S5 - YP11E07B (Engine P11-FM320)

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FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for P11C engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner's Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
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CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S5-YP11E07B

CHAPTER
MODEL P11C
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 EN12-001
AIR COMPRESSOR EN13-001
ENGINE P.T.O. (POWER TAKE-OFF) EN14-001
FUEL CONTROL DN02-001

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INDEX: ENGINE GROUP 1/2
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
WORKSHOP AIR INTAKE SYSTEM
MANUAL EXHAUST SYSTEM
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
FUEL INJECTION PUMP
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE P.T.O. (POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROL
All rights reserved. This manual may not be

reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
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INDEX: ENGINE GROUP 2/2
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
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GENERAL INTRODUCTION (ENGINE) GN01–1
GENERAL INTRODUCTION (ENGINE)

GN01
GN01-001
GENERAL INTRODUCTION (ENGINE) ...GN01-2

GENERAL PRECAUTIONS.............................GN01-2
HOW TO USE THIS WORKSHOP MANUAL ..GN01-4
IDENTIFICATION INFORMATION ..................GN01-5
SPECIFIED TORQUE FOR
STANDARD BOLTS AND NUTS .....................GN01-6
DISMOUNTING AND MOUNTING ..................GN01-7
GN01–2 GENERAL INTRODUCTION (ENGINE)
GENERAL INTRODUCTION (ENGINE)

GENERAL PRECAUTIONS
EN00109010100001
Some recommended and standard maintenance services for your engine are included in this section. When per-
forming 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.
WARNING
When working on your engine, observe the following general precautions to prevent personal injury and/or
property damage, in addition to the particular NOTES or WARNINGS 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 crossmem-
ber when attaching the towing chain. Never lift or tow the vehicle if
the chain is in direct contact with the bumper.
1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is
removed. When the differential gear or rear axle shaft is defective,
remove both right and left rear axle shafts, then cover the hub
opening to prevent loss of axle lubricant and entry of dirt or for-
eign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten
the cable securely to the towing hook on the frame. The hook
should be used only if the towed vehicle is not loaded.
(3) The angle of pulling direction of the cable fastened to the towing
hook must not exceed 15 in horizontal and vertical directions from
the straight ahead, level direction. Avoid using the hook in a way
that subjects it to jerk, as in towing a vehicle trapped in a gutter.
(4) Keep the gear shift lever in "Neutral".
(5) Make sure that the starter switch is kept in the "ON" position.
(6) Make sure that the engine of the towed vehicle is kept running. If
the engine is off, no compressed air/ no vacuum will be available
for the brake. This is dangerous, as the brake system does not
function if the engine is not running.
In addition, the power steering system will not function. The steer-
ing wheel, therefore, will become unusually hard to turn, making it
impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied,
if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be
less than 30 km/h {18 mile/h}.
2. If the engine of the towed vehicle is defective, make sure that

the vehicle is towed only by a tow truck designed for that pur-
pose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off
the ground, remove the rear axle shafts to protect the transmis-
sion and differential gears from being damaged. The hub open-
ings 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 vehi-
cles 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.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fas-
ten and secure the steering wheel in a straight ahead position.
HOW TO USE
THIS WORKSHOP MANUAL
EN00109010200001
This workshop manual is designed as a guide for servicing the vehi-

cles.
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 diagnosis.
SPECIAL TOOL are dealt with in each chapter.

When ordering a special tool, confirm the part number with the applica-
ble parts catalog.
SHTS001090100001
• REPAIR PROCEDURES
Repair procedures when self-explanatory, such as simple installa-
tion and removal of parts, have been omitted. Illustrations, such
as the one below, have been provided to make such simple pro-
cedures clear. Only essential procedures requiring specific direc-
tions have been dealt with explicitly.
TIMING GEAR AND CAMSHAFT

EXAMPLE:
OVERHAUL
3 5 A
12
13 5 B
4
12
C
5 13
2 6
1 7 12
5
13
8
11
5
10
9
SHTS001090100002
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
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A* T= 108 {1,100, 79} C* T= 172 {1,750, 125}
B* T= 108 {1,100, 79} D T= 55 {560, 39} Application of lock sealant
*=Apply oil to the threads and seat surface before tightening.
In some cases, illustrations may be of parts which differ in some nones-
sential 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.
IDENTIFICATION INFORMATION
EN00109010200002
• ENGINE SERIAL NUMBERS.

Please quote these numbers when ordering spare parts or report-
ing technical matter to receive prompt service attention.
The engine serial number is engraved on the engine cylinder
block.
SHTS001090100003
SPECIFIED TORQUE FOR

STANDARD BOLTS AND NUTS
EN00109013200001
1. FLANGE BOLT Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Class 7T 9T
Representation
7 q
Diameter x Pitch
M8 x 1.25 28.5 {290, 21.0} 36 {370, 26.8}
M10 x 1.25 60 {610, 44.1} 74.5 {760, 55.0}
M10 x 1.5 55 {560, 40.5} 68.5 {700, 50.6}
M12 x 1.25 108 {1,100, 79.6} 136 {1.390, 100.5}
M12 x 1.75 97 {990, 71.6} 125 {1,280, 92.6}
M14 x 1.5 171.5 {1,750, 126.6} 216 {2,210, 159.8}
M14 x 2 154 {1,570, 113.6} 199 {2.030, 146.8}
2. BOLT WITH WASHER Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Class 4T 7T 9T
Representation
7 q
Diameter x Pitch No Mark
M6 x 1 6 {60, 4.3} 10 {100, 7.2} 13 {130, 9.4}
M8 x 1.25 14 {140, 10.1} 25 {250, 18.1} 31 {320, 23.1}
M10 x 1.25 29 {300, 21.7} 51 {520, 37.6} 64 {650, 47.0}
M10 x 1.5 26 {270, 19.5} 47 {480, 34.7} 59 {600, 43.4}
M12 x 1.25 54 {550, 39.8} 93 {950, 68.7} 118 {1,200, 86.8}
M12 x 1.75 49 {500, 36.2} 83 {850, 61.5} 108 {1,100, 79.6}
M14 x 1.5 83 {850, 61.5} 147 {1,500, 108.5} 186 {1,900, 137.4}
M14 x 2 74 {750, 54.2} 132 {1,350, 97.6} 172 {1,750, 126.6}

DISMOUNTING AND MOUNTING

EN00109013200002
PROCEDURE FOR INSTALLING JOINTS AND GAS-

KETS OF ENGINE PIPING
1. Gasket seal type (aluminum + rubber, asbestos or copper).
Location of gasket seal
Tightening torque chart
Clamping screw size (Diameter) mm {in.} Tightening torque N⋅m {kgf⋅cm, lbf⋅ft}
8 {0.315} 13 {130, 9}
10 {0.394} 20 {200, 14}
12 {0.472} 25 {250, 18}
14 {0.551} 25 {250, 18}
16 {0.630} 29 {300, 22}
18 {0.709} 39 {400, 29}
20 {0.787} *39 {400, 29}
24 {0.945} 69 {700, 51}
28 {1.102} 127 {1,300, 94}

2. Metal seal type (Flare connector type).
Location of metal seal
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
10 {0.394} 11 {110, 8}
20 {0.787} 20 {200, 14}
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 installa-
tion 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.
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ENGINE INTRODUCTION (P11C) EN01–1
ENGINE INTRODUCTION (P11C)

EN01
EN01-001
ENGINE ASSEMBLY ................................ EN01-2

DATA AND SPECIFICATIONS........................ EN01-2
TROUBLESHOOTING..................................... EN01-3
TUNEUP .......................................................... EN01-7
SPECIAL TOOL ............................................. EN01-11
OVERHAUL CRITERIA ................................. EN01-12
DISMOUNTING AND MOUNTING ................ EN01-13
LIQUID GASKET AND
APPLICATION POINTS................................. EN01-16
EN01–2 ENGINE INTRODUCTION (P11C)
ENGINE ASSEMBLY
DATA AND SPECIFICATIONS
EN0110901I200001
Model P11C-UB
Diesel, 4 cycle, vertical, 6 cylinder, in-line overhead camshaft,

Type
water-cooled, direct injection
Aspiration Turbocharged with intercooler
Bore and stroke 122x150 mm {4.8x5.9 in.}
Piston displacement 10.520 L {641.9 cu.in.}
Compression ratio 16: 1
1-4-2-6-3-5 (The cylinder numbers are counted in order from

Firing order
the timing gear side)
Direction of rotation Counterclockwise viewed from flywheel
Compression pressure 2.8-3.0 MPa {29-31 kgf/cm2, 413-440 lbf/in.2} at 200 r/min
Maximum revolution (at full load) 2,150 r/min
Idling revolution 525 r/min
Dry weight Approximately 1,050 kg {2,315 lb}
Intake 30°
Valve seat angle
Exhaust 45°
Intake 30°
Valve face angle
Exhaust 45°
Intake opens 11° before top dead center
Valve timing Intake closes 22° after bottom dead center

(flywheel travel) Exhaust opens 59° before bottom dead center
Exhaust closes 13° after top dead center
Valve clearance Intake 0.45 mm {0.0177 in.}

(when cold) Exhaust 0.60 mm {0.0236 in.}
Type Full forced pressure feed by gear pump

Engine oil pump
Drive By gear
Engine oil cooler Multi-plate type, water cooled
Type Multi-hole nozzle type

Injection nozzle Valve opening 1st: 16.7 MPa {170 kgf/cm2, 2,417 lbf/in.2}
pressure 2nd: 27.5 MPa {280 kgf/cm2, 3,982 lbf/in.2}
Type Forced circulation by volute pump

Coolant pump
Drive By gear
Thermostat Type Wax.type, bottom bypass system
3° before top dead center for No.1 cylinder of the compres-

Injection timing (flywheel travel)
sion stroke
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TROUBLESHOOTING
EN0110901F300001
Engine overheating
Symptom Possible cause Remedy/Prevention
Engine overheating (Coolant) 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
Defective coolant pump Repair or replace.
Engine overheating (Radiator) Clogged with rust or scale Clean radiator.
Clogged with iron oxide due to leakage Clean coolant passage and correct
of exhaust into cooling system exhaust leakage.
Clogged radiator core due to mud or Clean radiator.
other debris
Defective radiator cap pressure valve Replace radiator cap.
Engine overheating (Abnormal Incorrect injection timing Adjust injection timing.
combustion) Reduced injection pressure Adjust injection pressure.
Poor fuel Use good quality fuel.
Poor nozzle spray Adjust or replace nozzle.
Unsatisfactory automatic timer Repair or replace timer.
advance angle
Engine overheating (Other prob- Defective or deteriorated engine oil Change engine oil.
lems) Unsatisfactory operation of oil pump Replace or repair.
Insufficient oil Add oil.
Brake drag Repair or adjust.
Excessive oil consumption

Excessive oil consumption (Pis- Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
tons, cylinder liners, and piston Worn, sticking or broken piston rings Replace piston rings and cylinder liner.
rings)
Insufficient tension on piston rings Replace piston rings and cylinder liner.
Unsatisfactory 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 Replace valve and valve guide.
and valve guides) Worn valve guide Replace valve guide.
Incorrectly fitted valve stem seal Replace the stem seal.
Excessive lubricant on rocker arm Check clearance of rocker arm and
shaft.
Excessive oil consumption (Excess Defective oil level gauge Replace oil level gauge.
oil feed) Oil level too high Drain excess oil.
Excessive oil consumption (Other Overcooled engine (low temperature Warm up engine before moving vehi-
problems) wear) cle. Check cooling system.
Oil leakage from miscellaneous parts Repair.
Piston seizure
Piston seizure (Operation) Abrupt stoppage of engine after run- Operate engine properly.
ning at high speed
Hill climbing using unsuitable gear Select suitable gear.
Piston seizure (Oil) Insufficient oil Add oil.
Dirty oil Change oil.
Poor quality oil Replace with proper engine oil.
High oil temperature Repair.
Low oil pressure Repair.
Defective oil pump Repair oil pump.
Reduced performance due to worn oil Replace oil pump.
pump
Suction strainer sucking air Add oil and/or repair strainer.
Piston seizure Abnormal combustion See Symptom: "Engine overheating".
Piston seizure Coolant See Symptom: "Engine overheating".
Lack of power
Lack of power Injection pump Refer to the chapter "FUEL CON-
TROL".
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 rings See Symptom: "Engine overheating".
Difficult starting engine

Difficult starting engine (Electrical Discharged battery Charge battery.
system) Defective wiring in starter circuit Repair wiring of starter.
Loose or open-circuit battery cable Tighten battery terminal connections
or replace battery cable.
Broken glow plug or intake air heater Replace.
(If so fitted)
Difficult starting engine Injection pump Refer to the chapter "FUEL CON-
TROL".
Difficult starting engine (Air Clogged element Clean the element or replace the ele-
cleaner) ment.
Difficult starting engine (Fuel sys- No fuel in tank Supply fuel and bleed air from fuel sys-
tem) tem.
Clogged fuel line 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.
Water in fuel Drain and clean fuel system.
Difficulty starting engine (Nozzles) Seized nozzle Replace nozzle.
Broken or fatigued nozzle spring Replace spring.
Difficulty starting engine (Oil sys- Oil viscosity too high Use proper viscosity oil, or install an oil
tem) immersion heater and warm up oil.
Difficulty starting engine (Other Seized piston Replace piston, piston rings, and liner.
problems) Seized bearing Replace bearing and/or crankshaft.
Reduced compression pressure Overhaul engine.
Ring gear damaged or worn Replace the ring gear and/or starter
pinion.
Improperly adjusted or broken acceler- Adjust or replace the accelerator
ator cable cable.
Rough idling
Rough idling Injection pump Refer to the chapter "FUEL CON-
TROL".
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.
Rough idling (Engine proper) Improper valve clearance Adjust valve clearance.
Improper contact of valve seat Replace or repair valve and valve seat.
Idling speed too low Warm up engine.
Compression pressure of cylinders Overhaul engine.
markedly different from one another
Leakage of exhaust
Leakage of exhaust (Cylinder head Fatigued gasket (aging) Replace gasket.
gasket) Damage Replace gasket.
Improper installation Replace gasket.
Leakage of exhaust (Cylinder head Loose bolts Tighten bolt.
bolts) Elongated bolts 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 Adjust injection timing.
lems)
TUNEUP
EN0110901H300001
VALVE CLEARANCE CHECKING AND ADJUSTING

PROCEDURES
! CAUTION
Valve clearance adjustment is performed only when the checking
result is not within the specified value.
1. PREPARATION OF CHECKING AND ADJUSTMENT

(1) Positioning the No.1 or No.6 piston at Top Dead Center of the
compression stroke.
a. Turn the crankshaft counterclockwise (viewed from the fly-
wheel side) to align mark 1/6 on the outer periphery of the fly-
wheel 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.
SHTS011090100001
b. Confirm whether No.1 or No.6 piston is at the Top Dead Cen-

ter 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.
SHTS011090100002
(2) Make sure that the valve stem is correctly inserted in the cross
head.
NOTICE
Click Move the cross head with fingers right and left to confirm the
valve stem is correctly inserted in the cross head by listening to
the clicking sound.
Good
(3) Confirm that there is no foreign particles or dust between the
cross head and the valve stem.
No Good
SHTS011090100003
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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.6 pis-
ton is at the Top Dead Center of the compression stroke by the fol-
lowing chart).
Cylinder 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
With No.1 pis-

ton at T.D.C. on

compression
stroke
With No.6 pis-

ton at T.D.C. on

compression
stroke
• Mark: Possible to check valve clearance

• Firing order: 1-4-2-6-3-5
• T.D.C.: Top Dead Center
(2) Insert a feeler gauge of the specified thickness as below between
FEELER the rocker arm and the cross head to check the valve clearance.
GAUGE VALVE CLEARANCE (when cold)
Intake valve 0.45 mm {0.0177 in.}
Exhaust valve 0.60 mm {0.0236 in.}
! CAUTION
CROSS Valve clearance adjustment is performed only when the checking
HEAD result is outside the specified value.
SHTS011090100004
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 "PREPA-
RATION 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 and rocker arm support
bolt are tightened to the specified torque.
(1) Loosen the adjusting screw lock nut of the rocker arm and cross
head fully.
14mm (2) The cross head adjusting screw must protrude 14 mm {0.551 in.}
OR MORE 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
"ZERO"
CLEARANCE
SHTS011090100005
(3) Insert a feeler gauge of the specified thickness shown below

between the rocker arm and the cross head, and adjust the valve
FEELER GAUGE clearance with the adjust screw of the rocker arm.
VALVE CLEARANCE (when cold)
Intake valve 0.45 mm {0.0177 in.}
Exhaust valve 0.60 mm {0.0236 in.}
(4) After completion of the adjustment, tighten the lock nut A securely
with the specified tightening torque.
Tightening Torque:
SHTS011090100006 44 N⋅m {450 kgf⋅cm, 33 lbf⋅ft}
(5) The condition of inserted feeler gauge, loosen the adjusting screw
of the cross head, make sure that the feeler gauge does not feel
loose.
NOTICE
If the feeling of the feeler gauge becomes loose, repeat steps from
(1).
NEED
CLEARANCE
SHTS011090100007
(6) Tighten the adjusting screw of the cross head until the feeler
gauge does not move.
NOTICE
In this situation, clearance between adjusting screw and valve
stem head is zero.
"ZERO"
CLEARANCE
SHTS011090100008
(7) While loosening the adjusting screw of the cross head gradually,
adjust the valve clearance. Tighten the lock nut of the cross head
securely with the specified tightening torque when the feeler
gauge feels correct.
Tightening Torque:
44 N⋅m {450 kgf⋅cm, 33 lbf⋅ft}
NOTICE
• Do not over loosen the adjusting screw of the cross head.
"ZERO" • Over loosening of the adjusting screw will cause the same
CLEARANCE condition as in step (3) again. The feeler gauge may feel cor-
rect, but there may be excessive clearance between the
SHTS011090100009
adjusting screw of the cross head and the valve stem head.
This does not allow for correct adjustment.
(8) 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
1. INSPECT THE INJECTION TIMING.

