MENU

FOREWORD

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

Applicable for J08E-VB, WU engine

When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Driver’s / Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular truck.

MANUAL NO. S5-UJ08E14A (U.S.A.), S5-CJ08E14A (CANADA)

CHAPTER
MODEL J08E-VB, WU

GENERAL INTRODUCTION GN01-001

ENGINE INTRODUCTION EN01-001

ENGINE MECHANICAL EN02-001

AIR INTAKE SYSTEM EN03-001

EXHAUST SYSTEM EN04-001

LUBRICATING SYSTEM EN05-001

COOLING SYSTEM EN06-001

FUEL SYSTEM EN07-001

TURBOCHARGER EN08-001

EMISSION CONTROL EN10-001

ALTERNATOR EN11-001

STARTER EN12-001

AIR COMPRESSOR EN13-001

ENGINE CONTROL EN16-001

 INDEX: ENGINE GROUP 1/2

GENERAL INTRODUCTION

ENGINE INTRODUCTION

ENGINE MECHANICAL

WORKSHOP AIR INTAKE SYSTEM

MANUAL EXHAUST SYSTEM

LUBRICATING SYSTEM

COOLING SYSTEM

FUEL SYSTEM

TURBOCHARGER

FUEL INJECTION PUMP

EMISSION CONTROL

ALTERNATOR

STARTER

AIR COMPRESSOR
ENGINE PTO
(POWER TAKE-OFF)

ENGINE RETARDER

ENGINE CONTROL
INDEX: ENGINE GROUP 2/2

VEHICLE CONTROL

FUEL CONTROL

BRAKE CONTROL

SUSPENSION CONTROL

CAB EQUIPMENT CONTROL

OTHERS
 GENERAL INTRODUCTION (ENGINE) GN01–1

GENERAL INTRODUCTION (ENGINE)

GN01

GN01-001

GENERAL INTRODUCTION (ENGINE) ...GN01-2

GENERAL PRECAUTIONS .............................GN01-2
HOW TO USE THIS WORKSHOP MANUAL...GN01-5
IDENTIFICATION INFORMATION ...................GN01-7
PRECAUTIONS ...............................................GN01-8
SPECIFIED TORQUE FOR STANDARD
BOLTS AND NUTS ........................................GN01-11
DISMOUNTING AND MOUNTING ................GN01-12
SYMPTOM SIMULATION ..............................GN01-15
GLOSSARY OF SAE AND HINO TERMS .....GN01-17
GN01–2 GENERAL INTRODUCTION (ENGINE)

GENERAL INTRODUCTION (ENGINE)

GENERAL PRECAUTIONS
EN00Z08010100001

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

WARNING
When working on your engine, observe the following general precautions to prevent death, personal injury and/or
property damage, in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICE in each chapter.

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

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

DEFINITION OF SAFETY TERMS

Indicates an extremely hazardous situation if proper procedures are not followed and could
result in death or serious injury.

Indicates a potential hazardous situation if proper procedures are not followed and could
result in death or serious injury.

Indicates a hazardous situation if proper procedures are not followed and could result in
serious injury or damage to parts/equipment.

Indicates the need to follow proper procedures and to pay attention to precautions so that
efficient service is provided.

Provides additional information to help you to perform the repair efficiently.

 GENERAL INTRODUCTION (ENGINE) GN01–3

TOWING
• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to
protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near
the No. 1 crossmember when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with
the bumper.

1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is
defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and
entry of dirt or foreign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame. The
hook should be used only if the towed vehicle is not loaded.
(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15 in horizontal and vertical
directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a
vehicle trapped in a gutter.
(4) Keep the gear shift lever in "Neutral".
(5) Make sure that the starter switch is kept in the "ON" position.
(6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will be
available for the brake. This is dangerous, as the brake system does not function if the engine is not running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn,
making it impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed
for that purpose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the
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 transmis-
sion, and for even short distance towing. After being towed, check and refill the rear axle housing with lubricant if neces-
sary.
(2) 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.
GN01–4 GENERAL INTRODUCTION (ENGINE)

CLEAN AIR ACT

1. Heavy-duty engine rebuilding practices.

§ 86.004-40
• The provisions of this section are applicable to heavy-duty engines subject to model year 2004 or later standards and are
applicable to the process of engine rebuilding (or rebuilding a portion of an engine or engine system). The process of
engine rebuilding generally includes disassembly, replacement of multiple parts due to wear, and reassembly, and also
may include the removal of the engine from the vehicle and other acts associated with rebuilding an engine. Any devia-
tion from the provisions contained in this section is a prohibited act under section 203(a) (3) of the Clean Air Act (42
U.S.C. 7522(a) (3)).
(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical basis for
knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configuration (i.e., tolerances,
calibrations, specifications) and the model year(s) of the resulting engine configuration must be identified. A reasonable
basis would exist if:
a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and func-
tion of motor vehicle engines would reasonably believe that the parts perform the same function with respect to emis-
sions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
 In accordance with the original engine manufacturer's instructions; or
 Where data or other reasonable technical basis exists that such parameter adjustment or design element change,
when performed on the engine or similar engines, is not expected to adversely affect in-use emissions.
(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a configu-
ration of the same or later model year as the original engine. When an engine is being replaced, the replacement engine
must be an engine of (or rebuilt to) a configuration of the same or later model year as the original engine.
(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or reset with-
out diagnosing and responding appropriately to the diagnostic codes, regardless of whether the systems are installed to
satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface. Diagnostic systems must be
free of all such codes when the rebuilt engine is returned to service. Such signals may not be rendered inoperative during
the rebuilding process.
(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt engine, all
critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by paragraphs (1) through (3) of
this section must be checked and cleaned, adjusted, repaired, or replaced as necessary, following manufacturer recom-
mended practices.
(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The records
shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the engine and emis-
sions-related control components including a listing of parts and components used, engine parameter adjustments, emis-
sions-related codes or signals responded to and reset, and work performed under paragraph (4) of this section.
a. Parties may keep records in whatever format or system they choose as long as the records are understandable to an
EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an understandable format
when requested.
b. Parties are not required to keep records of information that is not reasonably available through normal business prac-
tices including information on activities not conducted by themselves or information that they cannot reasonably
access.
c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual engine
rebuilt in cases where those rebuild practices are followed routinely.
d. Records must be kept for a minimum of two years after the engine is rebuilt.

2. Maintenance instructions.
§ 86.010-38
(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manufacturer
shall furnish or cause to be furnished to the ultimate purchaser a statement that
“This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for highway
diesel fuel, including a 15 ppm sulfur cap).”
 GENERAL INTRODUCTION (ENGINE) GN01–5

HOW TO USE THIS WORKSHOP MANUAL

EN00Z08010200001

This workshop manual is designed as a guide for servicing the vehicles.

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

TROUBLESHOOTING is dealt with in each chapter.

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

SPECIAL TOOLS are dealt with in each chapter.

When ordering a special tool, confirm the part number with the applicable
parts catalog.

SAPH00Z080100006 • REPAIR PROCEDURES

Repair procedures when self-explanatory, such as simple installation
and removal of parts, have been omitted. Illustrations, such as the
one below, have been provided to make such simple procedures
clear. Only essential procedures requiring specific directions have
been dealt with explicitly.
GN01–6 GENERAL INTRODUCTION (ENGINE)

TIMING GEAR AND CAMSHAFT

EXAMPLE:

D A

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

SAPH00Z080100007

1 Gasket 8 Main idle gear

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

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

A 108 {1,100, 80}# C 55 {560, 41} Application of lock sealant
B 172 {1,750, 127}# D 59 {600, 43}+90#
#=Apply oil to the threads and seat surfaces before tightening.

In some cases, illustrations may be of parts which differ in some nonessential way from the parts found on your particular vehi-
cle. In such cases, the principle or procedure being illustrated applies regardless of such nonessential differences.
• DEFINITION OF TERMS
This engine rotates counterclockwise viewed from the flywheel side.
 GENERAL INTRODUCTION (ENGINE) GN01–7

IDENTIFICATION INFORMATION
EN00Z08010200002

• ENGINE SERIAL NUMBERS.

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

SAPH00Z080100008
GN01–8 GENERAL INTRODUCTION (ENGINE)

PRECAUTIONS
EN00Z0801C100001

PRECAUTIONS FOR ELECTRICAL SYSTEM

1. REMOVING THE BATTERY CABLE

! WARNING
• Be sure to wait for at least ten minutes after the starter key is
Loosen turned to "LOCK" position before you disconnect the battery ter-
minals from the battery, as the vehicle data is recorded on ECU
and DCU starts working for the exhaust gas after treatment after
the starter key is turned to "LOCK" position. Otherwise, the vehi-
cle data will not be recorded on ECU properly and DCU will not
SAPH00Z080100009 complete working properly, which may result in the malfunction
of DPR system and DEF-SCR system.
• The MIL (malfunction indicator light) may come on when the
starter key is turned to "ON" position again, even if you wait for
at least ten minutes before disconnecting the battery terminals
from the battery after the starter key is turned to "LOCK" posi-
tion. In this case, use HINO DX Ⅱ to clear the DTC (P204F and
P068A), to turn off the MIL and to conduct DPR regeneration
manually.
(1) Before electrical system work, remove the cable from the minus termi-
nal of the battery in order to avoid burning caused by short-circuiting.
(2) To remove the battery cable, fully release the nut to avoid damage to
the battery terminal. Never twist the terminal.

2. HANDLING OF ELECTRONIC PARTS

(1) Never give an impact to electronic parts of a computer or relay.
(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.
(4) Do not remove the harness connector, electric component box, and
cover except for repair and inspection.
Incorrect If removal is necessary, pay attention that water and foreign matters
do not attach or enter to the connector, terminals, electric component
box, and cover.
In restoration, make sure there is no attachment or entry of water and
foreign matters and mount them properly, because it causes degrada-
SAPH00Z080100010 tion of waterproof function.

3. HANDLING OF WIRE HARNESS

Incorrect (1) Perform marking on a clamp and a clip and secure then in original
position so that the wire harness will not interfere with the end and
Incorrect
acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.

Incorrect

SAPH00Z080100011
 GENERAL INTRODUCTION (ENGINE) GN01–9

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 con-
nector.
(5) In case it is difficult to insert a test lead from behind the connector,
prepare a harness for inspection and perform inspection.

Incorrect
Incorrect

Correct

SAPH00Z080100012

5. INSTALLATION OF BATTERY DISCONNECT SWITCH

! WARNING
• Installation of the battery disconnect switch on the power supply
circuit for the dosing control unit of DEF-SCR (DCU) may dam-
age or result in the malfunction of DEF-SCR system.
• Be sure to read and follow the procedures and instructions on
the service bulletin before the installation of the battery discon-
nect switch.

6. HANDLING OF BATTERY DISCONNECT SWITCH

! WARNING
• Wait for at least one minute before using the battery disconnect
switch after the starter key is turned to "LOCK" position.
Otherwise, the vehicle data will not be recorded on ECU prop-
erly, which may result in the malfunction of DPR system.
GN01–10 GENERAL INTRODUCTION (ENGINE)

PRECAUTIONS FOR ELECTRIC WELDING

1. PRECAUTION FOR ELECTRIC WELDING

Electrical components such as the alternator and tachograph are
directly connected to the battery and one end is earthed to the
chassis frame. Under these conditions, welding current will flow
back along the earth circuit if electric welding is carried out and
damage may be caused to the alternator, tachograph, electrical
components, etc. Consequently, the following precautions are
always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment and
earth the welding equipment securely to the frame itself. (Do not fit
the welding equipment earth to such things as the tire rims, brake
pipes or fuel pipes and leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the battery’s negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the functioning of all instruments.

Computer

Alternator
etc. Battery

Disconnect the ground terminal for

battery at the connecting point on the
frame and disconnect the ground for
computer as well.

Chassis frame Chassis frame

Connect the ground of the ARC welding

machine near the place on the frame to be
ARC welding welded but not connect it to plated parts such
machine as fuel pipes, brake pipes and leaf spring.

SAPH00Z080100013
(2) In order to prevent damage to ancillary equipment components from
sparks during welding, take steps such as putting fire-resistant covers
over things like the engine, meters, steering wheel, hoses, tubes, leaf
spring and tires.
 GENERAL INTRODUCTION (ENGINE) GN01–11

SPECIFIED TORQUE FOR STANDARD

BOLTS AND NUTS
EN00Z08013200001

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

Class 7T 9T

Representation

7 q
Diameter x Pitch

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

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

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

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

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

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

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

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

Class 4T 7T 9T

Representation

7 q

Diameter x Pitch No Mark

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

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

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

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

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

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

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

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

GN01–12 GENERAL INTRODUCTION (ENGINE)

DISMOUNTING AND MOUNTING

EN00Z08013200002

PROCEDURE FOR INSTALLING JOINTS AND GAS-

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

Location of gasket seal

Tightening torque chart

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

8 {0.315} 13 {130, 9}

10 {0.394} 20 {200, 14}

12 {0.472} 25 {250, 18}

14 {0.551} 25 {250, 18}

16 {0.630} 29 {300, 22}

18 {0.709} 39 {400, 29}

20 {0.787} *39 {400, 29}

24 {0.945} 69 {700, 51}

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

 GENERAL INTRODUCTION (ENGINE) GN01–13

2. Metal seal type (Flare connector type).

Location of metal seal

Tightening torque chart

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

12 {0.472} 20 {200, 14}

14 {0.551} 31 {320, 23}

16 {0.630} 39 {400, 29}

18 {0.709} 59 {600, 43}

20 {0.787} 64 {650, 47}

GN01–14 GENERAL INTRODUCTION (ENGINE)

3. Metal seal type (Nipple connector type).

Location of metal seal

Tightening torque chart

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

10 {0.394} 11 {110, 8}

24 {0.945} 20 {200, 14}

NOTICE
• Before installing the joints, ensure that there is no dirt or burrs
adhering to the various seat faces (pipe joints, gasket, etc.)
• Because the pipes can move relatively freely during installation
and the seat faces are liable to tilt, first temporarily tighten the
pipes, then tighten them to the specified torque and ensure that
there is no leakage from them.
• When tightening two pipes together, be very careful that they do
not rotate together.
• After installing the pipes, apply the correct pressure to each pipe
joint and ensure that there is no leakage.
• Ensure that the various tightening torques conform to the above
table.
*If a soft washer #4840 FR–N (aluminum + rubber and carbon press fit
part) is loosened or removed subsequent to being installed, be sure
and replace it with a new one.
There is no need to replace it, however, for normal retightening.
 GENERAL INTRODUCTION (ENGINE) GN01–15

SYMPTOM SIMULATION
EN00Z08013200003

HINT
The most difficult case in troubleshooting is when no problem symp-
toms occur. In such a case, a thorough problem analysis must be car-
ried out. A simulation of the same or similar conditions and
environment in which the problem occurred in the customer's vehicle
should be carried out. No matter how much skill or experience a tech-
nician has, troubleshooting without confirming the problem symp-
toms will lead to important repairs being overlooked and mistakes or
delays.
For example:
With a problem that only occurs when the engine is cold or as a result
of vibration caused by the road during driving, the problem can never
be determined if the symptoms are being checked on a stationary
vehicle or a vehicle with a warmed-up engine. Vibration, heat or water
penetration (moisture) is difficult to reproduce. The symptom simula-
tion tests below are effective substitutes for the conditions and can
be applied on a stationary vehicle. Important points in the symptom
simulation test: In the symptom simulation test, the problem symp-
toms as well as the problem area or parts must be confirmed. First,
narrow down the possible problem circuits according to the symp-
toms. Then, connect the tester and carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal.
Also, confirm the problem symptoms at the same time. Refer to the
problem symptoms table for each system to narrow down the possi-
ble causes.

1. VIBRATION METHOD: When malfunction seems to occur as a

Vibrate slightly result of vibration.
(1) PART AND SENSOR
Apply slight vibration with a finger to the part of the sensor suspected
to be the cause of the problem, and check whether or not the malfunc-
tion occurs.
NOTICE
Applying strong vibration to relays may open relays
(2) CONNECTORS
Slightly shake the connector vertically and horizontally.
(3) WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
HINT
The connector joint and fulcrum of the vibration are the major areas
Shake slightly that should be checked thoroughly.

2. HEAT METHOD: When a malfunction seems to occur when the

area in question is heated.
(1) Heat the component that is the possible cause of the malfunction with
a hair dryer or similar device. Check if the malfunction occurs.
Vibrate
slightly NOTICE
• Do not heat to more than 60C (140F). Exceeding this tempera-
ture may damage components.
SAPH00Z080100027 • Do not apply heat directly to the parts in the ECU.
GN01–16 GENERAL INTRODUCTION (ENGINE)

3. WATER SPRINKLING METHOD: When a malfunction seems to

occur on a rainy day or in high-humidity.
(1) Sprinkle water onto the vehicle and check if the malfunction occurs.
NOTICE
• Never sprinkle water directly into the engine compartment. Indi-
rectly change the temperature and humidity by spraying water
onto the front of the radiator.
• Never apply water directly onto the electronic components.
HINT
If the vehicle has or had a water leakage problem, the leakage may
SAPH00Z080100028
have damaged the ECU or connections. Look for evidence of corro-
sion or short circuits. Proceed with caution during water tests.

4. HIGH ELECTRICAL LOAD METHOD: When a malfunction seems

to occur when electrical load is excessive.
(1) Turn on the heater blower, headlight, rear window defogger and all
other electrical loads. Check if the malfunction reoccurs.
 GENERAL INTRODUCTION (ENGINE) GN01–17

GLOSSARY OF SAE AND HINO TERMS

EN00Z08010200003

This glossary lists all SAE-J2403 terms and abbreviations used in this manual in compliance with SAE recommendation, as
well as their HINO equivalents.

SAE HINO TERMS

SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS

AAT AMBIENT AIR TEMPERATURE Ambient Air Temperature

ACL AIR CLEANER Air cleaner

ACL Element ACL (Air Cleaner) Element Air Cleaner element

ACL Element AIR CLEANER Element Air Cleaner element

ACL Housing AIR CLEANER Housing Air cleaner body assembly

ACL Housing Cover AIR CLEANER Housing Cover Air Cleaner Housing Cover

AFTERTREATMENT DIESEL EXHAUST

AFTDEF DEF
FLUID

AFTERTREATMENT DIESEL EXHAUST

AFTDEFDU DCU
FLUID DOSING UNIT

AFTERTREATMENT DIESEL OXIDATION

AFTDOC DOC (Diesel Oxidation Catalyst)
CATALYST

AFTDOS AFTERTREATMENT DOSER AFTDOS Dosing

AFTERTREATMENT DIESEL PARTICULATE

AFTDPF DPR filter
FILTER

Aftertreatment Diesel Particulate Filter Differ-

AFTDPFDP DPR differential pressure
ential Pressure

AFTERTREATMENT EXHAUST GAS TEM-

AFTEGT Exhaust gas temperature
PERATURE

AP ACCELERATOR PEDAL Accelerator pedal

AP Sensor ACCELERATOR PEDAL Sensor Accelerator Pedal Position Sensor

APP ACCELERATOR PEDAL POSITION Accelerator Pedal Position

CAC CHARGE AIR COOLER Intercooler

CPP Switch CLUTCH PEDAL POSITION Switch Clutch Switch

DCC DIAGNOSTIC CONNECTOR, Cab Diagnosis connector

DCU DIAGNOSTIC CONNECTOR, Underhood Diagnosis connector

DRIVER DRIVER Driver

DTC DIAGNOSTIC TROUBLE CODE Diagnosis Trouble Code

DTM Switch DIAGNOSTIC TEST MODE Switch Diagnosis switch

EBP EXHAUST BACK PRESSURE Back pressure

EBP EXHAUST BACK PRESSURE Exhaust back pressure

EBP Sensor EXHAUST BACK PRESSURE Sensor Back pressure sensor

EXHAUST BACK PRESSURE REGULATOR

EBPR Valve Exhaust control valve
Valve
GN01–18 GENERAL INTRODUCTION (ENGINE)

SAE HINO TERMS

SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS

EC ENGINE CONTROL Engine control

ECT ENGINE COOLANT TEMPERATURE Coolant Temperature

ECT ENGINE COOLANT TEMPERATURE Water Temperature

EFT ENGINE FUEL TEMPERATURE Fuel temperature

EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor

EGR EXHAUST GAS RECIRCULATION EGR

EGR Valve EXHAUST GAS RECIRCULATION Valve EGR valve

EXHAUST GAS RECIRCULATION TEMPER-

EGRT EGR temperature
ATURE

EXHAUST GAS RECIRCULATION TEMPER-

EGRT Sensor EGR exit temperature sensor
ATURE Sensor

EGT EXHAUST GAS TEMPERATURE Exhaust gas temperature

EI ELECTRONIC IGNITION Ignition coil

EOP ENGINE OIL PRESSURE Oil Pressure

EOT ENGINE OIL TEMPERATURE Oil Temperature

FP FUEL PUMP Fuel pump

FUEL PRESSURE Sensor FUEL PRESSURE Sensor Fuel Pressure sensor

GLOW PLUG GLOW PLUG Glow plug

GND GROUND GROUND

IA INTAKE AIR Air Intake

IA System INTAKE AIR System Air Intake System

IAT INTAKE AIR TEMPERATURE Intake temperature

IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor

IDLE IDLE idle

IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor

IMAT INTAKE MANIFOLD TEMPERATURE Intake manifold temperature sensor

INJ INJECTOR Injector

MAF Sensor MASS AIR FLOW Sensor Air flow sensor

MIL MALFUNCTION INDICATOR LIGHT Check engine

OSS Sensor OUTPUT SHAFT SPEED Sensor Output Speed Sensor

OSS Sensor OUTPUT SHAFT SPEED Sensor Speed Sensor

PC Solenoid Valve PRESSURE CONTROL Solenoid Valve Solenoid control valves

PCV POS CRANKCASE VENTILATION PCV (Positive Crankcase Vent)

PCV Valve POS CRANKCASE VENTILATION Valve PCV (Positive Crankcase Vent) Valve

PCV Valve POS CRANKCASE VENTILATION Valve PCV Valve

 GENERAL INTRODUCTION (ENGINE) GN01–19

SAE HINO TERMS

SAE TERMS
ABBREVIATIONS ( )--ABBREVIATIONS

PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve

PNP PARK/NEUTRAL POSITION Neutral position

PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch

RFP RAIL FUEL PRESSURE Common rail Pressure

RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor

SPARK PLUG SPARK PLUG Spark plug

SRI SERVICE REMINDER INDICATOR Check engine

ST SCAN TOOL Diagnostic tool

TC TURBOCHARGER Turbocharger

TCC TORQUE CONVERTER CLUTCH Torque Converter

TP Sensor THROTTLE POSITION Sensor Throttle Sensor

TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor

VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor

VLS VEHICLE LIMITING SPEED Speed Limiter Upper Limit

VSS VEHICLE SPEED SENSOR Vehicle Speed sensor

 ENGINE INTRODUCTION (J08E) EN01–1

ENGINE INTRODUCTION (J08E)

EN 01

EN01-001

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

DATA AND SPECIFICATIONS ......................... EN01-2
TROUBLESHOOTING ..................................... EN01-4
TROUBLESHOOTING
(COMMON RAIL SYSTEM) ........................... EN01-11
ENGINE TUNEUP ......................................... EN01-12
SPECIAL TOOL ............................................. EN01-18
OVERHAUL CRITERIA.................................. EN01-19
DISMOUNTING AND MOUNTING ................ EN01-20
LIQUID GASKET
AND APPLICATION POINTS......................... EN01-22
EN01–2 ENGINE INTRODUCTION (J08E)

ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
EN0160101I200001

Model J08E-VB

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

Type
water-cooled, direct injection

Aspiration Turbocharged with intercooler

Bore and stroke 112x130 mm {4.41x5.11 in.}

Piston displacement 7.684 L {468.9 cu.in.}

Compression ratio 17.5: 1

1-4-2-6-3-5 (The cylinder numbers are counted in order from the

Firing order
crankshaft pulley side)

Direction of rotation Counterclockwise viewed from flywheel

Compression pressure 3.2-3.4 MPa {33-35 kgf/cm2, 467-496 lbf/in.2} at 150 r/min

Maximum revolution (at full load) 2,600 r/min

Idling revolution 750 r/min

Dry weight Approximately 645 kg {1,422 lb}

Intake 30
Valve seat angle
Exhaust 45

Intake 30
Valve face angle
Exhaust 45

Intake opens 14 before top dead center

Valve timing Intake closes 30 after bottom dead center

(flywheel travel) Exhaust opens 54 before bottom dead center

Exhaust closes 13 after top dead center

Valve clearance Intake 0.30 mm {0.0118 in.}

(when cold) Exhaust 0.45 mm {0.0177 in.}

Type Full forced pressure feed by gear pump

Engine oil pump
Drive By gear

Engine oil cooler Multi-plate type, water cooled

Injector Type Multi-hole nozzle type

Type Forced circulation by volute pump

Coolant pump
Drive By V-belt

Thermostat Type Wax.type, bottom bypass system

0 before top dead center for No.1 cylinder of the compression

Injection timing (flywheel travel)
stroke
 ENGINE INTRODUCTION (J08E) EN01–3

Model J08E-WU

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

Type
water-cooled, direct injection

Aspiration Turbocharged with intercooler

Bore and stroke 112x130 mm {4.41x5.11 in.}

Piston displacement 7.684 L {468.9 cu.in.}

Compression ratio 17.5: 1

1-4-2-6-3-5 (The cylinder numbers are counted in order from the

Firing order
crankshaft pulley side)

Direction of rotation Counterclockwise viewed from flywheel

Compression pressure 3.2-3.4 MPa {33-35 kgf/cm2, 467-496 lbf/in.2} at 150 r/min

Maximum revolution (at full load) 2,600 r/min

Idling revolution 750 r/min

Dry weight Approximately 640 kg {1,411 lb}

Intake 30
Valve seat angle
Exhaust 45

Intake 30
Valve face angle
Exhaust 45

Intake opens 14 before top dead center

Valve timing Intake closes 30 after bottom dead center

(flywheel travel) Exhaust opens 54 before bottom dead center

Exhaust closes 13 after top dead center

Valve clearance Intake 0.30 mm {0.0118 in.}

(when cold) Exhaust 0.45 mm {0.0177 in.}

Type Full forced pressure feed by gear pump

Engine oil pump
Drive By gear

Engine oil cooler Multi-plate type, water cooled

Injector Type Multi-hole nozzle type

Type Forced circulation by volute pump

Coolant pump
Drive By V-belt

Thermostat Type Wax.type, bottom bypass system

0 before top dead center for No.1 cylinder of the compression

Injection timing (flywheel travel)
stroke
EN01–4 ENGINE INTRODUCTION (J08E)

TROUBLESHOOTING
EN0160101F300001

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 con- Retighten or replace clamp
nection
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 (Abnormal com- Poor fuel Use good quality fuel
bustion) Breakdown of injector Replace the injector
Engine overheating (Other prob- Defective or deteriorated engine oil Change engine oil
lems) Unsatisfactory operation of oil pump Replace or repair
Insufficient oil Add oil
Brake drag Repair or adjust
Break water temperature sensor Replace it
Engine overheating (Severe operat- Lugging the engine Operate engine properly
ing condition)
 ENGINE INTRODUCTION (J08E) EN01–5

Excessive oil consumption

Symptom Possible cause Remedy/Prevention
Excessive oil consumption (Pis- Wear of piston ring and cylinder liner Replace piston rings and cylinder liner
tons, cylinder liners, and piston Worn, sticking or broken piston rings Replace piston rings and cylinder liner
rings)
Insufficient tension on piston rings Replace piston rings and cylinder liner
Unsatisfactory breaking in of piston Replace piston rings and cylinder liner
rings
Unsuitable oil (viscosity too low) Change oil as required and replace
piston rings and cylinder liners
Incorrectly fitted piston rings (upside Replace piston rings
down)
Gaps of piston rings in cell with each Reassemble piston rings
other
Excessive oil consumption (Valve Worn valve stem Replace valve and valve guide
and valve guides) Worn valve guide Replace valve guide
Incorrectly fitted valve stem seal Replace the stem seal
Excessive lubricant on rocker arm Check clearance of rocker arm and
shaft
Excessive oil consumption (Excess Defective oil level gauge Replace oil level gauge
oil feed) Oil level too high Drain excess oil
Excessive oil consumption (Oil leak- Oil leakage from oil seal Replace oil seal
age from miscellaneous parts) Cracks or blowhole in cylinder block Replace cylinder block
Oil leakage from connections of oil Tighten connections of oil lines
lines
Oil leakage from oil cooler Replace oil cooler
Oil leakage from oil pan gasket Replace oil pan gasket
Oil leakage from O-ring Replace O-ring
Excessive oil consumption (Other Overcooled engine (low temperature Warm up engine before moving vehi-
problems) wear) cle. Check cooling system.

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.
EN01–6 ENGINE INTRODUCTION (J08E)

Piston seizure
Symptom Possible cause Remedy/Prevention
Piston seizure (Pistons, cylinder lin- Incorrect clearance between piston Replace piston, piston rings and cylin-
ers and piston rings) and cylinder liner der liner
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 overheating"
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 prob-
lems.
.

1. White smoke is emitted.

2. Lack of power
 ENGINE INTRODUCTION (J08E) EN01–7

Lack of power
Symptom Possible cause Remedy/Prevention
Lack of power (Supply pump) Damaged suction control valve (SCV) Replace the suction control valve (SCV)
Use of poor fuel Use good quality fuel
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
Clogged fuel filter Replace element
Use of poor fuel Use good quality fuel
Breakdown of injector Replace the injector
Lack of power (Pistons, cylinder lin- Seized or wear of piston Replace the piston, piston rings and
ers and piston rings) liner
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

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

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.
EN01–8 ENGINE INTRODUCTION (J08E)

Difficulty starting engine

Symptom Possible cause Remedy/Prevention
Difficulty starting engine (Electrical Discharged battery Charge battery
system) Defective wiring in starter circuit Repair wiring of starter
Loose or open-circuit battery cable Tighten battery terminal connections
or replace battery cable
Broken glow plug Replace
Difficulty starting engine (Supply Defective supply pump Replace the supply pump
pump) Use of poor fuel Use good quality fuel
Difficulty starting engine (Air Clogged element Replace the element
cleaner)
Difficulty starting engine (Fuel sys- No fuel in tank Supply fuel
tem) Clogged fuel line Clean fuel line
Air sucked into fuel system through fuel Tighten fuel line connections
line connections
Clogged fuel filter Replace element
Loose connection in high-pressure line Tighten sleeve nut of high-pressure
line
Water in fuel Drain and clean fuel system
Difficulty starting engine (Oil sys- Oil viscosity too high Use proper viscosity oil, or install an oil
tem) immersion heater and warm up oil
Difficulty starting engine (Other Seized piston Replace piston, piston rings, and liner
problems) Seized bearing Replace bearing and/or crankshaft
Reduced compression pressure Overhaul engine
Ring gear damaged or worn Replace the ring gear and/or starter
pinion
Improperly adjusted or broken Adjust

Rough idling
Symptom Possible cause Remedy/Prevention
Rough idling (Supply pump) Damaged suction control valve (SCV) Replace the suction control valve
(SCV)
Use of poor fuel Use good quality fuel
Rough idling (Injector) Breakdown of injector Replace the injector
Use of poor fuel Use good quality fuel
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
 ENGINE INTRODUCTION (J08E) EN01–9

Diesel knock
Symptom Possible cause Remedy/Prevention
Diesel knock (Supply pump) Damaged suction control valve (SCV) Replace the suction control valve (SCV)
Use of poor fuel Use good quality fuel
Diesel knock (Injector) Breakdown of injector Replace the injector
Use of poor fuel Use good quality fuel
Diesel knock (Fuel system) Use of poor fuel Use good quality fuel
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

Unusual engine noise

Symptom Possible cause Remedy/Prevention
Unusual engine noise (Piston) Wear of piston pin boss or piston pin Replace piston and/or piston pin
Seized, damaged, or worn piston pin Replace piston pin bushing
bushing
Worn pistons or cylinder liners Replace piston or cylinder liner
Damaged or seized piston Replace piston and cylinder liner
Foreign matter on top surface of the Remove foreign matter and repair or
piston replace piston, cylinder liner, and/or
cylinder head
Unusual engine noise (Valve mecha- Incorrect valve clearance Adjust valve clearance
nism) Valve cotter out of place Replace valve cotter
Seized valve stem Replace valve and valve guide
Broken valve Replace valve
Damaged rocker arm support Replace rocker arm support
Broken valve spring Replace valve spring
Unusual engine noise (Bearings sei- Insufficient lubricating oil Add oil
zure) Excessive or insufficient tightening of Retighten to specified torque
bearing housings
Pits and scratches on bearing surface Replace bearing and crankshaft
Oil film formed on back of bearing Replace bearing
Improper installation of bearing Replace bearing
Reduction of spread dimension of Replace bearing
bearing
Distorted bearing housing Replace or correct bearing housing
Excessive oil clearance Replace bearing
EN01–10 ENGINE INTRODUCTION (J08E)

Symptom Possible cause Remedy/Prevention

Unusual engine noise (Various other Exhaust gas leakage from exhaust Retighten joints
parts) pipe joints
Loosen or missing intake manifold Retighten or replace
flange gasket
Intake valve seating is not concentric Replace or correct the valve and valve
seat
Intake gas leakage Retighten
Unusual engine noise (Other prob- Loose cooling fan mounting bolts or fan Tighten the fan and crankshaft pulley
lems) pulley nut
Lack of lubricating oil (coolant pump, Lubricate
valves, etc.)
Worn timing gear Replace the timing gear
Breakage of turbine or blower Replace turbocharger

NOTICE
The items on this page concern unusual engine noise which is due to causes other than those given for diesel knock.
 ENGINE INTRODUCTION (J08E) EN01–11

TROUBLESHOOTING (COMMON RAIL SYSTEM)

EN0160101F300002

Engine does not start

Symptom Possible cause Remedy/Prevention
Engine does not start (Fuel not Fuel lines clogged or damaged Clean or replace fuel lines
reaching supply pump) Fuel filter clogged Clean or replace the filter element
Air in fuel caused by improper connec- Repair connections
tions of fuel line between fuel tank and
feed pump
Filter incorporated in inlet side of feed Remove foreign material
pump clogged
Breakdown feed pump Replace the supply pump
Engine does not start (Fuel reaching Leakage due to improper tightening of Tighten sleeve nut
supply pump) high pressure fuel line
Breakdown ECU Replace the ECU
Engine does not start (Injector Injector broken Replace the injector
faulty)
Engine does not start (Electrical Defective sensors or circuits Refer to the chapter TROUBLE
system) SHOOTING (S7-UNAE14* or S7-
CNAE14*).
Engine starts and stops Fuel lines clogged Clean or replace fuel lines
Air in fuel caused by damaged fuel Repair fuel lines or replace fuel lines
lines or improper connection of fuel and gaskets
lines
Engine has low power (Injector Injector broken Replace the injector
faulty)
Engine has low power (Electrical Defective sensors or circuits Refer to the chapter TROUBLE
system) SHOOTING (S7-UNAE14* or S7-
CNAE14*).

Excessive smoke
Symptom Possible cause Remedy/Prevention
Excessive smoke (Black smoke) Defective sensors or circuits Refer to the chapter TROUBLE
SHOOTING (S7-UNAE14* or S7-
CNAE14*).
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

Low idle speed irregular

Symptom Possible cause Remedy/Prevention
Low idle speed irregular Defective sensors or circuits Refer to the chapter TROUBLE
SHOOTING (S7-UNAE14* or S7-
CNAE14*).
Defective injector Replace the injector
EN01–12 ENGINE INTRODUCTION (J08E)

ENGINE TUNEUP
EN0160101H300001

VALVE CLEARANCE CHECKING AND ADJUSTING

PROCEDURES
NOTICE
Valve clearance adjustment is performed only when the checking
result is not within the specified value.

1. PREPARATION OF CHECKING AND ADJUSTMENT

(1) Positioning the No.1 or No.6 piston at Top Dead Center of the com-
pression stroke.
Flywheel a. Turn the crankshaft counterclockwise (viewed from the flywheel
side) to align mark "1/6" on the outer periphery of the flywheel
with the pointer of the flywheel housing.
1 NOTICE
Flywheel
housing • Always turn the crankshaft counterclockwise (viewed from the
flywheel side).
• In this position the No.1 or No.6 piston is at the Top Dead Center
of the compression stroke.
SAPH016010100001

b. Turn the crankshaft clockwise in the engine direction and align the
damper timing mark "1/6" to the pointer.
Pointer

1/6 mark

Damper

SAPH016010100002

NOTICE
Crank
pulley
When matching the pulley mark "1/6" of the crankshaft pulley, attach
the 3 pins on the special tool to any of the 6 corresponding holes on
SST the crank pulley. Then turn the torque wrench in a clockwise direction.
SST: Cranking Tool (S0940-91200)
Torque
wrench

SAPH016010100003

(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 pis-
ton is at the Top Dead Center of the compression stroke.

Drill hole

SAPH016010100004
 ENGINE INTRODUCTION (J08E) EN01–13

(3) Make sure that the valve stem is correctly inserted in the cross head.
NOTICE
Move the cross head with fingers right and left to confirm the valve
Click stem is correctly inserted in the cross head by listening to the clicking
sound.

Correct (4) Confirm that there are no foreign particles or dust between the cross
head and the valve stem.

Incorrect
SAPH016010100005

2. VALVE CLEARANCE CHECKING

NOTICE
Before beginning the checking, you must perform "PREPARATION OF
CHECKING AND ADJUSTMENT" described on page EN01-12.
(1) You can understand which valve to adjust when No.1 or No.6 piston is
at the Top Dead Center of the compression stroke by the following
chart).

Cylinder 1 2 3 4 5 6

Valve IN EX IN EX IN EX IN EX IN EX IN EX

Two drill holes

With No.1
and camshaft
piston at
housing is hori-
T.D.C. on
zontal.      
compres-
The rest of drill
sion Cam- hole is visible.
stroke shaft #1
gear
condi- Two drill holes
With No.6
tion and camshaft
piston at
housing is hori-
T.D.C. on
zontal.      
compres-
The rest of drill
sion
hole is invisi-
stroke
ble. #1

• #1= View from rear side of camshaft housing

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

SAPH016010100008
EN01–14 ENGINE INTRODUCTION (J08E)

(3) Insert a feeler gauge of the specified thickness as below between the
rocker arm and the cross head to check the valve clearance.
Rocker arm
VALVE CLEARANCE (when cold)
Feeler gauge
Intake valve 0.30 mm {0.0118 in.}
Exhaust valve 0.45 mm {0.0177 in.}
Cross head
NOTICE
Valve clearance adjustment is performed only when the checking
result is outside the specified value.

SAPH016010100009

3. VALVE CLEARANCE ADJUSTMENT

NOTICE
Valve clearance adjustment is performed only when the checking
result is outside the specified value.
NOTICE
• Before beginning the adjustment you must perform "PREPARA-
TION OF CHECKING AND ADJUSTMENT" described on page
EN01-12.
• As for the valve which can adjust the valve clearance refer to the
chart on page EN01-13.
• Make sure that the cylinder head bolt, rocker arm support bolt,
nozzle clamp bolt, cam housing bolt and cam bearing cap bolt
are tightened to the specified torque.
(1) Loosen the adjusting screw lock nut A, D of the rocker arm and cross
A B head fully.
Rocker arm (2) The cross head adjusting screw must protrude 10 mm {0.394 in.} or
10mm or more from the cross head upper face.
more NOTICE
Unless the adjusting screw is completely loose to the valve stem
C
D head, the following adjustments may be adversely affected.

"Zero" Need
clearance clearance
Cross head
SAPH016010100010

(3) Insert a feeler gauge of the specified thickness shown below between
the rocker arm and the cross head, and adjust the valve clearance
with the adjust screw of the rocker arm.
VALVE CLEARANCE (when cold)
Intake valve 0.30 mm {0.0118 in.}
Exhaust valve 0.45 mm {0.0177 in.}

(4) After completion of the adjustment, tighten the lock nut A securely
with the specified tightening torque.
Tightening Torque:
SAPH016010100011 25 Nm {250 kgfcm, 18.1 lbfft}
 ENGINE INTRODUCTION (J08E) EN01–15

(5) The condition of inserted feeler gauge, loosen the adjusting screw of
the cross head, make sure that the feeler gauge does not feel loose.
Loosen
NOTICE
C
If the feeling of the feeler gauge becomes loose, repeat steps from (1).

Need
clearance

SAPH016010100012

(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.

"Zero"
"Zero" clearance
clearance

SAPH016010100013

(7) While loosening the adjusting screw C of the cross head gradually,
adjust the valve clearance. Tighten the lock nut D of the cross head
securely with the specified tightening torque when the feeler gauge
C feels correct.
Tightening Torque:
25 Nm {250 kgfcm, 18 lbfft}
D

SAPH016010100014

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

"Zero" (8) Position each piston at Top Dead Center of compression stroke by
clearance
turning the crankshaft counterclockwise viewed from flywheel side.
Then adjust the valve clearance for each cylinder in the firing order.
SAPH016010100015
EN01–16 ENGINE INTRODUCTION (J08E)

INJECTION TIMING INSPECTION PROCEDURES

1. INSPECT THE INJECTION TIMING.

Flywheel (1) Turn the crankshaft counterclockwise, as viewed from the flywheel
side, and then align the timing mark in the check window of the fly-
wheel housing with a mark of "1/6". At this time, the No.1 cylinder or
1 the No.6 cylinder is in the top dead center.
Flywheel
housing

SAPH016010100001

(2) Make sure that the timing mark "1/6" on the damper is aligned with the
Pointer pointer.
(3) At this time, insert a guide bolt (SST) through the plug hole in the side
of the bearing holder case for installation of the supply pump.
1/6 mark
SST: Guide bolt (SZ105-08067)

a. If the guide bolt is fully inserted, the No.1 cylinder is at Top Dead
Center of compression stroke and the timing is correct.
b. If the guide bolt cannot be fully inserted, turn the crankshaft 1
Damper
more turn to obtain the 1/6 mark.

