Hino J08
Hino J08
Hino J08
ENGINE 3-1-1
3-228E-05
CHAPTER
ENGINE
Models: J08C-TP and J08C-TR
1 page 1
Models J08C-TP and J08C-TR
3-1-2 ENGINE
TROUBLESHOOTING
(ENGINE)
Symptom
Possible cause
Engine overheating
Coolant
Remedy/Prevention
Coolant leakage from coolant pump ............. Replace the coolant pump
Clogged with iron oxide due to leakage ........ Clean coolant passage and
of exhaust into cooling system
1 page 1
Models J08C-TP and J08C-TR
Symptom
Possible cause
Engine overheating
Other problems
ENGINE 3-1-3
Remedy/Prevention
Wear of piston rings and cylinder liner .......... Replace piston rings and
cylinder liner
Worn, sticking or broken piston rings ............ Replace piston rings and
cylinder liner
Unsuitable oil (viscosity too low) ................... Change oil as required and
replace piston rings and
cylinder liner
Gaps of piston rings in line with each other .. Reassemble piston rings
Valves and valve guides
Incorrectly fitted valve stem seal ................... Replace the stem seal
1 page 1
Models J08C-TP and J08C-TR
3-1-4 ENGINE
Symptom
Possible cause
Remedy/Prevention
Oil leakage from connections of oil lines ...... Tighten connections of oil lines
Oil leakage from oil pan gasket .................... Replace oil pan gasket
vehicle
Check cooling system
NOTE: If oil consumption is excessive, the problems above will occur. Complaints from the
customer are often related to such problems.
1.
White smoke is emitted continuously when the engine is run at high speed.
2.
White smoke is emitted only immediately after the engine speed is abruptly raised
when idling.
3.
The tail pipe is blackened with oil.
4.
Oil leaks from the flanges of the exhaust manifold.
5.
Lack of power.
6.
Excessive blow-by gas.
Piston seizure
1 page 1
Models J08C-TP and J08C-TR
Symptom
Possible cause
Piston seizure
Coolant
ENGINE 3-1-5
Remedy/Prevention
Suction strainer sucking air ........................... Add oil and/or repair strainer
Abnormal combustion
1 page 1
Models J08C-TP and J08C-TR
3-1-6 ENGINE
NOTE: If piston seizure occurs, the problems above will occur. Complaints from the customer
are often related to these problems.
1.
White smoke is emitted.
2.
Lack of power
3.
Excessive blow-by gas
Symptom
Possible cause
Remedy/Prevention
Lack of power
Intake
Clogged air cleaner ....................................... Clean element or replace
element
Overheating
Air in fuel system ........................................... Repair and bleed air from fuel
system
and liner
1 page 1
Models J08C-TP and J08C-TR
Symptom
Possible cause
Lack of power
Other problems
Remedy/Prevention
ENGINE 3-1-7
brake
muffler
Leakage of exhaust
Head gasket
1 page 1
Models J08C-TP and J08C-TR
3-1-8 ENGINE
Symptom
Possible cause
Leakage of exhaust
Other problems
Remedy/Prevention
NOTE: If leakage of the exhaust occurs, the problems above will occur. Complaints from the
customer are often related to these problems.
1.
Lack of power.
2.
The engine overheats.
3.
The coolant is discolored.
Electrical system
Air sucked into fuel system through .............. Tighten fuel line connections
fuel line connections
1 page 1
Models J08C-TP and J08C-TR
Symptom
Possible cause
Nozzles
ENGINE 3-1-9
Remedy/Prevention
Ring gear damaged or worn ......................... Replace the ring gear and/or
accelerator cable
starter pinion
Rough idling
1 page 1
Models J08C-TP and J08C-TR
3-1-10 ENGINE
Symptom
Possible cause
Rough idling
Other problems
Remedy/Prevention
cable
Diesel knock
Other problems
1 page 1
Models J08C-TP and J08C-TR
Symptom
Possible cause
Piston
ENGINE 3-1-11
Remedy/Prevention
Wear of piston pin boss or piston pin ............ Replace piston and/or piston
pin
Seized, damaged, or worn piston pin ........... Replace piston pin bushing.
bushing
Foreign matter on top surface of the piston .. Remove foreign matter and
repair or replace piston, cylinder
liner, and/or cylinder head
Valve mechanism
Pits and scratches on bearing surface .......... Replace bearing and crankshaft
1 page 1
Models J08C-TP and J08C-TR
3-1-12 ENGINE
Symptom
Possible cause
Remedy/Prevention
Intake valve seating is not concentric ........... Replace or correct the valve
and valve seat
Loose cooling fan mounting bolts or ............. Tighten the fan and
fan pulley nut
crankshaft pulley
NOTE: The items on this page concern unusual engine noise which is due to causes other than
those given for diesel knock.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-1-13
Possible cause
Remedy
correct it
1 page 1
Models J08C-TP and J08C-TR
3-1-14 ENGINE
Symptom
Possible cause
Remedy
fuel lines
Engine has low power
Fuel leakage from nozzle holder ................... Check and repair nozzle holder
Fuel leakage from delivery valve .................. Retighten the delivery valve
holder
1 page 1
Models J08C-TP and J08C-TR
Symptom
Possible cause
Excessive smoke
Black smoke
ENGINE 3-1-15
Remedy
Excessive fuel delivery caused by ................ Adjust fuel delivery on test stand
incorrect adjustment of full load
stopper screw
Bad nozzle fuel spray characteristics ........... Check and correct them
White smoke
Glow plug not operating ................................ Check glow plug circuit. Refer
to ELECTRICAL EQUIPMENT
in CHAPTER 20
irregular
Bad fuel spray characteristic of nozzles. ...... Check and repair them
Incorrect injection timing ............................... Correct it
Incorrect initial tension setting of................... Adjust or replace it
idling spring or the spring broken.
Control rack does not move smoothly ........... Disassemble pump and repair it
Large spread in fuel delivery ......................... Adjust it
Plunger worn ................................................. Replace it
Governor linkage does not move smoothly ... Correct it
Defective feed pump ..................................... Disassemble and repair it
at high speed
Loud knocking
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-2-1
SPECIAL TOOLS
Prior to starting an engine overhaul, it is necessary to have the following.
Shape
Parts No.
Parts name
No./unit
Application
09491 - 1010
Wire cable
Lifting engine
09433 - 1070
Eye bolt
SM3-J052
SM3-J048
Shape
Parts No.
Parts name
No./unit
Application
09472 - 1210
Bar
9800-06100
(Steel ball)
09552-1090
Compression gauge
adaptor
Measuring compression
(for size PF3/8)
SM3-J050
SM3-J054
SM3-J021
1 page 1
Models J08C-TP and J08C-TR
3-2-2 ENGINE
Shape
Parts No.
Parts name
No./unit
Application
Measuring compression
09472 - 2100
Bar
09471 - 1520
Guide
09420 - 1100
Sliding hammer
09420 - 1442
(Same as tool
Sliding hammer
for pulling out
injection nozzle)
Application
09552 - 1060
09552 - 1030
SM3-J022
SM3-J055
SM3-J051
SM3-J131
SM3-J132
Shape
SM3-J053
Parts No.
Parts name
No./unit
09431 - 1020
Valve wrapping
1 page 1
Models J08C-TP and J08C-TR
Shape
Parts No.
Parts name
09470 - 1170
No./unit
ENGINE 3-2-3
Application
SM3-J049
Shape
Parts No.
09481 - 1340
Parts name
Guide
No./unit
Application
SM3-J116
Shape
Parts No.
Parts name
No./unit
Application
09407 - 1030
09407 - 1040
09420 - 1731
SM3-J118
SM3-J115
1 page 1
Models J08C-TP and J08C-TR
3-2-4 ENGINE
Shape
Parts No.
Parts name
No./unit
Application
09420 - 1742
09420 - 1720
09471 - 1490
Guide
09411 - 1300
Socket wrench
09444 - 1630
Gauge
9001 - 24262
Check bolt
09472 - 1620
Tool
SM3-J117
SM3-J148
SM3-J149
SM3-J133
SM3-J146
SM3-J151
SM3-J780
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-2-5
Shape
Parts No.
Parts name
No./unit
Application
09441 - 1320
09442 - 1011
09481-1130
Guide
09402-1530
9233-10360
Wing nut
SM3-J153
SM3-J145
SM3-J781
SM3-J782
SM3-J783
1 page 1
Models J08C-TP and J08C-TR
3-2-6 ENGINE
(7) Related parts of connecting rod
Shape
Parts No.
Parts name
No./unit
09481 - 1540
Guide
09402-1540
9191 - 08252
Bolt
Application
SM3-J147
SM3-J152
SM3-J150
Shape
Parts No.
Parts name
No./unit
Application
09553 - 1021
09553 - 1010
SM3-J784
SM3-J785
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-2-7
Shape
Parts No.
09511 - 2500
Parts name
Wrench
No./unit
Application
SM3-J200
Shape
Parts No.
