Hino P11C Engine Workshop Manual

HINO P11C

ENGINE WORKSHOP MANUAL

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9 Group 10 Group 11 Group 12 Group 13 Group 14 Group 15 Group 16

General ........................................................................................ W5-1 Standard Value ............................................................................. W5-2 Parts to be prepared .................................................................... W5-3 Engine assembly/disassembly ..................................................... W5-4 Fuel System ................................................................................. W5-5 Emission Control .......................................................................... W5-6 Electrical........................................................................................ W5-7 Intake ............................................................................................ W5-8 Engine Mechanical ....................................................................... W5-9 Exhaust ...................................................................................... W5-10 Cooling ........................................................................................W5-11 Lubrication .................................................................................. W5-12 Starting and Charging ................................................................ W5-13 Turbocharger .............................................................................. W5-14 Failure Diagnosis for each Engine Status .................................. W5-15 Engine Diagnosis Code .............................................................. W5-16

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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  

                                      

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 

                 

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   



    

















 







 

  



 









 



 

 

   



 

  





  

 



  

  

 



   







 

      



   

           



 

  



  



        

  

    



 



 



  



  







  





    

    

    

  

     



     



    



     

   



I



 

  

 

         







  



  



  

 

 

  





 

 







 















 

  







 



 



 

































 



 

 

  





 

 

 

 

  

 



 

 







 









 







 

 

 



 

 



  

 





 





 

  











 







 



 











    

 

   

  





  





 







  

 





 

  



 





 

 

 



 







 



 





 

    



 

 











    



    

 



  



 





 

 

   























































 



 

   









































































 

  

    



 

 

  

  





 

   

   

 

  

 







  

 

 







 

    

 

  

  

 



        

    

  

    

 

     



    

    

        

    







 

 

         

    









































   

 





 







 

    

   







  

  

  

  

  

   





          



    



  





  

  





  

  





   

   



  



  

  

  



  

  

  



  

  

  



  

  

  



  

  

  



  

  

  

 

         





 

     













  

                 

    



  





 

   





 

  







   

   

   









  

  

  

  





 

   



       



  



       

 

 

            



  



  

 

    

   

   

  



 

  



  

 







 

  

  

   



  

  

 

 

 

  



   





 

     



 

 

 





















































 





  







  



 

  

 









    



    

 

            

   

    



 

 



 



    

     

     



 

                

       

   

 

 

   





 

 

  



 













    



 

 

 

 

  

   

  

    





        

 



   

  

  

 

 

    



  

  

  

  

 

  

  



   

    

     

 

  

  

  

  

  



   

  

 

   

 

 

  

   

  



  

  

  

  

   

     

    

    







   

    

    

    

    

    

  

  

      

  

   

   

    

   

   

  

     

  

    

   



     

   

   

    



    

     

   

      

   

   

    

   

  

  

     

  

  

    

  

   

  

  

 

 

   

 

 

    





 

 







 

  





 





 



  



 









 

    







 

 

 



 

     



      

    



 







  



   

      









 

   

















 

 

    

 



 

 

  



  

 

     





 

 

 

  

 

 





 

        





  



         

    





 



 

    

 



Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638





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  

                                                                                  

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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

  

   

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

















  

    





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

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





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

  





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





 

 











 







 

 













  

 





   

  

    



















Hino P11C Engine Specifications  

  

 









 

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

 











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

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







   



   



   

 



   



   



   

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638





 



 





 



 





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 

   

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   



   



   

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

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



Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638







 



 













 





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

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



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



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

 



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

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

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

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

  



  



  





  



  

 





   

  





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

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

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

 



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  

 

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



  

  

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

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

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

 

 

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

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 

 

 



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





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



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 

 

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









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





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 





 

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

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 

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    

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Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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 

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   

 

 



 

 



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 



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 

   

  







 

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



 









 



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





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





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





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

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

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

    







 



 

 

  

 



  





 

 



 

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



 









  

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





  

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

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



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





        

 



   

        







 

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 



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



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



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Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638









 

 





 



 



    



 



 

 

 

 



  





  

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 







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

 

  











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

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

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

     

 



     







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













 





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



 

  







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









 

 



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

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



 

  



 







 



 





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



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

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

 



 



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



 

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 

 

  

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



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



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 

       

 



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    

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  

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

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Hino P11C 

 

    





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

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



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

 

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 

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 

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 





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  

 



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

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

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

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

 













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

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















    

 

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Hino P11C Exhaust  

    

















Hino P11C Cooling  

  

     





  











 

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  

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 

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   

 

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

   

 

 



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  

 

 





   

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Hino P11C Tightening Torque Specifications 

    

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







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









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    

   

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 

 

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 

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

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 

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  



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

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

 

 

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 

 

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 

     



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



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

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

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

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

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

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

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

   



   



   



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

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

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  

     









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

 

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









 

 





















 

 







 







 



  

  







  

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







 





















 

    



 

 



































 

  





 

  

 

 



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

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   

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

    

   

  

 

  



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 



 

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 



 

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 





 

  

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



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



 

 

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





  

  

   



 



  

 







  





 

 

      















 





















 





























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



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

  

 

    

























 



  

  





  



 

 



 



 

    













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Hino P11C Engine Parts To Be Prepared  

                                                          

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

  

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

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

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

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  

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

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

 

 

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  

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 

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  

 

  

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

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

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

 

 



 

 

 





















 

  

















 





 





 

















































 



  











  

 









































 





    











  





























 



  





















  

 

   

      

  



   



  





     

  





 

 























 

 

  

 

 

 















 









 

















 













 

 





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

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

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  













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 

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

ENGINE ASSEMBLY/DISASSEMBLY

HINO P11C 4 ENGINE ASSEMBLY/DISASSEMBLY Service procedure Overhaul item

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

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-4-1

ENGINE ASSEMBLY/DISASSEMBLY

Inspection Before Service Measurement of compression pressure JP30002040702001

Measure the compression pressure before

NOTICE

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

Preparation before measurement (1) (2)

Charge the battery completely. Check the valve clearance and adjust it when exceeding the standard value.

(3)

Warm the engine and set the water temperature to 80

(4)

C{176 F}. Remove the air cleaner.

(5)

Remove the head cover.

(6)

Remove all injectors.

(7)

To prevent spread of engine oil, attach a jig which cuts a head cover in half. (Cut it so that the camshaft may be covered.

2.

Measurement (1)

Attach a special tool to the nozzle sheet of the cylinder where the compression pressure is measured. Special tool : 09952-1080, 09552-1060, 09552-1030 Compression gauge adapter

(2)

Turn the starter and measure the compression pressure.

! CAUTION SAPH300020400001

Do not operate the starter for 15 seconds or more. Since the air cleaner is removed, prevent entry of dirt.

(3)

Measure the compression pressure of each cylinder continuously. Engine revolution 200r/min {rpm} Unit : MPa {kgf/cm2,lbf/in.2} Compression pressure

(4)

Standard value

2.9 {30, 421}

Operation limit

2.5 {26, 362}

If the compression pressure is below the operation limit, overhaul the engine.

(5)

After measurement, reassemble the removed parts.

W5-4-2

ENGINE ASSEMBLY/DISASSEMBLY

Engine Body Removal JP30002040702002

1.

2.    

Preliminary work before removal of engine (1)

Place the machine on a level ground.

(2)

Remove the battery cable from the battery minus terminal.

Drain of coolant and engine oil (1)

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

NOTICE

drain. Connection of an appropriate hose to the oil cooler drain pipe facilitates drain of coolant without spread.

    SAPH300020400002

! CAUTION

To prevent burn, drain coolant after the temperature is sufficiently low. To dispose coolant, observe the specified method (waste disposal) or the method with attention to environment.

(2)

Drain engine oil from the oil pan drain plug as required.

! CAUTION

To prevent burn, drain coolant after the temperature is sufficiently low. Dispose coolant according to the specified method (waste treatment) or with a method considering the environment.



SAPH301090400003

3.

Removal of intake hose, intercooler hose and exhaust pipe

 

(1)

Loosen the clamp and remove the intake hose.

(2)

Remove nuts and remove the exhaust pipe.

! CAUTION

Close the opening of the intake manifold with a packing tape to prevent entry of dirt inside

  

the engine.

SAPH300020400004

W5-4-3

ENGINE ASSEMBLY/DISASSEMBLY 4. 

Disconnection of fuel hose (1)

Remove the fuel hoses (feed side (A) and return side (B)). Wrap the removed hose with a plastic sheet with its end



facing upward to prevent spill of fuel. ! CAUTION

Wipe spilled fuel with a rag.

SAPH301090400005

5.

Disconnection of water, engine oil pipes, etc. (1)

Disconnect the hose between the radiator and the engine.

(2)

Disconnect the car heater pipe.

(3)

Disconnect the oil filter pipe.

! CAUTION

6.

Wipe off spilled water and engine oil with a rag.

Engine lifting (1)

Place a hook on the hole in the engine hanger.

(2)

Keep a little slack of the wire rope.

(3)

When the wire is completely tense, make sure that the wire is firmly engaged with the engine hanger. Then, lift the engine slowly. Reference: "Lubrication, oil filter"

! CAUTION

Work carefully so that the engine may not come in contact with the frame and others.

SAPH301090400006

W5-4-4

ENGINE ASSEMBLY/DISASSEMBLY

Installation 1.

Connection of fuel hose (1)

Insert a fuel hose and fix it with a hose band.

Work after installation JP30002040702004

1.

Inspection of engine oil (1)

Make sure that the drain cock is closed.

(2)

Pour engine oil. Engine oil amount (L{us gal}) Oil pan

Oil filter and Remote hose

Approx. 35{9.25}

Approx. 7.5{1.98}

 

! CAUTION SAPH300020400009

Check the amount of oil with an oil level gauge. Multi grade

SAE #10W-30

Single grade

SAE #30

2. 

Air bleeding of fuel system (1)



Please use Hino genuine engine oil

Prepare a rag to receive fuel at the end of the drain hose (1).

(2)

Loosen the air bleeding bolt (2) of the fuel filter.

(3)

Turn the knob of the priming pump (3) to the left to let it float up, and then operate it.

(4)

Move the knob until fuel without bubble comes out from

(5)

Tighten the air bleeding plug (2).

the drain hose (1).

 SAPH301090400008

Tighening torque : 7N m{70kgf cm,7 lbf ft} ! CAUTION

Do not tighten the air bleeding plug (2) while operating the knob of the priming pump (3).

(6)

Turn the knob of the priming pump (3) again five or six

(7)

Press the priming pump (3) and tighten it fully to the right.

turns.

! CAUTION

After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel leak.

W5-4-5

ENGINE ASSEMBLY/DISASSEMBLY NOTE:

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-4-6

FUEL SYSTEM

HINO P11C ENGINE

5 FUEL SYSTEM ç\ê¨ê} ç\ê¨îzíuê}

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

W5-5-1

5

FUEL SYSTEM

Fuel System Fuel system diagram JP30109050402001

  







    

  

 







 



SAPH301090500001

1 - Overflow valve 2 - Overflow pipe 3 - Feed pump 4 - Common rail 5 - Injection pipe 6 - Flow damper 7 - Injector 8 - Leakage pipe 9 - Pressure limiter

10 - Return pipe 11 - Through feed pipe 12 - Priming pump 13 - Fuel tank 14 - Feed pipe 15 - Supply pump 16 - Through feed valve 17 - Fuel filter

W5-5-2

FUEL SYSTEM

Part layout (typical example) JP30109050402002

Fuel pipe

SAPH301090500002

23081

Leakage pipe

23811

Feed pipe

23300

Fuel filter

23811A

Feed pipe

23391

Leakage pipe

23812

Feed pipe

23701

Injection pipe

23815

Feed pipe

23702

Injection pipe

23816

Overflow pipe

23703

Injection pipe

23816A

Through feed pipe

23704

Injection pipe

23871

Pressure feed pipe

23705

Injection pipe

9655-10100

Gasket*

23706

Injection pipe

9655-14140

Gasket*

23766A

Fuel pipe

SZ209

Gasket*

23766B

Overflow pipe

*Parts not to be reused. Tightening torque 23081

20N m{200kgf cm,15 lbf ft}

23705

44N m{450kgf cm,32 lbf ft}

23701

44N m{450kgf cm,32 lbf ft}

23706

44N m{450kgf cm,32 lbf ft}

23702

44N m{450kgf cm,32 lbf ft}

23871

Common rail side:54N m{550kgf cm,40 lbf ft}

23703

44N m{450kgf cm,32 lbf ft}

23871

Supply pump side:44N m{450kgf cm,32 lbf ft}

23704

44N m{450kgf cm,32 lbf ft} W5-5-3

HINO P11C FUEL SYSTEM

Supply pump,Common rail,Injector

SAPH301090500003

11195

Injector clamp

22760

Common rail assembly

11491B

Common rail bracket

29611

Oil pipe

13610

Supply pump drive case assembly

9645A

O-ring*

13611

Supply pump drive shaft

9655-12100

Gasket*

13691

Bearing holder case

9655-15104

Oil seal*

13693

Bearing retainer

9851A

O-ring*

15773

Oil pipe

9851B

O-ring*

15774

Fuel pipe

900111

Shim

22730

Supply pump

993-302080

Bearing

23670

Injector

993-322070

Bearing

*Parts not to be reused. Tightening torque 22730

Cotter bolt:91N m{930kgf cm,67 lbf ft}

9181-08400

25N m{250kgf cm,18 lbf ft}

22730

Coupling bolt:61N m{620kgf cm,45 lbf ft}

9191-08901

28N m{290kgf cm,21 lbf ft}

900124

26N m{270kgf cm,19 lbf ft}

9219A

245N m{2,500kgf cm,181 lbf ft}

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-5-4

FUEL SYSTEM

Fuel filter

SAPH301090500004

23300

Fuel filter assembly

23316

Air bleeding plug

23401

Tightening torque 23316

7N m{70kgf cm,5 lbf ft}

W5-5-5

Fuel filter

E485B

FUEL SYSTEM

Priming pump

SAPH301090500005

22509

Knob

22570

W5-5-6

Priming pump assembly

FUEL SYSTEM åšä²óvóÃçÄñ êÆî€óvóÃ

Replacement of the fuel filter JP30109050704001

1.

Fuel filter removal (1)

Use the special tool and remove the fuel filter. Special tool : 09553-1010 Fuel filter wrench

! CAUTION

• Prepare a tray because the filter contains diesel fuel • Do not use a commercial chain-type filter wrench or similar to remove the filter. This can cause scratches or deformation for the

SAPH301090500006

outer circumference, which can lead to fuel leakage and fire. • For disposal of fuel, observe the local disposal procedure. 2.

Fuel filter installation (1)

Remove dirt and foreign matter from the installation surface.

(2)

Apply a thin coating of diesel oil to the gasket (2) of the new fuel filter.

(3)

Turn the fuel filter clockwise by hand until the gasket (2) comes into contact with the body seal face.

! CAUTION



(4)





• Confirm that the gasket (2) is in positive contact with the seal surface.

Use the special tool and tighten for approximately another 2/3 turns.

! CAUTION



• At the time of installation, take care that the gasket (2) is not damaged by twisting. • Replace the gasket (2) by the new one in the element kit (1). • Do not reuse an element (1). • After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel

SAPH301090500007

leak. • Do not use a commercial chain-type filter wrench or similar to install the filter. This can cause scratches or deformation for the outer circumference, which can lead to fuel leakage and fire. NOTICE

• The scale markings (3) are in the order of 1 2

3 4 5

6 1

2..., and one gradation

corresponds to 60 . • The above 2/3 turns corresponds to 4 gradations (240 ), and element (1) and body should be marked before turning. W5-5-7

E485B

FUEL SYSTEM 3.  

Fuel system air bleeding (1)

Prepare a shop towel or similar at the time of the drain

(2) (3)

Loosen the fuel filter air bleeding plug (2). Turn the knob of the priming pump (3) to the left to let it

hose (1) to receive fuel.

float up, and then operate it. (4)

Operate the knob until fuel without air bubbles flows from the hose (1).



(5) SAPH301090400008

Tighten the air bleeding plug (2). Tightening torque: 7 N m {70 kgf cm,5 lbf ft}

! CAUTION

• Do not tighten the air bleeding plug (2) while operating the knob of the priming pump (3).

(6)

Turn the knob of the priming pump (3) again five or six turns.

(7)

Press the priming pump (3) and tighten it fully to the right.

! CAUTION

• After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel leak.

W5-5-8

FUEL SYSTEM

Replacement of supply pump JP30109050704004

1.

Removal of supply pump • The supply pump (1) does not have to be adjusted.

NOTICE

• If insufficient discharge rate or a faulty subengine speed sensor occurs, contact the Denso service shop. (1) 

Remove the fuel pipe and oil pipe connected to the supply pump (1).

SAPH301090500009

(2)

Align the No. 1 cylinder to the compression top dead center and align the stamp lines (2) of the supply pump



(1).

 (3)

Remove the coupling bolt (3). Special tool : 09819-1707 Supply pump coupling wrench

SAPH301090500010

(4)

Remove four bolts (5) and remove the supply pump.

(5)

Loosen the cotter bolt (4) and ensure shaft play for reinstallation.



 SAPH301090500011

2.

Installation of supply pump (1)

Turn the crankshaft in the engine rotating direction (clockwise as viewed from the cooling fan side), align the "16" stamp line of the crankshaft damper with the pointer, and align the No. 1 cylinder to the compression top dead center.



! CAUTION

• If the pointer is matched with "16", but the supply pump bearing case shaft key or cotter bolt faces down, No. 6 is at the compression

SAPH301090500012

top dead center. Turn the crankshaft one turn and set the No. 1 cylinder at the compression top dead center.

W5-5-9

FUEL SYSTEM (2)

Make sure that the cotter bolt (4) is loose and install the supply pump on the bracket. Tightening torque : 28 N m {290 kgf cm, 20 lbf ft}



SAPH301090500013

(3) 

Install two bolts at the coupling (3) and tighten the coupling bolt by aligning the stamp line (2) of the supply



pump. Special tool : 09819-1707 Supply pump coupling wrench Tightening torque : 61 N m {620 kgf cm, 45 lbf ft} ! CAUTION



• Make sure that there is no clearance between laminate plates. Make sure that there is no

SAPH301090500014

flange deformation due to crashing of laminate plates. (4)

Tighten the cotter bolt (4). Tightening torque : 91 N m {930 kgf cm, 67 lbf ft}

! CAUTION

(5)

• Make sure that laminate plates are not deformed or there is no undue force on them.

Replace the gasket with a new one and connect the fuel pipe and oil pipe to the supply pump (1). Tightening torque : 44 N m {450 kgf cm, 32 lbf ft} (Fuel pipe M14) 54 N m {550 kgf cm, 40 lbf ft} (Fuel pipe M16)



SAPH301090500015

W5-5-10

FUEL SYSTEM

Replacement of injector JP30109050704005

1. 

Removal of injector harness (1)

Remove each connector and bolt and remove the injector harness (1).

! CAUTION

• Since the injector harness bracket is susceptible to distortion, be careful for handling. • Refer to the following for installation of the

NOTICE

engine retarder. "Reference: Engine SAPH301090500016

mechanical, Engine retarder, Removal" 2.

Removal of leakage pipe (1)

Remove the injector and cylinder head union bolts.

(2)

Remove bolts and remove the leakage pipe.

! CAUTION

• Since the leakage pipe is susceptible to distortion, be careful for handling.

SAPH301090500017

3.

Removal of injector (1) Remove the injection pipe seal. (2)



Remove the injector clamp mounting bolt and remove the injector (2) and injector clamp. • If it is difficult to pull it out, pull it out with a

NOTICE

special tool (3). Special tool (3):09420-2010 Puller (3)

Remove the O-ring from the cylinder head.



SAPH301090500018

W5-5-11

FUEL SYSTEM 4.

Installation of injector

 (1)

Install a new O-ring (4) on the cylinder head groove and insert the injector.

! CAUTION

• Apply engine oil to the O-ring and be careful to prevent pinching of the O-ring.

SAPH301090500019

(2)

Put a new injection pipe oil seal on the injector and install it with bolts and nuts.

! CAUTION

• Do not fix the injector clamp until the injection pipe is tack welded temporarily. • Install the injection pipe seal to prevent undue force to the injector. (Offset position between the injection pipe oil seal and the injector may cause oil leak or poor assembly of the injection pipe.)

SAPH301090500020

(3)

Replace the gasket with a new one and tack weld the leakage pipe to the injector and cylinder head temporarily.

! CAUTION

• Install the gasket in a direction in which it does not interfere with the valve spring. • Since the injector top union bolt and the cylinder head joint union bolt are different in screw thread pitch, be careful for handling.

Injector top union bolt (M10 x 1.0) SAPH301090500017

Cylinder head joint union bolt (M10 x 1.5) (4)





Tack weld the injection pipe (5) through the injection pipe seal (6) until it comes in contact with the seat.

! CAUTION

• Tack weld it by adjusting so that the injector is aligned with the injection pipe. • Make sure that the seal spring (7) is installed correctly.