SAPH016010100016

(4) Insert the guide bolt again and confirm the correct timing.

SST

0 mm
{0in.}

SAPH016010100017

START THE ENGINE

! WARNING
Do not leave tools on or around the engine. Contact of tools with mov-
ing parts may result in personal injury or damage to equipment.

1. PREPARATION
(1) Supply engine oil.

SAPH016010100018
 ENGINE INTRODUCTION (J08E) EN01–17

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

SAPH016010100019

(3) Bleed air from the fuel system.

Refer to the section "AIR BLEEDING" in the chapter "FUEL SYS-
TEM (J08E)" on page EN07-31.
(4) Check connection to the alternator.
NOTICE
Starting the engine without wiring in place may burn out the alterna-
tor.
(5) Check the engine stopping performance.

SAPH016010100020

LUBRICATION

1. CHECK THE ROCKER ARM.

(1) Remove the head cover.
(2) Set the engine revolution to the specified idling revolution.
(3) After the engine starts, check that oil is supplied to the following loca-
tions of all rocker arms within approximately 10 seconds.
a. Roller and cam face A
b. Cross head top C and spring upper seat top face D through
adjusting screw B
NOTICE
If the supply of oil is delayed or not happening, hydraulic pressure
may be low or the oil gallery may be clogged. Insufficient supply of oil
may lead to seizure, abnormal wear or abnormal noise. Recheck the
assembly.

SAPH016010100021
EN01–18 ENGINE INTRODUCTION (J08E)

SPECIAL TOOL
EN0160101K100001

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

Illustration Part number Tool name Remarks

COMPRESSION GAUGE
S0955-21110 For Overhaul criteria
ADAPTER (A)

COMPRESSION GAUGE For 3/4-16UNF Select

S0955-21030
ADAPTER (B) thread size accord-
ing to the
COMPRESSION GAUGE For W16 threads 18 thread
S0955-21060 size of air
ADAPTER (B) thread size
gauge.

S0940-91200 CRANKING TOOL

SZ105-08067 GUIDE BOLT

S1228-11901 ENGINE HANGER

SH782-41235 BOLT Use 2 pieces

 ENGINE INTRODUCTION (J08E) EN01–19

OVERHAUL CRITERIA
EN0160101H300002

FACTORS TO DETERMINE THE ENGINE OVERHAUL

1. LOW COMPRESSION PRESSURE.

(1) Before measurement
a. Charge the battery completely.
b. Set the valve clearance to the correct value.
c. Idle the engine (Coolant temperature at 80C {176F}).
d. Remove the air cleaner.
e. Remove all injectors.
(2) Measurement
a. Insert the gauge adaptor into the nozzles.
SST:
Compression gauge adaptor (A) (S0955-21110)
Compression gauge adaptor (B) (S0955-21030)
Compression gauge adaptor (B) (S0955-21060)
b. Run the engine with the starter and measure the compression
pressure.

Difference
Standard Limit between each
SAPH016010100028 cylinder
3.2-3.4 MPa 2.3 MPa 0.3 MPa
{33-35 kgf/cm2, {24 kgf/cm2, {3 kgf/cm2,
467-496 lbf/in2} 341 lbf/in2} 43 lbf/in.2} or less
Engine revolution 150r/min

NOTICE
Do not operate the starter for more than 15 seconds.
c. Measure the compression pressure of each cylinder.
NOTICE
Do not allow gas leakage from the seal face.
(3) Reassemble the removed parts.

2. ENGINE OIL PRESSURE.

(1) Check the oil pressure warning light when the oil and coolant temper-
ature is hot [about 80C {176F}].
a. If the warning light lightens, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure gauge.

SAPH016010100029
EN01–20 ENGINE INTRODUCTION (J08E)

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

Viscosity recommendations (SAE) {176F} or more.
Oil pressure
Standard Limit
SAE 5W-30
49-490 kPa Less than 49kPa
SAE 10W-30 {0.5-5.0 kgf/cm2, {0.5 kgf/cm2,
7.11-71.10 lbf/in.2} 7.11 lbf/in.2}
SAE 15W-40

3. OTHER FACTORS.
SAPH016010100030
(1) Increase of blow by 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

DISMOUNTING AND MOUNTING

EN0160101H100001

IMPORTANT POINT - DISMOUNTING

1. DISMOUNT THE ENGINE ASSEMBLY.

(1) Park the vehicle on level ground and then block the wheels.
(2) Tilt the hood.
(3) Drain coolant from the radiator and cylinder block, and engine oil from
the oil pan.
! WARNING
To avoid the danger of burns, do not drain the coolant and engine oil
while the engine and radiator are still hot.
(4) Remove the splash board and fender.
(5) Disconnect the power steering piping and hose.
NOTICE
Refer to CHAPTER POWER STEERING for details.
(6) Disconnect the electric lines, fuel lines and air lines.
NOTICE
• Disconnect the battery cable from the negative terminal (-) of the
battery and disconnect the electric lines.
• Cover open ends of the pipes, hoses and pumps to prevent entry
of dirt.
(7) Disconnect the hoses (coolant, heater and air intake) and remove the
radiator with the intercooler.
NOTICE
Do not damage the radiator.
(8) Remove the air cleaner and bracket.
(9) Disconnect the air intake and exhaust lines.
(10) Disconnect the propeller shaft.
(11) Disconnect the parking brake cable, transmission control lever and
transmission with clutch housing from the flywheel housing.
NOTICE
Refer to the chapter "TRANSMISSION/TRANSFER CONTROL" and the
chapter "TRANSMISSION MAIN UNIT" for details.
 ENGINE INTRODUCTION (J08E) EN01–21

(12) Dismount the engine assembly using the special tool.

SST:
Front Engine hanger (S1228-11901)
Bolt (SH782-41235)

Tightening Torque:
100 Nm {1020 kgfcm, 73.8lbfft}

(13) Connect a cable from an engine hanger to the hanger bracket (1

point) on the front of the engine, and to the hanger bracket (1 point) on
the flywheel housing at the rear of the engine. Using a hoist, raise the
hanger until there is a bit of slack in the cables.
Engine weight: Refer to the section "DATA AND SPECIFICA-
TIONS".
Hanger bolt
Rear

Engine
hanger

SAPH016010100031

NOTICE
When the cable connection of the engine hanger to the hanger
bracket causes infringement to the cab than follow procedure below.
.

1. Remove the fuel pipes (feed and return) to prevent damage.

2. Then remove the rear hanger bracket and install it on the front of
the flywheel housing as shown in the figure.
(14) Remove the engine mounting fitting nuts (front and rear, both sides).
(15) Lift the engine hanger so that the cables are fully tightened, then, after
checking that the cables are securely, lift gently and remove the
engine from the vehicle.
NOTICE
SAPH016010100032
When the transmission is attached to the engine, attach the third
cable to the hanger bolt.

IMPORTANT POINTS - MOUNTING

1. MOUNT THE ENGINE ASSEMBLY.

(1) Mount the engine assembly in the reverse order of dismounting.
Front side (chassis): 91 Nm {930 kgfcm, 67 lbfft}
Front side (engine): 157 Nm {1600 kgfcm, 115.7 lbfft}
Rear side (chassis): 91 Nm {930 kgfcm, 67 lbfft}
Rear side (engine): 91 Nm {930 kgfcm, 67 lbfft}
NOTICE
Check to see that there are no oil leaks, fuel leaks, coolant leaks, or
air leaks.
EN01–22 ENGINE INTRODUCTION (J08E)

LIQUID GASKET AND APPLICATION

POINTS
EN0160101H200001

• Liquid gasket is used at the following positions for the J08E series
engine.

Liquid gasket specification:

S0413-21217: Black
Liquid gasket specification:
S0413-21270: Silver
Liquid gasket specification:
S0413-21211: White

1. LIQUID GASKET APPLICATION AND PART ASSEMBLY PROCE-

DURE.
(1) Remove old liquid gasket from each part and matching parts and wipe
off oil, moisture or dirt with a rag.
(2) Overlap the liquid gasket at the start and end of application.
(3) Be careful of misalignment when assembling parts with liquid gasket.
If they are misaligned, reapply the liquid gasket.
(4) Assemble parts within 20 minutes of application.
If more than 20 minutes have passed, remove and reapply the liquid
gasket.
(5) Wait for at least 15 minutes or more after assembly of parts before
starting the engine.

2. REMOVE PARTS.
(1) When removing parts, do not use a tool for removal at one location
only. Use the tool at various locations such as a flange step or gap for
removal. When removing the gasket, be careful that gasket residue
does not enter the engine.

SAPH016010100033

3. OTHERS.
(1) For tube-type liquid gasket, use the winding tool that comes with the
liquid gasket.
(2) For cartridge-type gasket, use an application gun.

SAPH016010100034
 ENGINE INTRODUCTION (J08E) EN01–23

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

obtained by cutting the nozzle to suit.

1: Approximately 2 mm wide when cut at the first step

2: Approximately 5 mm wide when cut at the second step

SAPH016010100035

4. PARTS AND POSITIONS FOR LIQUID GASKET.

(1) Apply liquid gasket to positions and types of gasket according to the
table shown below.
Follow the application pattern at each position shown in the figures.
Unit: mm {in.}

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

Matching flange face with the block

1.5-2.5
1 Oil seal retainer {0.0591- Black
0.0984}

Matching flange face with the block

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

Matching flange face with the block

1.5-2.5
3 Oil cooler {0.0591- Black
0.0984}

Matching flange face with the cylinder head

1.5-2.5
4 Thermostat case {0.0591- Black
0.0984}
EN01–24 ENGINE INTRODUCTION (J08E)

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

Matching face with the rear edge

1.5-2.5
5 Flange {0.0591- Silver
0.0984}

Matching face with the intake manifold

Matching face with the intake manifold

Liquid gasket

1.5-2.5
6 Intake pipe {0.0591- Silver
0.0984}
 ENGINE INTRODUCTION (J08E) EN01–25

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

Matching parts of block upper face rear end, gas-

ket, rear end plate, flywheel housing, cylinder — White
head gasket

1.5-2.5
Matching parts of oil seal retainer and block lower
{0.0591- Silver
face front end
0.0984}

1.5-2.5
Matching parts of block lower rear end, gasket,
{0.0591- Silver
rear end plate and flywheel housing
0.0984}

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.
EN01–26 ENGINE INTRODUCTION (J08E)

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

Matching face of rear end plate

Matching face of rear end plate

Liquid
Liquid gasket
gasket 1.5-2.5
8 Flywheel housing {0.0591- Silver
0.0984}

1.5-2.5 Silver 2 locations

.

1. Matching faces with cam housing and plug

{0.0591- at front and
2. Matching parts of cam housing, plug, cylin-
0.0984} rear ends
der head cover and gasket

NOTICE
• Application area of liquid gasket is half circle
of cam housing. Never apply it to the upper
9 Cam housing half circle of the plug.
• Remove the excessive gasket completely.

Cylinder head cover

O-ring
Incorrect Correct
Excessive gasket
• When the cylinder head cover is assembled,
reapply the liquid gasket. (Assembly must be
done within 20 minutes.)

NOTICE
Figure on the right shows application "pattern" of the liquid gasket. Apply
the liquid gasket to the center of seal flange inside whenever possible.
 ENGINE MECHANICAL (J08E) EN02–1

ENGINE MECHANICAL (J08E)

EN02

EN02-001

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

COMPONENT LOCATOR................................ EN02-2
SPECIAL TOOL ............................................... EN02-5
OVERHAUL ..................................................... EN02-6
INSPECTION AND REPAIR .......................... EN02-17

CRANKSHAFT FRONT END.................. EN02-21

COMPONENT LOCATOR.............................. EN02-21
SPECIAL TOOL ............................................. EN02-22
OVERHAUL ................................................... EN02-23

FLYWHEEL
AND FLYWHEEL HOUSING................... EN02-25
COMPONENT LOCATOR.............................. EN02-25
SPECIAL TOOL ............................................. EN02-26
OVERHAUL ................................................... EN02-26
INSPECTION AND REPAIR .......................... EN02-32

TIMING GEAR......................................... EN02-33

COMPONENT LOCATOR.............................. EN02-33
SPECIAL TOOL ............................................. EN02-34
OVERHAUL ................................................... EN02-35
INSPECTION AND REPAIR .......................... EN02-37

MAIN MOVING PARTS

AND CYLINDER BLOCK........................ EN02-39
COMPONENT LOCATOR.............................. EN02-39
SPECIAL TOOL ............................................. EN02-42
OVERHAUL ................................................... EN02-44
INSPECTION AND REPAIR .......................... EN02-57
EN02–2 ENGINE MECHANICAL (J08E)

CYLINDER HEAD
COMPONENT LOCATOR
EN0110602D100001

1
2

3
5

D
20

C B
L
19
21
G
29 33
6
7 F
8 10
G

11

E-9 11
J
16 12 14
25

K 26
H
18 15
30
13
23 17
22

24
27
28 4
E
I

31

32

SAPH011060200001
 ENGINE MECHANICAL (J08E) EN02–3

1 Oil filler cap 18 Valve rocker shaft

2 Cylinder head cover 19 Camshaft bearing cap
3 Silent block 20 Camshaft gear
4 Heater plug 21 Camshaft
5 Head cover gasket * 22 Nut
6 Union bolt 23 Plate
7 Gasket 24 Injection pipe oil seal
8 Leakage pipe 25 Injector
9 Injector clamp bolt 26 O-ring
10 Rocker arm support bolt 27 Camshaft housing
11 Rocker arm assembly 28 Camshaft housing gasket
12 Lock nut 29 Camshaft bearing
13 Adjust screw 30 Plug
14 Rocker arm support 31 Cylinder head assembly
15 Rocker arm 32 Cylinder head gasket *
16 Injector clamp 33 Harness assy
17 Collar
*: Nonreusable. Be sure to use new parts.

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

A 28.5 {290, 21} G 12.3 {126, 9}
B 31 {320, 23} H 28.5 {290, 21}
C 31 {320, 23} I 59 {600, 43.4}+90+90 #
D 59 {600, 43.4}+90 # J 25 {250, 18.1}
E 25 {250, 18.1} K 6 {60, 4.3}
F 45 {459, 33.2} # L 25 {250, 18.1}
#=Apply oil to the threads and seat surfaces before tightening.
EN02–4 ENGINE MECHANICAL (J08E)

4
1

5
A
6 2
7
8
9 15
10
16
11

12

17

13

14

SAPH011060200002

1 Flange 10 Valve stem seal *

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

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

A 108 {1,100, 79.6}#
#=Apply oil to the threads and seat surfaces before tightening.
 ENGINE MECHANICAL (J08E) EN02–5

SPECIAL TOOL
EN0110602K100001

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

Illustration Part number Tool name Remarks

S0943-31070 EYE BOLT

S0949-11010 WIRE

S0947-01170 VALVE SPRING PRESS

S0943-11020 VALVE LAPPING TOOL

S0947-22100 VALVE STEM SEAL PRESS

S0947-21210 BAR For Nozzle sleeve

SN441-00610 STEEL BALL Used with S0947-21210

S0947-11520 GUIDE
EN02–6 ENGINE MECHANICAL (J08E)

OVERHAUL
EN0110602H200001

IMPORTANT POINTS - DISASSEMBLY

1. DISASSEMBLE THE CYLINDER HEAD.

(1) Clean parts around the injector and fuel system connections.
NOTICE
Entry of foreign particles into the combustion chamber may result in
engine trouble.
(2) Remove the injector harness assy.
a. Disconnect the connector of injector.
b. Remove the 7 nuts, disconnect the injector harness assy with
plate.
SAPH011060200011 (3) Remove the injector assembly.
NOTICE
Refer to the chapter "FUEL SYSTEM".

(4) Remove the rocker arm assembly.

a. Loosen the lock nut at the end of the rocker arm and turn the
Adjusting
screw adjusting screw counterclockwise completely.
NOTICE
Lock nut
Not untightening the adjusting screw may result in a bent rocker
shaft.

b. Loosen the injector clamp bolt.

SAPH011060200012

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

NOTICE
Rocker arm support If the cross head is removed from the valve during disassembly of the
rocker arm assembly, reassemble the cross head as it was.

(5) Remove the camshaft.

(6) Remove the camshaft housing.

7 5 3 1 2 4 6

SAPH011060200013

(7) Remove the cylinder head bolts.

a. Gradually loosen bolts three times in the order shown in the fig-
ure.
3

2
8 16 24 27 19 11
4 12 20 28 23 15 7 1

5 13 21 29 22 14 6
9 17 25 26 18 10

SAPH011060200014
 ENGINE MECHANICAL (J08E) EN02–7

(8) Lift and remove the cylinder head using the special tool and hoist.
SST:
Eye bolt (S0943-31070)
Wire (S0949-11010)

NOTICE
• Do not damage the cylinder head lower surface or cylinder block
upper surface during removal of the cylinder head.
• If it is difficult to lift off the cylinder head, pry with a chisel
between the cylinder head and cylinder block.

SAPH011060200015

2. DISASSEMBLE THE VALVE SYSTEM.

(1) Remove the valve spring retainer using the special tool.
SST: Valve spring press (S0947-01170)

SAPH011060200016

(2) Remove the intake and exhaust valve.

NOTICE
Attaching tags to the valves (giving corresponding cylinder Nos.) will
eliminate time required for lapping the valve seats on reassembly.

SAPH011060200017

3. CLEAN THE CYLINDER HEAD.

(1) Clean the cylinder head and remove carbon deposits or foreign parti-
cles.
NOTICE
Be careful not to damage the cylinder head lower surface when
removing carbon deposits or foreign particles.

SAPH011060200018
EN02–8 ENGINE MECHANICAL (J08E)

IMPORTANT POINTS - REPLACEMENT

1. REPLACE THE VALVE GUIDE.

(1) Remove the valve stem seal.
(2) For removal, strike the valve guide with a brass bar and hammer.
! WARNING
Be sure to wear protective goggles. Striking the valve guide when
removing the valve guide may cause metal chips to fly up.

(3) When installing a new valve guide, do not twist the end. Press fit the
valve guide using the special tool.
SAPH011060200019 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.

2. REPLACE THE VALVE SEAT.

(1) When replacing the valve seat, cut three places on the circumference
Valve seat
Back plate of an unwanted valve and weld it to the valve seat.
NOTICE
To protect the lower surface of the cylinder head from welding spatter,
be sure to apply grease before welding.

Electric
(2) Place a (brass) back plate at the top of the valve system and strike it
Valve welding with a hammer to remove the valve seat.
Cut three ! WARNING
places here Be sure to wear protective goggles. Striking the valve seat for removal
of valve seat may cause metal chips to fly up.
SAPH011060200020

(3) Machine the valve according to the valve seat dimensions.

Unit: mm {in.}
Intake Exhaust
41-41.016 39-39.016
A
Cylinder {1.6142-1.6148} {1.5355-1.5360}
head side 9.4-9.6 8.6-8.8
B
{0.3701-0.3779} {0.3386-0.3464}
41.085-41.1 39.12-39.135
C
Valve seat {1.6176-1.6181} {1.5402-1.5407}
side 7-7.2 6-6.2
D
SAPH011060200021 {0.2756-0.2834} {0.2363-0.2440}

(4) Heat the cylinder head to 80 - 100C {176 - 212F} in hot water.
After cooling the valve seat, insert it into the cylinder head.

! WARNING
Be sure to wear protective goggles. Punching the nozzle seat when
installing nozzle seat may cause metal chips to fly up.

SAPH011060200022
 ENGINE MECHANICAL (J08E) EN02–9

(5) Apply a small amount of lapping compound to the contact surfaces of

the valve and valve seat. Turn the valve using the special tool and tap
it lightly to lap.
SST: Valve lapping tool (S0943-11020)

SAPH011060200023

3. REPLACE THE VALVE STEM SEAL.

(1) After removing the valve stem seal, assemble the spring lower seat
Stem seal and apply engine oil to the stem seal lip. Punch it into the valve guide
Special tool
Spring using the special tool.
lower seat SST: Valve stem seal press (S0947-22100)

! WARNING
Be sure to wear protective goggles. Striking the valve stem seal for
installing of valve stem seal may cause metal chips to fly up.
NOTICE
After assembly of the stem seal, check for deformation or cracking of
the rubber or incline.

Application of oil
Rubber

SAPH011060200024

(2) After punching the valve stem seal, measure the height A.
Valve stem
seal spring Height A: 22.5-23.0 mm {0.886-0.906 in.}

Valve spring
lower seat
SAPH011060200025
EN02–10 ENGINE MECHANICAL (J08E)

4. REPLACE THE NOZZLE SEAT.

(1) Tap the nozzle seat from the cylinder head lower surface.
Then, screw in a suitable bolt and strike the bolt head with a hammer
to remove the nozzle seat from the cylinder head.
! WARNING
Be sure to wear protective goggles. Punching the nozzle seat when
installing nozzle seat may cause metal chips to fly up.
NOTICE
After removing the nozzle seat, remove the rest of liquid gasket or the
adhesion such as dust completely.

SAPH011060200026

(2) After inserting the O-ring into the nozzle seat insertion hole of the cyl-
inder head, apply liquid packing (Three Bond No. 1211 or equivalent)
to the lower part of the new nozzle seat and assemble it onto the cyl-
inder 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 cracking of
the cylinder head.

SAPH011060200027

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

SST:
Bar (S0947-21210)
Steel ball (SN441-00610)

SAPH011060200028

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE VALVE AND VALVE SPRING.

(1) Install the valve spring retainer at the valve spring upper seat using
the special tool.
SST: Valve spring press (S0947-01170)

NOTICE
• Be sure to apply engine oil to the contact surface of each part
before assembly.
• Be sure to place each valve in its original position.
SAPH011060200016
• When the valve spring is compressed, be careful of damage to
the stem seal due to contact of the upper seat.
• Since this valve spring is evenly pitched, it can be installed
either end up.
 ENGINE MECHANICAL (J08E) EN02–11

2. INSTALL THE CYLINDER HEAD GASKET.

NOTICE
• When installing the cylinder head, install the new gasket after
removing dirt, moisture and oil on the cylinder head and cylinder
block surface.
• Never reuse the gasket as it may cause engine damage.
• The twelve water hole seal rings between the bores are easily
damaged. Do not touch them with your hands or other objects.
Make sure that the seal rings are not loose or damaged.
• Since silicon material is used for the gear case print seal, make
sure that there is no peeling before assembly.
SAPH011060200029

(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 will be in a convex shape
above the head gasket upper surface.

SAPH011060200030

3. INSTALL THE CYLINDER HEAD.

(1) Using the special tool and hoist, install the cylinder head.
SST:
Eye bolt (S0943-31070)
Wire (S0949-11010)
NOTICE
When installing the cylinder head, pay attention to cam idle gear and
sub idle gear engagement.

SAPH011060200015
EN02–12 ENGINE MECHANICAL (J08E)

4. TIGHTEN THE CYLINDER HEAD BOLT.

(1) Measure the length of the M12 head bolts, if the length is A or more,
replace with new bolts.

Dimension A 125.5 mm {4.941 in.}

SAPH011060200031

(2) Apply clean engine oil to the bolt surface and bolt threads of the M10
and M12 bolts.
(3) Clean the bolt seats completely on the cylinder head upper surface.
27
(4) Tighten No. 1 - No. 26 (M12 bolts) in the order shown in the figure to
28 the specified torque.
20 12 4 5 13 21
24 16 8 1 9 17 25 29 Tightening Torque:
23 15 7 2 10 18 26
59 Nm {600 kgfcm, 43.4 lbfft}
19 11 3 6 14 22

SAPH011060200032

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

SAPH011060200033

(9) Tighten No. 27 - No. 29 (M10 bolts) in the order shown in the figure to
the specified torque below.
Tightening Torque:
59 Nm {600 kgfcm, 43.4 lbfft}
27

28
20 12 4 5 13 21
24 16 8 1 9 17 25 29

23 15 7 2 10 18 26
19 11 3 6 14 22

SAPH011060200034

5. INSTALL THE CAMSHAFT HOUSING.

 ENGINE MECHANICAL (J08E) EN02–13

6. INSTALL THE CAM IDLE GEAR.

NOTICE
Idle gear
thrust plate • Install the cam idle gear shaft through the thrust plate as shown
in the figure so that the lubrication hole is downward.
• Apply clean engine oil to the bolt seat and bolt threads.

Lubrication
Cylinder head hole

SAPH011060200035

7. ASSEMBLE THE CAMSHAFT GEAR.

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

Dimension A 30 mm {1.18 in.}

SAPH011060200036

(2) Make sure that there is neither damage to the camshaft gear or cam-
shaft 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, 43.4 lbfft}

SAPH011060200037

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

NOTICE
When adding torque, never untighten the bolt, even if it has been
Marking
overtightened.
90

SAPH011060200038
EN02–14 ENGINE MECHANICAL (J08E)

8. INSTALL THE CAMSHAFT.

(1) Align the mark on the flywheel with the flywheel housing pointer to set
the No. 1 piston to top dead center of the compression stroke.
NOTICE
Engine adjustment - Refer to "PREPARATION OF CHECKING AND
ADJUSTMENT".
(2) Install the camshaft into the cam housing.
NOTICE
Two drill holes on the camshaft gear should be located at left side and
lower drill hole should match with the camshaft housing upper sur-
face.
SAPH011060200039

(3) Install Camshaft bearing caps by fitting the position, in the stamped
Front order of 1, 2, 3, 4 and 5, with each engraved mark headed toward
engine front.
Tightening Torque:
31 Nm {320 kgfcm, 23 lbfft}
1

SAPH011060200040

9. INSTALL THE ROCKER ARM ASSEMBLY.

(1) Make sure that the cross head is on each valve.
NOTICE
If the cross head is assembled whilst off the valve, the upper seat will
be pressed, resulting in a loose valve.
(2) Make sure that the adjusting screw at the end of the rocker arm is
completely screwed in.
NOTICE
Make sure the oil hole is placed below.

SAPH011060200041

(3) Apply engine oil to the seat surface and threads of the rocker arm
support bolt and tighten the bolt by 1 or 2 threads by hand to set the
Rocker arm support position.
(4) Tighten the rocker arm support bolts gradually in the order as shown
in the figure.
Tightening Torque:
45 Nm {459 kgfcm, 33.2 lbfft}
7 5 3 1 2 4 6
(5) Tighten the injector clamp bolt to the specified torque.
Tightening Torque:
25 Nm {250 kgfcm, 18.1 lbfft}
SAPH011060200042
(6) Make sure that the rocker arm moves smoothly.
 ENGINE MECHANICAL (J08E) EN02–15

10. INSTALL THE HEAD COVER.

(1) Remove the camshaft housing plugs at the front and rear ends of the
camshaft housing.
NOTICE
Do not remove the plug except when there is oil leakage from plug.
(2) Remove the liquid gasket from camshaft housing plugs and camshaft
housing completely.

SAPH011060200043

(3) Apply liquid gasket to the front and rear half circles of the camshaft
housing.
NOTICE
Wipe out excess liquid gasket completely.

SAPH011060200044

(4) Install the camshaft housing plug to camshaft housing with torx bolt.
Tightening Torque:
6 Nm {60 kgfcm, 4.3 lbfft}

NOTICE
Make sure that the camshaft housing plug is installed with no tilt.

SAPH011060200045

(5) Install the head cover gasket into the gasket groove at the head cover
lower surface.
NOTICE
Make sure that there are no foreign particles (including liquid gasket),
or oil on the gasket grooves of the head cover, gasket or cam housing
upper surface nor damage to them.
Cylinder plug
(6) Apply liquid gasket to plug corner at the front and rear ends of the
cam housing before installing the head cover.

Cam housing

SAPH011060200046
EN02–16 ENGINE MECHANICAL (J08E)

(7) Insert the silent block from the head cover upper surface.
(8) Tighten the bolt through the silent block to the specified torque below
and fix the head cover on the cam housing.
Tightening Torque:
28.5 Nm {290 kgfcm, 21 lbfft}

SAPH011060200047
 ENGINE MECHANICAL (J08E) EN02–17

INSPECTION AND REPAIR

EN0110602H300001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Camshaft journal outside 40 39.85 Measure

Replace camshaft.
diameter {1.5748} {1.5689}

Camshaft bearing inside 40 40.15 Replace cam bear-

diameter {1.5748} {1.5807} ing.

Clearance between cam-

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

Measure

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

Measure
49.967-50.167
IN —
{1.9672-1.9751}
Cam height Replace camshaft.
52.004-52.204
EX —
{2.0474-2.0553}

Measure

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

Rocker arm bushing inside Measure

22 {0.866} 22.08 {0.8693} Replace rocker arm.
diameter

Rocker shaft outside diam- Replace rocker

22 {0.866} 21.92 {0.8630}
eter shaft.

Clearance between rocker

0.030-0.101 Replace rocker arm
shaft and rocker arm bush- 0.15 {0.0059}
{0.0012-0.0039} and/or rocker shaft.
ing
EN02–18 ENGINE MECHANICAL (J08E)

Inspection item Standard Limit Remedy Inspection procedure

Stem outside Measure

7 {0.2756} 6.92 {0.2724} Replace the valve.
diameter

Guide inside Replace the valve

Intake valve 7 {0.2756} 7.04 {0.2772}
diameter guide.

0.023-0.058 Replace the valve

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

Stem outside
7 {0.2756} 6.85 {0.2697} Replace the valve.
diameter

Guide inside Replace the valve

7 {0.2756} 7.04 {0.2772}
Exhaust diameter guide.
valve

0.050-0.083 Replace the valve

Clearance 0.15 {0.0059}
{0.0020-0.0032} and/or valve guide.

0.55-0.85 Replace the valve Measure

IN 1.1 {0.0433}
{0.0217-0.0334} and valve seat.
Valve sinkage

Valve sink
1.15-1.45 Replace the valve
EX 1.7 {0.0669}
{0.0453-0.0570} and valve seat.

Valve seat IN 30 30-3035' Measure

angle EX 45 45-4530'

IN 30 2930'-30

Resurface the valve

and/or valve seat.
Valve face
angle EX 45 4430'-45
 ENGINE MECHANICAL (J08E) EN02–19

Inspection item Standard Limit Remedy Inspection procedure

291.8 N Measure
314 N
{29.8 kgf,
Setting load {32.0 kgf, 70.5 lbf} Replace.
65.6 lbf}
at 46.8 {1.843}
at 46.8 {1.843}
Outer valve
spring Free length
(reference 75.7 {2.980} 72.7 {2.862} Replace.
value)

Squareness — 2.0 {0.0787} Replace.

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

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

Squareness — 2.0 {0.0787} Replace.

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

Measure

2.45-2.95 Replace nozzle

Nozzle protrusion —
{0.0965-0.1161} seat.

0.06 or less Measure

{0.0024 or less}
for longitudinal
direction

Replace.
Cylinder head lower sur-
0.20 {0.0078} NOTICE: Do not
face flatness
0.03 or less grind for repair.
{0.0012 or less}
for lateral direction
EN02–20 ENGINE MECHANICAL (J08E)

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Cracks or damage to cylin-

der head (Dye penetrant — — Replace.
check)

Visual check

Contact of valve (Use of Entire periphery of

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

Cam idle gear shaft outside Measure

34 {1.3386} — —
diameter

Cam idle gear shaft bush-

34 {1.3386} — —
ing inside diameter

Clearance between cam Replace idle gear

0.025-0.075
idle gear shaft and cam idle 0.2 {0.0078} shaft and/or idle
{0.0010-0.0029}
gear bushing gear.
 ENGINE MECHANICAL (J08E) EN02–21

CRANKSHAFT FRONT END

COMPONENT LOCATOR
EN0110602D100002

A
4

SAPH011060200063

1 Crankshaft pulley 3 Oil seal retainer

2 Torsional damper 4 Crankshaft oil seal

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

A 118 {1,200, 86.8}# B 108 {1,100, 79.6}#
#=Apply oil to the threads and seat surfaces before tightening.
EN02–22 ENGINE MECHANICAL (J08E)

SPECIAL TOOL
EN0110602K100002

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

Illustration Part number Tool name Remarks

S0942-01731 OIL SEAL PULLER

S0940-71030 OIL SEAL PRESS

 ENGINE MECHANICAL (J08E) EN02–23

OVERHAUL
EN0110602H200002

IMPORTANT POINTS - REPLACEMENT

1. REMOVE THE CRANKSHAFT FRONT OIL SEAL.

SST: Oil seal puller (S0942-01731)

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

Plate

SAPH011060200066

(2) Engage the hook with the oil seal notch and install the hook using the
Remove this after installing the hook bolt supplied.
(3) Remove the installed bolt in step (1).
Notch

Hook

SAPH011060200067

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

Center bolt

SAPH011060200068
EN02–24 ENGINE MECHANICAL (J08E)

2. INSTALL THE CRANKSHAFT FRONT OIL SEAL.

Guide SST: Oil seal press (S0940-71030)

(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

SAPH011060200069

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

SAPH011060200070

(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

SAPH011060200071

(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 accompanying
center bolt onto the oil seal press and tightening it until it stops.

Center bolt

SAPH011060200072
 ENGINE MECHANICAL (J08E) EN02–25

FLYWHEEL AND FLYWHEEL HOUSING

COMPONENT LOCATOR
EN0110602D100003

Example
D
(torx bolt)
4
A

D
1 5
D
7
2

3
6

B
C
SAPH011060200073

1 Flywheel housing 5 Ring gear

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

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

A 186 {1,900, 137.4}# D M8: 28.5 {290, 21}
B 97 {990, 71.6} D M8 Torx bolt: 36 {370, 26.8}
C 171.5 {1,750, 126.6} D M10: 55 {560, 40.5}
D M16: 196 {2,000, 145}
#=Apply oil to the threads and seat surface before tightening.
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
EN02–26 ENGINE MECHANICAL (J08E)

SPECIAL TOOL
EN0110602K100003

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

Illustration Part number Tool name Remarks

S0942-01742 REAR OIL SEAL PULLER

S0940-71040 OIL SEAL PRESS

S0948-11340 GUIDE BAR

OVERHAUL
EN0110602H200003

IMPORTANT POINT - DISASSEMBLY

1. REMOVE THE FLYWHEEL ASSY.

O-ring (1) Remove the main engine speed sensor from the flywheel housing.
NOTICE
When dismounting and remounting the flywheel. Remove the main
engine speed sensor. If not removed, it will result in damage of the
sensor.

Main engine
speed sensor
SAPH011060200077
 ENGINE MECHANICAL (J08E) EN02–27

(2) Remove the 8 bolts of the flywheel assy.

Example

SAPH011060200078

(3) Install the special tool, remove the flywheel assy.

Example SST: Guide bar (S0948-11340)

! WARNING
Be careful not to drop the flywheel on your foot when removing it,
because it is very heavy.
SST

SAPH011060200079

IMPORTANT POINTS - REPLACEMENT

Example
Collar
knock 1. REMOVE THE CRANKSHAFT REAR OIL SEAL.
SST: Oil seal puller (S0942-01742)

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

SAPH011060200080

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

SAPH011060200081
EN02–28 ENGINE MECHANICAL (J08E)

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

Center
bolt

SAPH011060200082

2. INSTALL THE CRANKSHAFT REAR OIL SEAL.

SST: Oil seal press (S0940-71040)

(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.

SAPH011060200083

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

SAPH011060200084

(3) Apply a little engine oil to the seal portion of the crankshaft oil seal.
Oil 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

SAPH011060200085
 ENGINE MECHANICAL (J08E) EN02–29

(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
(6) Press the crankshaft oil seal inside by attaching the accompanying
center bolt onto the oil seal press and tightening it until it stops.

Press

Center bolt

SAPH011060200086

3. REPLACE THE FLYWHEEL RING GEAR.

Example (1) Heat the ring gear evenly to about 200C {392F} with a torch. Tap the
ring gear periphery lightly using a cushion bar to remove the gear.
! WARNING
Never touch the heated ring gear or flywheel with your bare hand. This
can result in personal injury.

SAPH011060200087

(2) Heat the ring gear evenly to about 200C {392F} with a torch. Insert
Example 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.

SAPH011060200088

4. REPLACE THE FLYWHEEL HOUSING.

(1) Removing the flywheel housing.
a. Remove the flywheel housing stay.

Flywheel
housing stay
SAPH011060200089
EN02–30 ENGINE MECHANICAL (J08E)

b. Unfasten the bolts to remove the flywheel housing.

SAPH011060200090

(2) Mounting the flywheel housing.

Liquid gasket a. Using the scraper, remove dirt on the joint surfaces of the axle
housing and differential carrier assembly.
b. Apply a liquid gasket to the flywheel housing as shown in the fig-
ure.
Liquid gasket NOTICE
• Apply it seamlessly.
• Apply the liquid gasket with 1.5 to 2.5 mm width.
• Mount the case within 20 minutes after applying the liquid gas-
ket.
SAPH011060200091

c. Mount the rear engine mounting to the flywheel housing with

A B A bolts.
C Tightening torque:
C 196 Nm {2,000 kgfcm, 145 lbfft} (A)
36 Nm {370 kgfcm, 26.8 lbfft} (B)
C
C 55 Nm {560 kgfcm, 40.5 lbfft} (C)
D 55 Nm {560 kgfcm, 40.5 lbfft} (D)
A
A
A A

SAPH011060200092

d. Mount the flywheel housing stay.

Tightening torque:
97 Nm {990 kgfcm, 71.6 lbfft} (M12)
171.5 Nm {1,750 kgfcm, 126.6 lbfft} (M14)

Flywheel housing
SAPH011060200093
 ENGINE MECHANICAL (J08E) EN02–31

IMPORTANT POINT - ASSEMBLY

1. INSTALL THE FLYWHEEL.

(1) Make sure that there are no burns or dirt on the contact surface or in
the threaded holes of the crankshaft or flywheel. Install the special
tool onto the crankshaft.
SST: Guide bar (S0948-11340)

NOTICE
Place one guide bar at the collar knock and another at the opposite
side of the collar knock.
SAPH011060200094

(2) Insert the flywheel slowly until it contacts the collar knock to prevent
impact on the guide bar. Adjust the position, then insert the flywheel
Mark
Collar completely.
! WARNING
Be careful not to drop the flywheel on your foot when removing it,
because it is very heavy.
NOTICE
Align the "O" mark on the flywheel and crankshaft collar knock-pin.
(3) Apply clean engine oil to the threads of the flywheel bolt and the fly-
wheel bolt seat. Be sure to tighten the flywheel bolts (6 pieces) with a
SAPH011060200095 low-torque impact wrench.
(4) Pull out the guide bar and tighten the remaining two flywheel bolts
provisionally as in step (3).
(5) Tighten the flywheel in the order shown in the figure to the specified
torque below.
Tightening Torque:
186 Nm {1,900 kgfcm, 137.4 lbfft}
(6) Loosen all bolts and tighten them again to the specified torque.

SAPH011060200096

(7) Install the main engine speed sensor.

O-ring Tightening Torque:
10 Nm {102 kgfcm, 7.3 lbfft}

Main engine
speed sensor
SAPH011060200097
EN02–32 ENGINE MECHANICAL (J08E)

INSPECTION AND REPAIR

EN0110602H300002

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Measure

Flywheel surface deflec-

— 0.15 {0.0059} Repair.
tion

Measure

EATON
SAS1401
Flywheel SAS1402
thickness MD DM
43.5 {1.7126} 42.5 {1.6732} Repair.
(Dimen- series
sion A) (Diameter
350 mm {14 DIM "A"
in.})

Flywheel surface crank Visual check

— — Repair.
on heat spot
 ENGINE MECHANICAL (J08E) EN02–33

TIMING GEAR
COMPONENT LOCATOR
EN0110602D100004

D A

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

SAPH011060200100

1 Gasket 8 Main idle gear

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

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

A 108 {1,100, 79.6}# C 55 {560, 41} Application of lock sealant
B 172 {1,750, 127}# D 59 {600, 43}+90#
#=Apply oil to the threads and seat surfaces before tightening.
EN02–34 ENGINE MECHANICAL (J08E)

SPECIAL TOOL
EN0110602K100004

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

Illustration Part number Tool name Remarks

S0942-01100 SLIDING HAMMER For MAIN IDLE GEAR

For SUB AND CAM

S0942-01442 SLIDING HAMMER
IDLE GEAR

S0941-11300 SOCKET WRENCH For TORX BOLT

 ENGINE MECHANICAL (J08E) EN02–35

OVERHAUL
EN0110602H200004

IMPORTANT POINT - DISASSEMBLY

1. REMOVE THE IDLE GEAR SHAFT.

(1) Remove the idle gear shaft using the special tool.
SST:
Sliding hammer (for main idle gear) (S0942-01100)
Sliding hammer (for sub and cam idle gear) (S0942-01442)

SAPH011060200104

SAPH011060200105

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE REAR END PLATE.

(1) Apply lock sealant (Nut Lock Super 5M or equivalent) to the threads of
the torx bolts in the side of bearing holder case fitting (2 places) and
tighten to the specified torque using the special tool.
SST: Socket wrench (S0941-11300)

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

SAPH011060200106

2. INSTALL THE CRANKSHAFT GEAR.

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

SAPH011060200107
EN02–36 ENGINE MECHANICAL (J08E)

3. INSTALL THE IDLER GEAR SHAFT AND GEAR.

SAPH011060200108

NOTICE
• Install each idle gear shaft through the thrust plate as shown in
the figure so that the lubrication hole is downward.
• Adjust the timing of the main idle gear to align with the air com-
pressor gear as shown in the figure.

4. MEASUREMENT OF GEAR BACKLASH.

(1) Measure the backlash between the gears with a dial gauge. (Refer to
the table of "INSPECTION AND REPAIR")
NOTICE
• Measure the backlash with the drive-side gear fixed.
• After measurement of the backlash, apply engine oil to each gear
surface.