09420 - 1442
(Same as the
parts to remove
idler gear shaft)
Parts name
No./unit
Application
Sliding hammer
Adaptor
No./unit
Application
SM3-J132
09462 - 1130
SM3-J172
Shape
Parts No.
Parts name
09420 - 1820
Puller assembly
09420 - 1810
Puller assembly
SM3-J786
SM3-J787
1 page 1
Models J08C-TP and J08C-TR
3-2-8 ENGINE
Shape
Parts No.
Parts name
No./unit
09444 - 1210
Application
SM3-J788
Shape
Parts No.
Parts name
No./unit
09420 - 1670
Puller assembly
09482 - 2220
Press
1
sleeve
09482 - 2230
Press
1
seal
09420 - 1680
Puller assembly
Application
SM3-J002
SM3-J003
SM3-J004
SM3-J005
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-3-1
GENERAL
WARNING
The following items should be observed to prevent
injury to yourself and others when servicing the
engine or vehicle;
Stop the engine and keep the engine off during
checks and adjustments.
Place the starter key in the LOCK position.
Leave the engine stop knob pulled out fully.
(For model equipped with manual engine stop
control)
Place the transmission shift lever in NEUTRAL.
Apply the parking brake firmly.
Block the wheels.
SM3-J580
Fig. 1
1 page 1
Models J08C-TP and J08C-TR
3-3-2 ENGINE
SM3-J581
Fig. 2
(2) Measurement
1. Insert the gauge adaptor into the nozzle holder hole.
Special tool: Compression gauge adaptor
(09552 - 1090)
(09552 - 1060)
(09552 - 1030)
2. Run the engine with the starter and measure the
compression pressure.
NOTE: Do not operate the starter for more than 15 seconds.
3. Measure the compression pressure of each cylinder.
NOTE: Do not allow gas leakage from the seal face.
Unit: kg/cm2 (lb/sq.in.)
Assembly standard
35 - 38 (498-540)
Assembly limit
28 (398)
Difference among
Engine speed
individual cylinders
(rpm)
180 - 220
SM3-J580
Fig. 3
WARNING
Do not connect the electric harness with the engine stop motor while the engine starter key is at
ON position as this may operate the engine stop
motor instantaneously and the link lever of the
engine stop motor and the engine stop lever of the
fuel injection pump will move, resulting in your
fingers caught by the lever.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-3-3
2.
OIL
SM3-J024
Fig. 4
ATMOSPHERIC TEMPERATURE
S.A.E.
-10
32
50
70
90 100
10
21
32 39
GRADE
-23 -18
40
30
20W/20
Service Limit:
At idle speed 0.5 kg/cm2 (7.11 lb/sq.in.)
15W/40
10W/30
Fig. 5
3.
OTHER FACTORS
a. Blow-by gas increases.
b. Engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f.
Excessive oil consumption.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-4-1
2.
SM3-J500
Fig. 1
SM3-J580
Fig. 2
4.
5.
SM3-J582A
Fig. 3
3.
SM3-J583
Fig. 4
4.
SM3-J584
Fig. 5
1 page 1
3-4-2 ENGINE
NORMAL POSITION
OVER-TILTING
POSITION
SM3-J585
Fig. 6
6.
OPEN
WARNING
To avoid the danger of burns do not drain the engine oil and coolant while the engine and radiator
are still hot.
CLOSE
DRAINING PLUG
DRAINING PLUG
SM3-J705B
Fig. 7
Fig. 8
DRAINING PLUG
SM3-J791
Fig. 9
7.
SM3-J587
Fig. 10
8.
SM3-J589
Fig. 11
1 page 1
Models J08C-TP and J08C-TR
9.
ENGINE 3-4-3
SM3-J590
Fig. 12
SM3-J796
Fig. 13
SM3-J593
Fig. 14
SM3-J594
Fig. 15
SM3-J595
Fig. 16
1 page 1
3-4-4 ENGINE
SM3-J596A
Fig. 17
SM3-J597
Fig. 18
SM3-J598
Fig. 19
SM3-J599
Fig. 20
SM3-J600A
Fig. 21
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-4-5
SM3-J601A
Fig. 22
SM3-J602
Fig. 23
SM3-J502
WARNING
The engine must be suspended with a hoist until
completion of disassembly of the transmission
assembly.
Fig. 24
3.
1 page 1
3-4-6 ENGINE
Fig. 25
SM3-J604
Fig. 26
SM3-J746
Fig. 27
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-5-1
PREPARATION
1. Loosen the coolant drain cock of the oil cooler, then
discharge coolant.
2. Loosen the oil drain plug of the oil filter, then discharge oil.
SM3-J606
Fig. 1
3.
a.
b.
NOTE:
SM3-J504
Fig. 2
SM3-J607
Fig. 3
3.
SM3-J608
Fig. 4
4.
SM3-J609
Fig. 5
1 page 1
3-5-2 ENGINE
6.
SM3-J613
Fig. 6
SM3-J610A
Fig. 7
2.
Use the following special tool and loosen the adjusting bolt.
Special tool: Injection pump coupling wrench
(09511 - 2500)
SM3-J611C
Fig. 8
3.
SM3-J612
Fig. 9
7.
SM3-J614
Fig. 10
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-5-3
SM3-J615
Fig. 11
9.
SM3-J616
Fig. 12
SM3-J617
Fig. 13
SM3-J619A
Fig. 14
SM3-J620
Fig. 15
1 page 1
3-5-4 ENGINE
SM3-J621
Fig. 16
SM3-J622
Fig. 17
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-1
1
2
7
3
11
8
9
10
5
6
15
13
14
12
16
28
17
29
21
22
23
24
25
26
27
30
31
20
32
18
18 19
33
SM3-J264A
Fig. 1
1 page 1
3-6-2 ENGINE
35
34
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
SM3-J265
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-3
DISMOUNTING
1. REMOVE THE CYLINDER HEAD COVER.
NOTE: Clean all dust from around the cylinder head
cover before removing it to prevent foreign particles from getting in.
SM3-J623
Fig. 3
2.
NOZZLE CLAMP BOLT
LEAKAGE PIPE
CAM HOUSING
O-RING
NOZZLE HOLDER
ASSEMBLY
SM3-J178
Fig. 4
5.
SM3-J624
Fig. 5
1 page 1
3-6-4 ENGINE
ADJUSTING
SCREW
SM3-J056
Fig. 6
4.
ROCKER ARM SUPPORT
SM3-J266
Fig. 7
5.
SM3-J625
Fig. 8
6.
SM3-J626
Fig. 9
7.
SM3-J276B
Fig. 10
1 page 1
Models J08C-TP and J08C-TR
8.
SM3-J627
Fig. 11
ENGINE 3-6-5
1 page 1
3-6-6 ENGINE
DISASSEMBLING
REMOVE THE CAM IDLER GEAR.
1. Remove the cam idler gear.
SM3-J628
Fig. 12
SM3-J629
Fig. 13
SM3-J060
Fig. 14
2.
3.
IN
EX
SM3-J061A
Fig. 15
NOTE:
Do not remove the valve guide and valve spring seat
lower unless they need to be replaced.
Align the removed parts in the order of the cylinder
No.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-7
SM3-J062
Fig. 16
SM3-J103
Fig. 17
SM3-J630
Fig. 18
B
C
D
A
A
C
D
B
SM3-J505
Fig. 19
2.
Check the flatness of the intake and exhaust manifolds mounting surfaces.
Standard: 0.06 mm (0.0024 in.) or less for longitudinal direction
0.03 mm (0.0012 in.) or less for lateral direction
Service limit: 0.20 mm (0.0079 in.)
SM3-J506
Fig. 20
1 page 1
3-6-8 ENGINE
Fig. 21
2.
SM3-J632
Fig. 23
GRIND VALVES
NOTE:
Grinding of valves should only be performed when
hand-lapping does not result in proper seating.
Following hand-lapping, always recheck the seating
condition.
SM3-J507A
Fig. 24
SM3-J507
WARNING
When grinding, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-9
Assembly standard:
Valve seat (Intake):
Valve face (Intake):
Valve seat (Exhaust):
Valve face (Exhaust):
30
3000'
2930'
4500'
4430'
3035'
3000'
4530'
4500'
45
INTAKE
EXHAUST
SM3-J097
Fig. 25
BLOCK BRASS
HAMMER
VALVE SEAT
ELECTRIC WELDING
APPLIED
VALVE
INTAKE
EXHAUST
SM3-J065
Exhaust
Unit:in.
Unit:mm
Unit:in.
Clynder
head side
41-41.016
1.6142-1.6148
39-39.016
1.5355-1.5360
9.4-9.6
0.3701-0.3779
8.6-8.8
0.3386-0.3464
Valve seat
side
41.085-41.1
7-7.2
6-6.2
0.2363-0.2440
Fig. 27
4.