(1) 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 the section "DATA AND SPECI-
FICATIONS".
(2) Check that the injection timing mark on the coupling jaw is aligned
with the pointer of the pump.
SHTS011090100010 If not, adjust the injection timing as on the following page.
2. ADJUST THE INJECTION TIMING.

THROUGH TIMING MARK POINTER (1) Make sure that the timing mark on the outer periphery of the fly-
BOLT wheel is aligned with the timing pointer.
(2) Loosen two adjusting bolts of the injection pump coupling. Do not
remove the bolts.
SST: Injection pump coupling wrench (S0951-12510)
(3) Turn the coupling jaw to the left (counterclockwise viewed from
the drive shaft) to align the coupling jaw mark with the pointer of
the pump.
COUPLING ADJUSTING (4) Tighten the coupling bolt to the specified torque.
BOLT
SHTS011090100011
Tightening Torque:
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

OIL 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 equip-
ment.
1. PREPARATION.
(1) Supply engine oil.
SHTS011090100012
(2) Supply cooling water and bleed air from it.

RADIATOR CAP
SHTS011090100013
(3) Bleed air from the fuel system.

AIR BLEEDER
PLUG (4) Check connection to the alternator.
PRIMING PUMP NOTICE
Start the engine without wiring in place may burn out the alterna-
tor.
(5) Check the engine stopping performance.
DRAIN HOSE
SHTS011090100014
LUBRICATION
1. CHECK THE ROCKER ARM.

(1) Remove the head cover.
ROCKER ARM
(2) Set the engine revolution to the specified idling revolution.
CROSS HEAD (3) After the engine starts, check that oil is supplied to the following
locations of all rocker arms within approximately 10 seconds.
a. Push rod and adjusting screw
b. Cross head top and spring upper seat top face D through
adjusting screw
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.
PUSH ROD Recheck the assembly.
TAPPET
CAMSHAFT
SHTS011090100015
SPECIAL TOOL
EN0110901K100001
Prior to starting an engine overhaul, it is necessary to have these special tools.
Illustration Part number Tool name Remarks
COMPRESSION GAUGE
S0955-21080 For Overhaul criteria
ADAPTER (A)
S0955-21030 COMPRESSION GAUGE

S0955-21060 ADAPTER (B)
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧟㧝ಽ
OVERHAUL CRITERIA
EN0110901H200001
FACTORS TO DETERMINE THE ENGINE OVERHAUL
1. LOW COMPRESSION PRESSURE

(1) Before measurement
a. Charge the battery completely.
b. Set the valve clearance to the correct value.
c. Idle the engine (Coolant temperature at 80°C {176°F}).
d. Remove the air cleaner.
e. While the starter switch is at the LOCK position, disconnect
the engine stop motor.
f. Remove all nozzle holders.
(2) Measurement
a. Insert the gauge adaptor (A) and (B) into the nozzle holder
hole.
SST:
Compression gauge adaptor (A) (S0955-21080)
Compression gauge adaptor (B) (S0955-21030)
Compression gauge adaptor (B) (S0955-21060)
b. Run the engine with the starter and measure the compression
pressure.
Difference between
Standard Limit
each cylinder
SHTS011090100018
2.8-3.0 MPa 2.5 MPa 0.3 MPa
{29-31 kgf⋅cm2, {26 kgf⋅cm2, {3 kgf⋅cm2,
413-440 lbf/in2} 370 lbf/in2} 43 lbf/in2} or less
Engine revolution 200 r/min
NOTICE
Do not operate the starter for more than 15 seconds.
c. Measure the compression pressure of each cylinder.
NOTICE
Do not allow gas leakage from the seal face.
(3) Reassemble the removed parts.
! 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. ENGINE OIL PRESSURE.

(1) Check the oil pressure warning light when the oil and coolant tem-
perature is hot [about 80°C {176°F}].
a. If the warning light is lightens, check the oil level.
b. Check oil deterioration.
If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil pressure
gauge.
SHTS011090100019
d. Measure the oil pressure at a coolant temperature of 80°C

{176°F} or more.
Oil pressure
Standard Limit
49-490 kPa Less than 49 kPa
{0.5-5.0 kg/cm2, {0.5 kg/cm2,
7.11-71.10 lbf/in.2} 7.11 lbf/in.2}
3. OTHER FACTORS
SHTS011090100020
(1) Increase of blowby gas
(2) Defective engine start
(3) Decrease of engine output
(4) Increase of fuel consumption
(5) Increase of engine noise
(6) Increase of oil consumption

EN0110901H100001
IMPORTANT POINT - DISMOUNTING
1. DISMOUNT THE ENGINE ASSEMBLY.

(1) Park the vehicle on level ground and then block the wheels.
(2) Tilt the cab.
(3) 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 starter switch to the LOCK position.
(6) 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.
SHTS011090100021
(7) Disconnect the hoses (coolant, heater and air intake) and remove
the radiator.
NOTICE
Do not damage the radiator.
(8) Disconnect the air intake and exhaust lines.
(9) 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.
EXAMPLE
SHTS011090100022
(11) Connect a cable from an engine hanger to the hanger bracket (1

point) on the front of the engine, and to the hanger bolts (2 points)
EXAMPLE
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.
EXAMPLE
SHTS011090100023
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧟㧝ಽ
(12) Remove the engine mounting fitting bolts and nuts (front and rear,
EXAMPLE 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.
EXAMPLE
SHTS011090100024
IMPORTANT POINTS - MOUNTING
1. MOUNT THE ENGINE ASSEMBLY.

(1) Mount the engine assembly in the reverse order of dismounting.
Tightening Torque:
147 N⋅m {1,500 kgf⋅cm, 108 lbf⋅ft} (Engine mounting fitting
bolts and 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 electric motor harness.
! CAUTION
Do not connect the electric harness to the engine stop motor
while the 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.
SHTS011090100025
LIQUID GASKET AND

APPLICATION POINTS
EN0110901H000001
• Liquid gasket is used at the following positions for the P11C series
engine.
Liquid gasket specification:

Three Bond TB1207B: Black
Three Bond TB1207D: Silver
Three Bond TB1211: White
1. LIQUID GASKET APPLICATION AND PART ASSEMBLY PRO-

CEDURE.
(1) Remove old liquid gasket from each part and matching parts and
wipe off oil, moisture or dirt with a rag.
(2) Overlap the liquid gasket at the start and end of application.
(3) Be careful of misalignment when assembling parts with liquid gas-
ket. If they are misaligned, reapply the liquid gasket.
(4) Assemble parts within 20 minutes of application.
If more than 20 minutes have passed, remove and reapply the liq-
uid gasket.
(5) Wait for at least 15 minutes or more after assembly of parts before
starting the engine.
2. REMOVE PARTS.
(1) When removing parts, do not use a tool for removal at one loca-
tion only. Use the tool at various locations such as a flange step or
gap for removal. When removing the gasket, be careful that gas-
ket residue does not enter the engine.
3. OTHERS.
(1) For tube-type liquid gasket, use the winding tool that comes with
the liquid gasket.
SHTS011090100026
(2) For cartridge-type gasket, use an application gun.
SHTS011090100027
(3) For tube-type liquid gasket, required width of application can be

obtained by cutting the nozzle to suit.
1: Approximately 2 mm wide when cut at the first step

2: Approximately 5 mm wide when cut at the second step
SHTS011090100028
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧞㧢ಽ
ENGINE MECHANICAL (P11C) EN02–1
ENGINE MECHANICAL (P11C)

EN02
EN02-001
CYLINDER HEAD ..................................... EN02-2

COMPONENT LOCATOR ............................... EN02-2
SPECIAL TOOL ............................................... EN02-4
OVERHAUL ..................................................... EN02-5
INSPECTION AND REPAIR .......................... EN02-13
CRANKSHAFT FRONT END.................. EN02-17

COMPONENT LOCATOR ............................. EN02-17
SPECIAL TOOL ............................................. EN02-18
OVERHAUL ................................................... EN02-18
FLYWHEEL AND
FLYWHEEL HOUSING............................ EN02-20
SPECIAL TOOL ............................................. EN02-21
OVERHAUL ................................................... EN02-21
TIMING GEAR AND RELATED PARTS.. EN02-24

DESCRIPTION .............................................. EN02-24
SPECIAL TOOL ............................................. EN02-26
OVERHAUL ................................................... EN02-27
INJECTION PUMP DRIVE ...................... EN02-35

SPECIAL TOOL ............................................. EN02-35
OVERHAUL ................................................... EN02-36
MAIN MOVING PARTS AND

CYLINDER BLOCK................................. EN02-37
SPECIAL TOOL ............................................. EN02-40
OVERHAUL ................................................... EN02-41
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧞㧠ಽ
EN02–2 ENGINE MECHANICAL (P11C)
CYLINDER HEAD
COMPONENT LOCATOR
EN0110902D100001
SHTS011090200001
1 Oil filler cap 7 Cylinder head cover (Lower)

2 Cylinder hear cover (Upper) 8 Injection pipe oil seal
3 Ventilator 9 Cylinder head
4 O-ring 10 Cylinder head gasket
5 Ventilator hose 11 Valve stem seal
6 Cylinder head cover gasket 12 Ventilator baffle plate

A 54 {550, 40} C 294 {3,000, 217} #
B 74 {750, 54} #
#=Apply oil to the threads and seat surfaces before tightening.
SHTS011090200002
1 Cylinder head 11 Rocker support 21 Intake valve

2 Valve guide bushing 12 Expansion plug 22 Exhaust valve
3 Valve stem seal 13 Rocker shaft 23 Valve spring lower seat
4 Straight pin 14 Collar 24 Outer valve spring
5 O-ring 15 Rocker arm bushing 25 Inner valve spring
6 Nozzle seat 16 Rocker arm 26 Valve spring upper seat
7 Expansion plug 17 Rocker support 27 Valve spring retainer
8 Stud 18 Valve clearance adjusting 28 Cross head
screw
9 Exhaust valve seat 19 Push rod
10 Intake valve seat 20 Valve lifter

A 52 {530, 38} C 23 {230, 16.5}
B 44 {450, 32}
SPECIAL TOOL
EN0110902K100001
S0943-31030 EYE BOLT
S0962-11130 SOCKET WRENCH
S0947-01120 VALVE SPRING PRESS
S0943-11010 VALVE LAPPING TOOL
S0947-21870 VALVE STEM SEAL PRESS
S0947-21210 BAR For Nozzle sleeve
SN441-00610 STEEL BALL Used with S0947-21210
S0942-01442 SLIDING HAMMER

S0946-21560 ADAPTER Used with S0942-01442
OVERHAUL
EN0110902H200001
IMPORTANT POINTS - DISASSEMBLY
1. DISASSEMBLE THE CYLINDER HEAD.

(1) Clean parts around the nozzle holder and fuel system connec-
tions.
NOTICE
Entry of foreign particles into the combustion chamber may result
in engine trouble.
(2) Remove the nozzle holder assembly.
NOTICE
Refer to the chapter “FUEL SYSTEM”.
(3) 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.
SHTS011090200012
b. Loosen the rocker 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.
2 4 6 7 5 3 1
SHTS011090200013
(4) Remove the cylinder head cover (Lower).

a. Remove the push rod.
b. Remove the fifteen bolts, then remove the cylinder head cover
(Lower).
SHTS011090200014
(5) Remove the cylinder head bolts.

a. Gradually loosen bolts three times in the order shown in the
figure.
SHTS011090200015
(6) Lift and remove the cylinder head using the special tool and hoist.
SST: Eye bolt (S0943-31030)
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.
SHTS011090200016
2. DISASSEMBLE THE VALVE SYSTEM.

(1) Remove the valve spring retainer using the special tool.
SST: Valve spring press (S0947-01120)
SHTS011090200017
(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 reas-
sembly.
SHTS011090200018
3. CLEAN THE CYLINDER HEAD.

(1) 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.
SHTS011090200019
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) When installing a new valve guide, do not twist the end. Press fit
the valve guide.
SHTS011090200020 Unit: mm {in.}
Intake Exhaust
27.9-28.2 27.9-28.2
A
{1.0985-1.102} {1.0985-1.102}
88 88
B
{3.465} {3.465}
2. REPLACE THE VALVE SEAT.

(1) When replacing the valve seat, cut three places on the circumfer-
VALVE SEAT
BACK PLATE ence of an unwanted valve and weld it to the valve seat.
NOTICE
To protect the lower surface of the cylinder head from welding
spatter, be sure to apply grease before welding.
ELECTRIC
(2) Place a (brass) back plate at the top of the valve system and
VALVE WELDING strike it with a hammer to remove the valve seat.
CUT THREE ! CAUTION
PLACES HERE Striking the valve seat for removal may cause metal chips to fly
up. Be sure to wear protective goggles.
SHTS011090200021
(3) Machine the valve according to the valve seat dimensions.

Unit: mm {in.}
Intake Exhaust
44.1-44.116 42.1-42.116
A
Cylinder {1.7363-1.7368} {1.6575-1.6581}
head side 8.0-8.2 8.2-8.4
B
{0.3150-0.3228} {0.3229-0.3307}
44.185-44.2 42.196-42.206
C
Valve {1.7396-1.7401} {1.6613-1.6616}
seat side 6.0-6.2 6.0-6.2
D
SHTS011090200022 {0.2363-0.2440} {0.2363-0.2440}
(4) Heat the cylinder head to 80 - 100°C {176 - 212°F} in hot water.
After cooling the valve seat, insert it into the cylinder head.
! CAUTION
Striking the valve seat during installation may cause metal chips
to fly up. Be sure to wear protective goggles.
SHTS011090200023
(5) Apply a small amount of lapping compound to the contact sur-

faces of the valve and valve seat. Turn the valve using the special
tool and tap it lightly to lap.
SST: Valve lapping tool (S0943-11010)
SHTS011090200024
3. REPLACE THE VALVE STEM SEAL.

(1) After removing the valve stem seal, assemble the spring lower
STEM SEAL seat and apply engine oil to the stem seal lip. Punch it into the
SPECIAL TOOL
SPRING valve guide using the special tool.
LOWER SEAT SST: Valve stem seal press (S0947-21870)
! 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
SHTS011090200025
4. REPLACE THE NOZZLE SEAT.

(1) Tap the nozzle seat from the cylinder head lower surface.
Then, screw in a suitable bolt and strike the bolt head with a ham-
mer 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.
SHTS011090200026
(2) After inserting the O-ring into the nozzle seat insertion hole of the
NOZZLE SEAT O-RING cylinder head, apply liquid packing (Three Bond No. 1211 or
equivalent) to the lower part of the new nozzle seat and assemble
it onto the cylinder head.
NOTICE
Be sure to replace the O-ring with a new one. Reuse of the O-ring
may cause water or gas leakage, resulting in overheating or crack-
ing of the cylinder head.
SHTS011090200027
(3) Caulk the nozzle seat with the special tools.

