lined up and the dial gauge is pushed down until it contacts the
SPRING SEAT distance piece. Next, set the dial gauge to "0".
SHTS01Z010700071
(3) Insert the push rod and first pressure spring to the nozzle holder
CAP NUT body. Tighten the adjusting screw.
GASKET (4) Assemble the new gasket, tighten temporarily the cap nut.
ADJUSTING SCREW
FIRST PRESSURE
SPRING
PUSH ROD
NOZZLE HOLDER
SHTS01Z010700074
(5) Mount the above stated nozzle holder on the nozzle hand tester to
determine the pressure at the start of injection.
This value is used as the first opening pressure. The adjusting
screw is tightened or loosened to keep this value within a set
range.
First opening pressure
With new parts: 18.14-18.92 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
NOTICE
SHTS01Z010700075
• Tightening the adjusting screw → increases pressure
• Loosening the adjusting screw → decreases pressure
(6) After adjustment, a gasket is installed and the cap nut is tightened
down to anchor the adjusting screw.
Tightening Torque:
53.9 N⋅m {550 kgf⋅cm, 40 lbf⋅ft}
NOTICE
Make sure that the adjusting screw does not turn at the same time.
SHTS01Z010700076
(2) Adjustment
The nozzle holder is mounted on a nozzle hand tester to deter-
mine the pressure at the start of injection. This value is used as
the second valve opening pressure. Suitable shims are used to
keep this value within a standard range.
Second opening pressure
With new parts: 31.28-32.26 MPa {319-329 kgf/cm2,
4,537-4,678 lbf/in.2}
With reused parts: 30.80-31.77 MPa {314-324 kgf/cm2,
4,467-4,608 lbf/in.2}
NOTICE
SHTS01Z010700078
• Thick shims → increases pressure
• Thin shims → decreases pressure
• About 88.26 kPa {0.9 kgf/cm2, 12.8 lbf/in.2} of change is
obtained for every 0.01 mm {0.0004 in.} of shim thickness.
Second opening pressure adjusting shim line-up
Parts number Shim thickness
S2288-57670~ 1.0-1.375 {0.0394-0.0541}
S2288-57820 (jump at 0.025 {0.001})
S2288-57040~ 1.4-1.7 {0.0551-0.0669}
S2288-57160 (jump at 0.025 {0.001})
S2288-57180~ 1.725-2.1 {0.0679-0.0827}
S2288-57330 (jump at 0.025 {0.001})
SHTS01Z010700079
b. Measurement
The nozzle holder is mounted on the nozzle hand tester and a
check is made to determine if the pressure at the start of
injection (first opening pressure) is within the standard range.
If not within the specified pressure, readjust with the adjusting
screw.
First opening pressure
With new parts: 18.14-18.92 MPa {185-193 kgf/cm2,
2,632-2,745 lbf/in.2}
With reused parts: 17.66-18.43 MPa {180-188 kgf/cm2,
2,561-2,673 lbf/in.2}
SHTS01Z010700080
2A'0A/QMWLKMCKHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧟㧝ಽ
NOTICE
After tightening the bolt, make sure that the rocker arm moves
SHTS01Z010700081
smoothly.
(7) Tighten the nut of the injection pipe to the specified torque.
Tightening Torque:
34.3 N⋅m {350 kgf⋅cm, 25.3 lbf⋅ft}
SHTS01Z010700082
COMPONENT LOCATOR
EN01Z0107C100006
SHTS01Z010700083
FUEL TANK
COMPONENT LOCATOR
EN01Z0107J100006
4
C
B
SHTS01Z010700084
TURBOCHARGER EN08
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING..................................... EN08-3
SPECIAL TOOL ............................................. EN08-11
OVERHAUL CRITERIA ................................. EN08-12
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧥ಽ
TURBOCHARGER
DESCRIPTION
EN01Z0108C100001
B A
7 5 4
2 3 1
SHTS01Z010800001
TROUBLESHOOTING
EN01Z0108F300001
1. Table 1-1. Troubleshooting-Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
OR
ENGINE
ENGINE LACKS
SYMPTOM OR TROUBLE EXHAUST EMITS
POWER
BLACK SMOKE
(See Notes D and F✩) (See Notes K✩) (See Notes H✩) (See Note M✩)
Restricted duct Restricted duct
Leakage at Turbocharger
NO NO between air NO between NO
turbocharger rotating assembly
cleaner and compressor and
mounting flange binding or dragging
turbocharger engine intake
Engine malfunction
Restricted engine NO Restricted engine NO (fuel system
exhaust system intake or exhaust component, valves
(after turbocharger) manifold valve ring, ring
piston, etc.)
Remove restriction
Refer to engine Refer to engine
or replace
manufacturer's manufacturer's
turbocharger as
service manual service manual
necessary
SHTS01Z010800002
ENGINE EXHAUST
SYMPTOM O R TROUBL E EMITS WHITE OR
BLUE SMOKE
YES YES
Perform
Refer to engine
troubleshooting
manufacturer's
procedures outlined
service manual
in Table 1-7
SHTS01Z010800003
✩Shown on Table 1
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧥ಽ
ENGINE OIL
SYMPTOM OR TROUBLE CONSUMPTION
EXCESSIVE
SHTS01Z010800004
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧥ಽ
NOISY
SYMPTOM OR TROUBLE TURBOCHARGER
Clean housing or
Perform
replace turbocharger
troubleshooting
as required. Eliminate all leaks
procedures outlined
Check engine
in Table1-5
operating procedures
SHTS01Z010800005
TURBOCHARGER
ROTATING
SYMPTOM OR TROUBLE
ASSEMBLY BINDING
OR DRAGGING
Excessive carbon
build-up behind NO Sludged or cocked
turbine wheel center housing
YES YES
SHTS01Z010800006
Restricted duct
Loose compressor
Dirty air cleaner between air cleaner Leakage at engine
NO NO to intake manifold NO NO
element and turbocharger intake manifold
duct connection
compressor
Remove restriction
Tighten duct Refer to engine
Replace air cleaner or replace
connections as manufacturer's
element turbocharger as
required service manual
necessary
Turbocharger
Restricted turbo- Plugged engine Worn or damaged bearings, bearing
NO NO NO NO
charger oil drain line crankcase compressor wheel bores or shaft
journals worn
Engine malfunction
(excessive piston
blow by or high
internal crankcase
pressure)
YES
Refer to engine
manufacturer's
service manual
SHTS01Z010800007
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧥ಽ
SEAL LEAKAGE AT
SYMPTOM OR TROUBLE TURBINE END OF
TURBOCHARGER
Restricted
Plugged engine Sludged or cocked
Excessive pre-oiling NO NO turbocharger oil NO NO
crankcase breather center housing
drain line
Engine malfunction
Turbocharger
excessive piston
bearings, bearing
NO blow by or high
bores or shaft
internal
journals worn
crankcase pressure
YES YES
Perform
Refer to engine
troubleshooting
manufacturer's
procedures out-
service manual
lined in Table 1-8
SHTS01Z010800008
2A'0A806A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧥ಽ
TURBOCHARGER
SYMPTOM OR TROUBLE BEARINGS, BORES,OR
SHAFT JOURNAL WORN ✩
Inadequate pre-
Contaminated or
oiling following Insufficient engine
improper grade or Restricted
turbocharger oil supplied to
NO type of engine NO NO turbocharger oil NO
installation or turbocharger due to
lubricating oil used feed line
engine lube system "oil lag"
in engine
servicing
SHTS01Z010800009
SPECIAL TOOL
EN01Z0108K100001
OVERHAUL CRITERIA
EN01Z0108H300001
SHTS01Z010800013
SHTS01Z010800014
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
TURBOCHARGER EN08
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING..................................... EN08-3
SPECIAL TOOL ............................................. EN08-11
OVERHAUL CRITERIA ................................. EN08-11
COMPONENT LOCATOR ............................. EN08-14
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
TURBOCHARGER
DESCRIPTION
EN01Z0108C100001
SHTS01Z010800001
TROUBLESHOOTING
EN01Z0108F300001
1. Table 1-1. Troubleshooting -Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
SHTS01Z010800002
SHTS01Z010800003
SHTS01Z010800004
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
SHTS01Z010800005
SHTS01Z010800006
SHTS01Z010800007
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
SHTS01Z010800008
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
SHTS01Z010800009
j. Thorough cleaning of the air intake system is essential following compressor wheel damage due to foreign object
impact. In many cases, metal pieces from the wheel become imbedded in the air cleaner element. If the element is
not changed, these metal pieces can be drawn into the replacement turbocharger and cause it to fail in the same
manner as the original unit.
k. With the air inlet and exhaust gas ducting removed from the turbocharger, examine both the compressor and turbine
wheels for blade damage. Examine the outer blade tip edges for evidence of rubbing on housing surfaces.