 SAPH301090500021

W5-5-12

FUEL SYSTEM (5) 

Tighten the injector clamp (8) mounting bolts to fix the injector. Tightening torque : 26 N m {270 kgf cm, 19 lbf ft}

! CAUTION

• After tightening, make sure that the rocker arm moves smoothly. Make sure that there is no undue force on the injection pipe oil seal. (Otherwise, oil leak or



poor assembly of injection pipe (5) may occur.)

SAPH301090500022

(6)

Tighten the injection pipe (5).

(7)

Tighten the leakage pipe.

Tightening torque : 44 N m {450 kgf cm, 32 lbf ft}

Tightening torque : 20 N m {200 kgf cm, 15 lbf ft} ! CAUTION

• Assemble so that the gasket connection may not come in contact with the rocker arm.

SAPH301090500017

5. 

Installation of injector harness (1)

Connect each connector and install the injector harness (1).

SAPH301090500016

W5-5-13

E485B

FUEL SYSTEM 6. 

Entry of injector correction value to the engine ECU (entry using HinoDX and QR code reader)

! CAUTION

• When the injector is replaced, it is necessary to enter the injector correction value (QR code (9)) described on the new injector (2) to the engine ECU. Incorrect entry of the correction value may result in faulty engine.



• Available entry methods of the injector

NOTICE SAPH301090500024

correction value are the PC tool and the QR code reader (10). • The work flow is described below. For detailed procedures, refer to the operation manual of the HinoDX. (1)

Read the injector QR code (9) with the scanner of the QR code reader and prepare the correction data file.

(2)

Enter the injector correction value directly from the HinoDX to the engine ECU.

 









SAPH301090500025

W5-5-14

FUEL SYSTEM

Inspection of injector JP30109050704006

1.

Inspection of injector insulation (1)

Remove the injector plastic terminal cap (upper) (1).

(2)

Measure the insulation resistance between the injector upper body (2) and one terminal (no polarity) of two terminals (3) for the injector harness (4).

 Standard value



(normal temperature) (3)

1000 M

or more

Measure the resistance value between two terminals above.

 Standard value (at 20 C{68 F}) (4)

0.45

0.1

If the resistance value exceeds the standard value, replace the injector assembly.



2.

Cleaning of injector (1)

SAPH301090500026

Remove sludge at or around the terminal, if any.

! CAUTION

• In removing sludge, do not use a cleaning agent. Wipe it off with a rag. Use of a cleaning agent may result in electric failure due to penetration of the agent.

nomatch

W5-5-15

FUEL SYSTEM

Inspection of common rail function parts (evaluation) JP30109059999001

1.

Inspection of pressure sensor (1) If the check engine lamp illuminates and it applies to "Pressure sensor disconnection", "Pressure sensor shortcircuit" or "Pressure sensor output does not change" in inspection of failure diagnosis system, replace the pressure sensor.

2.

Inspection of pressure limiter (1)

Remove the hollow screw (1) of the pressure limiter.

(2)

Install a blank plug (2) on the pipe side using a bolt to prevent fuel discharge.

(3)

Install the union (3) on the pressure limiter and connect





SAPH301090500027

the plastic hose (4) to the tip of the union (3). (4)

Prepare a fuel container (5) at the tip of the plastic hose (4).

(5)



If the engine is started and fuel discharge is recognized continuously, replace the pressure limiter.

  SAPH301090500028

3.

Inspection of flow damper (1)

Start the engine, run it from idling to full throttle and check the diagnosis code of "flow damper operation".

(2)

If the diagnosis code of "flow damper operation" is detected, replace the applicable injector and inspect

(3)

If the failure is reproduced after the injector is replaced,

again. replace the flow damper with the common rail assembly. ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî€óvóÃ

W5-5-16

FUEL SYSTEM

Overhaul of supply pump drive bearing case JP30109050702001

1.

Removal of timing gear case cover "Reference: Engine mechanical, timing gear cover and flywheel housing, timing gear case cover replacement"

2.

Removal of supply pump drive gear (1)

Remove the drive gear mounting nut.

(2)

Remove the oil pipe connected to the supply pump drive bearing case.

SAPH301090500029

(3) ďƒŻ

Pull out the gear using a special tool or install a box nut (1) on the shaft, hit the shaft with a copper hammer, loosen and remove the gear with impact. Special tool : 09420-1111 Timing gear puller

(4)

Remove the supply pump drive bearing case.

SAPH301090500030

3.

Disassembly of supply pump drive bearing case (1)

Remove the bolt and disassemble the supply pump drive bearing case.

SAPH301090500031

W5-5-17

FUEL SYSTEM 4. 

Assembly and adjustment of supply pump drive bearing case (1)



Insert the bearing (1) and shaft (2) applied with engine oil into the case, replace the O-ring with a new one applied with engine oil and assemble the supply pump bearing case as shown in the figure. Tightening torque : 25 N m {250 kgf cm, 18 lbf ft}



• Adjust temporarily with a shim so that the

! CAUTION

drive shaft is turned manually and there is no

SAPH301090500032

axial backlash. • Assemble so that the bearing retainer protrusion (oil return groove (3)) is lower.

 SAPH301090500033

(2)

Measure the rolling torque using a torque wrench and adjust it so that it satisfies the standard value. Standard value (N m {kgf cm, lbf in.})

0.39 - 1.17 {4 - 12, 3.5 - 10.4}

(3)

Apply engine oil to the lip of a new oil seal.

(4)

Press fit the oil seal (5) using a special tool (4) so that the

SAPH301090500034

oil seal (5) is flush with the bearing retainer (6).



Special tool (4): 09482-2330 Press

  SAPH301090500035

W5-5-18

FUEL SYSTEM 5.

Installation of supply pump drive bearing case (1)

Replace the O-ring with a new one and install the supply

(2)

Fix the drive shaft, align the gear stamp, install the drive gear and tighten the nut.

pump bearing case with adjusted preload from the back.

Tightening torque : 245 N m {2,500 kgf cm, 180 lbf ft} 6.

Installation of timing gear cover "Reference: Engine mechanical, timing gear cover and

SAPH301090500036

flywheel housing, timing gear case cover replacement"

W5-5-19

E485B

FUEL SYSTEM

NOTE:

5

W5-5-20





  

        

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

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

   



   



   



   

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638



  

 



 







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

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

 

 



 





  



 





 

 



 

 







 











 



 



 

    

 

            



  

 

 



 

   





  

   

 

 

  





  

  

   



 



           





 

 



 



 











 

     

 



 





ELECTRICAL

ENGINE

7 ELECTRICAL ç\ê¨ê} ç\ê¨îzíuê}

Electrical System........................................................ 7-2 Part layout (typical example) .................................. 7-2 Layout of components............................................. 7-5 Inspection of components ....................................... 7-7 Installation of components ...................................... 7-9 Installation of starter................................................ 7-9 Installation of alternator......................................... 7-10

7

W5-7-1

HINO P11C ELECTRICAL SYSTEM

Electrical System Part layout (typical example) JP30109070402001

SAPH301090700001

22790

Fuel temperature sensor

89390

Boost pressure sensor

82030

Injector harness

89410

Engine speed sensor

82121

Engine harness

89441

Engine main revolution sensor

83420

Water temperature sender gauge

9659A

Soft washer*

83420

EGR water temperature sensor

9655-12100

Soft washer*

83530

Oil pressure warning switch

9655-14140

Soft washer*

*Parts not to be reused.

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-7-2

ELECTRICAL

SAPH301090700002

17171A

Gasket*

19201

*Parts not to be reused.

W5-7-3

Intake air heater

ELECTRICAL

SAPH301090700003

12281

Engine hanger

28100

Stator assembly

12509

Alternator brace

900149

V-belt

27060

Alternator assembly

Tightening torque 9189A

6N m{60kgf cm,4 lbf ft}

9201-10080

47N m{480kgf cm,35 lbf ft}

9201-14110

Starter: 127N m{1,300kgf cm,94 lbf ft}

9402-12000

83N m{846kgf cm,61 lbf ft}

Alternator through bolt: 132N m{1,350kgf cm,97 lbf ft}

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-7-4

ELECTRICAL

Layout of components Left side view

JP30109070402002















SAPH301090700004

1 - Boost pressure sensor 2 - Pressure control valve 3 - Common rail pressure sensor 4 - Fuel temperature sensor 5 - Engine main revolution sensor 6 - EGR gas temperature sensor 7 - Engine auxiliary rotation sensor

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-7-5

E485B

ELECTRICAL

Right side view



 





SAPH301090700005

5 - Main revolution sensor 8 - Engine speed sensor 9 - EGR water temperature sensor 11 - Oil pressure warning switch 10 - Coolant temperature sender gauge ì_åüóvóÃçÄñ êÆî óvóÃ

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-7-6

ELECTRICAL

Inspection of components JP30109070703001

1. 

Inspection of fuel temperature sensor (1)

Heat the fuel temperature sensor (4) using hot water.

(2)

Measure the resistance between terminals using a circuit tester. If it is faulty, replace the sensor. Temperat ure

-20{-4}

20{68}

80{176}

110{230}

13.84 16.33

2.32 2.59

0.31 0.326

0.1399 0.1435

( C{ F}) Resistanc

SAPH301090700006

e value ( ) 2.



Inspection of oil pressure warning switch (1)

Install the oil pressure warning switch (11) on the air tank, etc.

SAPH301090700007

(2)

Increase or decrease air tank pressure, check continuity between the terminal and switch main unit using a circuit tester. If it is faulty, replace it.

          

Operation standard



    

When 39.2 - 58.8 kPa {0.4 - 0.6kgf/cm2, 5.7 - 8.5 lbf/in.2} is exceeded during pressurization



ON OFF

The pressure that changes the switch from OFF to ON during pressure reduction is different from the

SAPH301090700008

pressure that changes the switch from ON to OFF during pressurization by within 2.9 kPa {0.03 kgf/ cm2, 4.6936 lbf/in.2}. 3.

Inspection of oil filter warning switch (1)

Check continuity between the tip of the switch (12) and the coupler (13) using a circuit tester.

(2)

If there is no electric continuity, replace the switch.



 SAPH301090700009

W5-7-7

E485B

ELECTRICAL 4.

Inspection of coolant temperature sender gauge Connector color: Darkgray





(1)

Heat the coolant temperature sender gauge (10) using hot

(2)

water. Measure the resistance between terminals using a circuit tester. If it is faulty, replace the gauge. Between A and C

 

Temperature

110

-20{-4}

20{68}

80{176}

Resistance

13.84 -

2.32 -

0.31 -

0.1399 -

value ( )

16.33

2.59

0.326

0.1435

( C{ F})

SAPH301090700010

{230}

Between B and body Temperature ( C{ F}) Resistance value ( ) 5.

75{167}

100{212}

79 - 92

35.5 42.5

Inspection of intake air heater (1)



Measure continuity between terminals and the body and the terminal using a circuit tester. If it is faulty, replace the heater (14). Between terminals Between the terminal and the body

With continuity Without continuity

SAPH301090700011

6.



Inspection and replacement of pressure control valve (PCV) and engine speed sensor (sub) (1)

If the pressure control valve (PCV) (2) and the engine speed sensor (8) are faulty, remove them from the engine in the supply pump assembly and request for reinspection at the Denso service shop.

 SAPH301090700012

W5-7-8

ELECTRICAL ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ

Installation of components JP30109070702001

1.

Pressure control valve (PCV) wire



! CAUTION

Wire the main harness with the "Front" label to the pressure control valve.

SAPH301090700013

2.

Installation of engine speed sensor (main) (1)

Make sure that the sensor has an O-ring (15). Install the sensor on the upper surface of the flywheel. Since this sensor is a flange type, gap does

NOTICE

not have to be adjusted.

 SAPH301090700014

Installation of starter JP30109070702002

1.

Installation of starter (1)

Install the starter (16) with bolts and nuts (17). Tightening torque : 127 N m {1,300 kgf cm, 94 lbf ft}



 SAPH301090700015

W5-7-9

E485B

ELECTRICAL

Installation of alternator JP30109070702003

1.

Installation of alternator

 



(1)

Hand-tighten the brace mounting bolt (1) to temporarily

(2)

Hand-tighten the through-bolt (3) to temporarily secure the alternator.

(3)

Hand-tighten the mounting bolt and nut on the brace side

(4)

Thread the adjusting bolt (6) into the mounting bolt on the brace side (5).

(5)

Fully tighten the brace mounting bolt (1).

(6)

Tighten the belt by turning the adjusting bolt with a

(7)

wrench. Fully tighten the alternator through-bolt (3).

(8)

Fully tighten the mounting bolt and nut on the brace side

secure the alternator brace (2).





(5) to temporarily secure the alternator (4) and brace (2).

 SAPH301090700016

Tightening torque : 83 N m {846 kgf cm, 61 lbf ft}

Tightening torque : 132 N m {1,350 kgf cm, 97 lbf ft} (5). (9)

Tightening torque : 47 N m {480 kgf cm, 35 lbf ft} Tighten the adjusting bolt (6) and make sure it is locked in place. Tightening torque : 6 N m {60 kgf cm, 4.4 lbf ft}

2.  

V belt tension adjustment (1)

Loosen the fixing bolt and through bolt on the alternator brace side and adjust the tension of the V belt (measurement position: A) using the adjusting bolt and the special tool.

 Item

When installing a new belt

Deflection (mm{in.})

14 - 16

15 - 17

{0.5512 -

{0.5906 -

0.6299}

0.6693}

640 - 690

590 - 640

{65 - 70,

{60 - 65,

144 - 155}

133- 144}

 SAPH301090700017

7- Water pump pulley 8 - Alternator pulley 9 - Crankshaft pulley

Tension (N{kgf,lbf})

At the time of inspection

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

W5-7-10

ELECTRICAL

! CAUTION

If the V belt is replaced with a new one, it becomes loose due to initial fitting. Run the engine for three to five minutes and adjust the tension of the belt again.

NOTICE

At the time of inspection, the new V-belt has reached the value after complete initial stretching. A new V-belt completes initial stretching after running the engine for approximately two hours.

W5-7-11

E485B

ELECTRICAL

NOTE:

7

W5-7-12

HINO P11C INTAKE



  

       







  

















































   

  

   



     

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638





 



 



 







 









 

   





 





     



   





 

       





HINO P11C ENGINE MECHANICAL

ENGINE

9 ENGINE MECHANICAL ç\ê¨ê} ç\ê¨îzíuê}

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

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-9-1

9

ENGINE MECHANICAL

Hino P11C Cylinder Head Part layout (typical example) JP30109090402001

SAPH301090900001

11101

Cylinder head assembly

12210A

Ventilator

11115

Head gasket*

12203

Ventilation pipe

11185

Head bolt (additional)

12261

Ventilator hose

11185A

Head bolt

12261A

Oil hose

11185B

Head bolt

12505

Silent block

11201

Head cover (lower)

13719

Valve stem oil seal*

11211

Head cover (upper)

18109

Terminal

11213

Gasket*

23745

Injection pipe oil seal

11213A

Gasket

9349A

Stud bolt (for exhaust manifold

11455

Plate

9851A

O-ring*

12108

Oil filler cap

9851C

O-ring*

12210

Ventilator

installation)

*Parts not to be reused.

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-9-2

ENGINE MECHANICAL Tightening torque 11185

69N m{700kgf cm,51 lbf ft}

9191-08401

25N m{250kgf cm,18 lbf ft}

11185A

118N m{1,200kgf cm,87 lbf ft}+90 +90

9349A

30N m{300kgf cm,22 lbf ft}

11185B

118N m{1,200kgf cm,87 lbf ft}+90 +90

9412-10301

54N m{550kgf cm,40 lbf ft}

9068-10250

68.5N m{700kgf cm,51 lbf ft}

9412-10551

54N m{550kgf cm,40 lbf ft}

9068-10350

68.5N m{700kgf cm,51 lbf ft}

9412-10851

54N m{550kgf cm,40 lbf ft}

9068-10600

68.5N m{700kgf cm,51 lbf ft}

SZ109

25N m{250kgf cm,18 lbf ft}

W5-9-3

ENGINE MECHANICAL

SAPH301090900002

11101

Hino P11C Cylinder head

11135

Valve seat

11122

Valve guide

11176

Nozzle seat

11131

Valve seat

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-9-4

ENGINE MECHANICAL å ä²óvóÃçÄñ êÆî óvóÃ

Replacement JP30109090704001

1. 



Removal of head cover (upper) (1)

Remove the ventilator hose (1) and the bolts (2) and remove the head cover (upper) (3).

! CAUTION



Be careful for fall of the silent block.

 SAPH301090900003

2.

Removal of injector Reference: "Replacement of fuel system, injector"

3.

Removal of rocker arm assembly Reference:" Engine mechanical, Overhaul of valve system"

4.

Removal of head cover (lower) (1)

Pull out the push rod.

! CAUTION

Do not pull out the tappet together with the push rod.

SAPH301090900004

(2)

Remove one fuel pipe at the rear of the head cover (lower).

! CAUTION

SAPH301090900005

W5-9-5

Wipe off spilled fuel.

ENGINE MECHANICAL (3)

Remove bolts and remove the head cover (lower).

SAPH301090900006

5.

Removal of cylinder head (1)

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

SAPH301090900007

(2)

Remove the cylinder head using a special tool and hoist. Special tool : 09433-1030 Eye bolt • If it is difficult to remove the cylinder head, insert a chisel between the cylinder head and

NOTICE

the cylinder block, and move the chisel vertically so that the contact surface may not be damaged. Then, separate the cylinder head. SAPH301090900008

6.

Inspection of head bolt length (1)

Measure the under head length of the head bolt using a vernier calipers. If it is out of the operation limit, replace it with a new one.

SAPH301090900009

Standard value

Operation limit

(mm{in.})

(mm{in.})

Long

250{9.843}

252{9.921}

Short

158{6.220}

161{6.338}

W5-9-6

ENGINE MECHANICAL 7.

Compression upper dead center setting of No.1 cylinder

 (1)

Turn the crankshaft in the engine rotating direction (clockwise as viewed from the cooling fan side), align the "16" stamp line of the crankshaft damper with the pointer, and set the No. 1 cylinder to the compression top dead center.

! CAUTION

If the pointer is matched with "16", but the supply pump bearing case shaft key (5) or the coupling cotter bolt (6) faces down, No. 6 is at

SAPH301090900010

the compression top dead center. Turn the crankshaft one turn and set the No. 1 cylinder at the compression top dead center.

 SAPH301090900011

8.

Installation of head gasket (1)

Place a new head gasket on the cylinder block.

! CAUTION

Remove dirt, water or oil from the mounting surfaces of the cylinder head and the cylinder block before work. Never reuse the gasket. Otherwise, it may damage the engine. Before installation of the head gasket, make sure

SAPH301090900012

that there is no fall of or damage to the seal ring. Do not apply liquid gasket to each seal. 9.

Installation of cylinder head (1)

Clean the head bolt seating at the cylinder head upper

(2)

Align the dowel pins of the cylinder block using a special

surface and the cylinder head lower surface. tool and hoist and mount the cylinder head. ! CAUTION

Before mounting the cylinder head, make sure that there is no foreign matter in the cylinder.

SAPH301090900008

Special tool : 09433-1030 Eye bolt

W5-9-7

ENGINE MECHANICAL (3)

Apply engine oil to the bolt seating and thread and tighten 19 head bolts in the order shown in the figure. Seating torque : 118 N m {1,200 kgf cm, 87 lbf ft}

SAPH301090900013

(4) (5)

Install the armature assembly. Install 7 rocker support bolts (head bolts) in the order shown in the figure. Seating torque : 118 N m {1,200 kgf cm, 87 lbf ft}

SAPH301090900014

(6)

Make sure the 26 head bolts are tightened to a torque value of 118N m {1,200kgf cm, 87lbf ft} and finally tighten the additional bolt (B). Tightening torque : 69 N m {700 kgf cm, 40 lbf ft}



SAPH301090900015

W5-9-8

ENGINE MECHANICAL



(7)

Mark the heads of the 26 head bolts in the above figure in the same direction using paint (7).

(8)

Tighten 26 head bolts at rotation angle 90 in the same order as above using a special tool and make sure that all paint marks are in the same direction. Tighten them further at rotation angle 90 and make sure that all paint marks (7) are in the same direction.

! CAUTION



If a bolt is turned excessively in retightening, do not loosen it.

SAPH301090900016

SAPH301090900017

10. Installation of head cover (lower) (1)

Replace the gasket with a new one and install the head cover (lower). Tightening torque : 54 N m {550 kgf cm, 40 lbf ft}

SAPH301090900018

(2)

Replace the gasket with a new one and install one fuel pipe.

SAPH301090900019

11. Installation of injector Reference: "Fuel system, Replacement of injector"

W5-9-9

ENGINE MECHANICAL 12. Installation of head cover (upper) 



(1)

Wipe dirt and oil on the joint surfaces of the head cover (upper) (3) and head cover (lower) and on the groove of the gasket and install the head cover (upper) (3) and gasket. Tightening torque : 25 N m {250 kgf cm, 18 lbf ft}

! CAUTION





Since the head covers are floating mount, do not overtighten the bolts (2).

SAPH301090900003

(2)

Connect the ventilator hose (1).

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ

Overhaul JP30109090702001

1.

Cleaning of cylinder head (1)

Remove carbon or other deposit using a scraper.

(2)

Clean the cylinder head.