SST:
Bar (S0947-21210)
Steel ball (SN441-00610)
SHTS011090200028
IMPORTANT POINTS - ASSEMBLY
1. ASSEMBLE THE VALVE AND VALVE SPRING.

(1) Install the valve spring retainer at the valve spring upper seat
using the special tool.
SST: Valve spring press (S0947-01120)
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.
SHTS011090200017
• 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 cyl-
inder block surface.
• Never reuse the gasket as it may cause engine damage.
SHTS011090200029
3. INSTALL THE CYLINDER HEAD.

(1) Using the special tool and hoist, install the cylinder head over the
dowels on the cylinder block.
SST: Eye bolt (S0943-31030)
(2) Apply clean engine oil to the bolt threads and under bolt head.
(3) Clean the bolt seats completely on the cylinder head upper sur-
face.
(4) Tighten the nineteen cylinder head bolts in the order as shown in
the figure to the specified torque.
Tightening Torque:
98 N⋅m {1,000 kgf⋅cm, 72 lbf⋅ft}
SHTS011090200030
(5) Set the No.1 piston to the Top Dead Center of the compression
stroke.
(6) Apply clean engine oil to the push rod both ends, insert the push
rod into the cylinder block.
SHTS011090200032
(7) Install the cross head on each valve.

NOTICE
If the cross head is assembly whilst off the valve, the upper seat
will be pressed, resulting in a loose valve.
GOOD WRONG
SHTS011090200033
(8) Put the rocker arm assembly on the cylinder head.

NOTICE
• Make sure that the rocker shaft is installed with the "UP"
mark on the shaft upward.
• Make sure that the push rods interlock with the adjusting
screws.
• Always loosen the locknuts and raise the adjusting screws
fully to the top.
(9) Temporarily tighten the twelve rocker support bolts in the order as
shown in the figure, until the rocker arm support fits on the cylin-
SHTS011090200034
der head upper surface.
NOTICE
Apply engine oil to the bolt threads and under the bolt head.
(10) Tighten the seven cylinder head bolts in the order as shown in the
figure to the specified torque.
NOTICE
Apply engine oil to the bolt threads and under the bolt head.
Tightening Torque:
98 N⋅m {1,000 kgf⋅cm, 72 lbf⋅ft}
(11) Tighten the twenty-six cylinder head bolts and cylinder head addi-
tional bolt in the order as shown in the figure to the specified
torque.
SST: Socket Wrench (S0962-11130)
Tightening Torque:
Cylinder head bolt: 294 N⋅m {3,000 kgf⋅cm, 217 lbf⋅ft}
Cylinder head additional bolt: 74 N⋅m {750 kgf⋅cm, 54 lbf⋅ft}
ADDITIONAL BOLT
(12) Tighten the six cylinder head bolts in the order as shown in the fig-
ure to the specified torque.
Tightening Torque:
294 N⋅m {3,000 kgf⋅cm, 217 lbf⋅ft}
(13) Finally, tighten the twelve rocker support bolts in the order as
shown in the figure to the specified torque.
Tightening Torque:
4. INSTALL THE NOZZLE HOLDER.

(1) Refer to the chapter “FUEL SYSTEM”.
INSPECTION AND REPAIR

EN0110902H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Measure
0.5
Push rod bend — Replace.
{0.0196}
Valve lifter guide outside 28 Measure

—
diameter {1.102}
Valve lifter guide inside 28

—
diameter {1.102}
Replace tappet.
Clearance between valve 0.020-0.066 0.10

lifter and valve lifter guide {0.0008-0.0025} {0.0039}
Valve lifter: Should not be Visual check

— Replace.
Wear worn unevenly.
Visual check
Adjusting screws and
push rods: — — Replace.
Damage
Visual check
Rocker arm and valve
stem cap: — — Replace.
Wear and damage
Rocker arm bushing Replace rocker Measure

28 {1.102} 28.08 {1.1055}
inside diameter arm.
Rocker shaft outside Replace rocker

28 {1.102} 27.92 {1.0992}
diameter shaft.
Clearance between rocker

0.044-0.120 Replace rocker arm
shaft and rocker arm 0.15 {0.0059}
{0.0018-0.0047} and/or rocker shaft.
bushing
Stem Measure
outside 8 {0.3150} 7.88 {0.3102} Replace the valve.
diameter
A and B = 8.12
Intake valve Guide inside {0.3197} Replace the valve
8 {0.3150}
diameter C = 8.18 guide.
{0.3220}
0.040-0.077
Clearance — —
{0.0016-0.0030}
Stem
outside 8 {0.3150} 7.88 {0.3102} Replace the valve.
diameter
Guide inside A and B = 8.14 Replace the valve

8 {0.3150} A B C
diameter {0.3205} guide.
Exhaust
valve
0.057-0.094
Clearance — —
{0.0023-0.0037}
0-0.2 Replace the valve Measure

IN 0.7 {0.0275}
{0-0.0078} and valve seat.
VALVE SINK
Valve sink
0.6-0.8 1.3 Replace the valve
EX
{0.0236-0.0314} {0.0512} and valve seat.
Valve seat IN 30° 30°-30°35' Measure

angle EX 45° 45°-45°30'
IN 30° 29°30'-30°
Resurface the
valve and/or valve
Valve face seat.
angle EX 45° 44°30'-45°
389.3 N 357.9 N Measure

Setting load {39.7 kgf, 87.5 lbf} {36.5 kgf, Replace.
at 58.1 {2.287} 80.5 lbf}
Outer valve Free length

spring (reference 93 {3.661} 91 {3.583} Replace.
value)
4.6 {0.1811}
Squareness — Replace.
(2.5°)
166.7 N 153.0 N
Setting load {17.0 kgf, 37.5 lbf} {15.6 kgf, Replace.
at 54.1 {2.130} 34.4 lbf}
Free length
(reference 72.0 {2.835} 70.0 {2.756} Replace.
Inner valve value)
spring
3.6 {0.1417}
Squareness — Replace.
(2.5°)
Visual check
Wear and damage of valve
spring seat upper and — — Replace.
lower
Measure
2.75-3.25 Replace nozzle

Nozzle protrusion —
{0.1083-0.1279} seat.
0.05 or less Measure

{0.0019 or less}
for longitudinal
direction
Cylinder head lower sur-

0.10 {0.0039} Regrind or replace.
face flatness 0.03 or less
{0.0012 or less}
for lateral
direction
Measure
Cylinder head height (H) 104 {4.094} 103.7 {4.0827} Replace.

Visual check
Cracks of damage to cylin-

der head
— — Replace.
*Dye penetrant check
(color check)
Visual check
Contact of valve (Use of Entire periphery

Red lead marking com- of valve head — Matches valve.
pound) evenly in contact
CRANKSHAFT FRONT END

COMPONENT LOCATOR
EN0110902D100002
SHTS011090200055
1 Collar 4 O-ring
2 Crankshaft pulley 5 Dust slinger
3 Torsional dumper 6 Oil seal sleeve

A 706 {7,200, 521}#
SPECIAL TOOL
EN0110902K100002
S0940-21161 OIL SEAL SLEEVE PRESS
S0940-21400 DUST SLINGER PRESS
SZ301-74001 O-RING
OVERHAUL
EN0110902H300002
1. REPLACE THE OIL SEAL SLEEVE.

(1) Remove the oil seal sleeve using a suitable puller.
SHTS011090200059
(2) Install the oil seal sleeve.

a. Install the new O-ring into the groove of the oil seal sleeve.
b. Coat the clean engine oil to inside surface of the oil seal
sleeve.
c. Install the oil seal sleeve on the crankshaft pulley using the
special tool.
SST: Oil seal sleeve press (S0940-21161)
NOTICE
Take care that the O-ring does not get cut or torn.
SHTS011090200060
2. REPLACE THE DUST SLINGER.

(1) Remove the oil seal sleeve.
(2) Remove the dust slinger with lever.
SHTS011090200061
(3) Using special tools, install the dust slinger.

SST:
Dust slinger press (S0940-21400)
O-ring (SZ301-74001)
NOTICE
To prevent wear of the side lip of the oil seal, apply about 0.5-1
cm3 {0.03-0.061 cu.⋅in.} of grease (lithium based) into the "U"
groove of the dust slinger.
SHTS011090200062
IMPORTANT POINT - MOUNTING
1. INSTALL THE CRACKSHAFT PULLEY.

NOTICE
Apply clean engine oil to the bolt thread and seat surfaces before
tightening.
SHTS011090200063
FLYWHEEL AND FLYWHEEL HOUSING

COMPONENT LOCATOR
EN0110902D100003
SHTS011090200064
1 Stay 7 Flywheel dust cover

2 Flywheel housing 8 Ring gear
3 Engine mounting bracket 9 Spacer (with Flywheel power Take-off)
4 Dust cover 10 Flywheel
5 Oil seal retainer 11 Pilot bearing
6 Oil seal

A 270 {2,750, 199}# C 127 {1,300, 94}
B 113 {1,150, 83} D 211 {2,150, 155}
#=Apply oil to the threads and seat surface before tightening.
SPECIAL TOOL
EN0110902K100003
S0942-01850 OIL SEAL PULLER
S0940-71110 OIL SEAL PRESS
OVERHAUL
EN0110902H200002
1. REMOVE THE CRANKSHAFT REAR OIL SEAL.

SST: Oil seal puller (S0942-01850)
(1) Assemble the special tools as shown in the figure.

(2) Engage the hook with the oil seal notch and secure the hook with
the sleeve.
SHTS011090200067
(3) Tighten the center bolt to remove the oil seal.
SHTS011090200068
2. INSTALL THE CRANKSHAFT REAR OIL SEAL.

SST: Oil seal press (S0940-71110)
(1) Clean the edges and surface of the crankshaft and the special
tools.
(2) Insert a new crankshaft oil seal into the guide of the oil seal press.
NOTICE
Pay attention to the orientation of the crankshaft oil seal (The felt
side should face the outside of the cylinder block).
(3) Apply a little engine oil to the seal portion of the crankshaft oil
seal.
SHTS011090200069
(4) Attach the oil seal press guide with the new crankshaft oil seal
onto the crankshaft using the attached guide bolt.
(5) Insert the oil seal press by adjusting the oil seal press hole to the
guide bolt.
(6) Press the crankshaft oil seal inside by attaching the accompany-
ing center bolt onto the oil seal press and tightening it until it
stops.
SHTS011090200070
3. REPLACE THE FLYWHEEL RING GEAR.

(1) Heat the ring gear evenly to about 200°C {392°F} with a torch. Tap
the ring gear periphery lightly using a cushion bar to remove the
gear.
! CAUTION
Never touch the heated ring gear or flywheel with your bare hand.
This can result in personal injury.
SHTS011090200071
(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.
SHTS011090200072
1. INSTALL THE OIL SEAL RETAINER.

(1) Apply liquid gasket (Three Bond TB1207C or equivalent) to the oil
seal retainer as shown in the figure.
NOTICE
• Make sure the liquid gasket bead is uniform and unbroken.
• Apply liquid gasket so that the bead width is 3.5-4.5 mm
{0.1378-0.1771 in.}
(2) Install the oil seal retainer on the cylinder block.
SHTS011090200073
2. INSTALL THE FLYWHEEL.

(1) Install the flywheel and tighten the bolts through several repetition
the tightening order so as to reach specified torque evenly and
gradually, then slacken and tighten them one by one to the speci-
fied torque.
! CAUTION
The flywheel is heavy, when installing, be careful not to drop it on
your feet.
Tightening Torque:
270 N⋅m {2,750 kgf⋅cm, 199 lbf⋅ft} 225 N⋅m {2,295 kgf⋅cm, 166
lbf⋅ft} (With Flywheel power take-off)
NOTICE
• Align the pin hold on the flywheel and crankshaft straight
pin.
• When tightening the bolt, apply clean engine oil to the bolt
threads and seat surfaces.
SHTS011090200074

EN0110902H300003
Unit: mm {in.}
Measure
Flywheel surface 0.2

— Repair.
deflection {0.0079}
Flywheel flange depth 48 48 Measure

Repair.
(Dimension A) {1.890} {1.890}
Flywheel thickness 22 20
Replace.
(Dimension B) {0.866} {0.787}
Flywheel surface crack Visual check

— — Replace.
or head spot
TIMING GEAR AND RELATED PARTS

DESCRIPTION
EN0110902C100001
SHTS011090200077
1 Coolant pump drive gear 6 Power steering oil pump drive gear
2 Air compressor drive gear 7 Camshaft idle gear
3 Air compressor idle gear 8 Crankshaft gear
4 Camshaft gear 9 Oil pump idle gear
5 Injection pump drive gear 10 Oil pump driven gear
COMPONENT LOCATOR
EN0110902D100004
SHTS011090200078
1 Oil seal 8 Pin 15 Camshaft

2 Timing gear case cover 9 Idle gear shaft 16 Idle gear shaft
3 Gasket 10 O-ring 17 Bushing
4 Timing pointer 11 Camshaft gear 18 Camshaft idle gear
5 Thrust plate 12 Spacer 19 Injection pump drive gear
6 Air compressor idle gear 13 Thrust plate 20 Front end plate
7 Bushing 14 Key

A 23 {230, 16.5} D 29 {300, 21}
B 108 {1,100, 79}# E 186 {1,900, 135}#
C 132 {1,350, 98} F 245 {2,500, 180}
SPECIAL TOOL
EN0110902K100004
S0946-21410 ADAPTER
S0942-01442 SLIDING HAMMER
S0945-11040 TAPPET HOLD STOPPER
S0942-01111 GEAR PULLER

OVERHAUL
EN0110902H200003
1. REMOVE THE AIR COMPRESSOR IDLE GEAR SHAFT.

(1) Using the special tools, remove the air compressor idle gear shaft.
SST:
Sliding hammer (S0942-01442)
Adapter (S0946-21410)
SHTS011090200083
2. REMOVE THE CAMSHAFT IDLE GEAR SHAFT WITH CAM-

SHAFT IDLE GEAR.
(1) Remove the bolt.
(2) Using the special tools, remove the idle gear shaft with camshaft
idle gear.
SST:
Sliding hammer (S0942-01442)
Adapter (S0946-21410)
(3) Remove the thrust plate.
SHTS011090200084
3. REMOVE THE INJECTION PUMP DRIVE GEAR.

(1) Remove the nut and oil pipe.
(2) Install the nut on the drive shaft, then using a copper hammer,
remove the drive gear by tapping the drive shaft.
NOTICE
When removing, hold the bearing holder case to prevent drop.
SHTS011090200085
4. REMOVE THE CAMSHAFT WITH CAMSHAFT GEAR.

(1) Using a special tool, suspend the valve lifter above the camshaft.
SST: Tappet hold stopper (S0945-11040)
SHTS011090200086
(2) Remove the camshaft thrust plate fitting bolts (4 pieces) and pull
out the camshaft with gear.
NOTICE
Pull the camshaft, slowly turning it so as not to damage the cam-
shaft bearings.
FITTING BOLT
SHTS011090200087
5. REMOVE THE VALVE LIFTER.

(1) Remove the special tool, remove the valve litter.
NOTICE
Knock pins have been inserted into the valve lifter holes in the cyl-
inder block to prevent the valve lifters from turning.
SHTS011090200088
! CAUTION
The tips of these knock pins have been specially heat processed
to ensure that they are sufficiently resistant to abrasion. For this
reason, they do not need to be replaced. Do not remove the set
screws that secure them in place for any reason.
If the set screws are loosened accidentally, follow the procedure
below to restore them to their original condition.
1. Wipe away all the sealant from around the screw holes in the
cylinder block.
2. After confirming that none of the knock pins have been
removed, tighten new set screws with a torque of 29 N⋅m {300
kgf⋅cm, 21 lbf⋅ft}.
SHTS011090200089 3. To prevent the new set screws from oil leakage or becoming
loose, they are covered with a special sealant. The benefits
of this sealant are lost if old set screws are reused, are this
could cause problems. Therefore, make sure to use new
screws.
6. REMOVE THE CAMSHAFT GEAR.