• Turn the rotating assembly by hand and feel for dragging or binding. Push the rotating assembly side-ways while
rotating to feel for wheel rub. If there is any indication of rubbing, perform the bearing clearance inspection procedure.
If the rotating assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that the tur-
bocharger is serviceable.
SPECIAL TOOL
EN01Z0108K100001
OVERHAUL CRITERIA
EN01Z0108H300001
SHTS01Z010800013
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
SHTS01Z010800014
(5) Release the air pressure at the sensing port. Note that the dial
gauge pointer returns exactly to zero.
(6) Repeat steps (4) through (5) several times to make sure that
wastegate valve or rod movement has been accurately measured.
(7) If the specified value or rod movement cannot be obtained within
the specified air pressure range. The turbine housing assembly or
actuator assembly must be replaced.
! CAUTION
Operation of the engine with the wastegate calibrated to some
value other than that specified can result in reduced performance
or severe engine damage.
(8) If wastegate performance is within specification, install the hose
onto the wastegate sensing port.
2A'0A9)A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧜ಽ
COMPONENT LOCATOR
EN01Z0108D100001
SHTS01Z010800016
17.16-17.65 MPa
Test nozzle opening pressure
{175-180 kgf/cm2, 2,490-2,560 lbf/in.2}
Overflow valve opening pressure 240.3-269.7 kPa {2.45-2.75 kgf/cm2, 34.9-39.1 lbf/in.2}
Pump
Rack position Measuring Injection volume Variation limit
revolution
mm {in.} stroke cm3 {cu.in.} cm3 {cu.in.}
r/min
INJECTION
VOLUME 9.3 {0.366} 500 3.75-4.75 {0.229-0.289} 1.5 {0.092} or less
ADJUSTMENT
13.9 {0.547} 750 500 79.0-80.5 {4.822-4.913} 3.5 {0.214} or less
GOVERNOR ADJUSTMENT
Boost
Pump speed pressure Control rack position
Adjusting item Adjusting lever position
r/min kPa mm {in.}
{mmHg, inHg}
Idling
325 0 {0, 0} 9.2-9.4 {0.362-0.370}
-2.5°±5°
LEVER ANGLE
38 3
STOP
31.5
15
RUN
VERTIAL POSITION
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
REMARKS
• Stop lever operation check: When the adjusting lever at "IDLING" position and pump speed is 0 r/min, con-
trol rack should be 5.0 mm {0.197 in.} or less.
• Boost compensator inside seal: When pump speed at 1,250 r/min and boost pressure is 93.3 kPa {700
mmHg, 27.6 inHg}, set the boost compensator stopper for control rack position to (A+0.7)±0.3 mm
{(A+0.028)±0.012 in.}. If turn back the full load stopper to end, then turn back to A with bolt.
NOTICE
A = 14.75-15.15 mm {0.581-0.596 in.}
• Set adjusting lever from idle to full load position when boost pressure and pump speed is 0, measure the
starting injection volume at pump speed at 100 r/min.
• Boost compensator air seal: Air pressure drop from 133 kPa {1,000 mmHg, 39.4 inHg} to 131 kPa {980
mmHg, 38.6 inHg} should be taken more than 10 seconds.
Rw Rw3
(mm) (11.9)=Rw2 (Np=750 r/min)
14 Q=107 2
13
12
(Rw2+0.2) 0.1
27.6
93.3
20 40 60 80 Pb
(kPa)
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
DESCRIPTION (NB-TYPE)
EN01Z0109C100001
SHTS01Z010900006
TROUBLESHOOTING
EN01Z0109F300001
Excessive smoke
Symptom Possible cause Remedy/Prevention
Excessive smoke (Black smoke) Excessive fuel delivery caused by Adjust fuel delivery on test stand.
incorrect adjustment of full-load stop-
per screw
Excessively advanced injection timing Correct it.
Large spread in fuel delivery Adjust it.
Bad nozzle fuel spray characteristics Check and correct them.
Excessive smoke (White smoke) Improper retarded injection timing Advance injection timing.
Water in fuel Check and clean fuel lines.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
Loud knocking
Symptom Possible cause Remedy/Prevention
Loud knocking Improper injection timing Correct it.
Bad fuel nozzle spray pattern after- Check and correct it.
dribble
High nozzle opening pressure Adjust the opening pressure.
Incorrect fuel deliveries to some noz- Readjust the fuel deliveries
zles
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900007
SPECIAL TOOL
EN01Z0109K100001
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
SPRING COMPRESSION
S0951-22410
TOOL
S0951-21620 TWEEZERS
CAMSHAFT PROTRUDANCE
S0951-22340
GUIDE RAIL
OVERHAUL
EN01Z0109H200001
SHTS01Z010900021
(2) Fix the special tool on the stud bolts, turn the guide until the clear-
ance between the washer and the handle is approximately 1-2
mm {0.0394-0.0787 in.}, to set the special tool.
NOTICE
The guide of the special tool is left-hand threaded.
SST: Delivery valve holder remover (S0951-22380)
SHTS01Z010900022
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(3) Turn the handle clockwise into the delivery valve holder. Continue
until the O-ring in the cylinder comes off the pump body.
SHTS01Z010900023
(4) Pull the special tool upward to remove the delivery valve group.
SHTS01Z010900024
SHTS01Z010900025
NOTICE
Set the camshaft at bottom dead center before removing the con-
trol sleeve.
SHTS01Z010900026
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SHTS01Z010900027
NOTICE
First bring the cam of the cylinder to bottom dead center.
SHTS01Z010900028
SHTS01Z010900029
NOTICE
The tappet can be removed more easily when the cam of the cylin-
der is at top dead center.
SHTS01Z010900030
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SHTS01Z010900031
SHTS01Z010900032
SHTS01Z010900033
(2) Use the special tool to remove the taper roller bearing at the gov-
ernor side.
SST: Bearing remover (S0951-01160)
SHTS01Z010900034
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(3) Use the special tool to tap out the outer race in the bearing cover.
SST: Outer race puller (S0951-22330)
SHTS01Z010900035
SHTS01Z010900036
(2) Install the camshaft adjusting ring, shim and taper roller bearing,
in that order, on the camshaft.
NOTICE
Put a round nut on the other end of the camshaft to protect the
threads.
SHTS01Z010900037
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900031
SHTS01Z010900038
(2) If the specification is not met, use appropriate shim at the gover-
nor end of camshaft until the specification is met.
SHTS01Z010900039
SHTS01Z010900040
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(2) If the specification is not met, use, appropriate shim at the drive
end of camshaft until the specification is met.
SHTS01Z010900041
NOTICE
Position the groove provided in the tappet in the axial direction of
the camshaft, and position it accurately so that the tappet is
retained in position by the tappet retainer pin which is driven
inside the pump housing.
SHTS01Z010900030
NOTICE
Be sure that the flange of the lower spring seat is accurately
seated in the groove of the tappet.
This is very important since an inaccurately positioned seat may
cause damage to the pump.
SHTS01Z010900042
SHTS01Z010900043
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(2) Attach the upper spring extractor, and fit the guide groove on the
extractor to the projected part of the upper spring seat.
SST: Spring compression tool (S0951-22410)
SHTS01Z010900044
(3) Push the handle down to compress the plunger spring, turn the
guide lever 90° toward you, and installing the upper spring seat
underneath the stopper pin which is driven inside the pump hous-
ing.
SHTS01Z010900045
NOTICE
• First bring the cam of the cylinder to bottom dead center.
• Check that the spring is accurately retained by the stopper
pin.
• Check that the projected part of the upper spring seat faces
away from the rack.
SHTS01Z010900046
SHTS01Z010900027
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900047
NOTICE
Position the flanges of the control sleeve and the plunger, and the
projected part of the upper spring seat correctly before inserting
the control sleeve.
SHTS01Z010900048
(3) Move the control rack until the ball in the control sleeve is accu-
rately inside the groove provided in the control rack.
NOTICE
• The plunger may slip out of its position during installation.
Check the following for a second time.
• The vertical groove of the plunger must face the spill side.
• The plunger must not come out when it is pulled up.
SHTS01Z010900049
SHTS01Z010900050
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(2) Put the delivery valve group in the support, and tighten the deliv-
ery valve holder on the delivery valve group.
SST: Setting support (S0951-22390)
Tightening Torque:
88.2 N⋅m {900 kgf⋅cm, 65 lbf⋅ft}
SHTS01Z010900051
SHTS01Z010900053
SHTS01Z010900054
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(3) Tighten the nuts finger tight. Then, tighten the nuts alternately to
their specified torque.