! CAUTION

To remove carbon or other deposit, do not damage the lower surface of the cylinder head.

SAPH301090900020

2. 

Replacement of valve guide (1)

Remove the valve stem seal.

(2)

Remove the valve guide (1) using a brass bar or press.

(3)

If a new valve guide (1) is assembled, press-fit carefully, being careful not to pry the end.

! CAUTION

In press fit, be careful not to damage the valve stem at the upper/lower ends of the guide. In press fit, be sure to apply engine oil to the circumference of the valve guide (1).

SAPH301090900021

3. 



Replacement of valve seat

! CAUTION

The valve seat (2) replacement procedure below may damage the cylinder head depending on the case. It is recommended that a request for replacement be made to a machining vendor.



 

(1)

If the valve seat (2) is replaced, use an out-of-use valve (3). After cutting three pieces (4) from the valve

SAPH301090900022

circumference, weld them (5) to the valve seat (2). ! CAUTION

Apply grease to protect the cylinder head lower surface from welding spatter before work.

W5-9-10

ENGINE MECHANICAL (2)

Put a backup metal (6) (e.g. brass bar) at the valve stem head and pull out the valve seat (2) using a press.

(3)

Remove welding spatter or dirt on the valve seat (2) surface.



 SAPH301090900023

A - Intake B - Exhaust

(4)

Heat the cylinder head to approx. 80 C{176 F} to 100 C {212 F} and strike the cooled valve seat into the mounting area of the cylinder head.

! CAUTION

Be careful not to break it because it is a sintered part.

SAPH301090900024

(5)

Apply small amount of lapping compound to the contact surface between the valve and the valve seat.

(6)

Strike gently while turning the valve using a special tool for adjustment. Special tool : 09431-1010 Valve lapping tool

SAPH301090900025

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-9-11

ENGINE MECHANICAL 4.

Replacement of nozzle seat (1)

Tap the nozzle seat (1) from the cylinder head lower part.

(2)

Hit the bolt head using a hammer and pull out the nozzle seat (1) toward the cylinder head upper part.

(3)

Remove the O-ring (2) from the cylinder head.

Then, put a bolt in the nozzle seat tap.

! CAUTION

After pulling out the nozzle seat, be sure to remove deposit such as remaining liquid gasket or dirt.

SAPH301090900026

(4) 



After attaching a new O-ring (2) applied with engine oil into the nozzle seat hole in the cylinder head, apply the liquid gasket [Threebond TB1211 (white) or equivalent] to the lower part of a new nozzle seat (1) and assemble it on the cylinder head.

! CAUTION

Be sure to replace the O-ring (2) with a new part. Reuse may cause water leak or gas leak, resulting in overheat or crack of the cylinder head.

SAPH301090900027

Install it within 20 minutes after application of the liquid gasket. (5)

Clamp the nozzle seat (1) using a special tool and a pneumatic hammer.

 

Special tool : 09472-1210 Bar (3)



9800-06100 Steel ball (4) Pressing tool (5)





! CAUTION

Do not strike out with a normal hammer. Conical surface (A) must be in close contact on the circumference after clamping.

SAPH301090900028

5.

Inspection of cylinder head (1)

Check for crack or damage using dye penetrant. If a faulty condition is found, replace the cylinder head.

SAPH301090900029

W5-9-12

ENGINE MECHANICAL (2)

Measure distortion of cylinder head lower surface (1) using a ruler (2). If the measurement value is beyond the repair limit, grind and correct it.

ďƒŽ

Standard value (mm{in.})

Repair limit (mm{in.})

0.05{0.0019}

0.15{0.0059}

ďƒŻ

SAPH301090900030

W5-9-13

ENGINE MECHANICAL

Hino P11C Cylinder Block ç\\ê ꨨîêzí }uê}

Part layout JP30109090402002

SAPH301090900031

11408

Cooling jet

11841

Camshaft bearing

11467

Cylinder liner

11851

Camshaft bearing

11811

Camshaft bearing

11861

Camshaft bearing

11821

Camshaft bearing

11871

Camshaft bearing

11831

Camshaft bearing

15605

Bolt

15605

23N m{230kgf cm,17lbf ft}

Tightening torque 11521

274N m{2,800kgf cm,203lbf ft}

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-9-14

ENGINE MECHANICAL ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

Overhaul JP30109090702002

1.

Removal of cylinder liner (1)

Put match marks on the flange surfaces of the cylinder block and the cylinder liner using a oil based marker.

! CAUTION

Store removed cylinder liners for each cylinder number. Never provide match marks with a punch.

SAPH301090900032

(2)

Pull out the cylinder liner toward the cylinder block upper part using a special tool. Special tool : 09420-1750 Cylinder liner puller

! CAUTION

Be careful for handling of the cylinder liner. Do not reuse the cylinder liner which has been dropped. Do not touch the cooling jet during work.

SAPH301090900033

2.

Installation of cylinder liner (1)

Apply engine oil to the inner bore of the cylinder block.

(2)

Align the match mark of the cylinder liner with that of the cylinder block. Install the cylinder liner using a special tool. Special tool : 09480-1190 Liner insertion guide

! CAUTION

When a new cylinder liner is installed, install the cylinder liner with the same identification

SAPH301090900034

mark (A, B, C) stamped on the cylinder block. 3.

Inspection of protrusion at cylinder liner flange (1)

Measure protrusion of the flange using a dial gauge.

Standard value (mm{in.})

SAPH301090900035

W5-9-15

0.04 - 0.10 {0.0016 - 0.0039}

E485B

ENGINE MECHANICAL 4.

Inspection of cooling jet (1)

Remove the standard oil check valve and install the cooling jet on the cylinder block using a special tool. Special tool (A): 9001-24262 Check bolt

 SAPH301090900036

(2)

Connect the injection test oil hose (1) from the lower part of the cylinder block to the special tool check bolt (A).

! CAUTION

Use new engine oil for injection of oil.

 

SAPH301090900037

(3)

Set a special tool (B) on the cylinder block (2). Special tool (B): 09470-1180 Test kit

 (4)

Inject oil from the nozzle of the cooling jet (3) at the hydraulic pressure of 196 kPa{2 kgf/cm2, 28 psi}.

 

SAPH301090900038

 

Refer to the drawing for the oil injection unit.

NOTICE



  

  SAPH301090900039

1- Oil hose 3- Cooling jet 4- Air tank (oil tank) 5- Pressure regulator 6- Air gauge 7- Air hose 8- Air compression 9- Valve

W5-9-16

ENGINE MECHANICAL (5) 



When the injection center (4) hits within the specified line of the gauge (5), it is considered normal.

! CAUTION

Oil is susceptible to combustion due to spread. Do not use fire near around. Work at well ventilated place.

(6)

Make sure that the jet position check gauge hole at the tool assembly end may not interfere with the cooling jet pipe.

SAPH301090900040

(7)

If injection does not hit the target circle, correct it with a special tool.

! CAUTION

If the injection position of the cooling jet is incorrect, replace parts with new ones instead of correction.

(8)

Remove the check bolt and install the cooling jet on the cylinder block using the genuine oil check valve.

(9)

After assembly of the piston, make sure that the cooling

Tightening torque : 23 N m {230 kgf cm, 17 lbf ft} jet does not interfere with the piston at the piston bottom dead center. 5.

Inspection of cylinder block

 (1)

Check for crack or damage using dye penetrant. If a faulty condition is found, replace the crankshaft.

(2)

Measure distortion on the cylinder block along measuring positions (6) using a ruler (7). If the measurement value is beyond the operation limit, replace it.



Standard value (mm{in.})

Repair limit (mm{in.})

0.05{0.0019}

0.15{0.0059}

ç\ê¨ê} ç\ê¨îzíuê}

 SAPH301090900041

Thickness gauge

W5-9-17

ENGINE MECHANICAL

Hino P11C Timing Gear Cover and Flywheel Housing Part layout JP30109090402003

SAPH301090900042

11306

Dust cover

11356

Flywheel housing stay

11311

Timing gear case assembly

11356A

Flywheel housing stay

11321

Timing gear case cover assembly

12281

Engine hanger

11351

Flywheel housing assembly

9828A

Crankshaft rear oil seal*

11328

Gasket*

9828B

Crankshaft front oil seal*

11329

Gasket* *Parts not to be reused.

Tightening torque 11185

211N m{2,150kgf cm,156 lbf ft}

9411-10502

44N m{450kgf cm,32 lbf ft}

900125

211N m{2,150kgf cm,156 lbf ft}

9411-10602

44N m{450kgf cm,32 lbf ft}

9409A

172N m{1,750kgf cm,127 lbf ft}

9411-10952

44N m{450kgf cm,32 lbf ft}

9411-10252

44N m{450kgf cm,32 lbf ft}

9412-14652

113N m{1,150kgf cm,83 lbf ft}

9411-10352

44N m{450kgf cm,32 lbf ft} ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

W5-9-18

ENGINE MECHANICAL

Replacement of flywheel housing JP30109090702003

1.

Removal of flywheel housing (1)

Remove the housing stay (1).

(2)

Remove bolts and then remove the flywheel housing.



 SAPH301090900043

2. 

Installation of flywheel housing (1)

Remove contamination from the joint surfaces of the

(2)

Apply the liquid gasket [Threebond TB1207D (red) or

flywheel housing and the cylinder block using a scraper. equivalent] to the flywheel housing as shown in the figure (3)

(2). Install the guide bolts at several mounting threads and align the flywheel housing with the cylinder block without shifting the liquid gasket.

SAPH301090900044

! CAUTION

Apply it continuously. Apply the liquid gasket at the width of 4 0.5mm{0.1575

0.0197in.}.

Install it within 20 minutes after application of the liquid gasket. (4)

Tighten the flywheel housing stay and flywheel housing bolts. Tightening torque :



Flywheel housing: M14 113 N m{1,150 kgf cm, 83 lbf ft} Flywheel housing stay: M16 211 N m{2,150 kgf cm, 156 lbf ft} 

å ä²óvóÃçÄñ

SAPH301090900043

W5-9-19

ENGINE MECHANICAL

Replacement of crankshaft front oil seal JP30109090704002

1.

Removal of crankshaft front oil seal (1)

Align the special tool with the convex in the crankshaft rear oil seal, insert the special tool sleeve and fix it. Special tool : 09420-1980 Puller

! CAUTION

Install the special tool so that the dowel pin of the crankshaft may not come in contact with it.

SAPH301090900045

(2)

Tighten the center bolt of the special tool gradually and pull out the crankshaft front oil seal.

! CAUTION

Check the engagement of the special tool and oil seal during work and pull it out so that the special tool is not removed.

SAPH301090900046

2.

Installation of crankshaft front oil seal (1)

Make sure that there is no impact mark or dirt on the oil seal insertion of the timing gear case cover and crankshaft.

(2)

Remove contamination from the special tool press.

(3)

Apply a small amount of engine oil to the lip of a new oil

(4)

seal. Insert the oil seal into the crankshaft manually until it stops paying attention to the direction of the oil seal.

SAPH301090900047

! CAUTION

Install the oil seal so that the felt surface is outside and the slinger (steel plate) surface is inside. Install the oil seal so that it is not tilted.

(5)

Install the plate on the end of the crankshaft with 2 bolts. Special tool : 09407-1180 Press

SAPH301090900048

W5-9-20

ENGINE MECHANICAL (6)

Align the press with the guide bolt, tighten the center bolt and press-fit the oil seal.

! CAUTION

(7)

Press-fit uniformly on the circumference.

Tighten until the press hits and make sure the oil seal is press-fit uniformly on the circumference.

SAPH301090900049

Replacement of crankshaft rear oil seal JP30109090704003

1.

Removal of crankshaft rear oil seal (1)

Align the special tool with the convex in the crankshaft rear oil seal, insert the special tool sleeve and fix it. Special tool : 09420-1850 Puller

SAPH301090900050

! CAUTION

Since the special tool can be used for K13C and P11C, align "K" and "P" with the positions shown in the figure and install it on the oil seal.

SAPH301090900051

(2)

Tighten the center bolt of the special tool gradually and pull out the crankshaft rear oil seal.

! CAUTION

Check the engagement of the special tool and oil seal during work and pull it out so that the special tool is not removed.

SAPH301090900052

W5-9-21

E485B

ENGINE MECHANICAL 2.  

Installation of crankshaft rear oil seal (1)

Make sure that there is no impact mark or dirt on the oil

(2) (3)

Remove contamination from the special tool press. Apply a small amount of engine oil to the lip of a new oil

seal (1) insertion of the flywheel housing and crankshaft.

seal (1). (4)

Insert it into the oil seal guide (2) of the special tool press, paying attention to the direction of the new oil seal (1). Special tool : 09407-1110. Press

SAPH301090900053

! CAUTION

Install the oil seal (1) so that the felt surface is outside and the slinger (steel plate) surface is inside of the engine. Install the oil seal (1) so that it is not tilted.

(5)

Install the oil seal guide (2) assembled with the oil seal (1) on the end surface of the crankshaft with 2 bolts.

! CAUTION

Make sure that the step of the crankshaft and the oil seal guide is uniform on the circumference after tightening the guide bolt.

SAPH301090900054

(6)

Align the press with the oil seal guide and tighten it with the center bolt.

! CAUTION

(7)

Press-fit uniformly on the circumference.

Tighten until the press hits and make sure that the oil seal is press-fit uniformly on the circumference.

SAPH301090900055

W5-9-22

ENGINE MECHANICAL

Replacement of timing gear case cover JP30109090704004

1.

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

2.

3.

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

Replace the gasket and O–ring with new ones and install the timing gear cover.

(2)

Tightening torque : 44 N m {450 kgf cm, 32 lbf ft} Cut the gasket projecting to the engine lower surface so that it becomes a flat surface.

4.

Installation of crankshaft front oil seal Reference: "Engine mechanical, Timing gear cover and flywheel housing, Replacement of crankshaft front oil"

W5-9-23

E485B

ENGINE MECHANICAL

Main Moving Parts ç\ê¨ê} ç\ê¨îzíuê}

Part layout JP30109090402004

SAPH301090900056

04132

Piston pin

13453

Ring gear

11011

Thrust bearing

13470

Crankshaft pulley assembly

11701

Crankshaft bearing

13471

Crankshaft pulley

13201

Connecting rod bearing

13521

Crankshaft gear

13260

Connecting rod assembly

13531

Oil pump drive gear

13265

Connecting rod bolt

9532-07220

Key

13272

Connecting rod bushing

9819A

Retainer ring*

13400

Crankshaft assembly

S1304

Piston ring

13407

Crankshaft damper

S130B

Piston assembly

900124

108N m{1,100kgf cm,80 lbf ft}

*Parts not to be reused. Tightening torque 13266

69N m{700kgf cm,51 lbf ft}+90 +90

13455

270N m{2,750kgf cm,200 lbf ft}(Standard) 900124A

245N m{2,500kgf cm,180 lbf ft}

13455

225N m{2,290kgf cm,166 lbf ft}(Vehicle

55N m{560kgf cm,41 lbf ft}

9068-10300

with PTO) å ä²óvóÃçÄñ êÆî óvóÃ

W5-9-24

ENGINE MECHANICAL

Replacement of piston and connecting rod JP30109090704005

1.

Removal of piston (1)

Remove nuts and remove the connecting rod cap.

! CAUTION

Fix the cylinder liner on the block. Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft. Store removed connecting rod cap for each

SAPH301090900057

cylinder number so that combinations of the connecting rod and the connecting rod cap may not be changed. (2)

Remove carbon on the cylinder liner inner surface with a scraper or a sand paper (No. 150 or so) in the circumferential direction.

! CAUTION

Do not damage parts lower than the carbon deposit area.

(3)

Fix the cylinder liner with bolts and a plate.

(4)

Hit the connecting rod from underneath the engine using the handle of a hammer. Remove the piston together with

SAPH301090900058

the connecting rod.

SAPH301090900059

NOTICE



In removing the piston, rotate the connecting rod as shown in the figure. Do not bend the cooling jet (1).

! CAUTION

Store removed pistons and connecting rods for each cylinder number. Be careful not to touch the cooling jet.

SAPH301090900060

W5-9-25

E485B

ENGINE MECHANICAL 2.

Disassembly of piston and connecting rod (1)

Remove the retainer ring using snap ring pliers.

(2)

Warm the piston to 50 C{122 F} or more.

(3)

Remove the piston pin using the brass bar and disconnect the piston from the connecting rod.

(4)

Remove the piston ring using a special tool.

SAPH301090900061

Special tool : 09442-1230 Piston ring expander ! CAUTION

Since the piston ring is susceptible to damage, be careful for handling. Store piston rings for each cylinder number. Store the piston rings so that the upper and lower surfaces may be identified.

SAPH301090900062

3.  



Assembly of piston and connecting rod

 

(1)

Warm the piston (2) to 50 C{122 F} or more.

(2)

Install the piston (2) on the connecting rod so that the "0" mark (3) on the piston (2) may be opposite to the match mark stamp (4) on the connecting rod.

 ! CAUTION

 (3)

Make sure that the oil hole (5) offset is as shown in the figure.

Install a new retainer ring using snap ring pliers.

SAPH301090900063

A - Exhaust side B - Intake side

! CAUTION

Make sure that there is no backlash in the retainer ring.

W5-9-26

ENGINE MECHANICAL (4)

Face the side with the piston ring identification print upward and install in the order of the oil ring (6), third ring (7), second ring (8) and top ring (9) using a special tool. Special tool : 09442-1230 Piston ring expander











(5)

Connect the joint (10) of the coil expander (11) and fit the oil ring (6) inside the ring. Offset the coil expander joint (10) with the ring joint by 180 deg for installation.





(6)

Allocate the joints (10) of the piston rings (6, 7, 8 and 9) with uniform intervals as shown in the figure.

 







 SAPH301090900064

A - Upper surface B - Lower surface

4. 

Installation of piston and connecting rod (1)

Apply engine oil to the inner diameter surface of the connecting rod.

(2)

Allocate the joints (10) of the piston rings (6, 7, 8 and 9)





with uniform intervals as shown in the figure.

 SAPH301090900065

(3)

Measure the overall length of the connecting rod bolt (X) using a vernier calipers. If it is out of the operation limit, replace it with a new one.



(4)

Standard value (mm{in.})

Operation limit (mm{in.})

102.5{4.0354}

105.0{4.1338}

Apply engine oil to the connecting rod bolt thread and the nut seat and install the piston on the connecting rod.

SAPH301090900066

(5)

Install the connecting rod bearing to suit concave shape of the connecting rod.

! CAUTION

Make sure that the oil hole of the connecting rod bearing is aligned with the oil hole of the connecting rod.

W5-9-27

E485B

ENGINE MECHANICAL (6)

Apply engine oil to the piston, cylinder liner and connecting rod bearing and compress the piston ring using a special tool. Special tool : 09441-1330 Piston ring holder

! CAUTION

Make sure that there is no deformation or damage to the special tool piston ring holder.

(7)

Insert the piston carefully so that the connecting rod may not come in contact with the cooling jet (1).

! CAUTION

Face the "0" mark on the piston toward the exhaust side for insertion. Set the crankshaft of the cylinder as the top dead center for assembly.



Do not damage the cylinder liner, crankshaft and cooling jet during work. SAPH301090900067

After assembly, make sure that the oil hole of the connecting rod is at the air intake side. (8)

Install the connecting rod bearing to suit concave shape of the connecting rod cap.

(9)



Apply engine oil to the bolt thread and seating, align the connecting rod cap and connecting rod match mark (12) directions and numbers and tighten nuts temporarily.

! CAUTION

Do not change the combination between the connecting rod and the connecting rod cap.

SAPH301090900068

(10) Tighten the connecting rod nut and mark the nut head in the same direction with paint (13).



Seating torque : 69 N m {700 kgf cm, 51 lbf ft} (11) Retighten the 90 deg connecting rod nut. (12) Retighten the 90 deg connecting rod nut. (13) Make sure that all marks (13) are in the same direction. ! CAUTION



If a bolt is turned excessively in retightening, do not loosen it.

SAPH301090900069

(14) Make sure that the end play is the standard value after installation. Standard value (mm{in.}) 0.15 - 0.32 {0.0059 - 0.0125} ì_åüóvóÃçÄñ

W5-9-28

Operation limit (mm{in.}) 0.6{0.0236}

ENGINE MECHANICAL

Inspection of piston and connecting rod JP30109090703001

1.

Inspection of piston clearance (1)

Measure the inner diameter of the cylinder liner sliding surface using a cylinder gauge. Standard value (mm{in.})

Operation limit (mm{in.})

122{4.803}

122.15{4.8090}

SAPH301090900070

(2)

Measure the piston outer diameter using a micrometer.

! CAUTION

• The measuring position is 25 mm{0.984 in.} above the piston lower end and square to the pin hole.

Standard value (mm{in.}) (3)

121.95{4.8012}

Calculate the difference between the inner diameter of the cylinder liner and the outer diameter of the piston. If it is beyond

SAPH301090900071

the standard value, replace the cylinder liner and the piston. Standard value (mm{in.})

Operation limit (mm{in.})

0.060 - 0.080 {0.0024 - 0.0031} 2.