(1) Hold the camshaft assembly with a vice through wooden plates.
(2) Remove the bolt.
(3) Using a special tool, remove the camshaft gear.
SST: Gear puller (S0942-01111)
SHTS011090200090
1. INSTALL THE CAMSHAFT GEAR TO THE CAMSHAFT.

(1) Install the spacer, thrust plate and key.
(2) Heat the camshaft gear in oil heated to about 100°C {212°F}.
! CAUTION
Never touch the heated gear with your bare hand. This can result
in personal injury.
(3) Install the camshaft gear to the camshaft using a press.
(4) Tighten the bolt.
SHTS011090200091
2. INSTALL THE CRANKSHAFT OIL SEAL.

(1) Using a special tool, install the new oil seal.
SHTS011090200092
3. INSTALL THE FRONT END PLATE.

(1) Align the cylinder block and front end plate using straight pin (B)
and the air compressor idle gear shaft.
NOTICE
If the cylinder block and front end plate are aligned using straight
pin (A) and (B), the air compressor idle gear shaft cannot be
inserted.
4. INSTALL THE AIR COMPRESSOR IDLE GEAR.

(1) Install the O-ring into the cylinder block side.
(2) Using a plastic hammer, install the idle gear shaft.
SHTS011090200093
NOTICE
• Install the compressor idle gear shaft with the oil hole point-
ing to the lower part of the engine.
• When installing the shaft, take care that O-ring does not be-
come cut or torn.
(3) Install the thrust plate and air compressor idle gear onto the idle
gear shaft.
(4) Apply clean engine oil to the bolt threads and seat surfaces, then
tighten the bolt.
5. INSTALL THE VALVE LIFTER.

(1) When inserting the valve lifters into the valve lifter guide holes of
the cylinder block, apply engine oil (new oil) to the entire circum-
ference of the portion of the valve lifters that rubs against the
guide holes and to the entire roller portion.
(2) Orient each tappet's turning prevention notch toward the exhaust
side of the engine and insert the valve lifter guide hole in the cylin-
der block. If the valve lifter is inserted the wrong way, it will inter-
fere the camshaft, making it impossible to install the camshaft.
(3) When installing the valve lifters, insert each until the turning pre-
vention notch at the bottom of the valve lifter engages the turning
prevention pin. Also confirm that the roller portion of each valve
lifter extends to the proper position from the valve lifter guide hole.
SHTS011090200094
6. INSTALL THE CAMSHAFT.

(1) Using a special tool, lift up the valve lifters and suspend them
above the camshaft.
SST: Tappet hold stopper (S0945-11040)
SHTS011090200095
(2) Lubricate all journals of the camshaft and insert the camshaft
assembly into the cylinder block.
NOTICE
Insert the camshaft, slowly turning while inserting so that the
bearing will not be damaged.
SHTS011090200096
7. INSTALL THE CAMSHAFT IDLE GEAR.

(1) Install the camshaft idle gear and thrust plate onto the idle gear
shaft.
(2) Align the camshaft idle gear matching marks with crankshaft gear
matching mark and camshaft gear matching mark, install the
camshaft idle gear.
NOTICE
Align the straight pin of the camshaft idle gear bore and the
groove of the camshaft idle shaft.
(3) Apply clean engine oil to the bolt thread and seat surfaces, then
install the bolt.
DETAIL OF A
DETAIL OF B
SHTS011090200097
8. INSTALL THE INJECTION PUMP DRIVE GEAR.

(1) Install the O-ring into the groove of the bearing holder case.
(2) Install the injection pump drive to the front end plate.
(3) Align the injection pump drive gear matching mark with the cam-
shaft idle gear matching mark.
(4) Install the nut.
(5) Install the timing gear case, and secure the injection pump drive
to the timing gear case with bolts.
DETAIL OF A
SHTS011090200098

EN0110902H300004
Unit: mm {in.}
No.1 65.0 Measure

Journal {2.5591}
No.2 64.6
Journal {2.5433}
No.3 64.2
Journal {2.5276}
Camshaft journal outside diam-
No.4 63.8
eter and camshaft bearing — —
Journal {2.5118}
inside diameter
No.5 63.4
Journal {2.4961}
No.6 63.0
Journal {2.4803}
No.7 62.6
Journal {2.4646}
Replace
camshaft
Clearance between camshaft 0.03-0.12 0.3
and/or cam-
journal and camshaft bearing {0.0012-0.0047} {0.0118}
shaft bear-
ing.
Measure
0.10-0.23 0.3 Replace

Camshaft end play
{0.0040-0.0090} {0.0118} thrust plate.
55.47 54.67 Measure

IN
{2.1839} {2.1524}
Cam Replace
height 53.69 52.89 camshaft.
EX
{2.1138} {2.0823}
Measure
0.04 0.1 Replace

Camshaft deflection
{0.0016} {0.0039} camshaft.
Shaft outside diam- 55 54.85 Measure

Replace.
eter {2.1654} {2.1594}
Bushing inside 55
— —
diameter {2.1654}
Camshaft Clearance 0.030-0.090 0.2 Replace gear

idle gear {0.0012-0.0035} {0.0079} and/or shaft.
and idle 44
gear shaft Gear width {1.732}
— —
44
Shaft length — —
{1.732}
0.049-0.140 0.3 Replace gear

End play
{0.0020-0.0055} {0.0118} and/or shaft.
Shaft outside diam- 34

— —
eter {1.3386}
Bushing inside 34
— —
diameter {1.3386}
0.025-0.075 0.2 Replace gear

Clearance
Air com- {0.0010-0.0029} {0.0079} and/or shaft.
pressor
22.5
idle gear Gear width — —
{0.8858}
and idle
gear shaft 25
Shaft length — —
{0.9843}
Thrust plate thick- 2.5

— —
ness {0.0984}
0.040-0.125 0.3 Replace gear

End play
{0.0016-0.0049} {0.0118} and/or shaft.
28 Measure
Valve lifter outside diameter — —
{1.1024}
Valve lifter guide inside diame- 28

— —
ter {1.1024}
Clearance between valve lifter 0.020-0.066 0.1 Replace

and valve lifter guide {0.0008-0.0025} {0.0039} valve lifter.
Visual check
Should not be worn

Valve lifter for wear — Replace.
unevenly.
Crankshaft - cam- 0.10-0.21 Measure

shaft idle {0.0040-0.0082}
Camshaft - Cam- 0.09-0.21

0.30
shaft idle {0.0035-0.0082}
{0.0118}
Camshaft idle -
0.08-0.23
Injection pump
{0.0031-0.0090}
drive
Crankshaft - Oil 0.08-0.28 0.35

pump idle {0.0031-0.0110} {0.0137}
Oil pump idle - Oil 0.08-0.20

Gear pump drive {0.0031-0.0078}
Replace.
Backlash
Camshaft - Air 0.14-0.25
compressor idle {0.0056-0.0098}
Air compressor 0.30

0.07-0.21 {0.0118}
idle - Air compres-
{0.0028-0.0082}
sor drive
Air compressor
0.06-0.24
drive - Coolant
{0.0023-0.0094}
pump drive
Injection pump
0.08-0.28 0.35
drive - Power steer-
{0.0031-0.0110} {0.0137}
ing oil pump
INJECTION PUMP DRIVE

COMPONENT LOCATOR
EN0110902D100005
SHTS011090200107
1 Collar 6 Woodruff key

2 Injection pump drive gear 7 Injection pump drive shaft
3 O-ring 8 Shim
4 Bearing holder case 9 Bearing retainer
5 Tapper roller bearing 10 Oil seal

A 245 {2,500, 181} B 25 {255, 18}
SPECIAL TOOL
EN0110902D100006
Prior to starting an engine overhaul, it is necessary to have this special tool.
S0948-22330 PRESS
OVERHAUL
EN0110902D100007
1. ASSEMBLY THE INJECTION PUMP DRIVE.

(1) Adjust the preload of injection pump drive shaft by shims.
Turning Torque: 0.39-1.17 N⋅m {4-12 kgf⋅cm, 0.29-0.86 lbf⋅ft}
NOTICE
Be sure that there is no loose rattling in the axis direction of the
drive shaft.
SHTS011090200109
2. INSTALL THE OIL SEAL.

(1) Apply clean engine oil to the inner and outer surface of the oil
seal.
(2) Install the oil seal to the bearing holder case using a special tool.
SST: Press (S0948-22330)
NOTICE
Install the oil seal so that the felt surface outward.
SHTS011090200110
MAIN MOVING PARTS AND CYLINDER BLOCK

COMPONENT LOCATOR
EN0110902D100008
SHTS011090200111
1 Main hole plug 12 Piston

2 Collar 13 Piston ring
3 Cylinder liner 14 Connecting rod
4 Plug 15 Connecting rod bearing
5 Seal plate 16 Bushing
6 Pin 17 Crankshaft gear
7 Straight pin 18 Key
8 Piston cooling jet 19 Crankshaft
9 Camshaft bearing 20 Thrust bearing
10 Retainer ring 21 Main bearing
11 Piston pin 22 Main bearing cap

A 22 {220, 15.5} C 274 {2,800, 200}#
B 69 {700, 50}+90°+90°#
SHTS011090200112
1 Push rod cover 6 Oil level gauge

2 Water gallery cover 7 Oil level gauge guide
3 Injection pump bracket 8 Oil pan
4 Oil pipe 9 Oil pan gasket
5 O-ring

A 74 {750, 54} C 23 {230, 16.5}
B 44 {450, 32}
SPECIAL TOOL
EN0110902K100005
S0944-21200 PISTON RING EXPANDER For Piston ring
S0942-01750 PULLER For Cylinder liner
SZ910-24098 CONNECTOR BOLT For Piston cooling jet
S0947-21620 ADJUSTING BAR
S0948-01190 GUIDE
S0944-11330 PISTON RING HOLDER
S0947-01180 TOOL ASSEMBLY

2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧞㧣ಽ
OVERHAUL
EN0110902H200004
1. REMOVE THE PISTONS WITH CONNECTING RODS.

(1) Remove the pistons and connecting rods from the cylinder block
upper side.
NOTICE
• Remove carbon deposits from the upper end inside the cylin-
der liner with a scraper or emery paper (recommended: No.
150) in a circular direction.
SHTS011090200120
• Arrange the removed pistons and connecting rod caps in the

order of cylinder numbers. Be careful not to change the com-
bination of the connecting rod and cap.
SHTS011090200121
2. REMOVE THE PISTON RINGS.

(1) Remove the piston ring using the special tool.
SST: Piston ring expander (S0944-21200)
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 separate.
SHTS011090200122
3. REMOVE THE CYLINDER LINER.

(1) Before removing the cylinder liner, put alignment marks on the
cylinder block and liner flange.
NOTICE
Do not make alignment marks with a punch.
SHTS011090200123
(2) Pull the cylinder liner from the cylinder block using the special
tool.
SST: Puller (S0942-01750)
NOTICE
• Carefully set the special tool to prevent touching to the pis-
ton cooling jet.
• After removing the cylinder liners, arrange them in sequence.
SHTS011090200124
1. INSPECT AND ADJUST THE PISTON COOLING JET.

(1) Install the piston cooling jet on the cylinder block using the special
tool.
SST: Connector bolt (SZ910-24098)
SHTS011090200125
(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.
SHTS011090200126
(3) Set the special tool on the cylinder block upper surface against
the dowel pin.
SST: Tool assembly (S0947-01180)
(4) Test jet oil flow from the piston cooling jet nozzle at a hydraulic
pressure of 196 kPa {2 kgf/cm2, 28 lbf/in2}.
SHTS011090200127
(5) If the center of the jet flow is within the target circle (10 mm
{0.3937 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.
SHTS011090200128
(6) If the center of the jet flow is out of the target circle, realign the
nozzle using the special tool.
SST: Adjusting bar (S0947-21620)
SHTS011090200129
2. INSTALL THE CYLINDER LINER.

(1) When a new cylinder liner is used, make sure that the liner has
the same mark as the mark on the cylinder block.
NOTICE
Cylinder liners and cylinder block are subject to selective fitting,
and so, in case new cylinder liners are to be used, confirm the
marks A, B, and/or C stamped at the flange areas of cylinder liners
and any combination of the marks A, B, and/or C stamped at the
upper and side surface of the cylinder block and insert the ones
with identical marks.
SHTS011090200130
(2) When reusing a liner the liner in its original position, put the align-
ing marks before disassembly.
SHTS011090200131
(3) Apply engine oil to the inner surface of the block bore and insert
the cylinder liner using the special tool.
SST: Guide (S0948-01190)
NOTICE
Handle the cylinder liner carefully because it is thin.
(If it falls on the floor, it cannot be used.)
SHTS011090200132
3. MEASURE THE PROTRUSION AT THE CYLINDER LINER

FLANGE.
Standard 0.04-0.10 mm {0.0016-0.0039 in.}
SHTS011090200133
4. INSTALL THE CRANKSHAFT.

(1) Install the main bearings 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 bearings along the groove of the cylinder block.
HINT
Apply engine oil or grease to the back of the bearing to prevent
loosening during crankshaft installation.
(3) Install the crankshaft onto the cylinder block.
SHTS011090200134
5. INSTALL THE MAIN BEARING CAP.

(1) Install the thrust bearing on the No.4 bearing cap.
(2) Install the bearing caps in numerical order from timing gear side
with the arrow point toward the timing gear side.
SHTS011090200135
(3) Tighten the cap bolts in three stages following the tightening
order.
Tightening Order: 4-3-5-2-6-1-7
Tightening torque
1st stage 50 % of specified torque
2nd stage 75 % of specified torque
3rd stage 100 % of specified torque
NOTICE
SHTS011090200136
• Apply clean engine oil to the bolt threads and seat surfaces.
• Make sure that the crankshaft rotates smoothly.
(4) After tightening, tap the front and back ends of the crankshaft
using a plastic hammer to allow complete fit.
(5) Measure the crankshaft end play.
Unit: mm {in.}
Assembly standard 0.011-0.029 {0.0005-0.0011}
6. ASSEMBLE THE PISTON AND CONNECTING ROD.

(1) Heat the piston to 50°C {122°F}.
(2) Assemble the piston O-mark to be opposite to connecting rod
match mark.
NOTICE
Replace the retainer ring with a new one.
SHTS011090200121
7. INSTALL THE PISTON RING.

(1) Install in the order of oil ring, third ring, second ring and top ring
RING UPPER
FACE
DISCRIMINATION
MARK
SHTS011090200137
NOTICE
Ring No. Description Install the third ring, second ring and top ring that turn the dis-
crimination mark on the piston ring to upper surface.
Top
2nd
3rd
Oil
SHTS011090200138
(2) Connect the joint of the coil expander for the oil ring and install it
inside the piston ring. Assemble the ring with the joint 180° oppo-
site to the matching point.
SHTS011090200139
(3) Position the matching points of the piston ring at a even distance
as shown in the figure.
SHTS011090200140
8. INSTALL THE PISTON.

(1) 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 (S0944-11330)
NOTICE
• When installing the piston, be careful that the cooling jet is
not struck by the connecting rod.
• Make sure that the O-mark on the piston is at the intake side.
SHTS011090200141
(2) Insert the piston into the cylinder liner.
SHTS011090200142
9. TIGHTEN THE CONNECTING ROD BOLT.

(1) Measure the length of the bolts, if the length is A or more, replace
with new bolts.
Dimension A 103.5 mm {4.0748 in.}
(2) Apply clean engine oil to the bolt thread and the nut seat surface
of the connecting rod cap.
SHTS011090200143
(3) Align the match marks on the connecting rod and cap.
MATCH
MARKS
1234 1234
SHTS011090200144
(4) Tighten the connecting rod nut to the specified torque.

Tightening Torque:
PAINT MARK 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}
゜
90
(5) Mark the nut heads in the same direction with paint.
90
(6) Tighten the connecting rod nut 90° (1/4 turn).

(7) Tighten the connecting rod nut 90° (1/4 turn).
(8) Make sure that the paint marks face the same direction.
NOTICE
PAINT MARK
When adding torque, never untighten the nuts, even if they have
been overtightened.
SHTS011090200145
10. INSTALL THE PUSH ROD COVER.

