Engine J08C-TI Service
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■■■■■■■■ 1 MENU
FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles. Applicable for J08C-TI engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Operation Manual. All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors reserves the right to make changes at any time without prior notice.
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL NO.
S5-YJ08E17A
CHAPTER MODEL
J08C-TI
GENERAL INTRODUCTION
GN01-001
ENGINE INTRODUCTION
EN01-001
ENGINE MECHANICAL
EN02-001
AIR INTAKE SYSTEM
EN03-001
EXHAUST SYSTEM
EN04-001
LUBRICATING SYSTEM
EN05-001
COOLING SYSTEM
EN06-001
FUEL SYSTEM
EN07-001
TURBOCHARGER
EN08-001
ALTERNATOR
EN11-001
STARTER
AIR COMPRESSOR
EN12-001
EN13-001
ENGINE P.T.O. (POWER TAKE-OFF)
FUEL CONTROL
EN11-002
EN13-002
EN14-001
DN02-001
DN02-002
INDEX: ENGINE GROUP 1/2
GENERAL INTRODUCTION ENGINE INTRODUCTION ENGINE MECHANICAL
WORKSHOP MANUAL
AIR INTAKE SYSTEM EXHAUST SYSTEM LUBRICATING SYSTEM COOLING SYSTEM FUEL SYSTEM TURBOCHARGER FUEL INJECTION PUMP EMISSION CONTROL ALTERNATOR STARTER AIR COMPRESSOR ENGINE PTO (POWER TAKE-OFF)
ENGINE RETARDER ENGINE CONTROL All rights reserved. This manual may not be reproduced or copied in whole in part, without the written consent of Hino Motors, Ltd.
INDEX: ENGINE GROUP 2/2
ENGINE CONTROL FUEL CONTROL BRAKE CONTROL SUSPENSION CONTROL CAB EQUIPMENT CONTROL OTHERS
GENERAL INTRODUCTION (ENGINE)
GN01
GENERAL INTRODUCTION (ENGINE)
GENERAL INTRODUCTION (ENGINE) ...GN01-2 GENERAL PRECAUTIONS .............................GN01-2 HOW TO USE THIS WORKSHOP MANUAL...GN01-3 IDENTIFICATION INFORMATION ...................GN01-5 SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS ...............................................................GN01-5 DISMOUNTING AND MOUNTING ..................GN01-6
GN01–1
GN01-001
GN01–2
GENERAL INTRODUCTION (ENGINE)
GENERAL INTRODUCTION (ENGINE) GENERAL PRECAUTIONS M00010101BEC1001
Some recommended and standard maintenance services for your engine are included in this section. When performing maintenance on your engine, be careful not to get injured by using improper work procedures. Improper or incomplete work can cause a malfunction of the engine, which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer. CAUTION When working on your engine, observe the following general precautions to prevent personal injury and/or property damage, in addition to the particular NOTICES or CAUTIONS in each chapter.
•
Always wear safety glasses or goggles to protect your eyes.
•
Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
•
Bind long hair securely behind the head.
•
When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and block the wheels.
•
Always stop the engine and turn off the starter switch, unless the operation requires the engine running. Removing the key from the switch is recommended.
•
To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, muffler, exhaust pipe and tail pipe.
•
Do not smoke while working on the vehicle, since fuel and gas from battery are flammable.
•
Take utmost care when working on the battery. It contains corrosive sulfuric acid.
•
Large electric current flows through the battery cable and starter cable. Be careful not to cause a short, which can result in personal injury and/or property damage.
•
Read carefully and observe the instructions placed on the jack before using it.
•
Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a vehicle supported only by a jack.
•
Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.
•
Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belt when the engine is running.
•
Be careful not to damage lines and hoses by stepping or holding on them.
•
Be careful not to leave any tool in the engine compartment. Tools may be hit by moving parts, which can cause personal injury.
TOWING •
When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 crossmember when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with the bumper.
1. (1)
Towing procedures Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and entry of dirt or foreign matter. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame. The hook should be used only if the towed vehicle is not loaded. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15 in horizontal and vertical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a vehicle trapped in a gutter.
(2)
(3)
GENERAL INTRODUCTION (ENGINE) (4) (5) (6)
(7) (8)
2.
(1)
(2)
GN01–3
Keep the gear shift lever in "Neutral". Make sure that the starter switch is kept in the "ON" position. Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not running. In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn, making it impossible to control the vehicle. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed. Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed for that purpose. Front end towing (with front wheels raised off the ground) When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles equipped with either automatic or manual transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with lubricant if necessary. Rear end towing When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight ahead position.
HOW TO USE THIS WORKSHOP MANUAL M000101BEC1002
This workshop manual is designed as a guide for servicing the vehicles. An INDEX is provided on the first page of each chapter. TROUBLESHOOTING is dealt with in each chapter. When beginning operations, refer to the TROUBLESHOOTING section for a guide to appropriate diagnoses. SPECIAL TOOL are dealt with in each chapter. When ordering a special tool, confirm the part number with the applicable parts catalog. M00010100001
•
REPAIR PROCEDURES Repair procedures when self-explanatory, such as simple installation and removal of parts, have been omitted. Illustrations, such as the one below, have been provided to make such simple procedures clear. Only essential procedures requiring specific directions have been dealt with explicitly.
GN01–4
GENERAL INTRODUCTION (ENGINE)
TIMING GEAR AND CAMSHAFT EXAMPLE:
OVERHAUL 3 12
A
5
13
4
B
5 12
1
6 7 5
2
C
13
5
12 13 8 11
5
10 9
D
M00010100002
1
Gasket
8
Main idle gear
2
Rear end plate
9
Crankshaft gear
3
Camshaft gear
10
Injection pump drive gear
4
Camshaft idle gear
11
Power steering pump drive gear
5
Idle gear thrust plate
12
Pin
6
Sub–idle gear
13
Idle gear shaft
7
Oil pump gear
C*
T= 172 {1,750, 125}
D
T= 55 {560, 39} Application of lock sealant
Tightening torque A* T= 108 {1,100, 79} B*
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
T= 108 {1,100, 79}
*=Apply oil to the threads and seat surface before tightening. In some cases, illustrations may be of parts which differ in some nonessential way from the parts found on your particular vehicle. In such cases, the principle or procedure being illustrated applies regardless of such nonessential differences.
•
DEFINITION OF TERMS This engine rotates counterclockwise viewed from the flywheel side.
GENERAL INTRODUCTION (ENGINE)
GN01–5
IDENTIFICATION INFORMATION M000101BEC1003
•
ENGINE SERIAL NUMBERS. Please quote these numbers when ordering spare parts or reporting technical matter to receive prompt service attention. The engine serial number is engraved on the engine cylinder block.
M00010100003
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS M000101BEC1004
1. FLANGE BOLT Class
7T
Unit: N⋅m {kgf⋅cm, lbf⋅ft} 9T
Representation
7
q
Diameter x Pitch M8 x 1.25
28.5 {290, 21.0}
36 {370, 26.8}
M10 x 1.25
60 {610, 44.1}
74.5 {760, 55.0}
M10 x 1.5
55 {560, 40.5}
68.5 {700, 50.6}
M12 x 1.25
108 {1,100, 79.6}
136 {1,390, 100.5}
M12 x 1.75
97 {990, 71.6}
125 {1,280, 92.6}
M14 x 1.5
171.5 {1,750, 126.6}
216 {2,210, 159.8}
M14 x 2
154 {1,570, 113.6}
199 {2,030, 146.8}
GN01–6
GENERAL INTRODUCTION (ENGINE) 2. BOLT WITH WASHER Class
4T
7T
Unit: N⋅m {kgf⋅cm, lbf⋅ft} 9T
Representation
7 Diameter x Pitch
q
No Mark
M6 x 1
6 {60, 4.3}
10 {100, 7.2}
13 {130, 9.4}
M8 x 1.25
14 {140, 10.1}
25 {250, 18.1}
31 {320, 23.1}
M10 x 1.25
29 {300, 21.7}
51 {520, 37.6}
64 {650, 47.0}
M10 x 1.5
26 {270, 19.5}
47 {480, 34.7}
59 {600, 43.4}
M12 x 1.25
54 {550, 39.8}
93 {950, 68.7}
118 {1,200, 86.8}
M12 x 1.75
49 {500, 36.2}
83 {850, 61.5}
108 {1,100, 79.6}
M14 x 1.5
83 {850, 61.5}
147 {1,500, 108.5}
186 {1,900, 137.4}
M14 x 2
74 {750, 54.2}
132 {1,350, 97.6}
172 {1,750, 126.6}
DISMOUNTING AND MOUNTING M000101BEH1001
PROCEDURE FOR INSTALLING JOINTS AND GASKETS OF ENGINE PIPING 1. Gasket seal type (aluminum + rubber, asbestos or copper). Location of gasket seal
GENERAL INTRODUCTION (ENGINE)
GN01–7
Tightening torque chart Clamping screw size (Diameter) mm {in.}
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
8 {0.315}
13 {130, 9}
10 {0.394}
20 {200, 14}
12 {0.472}
25 {250, 18}
14 {0.551}
25 {250, 18}
16 {0.630}
29 {300, 22}
18 {0.709}
39 {400, 29}
20 {0.787}
*39 {400, 29}
24 {0.945}
69 {700, 51}
28 {1.102}
127 {1,300, 94} 2. Metal seal type (Flare connector type). Location of metal seal
Tightening torque chart Clamping screw size (Diameter) mm {in.}
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
12 {0.472}
20 {200, 14}
14 {0.551}
31 {320, 23}
16 {0.630}
39 {400, 29}
18 {0.709}
59 {600, 43}
20 {0.787}
64 {650, 47} 3. Metal seal type (Nipple connector type). Location of metal seal
Tightening torque chart Clamping screw size (Diameter) mm {in.}
Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
10 {0.394}
11 {110, 8}
20 {0.787}
20 {200, 14}
GN01–8
GENERAL INTRODUCTION (ENGINE) NOTICE: • Before installing the joints, ensure that is no dirt or burrs adhering to the various seat faces (pipe joints, gasket, etc.) • Because the pipes can move relatively freely during installation and the seat faces are liable to tilt, first temporarily tighten the pipes, then tighten them to the specified torque and ensure that there is no leakage from them. • When tightening two pipes together, be very careful that they do not rotate together. • After installing the pipes, apply the correct pressure to each pipe joint and ensure that there is no leakage. • Ensure that the various tightening torques conform to the above table. *If a soft washer #4840 FR–N (aluminum + rubber and carbon press fit part) is loosened or removed subsequent to being installed, be sure and replace it with a new one. There is no need to replace it, however, for normal retightening.
ENGINE INTRODUCTION (J08C)
EN01
ENGINE INTRODUCTION (J08C)
ENGINE ASSEMBLY ................................ EN01-2 DATA AND SPECIFICATIONS ......................... EN01-2 TROUBLESHOOTING ..................................... EN01-4 ENGINE TUNEUP ........................................... EN01-7 SPECIAL TOOL ............................................. EN01-12 OVERHAUL CRITERIA.................................. EN01-12 DISMOUNTING AND MOUNTING ................ EN01-14 LIQUID GASKET AND APPLICATION POINTS ......................................................... EN01-16
EN01–1
EN01-001
EN01–2
ENGINE INTRODUCTION (J08C)
ENGINE ASSEMBLY DATA AND SPECIFICATIONS M01010101BEI2001
Model
J08C-UJ
Type
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft, water-cooled, direct injection
Aspiration
Turbocharged with intercooler
Bore and stroke
114x130 mm {4.49x5.11 in.}
Piston displacement
7.961 L {485.7 cu.in.}
Compression ratio
18: 1
Firing order
1-4-2-6-3-5 (The cylinder numbers are counted in order from the crankshaft pulley side)
Direction of rotation
Counterclockwise viewed from flywheel
Compression pressure
3.4-3.7 MPa {35-38 kgf/cm2, 495-540 lbf/in.2} at 280 r/min
Maximum revolution (at full load)
2,900 r/min
Idling revolution
550-570 r/min
Dry weight
Approximately 575 kg {1,268 lb} Intake
30°
Exhaust
45°
Intake
30°
Exhaust
45°
Intake opens
14° before top dead center
Intake closes
30° after bottom dead center
Exhaust opens
54° before bottom dead center
Exhaust closes
13° after top dead center
Intake
0.30 mm {0.0118 in.}
Exhaust
0.45 mm {0.0177 in.}
Type
Full forced pressure feed by gear pump
Drive
By gear
Valve seat angle
Valve face angle
Valve timing (flywheel travel)
Valve clearance (when cold)
Engine oil pump Engine oil cooler
Injection nozzle
Multi-plate type, water cooled Type
Multi-hole nozzle type
Valve opening pressure
1st:17.7 MPa {180 kgf/cm2, 2,560 lbf/in.2} 2nd:21.6 MPa {220 kgf/cm2, 3,128 lbf/in.2}
Type
Forced circulation by volute pump
Drive
By V-belt
Coolant pump Thermostat Type
Wax.type, bottom bypass system
Injection timing (flywheel travel)
3° before top dead center for No.1 cylinder of the compression stroke
ENGINE INTRODUCTION (J08C)
EN01–3
Model
J08C-UK
Type
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft, water-cooled, direct injection
Aspiration
Turbocharged with intercooler
Bore and stroke
114x130 mm {4.49x5.11 in.}
Piston displacement
7.961 L {485.7 cu.in.}
Compression ratio
18: 1
Firing order
1-4-2-6-3-5 (The cylinder numbers are counted in order from the crankshaft pulley side)
Direction of rotation
Counterclockwise viewed from flywheel
Compression pressure
3.4-3.7 MPa {35-38 kgf/cm2, 495-540 lbf/in.2} at 280 r/min
Maximum revolution (at full load)
2,900 r/min
Idling revolution
550-570 r/min
Dry weight
Approximately 595 kg {1,312 lb} with 1 cylinder air compressor Approximately 600 kg {1,323 lb} with 2 cylinder air compressor Intake
30°
Exhaust
45°
Intake
30°
Exhaust
45°
Intake opens
14° before top dead center
Intake closes
30° after bottom dead center
Exhaust opens
54° before bottom dead center
Exhaust closes
13° after top dead center
Intake
0.30 mm {0.0118 in.}
Exhaust
0.45 mm {0.0177 in.}
Type
Full forced pressure feed by gear pump
Drive
By gear
Valve seat angle
Valve face angle
Valve timing (flywheel travel)
Valve clearance (when cold)
Engine oil pump Engine oil cooler
Injection nozzle
Multi-plate type, water cooled Type
Multi-hole nozzle type
Valve opening pressure
1st:17.7 MPa {180 kgf/cm2, 2,560 lbf/in.2} 2nd:21.6 MPa {220 kgf/cm2, 3,128 lbf/in.2}
Type
Forced circulation by volute pump
Drive
By V-belt
Coolant pump Thermostat Type
Wax.type, bottom bypass system
Injection timing (flywheel travel)
3° before top dead center for No.1 cylinder of the compression stroke
EN01–4
ENGINE INTRODUCTION (J08C)
TROUBLESHOOTING M01010101BEF3001
Engine overheating Symptom
Possible cause
Engine overheating (Coolant)
Remedy/Prevention
Insufficient coolant
Add coolant.
Defective thermostat
Replace thermostat.
Coolant overflow due to leakage of Repair. exhaust into cooling system Coolant leakage from cylinder head Replace gasket. gasket Engine overheating (Radiator)
Defective coolant pump
Repair or replace.
Clogged with rust or scale
Clean radiator.
Clogged with iron oxide due to leakage Clean coolant passage and correct of exhaust into cooling system exhaust leakage. Clogged radiator core due to mud or Clean radiator. other debris Defective radiator cap pressure valve Engine overheating combustion)
(Abnormal Incorrect injection timing
Replace radiator cap. Adjust injection timing.
Reduced injection pressure
Adjust injection pressure.
Poor fuel
Use good quality fuel.
Poor nozzle spray
Adjust or replace nozzle.
Unsatisfactory advance angle
automatic
timer Repair or replace timer.
Engine overheating (Other prob- Defective or deteriorated engine oil lems) Unsatisfactory operation of oil pump
Change engine oil. Replace or repair.
Insufficient oil
Add oil.
Brake drag
Repair or adjust.
Excessive oil consumption Symptom
Possible cause
Excessive oil consumption (Pis- Wear of piston ring and cylinder liner tons, cylinder liners, and piston Worn, sticking or broken piston rings rings) Insufficient tension on piston rings
Remedy/Prevention Replace piston rings and cylinder liner. Replace piston rings and cylinder liner. Replace piston rings and cylinder liner.
Unsatisfactory braking in of piston Replace piston rings and cylinder liner. rings Unsuitable oil (viscosity too low)
Change oil as required and replace piston rings and cylinder liners.
Incorrectly fitted piston rings (upside Replace piston rings. down) Gaps of piston rings in cell with each Reassemble piston rings. other Excessive oil consumption (Valve Worn valve stem and valve guides) Worn valve guide
Replace valve and valve guide. Replace valve guide.
Incorrectly fitted valve stem seal
Replace the stem seal.
Excessive lubricant on rocker arm
Check clearance of rocker arm and shaft.
Excessive oil consumption (Excess Defective oil level gauge oil feed) Oil level too high
Replace oil level gauge. Drain excess oil.
Excessive oil consumption (Other Overcooled engine (low temperature Warm up engine before moving vehiproblems) wear) cle. Check cooling system. Oil leakage from miscellaneous parts
Repair.
ENGINE INTRODUCTION (J08C)
EN01–5
Piston seizure Symptom Piston seizure (Operation)
Piston seizure (Oil)
Possible cause
Remedy/Prevention
Abrupt stoppage of engine after run- Operate engine properly. ning at high speed Hill climbing using unsuitable gear
Select suitable gear.
Insufficient oil
Add oil.
Dirty oil
Change oil.
Poor quality oil
Replace with proper engine oil.
High oil temperature
Repair.
Low oil pressure
Repair.
Defective oil pump
Repair oil pump.
Reduced performance due to worn oil Replace oil pump. pump Suction strainer sucking air
Add oil and/or repair strainer.
Piston seizure
Abnormal combustion
See Symptom: "Engine overheating".
Piston seizure
Coolant
See Symptom: "Engine overheating".
Lack of power Symptom
Possible cause
Remedy/Prevention
Lack of power
Injection pump
Refer to CHAPTER FUEL CONTROL.
Lack of power (Intake)
Clogged air cleaner
Clean element or replace element.
Lack of power
Overheating
See Symptom: "Engine overheating".
Lack of power (Fuel and nozzle)
Poor nozzle spray
Adjust or replace injection nozzle.
Clogged nozzle with carbon
Clean nozzle.
Wear or seizure of nozzle
Replace nozzle.
Air in fuel system
Repair and bleed air from fuel system.
Clogged fuel filter
Replace element.
Use of poor fuel
Use good quality fuel.
Lack of power
Abnormal combustion
See Symptom: "Engine overheating".
Lack of power
Wear of cylinder liners, and piston See Symptom: "Engine overheating". rings
EN01–6
ENGINE INTRODUCTION (J08C)
Difficult starting engine Symptom
Possible cause
Difficult starting engine (Electrical Discharged battery system) Defective wiring in starter circuit Loose or open-circuit battery cable
Remedy/Prevention Charge battery. Repair wiring of starter. Tighten battery terminal connections or replace battery cable.
Broken glow plug or intake air heater Replace. (If so fitted) Difficult starting engine Difficult cleaner)
starting
engine
Injection pump (Air Clogged element
Difficult starting engine (Fuel sys- No fuel in tank tem) Clogged fuel line
Refer to CHAPTER FUEL CONTROL. Clean the element or replace the element. Supply fuel and bleed air from fuel system. Clean fuel line.
Air sucked into fuel system through Tighten fuel line connections. fuel line connections Clogged fuel filter
Replace element.
Loose connection in high-pressure line Tighten sleeve nut of high-pressure line. Difficulty starting engine (Nozzles)
Water in fuel
Drain and clean fuel system.
Seized nozzle
Replace nozzle.
Broken or fatigued nozzle spring
Replace spring.
Difficulty starting engine (Oil sys- Oil viscosity too high tem)
Use proper viscosity oil, or install an oil immersion heater and warm up oil.
Difficulty starting engine (Other Seized piston problems) Seized bearing
Replace piston, piston rings, and liner. Replace bearing and/or crankshaft.
Reduced compression pressure
Overhaul engine.
Ring gear damaged or worn
Replace the ring gear and/or starter pinion.
Improperly adjusted or broken accel- Adjust or replace the accelerator erator cable cable.
Rough idling Symptom
Possible cause
Remedy/Prevention
Rough idling
Injection pump
Refer to CHAPTER FUEL CONTROL.
Rough idling (Nozzles)
Uneven injection pressure
Adjust.
Poor nozzle spray
Adjust or replace nozzle.
Carbon deposit on nozzle tip
Remove carbon.
Seized needle valve
Replace nozzle.
Improper valve clearance
Adjust valve clearance.
Improper contact of valve seat
Replace or repair valve and valve seat.
Idling speed too low
Warm up engine.
Rough idling (Engine proper)
Compression pressure of cylinders Overhaul engine. markedly different from one another
ENGINE INTRODUCTION (J08C)
EN01–7
Leakage of exhaust Symptom
Possible cause
Leakage of exhaust (Cylinder head Fatigued gasket (aging) gasket) Damage Improper installation Leakage of exhaust (Cylinder head Loose bolts bolts) Elongated bolts
Remedy/Prevention Replace gasket. Replace gasket. Replace gasket. Tighten bolt. Replace bolt.
Improper tightening torque or tighten- Tighten properly. ing sequence Leakage of exhaust (Cylinder block) Cracking
Replace cylinder block.
Surface distortion
Repair or replace.
Fretting of cylinder liner insertion por- Replace cylinder liner or cylinder tion (insufficient projection of cylinder block. liner) Leakage of exhaust (Cylinder head)
Cracking
Replace cylinder head.
Surface distortion
Repair or replace.
Leakage of exhaust (Cylinder liners) Cracking
Replace cylinder liner.
Corrosion
Replace cylinder liner.
Insufficient projection of cylinder liner
Replace cylinder liner.
Leakage of exhaust (Other prob- Incorrect injection timing lems)
Adjust injection timing.
ENGINE TUNEUP M01010101BEH3001
VALVE CLEARANCE CHECKING AND ADJUSTING PROCEDURES CAUTION: Valve clearance adjustment is performed only when the checking result is not within the specified value. 1. (1)
PREPARATION OF CHECKING AND ADJUSTMENT Positioning the No.1 or No.6 piston at Top Dead Center of the compression stroke. a. Turn the crankshaft counterclockwise (viewed from the flywheel side) to align mark 16 on the outer periphery of the flywheel with the pointer of the flywheel housing. NOTICE: • Always turn the crankshaft counterclockwise (viewed from the flywheel side). • In this position the No.1 or No.6 piston is at the Top Dead Center of the compression stroke. M01010100069
b.
•
Confirm whether No.1 or No.6 piston is at the Top Dead Center of the compression stroke by the following two steps.
If the timer timing mark is nearly aligned with the pointer, the No.1 piston is at the Top Dead Center of the compression stroke. NOTICE: When the timing mark of the timer is at the rear (180° opposite), the No.6 piston is at the Top Dead Center of the compression stroke.
POINTER
TIMING MARK M01010100002
EN01–8
ENGINE INTRODUCTION (J08C) •
Among three drill holes on the camshaft gear, when two drill holes are on horizontal position, and the rest of the drill hole is visible, the No.1 piston is at the Top Dead Center of the compression stroke . NOTICE: If the rest of drill hole is invisible by camshaft housing, the No.6 piston is at the Top Dead Center of the compression stroke.
DRILL HOLE
M01010100046
(2)
Make sure that the valve stem is correctly inserted in the cross head. NOTICE: Move the cross head with fingers right and left to confirm the valve stem is correctly inserted in the cross head by listening to the clicking sound.
Click
Good
(3)
No Good M01010100004
Confirm that there is no foreign particles or dust between the cross head and the valve stem.
2. VALVE CLEARANCE CHECKING NOTICE: Before beginning the checking, you must perform "PREPARATION OF CHECKING AND ADJUSTMENT" described on page EN01-7. (1)
You can understand which valve to adjust when No.1 or No.4 piston is at the Top Dead Center of the compression stroke by the following chart).
Cylinder
1
Valve With No.1 piston at T.D.C. on compression stroke With No.6 piston at T.D.C. on compression stroke
Camshaft gear condition
Two drill holes and camshaft housing is horizontal. The rest of drill hole is visible. #1 Two drill holes and camshaft housing is horizontal. The rest of drill hole is invisible. #1
• • • •
2
IN
EX
IN
3 EX
IN
4 EX
IN
5 EX
IN
#1= View from rear side of camshaft housing Mark: Possible to check valve clearance Firing order : 1-4-2-6-3-5 T.D.C. : Top Dead Center
6 EX
IN
EX
ENGINE INTRODUCTION (J08C) (2)
EN01–9
Before checking the valve clearance, make sure that the roller is on the base circle of the camshaft.
M01010100005
(3) ROCKER ARM FEELER GAUGE
Insert a feeler gauge of the specified thickness as below between the rocker arm and the cross head to check the valve clearance. VALVE CLEARANCE (when cold) Intake valve
0.30 mm {0.0118 in.}
Exhaust valve
0.45 mm {0.0177 in.}
CROSS HEAD
CAUTION: Valve clearance adjustment is performed only when the checking result is outside the specified value. M01010100006
3. VALVE CLEARANCE ADJUSTMENT CAUTION: Valve clearance adjustment is performed only when the checking result is outside the specified value. NOTICE: • Before beginning the adjustment you must perform "PREPARATION OF CHECKING AND ADJUSTMENT" described on page EN01-7. • As for the valve which can adjust the valve clearance refer to the chart on page EN01-8. • Make sure that the cylinder head bolt, rocker arm support bolt, nozzle clamp bolt, cam housing bolt and cam bearing cap bolt are tightened to the specified torque. (1)
A ROCKER ARM
B
10mm or more C D "Zero" clearance
Loosen the adjusting screw lock nut A, D of the rocker arm and cross head fully. (2) The cross head adjusting screw must protrude 10 mm {0.394 in.} or more from the cross head upper face. NOTICE: Unless the adjusting screw is completely loose to the valve stem head, the following adjustments may be adversely affected.
Need clearance
CROSS HEAD M01010100007
(3)
Insert a feeler gauge of the specified thickness shown below between the rocker arm and the cross head, and adjust the valve clearance with the adjust screw of the rocker arm. VALVE CLEARANCE (when cold)
(4)
M01010100008
Intake valve
0.30 mm {0.0118 in.}
Exhaust valve
0.45 mm {0.0177 in.}
After completion of the adjustment, tighten the lock nut A securely with the specified tightening torque. Tightening Torque: 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
EN01–10
ENGINE INTRODUCTION (J08C) (5) LOOSEN C
D
The condition of inserted feeler gauge, loosen the adjusting screw of the cross head, make sure that the feeler gauge does not feel loose. NOTICE: If the feeling of the feeler gauge becomes loose, repeat steps from (1).
Need clearance
M01010100009
(6) ROCKER ARM
TIGHTEN C
Tighten the adjusting screw C of the cross head until the feeler gauge does not move. NOTICE: In this situation, clearance between adjusting screw C and valve stem head is zero.
"ZERO" clearance
"ZERO" clearance
M01010100010
(7)
C
While loosening the adjusting screw C of the cross head gradually, adjust the valve clearance. Tighten the lock nut D of the cross head securely with the specified tightening torque when the feeler gauge feels correct. Tightening Torque: 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
D
M01010100011
Not over loosen C
E
"ZERO" clearance
NOTICE: • Do not over loosen the adjusting screw. • Over loosening of the adjusting screw C will cause the same condition as in step (3) again. The feeler gauge may feel correct, but there may be excessive clearance between the adjusting screw C of the cross head and the valve stem head E. This does not allow for correct adjustment. (8)
M01010100012
Positioning each piston at Top Dead Center of compression stroke by turning the crankshaft counterclockwise view from flywheel side. Then adjust the valve clearance for each cylinder in the firing order.
INJECTION TIMING ADJUSTING PROCEDURES
M01010100013
1. (1)
INSPECT THE INJECTION TIMING. Turn the crankshaft clockwise (viewed from the timing gear side) to align the timing mark on the outer periphery of the flywheel at (A°) before Top Dead Center of the compression stroke with the pointer of the flywheel housing. Injection timing (A°):Refer to section "DATA AND SPECIFICATION".
(2)
Check that the injection timing mark on the automatic timer is aligned with the pointer of the pump. If not, adjust the injection timing as on the following page.
ENGINE INTRODUCTION (J08C) 2. (1) (2)
(3)
(4) M01010100014
EN01–11
ADJUST THE INJECTION TIMING. Make sure that the timing mark on the outer periphery of the flywheel is aligned with the timing pointer. Loosen two adjusting bolts of the injection pump coupling. Do not remove the bolts. SST: Injection pump coupling wrench (09511-2500) Turn the automatic timer to the left (counterclockwise viewed from the drive shaft) to align the automatic timer mark with the pointer of the pump. Tighten the adjusting bolt to the specified torque. SST: Injection pump coupling wrench (09511-2500: BOSCH) Tightening Torque: 88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}
NOTICE: • No clearance is allowed between thin plates. • No deformation of the flange is allowed due to distortion of a thin plate.
START THE ENGINE FILLER CAP
CAUTION: Do not leave tools on or around the engine. Contact of tools with moving parts may result in personal injury or damage to equipment. 1. (1)
PREPARATION Supply engine oil.
(2)
Supply cooling water and bleed air from it.
(3)
Bleed air from the fuel system.
M01010100015
M01010100016
BLEEDER PLUG
(4) Check connection to the alternator. NOTICE: Start the engine without wiring in place may burn out the alternator. (5)
M01010100017
Check the engine stopping performance.
EN01–12
ENGINE INTRODUCTION (J08C)
LUBRICATION 1. (1) (2) (3)
CHECK THE ROCKER ARM. Remove the head cover. Set the engine revolution to the specified idling revolution. After the engine starts, check that oil is supplied to the following locations of all rocker arms within approximately 10 seconds. a. Roller and cam face A b. Cross head top C and spring upper seat top face D through adjusting screw B NOTICE: If the supply of oil is delayed or not happening, hydraulic pressure may be low or the oil gallery may be clogged. Insufficient supply of oil may lead to seizure, abnormal wear or abnormal noise. Recheck the assembly.
M01010100018
SPECIAL TOOL M01010101BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09552-1090
COMPRESSION GAUGE ADAPTER (A)
09552-1030 09552-1060
COMPRESSION GAUGE ADAPTER (B)
Remarks
For Overhaul criteria
OVERHAUL CRITERIA M01010101BEH3002
FACTORS TO DETERMINE THE ENGINE OVERHAUL 1. (1)
LOW COMPRESSION PRESSURE Before measurement a. Charge the battery completely. b. Set the valve clearance to the correct value. c. Idle the engine (Coolant temperature at 80C {176°F}). d. Remove the air cleaner. e. While the starter switch is at the LOCK position, disconnect the engine stop motor. f. Remove all nozzle holders.
ENGINE INTRODUCTION (J08C) (2)
Measurement a. Insert the gauge adaptor into the nozzle holder hole. SST: Compression gauge adaptor(A) (09552-1090) Compression gauge adaptor(B) (09552-1030) Compression gauge adaptor(B) (09552-1060) b.
M01010100021
EN01–13
Run the engine with the starter and measure the compression pressure.
Standard
Limit
Difference between each cylinder
3.4-3.7 MPa {35-38 kgf⋅cm2, 497-540 lbf/in2}
2.7 MPa {28 kgf⋅cm2, 398 lbf/in2}
0.3 MPa {3 kgf⋅cm2, 43 lbf/in2} or less
Engine revolution 280r/min NOTICE: Do not operate the starter for more than 15 seconds. c. Measure the compression pressure of each cylinder. NOTICE: Do not allow gas leakage from the seal face. (3) Reassemble the removed parts. CAUTION: When the starter switch is at ON position, do not connect the engine stop motor connector. Connection operates the engine stop motor (motor link is at OFF position) and the lever may catch your finger. 2. (1)
ENGINE OIL PRESSURE Check the oil pressure warning lamp when the oil and coolant temperature is hot [about 80°C {176°F}]. a. If the warning lamp is lightens, check the oil level. b. c.
Check oil deterioration. If oil quality is poor, replace with a suitable grade oil. Remove the oil pressure switch and install the oil pressure gauge.
M01010100060
d. Measure the oil pressure at a coolant temperature of 80°C {176°F} or more. Oil pressure
M01010100023
3. (1) (2) (3) (4) (5) (6)
Standard
Limit
49-490 kPa {0.5-5.0 kg/cm2, 7.11-71.10 lbf/in.2}
Less than 49kPa {0.5 kg/cm2, 7.11 lbf/in.2}
OTHER FACTORS Increase of blowby gas Defective engine start Decrease of engine output Increase of fuel consumption Increase of engine noise Increase of oil consumption
EN01–14
ENGINE INTRODUCTION (J08C)
DISMOUNTING AND MOUNTING M01010101BEH1001
IMPORTANT POINT - DISMOUNTING 1. (1) (2) (3)
DISMOUNT THE ENGINE ASSEMBLY. Park the vehicle on level ground and then block the wheels. Tilt the cab. Drain coolant from the radiator and cylinder block, and engine oil from the oil pan. CAUTION: To avoid the danger of burns, do not drain the coolant and engine oil while the engine and radiator are still hot. (4) Disconnect the power steering pump. NOTICE: Refer to CHAPTER POWER STEERING for details. (5)
Disconnect the engine stop cable. a. Set the starter switch to the ON position. NOTICE: • Do not start the engine. • Checking the engine stop inner cable by turning the starter switch to the ON position facilitates dismounting, mounting and adjustment of the cable. b.
Make sure that the engine stop lever of the fuel injection pump is in the engine running position, then disconnect the connectors of the engine stop motor harness.
c. Set the engine starter switch to the OFF position. Disconnect the electric lines, fuel lines, air lines, speedometer cable, accelerator control cable and parking brake cable. NOTICE: • Disconnect the battery cable from the negative terminal (-) of the battery and disconnect the electric lines. • Cover open ends of the pipes, hoses and pumps to prevent entry of dirt. (6)
M01010100024
(7)
Disconnect the hoses (coolant, heater and air intake) and remove the radiator. NOTICE: Do not damage the radiator. (8) (9)
Disconnect the air intake and exhaust lines. Disconnect the transmission control and transmission with clutch housing from the flywheel housing. NOTICE: Refer to CHAPTER TRANSMISSION/TRANSFER CONTROL and CHAPTER TRANSMISSION MAIN UNIT for details. (10) Remove the cab mounting member from the frame.
ENGINE INTRODUCTION (J08C)
EN01–15
(11) Connect a cable from an engine hanger to the hanger bracket (1 point) on the front of the engine, and to the hanger bracket (1 point) on the flywheel housing at the rear of the engine. Using a hoist, raise the hanger until there is a bit of slack in the cables. Engine weight: Refer to section DATA AND SPECIFICATIONS. (12) Remove the engine mounting fitting nuts (front and rear, both sides). (13) Lift the engine hanger so that the cables are fully tightened, then, after checking that the cables are securely, lift gently and remove the engine from the vehicle. NOTICE: When the transmission is attached to the engine, attach the third cable to the hanger bolt.
IMPORTANT POINTS - MOUNTING 1. (1)
M01010100025
MOUNT THE ENGINE ASSEMBLY. Mount the engine assembly in the reverse order of dismounting. Tightening Torque: 74 N⋅m {750 kgf⋅cm, 54 lbf⋅ft} (Engine mounting fitting nuts)
NOTICE: Check to see that there are no oil leaks, fuel leaks, coolant leaks, or air leaks. 2. CONNECT THE ENGINE STOP CABLE. (1) Set the starter switch to the ON position. NOTICE: Do not start the engine. (2) Connect the connectors of the engine stop motor harness. CAUTION: Do not connect the electric harness to the engine stop motor while the engine starter switch is at the LOCK or ACC positions as this operates the engine stop motor instantaneously and the link lever of the engine stop motor and the engine stop lever of the injection pump move, resulting in your fingers being caught by the lever. (3)
Connect and adjust the engine stop cable with adjusting nut so that clearance "A" between the clevis and cable stopper is 1-3 mm {0.04-0.11 in.}.
(4) Set the starter switch to the LOCK position. NOTICE: After adjustment, confirm correct execution of engine start and stop.
M01010100026
EN01–16
ENGINE INTRODUCTION (J08C)
LIQUID GASKET AND APPLICATION POINTS M01010101BEH2001
•
Liquid gasket is used at the following positions for the J08C series engine. Liquid gasket specification: Three Bond TB1207B: Black Liquid gasket specification: Three Bond TB1207D: Silver Liquid gasket specification: Three Bond TB1211: White
1. (1) (2) (3) (4)
(5)
LIQUID GASKET APPLICATION AND PART ASSEMBLY PROCEDURE. Remove old liquid gasket from each part and matching parts and wipe off oil, moisture or dirt with a rag. Overlap the liquid gasket at the start and end of application. Be careful of misalignment when assembling parts with liquid gasket. If they are misaligned, reapply the liquid gasket. Assemble parts within 20 minutes of application. If more than 20 minutes have passed, remove and reapply the liquid gasket. Wait for at least 15 minutes or more after assembly of parts before starting the engine.
2. (1)
REMOVE PARTS. When removing parts, do not use a tool for removal at one location only. Use the tool at various locations such as a flange step or gap for removal. When removing the gasket, be careful that gasket residue does not enter the engine.
3. (1)
OTHERS. For tube-type liquid gasket, use the winding tool that comes with the liquid gasket.
(2)
For cartridge-type gasket, use an application gun.
(3)
For tube-type liquid gasket, required width of application can be obtained by cutting the nozzle to suit.
M01010100027
M01010100028
1: Approximately 2: Approximately
M01010100029
2 mm wide when cut at the first step 5 mm wide when cut at the second step
ENGINE INTRODUCTION (J08C) 4. (1)
No.