SST: Box wrench (S0951-21790)
Tightening Torque:
19.1 N⋅m {195 kgf⋅cm, 14 lbf⋅ft}
SHTS01Z010900055
Unit: mm {in.}
Measure
Total play of tappet
roller, Replace tappet
— 0.3 {0.0118}
roller bushing and roller assembly.
pin
Measure
Measure
Visual check
Visual check
ADJUSTMENT (NB-TYPE)
EN01Z0109H300002
PREPARATION
1. PREPARATION
(1) Mount the injection pump correctly on the pump tester.
SHTS01Z010900063
(2) Attach a rack position measuring device to the control rack and
set to "0".
SST: Rack position measuring assembly (95091-00170)
(3) Install calibration nozzles and lines.
Nozzle and lines: Refer to "DATA AND SPECIFICATIONS".
SHTS01Z010900064
SHTS01Z010900065
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900066
SHTS01Z010900067
(4) Move the angle dial to set the first cylinder of the pump to bottom
dead center and adjust the pre-stroke gauge to zero.
NOTICE
Bottom dead center is the point at which the pointer of the dial
gauge does not move even when the angle dial is rotated while
fuel is flowing from the overflow line.
SHTS01Z010900068
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(5) Turn the camshaft clockwise the angle dial and read the dial
gauge when the fuel stops running out of the overflow line. This
reading is the pre-stroke value of the pump.
Pre-stroke: Refer to "DATA AND SPECIFICATIONS".
(6) If the pre-stroke value is not within specification, change the
shims between the cylinder flange and the pump housing.
SHTS01Z010900069
SHTS01Z010900071
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900072
SHTS01Z010900073
SHTS01Z010900074
SHTS01Z010900075
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900076
SPECIAL TOOL
EN01Z0109K100002
Prior to starting an injection pump overhaul, it is necessary to have these special tools.
OVERHAUL
EN01Z0109H200002
SHTS01Z010900082
SHTS01Z010900083
(4) Install the special tool on the cover, and fix with the nut.
NOTICE
Do not tighten the nut but leave loosened.
SST: Timer wrench (S0951-22210)
SHTS01Z010900084
(5) Set the extension bar on the timer wrench, then loosen and
remove the timer cover.
SHTS01Z010900085
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900086
SHTS01Z010900087
SHTS01Z010900088
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900089
SHTS01Z010900086
SHTS01Z010900090
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900091
(2) Hook a spring balancer between the two socket bolts at the end of
the extension bar, then pull the spring balancer until it shows 213
N {22 kgf, 49 lbf} to tighten up the timer cover.
Tightening Torque:
319 N⋅m {3,250 kgf⋅cm, 235 lbf⋅ft}
SHTS01Z010900092
5. FILL THE PUMP TIMER OIL INTO THE TIMER THEN TIGHTEN-
ING THE SCREWS.
Oil grade: SAE 90
Oil Volume: 140-160 cm3 {8.54-9.76 cu.in.}
Tightening torque for timer hub screw:
13.7 N⋅m {140 kgf⋅cm,10 lbf⋅ft}
SHTS01Z010900083
SHTS01Z010900093
OVERHAUL
EN01Z0109H200003
SHTS01Z010900094
SHTS01Z010900095
SHTS01Z010900096
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900097
SHTS01Z010900094
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
GOVERNOR (R901)
DESCRIPTION
EN01Z0109C100002
SHTS01Z010900098
COMPONENT LOCATOR
EN01Z0109D100004
SHTS01Z010900099
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SPECIAL TOOL
EN01Z0109K100003
S0951-21770 WRENCH
CAMSHAFT BUSHING
S0951-22260 EXTRACTOR
(DAMPER WEIGHT MODEL)
S0951-22510 BIT
OVERHAUL
EN01Z0109H200004
SHTS01Z010900106
NOTICE
Before lifting the governor cover, be sure to pull up the supporting
lever as shown by dotted lines in the figure, so that its lower end
may not obstruct the lifting of the governor cover.
SHTS01Z010900107
SHTS01Z010900108
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900109
SHTS01Z010900110
SHTS01Z010900111
SHTS01Z010900112
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900113
SHTS01Z010900114
SHTS01Z010900115
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(4) Apply a dial gauge to the end face of the flyweight, and measure
the thrust clearance.
Thrust clearance: 0.02-0.10 mm {0.0008-0.0039 in.}
(5) If not within specification, adjust the clearance by inserting shims
between the bushing and the governor round nut.
SHTS01Z010900116
SHTS01Z010900117
SHTS01Z010900118
SHTS01Z010900119
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
ADJUSTMENT
EN01Z0109H300003
PREPARATION
1. PREPARATION
(1) Connect the rack measuring device to the control rack and set to
"0".
(2) Connect the fuel line.
(3) Refill the camshaft chamber with engine oil.
(4) Install the angle gauge on the speed control lever.
(5) Remove the rack limiter cover.
(6) Connect the boost line to the compensator port from the vacuum
pump on a test bench via a "T" connection to a pressure gauge.
SHTS01Z010900120
SHTS01Z010900121
SHTS01Z010900122
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900123
NOTICE
The idle adjusting screw will change the governor characteristics
as show on the left.
SHTS01Z010900124
SHTS01Z010900125
SHTS01Z010900126
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900127
SHTS01Z010900128
SHTS01Z010900129
SHTS01Z010900130
SHTS01Z010900131
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
SHTS01Z010900132
SHTS01Z010900133
SHTS01Z010900134
SHTS01Z010900136
SHTS01Z010900137
SHTS01Z010900138
SHTS01Z010900139
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
NOTICE
All adjusting devices on the fuel injection pump governor, except
the low idle adjustment screw, are secured with the special bolts
and crimp caps as a protection for the customer. This is to prevent
unauthorized readjustment which may cause engine malfunction
and/or engine failure. Periodically check to insure that special
bolts and crimp caps are not removed as this will void the war-
ranty.
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
BOOST COMPENSATOR
COMPONENT LOCATOR
EN01Z0109D100005
SHTS01Z010900141
1 Housing 9 Cover
2 Plate washer 10 Thrust washer
3 Screw plug 11 Diaphragm
4 Push rod 12 Spring upper seat
5 Screw 13 Spring
6 Cap 14 Clamp plate
7 Lock nut 15 Guide bushing
8 Stop screw
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
ADJUSTMENT
EN01Z0109H300004
SHTS01Z010900142
(2) Turn the guide bushing with a screw driver inserted through the
screw plug hole and set the "A" clearance to zero.
SHTS01Z010900143
(3) Tighten the stop screw until it comes in contact with the push rod
end, then further tighten the stop screw by 1/2 turn.
SHTS01Z010900144
(4) Set length "B", by means of the adjust with screw indicated in fig-
ure.
Length "B": 13.5 mm {0.531 in.}
SHTS01Z010900145
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧞ಽ
(5) Check screw traveling length, "E" while apply 133.3 kPa {1,000
mmHg} boost pressure to port "D".
Traveling length "E": 4-5 mm {0.157-0.196 in.}
(6) Check the boost compensator air seal. While applied 133.3 kPa
{1,000 mmHg} boost pressure to port "D", the time required for
pressure to drop to 130.7 kPa {980 mmHg} should be more than
10 seconds.
SHTS01Z010900146
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧟ಽ
EN10-001
7
X
4 B
6
b A
a b 5
a
b
SHTS01Z011000001
EGR VALVE
DESCRIPTION
EN01Z0110J100002
SHTS01Z011000002
SHTS01Z011000003
SHTS01Z011000004
SHTS01Z011000005
SHTS01Z011000006
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧟ಽ
SHTS01Z011000007
NOTICE
Use a new gasket.
SHTS01Z011000008
SHTS01Z011000009
SHTS01Z011000010
2A'0HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧟ಽ
(4) Connect the hose between EGR valve and coolant pipe.
(5) Connect the harness coupler.
SHTS01Z011000011
(6) Close the coolant plug of the oil cooler situated on the right side of
the engine.
SHTS01Z011000012
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS........................ EN11-2
DESCRIPTION ................................................ EN11-2
TROUBLESHOOTING..................................... EN11-4
COMPONENT LOCATOR ............................... EN11-5
SPECIAL TOOL ............................................... EN11-7
OVERHAUL ..................................................... EN11-7
INSPECTION AND REPAIR .......................... EN11-17
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
ALTERNATOR
DATA AND SPECIFICATIONS
EN01Z0111I200001
Regulator Mount-on
DESCRIPTION
EN01Z0111C100001
SHTS01Z011100001
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS01Z011100002
TROUBLESHOOTING
EN01Z0111F300001
Abnormal noise Stator coil faulty (Rare short, earth) Replace stator coil.