LIQUID GASKET (1) Apply a bead of liquid gasket [Three Bond TB1207C (red) or
equivalent] to the push rod cover and install the cover.
NOTICE
• Apply the liquid gasket so that the bead width is 1.5-2.5 mm
{0.0591-0.0984 in.}
SHTS011090200146
11. INSTALL THE WATER GALLERY COVER.

(1) Apply a bead of liquid gasket [Three Bond TB1207C (red) or
equivalent] to the water gallery cover and install the cover.
NOTICE
• Apply the liquid gasket so that the bead width is 1.5-2.5 mm
{0.0591-0.0984 in.}
SHTS011090200147

EN0110902H300005
Unit: mm {in.}
Cylinder block flange Measure

8 {0.3150} — —
depth
Cylinder liner flange

8 {0.3150} — —
thickness
Cylinder liner protru- 0.04-0.10 0.03

Replace.
sion {0.0016-0.0039} {0.0012}
A Reference only
Block
127
inside B — —
{5,000}
diameter
C
A Reference only
Liner out-
127
side diam- B — —
{5,000}
eter
C
Clearance A Reference only

between 0.0125-0.0290
B — —
block and {0.0005-0.0011}
liner C
Piston outside diame- 121.950 Measure

—
ter at A: 25 {0.9843} {4.8012}
Liner inside diameter

(Apply the value
obtained at the most 122 122.15 A
worn point to the cylin- {4.803} {4.809}
der liner inside diame- Replace liner.
ter.)
Clearance between pis- 0.051-0.090

—
ton and cylinder liner {0.0021-0.0035}
3.306 Measure
Top —
{0.1302}
3.306
Second —
Piston {0.1302}
—
ring width 2.0
Third —
{0.0787}
4.0
Oil —
{0.1575}
Top — — Measure
Second — —
Piston
groove 2.0 Replace piston.
Third —
width {0.0787}
4.0
Oil —
{0.1575}
Top —
Clearance —
between Second —
piston
0.04-0.08 0.20 Replace piston and/
ring and Third —
{0.0016-0.0031} {0.0078} or piston ring.
piston
ring
0.02-0.06 0.10
groove Oil
{0.0008-0.0023} {0.0039}
0.35-0.47 1.5 Measure

Top
{0.0138-0.0185} {0.0591}
Cylinder liner
Gap 0.35-0.47 1.2
between Second
{0.0138-0.0185} {0.0472}
ends of Replace piston ring.
piston 0.35-0.47 1.2
Third Piston ring
ring {0.0138-0.0185} {0.0472}
0.35-0.50 1.03
Oil
{0.0138-0.0196} {0.0393}
Piston pin outside 47 Measure

— —
diameter {1,850}
Piston pin bore inside 47

— —
diameter {1,850}
Clearance between pis-

0.011-0.029 0.05 Replace piston and/
ton pin and piston pin
{0.0005-0.0011} {0.0020} or piston pin.
bore
Measure
Connecting rod bush- 47

— —
ing inside diameter {1,850}
Clearance between pis- Replace piston pin

0.025-0.043 0.10
ton pin and connecting and/or connecting —
{0.0010-0.0016} {0.0039}
rod bushing rod bushing.
Visual check
Wear or damage of con-
necting rod
— — Replace.
(Color check)
Visual check
Clogging of connecting
— — Replace.
rod oil hole
Crankpin outside diam- 80 79.8 Measure

Replace crankshaft.
eter {3.150} {3.1417}
90
measure
2 part
Clearance between con-

0.033-0.074 0.3 Replace connecting
necting rod bearing and
{0.0013-0.0029} {0.0118} rod bearing.
crankpin
Connecting rod large 42.85 Measure

— —
end width {1.6870}
43
Crankpin width — —
{1.693}
Connecting rod end 0.15-0.32 0.6 Replace connecting

play {0.0060-0.0125} {0.0236} rod.
Crank journal outside 90 89.8 Measure

Replace crankshaft.
diameter {3.543} {3.5354}
90
Clearance between
0.050-0.096 0.3 Replace main bear-
crank journal and main
{0.0020-0.0037} {0.0118} ing.
bearing
46 Measure
Center journal width — —
{1.811}
Thrust bearing thick- 3.0

— —
ness {0.1181}
0.050-0.096 0.5 Replace thrust bear-

Crankshaft end play
{0.0020-0.0037} {0.0197} ing.
Measure
0.07
Crankshaft deflection — Replace crankshaft.
{0.0027}
Visual check
Clogging of crankshaft
— — Clean.
oil hole
Visual check
Crack and wear of

crankshaft
— — Replace.
(Color check)
Measure
Cylinder block upper 0.05 {0.0019} 0.1

Regrind.
surface flatness or less {0.0039}
Measure
Cylinder block height 353 352.95

Replace.
(H) {13.898} {13.8957}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧞㧢ಽ
AIR INTAKE SYSTEM (P11C) EN03–1
AIR INTAKE SYSTEM (P11C)

EN03
EN03-001
AIR INTAKE MANIFOLD AND PIPE ........ EN03-2

2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧞㧢ಽ
EN03–2 AIR INTAKE SYSTEM (P11C)
AIR INTAKE MANIFOLD AND PIPE

COMPONENT LOCATOR
EN0110903D100001
SHTS011090300001
1 Intake pipe 6 Intake manifold gasket

2 Waist gate safety valve 7 Boost compensator pipe
3 Clamp 8 Gasket
4 Air hose 9 Exhaust insulator
5 Intake manifold

A 23 {230, 17}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧞㧤ಽ
EXHAUST SYSTEM (P11C) EN04–1
EXHAUST SYSTEM (P11C)

EN 04
EN04-001
EXHAUST MANIFOLD AND PIPE............ EN04-2

OVERHAUL ..................................................... EN04-3
EN04–2 EXHAUST SYSTEM (P11C)
EXHAUST MANIFOLD AND PIPE

COMPONENT LOCATOR
EN0110904D100001
SHTS011090400001
1 Heat insulator 4 Spacer

2 Exhaust manifold 5 Gasket
3 Seal ring 6 Bracket

A 59 {600, 43}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧞㧥ಽ
EXHAUST SYSTEM (P11C) EN04–3
OVERHAUL
EN0110904H200001
IMPORTANT POINT - ASSEMBLY

RED PAINT
1. ASSEMBLE THE EXHAUST MANIFOLD.
GAS OUTLET
(1) Install the new seal rings on the exhaust manifold to prevent gas
leakage as shown in the figure.
YELLOW PAINT
120˚
3 2
3
120˚ 120˚
1 2
SHTS011090400002
EN04–4 EXHAUST SYSTEM (P11C)
IMPORTANT POINTS - MOUNTING
1. INSTALL THE EXHAUST MANIFOLD GASKET AS SHOWN IN

THE FIGURE.
NOTICE
Install the gasket with the dark gray side facing toward the
exhaust manifold.
SHTS011090400003
2. INSTALL THE EXHAUST MANIFOLD.

(1) Install the exhaust manifold onto the cylinder head and tighten the
mounting nut and bolt in the order shown in the figure to the spec-
ified torque.
Tightening Torque:
SHTS011090400004
(2) Tighten the mounting nut and bolt while in the order shown in the
figure to the specified torque below.
Tightening Torque:
SHTS011090400005
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧟㧜ಽ
LUBRICATING SYSTEM (P11C) EN05–1
LUBRICATING SYSTEM (P11C)

EN05
EN05-001
LUBRICATING SYSTEM .......................... EN05-2

DIAGRAM ........................................................ EN05-2
OIL PUMP AND OIL STRAINER .............. EN05-3

INSPECTION AND REPAIR ............................ EN05-4
OIL FILTER AND OIL COOLER ............... EN05-6

2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧠ಽ
EN05–2 LUBRICATING SYSTEM (P11C)
LUBRICATING SYSTEM
DIAGRAM
EN0110905J100001
SHTS011090500001
1 Oil pan 10 Check valve for turbocharger 22 Air compressor

2 Oil strainer 11 Turbocharger 23 Regulator valve
3 Oil pump 12 Main oil hole 422-480 {4.3-4.9, 62-69}
4 Oil pump safety valve 13 Camshaft bearing 24 Check valve
880-1.20 {8.8-11.2, 126-156} 14 Check valve for cooling jet 25 Rocker arm
5 Oil cooler 15 Sub oil hole 26 Cross head
6 Oil cooler safety valve 16 Piston cooling jet 27 Push rod
265-323 {2.7-3.3, 39-46} 17 Piston 28 Valve lifter
7 Oil filter (by-pass) 18 Main bearing 29 Camshaft
8 Oil filter safety valve 19 Fuel injection pump 30 Cylinder liner
127-167 {1.3-1.7, 19-24} 20 Oil pressure switch A To oil pan
9 Oil filter (full flow) 21 Air compressor idle gear
2 2
Unit: kPa {kgf/cm , lbf/in. }
OIL PUMP AND OIL STRAINER

COMPONENT LOCATOR
EN0110905D100001
SHTS011090500002
1 O-ring 8 Thrust plate

2 Oil feed pipe 9 Idle gear
3 Oil pump 10 Idle gear shaft
4 Oil strainer 11 Spring seat
5 Cover 12 Safety valve spring
6 Driven gear 13 Safety valve
7 Case 14 Cotter pin

A 21 {210, 15} D 23 {230, 17}
B 113 {1,150, 83} E 103-112 {1,050-1,150, 76-83}
C 47 {480, 35} F 19.7-25.5 {200-260, 15-18}

EN0110905H300001
Unit: mm {in.}
Measure
Tip clearance between

0.033-0.135 Replace driven gear
drive gear case, driven 0.17 {0.0066}
{0.0013-0.0053} and/or case.
gear and case
Measure
End play between drive

0.045-0.105 Replace driven gear
gear and case, driven 0.15 {0.0059}
{0.0018-0.0041} and/or case.
gear and case
Shaft out- Measure

side diam- 20 {0.787} — —
eter
Cover side
bushing
20 {0.787} — —
inside
Drive gear diameter
0.040-0.074 Replace cover and/

Clearance 0.17 {0.0066}
{0.0016-0.0029} or case.
Shaft out- Measure

side diam- 20 {0.787} — —
eter
Cover hole Replace case and/ or

20 {0.787} —
diameter cover.
0.022-0.065
Clearance 0.17 {0.0066} —
{0.0009-0.0025}
Driven Gear bush-
gear ing inside 20 {0.787} — —
diameter
0.040-0.074 Replace case and/or

Clearance 0.17 {0.0066}
{0.0016-0.0029} driven gear.
Measure
0.107-0.226 Replace case and/or

Gear backlash 0.4 {0.0157}
{0.0043-0.0088} driven gear.
Shaft out- Measure

side diam- 45 {1.772} — —
eter
Gear bush-
ing inside 45 {1.772} — —
diameter
Idle gear
Replace idle gear

0.03-0.08
Clearance 0.2 {0.0078} shaft and/or idle
{0.0012-0.0031}
gear.
Visual check
Gear teeth pitting or Replace case and/or

— —
wear driven gear.
OIL FILTER AND OIL COOLER

COMPONENT LOCATOR
EN0110905D100002
SHTS011090500010
1 Plug 9 Regulator valve

2 O-ring 10 Oil cooler safety valve
3 Valve spring 11 Gasket
4 Oil cooler case 12 Oil cooler cover
5 Oil filter body 13 Oil cooler gasket
6 Element set 14 Oil cooler element
7 Oil filter safety valve 15 OIl feed pipe
8 Coolant drain plug

A 29.4-39.2 {300-400, 22-28} F 14.7-19.7 {150-200, 11-14}
B 19.6-29.4 {200-300, 15-22} G 34.3-44.1 {350-450, 26-32}
C 24.5-34.3 {250-350, 19-25} H 9.8-14.8 {100-150, 8-10}
D 4.9-9.9 {50-100, 3.7-7.2} I 37 {380, 27}
E 44 {450, 33}

EN0110905H300002
Oil cooler air leakage Visual check

Replace, if neces-
Air pressure: 588 kPa {6 0 mL —
sary.
kgf/cm2, 85 lbf/in.2}
1. Damage to sliding
Wear or damage to
Replace, if neces- face of valve
valve spring of oil — —
sary. 2. Valve movement
cooler and oil filter
(smoothness)
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧟㧝ಽ
COOLING SYSTEM (P11C) EN06–1
COOLING SYSTEM (P11C)

EN06
EN06-001
COOLING SYSTEM .................................. EN06-2

DIAGRAM ........................................................ EN06-2
COOLANT PUMP...................................... EN06-3

SPECIAL TOOL ............................................... EN06-4
OVERHAUL ..................................................... EN06-5
THERMOSTAT .......................................... EN06-9

OVERHAUL ................................................... EN06-10
RADIATOR .............................................. EN06-11

OVERHAUL ................................................... EN06-11
COOLING FAN........................................ EN06-13

EN06–2 COOLING SYSTEM (P11C)
COOLING SYSTEM
DIAGRAM
EN0110906J100001
12
10
11
6
7 8 9
5
1
4
3 2
4 4
SHTS011090600001
1 Radiator 5 Water gallery 9 Car heater (If so equipped)

2 Coolant pump 6 Cylinder head 10 Header tank
3 Oil cooler 7 Turbocharger 11 Coolant temperature gauge
4 Drain plug 8 Air compressor 12 Radiator cap
COOLANT PUMP
COMPONENT LOCATOR
EN0110906D100001
SHTS011090600002
1 Outlet pipe 7 Cover gasket

2 O-ring 8 Coolant pump vane
3 Coolant pump assembly 9 Coolant pump seal
4 Through joint 10 Pump case
5 Water hose 11 Oil seal
6 Coolant pump cover 12 Coolant pump shaft

A 18-21 {180-220, 13.1-14.9}
SPECIAL TOOL
EN0110906K100001
Prior to starting a coolant pump overhaul, it is necessary to have these special tools.
S0942-01620 PULLER For coolant pump vane
S0948-21620 PRESS For coolant pump oil seal
S0948-21700 PRESS For coolant pump vane
S0948-22310 PRESS For coolant pump seal

2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧡ಽ
OVERHAUL
EN0110906H200001
IMPORTANT POINT - DISASSEMBLY
1. DISASSEMBLE THE COOLANT PUMP.

(1) Remove the coolant pump vane from the coolant pump shaft
SST: Puller (S0942-01620)
SHTS011090600007
(2) Remove the retainer ring from the coolant pump case using snap
ring pliers.
SHTS011090600008
(3) Push the coolant pump shaft from the coolant pump vane side
using a hydraulic press, and remove the coolant pump shaft from
the coolant pump case.
NOTICE
Before pressing, recheck that the retainer ring is removed com-
pletely.
SHTS011090600009
(4) Remove the coolant pump seal from the coolant pump case using
a hammer and brass bar.
NOTICE
Replace the removed coolant pump seal with a new one. Never
reuse it.
SHTS011090600010
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧡ಽ
(5) Remove the oil seal from the coolant pump.

NOTICE
Replace the removed oil seal with a new one. Never reuse it.
SHTS011090600011
1. ASSEMBLE THE COOLANT PUMP.

(1) Apply clean engine oil to the coolant pump case bore.
(2) Install the oil seal into the coolant pump case using the special
tool.
SST: Press (S0948-21620)
NOTICE
• Install the oil seal with main lip positioned to the gear side.
SHTS011090600010
• Apply lithium base grease to the oil seal lip.
(3) Install the coolant pump shaft onto the coolant pump case using a
hydraulic press.
NOTICE
Press until the bearing upper end surface comes into contact with
the retainer ring groove lower end surface.
SHTS011090600012
(4) Install the retainer ring onto the pump case using snap ring pliers.
SHTS011090600013
(5) Install the new coolant pump seal using the special tools.
SST: Press (S0948-22310)
SHTS011090600014
(6) Install the coolant pump vane onto the coolant pump shaft using
the special tool and a hydraulic press.
SST: Press (S0948-21700)
NOTICE
Press until the coolant pump vane end face comes into contact
with the coolant pump shaft end surface.
(7) Check the clearance between coolant pump vane and coolant
pump case.
Assembly standard: 0.7-1.3 mm {0.0276-0.051 in.}
(8) Install the gasket and coolant pump cover.
SHTS011090600015
(9) After assembly, turn the coolant pump shaft by hand and make
sure that there is no noise catching or rough movement in the
shaft direction and that it rotates smoothly.