Part name
EN01–17
PARTS AND POSITIONS FOR LIQUID GASKET. Apply liquid gasket to positions and types of gasket according to the table shown below. Follow the application pattern at each position shown in the figures. Unit:mm{in.}
Application position and pattern
Application width
Gasket to be used
Matching flange face with the block
1
Oil seal retainer
1.5-2.5 {0.05910.0984}
Black
1.5-2.5 {0.05910.0984}
Black
1.5-2.5 {0.05910.0984}
Silver
1.5-2.5 {0.05910.0984}
Silver
1.5-2.5 {0.05910.0984}
Silver
1.5-2.5 {0.05910.0984}
Silver
Matching flange face with the block
2
Coolant pump
Matching flange face with the block
3
Oil cooler
Matching flange face with the flywheel housing LIQUID GASKET
4
Dust cover
FLYWHEEL HOUSING OPENING
Matching flange face with the cylinder head
5
Thermostat case
Matching face with the rear edge
6
Flange
Remarks
EN01–18
No.
ENGINE INTRODUCTION (J08C)
Part name
Application position and pattern
Application width
Gasket to be used
Matching face with the intake manifold LIQUID GASKET
7
1.5-2.5 {0.05910.0984}
Black
—
White
Matching parts of oil seal retainer and block lower face front end
1.5-2.5 {0.05910.0984}
Black
Matching parts of block lower front end, gasket, rear end plate and flywheel housing
1.5-2.5 {0.05910.0984}
Silver
Intake pipe
Matching parts of block upper face rear end, gasket, rear end plate, flywheel housing, cylinder head gasket 8
8
Front and rear ends of upper/ lower faces of block
Front and rear ends of upper/ lower faces of block
NOTICE: Cut the rear end plate gasket with a craft knife flush with the block upper face.
Remarks
ENGINE INTRODUCTION (J08C)
No.
Part name
Application position and pattern
EN01–19
Application width
Gasket to be used
Remarks
Matching face of rear end plate
9
1.5-2.5 {0.05910.0984}
Flywheel housing
.
10
Cam housing
1.
Matching faces with cam housing and plug
2.
Matching parts of cam housing, plug, cylinder head cover and gasket
NOTICE: • Application area of liquid gasket is half circle of cam housing. Never apply it to the upper half circle of the plug. • Remove the excessive gasket completely.
•
When the cylinder head cover is assembled, reapply the liquid gasket. (Assembly must be done within 20 minutes.)
NOTICE: Figure on the right shows application "pattern" of the liquid gasket. Apply the liquid gasket to the center of seal flange inside whenever possible.
1.5-2.5 {0.05910.0984}
Silver
Black
2 locations at front and rear ends
ENGINE MECHANICAL (J08C)
ENGINE MECHANICAL (J08C)
EN 02
CYLINDER HEAD ..................................... EN02-2 COMPONENT LOCATOR................................ EN02-2 SPECIAL TOOL ............................................... EN02-5 OVERHAUL ..................................................... EN02-6 INSPECTION AND REPAIR .......................... EN02-15
CRANKSHAFT FRONT END.................. EN02-19 COMPONENT LOCATOR.............................. EN02-19 SPECIAL TOOL ............................................. EN02-20 OVERHAUL ................................................... EN02-20
FLYWHEEL AND FLYWHEEL HOUSING............................ EN02-22 COMPONENT LOCATOR.............................. EN02-22 SPECIAL TOOL ............................................. EN02-23 OVERHAUL ................................................... EN02-23 INSPECTION AND REPAIR .......................... EN02-26
TIMING GEAR......................................... EN02-27 COMPONENT LOCATOR.............................. EN02-27 SPECIAL TOOL ............................................. EN02-28 OVERHAUL ................................................... EN02-28 INSPECTION AND REPAIR .......................... EN02-30
MAIN MOVING PARTS AND CYLINDER BLOCK................................. EN02-32 COMPONENT LOCATOR.............................. EN02-32 SPECIAL TOOL ............................................. EN02-35 OVERHAUL ................................................... EN02-36 INSPECTION AND REPAIR .......................... EN02-45
EN02–1
EN02-001
EN02–2
ENGINE MECHANICAL (J08C)
CYLINDER HEAD COMPONENT LOCATOR M01020101BED1001
1 A
5
2
3 4 C 20 B 19
21
29 D
6 9
E
7 10
8
F 7
11
11
I 12
25 G
14
17 26 15
18
30
13
23 22
16
24
27 28 H
31 32 M01020100089
ENGINE MECHANICAL (J08C) 1
Oil filler cap
17
Bushing
2
Cylinder head cover
18
Valve rocker shaft
3
Silent block
19
Camshaft bearing cap
4
Silent block
20
Camshaft gear
5
Head cover gasket
21
Camshaft
6
Union bolt
22
Nut
7
Gasket
23
Plate
8
Leakage pipe
24
Injection pipe oil seal
9
Nozzle clamp bolt
25
Injection nozzle
10
Rocker arm support bolt
26
O-ring
11
Rocker arm assembly
27
Camshaft housing
12
Lock nut
28
Camshaft housing gasket
13
Adjust screw
29
Camshaft bearing
14
Rocker arm support
30
Plug
15
Rocker arm
31
Cylinder head assembly
16
Nozzle clamp
32
Cylinder head gasket
Tightening torque A 28.5 {290, 20}
F
14.5 {148, 10.7}
B
31 {320, 23}
G
23 {230, 16}
C
59 {600, 43}+90°#
H
59 {600, 43}+90°+90°#
D
25 {250, 18}
I
25 {250, 18}
E
59 {600, 43}
EN02–3
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
#=Apply oil to the threads and seat surfaces before tightening.
EN02–4
ENGINE MECHANICAL (J08C)
4 5
1
6
A 2
7
3
8 9 16
10 11
17
12 13
18
14 15
M01020100090
1
Flange
10
Valve spring inner
2
Idle gear thrust plate
11
Valve stem seal
3
Idle gear shaft
12
Valve spring seat lower
4
Camshaft idle gear
13
Valve stem guide
5
Idle gear thrust plate
14
Valve seat
6
Cross head
15
Valve
7
Valve spring retainer
16
Nozzle seat
8
Valve spring seat upper
17
O-ring
9
Valve spring outer
18
Cylinder head block
Tightening torque A 108 {1,100, 79}# #=Apply oil to the threads and seat surfaces before tightening.
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
ENGINE MECHANICAL (J08C)
EN02–5
SPECIAL TOOL M01020101BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
Remarks
09433-1070
EYE BOLT
09491-1010
WIRE
09470-1170
VALVE SPRING PRESS
09431-1020
VALVE LAPPING TOOL
09472-2100
VALVE STEM SEAL PRESS
09472-1210
BAR
For Nozzle sleeve
9800-06100
STEEL BALL
Used with 09472-1210
09471-1520
GUIDE
EN02–6
ENGINE MECHANICAL (J08C)
OVERHAUL M01020101BEH2001
IMPORTANT POINTS DISASSEMBLY 1. (1)
DISASSEMBLE THE CYLINDER HEAD. Clean parts around the nozzle holder and fuel system connections. NOTICE: Entry of foreign particles into the combustion chamber may result in engine trouble. (2) Remove the nozzle holder assembly. NOTICE: Refer to FUEL SYSTEM. (3) ADJUSTING SCREW LOCK NUT
Remove the rocker arm assembly. a. Loosen the lock nut at the end of the rocker arm and turn the adjusting screw counterclockwise completely. NOTICE: Not untightening the adjusting screw may result in a bent rocker shaft. b.
Loosen the nozzle clamp bolt.
M01020100010
c. Loosen the rocker arm support bolt as shown in the figure. NOTICE: If the cross head is removed from the valve during disassembly of the rocker arm assembly, reassemble the cross head as it was.
ROCKER ARM SUPPORT
7
5
3
1
2
4
6
M01020100094
(4)
M01020100091
Remove the cylinder head bolts. a. Gradually loosen bolts three times in the order shown in the figure.
ENGINE MECHANICAL (J08C) (5)
EN02–7
Lift and remove the cylinder head using the special tool and hoist. SST: Eye bolt (09433-1070) Wire (09491-1010)
NOTICE: • Do not damage the cylinder head lower surface or cylinder block upper surface during removal of the cylinder head. • If it is difficult to lift off the cylinder head, pry with a chisel between the cylinder head and cylinder block. M01020100013
2. (1)
DISASSEMBLE THE VALVE SYSTEM. Remove the valve spring retainer using the special tool. SST: Valve spring press (09470-1170)
M01020100014
(2) Remove the intake and exhaust valve. NOTICE: Attaching tags to the valves (giving corresponding cylinder Nos.) will eliminate time required for lapping the valve seats on reassembly.
M01020100015
3. (1)
CLEAN THE CYLINDER HEAD. Clean the cylinder head and remove carbon deposits or foreign particles. NOTICE: Be careful not to damage the cylinder head lower surface when removing carbon deposits or foreign particles.
M01020100016
EN02–8
ENGINE MECHANICAL (J08C)
IMPORTANT POINTS-REPLACEMENT 1. REPLACE THE VALVE GUIDE. (1) Remove the valve stem seal. (2) For removal, strike the valve guide with a brass bar and hammer. CAUTION: Striking the valve guide during removal may cause metal chips to fly up. Be sure to wear protective goggles. (3) M01020100017
When installing a new valve guide, do not twist the end. Press fit the valve guide using the special tool. SST: Guide (09471-1520)
NOTICE: • Be careful not to damage the valve stem at the upper or lower end of the guide during press-fitting. • Be sure to apply engine oil around the valve guide during press-fitting.
BACK PLATE
VALVE
VALVE SEAT
ELECTRIC WELDING CUT THREE PLACES HERE M01020100018
2. (1)
REPLACE THE VALVE SEAT. When replacing the valve seat, cut three places on the circumference of an unwanted valve and weld it to the valve seat. NOTICE: To protect the lower surface of the cylinder head from welding spatter, be sure to apply grease before welding. (2)
Place a (brass) back plate at the top of the valve system and strike it with a hammer to remove the valve seat. CAUTION: Striking the valve seat for removal may cause metal chips to fly up. Be sure to wear protective goggles. (3)
Machine the valve according to the valve seat dimensions. Unit: mm {in.}
Cylinder head side
Valve seat side M01020100019
(4)
Intake
Exhaust
A
41-41.016 {1.6142-1.6148}
39-39.016 {1.5355-1.5360}
B
9.4-9.6 {0.3701-0.3779}
8.6-8.8 {0.3386-0.3464}
C
41.085-41.1 {1.6176-1.6181}
39.12-39.135 {1.5402-1.5407}
D
7-7.2 {0.2756-0.2834}
6-6.2 {0.2363-0.2440}
Heat the cylinder head to 80 - 100°C {176 - 212°F} in hot water. After cooling the valve seat, insert it into the cylinder head.
CAUTION: Striking the valve seat during installation may cause metal chips to fly up. Be sure to wear protective goggles.
M01020100020
ENGINE MECHANICAL (J08C)
EN02–9
(5)
Apply a small amount of lapping compound to the contact surfaces of the valve and valve seat. Turn the valve using the special tool and tap it lightly to lap. SST: Valve lapping tool (09431-1020)
3. (1)
REPLACE THE VALVE STEM SEAL. After removing the valve stem seal, assemble the spring lower seat and apply engine oil to the stem seal lip. Punch it into the valve guide using the special tool. SST: Valve stem seal press (09472-2100)
M01020100021
STEM SEAL SPECIAL TOOL SPRING LOWER SEAT
CAUTION: Punching the valve stem seal during installation may cause metal chips to fly up. Be sure to wear protective goggles. NOTICE: After assembly of the stem seal, check for deformation or cracking of the rubber or incline.
APPLICATION OF OIL RUBBER
M01020100022
4. (1)
REPLACE THE NOZZLE SEAT. Tap the nozzle seat from the cylinder head lower surface. Then, screw in a suitable bolt and strike the bolt head with a hammer to remove the nozzle seat from the cylinder head. CAUTION: Punching the nozzle seat during installation may cause metal chips to fly up. Be sure to wear protective goggles. NOTICE: After removed the nozzle seat, removed the rest of liquid gasket or the adhesion such as dust completely. M01020100023
EN02–10
ENGINE MECHANICAL (J08C) (2)
After inserting the O-ring into the nozzle seat insertion hole of the cylinder head, apply liquid packing (Three Bond No. 1211 or equivalent) to the lower part of the new nozzle seat and assemble it onto the cylinder head. NOTICE: Be sure to replace the O-ring with a new one. Reuse of the O-ring may cause water or gas leakage, resulting in overheating or cracking of the cylinder head.
M01020100024
(3)
Caulk the nozzle seat with the special tools. SST: Bar (09472-1210) Steel ball (9800-06100)
M01020100025
IMPORTANT POINTS - ASSEMBLY 1. (1)
M01020100014
M01020100026
ASSEMBLE THE VALVE AND VALVE SPRING. Install the valve spring retainer at the valve spring upper seat using the special tool. SST: Valve spring press (09470-1170)
NOTICE: • Be sure to apply engine oil to the contact surface of each part before assembly. • Be sure to place each valve in its original position. • When the valve spring is compressed, be careful of damage to the stem seal due to contact of the upper seat. • Since this valve spring is evenly pitched, it can be installed either end up.
2. INSTALL THE CYLINDER HEAD GASKET. NOTICE: • When installing the cylinder head, install the new gasket after removing dirt, moisture and oil on the cylinder head and cylinder block surface. • Never reuse the gasket as it may cause engine damage. • The twelve water hole seal rings between the bores are easily damaged. Do not touch them with your hands or other objects. Make sure that the seal rings are not loose or damaged. • Since silicon material is used for the gear case print seal, make sure that there is no peeling before assembly.
ENGINE MECHANICAL (J08C)
EN02–11
(1)
Install the cylinder head gasket on the cylinder block and flywheel housing. (2) Fill the hole at the back of the cylinder head gasket with liquid gasket. NOTICE: Make sure that the liquid gasket surface is flush with the cylinder head gasket upper surface.
M01020100027
3. (1)
MEASURE THE CYLINDER HEAD BOLT. Measure the length of the M12 head bolts, if the length is A or more, replace with new bolts. Dimension A
126.5 mm {4.980 in.}
M01020100028
4. (1)
INSTALL THE CYLINDER HEAD. Using the special tool and hoist, put the cylinder head. SST: Eye bolt (09433-1070) Wire (09491-1010)
NOTICE: When put the cylinder head, attention to cam idle gear and sub idle gear engagement.
M01020100013
EN02–12
ENGINE MECHANICAL (J08C) (2) (3) (4)
Apply clean engine oil to the bolt surface and bolt threads of the M10 and M12 bolts. Clean the bolt seats completely on the cylinder head upper surface. Tighten No. 1 - No. 26 (M12 bolts) in the order shown in the figure to the specified torque. Tightening Torque: 59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100092
(5) (6) (7)
Mark the M12 bolts with paint to indicate the same directions as shown in the figure. Turn No. 1 - No. 26 (M12 bolts) 90° (1/4 turn) in the same order as in (4) . Retighten them 90° (1/4 turn) as step (6).
(8) Make sure that all paint marks face the same direction. NOTICE: When adding torque, never untighten the bolts, even if they have been overtightened.
M01020100031
(9)
Tighten No. 27 - No. 29 (M10 bolts) in the order shown in the figure to the specified torque below. Tightening Torque: 59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100093
IDLE GEAR THRUST PLATE
CYLINDER HEAD
LUBRICATION HOLE
M01020100033
5. INSTALL THE CAM IDLE GEAR. NOTICE: • Install the cam idle gear shaft through the thrust plate as shown in the figure so that the lubrication hole is downward. • Apply clean engine oil to the bolt seat and bolt threads.
ENGINE MECHANICAL (J08C) 6. (1)
EN02–13
ASSEMBLE THE CAMSHAFT GEAR. Measure the length of the camshaft gear bolts, if the length is A or more, replace with new bolts. Dimension A
51 mm {2.008 in.}
M01020100034
(2) (3)
Make sure that there is neither damage to the camshaft gear or camshaft nor dirt on them. Apply clean engine oil to the bolt surface and bolt threads and tighten them to the specified torque below. Tightening Torque: 59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100035
(4) Turn bolts an additional 90° (1/4 turn). NOTICE: When adding torque, never untighten the bolt, even if it has been overtightened.
M01020100036
7. (1)
INSTALL THE CAMSHAFT. Align the mark on the flywheel with the flywheel housing pointer to set the No. 1 piston to top dead center of the compression stroke. NOTICE: Engine adjustment - Refer to PREPARATION OF CHECKING AND ADJUSTMENT.
M01020100060
(2) Install the camshaft into the cam housing. NOTICE: Two drill holes on the camshaft gear should be located at left side and lower drill hole should match with the camshaft housing upper surface. (3)
Install the camshaft bearing cap, and tighten the bolts.
EN02–14
ENGINE MECHANICAL (J08C) 8. INSTALL THE ROCKER ARM ASSEMBLY. (1) Make sure that the cross head is on each valve. NOTICE: If the cross head is assembled whilst off the valve, the upper seat will be pressed, resulting in a loose valve.
ROCKER ARM SUPPORT
(2) 7
5
3
1
2
4
6
(3)
Make sure that the adjusting screw at the end of the rocker arm is completely screwed in. Tighten the rocker arm support bolt as shown in the figure to the specified torque. Tightening Torque: 59 N⋅m {600 kgf⋅cm, 43 lbf⋅ft}
M01020100094
(4)
Tighten the nozzle clamp bolt to the specified torque. Tightening Torque: 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
(5) Make sure that the rocker arm moves smoothly. HINT: When assembling the rocker arm assembly, fix the arm and nozzle clamp with an O-ring as shown in the figure to facilitate installation.
M01020100038
9. (1)
INSTALL THE HEAD COVER. Remove the camshaft housing plugs at the front and rear ends of the camshaft housing. NOTICE: Do not remove the plug except there is no oil leakage from plug. (2)
Remove the liquid gasket from camshaft housing plugs and camshaft housing completely.
M01020100039
(3)
Install the camshaft housing plug to camshaft housing with torx bolt. NOTICE: Make sure that the camshaft housing plug installed with no tilt.
M01020100040
(4)
Apply liquid gasket to the front and rear half circles of the camshaft housing. NOTICE: Wipe out excess liquid gasket completely.
M01020100041
ENGINE MECHANICAL (J08C)
EN02–15
(5)
Install the head cover gasket into the gasket groove at the head cover lower surface. NOTICE: Make sure that there are no foreign particles (including liquid gasket), or oil on the gasket grooves of the head cover, gasket or cam housing upper surface nor damage to them. CYLINDER PLUG
(6)
Apply liquid gasket to plug corner at the front and rear ends of the cam housing before installing the head cover.
(7) (8)
Insert the silent block (No.1) from the head cover lower surface. Tighten the bolt through the silent block (No.2) to the specified torque below and fix the head cover on the cam housing. Tightening Torque: 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
CAM HOUSING M01020100042
M01020100043
INSPECTION AND REPAIR M01020101BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Camshaft journal outside diameter
40 {1.5748}
39.85 {1.5689}
Replace camshaft.
Camshaft bearing inside diameter
40 {1.5748}
40.15 {1.5807}
Replace cam bearing.
Clearance between camshaft journal and camshaft bearing
0.020-0.063 (0.0008-0.0024)
—
Replace camshaft and/or cam bearing.
Inspection procedure Measure
Measure
Camshaft end play
IN
0.100-0.178 (0.0040-0.0070)
—
50.067{1.9711}
49.987 {1.9680}
52.104{2.0513}
52.024 {2.0482}
Cam height
Replace camshaft.
Measure
Replace camshaft. EX
EN02–16
ENGINE MECHANICAL (J08C)
Inspection item
Standard
Limit
Remedy
Inspection procedure Measure
Camshaft deflection
0.04 {0.0016}
0.1 {0.0039}
Rocker arm bushing inside diameter
22 {0.866}
22.08 {0.8693}
Replace rocker arm.
Rocker shaft outside diameter
22 {0.866}
21.92 {0.8630}
Replace rocker shaft.
0.030-0.101 {0.0012-0.0039}
0.15 {0.0059}
Replace rocker arm and/or rocker shaft.
7 {0.2756}
6.92 {0.2724}
Replace the valve.
7 {0.2756}
7.04 {0.2772}
Replace the valve guide.
0.023-0.058 {0.0010-0.0022}
0.12 {0.0047}
Replace the valve and/or valve guide.
Stem outside diameter
7 {0.2756}
6.85 {0.2697}
Replace the valve.
Guide inside diameter
7 {0.2756}
7.04 {0.2772}
Replace the valve guide.
Clearance
0.037-0.067 {0.0015-0.0026}
0.15 {0.0059}
Replace the valve and/or valve guide.
IN
0.55-0.85 {0.0217-0.0334}
1.1 {0.0433}
Replace the valve and valve seat.
EX
1.05-1.35 {0.0414-0.0531}
1.6 {0.0630}
IN
30°
30°-30°35'
EX
45°
45°-45°30'
IN
30°
29°30°-30'
Clearance between rocker shaft and rocker arm bushing Stem outside diameter Intake valve Guide inside diameter Clearance
Exhaust valve
Replace camshaft.
Measure
Measure
Measure VALVE SINK
Valve sink
Valve seat angle
Valve face angle
Replace the valve and valve seat.
Measure
Resurface the valve and/or valve seat. EX
45°
44°30°-45''
ENGINE MECHANICAL (J08C)
Inspection item
Outer valve spring
Standard
Limit
Remedy
Setting load
314 N {32.0 kgf, 70.5 lbf} at 46.8 {1.843}
291.8 N {29.8 kgf, 65.6 lbf}
Replace.
Free length (reference value)
75.7 {2.980}
72.7 {2.862}
Replace.
Squareness
—
2.6 {0.1023} (2.0°)
Replace.
Setting load
129 N {13.2 kgf, 29.1 lbf} at 44.8 {1.764}
119.5 N {12.2 kgf, 26.9 lbf}
Replace.
Free length (reference value)
64.6 {2.543}
61.6 {2.425}
Replace.
Squareness
—
2.3 {0.0905} (2.0°)
Replace.
EN02–17
Inspection procedure Measure
Inner valve spring
Visual check Wear and damage of valve spring seat upper and lower
—
—
Replace.
Measure
Nozzle protrusion
2.25-2.75 {0.0886-0.1083}
—
Replace nozzle seat.
0.06 or less {0.0024 or less} for longitudinal direction
Cylinder head lower surface flatness
Measure
0.20 {0.0078} 0.03 or less {0.0012 or less} for lateral direction
Replace. NOTICE: Do not grind for repair.
EN02–18
Inspection item
ENGINE MECHANICAL (J08C)
Standard
Limit
Remedy
Inspection procedure Visual check
Cracks of damage to cylinder head (Dye penetrant check)
—
—
Replace.
Visual check Contact of valve (Use of Red lead marking compound)
Entire periphery of valve head evenly in contact
—
Matches valve.
Cam idle gear shaft outside diameter
34 {1.3386}
—
—
Cam idle gear shaft bushing inside diameter
34 {1.3386}
—
—
0.025-0.075 {0.0010-0.0029}
0.2 {0.0078}
Clearance between cam idle gear shaft and cam idle gear bushing
Replace idle gear shaft and/or idle gear.
Measure
ENGINE MECHANICAL (J08C)
EN02–19
CRANKSHAFT FRONT END COMPONENT LOCATOR M01020201BED1001
M01020200017
1
Crankshaft pulley
4
Crankshaft oil seal
2
Torsional damper
5
Oil seal retainer
3
Seal sub-assembly
Tightening torque A 108 {1,100, 80}# #=Apply oil to the threads and seat surfaces before tightening.
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
EN02–20
ENGINE MECHANICAL (J08C)
SPECIAL TOOL M01020201BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09420-1731
OIL SEAL PULLER
09407-1030
OIL SEAL PRESS
Remarks
OVERHAUL M01020201BEH2001
IMPORTANT POINTS - REPLACEMENT 1.
REMOVE THE CRANKSHAFT FRONT OIL SEAL. SST: Oil seal puller (09420-1731)
(1)
Place the plate at the crankshaft end using the crankshaft pulley bolts.
(2) (3)
Engage the hook with the oil seal notch and install the hook using the bolt supplied. Remove the installed bolt in step (1).
(4)
Install the center bolt and tighten it to remove the oil seal.
PLATE
M01020200003
REMOVE THIS AFTER INSTALLING THE HOOK NOTCH
HOOK M01020200004
CENTER BOLT
M01020200005
ENGINE MECHANICAL (J08C)
EN02–21
2.
INSTALL THE CRANKSHAFT FRONT OIL SEAL. SST: Oil seal press (09407-1030)
(1)
Clean the edges and surface of the crankshaft and the special tools. Insert a new crankshaft oil seal into the guide of the oil seal press.
GUIDE
(2)
OIL SEAL M01020200006
NOTICE: Pay attention to the orientation of the crankshaft oil seal (The felt side should face the outside of the cylinder block).
M01020200007
(3) (4)
Apply a little engine oil to the seal portion of the crankshaft oil seal. Attach the oil seal press guide with the new crankshaft oil seal onto the crankshaft using the attached guide bolt.
GUIDE BOLT
M01020200008
(5) PRESS
(6)
CENTER BOLT
M01020200009
Insert the oil seal press by adjusting the oil seal press hole to the guide bolt. Press the crankshaft oil seal inside by attaching the accompanying center bolt onto the oil seal press and tightening it until it stops.
EN02–22
ENGINE MECHANICAL (J08C)
FLYWHEEL AND FLYWHEEL HOUSING COMPONENT LOCATOR M01020301BED1001
M01020300022
1
Flywheel housing
5
Ring gear
2
Dust cover
6
Flywheel
3
Crankshaft oil seal
7
Pilot bearing
4
Hanger bracket
8
Stay
Tightening torque A 186 {1,900, 137}#
D
M8: 28.5 {290, 21}
B
97 {990, 72}
D
M10: 55 {560, 40.5}
C
171.5 {1,750, 127}
D
M16: 176.5 {1,800, 130}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
#=Apply oil to the threads and seat surface before tightening. =Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
ENGINE MECHANICAL (J08C)
EN02–23
SPECIAL TOOL M01020301BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09420-1742
REAR OIL SEAL PULLER
09407-1040
OIL SEAL PRESS
09481-1340
GUIDE BAR
Remarks
OVERHAUL M01020301BEH2001
IMPORTANT POINTS - REPLACEMENT COLLAR KNOCK
1.
REMOVE THE CRANKSHAFT REAR OIL SEAL. SST: Oil seal puller (09420-1742)
(1) Place the plate at the crankshaft end using the flywheel bolts. NOTICE: Match the plate hole to the crankshaft collar knock part.
M01020300002
(2) HOOK
(3)
NOTCH
M01020300003
Engage the hook with the oil seal notch and install the hook using the bolt supplied. Remove the installed flywheel bolts in step (1).
EN02–24
ENGINE MECHANICAL (J08C) (4)
Install the center bolt and tighten it to remove the oil seal.
2.
INSTALL THE CRANKSHAFT REAR OIL SEAL. SST: Oil seal press (09407-1040)
(1)
Clean the edges and surface of the crankshaft and the special tools. Insert a new crankshaft oil seal into the guide of the oil seal press.
CENTER BOLT
M01020300004
(2)
M01020300005
NOTICE: Pay attention to the orientation of the crankshaft oil seal (The felt side should face the outside of the cylinder block).
M01020300006
(3) (4)
Apply a little engine oil to the seal portion of the crankshaft oil seal. Attach the oil seal press guide with the new crankshaft oil seal onto the crankshaft using the attached guide bolt.
GUIDE BOLT
M01020300007
(5) (6) PRESS
CENTER BOLT M01020300008
Insert the oil seal press by adjusting the oil seal press hole to the guide bolt. Press the crankshaft oil seal inside by attaching the accompanying center bolt onto the oil seal press and tightening it until it stops.
ENGINE MECHANICAL (J08C)
EN02–25
3. (1)
REPLACE THE FLYWHEEL RING GEAR. Heat the ring gear evenly to about 200°C {392°F} with a torch. Tap the ring gear periphery lightly using a cushion bar to remove the gear. CAUTION: Never touch the heated ring gear or flywheel with your bare hand. This can result in personal injury.
M01020300009
(2)
Heat the ring gear evenly to about 200°C {392°F} with a torch. Insert the ring gear into the flywheel so that the chamfered side is upward. CAUTION: Never touch the heated ring gear or flywheel with your bare hand. This can result in personal injury.
M01020300010
IMPORTANT POINT - ASSEMBLY 1. (1)
INSTALL THE FLYWHEEL. Make sure that there are no burns or dirt on the contact surface or in the threaded holes of the crankshaft or flywheel. Install the special tool onto the crankshaft. SST: Guide bar (09481-1340)
NOTICE: Place one guide bar at the collar knock and another at the opposite side of the collar knock. M01020300011
(2)
Insert the flywheel slowly until it contacts the collar knock to prevent impact on the guide bar. Adjust the position, then insert the flywheel completely. CAUTION: The flywheel is too heavy. When installing, be careful not to drop it on your feet. (3)
(4) (5)
(6)
M01020300012
Apply clean engine oil to the threads of the flywheel bolt and the flywheel bolt seat. Be sure to tighten the flywheel bolts (6 pieces) with a low-torque impact wrench. Pull out the guide bar and tighten the remaining two flywheel bolts provisionally as in step (3). Tighten the flywheel in the order shown in the figure to the specified torque below. Tightening Torque: 186 N⋅m {1,900 kgf⋅cm, 137 lbf⋅ft} Loosen all bolts and tighten them again to the specified torque.
EN02–26
ENGINE MECHANICAL (J08C)
INSPECTION AND REPAIR M01020301BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Measure
Flywheel surface deflection
Flywheel flange depth (Dimension A) Flywheel thickness (Dimension B) Flywheel flange depth (Dimension A) Flywheel thickness (Dimension B)
—
0.15 {0.0059}
Repair.
Measure CS350 series (Diameter 350 mm {14 in.})
43 {1.693}
43 {1.693}
Repair.
21 {0.827}
20 {0.787}
Repair.
48 {1.890}
48 {1.890}
Repair.
23 {0.906}
22 {0.866}
Repair.
—
—
Repair.
CS380 series (Diameter 380 mm {15 in.})
Flywheel surface crank on heat spot
Visual check
ENGINE MECHANICAL (J08C)
EN02–27
TIMING GEAR COMPONENT LOCATOR M01020401BED1001
M01020400001
1
Gasket
8
Main idle gear
2
Rear end plate
9
Crankshaft gear
3
Camshaft gear
10
Air compressor drive gear
4
Cam idle gear
11
Power steering pump drive gear
5
Idle gear thrust plate
12
Pin
6
Sub-idle gear
13
Idle gear shaft
7
Oil pump gear
Tightening torque A 108 {1,100, 80}#
C
172 {1,750, 127}#
B
D
55 {560, 41} Application of lock sealant
108 {1,100, 80}#
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
#=Apply oil to the threads and seat surfaces before tightening.
EN02–28
ENGINE MECHANICAL (J08C)
SPECIAL TOOL M01020401BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
Remarks
09420-1100
SLIDING HAMMER
For MAIN IDLE GEAR
09420-1442
SLIDING HAMMER
For SUB AND CAM IDLE GEAR
09411-1300
SOCKET WRENCH
For TORX BOLT
OVERHAUL M01020401BEH2001
IMPORTANT POINTS - DISASSEMBLY 1. (1)
M01020400005
M01020400006
REMOVE THE IDLE GEAR SHAFT. Remove the idle gear shaft using the special tool. SST: Sliding hammer (for main idle gear) (09420-1100) Sliding hammer (for sub and cam idle gear) (09420-1442)
ENGINE MECHANICAL (J08C)
EN02–29
IMPORTANT POINTS - ASSEMBLY 1. (1)
INSTALL THE REAR END PLATE. Apply lock sealant (Nut Lock Super 5M or equivalent) to the threads of the torx bolts in the side of the air compressor fitting (2 places) and tighten to the specified torque using the special tool. SST: Socket wrench (09411-1300) Tightening Torque: 55 N⋅m {560 kgf⋅cm, 41 lbf⋅ft}
M01020400007
2. (1)
INSTALL THE CRANKSHAFT GEAR. Heat the crankshaft gear in oil heated to 100°C -150°C {212°F302°F}. CAUTION: Never touch the heated gear with your bare hand. This can result in personal injury.
M01020300024
(2) (3)
Align the crankshaft gear groove with crankshaft pin. Install the crankshaft gear onto the crankshaft as shown in the figure. Dimension A: 22 mm {0.866 in.}
3.
INSTALL THE IDLER GEAR SHAFT AND GEAR.
M01020400008
NOTICE: • Install each idle gear shaft through the thrust plate as shown in the figure so that the lubrication hole is downward. • Adjust the timing of the main idle gear to align with the air compressor gear as shown in the figure.
EN02–30
ENGINE MECHANICAL (J08C) 4. (1)
MEASUREMENT OF GEAR BACKLASH. Measure the backlash between the gears with a dial gauge. (Refer to the table of INSPECTION AND REPAIR) NOTICE: After measurement of the backlash, apply engine oil to each gear surface.
M01020400009
INSPECTION AND REPAIR M01020401BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
CrankshaftMain idle
0.030-0.167 {0.0012-0.0065}
0.30 {0.0118}
Main idle-Air compressor
0.030-0.218 {0.0012-0.0085}
0.30 {0.0118}
Air compressor-Power steering pump
0.030-0.183 {0.0012-0.0072}
0.30 {0.0118}
0.030-0.162 {0.0012-0.0063}
0.30 {0.0118}
Sub idle-Oil pump
0.030-0.131 {0.0012-0.0051}
0.30 {0.0118}
Sub idle-Cam idle
0.050-0.218 {0.0020-0.0085}
0.30 {0.0118}
Cam idleCamshaft
0.030-0.253 {0.0012-0.0099}
0.30 {0.0118}
Timing gear backMain idle-Sub lash idle
Remedy
Inspection procedure
Measure
Replace gear.
ENGINE MECHANICAL (J08C)
Inspection item
Main idle shaft
Standard
Limit
Remedy
Shaft outside diameter
57 {2.244}
—
—
Bushing inside diameter
57 {2.244}
—
—
Clearance
0.030-0.090 {0.0012-0.0035}
0.20 {0.0079}
Replace gear and/ or shaft.
Gear width
44 {1.732}
—
—
Shaft length
44 {1.732}
—
—
0.114-0.160 {0.0045-0.0062}
0.30 {0.0118}
Replace gear and/ or shaft.
Shaft outside diameter
50 {1.969}
—
—
Bushing inside diameter
50 {1.969}
—
—
Clearance
0.025-0.075 {0.0010-0.0029}
0.20 {0.0079}
Replace gear and/ or shaft.
Gear width
22 {0.866}
—
—
Shaft length
22 {0.866}
—
—
0.040-0.095 {0.0016-0.0037}
0.30 {0.0118}
Replace gear and/ or shaft.
34 {1.339}
—
—
—
—
End play
Sub idle shaft
End play Shaft outside diameter Bushing inside diameter Cam idle shaft
EN02–31
Measure
34 {1.339}
Clearance
0.025-0.075 {0.0010-0.0029}
0.20 {0.0079}
Replace gear and/ or shaft.
Gear width
22 {0.866}
—
—
Shaft length
22 {0.866}
—
—
0.040-0.095 {0.0016-0.0037}
0.30 {0.0118}
Replace gear and/ or shaft.
End play
Inspection procedure
EN02–32
ENGINE MECHANICAL (J08C)
MAIN MOVING PARTS AND CYLINDER BLOCK COMPONENT LOCATOR M01020501BED1001
M01020500093
ENGINE MECHANICAL (J08C) 1
Cylinder liner
9
Connecting rod bushing
2
Cylinder block
10
Connecting rod bearing
3
Piston cooling jet
11
Crankshaft
4
Piston ring
12
Crankshaft thrust bearing
5
Piston
13
Crankshaft main bearing
6
Piston pin
14
Crankshaft gear
7
Retainer ring
15
Collar knock
8
Connecting rod
16
Main bearing cap
C
69 {700, 50}+90°+45°#
Tightening torque A 22 {220, 15.5} B
EN02–33
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
69 {700, 50}+90°+45°#
#=Apply oil to the threads and seat surfaces before tightening. =Tighten the bolt to the specified torque, then loosen it. Tighten to the specified torque again.
M01020500094
1
Injection pump bracket
EN02–34
ENGINE MECHANICAL (J08C)
M01020500095
1
Gasket
3
Soft washer
2
Oil pan
4
Drain plug
Tightening torque A 41 {420, 30}
Unit: N⋅m {kgf⋅cm, lbf⋅ft} B
30 {300, 21}
ENGINE MECHANICAL (J08C)
EN02–35
SPECIAL TOOL M01020501BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
Remarks
09442-1011
PISTON RING EXPANDER
For Piston ring
09420-1720
PULLER
For Cylinder liner
9001-24262
CONNECTOR BOLT
For Piston cooling jet
09472-1620
ADJUSTING BAR
09471-1490
GUIDE
09402-1540
SPINDLE
09481-1540
GUIDE
9191-08252
BOLT
09481-1130
GUIDE
For Connecting rod bushing
EN02–36
Illustration
ENGINE MECHANICAL (J08C)
Part number
Tool name
09402-1530
PRESS SUB-ASSEMBLY
9233-10360
WING NUT
09441-1320
PISTON RING HOLDER
09444-1630
GAUGE
Remarks
OVERHAUL M01020501BEH2001
IMPORTANT POINTS - DISASSEMBLY 1. (1)
REMOVE THE PISTONS WITH CONNECTING RODS. Remove the pistons and connecting rods from the cylinder block upper side. NOTICE: • Remove carbon deposits from the end inside the cylinder liner with a scraper or emery paper (recommended: No. 150) in a circular direction.
M01020500017
•
M01020500018
Arrange the removed pistons and connecting rod caps in the order of cylinder Numbers. Be careful not to change the combination of the connecting rod and cap.