Bumping inside Repair or replace.
(Bearing inside and bracket abrasion)
Tension of belt faulty (Belt slip) Repair.
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
COMPONENT LOCATOR
EN01Z0111D100001
SHTS01Z011100003
1 Brace 4 Bracket
2 Harness 5 V-belt
3 Alternator 6 Strap band
SHTS01Z011100004
SPECIAL TOOL
EN01Z0111K100001
OVERHAUL
EN01Z0111H200001
SHTS01Z011100008
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS01Z011100009
SHTS01Z011100010
(3) Remove the rotor from drive end frame, using a press.
NOTICE
• Do not damage to the screw tip.
• Hold rotor by hand so that it will not fall off.
SHTS01Z011100011
SHTS01Z011100012
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
SHTS01Z011100013
SHTS01Z011100015
SHTS01Z011100016
TERMINAL
LEAD WIRE
REGULATOR
SHTS01Z011100017
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
SHTS01Z011100018
SHTS01Z011100019
SHTS01Z011100020
(6) Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.
NOTICE
A removed bearing should not be reused. Replace it with a new
one.
SHTS01Z011100021
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
SHTS01Z011100022
SHTS01Z011100023
SHTS01Z011100024
(4) Install the space collar, fan and pulley, tighten the lock nut.
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
Wind V-belt around pulley groove and grip it securely in a vise so
V-BELT that pulley is held with V-belt as a cushion.
SHTS01Z011100025
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
ROLLER
BEARING
JIG B
SHTS01Z011100026
NOTICE
Tighten the bolt evenly.
SHTS01Z011100027
SHTS01Z011100028
NOTICE
Apply lock agent (ThreeBond TB1344) to the tip of mounting bolts
for rectifier and regulator.
SHTS01Z011100029
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
(4) Using a solder ring iron, solder the lead wire connecting the regu-
lator and field coil as well as the stator coil and diode.
NOTICE
• Soldering work should be done just after tightening the bolt.
• Solder lead wire after bending and fixing the terminal of regu-
lator.
• Solder field coil after caulking the tip of diode.
• Soldering work should be done for short moment (Within 5
sec.).
SHTS01Z011100030
TERMINAL
LEAD WIRE
REGULATOR
SHTS01Z011100031
HINT
Outer nut should be tightened after installing alternator and con-
necting its wiring.
SHTS01Z011100032
NOTICE
Tighten the through bolt evenly.
SHTS01Z011100033
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
SHTS01Z011100034
SHTS01Z011100035
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
SHTS01Z011100036
Test lead
Standard
(+) (–)
B E APPROX. 20 Ω
E B ∞Ω
P E APPROX. 7 Ω
E P ∞Ω
SHTS01Z011100037
E A B
R L
N P
DETAIL OF A
SHTS01Z011100038
2A'0AA#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧡ಽ
PERFORMANCE TEST
NOTICE
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1 MΩ or more — Replace.
field coil
Measure
W
Resistance of stator
0.31-0.33 Ω — Replace. U
coil [at 20°C (68°F)] V
WIRING
Measure
Insulation resistance of
1 MΩ or more — Replace.
stator
Measure
Normal direction
APPROX. 10 Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Measure
Measure
Normal direction
APPROX. 10 Ω E
Resistance of regulator — Replace.
Reverse direction
∞Ω
F
Resistance of con-
denser Indicate 800 Ω
NOTICE ↓ (Immediately) — Replace.
Do not use digital Indicate ∞ Ω
tester.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
EN11-002
ALTERNATOR
DATA AND SPECIFICATIONS
EN01Z0111I200001
Regulator Mount-on
DESCRIPTION
EN01Z0111C100001
SHTS01Z011100001
CIRCUIT
3
8
10
L 7
1.4 3W
R
9
P
N
5
6
4
11
SHTS01Z011100002
TROUBLESHOOTING
EN01Z0111F300001
Abnormal noise Stator coil faulty (Rare short, earth) Replace stator coil.
Bumping inside Repair or replace.
(Bearing inside and bracket abrasion)
Tension of belt faulty (Belt slip) Repair.
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
COMPONENT LOCATOR
EN01Z0111D100001
3
1
B
SHTS01Z011100003
1 Alternator 3 Brace
2 Bracket 4 Hanger
SHTS01Z011100004
SPECIAL TOOL
EN01Z0111K100001
OVERHAUL
EN01Z0111H200001
SHTS01Z011100008
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS01Z011100009
SHTS01Z011100010
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
(3) Remove the rotor from drive end frame, using a press.
NOTICE
• Do not damage to the screw tip.
• Hold rotor by hand so that it will not fall off.
SHTS01Z011100011
SHTS01Z011100012
SHTS01Z011100013
SHTS01Z011100015
SHTS01Z011100016
TERMINAL
LEAD WIRE
REGULATOR
SHTS01Z011100017
TERMINAL B
SHTS01Z011100018
SHTS01Z011100019
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
SHTS01Z011100020
(6) Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.
NOTICE
A removed bearing should not be reused. Replace it with a new
one.
SHTS01Z011100021
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
SHTS01Z011100022
SHTS01Z011100023
SHTS01Z011100024
(4) Install the space collar, fan and pulley, tighten the lock nut.
Tightening Torque:
127-157 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
NOTICE
Wind V-belt around pulley groove and grip it securely in a vise so
V-BELT that pulley is held with V-belt as a cushion.
SHTS01Z011100025
ROLLER
BEARING
JIG B
SHTS01Z011100026
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
NOTICE
Tighten the bolt evenly.
SHTS01Z011100027
SHTS01Z011100028
NOTICE
Apply lock agent (ThreeBond TB1344) to the tip of mounting bolts
for rectifier and regulator.
SHTS01Z011100029
(4) Using a solder ring iron, solder the lead wire connecting the regu-
REGULATOR lator and field coil as well as the stator coil and diode.
NOTICE
• Soldering work should be done just after tightening the bolt.
• Solder lead wire after bending and fixing the terminal of regu-
lator.
• Solder field coil after caulking the tip of diode.
• Soldering work should be done for short moment (Within 5
sec.).
SHTS01Z011100030
TERMINAL
LEAD WIRE
REGULATOR
SHTS01Z011100031
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
HINT
Outer nut should be tightened after installing alternator and con-
necting its wiring.
TERMINAL B
SHTS01Z011100032
NOTICE
Tighten the through bolt evenly.
SHTS01Z011100033
SHTS01Z011100034
NOTICE
Do not hit the cover since its hook is fragile.
SHTS01Z011100035
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
SHTS01Z011100036
Test lead
Standard
(+) (–)
B E APPROX. 20 Ω
E B ∞Ω
P E APPROX. 7 Ω
E P ∞Ω
SHTS01Z011100037
E
B
R L
N P
DETAIL OF A
SHTS01Z011100038
2A'0A#HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧝㧣ಽ
PERFORMANCE TEST
NOTICE
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
Unit: mm {in.}
Measure
Measure
Insulation resistance of
1 MΩ or more — Replace.
field coil
Measure
W
Resistance of stator
0.31-0.33 Ω — Replace. U
coil [at 20°C (68°F)] V
WIRING
Measure
Insulation resistance of
1 MΩ or more — Replace.
stator
Measure
Normal direction
APPROX. 10 Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Measure
Measure
Normal direction
E
APPROX. 10 Ω
Resistance of regulator — Replace.
Reverse direction
∞Ω
F
Resistance of con-
denser Indicate 800 Ω
NOTICE ↓ (Immediately) — Replace.
Do not use digital Indicate ∞ Ω
tester.
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
EN12-001
STARTER
DATA AND SPECIFICATIONS
EN01Z0112I200001
Module 3
DESCRIPTION
EN01Z0112C100001
SHTS01Z011200001
TROUBLESHOOTING
EN01Z0112F300001
COMPONENT LOCATOR
EN01Z0112D100001
SHTS01Z011200002
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
OVERHAUL
EN01Z0112H200001
SHTS01Z011200003
C TERMINAL LEAD
SHTS01Z011200004
SHTS01Z011200005
(2) Remove the bolt and O-ring, remove the commutator end frame.
COMMUTATOR
END FRAME
SHTS01Z011200006
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
SHTS01Z011200007
SHTS01Z011200008
G1
SHTS01Z011200009
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
SHTS01Z011200010
SHTS01Z011200011
SHTS01Z011200012
(4) Remove the lever and drive shaft assembly from the drive hous-
ing.