0.15{0.0059}

Inspection of clearance between piston ring and ring groove (1)

Measure the piston ring width using a micrometer. If it is beyond the operation limit, replace the piston ring. Standard value (mm{in.})

Operation limit (mm{in.})

3.312{0.1304}

(Taper)

2.306{0.0908}

(Taper)

Third ring

2.0{0.0787}

1.80{0.0708}

Oil ring

4.0{0.1575}

3.90{0.1535}

Top ring SAPH301090900072

Second ring

W5-9-29

E485B

ENGINE MECHANICAL (2)

Measure the piston ring groove using a thickness gauge. If it is out of the operation limit, replace the piston. Standard value (mm{in.}) Top ring groove

(Taper)

Second ring groove

(Taper)

Third ring groove

2.0{0.0787}

Oil ring groove

4.0{0.1575}

SAPH301090900073

(3)

Calculate the difference between the piston ring thickness and ring groove. If it is beyond the operation limit, replace the piston ring or the piston. Standard value (mm{in.})

Operation limit (mm{in.})

Top ring clearance

Second ring clearance

Third ring clearance

0.065 - 0.105 {0.0026 - 0.0041}

0.20{0.0078}

Oil ring clearance

3. 

0.025 - 0.065 {0.0010 - 0.0025}

0.10{0.0039}

Inspection of piston ring joint clearance (1)

Insert the piston ring (1) into the cylinder liner (2) by 80mm{3.150in.} horizontally using piston.

(2)

Measure the piston ring joint clearance using a thickness gauge. If it is out of the operation limit, replace the piston ring (1).



Standard value (mm{in.})

Operation limit (mm{ni.})

SAPH301090900074

Top ring

0.30 - 0.50{0.0118 - 0.0196}

1.5{0.0590}

Second ring

0.50 - 0.70{0.0197 - 0.0275}

1.2{0.0472}

Third ring

0.35 - 0.50{0.0138 - 0.0196}

1.2{0.0472}

Oil ring

0.30 - 0.50{0.0118 - 0.0196}

1.0{0.0393}

4.

Inspection of piston pin (1)

Measure the outer diameter of the contact area of the piston pin with the piston boss using a micrometer. Standard value (mm{in.})

SAPH301090900075

W5-9-30

47{1.850}

ENGINE MECHANICAL (2)

Measure the piston boss inner diameter using a cylinder gauge. Standard value (mm{in.})

(3)

47{1.850}

Calculate the difference between the outer diameter of the piston pin contact area with the piston boss and the inner diameter of the piston boss. If it is out of the operation limit, replace the piston pin.

SAPH301090900076

5.

Standard value (mm{in.})

Operation limit (mm{in.})

0.041 - 0.059{0.0017 - 0.0023}

0.05{0.0019}

Inspection of connecting rod bushing oil clearance (1)

Measure the outer diameter of the center of the piston pin using a micrometer. Standard value (mm{in.})

47{1.850}

SAPH301090900077

(2)

Measure the connecting rod bushing inner diameter using a cylinder gauge. Standard value (mm{in.})

(3)

47{1.850}

Calculate the difference between the outer diameter of the center of the piston pin and the inner diameter of the connecting rod bushing. If it is beyond the operation limit, replace the piston pin and connecting rod.

SAPH301090900078

6.

Standard value (mm{in.})

Operation limit (mm{in.})

0.025 - 0.043{0.0394 - 0.0016}

0.10{0.0039}

Inspection of connecting rod (1)

Check for crack or damage to the connecting rod using dye penetrant. If a faulty condition is found, replace the crankshaft.

SAPH301090900079

W5-9-31

E485B

ENGINE MECHANICAL (2)

Insert a rod with the diameter of 6 mm{0.236 in.} from the oil hole at the connecting rod large end and make sure that it goes through the oil hole at the small end. If the rod with the diameter of 6 mm{0.236 in.} does not through due to clogging of the oil hole, replace the connecting rod.

SAPH301090900080

7.

Inspection of connecting rod oil clearance (1)

Measure the outer diameter of the crankshaft crank pin using a micrometer. Standard value

Repair limit

Operation limit

(mm{in.})

(mm{in.})

(mm{in.})

80{3.150}

79.8{3.1417}

78.8{3.1023}

NOTE: Measure 2 perpendicular diameters. SAPH301090900081

(2)

Assemble the bearing on the connecting rod large end, install the cap and tighten the nut of the connecting rod bolt.

(3)

Measure the bearing inner diameter of the connecting rod

(4)

Calculate the difference between the outer diameter of the

large end using a cylinder gauge. crank pin of the crankshaft and the inner diameter of the connecting rod bearing. If it is beyond the operation limit, replace the connecting rod bearing and the crankshaft. SAPH301090900082

The crankshaft can be ground and corrected.

NOTICE

Standard value (mm{in.}) 0.025 - 0.084 {0.0010 - 0.0033} å ä²óvóÃçÄñ

W5-9-32

Operation limit (mm{in.}) 0.30{0.0118}

ENGINE MECHANICAL

Replacement of crankshaft JP30109090704006

1.

Removal of crankshaft (1)

Remove the main bearing cap and the crankshaft bearing. Remove the crankshaft using a hoist.

! CAUTION

Since the part is heavy, be careful for handling. Store removed main bearing caps and crankshaft bearings for each cylinder number.

SAPH301090900083

2.

Installation of crankshaft (1)

Place the bearing with oil hole on the cylinder block and apply engine oil.

(2)

Place the crankshaft.

(3)

Align the bearing with no hole with the bearing cap and

(4)

apply engine oil. Insert the thrust bearing applied with engine oil between the crankshaft and the cylinder block so that the dented surface (1) faces outside.

(5)

Apply engine oil to the thrust bearing at the cap side in the same way and install the cap with the dented surface (1) facing outside.

 SAPH301090900084

(6) 

Install it so that the triangular mark on the main bearing cap faces the front of the engine (X).



! CAUTION

Check the stamp number (2) of each main bearing cap with the stamp number (3) of the cylinder block.

(7)

Apply engine oil to the bolt seating and the bolt thread of the main bearing cap bolt and tighten the bolts three times



from the center to outside. SAPH301090900085

! CAUTION

Loosen the No. 4 cap bolt, tap the front/rear ends of the crankshaft with a plastic hammer for initial fit and tighten it while sometimes turning the crankshaft. Tightening order : 4 3 5 2 6 1 7

Tightening torque : 274 N m {2,800 kgf cm, 200 lbf ft} (8)

Make sure that the crankshaft turns smoothly.

ì_åüóvóÃçÄñ

W5-9-33

E485B

ENGINE MECHANICAL

Inspection of crankshaft JP30109090703002

1.

Inspection of end play (1)

Measure the end play of the crankshaft using a dial gauge. If it is beyond the operation limit, replace the thrust bearing. Standard value (mm{in.})

Operation limit (mm{in.})

0.110 - 0.240

0.5{0.0196}

{0.0044 - 0.0094} 2.

Inspection of rotation runout (1)

Hold the No. 1 and No. 7 journals with the V–block, measure the rotation runout of the crankshaft, and if it exceeds the operation limit, replace the crankshaft. Operation limit (mm{in.})

0.07{0.0027}

SAPH301090900086

3.

Inspection of crankshaft oil clearance (1)

Measure the outer diameter of the crankshaft journal using a micrometer. Standard value (mm{in.})

Operation limit (mm{in.})

90{3.543}

88.8{3.4960}

NOTE: Measure 2 perpendicular diameters. SAPH301090900087

(2)

Do not install the crankshaft. Install the crankshaft bearing and the main bearing cap on the cylinder block.

(3)

Measure the crankshaft bearing inner diameter using a

(4)

cylinder gauge. Calculate the difference between the outer diameter of the crankshaft journal and the inner diameter of the crankshaft bearing. If it is beyond the standard value, replace the crankshaft or crankshaft bearing.

SAPH301090900088

Standard value (mm{in.}) 0.044 - 0.097 {0.0018 - 0.0038}

W5-9-34

Operation limit (mm{in.}) 0.30{0.0118}

ENGINE MECHANICAL 4.

Inspection of crack and damage to crankshaft and of oil hole (1)

Check for crack or damage to the crankshaft using dye penetrant. If a faulty condition is found, replace the crankshaft.

SAPH301090900089

(2)

Check for clogging of the crankshaft oil hole. If faulty condition is found, replace the crankshaft.

SAPH301090900090 å ä²óvóÃçÄñ

Replacement of crankshaft pulley JP30109090704007

1.

Removal of crankshaft pulley (1)

Remove the 1 crankshaft pulley mounting bolt and install the guide bolt to prevent fall.

(2)

Remove the remaining bolts while supporting the crankshaft pulley, and remove the crankshaft pulley assembly.

! CAUTION

When the bolt is removed, the crankshaft pulley may fall. It must be firmly supported during removal.

SAPH301090900091

Insert a large flat tip screwdriver into the

NOTICE

flywheel gear from the flywheel housing inspection hole to prevent turning of the crankshaft. 2.

Installation of crankshaft pulley (1)

Assemble the crankshaft pulley and crankshaft damper. Tightening torque : 108 N m {1,100 kgf cm, 80 lbf ft}

W5-9-35

E485B

ENGINE MECHANICAL (2)

Apply engine oil to the bolt seat and the bolt thread of the crankshaft pulley mounting bolt.

(3)

Install the crankshaft pulley on the crankshaft and tighten it according to the figure. Tightening torque : 245 N m {2,500 kgf cm, 180 lbf ft} Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing

NOTICE

inspection hole to prevent turning of the crankshaft.

SAPH301090900092

Replacement of flywheel JP30109090704008

1. 

Removal of flywheel (1)

Remove the engine revolution sensor (1) on the flywheel housing.

! CAUTION



If the engine revolution sensor (1) is not removed before removing the flywheel, the engine revolution sensor (1) is damaged.

 SAPH301090900093

(2)

Remove the 2 flywheel mounting bolts and install the guide bolt to prevent fall.

(3)

Remove the remaining bolts while supporting the flywheel, and remove the flywheel.

! CAUTION

Since the part is heavy, be careful for handling.

SAPH301090900094

2.

Removal of ring gear (1)

Heat the entire ring gear circumference with a burner until it is about 200 C{392 F}.

! CAUTION

Do not touch the ring gear and the flywheel with bare hand while they are hot.

SAPH301090900095

W5-9-36

ENGINE MECHANICAL (2)

Hit the circumference of the ring gear gently using a backing rod to remove the ring gear from the flywheel.

! CAUTION

Do not touch the ring gear and the flywheel with bare hand while they are hot.

SAPH301090900096

3.

Installation of ring gear (1)

Heat the entire ring gear circumference with a burner until it is about 200 C{392 F}.

! CAUTION

Do not touch the ring gear and the flywheel with bare hand while they are hot.

SAPH301090900097

(2)

Face the chamfered side toward the flywheel and install it on the flywheel quickly.

! CAUTION

Do not touch the ring gear and the flywheel with bare hand while they are hot.

SAPH301090900098

W5-9-37

E485B

ENGINE MECHANICAL 4.

Installation of flywheel (1) Make sure that there is no burr or dirt on the joint surface of the crankshaft and the flywheel and the screw hole. (2)

Align the flywheel with the crankshaft with 2 guide bolts, apply engine oil to the bolt seating and thread and install the bolts. Tightening torque : Standard 270 N m{2,750 kgf cm, 200 lbf ft} Vehicle with PTO 225 N m{2,290 kgf cm, 166 lbf ft}

SAPH301090900094

! CAUTION

Since the flywheel is heavy, be careful for handling. Since the bolts for vehicles with PTO cannot be reused, replace them with new ones.

(3)

Install the engine revolution sensor (1) on the flywheel housing.

5. 

Installation of the engine rotation sensor (1)

Install engine revolution sensor (A).

(2)

Screw in engine revolution sensor (B) by hand, until its tip comes into contact with the ring gear, and then turn it one turn back.



! CAUTION

When a tool is used to screw in the engine rotation sensor (1), the sensor (1) may get damaged.

 SAPH301090900093

(3)

Match the gap between engine revolution sensor (B) and ring gear (2) to the reference value and secure with the



lock nut. Tightening torque: 49

4.9 N m {500

50 kgf cm,36 4

lbf ft} 

Standard value (mm{in.})

SAPH301090900099

W5-9-38

1.0 - 1.5{0.0394 - 0.0591}

ENGINE MECHANICAL ì_åüóvóÃçÄñ

Inspection of flywheel JP30109090703003

! CAUTION

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

1.

Inspection of flywheel plane run-out and axial run-out (1)

Hoist the flywheel side of the engine, so that no load acts onto the flywheel housing.

(2)

Push the crankshaft to the front of the engine and stabilize it.

! CAUTION

Take care not to include the end play of the crankshaft in the measurement.

SAPH301090900100

W5-9-39

E485B

ENGINE MECHANICAL (3)

Use a dial gauge to measure plane run-out (A) and axial run-out (B) of the flywheel (1). Repair limit (mm{in.})

! CAUTION

0.2{0.0078}

Measure in engine rotation direction (counterclockwise as seen from the flywheel) at eight positions in intervals of 45 .

SAPH301090900101







SAPH301090900102

(4)

If the plane run-out of the flywheel (1) is outside the reference values, clean the mounting surface for the flywheel (1) on the crankshaft and reassemble after using an oil stone to remove burr. If the value is still outside the reference values, replace the flywheel.

(5)

If the axial run-out of the flywheel (1) is outside the reference values, replace the flywheel (1).

ç\ê¨ê} ç\ê¨îzíuê}

W5-9-40

ENGINE MECHANICAL

Camshaft and Idle Gear Part layout JP30109090402005

SAPH301090900103

13505

Idle gear assembly

13580

Idle gear shaft assembly

13505A

Main idle gear assembly

13581

Idle gear shaft

13511

Camshaft

13613

Supply pump drive gear

13523

Camshaft gear

900116

Spacer

13571

Thrust plate

900116Ç`

Spacer

13572

Thrust plate

9532-07150

Key

13572A

Thrust plate

9851A

O-ring*

13572B

Thrust plate

9019A

137N m{1,400kgf cm,100 lbf ft}

*Parts not to be reused. Tightening torque 900124A

44N m{450kgf cm,32 lbf ft}

900124

108N m{1,100kgf cm,80 lbf ft}

W5-9-41

E485B

ENGINE MECHANICAL

Gear train layout JP30109090402006

   





 

SAPH301090900104

1 - Air compressor idle gear 2 - Main idle gear (No.1) 3 - Main idle gear (No.2) 4 - Supply pump drive gear 5 - Oil pump drive gear 6 - Oil pump driven gear 7 - Crankshaft gear 8 - Camshaft gear

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

W5-9-42

ENGINE MECHANICAL

Removal of camshaft JP30109090702004

1.

Removal of push rod cover (1)

Remove the push rod cover on the side of the engine.

(2)

Hold the roller tappet so that it does not fall using a special tool. Special tool : 09451-1040 Stopper

SAPH301090900105

2.

Removal of camshaft (1)

Turn the camshaft gear, align the camshaft gear hole with the thrust plate mounting bolt position, remove the bolt and remove the shaft.

! CAUTION

Pull out the cam bearing so that it is not damaged. Refer to the following for installation of the

NOTICE

camshaft. SAPH301090900106

Reference: "Engine mechanical, Camshaft and idle gear, Installation of camshaft"

Disassembly of camshaft JP30109090702005

1.

Removal of camshaft (1)

Fix the camshaft through an aluminum plate, etc. with a vice and remove the camshaft gear bolt.

! CAUTION

Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.

(2)

Pull out the main bearing from the crankshaft using a special tool. Special tool : 09420-1111 Timing gear puller

SAPH301090900107

NOTICE

Refer to the following for inspection and disassembly of the camshaft. Reference: "Engine mechanical, Camshaft and idle gear, Inspection of camshaft" Reference: "Engine mechanical, Camshaft and idle gear, Assembly of camshaft"

ì_åüóvóÃçÄñ

W5-9-43

E485B

ENGINE MECHANICAL

Inspection of camshaft JP30109090703004

1.

Inspection of cam height on camshaft (1)

Measure the cam height using a micrometer. If it is beyond the operation limit, replace the camshaft.

SAPH301090900108

2.

Standard value (mm{in.})

Operation limit (mm{in.})

Cam IN height EX

56.03{2.2059}

55.23{2.1744}

53.72{2.1150}

52.92{2.0835}

Cam

IN

6.63{0.2610}

6.48{0.2551}

lift

EX

8.72{0.3433}

8.57{0.3374}

Inspection of camshaft bearing oil clearance (1)

Measure the outer diameter of the camshaft journal using a micrometer. Standard value (mm{in.})

SAPH301090900109

(2)

Journal No. 1

65.0{2.5590}

Journal No. 2

64.6{2.5433}

Journal No. 3

64.2{2.5275}

Journal No. 4

63.8{2.5118}

Journal No. 5

63.4{2.4960}

Journal No. 6

63.0{2.4803}

Journal No. 7

62.6{2.4645}

Measure the camshaft bearing inner diameter using a cylinder gauge.

(3)

Calculate the difference between the outer diameter of the camshaft journal and the inner diameter of the camshaft bearing. If it is beyond the operation limit, replace the camshaft or camshaft bearing.

3.

Standard value (mm{in.})

Repair limit (mm{in.})

0.030 - 0.120{0.0012 - 0.0047}

0.30{0.0118}

Inspection of camshaft runout (1)

Hold the camshaft with the V block, measure the rotation runout of the camshaft using a dial gauge. If it is beyond the operation limit, replace the camshaft. Operation limit (mm{in.})

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ

SAPH301090900110

W5-9-44

0.05{0.0019}

ENGINE MECHANICAL

Assembly of camshaft JP30109090702006

1.

Installation of ring gear (1)

Insert the spacer and thrust plate into the camshaft.

(2)

Warm the cam gear to approx. 180 C{356 F} using a heater (piston heater, etc.). Do not touch parts with bare hand because

! CAUTION

they are hot. (3)

Apply engine oil to the bolt seating and thread, fix the cam gear using a vice with the part number stamp surface facing outside, and tighten the bolt. Tightening torque : 137 N m {1,400 kgf cm, 100 lbf ft} Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.

! CAUTION

(4)

Tighten the bolt again to the specified torque after the cam gear decreases to room temperature.

SAPH301090900111

2. 

Inspection of camshaft end play (1)

Measure the camshaft end play (1) using a thickness gauge and measure the thrust plate thickness (2) using calipers. If it is beyond the operation limit, replace the thrust plate.

 End play SAPH301090900112

Thrust plate thickness



SAPH301090900113

W5-9-45

Standard value

Operation limit

(mm{in.})

(mm{in.})

0.10 - 0.23 {0.0040 - 0.0090}

0.3{0.0118}

8{0.315}

E485B

ENGINE MECHANICAL

Installation of camshaft JP30109090702007

1.

Tappet installation (1)

Insert the tappet coated with engine oil.

! CAUTION

Check the tappet visually for absence of eccentric wear, cracks, scratches, etc.

(2)

Use the special tool and secure the tappet. Special tool : 09451-1040. Stopper

SAPH301090900114

2.

Installation of camshaft (1)

Apply engine oil to the camshaft journal and insert it into the cylinder block while turning the camshaft.

! CAUTION

Do not damage the camshaft bearing.

(2)

Install the camshaft using 4 bolts.

(3)

Make sure that the camshaft end play is the standard value. Standard value (mm{in.})

SAPH301090900106

0.10 - 0.23 {0.0040 - 0.0090}

(4)

Apply the liquid gasket [Threebond TB1207C (red) or equivalent] and install the push rod cover.

! CAUTION

Apply it continuously. Apply the liquid gasket at the width of 1.5 to 2.5 mm{0.0591 - 0.0984 in.}. Install it within 20 minutes after application of the liquid gasket.

SAPH301090900105

W5-9-46

ENGINE MECHANICAL

Removal of timing gear JP30109090702008

1.

Removal of supply pump drive gear Reference: "Fuel system, Overhaul of supply pump drive bearing case"

2.

Removal of idle gear and main idle gear (1)

Remove the idle gear shaft mounting bolts of the idle gear

(2)

and main idle gear. Remove the thrust plate and main idle gear at the main idle gear side.

SAPH301090900115

3.

Removal of idle gear shaft

 ! CAUTION

Do not remove the idle gear shaft unless necessary.

(1)

Pull out each idle gear shaft using the special tool. Special tool : 09420-1442. Sliding hammer 09462-1410. Idle gear shaft puller adapter

SAPH301090900116

! CAUTION

Refer to the following for installation of the timing gear. Reference: "Engine mechanical, Camshaft and idle gear, Assembly of timing gear"

ì_åüóvóÃçÄñ

W5-9-47

E485B

ENGINE MECHANICAL

Inspection of timing gear JP30109090703005

1.

Inspection of idle gear oil clearance (1)

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

Main

idle gear Bushing inner diameter

64{2.520} 64{2.520}

Shaft outer diameter

52{2.047}

Bushing inner diameter

52{2.047}

Idle gear

(2)

Calculate the difference between the idle gear shaft outer diameter and the idle gear bushing inner diameter. If it is beyond the operation limit, replace the idle gear shaft and the idle gear bushing.