EN0110906H300001
Unit: mm {in.}
Inspection item Standard LImit Remedy Inspection procedure
Visual check
Wear, damage and cor-

— — Replace parts.
rosion
Measure
Tightness of shaft and 0.017-0.048 Replace shaft and/or

—
vane {0.0007-0.0018} vane.
NOTICE
• Tightness= Outside diameter - Inside diameter
• Prevent a reassembly more than three times even if it is
within the standard value.
THERMOSTAT
COMPONENT LOCATOR
EN0110906D100002
SHTS011090600018
1 Thermostat case cover 4 Thermostat case

2 Gasket 5 Connector
3 Thermostat 6 Air escape pipe
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧢ಽ
OVERHAUL
EN0110906H200002
IMPORTANT POINT - INSPECTION AND REPAIR
1. INSPECT THE THERMOSTAT FUNCTION.

(1) Place the thermostat in hot water and check the valve opening
temperature and the valve lift.
Thermostat valve opening temperature:
Thermostat valve opening tem-
Service standard
perature (T1)
82°C {180°F} 80-84°C {176-183°F}
SHTS011090600019 NOTICE
Check that the thermostat valve opening temperature (T1) is
engraved on the thermostat seat.
Thermostat valve lift:

Thermostat valve Measuring temp.
Valve lift (L2-L1)
opening temp. (T1) (T2)
10 mm {0.394 in.} or
82°C {180°F} 95°C {203°F}
more
(2) Immerse the opened thermostat in water at normal temperature. If

it completely closes within 5 minutes, it is satisfactory. If it remains
slightly open, it is defective and must be replaced.
SHTS011090600020

NOTICE
• Remove water to 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.
SHTS011090600021
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧟㧢ಽ
RADIATOR
COMPONENT LOCATOR
EN0110906D100003
SHTS011090600022
1 Radiator stay bracket 5 Radiator

2 Radiator frame 6 Intercooler
3 Baffle plate 7 Radiator stay
4 Cushion
OVERHAUL
EN0110906H200003
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.

EN0110906H300002
Unit: kPa {kgf/cm2, lbf/in.2}
Air leakage (When the air Measure

pressure of 100 {1.14} is — — Replace radiator.
applied.)
Clogging of the Fines — — Clean.
Measure
Radiator cap
40-58
valve open- Mark 0.5 — Replace.
{0.4-0.6, 5.7-8.5}
ing pressure
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 clog-
ging, do not apply excessive pressure to the fins which may
cause deformation and consequent performance deteriora-
tion.
COOLING FAN
COMPONENT LOCATOR
EN0110906D100004
SHTS011090600025
1 Fan clutch 3 Fan shroud

2 Cooling fan 4 Spacer

A 42 {430, 31}
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.

EN0110906H300003
Unit: mm {in.}
Visual check
Cooling fan and fan clutch Replace if neces-

— —
deformation and damage sary.
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧟㧡ಽ
FUEL SYSTEM (P11C) EN07–1
FUEL SYSTEM (P11C)

EN 07
EN07-001
FUEL SYSTEM.......................................... EN07-2

DIAGRAM ........................................................ EN07-2
DESCRIPTION ................................................ EN07-3
SPECIAL TOOL ............................................... EN07-3
OVERHAUL ..................................................... EN07-4
INJECTION NOZZLE
(TWO-SPRING TYPE - BOSCH MAKE)... EN07-6
DESCRIPTION ................................................ EN07-6
SPECIAL TOOL ............................................... EN07-8
OVERHAUL ..................................................... EN07-9
EN07–2 FUEL SYSTEM (P11C)
FUEL SYSTEM
DIAGRAM
EN0110907J100001
SHTS011090700001
1 Fuel tank 5 Fuel injection pump

2 Fuel feed pump 6 Injection nozzle
3 Fuel filter 7 Bleeder plug
4 Pre-lift actuator 8 Through feed valve
DESCRIPTION
EN0110907C100001
SHTS011090700002
1 Injection nozzle 3 Fuel injection pump

2 Fuel filter

A 17.5 {180, 13} C 24.5 {250, 18}
B 34 {350, 25} D 47 {480, 35}
SPECIAL TOOL
EN0110907K100001
S0955-31010 FUEL FILTER WRENCH
INJECTION PUMP COUPLING

S0951-12510
WRENCH
2A'0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧝ಽ
OVERHAUL
EN0110907H200001

THROUGH TIMING MARK POINTER
BOLT 1. REMOVE THE FUEL INJECTION PUMP.
(1) Disconnect the fuel lines, oil lines and engine control lines.
(2) Remove the through bolt of the coupling jaw and loosen the
adjusting bolt using the special tool.
(3) Remove the injection pump mounting bolt and dismount the
pump.
COUPLING ADJUSTING NOTICE
BOLT
After dismounting the pump, cover the pump and high pressure
SHTS011090700005 pipe to prevent entry of dirt.
1. INSTALL THE FUEL INJECTION PUMP.

(1) 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 injec-
tion timing before top dead center for No.1 cylinder compression
stroke.
SHTS011090700006
(2) Turn the coupling jaw counterclockwise slowly viewed from the
TIMING MARK POINTER coupling (normal direction of engine) and align the mark on the
timer with the mark on the injection pump pointer.
SHTS011090700007
(3) Tighten the injection pump mounting bolt evenly to the specified
torque below.
Tightening Torque:
SHTS011090700008
(4) Tighten the adjusting bolt using the special tool.

THROUGH SST: Injection pump coupling wrench (S0951-12510)
BOLT
Tightening Torque:
(5) Tighten the through bolt at the flange.

Tightening Torque:
COUPLING ADJUSTING (6) Install pipes and engine control cables.
BOLT
NOTICE
SHTS011090700009 Cylinder numbers are stamped on the flare nuts at the pump side
of the injection pipe.
1. REMOVE THE FUEL FILTER.

(1) Remove the fuel filter using the special tool.
SST: Fuel filter wrench (S0955-31010)
SHTS011090700010
2. INSTALL THE FUEL FILTER.

(1) Remove the dust on installation surface.
(2) Apply light oil to gasket of new fuel filter.
(3) 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 (S0955-31010)
NOTICE
• Do not reuse the element.
• Be careful not to damage the gasket.
SHTS011090700011
AIR BLEEDING FROM FUEL SYSTEM.

AIR BLEEDER
PLUG
PRIMING PUMP 1. BLEED AIR FROM THE FUEL FILTER.
(1) Bleed air from the fuel filter.
(2) Loosen the bleeder plug on the fuel filter.
(3) Operate the priming pump knob until the air will not come out from
the bleeder plug.
(4) Tighten the bleeder plug.
Tightening Torque:
DRAIN HOSE
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.
INJECTION NOZZLE (TWO-SPRING TYPE - BOSCH MAKE)

DESCRIPTION
EN0110907C100002
SHTS011090700013
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
COMPONENT LOCATOR
EN0110907D100001
SHTS011090700014
1 Joint bolt 9 Second pressure adjusting shim

2 Gasket 10 Second pressure spring
3 Cap nut 11 Second pressure spring seat
4 Gasket 12 Lift piece
5 Adjusting screw 13 Pin
6 First pressure spring 14 Spacer
7 Push rod 15 Nozzle assembly
8 Nozzle holder 16 Retaining nut

A 17.5 {180, 13} C 68.5 {700, 51}
B 34 {350, 25}
SPECIAL TOOL
EN0110907K100002
For SUB AND CAM IDLE

S0942-01442 IDLE GEAR SLIDING HAMMER
GEAR
S0946-21130 NOZZLE HOLDER ADAPTER Used with S0942-01442
Length (L)
157892-4620 157892-4200: 160 mm
TOOL SET {6.300 in.}
NOTICE
157892-4300: 110 mm
It is BOSCH product NOTICE
{4.331 in.}
number that men- BOSCH product tool set
tioned part number.
OVERHAUL
EN0110907H200002
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.
2. REMOVE THE FUEL INJECTION PIPE.

(1) Remove the return pipe.
(2) Loosen the injection pipe nut.
SHTS011090700020
(3) Remove the bolt of the injection pipe seal and pull it with the injec-
tion pipe.
NOTICE
Cover open ends of the pipes and fuel injection pump to prevent
entry of dirt.
3. REMOVE THE NOZZLE HOLDER ASSEMBLY.

(1) Remove the nozzle clamp bolt.
(2) Pull out the nozzle holder assembly taking care not to contact
other parts. If it is difficult to remove the assembly, use of the spe-
cial tool.
SST:
Idle gear sliding hammer (S0942-01442)
Nozzle holder adapter (S0946-21130)
(3) Remove the O-ring.

NOTICE
Replace the O-ring with a new one.
SHTS011090700021
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 pre-
vent scattering of fuel.
SHTS011090700022
(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: 17.2-18.0 MPa {175-183 kgf/cm2,
2,489-2,602 lbf/in.2}
With reused parts: 16.7-17.4 MPa {170-178 kgf/cm2,
2,418-2,531 lbf/in.2}
SHTS011090700023
2. TEST THE SPRAY PROFILE.

(1) 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 60 strokes per minute. If spray is coarse, replace
or clean the nozzle.
SHTS011090700024
3. TEST THE FUEL LEAKAGE.

(1) 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.
SHTS011090700025
IMPORTANT POINT - DISASSEMBLY
1. REMOVE THE RETAINING NUT.

NOTICE
To prevent dropping parts, face the nozzle holder toward the
retaining nut side.
SHTS011090700026
IMPORTANT POINT - INSPECTION AFTER DISAS-

SEMBLY
1. TEST THE NOZZLE SINKING.

(1) Wash the nozzle proper with diesel fuel oil, them immerse it in die-
sel fuel oil.
(2) 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.
When assembling, you must reinstall the same parts in the same
nozzle holder. Do not mix them up.

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.
Check with nozzle cover method.

NOTICE: If pre- lift is not within specified value, replace
3. Checking of pre-lift
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.
Replace adjustable retaining nut with normal retaining

6. Replacement of the retaining nut
nut.
Check condition of the fuel spray with the nozzle and

7. Final inspection
nozzle holder assembly.
1. ADJUSTMENT OF THE FIRST OPENING PRESSURE

(WORK STEP 1.)
(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) Install the pins, lift piece, spacer and nozzle onto the nozzle
holder.
SHTS011090700028
(3) Put the gasket (special tool) onto the nozzle, then use the adjust-
able 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}
NOTICE
• Make sure that the pin is all the way in the nozzle and then
SHTS011090700029 tighten adjustable retaining nut.
• Finger-tighten the adjustable retaining nut until it no longer
turns and tighten the nut to specified torque.
(4) Install the push rod, first pressure spring and adjusting screw into
the nozzle holder.
(5) Install the gasket and cap nut onto the adjusting screw.
SHTS011090700030
(6) Attach the nozzle holder assembly to the nozzle tester.
SHTS011090700031
(7) Adjusting the first opening pressure to the specified value with the
first pressure adjusting screw.
First opening pressure
2,489-2,602 lbf/in.2}
2,418-2,531 lbf/in.2}
SHTS011090700032
(8) Holder the nozzle holder body using a adjustable wrench, then
tighten the cap nut to the specified torque.
Tightening Torque:
SHTS011090700033
2. CHECKING OF THE NEEDLE VALVE FULL-LIFTS

(WORK STEP 2.)
(1) Attach the gasket (special tool) and the plug (special tool) onto the
adjustable retaining nut.
SST:
Gasket (026508-1140)
Plug (157892-1600)
SHTS011090700034
(2) Turn the nozzle holder body so that the cap side is facing upward.
(3) Attach the holder (special tool) to the cap nut.
SST: Holder (157892-4100)
(4) Temporarily tighten the attachment nut (special tool) onto the
holder.
SST: Nut (157892-1000)
SHTS011090700035
(5) Screw the pin (special tool) into the dial gauge.
SST: Pin (157892-4200 or 157892-4300)
SHTS011090700036
(6) Tighten the nut so that it holds the dial gauge in place in the noz-
zle 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.
SHTS011090700037
(7) Attach the nozzle holder assembly to the nozzle tester and adjust
the dial gauge to zero.
(8) Operate the nozzle tester to bleed air in the adjustable retaining
nut. Make sure that there are no fuel leaks.
SHTS011090700038
(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 abnor-
mally worn or not and whether the nozzle is correctly assembled
or not.
SHTS011090700039
3. CHECKING OF THE PRE-LIFT (WORK STEP 3.)

(1) When the needle valve is full-lifted, release the nozzle tester han-
dle to lower pressure inside the tube so that decrease the needle
valve lift value (value indicated on dial gauge).
SHTS011090700040
(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.
SHTS011090700041
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'): 0.075 mm {0.0030 in.}
SHTS011090700042
(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.
SHTS011090700043
4. CHECKING OF THE SECOND OPENING PRESSURE

(WORK STEP 4.)
(1) 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.
(2) Release the nozzle tester handle to lower pressure inside the
tube, all the while watch the dial gauge indicate.
SHTS011090700044
(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
4,053-4,194 lbf/in.2}
4,124-4,266 lbf/in.2}
SHTS011090700045
5. ADJUSTING OF THE SECOND OPENING PRESSURE

(WORK STEP 5.)
(1) If the second opening pressure deviates from the specified value,
and the amount of that deviation is small, readjust the first open-
ing pressure within the specified value.
NOTICE
• If the second opening pressure is lower than the specified
value, readjust the first opening pressure to maximum speci-
fied 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 speci-
SHTS011090700046
fied value.
(2) If the first opening pressure has been readjusted and the second
opening pressure still deviates from the specified value, disas-
semble 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.
(4) After replacing the adjusting shim, remeasureing the second
opening pressure, and adjust the pressure until it comes to the
specified value.
Second opening pressure adjusting shim line-up

SHTS011090700047 Unit: mm {in.}
Parts number Shim thickness
150538-4900 0.40 {0.0157}
150538-5000 0.50 {0.0197}
150538-5100 0.52 {0.0205}
150538-5200 0.54 {0.0213}
150538-5300 0.56 {0.0220}
150538-5400 0.58 {0.0228}
150538-5500 0.60 {0.0236}
150538-5600 0.70 {0.0276}
6. REPLACEMENT OF THE RETAINING NUT (WORK STEP 6.)

(1) Remove the dial gauge, the nut, the holder and the gasket from
the cap nut.
(2) 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}
SHTS011090700048
7. FINAL INSPECTION (WORK STEP 7.)

(1) 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.
SHTS011090700022
(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.
SHTS011090700049
1. INSTALL THE NOZZLE HOLDER ASSEMBLY.

(1) Install a new O-ring into the groove of the cylinder head.
(2) 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) 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 oil seal to the cylinder head cover.
(5) Tighten the nut of the injection pipe provisionally.
(6) Tighten the nozzle clamp bolt to the specified torque.
Tightening Torque:
24.5 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}
NOTICE
After tightening the bolt, make sure that the rocker arm moves
SHTS011090700021
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.