SM3-J066
Fig. 28
Heat the cylinder head to approx. 80C (176F) 90C (194F) with hot water. Cool the valve seat with
dry ice for approx. 30 minutes. Hold the seat with
pincers and place it into the heated cylinder head.
The valve seat can be easily made to fit by lightly
hitting it.
WARNING
Never touch the cooled valve seat with your bear
hands.
When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
Following valve grinding, always recheck the
seating condition.
1 page 1
3-6-10 ENGINE
VALVE SEAT
VALVE
SINK
DIMENSION CYLINDER
HEAD
VALVE
SM3-J508
Fig. 29
SM3-J509
Fig. 30
2.
90
SM3-J510
Fig. 31
SM3-J511
Fig. 32
1 page 1
Models J08C-TP and J08C-TR
INTAKE
EXHAUST
ENGINE 3-6-11
3.
Press fit a new valve guide straight allowing it to protrude as shown in the figure.
NOTE: Apply engine oil lightly to the valve guide outer
circumference before installation.
SM3-J065
Fig. 33
VALVE STEM SEAL
VALVE SPRING SEAT
LOWER
SPECIAL
TOOL
VALVE
SM3-J068
Fig. 34
COAT OIL
B
A
SM3-J068
WARNING
When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
NOTE:
After installing the valve stem seal, make sure there
is a gap (A) and (B) as shown in the figure.
Do not use the special tool if its surface contacting
the valve spring lower seat is deformed.
Fig. 35
SM3-J098
Fig. 36
1 page 1
3-6-12 ENGINE
SM3-J098
Fig. 37
Outer spring
Inner spring
Nominal dimension
Service limit
Setting height
mm (in.)
Intake
75.7 (2.980)
75.4 (2.968)
46.8 (1.843)
46.4 (102.23)
Exhaust
75.7 (2.980)
75.4 (2.968)
46.8 (1.843)
44.2 (97.44)
Intake
64.6 (2.543)
64.3 (2.531)
44.8 (1.764)
21.7 (47.85)
Exhaust
64.6 (2.543)
64.3 (2.531)
44.8 (1.764)
20.4 (44.98)
3.
SM3-J099
Fig. 38
SM3-J069
Fig. 39
SM3-J070
WARNING
When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-13
2.
CYLINDER HEAD
O-RING
NOZZLE SLEEVE
SM3-J071
Fig. 40
SPECIAL
TOOL
NOZZLE
SLEEVE
CYLINDER
HEAD
SPECIAL
TOOL
SM3-J072
Fig. 41
4.
CYLINDER HEAD
SM3-J100
Fig. 42
SM3-J142
Fig. 43
SM3-J634
Fig. 44
1 page 1
3-6-14 ENGINE
SM3-J635
Fig. 45
2.
SM3-J517
Fig. 46
SM3-J570
Fig. 47
SM3-J518
Fig. 48
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-15
2.
SM3-J636
Fig. 49
SM3-J519A
Fig. 50
3.
a.
SM3-J637
Fig. 51
SM3-J638
Fig. 52
1 page 1
3-6-16 ENGINE
SM3-J639
Fig. 53
SM3-J080
Fig. 54
3.
90
SM3-J081
SM3-J082
Fig. 55
SM3-J640
Fig. 56
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-17
2.
SM3-J641
Fig. 57
SM3-J642
Fig. 58
1 page 1
3-6-18 ENGINE
ASSEMBLING
SM3-J060
Fig. 59
SM3-J643
Fig. 60
SM3-J644
Fig. 61
1 page 1
Models J08C-TP and J08C-TR
HEAD
SIDE HOLE
LIQUID
GASKET
SM3-J037
Fig. 63
ENGINE 3-6-19
1 page 1
3-6-20 ENGINE
MOUNTING
COOLANT
GEAR CASE
SEAL RING
PRINTED SEAL
SM3-J268
Fig. 64
LIQUID GASKET
APPLICATION POINT
PRINT SEAL
LIQUID GASKET
APPLICATION POINT
LIQUID GASKET
CYLINDER HEAD
CYLINDER
BLOCK
REAR END
PLATE
FLYWHEEL HOUSING
CORRECT
CLEARANCE
TOO POOR
CLEARANCE
CLEARANCE
PROTRUDING
A-A SECTION
SM3-J075
Fig. 65
2.
3.
SM3-J627
Fig. 66
SM3-J076A
Fig. 67
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-21
c.
SM3-J269B
Fig. 68
b.
PAINT
90
c.
d.
NOTE:
90
e.
SM3-J078
NOTE:
Fig. 69
Mark the bolts with paint to indicate the same directions as shown in the figure.
Turn No.1 - No.26 bolts 90 (1/4 turn).
Retighten them 90 (1/4 turn).
Total tightening amounts to 180. It must not become 200 or more.
Make sure that all paint marks face the same direction.
When adding torque, never untighten the nuts,
even if they have been overtightened.
f.
SM3-J288A
Fig. 70
4.
FLYWHEEL HOUSING
FLYWHEEL
SM3-J009
Fig.71
1 page 1
3-6-22 ENGINE
SM3-J647
Fig. 72
5.
ARROW OF
MARK
SCALE ETC...
SM3-J083
Fig. 73
2.
Install the camshaft bearing cap to the cam housing. Make sure there is no dirt or scratch on the tightening surfaces.
3. Apply clean engine oil to the bolt seating and bolt
thread, then tighten the bolt to the specified torque
below.
Tightening torque: 320 kgcm (23 lbft)
SM3-J648
Fig. 74
6.
MEASURE THE BACKLASH BETWEEN THE CAMSHAFT GEAR AND CAMSHAFT IDLER GEAR.
Measure the backlash between the camshaft gear and
camshaft idler gear with a dial gauge. If the value exceeds
the service limit, replace the camshaft gear.
Nominal backlash: 0.030 - 0.253 mm (0.0012 - 0.0099 in.)
Service limit: 0.30 mm (0.0118 in.)
SM3-J649
Fig. 75
7.
SM3-J650
Fig. 76
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-6-23
8.
6
SM3-J270
Fig. 77
9.
VALVE SPRING
INJECTION
PIPE NUT
ROCKER
ARM
INJECTION
PIPE SEAL
LEAKAGE PIPE
NOZZLE CLAMP
BOLT
CAM HOUSING
SM3-J199
Fig. 78
SM3-J651
Fig. 79
1 page 1
3-6-24 ENGINE
HEAD COVER
CAM HOUSING
CYLINDRICAL PLUG
SM3-J085
Fig. 80
2.
PHASE WHERE
NOT APPLIED
LIQUID
GASKET
CYLINDRICAL PLUG
GOOD
COARSE
PHASE WHERE
TO APPLY LIQUID GASKET
SM3-J086
Fig. 81
CLINDRICAL
PLUG
A
CAM HOUSING
SM3-J087
Fig. 82
4.
HEAD COVER
BOLT
SILENT BLOCK
HEAD
COVER
GASKET
SPACER
BOTTOM FACE
OF HEAD COVER
CAM HOUSING
SM3-J088
Fig. 83
Install the cylinder head cover gasket into the gasket groove at the head cover lower surface.
5. Insert the spacer from the head cover lower surface.
6. Install the cylinder head cover to the cam housing.
NOTE: If left more than 20 minutes, clean off the liquid
gasket completely and reapply the liquid gasket.
7. Tighten the mounting bolt of the head cover through
the silent block to the specified torque below and fix
the head cover on the cam housing.
Tightening torque: 250 kgcm (18 lbft)
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-7-1
7
6
3
1.
2.
3.
4.
5.
6.
7.
Fig. 1
1.
2.
3.
4.
5.
Flywheel housing
Dust cover
Crankshaft oil seal
Ring gear
Flywheel
SM3-J274A
Fig. 2
1 page 1
3-7-2 ENGINE
1
2
3
4
1.
2.
3.
4.
SM3-J273A
Fig. 3
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-7-3
DISMOUNTING
1.
2.
3.
4.
5.
SM3-J652
Fig. 4
SM3-J653
Fig. 5
SM3-J654
Fig. 6
SM3-J655
Fig. 7
SM3-J520
Fig. 8
1 page 1
3-7-4 ENGINE
WARNING
The flywheel is heavy. When removing, be careful
not to drop it on your feet.
SM3-J656
Fig. 9
6.
PLATE
SM3-J119
Fig. 10
b.
HOOK
REMOVE AFTER
HOOK INSTALLATION
SM3-J120
Fig. 11
d.
CENTER
BOLT
SM3-J121
Fig. 12
7.
SM3-J657
Fig. 13
1 page 1
Models J08C-TP and J08C-TR
8.
ENGINE 3-7-5
SM3-J658
Fig. 14
2.
3.
SM3-J659
Fig. 15
WARNING
The flywheel is heavy. When removing, be careful
not to drop it on your feet.
SM3-J646
Fig. 16
9.