SAPH301090900117

Main idle gear

Idle gear

Standard value

Operation limit

(mm{in.})

(mm{in.})

0.030 - 0.090 {0.0012 - 0.0035} 0.030 - 0.090 {0.0012 - 0.0035}

0.20{0.0078}

0.20{0.0078}

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ

Installation of timing gear JP30109090702009

1.

Temporary tightening of air compressor idle gear shaft (1)

Apply engine oil to the idle gear shaft.

(2)

Direct the identification hole (1) of the idle gear shaft to the lower part of the engine and fix the idle gear shaft, gear and thrust plate temporarily. Special tool : 13572-1021 Plate 09481-1660 Guide

 SAPH301090900118

! CAUTION

(3)

Press-fit vertically so that the idle gear shaft does not hit the timing gear case.

Remove the special tool, apply engine oil to the bolt seating and the bolt thread and fix it temporarily.

W5-9-48

ENGINE MECHANICAL 2. 

Installation of idle gear (1)



Align the gear mark and install each idle gear (2) and (3). Tightening torque : Main idle gear (2) 44 N m {450 kgf cm, 32 lbf ft} Idle gear (3) 108 N m {1,100 kgf cm, 80 lbf ft}

(2)

Make sure that each backlash and end play are within the standard value after installation. "Reference: Engine mechanical, Camshaft and idle gear, Inspection of timing gear installation status"







SAPH301090900119

ì_åüóvóÃçÄñ

W5-9-49

E485B

ENGINE MECHANICAL

Inspection of installation status for each gear JP30109090703006

1.

Inspection of backlash (1)

Measure backlash between gears using a dial gauge. If it is beyond the operation limit, replace the gear. Standard value (mm{in.}) Between supply

SAPH301090900120

pump drive gear and main idle

0.05 - 0.19 {0.0020 -

0.07 - 0.19 {0.0028 -

gear(No.2) Between camshaft gear and idle gear Between main idle

2.

0.30{0.0118}

0.0074}

gear(No.2) Between camshaft gear and main idle

Operation limit (mm{in.})

0.30{0.0118}

0.0074} 0.06 - 0.19 {0.0024 -

0.30{0.0118}

0.0074} 0.07 - 0.19

gear(NO.2) and

{0.0028 -

crankshaft gear

0.0074}

Between oil pump drive gear and oil

0.06 - 0.30 {0.0024 -

pump driven gear

0.0118}

0.30{0.0118}

0.40{0.0157}

Inspection of idle gear end play (1)

Measure the end play of the main idle gear and idle gear using a thickness gauge. If it is beyond the operation limit, replace the gear and shaft.

Main idle gear SAPH301090900121

Idle gear ç\ê¨ê} ç\ê¨îzíuê}

W5-9-50

Standard value

Operation

(mm{in.})

limit (mm{in.})

0.065 - 0.149 {0.0028 -0.0049} 0.070 - 0.125 {0.0026 -0.0058}

0.30{0.0118}

0.30{0.0118}

ENGINE MECHANICAL

Valve System Part layout JP30109090402007

SAPH301090900122

13706

Crosshead

13840

Rocker arm assembly

13707

Tappet

13901

Rocker shaft

13711

Intake valve

13951

Rocker arm support

13715

Exhaust valve

13951B

Rocker arm support

13731

Outer valve spring

13951C

Rocker arm support

13732

Inner valve spring

900126

Valve spring retainer

13734

Lower spring seat

900129

Collar

13735

Upper spring seat

S1306

Push rod

13830

Rocker arm assembly

9219A

Rocker arm:44N m{450kgf cm, 32lbf ft}

Tightening torque 900125

52N m{530kgf cm,38 lbf ft}

9219A

Crosshead:28N m{290kgf cm,20 lbf ft} ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

W5-9-51

E485B

ENGINE MECHANICAL

Overhaul of valve system JP30109090702010

1.

Removal of rocker arm assembly (1)

Loosen the lock nut and turn the adjusting screw completely.

! CAUTION

• Removal without turning the adjusting screw may bend the rocker shaft.

SAPH301090900123

(2)

Loosen the rocker arm support bolts gradually from the center and remove the rocker arm shaft.

SAPH301090900124

(3)

Pull out the push rod.

! CAUTION

• Do not pull out the tappet together with the push rod.

SAPH301090900125

2.

Inspection of rocker arm oil clearance (1)

Measure the outer diameter of the rocker shaft using a micrometer. Standard value (mm{in.})

Operation limit (mm{in.})

28{1.102}

27.92{1.0992}

SAPH301090900126

W5-9-52

ENGINE MECHANICAL (2)

(3)

Measure the rocker arm bushing inner diameter using a cylinder gauge. Standard value (mm{in.})

Operation limit (mm{in.})

28{1.102}

28.08{1.1055}

Calculate the difference between the outer diameter of the rocker shaft and the inner diameter of the rocker arm bushing. If it is beyond the standard value, replace the rocker shaft or the rocker arm bushing.

SAPH301090900127

Standard value (mm{in.})

3.

0.044 - 0.120 {0.0018 - 0.0393}

Removal of valve spring (1)

Compress the valve spring from the cylinder head using a special tool and remove the valve spring retainer. Special tool : 09470-1120 Valve spring press

SAPH301090900128

(2)

Remove the intake and exhaust valves.

! CAUTION

• Attach a tag with the applicable cylinder number to the valve so that combinations of the valve and the cylinder head may not be mixed.

SAPH301090900129

W5-9-53

E485B

ENGINE MECHANICAL 4. 



Replacement of valve stem seal (1)

After removing the valve stem seal (1), assemble the valve spring lower seat (2). Apply engine oil (3) to the lip



and the inner surface of the stem seal (1). Strike the valve stem seal (1) using a special tool (4) until the special tool (4) comes in contact with the valve spring lower seat (2). Special tool (4): 09472-1870 Valve stem seal press ! CAUTION

After assembly of the stem seal (1), make sure that there is no deformation, crack or



inclination of the rubber (5), or disconnection



of the spring (6).

 

SAPH301090900130

5. 

Inspection of valve spring (1)

Measure squareness of the valve spring using a square or a thickness gauge. If it is beyond the operation limit clearance (A), replace the valve spring. Clearance (A) (mm{in.})

2.0{0.0787}

SAPH301090900131

(2)

Measure the set load of the valve spring using a spring tester. If it is out of the operation limit, replace the valve spring.

Set length Intake (mm{in.}) Exhaust SAPH301090900132

Standard value (mm{in.})

Operation limit (mm{in.})

54.1{2.1299}

54.7{2.1535}

Inner Intake 166.7{17, 37.5} 153{15.6, 34.4} Set load (N{kgf,lbf}) Exhaust 160.8{16.4, 36.2} 147.1{15.0, 33.0} Set length

Intake

58.1{2.2874}

(mm{in.})

Exhaust

58.7{2.3110}

Set load

Intake

Outer 389.3{39.7, 87.5} 357.9{36.5, 80.5}

(N{kgf,lbf}) Exhaust 382.5{39.0, 86.0} 351.1{35.8, 78.9} W5-9-54

ENGINE MECHANICAL (3)

Measure the free length of the valve spring using a vernier calipers. If it is out of the operation limit, replace the valve spring. Standard value Operation limit (mm{in.}) (mm{in.}) Inner valve spring

72.0{2.8346}

70.0{2.7559}

Outer valve spring

93.0{3.6614}

91.0{3.5826}

SAPH301090900133

6.

Inspection of spring seat (1)

Check for wear and damage of the spring seats (upper and lower). If a faulty condition is found, replace the seats.

SAPH301090900134

7.

Inspection of oil clearance between valve guide and valve stem (1)

Measure the outer diameter of the valve stem using a micrometer. Standard value (mm{in.})

SAPH301090900135

(2)

Operation limit (mm{in.})

Intake valve stem

8{0.315}

7.88{0.3102}

Exhaust valve stem

8{0.315}

7.88{0.3102}

Measure the valve guide inner diameter using a cylinder gauge. Standard value (mm{in.})

SAPH301090900136

W5-9-55

Intake valve guide

8{0.315}

Exhaust valve guide

8{0.315}

E485B

ENGINE MECHANICAL (3)

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

Stem outer SAPH301090900137

diameter

Standard

Standard

Operation

value

clearance

limit

(mm{ni.})

(mm{in.})

(mm{in.})

8{0.315}

0.040 - 0.077 {0.0016 -

{0.0047}

8{0.315}

0.0030}

Following

8{0.315}

0.057 - 0.094

8{0.315}

{0.0023 0.0037}

0.12

Intake Guide inner diameter Stem outer diameter

0.14

Exhaust Guide inner diameter

{0.0055} Following

Guide inner diameter

Part A (mm{in.})

Part B (mm{in.})

Part C (mm{in.})

Intake

7.88{0.3102}

7.88{0.3102}

7.82{0.3079}

Exhaust

7.86{0.3094}

7.86{0.3094}

7.80{0.3071}

8. ďƒŠ

Inspection of valve sink (1)

Measure valve sink (7) using a straight edge, thickness gauge or dial gauge. If it is beyond the operation limit, replace the valve or the valve seat.

SAPH301090900138

9.

Standard value

Operation limit

(mm{in.})

(mm{in.})

Intake

-0.05 - 0.35

valve sink

{-0.0020 - 0.0137}

Exhaust

0.55 - 0.95

valve sink

{0.0217 - 0.0374}

0.7{0.0275}

1.3{0.0511}

Inspection of tappet oil clearance (1)

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

SAPH301090900139

diameter

W5-9-56

28{1.102} 28{1.102}

ENGINE MECHANICAL (2)

Calculate the difference between the tappet outer diameter and the tappet guide inner diameter. If it is beyond the operation limit, replace each part. Standard value (mm{in.})

Operation limit (mm{in.})

0.020 - 0.066 {0.0008 - 0.0260}

0.10{0.0039}

SAPH301090900140

10. Installation of valve and valve spring (1)

Place the lower seat, valve spring and upper seat on the

(2)

cylinder head in the order listed. Compress the valve spring using a special tool and install the valve spring retainer. Special tool : 09470-1120. Valve spring press

! CAUTION

Apply engine oil to the contact surface of each part before assembly.

SAPH301090900128

Be sure to assemble each valve at the original cylinder position. When the valve spring is compressed, avoid contact of the valve spring upper seat with the valve stem seal. Since the valve spring has equal spacing, vertical direction is not specified for assembly. Check for scratch on the valve stem seal when the valve is reused. 11. Installation of rocker arm assembly (1)

Apply engine oil to both ends of the push rod and insert it into the cylinder block.

SAPH301090900141

W5-9-57

E485B

ENGINE MECHANICAL (2)

Apply engine oil to the valve stem head.

(3)

Apply engine oil to the crosshead mounting area.

(4)

Attach the crosshead.

! CAUTION

Make sure that the crosshead is correctly placed on the valve.

SAPH301090900142

(5)

Place the rocker arm assembly on the cylinder head and temporarily tighten the 12 support bolts until it comes in contact with the cylinder head upper surface in the order shown in the figure.

! CAUTION

If an engine retarder is equipped, long bolts for tightening the engine retarder are used for the 4, 6, 10, 12 areas in the figure. Use substitute bolts (9001-24352). (Remove this bolt when installing the engine retarder.)

SAPH301090900143

Turn all adjusting screws and place the rocker arm assembly. (6)

Tighten 12 support bolts in the order shown in the figure. Tightening torque : 52 N m {530 kgf cm, 38 lbf ft}

(7)

If an engine retarder is equipped, remove the substitute bolts 4, 6, 10, 12 that tighten the rocker arm support.

NOTICE

Install the engine retarder on the area where the substitute bolt is used.

ëïíÖóvóÃçÄñ

W5-9-58

ENGINE MECHANICAL

Hino P11C Adjustment of valve clearance ! CAUTION

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

1.

Adjustment of valve clearance (1)



Turn the crankshaft and check that the timing mark at the flywheel inspection window (1) is at "1/6" and that the key on the shaft of the supply pump bearing case is pointing up to confirm that the No. 1 cylinder is at the compression



top dead center. ! CAUTION

If the timing mark is at "1/6", but the shaft key is pointing down, the No. 6 cylinder is at the compression top dead center. In this case,

SAPH301090900144

turn the crankshaft another turn to set the No. 1 cylinder to the compression top dead center.

W5-9-59

ENGINE MECHANICAL (2)

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

Cylinder

Valve

At the time of No. 1 cylinder at the

At the time of No. 6 cylinder at the

No.

layout

compression top

compression top

dead center

dead center

Suction 1 Exhaust Suction 2 Exhaust Suction 3 Exhaust Suction 4 Exhaust Suction 5 Exhaust Suction 6 Exhaust (3)

Loosen the adjusting screw (2) and the lock nut of the crosshead completely.

 



! CAUTION

Provide the adjusting screw protrusion of 14 mm{0.5512 in.} or more from the top surface of the crosshead. If the adjusting screw (2) is not completely separated from the valve stem, correct adjustment is not allowed.



SAPH301090900145

(4)



Insert a thickness gauge (1) between the rocker arm and the crosshead and adjust the clearance (X) with the adjusting screw (2) of the rocker arm. Tighten the lock nut.



Standard value (cold engine)

IN

0.45{0.0177}

(mm{in.})

EX

0.60{0.0236}



Tightening torque : 44 N m {450 kgf cm, 32 lbf ft} SAPH301090900146

W5-9-60

ENGINE MECHANICAL (5)

 

Loosen the adjusting screw of the crosshead with the thickness gauge inserted. Make sure that feel on the thickness gauge is appropriate.



! CAUTION



If it becomes lighter, make adjustments again from the beginning.



 SAPH301090900147

A - Start B- Nut fixing position J- Correct contact K - Do not move L- Feel does not change X- Feel of thickness gauge Y- Adjusting screen loosening amount Large

(6)

Tighten the adjusting screw of the crosshead until the thickness gauge (2) does not move.







SAPH301090900148

0 - Contact (7)

 



While loosening the adjusting screw of the crosshead gradually, tighten the lock nut of the crosshead at the position where feel on the thickness gauge is appropriate. Tightening torque : 28 N m {290 kgf cm, 20 lbf ft}

 ! CAUTION

Do not over-loosen the adjusting screw. Overloosening of the adjusting screw reproduces



the original status. Although feel on the thickness gauge is appropriate, there is a



clearance between the adjusting screw and

SAPH301090900149

A - Start B- Nut fixing position J- Correct contact K - Do not move L- Feel does not change X- Feel of thickness gauge Y- Adjusting screen loosening amount Large

the valve of the crosshead. Correct adjustment is not allowed.

W5-9-61

ENGINE MECHANICAL NOTE:

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

9

W5-9-62

EXHAUST

ENGINE

10 HINO P11C EXHAUST Setup layout Layout

Exhaust Manifold...................................................... 10-2 Part layout (typical example) ................................ 10-2 Replacement......................................................... 10-3

Hino P11C Engine Parts www.Hino-P11C.com Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638

W5-10-1

10

E485B

EXHAUST

Exhaust Manifold Part layout (typical example) JP30109100402001

SAPH301091000001

17044

Insulator

17105

Exhaust manifold

17044A

Insulator

17118

Exhaust manifold bracket

17104

Gasket*

17271

Insulator

17104D

Gasket*

9029B

68.5 m{700kgf cm, 50 lbf ft}

*Parts not to be reused. Tightening torque 9209A

59 m{600kgf cm, 44 lbf ft}

9068-10700

68.5 m{700kgf cm, 50 lbf ft} Service procedure Replacement procedure item

W5-10-2

EXHAUST

Replacement JP30109100704001

1.

2.

Removal of exhaust manifold (1)

Remove the turbocharger.

(2)

Remove the insulator.

(3) (4)

Remove the exhaust manifold bracket. Remove the exhaust manifold.

Replacement of stud bolt (1)

Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap (M10 x 1.5).

SAPH301091000002

(2)

Tighten the new stud bolt. Tightening torque : 30 N m {300 kgf cm, 22 lbf ft}

! CAUTION

Excessive tightening with overtorque may cause crack in the cylinder head.

3.

 

 

 











Installation of exhaust manifold (1)

Install a new gasket and align the exhaust manifold with the cylinder head.

(2)

Tighten the nuts from the top to the bottom and from the right to the left. Tightening torque : 44 N m {450 kgf cm, 32 lbf ft}

  

 

 











SAPH301091000003

(3)

Tighten the nuts again from the top to the bottom and from the right to the left. Tightening torque : 59 N m {600 kgf cm, 44 lbf ft}













 

 

 









 

 

 

! CAUTION



SAPH301091000004

W5-10-3

Be sure to retighten it.

E485B

EXHAUST



(4)



bracket (2) against the cylinder block (5), tighten the bolt



(3) at the manifold side and then tighten the bolt (4) at the



cylinder block side.





For the exhaust manifold (1) bracket (2) , fix the eight bolts (3) with spacer (6) and bolts (4) temporarily, push the

Tightening torque : 68.5 N m {700 kgf cm, 50 lbf ft} (5)

Connect the insulator.

(6)

Install the turbocharger.

 

 SAPH301091000005

W5-10-4

COOLING

ENGINE

11 COOLING ê°ñ@ê} ånìùê}

Cooling System ........................................................ 11-2 Cooling system drawing........................................ 11-2 Part layout............................................................. 11-3 Replacement of coolant pump .............................. 11-5 Replacement of thermostat case .......................... 11-5 Inspection of thermostat........................................ 11-6 Replacement of fan drive, tension pulley .............. 11-7 Replacement of cooling fan, fan spacer................ 11-9

11

W5-11-1

E485B

COOLING

Cooling System Cooling system drawing jp30109110804001





    

  







SAPH301091100001 ç\ê¨ê} ç\ê¨îzíuê}

1 - Reservoir 2 - Thermostat 3 - Thermostat case 4 - Oil cooler 5 - Drain cock 6 - Cylinder head 7 - Cylinder block 8 - Coolant pump 9 - Radiator cap 10 - Car heater 11 - Coolant temperature gauge 12 - Radiator 13 - Drain cock

W5-11-2

COOLING

Part layout jp30109110402001

Water pump, Thermostat

SAPH301091100002

16100

Coolant pump

16332

Coolant pump outlet pipe

16173

Coolant pump pulley

900234

Coolant hose

16303

Thermostat case

9644A

O-ring*

16308

Coolant pump pulley

9645A

O-ring*

16323

Thermostat case cover

9655-14140

O-ring*

16325

Gasket*

9778-04620

Clamp

16325A

Gasket*

9851A

O-ring*

9068-10950

55N m {560 kgf cm,40 lbf ft}

*Parts not to be reused. Tightening torque 9068-10800

55N m {560 kgf cm.40 lbf ft}

W5-11-3

E485B

COOLING

Fan drive system

SAPH301091100003

16365

Fan spacer

9201-14110

Pulley lock nut

16371

Fan drive pulley

9644C

O-ring*

16384

Tension pulley

9645B

O-ring*

16390

Fan drive assembly

9851C

O-ring*

16630

Tension pulley assembly

9851D

O-ring*

88444

Tension pulley bracket

S1637

Fan drive

9189A

Adjusting bolt

SZ910

Fan belt

*Parts not to be reused. Tightening torque 9068-10750

55 N m {560 kgf cm,40 lbf ft}

9201-14110

108 N m {1,100 kgf cm,80 lbf ft}

9201-10080

60 N m {610 kgf cm,44 lbf ft}

9419A

47 N m {480 kgf cm,35 lbf ft}

å ä²óvóÃçÄñ êÆî óvóÃ

W5-11-4

COOLING

Replacement of coolant pump jp30109110704004

1. 

Removal of coolant pump (1)



Loosen the coolant hose (14) clamp, remove bolts and remove the coolant pump (8).

2.

Installation of coolant pump (1) Insert the coolant hose (14) into the coolant pump (8) and install the coolant pump (8) on the timing gear case. (2)

Tighten the coolant hose clamp.

SAPH301091100004

Replacement of thermostat case jp30109110704003

1. 



2.

Removal of thermostat case (1)

Remove the coolant pump (8).

(2)

Remove the coolant hose (14) clamp, remove bolts and remove the thermostat case (3).

Installation of thermostat case (1)

Insert the coolant hose (14) into the thermostat case (3), replace the gasket with a new one and install the thermostat case (3) on the cylinder head (6). Tightening torque : 55 N m {560 kgf cm, 40 lbf ft}

SAPH301091100005

(2)

Tighten the coolant hose (14) clamp.

(3)

Replace the gasket with a new one and install the coolant pipe.

(4)

Replace the coolant pump (8).

ì_åüóvóÃçÄñ

W5-11-5

E485B

COOLING

Inspection of thermostat jp30109110703001

1. 



Individual inspection of thermostat (1)

Put the thermostat (2) in water as shown in the figure and heat it.

! CAUTION

Support the thermostat (2) in the center to prevent approach to the heat source.



Stir the water well so that water temperature



in the container may be uniform.  SAPH301091100006

A - Wire B - Thermometer

C - Heat source D - Valve lift

(2)

Measure the temperature (valve opening temperature) that opens the thermostat valve.

 

Thermostat valve opening temperature standard value :

74.5 - 78.5{166.1 - 173.3}

T1( C{ F}) 

  



 The thermostat valve opening temperature (T1) is stamped on the thermostat seat.