ENGINE MECHANICAL (J08C) 2. (1)
EN02–37
REMOVE THE PISTON RINGS. Remove the piston ring using the special tool. SST: Piston ring expander (09442-1011)
NOTICE: • Handle the piston rings carefully because they are made of a special casting which is easily broken. • Keep the piston rings for each cylinder separately.
M01020500019
3. (1)
REMOVE THE CYLINDER LINER. Before removing the cylinder liner, put alignment marks on the cylinder block and liner flange. NOTICE: Do not make alignment marks with a punch.
M01020500020
(2)
Pull the cylinder liner from the cylinder block using the special tool. SST: Puller (09420-1720)
NOTICE: • Carefully set the special tool to prevent touching to the piston cooling jet. • After removing the cylinder liners, arrange them in sequence.
M01020500021
IMPORTANT POINTS - ASSEMBLY 1. (1)
M01020500022
INSPECT AND ADJUST THE PISTON COOLING JET. Install the piston cooling jet on the cylinder block using the special tool. SST: Connector bolt (9001-24262)
EN02–38
ENGINE MECHANICAL (J08C) (2)
For the jet test, connect the oil hose to the connector bolt from the cylinder block lower side. NOTICE: Use clean engine oil for jet flow.
M01020500023
(3)
Set the special tool on the cylinder block upper surface against the dowel pin. SST: Gauge (09444-1630)
(4)
Test jet oil flow from the piston cooling jet nozzle at a hydraulic pressure of 196 kPa {2 kgf/cm2, 28 lbf/in2}.
M01020500096
(5)
If the center of the jet flow is within the target circle (7mm {0.2756 in} diameter: Red), the test is acceptable. NOTICE: • Fire may occur due to splattered oil during the jet flow test. Do not use naked lights near the test area. CAUTION: • Engine oil is flammable. Carry out this test in a well ventilated room and do not use naked lights in the room.
M01020500025
(6)
If the center of the jet flow is out of the target circle, realign the nozzle using the special tool. SST: Adjusting bar (09472-1620)
M01020500026
2. INSTALL THE CYLINDER LINER. NOTICE: • When assembling the cylinder liner with the cylinder block, clearance can be set to three levels. • The upper surface and side surface of the cylinder block are stamped A, B or C depending on the inside diameter. Insert a matching cylinder liner having the same symbol.
M01020500027
ENGINE MECHANICAL (J08C)
EN02–39
M01020500028
(1)
Apply engine oil to the inner surface of the block bore and insert the cylinder liner using the special tool. SST: Guide (09471-1490)
NOTICE: Handle the cylinder liner carefully because it is thin. (If it falls on the floor, it cannot be used.)
M01020500029
3.
MEASURE THE PROTRUSION AT THE CYLINDER LINER FLANGE. SST: Puller (09420-1720) Tightening Torque: 9.8 N⋅m {100 kgf⋅cm, 7 lbf⋅ft}
Standard
M01020500030
4. (1)
0.01-0.08 mm {0.0004-0.0031 in.}
MEASURE THE CRANKSHAFT. If necessary, grind the crankshaft and use an undersize bearing. Outside diameter
Bearing size
(2)
NOT "R"
SMALL "R"
STEPPED
STEPPED
R
GOOD
NOT GOOD
M01020500031
Crank pin
Journal
Standard
64.94-64.96 mm {2.5567-2.5574 in.}
79.94-79.96 mm {3.1473-3.1480 in.}
0.25US
64.69-64.71 mm {2.5469-2.5476 in.}
79.69-79.71 mm {3.1375-3.1381 in.}
0.50US
64.44-64.46 mm {2.5371-2.5377 in.}
79.44-79.46 mm {3.1276-3.1283 in.}
Dimension of fillet "R" Crank pin
5.0-5.5 mm {0.1969-0.2165 in.}
Journal
5.0-5.5 mm {0.1969-0.2165 in.}
EN02–40
ENGINE MECHANICAL (J08C) 5. (1)
INSTALL THE CRANKSHAFT. Install the main bearing onto the bearing caps and the cylinder block. NOTICE: • Install the bearing with the oil hole on the block side and the bearing without the oil hole on the cap side. • Apply clean engine oil to inner surfaces of the bearings. (2)
Install the thrust bearing with the groove side (front) toward the crank arm and with the part No. stamp (back) toward the main bearing cap or cylinder block. HINT: Apply engine oil or grease to the back of the bearing to prevent loosening during installation. (3)
Install the crankshaft onto the cylinder block.
M01020500032
6. INSTALL THE MAIN BEARING CAP. (1) Install the main bearing cap onto the cylinder block. NOTICE: Check the number stamped on the cap. (2)
Measure the length below the head of the bearing cap bolt and replace any bolts not meeting the limit with new ones. Dimension A
108 mm {4.252 in.}
M01020500033
(3) (4)
Apply clean engine oil to the bolt seat and bolt threads. Tighten the bolts in the order as shown in the figure to the specified torque. Tightening Torque: 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
(5) (6) (7)
Loosen all bolts, tap the front and back ends of the crankshaft using a plastic hammer. Tighten the bolts as in step (4). Mark the bolt heads with paint.
(8) (9)
Tighten the bolts 90° (1/4 turn) in the same order as in step (4). Retighten the bolts 45° (1/8 turn) as in step (8).
FRONT
4
2 1
2
1
6 3
3
8 4
5
10 5
7
12 6
9
14 7
11
13
M01020500097
(10) Make sure that all paint marks face the same direction. NOTICE: When adding torque, never untighten the bolt, even if they have been overtightened. (11) After tightening, tap the front and back ends of the crankshaft using a plastic hammer to allow complete fit.
M01020500035
ENGINE MECHANICAL (J08C) 7. (1)
M01020500036
EN02–41
REPLACE THE CONNECTING ROD BUSHING. Prepare the special tools. a. Assembly the guide and press sub-assembly inserting its pin into the guide then secure them with the wing nut. SST: Guide (09481-1130) Press sub-assembly (09402-1530) Wing nut (9233-10360)
NOTICE: • Bring lever "H" punched on the guide above the pin. • Making sure to align both supporting surfaces of the guide and press sub-assembly flush on a flat plane. (2)
Using a special tool, remove the connecting rod bushing. a. Set the connecting rod assembled without connecting rod bearing on the guide and press sub-assembly.
M01020500037
b. Install the spindle into the bushing. SST: Spindle (09402-1540) NOTICE: Align the groove of the spindle with the groove of the press sub assembly.
M01020500038
c. Using a hydraulic press, remove the bushing. NOTICE: Always operate the press slowly and smoothly.
M01020500039
(3)
Chamfer one edge of the bushing hole at the small end of the connecting rod uniformly by 0.5-1.0 mm {0.0197-0.0393 in.}. NOTICE: • Irregular chamfering can cause out-of-roundness of the pressed bushing, which may result in jamming during insertion. • Remove dust from the inner surface of the small-end hole.
M01020500040
EN02–42
ENGINE MECHANICAL (J08C) (4)
Mount the bushing on the spindle. a. Set the bushing and guide on the spindle as shown in the figure, then secure them with the bolt. SST: Spindle (09402-1540) Guide (09481-1540) Bolt (9191-08252) Tightening Torque: 5.0-6.8 N⋅m {50-70 kgf⋅cm, 3.62-5.06 lbf⋅ft} (Bolt)
M01020500041
NOTICE: • Align the groove of the spindle with the groove of the press sub assembly. • Make sure that the contact surfaces of the bushing seats firmly against the contact surfaces of the spindle and guide. b. Apply the fresh engine oil around the bushing and guide. Align the oil hole of the bushing with the oil hole of the connecting rod. NOTICE: • Put the connecting rod to the press sub assembly that chamfer side of the small end to the bushing side. • Apply the fresh engine oil to the bore of the connecting rod. (5)
(6)
Using a press, install the bushing in the connecting rod.
M01020500042
(7)
Inspect the bushing positioning after installation. a. Make sure that the oil hole of the bushing and the oil path of the connecting rod are suitably aligned allowing a 6 mm {0.2362 in.} diameter rod to penetrate. NOTICE: Misalignment can lead to insufficient lubrication, which may result in seizure. b.
Insert a new piston pin. When it is turned gently, make sure that there is no catch or rough movement.
M01020500043
8. (1) (2)
ASSEMBLE THE PISTON AND CONNECTING ROD. Heat the piston to 50°C {122°F}. Assemble the piston O-mark to be opposite to the connecting rod match mark. NOTICE: Replace the retainer ring with a new one.
M01020500018
ENGINE MECHANICAL (J08C) 9. (1)
EN02–43
ASSEMBLE THE PISTON RING. Install in the order of oil ring, second ring and top ring using the special tool. SST: Piston ring expander (09442-1011)
NOTICE: Install the second ring that turn the identification print on the piston ring to upper surface. (2)
Connect the joint of the coil expander for the oil ring and install it inside the piston ring. Assemble the ring with the joint 180° opposite to the matching point.
(3)
Position the matching points of the piston ring at a even distance as shown in the figure.
10. (1)
INSTALL THE PISTON. Apply engine oil to the piston, cylinder liner and connecting rod bearing, then compress the piston ring using the special tool. SST: Piston ring holder (09441-1320)
M01020500044
M01020500045
NOTICE: • When installing the piston, be careful that the cooling jet is not struck by the connecting rod. • Make sure that the 0-mark on the piston is at the exhaust side. M01020500046
(2)
M01020500047
Insert the piston into the cylinder liner.
EN02–44
ENGINE MECHANICAL (J08C) 11. (1)
TIGHTEN THE CONNECTING ROD BOLT. Measure the length of the bolts, if the length is A or more, replace with new bolts. Dimension A
82.5 mm {3.248 in.}
(2)
Apply clean engine oil to the bolt thread and the nut seat surface of the connecting rod cap.
(3)
Tighten the connecting rod nut to the specified torque. Tightening Torque: 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
M01020500050
(4) Mark the nut heads in the same direction with paint. (5) Tighten the connecting rod nut 90° (1/4 turn). (6) Tighten the connecting rod nut 45° (1/8 turn) . (7) Make sure that the paint marks face the same direction. NOTICE: When adding torque, never untighten the nuts, even if they have been overtightened. M01020500048
12. (1)
INSTALL THE OIL PAN. Make sure that there is no deformation, impact marks or foreign particles on the cylinder block, oil pan or flange surface. Apply liquid gasket to the front and back ends of the cylinder block lower surface. NOTICE: Refer to PARTS ANS POSITIONS FOR LIQUID GASKET. (2)
(3) (4)
(5)
Install the gasket so that the protrusion is at the flywheel housing side and the intake side. (the print seal surface is at the cylinder block side) Place a guide pin of 70 mm or more in the cylinder block and assemble the oil pan against the guide. Tighten oil pan fitting bolts in the order 1 - 2 - 3 - 4 with an impact wrench. Tightening Torque: 19.7-24.5 N⋅m {200-250 kgf⋅cm, 15-18 lbf⋅ft}
Finish tightening the bolts with a torque wrench to the specified torque. Tighten the bolts according to the arrow in the figure. NOTICE: Make sure that the washer is not on the flange.
M01020500049
ENGINE MECHANICAL (J08C)
EN02–45
INSPECTION AND REPAIR M01020501BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Cylinder block flange depth
8{0.3150}
—
—
Cylinder liner thickness
8{0.3150}
—
—
0.01-0.08 {0.0004-0.0031}
—
—
Cylinder liner protrusion
Block inside diameter
Liner outside diameter
Clearance between block and liner
A
117-117.008 {4.6063-4.6066}
B
117.008-117.014 {4.6067-4.6068}
C
117.014-117.022 {4.6069-4.6071}
A
116.982-116.990 {4.6056-4.6058}
B
116.990-116.996 {4.6059-4.6061}
C
116.996-117.004 {4.6062-4.6064}
A
0.010-0.026 {0.0004-0.0010}
B
0.012-0.024 {0.0005-0.0009}
C
0.010-0.026 {0.0004-0.0010}
Measure
Reference only
—
—
Reference only
—
—
Reference only
—
Piston outside diameter at A:21{0.8267}
113.877 {4.4833}
—
Liner inside diameter (Apply the value obtained at the most worn point to the cylinder liner inside diameter.)
114 {4.488}
114.15 {4.494}
Clearance between piston and cylinder liner
0.115-0.131 {0.00460.0051}
—
Top
2.5 {0.0984}
2.4 {0.0945}
Second
2.0 {0.0787}
1.9 {0.0748}
Oil
4.0 {0.1575}
3.9 {0.1535}
Piston ring width
Inspection procedure
—
Measure
A
Replace piston and/ or liner.
Measure
Replace ring.
EN02–46
ENGINE MECHANICAL (J08C)
Inspection item
Standard
Limit
Top
2.5 {0.0984}
2.7 {0.1062}
Second
2.0 {0.0787}
2.2 {0.0866}
Oil
4.0 {0.1575}
4.1 {0.1614}
Top
0.09-0.13 {0.0036-0.0051}
Second
0.04-0.08 {0.0016-0.0031}
Oil
0.02-0.06 {0.0008-0.0023}
Top
0.30-0.40 {0.0119-0.0157}
1.5 {0.0591}
Second
0.30-0.45 {0.0119-0.0177}
1.2 {0.0472}
0.30-0.45 {0.0119-0.0177}
1.2 {0.0472}
Piston pin outside diameter
37 {1.4567}
36.96 {1.4551}
Replace piston pin.
Piston pin bore inside diameter
37 {1.4567}
37.05 {1.4586}
Replace piston.
-0.013-0.014 {-0.0005-0.0006}
0.05 {0.0020}
Replace piston and/ or piston pin.
Piston groove width
Clearance between piston ring and piston ring groove
Gap between ends of piston ring
Oil
Clearance between piston pin and piston pin bore
Remedy
Inspection procedure Measure
Replace piston.
—
—
—
Measure Cylinder liner
Replace piston ring. Piston ring
Measure
Measure
Connecting rod bushing inside diameter
Clearance between piston pin and connecting rod bushing
37 {1.4567}
37.1 {1.4606}
Replace connecting rod bushing.
0.015-0.036 {0.0006-0.0014}
0.08 {0.0031}
Replace piston pin and/or connecting rod bushing
— Visual check
Wear or damage of connecting rod *Dye penetrant check (Color check)
—
—
Replace.
ENGINE MECHANICAL (J08C)
Inspection item
Standard
Limit
Remedy
EN02–47
Inspection procedure Visual check
Clogging of connecting rod oil hole
Crank pin outside diameter
—
—
65 {2.559}
More than 0.2 {0.0079} (Repair) 64.3 {2.5314} (Service)
Clearance between connecting rod bearing and crankpin
Replace.
Measure Regrind under size. Replace crankshaft.
0.031-0.082 {0.0013-0.0032}
0.2 {0.0079}
Replace connecting rod bearing.
Connecting rod large end width
34 {1.339}
33.2 {1.3071}
Replace connecting rod.
Crankpin width
34 {1.339}
34.8 {1.371}
Replace crankshaft.
0.20-0.52 {0.0079-0.0204}
1.0 {0.0394}
Replace connecting rod and/or crankshaft.
More than 0.2 {0.0079} (Repair)
Regrind under size.
79.3 {3.1220} (Service)
Replace crankshaft.
0.051-0.102 {0.0021-0.0040}
0.2 {0.0079}
Replace main bearing.
Center journal width
36 {1.417}
37 {1.456}
Replace crankshaft.
Thrust bearing thickness
2.5 {0.0984}
—
Connecting rod end play
Crank journal outside diameter
Clearance between crank journal and main bearing
Crankshaft end play
80 {3.150}
90 measure 2 part
Measure
Measure
90
Measure
0.050-0.219 {0.0020-0.0086}
—
More than 0.5 {0.0197} (Repair)
Replace over size thrust bearing.
1.0 {0.0393} (Service)
Replace crankshaft. Measure
Crankshaft deflection
—
0.15 {0.0059}
Regrind under size.
EN02–48
Inspection item
ENGINE MECHANICAL (J08C)
Standard
Limit
Remedy
Inspection procedure Visual check
Clogging of crankshaft oil hole
—
—
Clean.
Visual check Crack and wear of crankshaft *Dye penetrant check (Color check)
—
—
Replace.
Measure
Cylinder block upper surface flatness
0.05 {0.0019} or less
0.20 {0.0080}
Replace. NOTICE: Do not grind for repair.
AIR INTAKE SYSTEM (J08C)
AIR INTAKE SYSTEM (J08C)
EN03
AIR INTAKE MANIFOLD AND PIPE ........ EN03-2 COMPONENT LOCATOR................................ EN03-2 DISMOUNTING AND MOUNTING .................. EN03-2
EN03–1
EN03-001
EN03–2
AIR INTAKE SYSTEM (J08C)
AIR INTAKE MANIFOLD AND PIPE COMPONENT LOCATOR M01030101BED1001
M01030100003
1
Intake manifold gasket
4
Intake pipe gasket
2
Intake manifold
5
Boost compensator pipe
3
Intake pipe
DISMOUNTING AND MOUNTING M01030101BEH1001
IMPORTANT POINT - MOUNTING 1. (1)
M01030100002
INSTALL THE INTAKE MANIFOLD GASKET. Install the intake manifold gasket so that the protrusion is positioned at the stud bolt side of the cylinder head rear end.
EXHAUST SYSTEM (J08C)
EXHAUST SYSTEM (J08C)
EN04
EXHAUST MANIFOLD AND PIPE............ EN04-2 COMPONENT LOCATOR................................ EN04-2 DISMOUNTING AND MOUNTING .................. EN04-3
EN04–1
EN04-001
EN04–2
EXHAUST SYSTEM (J08C)
EXHAUST MANIFOLD AND PIPE COMPONENT LOCATOR M01040101BED1001
M01040100004
1
Heat insulator
8
Hose
2
Exhaust connector
9
Intake pipe
3
Coolant pipe
10
Safety valve
4
Oil pipe
11
Exhaust manifold
5
Turbocharger
12
Seal ring
6
Gasket
13
Exhaust manifold gasket
7
Clamp
14
Spacer
Tightening torque A 53 {540, 39}
C
56 {570, 41}
B
61 {620, 44}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
EXHAUST SYSTEM (J08C)
EN04–3
DISMOUNTING AND MOUNTING M01040101BEH1001
IMPORTANT POINT - MOUNTING 1. INSTALL THE EXHAUST MANIFOLD GASKET. NOTICE: Since the exhaust manifold gasket must be installed in one way, install the gasket with the black side facing toward the exhaust manifold.
M01040100002
2. (1)
INSTALL THE EXHAUSTMANIFOLD. Install the exhaust manifold onto the cylinder head and tighten the inner mounting nut in the order shown in the figure to the specified torque. Tightening Torque: 53 N⋅m {540 kgf⋅cm, 39 lbf⋅ft}
(2) Tighten the same nuts according to the same procedure again. NOTICE: Be sure to carry out the procedure. (3)
Tighten the outer mounting nut, while in the order shown in the figure to the specified torque below. Tightening Torque: 61 N⋅m {620 kgf⋅cm, 45 lbf⋅ft}
NOTICE: Be sure to hold the inner nut when tightening the outer nut.
M01040100005
LUBRICATING SYSTEM (J08C)
LUBRICATING SYSTEM (J08C)
EN05
LUBRICATING SYSTEM .......................... EN05-2 DIAGRAM ........................................................ EN05-2
OIL PUMP AND OIL STRAINER .............. EN05-4 COMPONENT LOCATOR................................ EN05-4 OVERHAUL ..................................................... EN05-4 INSPECTION AND REPAIR ............................ EN05-5
OIL FILTER AND OIL COOLER ............... EN05-6 COMPONENT LOCATOR................................ EN05-6 SPECIAL TOOL ............................................... EN05-7 DISMOUNTING AND MOUNTING .................. EN05-7 INSPECTION AND REPAIR ............................ EN05-8
EN05–1
EN05-001
EN05–2
LUBRICATING SYSTEM (J08C)
LUBRICATING SYSTEM DIAGRAM M01050101BEJ1001
M01050100003
LUBRICATING SYSTEM (J08C) 1
Oil pan
14
Crankshaft
2
Oil strainer
15
Piston
3
Oil pump
16
Valve rocker shaft
4
Oil pump safety valve
17
Camshaft
1,648-1,746 {16.8-17.8, 239-253}
18
Valve
Oil cooler and oil filter
19
Rocker arm
5 6
Oil cooler safety valve
20
Cross head
352-432 {3.6-4.4, 52-62}
21
Fuel injection pump
7
Oil filter (full flow)
22
Air compressor
8
Oil filter (by-pass)
23
Main idle gear
9
Pressure switch
24
Cam idle gear
10
Oil filter safety valve
25
Sub idle gear
176-216 {1.8-2.2, 26-31}
26
Check valve
11
Regulator valve 490-570 {5.0-5.8, 72-82}
27
Check valve for turbocharger
12
Main oil hole
28
Turbocharger
13
Piston cooling jet
A
To oil pan
2
245 {2.5, 36}
2
Unit: kPa {kgf/cm , lbf/in. }.
EN05–3
EN05–4
LUBRICATING SYSTEM (J08C)
OIL PUMP AND OIL STRAINER COMPONENT LOCATOR M01050201BED1001
M01050200001
1
Gasket
6
Safety valve
2
Oil pump
7
Relief spring
3
Driven gear
8
Spring seat
4
Oil strainer
9
Cotter pin
5
O-ring
B
31 {320, 23}
Tightening torque A 28.4 {290, 21}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
OVERHAUL M01050201BEH2001
IMPORTANT POINTS - ASSEMBLY 1. (1)
INSTALLING THE OIL PUMP. Apply oil to the pump case and bearings of the block (hatched area) before installing the oil pump. NOTICE: Not applying oil may cause oil suction failure at start-up, resulting in seizure and abnormality. (2) M01050200002
(3)
To prevent misalignment of the gasket, apply grease to the gasket matching face of the block. Then, place and fix the gasket. Tighten the oil pump mounting bolts provisionally in the order as shown in the figure. Tighten them to the specified torque.
LUBRICATING SYSTEM (J08C)
EN05–5
INSPECTION AND REPAIR M01050201BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Gear outside diameter
54 {2.126}
—
—
Block side pump body inside diameter
54 {2.126}
—
—
0.100-0.202 {0.004-0.0079}
0.30 {0.0118}
Gear width
37.5 {1.476}
—
—
Block side pump body inside depth
37.5 {1.476}
—
—
0.049-0.113 {0.0020-0.0044}
0.15 {0.0059}
Shaft outside diameter
18 {0.709}
—
—
Block side bushing inside diameter
18 {0.709}
—
—
Clearance
0.040-0.099 {0.0016-0.0038}
—
—
Shaft outside diameter
18 {0.709}
—
—
Block hole diameter
18 {0.709}
—
—
Clearance
0.030-0.075 {0.0012-0.0029}
—
—
Gear bushing inside diameter
18 {0.709}
—
—
Clearance
0.040-0.083 {0.0016-0.0032}
0.15 {0.0059}
Tip clearance
End play
Drive gear
Driven gear
Inspection procedure Measure
Replace gear or pump. Measure
Replace gear or pump. Measure
Measure
Replace gear.
Measure
Gear backlash
0.073-0.207 {0.0029-0.0081}
0.30 {0.0118}
Replace pump.
EN05–6
LUBRICATING SYSTEM (J08C)
OIL FILTER AND OIL COOLER COMPONENT LOCATOR M01050301BED1001
M01050300001
1
Oil cooler with filter assembly
6
Regulator valve
2
O-ring
7
Oil filter safety valve
3
Oil cooler element
8
Check valve
4
Gasket
9
Oil cooler safety valve
5
Oil cooler case
10
Oil filter element
LUBRICATING SYSTEM (J08C) Tightening torque A 29.5-39.2 {300-400, 22-28}
F
24.5-34.3 {250-350, 19-25}
B
24.6-34.3 {250-350, 19-25}
G
28.4 {290, 21}
C
14.7-24.5 {150-250, 11-18}
H
29.4-39.2 {300-400, 22-28}
D
19.7-29.4 {200-300, 15-21}
I
19.6-29.4 {200-300, 15-21}
E
14.7-19.5 {150-200, 11-14}
J
29.4-39.2 {300-400, 22-28}
EN05–7 Unit: N⋅m {kgf⋅cm, lbf⋅ft}
SPECIAL TOOL M01050301BEK1001
Prior to starting an engine overhaul, it is necessary to have this special tool. Illustration
Part number
Tool name
09503-1090
OIL FILTER WRENCH
Remarks
DISMOUNTING AND MOUNTING M01050301BEH2001
IMPORTANT POINTS - DISMOUNTING 1. (1)
REMOVE THE OIL FILTER. Remove the drain plug from bottom of the oil filter and drain the engine oil.
(2)
Using the special tool, remove the oil filter. SST: Oil filter wrench (09503-1090)
M01050300003
NOTICE: Make sure that O-rings are not on the oil cooler case side.
M01050300004
EN05–8
LUBRICATING SYSTEM (J08C)
IMPORTANT POINT - MOUNTING 1. (1) (2) (3)
M01050300005
INSTALL THE OIL FILTER. Remove the dust on installation surface of oil cooler case side. Apply the engine oil to the O-ring on new oil filter. Install the oil filter by turning it lightly to the right by hand until it comes in contact with the surface of the oil cooler. Then using the special tool, tighten the oil filter about 270°-360° (3/4-1 turn). SST: Oil filter wrench (09503-1090)
NOTICE: • Do not reuse the O-ring. • Attention the O-ring to damage.
2. INSTALL THE OIL COOLER AND OIL FILTER ASSEMBLY. (1) Insert the O-ring into the O-ring groove of the oil cooler. NOTICE: Face the flat area of the O-ring toward the oil cooler for installation. (2)
Apply liquid gasket to the oil cooler case and install it onto the cylinder block, then tighten the bolt to the specified torque. Tightening Torque: 28.4 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
M01050300006
INSPECTION AND REPAIR M01050301BEH3001
Inspection item
Standard
Limit
Oil cooler air leakage Air pressure: 588 kPa {6 kgf/cm2, 85 lbf/in.2}
0 mL
—
Replace, if necessary.
—
Replace, if necessary.
Wear or damage to valve spring of oil cooler and oil filter
—
Remedy
Inspection procedure Visual check
1. Damage to sliding face of valve 2. Valve movement (smoothness)
COOLING SYSTEM (J08C)
COOLING SYSTEM (J08C)
EN06
COOLING SYSTEM .................................. EN06-2 DIAGRAM ........................................................ EN06-2
COOLANT PUMP...................................... EN06-3 COMPONENT LOCATOR................................ EN06-3 SPECIAL TOOL ............................................... EN06-4 OVERHAUL ..................................................... EN06-4 INSPECTION AND REPAIR ............................ EN06-7
THERMOSTAT .......................................... EN06-8 COMPONENT LOCATOR................................ EN06-8 OVERHAUL ..................................................... EN06-8
RADIATOR .............................................. EN06-10 COMPONENT LOCATOR.............................. EN06-10 SPECIAL TOOL ............................................. EN06-11 OVERHAUL ................................................... EN06-11 INSPECTION AND REPAIR .......................... EN06-14
COOLING FAN........................................ EN06-15 COMPONENT LOCATOR.............................. EN06-15 INSPECTION AND REPAIR .......................... EN06-16
EN06–1
EN06-001
EN06–2
COOLING SYSTEM (J08C)
COOLING SYSTEM DIAGRAM M01060101BEJ1001
1 4 2 5 11
6 3
12 10
9
7
13
8
14
14
M01060100001
1
Reservoir tank
8
Coolant pump
2
Radiator cap
9
Air compressor
3
Radiator
10
Turbocharger
4
Coolant temperature gauge
11
Cylinder head
5
Thermostat case
12
Cylinder block
6
Thermostat
13
Oil cooler
7
Car heater (If so equipped)
14
Drain plug
COOLING SYSTEM (J08C)
EN06–3
COOLANT PUMP COMPONENT LOCATOR M01060201BED1001
M01060200028
1
Thermostat case
7
Pulley center
2
Cooling fan
8
Retainer ring
3
Fan clutch
9
Coolant shaft
4
Fan pulley spacer
10
Pump case
5
O-ring
11
Coolant seal
6
Coolant pump assembly
12
Vane
EN06–4
COOLING SYSTEM (J08C)
SPECIAL TOOL M01060201BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09420-1810
PULLER
09420-1820
PULLER
Remarks
OVERHAUL M01060201BEH2001
IMPORTANT POINTS - DISASSEMBLY 1. (1)
DISASSEMBLE THE COOLANT PUMP. Remove the vane from the shaft using the special tool. SST: Puller (09420 - 1820)
(2)
Remove the pulley center from the shaft using the special tool. SST: Puller (09420 - 1810)
(3)
Remove the retainer ring from the pump case using snap ring pliers.
M01060200002
M01060200003
M01060200004
COOLING SYSTEM (J08C)
EN06–5
(4)
Push the shaft from the vane side using a hydraulic press, and remove the coolant shaft from the pump case. NOTICE: Before pressing, recheck that the retainer ring is removed completely.
M01060200005
(5)
Remove the coolant seal from the pump case using a hammer and brass bar. CAUTION: Impact due to punching may cause metal chips to fly up. Be sure to wear protective goggles. NOTICE: Replace the removed coolant seal with a new one. Never reuse it.
M01060200006
IMPORTANT POINTS - ASSEMBLY 1. (1)
ASSEMBLE THE COOLANT PUMP. Install the coolant shaft onto the pump case using a hydraulic press. Assembly standard (A): 5.9-6.1 mm {0.2323-0.2401 in} NOTICE: Press until the bearing upper end surface comes into contact with the retainer ring groove lower end surface.
M01060200007
(2)
Install the retainer ring onto the pump case using snap ring pliers.
(3)
Install the pulley center onto the shaft using a hydraulic press. Standard: 129.0 - 129.8 mm {5.079 - 5.110 in.} from the pulley center mounting surface to the pump case end surface
M01060200004
M01060200008
EN06–6
COOLING SYSTEM (J08C) (4)
Install the new coolant seal. a. Apply liquid gasket (Three Bond #1104 or equivalent) to the seal outer circumference and case bore. b. Install the slinger and seal to the case using a press.
M01060200009
c. Install the seal to the vane. NOTICE: Replace the coolant seal with new one.
M01060200010
(5)
Install the vane onto the shaft using a hydraulic press. Assembly standard (B): 0.6-1.2 mm {0.0237-0.0472 in} NOTICE: Press until the vane end face comes into contact with the shaft end surface. (6)
M01060200011
After assembly, turn the shaft by hand and make sure that there is no noise, catching or rough movement in the shaft direction and that it rotates smoothly.
COOLING SYSTEM (J08C)
EN06–7
INSPECTION AND REPAIR M01060201BEH3001
Unit: mm {in.} Inspection item
Standard
LImit
Remedy
Inspection procedure Visual check
Wear, damage and corrosion
—
—
Replace parts.
Measure Tightness of shaft and vane
0.017-0.048 {0.0007-0.0018}
—
Replace shaft and/or vane.
Measure Tightness of shaft and pulley center
0.017-0.051 {0.0007-0.0020}
—
Replace shaft and/or pulley center.
NOTICE: • Tightness= Outside diameter - Inside diameter • Prevent a reassembly more than three times even if it is within the standard value.
EN06–8
COOLING SYSTEM (J08C)
THERMOSTAT COMPONENT LOCATOR M01060301BED1001
M01060300010
1
Thermostat case assembly
4
Thermostat case
2
Thermostat case cover
5
Thermostat
3
O-ring
6
Gasket
OVERHAUL M01060301BEH2001
IMPORTANT POINTS - INSPECTION AND REPAIR 1. (1)
INSPECT THE THERMOSTAT FUNCTION. Place the thermostat in hot water and check the valve opening temperature and the valve lift.
Thermostat valve opening temperature:
M01060300002
Thermostat valve opening temperture. (T1)
Service standard
82°C {180°F}
80-84°C {176-183°F}
NOTICE: Check that the thermostat valve opening temperature (T1) is engraved on the thermostat seat.
COOLING SYSTEM (J08C)
EN06–9
Thermostat valve lift: Thermostat valve opening temp. (T1)
Measuring temp. (T2)
Valve lift (L2-L1)
82°C {180°F}
95°C {203°F}
13 mm {0.512 in.} or more
(2)
Immerse the opened thermostat in water at normal temperature. If it completely closes within 5 minutes, it is satisfactory. If it remains slightly open, it is defective and must be replaced.
M01060300003
IMPORTANT POINTS - ASSEMBLY JIGGLE VALVE
M01060300004
1.
ASSEMBLE THE THERMOSTAT CASE.
NOTICE: • Remove water or dirt adhering to the thermostat case. • Be sure to replace the gasket if it is corroded, damaged or flattened. • Before installing the hose, apply liquid gasket to the hose installation part of the thermostat case cover. • To prevent clogging of the radiator, do not use a large amount of liquid gasket. • Be sure that the jiggle valve faces upward when installing it.
IMPORTANT POINTS - MOUNTING
LIQUID GASKET
1. (1)
INSTALL THE THERMOSTAT CASE ASSEMBLY. Apply liquid gasket to the thermostat case.
(2)
Install the o-ring into the groove of the coolant pump.
(3)
Temporarily tighten the bolts "1" and bolts "2" in that order, and securely contact the fitting surface.
(4)
Tighten the bolts in numeral order.
M01060300005
"2"
"1"
M01060300006
EN06–10
COOLING SYSTEM (J08C)
RADIATOR COMPONENT LOCATOR M01060401BED1001
M01060400018
1
Radiator cap
7
Drain plug
2
Upper tank
8
Lower tank
3
O-ring
9
O-ring
4
Coolant level switch
10
Distance piece
5
Radiator core
11
Radiator fitting cushion
6
Left support
12
Right support
Tightening torque A 6-7 {62-71, 4.5-5.1}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
COOLING SYSTEM (J08C)
EN06–11
SPECIAL TOOL M01060401BEK10001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
Remarks
09760-1030
RADIATOR TOOL
TOOL FOR UNCAULKING
09760-1040
RADIATOR TOOL
TOOL FOR CAULKING (USED WITH 09760-1030)
OVERHAUL M010604BEH2001
IMPORTANT POINTS - DISMOUNTING 1. DISMOUNT THE RADIATOR. CAUTION: To avoid the danger of burns and scalds, do not drain the coolant while the engine and radiator are still hot. NOTICE: When dismounting and mounting the radiator, do not damage the radiator core.
IMPORTANT POINTS - DISASSEMBLY NOTICE: Recaulking should be limited to twice. 1. (1)
DISASSEMBLE THE UPPER TANK, LOWER TANK AND RADIATOR CORE. Remove the left support and right support.
M01060400002
(2)
Grip the handle until it hits to the stopper bolt, then adjust the dimensions A with stopper bolt. Dimension A: 0.2-0.3 mm {0.0079-0.0118 in.} SST: Radiator (09760-1030)
NOTICE: Be sure to adjust the dimension to prevent damage of the crow.
M01060400003
EN06–12
COOLING SYSTEM (J08C) (3) Using a special tool, lift the staked part. NOTICE: Do not lift up tangs more than 90°.
M01060400004
(4)
Remove the upper tank and lower tank from the radiator core by tapping lightly with plastic hammer. NOTICE: Do not remove the tank by forcing or prying.
M01060400005
IMPORTANT POINTS - ASSEMBLY 1. (1)
ASSEMBLE THE UPPER TANK, LOWER TANK AND RADIATOR CORE. Exchange the crow of the radiator tool (09760-1030) for the radiator tool (09760-1040) as shown in the figure. SST: Radiator tool (09760-1030) Radiator tool (09760-1040)
M01060400006
(2)
Grip the handle of the radiator tool until it hits to the stopper bolt, then adjust the dimensions B with stopper bolt. Dimension B: 8.4 mm {0.3307 in.}
(3)
Install the new O-ring into the groove of the radiator core (upper and lower) in such away that it will not be twisted.
M01060400007
NOTICE: Be sure to clean the fitting portion before installing. When cleaning, lightly rub the inside portion of the groove with the emery paper. (4)
M01060400008
Install the upper tank and lower tank into the groove of the radiator core.
COOLING SYSTEM (J08C)
EN06–13
(5)
Frap the tangs to obtain a tight contact with the upper tank and lower tank.
(6)
Press the radiator tool (caulking tool) against the side portion. Temporarily caulk the tangs several times, then proceed to the final caulking by gripping the handle until it hits the stopper bolt.
M01060400009
NOTICE: For the positions where the radiator tool is not usable, perform the caulking with pliers.
M01060400010
NOTICE: Perform the caulking according to the sequence as shown in the figure.
M01060400011
(7)
M01060400012
Check the dimension C. Assembly standard: 7.27-7.85 mm {0.2863-0.3090 in.} If the dimension is out of the standard value, adjust the stopper bolt of the handle once again and perform the caulking again.
EN06–14
COOLING SYSTEM (J08C)
INSPECTION AND REPAIR M01060401BEH3001
Unit:MPa {kgf/cm2, lbf/in.2} Inspection item
Standard
Limit
Remedy
Air leakage (When the air pressure of 100 {1,14} is applied.)
—
—
Replace radiator.
Clogging of the Fines
—
—
Clean.
Inspection procedure Visual check
Radiator cap valve opening pressure
Measure
Mark 0.5
40-58 {0.4-0.6, 5.7-8.5}
—
Replace.
NOTICE: • The coolant filler cap valve opening pressure is indicated on the cap and it should be confirmed. If the cap pressure is incorrect, there is a risk of abnormally high pressure being generated in the cooling system, which may cause the hose to drop off or burst and may result in the damage of the engine. • When carrying out high pressure washing to remove fin clogging, do not apply excessive pressure to the fins which may cause deformation and consequent performance deterioration.