SM3-J660
Fig. 17
1 page 1
3-7-6 ENGINE
SM5-089
Fig. 19
SM5-040A
Fig. 20
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-7-7
3.
After grind the friction surface, adjust the friction surface depth of the flywheel within the service standard by grind the outer bosses of the flywheel.
Fly wheel depth: 48 mm (1.890 in.)
BOSS
FRICTION
SURFACE
SM5-098A
Fig. 21
SM3-J523
Fig. 22
WARNING
Never touch the ring gear or flywheel when they
are hot with your bare hands.
2.
1 page 1
3-7-8 ENGINE
MOUNTING
1.
LIQUID GASKET
SM3-J032
Fig. 24
MATCHING FACE WITH THE REAR END PLATE
LIQUID GASKET
SM3-J041
Fig. 25
3.
MATCHING FLANGE FACE WITH
THE FLYWHEEL HOUSING
FLYWHEEL
HOUSING
OPENING
LIQUID GASKET
SM3-J035
Fig. 26
1 page 1
Models J08C-TP and J08C-TR
4.
GUIDE
ENGINE 3-7-9
GUIDE
SM3-J806
Fig. 28
3.
4.
GUIDE BOLTS
SM3-J123
Fig. 29
5.
PRESS
6.
CENTER
BOLT
SM3-J124
Fig. 30
Insert the oil seal press by adjusting the oil seal press
hole to the guide bolt.
Press the crank shaft oil seal inside by attaching the
accompanying center bolt onto the oil seal press and
tightening it until it stops.
1 page 1
3-7-10 ENGINE
5.
SM3-J127
Fig. 31
TIGHTENING ORDER
1
5
CRANKSHAFT
COLLAR
8
4
7
2
SM3-J128
Fig. 32
8.
SM3-J129
Fig. 33
9.
SM3-J525
Fig. 34
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-7-11
6.
LIQUID GASKET
(TWO PARTS EACH)
SM3-J662
Fig. 35
BOLT
TIGHTENING
DIRECTION
w
q
REAR
LOBE
OIL
STRAINER
INTAKE
PORT SIDE
SM3-J112
Fig. 36
7.
7.
SM3-J663
Fig. 37
1 page 1
3-7-12 ENGINE
8.
9.
SM3-J653
Fig. 38
SM3-J652
Fig. 39
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-8-1
TIMING GEAR
CAMSHAFT GEAR
INJECTION
PUMP GEAR
SM3-J136
Fig. 1
12 5
13
4
5
13
6
7
2
1
5
12
12
5
13
8
11
10
9
1.
2.
3.
4.
Gasket
Rear end plate
Camshaft gear
Camshaft idler gear
5.
6.
7.
8.
9.
10.
11.
12.
13.
Crankshaft gear
Injection pump drive gear
Power steering pump drive gear
Pin
Idler gear shaft
SM3-J130
Fig. 2
1 page 1
3-8-2 ENGINE
DISMOUNTING
1.
SM3-J666
Fig. 3
3.
SM3-J667
Fig. 4
2.
SM3-J668
Fig. 5
3. Remove the sub idler gear shaft with the special tool.
Special tool: Sliding hammer (09420 - 1100)
SM3-J669
Fig. 6
3.
SM3-J670
Fig. 7
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-8-3
4.
SM3-J135
Fig. 8
2.
THREE
BOLTS
SM3-J671
Fig. 9
1 page 1
3-8-4 ENGINE
SM3-J526
Fig. 10
2.
Using a cylinder gauge, measure the inside diameter of the main idler gear bushing.
3. Calculate the clearance from the above measurement.
If the clearance exceeds the repair limit, replace the main
idler gear shaft and/or main idler gear bushing.
Assembly standard: 0.030 - 0.090 mm (0.0012 - 0.0035 in.)
Repair limit: 0.20 mm (0.0079 in.)
SM3-J673
Fig. 12
END PLAY
THRUST
BEARING
CYLINDER
BLOCK
SM3-J674
Fig. 13
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-8-5
2.
SM3-J634
Fig. 15
END PLAY
THRUST
BEARING
CYLINDER
BLOCK
Fig. 16
Using a cylinder gauge, measure the inside diameter of the sub idler gear bushing. If the diameter
exceeds the service limit, replace the sub idler gear.
+ 0.03
+ 0.0012
Nominal dimension: 50.0 + 0 mm (1.969 + 0
in.)
Service limit: 50.03 mm (1.970 in.)
3. Calculate the clearance from the above measurement.
If the clearance exceeds the repair limit, replace the sub
idler gear shaft and/or sub idler gear bushing.
Assembly standard: 0.025 - 0.075 mm (0.0010 - 0.0029 in.)
Repair limit: 0.20 mm (0.0079 in.)
SM3-J676
1 page 1
3-8-6 ENGINE
MOUNTING
1.
2.
SM3-J671
Fig. 18
2.
SM3-J164
Fig. 19
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-8-7
THRUST
PLATE
CAMSHAFT GEAR
INJECTION PUMP
DRIVE GEAR
CYLINDER
BLOCK
OIL HOLE
C-C SECTION
SM3-J137
THRUST
PLATE
CRANKSHAFT GEAR
CYLINDER
BLOCK
B-B SECTION
SM3-J138
THRUST
PLATE
MATCH
MATCH MARKS 1
MARKS 2
OIL HOLE
CYLINDER
BLOCK
A-A SECTION
SM3-J1369
SM3-J136
Fig. 20
3.
4.
SM3-J679
Fig. 22
1 page 1
3-8-8 ENGINE
CAMSHAFT GEAR
INJECTION PUMP
GEAR
SM3-J136A
Unit: mm (in.)
Fig. 23
Inspection item
Standard
Limit
0.30 (0.0118)
0.30 (0.0118)
0.30 (0.0118)
0.30 (0.0118)
0.30 (0.0118)
0.30 (0.0118)
0.30 (0.0118)
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-1
13
12
9
8
15
10
14
16
11
1.
2.
3.
4.
5.
6.
7.
8.
Cylinder liner
Cylinder block
Oil jet pipe
Piston ring
Piston
Piston pin
Retainer ring
Connecting rod
9.
10.
11.
12.
13.
14.
15.
16.
Fig. 1
1 page 1
3-9-2 ENGINE
3
5
1.
2.
3.
4.
5.
4
SM3-J277
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-3
DISMOUNTING
1.
SM3-J154
Fig. 3
SM3-J680
Fig. 4
SM3-J681
Fig. 5
SM3-J682
Fig. 6
1 page 1
3-9-4 ENGINE
SM3-J683
Fig. 8
4.
3.
a.
b.
c.
d.
e.
f.
g.
4.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-5
DISASSEMBLING
REMOVE THE CONNECTING ROD.
1. Remove the retainer rings from both ends of the piston pin using snap ring pliers.
WARNING
Removing the retainer rings may cause the retainer
rings to fly up. Be sure to wear protective goggles.
SM3-J684
Fig. 9
2.
WARNING
Never touch the piston with your bare hands when
it is hot.
NOTE: If it is difficult to punch out the piston pin, first
immerse the piston and piston pin in hot water,
80 - 90C (176 - 194F), for approximately five minutes to facilitate removal.
REMOVE THE PISTON RINGS.
1. Remove the piston ring using the special tool.
Special tool:
Piston ring expander (09442 - 1011)
NOTE:
Handle the piston rings carefully because they are
made of a special casting which is easily broken.
Arrange the piston rings in order of cylinder numbers.
SM3-J685
Fig. 10
1 page 1
3-9-6 ENGINE
SM3-J255
Fig. 11
2.
3.
SM3-J242
Fig. 12
SM3-J527A
SM3-J527
Limit:
Bend of connecting rod: 0.05 mm (0.0020 in.)
for each 100 mm (3.94 in.)
Distortion of connecting rod:
0.05 mm (0.0020 in.)
for each 100 mm (3.94 in.)
Fig. 13
SM3-J303
Fig. 14
SM3-J254
Fig. 15
1 page 1
Models J08C-TP and J08C-TR
WING NUT
GUIDE
PIN
SM3-J466
Fig. 16
CONNECTING ROD
ENGINE 3-9-7
GUIDE
SM3-J467
Fig. 17
SPINDLE
GROOVE
BUSHING
CONNECTING
ROD
OIL HOLE
PRESS SUB
ASSEMBLY
SM3-J468
Fig. 18
PRESS
SPINDLE
CONNECTING ROD
SM3-J469
3.
Fig. 19
C 0.5 - 1.0 mm
CONNECTING ROD
SM3-J470
Fig. 20
NOTE:
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 smaller
hole.
1 page 1
3-9-8 ENGINE
SPINDLE
GROOVE
OIL HOLE (B)
OIL HOLE
(A)
GUIDE
BUSHING
GROOVE
BOLT
GUIDE
SM3-J471
Fig. 21
PRESS
OIL HOLE (B)
SPINDLE
BUSHING
OIL PATH
GUIDE
CONNECTING
ROD
4.
a.