NOTICE SAPH301091100007

T1 - Valve opening temperature (start of valve opening)

T2 - Full open lift inspection temperature X - Temperature Y - Valve lift

(3)

Increase the water temperature to 90 C and measure the lift of the thermostat valve. Thermostat valve full

 

open lift inspection temperature : T2 ( C{ F})

Valve lift : L (mm{in.})

90{194}

10{0.394} or more

 (4) SAPH301091100008

Put the full open thermostat valve in water at normal temperature. Make sure that the thermostat valve closes completely within 5 minutes.

L : Valve lift L1 At cold open L2 : (T2) °C {°F}

(5)

If faulty item is found with the inspection above, replace the thermostat (2).

å ä²óvóÃçÄñ

W5-11-6

COOLING

Replacement of fan drive, tension pulley jp30109110704001

1.

Removal of fan drive, tension pulley (1)

Remove the cooling fan.

(2)

The pulley fixing nut (15) of the tension pulley (16), loosen the adjusting bolt (17) and remove the V belt (18).

 



 SAPH301091100009

(3)

Loosen the four fan drive mounting bolts (20) and remove the fan drive (19) from the timing gear case cover.

 (4)





Remove the tension pulley (16).

 SAPH301091100010

2.

Installation of fan drive, tension pulley (1)

Install the tension pulley (16) assembly on the timing gear case cover with the tension pulley bracket. Install the pulley fixing nut temporarily. Tightening torque : 55 N m {560 kgf cm, 40 lbf ft}

 SAPH301091100011

(2)

Install two new O rings (21) on the O ring groove at the timing case cover side and install the fan drive assembly on the timing gear case cover. Tightening torque : 47 N m {480 kgf cm, 35 lbf ft}

 SAPH301091100012

W5-11-7

E485B

COOLING (3) (4)

Fix the V belt temporarily. Install the cooling fan. Tightening torque : 66 7 N m {673 71 kgf cm, 487 5lbf ft}

3.

Adjustment of fan belt (1)

Loosen the tension pulley fixing nut (15) to the degree that the pulley (16) moves freely.

(2)

Adjust it with adjusting bolt (17) so that the fan belt tension between the tension pulley (16) and the fan drive pulley (19) is the standard value.



Item





When a new belt is installed

In inspection

9 - 11mm

12 - 14mm

Deflection

{0.3543 0.4331in.}

{0.4724 0.5512in.}

520 - 610 N

340 - 440 N

Tension

{53 - 62 kgf, 117

{35 - 45 kgf,76 -

- 137 lbf}

90 lbf}

 SAPH301091100013

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

If the fan belt is replaced with a new one, it becomes loose due to initial fitting. Run the engine for three to five minutes and adjust the tension of the belt again. At the time of inspection, the new fan belt has

NOTICE

reached the value after complete initial stretching. A new fan belt completes initial stretching after running the engine for approximately two hours. (3)

After adjustment, tighten the tension pulley fixing nut and fix the pulley. Tightening torque : 108 N m {1,100 kgf cm, 80 lbf ft}

W5-11-8

COOLING å ä²óvóÃçÄñ

Replacement of cooling fan, fan spacer jp30109110704002

1.

Removal of cooling fan (1)

Remove the cooling fan (22) from fan spacer (23).

(2)

Remove nuts (24) and remove the fan spacer (23) from

  SAPH301091100014

the fan drive pulley (19). 



 SAPH301091100015

2.

Installation of fan spacer (1)

Install the fan spacer (23) on the fan drive pulley (19). Tightening torque : 60 N m {610 kgf cm, 44 lbf ft}

3.

Installation of cooling fan (1)

Install the fan spacer (23) on the cooling fan (22). Tightening torque : 66 7 N m {673 71 kgf cm,49 5 lbf ft}

(2)

Fix the fan belt temporarily.

W5-11-9

E485B

COOLING

NOTE:

11

W5-11-10

LUBRICATION

ENGINE

12 LUBRICATION ê°ñ@ê} ånìùê}

Lubrication System .................................................. 12-2 System drawing .................................................... 12-2 Oil Pump.................................................................... 12-4 Part layout............................................................. 12-4 Replacement......................................................... 12-6 Overhaul ............................................................... 12-8 Oil Filter ................................................................... 12-11 Part layout........................................................... 12-11 Replacement....................................................... 12-13 Oil cooler ................................................................. 12-17 Part layout........................................................... 12-17 Replacement....................................................... 12-21 Overhaul ............................................................. 12-24 Oil pan ..................................................................... 12-27 Part layout........................................................... 12-27 Replacement....................................................... 12-28

12

W5-12-1

E485B

LUBRICATION

Lubrication System System drawing JP30109120804001





     

  



 





  













 

 









 



 







  

 





  

SAPH301091200001

W5-12-2

LUBRICATION 1 - Liner circumference cooling 2 - To oil pan 3 - Cam bearing circumference groove 4 - Sub oil hole 5 - Check valve 6 - Relief valve 7 - Main oil hole 8 - Rocker arm 9 - Crosshead 10 - Bushing rod 11 - Tappet 12 - Camshaft 13 - Sub oil hole for liner cooling 14 - Cooling jet 15 - Check valve (each cylinder) 16 - Piston 17 - To idle gear 18 - Crankshaft 19 - Air compressor To idle shaft To valve system 20 - Safety valve 21 - Filter warning switch 22 - Supply pump 23 - To supply pump drive unit 24 - Oil cooler 25 - Oil filter 26 - Pressure gauge 27 - Air compressor 28 - Oil pump 29 - Safety valve 30 - Oil strainer 31 - Bypass 32 - Turbocharger 33 - Air compressor idle gear 34 - Turbocharger check valve

W5-12-3

LUBRICATION

Oil Pump

ç\ê¨ê} ç\ê¨îzíuê}

Part layout JP30109120402001

SAPH301091200002

15110

Oil pump

9644E

O-ring*

15104

Oil strainer

9851A

O-ring*

15431

Oil feed pipe *Parts not to be reused.

Tightening torque 9181-08200

21N m{210kgf cm,15 lbf ft}

9411-10451

47N m{480kgf cm,35 lbf ft}

9181-08500

23N m{230kgf cm,17 lbf ft}

9411-14902

113N m{1,150kgf cm,83 lbf ft}

9181-08550

21N m{210kgf cm,15 lbf ft}

W5-12-4

LUBRICATION

SAPH301091200003

15101

Oil pump body assembly

15132

Relief valve spring

15107

Driven gear

15133

Plug

15110

Oil pump

900700

Bolt A

15115

Cover

9061-10350

Bolt B

15131

Relief valve

9061-10350

44.0 4.9N m{449 50kgf cm,32 4lbf ft}

Tightening torque 15133

83.4 4.9N m{850 50kgf cm,62 4lbf ft}

900700

22.6 2.9N m{230 30kgf cm,17 2lbf ft}

W5-12-5

E485B

LUBRICATION å ä²óvóÃçÄñ êÆî óvóÃ

Replacement JP30109120704002

1.

Removal of oil pump (1)

Remove bolts and remove the oil pan.

(2)

Remove bolts and remove the oil strainer.

(3)

Remove bolts and remove the oil feed pipe and the oil

SAPH301091200004

SAPH301091200005

pump.

SAPH301091200006

2.

Installation of oil pump (1)

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

! CAUTION

In installation, be careful that the O-ring may not be caught.

SAPH301091200006

W5-12-6

LUBRICATION (2)

Replace the O-ring with a new one and install the oil strainer. Tightening torque : 23 N m {230 kgf cm, 17 lbf ft}

! CAUTION

• In installation, be careful that the O-ring may not be caught.

SAPH301091200005

3.

Installation of oil pan "Reference: Lubrication, Oil pan, Replacement"

W5-12-7

E485B

LUBRICATION

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

Overhaul JP30109120702001

1.



Disassembly of oil pump (1)



Remove the plug (1) and remove the spring (2) and relief valve (3).



When the plug (1) is removed, the spring (2)

! CAUTION

and the relief valve (3) may eject out.

SAPH301091200007

(2) (3)

Remove bolts and remove the oil pump case cover. Remove the driven gear (4). Do not damage the joint surface during work.

! CAUTION

 SAPH301091200008

2.

Inspection of oil pump (1)

Inspection of clearance between drive gear (5) and oil pump case (tip clearance) a.

Measure the clearance between the drive gear (5) and the oil pump case using a thickness gauge. If it is beyond the operation limit, replace the oil pump assembly.



Standard value (mm{in.}) 0.038 - 0.115

SAPH301091200009

{0.0015 - 0.0045} (2)

Operation limit (mm{in.}) 0.17{0.0066}

Inspection of side clearance between drive gear (5) and oil pump case (end play)

 a.

Place the straight edge on the case and measure the drive gear (5) width and the oil pump case depth using a depth gauge.

b.

Calculate the difference between the width of the drive gear (5) and the oil pump case depth. If it is beyond the operation limit, replace the oil pump assembly.

SAPH301091200010

Standard value (mm{in.}) 0.045 - 0.105 {0.0018 - 0.0041} W5-12-8

Operation limit (mm{in.}) 0.15{0.0059}

LUBRICATION (3)

Inspection of clearance of drive gear shaft (6) outer diameter (X) and drive gear side hole inner diameter (Y) of oil pump case cover (7). a.

Measure the outer diameter (X) of the drive gear shaft (6) using a micrometer and measure the drive gear side hole inner diameter (Y) of the oil pump case cover (7) using a micrometer.

 

Standard value

Measuring area

(mm{in.})

SAPH301091200011

Outer diameter of drive gear shaft Drive gear side hole inner diameter of oil pump case cover b.

20{0.787} 20{0.787}

Calculate the difference between the outer diameter of the drive gear shaft (6) and the drive gear side hole



inner diameter of the oil pump case cover (7). If it is beyond the operation limit, replace the oil pump case cover (7). Standard value (mm{in.})

Operation limit (mm{in.})

0.040 - 0.074 {0.0016 - 0.0029}

0.17{0.0066}



SAPH301091200012

(4)

Inspection of oil clearance between outer diameter (Z) of driven gear shaft (8) and inner diameter of driven gear bushing (9). a.

Measure the outer diameter (Z) of the driven gear shaft (8) using a micrometer and measure the inner diameter of the driven gear bushing (9) using a cylinder gauge.



Standard value (mm{in.})

Measuring area



Outer diameter of driven gear

SAPH301091200013

shaft Inner diameter of driven gear bushing b.

20{0.787} 20{0.787}

Calculate the difference between the outer diameter (Z) of the driven gear shaft (8) and the inner diameter of the driven gear bushing (9). If it is beyond the operation limit, replace the oil pump or the driven gear.

Standard value (mm{in.}) 

0.040 - 0.074 {0.0016 - 0.0029}

SAPH301091200014

W5-12-9

Operation limit (mm{in.}) 0.17{0.0066}

E485B

LUBRICATION (5)

Inspection of drive gear backlash a.

Fix the oil pump with a vice.

b.

Measure backlash between the drive gear (5) and the driven gear (4) using a dial gauge. If it is beyond the operation limit, replace the oil pump.

Standard value (mm{in.}) 

0.072 - 0.208

0.4{0.0157}

{0.0029 - 0.0081}



Operation limit (mm{in.})

SAPH301091200015

3.



Assembly of oil pump (1)



Install the relief valve (3), spring (2) and plug (1) on the oil pump case cover.



Tightening torque : 83.4

4.9 N m {850

50 kgf cm, 62

48 lbf ft}

SAPH301091200007

(2)

Apply engine oil to the gear inner surface and the shaft, align the oil pump body dowel pin and assemble the oil pump. Tightening torque : 22.6

2.9 N m {230

30 kgf cm, 17

2 lbf ft}(Bolt 10)

44.0

4.9 N m {449

50 kgf cm, 32

4 lbf ft}(Bolt 11)

ç\ê¨ê} ç\ê¨îzíuê}

   SAPH301091200017

W5-12-10

LUBRICATION

Oil Filter Part layout JP30109120402003

SAPH301091200018

15600

Oil filter assembly

9655-12100

Gasket*

15671

Oil filter bracket

9644A

O-ring*

23201

Oil hose(Bypass)

9644B

O-ring*

23201A

Oil hose

9739A

Joint

23201B

Oil hose

*Parts not to be reused. Tightening torque 23301A

196N m{2,000kgf cm,145 lbf ft}

9411A-10002

47N m{480kgf cm,35 lbf ft}

23301B

196N m{2,000kgf cm,145 lbf ft}

9419A

47N m{480kgf cm,35 lbf ft}

9019A

25N m{255kgf cm,18 lbf ft}

W5-12-11

E485B

LUBRICATION

SAPH301091200019

15600

Oil filter assembly

15643

Drain plug

15604

Safety valve

15651

Center bolt

15607

Oil filter element

15651A

Center bolt

15607A

Oil filter element

15660

Oil filter warning switch

15612

Oil filter element cover

15691

O-ring*

15614

Cover

15691A

O-ring*

15614A

Cover

9851C

O-ring*

15615

Spring

9851D

O-ring*

15629

Gasket*

9851E

O-ring*

15629A

Gasket*

15651A

44 4.9N m{450 50kgf cm,32 4lbf ft}

*Parts not to be reused. Tightening torque 15643

17.2 2.5N m{175 25kgf cm,13 2lbf ft}

15651

44 4.9N m{450 50kgf cm,32 4lbf ft}

W5-12-12

LUBRICATION å ä²óvóÃçÄñ êÆî óvóÃ

Replacement JP30109120704001

The shape of brackets and hose joints in the

NOTICE

illustrations and the hose routing differ according to the model. 1.

Engine oil draining (1)

Prepare a tray or another container to receive engine oil, loosen the drain plug (1) at the lower end of the oil filter, and drain the engine oil.



! CAUTION

When draining the engine oil, follow the specified method (waste processing) or an environment-friendly method.



 SAPH301091200020

2.

Removal of oil filter element (1)

Loosen the center bolt (2) and remove the cover (3).

(2)

Remove the oil filter element (4).

SAPH301091200021

 



! CAUTION



Make sure that there is no O-ring (5) left at the oil cooler case.

 



SAPH301091200043

3.

Disconnecting the oil hose

 ! CAUTION

When disconnecting the oil hose (6), receive the oil remaining in the hose in a container



and plug the end of the hose with a shop towel or similar. (1)

Secure the joint (7) securely with a hand vise or similar, loosen the nut of the oil hose (6), and disconnect the oil hose from the oil filter assembly. (Inlet and outlet)

 SAPH301091200022

W5-12-13

E485B

LUBRICATION

! CAUTION

When working with two spanners, use spanners with the same length for the moment arm to make spanner control easier. Install the joint (7) on the oil filter bracket.

NOTICE

(2)

Loosen the union bolt (8) and disconnect the oil hose (6) (bypass) from the oil filter assembly. Remove the two gaskets.

4. 



Removal of the oil filter element cover (when required) (1)

Disconnect the oil filter warning (clogging alarm) connector (9).

(2)

Loosen the bolts (10) and remove the oil filter element cover (11) from the oil filter bracket (12).

(3)

Remove the three O-rings from the oil filter element cover (11) or the oil filter bracket (12).

  SAPH301091200023

5.

Removal of the oil filter bracket (when required) (1)

Loosen the bolts (13) and remove the oil filter bracket (12).

  SAPH301091200024

6.

Installation of the oil filter bracket (when it has been removed) (1)

Install the oil filter bracket with bolts (13) on the oil filter bracket (12).

  SAPH301091200024

W5-12-14

LUBRICATION





7.

Installation of the oil filter element cover (when it has been removed) (1)

Replace the O-ring by a new one and install the oil filter element cover (11) with bolts (10) on the oil filter bracket (12). Tightening torque : 47 N m {480 kgf cm, 35 lbf ft}

(2)



Connect the oil filter warning (clogging alarm) connector (9).

 SAPH301091200023

8.

Connecting the oil hose

 (1) 

Secure the joint (7) securely with a hand vise or similar, tighten the nut of the oil hose (6), and connect the oil hose (6) to the oil filter assembly. (Inlet and outlet) Tightening torque : 196 N m {2,000 kgf cm, 145 lbf ft} (PF1)

! CAUTION

When working with two spanners, use spanners with the same length for the



moment arm to make spanner control easier.

SAPH301091200022

If the joint part has been loosened, replace the O-ring by a new one. (2)

Replace the gasket by a new one and connect the oil hose (6) (bypass) with a union bolt (8) to the oil filter assembly. Tightening torque : 26.5 N m {270 kgf cm, 20 lbf ft}

9.  



Installation of oil filter element (1) Remove contamination or foreign matter on the mounting surface of the oil filter element cover (3).



 

(2)

Apply engine oil thinly to the O-ring (5) (large small) of a

(3)

new oil filter element (4). Install the oil filter element (4).

(4)

Tighten the center bolt (2). Tightening torque:



44 4.9N m{450 50kgf cm,32 4lbf ft}

SAPH301091200043

W5-12-15

E485B

LUBRICATION (5)

Replace the O ring of the drain plug (1) with a new one for installation. Tightening torque: 17.2 2.5N m{175 25kgf cm,13 2lbf ft}

! CAUTION

In installation, be careful that the O-ring may not be damaged by distortion. Do not reuse the O-ring. Assemble the full flow side (A) oil filter

NOTICE

element so that the top and the bottom are identified correctly. The oil filter element on the bypass side (B) 

can be installed in either orientation, as it has the same shape at top and bottom.



SAPH301091200027

10. Engine oil filling (1)

Confirm that the drain plug (1) at the lower end of the oil filter has been tightened, and then fill in engine oil while looking at the oil level gauge. Reference: "Engine removal/installation, work after installation, engine oil inspection"

W5-12-16

LUBRICATION

Oil cooler

ç\ê¨ê} ç\ê¨îzíuê}

Part layout JP30109120402005

SAPH301091200028

15431A

Coolant pipe

9644E

O-ring*

15710

Oil cooler assembly

9659A

Gasket*

9644A

O-ring*

9659B

Gasket*

9644D

O-ring* *Parts not to be reused.

Tightening torque 900124

39N m{400kgf cm,29 lbf ft}

9411-10001

47N m{480kgf cm,35 lbf ft}

900124A

39N m{400kgf cm,29 lbf ft}

9411-10501

55N m{560kgf cm,40 lbf ft}

9191-08002

25N m{250kgf cm,18 lbf ft}

9419A

47N m{480kgf cm,35 lbf ft}

W5-12-17

E485B

LUBRICATION

SAPH301091200029

23201

Oil hose(Bypass)

9644A

O-ring*

23201A

Oil hose

9655-12100

Gasket*

23201B

Oil hose

9739A

Joint

90404A

Joint

9019A

25N m{255kgf cm,18 lbf ft}

*Parts not to be reused. Tightening torque 23301A

196N m{2,000kgf cm,145 lbf ft}

23301B

196N m{2,000kgf cm,145 lbf ft}

W5-12-18

LUBRICATION

SAPH301091200030

24106

Oil pipe

9655-14140

Gasket*

9068-10180

55N m{560kgf cm,40 lbf ft}

*Parts not to be reused. Tightening torque 9019D

25N m{255kgf cm,18 lbf ft}

W5-12-19

E485B

LUBRICATION

SAPH301091200031

15612

Oil cooler cap

9851B

O-ring*

15621

Gasket*

9851C

O-ring*

15643

Drain plug

9851D

O-ring*

15662

Valve cap

9851E

O-ring*

15675

Relief valve

9851F

O-ring*

15710

Oil cooler assembly

9851G

O-ring*

15712

Oil cooler element

9851H

O-ring*

15714

Safety valve

9851J

O-ring*

15715

Gasket*

9851K

O-ring*

15716

Valve cap

9851L

O-ring*

15717

Gasket*

9851M

O-ring*

15717A

Gasket*

9851N

O-ring*

15721

Cover

9851P

O-ring*

15726

Valve cap

9851Q

O-ring*

15726A

Valve cap

S1148

Drain plug

15726B

Plug

S1565

Center bolt

15726C

Plug

S1571

Plug

23314

Plug

S1572

Plug

23322

Plug

S1572A

Oil cooler cover

9851A

O-ring*

S1572B

Oil cooler cover

9191-08401

19.6 4.9N m{200 50kgf cm,14 4lbf ft}

*Parts not to be reused. Tightening torque 9191-08301

19.6 4.9N m{200 50kgf cm,14 4lbf ft}

W5-12-20

LUBRICATION ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

Replacement JP30109120702003

The shape of brackets and hose joints in the

NOTICE

illustrations and the hose routing differ according to the model. 1.

Removal of pipes (1)

Disconnect all pipes connected to the oil cooler.

! CAUTION

Loosen the bolts after preparing containers to receive cooling water or engine oil respectively.

(2)

Remove O-rings and gaskets.

SAPH301091200032

2.

Disconnecting the oil hoses

! CAUTION

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

(1)

Secure the joint securely with a hand vise or similar, loosen the nut (1) of the oil hose, and disconnect the oil hose from the oil filter assembly. (Inlet and outlet)



! CAUTION

When working with two spanners, use spanners with the same length for the moment arm to make spanner control easier. Install the joint on the oil filter bracket.

NOTICE

(2)

Loosen the union bolt and disconnect the oil hose (Bypass) (2) from the oil filter assembly.Remove two gaskets.