COOLING SYSTEM (J08C)
EN06–15
COOLING FAN COMPONENT LOCATOR M01060601BED1001
M01060600006
1
Cooling fan
2
Fan clutch
3
Fan pulley spacer
NOTICE: • Shock to the fan clutch and fan. During maintenance and inspection, be careful not to drop or strike the fan clutch or fan itself. The resulting damage may lower the performance of the fan. Also, note that the fan is made of plastic and may become damaged or deformed if force is applied to it. • Replace the fan. Do not replace the fan unless it is faulty. When replacing the fan, replace with the same type. If the fan is replaced with one of a larger capacity because of overheating or, conversely is replaced with one of a smaller capacity due to overcooling, the performance may in fact be reduced and durability may be jeopardized. • Other items Check the bimetal to see if there is any mud or dust on it. If the bimetal is covered with mud or dust, the fan performance will be erratic, and may result in overheating or overcooling. In such case, carefully remove mud and dust adhering to the surface of the bimetal, using a wire brush, or the like. Take care not to apply excessive force particular. Do not paint the fan or fan clutch. Do not place any paint or other reagents which are likely to dissolve plastic in contact with the fan.
EN06–16
COOLING SYSTEM (J08C)
INSPECTION AND REPAIR M01060601BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Visual check
Cooling fan and fan clutch deformation and damage
—
—
Replace if necessary.
FUEL SYSTEM (J08C)
FUEL SYSTEM (J08C)
EN07
FUEL SYSTEM.......................................... EN07-2 DIAGRAM ........................................................ EN07-2 DESCRIPTION ................................................ EN07-3 SPECIAL TOOL ............................................... EN07-4 OVERHAUL ..................................................... EN07-4
INJECTION NOZZLE (TWO-SPRING TYPE - BOSCH MAKE)... EN07-7 DESCRIPTION ................................................ EN07-7 COMPONENT LOCATOR................................ EN07-8 SPECIAL TOOL ............................................... EN07-9 OVERHAUL ................................................... EN07-10
EN07–1
EN07-001
EN07–2
FUEL SYSTEM (J08C)
FUEL SYSTEM DIAGRAM M01070101BEJ1001
M01070100001
1
Return pipe
5
Feed pump
2
Injection nozzle
6
Fuel filter
3
Through feed pipe
7
Injection pipe
4
Fuel tank
FUEL SYSTEM (J08C)
EN07–3
DESCRIPTION M01070101BEC1001
M01070100019
1
Injection nozzle
2
Fuel filter
Tightening torque A 14.5 {148, 11} B
34 {350, 25}
3
Fuel injection pump
Unit: N⋅m {kgf⋅cm, lbf⋅ft} C
25 {250}
EN07–4
FUEL SYSTEM (J08C)
SPECIAL TOOL M01070101BEK1001
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09503-1040
FUEL FILTER WRENCH
09511-2500
INJECTION PUMP COUPLING WRENCH
09515-2470
WRENCH
Remarks
NOTICE: BOSCH: BOSCH AUTOMOTIVE SYSTEMS CORPORATION
OVERHAUL M01070101BEH2001
IMPORTANT POINTS - DISMOUNTING
M01070100006
1. (1) (2)
REMOVE THE FUEL INJECTION PUMP. Disconnect the fuel lines, oil lines and engine control lines. Remove the through bolt of the coupling and loosen the adjusting bolt using the special tool. SST: Injection pump coupling wrench (09511-2500)
(3)
Remove the injection pump mounting bolt and dismount the pump. SST: Wrench (09515-2470)
NOTICE: After dismounting the pump, cover the pump and high pressure pipe to prevent entry of dirt.
IMPORTANT POINTS - MOUNTING 1. (1)
M01070100007
INSTALL THE FUEL INJECTION PUMP. To adjust the injection timing, turn the flywheel in the rotation direction (counterclockwise viewed from the flywheel side). Align the pointer at the inspection side on the flywheel housing to injection timing before top dead center for No.1 cylinder compression stroke.
FUEL SYSTEM (J08C)
EN07–5
(2)
Turn the timer counterclockwise slowly viewed from the coupling (normal direction of engine) and align the mark on the timer with the mark on the injection pump pointer.
(3)
Tighten the injection pump mounting bolt evenly to the torque below. SST: Wrench (09515-2470)
M01070100008
Tightening Torque: 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
M01070100009
(4)
Tighten the adjusting bolt using the special tool. SST: Injection pump coupling wrench (09511-2500) Tightening Torque: 88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}
(5)
M01010100014
Tighten the through bolt at the flange. Tightening Torque: 88 N⋅m {897 kgf⋅cm, 65 lbf⋅ft}
(6) Install pipes and engine control cables. NOTICE: Cylinder numbers are stamped on the flare nuts at the pump side of the injection pipe.
IMPORTANT POINTS - REPLACEMENT 1. (1)
M01070100015
REMOVE THE FUEL FILTER. Remove the fuel filter using the special tool. SST: Fuel filter wrench (09503-1040)
EN07–6
FUEL SYSTEM (J08C) 2. (1) (2) (3)
INSTALL THE FUEL FILTER. Remove the dust on installation surface. Apply light oil to gasket of new fuel filter. Install the fuel filter by turning it lightly to the right by hand until it comes in contact with the surface of the fuel filter cover. Then using the special tool, tighten the fuel filter about 240° (2/3 turn). SST: Fuel filter wrench (09503-1040)
NOTICE: • Do not reuse the element. • Be careful not to damage the gasket. M01070100016
AIR BLEEDING FROM FUEL SYSTEM.
BLEEDER PLUG
M01070100017
1. (1) (2) (3)
BLEED AIR FROM THE FUEL FILTER. Bleed air from the fuel filter. Loosen the bleeder plug on the fuel filter. Operate the priming pump knob until the air will not come out from the bleeder plug.
(4)
Tighten the bleeder plug. Tightening Torque: 4.9-8.9 N⋅m {50-90 kgf⋅cm, 3.7-6.5 lbf⋅ft}
NOTICE: The bleeder plug should be tightened while the priming pump knob is operated. (5) Once again, operate the priming pump knob several times. (6) Push back the priming pump knob and tighten it. NOTICE: Wipe up any splashed fuel.
FUEL SYSTEM (J08C)
EN07–7
INJECTION NOZZLE(TWO-SPRING TYPE - BOSCH MAKE) DESCRIPTION M01070201BEC1002
M01070200026
1
Joint bolt
10
Second pressure spring
2
Gasket
11
Second pressure spring seat
3
Cap nut
12
Lift piece
4
Gasket
13
Spacer
5
Adjusting screw
14
Nozzle assembly
6
First pressure spring
15
Retaining nut
7
Push rod
16
Pre lift (L')
8
Nozzle holder
17
Valve lift (L)
9
Second pressure adjusting shim
EN07–8
FUEL SYSTEM (J08C)
COMPONENT LOCATOR M01070201BED1002
M01070200027
1
Joint bolt
8
Nozzle holder
2
Gasket
9
Second pressure adjusting shim
3
Cap nut
10
Second pressure spring
4
Gasket
11
Second pressure spring seat
5
Adjusting screw
12
Nozzle assembly
6
First pressure spring
13
Retaining nut
7
Push rod
C
68.5 {700, 51}
Tightening torque A 14.5 {148, 11} B
44 {450, 33}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
FUEL SYSTEM (J08C)
EN07–9
SPECIAL TOOL M01070201BEK1002
Prior to starting an engine overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09420-1442
IDLE GEAR SLIDING HAMMER
For SUB AND CAM IDLE GEAR
09462-1130
NOZZLE HOLDER ADAPTER
Used with 09420-1442
TOOL SET NOTICE: BOSCH product tool set
Length (L) 157892-4200: 160 mm {6.300 in} 157892-4300: 110 mm {4.331 in}
157892-4620 NOTICE: It is BOSCH product number that mentioned part number.
Remarks
EN07–10
FUEL SYSTEM (J08C)
OVERHAUL M01070201BEH2002
IMPORTANT POINTS - DISMOUNTING 1.
CLEAN OFF SURROUNDING AREA OF THE NOZZLE AND THE FUEL LINE CONNECTORS. NOTICE: If foreign matter is allowed to enter the combustion chamber, engine trouble may result.
M01070200007
2. (1) (2) (3)
REMOVE THE FUEL INJECTION PIPE. Remove the return pipe. Loosen the injection pipe nut. Remove the bolt of the injection pipe seal and pull it with the injection pipe from the camshaft housing. NOTICE: Cover open ends of the pipes and fuel injection pump to prevent entry of dirt. 3. (1) (2)
REMOVE THE NOZZLE HOLDER ASSEMBLY. Remove the nozzle clamp bolt. Pull out the nozzle holder assembly taking care not to contact other parts. If it is difficult to remove the assembly, use of the special tool. SST: Sliding hammer (09420-1442) Adapter (09462-1130)
(3) Remove the O-ring. NOTICE: Replace the O-ring with a new one.
M01070200008
IMPORTANT POINTS - INSPECTION 1. CHECK THE INJECTION PRESSURE. (1) Install the nozzle holder assembly to the nozzle tester. CAUTION: • Since diesel oil is flammable, check and adjust the nozzle in a well ventilated room. Never use naked lights in the room. • Since injected fuel is highly pressurized, direct contact with the body may be harmful to health. Provide a screen to prevent scattering of fuel. M01070200009
FUEL SYSTEM (J08C)
EN07–11
(2)
Operate the lever at the rate of 50 to 60 strokes per minute. If the injection pressure is not within specified value, adjust the injection pressure with adjusting screw. First opening pressure With new parts : 18.1-18.9 MPa {185-193 kgf/cm2, 2,632-2,745 lbf/in.2} With reused parts : 17.66-18.43 MPa {180-188 kgf/cm2, 2,561-2,673 lbf/in.2}
2. (1)
TEST THE SPRAY PROFILE. In the case of a new nozzle, operate the lever at the rate of 30 to 60 strokes per minute, and for a used nozzle, operate the lever at the rate of 15 to 16 strokes per minute. If spray is coarse, replace or clean the nozzle.
3. (1)
TEST THE FUEL LEAKAGE. When checking for fuel leakage from the nozzle, apply a pressure about 0.99-1.96 MPa {10-20 kgf/cm2, 142.3-284.4 lbf/in.2} lower than the correct injection pressure to the nozzle using a nozzle tester. If faulty, replace or clean the nozzle.
M01070200010
M01070200011
M01070200012
IMPORTANT POINTS - DISASSEMBLY 1. REMOVE THE RETAINING NUT. NOTICE: To prevent dropping parts, face the nozzle holder toward the retaining nut side.
M01070200013
EN07–12
FUEL SYSTEM (J08C)
IMPORTANT POINTS - INSPECTION AFTER DISASSEMBLY 1. (1)
M01070200014
TEST THE NOZZLE SINKING. Wash the nozzle proper with diesel fuel oil, them immerse it in diesel fuel oil. Next slide the needle inside the nozzle proper and ensure that it moves smoothly. The needle valve should fall under its own weight when withdrawn vertically about 1/3 its length and released. If its motion is sluggish, replace the nozzle with a new one. NOTICE: When assembling, you must reinstall the same parts in the same nozzle holder. Do not mix them up.
IMPORTANT POINTS - ASSEMBLY NOTICE: • The steps below for adjustment are made during parts assembly. • Because the nozzle holder is adjusted 1/100 mm units, it must be thoroughly washed to remove all dirt and foreign objects.
Work steps 1. Adjustment of first opening pressure
Adjust first opening pressure with the adjusting screw.
2. Checking of needle valve full-lifts
Check with nozzle cover method.
3. Checking of pre-lift
Check with nozzle cover method. NOTICE: If pre- lift is not within specified value, replace pins, lift piece, spacer and nozzle assembly with the nozzle service kit.
4. Checking of second opening pressure
Check with nozzle cover method.
5. Adjusting of second opening pressure
Adjust second opening pressure with adjusting shim.
6. Replacement of the retaining nut
Replace adjustable retaining nut with normal retaining nut.
7. Final inspection
Check condition of the fuel spray with the nozzle and nozzle holder assembly. 1.
ADJUSTMENT OF THE FIRST OPENING PRESSURE (WORK STEP1.) (1) Install the adjusting shim, second pressure spring and spring seat into the nozzle holder. NOTICE: The second pressure spring is the same as the first pressure spring. (2)
M01070200031
Install the pins, lift piece, spacer and nozzle onto the nozzle holder.
FUEL SYSTEM (J08C) (3)
EN07–13
Put the gasket (special tool) onto the nozzle, then use the adjustable retaining nut (special tool) to holder the nozzle in place on the nozzle holder. SST: Gasket (157892-1500) Adjustable retaining nut (157892-4000) Tightening Torque: 68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
M01070200032
NOTICE: • Make sure that the pin is all the way in the nozzle and then tighten adjustable retaining nut. • Finger-tighten the adjustable retaining nut until it no longer turns and tighten the nut to specified torque. (4) (5)
Install the push rod, first pressure spring and first pressure adjusting screw into the nozzle holder. Install the gasket and cap nut onto the first pressure adjusting screw.
M01070200033
(6)
Attach the nozzle holder assembly to the nozzle tester.
(7)
Adjusting the first opening pressure to the specified value with the first pressure adjusting screw. First opening pressure With new parts : 18.1-18.9 MPa {185-193 kgf/cm2, 2,632-2,745 lbf/in.2} With reused parts : 17.66-18.43 MPa {180-188 kgf/cm2, 2,561-2,673 lbf/in.2}
(8)
Holder the nozzle holder body using a adjustable wrench, then tighten the cap nut to the specified torque. Tightening Torque: 44 N⋅m {450 kgf⋅cm, 33 lbf⋅ft}
M01070200034
M01070200035
M01070200036
EN07–14
FUEL SYSTEM (J08C) 2. (1)
CHECKING OF THE NEEDLE VALVE FULL-LIFTS (WORK STEP 2.) Attach the gasket (special tool) and the plug (special tool) onto the adjustable retaining nut. SST: Gasket (026508-1140) Plug (157892-1600)
M01070200037
(2) (3)
Turn the nozzle holder body so that the cap side facing upward. Attach the holder (special tool) to the cap nut. SST: Holder (157892-4400)
(4)
Temporarily tighten the attachment nut (special tool) onto the holder. SST: Nut (157892-1000)
(5)
Screw the pin (special tool) into the dial gauge. SST: Pin (157892-4200 or 157892-4300)
M01070200038
M01070200039
FUEL SYSTEM (J08C)
EN07–15
(6)
Tighten the nut so that it holds the dial gauge in place in the nozzle holder assembly and so that the pin is in contact with the push rod upper surface. NOTICE: • Attach the dial gauge into place so that it can measure a stroke of approx. 2 mm {0.079 in.}. • Do not tighten the nut too much, or the dial gauge shaft will be stuck.
M01070200040
(7) (8)
Attach the nozzle holder assembly to the nozzle tester and adjust the dial gauge to zero. Operate the nozzle tester to bleed air in the adjustable retaining nut. Make sure that there are no fuel leaks.
M01070200041
(9)
Operate the nozzle tester to raise pressure to 34.3-44.1 MPa {350-450 kgf/cm2, 4,979-6,400 lbf/in.2} and check the needle valve lift fully. At this time, record the dimensions of full-lifts as "L". NOTICE: This check is made to determine whether the nozzle seat is abnormally worn or not and whether the nozzle is correctly assembled or not.
M01070200042
3. (1)
M01070200043
CHECKING OF THE PRE-LIFT (WORK STEP 3.) When the needle value is full-lifted, release the nozzle tester handle to lower pressure inside the tube so that decrease the needle valve lift value (value indicated on dial gauge).
EN07–16
FUEL SYSTEM (J08C) (2)
When the second pressure spring stop to action and the needle valve drop ends (the needle valve lift dimension "L'" ) read the dial gauge indication, make sure it is within specified values.
M01070200044
Pre-lift measuring points: Read the dial gauge at [First opening pressure + approx.1 MPa {10 kgf/cm2, 142 lbf/in.2}]. NOTICE: Watch the pressure decrease to find the point. Pre-lift (L'): 0.055 mm {0.0022 in.}
M01070200045
(3)
If pre-lift is not within the specified value, replace the pins, the lift piece, the spacer and the nozzle assembly with the nozzle service kit.
4.
CHECKING OF THE SECOND OPENING PRESSURE (WORK STEP 4.) Check the pre-lift, then operate the nozzle tester to raise pressure to 34.3-44.1 Mpa {350-450 kgf/cm2, 4,979-6,400 lbf/in.2} and lift the needle valve fully. Release the nozzle tester handle to lower pressure inside the tube, all the while watch the dial gauge indicate.
M01070200046
(1)
(2)
M01070200047
FUEL SYSTEM (J08C)
EN07–17
(3)
Read the value indicated on the pressure gauge at the instant the dial gauge needle indicates the specified needle valve lift value (pre-lift " L' " + 0.05 mm {0.0020 in.}). Second opening pressure With new parts : 22.1-23.1 MPa {225-235 kgf/cm2, 3,200-3,341 lbf/in.2} With reused parts : 21.6-22.6 MPa {220-230 kgf/cm2, 3,129-3,270 lbf/in.2}
5.
ADJUSTING OF THE SECOND OPENING PRESSURE (WORK STEP 5.) If the second opening pressure deviates from the specified value, and the amount of that deviation is small, readjust the first opening pressure within the specified value.
M01070200048
(1)
M01070200049
NOTICE: • If the second opening pressure is lower than the specified value, readjust the first opening pressure to maximum specified value, then measure the second opening pressure. • If the second opening pressure is higher than the specified value, readjust the first opening pressure to minimum specified value. (2)
If the first opening pressure has been readjusted and the second opening pressure still deviates from the specified value, disassemble the nozzle side of the nozzle holder and remove the adjusting shim.
(3)
If the second opening pressure is higher than the specified value, replace the adjusting shim with a thinner one. After replacing the adjusting shim, remeasure the second opening pressure, and adjust the pressure until it comes to the specified value.
(4)
M01070200050
Second opening pressure adjusting shim line-up Unit:mm {in.} Parts number
Shim thickness
22882-2850 22882-2860 22882-2870 22882-2880 22882-2890 22882-2900 22882-2910 22882-2920
0.40 {0.0157} 0.50 {0.0197} 0.52 {0.0205} 0.54 {0.0213} 0.56 {0.0220} 0.58 {0.0228} 0.60 {0.0236} 0.70 {0.0276}
EN07–18
FUEL SYSTEM (J08C) 6. (1) (2)
REPLACEMENT OF THE RETAINIG NUT (WORK STEP 6.) Remove the dial gauge, the nut, the holder and the gasket from the cap nut. Remove the adjustable retaining nut and the gasket, and attach a normal retaining nut. Tightening Torque: 68.5 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
M01070200051
7. (1)
FAINAL INSPECTION (WORK STEP 7.) Attach the nozzle holder to the nozzle tester and check the first opening pressure, the spray condition, the seat's oil seal, and whether are any oil leaks from any part.
M01070200009
(2)
To replace the nozzle, the lift piece, and the spacer, which are all in one set, with the nozzle service kit. NOTICE: Replacing only the nozzle will cause the amount of pre-lift deviate from the specified value.
M01070200052
FUEL SYSTEM (J08C)
EN07–19
IMPORTANT POINT - MOUNTING 1.
INSTALL THE NOZZLE HOLDER ASSEMBLY.
(1) (2)
Install a new O-ring into the groove of the cylinder head. Make sure that there is no dirt or foreign particles at the sealing part between the nozzle holder and related parts (O-ring, nozzle seat and injection pipe seal), and connecting part between the nozzle holder and nut of the injection pipe. (3) Insert the nozzle holder taking care not to contact the valve spring as shown in the figure. NOTICE: Apply clean engine oil to the O-ring and be careful that the O-ring is not caught. (4)
(5) (6)
M01070200025
Put the end of the injection pipe seal on the nozzle holder as shown in the figure and tighten the bolts to fasten the injection pipe seal to the camshaft housing. Tighten the nut of the injection pipe provisionally. Tighten the nozzle clamp bolt to the specified torque. Tightening Torque: 24.5 N⋅m {250 kgf⋅cm, 18.1 lbf⋅ft}
NOTICE: After tightening the bolt, make sure that the rocker arm moves smoothly. (7)
Tighten the nut of the injection pipe to the specified torque. Tightening Torque: 34.3 N⋅m {350 kgf⋅cm, 25.3 lbf⋅ft}
(8)
Install the return pipe.
TURBOCHARGER (J08C)
TURBOCHARGER (J08C)
EN08
TURBOCHARGER.................................... EN08-2 DESCRIPTION ................................................ EN08-2 TROUBLESHOOTING ..................................... EN08-3 SPECIAL TOOL ............................................. EN08-11 OVERHAUL CRITERIA.................................. EN08-12 COMPONENT LOCATOR.............................. EN08-14
EN08–1
EN08-001
EN08–2
TURBOCHARGER (J08C)
TURBOCHARGER DESCRIPTION M01080101BEC1001
M01080100001
1
Turbine housing
13
Hexagon nut
2
Compressor housing
14
Piston ring
3
Center bearing
15
Journal bearing
4
Clamp
16
Spacer
5
Bolt
17
Thrust bearing
6
Actuator bracket
18
Thrust collar
7
Actuator assembly
19
Seal ring
8
Hexagon nut
20
Backplate
9
Hose
21
Compressor wheel
10
Hose clamp
22
O-ring
11
Rod end
23
Turbine wheel assembly
12
Retaining nut
24
Wheel shroud
TURBOCHARGER (J08C)
EN08–3
TROUBLESHOOTING M01080101BEF3001
1.
Table 1-1. Troubleshooting -Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke
M01080100002
*Shown on Table 1-9
EN08–4 2.
TURBOCHARGER (J08C)
Table 1-2. Troubleshooting - Engine Exhaust Emits Blue Smoke
M01080100003
*Shown on Table 1-9
TURBOCHARGER (J08C) 3.
EN08–5
Table 1-3 Troubleshooting - Engine Oil Consumption Excessive
M01080100004
EN08–6 4.
TURBOCHARGER (J08C)
Table 1-4. Troubleshooting - Noisy Turbocharger
M01080100005
*Shown on Table 1-9
TURBOCHARGER (J08C) 5.
EN08–7
Table 1-5. Troubleshooting - Turbocharger Rotating Assembly Binding or Dragging
M01080100006
*Shown on Table 1-9
EN08–8 6.
TURBOCHARGER (J08C)
Table 1-6. Troubleshooting - Seal Leakage at Compressor End of Turbocharger
M01080100007
TURBOCHARGER (J08C) 7.
EN08–9
Table 1-7. Troubleshooting - Seal Leakage at Turbine End of Turbocharger
M01080100008
EN08–10 8.
TURBOCHARGER (J08C)
Table 1-8. Troubleshooting - Turbocharger Bearings, Bores, or Journals are Worn
M01080100009
*Overhaul turbocharger, then use this table to determine cause of failure.
TURBOCHARGER (J08C)
EN08–11
9.
Table 1-9. Troubleshooting Procedures Notes
a.
Refer to engine manufacturer's service manual for inspection requirements and replacement specifications.
b.
With engine stopped, check duct clamping devices for tightness.
c.
With engine running at idle speed, lightly spray duct connections with starting fluid. Leaks at connections will be indicated by an increase in engine speed due to the starting fluid being drawn into the compressor and pumped into the engine combustion chambers.
d.
With engine running at idle speed, check duct connections for leaks by applying lightweight oil or liquid soap to areas of possible leakage and checking for bubbles. Exhaust gas leakage between the engine block and the turbocharger inlet will also create a noise level change.
e.
With engine running at idle speed, check for unusual noise and vibration. If either condition is noted, shut down the engine immediately to protect the turbocharger and engine from further damage. With the engine stopped, check the turbocharger shaft wheel assembly for damage as outlined Note I, below.
f.
With engine running, a change in the noise level to a higher pitch can indicate air leakage between the air cleaner and the engine or a gas leak between the engine block and the turbocharger inlet.
g.
Exhaust gas leakage may be indicated by hat discoloration in the area of the leak.
h.
With the engine running, noise level cycling from one level to another can indicate a plugged air cleaner, a restriction in the air-cleaner to compressor duct, or a heavy build-up of dirt in the compressor housing or on the compressor wheel.
i.
Internal inspection of the center housing can be accomplished by removing the oil drain line and looking through the oil drain opening. When a slugged or coked condition exists, a heavy sludge build-up will be seen on the shaft between the bearing journals and in the center housing from the oil drain opening back to the turbine end.
j.
Thorough cleaning of the air intake system is essential following compressor wheel damage due to foreign object impact. in many cases, metal pieces from the wheel become imbedded in the air cleaner element. If the element is not changed, these metal pieces can be drawn into the replacement turbocharger and cause it to fail in the same manner as the original unit.
k.
With the air inlet and exhaust gas ducting removed from the turbocharger, examine both the compressor and turbine wheels for blade damage. Examine the outer blade tip edges for evidence of rubbing on housing surfaces.
•
Turn the rotating assembly by hand and feel for dragging or binding. Push the rotating assembly side-ways while rotating to feel for wheel rub. If there is any indication of rubbing, perform the bearing clearance inspection procedure. If the rotating assembly rotates freely and there is no evidence of binding or rubbing, it can be assumed that the turbocharger is serviceable.
.
SPECIAL TOOL M01080101BEK1001
Prior to starting a turbocharger overhaul, it is necessary to have this special tool. Illustration
Part number
09444-1130
Tool name
END PLAY GAUGE
Remarks
For measuring the turbine shaft end play with a dial gauge.
EN08–12
TURBOCHARGER (J08C)
OVERHAUL CRITERIA M01080101BEH3001
1.
CONDITION WHICH DETERMINE WHEN A TURBOCHARGER OVERHAUL MAY BE NEEDED ON ENGINE TROUBLESHOOTING.
The most common symptoms of turbocharger failure are related to engine performance:
• Lack of power • Excessive exhaust smoke • Unusual noise • Excessive oil or fuel consumption. NOTICE: Any of these symptoms could be the result of an internal engine problem, and might not involve the turbocharger at all. 2.
EXAMINE THE TURBOCHARGER EXTERIOR AND INSTALLATION. CAUTION: Do not work on the turbocharger while it is still hot. This can result personal injury. Visually check for: • Missing or loose nuts and bolts. • Loose or damaged intake and exhaust pipe. • Damaged oil supply and drain lines. • Cracked or deteriorating turbocharger housings. • External oil or coolant leakage. Correct any installation problems. If turbocharger parts are damaged, the unit should be overhauled after completion of the remainder of this troubleshooting procedure. CAUTION: Operation of the turbocharger without the intake pipe and air cleaner connected can result in personal injury and damage to equipment from foreign objects entering the turbocharger. 3.
INSPECTION TURBINE WHEEL AND HOUSING.
Remove the duct from the turbine outlet. Using a flash-light, check the turbine for wheel to housing rub, evidence of oil leakage or foreing object damage. Foreign object damage to the turbine is not usually visible through the turbine outlet unless the damage is severe. (1)
(2) M01080100011
(3)
Wheel to housing rub a. If wheel rub is found, and the housing attaching hardware is secure, then the turbocharger is probably damaged internally and must be overhauled. Oil leakage a. If oil deposits are found, determine whether the oil has come from the engine exhaust or from the turbocharger center housing. b. If the oil has come from the engine, consult CHAPTER ENGINE MECHANICAL and correct the problem. If oil deposits on the wheel are heavy the turbocharger should be disassembled, cleaned, and overhauled if necessary. Foreign object damage a. If foreign object damage to the turbine is visible, the turbocharger must be overhauled. Such damage destroys the wheel's balance and causes internal damage to the seal bores and journal bearings. Be sure to find the source of the foreign object. In many cases, the object has come out of the engine, and there may be engine damage as well.
TURBOCHARGER (J08C) 4.
EN08–13
EXAMINE COMPRESSOR WHEEL AND HOUSING.
Remove the ducting from the compressor inlet. Using a flashlight, check the compressor for wheel to housing rub, evidence of oil leakage, or foreign object damage. (1)
(2) M01080100012
(3)
5. (1)
Wheel to housing rub If wheel rub is found, and the housing attaching hardware is secure, then the turbocharger is probably damaged internally and must be overhauled. Oil leakage Oil leakage into the compressor can be caused by: a. Long periods of idling on a restricted oil drain line. b. Oil leakage into the compressor can also be caused by a restricted air intake system. c. Oil leakage into the compressor can be caused by frequent use of the engine as a brake. In this case, nothing is wrong with either the engine or the turbocharger, but frequent compressor wheel and housing clean-up is recommended. Foreign object damage If the compressor wheel has been damaged by a foreign object, the turbocharger must be overhauled. CHECK ROTATING ASSEMBLY FOR NOISE OR EXCESSIVE PLAY. If no damage is visible in the turbine and compressor areas, spin the rotating assembly by hand. It should spin freely with no drag or grinding noises.
M01080100013
6. (1)
CHECK AXIAL BEARING CLEARANCES. Check the turbine rotor (exhaust side) for axial play using the special tool and dial gauge. SST: End play gauge (09444-1130) Service limit: 0.045-0.090 mm {0.0018-0.0035 in.}
(2)
If the measurement is out of service limit, the turbocharger is worn or damaged internally and must be overhauled.
7. (1) (2)
CHECK WASTEGATE PERFORMANCE. Remove hose clamps and hose from wastegate sensing port. Attach a dial gauge, set to the turbocharger so that the dial gauge rests on the end of the actuator rod in the plane of the rod, as applicable.
M01080100014
(3) (4)
Set the dial indicator to zero. While gently tapping the turbine housing with a soft mallet, apply air pressure until the rod movement shows 0.38 mm {0.015 in.} on the dial gauge. Make sure that this pressure is within the specified value. Specified air pressure:
DIAL GAUGE
M01080100015
Parts No.
Air pressure: kPa {mmHg, inHg}
24100-3251
130-136 {975-1,025, 39-40}
EN08–14
TURBOCHARGER (J08C) (5)
Release the air pressure at the sensing port. Note that the dial gauge pointer returns exactly to zero. (6) Repeat steps (4) through (5) several times to make sure that wastegate valve or rod movement has been accurately measured. (7) If the specified value or rod movement cannot be obtained within the specified air pressure range.The turbine housing assembly or actuator assembly must be replaced. NOTICE: Operation of the engine with the wastegate calibrated to some value other than that specified can result in reduced performance or severe engine damage. (8)
If wastegate performance is within specification, install the hose onto the wastegate sensing port.
ALTERNATOR (J08C: 24V-50A)
ALTERNATOR (J08C: 24V-50A)
EN1
ALTERNATOR........................................... EN11-2 DATA AND SPECIFICATIONS ......................... EN11-2 DESCRIPTION ................................................ EN11-2 TROUBLESHOOTING ..................................... EN11-4 COMPONENT LOCATOR................................ EN11-5 SPECIAL TOOL ............................................... EN11-7 OVERHAUL ..................................................... EN11-7 INSPECTION AND REPAIR .......................... EN11-14
EN11–1
EN11-001
EN11–2
ALTERNATOR (J08C: 24V-50A)
ALTERNATOR DATA AND SPECIFICATIONS M01110101BEI2001
Nominal voltage
24V
Nominal output
24V-50A
Max. output
50A at 28V, 5,000 r/min
Initial output starting speed
950 r/min at 27V
Max. rotating
8,400 r/min
Rotating direction
Right (seen from pulley side)
Regulator
Mount-on
DESCRIPTION M01110101BEC1001
M01110100001
1
Rectifier holder
8
Fan
2
Lead wire connector
9
Pulley
3
Regulator
10
Ball bearing
4
Condenser
11
Drive end frame
5
Field coil
12
Retainer plate
6
Rotor assembly
13
Rectifier end frame
7
Stator assembly
14
Diode
ALTERNATOR (J08C: 24V-50A)
EN11–3
CIRCUIT
1 2 3
8
B
10
L R
7
P
9
5 6
11
4
E
M01110100002
1
Alternator
7
Charge warning lamp
2
Condenser
8
Fuse
3
Diode
9
Starter switch
4
Stator coil
10
Load
5
Field coil
11
Battery
6
IC Regulator
EN11–4
ALTERNATOR (J08C: 24V-50A)
TROUBLESHOOTING M01110101BEF3001
Symptom
Possible cause
Remedy/Prevention
Charging current does not flow I.C. regulator faulty Replace I.C. regulator. (Lamp does not light) Stator coil faulty (Disconnecting or Replace stator coil. rare short) Field coil faulty (Disconnecting or rare Replace field coil. short) Diode faulty (Open or short circuit)
Replace rectifier holder.
Lead wiring disconnected or loose Repair or replace. (Plate, support etc...) Wiring disconnection (Including fuse) Voltmeter indicates 29V or more I.C. regulator faulty (Lamp does not light) I.C. regulator installation faulty Installation support)
Replace. Replace I.C. regulator.
(EX: Repair or replace.
Charging current flows normally I.C. regulator faulty (Lamp does not light)
Replace I.C. regulator.
Charging current is always insuffi- Stator coil faulty Replace stator coil. cient (Battery goes dead) (Lamp Diode faulty (open or short circuit) Replace rectifier holder. remains dark) Lead wiring disconnecting or loose Repair or replace. (Plate or support) Volume of using load is too high (Vol- Decrease the load. ume of using load is imbalance) Charging current is always too I.C. regulator faulty Replace stator coil. great (Battery does dry in short I.C. regulator installation faulty (EX: Replace rectifier holder. amount of time) (Lamp remains Installation of support) dark) Battery nearly over its life period Repair it. Abnormal noise
Stator coil faulty (Rare short, earth)
Replace stator coil.
Bumping inside (Bearing inside and Repair or replace. bracket abrasion) Tension of belt faulty (Belt slip)
Repair.
ALTERNATOR (J08C: 24V-50A)
EN11–5
COMPONENT LOCATOR M01110101BED1001
M01110100040
1
Brace
4
Bracket
2
Harness
5
V-bolt
3
Alternator
6
Strap band
Tightening torque A 5.9 {60, 4.3}
C
3.3-4.4 {33-45, 2.4-3.2}
B
D
83 {850, 61}
51 {520, 38}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
EN11–6
ALTERNATOR (J08C: 24V-50A)
M01110100003
1
Cover
13
Field coil
2
Condenser
14
Stator assembly
3
Regulator
15
Roller bearing
4
Terminal insulator
16
Rotor assembly
5
Terminal insulator
17
Retainer plate
6
Rectifier holder
18
Ball bearing
7
Holder
19
Drive end frame
8
Terminal bolt
20
Space collar
9
Clamp
21
Fan
10
Lead wire connector
22
Pulley
11
Rectifier end frame
23
Lock nut
12
Through bolt
Tightening torque A 3.2-4.4 {33-45, 2.4-3.2}
Unit: N⋅m {kgf⋅cm, lbf⋅ft} E
2.9-3.9 {30-40, 2.2-2.8}
B
3.9-4.9 {40-50, 2.9-3.6}
F
7.8-9.8 {80-100, 5.8-7.2}
C
127-157 {1,300-1,600, 95-115}
G
1.9-2.5 {19-25, 1.4-1.8}
D
1.9-2.5 {19-25, 1.4-1.8}
ALTERNATOR (J08C: 24V-50A)
EN11–7
SPECIAL TOOL M01110101BEK1001
Prior to starting a alternator overhaul, it is necessary to have this special tool. Illustration
Part number
Tool name
09444-1210
Remarks
COMPRESSION GAUGE
OVERHAUL M01110101BEH2001
IMPORTANT POINTS - MOUNTING
FIXING NUT A
COOLANT PUMP PULLEY
ADJUSTING BOLT
ALTERNATOR PULLE Y
CRANK SHAFT PULLEY
1. (1) (2) (3)
THROUGH BOLT
ADJUST THE ALTERNATOR V-BELT DEFLECTION. Loosen the through bolt and the fixing nut. Apply a load of about 98N {10 kgf} by pressing the measuring point A. Turn the adjusting bolt, and adjust the deflection of the belt at measuring point A, so that it comes within the standard value. SST: Compression gauge (09444-1210) Standard: 8-10 mm {0.314-0.394 in.}
M01110100046
NOTICE: • When installing a new V-belt, be sure to repeat the adjustment two or three times, after running the engine. • When adjusting the V-belt, do not apply the lever directly against the alternator. (4) (5) (6)
After adjusting the deflection, tighten the through bolt and then securely tighten the fixing nut. Retighten the adjusting bolt. Connecting the harness.
IMPORTANT POINTS - DISASSEMBLY 1.
DISASSEMBLE THE RECTIFIER END FRAME AND DRIVE END FRAME. (1) Remove the cover. NOTICE: On removing the cover, push the cover claws part. In this time, take care not to damage claws part pushing by full force.
M01110100004
(2)
M01110100005
Remove the bolt and clamp.
EN11–8
ALTERNATOR (J08C: 24V-50A) (3)
Remove the through bolts, disassemble the rectifier end frame and drive end frame.
M01110100006
2. REMOVE THE ROTOR. (1) Remove the pulley lock nut. NOTICE: Wind V-belt around pulley groove and grip it securely in a vice so that pulley is held with V-belt as a cushion. (2)
Remove the pulley and fan.
M01110100007
(3) Remove the rotor from drive end frame, using a press. NOTICE: Hold rotor by hand so that it will not fall off.
M01110100008
3. (1)
REMOVE THE FRONT BALL BEARING. Remove the retainer plate.
M01110100009
(2) Using a press, remove the ball bearing. NOTICE: Attach the jig to inner race of the ball bearing and remove bearing, using a press.
M01110100010
ALTERNATOR (J08C: 24V-50A) 4. (1)
EN11–9
REMOVE THE STATOR. Unsolder the lead wire from the stator and remove it by pulling gently.
NOTICE: Unsolder the wiring connections at the stator and diode and take off excess solder spread claws part at the connections and disconnect stator lead wires.
M01110100011
(2)
Remove the stator from the rectifier end frame.
5. (1)
REMOVE THE RECTIFIER HOLDER, REGULATOR AND FIELD COIL. Unsolder lead wire from field coil.
(2)
Remove the rectifier holder, regulator and condenser.
(3)
Loosen the "B" terminal nut.
M01110100012
M01110100013
M01110100015
M01110100014
EN11–10
ALTERNATOR (J08C: 24V-50A) (4)
Remove the field coil.
M01110100016
6. REMOVE THE ROLLER BEARING. NOTICE: Attach the jig to inner race of the roller bearing and remove roller bearing, using a press.