SAPH011060200109
 ENGINE MECHANICAL (J08E) EN02–37

INSPECTION AND REPAIR

EN0110602H300003

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Crankshaft- 0.030-0.167
0.30 {0.0118}
Main idle {0.0012-0.0065}

Main idle-Air
0.020-0.096
compressor 0.10 {0.0039}
{0.0008-0.0038}
idle
Measure
Air compres-
sor idle-Air 0.020-0.083
0.10 {0.0039}
compressor {0.0008-0.0033}
gear
Timing Air compres-
gear back- 0.030-0.134 Replace gear.
sor-Power 0.30 {0.0118}
lash {0.0012-0.0052}
steering pump

Main idle-Sub 0.030-0.113

0.30 {0.0118}
idle {0.0012-0.0044}

Sub idle-Oil 0.030-0.131

0.30 {0.0118}
pump {0.0012-0.0052}

Sub idle-Cam 0.050-0.218

0.30 {0.0118}
idle {0.0020-0.0085}

Cam idle- 0.030-0.253

0.30 {0.0118}
Camshaft {0.0012-0.0099}
EN02–38 ENGINE MECHANICAL (J08E)

Inspection item Standard Limit Remedy Inspection procedure

Shaft outside
57 {2.244} — —
diameter

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

Gear width 44 {1.732} — —

Shaft length 44 {1.732} — —

0.114-0.160 Replace gear and/ Measure

End play 0.30 {0.0118}
{0.0045-0.0062} or shaft.

Shaft outside
50 {1.969} — —
diameter

Bushing
inside diame- 50 {1.969} — —
ter
Sub idle 0.025-0.075 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.

Gear width 22 {0.866} — —

Shaft length 22 {0.866} — —

0.040-0.120 Replace gear and/

End play 0.30 {0.0118}
{0.0016-0.0047} or shaft.

Shaft outside
34 {1.339} — —
diameter

Bushing
inside diame- 34 {1.339} — —
ter
Cam idle 0.025-0.075 Replace gear and/
shaft Clearance 0.20 {0.0079}
{0.0010-0.0029} or shaft.

Gear width 22 {0.866} — —

Shaft length 22 {0.866} — —

0.040-0.120 Replace gear and/

End play 0.30 {0.0118}
{0.0016-0.0047} or shaft.

Shaft outside
34 {1.339} — —
diameter

Bushing
inside diame- 34 {1.339} — —
ter
Air com-
pressor 0.025-0.057 Replace gear and/
Clearance 0.10 {0.0039}
idle {0.0010-0.0022} or shaft.

Gear width 28.5 {1.1220} — —

Shaft length 28.5 {1.1220} — —

0.160-0.220 Replace gear and/

End play 0.30 {0.0118}
{0.0063-0.0086} or shaft.
 ENGINE MECHANICAL (J08E) EN02–39

MAIN MOVING PARTS AND CYLINDER BLOCK

COMPONENT LOCATOR
EN0110602D100005

SAPH011060200112

1 Cylinder liner 10 Connecting rod bearing

2 Cylinder block 11 Crankshaft
3 Piston cooling jet 12 Crankshaft thrust bearing
4 Piston ring 13 Crankshaft main bearing
5 Piston 14 Crankshaft gear
6 Piston pin 15 Collar knock
7 Retainer ring 16 Main bearing cap
8 Connecting rod 17 Block heater assy
9 Connecting rod bushing 18 Dowel pin
EN02–40 ENGINE MECHANICAL (J08E)

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

A 22 {220, 15.9} C 69 {700, 51}+90+45#
B 69 {700, 51}+90+45#
#=Apply oil to the threads and seat surfaces before tightening.
=Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.

SAPH011060200113

1 Engine mounting bracket, front 3 Engine mounting, front

2 Engine mounting bracket, rear 4 Engine mounting, rear
 ENGINE MECHANICAL (J08E) EN02–41

A
2

3
4 A

SAPH011060200114

1 Gasket 3 Soft washer

2 Oil pan 4 Drain plug

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

A 41 {420, 30} B 30 {310, 22.4}
EN02–42 ENGINE MECHANICAL (J08E)

SPECIAL TOOL
EN0110602K100005

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

Illustration Part number Tool name Remarks

S0944-21011 PISTON RING EXPANDER For Piston ring

S0942-02100 PULLER For Cylinder liner

SZ910-24098 CONNECTOR BOLT For Piston cooling jet

S0947-11490 GUIDE

S0940-21540 SPINDLE

S0948-11540 GUIDE

SH691-20825 BOLT

S0948-11130 GUIDE For Connecting rod bushing

 ENGINE MECHANICAL (J08E) EN02–43

Illustration Part number Tool name Remarks

S0940-21530 PRESS SUB-ASSEMBLY

SL271-01036 WING NUT

S0944-11370 PISTON RING HOLDER

09219-E4010 GAGE
EN02–44 ENGINE MECHANICAL (J08E)

OVERHAUL
EN0110602H200005

IMPORTANT POINTS - DISASSEMBLY

1. REMOVE THE PISTONS WITH CONNECTING RODS.

(1) Remove the pistons and connecting rods from the cylinder block
upper side.
NOTICE
• Remove carbon deposits from the end inside the cylinder liner
with a scraper or emery paper (recommended: No. 150) in a cir-
cular direction.

SAPH011060200127

• Arrange the removed pistons and connecting rod caps in the

Hollow mark order of cylinder numbers. Be careful not to change the combi-
nation of the connecting rod and cap.
Piston

Exhaust side Intake side

Oil hole

Match mark

SAPH011060200128

2. REMOVE THE PISTON RINGS.

(1) Remove the piston ring using the special tool.
SST: Piston ring expander (S0944-21011)

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.

SAPH011060200129

3. REMOVE THE CYLINDER LINER.

(1) Before removing the cylinder liner, put alignment marks on the cylin-
der block and liner flange.
NOTICE
Do not make alignment marks with a punch.

SAPH011060200130
 ENGINE MECHANICAL (J08E) EN02–45

(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 the piston cool-
ing jet.
• After removing the cylinder liners, arrange them in sequence.

SAPH011060200131

4. REMOVE THE BLOCK HEATER.

(1) Remove the harness by loosening the cord nut.
(2) Loosen the socket head capscrew.
(3) Lever the heater out by using a bar.
NOTICE
• Do not damage the adapter installation hole, otherwise water will
leak.
• Do not reuse the V-lock.

SAPH011060200132

IMPORTANT POINT - ON - VEHICLE INSPECTION

1. INSPECT THE BLOCK HEATER.

(1) Measure the resistance between terminals.
If not standard value, replace block heater assembly.

Standard 13.1-15.2 

(2) Measure the resistance of insulation between terminals and heater

insulation. If not standard value, replace block heater assembly.

Standard More than 5 M

SAPH011060200133

IMPORTANT POINTS - ASSEMBLY

1. INSPECT AND ADJUST THE PISTON COOLING JET.

(1) Install the piston cooling jet on the cylinder block using the special
tool.
SST: Connector bolt (SZ910-24098)

SAPH011060200134
EN02–46 ENGINE MECHANICAL (J08E)

(2) For the jet test, connect the oil hose to the connector bolt from the cyl-
inder block lower side.
NOTICE
Use clean engine oil for jet flow.

SAPH011060200135

(3) Set the special tool on the cylinder block upper surface against the
dowel pin.
SST: Gage (09219-E4010)

(4) Test jet oil flow from the piston cooling jet nozzle at a hydraulic pres-
sure of 245 kPa {2.5 kgf/cm2, 35 lbf/in2}.

SAPH011060200136

(5) If the center of the jet flow is within the two target circles (8 mm
{0.3150 in} and 15 mm {0.5906 in} diameter: Red), the test is accept-
able.
! WARNING
• Engine oil is flammable.
• Never use an open flame or a naked bulb.
• Carry out the following inspection only in a well-ventilated area.

(6) If the center of the jet flow is out of the two target circles, adjust or
replace the jet.
SAPH011060200137
 ENGINE MECHANICAL (J08E) EN02–47

2. INSTALL THE CYLINDER LINER.

NOTICE
• When assembling the cylinder liner with the cylinder block,
clearance can be set to three levels.
• The upper surface and side surface of the cylinder block are
stamped A, B or C depending on the inside diameter. Insert a
matching cylinder liner having the same symbol.

SAPH011060200138

SAPH011060200139

(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.)

SAPH011060200140

3. MEASURE THE PROTRUSION AT THE CYLINDER LINER

FLANGE.
SST: Puller (S0942-02100)

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

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

SAPH011060200141
EN02–48 ENGINE MECHANICAL (J08E)

4. MEASURE THE CRANKSHAFT.

(1) If necessary, grind the crankshaft and use an undersize bearing.

Outside diameter
Bearing size
Crank pin Journal
64.94-64.96 mm 79.94-79.96 mm
Standard
{2.5567-2.5574 in.} {3.1473-3.1480 in.}
64.69-64.71 mm 79.69-79.71 mm
0.25US
{2.5469-2.5476 in.} {3.1375-3.1381 in.}
64.44-64.46 mm 79.44-79.46 mm
0.50US
{2.5371-2.5377 in.} {3.1276-3.1283 in.}

(2) Dimension of fillet "R".

Crank pin
Small "R"
2.5-3.0 mm {0.0985-0.1181 in.}
Not "R" Journal
Stepped Stepped
R

Good Not good

SAPH011060200142

5. INSTALL THE CRANKSHAFT.

(1) Install the main bearing onto the bearing caps and the cylinder block.
NOTICE
• Install the bearing with the oil hole on the block side and the
bearing without the oil hole on the cap side.
• Apply clean engine oil to inner surfaces of the bearings.
(2) Install the thrust bearing with the groove side (front) toward the crank
arm and with the part No. stamp (back) toward the main bearing cap
or cylinder block.
HINT
Apply engine oil or grease to the back of the bearing to prevent loos-
ening during installation.

(3) Install the crankshaft onto the cylinder block.

SAPH011060200143
 ENGINE MECHANICAL (J08E) EN02–49

6. INSTALL THE MAIN BEARING CAP.

(1) Install the main bearing cap onto the cylinder block.
NOTICE
Check the number stamped on the cap.
(2) Measure the length below the head of the bearing cap bolt and
Application replace any bolts not meeting the limit with new ones.
position of
A
engine oil Dimension A 106.5 mm {4.193 in.}

SAPH011060200144

(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 specified
Front torque.
Tightening Torque:
69 Nm {700 kgfcm, 51 lbfft}
2 4 6 8 10 12 14 (5) Loosen all bolts, tap the front and back ends of the crankshaft using a
1 2 3 4 5 6 7
plastic hammer.
1 3 5 7 9 11 13 (6) Tighten the bolts as in step (4).
(7) Mark the bolt heads with paint.

SAPH011060200145

(8) Tighten the bolts 90 (1/4 turn) in the same order as in step (4).
(9) Retighten the bolts 45 (1/8 turn) as in step (8).
(10) Make sure that all paint marks face the same direction.
NOTICE
When adding torque, never untighten the bolts, even if they have been
overtightened.
(11) After tightening, tap the front and back ends of the crankshaft using a
plastic hammer to allow complete fit.

SAPH011060200146

7. REPLACE THE CONNECTING ROD BUSHING.

(1) Prepare the special tools.
a. Assembly the guide and press sub-assembly inserting its pin into
the guide then secure them with the wing nut.
SST:
Guide (S0948-11130)
Press sub-assembly (S0940-21530)
Wing nut (SL271-01036)

NOTICE
• Bring lever "H" punched on the guide above the pin.
SAPH011060200147
• Making sure to align both supporting surfaces of the guide and
press sub-assembly flush on a flat plane.
EN02–50 ENGINE MECHANICAL (J08E)

(2) Using a special tool, remove the connecting rod bushing.

a. Set the connecting rod assembled without connecting rod bearing
on the guide and press sub-assembly.

SAPH011060200148

b. Install the spindle into the bushing.

SST: Spindle (S0940-21540)

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

SAPH011060200149

c. Using a hydraulic press, remove the bushing.

NOTICE
Always operate the press slowly and smoothly.

SAPH011060200150

(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 insertion.
• Remove dust from the inner surface of the small-end hole.

SAPH011060200151
 ENGINE MECHANICAL (J08E) EN02–51

(4) Mount the bushing on the spindle.

a. Set the bushing and guide on the spindle as shown in the figure,
then secure them with the bolt.
SST:
Spindle (S0940-21540)
Guide (S0948-11540)
Bolt (SH691-20825)

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

NOTICE
SAPH011060200152
• 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 and the cham-
fer side of the small end to the bushing side.
• Apply the fresh engine oil to the bore of the connecting rod.

(6) Using a press, install the bushing in the connecting rod.

SAPH011060200153

(7) Inspect the bushing positioning after installation.

a. Make sure that the oil hole of the bushing and the oil path of the
connecting rod are suitably aligned allowing a 6 mm {0.2362 in.}
diameter rod to penetrate.
NOTICE
Misalignment can lead to insufficient lubrication, which may result in
seizure.

b. Insert a new piston pin. When it is turned gently, make sure that
there is no catch or rough movement.

SAPH011060200154

8. ASSEMBLE THE PISTON AND CONNECTING ROD.

Hollow mark (1) Heat the piston to 50C {122F}.
(2) Assemble the piston O-mark to be opposite to the connecting rod
Piston
match mark.
Intake side NOTICE
Exhaust side
Replace the retainer ring with a new one.
Oil hole

Match mark

SAPH011060200128
EN02–52 ENGINE MECHANICAL (J08E)

9. ASSEMBLE THE PISTON RING.

(1) Install in the order of oil ring, second ring and top ring using the spe-
cial tool.
SST: Piston ring expander (S0944-21011)

NOTICE
Install the second ring with the identification print on the piston ring
facing towards the upper surface.
(2) Connect the joint of the coil expander for the oil ring and install it
inside the piston ring. Assemble the ring with the joint 180 opposite
to the matching point.

SAPH011060200155

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

Hollow-mark

Oil ring

Top ring

SAPH011060200156

10. CHECK THE PISTON.

Piston identification symbol Before assembling the piston with the connecting rod, check whether
the piston us specified for this engine.
NOTICE
Check using the engine compatible identification code on the top of
13

the piston.
Engine compatible identification code.

Top view

SAPH011060200157
 ENGINE MECHANICAL (J08E) EN02–53

11. INSTALL THE PISTON.

(1) Apply engine oil to the piston, cylinder liner and connecting rod bear-
ing, then compress the piston ring using the special tool.
SST: Piston ring holder (S0944-11370)

NOTICE
• When installing the piston, be careful that the cooling jet is not
struck by the connecting rod.
• Make sure that the hollow-mark on the piston is at the exhaust
side.

SAPH011060200158

(2) Insert the piston into the cylinder liner.

SAPH011060200159

12. TIGHTEN THE CONNECTING ROD BOLT.

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

Dimension A 67 mm {2.638 in.}

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

SAPH011060200160

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

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

(4) Mark the bolt heads in the same direction with paint.
(5) Tighten the connecting rod bolt 90 (1/4 turn).
(6) Tighten the connecting rod bolt 45 (1/8 turn).
(7) Make sure that the paint marks face the same direction.
NOTICE
When retightening the bolts, never adjust them by turning counter-
clockwise, even if they have been retightened more than the specified
angle above.
SAPH011060200161
If the angle of bolts is adjusted to the specified angle by turning coun-
terclockwise, the axial force of the bolts might fall short and it is
feared that this could reduce the engine reliability. Also there is a pos-
sibility that this could reduce the number of times a bolt can be
reused.
EN02–54 ENGINE MECHANICAL (J08E)

13. INSTALL THE OIL PAN.

(1) Make sure that there is no deformation, impact marks or foreign parti-
cles on the cylinder block, oil pan or flange surface. Apply liquid gas-
ket to the front and back ends of the cylinder block lower surface.
NOTICE
Refer to "PARTS AND POSITIONS FOR LIQUID GASKET".
(2) Install the gasket so that the protrusion is at the flywheel housing side
and the intake side. (the print seal surface is at the cylinder block side)
(3) Place a guide pin of 70 mm or more in the cylinder block and assem-
ble the oil pan against the guide.
(4) Tighten oil pan fitting bolts in the order 1 - 2 - 3 - 4 with an impact
wrench.
Tightening Torque:
19.7-24.5 Nm {200-250 kgfcm, 15-18 lbfft}
(5) Finish tightening the bolts with a torque wrench to the specified
torque. Tighten the bolts according to the arrow in the figure.
NOTICE
Make sure that the washer is not on the flange.

SAPH011060200162

14. INSTALL THE BLOCK HEATER.

(1) Apply silicone spray to O-ring. (LPS Laboratories: Parts No.01516 or
equivalent.)
NOTICE
If O-ring is not applied, it could damage and allow water to leak.

SAPH011060200163

(2) When installing the block heater, match the arrow mark on the heater
to the mark on the cylinder block protrusion.
NOTICE
• Do not damage the adapter installation hole, otherwise water will
leak.
• If the marks do not match, the heater coil will touch the cylinder
block.

SAPH011060200164
 ENGINE MECHANICAL (J08E) EN02–55

(3) Tighten the socket head capscrew.

Tightening Torque:
2.3-3.3 Nm {23-33 kgfcm, 1.7-2.3 lbfft}

NOTICE
Do not overtighten. If overtightened, the flat bar could come off the
socket head capscrew and drop into the water jacket. This could
cause the engine to overheat due to cooling system damage.
(4) Install the harness by tightening the cord nut fully by hand only.

SAPH011060200165

(5) Handling precaution

NOTICE
• Before using it, remove all the rust and dirt. Any rust and water
attached to the terminal can trip the breaker.
• First, put the harness in the socket of the chassis side and turn
on power (120 V).

! CAUTION
Make sure to disconnect the power source plug outlet before starting
the engine.
Starting the engine without disconnecting it can cause the breakdown
of the block heater.

SAPH011060200166
EN02–56 ENGINE MECHANICAL (J08E)

15. REFILL THE HINO LONG LIFE COOLANT.

(1) Concentration of Hino long life coolant.
• The freezing point of the coolant varies with the concentration of anti-
freeze. Select the appropriate concentration to protect against freez-
ing according to the following table.
NOTICE
If water to coolant ratio is not mixed according to the following table
the engine will overheat and block heater coil will melt.

LLC-Water Mixing Table

Freezing protec- Freezing temper-

LLC Water
tion ature

F C F C US Qt Liter % % US Qt Liter

J08E MT 12.4 11.75 12.4 11.75

-22 -30 -31.9 -35.5 50 50
engine AT 12.2 11.5 12.2 11.5

*AT=Available with automatic transmission

MT=Available with manual transmission

NOTICE
Do not mix more than 60% or less than 50% LLC.
Concentrations more than 63% result in a loss of freezing protection.
Concentrations below 50% result in a loss of corrosion protection.
 ENGINE MECHANICAL (J08E) EN02–57

INSPECTION AND REPAIR

EN0110602H300004

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Cylinder block flange Measure

3 {0.1181} — —
depth

Cylinder liner thickness 3 {0.1181} — —

0.01-0.08
Cylinder liner protrusion — —
{0.0004-0.0031}

117-117.008 Reference only

A
{4.6063-4.6066}
Block
117.008-117.014
inside B — —
{4.6067-4.6068}
diameter
117.014-117.022
C
{4.6069-4.6071}

116.982-116.990 Reference only

A
{4.6056-4.6058}
Liner out-
116.990-116.996
side diam- B — —
{4.6059-4.6061}
eter
116.996-117.004
C
{4.6062-4.6064}

0.010-0.026 Reference only

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

Piston outside diameter 111.927-111.943 Measure

—
at A: 17 {0.6693} {4.40657-4.40720}

Liner inside diameter

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

Clearance between pis- 0.057-0.073

—
ton and cylinder liner {0.0023-0.0028}
EN02–58 ENGINE MECHANICAL (J08E)

Inspection item Standard Limit Remedy Inspection procedure

Top — — Measure

1.970-1.990
Second 1.9 {0.0748}
Piston ring {0.0776-0.0783}
Replace ring.
width
3.970-3.990
Oil 3.9 {0.1535}
{0.1563-0.1570}

Top — — Measure

Piston 2.055-2.075
Second 2.2 {0.0866}
groove {0.0809-0.0817} Replace piston.
width
4.015-4.035
Oil 4.1 {0.1614}
{0.1581-0.1588}

Clearance Top —
between
0.065-0.105
piston Second
{0.0026-0.0041} — — —
ring and
piston ring 0.025-0.065
groove Oil
{0.0010-0.0025}

0.30-0.40 Measure
Top 1.5 {0.0591}
{0.0119-0.0157}
Cylinder liner
Gap 0.75-0.90
Second 1.2 {0.0472}
between {0.0296-0.0354}
Replace piston ring.
ends of 80 mm
{3.15 in.}
piston ring
0.15-0.30
Oil 1.2 {0.0472}
{0.0059-0.0118}
Piston ring

Piston pin outside diam- 37 Measure

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

Piston pin bore inside 37

37.05 {1.4586} Replace piston.
diameter {1.4567}

Clearance between pis-

0.011-0.032 Replace piston and/
ton pin and piston pin 0.05 {0.0020}
{0.00043-0.00126} or piston pin.
bore

Measure

Connecting rod bushing 37 Replace connecting

37.1 {1.4606}
inside diameter {1.4567} rod bushing.
 ENGINE MECHANICAL (J08E) EN02–59

Inspection item Standard Limit Remedy Inspection procedure

Clearance between pis- Replace piston pin

0.035-0.056
ton pin and connecting 0.08 {0.0031} and/or connecting —
{0.0014-0.0022}
rod bushing rod bushing.

Visual check
Wear or damage of con-
necting rod
— — Replace.
*Dye penetrant check
(Color check)

Visual check

Clogging of connecting
— — Replace.
rod oil hole

More than Measure

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

Clearance between con-

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

Connecting rod large 34 Replace connecting Measure

33.2 {1.3071}
end width {1.339} rod.

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

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

More than Measure

0.2 {0.0079} Regrind under size.
Crank journal outside (Repair)
80 {3.150}
diameter 90
79.3 {3.1220}
Replace crankshaft.
(Service)

Clearance between
0.051-0.102 Replace main bear-
crank journal and main 0.2 {0.0079}
{0.0021-0.0040} ing.
bearing
EN02–60 ENGINE MECHANICAL (J08E)

Inspection item Standard Limit Remedy Inspection procedure

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

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

More than
Replace over size
0.5 {0.0197}
0.050-0.270 {0.0020- thrust bearing.
Crankshaft end play (Repair)
0.0106}
1.270 {0.0499}
Replace crankshaft.
(Service)

Measure

Crankshaft deflection — 0.15 {0.0059} Regrind under size.

Visual check

Clogging of crankshaft
— — Clean.
oil hole

Visual check

Crack and wear of crank-

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

Measure

Longitudinal direc-
tion: 0.06 {0.0024} Replace.
Cylinder block upper
Right angle direc- 0.20 {0.0078} NOTICE: Do not grind
surface flatness
tion: 0.03 {0.0012} for repair.
or less
 AIR INTAKE SYSTEM (J08E) EN03–1

AIR INTAKE SYSTEM (J08E)

EN 03

EN03-001

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

COMPONENT LOCATOR................................ EN03-2
DISMOUNTING AND MOUNTING .................. EN03-3

AIR INTAKE .............................................. EN03-4

COMPONENT LOCATOR................................ EN03-4

AIR CLEANER .......................................... EN03-5

DESCRIPTION ................................................ EN03-5
OVERHAUL ..................................................... EN03-6

AIR HOSE ................................................. EN03-7

COMPONENT LOCATOR................................ EN03-7
OVERHAUL ..................................................... EN03-8

AIR FLOW SENSOR ................................. EN03-9

COMPONENT LOCATOR................................ EN03-9
REPLACEMENT ............................................ EN03-10

BOOST PRESSURE SENSOR ............... EN03-11

COMPONENT LOCATOR.............................. EN03-11
REPLACEMENT ............................................ EN03-12
EN03–2 AIR INTAKE SYSTEM (J08E)

AIR INTAKE MANIFOLD AND PIPE

COMPONENT LOCATOR
EN0110603D100001

2 A

5
4 6

SAPH01Z080300001

1 Intake manifold gasket 4 Intake throttle valve

2 Intake manifold 5 Bracket
3 Intake pipe 6 Gasket *
*: Nonreusable. Be sure to use new parts.

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

A 28.5 {290, 21}
 AIR INTAKE SYSTEM (J08E) EN03–3

DISMOUNTING AND MOUNTING

EN0110603H100001

IMPORTANT POINT - MOUNTING

1. INSTALL THE INTAKE MANIFOLD GASKET.
(1) Install the intake manifold gasket so that the protrusion is positioned
at the stud bolt side of the cylinder head rear end.

SAPH01Z080300002
EN03–4 AIR INTAKE SYSTEM (J08E)

AIR INTAKE
COMPONENT LOCATOR
EN0110603D100002

Example

Vehicle's
right side
7
1
4
5
6
Vehicle's
front
r
rge
ha
3 b oc
r
Tu
8 To

SAPH01Z080300003

1 Hood 5 Air flow sensor

2 Air intake grille 6 Air hose
3 Air cleaner 7 Air cleaner bracket
4 Air hose 8 Intake pipe
 AIR INTAKE SYSTEM (J08E) EN03–5

AIR CLEANER
DESCRIPTION
EN0110603D100003

SAPH01Z080300004

1 Body assembly 4 Unloader valve

2 Cover 5 Adapter
3 Thumb screw
EN03–6 AIR INTAKE SYSTEM (J08E)

OVERHAUL
EN0110603H100002

IMPORTANT POINTS - DISMOUNTING

1. REMOVE THE AIR CLEANER ELEMENT.

(1) Remove the thumb screw as shown in the figure and remove the
cover.
(2) Hold the outer projection end of the element and turn slightly, then
detach the element.
! CAUTION
• Never clean the element filter.
• When the element filter is subjected to blowing with compressed
air, is washed, hit, or dropped, the filter function will be impaired
SAPH01Z080300005
and engine damage can be caused.

IMPORTANT POINTS - MOUNTING

1. INSTALL THE AIR CLEANER ELEMENT.

(1) Install in the reverse order of removing.
NOTICE
Ensure the cover over the thumb screw is properly affixed.

IMPORTANT POINTS - INSPECTION

1. INSPECTING
(1) If on inspection the dust indicator is red replace it.

SAPH01Z080300006

(2) If the cover, case or 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.

SAPH01Z080300007
 AIR INTAKE SYSTEM (J08E) EN03–7

AIR HOSE
COMPONENT LOCATOR
EN0110603D100004

B 2
B

3 1
8 9
15
A
4

5
7 4
A
4
A
14 6

13

10
12
8 B

11

SAPH01Z080300009

1 Air cleaner bracket 9 Clamp (B)

2 Air cleaner 10 Clamp (B)
3 Air hose 11 Dust indicator
4 Clamp (A) 12 Intake throttle valve
5 Intake pipe 13 Separator
6 Air hose 14 Air hose
7 Air hose (Intercooler) 15 Air hose (Separator)
8 Clamp (B)

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

A 4.5-5.5 {46-56, 3.3-4.1} B 6.8-8.4 {70-85, 5.0-6.2}
EN03–8 AIR INTAKE SYSTEM (J08E)

OVERHAUL
EN0110603H100003

IMPORTANT POINTS - MOUNTING

1. INSTALL THE AIR HOSE.

(1) Location of the rotation direction of the intake pipe and the air hose
should match emboss mark as shown in the figure.
(2) Tighten the clamp.
Tightening Torque:
4.5-5.5 Nm {46-56 kgfcm, 3.3-4.1 lbfft}

SAPH01Z080300010

2. INSTALL THE AIR HOSE (INTER COOLER).

Stopper Clamp Straight Point m
line (Imagination point) (1) Install the air hose against the stopper as shown in the figure.
(2) Match the straight line mark of the air hose and match mark (stopper)
center of the intercooler.
(3) Set the point m of the clamp to blue circle mark on hose and tighten
with the following tightening torque.
Tightening Torque:
6.8-8.4 Nm {70-85 kgfcm, 5.0-6.2 lbfft}
From more
than 15 mm
to less
than 20 mm. (19 mm) Point m

SAPH01Z080300011
 AIR INTAKE SYSTEM (J08E) EN03–9

AIR FLOW SENSOR

COMPONENT LOCATOR
EN0110603D100005

3 A
1

5
3

SAPH01Z080300012

1 Air flow sensor 4 Clamp

2 Air cleaner 5 Dust indicator
3 Air hose

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

A 1.17-1.77 {12-17, 0.9-1.3}
EN03–10 AIR INTAKE SYSTEM (J08E)

REPLACEMENT
EN0110603H300001

1. REMOVE THE AIR FLOW SENSOR.

(1) Disconnect the connector of the air flow sensor.
Air flow sensor
(2) Remove a bolt to remove the air flow sensor.

SAPH01Z080300013

2. INSTALL THE AIR FLOW SENSOR.

(1) Install the air flow sensor, and tighten a bolt.
Air flow sensor
Tightening Torque:
1.17-1.77 Nm {12-18 kgfcm, 0.9-1.3 lbfft}
NOTICE
• Do not apply an excessive torque in tightening the mounting bolt
(M4) for air flow sensor.
• The connector of the air flow sensor must be positioned in the
frontward direction of the vehicle.
(2) Connect the connector of the air flow sensor.
SAPH01Z080300014
 AIR INTAKE SYSTEM (J08E) EN03–11

BOOST PRESSURE SENSOR

COMPONENT LOCATOR
EN0110603D100006

SAPH01Z080300015

1 Boost pressure sensor 3 Intake manifold

2 Intake pipe 4 Intake manifold gasket

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

A 10 {102, 7.3}
EN03–12 AIR INTAKE SYSTEM (J08E)

REPLACEMENT
EN0110603H300002

1. REMOVE THE BOOST PRESSURE SENSOR.

(1) Disconnect the connector of the boost pressure sensor.
(2) Remove two clamps to remove the hose from the boost pressure sen-
sor.
(3) Remove two bolts to remove the boost pressure sensor from the
intake pipe.

SAPH01Z080300016

2. INSTALL THE BOOST PRESSURE SENSOR

(1) Install the boost pressure sensor to the intake pipe, and tighten two
bolts.
Tightening Torque:
10 Nm {102 kgfcm, 7.3 lbfft}

(2) Insert a hose into the boost pressure sensor, and fasten two clamps.
(3) Connect the connector of the boost pressure sensor.

SAPH01Z080300017
 EXHAUST SYSTEM (J08E) EN04–1

EXHAUST SYSTEM (J08E)

EN 40

EN04-001

EXHAUST MANIFOLD AND PIPE............ EN04-2 EXHAUST GAS TEMPERATURE SENSOR 1

COMPONENT LOCATOR................................ EN04-2 (ATC UPSTREAM) AND EXHAUST GAS
DISMOUNTING AND MOUNTING .................. EN04-3 TEMPERATURE SENSOR 2 (ATC
DOWNSTREAM)..................................... EN04-72
EXHAUST PIPE AND MUFFLER UNIT .... EN04-4 COMPONENT LOCATOR ............................. EN04-72
DESCRIPTION ................................................ EN04-4 OVERHAUL ................................................... EN04-73
COMPONENT LOCATOR................................ EN04-5
REPLACEMENT OF ATC .............................. EN04-11
OVERHAUL ................................................... EN04-13

DPR (DIESEL PARTICULATE ACTIVE

REDUCTION SYSTEM) .......................... EN04-29
SYSTEM CONFIGURATION ......................... EN04-29
STRUCTURE OF DPR-CLEANER ................ EN04-30
DPR INSPECTION ........................................ EN04-31
INSPECTION PROCEDURE FOLLOWED
WHEN "DPR MAINTENANCE" IS
DISPLAYED ON THE
INFORMATION DISPLAY .............................. EN04-32
INSPECTION BY WAY OF HINO DX Ⅱ ........ EN04-33
INSPECTION PROCEDURE FOLLOWED
WHEN CHECK ENGINE LIGHT
ILLUMINATES (ABNORMAL) ........................ EN04-37
DETERMINATION BY WAY OF
DPR STATE DETERMINATION
MONITOR OF HINO DX Ⅱ ............................ EN04-40
CHECKING THE DPR STATE ....................... EN04-40
REPLACEMENT OF DPR FILTER ................ EN04-41
OVERALL OPERATION FLOW ..................... EN04-45

DIFFERENTIAL PRESSURE SENSOR.. EN04-53

COMPONENT LOCATOR.............................. EN04-53
DISMOUNTING AND MOUNTING ................ EN04-54
INSPECTION AND REPAIR .......................... EN04-54

AFTERTREATMENT FUEL INJECTOR.. EN04-57

COMPONENT LOCATOR.............................. EN04-57
OVERHAUL ................................................... EN04-58

EXHAUST CONTROL CYLINDER.......... EN04-68

SYSTEM CONFIGURATION ......................... EN04-68
DPR INSPECTION CHECK SHEET.............. EN04-69
EN04–2 EXHAUST SYSTEM (J08E)

EXHAUST MANIFOLD AND PIPE

COMPONENT LOCATOR
EN01Z0804D100001

1
5
A

4
SAPH01Z080400001

1 Exhaust manifold sub assembly 4 Heat insulator

2 Gasket * 5 Spacer
3 Bracket
*: Nonreusable. Be sure to use new parts.

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

A 65 {660, 48}
 EXHAUST SYSTEM (J08E) EN04–3

DISMOUNTING AND MOUNTING

EN01Z0804H100001

IMPORTANT POINT - MOUNTING

1. INSTALL THE EXHAUST MANIFOLD GASKET.

NOTICE
Since the exhaust manifold gasket must be installed in one way,
install the gasket with the black side facing toward the exhaust mani-
fold.

SAPH01Z080400002

2. INSTALL THE EXHAUST MANIFOLD.

(1) Install the exhaust manifold onto the cylinder head and tighten the
Tightening order .... New manifold mounting nut in the order shown in the figure to the specified torque.
Tightening Torque:
18 17 16 15 14 13 12 11 10 9 8 7 65 Nm {660 kgfcm, 48 lbfft}
(2) Retighten the same nuts according to the same procedure again.
NOTICE
1 2 5 6 Be sure to carry out the procedure.
3 4

Tightening order .... Reused manifold

14 15 8 9 2 3 5 6 11 12 17 18

13 7 10 16
1 4

Spacer

SAPH01Z080400003
EN04–4 EXHAUST SYSTEM (J08E)

EXHAUST PIPE AND MUFFLER UNIT

DESCRIPTION
EN01Z0804H200001

1 7
4

2 3 6

SAPH01Z080400004

1 Exhaust pipe No.1 (ATC) 5 Muffler unit

2 Gasket * 6 Tail pipe
3 Exhaust pipe No.2 7 Bracket sub assembly
4 Exhaust pipe No.3
*: Nonreusable. Be sure to use new parts.
 EXHAUST SYSTEM (J08E) EN04–5

COMPONENT LOCATOR
EN01Z0804D100002

EXHAUST PIPE

A B

3 4

4
A
1

SAPH01Z080400005

1 Exhaust pipe No.1 (ATC) 3 Exhaust pipe No.3

2 Exhaust pipe No.2 4 Gasket *
*: Nonreusable. Be sure to use new parts.

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

A 56-84 {571-856, 42-62} B 120 {1220, 88}
EN04–6 EXHAUST SYSTEM (J08E)

MUFFLER UNIT

12

10 A
9

2
8 14
A
A
2 A 14
14
7 6

B
4

11 5
A A
2
A B

13
15

3
2

A 10
16
A

SAPH01Z080400006

1 Inlet chamber sub assembly 9 Outlet chamber sub assembly

2 Gasket * 10 Flange
3 Particulate filter assembly (DOC) 11 Support (Front)
4 Particulate filter sub assembly (DPR filter) 12 Support (Rear)
5 Chamber sub assembly (Rear) 13 Bracket (Front)
6 Gasket * 14 Bracket (Rear)
7 Chamber sub assembly (Front) 15 Differential pressure pipe
8 Monolithic converter assembly 16 Exhaust pipe bracket support
*: Nonreusable. Be sure to use new parts.

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

A 64 {653, 47} M8: 23-32 {234-327, 17-24}
B 6.4-9.6 {65-98, 4.1-7.1}
 EXHAUST SYSTEM (J08E) EN04–7

MUFFLER SUPPORT

7
6

B A

2
4
A
1

5 C 3 A

8
SAPH01Z080400007

1 Support sub assembly (Front) 5 Bracket

2 Support sub assembly (Rear) 6 Insulator
3 Support sub assembly (Front, lower) 7 Protector
4 Support sub assembly (Rear, lower) 8 Muffler unit

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

A 80-120 {816-1,223, 59-88} C 33-59 {337-602, 24-44}
B 69-103 {704-1,050, 51-76} M8: 18-26 {184-265, 14-19}
EN04–8 EXHAUST SYSTEM (J08E)

TAIL PIPE (SHORT TAIL TYPE)

SAPH01Z080400008

1 Tail pipe 3 Gasket *

2 Muffler unit
*: Nonreusable. Be sure to use new parts.

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

A 108-132 {1,101-1,346, 80-97}
 EXHAUST SYSTEM (J08E) EN04–9

TAIL PIPE (STACK TYPE)

D 11
6
A 13

A
5
7 13

C
12

C
3
F

E 8

9
1 C
E 8

B 10

SAPH01Z080400009
EN04–10 EXHAUST SYSTEM (J08E)

1 Bracket sub assembly 8 Clamp *

2 Exhaust pipe bracket 9 Exhaust flexible pipe
3 Bracket 10 Muffler unit
4 Tail pipe sub assembly 11 Clamp *
5 Tail pipe sub assembly 12 Clamp
6 Tail pipe 13 U-bolt
7 Insulator
*: Nonreusable. Be sure to use new parts.

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

A 36-44 {367-448, 27-32} E 60-80 {612-815, 45-59}
B 108-132 {1,102-1,346, 80-97} F 20.4-30.4 {208-310, 15-22}
C 130-158 {1,326-1,611, 96-116} M8: 18-26 {184-265, 14-19}
D 37-50 {378-509, 28-36}
 EXHAUST SYSTEM (J08E) EN04–11

REPLACEMENT OF ATC
EN01Z0804H100002

REMOVE THE EXHAUST PIPE No.1 (ATC)

NOTICE
The ATC will have to be replaced together with the exhaust pipe No.1
(ATC).

1. REMOVE THE EXHAUST PIPE No.2

(1) Remove the bolts and nuts on the flange on the muffler unit side.

2. REMOVE THE AFTERTREATMENT FUEL INJECTOR

Reference: EXHAUST SYSTEM (J08E), AFTERTREATMENT FUEL
INJECTOR, OVERHAUL, REMOVING THE AFTERTREATMENT
FUEL INJECTOR (Page EN04-58)

Exhaust pipe No.2 Muffler unit

SAPH01Z080400010

3. DISCONNECT THE EXHAUST GAS TEMPERATURE SENSOR 1

Exhaust gas temperature sensor 1 (ATC UPSTREAM) OF CONNECTOR AND EXHAUST GAS TEM-
(ATC upstrerm) PERATURE SENSOR 2 (ATC DOWNSTREAM) OF CONNECTOR

Exhaust gas temperature

sensor 2 (ATC downstrerm)
Connector
SAPH01Z080400011

4. REMOVE THE EXHAUST PIPE No.1 (ATC)

(1) Unfasten the bolts (4 pcs.) to remove the bracket from the exhaust
pipe No.1 (ATC).
(2) Unfasten the nuts (3 pcs.) to remove the exhaust pipe No.1 (ATC) and
gasket from the exhaust brake.

Exhaust brake

Exhaust pipe No.1 (ATC)

SAPH01Z080400012
EN04–12 EXHAUST SYSTEM (J08E)

MOUNTING THE EXHAUST PIPE No.1 (ATC)

NOTICE
The ATC will have to be replaced together with the exhaust pipe No.1
(ATC).

1. MOUNTING THE EXHAUST PIPE No.1 (ATC)

(1) Replace with a new gasket and temporarily tighten the exhaust
pipe No.1 (ATC) to the exhaust brake with nuts (4 pcs.).
(2) Temporarily tighten the bracket with the bolts.
(3) Tighten the bracket fully.
Tightening Torque:
55 Nm {560 kgfcm, 40.6 lbfft}
Exhaust brake
(4) Tighten the exhaust pipe No.1 (ATC) fully.
Tightening Torque:
Exhaust pipe No.1 (ATC)
70 Nm {714 kgfcm, 51.6 lbfft}
SAPH01Z080400013

2. CONNECT THE EXHAUST GAS TEMPERATURE SENSOR 1 (ATC

Exhaust gas temperature sensor 1 UPSTREAM) OF CONNECTOR AND EXHAUST GAS TEMPERA-
(ATC upstrerm) TURE SENSOR 2 (ATC DOWNSTREAM) OF CONNECTOR

Exhaust gas temperature

sensor 2 (ATC downstrerm)
Connector
SAPH01Z080400014

3. MOUNTING THE AFTERTREATMENT FUEL INJECTOR

Reference: EXHAUST SYSTEM (J08E), AFTERTREATMENT FUEL
INJECTOR, OVERHAUL, MOUNTING AFTERTREATMENT FUEL
INJECTOR (Page EN04-58)

4. CONNECTING THE EXHAUST PIPE No.2

(1) Tighten the exhaust pipe No.2 fully.
Tightening Torque:
56-84 Nm {571-856 kgfcm, 41.3-61.9 lbfft}

Exhaust pipe No.2 Muffler unit

SAPH01Z080400015
 EXHAUST SYSTEM (J08E) EN04–13

OVERHAUL
EN01Z0804H200002

IMPORTANT POINT - DISMOUNTING

! WARNING
Do not touch the exhaust manifold when it could be hot. You can be
severely burned.

1. DISMOUNTING
(1) Disconnect the battery ground terminal.
! CAUTION
Be sure to disconnect the battery terminals from the battery in accor-
dance with the procedures in this manual and never use the battery
disconnect switch when it is necessary to break the supply of electric-
ity completely. Otherwise, electricity may remain supplied from the
battery by the circuit that bypasses the battery disconnect switch and
you may get burns or injury from the electricity.
(2) Remove the step (top) and the insulator on the right side of
the vehicle.