SM3-J472
Fig. 22
6.
a.
SM3-J242
Fig. 23
1 page 1
Models J08C-TP and J08C-TR
SM3-J527
ENGINE 3-9-9
Fig. 24
SM3-J528A
Fig. 25
SM3-J687
Fig. 26
X
SM3-J529
Fig. 27
1 page 1
3-9-10 ENGINE
SM3-J527
Fig. 28
SM3-J528
Fig. 29
1.
Measure the piston outside diameter at the following points using a micrometer. If the value exceeds
the limit, replace the piston with a new one.
Standard: 114 mm (4.4882 in.)
Limit:
113.92 mm (4.4850 in.)
SM3-J530
Fig. 31
21 mm
(0.83 in.)
OUTSIDE
DIAMETER
SM3-J540
Fig. 32
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-11
2.
SM3-J544
80 (3.15)
160 (6.30)
20 (0.79)
40 (1.57)
Fig. 33
Unit: mm (in.)
SM3-J251
Fig. 34
SM3-J303
Fig. 35
2.
90
SM3-J541
Fig. 36
1 page 1
3-9-12 ENGINE
Fig. 37
SM3-J546
Unit: mm (in.)
Fig. 38
Groove width
Ring thickness
Clearance
Assembly standard
Repair limit
Dimension
Service limit
Dimension
Service limit
Top ring
0.06-0.10 (0.0024-0.0039)
0.25 (0.0098)
2.5 (0.0984)
2.4 (0.0945)
2.5 (0.0984)
2.7 (0.1063)
2nd ring
0.04-0.08 (0.0016-0.0031)
0.25 (0.0098)
2.0 (0.0787)
1.9 (0.0748)
2.0 (0.0787)
2.2 (0.0866)
Oil ring
0.02-0.06 (0.0008-0.0023)
0.15 (0.0059)
4.0 (0.1575)
3.9 (0.1535)
4.0 (0.1575)
4.1 (0.1614)
Fig. 39
SM3-J253
Fig. 40
Unit: mm (in.)
Assembly standard
Service limit
Top ring
1.5 (0.0590)
2nd ring
1.2 (0.0472)
Oil ring
1.2 (0.0472)
1 page 1
Models J08C-TP and J08C-TR
SM3-J261
ENGINE 3-9-13
Fig. 41
2.
Check the condition of the crank journal and crankpin visually for damage or wear. Grind the crank journal and crankpin to correct as required, or replace
the crankshaft with a new one.
SM3-J262
Fig. 42
3.
SM3-J688
Fig. 43
SM3-J689
Fig. 44
45 45
X Z
Y
SM3-J547
Fig. 45
1 page 1
3-9-14 ENGINE
SM3-J690
Fig. 46
X'
Y'
SM3-J529
Fig. 47
2.
SM3-J689
Fig. 48
45 45
X Z
Y
SM3-J547
Fig. 49
Outside diameter
Under
size
Pin
Journal
STD
64.940 - 64.960
79.940 - 79.960
0.25US
64.690 - 64.710
79.690 - 79.710
0.50US
64.440 - 64.460
79.440 - 79.460
Fig. 50
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-15
WRONG
CORRECT
SM3-J234
Fig. 51
SM3-J548
Fig. 52
E
B
C
D
A
A
C
D
B
SM3-J505
Fig. 53
COOLING JET
SPECIAL TOOL
OIL HOSE
SM3-J159
Fig. 54
3.
Set the special tool on the cylinder block upper surface against the dowel pin.
Special tool: Gauge (09444 - 1630)
SPECIAL TOOL
CYLINDER BLOCK
SM3-J421
Fig. 55
1 page 1
3-9-16 ENGINE
SPRAY
Start the oil pump, let the engine oil spray out the
cooling jet nozzle to check that the center of the jet
flow is within the 7 mm (0.27 in.) reference line
of the gauge as well as to judge whether the jet flow
is good based on the figure.
NOTE: Use new engine oil.
TARGET
Fig. 56
SM3-J161
SPRAY PATTERN
WARNING
Engine oil is flammable.
This spray test should be done in a well ventilated
room and away from any open flames or electric
sparks.
SPRAY
COOLING JET
1
2
ABNORMAL
4
SM3-J549
Fig. 57
SM3-J550
Fig. 58
SM3-J277B
Fig. 59
1 page 1
Models J08C-TP and J08C-TR
MARKS OF
LINER
ENGINE NUMBER
FRONT
SM3-J231A
Fig. 60
ENGINE 3-9-17
MOUNTING
1. ASSEMBLE THE CYLINDER LINER.
NOTE:
When assembling the cylinder liner with the cylinder
block, clearance can be set to three levels.
When using a new cylinder liner, the upper surface
and side surface of the cylinder block are stamped A,
B or C. Insert a matching cylinder liner having the
same symbol.
CYLINDER LINER
LINER IDENTIFICATION
MARK
SM3-J232
Fig. 61
1.
MATCH
MARKS
SM3-J693
Fig. 63
2.
SM3-J233
Fig. 64
1 page 1
3-9-18 ENGINE
PROTRUSION
SM3-J250A
Fig. 65
3.
SM3-J551
Fig. 66
3.
SM3-J682
Fig. 67
NOTE:
When reusing a bearing, make sure you reassemble
the removed bearing as it was originally installed.
Install the thrust bearing with the groove side (front)
toward the crankarm and with the part number stamp
(back) toward the main bearing cap or cylinder block.
Apply engine oil or grease to the back of the bearing
to prevent loosening during installation.
Fit the bearing to the mounting groove of the block
and cap side.
4. Install the main bearing cap.
NOTE: Facing the arrow stamped on the cap forward,
install in the order of stamped numbers.
SM3-J235
Fig. 68
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-19
a.
SM3-J236
Fig. 69
c.
!0
!2
!4
FRONT
!1
!3
SM3-J280
Fig. 70
f.
PAINT MARK
90
45
SM3-J238
Fig. 71
SM3-J695
Fig. 72
6.
PISTON IDENTIFICATION SYMBOL
72
TOP VIEW
Fig. 73
SM3-J696
1 page 1
3-9-20 ENGINE
SM3-J697
Fig. 74
O MARK
EXHAUST PORT
SIDE
PISTON
INTAKE PORT
SIDE
OIL HOLE
MATCH MARKS
SM3-J234
Fig. 75
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-21
8.
RING UPPER FACE
IDENTIFICATION MARK
TOP RING
HARD
CHROME
PLATING
SECOND RING
OIL RING
HARD
HARD
CHROME CHROME
PLATING PLATING
JOINT
GAP
ASM3-J244
Fig. 76
2ND RING
O-MARK
OIL RING
TOP RING
SM3-J245
Fig. 77
SM3-J698
Fig. 78
SM3-J699
Fig. 79
1 page 1
3-9-22 ENGINE
COOLING JET
SM3-J246
Fig. 80
EXHAUST PORT SIDE
O MARK
SM3-J247
Fig. 81
SM3-J700
Fig. 82
1.
SM3-J248
Fig. 83
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-9-23
3.
PAINT MARK
45
90
SM3-J249
Fig. 84
SM3-J701
Fig. 85
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-10-1
LUBRICATING SYSTEM
No.1
No.2
No.3
No.4
No.5
20
19
17
16
22
24
23
26
18
15
21
A
13
25
14
28
27
12
10
A
5
4
2
8
A
7
1.
2.
3.
4.
5.
6.
7.
8.
9.
Oil pan
Oil strainer
Oil pump
Oil pump safety valve
16.8 - 17.8 (235 - 250)
Oil cooler and oil filter
Oil cooler safety valve
5 - 5.8 (71 - 82)
Oil filter (full flow)
Oil filter (by-pass)
Pressure switch
A
1
11
20.
21.
22.
23.
24.
25.
26.
27.
28.
A.
Cross head
Fuel injection pump
Air compressor
Main idler gear
Cam idler gear
Sub idler gear
Check valve 2.5 (35)
Check valve for turbocharger
Turbocharger
To oil pan
SM3-J281A
Fig. 1
1 page 1
3-10-2 ENGINE
3
1
5
4
6
2
7
8
9
10
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Safety valve
Relief valve spring
Seat 1
Seat 2
Oil strainer
SM44-0044
SM3-J163C
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-10-3
1
2
3
4
SM3-J165B
Fig. 3
1 page 1
3-10-4 ENGINE
OIL PUMP
DRIVE GEAR
DISASSEMBLING
1. Remove the driven gear from the shaft.
NOTE: Since the drive gear is a press-fit type, it cannot
be disassembled.
DRIVEN GEAR
SM3-J571A
Fig. 4
SM3-J702
Fig. 5
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-10-5
2.
SM44-0033
WARNING
Removing the cotter pin may cause Seat 2 and the
relief valve spring to spring out. Be sure to wear
protective goggles.
Fig. 8
ASSEMBLING
1. Attach the safety valve, the relief valve, Seat 1 and
Seat 2 onto the oil pump cover assembly using the
cotter pin.