M01110100017
IMPORTANT POINTS - ASSEMBLY 1. (1)
INSTALL THE ROTOR. Using a press and a jig, install the ball bearing into the drive end frame. NOTICE: Attach the jig on the outer race of the ball bearing.
M01110100018
(2)
M01110100009
Install the retainer plate.
ALTERNATOR (J08C: 24V-50A) (3)
EN11–11
Using a press, install the rotor.
NOTICE: Take care not to damage the rotor shaft.
M01110100019
(4) Install the space collar, fan and pulley, tighten the lock nut. NOTICE: Wind V-belt around pulley groove and grip it securely in a vice so that pulley is held with V-belt as a cushion.
M01110100020
2. (1)
INSTALL THE ROLLER BEARING. Using a press, jig A and jig B, install the roller bearing into the rectifier end frame. NOTICE: Press fit until jig A hits to the rectifier end frame.
M01110100021
3.
INSTALL THE FIELD COIL, REGULATOR AND RECTIFIER HOLDER. (1) Install the field coil to the rectifier end frame. NOTICE: Tighten the bolt evenly.
M01110100022
EN11–12
ALTERNATOR (J08C: 24V-50A) (2)
Refer to " COMPONENT LOCATOR ", then install the each parts.
(3)
Install the stator coil to the rectifier end frame.
M01110100023
NOTICE: Do not damage the stator coil.
M01110100024
(4)
Using a solder ring iron, solder the lead wire connecting the regulator and field coil as well as the stator coil and diode.
(5)
Install the condenser.
(6)
Tighten the inner nut of the B terminal.
M01110100025
M01110100026
4.
ASSEMBLE THE RECTIFIER END FRAME AND DRIVE END FRAME. (1) Assemble the rectifier end frame and drive end frame with the through bolts. NOTICE: Tighten the through bolt evenly.
M01110100027
ALTERNATOR (J08C: 24V-50A) (2)
EN11–13
Install the cover.
M01110100028
PERFORMANCE TEST NOTICE: • Note the battery polarity carefully so as not to make reverse connections. If the connections are reversed, the diodes will short the circuit and allow a large current to flow through and damage the diodes and I.C. regulator as well as burning the wiring harness. • Take care not to make wrong connections of terminals. • When charging the battery with a quick charge, disconnect the battery terminals. • Do not perform tests with high voltage insulation resistance tester. • In operation, never disconnect the battery. 1. (1) (2)
2. (1) M01110100029
ALTERNATOR PERFORMANCE TEST Turn switch SW1 on and SW2 off to increase the revolution of the alternator slowly. When voltage reaches 28V, turn on switch SW2 to regulate load resistance. Increase the revolution of the rotor keeping voltage at 28V. Standard output speed: 4,000 r/min at 27.5V 50A VOLTAGE REGULATOR TEST Turn switch SW1 on and SW2 off to increase the revolution of the rotor to 5,000 r/min. Standard voltage: 28.0-29.0V
EN11–14
ALTERNATOR (J08C: 24V-50A)
INSPECTION AND REPAIR M01110101BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Measure
Resistance of field coil [at 20°C (68°F)]
6.75-7.45Ω
—
Replace.
Measure Insulation resistance of field coil
1MΩ
0.5MΩ or less
Replace.
Measure
Resistance of stator coil [at 20°C (68°F)]
0.247-0.273Ω
—
Replace.
Measure
Insulation resistance of stator
1MΩ or more
0.5MΩ or less
Replace.
Measure
Resistance of diode
Normal direction 7-10Ω Reverse direction ∞Ω
—
Replace.
Measure Rotor shaft outside diameter (front bearing portion)
25 {0.984}
24.98 {0.984}
Replace.
Measure Rotor shaft outside diameter (rear bearing portion)
17 {0.669}
16.98 {0.669}
Replace.
ALTERNATOR (J08C: 24V-50A)
Inspection item
Standard
Limit
Remedy
EN11–15
Inspection procedure Measure
Drive end frame bearing bore inside diameter
62 {2.441}
62.1 {2.445}
Replace.
Measure Rectifier end frame bearing bore inside diameter
23.8 {0.937}
23.81 {0.937}
Replace.
Visual check
Bearing wear or damage
Rotates smoothly with no abnormal noise
—
Replace. Also, replace every 2 years.
ALTERNATOR (J08C: 24V-80A)
ALTERNATOR (J08C: 24V-80A)
EN1
ALTERNATOR........................................... EN11-2 DATA AND SPECIFICATIONS ......................... EN11-2 DESCRIPTION ................................................ EN11-2 TROUBLESHOOTING ..................................... EN11-4 COMPONENT LOCATOR................................ EN11-5 SPECIAL TOOL ............................................... EN11-6 OVERHAUL ..................................................... EN11-7 INSPECTION AND REPAIR .......................... EN11-15
EN11–1
EN11-002
EN11–2
ALTERNATOR (J08C: 24V-80A)
ALTERNATOR DATA AND SPECIFICATIONS M01110101BEI2001
Nominal voltage
24V
Nominal output
24V-80A
Max. output
80A at 28V, 5,000 r/min
Initial output starting speed
900 r/min at 27V
Max. rotating
8,400 r/min
Rotating direction
Right (seen from pulley side)
Regulator
Mount-on
DESCRIPTION M01110101BEC1001
M01110100047
1
Rectifier
7
Fan with pulley
2
Lead wire connector
8
Ball bearing
3
Condenser
9
Retainer plate
4
Regulator
10
Drive end frame
5
Rotor assembly
11
Field coil
6
Stator coil
12
Rectifier end frame
ALTERNATOR (J08C: 24V-80A)
EN11–3
CIRCUIT
1 2 3
8
B
10
L R
7
P 5
9
N 6
11
4
E
M01110100048
1
Alternator
7
Charge warning lamp
2
Condenser
8
Fuse
3
Diode
9
Starter switch
4
Stator coil
10
Load
5
Field coil
11
Battery
6
IC Regulator
EN11–4
ALTERNATOR (J08C: 24V-80A)
TROUBLESHOOTING M01110101BEF3001
Symptom
Possible cause
Remedy/Prevention
Charging current does not flow I.C. regulator faulty Replace I.C. regulator. (Lamp does not light) Stator coil faulty (Disconnecting or Replace stator coil. rare short) Field coil faulty (Disconnecting or rare Replace field coil. short) Diode faulty (Open or short circuit)
Replace rectifier holder.
Lead wiring disconnected or loose Repair or replace. (Plate, support etc...) Wiring disconnection (Including fuse) Voltmeter indicates 29V or more I.C. regulator faulty (Lamp does not light) I.C. regulator installation faulty Installation support)
Replace. Replace I.C. regulator.
(EX: Repair or replace.
Charging current flows normally I.C. regulator faulty (Lamp does not light)
Replace I.C. regulator.
Charging current is always insuffi- Stator coil faulty Replace stator coil. cient (Battery goes dead) (Lamp Diode faulty (open or short circuit) Replace rectifier holder. remains dark) Lead wiring disconnecting or loose Repair or replace. (Plate or support) Volume of using load is too high (Vol- Decrease the load. ume of using load is imbalance) Charging current is always too I.C. regulator faulty Replace stator coil. great (Battery does dry in short I.C. regulator installation faulty (EX: Replace rectifier holder. amount of time) (Lamp remains Installation of support) dark) Battery nearly over its life period Repair it. Abnormal noise
Stator coil faulty (Rare short, earth)
Replace stator coil.
Bumping inside (Bearing inside and Repair or replace. bracket abrasion) Tension of belt faulty (Belt slip)
Repair.
ALTERNATOR (J08C: 24V-80A)
EN11–5
COMPONENT LOCATOR M01110101BED1001
M01110100049
1
Distance piece
4
Bracket
2
Brace
5
V-belt
3
Alternator
C
83 {850, 61}
Tightening torque A 5.9 {60, 4.3} B
51 {520, 38}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
EN11–6
ALTERNATOR (J08C: 24V-80A)
M01110100050
1
Cover
12
Regulator
2
Rectifier
13
Field coil
3
Holder
14
Stator coil
4
Rectifier
15
Rotor assembly
5
Terminal insulator
16
Retainer plate
6
Connector
17
Shim
7
Holder insulator
18
Ball bearing
8
Condenser
19
Cover
9
Lead wire connector
20
Drive end frame
10
Rectifier end frame
21
Fan with pulley
11
Roller bearing
22
Lock nut
C
Unit: N⋅m {kgf⋅cm, lbf⋅ft} 113-147 {1,150-1,500, 84-108}
Tightening torque A 3.2-4.4 {33-45, 2.4-3.2} B
2.9-3.9 {30-40, 2.2-2.8}
SPECIAL TOOL M01110101BEK1001
Prior to starting an alternator overhaul, it is necessary to have this special tool. Illustration
Part number
09444-1210
Tool name
COMPRESSION GAUGE
Remarks
ALTERNATOR (J08C: 24V-80A)
EN11–7
OVERHAUL M01110101BEH2001
IMPORTANT POINTS - MOUNTING
FIXING BOLT A
ADJUSTING BOLT ALTERNATOR PULLE Y
COOLANT PUMP PULLEY
CRANK SHAFT PULLEY
1. (1) (2) (3)
THROUGH BOLT
ADJUST THE ALTERNATOR V-BELT DEFLECTION. Loosen the through bolt and the fixing bolt. Apply a load of about 98N {10 kgf} by pressing the measuring point A. Turn the adjusting bolt, and adjust the deflection of the belt at measuring point A, so that it comes within the standard value. SST: Compression gauge (09444-1210) Standard: 8-10 mm {0.314-0.394 in.}
M01110100051
NOTICE: • When installing a new V-belt, be sure to repeat the adjustment two or three times, after running the engine.
•
When adjusting the V-belt, do not apply the lever directly against the alternator.
(4)
After adjusting the deflection, tighten the through bolt and then securely tighten the fixing bolt. Retighten the adjusting bolt. Connecting the harness.
(5) (6)
IMPORTANT POINTS - DISASSEMBLY 1. (1)
DISASSEMBLE THE RECTIFIER END FRAME AND DRIVE END FRAME. Remove the cover.
M01110100052
(2)
M01110100053
Remove the through bolts, disassemble the rectifier end frame and drive end frame.
EN11–8
ALTERNATOR (J08C: 24V-80A) 2. REMOVE THE ROTOR. (1) Remove the pulley lock nut. NOTICE: Wind V-belt around pulley groove and grip it securely in a vice so that pulley is held with V-belt as a cushion. (2)
Remove the fan with pulley.
M01110100054
(3) Remove the rotor from drive end frame, using a press. NOTICE: Hold rotor by hand so that it will not fall off.
M01110100008
3. (1)
REMOVE THE FRONT BALL BEARING. Remove the retainer plate and shim.
M01110100055
(2) Using a press, remove the ball bearing. NOTICE: Attach the jig to inner race of the ball bearing and remove the ball bearing, using a press.
M01110100010
4. (1)
M01110100056
DISASSEMBLE THE RECTIFIER END FRAME. Remove the clamp and connector.
ALTERNATOR (J08C: 24V-80A) (2)
EN11–9
Unsolder the stator coil lead wires from the diode.
NOTICE: Raise the positive diode terminal upward, then unsolder the stator lead wires form the negative diode terminal.
M01110100057
(3)
Unsolder the field coil lead wires and condenser lead wire from the connector.
NOTICE: After opening the crimped section, remove the soldered portion.
M01110100058
(4)
Unsolder the lead wire P and stator coil lead wire from the connector.
NOTICE: After opening the crimped section, remove the soldered portion.
M01110100059
(5)
Unsolder the lead wires from the regulator. (connector lead wire L, lead wire N, lead wire R, field coil lead wire, stator coil lead wire N)
(6)
Loosen the B terminal nut.
M01110100060
NOTICE: Loosen the nut part way but make sure that it does not come off of bolt B.
M01110100061
EN11–10
ALTERNATOR (J08C: 24V-80A) (7)
Remove the regulator fixing bolt, then remove the terminal insulator.
(8)
Refer to "COMPONENT LOCATOR", then remove the each parts.
(9)
Remove the bolts, then remove the connector with lead wire, clamp, connector and regulator.
M01110100062
M01110100063
M01110100064
(10) Remove the condenser.
M01110100065
5.
M01110100066
REMOVE THE RECTIFIER END FRAME FROM STATOR COIL.
ALTERNATOR (J08C: 24V-80A)
EN11–11
6. (1)
REMOVE THE FIELD COIL. Remove the bolt, then remove the field coil from the rectifier end flame.
7. (1)
REMOVE THE ROLLER BEARING. Using a press, jig A and jig B, remove the roller bearing.
M01110100067
M01110100068
IMPORTANT POINTS - ASSEMBLY 1. (1)
INSTALL THE ROTOR. Using a press and a jig, install the ball bearing into the drive end frame. NOTICE: Attach the jig on the outer race of the ball bearing.
M01110100018
(2)
M01110100069
Install the retainer plate. Tightening Torque: 1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}
EN11–12
ALTERNATOR (J08C: 24V-80A) (3)
Using a press, install the rotor.
NOTICE: Take care not to damage the rotor shaft.
M01110100019
(4) Install the fan with pulley, tighten the lock nut. NOTICE: Wind V-belt around pulley groove and grip it securely in a vice so that pulley is held with V-belt as a cushion.
M01110100020
2. (1)
INSTALL THE ROLLER BEARING. Using a press, jig A and jig B, install the roller bearing into the rectifier end frame. NOTICE: Press fit until jig A hits the rectifier end frame.
M01110100021
3. (1)
M01110100070
INSTALL THE FIELD COIL. Install the field coil to the rectifier end frame. Tightening Torque: 2.9-3.9 N⋅m {30-40 kgf⋅cm, 2.2-2.8 lbf⋅ft}
ALTERNATOR (J08C: 24V-80A)
EN11–13
4. (1)
ASSEMBLE THE RECTIFIER END FRAME. Install the condenser.
(2)
Refer to "COMPONENT LOCATOR", then install the each parts. Tightening Torque: Rectifier and regulator fixing bolt: 1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}
(3)
Install the rectifier end frame to the stator coil.
M01110100071
M01110100072
NOTICE: Do not damage the stator coil.
M01110100073
(4)
Using a soldering iron, solder the lead wires to the regulator. (connector lead wire L, lead wire N, lead wire R, field coil lead wire, stator coil lead wire N)
(5)
Using a soldering iron, solder the lead wire P to the connector.
M01110100074
M01110100075
EN11–14
ALTERNATOR (J08C: 24V-80A) (6)
Using s soldering iron, solder the stator coil lead wire, diode lead wire and connector.
(7)
Using a soldering iron, solder the stator coil lead wires to the diode.
(8)
Install the connector and clamp. Tightening Torque: 1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}
5.
ASSEMBLE THE RECTIFIER END FRAME AND THE DRIVE END FRAME. Assemble the rectifier end frame and the drive end frame with the through bolts.
M01110100076
M01110100077
M01110100078
(1)
NOTICE: Tighten the through bolt evenly.
M01110100079
(2)
M01110100080
Install the cover. Tightening Torque: 1.9-2.5 N⋅m {19-25 kgf⋅cm, 1.4-1.8 lbf⋅ft}
ALTERNATOR (J08C: 24V-80A)
EN11–15
PERFORMANCE TEST NOTICE: • Note the battery polarity carefully so as not to make reverse connections. If the connections are reversed, the diodes will short the circuit and allow a large current to flow through and damage the diodes and I.C. regulator as well as burning the wiring harness. • Take care not to make wrong connections of terminals. • When charging the battery with a quick charge, disconnect the battery terminals. • Do not perform tests with high voltage insulation resistance tester. • In operation, never disconnect the battery. 1. (1) (2)
2. (1) M01110100029
ALTERNATOR PERFORMANCE TEST Turn switch SW1 on and SW2 off to increase the revolution of the alternator slowly. When voltage reaches 28V, turn on switch SW2 to regulate load resistance. Increase the revolution of the rotor keeping voltage at 28V. Standard output speed: 4,000 r/min at 27.5V 80A VOLTAGE REGULATOR TEST Turn switch SW1 on and SW2 off to increase the revolution of the rotor to 5,000 r/min. Standard voltage: 28.0-29.0V
INSPECTION AND REPAIR M01110101BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Measure
Resistance of field coil [at 20°C (68°F)]
5.86-6.51 Ω
—
Replace.
Measure Insulation resistance of field coil
1 MΩ or more
0.5MΩ or less
Replace.
Measure
Resistance of stator coil [at 20°C (68°F)]
0.152-0.168 Ω
—
Replace.
EN11–16
Inspection item
ALTERNATOR (J08C: 24V-80A)
Standard
Limit
Remedy
Inspection procedure Measure
Insulation resistance of stator
1MΩ or more
0.5MΩ or less
Replace.
Measure Normal direction 7-10Ω Resistance of diode
—
Replace.
Reverse direction ∞Ω
Measure Rotor shaft outside diameter (front bearing portion)
30 {1.181}
29.98 {1.180}
Replace.
Measure Rotor shaft outside diameter (rear bearing portion)
17 {0.669}
16.98 {0.669}
Replace.
Measure
Drive end frame bearing bore inside diameter
72 {2..835}
72.1 {2.839}
Replace.
Measure Rectifier end frame bearing bore inside diameter
23.8 {0.937}
23.81 {0.937}
Replace.
Visual check
Bearing wear or damage
Rotates smoothly with no abnormal noise
—
Replace. Also, replace every 2 years.
STARTER (J08C)
STARTER (J08C)
EN 12
STARTER .................................................. EN12-2 DATA AND SPECIFICATIONS ......................... EN12-2 DESCRIPTION ................................................ EN12-2 TROUBLESHOOTING ..................................... EN12-3 COMPONENT LOCATOR................................ EN12-4 OVERHAUL ..................................................... EN12-5 INSPECTION AND REPAIR .......................... EN12-12
EN12–1
EN12-001
EN12–2
STARTER (J08C)
STARTER DATA AND SPECIFICATIONS M01120101BEI2001
Type
Reduction gear type
Rated output
24 V, 4.5 kW
Number of teeth of pinion
11
Module
3
Rotating direction
Clockwise (Seen from pinion side)
DESCRIPTION M01120101BEC1001
M01120100001
1
Holder assembly
7
Pinion gear
2
Brush
8
Drive housing assembly
3
Yoke assembly
9
Gear housing
4
Magnetic switch assembly
10
Armature assembly
5
Lever
11
Field coil
6
Drive shaft assembly
12
Commutator end frame
STARTER (J08C)
EN12–3
TROUBLESHOOTING M01120101BEF3001
Symptom
Possible cause
Remedy/Prevention
Engine does not crank, or cranks Poor contact slowly. (Starter switch)
Clean or replace contacts.
Engine does not crank, or cranks Discharged battery slowly. (Battery) Short circuited between electrodes
Charge.
Poor contact at battery terminal Engine does not crank, or cranks Improper viscosity oil slowly. (Engine oil)
Replace battery. Clean or retighten. Change oil.
Engine does not crank, or cranks Poor contact caused by burnt contact Clean or replace contact plate. slowly. (Magnetic switch) plate Contact plate worn out
Repair.
Holding coil disconnected (Overrun- Replace field coil. ning clutch moves back and forth) Pull-in coil disconnected or short cir- Replace. cuited Engine does not crank, or cranks Defective or poor contact slowly. (Starter relay)
Repair or replace.
Engine does not crank, or cranks Brush worn out slowly. (Starter) Commutator burnt out
Replace. Correct on lathe.
Commutator worn out
Correct by undercutting.
Field winding shorted or grounded
Rewind or replace.
Armature winding shorted or grounded Replace armature. Insufficient brush spring tension
Replace brush spring.
Poor contact between magnetic switch Repair. and field windings Armature contact pole core because of Replace bearing brush or armature. worn bearing bushing or bent armature shaft Overrunning clutch malfunction
Replace.
Engine does not crank while starter Overrunning clutch malfunction is running in good condition (Over- Pinion teeth worn out running clutch) Poor sliding of spline teeth
Replace.
Starter does not stop running. Contacts keep closing (Starter switch) Key switch sticks Overrunning clutch sticks to armature Starter does not stop running. Contacts keep closing (Starter relay)
Replace. Remove replace.
foreign
particles,
dirt
or
Replace. Replace. Repair or replace overrunning armature. Repair or replace.
or
EN12–4
STARTER (J08C)
COMPONENT LOCATOR M01120101BED1001
M01120100002
STARTER (J08C) 1
"C" terminal lead
14
Spring
2
Magnetic switch assembly
15
Holder
3
O-ring
16
Pin
4
Through bolt
17
Lever
5
Commutator end frame
18
Packing
6
Brush holder assembly
19
Plate
7
Brush spring
20
Drive shaft assembly
8
Brush
21
Drive housing assembly
9
Yoke assembly
22
Bushing
10
Felt
23
Dust cover
11
Armature assembly
24
Pinion gear
12
Needle roller bearing
25
Retainer ring
13
Gear housing
26
Starter
Tightening torque A 14-16 {140-160, 10.2-11.5}
E
2-3 {19-25, 1.4-1.8}
B
4-5 {37-50, 2.7-3.6}
F
154 {1,570, 114}
C
14-16 {140-160, 10.2-11.5}
G
12-15 {125-155, 10-11}
D
154 {1,570, 114}
EN12–5
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
OVERHAUL M01120101BEH2001
IMPORTANT POINTS - DISASSEMBLY When disassembling the starter, prepare a work stand as shown in the figure. D:Diameter = 110 mm {4.331 in.} T:Thickness = 10 mm {0.394 in.} H:Height = 120 mm {4.724 in.}
M01120100003
M TERMINAL LEAD
CAP
CAP
C TERMINAL LEAD
M01120100004
1. (1) (2)
REMOVE THE TERMINAL LEAD. Remove the bolt, disconnect the "C" terminal lead. Remove the nut, disconnect the "M" terminal lead.
EN12–6
STARTER (J08C) 2. (1)
REMOVE THE COMMUTATOR END FRAME. Remove the through bolt.
(2)
Remove the bolt and O-ring, remove the commutator end frame.
3. (1)
REMOVE THE HOLDER ASSEMBLY. Using a long nose plier, remove the brush of the yoke from the holder.
M01120100005
COMMUTATOR END FRAME
M01120100006
M01120100007
(2) Remove the holder assembly from the armature. NOTICE: Do not cut the fixed clamp of brush lead.
M01120100008
STARTER (J08C) 4.
G1
(1)
EN12–7
REMOVE THE YOKE ASSEMBLY AND ARMATURE ASSEMBLY. Remove the yoke assembly and armature assembly from the gear housing.
G1
M01120100009
5. REMOVE THE START MAGNET SWITCH ASSEMBLY. (1) Remove two bolts. (2) Remove the start magnet switch assembly. NOTICE: When removing the start magnet switch assembly, tilt the head of the start magnet switch assembly to the side A, and then remove it pulling to the side B (upper side).
A
B
M01120100010
6. (1)
REMOVE THE DRIVE SHAFT ASSEMBLY. Remove the gear housing from the drive housing
(2) (3)
Remove the retainer ring. Remove the pinion gear.
(4)
Remove the lever and drive shaft assembly from the drive housing.
M01120100011
M01120100012
PIN
HOLDER LEVER
SHAFT ASSEMBLY M01120100013
EN12–8
STARTER (J08C)
IMPORTANT POINTS - ASSEMBLY DRIVE HOUSING DUST SEAL
BUSHING
1. (1)
INSTALL THE DRIVE SHAFT ASSEMBLY. Fill up the grease (Multemp AC-N) to the reservoir from bushing hole that until overflow from other hole.
(2) (3)
Assemble the holder, pin and lever. Apply the grease (G1: Multemp AC-N, G2: Pyronoc No.2) to the portion as shown in the figure.
HOLE
RESERVOIR M01120100014
HOLDER G1
(4)
Install the drive shaft assembly and lever into the drive housing assembly at the same time. NOTICE: Make sure that the holder is installed securely and it slides smoothly.
G2
G2
G1 M01120100015
2. (1)
INSTALL THE PINION GEAR. Put the drive shaft assembly on the working bench. Using a brass bar and a hammer, install the pinion gear in the drive shaft assembly with tapping the pinion gear evenly.
(2)
Using a pair of pliers, install a new retainer ring in the drive shaft assembly to fix the pinion gear. NOTICE: Install the pinion gear facing its chamfered surface outward.
M01120100016
PACKING
PLATE G1
3.
INSTALL THE GEAR HOUSING.
(1)
Apply the grease (G1: Multemp AC-N) to the portion as shown in the figure. Install the spring, new packing and plate. Install the gear housing.
SPRING
(2) (3)
G1
M01120100017
STARTER (J08C)
EN12–9
4. INSTALL THE START MAGNET SWITCH ASSEMBLY. (1) Install the start magnet switch assembly. NOTICE: When installing the start magnet switch assembly, tilt the head of the start magnet switch assembly to the side A, and then insert it into direction B.
A
B
M01120100046
5. (1)
G1
G1
(2) (3)
INSTALL THE ARMATURE ASSEMBLY. Apply the grease (G1: Multemp AC-N) to the portion as shown in the figure. Install the new felt to the armature assembly. Install the armature assembly to the gear housing.
6. (1)
INSTALL THE YOKE ASSEMBLY. Align the notches, install the yoke assembly.
7.
INSTALL THE HOLDER ASSEMBLY AND THE COMMUTATOR END FRAME. Install the holder assembly in the commutator of the armature assembly aligning two location notches (concavity) of the holder assembly with convexity of the M lead wire and with convexity on the opposite surface of the M lead wire.
M01120100009
M01120100018
(1)
M01120100019
EN12–10
STARTER (J08C) (2)
Install the brush to the brush holder.
(3)
Apply grease (G1: Multemp AC-N) to the portion as shown in the figure. Install the commutator end frame aligning the location guide of the commutator end frame (convexity) with notches of the holder assembly (concavity).
M01120100020
LOCATION GIDE
G1
(4)
NOTCH HOLDER ASSEMBLY M LEAD WIRE M01120100021
M TERMINAL LEAD
CAP
CAP
(5) (6) (7)
Secure the brush holder with the bolt and a new O-ring. Secure the drive housing assembly and commutator end frame with the through bolt. Connect the terminal lead, install the cap.
C TERMINAL LEAD
M01120100004
8. C S1 M
(1) (2) (3)
AFTER ASSEMBLING THE STARTER, MEASURE THE PINION GEAR THRUST GAP. Arrange the circuit. Close switches S1 and S2. Open S2 alone when the pinion pops out.
S2 M
24V
M01120100022
(4)
If the above condition, push pinion back to measure the gap. Standard: 0.5-0.3 mm {0.020-0.118 in.} NOTICE: Perform the inspection work for an instance (within 15 seconds). PUSH BACK THE PINION SLIGHTLY.
GAP 0.5-3.0 mm {0.020-0.118 in.} M01120100023
STARTER (J08C)
EN12–11
IMPORTANT POINTS - INSPECTION NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. 1. (1) (2) (3)
PERFORM PULL-IN TEST. Disconnect the field coil lead wire from the terminal M. Connect battery to the magnetic switch as shown. Check that the pinion gear moves outward.
2. (1)
PERFORMANCE HOLD-IN TEST. While connected as above with the pinion gear out, disconnect the negative (-) lead from terminal M. Check that the pinion gear remains out.
M01120100024
(2)
M01120100025
3. (1) (2)
M01120100026
INSPECTION PLUNGER RETURN. (Solenoid Coil Balance Check) Disconnect the positive (+) lead from the terminal C. Check that the pinion gear returns inward.
EN12–12
STARTER (J08C) 4. (1)
PERFOM NO-LOAD PERFOMANCE TEST. The following test should be carried out after reassembling the starter. If suitable equipment is not available, at least the no-load test should be carried out.
No-load test
• • • •
With the starter securely clamped in a vise.
(2)
The starter should show smooth and steady rotation immediately after jumping out of the pinion and should draw less than the specified current.
Using a battery and suitable ammeter. Connect the positive lead to the ammeter, "B" and "C" terminal. Connect the negative lead to the starter body.
Revolution
4,000 r/min or more
Current
100 A or less
M01120100027
INSPECTION AND REPAIR M01120101BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Measure
Armature short circuit test (Using a growler tester)
If the iron rod does not vibrated, the armature is good.
—
Replace.
Measure
Armature insulation
More than 1 MΩ
Less than 0.5 MΩ
Replace.
Measure Continuity between the segments of the commutator
Continuity
—
Replace.
Measure Outside diameter of the commutator
32.0 {1.260}
30.0 {1.181} or less
Replace.
STARTER (J08C)
Inspection item
Standard
Limit
EN12–13
Remedy
Inspection procedure Measure
Depth between the mica and the commutator (Under cut depth)
0.5-0.8 {0.0197-0.0314}
0.2 {0.0078} or less
Replace or repair.
Measure Continuity between the brush and the "M" terminal
Continuity
—
Replace.
Measure Insulation between the brush and the yoke body
Outside diameter of the armature assembly
More than 1 MΩ
Less than 0.5 MΩ
A: 12.0 {0.472} B: 15.0 {0.591}
A: 11.98 {0.471} B: 14.98 {0.589}
Replace.
Measure Replace.
B A
Measure
Insulation between the brush and brush holder
More than 1 MΩ
Less than 0.5 MΩ
Replace.
Measure Brush length
18.0 {0.709}
12.0 {0.472}
Replace.
Measure Outside diameter of the drive shaft assembly
A: 26.0 {1.024} B: 12.1 {0.476}
A: 25.88 {1.018} B: 12.0 {0.472}
B
Replace.
Measure
Inside diameter of the drive housing assembly
26.0 {1.024}
26.2 {1.031} or more
Replace the metal.
A
EN12–14
Inspection item
STARTER (J08C)
Standard
Limit
Remedy
Inspection procedure Measure
Inside diameter of the gear housing
12.1 {0.476}
12.3 {0.484} or more
Replace.
Measure Inside diameter of commutator end frame
12 {0.472}
12.2 {0.480} or more
Replace.
Visual check
Rotating of needle roller bearing
—
—
NEEDLE ROLLER BEARING
Replace.
Visual check
Rotating of pinion
—
—
Replace, if both side turn or does not turn at all.
Measure
Resistance between the C terminal and M terminal (Pulling Coil)
0.16-0.19 Ω
—
Replace.
Measure Resistance between the C Terminal and the body (Holding Coil)
0.84-0.94 Ω
—
Replace.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
EN13–1
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
EN 13
EN13-001
AIR COMPRESSOR.................................. EN13-2 DATA AND SPECIFICATIONS ......................... EN13-2 DESCRIPTION ................................................ EN13-2 TROUBLESHOOTING ..................................... EN13-3 COMPONENT LOCATOR................................ EN13-4 SPECIAL TOOL ............................................... EN13-6 OVERHAUL ..................................................... EN13-7 INSPECTION AND REPAIR .......................... EN13-14
EN13–2
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
AIR COMPRESSOR DATA AND SPECIFICATIONS M01130101BEI2001
Type
Reciprocating, single cylinder
Discharge amount
271 cm3 {16.5 cu.in.}
Bore x stroke
80 mm x 54 mm {3.15 in. x 2.13 in.}
Lubrication system
Forced feed lubrication
Cooling system
Forced water-circulated
DESCRIPTION M01130101BEC1001
M01130100001
1
O-ring
8
Crankshaft
2
Cylinder head assembly
9
Crankcase
3
Gasket
10
Piston pin
4
Valve seat
11
Piston ring
5
Piston
A
Suction
6
Connecting rod
B
Delivery
7
Bearing
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
EN13–3
TROUBLESHOOTING M01130101BEF3001
Symptom
Possible cause
Remedy/Prevention
Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace. tact Charging efficiency dropped (Pis- Worn piston and cylinder liner ton, Cylinder liner and piston rings) Seized piston Worn or broken piston ring Charging efficiency dropped (Air Leakage of high-pressure air pipe and joints) Clogged air pipe Charging efficiency dropped (Air Clogged element cleaner)
Symptom Noisy operation (Piston)
Possible cause Wear of piston pin boss or piston pin
Replace. Replace (piston, piston rings and cylinder liner). Replace. Replace or tighten pipe joint. Replace. Clean or replace element.
Remedy/Prevention Replace.
Seized, damaged or worn connecting Replace. rod small end Worn piston or cylinder liner
Replace.
Damaged or seized piston
Replace.
Foreign particles on the top surface of Clean or replace. piston Noisy operation (Bearing)
Symptom
Damaged, or worn ball bearing and/or Replace. connecting rod bearing
Possible cause
Excessive carbon or oil in the com- Worn, sticking or broken piston rings pressor cylinder head or discharge line (Piston ring) Insufficient piston ring tension Malfunction of piston rings Excessive carbon or oil in the com- Worn cylinder liner and piston rings pressor cylinder head or discharge line (Cylinder liner and piston rings)
Remedy/Prevention Replace piston rings and/or cylinder liner. Replace piston rings and/or cylinder liner. Replace piston rings and/or cylinder liner. Replace.
EN13–4
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
COMPONENT LOCATOR M01130101BED1001
M01130100043
1
Air compressor
Tightening torque A 353 {3,600, 260} # #= Apply oil to the threads and seat surface before tightening.
Unit: N⋅m{ kgf⋅cm, lbf⋅ft}
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
EN13–5
M01130100002
1
Cylinder head
12
Retainer ring
2
Gasket
13
Bearing retainer
3
Valve seat
14
Ball bearing
4
O-ring
15
Cylinder block
5
Cylinder liner
16
Crankshaft
6
Piston ring
17
Woodruff key
7
Piston
18
Bearing holder
8
Connecting rod
19
Oil seal
9
Connecting rod bearing
20
Oil seal sleeve
10
Lock washer
21
Drive gear
11
Piston pin
22
Lock nut
Tightening torque A T= 25-30 {255-305, 19-22}
Unit: N⋅m {kgf⋅cm, lbf⋅ft} D
T= 14-18 {143-183, 11-13}
B
T= 23-26 {235-265, 17-19}
E
T= 25-30 {255-305, 19-22}
C
T= 353 {3,600, 260} #
#= Apply oil to the threads and seat surfaces before tightening.
EN13–6
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
SPECIAL TOOL M01130101BEK1001
Prior to starting an air compressor overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09420-1830
PULLER
09420-1670
PULLER ASSEMBLY
09482-2220
SLEEVE PRESS
09482-2230
OIL SEAL PRESS
09650-1101
BEARING PULLER
09440-1060
PISTON RING EXPANDER
Remarks
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
EN13–7
OVERHAUL M01130101BEH2001
IMPORTANT POINTS - DISMOUNTING Remove the five air compressor mounting bolts and remove the air compressor without applying excessive force. NOTICE: Excessive force to the air compressor may damage the mounting spigot or may cause oil leakage due to flaking of liquid gasket between the flywheel housing and plate.
IMPORTANT POINTS - MOUNTING 1. (1)
INSTALLATION PROCEDURES. Fit the No.1 cylinder to the Top Dead Center.
(2)
Align the aligning mark (two drill hole) on the side of gear teeth with protrusion on the compressor housing.
(3)
Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or more) in the flywheel housing as shown in the figure and insert the compressor onto the stud bolt. Tighten the mounting bolts (other than the stud bolt) then remove the stud bolt. Insert a bolt in the place of the stud bolt.
M01130100003
M01130100004
(4)
M01130100005
(5)
M01130100006
Make sure that the compressor crankshaft key is aligned with aligning mark (J) on the bearing holder.
EN13–8
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) NOTICE: When installing the injection pump, make sure that the coupling phase adjusting bolt is at the center of the slot. 2.
INSTALL THE FUEL PIPES FOR THE INJECTION PUMP AND AIR COMPRESSOR. Refer to CHAPTER FUEL SYSTEM.
M01130100007
IMPORTANT POINTS - DISASSEMBLY 1. REMOVE THE DRIVE GEAR. (1) Remove the lock nut from the compressor drive gear. NOTICE: If the spread is insufficient, the drive gear will be damaged when loosing the nut.
M01130100008
(2)
Pull the drive gear from the crankshaft, then remove the woodruff key. SST: Puller (09420-1830)
M01130100009
2.
REMOVE THE CYLINDER HEAD, GASKET, VALVE SEAT AND O-RING. (1) Remove the cylinder head, gasket, valve seat and o-ring. NOTICE: • Put the marking through the cylinder head to the cylinder liner. • Do not disassemble the valve seat.
M01130100010
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) 3. (1) (2) (3)
EN13–9
REMOVE THE CONNECTING ROD WITH THE PISTON. Rotate the crankshaft to the top dead center position. Spread the staking of the nut completely with a chisel, then loosen the nut. Remove the connecting rod with piston.
M01130100011
4. (1)
REMOVE THE PISTON RINGS. Remove the piston rings. SST: Piston ring expander (09440-1060)
NOTICE: • Handle the piston rings carefully because they are made of a special casting which is easily broken. • When reusing the piston rings, first arrange them face up and in the correct installation sequence in order to prevent installing them incorrectly. M01130100012
5. (1)
REMOVE THE PISTON. Remove the retainer rings installed on both ends of the piston, using retainer ring pliers. CAUTION: Wear a pair of safety goggles, because the retainer rings may spring out the groove at the time of removal. (2) Strike out the piston pin. NOTICE: Warm up the piston first in hot water, 80-90°C {176-194°F}, for approximately 5 minutes before removing the piston pin. M01130100042
6. (1) (2) (3)
M01130100013
REMOVE THE CRANKSHAFT. Remove the bearing holder fitting bolts. Using a press, remove the crankshaft with bearing holder. Using a plastic hammer, strike out the bearing holder from the crankshaft.
EN13–10
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) 7. (1)
REMOVE THE BEARING HOLDER. Strike the circumference of the holder lightly with a plastic hammer or a mallet and remove the holder.
NOTICE: Be careful not to damage the bearing holder.