SAPH01Z080400016

(3) Remove the harness clamp.

(4) Disconnect the connector connected to the injector.

Injector
connector Injector Clamp
SAPH01Z080400017

(5) Disconnect the clamps (2 pcs.) and the coolant hose connected to the
injector.
NOTICE
When the coolant hose is disconnected, coolant will flow out. Drain
coolant beforehand or plug the end of the pipe.

Clamp

Injector
Coolant hose

SAPH01Z080400018
EN04–14 EXHAUST SYSTEM (J08E)

(6) Remove the clip and the DEF hose from the injector.
Clip NOTICE
After removing the clip and the DEF hose, do not allow foreign matter
to infiltrate the pipe.
HINT
Remove the DEF hose by pushing inward the white knobs (2 pcs.) of
Injector the connector.

DEF hose

SAPH01Z080400019

(7) Disconnect the connector connected to the exhaust gas temperature

Connector
sensor 3 (DOC inlet) and the exhaust gas temperature sensor 4 (DPR
inlet).
(8) Remove the clips (3 pcs.), and the exhaust temperature sensor 3
(DOC inlet) and the exhaust gas temperature sensor 4 (DPR inlet).
Clip

Clip
Exhaust gas temperature Exhaust gas
sensor 3 (DOC inlet) temperature sensor 4
(DPR inlet)
SAPH01Z080400020

(9) Disconnect the connector connected to the exhaust gas temperature

sensor 5 (DPR outlet) and remove the clips (2 pcs.).
(10) Remove the exhaust gas temperature sensor 5 (DPR outlet).

Connector

Exhaust gas temperature

sensor 5 (DPR outlet)
Clip
SAPH01Z080400021
 EXHAUST SYSTEM (J08E) EN04–15

(11) Disconnect the NOx sensor 1 controller with the nuts (2 pcs.), and dis-
connect the connector.
NOx sensor 1 connector NOx sensor 1
controller
(12) Remove the clips (3 pcs.) and the NOx sensor 1.

NOx sensor 1
Clip
SAPH01Z080400022

(13) Disconnect the connector connected to the NOx sensor 2 controller.

Connector (14) Remove the clips (3 pcs.) and the NOx sensor 2 .

NOx sensor 2
controller

Clip
SAPH01Z080400023

(15) Disconnect the connector connected to the PM sensor controller.

Connector

PM sensor
controller

SAPH01Z080400024
EN04–16 EXHAUST SYSTEM (J08E)

(16) Remove the clips (5 pcs.) and the PM sensor.

Clip

PM sensor Clip

SAPH01Z080400025

(17) Remove the clip and disconnect the connector of exhaust gas temper-
Connector ature sensor (SCR inlet).
(18) Remove the exhaust gas temperature sensor (SCR inlet) .

Clip

Exhaust gas temperature

sensor (SCR inlet)

SAPH01Z080400026

(19) Remove the clamps (4 pcs.) and the differential pressure hoses (2
pcs.).

Clamp

Differential
pressure hose

Clamp
SAPH01Z080400027
 EXHAUST SYSTEM (J08E) EN04–17

(20) Remove the clips (2 pcs.) and the differential pressure pipe.
Differential
pressure pipe

Clip

SAPH01Z080400028

(21) Remove the nuts (4 pcs.) of the exhaust pipe No. 2 and gasket.

Nut
Gusket

Exhaust pipe No.2

Muffler unit
SAPH01Z080400029
EN04–18 EXHAUST SYSTEM (J08E)

(22) Remove the bolts (4 pcs.) and nuts (4 pcs.) of exhaust pipe No. 2 and
gasket.

Gasket

Nut

Bolt

Exhaust pipe No.2

Muffler unit
SAPH01Z080400030

(23) Remove the bolts (4 pcs.) and nuts (4 pcs.) of the exhaust pipe
bracket from the muffler unit.

Bolt and Nut

SAPH01Z080400031

(24) Remove the bolts (3 pcs.) and nuts (3 pcs.) of exhaust pipe No. 3 and
gasket from the muffler unit.
Gasket

Exhaust
Nut pipe No.3

Muffler unit
SAPH01Z080400032
 EXHAUST SYSTEM (J08E) EN04–19

(25) Remove the bolts (2 pcs.) and nuts (2 pcs.) of the tail pipe and the
gasket from the muffler unit.
Muffler unit

Gasket Bolt
Nut
Tail pipe

SAPH01Z080400033

(26) Remove the front side bracket and bolts (2 pcs.) and nuts (2 pcs.) of
the muffler unit.

Bracket

Muffler unit

SAPH01Z080400034

(27) Remove the rear side bracket bolts (2 pcs.) and nuts (2 pcs.) of the
Nut muffler unit.

Muffler unit
SAPH01Z080400035

(28) Support the muffler unit using the jack and Banco.
H=240 mm
{9.45in.} NOTICE
Muffler unit Be extremely careful when handling the muffler unit because it is
heavy.
HINT
H=170 mm
{6.69in.} The jack can be operated easily by placing a banco as shown in the
figure.

Banco

Transmission
Jack

SAPH01Z080400036
EN04–20 EXHAUST SYSTEM (J08E)

(29) Remove the muffler unit by removing the bolts (2 pcs.) and nuts (2
Nut pcs.).
NOTICE
Do not apply heavy load or impact to the muffler unit when mounting
and dismounting.

Bolt

SAPH01Z080400038
 EXHAUST SYSTEM (J08E) EN04–21

IMPORTANT POINT -MOUNTING

1. MOUNTING
(1) Support the muffler unit using the jack and Banco.
H=240 mm
{9.45in.} NOTICE
Muffler unit Be extremely careful when handling the muffler unit because it is
heavy.
HINT
H=170 mm
{6.69in.} The jack can be operated easily by placing a banco as shown in the
figure.

Banco

Transmission
Jack

SAPH01Z080400039

(2) Mount the muffler unit with the bolts (2 pcs.) and nuts (2 pcs.).
Nut
Tightening Torque:
69-103 Nm {704-1,050 kgfcm, 51-76 lbfft}

Bolt

SAPH01Z080400040

(3) Install the rear side bracket bolts (2 pcs.) and nuts (2 pcs.) of the muf-
Nut fler unit.
Tightening Torque:
69-103 Nm {704-1,050 kgfcm, 51-76 lbfft}

Muffler unit
SAPH01Z080400041

(4) Install the front side bracket bolts (2 pcs.) and nuts (2 pcs.) of the muf-
fler unit.
Tightening Torque:
33-59 Nm {337-602 kgfcm, 24-44 lbfft}

Bracket

Muffler unit

SAPH01Z080400042
EN04–22 EXHAUST SYSTEM (J08E)

(5) Replace with new gasket and attach the tail pipe to the muffler unit
with the bolts (2 pcs.) and nuts (2 pcs.).
Muffler unit
Tightening Torque:
108-132 Nm {1,101-1,346 kgfcm, 80-97 lbfft}

Gasket Bolt
Nut
Tail pipe
SAPH01Z080400033

(6) Replace with new gasket and attach exhaust pipe No. 3 to the muffler
unit with the bolts (3 pcs.) and nuts (3 pcs.).

Gasket Tightening Torque:

120 Nm {1,200 kgfcm, 88 lbfft}

Exhaust
Nut pipe No.3

Muffler unit

SAPH01Z080400043

(7) Attach the exhaust bracket to the muffler unit with the bolts (4 pcs.)
and nuts (4 pcs.).
Tightening Torque:
56-84 Nm {571-856 kgfcm, 42-62 lbfft}

Bolt and Nut

SAPH01Z080400044
 EXHAUST SYSTEM (J08E) EN04–23

(8) Replace with new gasket and install exhaust pipe No. 2 with the bolts
(4 pcs.) and nuts (4 pcs.).
Tightening Torque:
56-84 Nm {571-856 kgfcm, 42-62 lbfft}
Gasket

Nut

Bolt

Exhaust pipe No.2

Muffler unit

SAPH01Z080400045

(9) Replace with new gasket and install exhaust pipe No. 2 with the nuts
(4 pcs.).
Tightening Torque:
56-84 Nm {571-856 kgfcm, 42-62 lbfft}

Nut
Gusket

Exhaust pipe No.2

Muffler unit

SAPH01Z080400046
EN04–24 EXHAUST SYSTEM (J08E)

NOTICE
If the exhaust pipe is removed, make sure to mount the bellows tube
of the exhaust pipe as in the figure to secure durability.

SAPH01Z080400047

(10) Install the differential pressure pipe with the clips (2 pcs.).
Differential NOTICE
pressure pipe
When installing the differential pressure sensor pipe, wipe off the old
anti-seizure lubricant on the flare nut and apply new anti-seizure lubri-
cant.
Recommended anti-seizure lubricant: NEVER-SEEZ Pure Nickel
Clip Special (Bostic inc.)

Tightening Torque:
25-35 Nm {255-356 kgfcm, 19-25 lbfft} (Flare nut)
SAPH01Z080400028

(11) Install the differential pressure hoses (2 pcs.) with the clamps (4 pcs.).

Clamp

Differential
pressure hose

Clamp

SAPH01Z080400048

NOTICE
Assemble without crossing hoses.

Correct Incorrect
SAPH01Z080400049
 EXHAUST SYSTEM (J08E) EN04–25

(12) Install the exhaust gas temperature sensor (SCR inlet) .

Connector Tightening Torque:
25-40 Nm {255-407 kgfcm, 19-29 lbfft}

(13) Install the clip and connect the connector of exhaust gas temperature
sensor (SCR inlet).
Clip

Exhaust gas temperature

sensor (SCR inlet)

SAPH01Z080400026

(14) Install the PM sensor controller with the nuts (2 pcs.), and connect the
connector.
Connector Tightening Torque:
3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft}
PM sensor
controller

SAPH01Z080400024

(15) Install the clips (5 pcs.) and the PM sensor.

Clip Tightening Torque:
28-42 Nm {286-428 kgfcm, 21-30 lbfft}

PM sensor Clip

SAPH01Z080400025
EN04–26 EXHAUST SYSTEM (J08E)

(16) Install the nuts (2 pcs.) and the NOx sensor 2 controller and connect
Connector the connector.
Tightening Torque:
3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft}
NOx sensor 2
controller
(17) Install NOx sensor 2 with the clips (3 pcs.).
Tightening Torque:
40-60 Nm {408-612 kgfcm, 29.5-44.2 lbfft}

Clip
SAPH01Z080400050

(18) Install the NOx sensor 1 controller with the nuts (2 pcs.), and connect
the connector.
NOx sensor 1 connector NOx sensor 1
controller Tightening Torque:
3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft}

(19) Install NOx sensor 1 with the clips (3 pcs.).

Tightening Torque:
40-60 Nm {408-612 kgfcm, 29.5-44.2 lbfft}

NOx sensor 1
Clip
SAPH01Z080400051
 EXHAUST SYSTEM (J08E) EN04–27

(20) Install the exhaust gas temperature sensor 5 (DPR outlet).

Tightening Torque:
25-35 Nm {255-357 kgfcm, 18.4-25.8 lbfft}

(21) Connect the connector of exhaust gas temperature sensor 5 (DPR

outlet) and install the clip (2 pcs.).

Connector

Exhaust gas temperature

sensor 5 (DPR outlet)
Clip
SAPH01Z080400052

(22) Connect the the connector of exhaust gas temperature sensor 3

Connector
(DOC inlet) and exhaust gas temperature sensor 4 (DPR inlet).
(23) Install the clips (3 pcs.) exhaust gas temperature sensor 3 (DOC inlet)
and exhaust gas temperature sensor 4 (DPR inlet).
Tightening Torque:
Clip
25-35 Nm {255-357 kgfcm, 18.4-25.8 lbfft}

Clip
Exhaust gas temperature Exhaust gas
sensor 3 (DOC inlet) temperature sensor 4
(DPR inlet)
SAPH01Z080400053

(24) Connect the DEF hose to the injector with the clip.
Clip NOTICE
Before reassembling, wash away crystallized DEF on the connector
with water.

Injector

DEF hose

SAPH01Z080400019
EN04–28 EXHAUST SYSTEM (J08E)

(25) Connect the coolant hose to the injector with the clamps (2 pcs.).

Clamp

Injector
Coolant hose

SAPH01Z080400018

(26) Connect the harness connector to the injector.

(27) Install the harness with the clamp.

Harness
connector Injector Clamp
SAPH01Z080400054
(28) Mount the step (top) and the insulator on the right side of the vehicle.
Tightening Torque:
18-26 Nm {184-265 kgfcm, 14-19 lbfft}

SAPH01Z080400016

(29) Connect the battery ground terminal.

 EXHAUST SYSTEM (J08E) EN04–29

DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM)

SYSTEM CONFIGURATION
EN01Z0804D100003

10 11

12

15
9

15

6
16
7
15 15
15
3 17
4
13 DPR DOC

8
14

NH3 slip catalyst

SAPH01Z080400055

1 Engine 10 DPR-manual regeneration switch

2 Engine ECU 11 DPR indicator light
3 Exhaust pipe No.1 (ATC) 12 Check engine light
4 Exhaust pipe No.2 13 DEF injector
5 Exhaust pipe No.3 14 PM sensor
6 Exhaust control valve 15 Exhaust temperature sensor
7 Catalyst coated filter 16 ATC
8 Oxidation catalyst 17 Aftertreatment fuel injector
9 Differential pressure sensor
EN04–30 EXHAUST SYSTEM (J08E)

STRUCTURE OF DPR-CLEANER
EN01Z0804D100004

10
9

2
8 14
A
14
2
14

7 6 A

5
A
2

12 15
13 A A

11 3
2

10
16
A

SAPH01Z080400056

1 Inlet chamber sub assembly 9 Outlet chamber sub assembly

2 Gasket * 10 Flange
3 Particulate filter assembly (DOC) 11 Bracket
4 Particulate filter sub assembly (DPR filter) 12 Bracket
5 Chamber sub assembly (Rear) 13 Bracket (Front)
6 Gasket * 14 Bracket (Rear)
7 Chamber sub assembly (Front) 15 Differential pressure pipe
8 Monolithic converter assembly 16 Exhaust pipe bracket support
*: Nonreusable. Be sure to use new parts.

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

A 64 {653, 47}
EXHAUST SYSTEM (J08E) EN04–31

DPR INSPECTION
EN01Z0804H200003

1. ROUTINE INSPECTION ITEMS

(1) Check the exhaust system tightening portions (exhaust pipe, main
unit flange) for looseness or exhaust leakage.
(2) Check external appearance of the harness of the exhaust tempera-
ture sensor for trouble (cracks in coating or missing clip).
(3) Inspect the hose of the differential pressure sensor and check the
hose for deterioration or cracks. Replace a hose which has been used
for three years or more with a new one.
(4) Check for a blown indicator light or wire break in the DPR-cleaner
switch and meter. (Stop the engine, turn ON the starter switch, and
press the DPR-cleaner switch. If both the light in the switch and indi-
cator light in the meter illuminate, the lights are normal.)
EN04–32 EXHAUST SYSTEM (J08E)

INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE"

IS DISPLAYED ON THE INFORMATION DISPLAY
EN01Z0804H300001

NORMAL TRAVELING

DPR MAINTENANCE
DISPLAY

RECEIVING THE VEHICLE

FOR SAFETY CHECK

CONNECT HINO DX
<Checking a fault code against HINO-DX>
PAST FAULT CHECK
1. CHECKING THE CURRENT CONDITION
DPR STATE MONITOR CHECK

(If the engine has a past fault history,

2. DIAGNOSIS ENGINE INSPECTION
inspect the engine before inspecting DPR.)

<Forced regeneration by way of HINO-DX>

3. FORCED REGENERATION
Execution of manual regeneration
Confirm the combustible doesn't exist near the exhaust pipe.

4. FORCED REGENERATION
COMPLETION

(Regeneration is not complete and the check

5. DIAGNOSIS FILTER CLEANING
engine light comes on.)

<Check the differential pressure sensor value while raising

the engine revolution up to the no load maximum revolution.>
6. MEASUREMENT OF
Monitor the backpressure value of the differential pressure sensor.
BACKPRESSURE
Monitor the engine revolution.

(Predetermined backpressure tolerance is exceeded.)

7. DIAGNOSIS FILTER CLEANING

The display will be cleared by Hino-DX.

COMPLETION
SAPH01Z080400057
EXHAUST SYSTEM (J08E) EN04–33

INSPECTION BY WAY OF HINO DX Ⅱ

EN01Z0804H200004

1. DPR status check

(1) Select the "DPR check" in the "Inspection Menu" of HINO DX Ⅱ .
(2) Confirm Data View of the "DPR check" display (monitor), if the value
for all the items are "OFF", DPR functions normally.
Then "Manual forced regeneration" and "DPR differential pressure
check" can be done.
(3) In case "ON" is displayed in Data view of the "DPR check" display
(monitor), check according to the procedure on page EN04-40,
"DETERMINATION BY WAY OF DPR STATE DETERMINATION
MONITOR OF HINO DX Ⅱ ".

SAPH01Z080400058
EN04–34 EXHAUST SYSTEM (J08E)

2. Forced regeneration
(1) Forced regeneration is done by the "Manual forced regeneration"
screen.
! CAUTION
• Confirm safety of the surrounding area, then press DPR regener-
ation switch inside the cabin to execute the regeneration.
• Confirm the PTO switch is OFF.
(2) When the "Regeneration switch ON identification" value is ON,
inspection of wash or replace the filter.
When the value is OFF, DPR functions normally.

SAPH01Z080400059
EXHAUST SYSTEM (J08E) EN04–35

3. DPR differential pressure check

(1) Check the DPR differential pressure through the "DPR check" display.
(2) Confirm the exhaust gas temperature (in and out) is less than 200C
{392F}.
(3) Engine speed will rise automatically, then record the indicated maxi-
mum DPR differential pressure.
(4) In case the central value of the recorded DPR differential pressure
value exceeds the specific value, clean or replace the filter.
Then "Stop" the DPR differential pressure check.

Specific value

Differential pressure inspection

Engine speed
standard value
(no load maximum revolution)
(kPa {kgf/cm2, lbf/in.2})
2,800 r/min. 5.0 {0.05, 0.7}

(5) When the differential pressure is unchanged check the following.

If the following are normal, the differential pressure sensor should be
replaced.
a. Check differential pressure hose for cracks or hole openings.
b. Check that the hose clamp is neither loose nor disconnected.
c. Check whether there is clogging in the differential pressure pipe
(DPR cleaner side).
Use the compressed air from one end of the pipe to check for
clogging. If the air passes to the other side easily, it is clear.
EN04–36 EXHAUST SYSTEM (J08E)

SAPH01Z080400060
 EXHAUST SYSTEM (J08E) EN04–37

INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT

ILLUMINATES (ABNORMAL)
EN01Z0804H300002

NORMAL TRAVELING DPR inspection refers to check for a melting,

cracks or leakage of black smoke on the
rear of the filter. Replace if any is found.
CHECK ENGINE LIGHTS ILLUMINATES At the same time, also replace the PM sensor
with a new one.
RECIEVING THE VEHICLE FOR SAFETY CHECK

CONNECT HINO DX

1. CHECKING THE CURRENTCONDITION

PAST FAULT CHECK

2. DIAGNOSIS (Inspection of engine system including trouble ENGINE INSPECTION
in exhaust control system)
PAST FAULT CHECK (determination of sensor system trouble)
Exhaust gas temperature sensor 1 (ATC upstream) trouble:
DTC code P0545, P0546, P2080
Exhaust gas temperature sensor 2 (ATC downstream) trouble:
DTC code P2032, P2033, P2084
Exhaust gas temperature sensor 3 (DOC inlet) trouble:
DTC code P242B, P242C, P242D
Exhaust gas temperature sensor 4 (DPR inlet) trouble:
DTC code P246F, P2470, P2471 SENSOR CIRCUIT
Exhaust gas temperature sensor 5 (DPR outlet) trouble: INSPECTION/
3. DIAGNOSIS DTC code P2480, P2482, P2483
DPR differential pressure sensor trouble: REPLACEMENT
DTC code P1427, 1428, P1426 ∗4
PM sensor trouble:
DTC code P24B0, P24B1, P24B4, P24A3, P24B6, P24AF
DPR trouble: DTC code P141F, P200C, P2459, P244A, P244B, P2463, P2002

4.DIAGNOSIS (DPR STATE DPR STATE MONITOR CHECK

FILTER CLEANING
DISPLAY MONITOR) (Determination of DPR fault mode) BY HINO-DX
(MANUAL REGENERATION)
DPR CLOGGED WARNING · DPR-calculated soot build-up CLOGGING ∗1
LEVEL FLAG amount exceeds the limit.
(With output limitation) CLOGGING FILTER CLEANING
DPR CLOGGED DANGER (REMOVE AND CLEANING
LEVEL FLAG BY WASHING MACHINE)
∗2
DPR MANUAL · DPR temperature will not rise DETERIORATION
under DPR control.
REGENERATION FAILURE ENGINE INSPECTION
FLAG FILTER CLEANING
(+ INSPECTION OF
DPR ACTIVE · Engine exhaust temperature
will not rise under DPR
ENGINE-SIDE INJECTION
REGENERATION FAILURE ENGINE INSPECTION SYSTEM/EXHAUST
control. CONTROL SYSTEM)
FLAG
Abnormally high temperature DAMAGE
DPR OVER TEMPERATURE · is detected by the rear
FLAG BY REAR EXH GAS temperature sensor. FILTER CLEANING
TEMP (+ INSPECTION OF
Clogging of DPR is detected CLOGGING ENGINE-SIDE
DPR EXCESSIVE · by the diifferential pressure INJECTION SYSTEM
(+ ENGINE TROUBLE)
BACKPRESSURE FLAG sensor. /LUBRICATION SYSTEM)
DAMAGE/BREAKAGE DPR INSPECTION
DPR MISSING SUBSTRATE DPR backpressure of the
FLAG · differential pressure sensor DPR INSPECTION
has dropped abnormally. DAMAGE (+ INSPECTION OF
DPR OVER TEMPERATURE Abnormality of DPR filter is ENGINE-SIDE
· detected by PM sensor. (+ ENGINE TROUBLE) INJECTION SYSTEM
FLAG BY FRONT EXH GAS /LUBRICATION SYSTEM)
TEMP Abnormally high temperature
· is detected by the exhaust gas
temperature sensor 4 (DPR inlet)
SAPH01Z080400061
EN04–38 EXHAUST SYSTEM (J08E)

*1 Additional information for inspections with HINO DX Ⅱ

Light cases of DPR clogging can be treated without removing the housing.
The procedure is shown below.

The "DPR STATUS" can be checked with the HINO DX Ⅱ , and when only the "Clogging warning level indication" is "ON",
regeneration processing can be performed with the DPR SW or the tool.

Confirmation method:
Use the HINO DX Ⅱ , select [Engine], then open screens in the order of Inspection Menu DPR check  Start inspection, and
confirm that "value" is "ON" for the item "Clogging warning level indication" of the DPR check. Only when this is "ON" can man-
ual regeneration by pressing the DPR manual regeneration switch or manual regeneration by HINO DX Ⅱ setting be per-
formed.
.

1. Press the DPR Manual regeneration switch. When manual regeneration has started, wait until regeneration has been
completed and confirm that the engine check light has gone out.
2. If the operation by means of the DPR SW is not accepted, connect the HINO DX Ⅱ to the vehicle, erase the trouble code,
and then perform manual regeneration according to the following procedure. When manual regeneration has started, wait
until regeneration has been completed and confirm that the engine check light has gone out.

Confirmation method:
Use the HINO DXⅡ , select [Engine], and then continue in the order of Inspection Menu  DPR check  Start inspection
 Manual forced regeneration.
3. After completion of manual regeneration by (1) or (2), keep the engine running and wait for the exhaust temperature (IN
side) to drop. Confirm a drop to 200 degrees or lower and then inspect the exhaust gas backpressure according to the fol-
lowing procedure.

Confirmation method:
Execute in the order of Start inspection DPR differential pressure check Start.
4. Confirm that the values of the exhaust gas backpressure are at or below the standard.
Standard:
Engine model DPR Backpressure (Units: kPa {kgf/cm2, lbf/in.2})
J08E 5.0 {0.05, 0.7}

5. When the confirmation result in (4) is at or below the standard, DPR manual regeneration and the confirmation work have
been completed. Click "Stop" on the DPR differential pressure Check screen to end the work with the HINO DX Ⅱ .
6. If the exhaust gas backpressure with the inspection in (5) exceeds the standard, repeat the steps (2), (3), (4), and (5).
7. If the exhaust gas backpressure with the work in (6) is within the standard, DPR manual regeneration and the confirma-
tion work have been completed. Click "Stop" on the DPR differential pressure check screen to end the work with the
HINO DX Ⅱ .
8. If the exhaust gas backpressure still exceeds the standard with the second manual regeneration, the DPR filter is defec-
tive and must be replaced. At the same time, also replace the PM sensor with a new one.
 EXHAUST SYSTEM (J08E) EN04–39

*2 Additional information for filter cleaning with a washing machine

Confirm the following for filter cleaning with a washing machine.
Use a washing machine from a manufacturer recommended by Hino Motors.
Perform cleaning with correct installation of the attachment for DPR filters made by Hino Motors.
In the following instances the filter cannot be cleaned. In these cases, the filter must be replaced.
.

1. Cleaning is not possible for filters where soot has escaped and the surroundings have turned black when the filter body is
seen from the gas flow outlet side.
2. Cleaning is not possible when a large quantity of oil adheres to the filter body as seen from the gas flow inlet side.
3. Cleaning is not possible when the filter or the catalyst shows cracks or damage seen from any side.
When cleaning has been completed and the filter has been installed again, perform the following inspections.
4. Use the HINO DX Ⅱ to perform DPR forced regeneration, then confirm normal completion.
5. In this condition, wait for the exhaust gas temperature to drop to 200C or lower, perform the backpressure inspection,
and confirm that the inspection value is at or below the standard.
6. If the backpressure value is high, the filter is defective and must be replaced.

*3 Check for sensor coupler disconnection even when DPR and DTC code is displayed.

*4 Pay attention to the following when the temperature sensor is inspected because of DPR
and DTC code or a temperature sensor DTC code.
.

1. Replace if the tip is bent.

2. Do not bend the tip when it is normal.
3. When the sensor tip is bent, normal control may not be possible and this can lead to DPR trouble.
4. When disconnecting the sensor, remove the sensor body from the muffler after completely removing the harness fixing
clips. If this is not done, the sensor tip could get damaged.
EN04–40 EXHAUST SYSTEM (J08E)

DETERMINATION BY WAY OF DPR STATE

DETERMINATION MONITOR OF HINO DXⅡ
EN01Z0804H200005

1. CHECK THAT THE CHECK ENGINE LIGHT COMES ON.

2. CONNECT HINO DX Ⅱ .

3. CHECK PAST FAULTS.

(1) Check past faults by way of HINO DX Ⅱ . In case a general engine
fault such as a trouble of an exhaust control system is displayed,
inspect and repair the pertinent section.
(2) Inspect and repair general engine faults and check past faults again.
In case a code indicating a sensor system trouble is displayed,
inspect and replace the sensor circuit.

DTC code
Exhaust gas temperature sensor 1
P0545, P0546, P2080
(ATC upstream) trouble
Exhaust gas temperature sensor 2
P2032, P2033, P2084
(ATC downstream) trouble
Exhaust gas temperature sensor 3
P242B, P242C, P242D
(DOC inlet) trouble
Exhaust gas temperature sensor 4
P246F, P2470, P2471
(DPR inlet) trouble
Exhaust gas temperature sensor 5
P2480. P2482, P2483
(DPR outlet) trouble
DPR differential pressuer
P1426, P1427, P1428
sensor trouble
P24B0, P24B1, P24B4,
PM sensor trouble
P24A3, P24B6, P24AF

(3) Check past faults. In case DPR trouble (DTC code: P141F, P200C,
P2459, P244A, P2002, P244B, P2463) is displayed, check the DPR
state monitor.

CHECKING THE DPR STATE

EN01Z0804H200006

1. CHECK THE DPR STATE MONITOR.

(1) Refer to "INSPECTION BY WAY OF HINO DX Ⅱ " and check the DPR
state monitor. Perform inspection as per the procedure under
"INSPECTION BY WAY OF HINO DX Ⅱ ".
 EXHAUST SYSTEM (J08E) EN04–41

REPLACEMENT OF DPR FILTER

EN01Z0804H200007

! WARNING

Do not touch the muffler unit when it could be hot. You can be
severely burned.
NOTICE
Replace the DPR filter with a new one and install it on the vehicle. At
the same time, also replace the PM sensor with a new one.
1. REMOVE THE DPR FILTER.
(1) Dismount the muffler unit of the vehicle.
Reference: EXHAUST SYSTEM (J08E), EXHAUST PIPE AND MUF-
FLER UNIT, OVERHAUL, IMPORTANT POINT -DISMOUNTING
(Page EN04-13)
(2) Remove the bolts (4 pcs.) and nuts (2 pcs.) of the bracket (front) (A)
in-between the chamber sub assembly (front) (B) and inlet chamber
sub assembly (C).
(3) Remove the bolts (2 pcs.) and nuts (2 pcs.) of the bracket in-between
the support sub assembly (front) (D) and inlet chamber sub assembly
(C).
(4) Remove the bolts (8 pcs.) and nuts (8 pcs.) of the flange (E) and
exhaust pipe bracket support (F) and gasket (G) and inlet chamber
sub assembly (C).
(5) Remove the bolts (4 pcs.) and nuts (4 pcs.) of the rear flange bracket
(H) of the monolithic converter assembly (I) and particulate filter
assembly (DOC) (J).
(6) Remove the bolts (2 pcs.) and nuts (2 pcs.) of the rear flange bracket
(K) of the particulate filter assembly (DOC) (J) .

(I)
(H)

(B)

(A)

(K)

(J)
(G)
(D) (C)
(E)
(F)

SAPH01Z080400062
EN04–42 EXHAUST SYSTEM (J08E)

(7) Remove the front flange fasteners (6 pcs.) of the particulate filter sub
assembly (DPR filter).
NOTICE
The frame side bracket cannot be removed, because the differential
pressure pipe extends through the bracket.

SAPH01Z080400063

(8) Pull the particulate filter assembly (DOC) from the stud bolts of the
chamber sub assembly (rear).
Gasket NOTICE
• During work, use the jack for safety's sake.
Particulate filter • When working, be careful that the particulate filter sub assembly
assembly (DOC) (DPR filter) does not come off.
Chamber sub
assembly (rear)
(9) Pull the particulate filter sub assembly (DPR filter) and gasket from
Bracket the stud bolts of the chamber sub assembly (rear).
Particulate filter sub assembly
(DPR filter)
SAPH01Z080400064

2. INSTALL THE DPR FILTER.

NOTICE
• Before installing check if the particulate filter sub assembly (DPR
filter) has the “HINO S1805E069” mark on it.
• Replace the gasket with a new gasket.
• Tighten the fastening bolts in diagonal order.

"HINO S1805E069" mark

SAPH01Z080400065

(1) Insert the particulate filter sub assembly (DPR filter) and new gasket
over the stud bolts of the chamber sub assembly (rear).
Gasket NOTICE
During work, use the jack for safety's sake.
Particulate filter (2) Insert the particulate filter sub assembly (DOC) over the stud bolts of
assembly (DOC)
Chamber sub the chamber sub assembly (rear).
assembly (rear)

Bracket
Particulate filter sub assembly
(DPR filter)
SAPH01Z080400066
 EXHAUST SYSTEM (J08E) EN04–43

(3) Install the front flange fasteners (6 pcs.) of the particulate filter sub
assembly (DPR filter).
Tightening Torque:
64 Nm {653 kgfcm, 47 lbfft}

SAPH01Z080400067
EN04–44 EXHAUST SYSTEM (J08E)

(4) Install the rear flange bracket (K) of the particulate filter assembly
(DOC) (J) with the bolts (2 pcs.) and nuts (2 pcs.).
Tightening Torque:
64 Nm {653 kgfcm, 47 lbfft}
(5) Install the rear flange bracket (H) of the monolithic converter assembly
(I) and particulate filter assembly (DOC) (J) with the bolts (4 pcs.) and
nuts (4 pcs.).
Tightening Torque:
64 Nm {653 kgfcm, 47 lbfft}
(6) Install the flange (E) and inlet chamber sub assembly (C) and exhaust
pipe bracket support (F) and gasket (M) with the bolts (8 pcs.) and
nuts (8 pcs.).
Tightening Torque:
64 Nm {653 kgfcm, 47 lbfft}
(7) Install the bracket in-between the support sub assembly (front) (D) and
inlet chamber sub assembly (C) with the bolts (2 pcs.) and nuts (2 pcs.).
Tightening Torque:
64 Nm {653 kgfcm, 47 lbfft}
(8) Install the bracket (front) (A) in-between the chamber sub assembly
(front) (B) and inlet chamber sub assembly (C) with the bolts (4 pcs.)
and nuts (2 pcs.).
Tightening Torque:
64 Nm {653 kgfcm, 47 lbfft}

(I)
(H)

(B)

(A)

(K)

(J)
(G)
(D) (C)
(E)
(F)

SAPH01Z080400068
(9) Mount the muffler unit to the vehicle.
Reference: EXHAUST SYSTEM (J08E), EXHAUST PIPE AND MUF-
FLER UNIT, OVERHAUL, IMPORTANT POINT -MOUNTING (Page
EN04-19)
 EXHAUST SYSTEM (J08E) EN04–45

OVERALL OPERATION FLOW

EN01Z0804H100003

1. VEHICLE RECEIPT FOR INSPECTION

(1) Check the malfunction code with the HINO DX Ⅱ .
Standard value: No malfunction code

SAPH01Z080400069
.

NO
• 4. For P141F, P200C, P244B, P2002, P244A,
P2459, P2463
YES • 5. For others than above

2. MANUAL REGENERATION

2. MANUAL REGENERATION
(1) After a manual regeneration, check the differential pressure with the
HINO DX Ⅱ .
Standard value:
Refer to "LIST OF STANDARD VALUES FOR DIFFERENTIAL
PRESSURE INSPECTION" on page EN04-12.

Exhaust gas purification switch

SAPH01Z080400070
.

NO
3. INSPECT THE DPR FILTER.

YES

No clean up necessary
Vehicle delivery

.
EN04–46 EXHAUST SYSTEM (J08E)

3. INSPECT THE DPR FILTER.

(1) Dismount the DPR filter from the vehicle.
Refer to "1. REMOVE THE DPR FILTER" on page EN04-41.
(2) Inspect the status of the DPR filter rear surface.
Refer to "INSPECT INSIDE THE DPR FILTER" on page EN04-49.
Standard value: No soot escape

SAPH01Z080400071

NO
Replace the DPR filter with a new one and install it
on the vehicle. At the same time, also replace the
PM sensor with a new one.
YES
Refer to "2. INSTALL THE DPR FILTER" on
page EN04-42.
NOTICE
Recheck the differential pressure after the
installation. Make sure it is within the standard
value and deliver the vehicle.

Perform ash cleaning to the DPR filter and then install it on the vehi-
cle.
Refer to "2. INSTALL THE DPR FILTER" on page EN04-42.
NOTICE
Recheck the differential pressure after the installation. Make
sure it is within the standard value and deliver the vehicle.

.
 EXHAUST SYSTEM (J08E) EN04–47

4. IN CASE THAT DPR DTC CODE IS DISPLAYED

(1) Dismount the DPR filter from the vehicle.
Refer to "1. REMOVE THE DPR FILTER" on page EN04-41.
(2) Inspect the status of the DPR filter rear surface.
Refer to "INSPECT INSIDE THE DPR FILTER" on page EN04-49.
Standard value: No soot escape

SAPH01Z080400072

NO
Replace the DPR filter with a new one and install it
on the vehicle. At the same time, also replace the
PM sensor with a new one.
YES
Refer to "2. INSTALL THE DPR FILTER" on
page EN04-42.
NOTICE
After the installation, regenerate the DPR filter
manually and recheck the differential pressure.
Make sure it is within the standard value and
deliver the vehicle.

Perform soot cleaning to the DPR filter and then install it on the
vehicle.
Refer to "2. INSTALL THE DPR FILTER" on page EN04-42.
NOTICE
After the installation, regenerate the DPR cleaner manually and
recheck the differential pressure. Make sure it is within the
standard value and deliver the vehicle.

.
EN04–48 EXHAUST SYSTEM (J08E)

5. FOR OTHERS THAN DPR DTC CODE IS DISPLAYED

(1) Check the engine body and repair or replace defective parts if any.
(2) Dismount the DPR filter from the vehicle.
Refer to "1. REMOVE THE DPR FILTER" on page EN04-41.
(3) Inspect the status of the DPR filter rear surface.
Refer to "INSPECT INSIDE THE DPR FILTER" on page EN04-49.
Standard value: No soot escape

SAPH01Z080400073

NO
Replace the DPR filter with a new one and install it
on the vehicle. At the same time, also replace the
PM sensor with a new one.
YES
Refer to "2. INSTALL THE DPR FILTER" on
page EN04-42.
NOTICE
After the installation, regenerate the DPR
cleaner manually and recheck the differential
pressure. Make sure it is within the standard
value and deliver the vehicle.

Perform soot cleaning to the DPR filter and then install it on the
vehicle.
Refer to "2. INSTALL THE DPR FILTER" on page EN04-42.
NOTICE
• After the installation, regenerate the DPR cleaner manually
and recheck the differential pressure. Make sure it is within
the standard value and deliver the vehicle.
• If the differential pressure is out of the standard value, per-
form ash cleaning.

.
 EXHAUST SYSTEM (J08E) EN04–49

LIST OF STANDARD VALUES FOR DIFFERENTIAL

PRESSURE INSPECTION
Engine no-load Differential pressure
Engine type
maximum revolution speed (r/min) (kPa {kgf/cm2, lbf/in.2})
J08E 2,800 5.0 {0.05, 0.7}

INSPECT INSIDE THE DPR FILTER.

HINT
This is for detecting abnormalities inside the DPR filter.

1. VISUALLY INSPECT THE FILER REAR SURFACE.

(1) Visually inspect the filter rear surface to detect soot escapes (black
part).
Standard value: No soot escape

Catalyst coated Oxidation

filter catalyst

DPR DOC

DOC SCR catalyst

Ammonia slip DEF SCR catalyst

catalyst

SAPH01Z080400074
.

NO
3. INSPECT THE DPR FILTER WITH THE DEDI-
CATED CHECK PROBE.
YES

2. VISUALLY INSPECT THE CASE EDGE.

.
EN04–50 EXHAUST SYSTEM (J08E)

2. VISUALLY INSPECT THE CASE EDGE.

(1) Visually inspect the case edge to detect soot escapes (black part).

Catalyst coated Oxidation

filter catalyst

DPR DOC

DOC SCR catalyst

Ammonia slip DEF SCR catalyst

catalyst

SAPH01Z080400075
Standard value: No soot escape
.

NO
3. INSPECT THE DPR FILTER WITH THE DEDI-
CATED CHECK PROBE.
YES

The DPR filter is normal.

.
 EXHAUST SYSTEM (J08E) EN04–51

3. INSPECT THE DPR FILTER WITH THE DEDICATED CHECK

PROBE.
(1) Insert the check probe from the rear surface to inspect the inside.
SST: FILTER GAGE ASSEMBLY (BOSCH part No. HDT650590)

! CAUTION
• DPR filter internal wall may be damaged if the check probe is sig-
nificantly bent or skewed. Repair or replace the check probe.
• Do not force the check probe into the DPR filter or push the
check probe past the DPR filter length, otherwise DPR filter may
be damaged.

Piano wire
0.8 mm {0.0315 in.}

280 mm {11.024 in.} Grip for depth check

Gas flow
Rear side

DOC DPR

Using the check probe the exhaust side of

the DPR filter in the locations specified by
the diagram. Deeply inspect around black
Filter spot if the DPR outlet filter is partially black.

SAPH01Z080400076
EN04–52 EXHAUST SYSTEM (J08E)

(2) Does the check probe reach the desired depth?

Unit: mm {in.}

Relevant models Standard value (Desired depth)

2008-2010MY
(HINO 145, 165, 185, 238, 258,
268, 308, 338) 237.5-250.5 {9.351-9.862}
2008-2018MY
(HINO 155, 195, 155h, 195h)

2011-2018MY
175.9-184.9 {6.926-7.279}
(HINO 238, 258, 268, 338, 358)

NO
Replace the DPR filter with a new one and
install it on the vehicle. At the same time, also
replace the PM sensor with a new one.
YES
Refer to "2. INSTALL THE DPR FILTER" on
page EN04-42.

DPR filter is normal, clean the tail pipe and then install it on the
vehicle.
Refer to "2. INSTALL THE DPR FILTER" on page EN04-42.

AIR CLEANING FLOW

(SOOT CLEANING)

SOOT SUCTION

SOOT AIR BLOW

DISPOSE OF THE WASTE AND THE POWDER AS INDUSTRIAL WASTES.

SAPH01Z080400077
 EXHAUST SYSTEM (J08E) EN04–53

DIFFERENTIAL PRESSURE SENSOR

COMPONENT LOCATOR
EN01Z0804D100005

SAPH01Z080400078

1 Differential pressure sensor 3 Muffler unit

2 Hose

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

A 18-26 {183-265, 13-19}
EN04–54 EXHAUST SYSTEM (J08E)

DISMOUNTING AND MOUNTING

EN01Z0804H100004

REMOVAL OF THE DIFFERENTIAL PRESSURE SEN-

SOR

1. REMOVE THE HARNESS.

Differential
pressure sensor (1) Disconnect the connector attached to the differential pressure sensor.

Connector

SAPH01Z080400079

2. DISCONNECT THE HOSE.

Differential
pressure sensor (1) Remove the clamps and disconnect the hose from the differential
pressure sensor.
Clamp
NOTICE
Do not allow foreign objects to get into the differential pressure pipe
and hose.