HOLDER
PIN
LEVER
SHAFT ASSEMBLY
SHTS01Z011200013
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
RESERVOIR
SHTS01Z011200014
G1
SHTS01Z011200015
SHTS01Z011200016
SHTS01Z011200017
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
SHTS01Z011200018
SHTS01Z011200009
SHTS01Z011200019
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
SHTS01Z011200020
SHTS01Z011200021
(3) Apply grease (G1: Multemp AC-N) to the portion as shown in the
LOCATION G1 figure.
GUIDE (4) Install the commutator end frame aligning the location guide of the
commutator end frame (convexity) with notches of the holder
assembly (concavity).
NOTCH
HOLDER
ASSEMBLY
M LEAD WIRE
SHTS01Z011200022
(5) Secure the brush holder with the bolt and a new O-ring.
M TERMINAL LEAD CAP (6) Secure the drive housing assembly and commutator end frame
with the through bolt.
CAP (7) Connect the terminal lead, install the cap.
C TERMINAL LEAD
SHTS01Z011200004
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
SHTS01Z011200023
(4) If the above condition, push pinion back to measure the gap.
Standard: 0.5-0.3 mm {0.020-0.118 in.}
NOTICE
Perform the inspection work for an instance (within 15 seconds).
PUSH BACK THE
PINION SLIGHTLY.
GAP
0.5-0.3 mm
{0.020-0.118 in.}
SHTS01Z011200024
SHTS01Z011200025
SHTS01Z011200026
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
SHTS01Z011200027
No-load test
• With the starter securely clamped in a vise.
• Using a battery and suitable ammeter.
• Connect the positive lead to the ammeter, "B" and "C" terminal.
• Connect the negative lead to the starter body.
(2) The starter should show smooth and steady rotation immediately
after jumping out of the pinion and should draw less than the
specified current.
SHTS01Z011200028
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
Unit: mm {in.}
Measure
Measure
Measure
Measure
Measure
Depth between the mica
0.5-0.8 0.2 {0.0078} or
and the commutator Replace or repair.
{0.0197-0.0314} less
(Under cut depth)
Measure
Measure
A: 11.98 Measure
Outside diameter of the A: 12.0 {0.472} {0.471}
Replace. B
armature assembly B: 15.0 {0.591} B: 14.98 A
{0.589}
Measure
Measure
Measure
A: 25.88 B A
Outside diameter of the A: 26.0 {1.024}
{1.018} Replace.
drive shaft assembly B: 12.1 {0.476}
B: 12.0 {0.472}
Measure
Measure
Measure
Visual check
NEEDLE
ROLLER
Rotating of needle roller
— — Replace. BEARING
bearing
2A'0AM9HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧡ᣣޓ㊄ᦐᣣޓඦ೨㧥ᤨ㧡ಽ
Visual check
Measure
Measure
EN12-002
STARTER
DATA AND SPECIFICATIONS
EN01Z0112I200001
Module 3
DESCRIPTION
EN01Z0112C100001
SHTS01Z011200001
TROUBLESHOOTING
EN01Z0112F300001
COMPONENT LOCATOR
EN01Z0112D100001
SHTS01Z011200002
OVERHAUL
EN01Z0112H200001
SHTS01Z011200003
SHTS01Z011200004
REAR BRACKET
SHTS01Z011200005
BOLT
SHTS01Z011200006
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
SHTS01Z011200007
SHTS01Z011200008
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
SHTS01Z011200009
PULLER
SHTS01Z011200010
SHTS01Z011200011
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
PLANETARY
GEAR
CARRIER PIN
INTERNAL
GEAR
SHTS01Z011200012
SHTS01Z011200013
SHTS01Z011200014
RETAINER
RING
SHTS01Z011200015
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
SHTS01Z011200016
SHTS01Z011200017
SHTS01Z011200018
SHTS01Z011200019
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
BRAKE PLATE
SHTS01Z011200020
SHTS01Z011200021
SHAFT ASSEMBLY
SHTS01Z011200022
PACKING
SHTS01Z011200023
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
1. ASSEMBLING PROCEDURE
(1) Follow the assembling procedure in the reverse order from the
final process.
2. TIGHTENING TORQUE
(1) Refer to the section "COMPONENT LOCATOR".
3. LUBRICATION
(1) Apply the grease to the portion as shown in the figure.
G1: Multemp AC-N
G2: Pyronoc No.2
NOTICE
Grease should be adhered on commutator surface, brash nor
other connecting points.
G1
G1
G1
G1
G1
G2
G1 G1
G1 G1
G2 G2 G1
G1
SHTS01Z011200024
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
SHTS01Z011200025
SHTS01Z011200026
SHTS01Z011200027
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
No-load test
• With the starter securely clamped in a vise.
• Using a battery and suitable ammeter.
• Connect the positive lead to the ammeter, "B" and "C" terminal.
• Connect the negative lead to the starter body.
(2) The starter should show smooth and steady rotation immediately
after jumping out of the pinion and should draw less than the
specified current.
SHTS01Z011200028
2A'0AHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧝ಽ
Unit: mm {in.}
Measure
Measure
Measure
Measure
Measure
Depth between the mica
0.5-0.8 0.2 {0.0078} or
and the commutator Replace or repair.
{0.0197-0.0314} less
(Under cut depth)
Measure
Measure
A: 11.98 Measure
Outside diameter of the A: 12.0 {0.472} {0.471} A
Replace.
armature assembly B: 9.0 {0.354} B: 8.98
{0.354} B
Measure
Measure
Measure
A: 25.90
Outside diameter of the A: 26.0 {1.024} {1.020}
Replace.
drive shaft assembly B: 12.1 {0.476} B: 12.04 B A
{0.474}
Measure
Measure
Measure
Measure
Measure
Visual check
Visual check
Measure
C
Measure
Measure
M CONNECTOR
Continuity between B
No continuity — Replace.
terminal and M terminal
B CONNECTOR
Measure
Continuity between B
Continuity — Replace.
terminal and M terminal
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
AIR COMPRESSOR
DATA AND SPECIFICATIONS
EN01Z0113I200001
DESCRIPTION
EN01Z0113C100001
B
13
2
A
4
3
12 11
1
10 5
SHTS01Z011300001
1 O-ring 9 Crankcase
2 Cylinder head assembly 10 Piston pin
3 Gasket 11 Piston ring
4 Valve seat 12 Suction valve
5 Piston 13 Delivery valve
6 Connecting rod A Suction
7 Bearing B Delivery
8 Crankshaft
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
TROUBLESHOOTING
EN01Z0113F300001
COMPONENT LOCATOR
EN01Z0113D100001
(REPRESENTATIVE TYPE)
b
a
a
a b
c
a
1 Z
Y
Y
Z
SHTS01Z011300002
1 Air compressor
1
6
12
7
2
11
3 B
8 D
4 10
9
5 17
A
14
18
4
14
16
9
13
8
C
15
SHTS01Z011300003
SPECIAL TOOL
EN01Z0113K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
OVERHAUL
EN01Z0113H200001
1. INSTALLATION PROCEDURES
(1) Fit the No.1 cylinder to the Top Dead Center.
FLYWHEEL
NOTICE
Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
FLYWHEEL INTRODUCTION ".
HOUSING
SHTS01Z011300007
(2) Align the aligning mark "0" on the top of coupling flange with pro-
trusion on the compressor housing.
(3) Insert the O-ring into the O-ring groove of the air compressor of
"0" MARK bearing holder side.
(4) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or
(EXAMPLE)
more) in the flywheel housing as shown in the figure and insert
the compressor onto the stud bolt.
(5) Tighten the mounting bolts (other than the stud bolt) then remove
the stud bolt. Insert a bolt in the place of the stud bolt.
Tightening Torque:
28.5 N⋅m {290 kgf⋅cm, 20 Ibf⋅ft}
SHTS01Z011300009
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧠㧝ಽ
(6) Make sure that the aligning mark "0" on the top of the coupling
"0" MARK
flange is aligning with protrusion on the compressor housing.
SHTS01Z011300010
SHTS01Z011300011
(2) Pull the drive gear from the crankshaft, then remove the woodruff
key.
SST: Bearing puller (S0965-01101)
SHTS01Z011300012
MARKING
SHTS01Z011300013
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
SHTS01Z011300014
NOTICE
• Handle the piston rings carefully because they are made of a
special casting which is easily broken.
• When reusing the piston rings, first arrange them face up
and in the correct installation sequence in order to prevent
installing them incorrectly.
SHTS01Z011300015
SHTS01Z011300017
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
SHTS01Z011300018
SHTS01Z011300019
SHTS01Z011300020
STRIKING
TOOL
SHTS01Z011300021
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
SHTS01Z011300022
SHTS01Z011300023
SHTS01Z011300024
SHTS01Z011300025
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
SHTS01Z011300026
SHTS01Z011300027
END PLAY
SHTS01Z011300028
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS01Z011300029
! WARNING
The retainer ring may spring out of the groove during assembly.