 3. SAPH301091200033

Oil cooler removal (1) Remove the bolts and take off the oil cooler.

W5-12-21

E485B

LUBRICATION 4.

Installation of oil cooler (1)

Use a scraper to remove any dirt from the connection

(2)

Install new O-rings (5) in the O-ring installation grooves of the oil cooler (3).



surfaces of oil cooler (3) and cylinder block (4).

! CAUTION

At the time of installation, take care that the Oring is not damaged by twisting. Install O-rings on the oil cooler side.









SAPH301091200034

(3)

Insert positioning stud bolts in the cylinder block mounting holes and install the oil cooler.

(4)

After temporary tightening of the bolts, remove the positioning stud bolts and tighten the bolts securely. Tightening torque : 25 N m {250 kgf cm, 18 lbf ft}(M8) : 47 N m {480 kgf cm, 35 lbf ft}(M10)

SAPH301091200035

W5-12-22

LUBRICATION 5.

Connecting the oil hoses (1)

Secure the joint securely with a hand vise or similar, tighten the nut (1) of the oil hose, and connect the oil hose to the oil filter assembly. (Inlet and outlet) Tightening torque : 196 N m {2,000 kgf cm, 145 lbf ft}(PF1)

! CAUTION

When working with two spanners, use spanners with the same length for the



moment arm to make spanner control easier. If the joint part has been loosened, replace the O-ring by a new one. (2)

Replace the gasket by a new one and connect the oil hose (Bypass) (2) with a union bolt to the oil filter assembly. Tightening torque : 26 N m {270 kgf cm, 20 lbf ft}



6.

Pipe installation (1)

SAPH301091200033

Replace O-rings and gaskets by new ones and connect the pipes to the oil cooler. Unit : N m{kgf cm,lbf ft} TightenPosition

Coolant pipe

M radius Quantity

IN

M10

2

M24

1

M14

1

M10

1

ing torque 55 {560,40} 39 {400,29}

Union Oil pipe

Clip

W5-12-23

25 {250,18} 55 {560,40}

E485B

LUBRICATION ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî óvóÃ

Overhaul JP30109120702002

1. 

Removal of oil cooler element (1)

Remove the bolts (1) and take off the cover (2) of the oil

(2)

Remove the nuts (3) and remove the oil cooler element (4) from the oil cooler.

cooler. 

     

 SAPH301091200036

2.

Disassembly oil cooler cap.

 ! CAUTION

Do not remove the plug unless necessary.

(1)

Remove the safety valve (5).

(2)

Remove the relief valve (6).

(3)

Remove the oil filter warning switch (7).



 SAPH301091200037

W5-12-24

LUBRICATION 3.

Safety valve wear and tear inspection (1)

Inspect the safety valve (5) visually and replace it in case of wear or damage.

 SAPH301091200038

4.

Relief valve wear and tear inspection (1)

Inspect the relief valve (6) visually and replace it in case of wear or damage.

 SAPH301091200039

5.

Assembly of oil cooler case (1)

Replace the O-ring with a new one and install each valve. Tightening torque : 19 N m {190 kgf cm, 141 lbf ft}(Oil pressure warning switch) 24.5±4.9 N m {250±50 kgf cm, 18±4 lbf ft}(Valve cap: M14) 34.3±4.9 N m {350±50 kgf cm, 25±4 lbf ft}(Valve cap: M26) 24.5±4.9 N m {250±50 kgf cm, 18±4 lbf ft}(Valve cap: M20)

SAPH301091200040

W5-12-25

E485B

LUBRICATION 6. 

Installation of oil cooler element (1)

Replace the gasket (8) and O-ring (9) with new ones and install the oil cooler element (4).



Tightening torque : 19.6 4.9N m{200 50kgf cm,14 4lbf ft} (2) 

Replace the gasket (10) of the cover (2) with a new one and install it.

    

 SAPH301091200036

W5-12-26

LUBRICATION ç\ê¨ê} ç\ê¨îzíuê}

Oil pan

Part layout JP30109120402004

SAPH301091200041

12111

Oil pan

12151

Gasket*

12149

Drain cock

9659C

Gasket*

9191-10451

51N m{520kgf cm,38 lbf ft}

*Parts not to be reused. Tightening torque 12149

69N m{703kgf cm,51 lbf ft}

9191-08452

31N m{320kgf cm, 23 lbf ft}

W5-12-27

E485B

LUBRICATION å ä²óvóÃçÄñ êÆî óvóÃ

Replacement JP30109120704004

1.

Removal of oil pan (1)

Remove bolts and remove the oil pan.

! CAUTION

2. 



If the gasket is sticking, remove it using a scraper, etc.

Installation of oil pan (1)

Apply a small amount of liquid gasket (G) [Threebond TB1211 (white)] to the step of the joint surface between the timing gear case and the cylinder block and between the flywheel housing and the cylinder block.

(2)

Replace the gasket with a new one and install the oil pan. Tightening torque : 25 N m {250 kgf cm, 18 lbf ft}

! CAUTION SAPH301091200042

W5-12-28

Wipe off oil on the oil pan and cylinder block before installation.

STARTING AND CHARGING

ENGINE

13 STARTING AND CHARGING Setup layout Layout

Starter ........................................................................ 13-2 Part layout (typical example) ................................ 13-2 Disassembly ......................................................... 13-3 Inspection of components ..................................... 13-9 Assembly ............................................................ 13-14 Alternator (60A) ...................................................... 13-16 Part layout (typical example of 60A) ................... 13-16 Circuit drawing (60A) .......................................... 13-17 Disassembly (60A).............................................. 13-18 Inspection of components (60A) ......................... 13-21 Assembly (60A) .................................................. 13-24 Inspection after assembly (60A) ......................... 13-28

W5-13-1

E485B

STARTING AND CHARGING

Starter Part layout (typical example) JP30002130402001

SAPH300021300001

28011

Clutch subassembly

28138

Packing*

28100

Starter

28140

Brush holder assembly

28111

Bushing

28142

Brush

28111A

Bushing

28143

Spring

28113

Lever

28150

Center bracket

28115

Start drive housing

28160

Armature assembly

28117

Packing*

28168

Pinion stopper

28117A

Packing*

28199

Dust protector

28118

Plate

28240

Start magnet switch

28118A

Plate

28251

Pinion

28118B

Plate

28252

Bearing

28118C

Plate

28255

Shaft assembly

28118D

Cover

28253

Planetary gear

28120

Yoke assembly

28253A

Internal gear

28133

Commutator end frame

28112E

15.7-17.6 N m{160-179kgf cm, 1213lbf ft}

*Parts not to be reused. Tightening torque 28112

14-16 N m{140-160kgf cm, 10-12lbf ft}

28112A

3.6-4.9 N m{37-49kgf cm, 3-4lbf ft} Service procedure Overhaul item

W5-13-2

STARTING AND CHARGING

Disassembly JP30002130702001

  

Fix the starter on the working table to ease

NOTICE

accessibility.

 

1.

MRemoval of lead wire (1) Remove the cap of the M terminal. (2)

Remove nuts and remove the M lead wire.

SAPH300021300002

2.  

Removal of commutator end frame (1)

Loosen and remove two through bolts.

(2)

Remove two set bolts and remove the commutator end

  

SAPH300021300003

frame.

 

! CAUTION

Hold the M lead wire and remove the commutator end frame by lifting.

SAPH300021300004

W5-13-3

E485B

STARTING AND CHARGING 3.   

Removal of brush holder assembly (1)

Lift the spring using a flat tip screwdriver or pliers. Remove four brushes from the brush holder assembly.

! CAUTION

(2)

Do not cut the brush lead fixing clamp.

Remove the brush holder assembly from the armature assembly.

 

  

SAPH300021300005

4.   

Removal of yoke assembly (1)

 

Remove the yoke assembly from the center bracket assembly.

! CAUTION

Do not hold the M lead wire and hold the yoke assembly outer diameter for removal.

   SAPH300021300006

5.  

Removal of packing (1)

Remove the packing from the centering parts at both ends of the yoke assembly.

! CAUTION

Damaged packing must not be resued. Replace it with a new part.



 SAPH300021300007

W5-13-4

STARTING AND CHARGING 6.  

Removal of armature assembly (1) Remove the armature assembly by lifting.

! CAUTION

When the armature assembly is removed, the washer at the end of the gear may be dropped and lost. Be careful for handling.

  

SAPH300021300008

7.

Removal of rear bearing (1)

Pull out the bearing of the armature assembly using a puller or press.

 

! CAUTION

Removed bearing must not be reused. Replace it with a new one.

 SAPH300021300009

8. 



Removal of cover (1) Remove the cover from the center bracket assembly. (2)

Remove the packing.

! CAUTION

Damaged packing must not be resued. Replace it with a new part.

SAPH300021300010

9.

Removal of planetary gear (1)

 

Remove the planetary gear from the carrier pin.

! CAUTION

Make sure that the gear is not damaged or chipped.

 

SAPH300021300011

W5-13-5

E485B

STARTING AND CHARGING 10. Removal of internal gear (1) Remove the internal gear from the center bracket. ! CAUTION

Make sure that the gear is not damaged or chipped.

   

SAPH300021300012

11. Removal of shim washer (1)

Remove the shim washer from the center bracket.



SAPH300021300013

12. Removal of pinion (1)

Remove the retainer clip using a tool such as snap ring pliers.

 

! CAUTION

 

Retainer clip must not be reused. Replace it with a new one. Push upward or pull out the chipped part of

NOTICE

the clip mouth.  SAPH300021300014

(2)

Remove the pinion stopper.

(3)

Remove the pinion.

 

! CAUTION

Make sure that the gear is not damaged or chipped.



SAPH300021300015

W5-13-6

STARTING AND CHARGING 13. Removal of pinion case (1) Remove two set bolts at the switch using a box screwdriver or offset wrench. (2)

Lift and remove the pinion case (1).

SAPH301091300017

14. Removal of lever (1)

Hold the lever holder and press the entire lever to the clutch. Remove the link with the plunger.

(2)

Turn and pull out the lever assembly using the clutch as



  

SAPH300021300018

the axis.

  SAPH300021300019

15. Removal of brake plate (1)

Hold the clutch case outer diameter and slide the clutch assembly upward. Pinch the clip end fixing the brake plate and remove it by bending.

SAPH300021300020

W5-13-7

E485B

STARTING AND CHARGING (2)

Remove the brake plate.

 

SAPH300021300021

16. Removal of clutch assembly (1)  

While pressing the clutch assembly to the center bracket assembly, offset the helical spline by one tooth. Pull out the clutch assembly upward from the offset position and remove it.

  

SAPH300021300022

17. Removal of shaft assembly 

(1)

Turn the center bracket assembly upside down. Hold the carrier plate and pull out the shaft assembly.

! CAUTION

Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.

 

SAPH300021300023

18. Removal of packing (1)

Turn the center bracket upside down again and remove the packing.

! CAUTION



SAPH300021300024

Inspection procedure item

W5-13-8

Packing must not be reused.

STARTING AND CHARGING

Inspection of components JP30002130703001

1.

Inspection of yoke assembly (1)

Make sure that the coil lead wire has electric continuity using a circuit tester.

(2)

Make sure that there is no discoloration at the coil.

(3)

Measure the resistance between the coil lead wire and the

SAPH300021300025

 

yoke with a circuit tester and check insulation. When the value is below the service limit, replace it.  

Service limit ! CAUTION

1k

or less

After cleaning and drying, take measurements.

 

SAPH300021300026

(4)

Measure the brush length using vernier calipers. Standard value (mm{in.})

Service limit (mm{in.})

18{0.7087}

13{0.5118} or less

SAPH300021300027

2.

Inspection of armature assembly (1)

  

Turn the armature assembly using a commercially available growler tester and put a piece of steel on the armature assembly. Make sure that the steel piece is not vibrating on the core circumference.

 

SAPH300021300028

W5-13-9

E485B

STARTING AND CHARGING (2)

Make sure that adjacent segments of the commutator have electric continuity using a circuit tester.

(3)

Make sure that there is no discoloration at the coil.

(4)

Measure the resistance between the commutator and the

SAPH300021300029

core using a circuit tester and check insulation. Standard value



1M



! CAUTION

Service limit

or more

1k

or less

After cleaning and drying, take measurements.

SAPH300021300030

(5)

Measure the commutator outer diameter using vernier calipers.

! CAUTION

After removing roughness on the surface (after polishing), take measurements.

Commutator outer diameter Standard value (mm{in.})

Service limit (mm{in.})

36{1.4173}

34{1.3386} or less

 SAPH300021300031

(6)

Measure the undercut depth between segments. If the undercut depth is beyond the service limit, repair it.



        

Standard value (mm{in.})

Service limit (mm{in.})

0.5 - 0.8{0.0197 - 0.0315}

0.2{0.0079} or less

! CAUTION

In repair, do not leave insulation material at the end of the segment.

  SAPH300021300032

W5-13-10

STARTING AND CHARGING (7)



Measure the shaft outer diameter using a micrometer. If it is beyond the service limit, replace the shaft.

Measuring area

Standard value

Service limit

(mm{in.})

(mm{in.})



Area

12{0.4724}

Area

9{0.3543}

11.98{0.4717} or less 8.98{0.3535} or less

SAPH300021300033

3.

Inspection of brush holder assembly (1)

Measure the resistance between the holder (plus) and the plate using a circuit tester and check insulation. When the value is below the service limit, replace it. Service limit

! CAUTION

1k

or less

After cleaning and drying, take measurements.

SAPH300021300034

(2) 

Measure the brush length using vernier calipers.



(3)

Standard value (mm{in.})

Service limit (mm{in.})

18{0.7087}

13{0.5118} or less

Make sure that the spring has pressure.

 SAPH300021300035

4.

Inspection of shaft assembly (1)

Measure the outer diameter of the shaft using a micrometer If it is beyond the service limit, replace the shaft.





Measuring area

Standard value

Service limit

(mm{in.})

(mm{in.})

Area

26{1.0236}

Area

14.1{0.5552}

SAPH300021300036

W5-13-11

25.90{1.0197} or less 14.04{0.5528} or less

E485B

STARTING AND CHARGING 5.

Inspection of clutch assembly (1) Measure the outer diameter of the inner sleeve using a micrometer. Standard value (mm{in.})

Service limit (mm{in.})

25{0.9843}

24.90{0.9803} or less

SAPH300021300037

6.

Inspection of bearing (1)

Measure the bearing metal inner diameter (1 in the figure) of the pinion case using a cylinder gauge. If it is beyond the service limit, replace the bushing.



Standard value (mm{in.})

Service limit (mm{in.})

25{0.9843}

25.2{0.9921} or more

SAPH300021300038

(2)

Measure the bearing metal inner diameter (2 in the figure) of the center bracket using a cylinder gauge. If it is beyond the service limit, replace the center bracket. Standard value (mm{in.})

Service limit (mm{in.})

26{1.0236}

26.2{1.0315}



SAPH300021300039

(3) 

Measure the bearing metal inner diameter (3 in the figure) of the shaft assembly using a cylinder gauge. If it is



beyond the service limit, replace the shaft assembly.

(4) SAPH300021300040

Standard value (mm{in.})

Service limit (mm{in.})

9{0.3543}

9.2{3.6220}

Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder gauge. If it is beyond the service limit, replace the commutator end frame. Standard value (mm{in.})

Service limit (mm{in.})

28{1.1024}

28.1{1.1063} or more

W5-13-12

STARTING AND CHARGING 7.  

Inspection of start magnet switch assembly (resistance of P coil) (1)

 

Measure the P coil resistance between the C terminal and the M terminal using a circuit tester. Standard value (

)

0.12 - 0.14

SAPH300021300041

8.

Inspection of start magnet switch assembly (resistance of H coil) (1)

 

Measure the H coil resistance between the C terminal and the body using a circuit tester. Standard value(

)

1.13 - 1.25



SAPH300021300042

9.

Inspection of start magnet switch assembly (electric continuity inspection) (1)

 

Check electric continuity between the B terminal and the M terminal using a circuit tester, and make sure that there is no electric continuity.

  SAPH300021300043

(2)

Push the end of the start magnet switch assembly (close the internal contact) and make sure that there is electric continuity between the B terminal and the M terminal using a circuit tester.

SAPH300021300044 Overhaul item

W5-13-13

E485B

STARTING AND CHARGING

Assembly JP30109130702002

1.

Assembly procedure Perform assembly procedure in the reverse order disassembly.

2.

Tightening torque For the bolt tightening torque, refer to the parts layout.

3.

Lubrication Refer to the following figure and table for lubricant to be applied.

! CAUTION

• There shall be no lubricant on the commutator surface, brush and contact.

SAPH301091300045

W5-13-14

STARTING AND CHARGING Table of lubricant Code

1

2

Lubricating point Pinion case metal and grease reservoir Bracket center metal and grease reservoir

Lubricant used

Multemp AC-N

Multemp AC-N

3

Shim washer

Multemp AC-N

4

Armature front metal

Multemp AC-N

5

Shim washer

Multemp AC-N

Amount (g{oz})

Remark

0.8 - 1.5

Kyodo Yushi

{0.03 - 0.05} 0.5 - 1.5

Kyodo Yushi

{0.03 - 0.05} 0.2 - 0.5

Applied to both sides

{0.01 - 0.02} of washer. 0.5 - 1

Kyodo Yushi

Kyodo Yushi

{0.02 - 0.04} 0.2 - 0.5

Lubricant manufacturer

Applied to both sides

{0.01 - 0.02} of washer.

Kyodo Yushi

Internal gear 6

Armature gear

Multemp AC-N

7 -11

Kyodo Yushi

{0.25 - 0.39}

Planetary gear 7

Pinion straight Spline

Multemp AC-N

0.5 - 1

Kyodo Yushi

{0.02 - 0.04} 0.3 - 0.6

8

Inner sleeve metal

Multemp AC-N

9

Helical spline

Multemp AC-N

0.5 - 1 {0.02 - 0.04}

Kyodo Yushi

10

Clutch case lever shifter

Pyroknock No.2

1-2 {0.04 - 0.07}

Nisseki Mitsubishi

0.2 - 0.5

Nisseki

{0.01 - 0.02}

Mitsubishi

11

Bracket rear bearing housing

Pyroknock No.2

12

Planetary gear metal

Multemp AC-N

13

Lever holder

Multemp AC-N

Kyodo Yushi

{0.01 - 0.02}

1-2

Kyodo Yushi

{0.04 - 0.07} 0.4 - 0.8

Kyodo Yushi

{0.01 - 0.03} Assemble the roller

14

Lever roller rod

Pyroknock No.2

after application of 0.2 - 0.5 grease to prevent fall {0.01 - 0.02} of the roller in assembly.

Setup layout Layout

W5-13-15

Nippon Oil Corporation

E485B

STARTING AND CHARGING

Alternator (60A) Part layout (typical example of 60A) JP30002130402002

SAPH300021300048

27017

Feed coil

27383A

Insulator

27040

Alternator

27389

Insulator

27310

Drive end frame assembly

27392

Cover

27311

Drive end frame

27410

Stator coil

27312

Bearing cover

27412

Collar

27330

Rotor assembly

27431

Pulley

27350

End frame assembly

27441

Fan

27353

Rectifier minus

27445A

Coupler holder

27356

Rectifier plus

27700

Regulator

27359

End frame

28252

Front bearing

27383

Insulator

28252A

Rear bearing

1.9-2.5 N m{20-25 kgf cm, 1-2lbf ft}

Tightening torque 27317

7.8-9.8 N m{80-99 kgf cm, 6-7lbf ft}

27317C

27317A

1.9-2.5 N m{20-25 kgf cm, 1-2lbf ft}

27391

127 - 157 N m{1, 300 - 1, 600 kgf cm, 94116lbf ft}

27317B

2.9 - 3.9 N m{30 - 39 kgf cm, 2-3lbf ft}

27391A

System drawing

W5-13-16

Internal nut : 4.9-5.9 N m{50-60 kgf cm, 3.6-4.3lbf ft}

STARTING AND CHARGING

Circuit drawing (60A) JP30002130803001

   



   

 

 

  

  

 

 

SAPH300021300049 Service procedure Overhaul item

W5-13-17

E485B

STARTING AND CHARGING

Disassembly (60A) JP30002130702003

! CAUTION

Place a rubber mat and perform work on the mat.

1.

Disconnection of front from rear (1)

Remove fixing bolts and remove the cover.

! CAUTION

Press the tabs of the cover for removal. Be careful not to break the tab with excessive force.

SAPH300021300050

(2)

Remove bolts with a screwdriver and remove the coupler holder.

SAPH300021300051

(3)

Remove three through bolts and disconnect the front from the rear.

SAPH300021300052

2.

Disassembly of front (1)

Remove nuts and remove the pulley, fan and collar.

! CAUTION

Tie around a general V belt in the pulley groove and fix the pulley with a vice.

SAPH300021300053

W5-13-18

STARTING AND CHARGING (2)

Remove the rotor assembly using a press.

! CAUTION

Do not damage the end of the thread. Support the rotor assembly to prevent fall of the rotor assembly.

SAPH300021300054

(3)

Remove three bolts with a screwdriver and remove the bearing cover.

(4)

Remove the ball bearing from the front bracket using a press or jig C.