Hose

SAPH01Z080400080

3. REMOVE THE DPR DIFFERENTIAL PRESSURE SENSOR.

Differential
pressure sensor (1) Remove the nut and the differential pressure sensor from the bracket.
Bracket

SAPH01Z080400081

INSPECTION AND REPAIR

EN01Z0804H100005

Items Content Action Travel distance

Hose for differential
Replacement Replacement 3 years
pressure sensor
 EXHAUST SYSTEM (J08E) EN04–55

UNIT CHECK

1. RESISTANCE CHECK
(1) Measure the resistance of the differential pressure sensor with a cir-
cuit tester. If the value exceeds the standard value, replace it.

Measurement item Standard value (k)

AB 15
BC 15
C

B
Differential
Pressure sensor A

SAPH01Z080400082

INSTALL THE DIFFERENTIAL PRESSURE SENSOR.

1. INSTALL THE DIFFERENTIAL PRESSURE SENSOR.

(1) Install the differential pressure sensor to the bracket with a nut.
Differential
pressure sensor Tightening Torque: 18-26 Nm {183-265 kgfcm, 13-19 lbfft}
Bracket

SAPH01Z080400083
EN04–56 EXHAUST SYSTEM (J08E)

2. CONNECT THE HOSE.

Differential
pressure sensor
(1) Install the hose to the differential pressure sensor with clamps (4 pcs).
NOTICE
Clamp
If the differential pressure sensor hose is inserted incorrectly, the
DPR will not operate properly.

Hose

SAPH01Z080400084

! CAUTION
• Insert the hoses certainly against the sensor body.
• Insert the hoses certainly against the pipe spool.

3. INSTALL THE HARNESS.

SAPH01Z080400085

(1) Connect the connector to the differential pressure sensor.

Differential
pressure sensor

Connector

SAPH01Z080400086
 EXHAUST SYSTEM (J08E) EN04–57

AFTERTREATMENT FUEL INJECTOR

COMPONENT LOCATOR
EN01Z0804D100006

C
D
11
x2

6 5
7
B 3
1 8

x3
2 x3 3
9
A
B 3 10
SAPH01Z080400087

1 Coolant pipe D 6 Nozzle clamp

2 Coolant pipe E 7 Aftertreatment fuel injector
3 Gasket * 8 O-ring *
4 Fuel feed pipe No.5 9 Holder
5 Fuel delivery 10 Stud Bolt
11 Aftertreatment fuel injection line pressure sensor
*: Nonreusable. Be sure to use new parts.

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

A 36 {367, 26.5} C 19.6 {200, 14.5}
B 24.5 {250, 18.1} D 28.5 {290, 21.0}
EN04–58 EXHAUST SYSTEM (J08E)

OVERHAUL
EN01Z0804H100006

REMOVING THE AFTERTREATMENT FUEL INJECTOR

! CAUTION
• Perform replacement after cooling to prevent burns. (Turn the
starter key to the "LOCK" position and leave it for more than 30
minutes to cool.)

1. DRAINING THE COOLANT

(1) Drain coolant from the drain cock of the radiator and the drain plug of
the oil cooler.

! WARNING
To avoid burns, do not remove the radiator cap when the engine and
the radiator are hot. Pressure causes the liquid and vapor to burst
forth

! CAUTION
Dispose the coolant in accordance with the specified procedures
(industrial waste disposal) or other environment-friendly practices.
SAPH01Z080400088
NOTICE
With the radiator cap removed, coolant can be drained faster.

2. DISCONNECTING THE HARNESS

(1) Disconnect the connector from the aftertreatment fuel injector.
! CAUTION
When disconnecting, do not apply excessive force to the connector
on the fuel addition valve side. The connector may be damaged.

Aftertreatment fuel injector

SAPH01Z080400089

3. DISCONNECTING PIPES
Fuel feed pipe No. 5 (1) Unfasten the union bolt to remove the fuel feed pipe No.5 and gaskets
(2 pcs.) from the fuel delivery.
NOTICE
Prepare the reservoir and waste to collect dripping fuel when discon-
necting the pipe.

Fuel
delivery

SAPH01Z080400090
 EXHAUST SYSTEM (J08E) EN04–59

(2) Remove the nut and then the clip.

Turbocharger Oil
assembly cooler (3) Unfasten the union bolts (2 pcs.) to remove the coolant pipe D and
assembly gaskets (4 pcs.) from the holder and turbocharger assembly.
Coolant ! CAUTION
pipe D
Pay attention to weight balance.
NOTICE
Prepare the reservoir and clean clothes to collect dripping coolant
when disconnecting the pipe.
Coolant
Holder pipe E (4) Unfasten the union bolts (2 pcs.) to remove the coolant pipe E and
SAPH01Z080400091
gaskets (4 pcs.) from the holder and oil cooler assembly.
NOTICE
Prepare the reservoir and clean clothes to collect dripping coolant
when disconnecting the pipe.
EN04–60 EXHAUST SYSTEM (J08E)

4. REMOVING THE AFTERTREATMENT FUEL INJECTOR

(1) Unfasten the bolts (2 pcs.) to remove the fuel delivery from the holder.
Fuel
delivery
! CAUTION
• Do not allow the O-ring on the aftertreatment fuel injector to
come off. If it came off, mount the O-ring following "How to
mount the aftertreatment fuel injector O-ring".
• If it did not come off, it can be reused.

Holder
SAPH01Z080400092

(2) Unfasten the bolt to remove the nozzle clamp from the holder.

Nozzle
clamp

Holder

SAPH01Z080400093

(3) Remove the aftertreatment fuel injector, O-ring, and gasket from the
Aftertreatment holder.
fuel injector
! CAUTION
O-ring When overhauling a aftertreatment fuel injector, not to damage an
Gasket
electrical connector part, hang finger on a connector area, push, or
work not to apply excessive power.

Holder

SAPH01Z080400094

(4) Unfasten the nuts (3 pcs.) to remove the holder and gasket from the
exhaust pipe No.1 (ATC).
Exhaust pipe No.1 (ATC)

Holder

Gasket
SAPH01Z080400095
 EXHAUST SYSTEM (J08E) EN04–61

HOW TO MOUNT THE AFTERTREATMENT FUEL INJEC-

TOR

1. CAUTIONS
(1) Replace with a new O-ring, backup ring, and E-ring and mount them
E-ring
as shown in the figure.

Backup ! CAUTION
ring No.3
• Mount the backup ring No.1 and No.2 paying attention to their
O-ring directions.
Backup • Mount the backup ring and O-ring in the right order.
ring No.2

Backup
ring No.1

SAPH01Z080400096

• Check the backup ring closed gap for overriding and gaping as
Backup ring closed gap shown in the figure.

No good Good No good

Overriding Gaping

SAPH01Z080400097

2. CHECKING AFTER MOUNTING

(1) After mounting the O-ring, backup ring, and E-ring to the
Good No good No good aftertreatment fuel injector, check the seal for damage, collapse, and
protrusion from the seal groove.

! CAUTION
Check the O-ring groove of the aftertreatment fuel injector for foreign
matter or damage.

Correction Collapse
failure
SAPH01Z080400098
EN04–62 EXHAUST SYSTEM (J08E)

SINGLE UNIT INSPECTION

1. INSULATION RESISTANCE TEST

(1) Using the 500 V megohmmeter, measure the insulation resistance
between the aftertreatment fuel injector upper body and connector
(part side). Replace if the measurement reading exceeds the stan-
dard value.

Megohmmeter Standard value 10M or more

(Room temperature) (Using the 500 V megohmmeter)

! CAUTION
Never measure between the terminals, or the aftertreatment fuel injec-
tor will be damaged.
SAPH01Z080400099

2. RESISTANCE TEST BETWEEN TERMINALS

(1) Using the circuit tester, measure the resistance between the
aftertreatment fuel injector terminals. Replace if the measurement
reading exceeds the standard value.

Standard value
7.1-7.9
(20C {68F})

SAPH01Z080400100
 EXHAUST SYSTEM (J08E) EN04–63

CLEANING CARBON

1. CLEANING CARBON
! CAUTION
• The carbon cleaner is alkali. Wear protective equipment (glasses,
rubber gloves, and protective garment) to prevent it from con-
tacting eyes, skin, and clothes.
If it should contact the skin, wash it off with running water imme-
diately. If it should get into eyes, rinse thoroughly with running
water and consult a physician.
• Do not allow the carbon cleaner to adhere to the resin parts, ter-
minals, and O-ring of the aftertreatment fuel injector. If adhered,
immediately wipe it off.
(1) Spray the carbon cleaner to the aftertreatment fuel injector nozzle
hole.
Aftertreatment fuel injector
SST: Carbon cleaner (S0826-E3065)

! CAUTION
• Do not touch the nozzle hole with hands or wipe it with a waste.
• Do not apply excessive force or weight to the connector to avoid
the risk of breakage.

Nozzle hole (2) Leave it for a while until carbon is dissolved and then blow it off by
an air blower.
SAPH01Z080400101

(3) Similarly, remove the carbon deposited inside the holder by air
blowing after spraying the carbon cleaner.
Holder

SAPH01Z080400102
EN04–64 EXHAUST SYSTEM (J08E)

MOUNTING THE AFTERTREATMENT FUEL INJECTOR

! CAUTION
• While working, do not allow dirt and water to enter the parts.
• Before mounting parts, make sure that there is no dirt on the
connection between them.
• Air enters the fuel pipe in the process of mounting the pre fuel fil-
ter case. After mounting is completed, thoroughly purge air from
the fuel pipe.

1. MOUNTING THE AFTERTREATMENT FUEL INJECTOR

Exhaust pipe No.1 (ATC) NOTICE

• Never reuse the gasket or O-ring as it may cause engine damage.
Holder (1) Replace with a gasket and mount the holder to the exhaust pipe No.1
(ATC) with nuts (3 pcs.).
Tightening Torque:
36 Nm {367 kgfcm, 26.5 lbfft}

Gasket
SAPH01Z080400103

(2) Replace with a O-ring and gasket and mount the aftertreatment fuel
Aftertreatment injector to the holder.
fuel injector
! CAUTION
O-ring • Apply engine oil to the O-ring. Use care not to get the O-ring
Gasket jammed when inserting.
• Do not apply excessive force or weight to the connector to avoid
the risk of breakage.
• Check the O-ring seal for dirt before mounting.
Holder
• Take care not to damage or bend the nozzle head part when
SAPH01Z080400104
installing the aftertreatment fuel injector into the holder.
 EXHAUST SYSTEM (J08E) EN04–65

(3) Mount the nozzle clamp to the holder with the bolt.
Tightening Torque:
28.5 Nm {290 kgfcm, 21.0 lbfft}

Nozzle
clamp

Holder

SAPH01Z080400105

! CAUTION
• When mounting the nozzle clamp to the holder, align the nozzle
clamp with the aftertreatment fuel injector groove.
• If the nozzle clamp is mounted without aligning with the
aftertreatment fuel injector, it cannot be reused.

Correct Incorrect
SAPH01Z080400106

(4) Mount the fuel delivery to the holder with the bolts (2 pcs.).

Fuel Tightening Torque:

delivery 28.5 Nm {290 kgfcm, 21.0 lbfft}
! CAUTION
• Apply engine oil to the O-ring. Use care not to get the O-ring
jammed when inserting the fuel delivery.
• Check the O-ring seal for dirt before mounting.

Holder
SAPH01Z080400107

2. CONNECTING PIPES
Turbocharger Oil
assembly cooler (1) Replace with gaskets (4 pcs.) and connect the coolant pipe E to the
assembly holder and oil cooler assembly with union bolts (2 pcs.).
Coolant Tightening Torque:
pipe D 24.5 Nm {250 kgfcm, 18.1 lbfft}
(2) Replace with gaskets (4 pcs.) and connect the coolant pipe D to the
holder and turbocharger assembly with union bolts (2 pcs.).
Tightening Torque:
24.5 Nm {250 kgfcm, 18.1 lbfft}
Coolant (3) Mount the clip with the nut and secure the coolant pipe D and
Holder pipe E coolant pipe E.
SAPH01Z080400108
EN04–66 EXHAUST SYSTEM (J08E)

(4) Replace with 2 new gaskets and connect the fuel feed pipe No.5 to
Fuel feed pipe No. 5 the fuel delivery with the union bolt.
Tightening Torque:
19.6 Nm {200 kgfcm, 14.5 lbfft}

Fuel
delivery

SAPH01Z080400109

3. CONNECTING THE HARNESS

(1) Connect the connector to the aftertreatment fuel injector.

! CAUTION
• Before inserting the connector, check that there are no spark
traces on the terminals.
• When connecting, do not apply excessive force to the connector
on the aftertreatment fuel injector side. The connector may be
damaged.

Aftertreatment fuel injector

SAPH01Z080400110

4. ADDING THE COOLANT

(1) Tighten the drain cock of the radiator and the drain plug of the oil
cooler.
(2) Remove the radiator cap.
! CAUTION
Improper or careless removal of the radiator cap may cause burns
from spewing hot water or vapor. Remove the cap after the coolant
temperature meter reads below the specified temperature.
(3) Top up with coolant to the inlet.

SAPH01Z080400111
! CAUTION
• A sudden injection prevents air in the cooling pipe system from
bleeding smoothly, resulting in a prolonged injection.
• If air blows back, once stop adding coolant and wait for a while
before resuming.
NOTICE
Bring pressure on the two radiator hoses for a few times with hands. If
the coolant level of the radiator inlet decreases, add coolant.
(4) Mount the radiator cap.
(5) Add the coolant into the reserve tank to FULL, and tighten the cap.
(6) Warm up the engine until the thermostat injection valve opens.
NOTICE
Bring pressure on the 2 radiator hoses for a few times during engine
warming up
(7) After stopping the engine, check the water level. If the water level has
decreased, add coolant by following steps (3) through (7). Repeat it
until the water level no longer lowers and bleed air in the radiator and
engine.
EXHAUST SYSTEM (J08E) EN04–67

! CAUTION
Entry of air causes overheat and coolant leakage from the coolant
pump.
NOTICE
Check that hot air flows out from the foot duct during engine racing.
(8) Add the coolant into the reserve tank to FULL, and tighten the cap.

5. AIR BLEEDING OF FUEL SYSTEM

Reference: FUEL SYSTEM (J08E), PRE FUEL FILTER , AIR
BLEEDING
(Page EN07-31)
EN04–68 EXHAUST SYSTEM (J08E)

EXHAUST CONTROL CYLINDER

SYSTEM CONFIGURATION
EN01Z0804D100007

Common rail ACT

power relay
12

10 2 11

SAPH01Z080400112

1 Exhaust brake switch 7 Butterfly valve

2 Vehicle control unit 8 Accelerator pedal
3 Solenoid valve 9 Accelerator sensor
4 Exhaust control cylinder (Exhaust brake) 10 Engine ECU
5 Air tank 11 Combination meter ECU
6 Exhaust pipe 12 Exhaust brake light
 EXHAUST SYSTEM (J08E) EN04–69

DPR INSPECTION CHECK SHEET

EN01Z0804D100008

HINT
After the inspection, enter check marks into the empty check boxes.

Step 1 2 3 4

Inspection
Fuel tank, Filter Air intake system parts Engine ECM VNT turbocharger
part

Inspection  Dirty or clogged fuel fil-  Air filter element dirty,  Most recent program  Following characteris-
items ter element clogged, etc. No.? tic at the time of inspec-
 Entry of foreign matter  Damage to air cleaner tion (Error within  5%)
or water into the fuel tank body or air intake stack
 Use of bad fuel  Damaged or bent air
hose
 Damaged inter cooler
body or hose

YES NO YES NO YES NO YES NO

Handling • Element replace- • Element replace- • Updating to the most • Replacement in

in case of ment ment recent software ver- case of bad following
"NO" judg- • Fuel sampling  • Inspection of body sion
ment Investigation and air intake stack (**).
*Sampling from the fuel • Replacement of
tank intercooler body or
hose

(**)As long as the injection quantity is normal at the time of exhaust control valve is operating, there is no problem.
EN04–70 EXHAUST SYSTEM (J08E)

EN01Z0804D100009

HINT
After the inspection, enter check marks into the empty check boxes.

5 6 7 8

EGR valve Supply pump, Injector Fuel injection quantity Manual regeneration

 Following characteristic at  Stability of the pump elec-  Injection quantity *To be performed with all
the time of inspection (Error trical current value auxiliary equipment load off.
.

1. At the time of idle

within  5%) *Standard = Refer to the sup-  Gas leakage at the time of
2. At the time of exhaust
ply pump inspection. regeneration
control valve is in oper-
 Injector correction value  Discharge of white or black
ation
*Guide value = "Correction smoke at the time of regener-
 Exhaust control valve
value for the correction injec- ation
operation (No clinging or air
tion quantity between cylin-  Exhaust gas temperature
leakage etc.?)
ders" at the time of idle at the time of regeneration
*At the time of exhaust con-
speed within  5 mm3/st *Peak temperature: 500 C or
trol valve opening adjust-
more (guide value)
ment, refer to the standard
 Regeneration time
value table shown blow left.
*Guide value: Approximately
*Confirm the injection quan-
20 min
tity at the time of exhaust
control valve is operating
when the exhaust tempera-
ture has stabilized.

YES NO YES NO YES NO YES NO

• Replacement in case of • Supply pump replace- Repair or replacement the White smoke means exces-
bad following ment when the inspec- exhaust control valve in case sively closed exhaust control
tion result is NG of problems with exhaust valve  Readjustment. Black
• Injector replacement control valve operation. smoke requires DPR filter
when the injector cor- (***) confirmation.  Replace if
rection value is not the rear part is black.
within  5 mm3/st • If the temperature rise
is bad although injec-
tor, VNT, and EGR all
are OK, inspect the
temperature sensor and
the front of the DPR. 
Clean if the front is
clogged.

(***) Caution items before inspection of the fuel injection quantity

1. Connect the HINO DX Ⅱ and perform warm-up until the engine temperature becomes 82C {180F} or higher.
2. Set the gear to neutral and pull the parking brake lever sufficiently.
3. Switch off the air conditioner and the headlights.
4. Confirm that charging of the air compressor has been completed.
5. Switch off all other auxiliary equipment loads. (Refrigeration compressor, PTO, etc.)
 EXHAUST SYSTEM (J08E) EN04–71

Injection quantity and engine speed standard value table (value with all auxiliary equipment
loads off)
Speed (r/min) 750
Idling (normal)
Injection quantity (q) 7 - 16
At the time of manual regeneration
Speed (r/min) 980
(guide value)
Speed (r/min) 2,800
Backpressure standard
Backpressure (kPa {kgf/cm2, lbf/in.2} 5.0 {0.05, 0.7}
EN04–72 EXHAUST SYSTEM (J08E)

EXHAUST GAS TEMPERATURE SENSOR 1

(ATC UPSTREAM) AND EXHAUST GAS TEMPERATURE
SENSOR 2 (ATC DOWNSTREAM)
COMPONENT LOCATOR
EN01Z0804D100010

1 A

2 A

SAPH01Z080400113

1 Exhaust gas temperature sensor 1 (ATC upstream) 2 Exhaust gas temperature sensor 2 (ATC down-
stream)

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

A 25-35 {255-357, 18.4-25.8}
 EXHAUST SYSTEM (J08E) EN04–73

OVERHAUL
EN01Z0804H100007

IMPORTANT POINTS DISMOUNTING

1. DISCONNECTING THE HARNESS

(1) Disconnect a connector from the exhaust gas temperature sensor 1
Exhaust gas temperature sensor 1 (ATC upstream) and exhaust gas temperature sensor 2 (ATC down-
(ATC upstrerm) stream).

2. REMOVING THE EXHAUST GAS TEMPERATURE SENSOR 1 (ATC

UPSTREAM) AND EXHAUST GAS TEMPERATURE SENSOR 2
(ATC DOWNSTREAM)
(1) Remove the exhaust gas temperature sensor 1 (ATC upstream) and
Exhaust gas exhaust gas temperature sensor 2 (ATC downstream) together with
temperature sensor 2 harness clamps from the exhaust pipe No.1 (ATC).
(ATC downstrerm)
SAPH01Z080400114

SINGLE UNIT INSPECTION

1. INSPECTING THE RESISTANCE

(1) Use water and a circuit tester to measure resistance between termi-
(Example) ATC upstream
temperature sensor
nals. Replace if a measurement reading exceeds the standard value.
Thermometer

B Temperature Standard value

A 20C {68F} 13.7-29.8k
50C {122F} 7.13-13.7k
A 80C {176F} 4.1-7.13k

Heat source B
SAPH01Z080400115

MOUNTING THE ATC UPSTREAM TEMPERATURE SEN-

SOR

1. INSULATION RESISTANCE TEST

(1) Using the 500 V megohmmeter, measure the insulation resistance
Exhaust gas temperature sensor 1
between the aftertreatment fuel injector upper body and connector
(ATC upstrerm)
(part side). Replace if the measurement reading exceeds the stan-
dard value.

Standard value 10M or more

(Room temperature) (Using the 500 V megohmmeter)

Exhaust gas
temperature sensor 2 ! CAUTION
(ATC downstrerm) Never measure between the terminals, or the aftertreatment fuel injec-
tor will be damaged.
SAPH01Z080400114
 LUBRICATING SYSTEM (J08E) EN05–1

LUBRICATING SYSTEM (J08E)

EN05

EN05-001

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

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

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

COMPONENT LOCATOR................................ EN05-4
OVERHAUL ..................................................... EN05-5
INSPECTION AND REPAIR ............................ EN05-6

OIL FILTER AND OIL COOLER ............... EN05-8

COMPONENT LOCATOR................................ EN05-8
SPECIAL TOOL ............................................... EN05-9
DISMOUNTING AND MOUNTING ................ EN05-10
INSPECTION AND REPAIR .......................... EN05-11
EN05–2 LUBRICATING SYSTEM (J08E)

LUBRICATING SYSTEM
DIAGRAM
EN0110605J100001

SHTS011060500001
 LUBRICATING SYSTEM (J08E) EN05–3

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

1 Oil pan 15 Piston
2 Oil strainer 16 Rocker arm shaft
3 Oil pump 17 Camshaft
4 Oil pump safety valve 18 Valve
1,648-1,746 {16.8-17.8, 239-253} 19 Rocker arm
5 Oil cooler and oil filter 20 Cross head
6 Oil cooler safety valve 21 Supply pump
352-432 {3.6-4.4, 52-62} 22 Air compressor
7 Oil filter (full flow) 23 Main idle gear
8 Oil filter (by-pass) 24 Cam idle gear
9 Pressure switch 25 Sub idle gear
10 Oil filter safety valve 26 Check valve
137-157 {1.3-1.6, 20-23} 147-205 {1.5-2.0, 21-29}
11 Regulator valve 27 Check valve for turbocharger
490-570 {5.0-5.8, 72-82} 28 Turbocharger
12 Main oil hole 29 Idle gear
13 Piston cooling jet A To oil pan
14 Crankshaft
EN05–4 LUBRICATING SYSTEM (J08E)

OIL PUMP AND OIL STRAINER

COMPONENT LOCATOR
EN0110605D100001

2
1 A
3

7
8

SHTS011060500002

1 Gasket 6 Safety valve

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

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

A 28.5 {291, 21} B 30 {306, 22}
 LUBRICATING SYSTEM (J08E) EN05–5

OVERHAUL
EN0110605H200001

IMPORTANT POINTS - ASSEMBLY

1. INSTALLING THE OIL PUMP.

(1) Apply oil to the pump case and bearings of the block (hatched area)
before installing the oil pump.
NOTICE
Not applying oil may cause oil suction failure at start-up, resulting in
seizure and abnormality.
9
(2) To prevent misalignment of the gasket, apply grease to the gasket
Application of oil matching face of the block. Then, place and fix the gasket.
(Hatched area)
NOTICE
SHTS011060500003
If you change with the gasket misaligned, the seal will be defective
and cause all the oil in the oil pump to flow out when the engine is
stopped. The defective seal may also result in an insufficient oil suc-
tion quantity in the initial rotation when restarting the engine and
cause seizure or abnormal wear.
(3) Tighten the oil pump mounting bolts provisionally in the order as
shown in the figure. Tighten them to the specified torque.
NOTICE
• Note that failure to observe the tightening order may result in
damage to the oil pump.
• After tightening, check that the gear can be turned easily by
hand.
EN05–6 LUBRICATING SYSTEM (J08E)

INSPECTION AND REPAIR

EN0110605H300001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Gear outside diameter 54 {2.126} — — Measure

Block side pump body

54 {2.126} — —
inside diameter

0.093-0.252
Tip clearance 0.30 {0.0118} Replace oil pump.
{0.0037-0.0099}

Gear width 43 {1.693} — — Measure

Block side pump body

43 {1.693} — —
inside depth

0.047-0.150
With gasket 0.15 {0.0059} Replace oil pump.
{0.0019-0.0059}
End play
Without -0.013-0.050
— —
gasket {-0.0005-0.0020}

Shaft out- Measure

side diame- 18 {0.709} — —
ter

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

0.040-0.099
Clearance — Replace oil pump.
{0.0016-0.0039}

Shaft out- Measure

side diame- 18 {0.709} — —
ter

Block hole
18 {0.709} — —
diameter

0.030-0.075
Clearance — Replace oil pump.
Driven {0.0012-0.0030}
gear
Gear bush-
ing inside 18 {0.709} — —
diameter

0.040-0.083 Replace driven gear

Clearance 0.15 {0.0059}
{0.0016-0.0033} or oil pump.
 LUBRICATING SYSTEM (J08E) EN05–7

Inspection item Standard Limit Remedy Inspection procedure

Measure

0.073-0.207
Gear backlash 0.30 {0.0118} Replace pump.
{0.0029-0.0082}
EN05–8 LUBRICATING SYSTEM (J08E)

OIL FILTER AND OIL COOLER

COMPONENT LOCATOR
EN0110605D100002

5 2
A 6
3 2

8
2
B

E 7 K
2

C
D
J
2 2

I F

H
11-M
9

10-L

SHTS011060500009
 LUBRICATING SYSTEM (J08E) EN05–9

1 Oil cooler with filter assembly 7 Oil filter safety valve

2 O-ring 8 Check valve
3 Oil cooler element 9 Oil cooler safety valve
4 Gasket 10 Oil filter element
5 Oil cooler case 11 Insert
6 Regulator valve

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

A 29.4-39.2 {300-400, 22-28} H 29.4-39.2 {300-400, 22-28}
B 24.5-34.3 {250-350, 19-25} I 19.6-29.4 {200-300, 15-21}
C 39.2-49 {400-500, 29-36} J 29.4-39.2 {300-400, 22-28}
D 19.6-29.4 {200-300, 15-21} K 19.6-29.4 {200-300, 15-21}
E 19.6-29.4 {200-300, 15-21} L 39.2-49 {400-500, 29-36}
F 24.5-34.3 {250-350, 19-25} M 98.1-117.7 {1,000-1,200, 72-87}
G 28.5 {291, 21}

SPECIAL TOOL
EN0110605K100001

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

Illustration Part number Tool name Remarks

S0950-31110 OIL FILTER WRENCH

EN05–10 LUBRICATING SYSTEM (J08E)

DISMOUNTING AND MOUNTING

EN0110605H200002

REPLACE ENGINE OIL FILTER

! WARNING
To avoid burns or serious injury, wait until the engine oil is completely
cooled down before starting to replace the filter. Engine oil could be
still very hot immediately after driving. To reduce risk of fire, be sure
to follow the instructions below.
• To avoid damaging the oil filter during installation, never twist
the filter gasket.
• Always use a new oil filter element during filter replacement.
• Wipe off any oil spilled on vehicle components.
• Never drive the vehicle with the filler cap and/or level gauge
removed.

IMPORTANT POINTS - DISMOUNTING

1. REMOVE THE OIL FILTER.

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

Drain plug

SHTS011060500011

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

SST: Oil filter wrench (S0950-31110)

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

SHTS011060500012

IMPORTANT POINT - MOUNTING

1. INSTALL THE OIL FILTER.

(1) Remove the dust on installation surface of oil cooler case side.
(2) Apply the engine oil to the O-ring on new oil filter.
(3) Install the oil filter by turning it lightly to the right by hand until it comes
in contact with the surface of the oil cooler. Then using the special
tool, tighten the oil filter about 270-360 (3/4-1 turn).
SST: Oil filter wrench (S0950-31110)

NOTICE
SHTS011060500013 • Do not reuse the O-ring.
• Attention to damage of O-ring to damage.
 LUBRICATING SYSTEM (J08E) EN05–11

2. INSTALL THE OIL COOLER AND OIL FILTER ASSEMBLY.

(1) Insert the O-ring into the O-ring groove of the oil cooler.
NOTICE
Face the flat area of the O-ring toward the oil cooler for installation.

(2) Apply liquid gasket to the oil cooler case and install it onto the cylinder
block, then tighten the bolt to the specified torque.
Tightening Torque:
28.5 Nm {291 kgfcm, 21 lbfft}

SHTS011060500014

INSPECTION AND REPAIR

EN0110605H300002

Inspection item Standard Limit Remedy Inspection procedure

Oil cooler air leakage Air Visual check

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

1. Damage to sliding
Wear or damage to valve
Replace, if neces- face of valve
spring of oil cooler and — —
sary. 2. Valve movement
oil filter
(smoothness)
 COOLING SYSTEM (J08E) EN06–1

COOLING SYSTEM (J08E)

EN06

EN06-001

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

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

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

COMPONENT LOCATOR................................ EN06-3

THERMOSTAT .......................................... EN06-4

COMPONENT LOCATOR................................ EN06-4
OVERHAUL ..................................................... EN06-5

RADIATOR AND INTERCOOLER ............ EN06-7

COMPONENT LOCATOR................................ EN06-7
OVERHAUL ..................................................... EN06-7

RADIATOR ................................................ EN06-9

COMPONENT LOCATOR................................ EN06-9
SPECIAL TOOL ............................................. EN06-10
OVERHAUL ................................................... EN06-10
INSPECTION AND REPAIR .......................... EN06-14

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

COMPONENT LOCATOR.............................. EN06-15
INSPECTION AND REPAIR .......................... EN06-16
EN06–2 COOLING SYSTEM (J08E)

COOLING SYSTEM
DIAGRAM
EN01Z0806J100001

2 11

5 17
4
3 6
12
8 7
16

13
15

10
14
For cooling
engine

For cooling 15
Auxiliary units

Air bleeding 9

SAPH01Z080600001

1 Reservoir tank 10 Coolant pump

2 Radiator cap 11 EGR cooler
3 Radiator 12 Cylinder head
4 Coolant temperature gauge 13 Cylinder block
5 Thermostat case cover (Outlet) 14 Oil cooler
6 Thermostat case 15 Drain plug
7 Thermostat 16 Turbocharger
8 Thermostat case cover (Inlet) 17 Car heater
9 Air compressor
 COOLING SYSTEM (J08E) EN06–3

COOLANT PUMP
COMPONENT LOCATOR
EN01Z0806D100001

SAPH01Z080600002

1 Coolant pump assembly 3 O-ring

2 Pulley
EN06–4 COOLING SYSTEM (J08E)

THERMOSTAT
COMPONENT LOCATOR
EN01Z0806D100002

3
5
4

SAPH01Z080600003

1 Thermostat case 4 Water inlet

2 Water outlet 5 O-ring
3 Thermostat
 COOLING SYSTEM (J08E) EN06–5

OVERHAUL
EN01Z0806H200001

IMPORTANT POINTS - INSPECTION AND REPAIR

1. INSPECT THE THERMOSTAT FUNCTION.

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

SAPH01Z080600004 NOTICE
Check that the thermostat valve opening temperature (T1) is engraved
on the thermostat seat.

Thermostat valve lift:

Thermostat valve
Measuring temp. (T2) Valve lift (L2-L1)
opening temp. (T1)
13 mm {0.512 in.} or
82C {180F} 95C {203F}
more

(2) Immerse the opened thermostat in water at normal temperature. If it

completely closes within 5 minutes, it is satisfactory. If it remains
slightly open, it is defective and must be replaced.

SAPH01Z080600005

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE THERMOSTAT CASE.

NOTICE
Jiggle valve • Remove water or dirt adhering to the thermostat case.
• Be sure to replace the gasket if it is corroded, damaged or flat-
tened.
• Before installing the hose, apply liquid gasket to the hose instal-
lation part of the thermostat case cover.
• To prevent clogging of the radiator, do not use a large amount of
liquid gasket.
• Be sure that the jiggle valve faces upward when installing it.
SAPH01Z080600006
EN06–6 COOLING SYSTEM (J08E)

IMPORTANT POINTS - MOUNTING

1. INSTALL THE THERMOSTAT CASE ASSEMBLY.

(1) Apply liquid gasket to the thermostat case.
Liquid gasket (2) Install the o-ring into the groove of the coolant pump.

SAPH01Z080600007

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

"2" (4) Tighten the bolts in numeral order.

"1"

SAPH01Z080600008
 COOLING SYSTEM (J08E) EN06–7

RADIATOR AND INTERCOOLER

COMPONENT LOCATOR
EN01Z0806D100003

6
2
4
3

5
9

SAPH01Z080600009

1 Radiator 6 Inter cooler

2 Inlet hose 7 Radiator stay, RH
3 Reservoir tank 8 Radiator stay, LH
4 Hose 9 Baffle plate
5 Outlet hose

OVERHAUL
EN01Z0806H200002

IMPORTANT POINTS - DISMOUNTING

1. DISMOUNT THE RADIATOR.

! WARNING
Do not drain the coolant while the engine and radiator are still hot to
avoid burns and scalds.
NOTICE
When dismounting and mounting the radiator, do not damage the
radiator core.
EN06–8 COOLING SYSTEM (J08E)

IMPORTANT POINTS - MOUNTING

1. INSTALL THE RADIATOR INLET HOSE.

NOTICE
• Install the radiator hose against the convex portion of the radia-
tor.
• Match the red mark of the radiator hose and match mark (convex
portion) of the radiator.

SAPH01Z080600010

2. INSTALL THE RADIATOR OUTLET HOSE.

NOTICE
• Install the radiator hose against the convex portion of the radia-
tor.
• Match the red mark of the radiator hose and match mark (convex
portion) of the radiator.

SAPH01Z080600011
 COOLING SYSTEM (J08E) EN06–9

RADIATOR
COMPONENT LOCATOR
EN01Z0806D100004

4 6,7 9

SAPH01Z080600012

1 Radiator assy 6 Sensor

2 Intercooler assy 7 Packing
3 Fan shroud 8 Drain plug
4 Radiator cap 9 Seal
5 Bracket
EN06–10 COOLING SYSTEM (J08E)

SPECIAL TOOL
EN01Z0806K100001

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

Illustration Part number Tool name Remarks

S0976-01030 RADIATOR TOOL TOOL FOR UNCAULKING

TOOL FOR CAULKING

S0976-01040 RADIATOR TOOL
(USED WITH S0976-01030)

OVERHAUL
EN01Z0806H200003

IMPORTANT POINTS - DISMOUNTING

1. DISMOUNT THE RADIATOR.

! WARNING
Do not drain the coolant while the engine and radiator are still hot to
avoid burns and scalds.
NOTICE
When dismounting and mounting the radiator, do not damage the
radiator core.

IMPORTANT POINTS - DISASSEMBLY

NOTICE
Re caulking should be limited to twice.

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

TOR CORE.
(1) Remove the left support and right support.

Right support

SAPH01Z080600015
 COOLING SYSTEM (J08E) EN06–11

(2) Grip the handle until it hits to the stopper bolt, then adjust the dimen-
sions 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 claw.

SAPH01Z080600016

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

NOTICE
Do not lift up tangs more than 90.

SAPH01Z080600017

(4) Remove the upper tank and lower tank from the radiator core by tap-
ping lightly with plastic hammer.
NOTICE
Do not remove the tank by forcing or prying.

SAPH01Z080600018

IMPORTANT POINTS - ASSEMBLY

1. ASSEMBLE THE UPPER TANK, LOWER TANK AND RADIATOR

CORE.
(1) Exchange the crow of the radiator tool (S0976-01030) for the radiator
tool (S0976-01040) as shown in the figure.
SST:
Radiator tool (S0976-01030)
Radiator tool (S0976-01040)

SAPH01Z080600019
EN06–12 COOLING SYSTEM (J08E)

(2) Grip the handle of the radiator tool until it hits the stopper bolt, then
adjust the dimension B with stopper bolt.
Dimension B: 9.5mm {0.374 in.}

SAPH01Z080600020

(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 cleaning,
lightly rub the inside portion of the groove with the emery paper.
(4) Install the upper tank and lower tank into the groove of the radiator
core.

SAPH01Z080600021

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

SAPH01Z080600022

(6) Press the radiator tool (caulking tool) against the side portion. Tempo-
rarily 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.

SAPH01Z080600023
 COOLING SYSTEM (J08E) EN06–13

NOTICE
Perform the caulking according to the sequence as shown in the fig-
ure.

SAPH01Z080600024

(7) Check the dimension C.

Assembly standard: 8.2-8.8 mm {0.323-0.346 in.}
If the dimension is out of the standard value, adjust the stopper bolt of
the handle once again and perform the caulking again.

SAPH01Z080600025
EN06–14 COOLING SYSTEM (J08E)

INSPECTION AND REPAIR

EN01Z0806H300001

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

Inspection item Standard Limit Remedy Inspection procedure

Air leakage (When the air Visual check

pressure of 100 {1,14} is — — Replace radiator.
applied.)

Clogging of the fins — — Clean.

Radiator cap Measure

valve open-
ing pressure
40-58
Mark 0.5 — Replace.
{0.4-0.6, 5.7-8.5}

Intercooler
• Air leakage test
(when the air pressure 0 mL — Replace the inter-
of 196 {2.0, 28} 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 pres-
sure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system, which may
cause the hose to drop off or burst and may result in the damage of the engine.
• When carrying out high pressure washing to remove fin clogging, do not apply excessive pressure to the fins
which may cause deformation and consequent performance deterioration.
 COOLING SYSTEM (J08E) EN06–15

COOLING FAN
COMPONENT LOCATOR
EN01Z0806D100005

5 1

SAPH01Z080600029

1 Cooling fan 4 Seal

2 Fan clutch 5 Bracket
3 Fan shroud
NOTICE
• Shock to the fan clutch and fan.
During maintenance and inspection, be careful not to drop or strike the fan clutch or fan itself. The resulting
damage may lower the performance of the fan. Also, note that the fan is made of plastic and may become dam-
aged or deformed if force is applied to it.
• Replace the fan.
Do not replace the fan unless it is faulty. When replacing the fan, replace with the same type. If the fan is
replaced with one of a larger capacity because of overheating or, conversely is replaced with one of a smaller
capacity due to overcooling, the performance may in fact be reduced and durability may be jeopardized.
• Other items
Check the bimetal to see if there is any mud or dust on it. If the bimetal is covered with mud or dust, the fan per-
formance will be erratic, and may result in overheating or overcooling. In such case, carefully remove mud and
dust adhering to the surface of the bimetal, using a wire brush, or the like.
Take particular care not to apply excessive force.
Do not paint the fan or fan clutch. Do not place any paint or other reagents which are likely to dissolve plastic in
contact with the fan.
EN06–16 COOLING SYSTEM (J08E)

INSPECTION AND REPAIR

EN01Z0806H300002

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Cooling fan and fan clutch Replace if neces-

— —
deformation and damage sary.
 FUEL SYSTEM (J08E) EN07–1

FUEL SYSTEM (J08E)

EN07

EN07-001

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

DIAGRAM ........................................................ EN07-2
COMPONENT LOCATOR................................ EN07-3

SUPPLY PUMP ......................................... EN07-4

DESCRIPTION ................................................ EN07-4
COMPONENT LOCATOR................................ EN07-5
SPECIAL TOOL ............................................... EN07-5
OVERHAUL ..................................................... EN07-6

COMMON RAIL....................................... EN07-15

DESCRIPTION .............................................. EN07-15
INSPECTION ................................................. EN07-16
REPLACEMENT ............................................ EN07-17

INJECTOR............................................... EN07-21
DESCRIPTION .............................................. EN07-21
REPLACEMENT ............................................ EN07-22

PRE FUEL FILTER.................................. EN07-30

DESCRIPTION .............................................. EN07-30
AIR BLEEDING.............................................. EN07-31

FUEL FILTER .......................................... EN07-33

DESCRIPTION .............................................. EN07-33
OVERHAUL ................................................... EN07-34

FUEL TANK............................................. EN07-37

COMPONENT LOCATOR.............................. EN07-37

FUEL CUTOFF VALVE ........................... EN07-39

COMPONENT LOCATOR.............................. EN07-39
OVERHAUL ................................................... EN07-40
EN07–2 FUEL SYSTEM (J08E)

FUEL SYSTEM
DIAGRAM
EN01Z0807J100001

4 3 2

11

5
9
10

8
12 7

SAPH01Z080700001

1 Injector 7 Pre fuel filter

2 Injection pipe 8 Fuel tank
3 Common rail 9 Through feed pipe
4 Pressure feeding pipe 10 Overflow pipe
5 Pressure limiter 11 Leakage pipe
6 Supply pump 12 Fuel filter
 FUEL SYSTEM (J08E) EN07–3

COMPONENT LOCATOR
EN01Z0807C100001

B
1

f
Y
2
e
f

Z e e

SAPH01Z080700002

1 Injector 3 Common rail

2 Supply pump 4 Fuel filter

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

A 13.5 {138, 10} C 25 {250, 18}
B 44 {450, 32.5}
EN07–4 FUEL SYSTEM (J08E)

SUPPLY PUMP
DESCRIPTION
EN01Z0807J100002

SAPH01Z080700003

1 Supply pump assembly

 FUEL SYSTEM (J08E) EN07–5

COMPONENT LOCATOR
EN01Z0807C100002

5
C

3 A
4

SAPH01Z080700004

1 Supply pump assembly 5 Bracket

2 Bearing holder case 6 Coupling assembly
3 O-ring * 7 Plug
4 Coupling flange
*: Nonreusable. Be sure to use new parts.

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

A 63.7 {650, 47} C 28.5 {290, 21}
B 28.5 {290, 21}

SPECIAL TOOL
EN01Z0807K100001

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

Illustration Part number Tool name Remarks

SZ105-08067 GUIDE BOLT

EN07–6 FUEL SYSTEM (J08E)

OVERHAUL
EN01Z0807H200001

IMPORTANT POINTS - DISMOUNTING

! CAUTION
While working, be careful not to make dirt and water enter parts.