M01130100014
8. (1)
REMOVE THE OIL SEAL SLEEVE. Remove the oil seal sleeve with the special tool. SST: Puller assembly (09420-1670)
9. (1)
REMOVE THE BALL BEARING. Using the special tool, remove the ball bearing from the end of the crankshaft. SST: Bearing puller (09650-1101)
M01130100015
M01130100016
IMPORTANT POINTS - ASSEMBLY 1. (1) (2)
M01130100017
INSTALL THE BALL BEARING AND OIL SEAL SLEEVE. Install the ball bearing. Install the oil seal sleeve with the special tool. SST: Sleeve press (09482-2220)
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) 2. (1)
EN13–11
INSTALL THE OIL SEAL. Install the oil seal with the special tool. SST: Oil seal press (09482-2230)
NOTICE: Coal lithium base grease to the sliding surface between seal lips.
M01130100018
3. (1) (2) (3) (4) (5)
INSTALL THE CRANKSHAFT. Using a copper hammer, install the crankshaft to the bearing holder. Install the crankshaft and bearing holder in the crankcase. Tighten the bearing holder fitting bolt. Install the ball bearing to the crankshaft. Install the bearing retainer.
M01130100019
4.
INSTALL THE CONNECTING ROD AND MEASURE THE END PLAY. NOTICE: • Be sure to align the aligning mark. • Apply engine oil to the bearing. (1)
Apply engine oil to the thread before installing the connecting rod bolt.
(2)
Measure the connecting rod end play. Assembly standard: 0.2-0.4 {0.008-0.015 in.} Limit: 0.5 mm {0.02 in.}
(3)
Lock the nut with a lock washer.
M01130100020
M01130100021
M01130100022
EN13–12
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE) 5.
MEASURE THE END PLAY OF THE CRANKSHAFT. Assembly standard: 0-0.3 mm {0-0.012 in.} Limit: 0.4 mm {0.016 in.}
M01130100023
6. ASSEMBLE THE PISTON. NOTICE: Assemble the various parts after applying engine oil to the sliding parts. (1)
When installing the piston rings on the piston, ensure that the piston skirt is at the bottom, and use the special tool. SST: Piston ring expander (09440-1060)
NOTICE: Install the piston rings with the identification mark at the top of the ring facing up.
M01130100024
7. ASSEMBLE THE PISTON AND CONNECTING ROD. NOTICE: Warm up the piston first in hot water, to 80-90°C {176-194°F}, for approximately 5 minutes. (1) (2) (3) (4)
M01130100025
Install the retainer ring at one end of the piston holes. Apply engine oil to the piston pin. Fix the piston and connecting rod by inserting the pin. Fit the new retainer ring at the other end.
CAUTION: The retainer ring may spring out of the groove during assembly. Wear a pair of safety goggles during assembly.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
EN13–13
8. INSTALL THE CYLINDER LINER AND CYLINDER HEAD. NOTICE: Do not twist the O-ring when installing it on the cylinder liner and cylinder head. (1) (2) (3)
Rotate the crankshaft to the top dead center position. Arrange the piston rings so that their gaps are equally spaced. Install the cylinder liner and cylinder head.
9. (1) (2) (3)
INSTALL THE DRIVE GEAR. Install the key to the crankshaft. Insert the drive gear. Insert the collar and lock nut. Tightening Torque: 353 N⋅m {3,600 kgf⋅cm, 260 lbf⋅ft}
NOTICE: Apply oil to the threads and seat surface before tightening.
M01130100026
EN13–14
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
INSPECTION AND REPAIR M01130101BEH3001
Unit: mm {in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Visual check
Cracks or defects of the connecting rod
—
—
Outside diameter of piston pin
16.0 {0.630}
—
Clearance between the piston pin and connecting rod
0.016-0.044 {0.0007-0.0017}
0.07 {0.0028}
Inside diameter of the connecting rod (without bearings): A #Tighten the bearing cap to the specified torque
37 {1.457}
—
Thickness of the connecting rod bearing: B,C
1.5 {0.0591}
—
34 {1.339}
—
Outside diameter of the crank pin: D
Replace.
Measure
Replace.
Replace.
Oil clearance between the connecting rod and the crank pin: E # Oil clearance E= A-(B+C+D)
0.017-0.083 {0.0007-0.0032}
0.1 {0.0039}
Connecting rod end play
0.2-0.4 {0.0079-0.0157}
0.5 {0.0197}
Replace connecting rod or crankshaft.
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
Inspection item
Standard
Limit
Remedy
EN13–15
Inspection procedure Visual check
Damage and scratches of the cylinder liner
—
Outside diameter of the piston
A:79.79-79.82 {3.1414-3.1425} B:79.90-79.93 {3.1457-3.1468}
—
Inside diameter of the cylinder liner
80.00-80.03 {3.1496-3.1507}
—
Clearance between the piston and the cylinder liner
Clearance between the piston pin hole and the piston pin
—
Replace.
Measure
Replace.
A:0.18-0.24 {0.0071-0.0094}
0.33 {0.0130}
B:0.07-0.13 {0.0028-0.0051}
0.18 {0.0071}
0-0.028 {0-0.0011}
0.08 {0.0031}
Measure
Replace. Outer diameter of the piston pin
Piston ring thickness
Piston ring groove
16 {0.630}
—
Compression ring
3.0 {0.1181}
—
Oil ring
4.0 {0.1575}
—
Compression ring
3.0 {0.1181}
—
Oil ring
4.0 {0.1575}
—
0.02-0.055 {0.0008-0.0021}
0.08 {0.0031}
Clearance between the ring groove and the compression ring
Measure
Replace.
Visual check Worn or damaged bearing
—
—
Replace.
EN13–16
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE)
Inspection item
Standard
Limit
Remedy
Inspection procedure Visual check
Worn or damaged delivery valve
—
—
Replace valve seat.
Visual check Worn or damaged suction valve
Top Second Piston ring gap: comThird pression ring, oil ring Oil ring
Outside diameter of the crankshaft journal
Inside diameter of the bearing holder
—
—
Replace valve seat.
0.3-0.5 {0.0119-0.0196} 0.1-0.3 {0.0040-0.0118}
Measure
1.0{0.0394}
Replace.
0.2-0.8 {0.0079-0.0314}
Drive side
35 {1.378}
34.985 {1.3774}
Opposite drive side
35 {1.378}
34.985 {1.3774}
Cylinder block
80 {3.1496}
79.996 {3.1494}
72.0 {2.8346}
71.996 {2.8345}
Measure
Replace.
Measure
Replace. Bearing holder
Measure
Crankshaft end play
0-0.3 {0-0.012}
0.4 {0.06}
Replace crank shaft bearing
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–1
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN 13
EN13-002
AIR COMPRESSOR.................................. EN13-2 DATA AND SPECIFICATIONS ......................... EN13-2 DESCRIPTION ................................................ EN13-2 TROUBLESHOOTING ..................................... EN13-3 COMPONENT LOCATOR................................ EN13-4 SPECIAL TOOL ............................................... EN13-6 OVERHAUL ..................................................... EN13-7 INSPECTION AND REPAIR .......................... EN13-17
EN13–2
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
AIR COMPRESSOR DATA AND SPECIFICATIONS M01130101BEI2001
Type
Reciprocating, V-type two cylinder
Discharge amount
271 cm3 {16.5 cu.in.} x 2 cylinders
Bore x stroke
80 mm x 54mm {3.15 in. x 2.13 pin.}
Lubrication system
Forced feed lubrication
Cooling system
Forced water-circulated
DESCRIPTION M01130101BEC1001
M01130100081
1
Unloader valve
8
Cylinder liner
2
Inlet valve
9
Connecting rod
3
Piston ring
10
Crankshaft
4
Piston pin
11
Bearing
5
Delivery valve
A
From pressure regulator
6
Cylinder head
B
To tank
7
Piston
C
Air suction
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–3
TROUBLESHOOTING M01130101BEF3001
Symptom
Possible cause
Remedy/Prevention
Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace. tact Charging efficiency dropped (Pis- Worn piston and cylinder liner ton, Cylinder liner and piston rings) Seized piston Worn or broken piston ring Charging efficiency dropped (Air Leakage of high-pressure air pipe and joints) Clogged air pipe Charging efficiency dropped (Air Clogged element cleaner)
Symptom Noisy operation (Piston)
Possible cause Wear of piston pin boss or piston pin
Replace. Replace (piston, piston rings and cylinder liner). Replace. Replace or tighten pipe joint. Replace. Clean or replace element.
Remedy/Prevention Replace.
Seized, damaged or worn connecting Replace. rod small end Worn piston or cylinder liner
Replace.
Damaged or seized piston
Replace.
Foreign particles on the top surface of Clean or replace. piston Noisy operation (Bearing)
Damaged, or worn ball bearing and/or Replace. connecting rod bearing
Noisy operation (Valve)
Inlet valve is lowered excessively
Repair or replace.
Loosen discharge valve holder
Tighten it.
Symptom
Possible cause
Excessive carbon or oil in the com- Worn, sticking or broken piston rings pressor cylinder head or discharge line (Piston ring) Insufficient piston ring tension Malfunction of piston rings Excessive carbon or oil in the com- Worn cylinder liner and piston rings pressor cylinder head or discharge line (Cylinder liner and piston rings)
Symptom Malfunction of (Unloader valve)
unloader
Possible cause valve Sticky Deflection or wear
Remedy/Prevention Replace piston rings and/or cylinder liner. Replace piston rings and/or cylinder liner. Replace piston rings and/or cylinder liner. Replace.
Remedy/Prevention Clean or replace. Repair or replace unloader valve assembly.
Malfunction of unloader valve (Air Air leakage pipe and joints)
Replace or tighten pipe joints.
Malfunction of unloader (Pressure regulator)
Adjust and/or repair pressure regulator.
valve Function
EN13–4
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
COMPONENT LOCATOR M01130101BED1001
M01130100123
1
Air compressor
Tightening torque A 353 {3,600, 260}# #=Apply oil to the threads and seat surfaces before tightening.
Unit:N⋅m{kgf⋅cm,lbf⋅ft}
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–5
M01130100122
1
Cylinder block
23
Cylinder liner gasket
2
Crank shaft
24
Cylinder liner
3
Oil seal sleeve
25
Cylinder liner gasket
4
O-ring
26
Cylinder head assembly
5
Suction valve assembly
27
Cylinder head
6
Bearing holder assembly
28
O-ring
7
Bearing holder
29
Delivery valve assembly
8
Oil seal
30
Delivery valve holder
9
O-ring
31
Bolt
10
Bearing retainer
32
Bolt
11
Bolt
33
Through bolt
12
Woodruff key
34
Lock washer
13
Connecting rod assembly
35
Bearing
14
Connecting rod bearing
36
Bearing
15
Connecting rod bolt
37
Piston ring set
16
Connecting rod nut
38
Unloader valve assembly
17
Connecting rod washer
39
Unloader valve holder
18
Piston
40
Unloader valve spring
19
Piston pin
41
Unloader valve
20
Retainer ring
42
O-ring
21
Bolt
43
Spacer
22
Straight pin
44
Retainer ring
EN13–6
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
Tightening torque A 98.1-117.7 {1,000-1,200, 73-86}
Unit:N⋅m{kgf⋅cm,lbf⋅ft} D
24.5-29.4 {250-300, 19-21}
B
39.2-49.0 {400-500, 29-36}
E
13.7-17.6 {140-180, 11-13}
C
22.6-25.5 {230-260, 17-18}
SPECIAL TOOL M01130101BEK1001
Prior to starting an air compressor overhaul, it is necessary to have these special tools. Illustration
Part number
Tool name
09420-1830
PULLER
09420-1670
PULLER ASSEMBLY
09482-2220
SLEEVE PRESS
09482-2230
OIL SEAL PRESS
09650-1101
BEARING PULLER
09440-1060
PISTON RING EXPANDER
09481-1090
INLET VALVE HOLDER ADAPTER
Remarks
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–7
OVERHAUL M01130101BEH2001
IMPORTANT POINTS - DISMOUNTING Remove the five air compressor mounting bolts and remove the air compressor without applying excessive force. NOTICE: Excessive force to the air compressor may damage the mounting spigot or may cause oil leakage due to flaking of liquid gasket between the flywheel housing and plate.
IMPORTANT POINTS - MOUNTING 1. (1)
INSTALLATION PROCEDURES. Fit the No.1 cylinder to the Top Dead Center.
(2)
Align the aligning mark (two drill hole) on the side of gear teeth with protrusion on the compressor housing.
(3)
Place a guide stud bolt (M8 x 1.25, length: 50 mm {1.968 in.} or more) in the flywheel housing as shown in the figure and insert the compressor onto the stud bolt. Tighten the mounting bolts (other than the stud bolt) then remove the stud bolt. Insert a bolt in the place of the stud bolt.
M01130100124
M01130100004
(4)
M01130100125
(5)
M01130100006
Make sure that the compressor crankshaft key is aligned with aligning mark (J) on the bearing holder.
EN13–8
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) NOTICE: When installing the injection pump, make sure that the coupling phase adjusting bolt is at the center of the slot. 2.
INSTALL THE FUEL PIPES FOR THE INJECTION PUMP AND AIR COMPRESSOR. Refer to CHAPTER FUEL SYSTEM.
M01130100007
IMPORTANT POINTS - DISASSEMBLY 1. REMOVE THE DRIVE GEAR. (1) Remove the lock nut from the compressor drive gear. NOTICE: If the spread is insufficient, the drive gear will be damaged when loosing the nut.
M01130100126
(2)
Pull the drive gear from the crankshaft, then remove the woodruff key. SST: Puller (09420-1830)
2.
REMOVE THE CYLINDER HEAD, O-RING AND CYLINDER LINER. Remove the cylinder head, O-ring and cylinder liner.
M01130100009
(1)
NOTICE: Put the aligning mark through the cylinder head to the cylinder liner.
M01130100083
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–9
3. (1)
REMOVE THE PISTON. Remove the retainer rings installed on both ends of the piston, using retainer ring pliers. CAUTION: Wear a pair of safety goggles, because the retainer rings may spring out the groove at the time of removal. (2) Strike out the piston pin, using a tapping rod and a hammer. NOTICE: Warm up the piston first in hot water, 80-90°C {176-194°F}, for approximately 5 minutes before removing the piston pin. M01130100086
4. (1) (2) (3)
REMOVE THE CONNECTING ROD. Rotate the crankshaft to the top dead center position. Spread the staking of the nut completely with a chisel, then loosen the nut. Remove the connecting rod.
M01130100084
5. (1)
REMOVE THE PISTON RINGS. Remove the piston rings. SST: Piston ring expander (09440-1060)
NOTICE: • Handle the piston rings carefully because they are made of a special casting which is easily broken. • When reusing the piston rings, first arrange them face up and in the correct installation sequence in order to prevent installing them incorrectly.
M01130100085
6. (1)
M01130100087
REMOVE THE CRANKSHAFT. Remove the bearing retainer.
EN13–10
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) (2)
Press the crankshaft end face and remove the crankshaft with the bearing holder.
M01130100088
7. (1)
REMOVE THE BEARING HOLDER. Strike the circumference of the holder lightly with a plastic hammer or a mallet and remove the holder. NOTICE: Be careful not to damage the bearing holder.
M01130100089
8. (1)
REMOVE THE OIL SEAL SLEEVE. Using the special tool, remove the oil seal sleeve. SST: Puller assembly (09420-1670)
9. (1)
REMOVE THE BALL BEARING. Using the special tool, remove the ball bearing from the end of the crankshaft. SST: Bearing puller (09650-1101)
M01130100090
M01130100016
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–11
10. (1)
REMOVE THE SUCTION VALVE ASSEMBLY. Using the special tool, remove the suction valve holder. SST: Adapter (09482-1090)
(2)
Disassemble the suction valve.
11. (1)
REMOVE THE UNLOADER VALVE ASSEMBLY. Loosen the unloader valve guide and take it out together with the unloader valve.
(2)
Remove the retainer ring and disassemble the unloader valve.
12. (1)
REMOVE THE DELIVERY VALVE ASSEMBLY. Remove the delivery valve holder.
M01130100091
M01130100092
M01130100093
M01130100127
M01130100095
EN13–12
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) (2)
Disassemble the delivery valve.
M01130100096
IMPORTANT POINTS - ASSEMBLY 1. ASSEMBLE THE SUCTION VALVE ASSEMBLY. NOTICE: Replace the gasket with new one. (1)
Assemble the gasket, valve seat, suction valve and valve spring in that order from the lower side of the cylinder head, then install the suction valve holder and tighten provisionally.
(2)
Before completely tightening the suction valve holder, push in the suction valve with a finger or bar from the upper side of cylinder head (unloader valve side), and check that the suction valve and valve spring moves smoothly.
(3)
Tighten the suction valve holder to the specified torque using a special tool. SST: Adapter (09481-1090)
(4)
Make sure that the suction valve stroke is approximately 2.5 mm {0.0984 in.}.
M01130100097
M01130100059
M01130100098
(5)
Caulk three places on the outer periphery of the suction valve holder. NOTICE: In this case, be sure that the lower face of the valve holder is not protruding from the head lower face. (The faces should be flush or the lower face of the valve holder should be recessed from the head lower face.)
M01130100099
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–13
2. ASSEMBLE THE DELIVERY VALVE ASSEMBLY. NOTICE: O-ring should be replaced with new one. (1)
(2)
Assemble the valve seat, delivery valve, valve spring and O-ring from the upper side of cylinder head, then install the delivery vale holder and tighten provisionally. Push in the delivery valve with a finger or bar from the lower side of the cylinder head, and check that the delivery valve and valve spring move smoothly.
M01130100100
(3) (4)
Tighten the delivery valve holder to the specified torque. Make sure that the delivery valve stroke is approximately 1 mm {0.0394 in.}.
3. (1)
ASSEMBLE THE UNLOADER VALVE Assemble the valve spring, unloader valve with O-ring and spacer in the unloader valve holder, and secure them with the retainer ring.
(2)
Push the unloader valve from the upper side with a finger or bar, and check that the unloader valve and valve spring move smoothly. Assemble the unloader valve holder from the upper side of the cylinder head and tighten the unloader valve holder to the specified torque.
M01130100063
(3)
M01130100101
4. (1)
M01130100102
INSTALL THE BALL BEARING. Install the ball bearing on the both end of the crankshaft.
EN13–14
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) 5. (1)
INSTALL THE OIL SEAL SLEEVE. Using the special tool, install the oil seal sleeve onto the crankshaft. SST: Sleeve press (09482-2220)
6. (1)
INSTALL THE OIL SEAL. Using the special tool, install the oil seal into the bearing holder. SST: Oil seal press (09482-2230)
7. (1)
INSTALL THE CRANKSHAFT. Using a copper hammer, install the crankshaft to the bearing holder.
(2) (3)
Install the crankshaft and bearing holder in the crankcase. Tighten the bearing holder fitting bolt.
M01130100120
M01130100109
M01130100103
M01130100087
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
EN13–15
8.
INSTALL THE CONNECTING ROD AND MEASURE THE END PLAY. NOTICE: • Be sure to align the aligning mark. • Apply engine oil to the bearing. (1)
Apply engine oil to the thread before installing the connecting rod bolt.
(2)
Measure the connecting rod end play. Assembly standard: 0.2-0.4 mm {0.0079-0.0157 in.} Limit: 0.5 mm {0.0197 in.}
(3)
Lock the nut with a lock washer.
9.
MEASURE THE END PLAY OF THE CRANKSHAFT. Assembly standard: 0-0.3 mm {0-0.0118 in.} Limit: 0.4 mm {0.0157 in.}
M01130100105
M01130100106
M01130100107
M01130100110
10. ASSEMBLE THE PISTON. NOTICE: Assemble the various parts after applying engine oil to the sliding parts. (1)
When installing the piston rings on the piston, ensure that the piston skirt is at the bottom, and use the special tool. SST: Piston ring expander (09440-1060)
NOTICE: Install the piston rings with the identification mark at the top of the ring facing up. M01130100069
EN13–16
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
M01130100111
11. ASSEMBLE THE PISTON AND CONNECTING ROD. NOTICE: Warm up the piston first in hot water, to 80-90°C {176-194°F}, for approximately 5 minutes.
M01130100086
(1) Install the retainer ring at one end of the piston holes. (2) Apply engine oil to the piston pin. (3) Fix the piston and connecting rod by inserting the pin. (4) Fit the new retainer ring at the other end. CAUTION: The retainer ring may spring out of the groove during assembly. Wear a pair of safety goggles during assembly.
12. (1)
INSTALL THE CYLINDER LINER AND CYLINDER HEAD. Arrange the piston rings so that their gaps are equally spaced.
(2)
Install the cylinder liner and cylinder head.
M01130100113
M01130100083
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE) 13. (1) (2) (3)
EN13–17
INSTALL THE DRIVE GEAR. Install the woodruff key to the crankshaft. Install the drive gear. Install the collar and lock nut.
M01130100128
INSPECTION AND REPAIR M01130101BEH3001
Unit:mm{in.} Inspection item
Standard
Limit
Remedy
Inspection procedure Visual check
Cracks or defects of the connecting rod
—
—
Outside diameter of piston pin
16 {0.630}
—
Clearance between the piston pin and connecting rod
0.02-0.04 {0.0008-0.0016}
0.07 {0.0027}
Replace.
Measure
Replace.
EN13–18
Inspection item
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
Standard
Limit
Inside diameter of the connecting rod (without bearings): A #Tighten the bearing cap to the specified torque
37 {1.457}
—
Thickness of the connecting rod bearing: B,C
1.5 {0.0594}
—
Outside diameter of the crank pin: D
34 {1.339}
—
Remedy
Inspection procedure Measure
Replace.
Oil clearance between the connecting rod and the crank pin: E # Oil clearance E= A-(B+C+D)
0.02-0.09 {0.0008-0.0035}
0.1 {0.0039}
Measure
Connecting rod end play
0.2-0.4 {0.0079-0.0157}
0.5 {0.0197}
Replace connecting rod or crankshaft.
Visual check
Damage and scratches of the cylinder liner
—
—
Outside diameter of the piston
80 {3.150}
—
Inside diameter of the cylinder liner
80 {3.150}
—
A: 0.25-0.30 {0.0099-0.0118}
0.33 {0.0130]
B: 0.07-0.13 {0.0028-0.0051}
0.18 {0.0071}
Clearance between the piston and the cylinder liner
Replace.
Measure
Replace.
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
Inspection item
Standard
Limit
Clearance between the piston pin hole and the piston pin
0-0.026 {0-0.0010}
0.08 {0.0031}
Outside diameter of the piston pin
16 {0.630}
Remedy
EN13–19
Inspection procedure Measure
Replace.
Piston ring gap: compression ring, oil ring
Piston ring thickness
Piston ring groove
Compression ring (Top, Second)
0.3-0.5 {0.0119-0.0196}
Compression ring (Third)
0.1-0.3 {0.0040-0.0118}
Oil ring
0.2-0.8 {0.0079-0.0314}
—
Measure
1.0 {0.0394}
Compression ring
3.0 {0.1181}
—
Oil ring
4.0 {0.1575}
—
Compression ring
3.0 {0.1181}
—
Oil ring
4.0 {0.1575}
—
0.02-0.055 {0.0008-0.0021}
0.08 {0.0031}
Clearance between the ring groove and the compression ring
Replace.
Measure
Replace.
Visual check Worn or damaged bearing
—
—
Replace.
Visual check
Worn or damaged delivery valve and valve seat
—
—
Replace delivery valve assembly.
Visual check Worn or damaged suction valve and valve seat
—
—
Replace suction valve assembly.
EN13–20
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE)
Inspection item
Outside diameter of the crankshaft journal
Inside diameter of the bearing holder
Standard
Limit
Drive side (A)
34.99-35.0 {1.3776-1.3779}
34.985 {1.3774}
Opposite drive side (B)
35.002-35.013 {1.3781-1.3784}
34.997 {1.3778}
Cylinder block
80 {3.1496}
79.996 {3.1494}
Bearing holder
72 {2.8346}
71.996 {2.8345}
Remedy
Inspection procedure Measure
Replace.
Measure
Replace.
Measure
Crankshaft end play
0-0.3 {0-0.0118}
0.4 {0.0157}
Suction valve spring setting load
4.41 N {0.45 kgf, 0.992 lbf} at 7.0mm {0.276 in.}
3.63 N {0.36 kgf, 0.794 lbf}
Replace.
Delivery valve spring
4.5 N {0.46 kgf, 1.019 lbf} at 9.5 mm {0.374 in.}
3.6 N {0.37 kgf, 0.816 lbf}
Replace.
Wear or damage of the suction valve spring and delivery valve spring
Replace crank shaft bearing
Measure
Visual check —
—
Replace.
ENGINE P.T.O. (POWER TAKE-OFF)
EN14–1
ENGINE P.T.O. (POWER TAKE-OFF) (J08C)
EN14
EN14-001
POWER TAKE-OFF ASSEMBLY .............. EN14-2 DESCRIPTION ................................................ EN14-2 COMPONENT LOCATOR................................ EN14-3 OVERHAUL ..................................................... EN14-4 INSPECTION AND REPAIR ............................ EN14-9
EN14–2
ENGINE P.T.O. (POWER TAKE-OFF)
POWER TAKE-OFF ASSEMBLY DESCRIPTION M01140102BEC1001
M01140100028
1
Case cover
5
Crankshaft gear
2
Power take off assembly
6
Drive gear
3
Output coupling
7
Ball bearing
4
Main idle gear
8
Oil seal
ENGINE P.T.O. (POWER TAKE-OFF)
EN14–3
COMPONENT LOCATOR M01140102BED1001
M01140100029
1
Case cover
4
Ball bearing
7
Gear cover
2
Gear case
5
Drive gear
8
Oil seal
3
Knock pin
6
Driven shaft
9
Output coupling
Tightening torque A 226 {2,300, 160}
Unit:N⋅m{kgf⋅cm,lbf⋅ft} B
28.4 {290, 21}
EN14–4
ENGINE P.T.O. (POWER TAKE-OFF)
OVERHAUL M01040102BEH2001
IMPORTANT POINTS - DISASSEMBLY CAUTION: Do not work on the while engine is still hot. This can result in personal injury. 1. (1)
DISASSEMBLE THE POWER TAKE-OFF. Remove the output coupling.
(2) (3)
Remove the bolt. Using flathead drivers, pry up the flange of the gear cover from the gear case.
M01140100030
NOTICE: When removing the gear cover, pry up by an even amount at each gap until the gear cover comes off.
M01140100031
(4) (5)
Using a suitable sliding hammer, remove the driven shaft with ball bearing. Remove the drive gear.
(6)
Using a press, remove the ball bearing from the driven shaft.
M01140100032
M01140100033
ENGINE P.T.O. (POWER TAKE-OFF)
EN14–5
(7)
Using a press, press the driven shaft into the ball bearing.
(8)
Using a suitable sliding hammer, remove the ball bearing with driven shaft.
(9)
Using a press, remove the ball bearing from the driven shaft.
M01140100034
M01140100035
M01140100036
(10) Using a flathead screwdriver, pay off the oil seal evenly until the oil seal comes off.
M01140100037
IMPORTANT POINTS - ASSEMBLY 1. (1)
ASSEMBLE THE POWER TAKE-OFF. Using the suitable tool, press a new oil seal into the gear cover.
NOTICE: To prevent gouging of the rubber around the outside edge of the oil seal, apply engine oil to the portion of the gear cover where the oil seal will be pressed.
M01140100038
EN14–6
ENGINE P.T.O. (POWER TAKE-OFF) NOTICE: • Apply lithium based grease between the main lip and sub-lip of the oil seal and to the back of the main lip.
•
Do not use too much grease. Also, apply grease evenly around entire circumference.
(2)
Using a press, press the driven shaft into the ball bearing.
(3)
Using the suitable tool and a press, press the ball bearing into the gear case.
(4)
Set the drive gear in position, then press the driven shaft with ball bearing into the ball bearing.
M01140100039
M01140100040
M01140100041
M01140100042
(5) Apply liquid gasket to the gear cover, then install the gear cover. NOTICE: Align the threaded hole of the gear case and the bolt hole of the gear cover. (6)
M01140100043
Tighten the bolts evenly.
ENGINE P.T.O. (POWER TAKE-OFF) (7)
EN14–7
Install the output flange, then tighten the lock nut.
M01140100044
IMPORTANT POINTS - MOUNTING 1. (1)
INSTALL THE POWER TAKE-OFF. Insert two knock pins.
(2) (3)
Apply liquid gasket to the gear case and the flywheel housing. Install the power take-off and case cover with 4 bolts.
M01140100045
M01140100046
EN14–8
ENGINE P.T.O. (POWER TAKE-OFF) 2. (1)
M01140100047
CHECK THE GEAR BACKLASH. Using a dial gauge, measure the backlash between gears at the bolt hole of the output flange. Standard: 0.035-0.211 mm {0.0014-0.0083 in.}
ENGINE P.T.O. (POWER TAKE-OFF)
EN14–9
INSPECTION AND REPAIR M01040102BEH3001
Unit:mm{in.} Inspection item
Standard
Limit
Shaft and gear: Wear and damage
—
—
Replace, if necessary.
Visual check
Oil seal lip: Wear and damage
—
—
Replace, if necessary.
Visual check
Bearing improper rotation
—
—
Replace, if necessary.
Visual check
0.035-0.211 {0.0014-0.0083}
0.3 {0.0118}
Replace, if necessary.
Measure
Drive gear backlash (Measure at bolt of output coupling P.C.D: 100 mm {3.937 in.})
Remedy
Inspection procedure
FUEL CONTROL (J08C: PRE-STROKE PUMP)
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–1
DN02
DN02
TE SYSTEM ..............................................DN02-2 OUTLINE OF THE TE SYSTEM...................... DN02-2 OUTLINE OF THE PRE-STROKE PUMP SYSTEM............................................... DN02-2 COMPONENT LOCATOR................................ DN02-3 DIAGRAM ........................................................ DN02-9 PRECAUTIONS ............................................. DN02-11 INSPECTION ................................................. DN02-12 DIAGNOSIS USING THE DIAGNOSIS MONITOR ......................... DN02-14 ENGINE SPEED SENSOR NO PULSE (MALFUNCTION CODE:2-1) ......................... DN02-16 ABNORMALITY OF ENGINE SPEED SENSOR (MALFUNCTION CODE:3-1) ......................... DN02-17 ABNORMALITY OF COOLANT TEMPERATURE SENSOR (MALFUNCTION CODE:4-1)......... DN02-18 ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE:6-1) ......................... DN02-19 ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE:14-1) ....................... DN02-20 ABNORMALITY OF PRE-STROKE SENSOR (MALFUNCTION CODE:16-1) ....................... DN02-21 ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE:16-2) ....................... DN02-22 ABNORMALITY OF PRE-STROKE LEARNING (MALFUNCTION CODE:16-3) ....................... DN02-23 ABNORMALITY OF PRE-STROKE POWER SUPPLY (MALFUNCTION CODE:16-4) ....................... DN02-24 ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY) CONTROL CIRCUIT (MALFUNCTION CODE:16-6) ....... DN02-25 ABNORMALITY OF ECU (MALFUNCTION CODE:22-1) ....................... DN02-27 ENGINE OVERRUN (MALFUNCTION CODE:23-1) ....................... DN02-27 ENGINE OVERHEAT (MALFUNCTION CODE:24-1) ....................... DN02-27 ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT ............................................... DN02-28 DISMOUNTING AND MOUTING................... DN02-30
DN02-001
DN02–2
FUEL CONTROL (J08C: PRE-STROKE PUMP)
TE SYSTEM OUTLINE OF THE TE SYSTEM M16020101BEF2001
The TE (Total Electronics) system uses electronic control to regulate every aspect of the engine's running condition. It is a comprehensive electronic control system developed to extract maximum power and low-pollution of the engine. There are 4 types of the TE system, detail at below, this engine employ the "Pre-stroke" type.
Control of the Intake Air Type Pre-stroke Pump Type Hino TE System Electronic Governer Type Common Rail Fuel Injection Type
OUTLINE OF THE PRE-STROKE PUMP SYSTEM M16020101BEF2002
The Pre-stroke Pump System has a lot of control functions than the conventional injection pump system, These functions are controlled by the ECU (Electronic Control Unit).
Control of the Fuel Injection
Control of the Injection Timing
Function of Diagnosis
Control of the Injection Rate
Pre-stroke Type Fuel Injection System Function of Tachometer Driver
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–3
COMPONENT LOCATOR M16020101BEF2003
M16020100060
1
ECU main relay
5
Speed sensor
2
Actuator power supply
6
Pre-stroke actuator and pre-stroke sensor
3
Control unit (ECU)
7
Rack sensor
4
Coolant temperature sensor
DN02–4
FUEL CONTROL (J08C: PRE-STROKE PUMP)
M16020100061
1
Straight pin
17
Tappet roller
2
Control rack
18
Adapter
3
Housing
19
Tappet sub assembly
4
Element sub assembly
20
Plunger spring lower seat
5
Timing rod
21
Plunger spring
6
Bearing
22
Plunger spring upper seat
7
Bushing
23
Plunger control sleeve
8
Connector
24
Camshaft adjust ring
9
Shim
25
Over flow valve
10
Pointer
26
Delivery valve holder
11
Sleeve
27
Delivery valve stopper
12
Oil seal
28
Delivery valve spring
13
Bearing cover
29
Delivery valve
14
O-ring
30
Element holder
15
Camshaft
31
Tappet sub assembly for feed pump
16
Woodruff key
Tightening torque A 108 {1,100, 80}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–5
M16020100122
1
Boost compensator cover
15
Screw plug
29
Start spring
2
Gasket
16
Joint bolt
30
Spring shaft
3
Stroke adjust screw
17
Pin
31
Adapter
4
Diaphragm
18
Shaft
32
Flyweight sleeve
5
Governor spring
19
Cam plate
33
Round nut
6
Nut
20
Load lever
34
Flyweight
7
Bushing
21
Bracket
35
Governor housing
8
Spring plate
22
Boost compensator shaft
36
Load control lever
9
Return spring
23
Tension lever
37
Stop lever
10
Speed control lever
24
Guide lever
38
Collar
11
Oil seal
25
Floating lever
39
Plain washer
12
Governor cover
26
Link
40
Rack position sensor
13
Shim
27
Load control lever
14
Screw
28
Spring plate
DN02–6
FUEL CONTROL (J08C: PRE-STROKE PUMP)
M16020100040
1
Screw plug
9
Timer spring
2
Gasket
10
Shim
3
Timer hub
11
Retainer ring
4
Timer cam
12
Timer weight
5
Nut
13
Plain washer
6
Timer driving flange
14
O-ring
7
Shaft
15
Timer cover
8
Timer spring seat
16
Oil seal
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–7
M16020100123
1
Joint bolt
7
Plug
2
Gasket
8
Priming pump
3
Feed pump housing
9
Piston spring
4
Check valve
10
Piston
5
Check valve spring
11
Push rod
6
O-ring
DN02–8
FUEL CONTROL (J08C: PRE-STROKE PUMP)
M16020100042
1
Pre-stroke actuator and pre-stroke sensor
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–9
DIAGRAM M16020101BEJ1001
FUEL SYSTEM
M16020100035
DN02–10
FUEL CONTROL (J08C: PRE-STROKE PUMP)
ELECTRICAL SYSTEM CONTROL UNIT
+24V ACTUATOR POWER SUPPLY RELAY (N.C)
ENGINE SPEED SENSOR
PRE-STROKE ACTUATOR
COOLANT TEMPERATURE SENSOR RACK SENSOR PRE-STROKE SENSOR ECU TACHOMETER
CHECK ENGINE LAMP
ECU MAIN RELAY (N.O)
EXHAUST BRAKE INDICATOR LAMP
STARTER SWITCH
DIAG
KEY SWITCH
N.O: Normal Open
EXHAUST BRAKE SWITCH
N.C: Normal Close
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–11
PRECAUTIONS M16020101BEC1011
1.
BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE ACTUATOR OR MAGNETIC VALVES.
2.
PRE-STROKE ACTUATOR.
•
Never apply electricity to the pre-stroke actuator except through the control unit. Never connect the actuator connectors directly to a power source. Doing so could burn out the actuator coil.
•
Also, note that the mounting position of the actuator is carefully adjusted. Never do anything that could change the actuator's mounting position.
•
To have the actuator or sensor replaced, contact an establishment specializing in BOSCH (ZEXEL).
3. (1)
HARNESS WIRE CONNECTOR. Multi-contact connectors suitable for the small electrical signals of electronic circuity are used for wiring connections to the sensors, actuator and control unit. Be very careful when handling them.
•
Before disconnecting any connectors, make sure that the starter switch is in the "LOCK" position.
•
When disconnecting connectors, try to pull them out in a straight line, disengaging the lock and holding onto the housing.
•
Do not try to disconnect connectors by gripping the wires or twisting them, as this could bend the contacts.
• •
Do not disconnect connectors unnecessarily.
•
Do not let water, oil or dust get on the connector when it is disconnected, as this could cause poor contacts when the connector is reconnected.
•
Do not open the control unit cover. It could malfunction if dust or water get inside.
•
Take care to ensure that water, oil or dust do not get on or inside parts.
•
When connecting in connectors, push them in all the way and make sure that the lock engages.
4.
ERASING THE MALFUNCTION MEMORY STORED IN THE PAST, CHECK THE CURRENT MALFUNCTION BY PERFORMING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
When using a circuit tester, apply the tester probe to the harness wire side only. Never stick the tester probe into the holes on the connector terminal side, as this could cause poor contacts when the connector is reconnected.
DN02–12
FUEL CONTROL (J08C: PRE-STROKE PUMP) 5.
AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE THE MALFUNCTION MEMORY STORED IN THE PAST. OTHERWISE, THE MALFUNCTION LAMP IN THE DISPLAY WILL REMAIN LIT.
6.
CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING LEAD FROM THE BACKSIDE.
7.
USING A CIRCUIT TESTER
•
Use a circuit tester with an internal resistance of 100kΩ or greater in the voltage measuring range.
8. •
RADIO INSTALLATION
9.
USING A QUICK CHARGER
•
Disconnect both battery terminal before using a quick charger.
There is a danger that the control unit might malfunction if a high output radio transmitter (over 50W) is installed in the vehicle.