SHTS01Z011300030 Wear a pair of safety goggles during assembly.
OIL
RING
SECOND
RING PIN HOLE
SHTS01Z011300031
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
ALIGNIG MARK
SHTS01Z011300032
O-RING
MARKING
SHTS01Z011300033
SHTS01Z011300034
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
Unit: mm {in.}
Visual check
Visual check
Visual check
Replace valve
Worn or damaged delivery valve — —
seat.
Visual check
Replace valve
Worn or damaged suction valve — —
seat.
Measure
Replace pis-
ton pin or con-
necting rod.
Measure
Outside diameter of the piston
70 {2.756} —
(Measure at A and B)
Measure
Clearance
Replace pis-
between the ring Top, second 0.005-0.040
0.08 {0.0031} ton or piston
groove and the ring {0.0002-0.0016}
ring.
piston ring
2A'0AA0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧞ಽ
Measure
0.15-0.35
Top ring 1.0 {0.0394}
{0.0060-0.0137}
Piston ring gap:
Replace.
compression ring
Second, 0.1-0.3
1.0 {0.0394}
third ring {0.0040-0.0118}
Measure
A: 40.002-40.013
39.995 {1.575}
{1.5749-1.5753}
B: 50.002-50.011
49.995 {1.968}
{1.9686-1.9689}
Measure
Cylinder
80 {3.1496} 80.04 {3.151}
block
Inside
diameter of the Replace.
bearing holder
Bearing
90 {3.543} 90.04 {3.545}
holder
Visual check
Measure
Replace
END PLAY
0.2-0.4 connecting
Connecting rod end play 0.5 {0.0197}
{0.0079-0.0157} rod or
crankshaft.
Measure
Replace
Crankshaft end play 0-0.6 {0-0.023} 1.0 {0.039} crankshaft
bearing.
2A'0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦ೨㧤ᤨ㧞㧟ಽ
ENGINE CONTROL
EN16
ACCELERATOR PEDAL
DESCRIPTION
EN01Z0116C100001
SHTS01Z011600001
ADJUSTMENT
EN01Z0116H300001
SHTS01Z011600002
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
COMPONENT LOCATOR
EN16Z0102F200002
a e
6 5
d 9
8
4
7
e 10
c c
2
a f
b d
b
15
13
16
g
11
14
18
12
20 17
21
19
SHTS16Z010200002
DIAGRAM
EN16Z0102F200003
6
7
2 3
9
8
10
13 12 11
SHTS16Z010200003
ELECTRICAL
EN16Z0102F200004
Actuator relay
Fuse
To Each sensor (power)
Fuse
Battery
ECU main relay
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
Accelerator sensor 1,2
Interface PC
diagnosis
Idle volume
Brake SW
Stop light SW
Accelerator SW
Check engine light
Clutch SW Tachometer (Drive signal)
Diagnosis SW
Neutral SW
Exhaust brake
combination SW
PTO switch
Idle-up signal 1
CAN communication (VNT)
Idle-up signal 2
Exhaust brake drive signal
AT identification signal
CAN communication
Meter ECU
Exhaust brake light
AT
ECU
Common rail
pressure sensor 1 ENGINE ECU
Common rail Coolant
temperature T
P
sensor DC/DC
Air flow converter
T meter
P
G
ENGINE
N
Exhaust
EGR valve 1 muffler
(Linear solenoid) Turbo charger
Exhaust brake
DC motor solenoid
VNT actuator
NOTICE:
SW = Switch
SHTS16Z010200004
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
Battery
Starter SW singal
Diagnosis monitor
Starter singal
Diagnosis tool
Accelerator sensor 1,2
Interface PC
diagnosis
Idle volume
Stop light SW
Accelerator SW
Exhaust brake
combination SW
PTO switch
Idle-up signal 1
Idle-up signal 2
Common rail
pressure sensor 2
Coolant temperature sensor
Common rail
pressure sensor 1 ENGINE ECU
Common rail
P
T
P
G
ENGINE
N
Exhaust
muffler
Exhaust brake
solenoid
NOTICE:
SW = Switch
SHTS16Z010200005
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
PRECAUTIONS
EN16Z0102F200005
! WARNING
Approximately 110V is generated for the injector drive actuation system. For this reason, electrical shock may
result if the injector drive circuit is touched directly by hand. Turn the starter switch to the LOCK position if it is
necessary to check or repair the computer, harnesses, or connectors.
1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE ACTUATOR OR MAGNETIC VALVES.
SHTS16Z010200006
• Do not let water, oil or dust get on the connector when it is disconnected, as this could cause poor contacts when the
connector is reconnected.
• Do not open the control unit cover. It could malfunction if dust or water gets inside.
• Take care to ensure that water, oil or dust do not get on or inside parts.
• When connecting in connectors, push them in all the way and make sure that the lock engages.
3. ERASING THE MALFUNCTION MEMORY STORED IN THE PAST, CHECK THE CURRENT MALFUNCTION BY
PERFORMING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
4. AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE THE MALFUNCTION MEMORY STORED IN
THE PAST. OTHERWISE, THE MALFUNCTION CODES IN THE DISPLAY WILL REMAIN INDICATED.
5. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE SEEN FROM THE CONNECTION SIDE, INSERT
THE TESTING LEAD FROM THE BACKSIDE.
EXAMPLE:
ECU: A5 TERMINAL
SIGNAL CHECK HARNESS
CONTACT BOX:
A5 TERMINAL B29 B28 A34 A33 A32 A31 A30 A29 A28
B21 B20 A27 A26 A25 A24 A23 A22 A21 E20 A19 A18
COMPUTER (ECU)
TERMINAL No. 0 B9 B8 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8
A5 A
B1 A7 A6 A5 A4 A3 A2 A1
A
SIGNAL CHECK
HARNESS
(CONTACT BOX)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
SHTS16Z010200007
SHTS16Z010200008
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
Common Rail
09049-1080
A B C D E
SHTS16Z010200009
DN02–10
VIEW
COMPUTER (ECU) TERMINAL SIGNAL
THF+ AGD3 AGD2 AGD1 GVCC PCR2 GGND DGSW NUSW AVC5 AFT+ IVS
CASE CANL CANH THW+ PIM EGS1 AVC1 AVC2 AVC3 PCR1 G3+ ADG6 CA2L CA2H BUSW PTO BSW1 IDLE AVC4 SWSS AGD5 AGD4 VS ASCS ACS2 ACS1 ISOK
SCVH SCVH SCVL SCVL EGR1 CE/G FIUP CLSW BSW2 STOP EBSW ST SSWS TACH
I2+S IJ2+ PGD3 PGD2 INJ2 INJ3 I1+S IJ1+ INJ4 INJ1 PGD1 +BF1 MRL2 MRL1 CGD2 CGD1 GRY2 GRY1 NE1- NE1+ NESD EBMV +BF2 VB3 VB2 VB1
E31 E30 E29 E28 E27 E26 D35 D34 D33 D32 D31 D30 D29 D28 C32 C31 C30 C29 C28 B35 B34 B33 B32 B31 B30 B29 B28 A34 A33 A32 A31 A30 A29 A28
E25 E24 E23 E22 E21 E20 E19 E18 D27 D26 D25 D24 D23 D22 D21 D20 D19 D18 D17 C27 C26 C25 C24 C23 C22 C21 C20 C19 C18 B27 B26 B25 B24 B23 B22 B21 B20 A27 A26 A25 A24 A23 A22 A21 E20 A19 A18
E17 E16 E15 E14 E13 E12 E11 E10 E9 E8 D16 D15 D14 D13 D12 D11 D10 D9 D8 D7 C17 C16 C15 C14 C13 C12 C11 C10 C9 C8 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8
E7 E6 E5 E4 E3 E2 E1 D6 D5 D4 D3 D2 D1 C7 C6 C5 C4 C3 C2 C1 B7 B6 B5 B4 B3 B2 B1 A7 A6 A5 A4 A3 A2 A1
FUEL CONTROL (J05D, J05E: COMMON RAIL)
SHTS16Z010200010
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
4 – 24 –
8 – 28 –
9 TACH Tachometer 29 –
11 – 31 –
13 – 33 –
14 – 34 –
15 –
16 –
18 –
20 –
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
8 – 28 –
9 – 29 –
10 – 30 –
13 – 33 –
17 –
18 –
9 – 29 –
10 – 30 –
11 – 31 –
14 –
15 –
16 –
17 –
18 –
19 –
5 IJ1+ No.1, 4 Fuel injector (+) 25 AVC1 Boost pressure sensor (Power)
8 – 28 –
9 – 29 –
16 –
18 –
3 – 23 –
7 I2+S No.2, 3 Fuel injector (+) 27 THF+ Fuel temperature sensor (+)
12 –
13 –
14 –
15 –
16 –
17 –
18 –
20 –
14. OTHER
• Make sure to check the other connectors before connecting them in to prevent incorrect connections.