1. TURN THE STARTER SWITCH TO THE LOCK POSITION.

! WARNING
Perform the following work after the engine cools off to avoid fire or
burning. The fuel in the common rail could have a high temperature
(approx. 100C {212F}) immediately after driving.

SAPH01Z080700006

2. FUEL DISCHARGE
Air bleeder plug
(1) Prepare reservoir under the drain pipe to receive the drained fuel.

(2) Remove the drain plug of the fuel filter.

(3) Loosen the air bleeder plug of the fuel filter.
(4) Drain until no more fuel comes out.
(5) Tighten the drain plug and the air bleeder plug of the fuel filter.
Tightening Torque:
Drain plug: 5.9-7.9 Nm {60.2-80.5 kgfcm, 4.4-5.8 lbfft}
Air bleeder plug : 5-8.8 Nm {51-89.7 kgfcm, 3.7-6.5 lbfft}
Drain plug

SAPH01Z080700007 ! CAUTION
Drain the fuel in accordance with the regulation of disposal specified
in each region.

3. REMOVING THE FUEL FILTER

Reference:
FUEL SYSTEM, FUEL FILTER,
OVER HAUL, REMOVING THE FUEL FILTER
(Page EN07-36)

4. REMOVING THE INTAKE PIPE

(1) Remove the intake pipe.
Refer to the chapter "AIR INTAKE SYSTEM"

5. DISCONNECTING THE HARNESS

(1) Disconnect the connector connected to each of the suction control
Fuel temperature valve of the supply pump and the fuel temperature sensor.
sensor

Suction control
valve

SAPH01Z080700009
 FUEL SYSTEM (J08E) EN07–7

6. REMOVING THE FUEL PIPE

(1) Unfasten the nuts (3 pcs.) to remove the clips (3 pcs.).
(2) Unfasten the union bolts (3 pcs.) securing return pipe No.1 to the
pressure limiter, the inlet manifold, and the supply pump, and discon-
nect the return pipe No.1.
Return pipe No.1
NOTICE
Prepare a reservoir and a waste cloth because fuel spills when dis-
connecting the fuel pipe.
Supply pump

SAPH01Z080700010

7. REMOVING THE PRESSURE FEEDING PIPE

(1) Unfasten the nuts (2 pcs.) securing the clips, and remove the clips (2
pcs.).

Pressure (2) Loosen the nut, and remove the pressure feeding pipe.
feeding pipe NOTICE
Prepare a reservoir and a waste cloth because fuel spills when remov-
ing the pressure feeding pipe.

! CAUTION
• The pressure feeding pipes are nonreusable.
SAPH01Z080700011
• Be careful when numbering the pipe because the fuel pipe may
be deformed.

8. SETTING THE COMPRESSION STROKE TOP DEAD CENTER OF

No.1 CYLINDER
(1) Unfasten the bolts (2 pcs.) securing the flywheel housing cover, and
remove the flywheel housing cover from the flywheel housing.

Flywheel housing
cover

SAPH01Z080700012

(2) Turn the flywheel clockwise in the engine direction and align the No.1
cylinder mark to the pointer in the flywheel housing inspection open-
ing.
Flywheel

Flywheel
housing

SAPH01Z080700013
EN07–8 FUEL SYSTEM (J08E)

(3) Remove the timing check window plug from the bearing holder case
Bearing holder case of the supply pump.

Seated (4) Mount the special tool specified below to the timing check window of
the bearing holder case to see that the bearing surface of the special
tool is seated on the supply pump.
Special tool SST: Guide bolt (SZ105-08067)
! CAUTION
Not seated
• If the special tool is not seated, it is in contact with a part other
than the detent of the coupling flange. Do not forcibly tighten the
special tool.
SAPH01Z080700014 • If the special tool is not seated, the No.1 cylinder is not set at the
compression stroke top dead center. In this case, remove the
special tool, turn the crankshaft, and install the special tool
again to see if it is seated.
• Before turning the crankshaft, do not fail to pull out the special
tool.
• Do not perform cranking with the special tool inserted.

9. REMOVING THE SUPPLY PUMP

Do not remove ! CAUTION

pipe A. • While working, be careful not to make dirt and water enter parts.
• Do not remove pipe A and pipe B.
• Be careful not to apply excessive load on pipe A and pipe B.
(Pipe twist will cause fuel leakage.)
• Do not hold pipe A or pipe B when carrying the pump.
Do not remove
pipe B.

SAPH01Z080700015

Incorrect Incorrect Correct

Do not grip pipes and joint bolts when holding the supply pump Hold in your arms
SAPH01Z080700016
 FUEL SYSTEM (J08E) EN07–9

(1) Unfasten the bolts (4 pcs.) securing the supply pump, and remove the
Bearing holder case Coupling supply pump, the coupling, and the O-ring from the air compressor.
Bolt
! CAUTION
Remove the supply pump and the bearing holder case together.

Supply pump
O-ring
Air compressor
SAPH01Z080700017

(2) Unfasten the nut with the coupling flange locked with a vise, and
Bearing holder case remove the coupling flange.

Shaft

Nut

Coupling flange
SAPH01Z080700018

(3) Unfasten the bolts (3 pcs.) to remove the bearing holder case and the
Supply pump
O-ring from the supply pump.

O-ring

Bolt

Bearing holder
case
SAPH01Z080700019

INSPECTING THE COMPONENT PARTS

1. INSPECTING THE SUCTION CONTROL VALVE AND THE FUEL

Fuel temperature TEMPERATURE SENSOR
sensor (1) Using HINO DX Ⅱ , inspect the suction control valve and the fuel tem-
perature sensor. If some abnormalities are found, replace the supply
Suction control pump.
valve

SAPH01Z080700020
EN07–10 FUEL SYSTEM (J08E)

2. INSPECTING THE RESISTANCE OF THE SUCTION CONTROL

VALVE
Suction control valve (1) Using a circuit tester, measure the resistance between the terminals.
If the measured value is in excess of the standard value, replace the
supply pump.

Standard value
1.6-2.6 
(at a temperature of 20C {68F})

SAPH01Z080700021

3. INSPECTING THE RESISTANCE OF THE FUEL TEMPERATURE

Fuel temperature SENSOR
sensor (1) Using a circuit tester, measure the resistance between the terminals.
If the measured value is in excess of the standard value, replace the
supply pump.

Temperature 20C {68F} Resistance (k)

-20 {-4} 13.84 - 16.33
20 {68} 2.32 - 2.59
80 {176} 0.310 - 0.326
SAPH01Z080700022 110 {230} 0.1399 - 0.1435

NOTICE
If SCV and fuel temperature sensor need replacements, they should
be serviced by Denso Service Dealer.

MOUNTING THE SUPPLY PUMP

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Before mounting parts, make sure that there is no dirt on the
connection between them.
• Air enters the fuel pipe in the process of mounting the pre fuel fil-
ter case. After mounting is completed, thoroughly purge air from
the fuel pipe.

1. COMPRESSION UPPER DEAD CENTER SETTING OF NO.1 CYL-

INDER
(1) Turn the flywheel clockwise in the engine direction and align the No.1
Flywheel cylinder mark to the pointer in the flywheel housing inspection open-
ing.
NOTICE
1
• Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
Flywheel INTRODUCTION".
housing • Make sure that the No.1 cylinder is positioned at the top dead
center point of the compression stroke.

SAPH01Z080700023
 FUEL SYSTEM (J08E) EN07–11

2. ADJUSTING THE TOP OF THE AIR COMPRESSOR

(1) Align the cast mark on the air compressor with the "" mark put on
the front face of the coupling.
" " mark is put on
the front face of
the coupling.

Cast mark

SAPH01Z080700024

3. MOUNTING THE SUPPLY PUMP

Supply pump
(1) Replace the O-ring with a new one, and mount the bearing holder
case to the supply pump using the bolts (3 pcs.).
O-ring
Tightening Torque:
28.5 Nm {290 kgfcm, 21 lbfft}

Bolt

Bearing holder
case
SAPH01Z080700025

(2) Install the coupling flange to the shaft.

Bearing holder case (3) Fix the supply pump and tighten the nuts while preventing the cou-
pling flange from rotating using a vise.
Shaft Tightening Torque:
63.7 Nm {650 kgfcm, 47 lbfft}

Nut ! CAUTION
Do not use an special tool to lock the shaft.

Coupling flange
SAPH01Z080700026

(4) Insert the special tool specified below into the bearing holder case
Bearing holder case and bring it into close contact with the detent of the coupling flange.
SST: Guide bolt (SZ105-08067)
! CAUTION
• Do not tighten the special tool by applying it to a part other than
the detent of the coupling, or do not use a tool other than the
Special special tool for locking.
tool Coupling
flange • The special tool is not designed to allow its tip to come into con-
tact with the end of the detent hole. (The clearance at the tip is 2
Detent hole mm {0.079 in.}.)
SAPH01Z080700027
EN07–12 FUEL SYSTEM (J08E)

(5) Replace with a new O-ring, and mount the coupling and the supply
Bearing holder case Coupling
pump to the air compressor using the bolts (4 pcs.).
Bolt Tightening Torque:
28.5 Nm {290 kgfcm, 21 lbfft}

! CAUTION
Mount the coupling and the supply pump to the air compressor with
the No.1 cylinder set at the compression stroke top dead center and
Supply pump
the cast mark on the air compressor and the "" mark on the front
O-ring face of the coupling aligned with each other.
Air compressor
SAPH01Z080700028

(6) Make sure that the No.1 cylinder is set at the compression stroke top
Bearing holder case dead center, and then remove the special tool and mount the timing
checking window plug.

! CAUTION
• After all parts are assembled, do not fail to remove the special
tool and mount the timing checking window plug.
• Before turning the crankshaft, do not fail to pull out the special
Special
tool.
tool
• Do not perform cranking with the special tool inserted.

SAPH01Z080700029

(7) Mount the flywheel housing cover to the flywheel housing with the
bolts (2 pcs.).

Flywheel housing
cover

SAPH01Z080700030

4. MOUNTING THE PRESSURE FEEDING PIPE

(1) Mount the pressure feeding pipe.
Tightening torque:
Pressure (Supply pump side)
feeding pipe 44 Nm {450 kgfcm, 32.5 lbfft}
(Common rail side)
44 Nm {450 kgfcm, 32.5 lbfft}
! CAUTION
Always replace the pressure feeding pipe by a new one because the
pipe is subjected to high pressure; reusing the same pipe may result
SAPH01Z080700031
in a fuel leak.
(2) Mount the clips (2 pcs.) with the nuts (2 pcs.) and fix the pressure
feeding pipe.
 FUEL SYSTEM (J08E) EN07–13

5. MOUNTING THE FUEL PIPE

(1) Replace the gasket with a new one, and mount return pipe No.1 on
the supply pump, the inlet manifold, and the pressure limiter with the
union bolts (3 pcs.) that secured the return pipe.
Tightening torque:
Return pipe No.1
(Supply pump side)
7.9-12.7 Nm {80-129 kgfcm, 5.8-9.3 lbfft}
(Inlet manifold side)
Supply pump
30 Nm {305 kgfcm, 22 lbfft}
(Pressure limiter side)
20 Nm {205 kgfcm, 15 lbfft}
SAPH01Z080700032
NOTICE
• Do not use a power tool.
• For supply pump, use M10 x 1.0 union bolt (Banjo bolt) without
any engraved marking.
• For inlet manifold, use M14 x 1.5 union bolt (Banjo bolt) without
any engraved marking.
• For pressure limiter, use colored M10 x 1.0 union bolt (Banjo
bolt).
(2) Mount the clips (3 pcs.) with the nuts (3 pcs.) and fix the return pipe.

6. CONNECTING THE HARNESS

Fuel temperature (1) Connect the connector to the fuel temperature sensor and suction
sensor
control valve of the supply pump.

Suction control ! CAUTION

valve Before connecting the connectors, make sure that the terminals are
free of a spark mark.

SAPH01Z080700033
EN07–14 FUEL SYSTEM (J08E)

7. MOUNTING THE INTAKE PIPE

(1) Mount the intake pipe.
Refer to the chapter "AIR INTAKE SYSTEM"

8. MOUNTING THE FUEL FILTER

Reference:
FUEL SYSTEM, FUEL FILTER,
OVER HAUL, MOUNTING THE FUEL FILTER
(Page EN07-36)

9. AIR BLEEDING OF FUEL SYSTEM

(1) Air bleeding.
Refer to the chapter "AIR BLEEDING"

10. RESET THE ECU DEFAULT VALUE.

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.
• Diagnosis tool refer to chapter "TROUBLE SHOOTING" (S7-
UNAE13* or S7-CANE13*). ECU default value can be reset by
SAPH01Z080700034 "Difference learning after pump replacement" in the "Initial set-
ting/Initial learning" menu on HINO DX Ⅱ "Customization" func-
tion.

SAPH01Z080700035
 FUEL SYSTEM (J08E) EN07–15

COMMON RAIL
DESCRIPTION
EN01Z0807J100003

2 1

SAPH01Z080700036

1 Common rail 3 Pressure sensor *

2 Pressure limiter
*: Nonreusable. Be sure to use new parts.
EN07–16 FUEL SYSTEM (J08E)

INSPECTION
EN01Z0807J100004

INSPECTING THE COMMON RAIL

1. INSPECTING THE PRESSURE LIMITER

Stop the return (1) Unfasten the union bolt securing the pressure limiter.
pipe No.1 side with (2) Stop the return pipe No.1 side with a blank cap to prevent the outflow
a blank cap. of fuel.
! CAUTION
While working, be careful not to make dirt and water enter parts.

Pressure limiter
Union bolt

SAPH01Z080700037

(3) Mount the union to the pressure limiter, and connect a vinyl hose to
the end of the union.
Union (4) Place a fuel reservoir under the free end of the vinyl hose.
(5) Start the engine. If the fuel continuously flows out, replace the pres-
sure limiter with a common rail assembly.
! WARNING
Pressure When the pressure limiter is working, fuel flows out at a high tempera-
limiter
ture and pressure. Serious injury like scalding could result from this
Vinyl hose
hot fuel being blown out under pressure.
Reservoir
SAPH01Z080700038

2. INSPECTING THE COMMON RAIL PRESSURE SENSOR

3 2 1 (1) Using a circuit tester, measure the resistance between the terminals.
If the measured value is in excess of the standard value, replace the
common rail assembly.

Standard value (k)

Terminal to be measured At 20C {68F} with the
engine turned off
12
1.05-3.55
6 5 4 56
SAPH01Z080700039 23
6.7-18.7
45
 FUEL SYSTEM (J08E) EN07–17

REPLACEMENT
EN01Z0807H200002

REMOVING THE COMMON RAIL

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Clean off surrounding area of the nozzle and the fuel line con-
nectors.

1. DISCONNECTING THE HARNESS

(1) Disconnect the connector connected to the common rail pressure
sensor.

SAPH01Z080700040
! CAUTION
Pressing the spring lock of the female connector, disengage the
Common rail side Male connector
female connector from the male connector.

Harness
side

Female
connector
Spring lock
SAPH01Z080700041

2. DISCONNECTING THE FUEL PIPE

(1) Unfasten the union bolt securing return pipe No.1, and disconnect the
return pipe No.1 from the pressure limiter.
NOTICE
Prepare a reservoir and a waste cloth because fuel spills when dis-
connecting the fuel pipe.

3. REMOVING THE INJECTION PIPE

Pressure (1) Remove the injection pipe from the common rail.
limiter

SAPH01Z080700042
4. REMOVING THE PRESSURE FEEDING PIPE
(1) Remove the pressure feeding pipe from the common rail and the sup-
ply pump.
EN07–18 FUEL SYSTEM (J08E)

5. REMOVING THE COMMON RAIL

(1) Unfasten the bolts (2 pcs.) securing the common rail, and remove the
common rail and the bracket from the intake manifold.
Common rail
pressure sensor
! CAUTION
• Protect with clean vinyl to avoid entry of dirt into the common
rail.
Bracket
• Remove dirt from around each part, and detach the common rail.
• Remove the common rail together with, the common rail pres-
sure sensor, and the pressure limiter.
NOTICE
Prepare a reservoir and a waste cloth because fuel spills when remov-
ing the common rail.

Pressure limiter

Bolts

Common rail

SAPH01Z080700043

MOUNTING OF THE COMMON RAIL

1. INSTALL THE COMMON RAIL ASSY.

(1) Install the common rail with 2 bolts.
Tightening Torque:
28.5 Nm {290 kgfcm, 21 lbfft}

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Before mounting a part, check that there is no dirt on the con-
nection between the parts.
(2) Connect the connector.
SAPH01Z080700044
! CAUTION
Before inserting the connector, check that there are no spark traces
on the terminals.
NOTICE
• Be careful to prevent dust from entering inside the common rail
and parts when the mounting is performed. Dust and foreign
matter must not adhere to the seats of the parts and common rail
main unit.
• After mounting is completed, check fuel leak using "Activation
Test" menu of HINO DX Ⅱ .
 FUEL SYSTEM (J08E) EN07–19

(3) Tighten the injection pipe nuts to the specified torque.

Tightening Torque:
44 Nm {450 kgfcm, 32.5 lbfft}

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Before mounting a part, check that there is no dirt on the con-
nection between the parts.
• Air enters the fuel pipe while working. After working, be sure to
purge air.
SAPH01Z080700045

NOTICE
When installing the fuel injection pipe, do not make a mistake to
(1-6) assemble 2015 model fuel injection pipe.

After 2016 Model 2015 Model

After 2016 Model Fuel injection pipe
(J08E-VB, VC) (J08E-VB, VC)
(1-6)
No.1 injector 1D 1B

No.2 injector 2D 2B
2015 Model No.3 injector 3D 3B
SAPH01Z080700046

No.4 injector 4D 4B

No.5 injector 5D 5B

No.6 injector 6D 6B

(4) Fit the clips (5 pcs) and fix the injection pipe.

SAPH01Z080700047

(5) Tighten the pressure feeding pipe nuts to the specified torque.
Air compressor
(6) Fit the clips (2 pcs) and fix the pressure feeding pipe.
Tightening Torque:
44 Nm {450 kgfcm, 32.5 lbfft}

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Before mounting a part, check that there is no dirt on the con-
nection between the parts.
• Air enters the fuel pipe while working. After working, be sure to
SAPH01Z080700048
purge air.
EN07–20 FUEL SYSTEM (J08E)

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 negative influ-
ence on the engine function. As a result, always perform torque
management.
• After mounting is completed, check fuel leak by using "Fuel leak
inspection" function of HINO DX Ⅱ .
 FUEL SYSTEM (J08E) EN07–21

INJECTOR
DESCRIPTION
EN01Z0807C100003

1
2

SAPH01Z080700049

1 Return joint bolt 3 Injector assembly

2 Gasket
EN07–22 FUEL SYSTEM (J08E)

REPLACEMENT
EN01Z0807H200003

REMOVING THE INJECTOR

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Clean off surrounding area of the nozzle and the fuel line con-
nectors.

1. REMOVING THE HEAD COVER

(1) Remove the head cover.
Refer to the chapter "ENGINE MECHANICAL"

2. REMOVING THE LEAKAGE PIPE

Union bolts Union bolts
(1) Unfasten the union bolts (7 pcs.) to remove the leakage pipe and the
gaskets (7 pcs.).
! CAUTION
The leakage pipe can be twisted easily. Use care in handling.

Leakage pipe
SAPH01Z080700050

3. REMOVING THE INJECTOR HARNESS

(1) Disconnect each connector connected to the injector.
(2) Unfasten the nuts (7 pcs.) securing the injector harness, and remove
Connector the injector harness together with the injector harness bracket.
Injector
harness
! CAUTION
bracket
The injector harness bracket can be twisted easily. Use care in han-
Nut
dling.
Injector
harness

SAPH01Z080700051

NOTICE
Connector It is easy to disconnect the connectors by last disconnecting the one
connected to the camshaft housing.

Injector Camshaft
harness housing
SAPH01Z080700052
 FUEL SYSTEM (J08E) EN07–23

4. REMOVING THE INJECTION PIPE

(1) Unfasten the nuts (5 pcs.) securing the clips, and remove the clips.

SAPH01Z080700047

(2) Loosen the nuts securing the injection pipes (6 pcs.) to remove them
from the injector and the common rail.

! CAUTION
Do not reuse the injection pipes.
NOTICE
Prepare a reservoir and a waste cloth because fuel spills when remov-
ing the injection pipes.

SAPH01Z080700045

5. REMOVING THE INJECTOR

(1) Unfasten the bolts (2 pcs.) to remove the injection pipe oil seals (6
pcs.) and plates (6 pcs.) from the cylinder head.
Plate
Injection pipe
oil seal

Bolt

SAPH01Z080700053

(2) Unfasten the injector clamp mounting bolts to remove the injector and
Mounting Injector injector clamp.
bolt (3) Remove the O-ring.
NOTICE
Injector Replace the O-ring with new one.
clamp

O-ring

SAPH01Z080700054
EN07–24 FUEL SYSTEM (J08E)

INSPECTION

1. INSPECTING THE RESISTANCE

Megohmmeter (1) Using a 1,000V megohmmeter, measure the insulation resistance
between either of the 2 terminals (no polarity) to which the injector
Upper body harness is connected and the upper body of the injector.
! CAUTION
Never measure between the terminals, or the injector will be dam-
aged.

Standard value 10 M or more

(Normal temperature) (Use a 1,000V megohmmeter.)
SAPH01Z080700055

(2) Using a circuit tester, measure the resistance between terminals.

Standard value
0.37-0.57 
Upper body (at a temperature of 20C {68F})

(3) The resistance values of (1) and (2) exceed the standard value,
replace the injector.

SAPH01Z080700056

2. CLEANING THE INJECTOR 2

(1) Use clean clothes to remove sludge adhered to the terminal part and
its perimeter.
! CAUTION
• Use clean clothes to wipe off sludge without using any deter-
gent.
• Use of detergent causes it to penetrate, which may lead to elec-
tric failure.

3. CLEANING THE INSIDE OF THE NOZZLE SEAT

Cylinder head
(1) If sludge sticks to the inside of the nozzle seat, spray a detergent over
it, wipe it off with a waste cloth, and wash it out with the detergent.
NOTICE
Nozzle seat • If sludge sticks hard to the inside of the nozzle seat, remove it
with brush and a detergent.
• It is advisable to perform a contact check using red lead primer.
(2) Make sure that the inside of the nozzle seat is free of sludge or foreign
matters.

SAPH01Z080700057
 FUEL SYSTEM (J08E) EN07–25

MOUNTING THE INJECTOR

! CAUTION
• While working, be careful not to make dirt and water enter parts.
• Before mounting parts, make sure that there is no dirt on the
connection between them.
• Air enters the fuel pipe in the process of mounting the pre fuel fil-
ter case. After mounting is completed, thoroughly purge air from
the fuel pipe.

1. MOUNTING THE INJECTOR AND THE INJECTION PIPE

(1) Apply engine oil to a new O-ring and mount it to the injector. Then
Mounting bolt temporarily fit the injector clamp and injector at the same time.
Injector
Injection
! CAUTION
pipe
• Apply engine oil to the O-ring. Use care not to get the O-ring
jammed when inserting it.
• Note that if the O-ring is damaged, fuel will leak out and the
engine will fail to start to run.
Injector
• Do not fix the injector clamp until the injection pipe is fit tempo-
clamp
rarily.

Bolt
(2) Slip a new injection pipe oil seal on the injector, and mount the plate
with the bolts (2 pcs.) that secured it.
Plate
! CAUTION
Injection pipe Mount the injection pipe oil seal so that excessive force will not be
oil seal applied to the injection nozzle. (If the injection pipe oil seal and the
O-ring
injection nozzle are out of position, oil leakage or improper assembly
of the injection pipe will result.)

SAPH01Z080700058

(3) Temporarily mount new injection pipes (6 pcs.) on the injector and the
common rail.

! CAUTION
• Do not fail to replace the injection pipes with new ones because
they are subjected to high pressure and may cause fuel leakage.
• Fuel will leak out if the injection pipes are not properly con-
nected. Follow the procedure.
• Fuel leakage will cause damage to the engine.

SAPH01Z080700045
EN07–26 FUEL SYSTEM (J08E)

• Arrange the injector and the injection pipes in a straight line.

Injector Injection pipe
clamp

Injector
SAPH01Z080700059

NOTICE
Mount the injection pipes so that the flare tightening nuts of the injec-
tion pipes will be arranged in the order of the numbers engraved on
the nuts shown in the figure below.

Engraving: 1D

Engraving: 5D

Engraving: 2D
Engraving: 3D Engraving: 4D Engraving: 6D
SAPH01Z080700060
(4) Tighten the injector clamp mounting bolt.
Injector Tightening Torque:
Mounting
bolt
25 Nm {250 kgfcm, 18 lbfft}

! CAUTION
• Insufficient tightening will cause gas leakage, which will result in
the seizure of the nozzle.
Injector • Before reusing the injector clamp bolt, be sure to apply oil to its
clamp washer and thread.
• Use the torque wrench to tighten the bolt with the specified
torque.
SAPH01Z080700061

(5) Tighten the injection pipe to the specified torque.

Tightening Torque:
44 Nm {450 kgfcm, 32.5 lbfft}

SAPH01Z080700045
 FUEL SYSTEM (J08E) EN07–27

(6) Mount the clips with the nuts (5 pcs.), and fix the injection pipes.

SAPH01Z080700047

2. WRITING A INJECTOR COMPENSATION VALUE TO THE ENGINE

ECU (WRITING BY MEANS OF RE-PROGRAMMING)
QR code
! CAUTION
• If an injector is replaced, write an injector compensation value
(QR code) indicated on a new injector in the engine ECU.
• Writing an incorrect compensation value may cause engine trou-
bles.
Injector NOTICE
Injector compensation value can be written by means of a combined
use of the PC tool and QR code reader.
SAPH01Z080700062

(1) Read the QR code of the injector by using the scanner of the QR code
reader to create a compensation data file.
(2) Write the injector compensation value in the engine ECU from a com-
puter.

QR code Computer

QR code reader

Injector

Connector

Engine type code

QR code

New injector

Engine ECU

SAPH01Z080700063
EN07–28 FUEL SYSTEM (J08E)

3. MOUNTING THE INJECTOR HARNESS

(1) Mount the injector harness together with the injector bracket with the
Connector bolts (7 pcs.) that secured them.
Injector
harness
(2) Connect each connector of the injector harness.
bracket
Nut ! CAUTION
Before connecting the connectors, make sure that the terminals are
Injector free of a spark mark.
harness

SAPH01Z080700064

NOTICE
Connector It is easy to connect the connectors by first connecting the one to the
camshaft housing.

Injector Camshaft
harness housing
SAPH01Z080700065

4. MOUNTING THE LEAKAGE PIPE

Union bolts
Union bolts
(1) Remove dirt or foreign matters from the gasket mounting surface.
(2) Replace the gasket with a new one, and mount the leakage pipe on
the injector and the camshaft housing with the union bolts (7 pcs.) that
fastened them.
Tightening Torque:
13.5 Nm {138 kgfcm, 10 lbfft}

! CAUTION
Leakage pipe • Do not reuse the old gasket.
SAPH01Z080700066 • The leakage pipe can be twisted easily. Use care in handling.
• Note that the thread pitch is different between the union bolts (6
A : Injector (M8 1.0) pcs.) for the injector and the union bolt for the camshaft housing.
B : Camshaft housing (M8 1.25)

Leakage pipe
SAPH01Z080700067
 FUEL SYSTEM (J08E) EN07–29

• An "X" mark is put on the union bolt for the camshaft housing.

Camshaft housing
side union bolt
SAPH01Z080700068

5. MOUNTING THE HEAD COVER

(1) Mount the head cover.
Refer to the chapter "ENGINE MECHANICAL"

6. AIR BLEEDING OF FUEL SYSTEM

(1) Perform air bleeding.
Refer to the chapter "AIR BLEEDING"
EN07–30 FUEL SYSTEM (J08E)

PRE FUEL FILTER

DESCRIPTION
EN01Z0807J100005

4
5

2 10

1 11
8

9
12

13

14

SAPH01Z080700069

1 Body 8 Stud
2 Cover 9 Drain valve
3 Collar 10 Filter
4 Vent cap 11 Label
5 Spring 12 Heater
6 Fuel pipe (Out) 13 Water level sensor
7 Seal 14 Fuel pipe (in)
 FUEL SYSTEM (J08E) EN07–31

AIR BLEEDING
EN01Z0807H200004

1. AIR BLEEDING
(1) Remove the vent cap from the top of the cover by turning the vent cap
counterclockwise. Fill the cover full of clean fuel. Reinstall the cap and
tighten.
Vent cap
(2) Start the engine. When the lubrication system reaches its normal
operating pressure, increase engine speed to high for 2 to 3 minutes.
(3) After the air is purged, and the engine is running, loosen the vent cap.
Pre fuel When the fuel level fills to following position, quickly tighten the vent
filter cap. Tighten the vent cap until the vent cap run idle with click sounds.
Fuel level:
12.7-38 mm {0.5-1.5 in.} Above top of collar.
NOTICE
• Thoroughly wipe off any spilled fuel.
• Start the engine and check the fuel system for leaks.

! WARNING
• Always drain the fuel into a container and dispose of it properly.
Be careful not to spill any of the fuel.
• If fuel is spilled on engine parts, wipe it off entirely. It is danger-
ous since it can cause a fire which can result in serious personal
injury or death.
• Do not smoke when performing maintenance on the fuel system.
• Keep flame and heat away from the fuel system since the fuel is
SAPH01Z080700070 flammable and can cause a fire resulting in serious personal
injury or death.
• Any of these can result in personal injury and/or property dam-
age due to fire.
• Use the designated special tool and pre fuel filter wrench to
tighten the pre fuel filter. Use of an ordinary tool (for example,
chain-type tool) can scratch or dent the peripheral surface of the
pre fuel filter. If the pre fuel filter is damaged, it can cause fuel to
leak, thus resulting in a fire or other serious accidents and can
result in serious personal injury or death.
• After replacing the filter, inspect the external surface of the pre
fuel filter for checking scratches and dents. It is dangerous to
use a scratched or dented pre fuel filter, since it can cause fuel to
leak and lead to a fire or other serious accidents and can result
in serious personal injury or death.
• After replacement of the element, operate the engine for trial to
check to see if there is any fuel leakage around the pre fuel filter.
Fuel leakage can cause a fire and can result in serious personal
injury or death.
EN07–32 FUEL SYSTEM (J08E)

2. DRAIN WATER
(1) Connect specific tube to drain outlet.
To protect steering joint by draining liquids. Specific tube is available
at HINO dealer. (Part No. SZ950-61502)
Vent cap
(2) Loose the vent cap and after open drain valve.
(3) Collect water in to cup.
(4) Allow any water to drain out, then close the drain valve and vent cap.
(Drain minimum amount of fuel possible)

Drain
valve

SAPH01Z080700071
 FUEL SYSTEM (J08E) EN07–33

FUEL FILTER
DESCRIPTION
EN01Z0807J100006

1
A
4

SEC A-A (1 : 1)
A

10

8 6

9
SEC C-C (1 : 1)

SAPH01Z080700072

1 Body 6 Cartridge
2 Insert 7 Valve
3 Air bleeder plug 8 Spring
4 Pipe 9 Plug
5 Drain plug 10 O-ring
EN07–34 FUEL SYSTEM (J08E)

OVERHAUL
EN01Z0807H200005

REPLACING THE ELEMENT

NOTICE
• Take care that no dirt or water gets onto the components during
the work.
• When re-installing the parts, make sure that the contact surfaces
between the parts are free of dirt.
• As air enters the fuel piping during the work, air venting must be
performed after completion of the work.
• Use a genuine Hino fuel filter element.

1. FUEL DISCHARGE
(1) Place a container for receiving the discharged fuel under the drain
Fuel filter case plug.

Element

Drain plug
SAPH01Z080700073

(2) Remove the drain plug, loosen the air bleeder plug, and discharge the
Air bleeder fuel and water collected in the fuel filter.
plug NOTICE
If the fuel is to be disposed of, observe the local disposal regulations.

Air vent pipe

Fuel filter
SAPH01Z080700074

2. REMOVING THE ELEMENT

(1) Use the special tool to remove the element from the fuel filter case.
Fuel filter case SST: Filter wrench (S0955-31010)
NOTICE
• Confirm that the O-ring on the fuel filter case side has been
removed.
• Remove dirt from the mounting surface for the O-ring.
• Do not reuse an O-ring.
Element Reference: Prepare a container and a shop towel as fuel will spill
when the element is replaced.
Drain plug
SAPH01Z080700075
 FUEL SYSTEM (J08E) EN07–35

3. ELEMENT INSTALLATION
Fuel filter case (1) Remove dirt from the mounting surface for the element on the inside
of the fuel filter case.
(2) Install the new element after applying fuel to the surface of the O-ring,
and then tighten by hand until there is contact with the seal surface of
the fuel filter case.
NOTICE
Element • Do not reuse the element.
• Take care that the O-ring does not become twisted and damaged.
Drain plug
(3) Use the special tool and tighten the element for another 2/3 of a turn.
SAPH01Z080700076
SST: Filter wrench (S0955-31010)
NOTICE
• Take care that the O-ring does not become twisted and damaged.
• After completion of the work, wipe up any spilled water or fuel;
after starting the engine, confirm that there is no fuel leakage.

4. BLEEDING AIR FROM THE FUEL SYSTEM

Refer to chapter “AIR BLEEDING”
EN07–36 FUEL SYSTEM (J08E)

REMOVING THE FUEL FILTER

1. DISCONNECT THE FUEL PIPE

(1) Disconnect the 3 union bolts then disconnect the 5 gaskets and
Fuel pipe No.1 remove the No.4 fuel pipe and No.1 return pipe.
NOTICE
When the fuel hose is disconnected, as fuel falls, prepare the con-
tainer and rag.
Fuel pipe No.3 (2) Remove the fuel pipe No.2.
(3) Remove the fuel pipe No.3.
Fuel pipe No.2
2. REMOVE THE FUEL FILTER
Fuel filter (1) Remove 2 bolt and fuel filter assembly from the fuel filter bracket.
Supply pump
SAPH01Z080700077

MOUNTING THE FUEL FILTER

1. MOUNTING THE FUEL FILTER

(1) Mount 2 bolt and fuel filter assembly from the fuel filter bracket.
Fuel pipe No.1 Tightening Torque:
55 Nm {560 kgfcm, 41 lbfft}

2. CONNECTING THE FUEL PIPE

(1) Mount the fuel pipe No.3.
Fuel pipe No.3
Tightening Torque:
24.5 Nm {250 kgfcm, 18.1 lbfft}
Fuel pipe No.2
(2) Mount the fuel pipe No.2.
Supply pump Fuel filter Tightening Torque:
SAPH01Z080700078 24.5 Nm {250 kgfcm, 18.1 lbfft}

NOTICE
11 to 14 MY 15 to 17 MY
• Do not use a power tool.
• For fuel pipe No.1 and No.3, use M14 x 1.5 union bolt (Banjo bolt)
without any engraved marking.
• For fuel pipe No.2, use M14 x 1.0 union bolt (Banjo bolt) with
engraved “X” marking. (11 to 14 MY)
• For fuel pipe No.2, use M14 x 1.0 union bolt (Banjo bolt) with
engraved “O” marking. (15 to 17 MY)

Mark “X” engraved Mark “O” engraved

SAPH01Z080700079

(3) Mount the 3 union bolts then disconnect the 5 gaskets and remove
the No.4 fuel pipe and No.1 return pipe.
Tightening Torque:
24.5 Nm {250 kgfcm, 18.1 lbfft}

NOTICE
When the fuel hose is disconnected, as fuel falls, prepare the con-
tainer and rag.
 FUEL SYSTEM (J08E) EN07–37

FUEL TANK
COMPONENT LOCATOR
EN01Z0807J100007

8 UP
50GAL+50GAL

FR LH
5,6 C

9 A

1
B

UP UP
90GAL 50GAL

RH FR RH FR

LH.side LH.side

SAPH01Z080700080
EN07–38 FUEL SYSTEM (J08E)

1 Fuel tank 6 Gasket

2 Fuel tank band 7 Plug
3 Pin 8 Joint
4 Fuel tank support 9 Plate, fuel tank set
5 Fuel sender

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

A 91.2-136.8 {930-1,396, 67-100} C 0.5-0.7 {5-7, 0.362-0.506}
B 23-29 {234.5-296, 17-21.4}*
*: Nonreusable. Be sure to use new parts.
 FUEL SYSTEM (J08E) EN07–39

FUEL CUTOFF VALVE

COMPONENT LOCATOR
EN01Z0807J100008

A
1
A

2 2

B
x2

SAPH01Z080700081

1 Fuel feed pipe No.3 3 Fuel cutoff valve

2 Gasket * 4 Fuel feed pipe No.5
*: Nonreusable. Be sure to use new parts.

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

A 19.6 {200, 14.5} B 28.5 {290, 21.0}
EN07–40 FUEL SYSTEM (J08E)

OVERHAUL
EN01Z0807H200006

IMPORTANT POINT DISASSEMBLY

1. DISCONNECTING THE HARNESS

Connector Fuel cutoff valve
(1) Disconnect the connector from the fuel cutoff valve.
Fuel feed
pipe No.3 2. DISCONNECTING PIPES
(1) Unfasten the 2 union bolts to disconnect the fuel feed pipe No.3, fuel
feed pipe No.5, and 2 gaskets from the fuel cutoff valve.
NOTICE
Fuel feed
Prepare the reservoir and waste to collect dripping fuel when discon-
pipe No.5 necting the pipe.
Air pipe
bracket 3. REMOVING THE FUEL CUTOFF VALVE
SAPH01Z080700082 (1) Unfasten the bolts (2 pcs.) to remove the fuel cutoff valve from the air
pipe bracket.

IMPORTANT POINTS REPLACEMENT

1. CAUTIONS
! CAUTION
• While working, do not allow dirt and water to enter the parts.
• Before mounting parts, make sure that there is no dirt on the
connection between them.
• Air enters the fuel pipe in the process of mounting the pre fuel fil-
ter case. After mounting is completed, thoroughly purge air from
the fuel pipe.

2. MOUNTING THE FUEL CUTOFF VALVE

(1) Mount the fuel cutoff valve to the air pipe bracket with the bolts (2
pcs.).
Tightening Torque:
28.5 Nm {290 kgfcm, 21.0 lbfft}

3. CONNECTING PIPES
(1) Replace with 2 new gaskets and connect the fuel feed pipe No.3 and
fuel feed pipe No.5 to the fuel cutoff valve with 2 union bolts.
Tightening Torque:
19.6 Nm {200 kgfcm, 14.5 lbfft}

! CAUTION
Before mounting the parts, check the joints for dirt.

4. CONNECTING THE HARNESS

(1) Connect the connector to the fuel cutoff valve.

5. AIR BLEEDING OF FUEL SYSTEM

Reference: FUEL SYSTEM (J08E), PRE FUEL FILTER, AIR
BLEEDING
(Page 7-31)
 TURBOCHARGER (J08E) EN08–1

TURBOCHARGER (J08E)
EN08

EN08-001

TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
TROUBLESHOOTING ..................................... EN08-3
REPLACEMENT ............................................ EN08-12
INSPECTION AFTER MOUNTING................ EN08-18
EN08–2 TURBOCHARGER (J08E)

TURBOCHARGER
DESCRIPTION
EN0110608C100001

SAPH01Z080800001

1 Turbine housing 3 Center housing and rotating assy

2 Compressor housing 4 Actuator assembly
NOTICE
This turbocharger should not be disassembled unless by turbocharger manufacture. The turbocharger parts cannot
be replaced.
 TURBOCHARGER (J08E) EN08–3

TROUBLESHOOTING
EN0110608F300001

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

Possible causes and remedies

(See Notes A and H✩) (See Notes B and C✩) (See Notes D,F and G✩)
NO Loose compressor NO NO NO
Dirty air cleaner Leakage at engine Leakage at engine
to intake manifold
element intake manifold exhaust manifold
duct connections

YES YES YES YES

Tighten duct Refer to engine Refer to engine

Replace air cleaner
connections as manufacturer's manufacturer's
element
required service manual service manual

(See Notes D and F✩) (See Notes K✩) (See Notes H✩) (See Note H✩)
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

YES YES YES YES

Check condition of Perform

Remove restriction Remove restriction
gasket at troubleshooting
or replace or replace
turbocharger procedures
turbocharger as turbocharger as
mounting flange and outlined in table 1-
necessary necessary
tighten loose bolts 7

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.)

YES YES YES

Remove restriction
Refer to engine Refer to engine
or replace
manufacturer's manufacturer's
turbocharger as
service manual service manual
necessary

SAPH01Z080800002

✩ Shown on Table 1-9

EN08–4 TURBOCHARGER (J08E)

2. Table 1-2 Troubleshooting Engine Exhaust Emits WHITE or BLUE SMOKE

ENGINE EXHAUST
Symptom or trouble EMITS WHITE OR
BLUE SMOKE

Possible causes and remedies

(See Notes A and H✩) (See Notes B and C✩)

Dirty air cleaner Loose compressor Plugged engine oil

NO NO Leakage at engine NO NO
element to intake manifold filter
intake manifold
duct connections

YES YES YES YES

Service oil filter in

Replace air cleaner Tighten duct Refer to engine accordance with
element connections as manufacturer's engine
required service manual manufacturer's
service manual

(See Notes H✩)

Restricted duct be- Engine malfunction Seal leakage at

Seal leakage at
tween air cleaner NO NO (rings, pistons, NO turbine end of
compressor end of
and turbocharger valves, etc.) turbocharger
turbocharger
compressor

YES YES YES YES

Perform Perform
Remove restriction Refer to engine
troubleshooting troubleshooting
or replace damaged manufacturer's
procedures outlined procedures outlined
parts as necessary service manual
in Table 1-6 in Table 1-7

SAPH01Z080800003

✩ Shown on Table 1-9

 TURBOCHARGER (J08E) EN08–5

3. Table 1-3 Troubleshooting Engine Oil Consumption Excessive

ENGINE OIL
Symptom or trouble CONSUMPTION
EXCESSIVE

Possible causes and remedies

Seal leakage at Seal leakage at Oil in engine exhaust

Wrong type or vis- compressor end of turbine end of manifold (indicating
cosity of engine NO turbocharger (indicated NO turbocharger NO malfunction of
lubricating oil by oil in housing or on (indicated by oil in rings, pistons, valves,
wheel) housing or on wheel) etc.)