10. AIR CONDITIONER INSTALLATION • Be careful not to scratch or damage the engine, chassis or the harness inside the cab when installing an air conditioner. Also, make sure to reattach afterward any connectors that were disconnecting during the installation process. 11. ELECTRIC WELDING PERFORMING • Disconnect connector to the control unit before performing any electric welding. 12.
OTHER
•
Make sure to check the fellow of connectors before connecting them in to prevent incorrect connections.
•
Be careful not to allow the connectors to become soiled with dust, water, fuel or oil when performing inspections or removing and replacing parts.
INSPECTION M16020101BEH3001
CHECK ENGINE LAMP STATUS 1. (1)
INSPECTION PROCEDURE Turn the starter switch to the ON position (do not start the engine) and confirm that the Check Engine Lamp in the indicator area lights up.
(2) (3) (4)
Start the engine. If the engine is normal, the Check Engine Lamp goes out. If the Check Engine Lamp does not light up or if it blinks, there is trouble in the system. Check the system according to the following chart.
. M16020100033
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–13
CHECK ENGINE LAMP ILLUMINATION PATTERN
ON
BLINKING
Major
OFF 0.5 sec
0.5 sec
0.5 sec
0.5 sec
0.5 sec
Degree of trouble
ON ON (1) OFF
ON Minor OFF
ON (2) Light up 30 seconds after engine started
The lamp ON/OFF status and illumination pattern as well as the corresponding conditions they indicate and the measures to be taken-are shown in the following table. Lamp ON/OFF STATUS
Blinking
This indicates that the engine has stopped or it will not start. Turn the starter switch to the [LOCK] position and wait few seconds. If the engine does not start and the lamp lights in continuously or blinking after the starter switch is turned to the [START] position, and move the vehicle to a safe location by traction.
ON (1)
This indicates that the engine has insufficient force and irregular idling occurred due to a system damage. This condition must be inspected at a Hino service dealer as soon as possible.
ON (2)
This indicates that a light damage has occurred in the system. Driving is possible, but this condition must be inspected at a HIno service dealer as soon as possible.
DN02–14
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DIAGNOSIS USING THE DIAGNOSIS MONITOR M16020101BEF2151
1.
CONNECT THE DIAGNOSIS MONITOR. SST: Diagnosis monitor (09630-1370)
NOTICE: Trouble diagnosis also can be performed using the diagnosis monitor. The malfunction codes are indicated by sound and light. (1)
Turn the starter switch to the "ON".
(2)
Connect the harness to the diagnosis connector. SST: Harness (09630-2300)
(3)
Connect the diagnosis monitor to the connector which tagged a "STD-ENG" label.
2. (1)
READ OUT THE MALFUNCTION CODE. Turn on the exhaust brake switch.
M16020100001
M16020100002
M16020100003
M16020100004
FUEL CONTROL (J08C: PRE-STROKE PUMP) (2)
DN02–15
Check engine lamp and exhaust brake indicator lamp flashes on and off to inform the malfunction codes.
(3)
Read out the malfunction codes and write down the malfunction codes that are displayed. NOTICE: Malfunction codes are displayed, starting from the lowest and progressing upward, with no distinction between present and past malfunction codes.
M16020100005
MALFUNCTION CODE DISPLAY PATTERN
Malfunction Code 9 - 2 Check Engine Lamp
Code 9
Turn ON
Turn OFF 2.0s
1.5s a a a a a a a a a
Exhaust Brake Indicator Lamp
2.0s
Turn ON
Turn OFF a a a a
a = about 0.2 seconds
2.0s
Code 2
Malfunction Code 3 - 1 and 6 - 1
Check Engine Lamp
2s
Code 3 - 1
Exhaust Brake Indicator Lamp
2s
Code 6 - 1
Code 3 - 1
Code 6 - 1 M16020100006
3. (1)
ERASE THE MALFUNCTION CODE MEMORY. Disconnect the diagnosis monitor with the starter switch set to "ON". NOTICE: In case of disconnecting with the starter switch set to "LOCK", the malfunction code memory will not be erased. Always disconnect the diagnosis monitor with the starter switch set to ON. (2) (3) (4) M16020100007
Wait 5 seconds and connect the diagnosis monitor. This time, only the present malfunction codes are displayed. Compare the two sets of codes you get to determine which are the present codes and which are the past one's.
DN02–16
FUEL CONTROL (J08C: PRE-STROKE PUMP)
MALFUNCTION CODE TABLE CODE 1
MALFUNCTION CONTENTS
PROBABLE CAUSE
Normal function of system
—
2-1
Engine speed sensor no pulse
Excessive air gap or abnormality of sensor
3-1
Abnormality of engine speed sensor
Harness disconnection, short circuit or abnormality of sensor
4-1
Abnormality of coolant temperature sensor
Harness disconnection, short circuit or abnormality of sensor
6-1
Abnormality of starter switch
Short circuit or abnormality of starter switch
14-1
Abnormality of rack sensor
Harness disconnection, short circuit or abnormality of sensor
16-1
Abnormality of pre-stroke sensor
16-2
Abnormality of pre-stroke F/B
16-3
Abnormality of pre-stroke learning
16-4
Abnormality of pre-stroke power supply
Harness disconnection, short circuit
16-6
Abnormality of pre-stroke power supply relay control circuit
Harness disconnection, short circuit or abnormality of relay
22-1
Abnormality of ECU
Abnormality of ECU
23-1
Engine overrun
Engine speed is 3,800 r/min or more or abnormality of engine speed sensor
24-1
Engine over heat
Engine coolant temperature is 115°C {239°F} or abnormality of coolant temperature sensor
Harness disconnection, short circuit or abnormality of sensor
.
ENGINE SPEED SENSOR NO PULSE (MALFUNCTION CODE:2-1) M16020101BEF2011
1.
Check to see if the sensor is mounted loosely (Turn it by hand) NOTICE: This "Error" is generated (or displayed) when the starter switch is "ON" position and the Engine is not running, which does not mean "Abnormal status of the system". However, if this "Error" persists after the Engine starts, perform an inspection by the following steps: .
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–17
ABNORMALITY OF ENGINE SPEED SENSOR (MALFUNCTION CODE:3-1) M16020101BEF2021
1. (1) NE1+
(2) 1
2
3
4 5
6
7
8 9 10 11 12 13
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK" and disconnect the 26 pin connectors of ECU. Measure the resistance between NE1+ and NE1- terminals of 26 pin connectors (Chassis harness side). Standard: APPROX. 1.8kΩ at 20°C {68°F}
14 15 16 17 18 19 20 21 22 23 24 25 26
NE1-
M16020100008 .
NG
Proceed to 3
OK 2. (1) (2)
RECHECK THE MALFUNCTION CODE. Connect the 26 pin connectors and erase the past malfunction code. Check the malfunction code with the diagnosis monitor. Standard: code 1 (Normal function)
.
NG OK
Normal
• Bad contact of ECU connectors • Abnormality of ECU • Abnormality of ECU connectors
DN02–18
FUEL CONTROL (J08C: PRE-STROKE PUMP)
NE-
NE+
3. (1) (2)
CHECK THE ENGINE SPEED SENSOR. Disconnect the connectors of engine speed sensor. Measure the resistance between NE+ and NE- terminals of sensor connectors (Sensor harness side). Standard: APPROX. 1.8 kΩ at 20°C {68°F}
M16020100009 .
NG
Abnormality of sensor
OK
• Harness disconnection or short circuit • Bad contact of connectors
.
ABNORMALITY OF COOLANT TEMPERATURE SENSOR (MALFUNCTION CODE:4-1). M16020101BEF2031
1. (1) (2) (3)
CHECK THE RESISTANCE BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 16 pin connectors of ECU. Measure the resistance between THW+ and THW- terminals of 16 pin connectors (Chassis harness side). HINT: Measure the resistance under any condition of the following.
THW+
1
2
3
4 5
6
7
8
9 10 11 12 13 14 15 16
Standard: APPROX. 2.4 kΩ at 20°C {68°F} APPROX. 1.5 kΩ at 40°C {104°F} APPROX. 870 Ω at 60°C {140°F} APPROX. 530 Ω at 80°C {176°F}
THW-
M16020100022 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–19
2. CHECK THE COOLANT TEMPERATURE SENSOR. (1) Disconnect the connector of coolant temperature sensor. (2) Measure the resistance between terminals(Sensor side). HINT: Measure the resistance under any condition of the following. Standard: APPROX. 2.4 KΩ at 20°C {68°F} APPROX. 1.5 KΩ at 40°C {104°F} APPROX. 870 Ω at 60°C {140°F} APPROX. 530 Ω at 80°C {176°F} M16020100023 .
NG
Abnormality of coolant temperature sensor
OK
• Harness disconnection or short circuit • Abnormality of connectors • Bad contact of connectors
.
ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE:6-1) M16020101BEF2041
CAUTION: Make sure that transmission is in neutral position. 1. (1) ST
(2) 1
2
3
4 5
6
7
8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
+ -
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "LOCK" and disconnect the 22 pin connectors of ECU. Measure the voltage between ST and MGD1 terminals of 22 pin connectors. (Chassis harness side) Standard: Starter switch "LOCK" : 0V Starter switch "START" : 24V
MGD1
M16020100036 .
NG
Abnormality of harness
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
.
DN02–20
FUEL CONTROL (J08C: PRE-STROKE PUMP)
ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE:14-1) M16020101BEF2051
1. (1) (2)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 26 pin connectors of ECU and 4 pin connectors of injection pump. (3) Measure the resistance between terminals of 26 pin connectors and 4 pin connectors of injection pump (Chassis harness side). NOTICE: Combinations of terminals (26 pin connectors-4 pin connectors): RWGD-GND, RWML-MDL, RWOC-OSC.
RWML
1
2
3
4 5
6
7
8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard: 1 Ω or less RWOC RWGD MDL
1
2
3
4
GND
OSC
M16020100011 .
NG
Abnormality of harness and connectors
OK
• Abnormality of injection pump • Abnormality of ECU connectors • Bad contact of ECU connectors
.
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–21
ABNORMALITY OF PRE-STROKE SENSOR (MALFUNCTION CODE:16-1) M16020101BEF2061
1. (1) (2) (3)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 26 pin connectors of ECU. Measure the resistance between PMDL and PGND, PMDL and POSC terminals of 26 pin connectors (Chassis harness side). Standard: 4-9 Ω
PMDL
1
2
3
4 5
6
7
8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
PGND POSC
M16020100012 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
DN02–22
FUEL CONTROL (J08C: PRE-STROKE PUMP) 2. (1) (2)
PGND
CHECK THE PRE-STROKE SENSOR. Disconnect the connector of pre-stroke sensor. Measure the resistance between PMDL and PGND, PMDL and POSC terminals of sensor connectors (Sensor harness side) Standard: 4-9 Ω
PMDL
POSC
M16020100013 .
NG
Abnormality of pre-stroke sensor (Injection pump)
OK
• Harness disconnection or short circuit • Abnormality of connectors • Bad contact of connectors
.
ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE:16-2) M16020101BEF2071
1. (1) (2) (3)
PS+
1
2
3
4 5
6
7
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 26 pin connectors of ECU. Measure the resistance between PS+ and PS- terminals of 26 pin connectors (Chassis harness side). Standard: 2-4 Ω
8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
PS-
M16020100014 .
NG
Proceed to 2
OK
• • • •
Malfunction of pre-stroke actuator Malfunction of injection pump link mechanism Abnormality of ECU Abnormality of ECU connectors
FUEL CONTROL (J08C: PRE-STROKE PUMP)
PS-
2. (1) (2)
PS+
DN02–23
CHECK THE PRE-STROKE ACTUATOR. Disconnect the connector of pre-stroke actuator. Measure the resistance between PS+ and PS- terminals of actuator connectors (Actuator harness side). Standard: 2-4 Ω
M16020100015 .
NG
Abnormality of pre-stroke actuator (Injection pump)
OK
• Harness disconnection or short circuit • Abnormality of connectors • Bad contact of connectors
.
ABNORMALITY OF PRE-STROKE LEARNING (MALFUNCTION CODE:16-3) M16020101BEF2081
1.
Check that the malfunction code, 16-1, is being displayed, together with 16-3 in the order at the same time.
M16020100016 .
NG
Abnormal adjustment of pre-stroke sensor (Injection pump)
OK
Make sure to inspect it in accordance with the contents of Malfunction Code 16-1.
.
DN02–24
FUEL CONTROL (J08C: PRE-STROKE PUMP)
ABNORMALITY OF PRE-STROKE POWER SUPPLY (MALFUNCTION CODE:16-4) M16020101BEF2091
1. (1) (2) (3) (4)
PSP+
1
2
3
4 5
6
7
8 9 10 11 12 13
+
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 26 pin connectors of ECU. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between PSP+ and PSGD terminals of 26 pin connectors (Chassis harness side). Standard: Starter switch "LOCK" : 0V Starter switch "ON" : 24V
-
14 15 16 17 18 19 20 21 22 23 24 25 26
PSGD
M16020100017 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
2.
S-
CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY). Set the starter switch to "LOCK". Disconnect the pre-stroke power supply relay. Measure the resistance between B and NC terminals. Standard: 1 Ω or less
(1) (2) (3)
B
NC S+
M16020100018 .
NG
Abnormality of pre-stroke power supply relay
OK
• Harness disconnection or short circuit • Abnormality of connectors
.
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–25
ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY) CONTROL CIRCUIT (MALFUNCTION CODE:166) M16020101BEF2101
1. (1) (2) (3) (4)
PSRY
1
2
3
4 5
6
7
8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 26 pin connectors of ECU. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between PSRY and PSGD terminals of 26 pin connectors (Chassis harness side). Standard: Starter switch "LOCK" : 0V Starter switch "ON" : 24V
PSGD M16020100019 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
2. (1) (2) (3)
S-
CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY). Set the starter switch to "LOCK". Disconnect the pre-stroke power supply relay. Measure the resistance between S+ and S- terminals. Standard: 390-490 Ω
S+
M16020100020 .
NG OK
Abnormality of pre-stroke power relay
DN02–26
FUEL CONTROL (J08C: PRE-STROKE PUMP) 3. (1) (2)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch "LOCK". Disconnect the pre-stroke power supply relay and 26 pin connectors of ECU. Measure the resistance between PSRY terminal of 26 pin connectors (Chassis harness side) and S- terminal of relay connectors (Relay panel side). Standard: 1 Ω or less
(3)
S-
PSRY
1
2
3
4 5
6
7
8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
M16020100021 .
NG
• Harness disconnection • Abnormality of connectors
OK
Bad contact of connectors
.
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–27
ABNORMALITY OF ECU (MALFUNCTION CODE:22-1) M16020101BEF2111
1.
After the starter switch is positioned on the "LOCK" once, it shall be turned to "ON" position again.
2.
After erasing the malfunction memory stored in the past, check that the same code is displayed again.
M16020100016 .
NG
The same code is being shown up: Malfunction of ECU.
OK
Normal (Temporary malfunction because of radio interference noise)
.
ENGINE OVERRUN (MALFUNCTION CODE:23-1) M16020101BEF2121
1.
The malfunction code will be displayed, once detected over 3,800 r/min. in the Engine revolution. Also, the fuel injection will be suspended during the malfunction code to be detected and the fuel injection will be resumed when Engine revolution goes down less than 3,600 r/min. NOTICE: The malfunction code is aimed not for detecting the Engine overrun under abnormal operation of the system, but for storing in memory the high revolution of the Engine. (For detection of wrong shifting, etc.) Also, there is a case in which "over-run" will be detected by misunderstanding the Engine revolution, with a noise to be generated by harness abnormality and its modification. .
ENGINE OVERHEAT (MALFUNCTION CODE:24-1) M16020101BEF2131
1. (1) (2)
CHECK THE COOLANT TEMPERATURE SENSOR. Disconnect the connector of coolant temperature sensor. Measure the resistance between terminals.
HINT: Measure the resistance under any condition of the following. Standard: APPROX. 2.4 KΩ at 20°C {68°F} APPROX. 1.5 KΩ at 40°C {104°F} APPROX. 870 Ω at 60°C {140°F} APPROX. 530 Ω at 80°C {176°F} M16020100023
DN02–28
FUEL CONTROL (J08C: PRE-STROKE PUMP)
.
NG
Abnormality of coolant temperature sensor
OK
Abnormality of engine cooling system
HINT: This code will be displayed when the coolant temperature sensor operates normally and coolant temperature ascends over 115°C {239°F}. Also, while the malfunction code is being detected, Max. volume of fuel injection will be limited and will return back to normal control volume when it descends less than 105°C {221°F}. .
ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT M16020101BEF2141
26 PIN CONNECTORS
1
2
3
4 5
6
7
8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
VIEW
No.
SIGNAL
1
CONNECTING DESTINETION
CHASSIS HARNESS
No.
SIGNAL
—
14
—
2
—
15
—
3
—
16
—
4
MVB
Power source VB
17
EBLP
5
RWML
Rack sensor (Signal)
18
—
6
RWOC
Rack sensor (Power source)
19
RWGD
Rack sensor ground
7
PMDL
20
PSLD
Pre-stroke sensor shield
8
PGND
21
POSC
Pre-stroke sensor
9
—
22
—
10
NE+
23
NE-
11
—
24
PSRY
Pre-stroke power supply relay control
12
PSP+
Pre-stroke power supply
25
PSGD
Pre-stroke actuator ground
13
PS+
Pre-stroke actuator +
26
PS-
Pre-stroke sensor ground
Engine speed sensor +
CONNECTING DESTINETION
Exhaust brake indicator lamp
Engine speed sensor -
Pre-stroke actuator-
FUEL CONTROL (J08C: PRE-STROKE PUMP)
DN02–29
22 PIN CONNECTORS
1
2
3
4 5
6
7
8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
CHASSIS HARNESS
VIEW
No.
SIGNAL
1
—
2
VB1
3
CONNECTING DESTINETION
No.
SIGNAL
12
—
Power source (ECU main relay)
13
MGD1
MRL1
ECU main relay control
14
—
4
DGSW
Diagnosis monitor
15
IDLE
5
—
16
—
6
—
17
EBSW
7
ST
18
—
8
—
19
—
9
CE/G
Engine check warning lamp
20
—
10
SSWS
Power source (Fuse E/G2)
21
—
11
—
22
—
Power source (Starter switch)
CONNECTING DESTINETION
Ground
Exhaust brake accelerator switch
Exhaust brake switch
16 PIN CONNECTORS
1
2
3
4 5
6
7
8
9 10 11 12 13 14 15 16
VIEW
No.
SIGNAL
1
CONNECTING DESTINETION
CHASSIS HARNESS
No.
SIGNAL
—
9
—
2
—
10
—
3
—
11
—
4
—
12
—
5
—
13
—
6
THW+
14
THW-
7
—
15
—
8
CGD1
16
—
Coolant temperature sensor +
Ground
CONNECTING DESTINETION
Coolant temperature sensor -
DN02–30
FUEL CONTROL (J08C: PRE-STROKE PUMP)
12 PIN CONNECTORS
1
2
7 8
SIGNAL
1
4 5
6
CHASSIS HARNESS
VIEW
No.
3
9 10 11 12
CONNECTING DESTINETION
No.
SIGNAL
—
7
—
2
—
8
—
3
—
9
—
4
—
10
—
5
—
11
CASE
6
TACH
12
—
Tachometer
CONNECTING DESTINETION
ECU case ground
DISMOUNTING AND MOUTING M16020101BEF2150
IMPORTANT POINT - DISMOUNTING 1. (1) (2)
REMOVE THE SPEED SENSOR. Disconnect the connector (Black), loosen the lock nut using two wrenches. Remove the speed sensor from the adapter plate.
IMPORTANT POINT - MOUNTING 1. (1)
INSTALL THE SPEED SENSOR. Turn the crankshaft to align the mark 16, 34 or 25 on the outer periphery of the flywheel with the pointer of the flywheel housing. NOTICE: • The pulse protrusion will line up with the center of the hole at the piston top dead center point. • The speed sensor damage may occur during engine operation if these adjustments are neglected. M01010100061
(2)
Coat a sealing compound (Three-Bond 1215 or equivalent) on the thread face and lock nut sealing surface of the sensor. NOTICE: Sensor adjustment should be carried out within 30 minutes from application of the sealing compound. After 30 minutes, the sealing compound will harden and it will become difficult to turn the sensor by hand.
FUEL CONTROL (J08C: PRE-STROKE PUMP) (3)
Screw in the sensor by hand until the leading edge of the sensor lightly contacts to the protrusion.
(4)
After contacting the sensor to the protrusion, unscrew the sensor 1.0-1.5 turns (to create a gap of 1.0-1.5 mm {0.0394-0.0590 in.}). Tighten the lock nut while the hexagonal part on the sensor is held to prevent the gap from changing. Tightening Torque: 45-54 N⋅m {450-550 kgf⋅cm, 33-39 lbf⋅ft}
(5)
M16020100067
DN02–31
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–1
DN02
DN 02
TE SYSTEM ..............................................DN02-2 OVERVIEW ...................................................... DN02-2 COMPONENT LOCATOR................................ DN02-3 DIAGRAM ........................................................ DN02-9 PRECAUTIONS ............................................. DN02-11 INSPECTION ................................................. DN02-12 DIAGNOSIS USING THE DIAGNOSIS MONITOR (WITH MECHANICAL TRANSMISSION) ...... DN02-14 DIAGNOSIS USING THE DIAGNOSIS MONITOR (WITH AUTOMATIC TRANSMISSION). ........ DN02-16 ABNORMALITY OF MAIN ENGINE SPEED SENSOR (MALFUNCTION CODE:3-1) ......................... DN02-20 ABNORMALITY OF SUB ENGINE SPEED SENSOR (MALFUNCTION CODE:3-2) ......................... DN02-21 ABNORMALITY OF MAIN AND SUB ENGINE SPEED SENSOR (MALFUNCTION CODE:3-1 & 2) .. DN02-22 ABNORMALITY OF COOLANT TEMPERATURE SENSOR (MALFUNCTION CODE:4-1)......... DN02-23 ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE:6-1) ......................... DN02-24 ABNORMALITY OF BOOST PRESSURE SENSOR (MALFUNCTION CODE:7-1) ......................... DN02-24 ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 1 (MALFUNCTION CODE: 8-1)..... DN02-27 ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 2 (MALFUNCTION CODE: 8-2)..... DN02-29 ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 1 &2 (MALFUNCTION CODE 8-1 & 2)................... DN02-30 ABNORMALITY OF OUTPUT VOLTAGE OF ACCELERATOR SENSOR 1 (MALFUNCTION CODE: 8-3) ........................ DN02-31 ABNORMALITY OF OUTPUT VOLTAGE OF ACCELERATOR SENSOR 2 (MALFUNCTION CODE: 8-4) ........................ DN02-32 ABNORMALITY OF ACCELERATOR SWITCH (MALFUNCTION CODE: 8-6) ........................ DN02-33 ABNORMALITY OF Q-ADJUSTMENT RESISTER (MALFUNCTION CODE: 9-1) ........................ DN02-34 ABNORMALITY OF IDLE SET CONTROLLER (MALFUNCTION CODE: 9-2) ........................ DN02-35 ABNORMALITY OF VEHICLE SPEED SENSOR (MALFUNCTION CODE: 11-1) ...................... DN02-38 ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE:14-1) ....................... DN02-40 ABNORMALITY OF PRE-STROKE SENSOR (MALFUNCTION CODE:16-1) ....................... DN02-41 ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE:16-2) ....................... DN02-42
DN02-002
ABNORMALITY OF PRE-STROKE LEARNING (MALFUNCTION CODE:16-3) ....................... DN02-43 ABNORMALITY OF PRE-STROKE POWER SUPPLY (MALFUNCTION CODE:16-4) ....................... DN02-44 ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY) CONTROL CIRCUIT (MALFUNCTION CODE:16-6) ....... DN02-45 ABNORMALITY OF GOVERNOR F/B (MALFUNCTION CODE: 17-1) ...................... DN02-46 ABNORMALITY OF GOVERNOR (MALFUNCTION CODE: 17-2) ...................... DN02-47 ABNORMALITY OF ECU (MALFUNCTION CODE:22-1) ....................... DN02-49 ENGINE OVERRUN (MALFUNCTION CODE:23-1) ....................... DN02-49 ENGINE OVERHEAT (MALFUNCTION CODE:24-1) ....................... DN02-50 ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT ............................................... DN02-51 DISMOUNTING AND MOUTING................... DN02-55
DN02–2
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
TE SYSTEM OVERVIEW M16020101BEC1001
TE SYSTEM The TE (Total Electronics) system uses electronic control to regulate every aspect of the engine's running condition. It is a comprehensive electronic control system developed to extract maximum power and low-pollution of the engine. There are 4 types of the TE system, detail at below, this engine employ the "Pre-stroke" and "Electronic Governor" type.
Control of the Intake Air Type Pre-stroke Pump Type Hino TE System Electronic Governor Type Common Rail Fuel Injection Type M16020100081
PRE-STROKE PUMP AND ELECTRONIC GOVERNOR SYSTEM The Pre-stroke Pump and Electronic Governor System have a lot of control functions than the conventional injection pump system, These functions are controlled by the ECU (Electronic Control Unit).
Control of the Fuel Injection
Control of the Injection Timing
Function of Diagnosis
Control of the Injection Rate
Pre-stroke Pump and Electronic Governor Fuel Injection System Function of Tachometer Driver
M16020100082
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–3
COMPONENT LOCATOR M16020101BED1001
M16020100107
1
ECU main relay
8
Coolant temperature sensor
2
Actuator power supply relay
9
Booster pressure sensor
3
Pulse adjust computer
10
Electronic governor
4
Electronic governor ECU
11
Rack sensor and sub engine speed sensor
5
Accelerator sensor
12
Pre-stroke actuator and pre-stroke sensor
6
Accelerator switch
13
Main engine speed sensor
7
Q-adjustment resistor
DN02–4
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
M16020100069
1
Straight pin
17
Tappet roller
2
Control rack
18
Adapter
3
Housing
19
Tappet sub assembly
4
Element sub assembly
20
Plunger spring lower seat
5
Timing rod
21
Plunger spring
6
Bearing
22
Plunger spring upper seat
7
Bushing
23
Plunger control sleeve
8
Connector
24
Camshaft adjust ring
9
Shim
25
Over flow valve
10
Pointer
26
Delivery valve holder
11
Sleeve
27
Delivery valve stopper
12
Oil seal
28
Delivery valve spring
13
Bearing cover
29
Delivery valve
14
O-ring
30
Element holder
15
Camshaft
31
Tappet sub assembly for feed pump
16
Woodruff key
Tightening torque A 108 {1,100, 80}
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–5
M16020100125
1
Control unit
4
Governor housing sub assembly
2
Load sensor sub assembly
5
Governor housing
3
Gasket
6
Governor cover sub assembly
DN02–6
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
M16020100070
1
Screw plug
10
Shim
2
Gasket
11
Retainer ring
3
Timer hub
12
Timer weight
4
Timer cam
13
Plain washer
5
Nut
14
O-ring
6
Timer driving flange
15
Timer cover
7
Shaft
16
Oil seal
8
Timer spring seat
17
Speed sensor
9
Timer spring
18
Bracket
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–7
M16020100071
1
Joint bolt
7
Priming pump
2
Gasket
8
Connector
3
Feed pump housing
9
Plug
4
Check valve
10
Piston spring
5
Check valve spring
11
Piston
6
O-ring
12
Push rod
DN02–8
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
M16020100042
1
Pre-stroke actuator and pre-stroke sensor
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–9
DIAGRAM M16020101BEJ1001
FUEL SYSTEM
ELECTRICAL WIRING CHECK ENGINE LAMP
ACCELERATOR SENSOR
CONTROL UNIT POWER SUPPLY
COOLANT TEMPERATURE SENSOR
SUB ENGINE SPEED SENSOR, RACK SENSOR AND ELECTRONIC GOVERNOR ACTUATOR
PRE-STROKE ACTUATOR
MAIN ENGINE SPEED SENSOR INJECTION PUMP
M16020100072
DN02–10
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ELECTRICAL SYSTEM +24 V CONTROL UNIT MAIN ENGINE SPEED SENSOR
ACTUATOR POWER SUPPLY RELAY (N.C)
SUB ENGINE SPEED SENSOR
PRE-STROKE ACTUATOR
COOLANT TEMPERATURE SENSOR
GOVERNOR ACTUATOR
RACK SENSOR PRE-STROKE SENSOR
EXHAUST BRAKE SWITCH
BOOST PRESSURE SENSOR ACCELERATOR SENSOR 1
CPU
CHECK ENGINE WARNING LAMP
ACCELERATOR SENSOR 2
BRAKE SWITCH 2 (WITH AUTOMATIC TRANSMISSION)
IDLE SETTING BUTTON
POWER TAKE-OFF CLUTCH SWITCH (WITH MECHANICAL TRANSMISSION)
Q-ADJUSMENT RESISTER VEHICLE SPEED SENSOR TACHOMETER ECU MAIN RELAY (N.O)
EXHAUST BRAKE INDICATOR LAMP
STARTER SWITCH
DIAG
N.O: Normal open, N.C: Normal close M16020100126
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–11
PRECAUTIONS M16020101BEC1011
1.
BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE ACTUATOR OR MAGNETIC VALVES.
2.
PRE-STROKE ACTUATOR.
•
Never apply electricity to the pre-stroke actuator except through the control unit. Never connect the actuator connectors directly to a power source. Doing so could burn out the actuator coil.
•
Also, note that the mounting position of the actuator is carefully adjusted. Never do anything that could change the actuator's mounting position.
•
To have the actuator or sensor replaced, contact an establishment specializing in BOSCH (ZEXEL).
3. (1)
HARNESS WIRE CONNECTOR. Multi-contact connectors suitable for the small electrical signals of electronic circuity are used for wiring connections to the sensors, actuator and control unit. Be very careful when handling them.
•
Before disconnecting any connectors, make sure that the starter switch is in the "LOCK" position.
•
When disconnecting connectors, try to pull them out in a straight line, disengaging the lock and holding onto the housing.
•
Do not try to disconnect connectors by gripping the wires or twisting them, as this could bend the contacts.
• •
Do not disconnect connectors unnecessarily. When using a circuit tester, apply the tester probe to the harness wire side only. Never stick the tester probe into the holes on the connector terminal side, as this could cause poor contacts when the connector is reconnected.
M16020100032
•
Do not let water, oil or dust get on the connector when it is disconnected, as this could cause poor contacts when the connector is reconnected.
•
Do not open the control unit cover. It could malfunction if dust or water get inside.
•
Take care to ensure that water, oil or dust do not get on or inside parts.
•
When connecting in connectors, push them in all the way and make sure that the lock engages.
4.
ERASING THE MALFUNCTION MEMORY STORED IN THE PAST, CHECK THE CURRENT MALFUNCTION BY PERFORMING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
DN02–12
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) 5.
AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE THE MALFUNCTION MEMORY STORED IN THE PAST. OTHERWISE, THE MALFUNCTION LAMP IN THE DISPLAY WILL REMAIN LIT.
6.
CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING LEAD FROM THE BACKSIDE.
7.
USING A CIRCUIT TESTER
•
Use a circuit tester with an internal resistance of 100 kΩ or greater in the voltage measuring range.
8. •
RADIO INSTALLATION
9.
USING A QUICK CHARGER
•
Disconnect both battery terminal before using a quick charger.
There is a danger that the control unit might malfunction if a high output radio transmitter (over 50W) is installed in the vehicle.
10. AIR CONDITIONER INSTALLATION • Be careful not to scratch or damage the engine, chassis or the harness inside the cab when installing an air conditioner. Also, make sure to reattach afterward any connectors that were disconnecting during the installation process. 11. ELECTRIC WELDING PERFORMING • Disconnect connector to the control unit before performing any electric welding. 12.
OTHER
•
Make sure to check the fellow of connectors before connecting them in to prevent incorrect connections.
•
Be careful not to allow the connectors to become soiled with dust, water, fuel or oil when performing inspections or removing and replacing parts.
INSPECTION M16020101BEH3001
CHECK ENGINE LAMP STATUS 1. (1)
INSPECTION PROCEDURE Turn the starter switch to the ON position (do not start the engine) and confirm that the Check Engine Lamp in the indicator area lights up.
(2) (3) (4)
Start the engine. If the engine is normal, the Check Engine Lamp goes out. If the Check Engine Lamp does not light up or if it blinks, there is trouble in the system. Check the system according to the following chart.
. M16020100033
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–13
CHECK ENGINE WARNING LAMP ILLUMINATION PATTERN
ON
BLINKING
Major
OFF 0.5 sec
0.5 sec
0.5 sec
0.5 sec
0.5 sec
Degree of trouble
ON ON (1) OFF
ON Minor OFF
ON (2) Light up 30 seconds after engine started
M16020100034
The lamp ON/OFF status and illumination pattern as well as the corresponding conditions they indicate and the measures to be taken-are shown in the following table. Lamp ON/OFF STATUS
Blinking
This indicates that the engine has stopped or it will not start. Turn the starter switch to the [LOCK] position and wait few seconds. If the engine does not start and the lamp lights in continuously or blinking after the starter switch is turned to the [START] position, and move the vehicle to a safe location by traction.
ON (1)
This indicates that the engine has insufficient force and irregular idling occurred due to a system damage. This condition must be inspected at a Hino service dealer as soon as possible.
ON (2)
This indicates that a light damage has occurred in the system. Driving is possible, but this condition must be inspected at a HIno service dealer as soon as possible.
DN02–14
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DIAGNOSIS USING THE DIAGNOSIS MONITOR (WITH MECHANICAL TRANSMISSION) M16020101BEF2001
1.
CONNECT THE DIAGNOSIS MONITOR. SST: Diagnosis monitor (09630-1370)
NOTICE: Trouble diagnosis also can be performed using the diagnosis monitor. The malfunction codes are indicated by sound and light. (1)
Turn the starter switch to the "ON" (Do not start the engine).
(2)
Connect the harness to the diagnosis connector. SST: Harness (09630-2300)
(3)
Connect the diagnosis monitor to the connector which tagged a "STD-ENG" label.
2. (1)
READ OUT THE MALFUNCTION CODE. Turn on the exhaust brake switch.
M16020100001
M16020100002
M16020100003
M16020100004
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (2)
DN02–15
Check engine lamp and exhaust brake indicator lamp flashes on and off to inform the malfunction codes.
(3)
Read out the malfunction codes and write down the malfunction codes that are displayed. NOTICE: Malfunction codes are displayed, starting from the lowest and progressing upward, with no distinction between present and past malfunction codes.
M16020100005
MALFUNCTION CODE DISPLAY PATTERN
Malfunction Code 9 - 2 Check Engine Lamp
Code 9
Turn ON
Turn OFF 2.0s
1.5s a a a a a a a a a
Exhaust Brake Indicator Lamp
2.0s
Turn ON
Turn OFF a a a a
a = about 0.2 seconds
2.0s
Code 2
Malfunction Code 3 - 1 and 6 - 1
Check Engine Lamp
2s
Code 3 - 1
Exhaust Brake Indicator Lamp
2s
Code 6 - 1
Code 3 - 1
Code 6 - 1 M16020100006
3. (1)
ERASE THE MALFUNCTION CODE MEMORY. Disconnect the diagnosis monitor with the starter switch set to "ON". NOTICE: In case of disconnecting with the starter switch set to "LOCK", the malfunction code memory will not be erased. Always disconnect the diagnosis monitor with the starter switch set to ON. (2) (3) (4) M16020100007
.
Wait 5 seconds and connect the diagnosis monitor. This time, only the present malfunction codes are displayed. Compare the two sets of codes you get to determine which are the present codes and which are the past one's.
DN02–16
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DIAGNOSIS USING THE DIAGNOSIS MONITOR (WITH AUTOMATIC TRANSMISSION). M16020101BEF2023
1. (1) (2)
REMOVE THE FUSE OF THE AUTOMATIC TRANSMISSION ECU. Set the starter switch to the "LOCK". Remove the fuse (TRANSFER CONTROL AUTO T/M) of the automatic transmission ECU.
M16020100127
2.
CONNECT THE DIAGNOSIS MONITOR. SST: Diagnosis monitor (09630-1370)
NOTICE: Trouble diagnosis also can be performed using the diagnosis monitor. The malfunction codes are indicated by sound and light. (1)
Turn the starter switch to the "ON" (Do not start the engine).
(2)
Connect the harness to the diagnosis connector. SST: Harness (09630-2300)
M16020100001
M16020100002
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–17
(3)
Connect the diagnosis monitor to the connector which tagged a "STD-ENG" label.
3. (1)
READ OUT THE MALFUNCTION CODE. Turn on the exhaust brake switch.
(2)
Check engine lamp and exhaust brake indicator lamp flashed on and off to inform the malfunction codes.
M16020100003
M16020100004
(3)
Read out the malfunction codes and write down the malfunction codes that are displayed. NOTICE: Malfunction codes are displayed, starting from the lowest and progressing upward, with to distinction between present and past malfunction codes.
M16020100005
DN02–18
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
MALFUNCTION CODE DISPLAY PATTERN
Malfunction Code 9 - 2 Check Engine Lamp
Code 9
Turn ON
Turn OFF 2.0s
1.5s a a a a a a a a a
Exhaust Brake Indicator Lamp
2.0s
Turn ON
Turn OFF a a a a
a = about 0.2 seconds
2.0s
Code 2
Malfunction Code 3 - 1 and 6 - 1
Check Engine Lamp
2s
Code 3 - 1
Exhaust Brake Indicator Lamp
2s
Code 6 - 1
Code 3 - 1
Code 6 - 1 M16020100006
4. (1)
ERASE THE MALFUNCTION CODE MEMORY. Disconnect the diagnosis monitor with the starter switch set to "ON". NOTICE: In case of disconnecting with the starter switch set to "LOCK", the malfunction code memory will not be erased. Always disconnect the diagnosis monitor with the stater switch set to "ON". (2) (3) (4) M16020100007
Wait 5 seconds and connect the diagnosis monitor. This time, only the present malfunction codes are displayed. Compare the two sets of codes you get to deter mine which are the present codes and which are the past one's.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) 5. (1) (2)
DN02–19
INSTALL THE FUSE OF AUTOMATIC TRANSMISSION ECU. Set the starter switch to the "LOCK". Install the fuse (TRANSFER CONTROL AUTO T/M: 10A) of the automatic transmission ECU.