WARNING
When assembling, the spring and the spring seal
may spring out. Be sure to wear protective goggles.
SM3-J705B
Fig. 10
1 page 1
3-10-6 ENGINE
SM3-J705
Fig. 11
ASSEMBLING
Tighten the nut and install the oil cooler element onto the
oil cooler element cover.
Tightening torque: 200 - 300 kgcm (15 -21 lbft)
SM3-J705
Fig. 13
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-10-7
2
1
4
5
SM3-J573A
Fig. 14
1 page 1
3-10-8 ENGINE
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-11-1
COOLING SYSTEM
RESERVOIR
TANK
COOLANT TEMPERATURE GAUGE
RADIATOR
CAP
THERMOSTAT CASE
RADIATOR
CYLINDER HEAD
THERMOSTAT
CYLINDER BLOCK
AIR
COMPRESSOR
CAR
HEATER
COOLANT
PUMP
OIL COOLER
DRAIN COCK
DRAIN COCK
SM3-J207
Fig. 1
5
3
2
1.
2.
3.
4.
5.
SM3-J574B
Fig. 2
1 page 1
3-11-2 ENGINE
3
4
5
1
THERMOSTAT
1. Thermostat case cover
2. O-ring
3. Thermostat case
4. Thermostat
5. Gasket
SM3-J284
Fig. 3
THERMOSTAT
DISASSEMBLING
1. Remove the three mounting bolts from the thermostat case cover, then remove the thermostat case
cover from the thermostat case.
2. Remove the thermostat from the thermostat case.
SM3-J706
Fig. 4
SM3-J707
Fig. 5
1 page 1
Models J08C-TP and J08C-TR
2.
STIRRING ROD
THERMOSTAT
ENGINE 3-11-3
THERMOMETER
WARNING
Never touch hot water and heated thermostat with
your bare hands. This can result in personal injury.
HEATER
SM3-J555
Fig. 6
T1 : VALVE OPENING TEMPERATURE
T2 : VALVE OPENED TEMPERATURE
LIFT
10 mm
(0.4 in)
0C
10C
T1C
T2C
a.
Measure the valve opening temperature using a coolant temperature gauge. If the value exceeds the limit,
replace the thermostat with a new one.
Standard: 74.5 - 78.5C (166 - 173F)
NOTE: Check that the thermostat valve opening temperature (T1) is engraved on the thermostat seat.
TEMP.
SM3-J210
Fig. 7
b.
L1 : WHEN COLD
L2 : WHEN (T2)C
L3 : VALVE LIFT
L3
L1
L2
SM3-J211
Fig. 8
JIGGLE VALVE
SM3-J212A
Fig. 9
1 page 1
3-11-4 ENGINE
3
2
6
1
5
COOLANT PUMP
1. Pulley center
2. Retainer ring
3. Shaft assembly
4. Pump case
5. Coolant seal sub assembly
6. Vane
SM3-J575
Fig. 10
COOLANT PUMP
DISASSEMBLING
1. Remove the vane from the shaft using the special
tool.
Special tool: Puller (09420 - 1820)
SM3-J817
Fig. 11
2.
SM3-J818
Fig. 12
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-11-5
3.
4.
SM3-J710
Fig. 13
NOTE:
Before pressing, recheck that the retainer ring is removed completely.
Replace the removed bearing with a new one. Never
reuse it.
SM3-J711
Fig. 14
5.
WARNING
Impact due to punching may cause metal chips to
fly up. Be sure to wear protective goggles.
NOTE: Replace the removed coolant seal with a new one.
Never reuse it.
SM3-J712
Fig. 15
1 page 1
3-11-6 ENGINE
Fig. 16
2.
SM3-J715
Fig. 17
3.
Install the pulley center onto the shaft using a hydraulic press.
Standard: 129.0 - 129.8 mm (5.0788 - 5.1102 in.) from the
pulley center mounting surface to the pump
case end surface
SM3-J716
Fig. 18
4.
a.
SM3-J793
Fig. 19
SM3-J794
Fig. 20
1 page 1
Models J08C-TP and J08C-TR
SM3-J717
Fig. 21
ENGINE 3-11-7
1 page 1
3-11-8 ENGINE
1
4
2
SM3-J285A
SM3-J285
1.
2.
3.
4.
Fig. 22
Cooling fan
Fan clutch
Coolant pump pulley
Fan shroud (If so equipped)
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-11-9
1 page 1
3-11-10 ENGINE
RADIATOR
INTERCOOLER
SM3-J719
Fig. 25
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-11-11
RADIATOR
INTERCOOLER
SM3-J719
Fig. 26
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-12-1
FUEL SYSTEM
LEAKAGE PIPE
FUEL FILTER
INJECTION PIPE
INJECTION NOZZLE
FUEL TANK
FEED PUMP
SM3-J167A
Fig. 1
6
5
7
2
3
8
1.
2.
3.
4.
5.
Fuel filter
Injection nozzle
O-ring
Nozzle clamp bolt
Leakage pipe
6. Gasket
7. Injection pipe
8. Injection pump
SM3-J167E
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
3-12-2 ENGINE
9
1
4
5
6.
7.
8.
9.
8
Coupling flange
Rack sensor
Lamination coupling
Air bleeder screw
SM3-J720B
Fig. 3
NOTE : Functional structure and system checking methods are reviewed in CHAPTER 78, TOTAL
ELECTRONIC SYSTEM.
1
2
3
6
7
NOZZLE HOLDER
1. Joint bolt
2. Gasket
3. Nozzle holder cap nut
4. Adjusting screw
5. Pressure spring
6. Nozzle
7. Nozzle retaining nut
SM3-J721A
Fig. 4
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-12-3
4
A
3
SM3-J722
Fig. 5
8
9
5
3
7
6
SM3-J723
Fig. 6
1 page 1
Models J08C-TP and J08C-TR
3-12-4 ENGINE
1
B
FUEL FILTER
1. Fuel filter cover
2. Fuel filter element
Fig. 7
3
2
4
FUEL FILTER (SECONDARY)
1. Fuel filter element assembly
2. Fuel filter cover
3. Bleeder screw
4. Soft washer
SM3-J725
Fig. 8
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-12-5
INJECTION NOZZLE
SM3-J556
Fig. 9
60
SM3-J185
Fig. 10
DISASSEMBLING
1. Remove the adjusting screw from the nozzle holder
upper part, then pull the nozzle spring and pressure
pin out of the nozzle holder.
2. Mount the nozzle holder in a vise, remove the retaining nut from the nozzle holder lower part and remove the nozzle assembly.
NOTE:
When disassembling a nozzle holder, take care to
prevent adherence of dust or dirt. Always be sure to
clean the work place and tools.
When removing a retaining nut, take care not to drop
the nozzle assembly, which may cause damage.
Be sure to put the disassembled parts in order, according to the combination in which they were.
INSPECTION AND REPAIR
INSPECT THE NOZZLE ASSEMBLY.
NOTE: Before inspection, clean the nozzle assembly by
immersing in clean diesel oil.
Hold the needle valve in your fingers, slide it inside the
nozzle body, then check that the valve moves smoothly.
When the nozzle body is tilted at approximately 60, the
nozzle assembly is good if the needle valve is not caught
and slips down smoothly under its own weight. If there is
any malfunction or catching, replace the nozzle assembly with a new one.
1 page 1
Models J08C-TP and J08C-TR
3-12-6 ENGINE
SM3-J556
Fig. 11
SM3-J726
Fig. 12
ASSEMBLING
1. Assemble the pressure pin and nozzle spring onto
the nozzle holder upper part.
2. Mount the nozzle holder in a vise, assemble the nozzle assembly onto the nozzle holder lower part, and
tighten the retaining nut to the specified torque below.
Tightening torque: 650 kgcm (47 lbft)
NOTE:
When assembling the nozzle holder, take care to prevent adherence of dust or dirt. Always be sure to clean
the work place and tools.
Take care not to drop the nozzle assembly, which may
cause damage.
CHECK THE INJECTION OPENING PRESSURE.
Operate the lever at the rate of 15 to 16 strokes per minute
using a nozzle hand tester to read the injection start pressure. If the injection opening pressure is out of the standard value, adjust the injection opening pressure.
Injection opening pressure: 220 kg/cm2 (3,129 lb/sq. in.)
WARNING
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.
GOOD
COARSE
COARSE
COARSE
SM3-J182A
Fig. 13
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-12-7
2.
3.
4.
5.
SM3-J744
Fig. 15
6.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-13-1
Waste gate
Engine
Blower impeller
Intercooler
EXHAUST PIPE
Exhaust gas
Compressed air
AIR
TURBOCHARGER
CLEANER ASSEMBLY
Turbine wheel
1 page 1
Models J08C-TP and J08C-TR
3-13-2 ENGINE
7
11
10
8
9
6
5
3
1
4
12
11
1
13
3
9
15
3
14
AIR INTAKE AND EXHAUST SYSTEM
(ENGINE SIDE)
1. Clamp
2. Inter cooler hose
3. Intake pipe
4. Safety valve
5. Hose
6. Coolant pipe
7. Oil pipe
8. Turbo charger
1
9.