YES YES YES YES

Service engine lube

system in Perform
Perform troubleshoot- Refer to engine
accordance with troubleshooting
ing procedures out- manufacturer's
engine procedures outlined
lined in Table 1-6 service manual
manufacturer's in Table 1-9
service manual

SAPH01Z080800004
EN08–6 TURBOCHARGER (J08E)

4. Table 1-4 Troubleshooting Noisy Turbocharger

NOISY
Symptom or trouble TURBOCHARGER

Possible causes and remedies

(See Notes A and H✩) (See Notes H✩)
Foreign object or
Foreign object or
material in Foreign object in
Dirty air cleaner NO NO material in NO
compressor inlet engine exhaust
element compressor to intake
duct or system
manifold duct
compressor housing

YES YES YES YES

Remove foreign Remove foreign Remove foreign

object. Repair air object. Repair air object. Repair NO
Replace air
intake system and intake system and exhaust system and
cleaner element
replace turbocharger replace turbocharger replace turbocharger
as necessary as necessary as necessary

NO Turbocharger rotating NO Loose intake or

Carbon build-up in
assembly binding or exhaust duct
turbine housing
dragging systems

YES YES YES

Clean housing or
Perform
replace turbocharger
troubleshooting
as required. Eliminate all leaks
procedures outlined
Check engine
in Table1-5
operating procedures

SAPH01Z080800005

✩ Shown on Table 1-9

 TURBOCHARGER (J08E) EN08–7

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

TURBOCHARGER
ROTATING
Symptom or trouble
ASSEMBLY BINDING
OR DRAGGING

Possible causes and remedies

(See Notes J✩)
Damaged
Damaged turbine Compressor wheel or Excessive dirt build-
compressor wheel NO NO NO NO
wheel due to foreign turbine wheel rubbing up in compressor fan
due to foreign object
object impact on housing housing or wheel
impact

YES YES YES YES

Clean and repair air Clean and repair air

Clean and repair Worn bearings,shaft
intake system as intake system as
engine exhaust journals,or bearing
necessary. Replace necessary. Clean
system as necessary. bores. Replace
turbocharger compressor or
Replace turbocharger turbocharger
replace turbocharger

(See Notes I✩ )

Excessive carbon
build-up behind NO Sludged or cocked
turbine wheel center housing

YES YES

Coked oil combustion

Service engine
deposits.
lubrication system.
Replace
Replace
turbocharger
turbocharger

SAPH01Z080800006

✩ Shown on Table 1-9

EN08–8 TURBOCHARGER (J08E)

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

OIL SEAL LEAKAGE AT

Symptom or trouble COMPRESSOR END OF
TURBOCHARGER

Possible causes and remedies

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

YES YES YES YES

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

YES YES YES YES

Clean and remove Clean and repair air Perform

Refer to engine
restriction or intake system as troubleshooting
manufacturer's
replace oil drain line necessary. Replace procedures outlined
service manual
as required turbocharger in Table 1-8

Engine malfunction
(excessive piston
blow by or high
internal crankcase
pressure)

YES

Referto engine
manufacturer's
service manual

SAPH01Z080800007
 TURBOCHARGER (J08E) EN08–9

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

SEAL LEAKAGE AT
Symptom or trouble TURBINE END OF
TURBOCHARGER

Possible causes and remedies

Restricted
Plugged engine Sludged or cocked
Excessive pre-oiling NO NO turbocharger oil NO NO
crankcase breather center housing
drain line

YES YES YES YES

Clean and remove Service engines

Refer to engine
Oil will burn away restriction or lubrication system.
manufacturer's
No action required replace oil drain line Replace
service manual
as required turbocharger

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

SAPH01Z080800008
EN08–10 TURBOCHARGER (J08E)

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

TURBOCHARGER
Symptom or trouble BEARINGS, BORES,OR
SHAFT JOURNAL WORN ✩

Possible causes and remedies

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

YES YES YES YES

Service engine lube

system in Remove restriction
Follow proper
Follow pre-oiling accordance with or replace
engine operating
instructions engine turbocharger as
procedures
manufacturer's necessary
service manual

Abrasive wear due Insufficient lube oil

to flaking of supplied to
Plugged engine oil
NO particles from NO turbocharger due to
filter
center housing engine oil pump
internal surfaces malfunction

YES YES YES

Service engine lube

system in
Refer to engine Refer to engine
accordance with
manufacturer's manufacturer's
engine
service manual service manual
manufacturer's
service manual

SAPH01Z080800009

✩ Replace turbocharger, then use this table to determine cause of failure.

 TURBOCHARGER (J08E) EN08–11

9. Table 1-9. Troubleshooting Procedures Notes

A Refer to engine manufacturer's service manual for inspection requirements and replacement specifications.

B With engine stopped, check duct clamping devices for tightness.

C With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connections will be indi-
cated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the
engine combustion chambers.

D With engine running at idle speed, check duct connections for leaks by applying lightweight oil or liquid soap to areas
of possible leakage and checking for bubbles. Exhaust gas leakage between the engine block and the turbocharger
inlet will also create a noise level change.

E With engine running at idle speed, check for unusual noise and vibration. If either condition is noted, shut down the
engine immediately to protect the turbocharger and engine from further damage. With the engine stopped, check the
turbocharger shaft wheel assembly for damage as outlined Note I, below.

F With engine running, a change in the noise level to a higher pitch can indicate air leakage between the air cleaner and
the engine or a gas leak between the engine block and the turbocharger inlet.

G Exhaust gas leakage may be indicated by hat discoloration in the area of the leak.

H With the engine running, noise level cycling from one level to another can indicate a plugged air cleaner, a restriction in
the air-cleaner to compressor duct, or a heavy build-up of dirt in the compressor housing or on the compressor wheel.

I Internal inspection of the center housing can be accomplished by removing the oil drain line and looking through the oil
drain opening. When a slugged or cocked condition exists, a heavy sludge build-up will be seen on the shaft between
the bearing journals and in the center housing from the oil drain opening back to the turbine end.

J Thorough cleaning of the air intake system is essential following compressor wheel damage due to foreign object
impact. In many cases, metal pieces from the wheel become embedded 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 man-
ner 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 rotat-
ing assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that the turbocharger is ser-
viceable.
EN08–12 TURBOCHARGER (J08E)

REPLACEMENT
REMOVING THE TURBOCHARGER ASSEMBLY
NOTICE
• Use care not to touch the link rod and adjusting screw.
• The link rod the electric actuator has been adjusted. Do not
remove it. Removal of the link rod may cause misalignment,
resulting in turbocharger functional decline.
• The adjusting screw for opening/closing operation of the turbo-
charger assembly has been adjusted. Do not loosen it.

1. DRAINING THE COOLANT

(1) Drain the coolant.
Reference: COOLING SYSTEM (J08E)

2. DISCONNECTING THE HARNESS

(1) Disconnect the electric actuator connector.

Electric
actuator

Connector

SAPH01Z080800010

3. REMOVING THE INTAKE PIPE(EXHAUST SIDE)

(1) Remove the intake pipe (exhaust side).
Reference: AIR INTAKE SYSTEM (J08E)

4. REMOVING THE TURBOCHARGER INSULATOR

(1) Unfasten the bolts to remove a turbocharger insulator (upper) from a
turbocharger assembly.

Turbocharger
insulator(upper)

SAPH01Z080800011

(2) Unfasten the bolts to remove the turbocharger insulator (lower) from
the turbocharger assembly.

Turbocharger
insulator(lower)

SAPH01Z080800012
 TURBOCHARGER (J08E) EN08–13

5. DISCONNECTING THE COOLANT PIPE

(Example) Turbocharger
(1) Unfasten the union bolts to remove the coolant pipe E and gaskets
assembly
from turbocharger assembly and exhaust pipe No.1 (ATC).
NOTICE
Use care not to splash the coolant in the pipes and turbocharger
assembly.
HINT
Use a container and a waste cloth to avoid spillage of coolant when
disconnecting the coolant pipe.
Exhaust pipe
No.1 (ATC) Coolant pipe E
SAPH01Z080800013

(2) Unfasten the union bolts to remove the coolant pipe F and gaskets
from the turbocharger assembly.
NOTICE
Use care not to splash the coolant in the pipes and turbocharger
assembly.
HINT
Use a container and a waste cloth to avoid spillage of coolant when
Coolant pipe F
disconnecting the coolant pipe.
Turbocharger
assembly
SAPH01Z080800014

(3) Block water holes of the turbocharger assembly to prevent entry of

foreign matters.
! CAUTION
Use special care to prevent the entry of foreign matter into the turbo-
charger assembly.

6. REMOVING THE EXHAUST PIPE

(1) Inspect the turbine shaft play on the exhaust side.
Reference: EXHAUST SYSTEM(J08E)

7. DISCONNECTING THE OIL PIPE

Turbocharger (1) Unfasten the bolt and union bolts to remove the oil pipe A and gaskets
assembly from the turbocharger assembly.
NOTICE
Use care not to splash the oil in the pipes and turbocharger assembly.
HINT
When disconnecting the oil pipe, engine oil will spill. Prepare a reser-
voir and clean cloths.

Oil pipe A
SAPH01Z080800015
EN08–14 TURBOCHARGER (J08E)

(2) Unfasten the bolts to remove the oil pipe B and gaskets from the tur-
Oil pipe B Gasket bocharger assembly.
NOTICE
Use care not to splash the oil in the pipes and turbocharger assembly.

Turbocharger
HINT
assembly When disconnecting the oil pipe, engine oil will spill. Prepare a reser-
voir and clean cloths.
Gasket Oil cooler (3) Block oil holes of the turbocharger assembly to prevent entry of for-
assembly eign matters.

SAPH01Z080800016
! CAUTION
Use special care to prevent the entry of foreign matter into the turbo-
charger assembly.

8. REMOVING THE TURBOCHARGER ASSEMBLY

Nuts (1) Unfasten the nuts to remove the turbocharger assembly and gasket
Gasket from the exhaust manifold.

Turbocharger
assembly

SAPH01Z080800017
! CAUTION
Turbocharger • The electric actuator is plastic and easily damaged. Use care to
assembly place it in an appropriate direction for storage after removal.
• Heat-resisting steel is used for bolts and nuts. Do not mix them
with ordinary bolts and nuts when mounting.

Electric actuator
SAPH01Z080800018

(2) After removing the turbocharger assembly, block the exhaust manifold
port to prevent entry of foreign matters.
 TURBOCHARGER (J08E) EN08–15

MOUNTING THE TRURBOCHARGER ASSEMBLY

! CAUTION
Observe the following instructions when mounting the turbocharger
assembly to the engine or handling after installation. Use special care
to prevent the entry of foreign matter into the turbocharger assembly.

1. MOUNTING THE TURBOCHARGER ASSEMBLY

(1) Before mounting, add engine oil from the oil inlet. Rotate the turbo-
Turbocharger
charger assembly by hand to lubricate the ball bearing.
assembly
(2) Check the exhaust pipe system for dirt or foreign matter.

Oil inlet hole

SAPH01Z080800019

(3) Replace with a new gasket and mount the turbocharger assembly to
Nuts the exhaust manifold with nuts.
Gasket
Tightening Torque:
74.5 Nm {760 kgfcm, 55 lbfft}

! CAUTION
• Heat-resisting steel is used for bolts and nuts. Do not mix them
with ordinary bolts and nuts when mounting.
Turbocharger • Mount the turbocharger securely so that there is no gas leakage
assembly
from the connections of the exhaust pipe.
SAPH01Z080800020
NOTICE
If the stud bolt of the exhaust flange is stuck, use a commercially
available stud bolt remover to remove and replace the stuck stud bolt.

2. MOUNTING THE OIL PIPE

(1) Replace with new gaskets and connect the oil pipe B to the turbo-
Oil pipe B Gasket charger assembly with bolts.
NOTICE
• Clean the oil pipe and check the pipe for collapse and dirt and
foreign matters inside.
Turbocharger
• Do not use any sealant on the oil pipe installation surface to
assembly
avoid defects such as damage by clogging or loosening at the
Gasket tightening portion.
Oil cooler
assembly

SAPH01Z080800021
EN08–16 TURBOCHARGER (J08E)

(2) Replace with new gaskets and connect the oil pipe A to the turbo-
Turbocharger charger assembly with a bolt and union bolts .
assembly
NOTICE
• Clean the oil pipe and check the pipe for collapse and dirt and
foreign matters inside.
• Do not use any sealant on the oil pipe installation surface to
avoid defects such as damage by clogging or loosening at the
tightening portion.

Oil pipe A
SAPH01Z080800022

3. MOUNTING THE EXHAUST PIPE

(1) Mount the exhaust pipe.
Reference: EXHAUST SYSTEM(J08E)

4. CONNECTING THE COOLANT PIPE

(1) Replace with new gaskets and connect the coolant pipe F to the tur-
bocharger assembly with union bolts .
NOTICE
• Clean the oil pipe and check the pipe for collapse and dirt and
foreign matters inside.
• Do not use any sealant on the oil pipe installation surface to
avoid defects such as damage by clogging or loosening at the
Coolant pipe F
tightening portion.
Turbocharger
assembly
SAPH01Z080800023

(2) Replace with new gaskets and connect the coolant pipe E to the tur-
(Example) Turbocharger bocharger assembly with union bolts .
assembly
NOTICE
• Clean the oil pipe and check the pipe for collapse and dirt and
foreign matters inside.
• Do not use any sealant on the oil pipe installation surface to
avoid defects such as damage by clogging or loosening at the
tightening portion.
Exhaust pipe
No.1 (ATC) Coolant pipe E
SAPH01Z080800024
 TURBOCHARGER (J08E) EN08–17

5. MOUNTING THE TURBOCHARGER INSULATOR

(1) Replace with new bolts and mount the turbocharger insulator (lower)
to the turbocharger assembly.

Turbocharger
insulator(lower)

SAPH01Z080800025

(2) Replace with new bolts and install the turbocharger insulator (upper)
to the turbocharger assembly.

Turbocharger
insulator(upper)

SAPH01Z080800026

6. MOUNTING THE INTAKE PIPE (EXHAUST SIDE)

(1) Mount the intake pipe (exhaust side).
Reference: AIR INTAKE SYSTEM (J08E)

7. CONNECTING THE HARNESS

(1) Connect the connector to the electric actuator.

Electric
actuator

Connector

SAPH01Z080800027

8. FEEDING ENGINE OIL

(1) Inspect the engine oil level. if insufficient, add engine oil.
Reference: ENGINE INTRODUCTION(J08E)

9. ADDING THE COOLANT

(1) Add the coolant.
Reference: COOLING SYSTEM and ENGINE MAECHANI-
CAL(J08E)
EN08–18 TURBOCHARGER (J08E)

INSPECTION AFTER MOUNTING

EN01Z08080000001

1. PROCEDURES FOR OPERATION

(1) After mounting the turbocharger assembly to the engine, start the
engine and inspect each part for leakage of oil, coolant and exhaust
gas.
! CAUTION
• Do not run engine at idle or at a high speed immediately after
starting the engine. If the turbocharger is operated without suffi-
cient lubrication at the beginning of engine start, it may cause
bearing seizure.
• If the engine is stopped suddenly, the turbocharger keeps rotat-
ing with no oil pressure applied, which may result in a worn bear-
ing due to absence of oil film.
NOTICE
Run the engine at idle for about 5 minutes before stopping the engine.
 EMISSION CONTROL (J08E) EN10–1

EMISSION CONTROL (J08E)

EN10

EN10-001

EGR VALVE AND EGR PIPE.................... EN10-2

COMPONENT LOCATOR................................ EN10-2

EGR VALVE............................................... EN10-3

DESCRIPTION ................................................ EN10-3
DISMOUNTING AND MOUNTING .................. EN10-4

CLOSED VENTILATOR ............................ EN10-7

DESCRIPTION ................................................ EN10-7
REPLACEMENT OF
CLOSED VENTILATOR ................................... EN10-7

REPLACEMENT ....................................... EN10-8

REPLACING THE ELEMENT .......................... EN10-8

SELECTIVE CATALYTIC
REDUCTION (SCR) .................................. EN10-9
GENERAL DESCRIPTION .............................. EN10-9
COMPONENT LOCATOR.............................. EN10-11
INSPECTION ................................................. EN10-12
SPECIAL TOOL ............................................. EN10-13
DISMOUNTING AND MOUNTING ................ EN10-14
INSPECTION AND REPAIR .......................... EN10-30
EN10–2 EMISSION CONTROL (J08E)

EGR VALVE AND EGR PIPE

COMPONENT LOCATOR
EN01Z0810J100001

B B

SAPH01Z081000001

1 EGR cooler sub assembly 6 Water pipe sub assembly

2 Gasket * 7 Water pipe sub assembly
3 EGR pipe assembly 8 Water pipe
4 Gasket * 9 Water hose
5 EGR valve
*: Nonreusable. Be sure to use new parts.

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

A 55 {560, 40} B 68.5 {700, 50.6}
 EMISSION CONTROL (J08E) EN10–3

EGR VALVE
DESCRIPTION
EN01Z0810J100002

SAPH01Z081000002

1 EGR valve assembly 3 Butterfly valve

2 DC Motor
EN10–4 EMISSION CONTROL (J08E)

DISMOUNTING AND MOUNTING

EN01Z0810H200001

IMPORTANT POINTS - DISMOUNTING

1. REMOVE THE EGR VALVE AND EGR COOLER.

EGR pipe NOTICE
To prevent burns ensure the engine is cold before changing the valve.
(At least 30 minutes after switching off the engine)
EGR valve
(1) Disconnect the harness coupler.
Coupler
Front of
vehicle

SAPH01Z081000003

(2) Drain the coolant out of the drain plug of oil cooler situated on the
right side of the engine.

SAPH01Z081000004

(3) Disconnect and remove all pipes connected to the EGR pipe as well
as coolant hose and related parts.

EGR cooler

SAPH01Z081000005

(4) Remove EGR pipe.

(5) Remove EGR cooler sub assembly.
(6) Remove EGR valve from intake pipe.

SAPH01Z081000006
 EMISSION CONTROL (J08E) EN10–5

NOTICE
• If you have to place your feet on the engine while working on it,
be careful not to fall off the engine or get your foot caught in the
engine parts.
• Be careful not to step on the EGR valve when servicing the
engine.
• Do not loosen or tighten the bolts and nuts and snaprings secur-
ing the EGR valve components; otherwise, the valve will not per-
form properly. If you remove the nuts and bolts and snaprings
and dismantle a component, do not re-assemble it; instead,
replace the valve with a new one.
• Be careful not to hit the EGR valve lever with a tool when you are
removing or installing the valve.

2. INSPECT THE EGR COOLER.

(1) Visually inspect cracks or clogging in the main body gas passage and
sub-coolant piping. In case a trouble is found, replace the EGR cooler
with a new one.

IMPORTANT POINTS - MOUNTING

1. INSTALL THE EGR VALVE.

(1) Install the EGR valve to the intake pipe. (with new gaskets)
(2) Install the EGR cooler.
(3) Install the EGR pipe.
Tightening Torque:
55 Nm {560 kgfcm, 40 lbfft}
68.5 Nm {700 kgfcm, 50.6 lbfft} (exhaust side EGR pipe)

NOTICE
Fit the exhaust manifold gasket with the claw of the gasket facing
down.

SAPH01Z081000007

(4) Connect and install all pipes connected to the EGR pipe as well as
coolant hose and related parts.
NOTICE
Install all pipes with new gasket.

EGR cooler

SAPH01Z081000008
EN10–6 EMISSION CONTROL (J08E)

(5) Close the coolant plug of the oil cooler situated on the right side of the
engine.
NOTICE
Fit the exhaust manifold gasket with the claw of the gasket facing
down.

SAPH01Z081000009

(6) Connect the harness coupler.

EGR pipe

EGR valve

Coupler
Front of
vehicle

SAPH01Z081000010
 EMISSION CONTROL (J08E) EN10–7

CLOSED VENTILATOR
DESCRIPTION
EN01Z0810C100001

5
4

SAPH01Z081000011

1 Body 4 Cap
2 Filter 5 Safety valve
3 PCV valve

REPLACEMENT OF CLOSED VENTILATOR

EN01Z0810H200002

1. REMOVE THE CLOSED VENTILATOR.

(1) Remove the hoses and then the closed ventilator.

2. INSTALL THE CLOSED VENTILATOR.

(1) Connect the hoses and install the closed ventilator.

SAPH01Z081000012
EN10–8 EMISSION CONTROL (J08E)

REPLACEMENT

REPLACING THE ELEMENT

EN01Z0810H200003

1. REPLACING THE ELEMENT.

Cap (1) Remove the cap by turning it counterclockwise while pushing it down.

Closed
ventilator

SAPH01Z081000013

(2) Remove the element from the body.

Cap
(3) Remove the O-ring from the cap.

Element O-ring

Body

SAPH01Z081000014

2. INSTALLING THE ELEMENT.

Cap (1) Replace the O-ring with a new one, apply engine oil to it, and install it
Center boss
in the cap.
(2) After replacing the element with a new one, install it so it is lined up
O-ring
with the center boss of the body.
Element

Body

SAPH01Z081000015

(3) Install the cap by turning it clockwise until it is pushed up.

Cap NOTICE
• Do not tighten the cap excessively.
Closed
• Do not reuse an O-ring.
ventilator
• Remove dirt and foreign matter from the mounting surface of the
O-ring.
Reference: It is recommended to replace the closed ventilation
element every second time the oil filter is replaced. Refer to page
chapter “EN05“ for the oil filter replacement.

SAPH01Z081000016
 EMISSION CONTROL (J08E) EN10–9

SELECTIVE CATALYTIC REDUCTION (SCR)

GENERAL DESCRIPTION
EN01Z0810C100002

• What is SCR?
SCR is an abbreviation of "Selective Catalytic Reduction", a general
term for aftertreatment equipment which promotes a chemical reac-
tion by using a catalyst for eliminating or detoxifying particular chemi-
cal ingredients. To meet the EPA2010 regulation the vehicle out NOx
level will be extremely close to zero (0.2 Grams per brake horse-
power). By mixing the NOx with the ammonia contained in DEF, it will
be separated it to harmless water and nitrogen. It is an extremely
effective, dependable efficient and economical selection.
• What is DEF?
DEF is an abbreviation for "Diesel Exhaust Fluid", a solution made
from 67.5% purified water and 32.5% automotive-grade urea that
serves as a carrying agent for the ammonia needed to reduce nitro-
gen oxide (NOx) emissions from diesel engines. When DEF is
injected into the engine exhaust gas downstream of the DPF, it will be
rapidly hydrolyzed producing the oxidizing ammonia needed by the
SCR catalyst to complete NOx emissions reductions.
• The system consists of the DEF adding device and its accessories,
SCR (Selective Catalytic Reduction) catalyst, DCU, and sensors.
! CAUTION
• Do not add solutions other than DEF in the DEF tank.
• Make sure to add API-compliant DEF. It is urea solution with a
32.5% concentration. Addition of DEF other than the above or
diluted DEF into the DEF tank will not only deteriorate exhaust
gas but will also damage the DEF pump and DEF injector.
• If diesel fuel has been mistakenly added into the DEF tank.
Once the engine is started and DEF pump is activated, diesel fuel
will enter the DEF piping, DEF pump and DEF injector. If diesel
fuel has entered the DEF piping, DEF pump and DEF injector,
replace them along with DEF tank and DEF sensor. If the engine
has not yet been started, the areas exposed to diesel fuel are
only the DEF tank and the DEF piping inside the tank. Discon-
nect the piping from the DEF tank and replace the DEF tank and
DEF sensor. In this case, no other parts need to be replaced.
EN10–10 EMISSION CONTROL (J08E)

Aftertreatment fuel
EGT sensor*1 pressure sensor
Wire harness (ATC upstream)

CAN bus line Aftertreatment Fuel

cutoff valve
Engine coolant return line

Engine coolant feed line (for DEF injector cooling) Engine Fuel supply pump
ECU

DEF pump DEF tank

heater valve
(coolant cut off
valve)
Turbocharger
Engine
line with heater

line with heater

line with heater Engine Intercooler

DEF pressure

DEF backflow
Engine coolant feed line
DEF suction

(for DEF tank and coolant

line defrosting) feed line
Exhaust brake
DEF temperature
sensor ATC
DeNOx ECU
(DCU)
EGT sensor*2
Wire Ambient air (ATC downstream)
harness temperature
DEF tank (DCU) sensor
EGT sensor*5
(DPR outlet) EGT sensor*4
(DPR inlet)
Differential
pressure
sensors EGT sensor*3
(DOC inlet)

DPR DOC

Aftertreatment Fuel injector

SCR catalyst
NOx sensor
(SCR up DEF
stream) injector
NH3 Slip catalyst EGT sensor*
(SCR inlet)
NOx sensor (SCR down stream) PM sensor

: Coolant line : Exhaust gas temperature sensor

: DEF line (with electric heater) : Temperature sensor
: Wire harness : NOx sensor
: CAN bus line : Pressure sensor *Exhaust gas temperature sensor
: PM sensor
SAPH01Z081000017
 EMISSION CONTROL (J08E) EN10–11

COMPONENT LOCATOR
EN01Z0810J100003

Exhaust gas temperature

1 1 9 sensor 5 (DPR outlet)
2
7 6 8
3
10
4

11

Exhaust gas temperature 6 Exhaust gas temperature

sensor 3 (DOC inlet) sensor 4 (DPR inlet)

SAPH01Z081000018

1 DEF tank 7 NOx sensor 1

2 DEF level sensor 8 NOx sensor 2
3 DCU (Dosing control unit) 9 SCR catalyst inlet temperature sensor
4 DEF pump 10 DEF heater
5 DEF injector 11 PM sensor
6 Exhaust gas temperature sensor
EN10–12 EMISSION CONTROL (J08E)

INSPECTION
EN01Z0810H300001

DEF CONCENTRATION INSPECTION

NOTICE
There are three inspection methods for DEF; urea analyzer inspec-
tion, pH test paper inspection and refractive index measurement
inspection. Use one method from three for inspection.

1. UREA ANALYZER INSPECTION

(1) Extract DEF, put few drops on the urea analyzer to measure the urea
concentration and replace the DEF if the value is outside the standard
value.
Standard value: Concentration 31.8-33.2%

SAPH01Z081000019

2. PH TEST PAPER INSPECTION

(1) Extract DEF, put few drops on the pH test paper to measure the color
change and replace the DEF if the value is outside the standard value.

Concentration (%) Standard value (number)

31.8-33.2 9

HINT
When the digital type tester is used, standard value is 9.0 to 9.5.

SAPH01Z081000020

3. REFRACTIVE INDEX MEASUREMENT INSPECTION

1.40
(1) Extract DEF, put few drops on the refractometer to measure the
1.35
refractive index and replace the DEF if the value is outside the stan-
1.30 dard value.
1.25
1.20 Concentration (%) Standard value (%)
㧑

1.15
͠

1.10
31.8-33.2 1.3814-1.3843

1.00

SAPH01Z081000021
 EMISSION CONTROL (J08E) EN10–13

SPECIAL TOOL
EN01Z0810K100001

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

Illustration Part number Tool name Remarks

S0920-E0020 HOSE SUB ASSY UREA

EN10–14 EMISSION CONTROL (J08E)

DISMOUNTING AND MOUNTING

EN01Z0810H100001

1. PREPARATION
! WARNING
Do not touch the exhaust pipe and muffler unit when it could be hot.
You can be severely burned.
NOTICE
• If the quick joint used in DEF piping is once removed, DEF pow-
der will precipitate on the seal surface and leakage may occur
after reconnection. Before reconnecting, thoroughly check the
crystallize (=urea) for deposition of crystallized urea and foreign
matter. If deposition of crystallized urea is found, wash it with
hot water.
• If you perform work with after-run not finished, an DEF filled in
the pipe will flow out when the quick connector is disconnected.
Be sure that after-run is finished.
• What is after-run?
Remained DEF in the DEF injector, DEF pump and plumbing is
returned to DEF tank after engine off in order to prevent DEF fro-
zen in the plumbing and crystallization.
• If you perform work immediately after the engine is stopped, hot
coolant may spout and you may get burned.
Before performing work, be sure that engine coolant is thor-
oughly cooled.
• Formed tubes are used for DEF plumbing. Do not apply an
excessive force to tubes when working. If a tube is bent, must to
be replaced.
• Do not directly touch an DEF or coolant flowing out from the
plumbing. If you have touched it, thoroughly rinse it out.
• After removal, place a plastic cover to avoid entry of foreign mat-
ter into the pipe.
• Place a cover immediately after removing the joint to avoid entry
of foreign matter into the DEF tank, DEF pump, and DEF injector.
• When covering, use separate covers to avoid mixing of DEF and
coolant.
• If removed by forcing, the quick connector may be damaged. If
removal is difficult to do, do not apply an excessive force but
remove dust attached around the joint.
• The coolant pipe and DEF pipe are assembled for piping. Do not
disassemble them.
• Do not use tools when disconnecting the quick connector.
• Perform work with all the harness connectors fitted. If you per-
form work with connectors removed, rusting may result. Cover
the connectors to avoid splashing of coolant and DEF.
 EMISSION CONTROL (J08E) EN10–15

(1) Disconnect the battery ground terminal.

! CAUTION
• Be sure to disconnect the battery terminals from the battery in
accordance with the procedures in this manual and never use
the battery disconnect switch when it is necessary to break the
supply of electricity completely. Otherwise, electricity may
remain supplied from the battery by the circuit that bypasses the
battery disconnect switch and you may get burns or injury from
the electricity.
(2) Dismount the steps (top and bottom) and insulator on the right side of
the vehicle.

SAPH01Z081000023

(3) Dismount the front fender.

SAPH01Z081000024
EN10–16 EMISSION CONTROL (J08E)

2. DOSING CONTROL UNIT (DCU)

(1) IMPORTANT POINT - DISMOUNTING
a. Remove the bolt and then the DCU cover.
! CAUTION
When dismounting/mounting the DCU, wear the glove to avoid injury.

SAPH01Z081000025

SAPH01Z081000026

b. Disconnect the harness connectors (53 pin and 86 pin) from the
DCU.
NOTICE
• Pull the tab on the connector side surface to remove the connec-
tor.
• Do not touch the connector pin with bare hand.
• Do not have an impact on DCU. If dropping the DCU, do not reuse
it because of concern that inside of DCU is damaged.
• Protect the removed connectors from dirt and dust.
c. Remove the DCU bracket mounting nut. Dismount the DCU along
with the bracket.
d. Remove the nut and then dismount the DCU from the bracket.

SAPH01Z081000027
 EMISSION CONTROL (J08E) EN10–17

(2) IMPORTANT POINT - MOUNTING

a. Mount the DCU to the DCU bracket and then mount the assembly
to the vehicle.
Tightening Torque:
18-26 Nm {184-265 kgfcm, 14-19 lbfft} (DCU)

Tightening Torque:
18-26 Nm {184-265 kgfcm, 14-19 lbfft} (DCU bracket)
b. Connect the harness connectors (53 pin and 86 pin) to the DCU.
NOTICE
Press the tab on the connector side surface until a "click" is heard.

SAPH01Z081000028

c. Mount the DCU cover.

Tightening Torque:
18-26 Nm {184-265 kgfcm, 14-19 lbfft}

SAPH01Z081000029

SAPH01Z081000030
EN10–18 EMISSION CONTROL (J08E)

3. DEF TANK
DEF hose Harness
wire (1) IMPORTANT POINT - DISMOUNTING
a. Dismount the DCU.
Refer to "DOSING CONTROL UNIT (DCU)" for details.
b. Remove the drain plug from the DEF tank to drain the DEF.

Coolant hose
SAPH01Z081000031

c. Remove the nut and then the stay and rod from the bracket.
d. Move the DEF tank toward outside the vehicle and remove the
coolant and DEF hoses.
NOTICE
Remove the coolant hose first to prevent the coolant residue in the
hose from entering the DEF tank via the DEF hose connection when
removing it.

SAPH01Z081000032

HINT
Coolant will spout if the coolant hose is removed. Drain coolant
beforehand or block the hose with the vice grip plier. If you use the
vice grip at the ✩ area as shown in the figure below, you can minimize
leakage of coolant.

SAPH01Z081000033

e. Disconnect the harness connector and then remove the DEF

tank.
NOTICE
• Remove the harness connector last to prevent the coolant and
DEF residues in the coolant and DEF hoses from wetting the har-
ness connector terminal.
• Protect the removed connector from dirt and dust.
• Protect against water, mud and dust do not enter the DEF sensor
connector part of a DEF tank.
• Do not leave outdoors the connector part of the DEF sensor in
the DEF tank assembly without having to waterproof treatment.
 EMISSION CONTROL (J08E) EN10–19

(2) IMPORTANT POINT - MOUNTING

a. Set the DEF tank on the bracket.
b. Mount the coolant and DEF hoses.
DEF hose Harness
wire c. Connect the harness connector.
NOTICE
Tighten clockwise the connector connecting to the DEF sensor until a
"click" is heard.

Coolant hose
SAPH01Z081000034

d. Fix the DEF tank with the rod, stay and nut.
Tightening Torque:
23.5-36.5 Nm {230-357 kgfcm, 17.6-27.3 lbfft}
e. Mount the drain plug to the DEF tank. Pour the DEF.

SAPH01Z081000035
EN10–20 EMISSION CONTROL (J08E)

(3) MOUNTING/DISMOUNTING AND INSPECTING DEF SENSOR

! WARNING
• If the DEF is frozen, do not mount or dismount the DEF sensor.
• Do not allow foreign objects to enter the DEF tank from the open-
ing.
a. Dismount the DEF tank.
Refer to "DEF TANK" for details.
b. Remove the DEF sensor by turning it counterclockwise.
NOTICE
• When removing, be careful not to bend the DEF sensor pipe.
DEF sensor
• When taking out the sensor from inside the tank, be careful not
to damage the sensor by hitting the tank edge.

DEF tank

SAPH01Z081000036

c. Check if the DEF sensor float moves smoothly.

DEF sensor

Float

SAPH01Z081000037

d. Insert the DEF sensor to the DEF tank. Rotate it to mount.

NOTICE
• Replace the O-ring between the tank and sensor with a new one.
DEF sensor
• Thoroughly wipe off crystals of DEF precipitating on the mount-
ing surface with a clean cloth.
• Check that the tank center and DEF sensor pipe center are
assembled in parallel to each other.

DEF tank

SAPH01Z081000038
 EMISSION CONTROL (J08E) EN10–21

4. DEF PUMP
(1) IMPORTANT POINT - DISMOUNTING
a. Dismount the DCU.
Refer to "DOSING CONTROL UNIT (DCU)" for details.
b. Dismount the DEF tank.
Refer to "DEF TANK" for details.
c. Remove the hose clamp and harness clip.
Harness clip Remove the DEF tank bracket.
d. Release the lock of the harness wire connector. Disconnect it
from the DEF pump.
NOTICE
• Be careful to prevent the coolant and DEF residues in the cool-
ant and DEF hoses from wetting the harness connector terminal.
Hose clamp • Protect the removed connector from dirt and dust.

SAPH01Z081000039

e. Remove the mounting bolt of the DEF pump.

SAPH01Z081000040

f. Remove the coolant and DEF hoses connected to the DEF pump.
HINT
Lower the DEF pump to secure working space.
g. Dismount the DEF pump.

SAPH01Z081000041
EN10–22 EMISSION CONTROL (J08E)

(2) IMPORTANT POINT - MOUNTING

a. Set the DEF pump at the mounting position.
b. Connect the harness wire connector to the DEF pump.

Band
clamp DEF
pump

Connector

SAPH01Z081000042

c. Mount the coolant and DEF hoses to the DEF pump.

SAPH01Z081000043

d. Mount the DEF pump to the specified position.

Tightening Torque:
15.2-22.8 Nm {155-232 kgfcm, 11.2-16.8 lbfft}

SAPH01Z081000044

(3) REPLACE THE COOLANT CONNECTOR OF THE DEF PUMP.

a. When the connector is exchanged, the O-ring must not be used
two times.
NOTICE
Coolant • All sealing surface must be clean, contamination or particles are
connector not acceptable.
• Mounting torque for connector: 5.0-6.0 Nm {51-61 kgfcm, 3.7-4.4
lbfft}
• Wrench size: 15 mm {0.59 in.}
18 mm 77 mm {3.03 in.}
{0.71 in.} • For the mounting process, oil the O-ring with Mobil velocite oil
SAPH01Z081000045 No.6 or equivalent.
 EMISSION CONTROL (J08E) EN10–23

(4) REPLACE THE DEF INLET CONNECTOR OF THE DEF PUMP.

a. When the connector is exchanged, the O-ring must not be used
two times.

Inlet NOTICE
connector • All sealing surface must be clean.
Contamination or particles are not acceptable.
• Mounting torque for connector: 4.0-5.0 Nm {41-51 kgfcm, 3.0-3.6
lbfft}
• Wrench size: 17 mm {0.67 in.}
22 mm 88 mm {3.39 in.}
{0.87 in.} • For the mounting process, oil the O-ring with Mobil velocite oil
SAPH01Z081000046 No.6 or equivalent.

(5) REPLACE THE DEF OUTLET CONNECTOR OF THE DEF PUMP.

a. When the connector is exchanged, the O-ring must not be used
two times.
NOTICE
Outlet • All sealing surface must be clean.
connector Contamination or particles are not acceptable.
• Mounting torque for connector: 4.0-5.0 Nm {41-51 kgfcm, 3.0-3.6
lbfft}
• Wrench size: 17 mm {0.67 in.}
20 mm 88 mm {3.39 in.}
{0.78 in.} • For the mounting process, oil the O-ring with Mobil velocite oil
SAPH01Z081000047 No.6 or equivalent.

(6) REPLACE THE DEF BACKFLOW CONNECTOR OF THE DEF

PUMP.
a. When the connector is exchanged, the O-ring must not be used
two times.

Backflow NOTICE
connector • All sealing surface must be clean.
Contamination or particles are not acceptable.
• Mounting torque for connector: 4.0-5.0 Nm {41-51 kgfcm, 3.0-3.6
lbfft}
25 mm 81 mm {3.19 in.}
{0.98 in.} • Wrench size: 17 mm {0.67 in.}
SAPH01Z081000048 • For the mounting process, oil the O-ring with Mobil velocite oil
No.6 or equivalent.
(7) REPLACE THE DEF PUMP FILTER.
a. Remove the filter cover.
NOTICE
Contamination or damage of the sealing surface on the housing is not
acceptable.
Wrench size: 27 mm {1.063 in.}

SAPH01Z081000049
EN10–24 EMISSION CONTROL (J08E)

b. Remove the equalizing element and the filter element.

NOTICE
• Protect filter area in the housing from contamination.
• Prying forcefully with a screwdriver when replacing the filter ele-
ment may cause damage to the DEF pump body and DEF leak-
age.

Equalizing element Filter element

SAPH01Z081000050

c. Replace the filter element and the equalizing element.

NOTICE
The sealing surface on the housing must be clean.
No contamination or particles acceptable.

Filter element
Equalizing element

O-ring
95 mm {3.74 in.}

53 mm
{2.08 in.}
SAPH01Z081000051

d. Mount the filter cover.

NOTICE
• All sealing surface must be clean.
Contamination or particles are not acceptable.
• It must be checked if there are cracks around the area of the filter
cover. No cracks in the material are allowed. If there are cracks in
the housing the entire supply module must be exchanged. If
there are cracks in the filter cover, the filter cover must be
exchanged.
20-25 N·m {204-255 kgf·cm, 15-18 lbf·ft} • Wrench size: 27 mm {1.06 in.}
SAPH01Z081000052 • Mounting torque for filter cover: 20-25 Nm {204-255 kgfcm, 15-
18 lbfft}
 EMISSION CONTROL (J08E) EN10–25

5. DEF INJECTOR
(1) IMPORTANT POINT - DISMOUNTING
DEF hose
a. Disconnect the harness wire connector from the DEF injector.

Harness
wire

Connector
Coolant
Injector

SAPH01Z081000053

b. Disconnect the DEF and coolant hoses connected to the DEF

injector.
HINT
Coolant will spout if the coolant hose is removed. Drain coolant
☆ beforehand or block the hose with the vice grip. If you use the vice
☆
grip at the ✩ area as shown in the figure below, you can minimize
leakage of coolant.

SAPH01Z081000054

c. Remove the nut and then dismount the DEF injector and gasket
Muffler unit from the muffler unit.

DPR
chamber Injector

SAPH01Z081000055

(2) IMPORTANT POINT - MOUNTING

Muffler unit a. When the DEF injector is reused, must to replace with a new gas-
ket and attach the DEF injector to the muffler unit with the nut.
DPR Tightening Torque:
chamber Injector 6-10 Nm {61-102 kgfcm, 4.4-7.4 lbfft}

SAPH01Z081000056
EN10–26 EMISSION CONTROL (J08E)

b. Connect the DEF and coolant hoses to the DEF injector.

DEF hose c. Connect the harness wire connector to the DEF injector.