SAPH300021300055

 

! CAUTION

Place jig C at the inner race of the front bearing. Removed bearing must not be reused.

SAPH300021300056

3.

Disassembly of rear (1)

Remove solder of the lead wire connecting the stator coil and the diode using a soldering bit and suction line or a solder suction device

! CAUTION

At solder of the stator coil and the diode, the end of the diode is clamped. Do not damage the diode by prying. Deformed diode must not be reused. Perform soldering in a short time (within 5 seconds).

SAPH300021300057

W5-13-19

E485B

STARTING AND CHARGING (2)

Remove the stator coil from the rear bracket.

! CAUTION

Do not damage the stator coil.

SAPH300021300058

(3)

Remove solder of the lead wire connecting the regulator and the field coil using a soldering bit.

! CAUTION

Remove the lead wire of the field coil by raising the terminal of the regulator. Perform soldering in a short time (within 5 seconds).

SAPH300021300059

  

 

SAPH300021300060

(4)

Loosen the nut at the B terminal.

! CAUTION

Loosen the nut to some extent and do not remove it from the B terminal.

SAPH300021300061

W5-13-20

STARTING AND CHARGING (5)

Remove five bolts using a screwdriver and remove the heat sink assembly (plus), heat sink assembly (minus) and regulator all together. Screw lock is used. Since torque is high until

! CAUTION

bolt is removed, be careful not to damage the groove of the bolt head. When the rear bracket is reused, clean the screw hole. SAPH300021300062

(6)

Remove the capacitor.

(7)

Remove three bolts with a screwdriver and remove the field coil from the rear bracket.

SAPH300021300063

(8)

Remove the roller bearing from the rear bracket using a press, jig A and jig B. Removed bearing must not be reused.

! CAUTION

SAPH300021300064 Inspection procedure item

Inspection of components (60A) JP30002130703002

Place a rubber mat and perform work on the mat.

! CAUTION

1.

Inspection of stator coil and field coil (1)

Measure the resistance between U-V, V-W and W-U terminals of the stator coil using a circuit tester. Standard value (

SAPH300021300065

W5-13-21

)

0.15 - 0.17

E485B

STARTING AND CHARGING (2)

Measure the resistance between the stator coil core and each terminal using a megger tester. Standard value (M

)

1 or more

SAPH300021300066

(3)

Measure the resistance of the field coil using a circuit tester. Standard value (

! CAUTION

)

6.4 - 7.0

• Do not damage the circumferential surface of the coil. • Damaged coil circumference must not be reused.

SAPH300021300067

(4)

Measure the resistance between the core and the coil using a megger tester. Standard value (M

)

1 or more

SAPH300021300068

2.

Inspection of rotor assembly (1)

Measure the outer diameter of the shaft at the ball bearing insertion area of the rotor assembly using a micrometer. Standard value (mm{in.})

25{0.9843}

Service limit (mm{in.})

24.98{0.9835}

SAPH300021300069

W5-13-22

STARTING AND CHARGING (2)

Measure the outer diameter of the shaft at the roller bearing insertion area of the rotor assembly using a micrometer. Standard value (mm{in.})

17{0.6693}

Service limit (mm{in.})

16.98{0.6685}

SAPH300021300070

3.

Inspection of diode, capacitor and regulator (1)

Measure the resistance of the holder between the minus diode and the heat sink holder using a circuit tester. Standard value Forward resistance value Reverse resistance value

Approx. 10 Infinite

SAPH300021300071

(2)

Measure the resistance between the capacitor terminal and the body using a circuit tester. Make sure that it indicates 800 k

and then immediately indicates infinite

value.

SAPH300021300072

(3)

Inspection of regulator Measure the resistance between regulator terminals F and E using a circuit tester. Standard value Forward resistance value Reverse resistance value

Overhaul item

SAPH300021300073

W5-13-23

Approx. 10 Infinite

E485B

STARTING AND CHARGING

Assembly (60A) JP30002130702004

! CAUTION

Place a rubber mat and perform work on the mat.

 

1.

Assembly of front (1)

Press fit a new ball bearing into the front bracket using a press and jig C.

! CAUTION

Place jig C at the outer race of the ball bearing. Removed bearing must not be reused.

SAPH300021300074

(2)

Install the bearing cover with bolts. Tightening torque : 1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}

SAPH300021300075

(3)

Install the rotor assembly using a press.

! CAUTION

Be sure to support the inner race of the bearing for press fit of the rotor. Do not damage the shaft.

SAPH300021300076

(4)

Install the space collar, fan and pulley on the shaft of the rotor assembly. Tightening torque : 127 - 157 N m {1,300 - 1,600 kgf cm, 94 - 116 lbf ft}

! CAUTION

Tie around a general V belt in the pulley groove and fix the pulley with a vice.

SAPH300021300077

W5-13-24

STARTING AND CHARGING 2.

Assembly of rear (1)

 

Press fit a new roller bearing into the rear bracket using a press, jig A and jig B.

! CAUTION

Press fit until jig A comes in contact with the rear bracket.

   

SAPH300021300078

(2)

Install the field coil on the rear bracket. Tightening torque : 2.9 - 3.9 N m {30 - 39 kgf cm, 2 - 3 lbf ft}

! CAUTION

Tighten bolts finally after temporary tightening. Tighten them evenly.

SAPH300021300079

(3)

Assemble the stator coil on the rear bracket temporarily.

! CAUTION

Do not damage the stator coil.

SAPH300021300080

(4)

Install parts referring to the part layout. Tightening torque : 1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}

! CAUTION

Apply screw lock to the ends of the heat sink mounting bolt and the regulator mounting bolt.

SAPH300021300081

W5-13-25

E485B

STARTING AND CHARGING (5)

Solder the lead wire connecting the regulator and the field coil, and connecting the stator coil and the diode using a soldering bit.

! CAUTION

Perform soldering after tightening of bolts. Bend and fix the regulator terminal before soldering the lead wire of the field coil. Clamp the end of the diode of the stator coil before soldering. Perform soldering in a short time (within 5 seconds).

SAPH300021300082

  

 

SAPH300021300083

(6)

Tighten the nut inside the B terminal. Tightening torque : 4.9 - 5.9 N m {50 - 60 kgf cm, 3.6 - 4.3 lbf ft} After installation of the alternator, connect

NOTICE

the wire and tighten the outside nut

SAPH300021300084

3.

Joint of front and rear (1)

Joint the front with the rear with bolts. Tightening torque : 7.8 - 9.8 N m {80 - 99 kgf cm, 6 - 7 lbf ft}

! CAUTION

SAPH300021300085

W5-13-26

Tighten bolts evenly.

STARTING AND CHARGING (2)

Install the coupler holder and tighten bolts. Tightening torque : 1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}

SAPH300021300086

(3)

Align the tab and install the cover. Fix it with bolts. Tightening torque : 3.3 - 4.4 N m {34 - 44 kgf cm, 2 - 3 lbf ft}

! CAUTION

Inspection procedure item

SAPH300021300087

W5-13-27

• Do not hit the cover because the tab may be broken.

E485B

STARTING AND CHARGING

Inspection after assembly (60A) JP30002130703003

! CAUTION

Place a rubber mat and perform work on the mat.

1.

Inspection of rotation (1) Turn the pulley with hand to check if there is no interference with internal parts and if rotation is smooth.

SAPH300021300088

(2)

Measure the resistance between B and E terminals and between P and E terminals using a circuit tester. If it is beyond the standard value (e.g. 0

), disassemble it

again and reassemble the unit correctly. Circuit tester lead Standard value

SAPH300021300089

(+)

( )

B

E

E

B

Infinite

P

E

Approx.7

E

P

Infinite

Approx. 20









   

SAPH300021300090

W5-13-28

TURBOCHARGER

ENGINE

14 TURBOCHARGER ç\ê¨ê} ç\ê¨îzíuê}

Turbocharger Assembly .......................................... 14-2 Assembly/disassembly layout ............................... 14-2 Inspection ............................................................. 14-3 Inspection procedure with special tool.................. 14-3 Removal................................................................ 14-7 Installation............................................................. 14-8

14

W5-14-1

E485B

TURBOCHARGER

Turbocharger Assembly Assembly/disassembly layout JP30109140402001

SAPH301091400001

15474

Oil outlet pipe

24135

Gasket*

17159

Exhaust manifold connector

9655-12100

Gasket*

24106

Oil inlet pipe

9655-14140

Gasket*

24109

Gasket*

9851A

O-ring*

24109A

Gasket*

S1760

Turbocharger assembly

*Parts not to be reused. Tightening torque 9209A

59N m{600kgf cm,44lbf ft} ëïíÖóvóÃçÄñ êÆî€óvóÃ

W5-14-2

TURBOCHARGER

Inspection JP30109140706001

1.

Hold the lock nut at the end of the blower impeller, turn the turbine shaft gently by hand and inspect rotation.

2.

Hold the lock nut at the end of the blower impeller and inspect the radial play of the turbine shaft by hand. (To compare degrees of play, use the metal wear limit sample turbocharger.)

3.

If the turbine shaft does not turn, rotation sticks, the radial play is large, or the blower impeller comes in contact with the blower case, it is considered the metal area has a failure. Overhaul or replace the turbocharger.

4.

If it is difficult to judge the amount of play, judge the play using a special tool shown below and determine if the turbocharger needs to be replaced or overhauled.

5.

If the turbocharger is overhauled or the assembly is replaced, inspections after this item are not necessary. Part No. 24100– 2360

Part name

Remark

Turbocharger

Limit sample for recognizing

assembly

the backlash of the turbine shaft by the feel of hand.

Inspection procedure with special tool JP30109140706002

1.

Inspection of radial play (1)

Put the stopper (1) on the thread protruding to the lock nut at the end of the blower impeller. (The stopper is left-hand thread.)



SAPH301091400002

(2)

Insert the guide (2) at the air inlet of the blower case and tighten bolts (3) and fix it.



 SAPH301091400003

W5-14-3

E485B

TURBOCHARGER (3)

Put a bar (4) on the stopper and lock it.

(4)

Insert a dial gauge (5) into the plate and fix it with bolts

 SAPH301091400004

(6).



 SAPH301091400005

(5)

Attach a bar to the hook at the tip of the bar, set the dial gauge (5) to 0 while pull the bar down with a force of 4.9 5.9 N{0.5 - 0.6 kgf, 1.1 - 1.3 lbf}.



SAPH301091400006

(6)

Pull the bar up with a force of 4.9 - 5.9 N{0.5 - 0.6 kgf, 1.1 - 1.3 lbf} and measure radial motion with a dial gauge.

SAPH301091400007

(7)

Take three measurements and take an average. If it is beyond the operation limit, overhaul or replace it with a new one. Radial play Operation limit (mm{in.})

! CAUTION

0.205{0.0081}

• If the turbocharger is overhauled or the assembly is replaced, inspections after this item are not necessary.

W5-14-4

TURBOCHARGER 2.

Inspection of axial (thrust) play (1) Remove the dial gauge, loosen the guide bolt and turn the guide 90 . Put the dial gauge into the plate that is inspected for axial play, and tighten the bolt (6) for fixing.

SAPH301091400008

ďƒŞ SAPH301091400009

(2)

Insert the guide (7) to prevent horizontal movement of the measuring instrument.

SAPH301091400010

(3)

When the guide is fixed, move the bar vertically and fix the guide with a stopper so that the dial gauge pointer is at the center.

SAPH301091400011

W5-14-5

E485B

TURBOCHARGER (4)

Hold the puller and press it toward the turbine in the axial direction. Set the dial gauge (5) reading to 0.

(5)

Pull it to the opposite side and measure movement in the

 SAPH301091400012

axial direction. (6)

Take three measurements and take an average. If it is beyond the operation limit, overhaul or replace it with a new one. Radial play Operation limit (mm{in.})

ÉIÅ[ÉoÅ[ÉzÅ[ÉãçÄñ êÆî€óvóÃ

SAPH301091400013

W5-14-6

0.110{0.0043}

TURBOCHARGER

Removal JP30109140702001

1.

Disconnect the boost pipe and the air pipe.

2.

Remove the insulator (1).

3.

Disconnect all pipes connected to the turbocharger (2).



SAPH301091400014

 ! CAUTION

• Loosen the union bolt of the coolant pipe, remove it after water draining, separate in the same way also at the bottom, and then remove the oil pipe (3). • After removal of each pipe, seal the water hole and the holes on the cylinder block side to prevent entry of dirt etc.

 SAPH301091400015

4. 

Remove the nuts (4) and take off the turbocharger (2).

! CAUTION

• After removal, seal the opening on the exhaust manifold side and on the exhaust pipe side to prevent entry of foreign objects. • If the stud bolts should be difficult to remove, use a commercial stud remover to remove them and then replace them.

 SAPH301091400016

W5-14-7

E485B

TURBOCHARGER

Installation JP30109140702002

1.

Before installation on the engine, pour new engine oil from the oil inlet and turn the turbocharger with hand to lubricate the journal bearing and the thrust bearing.

2. 

Replace the gasket by a new one, install exhaust pipe and turbocharger (2), and install the turbocharger (2) to the engine. Tightening torque : 59 N m {600 kgf cm, 44 lbf ft} (Nuts (4) between turbocharger and exhaust manifold)

! CAUTION



• Make sure that there is no dirt or foreign matter in the exhaust piping system. • Since heat resistant steel is used for bolts and nuts, do not mix them with normal bolts for

SAPH301091400016

installation. 3. 

Replace the gasket with a new one and connect the coolant pipe (3) and oil pipe to the turbocharger (2).

! CAUTION

• Clean the pipe and make sure that there is no pipe deformation or no dirt or foreign matter in the pipe. • Do not use sealant at the installation surface of the oil pipe and the coolant pipe or joint between the coolant hose and the coolant



pipe to prevent failures such as damage due

SAPH301091400015

to clogging or loosening of tightened areas. 4.

Install the insulator (1) on the turbocharger (2).

5.

Install the boost pipe and U-turn pipe.



SAPH301091400014

! CAUTION

• Make sure that there is no dirt or foreign matter in the air intake system. Do not use sealant at the inlet/outlet of air to prevent failures such as damage due to clogging or loosening of tightened areas. • Be sure to install the air feed pipe and the air hose correctly to prevent air leak from connections.

W5-14-8

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

ENGINE

15 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS åÃè·êfífàÍóóï\ åÃè·êfíf

Engine mechanical ............................................... 15-2 Alternator .............................................................. 15-5 Starter ................................................................... 15-6 Turbocharger ........................................................ 15-7

16

W5-15-1

E485B

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Engine mechanical JP03Z01020601001

Status Engine overheat (coolant)

Cause Insufficient coolant

Action Replenish coolant

Faulty thermostat

Replace thermostat

Water leak from cooling system

Correction

Water leak from EGR cooler

Replace EGR cooler.

Faulty coolant pump

Repair or replace

Faulty head gasket

Replace head gasket

Engine overheat

Clogging of radiator

Cleaning of radiator

(radiator)

Corrosion of cooling system

Clean and repair cooling system

Clogging of radiator core front part

Clean radiator

Faulty radiator cap

Replace radiator cap

Clogging of flyscreen (vehicle with flyscreen)

Cleaning of flyscreen

Clogging of intercooler core front

Cleaning of intercooler core

part Engine overheat (compression pressure)

Non-synchronous injection timing

Inspection of supply pump timing

Faulty fuel

Replace with correct fuel

Faulty injector

Replace injector

Deterioration of engine oil

Replace engine oil

Faulty oil pump

Replace oil pump

Insufficient engine oil

Replenish engine oil

Large engine oil consumption

Wear of piston ring and cylinder

Replace piston ring and cylinder

(piston, cylinder liner and piston ring)

liner

liner

Damage to piston ring

Replace piston ring and cylinder

Engine overheat (lubrication unit)

liner Faulty fixing of piston ring

Replace piston ring and cylinder

Faulty assembly of piston ring

Replace piston ring and cylinder

liner liner Faulty engine oil

Replace engine oil

Faulty piston ring joint

Reassemble piston ring

Large engine oil consumption

Wear of valve stem

Replace valve and valve guide

(valve and valve guide)

Wear of valve guide

Replace valve guide.

Faulty assembly of valve stem seal

Replace stem seal

Excessive oil lubrication to rocker

Inspection of clearance between

arm

rocker arm and rocker arm shaft

Large engine oil consumption

Faulty oil level gauge

Replace with correct level gauge

(others)

Excessive filling of engine oil

Fill with appropriate amount of oil.

Leak of engine oil

Repair or replace the part of oil leak.

Piston seizure (in operation)

Faulty ventilator

Replace ventilator.

Sudden stop of engine

Perform warm-up before stop of engine

W5-15-2

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Piston seizure (lubrication unit)

Cause

Action

Insufficient engine oil

Replenish engine oil

Deterioration of engine oil

Replace engine oil

Incorrect engine oil

Replace with correct engine oil.

Low oil pressure

Inspection of lubrication unit

Faulty oil pump

Replace oil pump

Piston seizure

Abnormal combustion

Refer to overheat section.

Piston seizure

Cooling unit

Refer to overheat section.

Insufficient engine power (air

Clogging of air cleaner element

Clean or replace air cleaner

Insufficient engine power

Overheat

Refer to overheat section.

Insufficient engine power (fuel

Faulty injection of injector

Replace injector

unit)

Faulty injector due to deposit of

Replace injector

cleaner)

element

carbon Entry of air into fuel system

Air bleeding of fuel system

Faulty fuel filter

Replace element

Faulty fuel

Replace with correct fuel

Insufficient engine power

Abnormal compression pressure

Refer to overheat section.

Insufficient engine power

Piston, cylinder liner and piston ring

Refer to overheat section.

Faulty engine start (electric unit)

Faulty battery

Check battery

Faulty wiring of starter

Replace starter wiring

Loose battery cable

Tighten battery terminal connection or replace cable

Faulty operation of starter Faulty engine start (air cleaner)

Replace starter assembly

Faulty start assist unit

Replace start assist unit

Clogging of air cleaner element

Clean or replace air cleaner element

Faulty engine start (fuel unit)

Insufficient fuel

Replenish fuel and bleed air from fuel system

Clogging of fuel system

Clean fuel system.

Air intake from connection of fuel

Tighten connections

system Clogging of fuel filter

Replace fuel filter

Loose connection of injection pipe

Tighten connecting nut of injection pump

Faulty engine start (injector)

Injector seizure

Replace injector

Faulty engine start (lubrication

Excessive viscosity of engine oil

Replace with engine oil with correct

unit) Faulty engine start (others)

viscosity Piston seizure

Replace piston, piston ring and

Bearing seizure

Replace bearing and crankshaft

Low compression pressure

Overhaul engine

Damage to ring gear

Replace ring gear and replace

cylinder liner

starter pinion gear.

W5-15-3

E485B

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status

Faulty idling (injector) Faulty idling (nozzle)

Faulty idling (engine)

Cause

Action

Faulty injection pressure

Adjust injection pressure.

Faulty injection status

Adjust or replace injector.

Faulty injection pressure

Adjust injection pressure.

Faulty spray status

Adjust or replace nozzle

Carbon deposit at nozzle end

Remove carbon

Seizure of needle valve

Replace nozzle

Faulty valve clearance

Adjustment of valve clearance

Faulty contact of valve seat

Adjust or replace valve and valve

Low coolant temperature

Perform warm-up.

Large variation of compression

Overhaul engine

seat.

pressure between cylinders Gas leak (head gasket)

Gas leak (head bolt)

Reuse

Replace gasket.

Damage

Replace gasket.

Poor assembly

Replace gasket.

Loose head bolt

Tighten bolt.

Incorrect tightening sequence or incorrect tightening torque

Tighten bolt to correct torque according to the correct tightening

Crack

Replace cylinder block.

Distortion of cylinder block upper

Repair or replace cylinder block.

sequence. Gas leak (cylinder block)

surface Depression of cylinder liner

Replace cylinder liner or block.

insertion (insufficient protrusion of cylinder liner) Gas leak (cylinder head)

Crack of cylinder head

Replace cylinder head.

Distortion of cylinder head lower

Repair or replace cylinder head.

surface Gas leak (cylinder liner)

Crack of cylinder liner

Replace cylinder liner.

Corrosion of cylinder liner

Replace cylinder liner.

Insufficient protrusion of cylinder

Replace cylinder liner or block.

liner Gas leak (others)

Incorrect injection timing

W5-15-4

Adjust injection timing.

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Alternator Status Lamp is ON.

Cause

Charge current

does not run (alternator).

Action

Faulty regulator (open PTr)

Replace regulator.

Faulty stator coil (disconnection, rare shorting)

Replace stator coil.

Fault feed coil (disconnection, rare

Replace feed coil.

shorting) Faulty diode (open, shorting)

Replace rectifier.

Disconnection or poor contact of

Repair or replace lead wire.

lead wire (plate, support, etc.) Lamp is ON.

Charge current

Disconnection of wire (fuse)

Replace wire (fuse).

Lamp is ON. Voltmeter indicates 29V or more

Faulty regulator (shorting of PTr)

Replace regulator.

Faulty tightening of voltage

Repair, replace voltage detection

(alternator).

detection circuit (e.g. support)

circuit or replace regulator.

Charge current is Lamp is ON. correctly running (alternator).

Faulty regulator (open Tr)

Replace regulator.