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TURBOCHARGER (P11C) EN08–1
TURBOCHARGER (P11C)
EN08
EN08-001
TURBOCHARGER.................................... EN08-2
DESCRIPTION ................................................ EN08-2
SPECIAL TOOL ............................................... EN08-4
OVERHAUL CRITERIA ................................... EN08-5
OVERHAUL ................................................... EN08-10
EN08–2 TURBOCHARGER (P11C)
TURBOCHARGER
DESCRIPTION
EN0110908C100001
SHTS011090800001
1 Turbine shaft 6 Seal ring 11 Bearing

2 Heat protector 7 Oil thrower 12 Retainer ring
3 Thrust bushing 8 Blower impeller 13 Turbine case
4 Thrust bearing 9 Blower case
5 Seal plate 10 Bearing case
TROUBLESHOOTING
EN0110908F300001

Dense black smoke (Insufficient Air cleaner is choked with dust, caus- Disassemble and clean or replace the
intake) ing greater intake air resistance. air cleaner element.
Air inlet is choked Repair.
Air is leaking from intake manifold Repair.
Blower impeller and turbine shaft not Disassemble and repair.
turning freely
Waste gate system malfunction Inspect and replace.
Dense black smoke (Turbocharger Engine oil impurities deposited on Overhaul and clean turbocharger and/
does not rotate smoothly.) rotor, resulting in heavy rotation or or repair.
sticking.
Dense black smoke (Bearing stick- Insufficient lubrication or blockage of Check lubricating oil system, and/or
ing.) lubricating oil lines. repair.
Temperature of lubricating oil too high Check cooling system and lubrication
system.
Unbalanced rotating parts Check rotating parts.
Incomplete warming-up, failure to idle Operate vehicle properly.
before stopping engine, or rapid starts.
Dense black smoke (Loose or dam- Over-rotation Check and adjust the engine.
aged turbine rotor or blower impel- Temperature of exhaust gas too high Check and adjust the engine.
ler.)
Foreign matter present Remove foreign material. Inspect the
air cleaner and air intake manifold.
Repair if necessary.
Worm thrust bearing Overhaul and repair.
Incomplete assembly Reassemble correctly.
Deformed or blacked exhaust gas lines Repair.
therefore insufficient revolution.
High volume exhaust like noise. Exhaust gas leaking before turbo- Check and repair connections.
charger, therefore insufficient revolu-
tion.
White smoke Choking defects, or deformation of oil Repair and replace the lines.
return lines so that oil leaks around
blower or turbine sides.
Seal ring may be broken or worn due Replace the thrust washer.
to abnormal wear of thrust washer.
Increase in pressure on rear of blower Inspect and replace pipes and hoses.
impeller, causing oil to flow into the Clean or replace air cleaner element.
blower side.
Loss of power Gas leakage from exhaust system Repair.
Air leakage from air manifold Repair.
Clogged air cleaner element Clean or replace.
Turbocharger dirty or damaged Repair or replace.
Poor response of turbocharger Carbon accumulation on the turbine Change engine oil, clean turbocharger.
side seal ring and heavy rotation
Poor combustion Check fuel system and improve com-
bustion.
Air or gas leaking from parts of the Inspect and repair the problem area.
intake or exhaust system

High pitched noise and vibration So called "surging" surging sometimes Overhaul and clean turbocharger.
(Noise) occurs when the gas passage at the
nozzle of the turbine housing is
choked or when compressed air does
not flow in proper responses to accel-
eration.
Loosen rotating parts Replace.
Air or gas leaking from parts of the Inspect and repair the problem area.
intake or exhaust system
Waste gate system malfunction Inspect and repair.
High pitched noise and vibration Joints loose between turbocharger Check the mounting and repair.
(Vibration) and intake, exhaust manifold or oil
lines
Damaged bearing, loosen rotating Repair.
parts, imbalanced rotating parts, etc.
Sudden shortage of lubricating oil Abnormal wear or damage of seal ring Overhaul and repair.
caused by wear of journal bearing.
Oil is mixed with exhaust before turbo- Inspect and adjust the relevant parts of
charger is engaged the engine.
SPECIAL TOOL
EN0110908K100001
Prior to starting a turbocharger overhaul, it is necessary to have this special tool.
For measuring the turbine

S0947-01230 TOOL ASSEMBLY shaft radial play and thrust
play.
OVERHAUL CRITERIA
EN0110908H300001
! CAUTION
Do not work on the turbocharger while it is still hot. This can
result personal injury.
1. INSPECT TURBINE SHAFT ROTATION.

(1) Rotate the blower impeller by hand to see if it turns smoothly.
(2) If it does not turn smoothly, clean and inspect the bearing and tur-
bine rotor.
SHTS011090800003
2. INSPECT THE TURBINE SHAFT RADIAL PLAY.

(1) Screw a stopper onto the threaded portion sticking out of the lock
nut on the end of the blower impeller. (Turn the stopper to counter-
clockwise for fitting it, because the stopper is left hand threads)
SHTS011090800004
(2) Insert a guide into the air intake side of the blower case and
tighten the bolt to secure it in place.
SHTS011090800005
(3) Screw a bar into the stopper to lock it.
SHTS011090800006
(4) Insert a dial gauge into the plate and secure it in place with a bolt.
SHTS011090800007
(5) Attach a bar onto the hook on the end of the bar.
(6) Then, while pulling down with a force of 4.9-5.9 N {0.5-0.6 kgf,
1.12-1.32 lbf}, set the needle of the dial gauge to zero.
SHTS011090800008
(7) While pulling up on the bar with a force of 4.9-5.9 N {0.5-0.6 kgf,
1.12-1.32 lbf}, measure the radial play using the dial gauge.
(8) Perform the measurement three times and calculate the average
value. If this value exceeds the service limit, either perform an
overhaul or replace the part with a new one.
Service limit 1.4 mm {0.0551 in.}
SHTS011090800009
3. INSPECT THE TURBINE SHAFT THRUST PLAY.

(1) Remove the dial gauge, loosen the bolt on the guide, and turn the
guide 90°.
(2) Insert a dial gauge into the plate undergoing the thrust play
inspection and secure it in place with a bolt.
SHTS011090800010
(3) Insert a dial gauge into the plate undergoing the thrust play
inspection and secure it in place with a bolt.
SHTS011090800011
(4) To prevent the measuring tool from moving to the left or right,
insert a guide.
SHTS011090800012
(5) To secure the guide in place, move the bar up and down and
secure the guide with a stopper so that the movement of the nee-
dle of the dial gauge is centered in the middle.
SHTS011090800013
(6) Grasp the puller and while pushing it against the turbine in the
thrust direction, set the needle of the dial gauge to zero.
SHTS011090800014
(7) Then, pull in the opposite direction and measure movement in the
thrust direction.
(8) Perform the measurement three times and calculate the average
value. If this value exceeds the service limit, either perform an
overhaul or replace the part with a new one.
Service limit 0.11 mm {0.0043 in.}
SHTS011090800015
COMPONENT LOCATOR
EN0110908D100001
SHTS011090800016
1 Oil inlet pipe 9 Waste gate valve control pipe

2 O-ring 10 Waste gate valve
3 Oil hose 11 Gasket
4 Turbocharger 12 Water hose
5 Exhaust insulator 13 Coolant pipe
6 Exhaust brake gasket 14 Oil outlet gasket
7 Spacer 15 Oil outlet pipe
8 Exhaust manifold connector

A 59 {600, 43}
SHTS011090800017
1 Turbine case 6 Bearing case 11 Oil thrower

2 Plate 7 Nozzle ring 12 Back plate
3 Turbine shaft 8 Bearing 13 Blower impeller
4 Seal ring 9 Bushing 14 Blower case
5 Heat protector 10 Thrust bearing

A 34-38 {345-385, 25-27} D 22-24 {220-240, 16-17}
B 1.17-1.37 {12-14, 0.87-1.01} E 7.3-8.3 {75-85, 5.5-6.1}
C 22-24 {220-240, 16-17}
OVERHAUL
EN0110908H200001

NOTICE
Make aligning marks on the turbine case, bearing case and blower
case to aid alignment during reassembly.
SHTS011090800018
1. REMOVE THE BLOWER CASE.

(1) Remove the blower case fitting bolt.
NOTICE
• If the blower case cannot easily be removed by hand, tap it
carefully all around using a plastic hammer and carefully
remove it.
• Do not damage the blower impeller.
SHTS011090800019
2. REMOVE THE BLOWER IMPELLER.

(1) Remove the blower impeller fitting nut.
NOTICE
Turn the lock nut clockwise to loosen the nut (Left hand threads).
SHTS011090800020
SHTS011090800021
3. REMOVE THE TURBINE CASE.

(1) Remove the turbine case fitting bolt.
NOTICE
Because the bolts on the turbine side are exposed to high temper-
ature, if they have seized, do no apply an unreasonable force to
remove them because they may break. Spray a lubricant onto
them, then wait for about 15 minutes and loosen them.
SHTS011090800022
(2) Remove the turbine case with the turbine shaft.

NOTICE
• If the turbine case cannot easily be removed by hand, tap it
carefully all round using a plastic hammer and carefully
remove it.
• Do not drop the turbine shaft when removing the turbine
case from the bearing case.
SHTS011090800023
4. PULL OUT THE TURBINE SHAFT.

(1) Remove the turbine shaft with heat protector.
NOTICE
• If the turbine shaft cannot easily be removed by hand, tap the
shaft end of blower side.
• If the heat protector cannot easily be removed, tap it with a
chisel.
SHTS011090800024
5. DISASSEMBLY THE BEARING CASE.

(1) Remove the back plate fitting bolts with a hexagon wrench attach-
ment and a sliding hammer.
(2) Remove the back plate from the bearing case.
NOTICE
If the back plate cannot be easily removed by hand, tap it carefully
all around with a plastic hammer.
(3) Remove the oil thrower from the back plate.
SHTS011090800025
(4) Remove the thrust bearing fitting screws with a torx screw driver.
SHTS011090800026
(5) Remove the thrust bearing and thrust bushing with a 10 mm

{0.394 in.} diameter copper rod.
NOTICE
When removing the thrust bearing and thrust bushing, be careful
not to damage the thrust bearing hole in the bearing case.
(6) Remove the bearing for blower side.
SHTS011090800027
(7) Remove the outer nozzle ring for turbine side.

NOTICE
When removing the nozzle ring, be careful not to damage the front
face of the hold in the bearing case.
SHTS011090800028
(8) Remove the bearings.
SHTS011090800029
6. REMOVE THE SEAL RINGS.

NOTICE
When removing the seal ring, do not damage the turbine shaft sur-
face and groove of the seal ring.
SHTS011090800030
SHTS011090800031
INPORTANT POINTS - ASSEMBLY
1. CLEAN ALL PARTS.

(1) Before cleaning, the disassembled parts should be visually
inspected to check for burning, abrasion, carbon deposits, gas
and oil leakage.
(2) Thoroughly clean all the pars with diesel fuel, using a soft brush,
and dry with compressed air.
NOTICE
• Never use a caustic cleaning solution, as it may attack alumi-
num.
• Never use a wire brush.
2. ASSEMBLE THE JOURNAL BEARINGS.

(1) After fitting the nozzle ring into the bearing case, mount the jour-
nal bearings. Fit the nozzle ring onto the outside to secure the
journal bearings in place.
SHTS011090800032
SHTS011090800033
(2) After fitting the nozzle ring into the turbine case on the blower
side, mount the journal bearings.
SHTS011090800034
NOTICE
When mounting the nozzle ring, the side with the rounded corner
should be facing the metal.
SHTS011090800035
NOTICE
• Make sure that the alignment openings of the nozzle rings all
face the outlet side.
However, the alignment opening of the outermost nozzle ring
on the turbine side should be positioned as shown in the fig-
ure.
• Apply engine oil to the journal bearings before mounting
them.
SHTS011090800036
3. ASSEMBLE THE TURBINE SHAFT.

(1) Install the seal ring into the ring groove of the turbine shaft.
NOTICE
• The seal ring should be replaced with a new one.
• Insert the seal ring concentric with the turbine shaft. If it is
inserted with unreasonable force, it may be damaged.
SHTS011090800037
(2) Position the heat protector on the bearing case.

(3) Coat the journals of the turbine rotor with clean engine oil and
install the turbine rotor in the bearing case.
NOTICE
• The gap in the seal ring of the turbine shaft must face
towards the oil inlet.
• When inserting the turbine shaft, be very careful not damage
the journal bearing.
SHTS011090800038
4. ASSEMBLE THE THRUST BUSHING AND THRUST BEARING.

(1) Coat the thrust bushing with clean engine oil and install it onto the
turbine shaft.
SHTS011090800039
(2) Coat the clean engine oil to the thrust bearing and put it on the
bearing case.
(3) Tighten the thrust bearing fitting screws with a torx screw driver.
NOTICE
• The screws should be replaced with new one.
• Apply LOCTITE No.242 or equivalent to thread of the screws.
SHTS011090800040
5. INSTALL THE BACK PLATE.

(1) Insert two seal rings on the oil thrower.
NOTICE
The seal rings should be replaced with new one.
SHTS011090800041
(2) Install the oil thrower into the seal plate.

NOTICE
• The openings of seal rings should be positioned as shown.
• If it is inserted with unreasonable force, it may be damaged.
SHTS011090800042
(3) Apply a thin (approximately 0.1-0.2 mm {0.0040-0.0078 in.}) layer

or liquid gasket to the turbine side flange surface of the back
plate. Then mount the bearing case and use a torque wrench to
tighten the hexagonal bolt, to which LOCTITE (No.242) has been
applied, to the rated torque.
SHTS011090800043
NOTICE
Take care that the sealer does not protrude from the flange.
SHTS011090800044
6. ASSEMBLE THE BLOWER IMPELLER ON THE TURBINE

SHAFT.
(1) Install the blower impeller to the turbine shaft and tighten the nut.
NOTICE
Take care that this nut has left hand threads.
SHTS011090800045
7. ASSEMBLE THE TURBINE CASE.

(1) Align the aligning marks which was made before disassembly.
NOTICE
In case of replacing the parts, confirm the oil port position and
exhaust gas inlet port position.
SHTS011090800018
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧠ಽ
(2) Install the turbine case to the bearing case by lock plate.
NOTICE
Coat tightening bolt with liquid packing (Three Bond No.1107C or
equivalent) before installation.
SHTS011090800046
8. MOUNT THE BLOWER CASE.

(1) Apply a thin (approximately 0.1-0.2 mm {0.0040-0.0078 in.}) layer
of liquid gasket to the turbine side flange surface of the back plate.
NOTICE
Be careful not to let any the liquid gasket leak into the center.
SHTS011090800047
(2) Align the aligning mark of blower case and bearing case.
NOTICE
In case of replacing the parts, confirm the oil port position and air
outlet port position.
9. ASSEMBLY TEST.
(1) Rotate the blower impeller by hand to see if it turns smoothly.
NOTICE
Refer to the section “OVERHAUL CRITERIA”.
(2) Check the turbine rotor for thrust play.
SHTS011090800048
NOTICE
(3) Check the turbine rotor for radial play.
NOTICE

EN0110908H300002
Unit: mm {in.}
Measure
13.98
Turbine shaft diameter — Replace.
{0.5504}
Measure
0.11
Turbine shaft bend — Replace.
{0.0004}
Measure
Seal ring groove width 1.85 Replace shaft

—
of turbine shaft {0.0728} assembly.
Measure
A: 22.45
{0.8839}
Bearing case inside
— Replace.
diameter
B:20.12
{0.7921}
Journal bearing inside 14.07 Measure

— Replace.
diameter {0.5540}
Journal bearing out- 19.97

— Replace.
side diameter {0.7862}
Measure
5.11
Thrust bush height — Replace.
{0.2012}
Measure
G1: 2.2
{0.0866}
Seal ring groove width
— Replace.
of oil thrower
G2: 1.75
{0.0689}
Measure
Thrust bearing thick- 4.98

— Replace.
ness {0.1961}
Measure
H1: 20.05
{0.7894}
Sealing bore of seal
— Replace.
plate
H2: 16.05
{0.6319}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧠㧜ಽ
ALTERNATOR (P11C) EN11–1
ALTERNATOR (P11C)
EN1
EN11-001
ALTERNATOR........................................... EN11-2
DESCRIPTION ................................................ EN11-2
SPECIAL TOOL ............................................... EN11-7
OVERHAUL ..................................................... EN11-7
EN11–2 ALTERNATOR (P11C)
ALTERNATOR
EN0110911I200001
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
EN0110911C100001
SHTS011091100001
1 Rectifier holder 8 Fan

2 Condenser 9 Pulley
3 Lead wire connector 10 Ball bearing
4 Regulator 11 Drive end frame
5 Field coil 12 Retainer plate
6 Rotor assembly 13 Rectifier end frame
7 Stator assembly 14 Diode
CIRCUIT
SHTS011091100002
1 Alternator 7 Charge warning light

2 Condenser 8 Fuse
3 Diode 9 Starter switch
4 Stator coil 10 Load
5 Field coil 11 Battery
6 IC Regulator
TROUBLESHOOTING
EN0110911F300001

Charging current does not flow I.C. regulator faulty Replace I.C. regulator.
(Light does not light) Stator coil faulty (Disconnecting or rare Replace stator coil.
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) Replace.
Voltmeter indicates 29V or more I.C. regulator faulty Replace I.C. regulator.
(Light does not light) I.C. regulator installation faulty (EX: Repair or replace.
Installation support)
Charging current flows normally I.C. regulator faulty Replace I.C. regulator.
(Light does not light)
Charging current is always insuffi- Stator coil faulty Replace stator coil.
cient (Battery goes dead) (Light 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) (Light 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.
COMPONENT LOCATOR
EN0110911D100001
SHTS011091100003
1 V-belt 6 Brace
2 Fixing bolt 7 Adjusting bolt
3 Spacer 8 Alternator
4 Engine hanger 9 Alternator bracket
5 Plain washer 10 Through bolt

A 47 {480, 37} C 132 {1,350, 98}
B 6 {60, 4.3} D 47 {750, 54}
SHTS011091100004
1 Cover 13 Field coil

2 Connector 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 Condenser 21 Fan
10 Lead wire connector 22 Pulley
11 Rectifier end frame 23 Lock nut
12 Through bolt

A 3.3-4.4 {33-45, 2.4-3.2} 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}
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧥ಽ
SPECIAL TOOL
EN0110911K100001
Prior to starting an alternator overhaul, it is necessary to have this special tool.
S0944-41210 COMPRESSION GAUGE
OVERHAUL
EN0110911H200001
1. ADJUST THE ALTERNATOR V-BELT DEFLECTION.