M16020100128
MALFUNCTION CODE TABLE CODE 1
MALFUNCTION CONTENTS Normal function of system
3-1
Abnormality of main engine speed sensor
3-2
Abnormality of sub engine speed sensor
PROBABLE CAUSE —
Harness disconnection, short circuit or abnormality of sensor
3-1 & 2
Abnormality of main and sub engine sensor
4-1
Abnormality of coolant temperature sensor
Harness disconnection, short-circuit or abnormality of sensor
6-1
Abnormality of starter switch
Short-circuit or abnormality of starter switch
7-1
Abnormality of boost pressure sensor
Harness disconnection, short circuit or abnormality of sensor
8-1
Abnormality of voltage of accelerator sensor 1
8-2
Abnormality of voltage of accelerator sensor 2
8-1 & 2
Abnormality of voltage of accelerator sensor 1&2
8-3
Abnormality of output voltage of accelerator sensor 1
8-4
Abnormality of output voltage of accelerator sensor 2
8-6
Abnormality of accelerator switch
Short-circuit of accelerator switch
9-1
Abnormality of Q-adjustment resistor
Q-adjustment resistor is not installed. Short-circuit
9-2
Abnormality of idle set controller
Short-circuit or abnormality of idle set controller
11-1
Abnormality of vehicle speed sensor
Harness disconnection, short circuit or abnormality of sensor
14-1
Abnormality of rack sensor
Harness disconnection, short circuit or abnormality of sensor
16-1
Abnormality of pre-stroke sensor
16-2
Abnormality of pre-stroke F/B
16-3
Abnormality of pre-stroke learning
16-4
Abnormality of pre-stroke power supply
Harness disconnection, short-circuit
16-6
Abnormality of pre-stroke power supply relay control circuit
Harness disconnection, short-circuit or abnormality of relay
17-1
Abnormality of governor F/B
Abnormality of injection pump
Harness disconnection, short-circuit or abnormality of sensor
Harness disconnection, short-circuit or abnormality of sensor
DN02–20
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
MALFUNCTION CODE TABLE CODE
MALFUNCTION CONTENTS
PROBABLE CAUSE
17-2
Abnormality of governor F/B
Harness disconnection
22-1
Abnormality of ECU
Abnormality of ECU
23-1
Engine overrun
Engine speed is 3,800 r/min or more or abnormality of engine speed sensor
24-1
Engine over heat
Engine coolant temperature is 115°C {239°F} or above or abnormality of coolant temperature sensor *Q-adjustment resistor: Resistor for adjusting MAX. injection volume .
ABNORMALITY OF MAIN ENGINE SPEED SENSOR (MALFUNCTION CODE:3-1) M16020101BEF2021
1. (1)
NE1+
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK" and disconnect the 32 pin connectors of ECU. Measure the resistance between NE1+ and NE1- terminals of 32 pin connectors (Chassis harness side). Standard: APPROX. 1.8kΩ at 20°C {68°F}
(2) 1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
NE1M16020100074 .
NG
Proceed to 3
OK 2. (1)
RECHECK THE MALFUNCTION CODE. Connect the 32 pin connectors and erase the past malfunction code. Check the malfunction code with the diagnosis monitor. Standard: code 1 (Normal function)
(2) .
NG OK
Normal
• Bad contact of ECU connectors • Abnormality of ECU • Abnormality of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
NE+
NE-
3. (1) (2)
DN02–21
CHECK THE MAIN ENGINE SPEED SENSOR. Disconnect the connectors of main engine speed sensor. Measure the resistance between NE+ and NE- terminals of sensor connectors (Sensor harness side). Standard: APPROX. 1.8 kΩ at 20°C {68°F}
M16020100075 .
NG
Abnormality of sensor (Injection pump)
OK
• Harness disconnection or short circuit • Bad contact of connectors
.
ABNORMALITY OF SUB ENGINE SPEED SENSOR (MALFUNCTION CODE:3-2) M16020101BEF2037
1. (1)
NE2+
(2) 1 2 3 4
5 6 7
8 9 10 11
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK" and disconnect the 32 pin connectors of ECU. Measure the resistance between NE2+ and NE2- terminals of 32 pin connectors (Chassis harness side). Standard: APPROX. 1.8kΩ at 20°C {68°F}
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
NE2M16020100076 .
NG OK
Proceed to 3
DN02–22
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) 2. (1)
RECHECK THE MALFUNCTION CODE. Connect the 32 pin connectors and erase the past malfunction code. Check the malfunction code with the diagnosis monitor. Standard: code 1 (Normal function)
(2) .
NG OK
• Bad contact of ECU connectors • Abnormality of ECU • Abnormality of ECU connectors
Normal
NE+
3. (1) (2)
NE-
CHECK THE SUB ENGINE SPEED SENSOR. Disconnect the connectors of sub engine speed sensor. Measure the resistance between NE+ and NE- terminals of sensor connectors (Sensor harness side). Standard: APPROX. 1.8 kΩ at 20°C {68°F}
M16020100129 .
NG
Abnormality of sensor (Injection pump)
OK
• Harness disconnection or short circuit • Bad contact of connectors
.
ABNORMALITY OF MAIN AND SUB ENGINE SPEED SENSOR (MALFUNCTION CODE:3-1 & 2) M16020101BEF2024
1. .
MAKE SURE TO INSPECT IT IN ACCORDANCE WITH THE CONTENTS OF MALFUNCTION CODE 3-1 AND 3-2.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–23
ABNORMALITY OF COOLANT TEMPERATURE SENSOR (MALFUNCTION CODE:4-1) M16020101BEF2031
1. (1) (2) (3)
CHECK THE RESISTANCE BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 32 pin connectors of ECU. Measure the resistance between THW+ and THW- terminals of 32 pin connectors (Chassis harness side). HINT: Measure the resistance under any condition of the following.
THW+
1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
Standard: APPROX. 2.4 kΩ at 20°C {68°F} APPROX. 1.5 kΩ at 40°C {104°F} APPROX. 870 Ω at 60°C {140°F} APPROX. 530 Ω at 80°C {176°F}
THWM16020100077 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
2. CHECK THE COOLANT TEMPERATURE SENSOR. (1) Disconnect the connector of coolant temperature sensor. (2) Measure the resistance between terminals. HINT: Measure the resistance under any condition of the following. Standard: APPROX. 2.4 KΩ at 20°C {68°F} APPROX. 1.5 KΩ at 40°C {104°F} APPROX. 870 Ω at 60°C {140°F} APPROX. 530 Ω at 80°C {176°F} M16020100023 .
NG
Abnormality of coolant temperature sensor
OK
• Harness disconnection or short circuit • Abnormality of connectors • Bad contact of connectors
.
DN02–24
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE:6-1) M16020101BEF2041
CAUTION: Make sure that transmission is in neutral position. 1. (1)
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "LOCK" and disconnect the 25 pin connectors of ECU. Measure the voltage between ST and MGD1 terminals of 25 pin connectors. (Chassis harness side) Standard: Starter switch "LOCK" : 0V Starter switch "START" : 24V
ST
(2) 1 2 3
4 5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 2021
22 23
+ -
24 25
MGD1 M16020100078 .
NG
Abnormality of harness
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
.
ABNORMALITY OF BOOST PRESSURE SENSOR (MALFUNCTION CODE:7-1) M16020101BEF2043
1. (1)
PIM 1 2 3 4
5 6 7
25
26 27 2829
(2)
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the stater switch to "ON" (ECU connectors remain connected and the engine is stopped). Measure the voltage between PIM and PIM- terminals of 32 pin connectors. Standard: 0.2-4.8V
+
-
30 31 32
PIMECU
VIEW M16020100145
.
NG
Proceed to (3)
OK
• Abnormality of ECU • Abnormality of ECU connectors • Bad contact of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (3) GND
VCC
(4)
DN02–25
Set the starter switch to "LOCK" and disconnect the connector of boost pressure sensor. Set the starter switch to"ON" and measure the voltage between VCC and GND Terminals (Chassis harness side). Standard: 4.5V or more
M16020100053 .
NG
Proceed to 2 - (4)
OK PIM
1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
SIG
2. (1) (2) (3)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the stater switch to "LOCK". Disconnect the 32 pin connectors of ECU and connector of boost pressure sensor. Measure the resistance between PIM terminal of 32 pin connectors and SIG connector of boost pressure sensor (Chassis harness side). Standard: 2Ω or less
M16020100146 .
NG
Abnormality of harness
OK
• Abnormality of boost pressure sensor • Bad contact of connectors
DN02–26
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
PIM+
(4) (5) 1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
Set the starter switch to "LOCK". Disconnect the 32 pin connectors of ECU and connector of boost pressure sensor. Measure the resistance between PIM+ terminal of 32 pin connectors and VCC terminal of boost pressure sensor (Chassis harness side), PIM- terminal of 32 pin connectors and GND terminal of boost pressure sensor (Chassis harness side). Standard: 2Ω or less
30 31 32
(6)
VCC
M16020100147
PIM1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
GND
M16020100148 .
NG
Abnormality of harness
OK
• Abnormality of ECU • Bad contact of connectors
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–27
ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 1 (MALFUNCTION CODE: 8-1) M16020101BEF2025
1. (1) GND1
(2) (3)
CHECK THE VOLTAGE BETWEEN TERMINALS. Disconnect the connector of the accelerator sensor (ECU connectors remain connected). Set the starter switch to "ON" (The engine is stopped). Measure the voltage between VCC1 and GND1 terminals of accelerator sensor (Chassis harness side). Standard: 4.5-5.5 V
VCC1
M16020100130 .
NG
Proceed to (4)
OK
Proceed to (5)
(4) VAC1
10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
Measure the voltage between VAC1 and AGD1 terminals of 31 pin connectors. Standard: 4.5-5.5 V
+ -
252423
AGD1 ECU
VIEW M16020100079
.
NG
• Abnormality of ECU • Abnormality of ECU connectors
OK
Abnormality of harness
DN02–28
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (5) (6) (7) (8)
ACS1 10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
Set the starter switch to "LOCK". Connect the connector of the accelerator sensor. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between ACS1 and AGD1 terminals of 31 pin connectors. Standard: 0.7-1.0 V: Release the accelerator pedal. 3.55-4.0 V: Depress the accelerator pedal fully.
+ -
252423
AGD1 ECU
VIEW M16020100080
.
NG
Proceed to (9)
OK
• Abnormality of ECU • Abnormality of ECU connectors
(9)
Measure the voltage between SIG1 and GND1 terminals of accelerator sensor. (Chassis harness side). Standard: 0.7-1.0 V: Release the accelerator pedal. 3.55-4.0 V: Depress the accelerator pedal fully.
GND1
1 2 3
+ -
4 5 6
SIG1 VIEW CHASISS HARNESS SIDE M16020100083 .
NG
Abnormality of accelerator sensor
OK
Harness disconnection or short circuit
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–29
ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 2 (MALFUNCTION CODE: 8-2) M16020101BEF2026
1. (1) VCC2
GND2
(2) (3)
CHECK THE VOLTAGE BETWEEN TERMINALS Disconnect the connector of the accelerator sensor (ECU connectors remain connected). Set the starter switch to "ON" (The engine is stopped). Measure the voltage between VCC2 and GND2 terminals of accelerator sensor (Chassis harness side). Standard: 4.5-5.5 V
M16020100110 .
NG
Proceed to (4)
OK
Proceed to (5)
(4) VAC2
10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
Measure the voltage between VAC2 and AGD2 terminals of 31 pin connectors. Standard: 4.5-5.5 V
+ -
252423
AGD2 ECU
VIEW M16020100085
.
NG
• Abnormality of ECU • Abnormality of ECU connectors
OK
Abnormality of harness
DN02–30
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (5) (6) (7) (8)
ACS2 10 9 8 7
6 5 4
3 2 1
+ -
222120191817161514131211 313029
282726
Set the starter switch to "LOCK". Connect the connector of the accelerator sensor. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between ACS2 and AGD2 terminals of 31 pin connectors. Standard: 0.7-1.0 V: Release the accelerator pedal. 3.55-4.0 V: Depress the accelerator pedal fully.
252423
AGD2 ECU
VIEW M16020100086
.
NG
Proceed to (9)
OK
• Abnormality of ECU • Abnormality of ECU connectors
(9)
Measure the voltage between SIG2 and GND2 terminals of accelerator sensor. (Chassis harness side). Standard: 0.7-1.0 V: Release the accelerator pedal. 3.55-4.0 V: Depress the accelerator pedal fully.
GND2
1 2 3
+ -
4 5 6 SIG2
VIEW CHASISS HARNESS SIDE M16020100087 .
NG
Abnormality of accelerator sensor
OK
Harness disconnection or short circuit
.
ABNORMALITY OF VOLTAGE OF ACCELERATOR SENSOR 1 &2 (MALFUNCTION CODE 8-1 & 2) M16020101BEF2027
1. .
MAKE SURE TO INSPECT IT IN ACCORDANCE WITH THE CONTENTS OF MALFUNCTION CODE 8-1 AND 8-2.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–31
ABNORMALITY OF OUTPUT VOLTAGE OF ACCELERATOR SENSOR 1 (MALFUNCTION CODE: 8-3) M16020101BEF2028
1. (1) (2)
ACS1 10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
+ -
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between ACS1 and AGD1 terminals of 31 pin connectors (ECU connectors remain connected). Standard: 0.7-1.0 V: Release the accelerator pedal
252423
AGD1 ECU
VIEW M16020100080
.
NG
Abnormality of accelerator sensor
OK (3) ACS1 10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
+ -
Measure to voltage between ACS1 and AGD1 by depressing acceleration pedal deeply. Standard: More than 1.0 V (The voltage should be changed in proportion to depressing amount of the accelerator.)
252423
AGD1 ECU
VIEW M16020100080
.
NG
Abnormality of accelerator sensor
OK
Abnormality of harness
.
DN02–32
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ABNORMALITY OF OUTPUT VOLTAGE OF ACCELERATOR SENSOR 2 (MALFUNCTION CODE: 8-4) M16020101BEF2029
1. (1) (2)
ACS2 10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between ACS2 and AGD2 of 31 pin connectors (ECU connectors remain connected).
+ -
Standard: 0.7-1.0 V: Release the accelerator pedal
252423
AGD2 ECU
VIEW M16020100086
.
NG
Abnormality of accelerator sensor
OK (3)
Measure to voltage between ACS2 and AGD2 by depressing acceleration pedal deeply. Standard: More than 1.0 V (The voltage should be changed in proportion to depressing amount of the accelerator.)
ACS2 10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
+ -
252423
AGD2 ECU
VIEW M16020100086
.
NG
Abnormality of accelerator sensor
OK
Abnormality of harness
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–33
ABNORMALITY OF ACCELERATOR SWITCH (MALFUNCTION CODE: 8-6) M16020101BEF2030
1. (1)
IDLE
10 9 8 7
6 5 4
3 2 1
222120191817161514131211 313029
282726
(2)
+ -
252423
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "ON" (ECU connector remain connected and the engine is stopped). Measure the voltage between IDLE and CASE terminals of 31 pin connectors. Standard: 19 V or more: Release the accelerator pedal 0 V: Depress the accelerator pedal fully
CASE ECU
VIEW M16020100090
.
NG
Proceed to 2
OK
Abnormality of ECU
2. (1) (2) (3)
CHECK THE CONTINUTY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the connector of accelerator switch. Measure the resistance between terminals of switch connector (Switch side). Standard: 2 Ω or less: Release the accelerator pedal ∞ Ω: Depress the accelerator pedal fully
M16020100111 .
NG
Abnormality of accelerator switch
OK
Abnormality of harness
.
DN02–34
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ABNORMALITY OF Q-ADJUSTMENT RESISTER (MALFUNCTION CODE: 9-1) M16020101BEF2100
1.
CHECK IF CORRECTLY INSTALLED THE Q-ADJUSTMENT RESISTOR.
.
NG OK
2. (1)
CHECK THE RESISTENCE BETWEEN TERMINALS. Set the starter switch to "LOCK" and disconnect the 25 pin connectors of ECU. Measure the resistance between QREG and QGND terminals of 25 pin connectors (Chassis harness side). Standard:
QREG
(2) 1 2 3
4 5 6
7 8
9 10 11 12 13 14 15 16 17 18 192021
22 23
24 25
No resistance of Q-adjustment resistor: Install the register No.4 of Q-adjustment resistor as listed below.
Resistor NO.
Part number
Resistor value (Unit: Ω)
1
21109-1010
270 Ω
Black
White
2
21109-1020
510 Ω
↑
Green
3
21109-1030
820 Ω
↑
Yellow
4
21109-1040
1,300 Ω
↑
Brown
5
21109-1050
2,000 Ω
Blue
White
6
21109-1060
3,300 Ω
↑
Green
7
21109-1070
5,600 Ω
↑
Yellow
8
21109-1080
15,000 Ω
↑
Brown
QGND M16020100091
.
NG
Proceed to (3)
OK
• Abnormality of ECU • Abnormality of ECU connector
Color of identification Main body
Connector
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (3) (4)
DN02–35
Remove the Q-adjustment resistor. Measure the resistance between terminals of resistor (Resistor side). Standard:
Resistor NO.
Part number
Resistor value (Unit: Ω)
1
21109-1010
2
21109-1020
3 4
Color of identification Main body
Connector
270 Ω
Black
White
510 Ω
↑
Green
21109-1030
820 Ω
↑
Yellow
21109-1040
1,300 Ω
↑
Brown
5
21109-1050
2,000 Ω
Blue
White
6
21109-1060
3,300 Ω
↑
Green
7
21109-1070
5,600 Ω
↑
Yellow
8
21109-1080
15,000 Ω
↑
Brown
M16020100112
.
NG
Abnormality of Q-adjustment resistor
OK
Harness disconnection or short circuit
.
ABNORMALITY OF IDLE SET CONTROLLER (MALFUNCTION CODE: 9-2) M16020101BEF2032
1. (1) GND
(2) (3)
CHECK THE VOLTAGE BETWEEN TERMINALS. Disconnect the connector of idle set controller (ECU connectors remain connected). Set the starter switch to "ON" (The engine is stopped). Measure the voltage between + and GND terminals of idle set controller connectors (Chassis harness side). Standard: 4.5-5.5 V
+
M16020100113 .
NG OK
Proceed to (5)
Proceed to (4)
DN02–36
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (4)
Measure the voltage between IV+ and IVG terminals of 26 pin connectors. Standard: 4.5-5.5 V
IV+
13 12 11 10 9 8 7 6 5 4 3 2 1
+ -
26 25 24 23 22 21 20 19 18 17 16 15 14
IVG ECU
VIEW M16020100093
.
NG
• Abnormality of ECU • Abnormality of ECU connectors
OK
Harness disconnection
IVS
13 12 11 10 9 8 7 6 5 4 3 2 1
+ -
(5) (6) (7) (8)
Set the starter switch to "LOCK" Connect the connector of idle set controller. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between IVS and IVG terminals of 26 pin connectors. Standard: APPROX. 0 V: Turn idle control knob to left fully APPROX. 0.7 V: Turn idle control knob to left. APPROX. 4.3 V: Turn idle control knob to right fully
26 25 24 23 22 21 20 19 18 17 16 15 14
IVG ECU
VIEW M16020100094
.
NG
Proceed to (9)
OK
• Abnormality of ECU • Abnormality of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (9)
Measure the voltage between SIG and GND terminals of Idle set controller connectors (Chassis harness side). Standard: APPROX. 0 V: Turn idle control knob to left fully APPROX. 0.7 V: Turn idle control knob to left. APPROX. 4.3 V: Turn idle control knob to right fully
M16020100114 .
NG
Abnormality of idle set controller
OK
Harness disconnection or short circuit
.
DN02–37
DN02–38
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ABNORMALITY OF VEHICLE SPEED SENSOR (MALFUNCTION CODE: 11-1) M16020101BEF2033
1. (1) (2)
VS
10 9 8 7
6 5 4
3 2 1
+ -
222120191817161514131211 313029
282726
252423
CHECK THE VOLTAGE BETWEEN TERMINALS. Start the engine (ECU connectors remain connected). Prepare the voltage measurement between VS and CASE terminals of 31 pin connectors. (3) Measure the voltage while the vehicle starts to run at the speed of 10 km/h{6.2 miles/h} NOTICE: Start the vehicle with much caution around.
CASE ECU
Standard: Pulse wave-shape by 12 V-0 V Stop the vehicle.
(4)
VIEW M16020100084
.
NG
Proceed to
OK
• Abnormality of ECU • Bad contact of harness connector
1 2 3
4 5 6
7 8 9 10
111213141516171819202122
1 2 3 4 5 6 7 8
2. (1) (2)
9 10 11 12 13 14 15 16
232425
VS
262728
293031
(3)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 31 pin connectors of ECU and connectors of pulse adjust computer. Measure the resistance between VS terminal of 31 pin connectors and PCO4 terminal of pulse adjust computer connectors (Chassis harness side). Standard: 1 Ω or less
PCO4
M16020100089 .
NG OK
Harness disconnection of vehicle speed sensor circuit
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (4) (5)
10 9 8 7
6 5 4
3 2 1
DN02–39
Connect the 31 pin connectors of ECU. Measure the resistance between VS terminal of 31 pin connectors and ground. Standard: ∞ Ω
GROUND
222120191817161514131211 313029
282726
252423
VS
ECU
VIEW
M16020100131 .
NG
Short circuit of vehicle speed sensor circuit
OK
Speed Sensor Fault (The speed sensor of vehicle should be solely checked. Delete the fault records in the past and if displayed again the same code on the screen after testing, ECU should be replaced with a new one.)
.
DN02–40
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE:14-1) M16020101BEF2051
1. (1) (2) 1 2 3
VIST
7 8
(3)
9 10 11 12 13 14 15 16 17 18 192021
1 2 3 4 5 6 7 8
4 5 6
22 23
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 25 pin connectors of ECU and 8 pin connectors of injection pump. Measure the resistance between VIST terminal of 25 pin connectors and VIST terminal of 8 pin connectors of injection pump (Chassis harness side). Standard: 1 Ω or less
24 25
VIST
M16020100098 .
NG
Abnormality of harness and connectors
OK
• Abnormality of injection pump • Abnormality of ECU connectors • Bad contact of ECU connectors
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–41
ABNORMALITY OF PRE-STROKE SENSOR (MALFUNCTION CODE:16-1) M16020101BEF2061
1. (1) (2) (3)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 32 pin connectors of ECU. Measure the resistance between PMDL and PGND, PMDL and POSC terminals of 32 pin connectors (Chassis harness side). Standard: 4-9 Ω
POSC PMDL
1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
PGND
M16020100099 .
NG
Proceed to 2
OK
• • • •
Abnormality of injection pump Abnormality of ECU Abnormality of ECU connectors Bad contact of ECU connectors
DN02–42
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) 2. (1) (2)
PGND
CHECK THE PRE-STROKE SENSOR. Disconnect the connector of pre-stroke sensor. Measure the resistance between PMDL and PGND, PMDL and POSC terminals of sensor connectors (Sensor harness side) Standard: 4-9 Ω
PMDL
POSC
M16020100013 .
NG
Abnormality of pre-stroke sensor (Injection pump)
OK
• Harness disconnection or short circuit • Abnormality of connectors • Bad contact of connectors
.
ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE:16-2) M16020101BEF2071
1. (1) (2) (3)
PS-
1 2 3 4
5 6 7
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 32 pin connectors of ECU. Measure the resistance between PS+ and PS- terminals of 32 pin connectors (Chassis harness side). Standard: 2-4 Ω
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
PS+ M16020100100 .
NG
Proceed to 2
OK
• • • •
Malfunction of pre-stroke actuator Malfunction of injection pump link mechanism Abnormality of ECU Abnormality of ECU connectors
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
PS-
2. (1) (2)
PS+
DN02–43
CHECK THE PRE-STROKE ACTUATOR. Disconnect the connector of pre-stroke actuator. Measure the resistance between PS+ and PS- terminals of actuator connectors (Actuator harness side). Standard: 2-4 Ω
M16020100015 .
NG
Abnormality of pre-stroke actuator (Injection pump)
OK
• Harness disconnection or short circuit • Abnormality of connectors • Bad contact of connectors
.
ABNORMALITY OF PRE-STROKE LEARNING (MALFUNCTION CODE:16-3) M16020101BEF2081
1.
Check that the malfunction code 16-1 is being displayed together with 16-3 in the order at the same time.
M16020100016 .
NG
Abnormal adjustment of pre-stroke sensor (Replace the injection pump)
OK
Make sure to inspect it in accordance with the contents of Malfunction Code 16-1.
.
DN02–44
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ABNORMALITY OF PRE-STROKE POWER SUPPLY (MALFUNCTION CODE:16-4) M16020101BEF2091
PSP+
+ 1 2 3 4
5 6 7
8 9 10 11
1. (1) (2) (3) (4)
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 32 pin connectors of ECU. Set the starter switch to "ON" (The engine is stopped). Measure the voltage between PSP+ and PSGD terminals of 32 pin connectors (Chassis harness side). Standard: Starter switch "LOCK" : 0V Starter switch "ON" : 24V
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
30 31 32
PSGD M16020100088 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors
2.
S-
CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY). Set the starter switch to "LOCK". Disconnect the pre-stroke power supply relay. Measure the resistance between B and NC terminals. Standard: 1 Ω or less
(1) (2) (3)
B
NC S+
M16020100018 .
NG
Abnormality of pre-stroke power supply relay
OK
• Harness disconnection or short circuit • Abnormality of connectors
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–45
ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY) CONTROL CIRCUIT (MALFUNCTION CODE:166) M16020101BEF2101
1. (1) (2) (3) (4)
PSRY
1 2 3
4 5 6
7 8 9 10
111213141516171819202122 232425
262728
+ -
293031
CHECK THE VOLTAGE BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 31 pin connectors of ECU. Set the starter switch to "ON". Measure the voltage between PSRY and CASE terminals of 31 pin connectors (Chassis harness side). Standard: Starter switch "LOCK" : 0V Starter switch "ON" : 24V
CASE M16020100092 .
NG
Proceed to 2
OK
• Abnormality of ECU • Abnormality of ECU connectors
2. (1) (2) (3)
S-
CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER SUPPLY CUT RELAY). Set the starter switch to "LOCK". Disconnect the pre-stroke power supply relay. Measure the resistance between S+ and S- terminals. Standard: 390-490 Ω
S+
M16020100020 .
NG OK
Abnormality of pre-stroke power supply relay
DN02–46
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) 3. (1) (2)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch "LOCK". Disconnect the pre-stroke power supply relay and 31 pin connectors of ECU. Measure the resistance between PSRY terminal of 31 pin connectors (Chassis harness side) and S- terminal of relay connectors (Relay panel side). Standard: 1 Ω or less
(3)
S-
1 2 3
4 5 6
7 8 9 10
111213141516171819202122 232425
262728
293031
PSRY
M16020100101 .
NG
• Harness disconnection • Abnormality of connectors
OK
Bad contact of connectors
.
ABNORMALITY OF GOVERNOR F/B (MALFUNCTION CODE: 17-1) M16020101BEF2034
1. (1) (2) 1 2 3
VIST
7 8
(3)
9 10 11 12 13 14 15 16 17 18 192021
1 2 3 4 5 6 7 8
4 5 6
22 23
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 25 pin connectors of ECU and 8 pin connectors of injection pump. Measure the resistance between VIST terminal of 25 pin connectors and VIST terminal of 8 pin connectors of injection pump (Chassis harness side). Standard: 1 Ω or less
24 25
VIST
M16020100098 .
NG
Abnormality of harness and connectors
OK
Abnormality of injection pump (Replace the injection pump)
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–47
.
ABNORMALITY OF GOVERNOR (MALFUNCTION CODE: 17-2) M16020101BEF2035
1. (1)
CHECK THE POSITION OF THE EMERGENCY ENGINE STOP KNOB AND STOP LEVER. Make sure that the emergency engine stop knob and the stop lever of the injection pump are returned to the engine start (drive) position.
.
NG
Return the emergency engine stop knob and stop lever to the engine start (drive) position
OK 2. (1) (2) (3)
CHECK THE CONTINUITY BETWEEN TERMINALS. Set the starter switch to "LOCK". Disconnect the 25pin connectors of ECU, 7 pin connectors of injection pump and 8 pin connectors of injection pump. Measure the resistance between terminals of 25 pin connectors and 7 pin connectors, 25 pin connectors and 8 pin connectors (Chassis harness side). Combination of terminals 7 pin connectors
1 2 3 1 2 3 4 5 6 7
4 5 6
7 8
25 pin connectors
Terminal No.
Terminal name
Terminal No.
Terminal name
1
GVB 2
7
GVB 2
2
GND 1
17
GND 1
3
SOL 1
6
SOL 1
4
+5V 1
5
+5V 1
9 10 11 12 13 14 15 16 17 18 19 2021
22 23
24 25
M16020100095
DN02–48
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
8 pin connectors
1 2 3 1 2 3 4 5 6 7 8
4 5 6
Terminal No.
Terminal name
Terminal No.
Terminal name
1
GVB 1
8
GVB 1
2
GND 2
24
GND 2
3
SOL 2
15
SOL 2
4
+5V 2
14
+5V 2
7 8
Standard: 1 Ω or less
9 10 11 12 13 14 15 16 17 18 19 2021
22 23
25 pin connectors
24 25
M16020100096 .
NG
Abnormality of harness and connectors
OK
• Abnormality of injection pump • Bad contact of connectors
.
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–49
ABNORMALITY OF ECU (MALFUNCTION CODE:22-1) M16020101BEF2111
1.
After the starter switch is positioned on the "LOCK" once, it shall be turned to "ON" position again.
2.
After erasing the malfunction memory stored in the past, check that the same code is displayed again.
M16020100016 .
NG
The same code is being shown up: Malfunction of ECU.
OK
Normal (Temporary malfunction because of radio interference noise)
.
ENGINE OVERRUN (MALFUNCTION CODE:23-1) M16020101BEF2121
1.
The malfunction code will be displayed, once detected over 3,800 r/min. in the Engine revolution. Also, the fuel injection will be suspended during the malfunction code to be detected and the fuel injection will be resumed when Engine revolution goes down less than 3,600 r/min. NOTICE: The malfunction code is aimed not for detecting the Engine overrun under abnormal operation of the system, but for storing in memory the high revolution of the Engine. (For detection of wrong shifting, etc.) Also, there is a case in which "over-run" will be detected by misunderstanding the Engine revolution, with a noise to be generated by harness abnormality and its modification. .
DN02–50
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
ENGINE OVERHEAT (MALFUNCTION CODE:24-1) M16020101BEF2131
1. (1) (2)
CHECK THE COOLANT TEMPERATURE SENSOR. Disconnect the connector of coolant temperature sensor. Measure the resistance between terminals.
HINT: Measure the resistance under any condition of the following. Standard: APPROX. 2.4 KΩ at 20°C {68°F} APPROX. 1.5 KΩ at 40°C {104°F} APPROX. 870 Ω at 60°C {140°F} APPROX. 530 Ω at 80°C {176°F} M16020100023 .
NG
Abnormality of coolant temperature sensor
OK
Abnormality of engine cooling system
HINT: This code will be displayed when the coolant temperature sensor operates normally and coolant temperature ascends over 115°C {239°F}. Also, while the malfunction code is being detected, Max. volume of fuel injection will be limited and will return back to normal control volume when it descends less than 105°C {221°F}. .
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–51
ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT M16020101BEF2141
32 PIN CONNECTORS
1 2 3 4
5 6 7
8 9 10 11
12 13 14 1516 17 18 19 20 21 2223 24 25
26 27 2829
VIEW
30 31 32
CHASSIS HARNESS M16020100102
•
No.
SIGNAL
1
MVB
2
CONNECTING DESTINETION
No.
SIGNAL
Power source
17
—
PSP+
Pre-stroke power supply
18
PIM
Booster sensor (Signal)
3
PDWN
Rack sensor
19
NE2-
Sub engine speed sensor -
4
POSC
Pre-stroke sensor
20
THW+
Coolant temperature sensor +
5
—
21
NE1-
Main engine speed sensor -
6
PIM+
Boos sensor +
22
—
7
NE2+
Sub engine speed sensor -
23
—
8
NE1+
Main engine speed sensor +
24
—
9
—
25
PSGD
Pre-stroke actuator ground
10
—
26
PGND
Pre-stroke sensor ground
11
PTO
Position switch (with P.T.O.)
27
PSLD
Pre-stroke sensor shield
12
PS-
Pre-stroke actuator -
28
—
13
PS+
Pre-stroke actuator +
29
PIM-
Boos sensor -
14
LPHM
Rack sensor
30
THW-
Coolant temperature sensor +
15
PMDL
Pre-stroke sensor
31
—
16
BSW1
Stop lamp switch
32
—
with P.T.O.: with Power take-off
CONNECTING DESTINETION
DN02–52
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
25 PIN CONNECTORS
1 2 3
4 5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 2021
VIEW
22 23
24 25
CHASSIS HARNESS M16020100103
•
No.
SIGNAL
1
—
2
DGSW
3
—
4
QREG
5
CONNECTING DESTINETION
No.
SIGNAL
14
+SV2
Rack sensor
15
SOL2
Rack sensor
16
VIST
Rack sensor
Q-Adjustment resistor+
17
GND1
Governor actuator ground
+5V1
Rack sensor
18
MGD1
Ground
6
SOL1
Rack sensor
19
—
7
GVB2
Governor actuator power supply
20
BSW2
8
GVB1
Governor actuator power supply
21
—
9
EBSW
Exhaust brake switch
22
SLD
Rack sensor
10
—
23
SGND
Rack sensor
11
ST
Power source (starter switch)
24
GND2
Ground
12
SSWS
Power source
25
MGD2
Ground
13
QGND
Q-Adjustment resistor -
Diagnosis monitor
with ATM: with Automatic transmission
CONNECTING DESTINETION
Brake switch (with ATM)
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–53
31 PIN CONNECTORS
1 2 3
4 5 6
7 8 9 10
111213141516171819202122 232425
VIEW
262728
2930 31
CHASSIS HARNESS M16020100104
• •
No.
SIGNAL
1
CONNECTING DESTINETION
No.
SIGNAL
—
17
ACS1
Accelerator sensor 1 (signal)
2
—
18
CLST
Power take off clutch switch (with MTM)
3
—
19
NUSW
Neutral switch (with P.T.O.)
4
IDLE
Accelerator switch
20
—
5
VAC2
Accelerator sensor 2
21
—
6
VAC1
Accelerator sensor 1
22
—
7
—
23
—
8
—
24
CASE
9
—
25
—
10
—
26
—
11
—
27
AGD2
Accelerator sensor 2
12
—
28
AGD1
Accelerator sensor 1
13
VS
Pulse adjust computer
29
—
14
PSRY
Actuator power supply relay
30
—
15
PWTM
Automatic transmission ECU
31
—
16
ACS2
Accelerator sensor 2 (signal)
with MTM: with Mechanical transmission with P.T.O.: with Power take-off
CONNECTING DESTINETION
Ground
DN02–54
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
16 PIN CONNECTORS
1
2 3 4
5
6 7 8 9 101112 13
VIEW
141516
CHASSIS HARNESS M16020100105
No.
SIGNAL
1
VB2
2
CONNECTING DESTINETION
No.
SIGNAL
ECU main relay
9
—
VB1
Power source
10
—
3
CE/G
Check engine lamp
11
TACH
4
—
12
—
5
—
13
MRL2
6
CGD1
ECU ground 1
14
—
7
CGD2
ECU ground 2
15
—
8
MRL1
Power source
16
—
CONNECTING DESTINETION
Pulse adjust computer
ECU main relay
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR)
DN02–55
26 PIN CONNECTORS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1617181920212223 24 25 26
CHASSIS HARNESS
VIEW
M16020100106
No.
SIGNAL
1
CONNECTING DESTINETION
No.
SIGNAL
—
14
—
2
—
15
—
3
IV+
Idle set controller +
16
IVS
Idle set controller (signal)
4
EBLP
Exhaust brake indicator lamp
17
IVG
Idle set controller -
5
AT
Ground
18
—
6
—
19
—
7
—
20
—
8
—
21
—
9
—
22
—
10
—
23
—
11
—
24
—
12
SWSS
25
—
13
—
26
—
Power source (Fuse E/G2)
CONNECTING DESTINETION
DISMOUNTING AND MOUTING M16020101BEF2036
IMPORTANT POINT - DISMOUNTING 1. (1) (2)
REMOVE THE SPEED SENSOR. Disconnect the connector (Black), loosen the lock nut using two wrenches. Remove the speed sensor from the adapter plate.
IMPORTANT POINT - MOUNTING 1. (1)
INSTALL THE SPEED SENSOR. Turn the crankshaft to align the mark 16, 25 or 34 on the outer periphery of the flywheel with the pointer of the flywheel housing. NOTICE: • The pulse protrusion will line up with the center of the hole at the piston top dead center point. • The speed sensor damage may occur during engine operation if these adjustments are neglected. M16020100068
DN02–56
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR) (2)
Coat a sealing compound (Three-Bond 1215 or equivalent) on the thread face and lock nut sealing surface of the sensor. NOTICE: Sensor adjustment should be carried out within 30 minutes from application of the sealing compound. After 30 minutes, the sealing compound will harden and it will become difficult to turn the sensor by hand. (3)
Screw in the sensor by hand until the leading edge of the sensor lightly contacts to the protrusion.
(4)
After contacting the sensor to the protrusion, unscrew the sensor 1.0-1.5 turns (to create a gap of 1.0-1.5 mm {0.0394-0.0590 in.}). Tighten the lock nut while the hexagonal part on the sensor is held to prevent the gap from changing. Tightening Torque: 45-54 N⋅m {450-550 kgf⋅cm, 33-39 lbf⋅ft}
(5)
M16020100067
1-1, HINODAI 3-CHOME, HINO-SHI, TOKYO 191-8660 JAPAN
PRINTED IN JAPAN Pub. No. S5-YJ08E17A ’02-11