10.
11.
12.
13.
14.
15.
Gasket
Exhaust connector
Heat insulator
Exhaust manifold
Intake manifold
Boost compensator pipe
Intake air temperature sensor
SM3-J405B
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-13-3
10
Insulator
Mesh
Hood
Bracket
Band
ASM3-159
Fig. 3
1 page 1
3-13-4 ENGINE
10
8
6
7.
8.
9.
10.
ASM3-160
Fig. 4
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-13-5
AIR CLEANER
4
3
7
5
4
AIR CLEANER
1. Air cleaner body
2. Unloader valve
3. Gasket
4. Wing nut
5. Cover
6. Element
7. Clamp
SM3-J731
Fig. 5
1 page 1
3-13-6 ENGINE
4.
SM3-J558
Fig. 6
SM3-J559
Fig. 7
SM3-J732
Fig. 8
WARNING
To prevent injury, always select appropriate type of
safety glasses for the job.
NOTE:
When cleaning the element, do not strike, knock or
drop it, as this will cause damage.
To prevent damaging the element, keep the air pressure below 7 kg/cm2 (99.6 lb/sq.in).
2. When the element is fouled by soot or oil mist, wash
the element thoroughly with 300 g (0.66 lb) of element detergent (Donaldson type ND-1500 or D-1400)
dissolved in 5 liters (5.3 US.qts) of hot water diluted
to 20 liters (21.1US.qts).
NOTE: Never clean the element with gasoline, fuel oil,
kerosene, or solutions containing any of these.
a.
SM3-J560
Fig. 9
1 page 1
Models J08C-TP and J08C-TR
b.
ENGINE 3-13-7
SM3-J560
Fig. 10
5.
6.
SM3-J733
Fig. 11
SM3-J561
Fig. 12
1 page 1
3-13-8 ENGINE
SM3-J601A
Fig. 13
2.
SM3-J735
Fig. 14
INSPECTION
SM3-J562
Fig. 15
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-13-9
MOUNTING
1.
SM3-J735
Fig. 16
SM3-J601A
Fig. 17
WARNING
If the position of the tail pipe is incorrect, exhaust
fumes may blow onto passers by and burns may
also result.
2. Connect the exhaust pipe to the exhaust manifold.
NOTE:
Replace the gasket with new one.
The mounting portion of the exhaust manifold is
subjected to heat and is likely to come loose, so special nuts are employed. Be sure to use the correct
nuts.
When tightening the clamp, arrow mark on the clamp
or rounded part must direct upward.
Tightening torque:
M8 T = 222-226 kgcm (16.0-16.3 lbft)
M10 T = 515-525 kgcm (37.2-38.0 lbft)
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-14-1
3
4
5
7
6
8
6.
7.
8.
9.
Stopper bolt
Clamp
Engine stop cable
Accelerator cable
SM3-J563A
Fig. 1
1 page 1
Models J08C-TP and J08C-TR
3-14-2 ENGINE
DISASSEMBLY
1.
FOR FD, FE
FOR FF, SG
SM3-J564
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
3.
ENGINE 3-14-3
SM3-J580
Fig. 3
ACCELERATOR
CABLE
ENGINE STOP
CABLE
ADJUSTING
NUT
ENGINE
ENGINE
STOP
RUNNING
POSITION POSITION SM3-J565
Fig. 4
INSPECTION
1.
2.
1 page 1
Models J08C-TP and J08C-TR
3-14-4 ENGINE
SM3-J736A
NOTE : Install the cables in the reverse sequence of removal, and be careful of the following points.
1. INSTALLATION OF ACCELERATOR CONTROL
MECHANISM
Both the accelerator cable and engine stop cable are taped
in order to facilitate identification during installation. After
being sure to connect the correct cable, successively clip
the cables, ensuring that they do not sag.
Fig. 5
MARKING CLAMP
POSITION
RADIATOR
SM3-J737A
Fig. 6
2.
SM3-J566
Fig. 7
2.
A
SM3-J567
Fig. 8
Set the accelerator pedal at an angle of A with respect to the floor surface.
Accelerator pedal angle (A) : 50
3. Eliminate slack in the cable of the control lever of
the injection pump.
4. Adjust the stopper bolts so that the clearance between the pedal and the stopper is 2 - 5 mm (0.079
- 0.196 in)
5. For the model equipped with a manual transmission ;
confirm that the amount of force applied on the pedal
(measured point P) is 4 kg (9 lb) at the initial stage
[2 - 3 mm (0.079 - 0.11 in)] and 7 kg (15 lb) at full
stroke.
1 page 1
Models J08C-TP and J08C-TR
2(0 5 m
.07 m
90.1
96
in.
)
6.
P POINT
7.
ENGINE 3-14-5
For the model equipped with an automatic transmission ; confirm that the amount of force applied on
the pedal is 7 kg (15 lb) at the initial stage and 11 kg
(24 lb) at full stroke.
Check the engine idle speed (700 - 750 rpm).
STOPPER
BOLT
SM3-J568
Fig. 9
4.
SM3-J580
Fig. 10
4.
ACCELERATOR
CABLE
ENGINE
STOP
CABLE
ADJUSTING
NUT
Fig. 11
WARNING
Do not start the engine.
5.
ENGINE
STOP
POSITION
ENGINE
RUNNING
POSITION SM3-J569
WARNING
Do not connect the electric harness with the engine stop motor while the engine starter key is at
LOCK or ACC position 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 will move, resulting in your fingers
being caught by the lever.
6.
7.
Connect and adjust the engine stop cable with adjusting nut so that the clearance A between the
clevis and cable stopper is 1 - 3 mm (0.04 - 0.11 in.).
After adjustment, confirm correct execution of engine
start and stop.
1 page 1
Models J08C-TP and J08C-TR
3-14-6 ENGINE
5.
COOLANT
HEATER
SM3-J738
Fig. 12
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-15-1
ELECTRICAL PARTS
3
6
ELECTRICAL PARTS
1. Alternator
2. Coolant temperature gauge
3. Oil pressure switch
4. Engine speed sensor
5. Starter
6. Intake air temperature sensor
SM3-J286A
Fig. 1
1 page 1
3-15-2 ENGINE
ALTERNATOR
DISMOUNTING
NOTE: Refer to page 3-5-3.
DISASSEMBLING AND ASSEMBLING
NOTE: Refer to ALTERNATOR in CHAPTER 21.
MOUNTING
NOTE: Refer to page 3-17-2.
SM3-J619A
Fig. 2
STARTER
DISMOUNTING
NOTE: Refer to page 3-5-1.
DISASSEMBLING AND ASSEMBLING
NOTE: Refer to STARTER in CHAPTER 22.
MOUNTING
NOTE: Refer to page 3-17-6.
SM3-J608
Fig. 3
SM3-J596A
Fig. 4
DISMOUNTING
NOTE: Refer to TOTAL ELECTRONICS SYSTEM in CHAPTER 78.
INSPECTION AND REPAIR
NOTE: Refer to ELECTRICAL EQUIPMENT in CHAPTER
20.
MOUNTING
NOTE: Refer to TOTAL ELECTRONICS SYSTEM in CHAPTER 78.
SM3-J596A
Fig. 5
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-16-1
1 page 1
3-16-2 ENGINE
AIR COMPRESSOR
DISMOUNTING
NOTE: Refer to page 3-5-2.
DISASSEMBLING AND ASSEMBLING
NOTE: Refer to AIR COMPRESSOR in CHAPTER 23.
MOUNTING
NOTE: Refer to page 3-17-4.
SM3-J614
Fig. 2
1 page 1
Models J08C-TP and J08C-TR
SM3-J033
Fig. 1
SM3-J036
Fig. 2
UPPER BOLT
SIDE BOLT
THERMOSTAT
CASE
O-RING
COOLANT
PUMP
SM3-J750
Fig. 3
ENGINE 3-17-1
1 page 1
3-17-2 ENGINE
SM3-J620
Fig. 4
4.
SM3-J619A
Fig. 5
(EXAMPLE)
CENTER POINT
SM3-J748
Fig. 6
SM3-J739
Fig. 7
6.
BLACK SIDE
SM3-J107
Fig. 8
1 page 1
Models J08C-TP and J08C-TR
2.
8 7
13
10
ENGINE 3-17-3
16
SM3-J034
Fig. 9
LIQUID GASKET
SM3-J034
Fig. 10
2.
D-RING
BLOCK D-RING
OIL
COOLER
PLANE PART
SM3-J166
Fig. 11
3.
Apply liquid gasket to the oil cooler housing and install it onto the cylinder block within 20 minutes.