• Be careful not to allow the connectors to become soiled with dust, water, fuel or oil when performing inspections or
removing and replacing parts.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
INSPECTION
EN16Z0102F200006
SHTS16Z010200011
START
STARTER ON
SWITCH
LOCK
RUNNING
ENGINE
STOP
CHECK
ON
ENGINE
LIGHT OFF
SHTS16Z010200012
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
NOTICE
Trouble diagnosis also can be performed using the diagnosis
monitor. The malfunction codes are indicated by sound and light.
(1) Turn the starter switch to "ON".
SHTS16Z010200013
BLACK CONNECTOR
WHITE CONNECTOR
SHTS16Z010200014
SHTS16Z010200015
SHTS16Z010200016
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
0.5S 0.5S
Turn ON
Turn OFF
1.5S 4.3S
Code 32 Code 21
Repeat
Normal
0.3S
Turn ON
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC diagnosis tool.
By connection to the diagnosis connector, the trouble location is
indicated.
SST:
Communication interface assembly (09993-E9070)
Cable communication (S0904-21220)
Diagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager
NOTICE
SHTS16Z010200018
Only ECU reprogramming can be performed by authorized HINO
dealer.
P P
INTERFACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS16Z010200019
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
NOTICE
MC No.: Diagnosis Monitor Code (Using the diagnosis monitor)
DTC No.: Diagnosis Trouble Code (Using the PC diagnosis tool)
A: Engine does not start
B: Engine stops
C: Engine has low power
D: Difficulty starting engine
YES: Check engine light: Light
NO: Check engine light: Not light
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
YES A, B 13 P0335 Engine speed main and sub sensor circuit malfunction DN02-31
YES A, B 74 P0629 Supply pump SCV malfunction (Power source line short) DN02-65
YES C 67 P0192 Common rail pressure sensor circuit low input DN02-44
YES C 67 P0193 Common rail pressure sensor circuit high input DN02-44
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
YES C 81 P0489 EGR solenoid 1 malfunction (Open circuit or ground line short) DN02-67
YES C 81 P0490 EGR solenoid 1 malfunction (Power source line short) DN02-67
YES C 75 P0628 Supply pump SCV malfunction (All discharge mode) DN02-65
YES 16 P0112 Intake air temperature sensor circuit low input DN02-40
YES 16 P0113 Intake air temperature sensor circuit high input DN02-40
CHECK
DTC REFER
ENGINE SYMPTOM MC No. PRESUMED CAUSE OF TROUBLE
No. PAGE
LIGHT
NOTICE
• It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service
replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at
the time of ECU service replacement, so ensure sufficient time (Several minutes) is available.
• When an injector is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using
the diagnosis tool.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200022
NO
• 0V: Fuse blows, harness malfunction,
ground malfunction.
YES • Less than 20V: Battery retrogradation,
ground malfunction.
Normal.
SHTS16Z010200023
NO
• Ground harness disconnection.
• Bad contact of terminal.
YES
Normal.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 13 DTC No. P0335 Engine speed main sensor circuit malfunction
SHTS16Z010200024
NO
Proceed to 3.
YES
NO
• Bad contact of ECU connectors.
• Malfunction of ECU.
YES • Malfunction of harness (Short circuit).
Normal.
SHTS16Z010200025
NO
Malfunction of engine speed main sensor.
YES
• Harness disconnection.
• Bad contact of connectors.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 13 DTC No. P0336 Engine speed main sensor pulse abnormal
SHTS16Z010200026
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS16Z010200027
NO
Malfunction of harness.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200028
NO
• Engine speed main senor malfunction.
• Flywheel signal hole abnormal.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 12 DTC No. P0340 Engine speed sub sensor circuit malfunction
SHTS16Z010200029
NO
Proceed to 2.
YES
Proceed to 3.
SHTS16Z010200030
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200031
NO
Proceed to 4.
YES
SHTS16Z010200032
NO
Malfunction of harness.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 12 DTC No. P0341 Engine speed sub sensor pulse abnormal
SHTS16Z010200033
NO
Proceed to 2.
YES
Proceed to 3.
SHTS16Z010200034
NO
Malfunction of harness.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200035
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS16Z010200036
NO
• Engine speed sub senor malfunction.
• Camshaft gear signal pin abnormal.
YES
MC No. 13 DTC No. P0335 Engine speed main and sub sensor circuit malfunction
MC No. 11 DTC No. P0117 Coolant temperature sensor circuit low input
MC No. 11 DTC No. P0118 Coolant temperature sensor circuit high input
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
SHTS16Z010200038
NO
Malfunction of coolant temperature sensor.
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
ENGINE OVERHEAT
EN16Z0102F200019
NO
Malfunction of coolant temperature sensor.
YES
HINT
This code will be displayed when the coolant temperature sensor
operates normally and coolant temperature ascends over 115°C
{239°F}. Also, while the MC or DTC is being detected, Max. volume
of fuel injection will be limited and will return back to normal con-
trol volume when it descends less than 80°C {176°F}.
.
ENGINE OVERRUN
EN16Z0102F200020
MC No. 14 DTC No. P0182 Fuel temperature sensor circuit low input
MC No. 14 DTC No. P0183 Fuel temperature sensor circuit high input
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
SHTS16Z010200041
NO
Malfunction of fuel temperature sensor.
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 37 DTC No. P0108 Boost pressure sensor circuit high input
MC No. 37 DTC No. P0237 Boost pressure sensor circuit low input
SHTS16Z010200042
NO
Proceed to 2.
YES
Proceed to 3.
SHTS16Z010200043
NO
• Malfunction of ECU.
• Malfunction of ECU connector.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧠㧠ಽ
SHTS16Z010200044
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
• Malfunction of harness.
A
GND
SIG
VIEW A
SHTS16Z010200045
NO
Malfunction of boost pressure sensor.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200046 Standard: More than 110 kPa {1.122 kgf/cm2, 15.95 Ibf/in.2}
.
NO
Malfunction of boost pressure sensor.
YES
Normal.
NO
Malfunction of VNT turbocharger control.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 17 DTC No. P0102 Air flow sensor circuit low input
MC No. 17 DTC No. P0103 Air flow sensor circuit high input
SHTS16Z010200047
NO
Malfunction of harness.
YES
Proceed to 2.
SHTS16Z010200048
NO
Proceed to 3.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200049
NO
Malfunction of air flow sensor.
YES
Malfunction of harness.
SHTS16Z010200051
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 16 DTC No. P0112 Intake air temperature sensor circuit low input
MC No. 16 DTC No. P0113 Intake air temperature sensor circuit high input
Standard:
13.6-18.4 kΩ at -20°C {-4°F}
2.21-2.69 kΩ at 20°C {68°F}
SHTS16Z010200052
0.49-0.67 kΩ at 60°C {140°F}
.
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Malfunction of harness (Short circuit).
Standard:
13.6-18.4 kΩ at -20°C {-4°F}
2.21-2.69 kΩ at 20°C {68°F}
0.49-0.67 kΩ at 60°C {140°F}
SHTS16Z010200053
NO
Malfunction of intake air temperature (air flow)
sensor.
YES
• Harness disconnection.
• Malfunction of connectors.
• Bad contact of connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 68 DTC No. P0088 Excessive common rail pressure (1st step)
MC No. 69 DTC No. P0088 Excessive common rail pressure (2nd step)
SHTS16Z010200054
NO
• Malfunction of ECU.
• Bad contact of harness connector.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200055
.
NO
Malfunction of common rail pressure sensor.
YES
SHTS16Z010200057
NO
• Malfunction of ECU.
• Bad contact of harness connector.
YES
SHTS16Z010200058
NO
• Malfunction of common rail pressure sen-
sor.
YES • Bad contact of harness connector.
• Malfunction of ECU.
• Bad contact of harness connector.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 67 DTC No. P0192 Common rail pressure sensor circuit low input
MC No. 67 DTC No. P0193 Common rail pressure sensor circuit high input
SHTS16Z010200059
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS16Z010200060
NO
Proceed to 3-(3).
YES
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200061
NO
Malfunction of harness.
YES
(3) Disconnect the signal check harness connector on the ECU side.