Harness
wire

Connector
Coolant
Injector

SAPH01Z081000057

(3) REPLACE THE DEF INJECTOR GASKET.

a. Remove the gasket.
NOTICE
• Use pliers, no sharp tools permitted.
• Disassembling of the gasket is only allowed at the 3 clips.

SAPH01Z081000058

b. Clean the sealing surface on the cooling body (if necessary).

Orifice Sealing NOTICE

plate interfaces Take care when cleaning the sealing interfaces (avoid scratches).
Do not touch the orifice plate.

SAPH01Z081000059

c. Mount new gasket.

NOTICE
Gasket
• The sealing interfaces must be clean.
• Place the gasket on the interface and press on.
• Avoid any damages or scratches on the gasket.
• Dosing module with fully mounted gasket see figure.

SAPH01Z081000060
 EMISSION CONTROL (J08E) EN10–27

(4) REPLACE THE DEF INJECTOR COOLANT PIPE.

Coolant a. When the connector is exchanged, The O-ring must not be used
connector two times.
20 mm
{0.79 in.} NOTICE
• All sealing surface must be clean.

70 mm {2.76 in.}
• Contamination or particles are not acceptable.
• Mounting torque for connector: 5.0-6.0 Nm {51-61 kgfcm, 3.7-4.4
lbfft}
• Wrench size: 15 mm {0.59 in.}
• For the mounting process, oil the O-ring with Mobil velocite oil
SAPH01Z081000061
No.61

6. ENGINE COOLANT VALVE

Harness connector (1) IMPORTANT POINT - DISMOUNTING
Hose 1 a. Dismount the DCU.
Refer to "DOSING CONTROL UNIT (DCU)" for details.
b. Remove the hose 1 clamp and remove the hose 1 (engine coolant
valve side only).
Hose 2 c. Disconnect the harness connector.
d. Remove the engine coolant valve mounting bolt.
e. Remove the hose 2 clamp and remove the hose 2 (engine coolant
Engine valve side only).
coolant valve
SAPH01Z081000062

NOTICE
Coolant will spout if the coolant hose is removed. Drain coolant
beforehand or block the hose with the vice grip. If you use the vice
grip at the ✩ area as shown in the figure below, you can minimize
leakage of coolant.

SAPH01Z081000063

(2) IMPORTANT POINT - MOUNTING

Harness connector a. Connect the hose 2 to the engine coolant valve and fix it with
Hose 1 clamp.
b. Mount the engine coolant valve.
Tightening Torque:
18-26 Nm {184-265 kgfcm, 14-19 lbfft}
Hose 2
c. Connect the harness coupler.
d. Connect the hose 1 to the engine coolant valve and fix it with
Engine clamp.
coolant valve e. Mount the DCU.
SAPH01Z081000064 Refer to "DOSING CONTROL UNIT (DCU)" for details.
EN10–28 EMISSION CONTROL (J08E)

7. EXHAUST GAS TEMPERATURE SENSOR (SCR INLET)

(1) IMPORTANT POINT - DISMOUNTING
Connector
a. Remove the clips.
b. Disconnect the harness connector.
c. Remove the exhaust gas temperature sensor (SCR inlet).
NOTICE
After removing the sensor, check that there is no entry of foreign mat-
Clip
ters inside the muffler.
Exhaust gas
temperature
sensor (SCR inlet)
SAPH01Z081000065

(2) IMPORTANT POINT - MOUNTING

a. Mount the exhaust gas temperature sensor (SCR inlet).
Connector
Tightening Torque:
25-40 Nm {255-407 kgfcm, 19-29 lbfft}
b. Connect the harness connector.
c. Mount the clips.
NOTICE
Clip
When reassembling, apply anti-seizure lubricant to the temperature
Exhaust gas sensor.
temperature
sensor (SCR inlet)
SAPH01Z081000066

8. NOx SENSOR 1
Harness
(1) IMPORTANT POINT - DISMOUNTING
connector
a. Remove the clips.
b. Disconnect the harness connector.
c. Remove the NOx sensor 1 controller.
d. Remove the NOx sensor 1.
NOTICE
NOx sensor 1 After removing the sensor, check that there is no entry of foreign mat-
ters inside the muffler.

Clip
SAPH01Z081000067

(2) IMPORTANT POINT - MOUNTING

Harness
a. Mount the NOx sensor 1.
connector
Tightening Torque:
40-60 Nm {407-611 kgfcm, 29-44 lbfft} (Sensor)

b. Mount the NOx sensor 1 controller.

Tightening Torque:
3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft} (Controller)
NOx sensor 1
c. Connect the harness connector.
d. Mount the clips.
Clip NOTICE
SAPH01Z081000068
When reassembling, apply anti-seizure lubricant to the NOx sensor.
 EMISSION CONTROL (J08E) EN10–29

9. NOx SENSOR 2
(1) IMPORTANT POINT - DISMOUNTING
Harness connector a. Remove the clips.
b. Disconnect the harness connector.
c. Remove the NOx sensor 2 controller.
d. Remove the NOx sensor 2.
NOTICE
After removing the sensor, check that there is no entry of foreign mat-
ters inside the muffler.

NOx sensor 2 Clip

SAPH01Z081000069

(2) IMPORTANT POINT - MOUNTING

a. Mount the NOx sensor 2.
Harness connector Tightening Torque:
40-60 Nm {407-611 kgfcm, 29-44 lbfft} (Sensor)

b. Mount the NOx sensor 2 controller.

Tightening Torque:
3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft} (Controller)

c. Connect the harness connector.

NOx sensor 2 Clip d. Mount the clips.
SAPH01Z081000070
NOTICE
When reassembling, apply anti-seizure lubricant to the NOx sensor.

10. PM sensor
Harness connector
(1) IMPORTANT POINT - DISMOUNTING
a. Remove the clips.
b. Disconnect the harness connector.
c. Remove the PM sensor controller.
d. Remove the PM sensor.
NOTICE
After removing the sensor, check that there is no entry of foreign mat-
ters inside the muffler.
Clip
PM sensor
SAPH01Z081000071

(2) IMPORTANT POINT - MOUNTING

Harness connector
a. Mount the PM sensor.
Tightening Torque:
28-42 Nm {286-428 kgfcm, 20-30 lbfft} (Sensor)

b. Mount the PM sensor controller.

Tightening Torque:
3.9-7.1 Nm {40-72 kgfcm, 2.9-5.2 lbfft} (Controller)

Clip c. Connect the harness connector.

PM sensor d. Mount the clips.
SAPH01Z081000072
NOTICE
When reassembling, do not exceed tightening torque. Before assem-
bling PM sensor, clean up oil and foreign matters of PM sensor boss
at pare cleaner.
EN10–30 EMISSION CONTROL (J08E)

INSPECTION AND REPAIR

EN01Z0810H300002

Inspect the SCR-related components in accordance with the table

below and perform a repair or replacement if necessary.

Months
Item Content Action Travel distance
(Year)

DEF filter element (& equalizing element) Replacement Replacement 150,000 mile –

60
PM sensor Replacement Replacement 150,000 mile
(5)
 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A) EN11–1

ALTERNATOR (J08E: REMY 12V-130A,135A,180A,

EN1

200A) EN11-001

ALTERNATOR........................................... EN11-2
DATA AND SPECIFICATIONS ......................... EN11-2
TROUBLESHOOTING ..................................... EN11-2
COMPONENT LOCATOR................................ EN11-3
OVERHAUL ..................................................... EN11-4
INSPECTION AND REPAIR ............................ EN11-7
EN11–2 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A)

ALTERNATOR
DATA AND SPECIFICATIONS
EN0110611I200001

Nominal voltage 12V

Nominal output 12V-130A/135A/180A/200A

Max. output 126A/130A/176A/207A at 13.5V, 5,000 r/min

Max. rotating 10,000 r/min

Rotating direction Right (seen from pulley side)

Regulator Mount-on

TROUBLESHOOTING
EN0110611F300001

Symptom Possible cause Remedy/Prevention

Charge warning light does not light Fuse blown Determine cause and replace fuse
with starter switch ON and engine Light burned out Replace light
off
Wiring connection loose Tighten loose connections
IC regulator faulty Replace IC regulator
Charge warning light does not go Drive belt loose or worn Adjust or replace drive belt
out with engine running (Battery Battery cables loose, corroded or worn Repair or replace cables
requires frequent recharging)
Fuse blown Determine cause and replace fuse
Fusible link blown Replace fusible link
IC regulator or alternator faulty Check charging system
Wiring faulty Repair wiring
 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A) EN11–3

COMPONENT LOCATOR
EN0110611D100001

(Example) A

B
3

D E C 2

SHTS011061100001

1 Brace 4 Bracket
2 Tensioner pulley 5 V-belt
3 Alternator 6 Idler pulley

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

A 88 {897, 65} D 68.5 {700, 51}
B 93 {948, 69} E 68.5 {700, 51}
C 80-95 {816-968, 59-70}
EN11–4 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A)

OVERHAUL
EN0110611H200001

IMPORTANT POINTS - DISMOUNTING

Idler pulley
Fun pulley 1. REMOVE THE ALTERNATOR.
(1) Remove the drive belt.
(2) Remove the through bolt and the fixing belt.
Alternator NOTICE
To remove the belt, turn the nut of the tension pulley with a wrench in
counterclockwise direction to turn the tension pulley in arrow direc-
Auto tensioner
tion. Then the belt becomes loose and can be removed.
Crankshaft pulley

SHTS011061100002
! CAUTION
• As the belt is under tension, take care not to get your hand
Radiator caught at the time of removal.
stay (right)
• Remove the following parts because your hand might be stuck
when replacing the belt.
.

a. Engine side cover

b. Suction hose
c. Fun shroud bracket (Engine side)
Radiator Radiator d. Radiator stay
stay (left)
e. Radiator stay bracket

SHTS011061100003

Failure to disconnect negative battery cable at battery before remov-

Alternator ing or attaching alternator "BAT" terminal lead may result in an injury.
If a tool is shorted at alternator "BAT" terminal, the tool can quickly
heat enough to cause a skin burn.

Wrench NOTICE
Always reinstall fasteners at original location. If necessary to replace
fasteners, use only correct part number or equivalent.
• If correct part number is not available, use only equal size and
strength. For alternator internal fasteners, refer to Delco Remy
America Standard Hardware Fasteners section in Service Parts
Catalog.
SHTS011061100004
• Fasteners that are not to be reused will be noted in procedure.
• Fasteners requiring thread locking compound will be noted in
procedure.
• Use specified torque values when shown.
Using or replacing fasteners in any other manner could result in part
or system damage.
If diagnosis determines that alternator repair is needed, remove alter-
nator from engine according to manufacturer's instructions.
 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A) EN11–5

IMPORTANT POINTS - MOUNTING

Idler pulley
Fun pulley 1. INSTALL THE ALTERNATOR.
(1) Install the alternator with through bolt and fixing bolt.
Tightening Torque:
Through bolt: 93 Nm {948 kgfcm, 69 lbfft}
Alternator
Fixing bolt: 88 Nm {897 kgfcm, 65 lbfft}

Auto tensioner

Crankshaft pulley
SHTS011061100005

(2) Install the drive belt.

Alternator NOTICE
Turn the tension pulley in the same way as for the belt removal and
install the belt.
Wrench

SHTS011061100006

NOTICE
When installing the drive belt, use the gauge on the belt tensioner (1)
to confirm that the tensioner arm is correctly positioned. (View from
Alternator A.)

View A

View A

Belt usage limit line

Belt usable range

New belt setting range

Indicator (Engraved line)

SHTS011061100007
EN11–6 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A)

2. INSTALL OR CONNECT
(1) "I" and/or "R" terminal lead(s) (108 or 109), if used, to threaded termi-
nal stud(s) (136 and/or 146), washer(s) and hexagon nut(s) (131 and/
or 141).
NOTICE
Use suitable open end wrench to hold nut portion of terminal stud(s)
(125, 136 and/or 146).
Tightening Torque:
130A/135A : 2.0 Nm {20 kgfcm, 17.7 lbfin}
180A/200A : 4.0 Nm {40 kgfcm, 35.4 lbfin}

SHTS011061100008
(2) Cap (138) to the "R" (or "Relay") pin terminal stud (146A) if necessary.
(3) Ground lead (110) to "GRD" hole in SRE housing (1), with screw
assembly (159).
Tightening Torque:
6 Nm {61 kgfcm, 55 lbfin}
(4) "BAT" output lead (111), washer (122) and nut (121) to "BAT" terminal
stud (125).
Tightening Torque:
130A/180A/200A: 11 Nm {112 kgfcm, 97.4 lbfin}
135A: 9 Nm {92 kgfcm, 79.7 lbfin}

SHTS011061100009
 ALTERNATOR (J08E: REMY 12V-130A,135A,180A, 200A) EN11–7

IMPORTANT POINTS - ON - VEHICLE INSPECTION

1. INSPECT THE DRIVE BELT

Alternator If the indicator (engraved line) is out of the belt usage limit line,
or if the belt is damaged, replace the belt.

View A

View A

Belt usage limit line

Belt usable range

New belt setting range

Indicator (Engraved line)

SHTS011061100010

INSPECTION AND REPAIR

EN0110611H300001

Inspect the alternator-related components in accordance with the

table below and perform a repair or replacement if necessary.

Item Content Action Travel distance

130A/180A/200A Alternator Replacement Replacement 250,000 mile
135A Alternator Replacement Replacement 350,000 mile
 STARTER (J08E) EN12–1

STARTER (J08E)
EN12

EN12-001

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

DATA AND SPECIFICATIONS ......................... EN12-2
DESCRIPTION ................................................ EN12-2
TROUBLESHOOTING ..................................... EN12-3
COMPONENT LOCATOR................................ EN12-4
OVERHAUL ..................................................... EN12-5
INSPECTION AND REPAIR ............................ EN12-9
EN12–2 STARTER (J08E)

STARTER
DATA AND SPECIFICATIONS
EN0110612I200001

Type Planetary reduction gear type

Rated output 12 V, 4.8 kW

Number of teeth of pinion 11

Module 3

Rotating direction Clockwise (Seen from pinion side)

DESCRIPTION
EN0110612C100001

SHTS011061200001

1 Holder assembly 7 Pinion gear

2 Brush 8 Drive housing assembly
3 Yoke assembly 9 Armature assembly
4 Magnetic switch assembly 10 Field coil
5 Lever 11 Commutator end frame
6 Drive shaft 12 Clutch assembly
 STARTER (J08E) EN12–3

TROUBLESHOOTING
EN0110612F300001

Symptom Possible cause Remedy/Prevention

Engine does not crank, or cranks Poor contact Replace the starter switch.
slowly. (Starter switch)
Engine does not crank, or cranks Discharged battery Charge.
slowly. (Battery) Short circuited between electrodes Replace battery.
Poor contact at battery terminal Clean or retighten.
Engine does not crank, or cranks Improper viscosity oil Change oil.
slowly. (Engine oil)
Engine does not crank, or cranks Poor contact caused by burnt contact Replace the magnetic switch assem-
slowly. (Magnetic switch) plate bly.
Contact plate worn out Replace the magnetic switch assem-
bly.
Holding coil disconnected (Overrun- Replace the magnetic switch assem-
ning clutch moves back and forth) bly.
Pull-in coil disconnected or short cir- Replace the magnetic switch assem-
cuited bly.
Engine does not crank, or cranks Defective or poor contact Repair or replace the starter relay.
slowly. (Starter relay)
Engine does not crank, or cranks Brush worn out Replace.
slowly. (Starter) Commutator burnt out Replace the armature assembly.
Commutator worn out Replace the armature assembly.
Field winding shorted or grounded Replace the yoke assembly.
Armature winding shorted or grounded Replace the armature assembly.
Insufficient brush spring tension Replace the brush spring.
Poor contact between magnetic switch Repair.
and field windings
Armature contact pole core because of Replace the end frame or armature
worn bearing bushing or bent arma- assembly.
ture shaft
Overrunning clutch malfunction Replace.
Engine does not crank while starter Overrunning clutch malfunction Replace.
is running in good condition. Pinion teeth worn out Replace.
(Overrunning clutch)
Poor sliding of spline teeth Remove foreign particles, dirt or
replace.
Starter does not stop running. Contacts keep closing Replace.
(Starter switch) Key switch sticks Replace.
Overrunning clutch sticks to armature Repair or replace overrunning or
armature.
Starter does not stop running. Contacts keep closing Repair or replace.
(Starter relay)
EN12–4 STARTER (J08E)

COMPONENT LOCATOR
EN0110612D100001

SHTS011061200002

1 Pinion gear 9 Brush holder

2 Drive housing assembly 10 End frame
3 Main switch assembly 11 Through bolt
4 Clutch assembly 12 Lever assembly
5 Internal gear assembly 13 Terminal
6 O-ring 14 Cover
7 Armature assembly 15 Plate
8 Yoke assembly

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

A 17 {173, 12.5} C 139-169 {1,418-1,723, 103-124}
B 21 {214, 15.5}
 STARTER (J08E) EN12–5

OVERHAUL
EN0110612H200001

IMPORTANT POINTS - DISASSEMBLY

When disassembling the starter, prepare a work stand as shown in
the figure.
D: Diameter = 110 mm {4.331 in.}
T: Thickness = 10 mm {0.394 in.}
H: Height = 120 mm {4.724 in.}

SHTS011061200003

1. REMOVE THE PINION GEAR.

Pinion gear (1) Remove the retainer ring.
Pinion stopper
! CAUTION
Retainer
ring
Wear a pair of safety goggles, because the retainer ring may spring
out the groove at the time of removal.
(2) Remove the pinion stopper.
(3) Remove the pinion gear.
Return spring (4) Remove the return spring.

SHTS011061200004

2. REMOVE THE TERMINAL LEAD.

(1) Remove the nut, disconnect the "M" terminal lead.

SHTS011061200005

3. REMOVE THE COMMUTATOR END FRAME.

(1) Remove the bolt.

SHTS011061200006
EN12–6 STARTER (J08E)

(2) Remove the through bolt, remove the commutator end frame.

SHTS011061200007

4. REMOVE THE HOLDER ASSEMBLY.

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

SHTS011061200008

(2) Remove the holder assembly from the armature.

SHTS011061200009

5. REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEMBLY.

(1) Remove the yoke assembly and armature assembly from the center
bracket assembly.

SHTS011061200010
 STARTER (J08E) EN12–7

6. REMOVE THE GEAR.

(1) Remove the cover and plate.
NOTICE
Remember the assembled position and direction of the plate.

SHTS011061200011

(2) Remove the planetary gear.

(3) Remove the internal gear.

SHTS011061200012

7. REMOVE THE DRIVE HOUSING ASSEMBLY.

(1) Remove the bolt, remove the drive housing assembly.

SHTS011061200013

8. REMOVE THE CLUTCH ASSEMBLY.

(1) Remove the retainer ring.
(2) Pushing the clutch assembly toward yoke assembly.
(3) Remove the clutch assembly.

SHTS011061200014
EN12–8 STARTER (J08E)

9. REMOVE THE LEVER.

(1) Remove the lever assembly.

SHTS011061200015

IMPORTANT POINTS - ASSEMBLY

NOTICE
Reverse the order of disassembly to reassemble the starter.

1. LUBRICATION
(1) Before reassembling, apply the recommended grease to the following:
[Apply Nippondenso No. HL50 grease (Shin-nisseki U3311 grease)]
or equivalent.
(1) Front bearing
(2) Internal gear assembly
SHTS011061200016 (3) Clutch assembly (Excluding the clutch roller.)
(4) Pinion gear
(5) Lever assembly

IMPORTANT POINTS - INSPECTION

NOTICE
These tests must be performed within 3 to 5 seconds to avoid burning
out the coil.

1. PERFORM NO-LOAD PERFORMANCE TEST.

(1) Connect battery and ammeter to the starter as shown.
(2) Check that the starter rotates smoothly and steadily with the pinion
gear moving out. Check the reading on the ammeter.

Standard amperage:
220 A or less/11 V

SHTS011061200017
 STARTER (J08E) EN12–9

INSPECTION AND REPAIR

EN0110612H300001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Measure
Ohmmeter
Continuity between the Continuity
segments of the commu- 1  or less 1 Replace.
tator

Measure
Ohmmeter
No continuity between
the connector and arma- 10 k or more 10 k Replace.
ture coil core.

Measure

Hacksaw
If the iron piece does blade
Armature short circuit
not vibrate,
test (Using a growler — Replace.
the armature is
tester)
good.
Growler
tester

Measure

Measure the circle run-

— 0.05 {0.0020} Replace.
out

Measure

Outside diameter of the

34.0 {1.338} 33.0 {1.299} Replace.
commutator

Measure

Depth between the mica Undercut depth

and the commutator 0.7 {0.028} 0.2 {0.008} Replace or repair.
(Under cut depth)
EN12–10 STARTER (J08E)

Inspection item Standard Limit Remedy Inspection procedure

Measure
Ohmmeter
Continuity between the Continuity
field coil end and the 1  or less 1 Replace.
read wire.

Measure
No Ohmmeter
No continuity between continuity
the field coil end and 10 k or more 10 k Replace.
yoke out side

Measure

Brush length 20.5 {0.807} 11 {0.433} Replace.

LENGTH

Measure

Brush spring load 45 N {162 oz} 17 N {61.20 oz} Replace.

Measure
No continuity
Ohmmeter
w
Insulation between the
10 k or more 10 k Replace.
brush and brush holder

Visual check

FREE
Rotating of pinion — — Replace. LOCK

Visual check

Rotating of needle roller Sticks or does

— Replace.
front bearing not rotate
 STARTER (J08E) EN12–11

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Rotating of needle roller Sticks or does

— Replace.
rear bearing not rotate

Measure

Continuity
Continuity between ter- Ohmmeter
1  or less 1 Replace.
minals 50 and C
Terminal
C
Terminal 50

Measure
Continuity
Continuity between ter- Ohmmeter
minal 50 and the switch 2  or less 2 Replace.
body

Terminal 50
 AIR COMPRESSOR (J08E: 340 cm3) EN13–1

AIR COMPRESSOR (J08E: 340 cm3)

EN13

EN13-001

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

DATA AND SPECIFICATIONS ......................... EN13-2
DESCRIPTION ................................................ EN13-3
TROUBLESHOOTING ..................................... EN13-4
COMPONENT LOCATOR................................ EN13-5
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-6
INSPECTION AND REPAIR .......................... EN13-14
EN13–2 AIR COMPRESSOR (J08E: 340 cm3)

AIR COMPRESSOR
DATA AND SPECIFICATIONS
EN0110613I200001

Type Reciprocating, single cylinder

Discharge amount 340 cm3 {20.7 cu.in.}

Bore x stroke 85 mm x 60 mm {3.35 in. x 2.36 in.}

Lubrication system Forced feed lubrication

Cooling system Forced water-circulated

 AIR COMPRESSOR (J08E: 340 cm3) EN13–3

DESCRIPTION
EN0110613C100001

A
B

3 1

11 4

5
10

7
6

8 9

SAPH011061300001

1 O-ring * 8 Bearing holder

2 Cylinder head assembly 9 Crankcase
3 Suction valve * 10 Piston pin
4 Piston 11 Piston ring
5 Connecting rod A Suction
6 Bearing B Delivery
7 Crankshaft
* Nonreusable part
EN13–4 AIR COMPRESSOR (J08E: 340 cm3)

TROUBLESHOOTING
EN0110613F300001

Symptom Possible cause Remedy/Prevention

Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace.
tact
Charging efficiency dropped (Pis- Worn piston and cylinder liner Replace.
ton, cylinder liner and piston rings) Seized piston Replace (piston, piston rings and cylin-
der liner).
Worn or broken piston ring Replace.
Charging efficiency dropped (Air Leakage of high-pressure air Replace or tighten pipe joint.
pipe and joints) Clogged air pipe Replace.
Charging efficiency dropped (Air Clogged element Clean or replace element.
cleaner)
Noisy operation (Piston) Wear of piston pin boss or piston pin Replace.
Seized, damaged or worn connecting Replace.
rod small end
Worn piston or cylinder liner Replace.
Damaged or seized piston Replace.
Foreign particles on the top surface of Clean or replace.
piston
Noisy operation (Bearing) Damaged, or worn ball bearing and/or Replace.
connecting rod bearing
Excessive carbon or oil in the com- Worn, sticking or broken piston rings Replace piston rings and/or cylinder
pressor cylinder head or discharge liner.
line (Piston ring) Insufficient piston ring tension Replace piston rings and/or cylinder
liner.
Malfunction of piston rings Replace piston rings and/or cylinder
liner.
Excessive carbon or oil in the com- Worn cylinder liner and piston rings Replace.
pressor cylinder head or discharge
line (Cylinder liner and piston rings)
 AIR COMPRESSOR (J08E: 340 cm3) EN13–5

COMPONENT LOCATOR
EN0110613D100001

20

A
5
11 A

6 1 E

10

7 C

9
2
16 B
8
4
13

12

19 13 3
15
8

17 14
18
21
D
E
SAPH011061300002
EN13–6 AIR COMPRESSOR (J08E: 340 cm3)

1 Cylinder head assembly ** 14 Crankcase

2 Suction valve * 15 Crankshaft
3 O-ring * 16 Woodruff key
4 Cylinder liner 17 Coupling
5 Piston ring 18 Coupling bolt
6 Piston 19 Pin
7 Connecting rod 20 Air compressor assembly
8 Connecting rod bearing 21 Screw
9 Lock washer *
10 Piston pin
11 Retainer ring *
12 Bearing holder
13 Ball bearing
* Nonreusable part. ** Do not decompose the cylinder head assembly.

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

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

SPECIAL TOOL
EN0110613K100001

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

Illustration Part number Tool name Remarks

S0965-01101 BEARING PULLER

S0944-01060 PISTON RING EXPANDER

OVERHAUL
EN0110613H200001

IMPORTANT POINTS - DISMOUNTING

1. REMOVE THE SUPPLY PUMP

(1) Refer to the chapter "FUEL SYSTEM".

2. REMOVE THE AIR COMPRESSOR.

(1) Remove the six air compressor mounting bolts and remove the air
compressor without applying excessive force.
NOTICE
Excessive force to the air compressor may damage the mounting
spigot or may cause oil leakage due to flaking of liquid gasket
between the flywheel housing and plate.
 AIR COMPRESSOR (J08E: 340 cm3) EN13–7

IMPORTANT POINTS - MOUNTING

Pointer
1. INSTALLATION PROCEDURES
(1) Fit the No.1 cylinder to the Top Dead Center.
1/6 Mark
NOTICE
Refer to the section "ENGINE TUNEUP" in the chapter "ENGINE
INTRODUCTION".

Damper

SAPH011061300005

(2) Align the aligning mark "0" on the top of coupling flange with protru-
sion on the compressor housing.
(3) Insert the O-ring in to the O-ring groove of the air compressor of bear-
ing holder side.

Protrusion

"0" -Mark
Coupling flange

SAPH011061300006

(4) Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or more)
in the flywheel housing as shown in the figure and insert the compres-
sor onto the stud bolt.
(5) Tighten the mounting bolts (other than the stud bolt) then remove the
stud bolt. Insert a bolt in the place of the stud bolt.
Tightening Torque:
28.5 Nm {290 kgfcm, 20 lbfft}

SAPH011061300007
EN13–8 AIR COMPRESSOR (J08E: 340 cm3)

(6) Make sure that the aligning mark "0" on the top of coupling flange is
aligned with protrusion on the compressor housing.

2. INSTALL THE SUPPLY PUMP AND AIR COMPRESSOR.

(1) Refer to the chapter "FUEL SYSTEM".

Protrusion

"0" -Mark
Coupling flange

Body
SAPH011061300008

IMPORTANT POINTS - DISASSEMBLY

1. REMOVE THE DRIVE GEAR.

(1) Remove the lock nut from the compressor drive gear.
NOTICE
If the spread is insufficient, the drive gear will be damaged when loos-
ing the nut.

SAPH011061300009

(2) Pull the drive gear from the crankshaft, then remove the woodruff key.
SST: Bearing puller (S0965-01101)

SAPH011061300010
 AIR COMPRESSOR (J08E: 340 cm3) EN13–9

2. REMOVE THE CYLINDER HEAD ASSEMBLY, ASSEMBLY AND O-

RING.
(1) Remove the cylinder head assembly, assembly and O-ring.
NOTICE
• Put the marking through the head cover to the cylinder liner.
E

• Do not decompose the cylinder head assembly.

SAPH011061300011

3. REMOVE THE CONNECTING ROD WITH THE PISTON.

(1) Rotate the crankshaft to the top dead center position.
(2) Spread the staking of the nut completely with a chisel, then loosen the
nut.
(3) Remove the connecting rod with piston.

SAPH011061300012

4. REMOVE THE PISTON RINGS.

(1) Remove the piston rings.
SST: Piston ring expander (S0944-01060)

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.

SAPH011061300013

5. REMOVE THE PISTON.

(1) Remove the retainer rings installed on both ends of the piston, using
retainer ring pliers.
! WARNING
Wear a pair of safety goggles, because the retainer rings may spring
out the groove at the time of removal.
(2) Strike out the piston pin.
NOTICE
Warm up the piston first in hot water, 80-90C {176-194F}, for approx-
imately 5 minutes before removing the piston pin.
SAPH011061300014
EN13–10 AIR COMPRESSOR (J08E: 340 cm3)

6. REMOVE THE CRANKSHAFT.

(1) Remove the bearing holder fitting screw.
(2) Use the press to remove the crankshaft together with the bearing
Bearing holder.
holder
NOTICE
Be careful not to damage the bearing holder.

Crankshaft
SAPH011061300015

7. REMOVE THE BEARING HOLDER.

Bearing holder (1) Use the press to remove the bearing holder.
NOTICE
Be careful not to damage the bearing holder.

Crankshaft

SAPH011061300016

8. REMOVE THE BALL BEARING.

(1) Using the special tool, remove the ball bearing from the end of the
crankshaft.
SST: Bearing puller (S0965-01101)

SAPH011061300017
 AIR COMPRESSOR (J08E: 340 cm3) EN13–11

IMPORTANT POINTS - ASSEMBLY

1. INSTALL THE BALL BEARING.

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

SAPH011061300018

2. INSTALL THE CRANKSHAFT.

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

SAPH011061300019

3. INSTALL THE CONNECTING ROD AND MEASURE THE END

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

SAPH011061300020

(2) Measure the connecting rod end play.

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

SAPH011061300021
EN13–12 AIR COMPRESSOR (J08E: 340 cm3)

(3) Lock the nut with a lock washer.

SAPH011061300022

4. MEASURE THE END PLAY OF THE CRANKSHAFT.

Assembly standard: 0-0.6 mm {0-0.0236 in.}
Limit: 1.0 mm {0.0394 in.}

SAPH011061300023

5. ASSEMBLE THE PISTON.

NOTICE
Assemble the various parts after applying engine oil to the sliding
parts.
(1) When installing the piston rings on the piston, ensure that the piston
skirt is at the bottom, and use the special tool.
SST: Piston ring expander (S0944-01060)

NOTICE
Install the piston rings in order shown in the figure.

SAPH011061300024
 AIR COMPRESSOR (J08E: 340 cm3) EN13–13

6. ASSEMBLE THE PISTON AND CONNECTING ROD.

NOTICE
Warm up the piston first in hot water, to 80-90C {176-194F}, for
approximately 5 minutes.
(1) Install the retainer ring at one end of the piston pin holes.
(2) Apply engine oil to the piston pin.
(3) Fix the piston and connecting rod by inserting the pin.
(4) Fit the new retainer ring at the other end.

! CAUTION
The retainer ring may spring out of the groove during assembly. Wear
SAPH011061300025 a pair of safety goggles during assembly.

7. INSTALL THE CYLINDER LINER AND CYLINDER HEAD.

NOTICE
Do not twist the O-ring when installing it on the cylinder liner and cyl-
inder head assembly.
(1) Rotate the crankshaft to the top dead center position.
(2) Arrange the piston rings so that their gaps are equally spaced.
(3) Install the cylinder liner and cylinder head assembly.
Tightening Torque:
Cylinder liner: 25-29 Nm {255-295 kgfcm, 19-21 lbfft}
Cylinder head: 29-34 Nm {295-347 kgfcm, 21-25 lbfft}

8. INSTALL THE DRIVE GEAR.

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

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

SAPH011061300026
EN13–14 AIR COMPRESSOR (J08E: 340 cm3)

INSPECTION AND REPAIR

EN0110613H300001

Unit: mm {in.}

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Cracks or defects of the con-

— — Replace.
necting rod

Outside diameter of piston pin 18 {0.709} — Measure

Clearance between the piston 0.016-0.044 Replace.

0.07 {0.0028}
pin and connecting rod {0.0007-0.0017}

Inside diameter of the connect- Measure

ing rod
34 {1.339} —
(Tighten the bearing cap to the
specified torque.)

Outside diameter of the crank

34 {1.339} —
pin

Replace.

Oil clearance between the con- 0.025-0.075

0.1 {0.0039}
necting rod and the crank pin {0.0010-0.0029}

Measure

Replace con-
0.2-0.4
Connecting rod end play 0.5 {0.0197} necting rod or
{0.0079-0.0157}
crankshaft.
 AIR COMPRESSOR (J08E: 340 cm3) EN13–15

Inspection item Standard Limit Remedy Inspection procedure

Visual check

Damage and scratches of the

— — Replace.
cylinder liner

Outside diameter of the piston 85 {3.346} — Measure

Inside diameter of the cylinder

85 {3.346} —
liner

A: 0.23-0.295
0.335 {0.0132}
{0.0091-0.0116}
Replace.

Clearance between the piston

and the cylinder liner B: 0.09-0.155
0.195 {0.0077}
{0.0036-0.0061}

Clearance between the piston 0-0.028 Measure

0.08 {0.0031}
pin hole and the piston pin {0-0.0011}

Replace.
Outer diameter of the piston
18 {0.709} —
pin

Compression Measure
Piston ring 2.0 {0.0787} —
ring
thickness
Oil ring 4.0 {0.1575} —

Compression
Piston ring 2.0 {0.0787} —
ring
groove
Oil ring 4.0 {0.1575} — Replace.

Clearance between the ring

0.01-0.045
groove and the compression 0.08 {0.0031}
{0.0004-0.0017}
ring
EN13–16 AIR COMPRESSOR (J08E: 340 cm3)

Inspection item Standard Limit Remedy Inspection procedure

0.1-0.3 Measure
Top 1.0 {0.0394}
{0.0040-0.0118}

0.35-0.55
Gap between 2nd 1.0 {0.0394}
{0.0137-0.0216}
ends of piston Replace.
ring
0.2-0.4
Oil 1.0 {0.0394}
{0.0079-0.0157}

Visual check

Worn or damaged bearing — — Replace.

Visual check

Worn or damaged cylinder

— — Replace.
head assembly

Visual check

Worn or damaged suction

— — Replace.
valve

Drive gear side 45 {1.7716} 44.995 {1.7714} Measure

Outside diam-
eter of the
Opposite drive Replace.
crankshaft 55 {2.1654} 54.995 {2.1651}
journal gear side

100.04 Measure
Cylinder block 100 {3.9370}
{3.9385}
Inside diame-
ter of the
Replace.
bearing 100.04
holder Bearing holder 100 {3.9370}
{3.9385}

Measure

Replace crank-
Crankshaft end play 0-0.6 {0-0.0236} 1.0 {0.0394} shaft and/or
ball bearing.
 ENGINE CONTROL (J08E) EN16–1

ENGINE CONTROL (J08E)

EN16

EN16-001

ACCELERATOR PEDAL........................... EN16-2

DESCRIPTION ................................................ EN16-2

ENGINE ECU ............................................ EN16-3

COMPONENT LOCATOR................................ EN16-3
REPLACEMENT .............................................. EN16-4
EN16–2 ENGINE CONTROL (J08E)

ACCELERATOR PEDAL
DESCRIPTION
EN0110616F200001

(5.5315 -5.9251 in.)

140.5 -150.5 mm

Floor board

SAPH011061600001

1 Accelerator pedal assy

 ENGINE CONTROL (J08E) EN16–3

ENGINE ECU
COMPONENT LOCATOR
EN0110616J100001

SAPH011061600002

1 Engine ECU

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

A 28.5 {291, 21}
EN16–4 ENGINE CONTROL (J08E)

REPLACEMENT
EN0110616H100001

DISCONNECTING THE ENGINE ECU CONNECTOR

! WARNING
Perform replacement after cooling to prevent burns. (Wait for at least
30 minutes after setting the starter key to the "LOCK" position.)

Engine ECU

Connector

SAPH011061600003

1. CLEANING AND DISCONNECTING THE ENGINE ECU CONNEC-

TOR
(1) Check that the engine ECU connector is completely connected to the
engine ECU.
Engine ECU (2) Directly spray water around the engine ECU connector by using a
spray bottle.
NOTICE
While working, do not disconnect the connectors.
HINT
Connector If it is much dirty, squirt water at the connector sliding portion and
SAPH011061600004 connector surface.
(3) Blow air around the engine ECU connector and engine ECU surface
to remove dirt and foreign matter.
NOTICE
• While working, do not disconnect the connectors.
• Blow off water with air as much as possible for drying.
 ENGINE CONTROL (J08E) EN16–5

(4) Using a small brush, carefully remove dirt and foreign matter remain-
ing at the sliding portion.
NOTICE
While working, do not disconnect the connectors.
(5) Using a waste cloth, wipe off around the engine ECU connector and
engine ECU surface.
NOTICE
Lever • While working, do not disconnect the connectors.
Sliding • Wipe up water thoroughly.
portion
SAPH011061600005 (6) If you feel the movement of the lever unsmooth, repeat steps (1)
through (5).
(7) Disconnect the engine ECU connector and check it for deposition of
dirt and foreign matter.
a. Set the hook of the connector in the direction of the arrow to
release the lock.

Hook

SAPH011061600006

b. While pushing the primary latch of the connector, move the lever
in the direction of the arrow as shown in the figure until a "click" is
heard and then disconnect the connector.

Primary latch Lever

SAPH011061600007

c. Pull out the connector straight.

NOTICE
• Do not insert and remove the connector more than necessary.
• Do not give shocks to the engine ECU.
• Never disconnect the harness by holding and pulling or prying
as it may result in wire or terminal deformation.
• Never insert a test lead from the rear of the connector.
• Do not paint or apply grease or oil to the ECU surface and con-
nector to maintain their functions and durability.
SAPH011061600008 HINT
If it cannot be pulled out with a light force, check if the lever is fully
open.
EN16–6 ENGINE CONTROL (J08E)

(8) If the side of the harness side connector is found dirty, wipe it off with
a moistened waste cloth while being careful not allowing dirt and for-
Do not wipe Portions to eign matter to drop.
off the be wiped
terminal. clean NOTICE
• Use a thoroughly wrung waste cloth.
• Do not wipe off the terminal opening.
Harness • Do not directly spray water.
side
connector

SAPH011061600009

(9) If the engine ECU side connector is found dirty, wipe off its side with a
Portions to moistened waste cloth.
be wiped Do not wipe
clean off the NOTICE
terminal.
• Use a thoroughly wrung waste cloth.
• Do not wipe off the terminal opening.
• Do not directly spray water.
Engine ECU
(10) Blow air on the terminal part inside the engine ECU side connector to
side
connector remove dirt and foreign matter.

SAPH011061600010
 ENGINE CONTROL (J08E) EN16–7

REMOVING THE ENGINE ECU

1. REMOVING THE ENGINE ECU

Cylinder block
Engine ECU (1) Unfasten the bolts (4 pcs.) and remove the engine ECU from the cylin-
der block.
NOTICE
• Protect with plastic covers to avoid entry of dirt and foreign mat-
ter into the connectors of the engine ECU.
• Do not give shocks to the ECU.
• Do not use the engine ECU if dropped.
• Do not directly touch the connector terminals by hand.
• The engine ECU is non-disassemblable.
SAPH011061600011 • Do not paint or apply grease or oil to the ECU surface and con-
nector to maintain their functions and durability.

MOUNTING THE ENGINE ECU

1. MOUNTING THE ENGINE ECU

Cylinder block
Engine ECU (1) Mount the engine ECU the cylinder block with the bolts (4 pcs.). For
the tightening order, tighten them diagonally.
Tightening Torque:
28.5 Nm {291 kgfcm, 21 lbfft}

NOTICE
• Check that there are no dirt and foreign matter in the engine ECU
connectors.
• Do not give shocks to the ECU.
• Do not use the engine ECU if dropped.
SAPH011061600012
• Do not directly touch the connector terminals by hand.
• The engine ECU is non-disassemblable.
• Do not paint or apply grease or oil to the ECU surface and con-
nector to maintain their functions and durability.
• Check that there is no dirt on the bosses (4 places) on the back
of the engine ECU.
• Check that there are no grease and damage on the filter (resin
housing) on the back of the engine ECU.
Filter
(resin housing)

Boss

SAPH011061600013
EN16–8 ENGINE CONTROL (J08E)

CONNECTING THE ENGINE ECU CONNECTOR

1. CONNECTING THE ENGINE ECU CONNECTOR

(1) Check that the harness side connector lever is fully open and place it
straight on the engine ECU side connector.
Lever NOTICE
At this time, check that the lever is fully open.

SAPH011061600014

HINT
Check that it is inserted along the wrong fitting prevention keyway.

Wrong fitting prevention keyway

SAPH011061600015

(2) Press the upper part of the harness side connector and insert the
connector uniformly.

Lever

SAPH011061600016

(3) Move the lever in the direction of the arrow as shown in the figure until
a "click" is heard and connect the connector.
NOTICE
If the lever cannot move smoothly, repeat steps (1) and (2). Also drop
a few drops of water to the sliding portion to make it smooth.

Sliding Lever
portion
SAPH011061600017
 ENGINE CONTROL (J08E) EN16–9

(4) Move the hook in the direction of the arrow as shown in the figure until
a "click" is heard in order to lock the connector.

Hook

SAPH011061600018
Hino Motors Sales U.S.A., Inc.
41180 Bridge Street, Novi, MI 48375
Telephone: (248) 699-9300
PRINTED IN JAPAN

Pub.No. S5-UJ08E14A '16.10