4. Install the oil line.
Liquid gasket: ThreeBond No. 1207B
Coating width: 1.5 - 2.5 mm (0.06 - 0.10 in.)
NOTE:
If more than 20 minutes have passed since the liquid
gasket was applied, do not assemble. After removing
the liquid gasket completely, reapply it to assemble.
When installing the oil cooler, the earth wire of alternator must be tightened with the coolant pipe bracket
for turbocharger.
Refer to page 3-20-1.
1 page 1
3-17-4 ENGINE
SM3-J615
Fig. 13
FLYWHEEL HOUSING
FLYWHEEL
SM3-J202
Fig. 14
PROJECTION
2.
MATCH
MARK H
3.
MATCH MARK H
SM3-J220
Fig. 15
STUD BOLT
SM3-J221
Fig. 16
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-17-5
LOBE
SM3-J106
Fig. 17
MATCHING FACE WITH INTAKE MANIFOLD
LIQUID
GASKET
SM3-J038
Fig. 18
FLYWHEEL HOUSING
FLYWHEEL
SM3-J202
Fig. 19
2.
COUPLING
TIMER
Fig. 20
COTTER
BOLT
FLANGE
BOLT
SM3-J740
1 page 1
3-17-6 ENGINE
SM3-J609
Fig. 21
SM3-J608
Fig. 22
SM3-J607
Fig. 23
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-18-1
ENGINE TUNEUP
HOW TO GET THE TOP DEAD CENTER OF THE COMPRESSION STROKE FOR NO.1 PISTON
1. Turn the crankshaft to align mark 1-6 on the outer
periphery of the flywheel with the pointer of the flywheel housing.
NOTE: In this position the No. 1 and No. 6 pistons are
at the top dead center.
Fig. 1
MATCHING MARK
Before installing the injection pump, the No. 1 piston is at the top dead center of the compression
stroke when the coupling mounting key of the air
compressor is at the upper side.
5
48.
KEY
SM3-J002
Fig. 2
POINTER
NOTE: If not, turn the crankshaft one complete revolution and align marks as shown above.
TIMING MARK
Fig. 3
The No.1 piston is at the top dead center of the compression stroke when the arrow printed on the camshaft points up and the underline is horizontal.
Fig. 4
INTAKE ROLLER
EXHAUST
ROLLER
Fig. 5
1 page 1
Models J08C-TP and J08C-TR
3-18-2 ENGINE
SM3-J807
1.
2.
FORWARD DIRECTION
3.
Fig. 6
Fig. 7
NOTE: Make sure that the roller is on the base circle of the camshaft.
EXAMPLE
BASE CIRCLE
OF THE CAMSHAFT
Fig. 8
CLICK
GOOD
NO GOOD
SM3-J812
Fig. 9
4.
1 page 1
5.
10mm
or more
ADHESION
ENGINE 3-18-3
Fig. 11
6.
7.
NUT FIXING
POSITION
PROPER
CONTACT
FEELING IS SAME
LOOSENING AMOUNT =>
LARGE
OF ADJUSTING SCREW
SM3-J007
Fig. 14
NOTE: The feeling of the feeler gauge during clearance adjustment is same as before.
Do not overloosen the adjusting screw.
Overloosening of the adjusting screw will
cause the same condition as in 5 again. The
feeler gauge may feel correct, but there may
be excessive clearance between the adjusting screw of the cross head and the valve.
This does not allow for correct adjustment.
Fig. 15
1 page 1
Models J08C-TP and J08C-TR
3-18-4 ENGINE
Cylinder
ROCKER ARM
Camshaft gear
condition
Valve
CROSS HEAD
IN EX IN EX IN EX IN EX IN EX IN EX
Arrow points up
and underline is
horizontal.
Arrow points
down and underline is horizontal.
10. Finally, tighten all the lock nuts of the rocker arm and
the cross head with the following torques and make
sure that they are all tight (the nuts do not turn).
NOTE: Never overtighten with more than the following torque.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-18-5
1.
2.
SM3-J808
Fig. 17
Fig. 18
1.
Make sure that the timing mark on the outer periphery of the flywheel is aligned with the timing pointer.
2.
SM3-J808
Fig. 19
3.
4.
1 page 1
3-18-6 ENGINE
SM3-J015
SM3-J016
WARNING
Do not leave tools on or around the engine. Contact of tools with moving parts may result in injury
or damage to equipment.
PREPARATION
SM3-J017
SM3-J018
1.
2.
3.
4.
5.
6.
SM3-J019
Fig. 21
C
D
1.
2.
3.
1)
2)
CAM
ROLLER
OIL FILM IS
CONTINUOUS
GOOD EXAMPLE
Fig. 22
NOTE: 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.
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-19-1
CRANKSHAFT
PULLEY
V-BELT
DEFLECTION
TENSION PULLEY
LOCK NUT
ADJUSTING
BOLT
SM3-J795
Fig. 1
SM3-J746
Fig. 2
3.
SM3-J604
Fig. 3
4.
1 page 1
3-19-2 ENGINE
SM3-J747
Fig. 5
NOTE:
Apply grease to the input shaft spline.
Refer to TRANSMISSION in CHAPTER 7.
Be sure to install the transmission straight while
matching the engine angle with the transmission
angle using a jack.
SM3-J502
Fig. 6
6.
SM3-J602
Fig. 7
SM3-J601A
Fig. 8
1 page 1
Models J08C-TP and J08C-TR
8.
ENGINE 3-19-3
SM3-J600A
Fig. 9
9.
SM3-J599
Fig. 10
SM3-J598
Fig. 11
SM3-J597
Fig. 12
SM3-J596A
Fig. 13
1 page 1
3-19-4 ENGINE
SM3-J595
Fig. 14
SM3-J594
Fig. 15
Fig. 16
SM3-J796
Fig. 17
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-19-5
SM3-J590
Fig. 18
SM3-J587
Fig. 20
OPEN
CLOSE
DRAINING PLUG
SM3-J586
Fig. 21
OVER-TILTING
POSITION
NORMAL POSITION
SM3-J585
Fig. 22
1 page 1
3-19-6 ENGINE
SM3-J584
Fig. 23
SM3-J583
Fig. 24
SM3-J580
Fig. 25
4.
5.
SM3-J582A
Fig. 26
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-20-1
Black
White
Be careful not to apply excessive or insufficient liquid gasket. Also, be sure to overlap the start
and end of each coating.
3.
When assembling coated parts, be careful that there is no misalignment between mating parts.
If there is any misalignment, coat the parts again.
4.
Assemble the various parts within 20 minutes after applying liquid gasket. If more than 20 minutes have elapsed, remove the liquid gasket and apply it again.
After assembling the various parts, wait for at least 15 minutes before starting the engine.
5.
2. REMOVING PARTS
When removing each part, do not attempt to pry one portion of the flange alone but use flange collar or
clearance to pry the flange at several points alternately.
When using a tube of liquid gasket, use the winding key provided. In the case of a catridge type, use
commercially available application gun.
Application gun
Winding key
Tube 100 g (0.22 lb)
SM3-J029
Fig. 1
Fig. 2
Also, when using a tube, you can regulate the coating width by cutting the end of the nozzle at a
suitable position.
(1): Coating width approx. 2 mm (0.08 in.) when nozzle cut at 1st step
(2): Coating width approx. 5 mm (0.20 in.) when nozzle cut at 2nd step
(2) (1)
Tube nozzle
Fig. 3
SM3-J031
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-21-1
POWER TAKE-OFF
7
6
5
2
4
1
1
2
POWER TAKE-OFF
1. Gear case
2. Ball bearing
3. Drive gear subassembly
Fig. 1
SM3-J450
4. Driven shaft
5. Gear cover
6. Oil seal
7. Output coupling
8. Flange bolt
1 page 1
3-21-2 ENGINE
REMOVING
1.
2.
SM3-J452
Fig. 2
SM3-J453
Fig. 3
2.
SM3-J454
Fig. 4
3.
SM3-J455
Fig. 5
IDENTIFICATION
PAINT COLOR:
YELLOW
MAIN LIP
SUB-LIP
SM3-J456
Fig. 6
1 page 1
Models J08C-TP and J08C-TR
ENGINE 3-21-3
NOTE:
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 pressure
mounted.
Align the edges of the oil seal and gear cover.
After inserting the oil seal, completely wipe away any
oil that has oozed out using a rag.
SM3-J457
Fig. 7
2.
SM3-J459
Fig. 9
1 page 1
3-21-4 ENGINE
KNOCK-PIN
ASM3-145
Fig. 10
LIQUID GASKET
APPLICATION POSITION
FLYWHEEL HOUSING
SM3-J460
Fig. 11
PTO GEAR
CASE COVER
50 MM
{1.97 IN}
PTO
FLYWHEEL
HOUSING
MAIN IDLER
GEAR
CRANKSHAFT
GEAR
ASM3-146
Fig. 12
Unit: mm (in.)
Inspection item
Standard
Limit
0.30 (0.0118)