(4) Measure the resistance between AVC2 (D24) terminals and
D PCR+ PCR+ terminal of common rail pressure sensor (Vehicle harness
D24 side), AGD1 (D33) terminal and PCR- terminal of common rail
pressure sensor (Vehicle harness side).
Standard: Less than 2 Ω
SHTS16Z010200062
D PCR-
D33
SHTS16Z010200063
.
NO
Malfunction of harness.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200064
NO
Proceed to 2.
YES
Proceed to 3.
SHTS16Z010200065
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧠㧠ಽ
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
NO
Malfunction of accelerator sensor.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
ACCELERATOR SENSOR 1
EN16Z0102F200033
SHTS16Z010200068
NO
Malfunction of accelerator sensor.
YES
(4) Measure the voltage between ACS1 (A21) and AGD4 (B20) ter-
minals while depressing the accelerator pedal.
A B
A21 B20 Standard: 1V or more, with the voltage change proportional
to the accelerator pedal depression amount.
(After measurement, turn the starter switch to "LOCK" position.)
SHTS16Z010200069
NO
Malfunction of accelerator sensor.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200070
NO
Proceed to 2.
YES
Proceed to 3.
B31
SHTS16Z010200071
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧠㧠ಽ
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
NO
Malfunction of accelerator sensor.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
ACCELERATOR SENSOR 2
EN16Z0102F200035
SHTS16Z010200074
NO
Malfunction of accelerator sensor.
YES
(4) Measure the voltage between ACS2 (A22) and AGD5 (B21) ter-
minals while depressing the accelerator pedal.
A B
A22 Standard: 1V or more, with the voltage change proportional
B21
to the accelerator pedal depression amount.
(After measurement, turn the starter switch to "LOCK" position.)
SHTS16Z010200075
NO
Malfunction of accelerator sensor.
YES
Malfunction of harness.
MC No. 23 DTC No. P1132 P.T.O. accelerator sensor circuit low voltage
MC No. 23 DTC No. P1133 P.T.O. accelerator sensor circuit high voltage
SHTS16Z010200076
NO
Proceed to 2.
YES
Proceed to 3.
SHTS16Z010200077
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Malfunction of harness.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200078
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS16Z010200079
NO
Malfunction of accelerator sensor.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧠㧠ಽ
MC No. 21 DTC No. P0500 Vehicle speed sensor circuit low input
MC No. 21 DTC No. P0501 Vehicle speed sensor circuit high input
SHTS16Z010200080
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
SHTS16Z010200081
NO
Harness disconnection of vehicle speed sen-
sor circuit.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200082
NO
Short circuit of vehicle speed sensor circuit.
YES
ECU
EN16Z0102F200039
MC No. 15 DTC No. P2228 Atmospheric pressure sensor circuit low input
MC No. 15 DTC No. P2229 Atmospheric pressure sensor circuit high input
2. After erasing the MC or DTC, check that the same code is dis-
played again.
.
NO
Malfunction of ECU.
YES
Normal.
(Temporary malfunction because of radio interference noise.)
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
Standard: ∞ Ω
.
NO
Proceed to 3.
YES
SHTS16Z010200084
No.1 injector 2, 5
57 P1211
No.4 injector 6, 10
ECU case GND
No.2 injector 3, 7
58 P1214
No.3 injector 8, 11
Standard: ∞ Ω
.
NO
Malfunction of harness.
(The harness is defective if the resistance
value is out of standard.)
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 57 DTC No. P1212 Injector common 1 power source line short
MC No. 58 DTC No. P1215 Injector common 2 power source line short
NO
Proceed to 3.
YES
SHTS16Z010200086
No.1 injector 5
57 P1212
No.4 injector 6
ECU case GND
No.2 injector 7
58 P1215
No.3 injector 8
NO
Malfunction of harness.
(The harness is defective if the resistance
value is out of standard.)
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200087
.
NO
Proceed to 3.
YES
NO
Proceed to 4.
YES
SHTS16Z010200089
NO
Proceed to 5.
YES
SHTS16Z010200090
NO
Injector coil disconnection. (Replace the injec-
tor assembly.)
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
CYLINDER CONTRIBUTION/BALANCE
EN16Z0102F200043
Inspection:
a. When removing the flow damper from the common rail, check that
a the piston is not sticking in the body. If the piston sticks, replace
d the flow damper.
b. Inspect the contact surface 1 between piston and fuel supply port.
b If there is wear and damage, replace the flow damper assembly.
c. Inspect clogging on the piston orifice. Clean or replace the flow
c damper assembly.
SHTS16Z010200091
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 74 DTC No. P0629 Supply pump SCV malfunction (Power source line short)
MC No. 75 DTC No. P0628 Supply pump SCV malfunction (All discharge mode)
SHTS16Z010200093
NO
Malfunction of SCV.
(Replace the supply pump)
YES
SHTS16Z010200094
NO
• Harness disconnection.
• Bad contact of harness connector.
YES
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200095
NO
Malfunction of ECU connector.
YES
Malfunction of ECU.
SUPPLY PUMP
EN16Z0102F200045
MC No. 79 DTC No. P2635 Supply pump abnormal high pressure record
NO
Replace supply pump.
YES
SHTS16Z010200096 .
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 81 DTC No. P0489 EGR solenoid 1 malfunction (Open circuit or ground line short)
MC No. 81 DTC No. P0490 EGR solenoid 1 malfunction (Power source line short)
SHTS16Z010200097
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES • Malfunction of harness (Short circuit).
Proceed to 2.
SHTS16Z010200098
NO
Malfunction of EGR Solenoid 1.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200099
NO
• Harness disconnection.
• Malfunction of connectors.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧞㧝ᣣᦐޓᣣޓඦᓟ㧠ᤨ㧠㧡ಽ
EGR
EN16Z0102F200047
NO
Malfunction of ECU.
YES
Normal.
EGR VALVE 1
EN16Z0102F200048
NO
Malfunction of EGR valve 1.
YES
Normal.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MC No. 86 DTC No. P0405 EGR lift sensor 1 circuit low input
MC No. 86 DTC No. P0406 EGR lift sensor 1 circuit high input
SHTS16Z010200101
NO
Proceed to 2.
YES
Proceed to 3.
SHTS16Z010200102
NO
• Malfunction of ECU.
• Malfunction of ECU connector.
YES
Proceed to 3.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200103
NO
Proceed to 4.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
SHTS16Z010200104
NO
Malfunction of EGR lift sensor1.
(Replace the EGR assembly)
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200105
NO
Malfunction of harness.
YES
Proceed to 2.
SHTS16Z010200106
NO
• Harness disconnection, short circuit
(Ground line, power source line).
YES • Bad contact of harness or connector.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200107
NO
Malfunction of EGR.
YES
Normal.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
+ side – side
NO
Proceed to 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connector.
SHTS16Z010200109
NO
Malfunction of exhaust brake magnetic valve.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
NO
Re-input the QR codes.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
MAIN RELAY
EN16Z0102F200054
SHTS16Z010200110
NO
Proceed 2.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
1 2
SHTS16Z010200111
NO
Malfunction of main relay.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
IDLE VOLUME
EN16Z0102F200055
SHTS16Z010200112
.
NO
Proceed to (5).
YES
Proceed to (7).
SHTS16Z010200113
.
NO
• Malfunction of ECU.
• Malfunction of ECU connectors.
YES
Harness disconnection.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
SHTS16Z010200114
.
NO
Proceed to (10).
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
SHTS16Z010200115
.
NO
Malfunction of idle set controller.
YES
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
ACCELERATOR SWITCH
EN16Z0102F200056
SHTS16Z010200116
NO
Proceed to 2.
YES
Malfunction of ECU.
SHTS16Z010200117
NO
Malfunction of accelerator switch.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
STARTER SWITCH
EN16Z0102F200057
NO
Malfunction of harness.
YES
• Malfunction of ECU.
• Malfunction of ECU connectors.
• Bad contact of ECU connectors.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
CLUTCH SWITCH
EN16Z0102F200058
SHTS16Z010200119
NO
Proceed to 2.
YES
Malfunction of ECU.
SHTS16Z010200120
NO
Malfunction of clutch switch.
YES
Malfunction of harness.
.
2A&0A0QVTGGHOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧝ಽ
NEUTRAL SWITCH
EN16Z0102F200059
SHTS16Z010200121
NO
Proceed to 2.
YES
Malfunction of ECU.
SHTS16Z010200122
NO
Malfunction of neutral switch.
YES
Malfunction of harness.
.
%1.12*10HOࡍࠫ㧞㧜㧜㧤ᐕ㧣㧝㧤ᣣޓ㊄ᦐᣣޓඦᓟ㧟ᤨ㧞㧟ಽ