(1) Loosen the through bolt and the fixing bolt.
(2) Apply a load of about 98N {10 kgf} by pressing the measuring
point A.
(3) 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 (S0944-41210)
Standard: 16-19 mm {0.630-0.748 in.}

• When installing a new V-belt, be sure to repeat the adjust-
ment 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 nut.
(5) Retighten the adjusting bolt.
(6) Connecting the harness.
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.
SHTS011091100007
(2) Remove the condenser and lead wire connector.
SHTS011091100008
(3) Remove the through bolts, disassemble the rectifier end frame
and drive end frame.
SHTS011091100009
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.
SHTS011091100010
(3) Remove the rotor from drive end frame, using a press.
NOTICE
Hold rotor by hand so that it will not fall off.
SHTS011091100011
3. REMOVE THE FRONT BALL BEARING.

(1) Remove the retainer plate.
SHTS011091100012
(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.
SHTS011091100013
4. REMOVE THE STATOR.

(1) 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 dis-
connect stator lead wires.
SHTS011091100014
(2) Remove the stator from the rectifier end frame.
SHTS011091100015
5. REMOVE THE RECTIFIER HOLDER, REGULATOR AND FIELD

COIL.
(1) Unsolder lead wire from field coil.
SHTS011091100016
(2) Remove the rectifier holder, regulator and condenser.
SHTS011091100017
(3) Loosen the "B" terminal nut.
SHTS011091100018
(4) Remove the field coil.
SHTS011091100019
6. REMOVE THE ROLLER BEARING.

NOTICE
Attach the jig to inner race of the roller bearing and remove roller
bearing, using a press.
SHTS011091100020
1. INSTALL THE ROTOR.

(1) 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.
SHTS011091100021
(2) Install the retainer plate.
SHTS011091100012
(3) Using a press, install the rotor.

NOTICE
Take care not to damage the rotor shaft.
SHTS011091100022
(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.
SHTS011091100023
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧥ಽ
2. INSTALL THE ROLLER BEARING.

(1) Using a press, jig A and jig B, install the roller bearing into the rec-
tifier end frame.
NOTICE
Press fit until jig A hits to the rectifier end frame.
SHTS011091100024
3. INSTALL THE FIELD COIL, REGULATOR AND RECTIFIER

HOLDER.
(1) Install the field coil to the rectifier end frame.
NOTICE
Tighten the bolt evenly.
SHTS011091100025
(2) Refer to the section "COMPONENT LOCATOR", then install the

each parts.
SHTS011091100026
(3) Install the stator coil to the rectifier end frame.

NOTICE
Do not damage the stator coil.
SHTS011091100027
(4) Using a solder ring iron, solder the lead wire connecting the regu-
lator and field coil as well as the stator coil and diode.
(5) Install the condenser.
SHTS011091100028
(6) Tighten the inner nut of the B terminal.
SHTS011091100029
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.
SHTS011091100030
(2) Install the cover.
SHTS011091100031
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧟㧥ಽ
PERFORMANCE TEST
NOTICE
• Note the battery polarity carefully so as not to make reverse
connections.
If the connections are reversed, the diodes will short the cir-
cuit and allow a large current to flow through and damage the
diodes and I.C. regulator as well as burning the wiring har-
ness.
• Take care not to make wrong connections of terminals.
• When charging the battery with a quick charge, disconnect
the battery terminals.
• Do not perform tests with high voltage insulation resistance
tester.
• In operation, never disconnect the battery.
1. ALTERNATOR PERFORMANCE TEST

(1) Turn switch SW1 on and SW2 off to increase the revolution of the
alternator slowly.
(2) 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
2. VOLTAGE REGULATOR TEST

(1) Turn switch SW1 on and SW2 off to increase the revolution of the
rotor to 5,000 r/min.
SHTS011091100032 Standard voltage: 28.0-29.0V

EN0110911H300001
Unit: mm {in.}
Measure
Resistance of field coil

6.75-7.45Ω — Replace.
[at 20°C (68°F)]
Measure
Insulation resistance of
1MΩ 0.5MΩ or less Replace.
field coil
Measure
Resistance of stator
0.247-0.273Ω — Replace.
coil [at 20°C (68°F)]
Measure
Insulation resistance of
1MΩ or more 0.5MΩ or less Replace.
stator
Measure
Normal direction
7-10Ω
Resistance of diode — Replace.
Reverse direction
∞Ω
Measure
Rotor shaft outside

diameter (front bearing 25 {0.984} 24.98 {0.984} Replace.
portion)
Measure
Rotor shaft outside

diameter (rear bearing 17 {0.669} 16.98 {0.669} Replace.
portion)
Measure
Drive end frame bearing

62 {2.441} 62.1 {2.445} Replace.
bore inside diameter
Measure
Rectifier end frame

bearing bore inside 23.8 {0.937} 23.81 {0.937} Replace.
diameter
Visual check
Rotates smoothly Replace.

Bearing wear or dam-
with no abnormal — Also, replace every 2
age
noise years.
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧠㧞ಽ
STARTER (P11C) EN12–1
EN12 STARTER (P11C) EN12-001
STARTER .................................................. EN12-2

DESCRIPTION ................................................ EN12-2
PROPOSAL TOOL .......................................... EN12-5
OVERHAUL ..................................................... EN12-6
EN12–2 STARTER (P11C)
STARTER
EN0110912I200001
Type Reduction gear type
Rated output 24 V, 6.0 kW
Number of teeth of pinion 11
Module 3.5
Rotating direction Clockwise (Seen from pinion side)
DESCRIPTION
EN0110912C100001
SHTS011091200001
1 Brush holder 7 Pinion set stopper

2 Brush 8 Drive housing
3 Yoke assembly 9 Gear housing
4 Magnet switch assembly 10 Armature assembly
5 Pinion drive lever 11 Field coil
6 Clutch sub assembly 12 Commutator end frame
TROUBLESHOOTING
EN0110912F300001

Engine does not crank, or cranks Poor contact Clean or replace contacts.
slowly. (starter switch)
Engine does not crank, or cranks Discharged battery Charge.
slowly. (Battery) Short circuit between electrodes Replace battery.
Poor contact at battery terminal Clean or retighten.
Engine does not crank, or cranks Improper viscosity oil Change oil.
slowly. (Engine oil)
Engine does not crank, or cranks Poor contact caused by burnt contact 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.
cuit
Engine does not crank, or cranks Defective or poor contact Repair or replace.
slowly. (Starter relay)
Engine does not crank, or cranks Brush worn out Replace.
slowly. (Starter) Commutator burnt out 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 arma-
ture shaft
Overrunning clutch malfunction Replace.
Engine does not crank while starter Overrunning clutch malfunction Replace.
is running in good condition (Over- Pinion teeth worn out Replace.
running clutch)
Poor sliding of spline teeth Remove foreign particles, dirt or
replace.
Starter does not stop running. (Key Contacts keep closing Replace.
switch) Key switch sticks Replace.
Overrunning clutch sticks to armature Repair or replace overrunning or
armature.
Starter does not stop running. Contacts keep closing Repair or replace.
(Starter relay)
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧟㧝ಽ
COMPONENT LOCATOR
EN0110912D100001
SHTS011091200002
1 Battery cable 11 Brush spring 21 Holder

2 Starter 12 Yoke assembly 22 Pinion drive lever
3 Lead wire with connector 13 Armature assembly 23 Drive lever pin
4 Bolt 14 Bearing 24 Clutch sub assembly
5 Magnet switch assembly 15 Gear housing 25 Pinion set stopper
6 Set bolt 16 Plate 26 Hook
7 Through bolt 17 Packing 27 Oil felt
8 Commutator end frame 18 Drive shaft 28 Drive housing
9 Brush holder 19 Center bearing 29 Bushing
10 Brush 20 Spring 30 Cover

A 16-22 {164-244, 12-16} D 4-5 {41-50, 3.0-3.6}
B 127 {1,300, 94} E 14-16 {143-163, 10.4-11.7}
C 2-3 {21-30, 1.52-2.16}
PROPOSAL TOOL
EN0110912K100001
JIG-A JIG-B JIG-C

(Shaft for drive housing (Guide for drive housing (Collar for pinion stopper
cover installing) cover installing) removing)
ø34 ø34
{1.339} {1.339}
ø15.9
{0.6260}
15
{0.591}
ESCAPE 50
GUTTER {1.969}
122 83 30
84 {4.803} {3.268} {1.181}
{3.307}
R37
{1.457}
1 ø18
{0.0394} {0.709}
ø24 ø30
ø14.9 {0.9449} {1.181}
{0.5866}
Unit = mm {in.}
SHTS011091200003
OVERHAUL
EN0110912H200001

When disassembling the starter, prepare a work stand as shown in the
figure.
D: Diameter = 130 mm {5.118 in.}
T: Thickness = 10 mm {0.394 in.}
H: Height = 120 mm {4.724 in.}
SHTS011091200004
1. REMOVE THE TERMINAL LEAD.

"M" TERMINAL LEAD (1) Remove the nut, disconnect the "M" terminal lead.
"M" TERMINAL
SHTS011091200005
2. REMOVE THE MAGNET SWITCH ASSEMBLY.

(1) Remove two bolts.
(2) Remove the magnet switch assembly.
MAGNETIC
SWITCH
SHTS011091200006
3. REMOVE THE COMMUTATOR END FRAME.

(1) Remove the through bolt.
SHTS011091200007
(2) Remove the set bolt, then remove the commutator end frame.
SHTS011091200008
4. REMOVE THE HOLDER ASSEMBLY.

(1) Using a driver, remove the brush of the yoke from the holder.
(2) Remove the brush holder from the armature.
SHTS011091200009
NOTICE
Do not cut the fixed clamp of brush lead.
SHTS011091200010
5. REMOVE THE YOKE ASSEMBLY.

(1) Remove the yoke assembly from the gear housing.
SHTS011091200011
6. REMOVE THE ARMATURE ASSEMBLY.

(1) Remove the set bolt.
SHTS011091200012
(2) Remove the gear housing with the armature assembly from the
drive housing.
(3) Remove the plate.
SHTS011091200013
(4) Remove the armature assembly from the gear housing using a
press.
SHTS011091200014
(5) Remove the bearing from the armature assembly using a press or
a suitable puller.
SHTS011091200015
7. REMOVE THE CLUTCH ASSEMBLY.

(1) Remove the gasket.
(2) Remove the holder spring.
SHTS011091200016
(3) Remove the clutch assembly with the lever from the drive hous-
ing.
SHTS011091200017
8. DISASSEMBLE THE CLUTCH SUB ASSEMBLY AND DRIVE

SHAFT.
(1) Remove the felt.
(2) Press down the pinion set stopper using the JIG-C.
(3) Remove the hook.
SHTS011091200018
(4) Remove the clutch sub assembly, center bearing and plate from
drive shaft.
SHTS011091200019
IMPORTANT POINT - REPLACEMENT

PRESS
1. REPLACE THE DRIVE HOUSING BUSHING.
(1) Press out the old bushing from drive housing stopper side.
DRIVE
HOUSING
STOPPER
BUSHING
SHTS011091200020
(2) Fill up grease to the grease reservoir at the bushing hole of the
DRIVE HOUSING driving housing.
GREASE GUN
RESERVOIR
SHTS011091200021
(3) Set the drive housing on a stand, press in a new bushing by a just
PRESS fitted size JIG.
JIG NOTICE
Press in a new bushing to fit the stopper.
GREASE NEW BUSHING
RESERVOIR (4) Fill up grease to the grease reservoir again by grease gun.
STAND DRIVE HOUSING
STOPPER
SHTS011091200022
(5) Set the JIG-A, B and a new cover to the driver housing as shown
in the figure.
(6) Hit the JIG-A to bent the cover 1.5 - 2.0 mm {0.06 - 0.08 in.}.
JIG-A
JIG-B
NEW COVER
DRIVE
HOUSING
COVER
1.5 - 2.0 mm
(0.06 - 0.08 in.)
SHTS011091200023
1. ASSEMBLE THE CLUTCH SUB ASSEMBLY AND DRIVE

SHAFT.
(1) Apply the grease (G1: Multemp AC-N) to the plate, then install it to
the drive shaft.
(2) Apply the grease (G1: Multemp AC-N) to the portion as shown in
the figure.
SHTS011091200024
NOTICE
Fill up the grease (G1: Multemp AC-N) to the reservoir of center
bearing from bushing hole that until overflow from other hole.
SHTS011091200025
(3) Install the center bearing and clutch sub assembly to the drive
shaft.
(4) Install the pinion set stopper onto the drive shaft, then install the
hook on the drive shaft.
(5) Press the pinion set stopper onto the hook.
(6) Install the felt to the drive shaft.
SHTS011091200026
2. INSTALL THE BEARING ONTO THE ARMATURE ASEEMBLY.

(1) Install the bearing (gear housing side and brush holder side) onto
the armature assembly using a jig and a press.
SHTS011091200027
3. INSTALL THE ARMATURE ASSEMBLY.

(1) Install the armature assembly to the gear housing using a press.
SHTS011091200028
4. INSTALL THE PINION DRIVE LEVER AND CLUTCH SUB

ASSEMBLY.
(1) Fill up the grease (G1: Multemp AC-N) to the reservoir from bus-
ing hole that until overflow from other hole.
SHTS011091200029
(2) Assemble the holder, drive lever pin and pinion drive lever.
(3) Apply the grease (G1: Multemp AC-N, G2: Pyronoc No.2) to the
portion as shown in the figure.
(4) Install the pinion drive lever and clutch sub assembly into the drive
housing at the same time.
NOTICE
Make sure that the holder is installed securely and it slides
smoothly.
SHTS011091200030
5. INSTALL THE GEAR HOUSING.

(1) Install the spring to the holder.
(2) Install the new packing to the center bearing.
SHTS011091200031
(3) Apply the grease (G1: Multemp AC-N) to the portion as shown in
the figure.
(4) Install the plate.
(5) Install the gear housing to the drive housing.
SHTS011091200032
6. INSTALL THE YOKE ASSEMBLY.

(1) Align the notches, install the yoke assembly.
SHTS011091200033
7. INSTALL THE HOLDER ASSEMBLY AND THE COMMUTATOR

END FRAME.
(1) Align the notch with M lead, install the brush holder to the commu-
tator of the armature assembly.
(2) Install the brush to the brush holder.
SHTS011091200034
(3) Apply grease (G2: Pyronoc No.2) to the portion as shown in the
figure.
(4) Install the commutator end frame aligning the location guide of the
commutator end frame (convexity) with notches of the holder
assembly (concavity).
(5) Secure the brush holder with the bolt.
(6) Secure the drive housing assembly and commutator end frame
with the through bolt.
SHTS011091200035
8. INSTALL THE MAGNET SWITCH ASSEMBLY.

(1) Install the magnet switch assembly.
(2) Connect the M-lead to M-terminal.
(3) Connect the C-lead to C-terminal.
SHTS011091200036
9. AFTER ASSEMBLING THE STARTER, MEASURE THE PINION

GEAR THRUST GAP.
(1) Arrange the circuit.
(2) Close switches S1 and S2.
(3) Open S2 alone when the pinion pops out.
SHTS011091200037
(4) If the above condition, push pinion back to measure the gap.
Standard: 0.5-3.0 mm {0.020-0.118 in.}
NOTICE
Perform the inspection work for an instance (within 15 seconds).
SHTS011091200038
IMPORTANT POINTS - INSPECTION

NOTICE
These tests must be performed within 3 to 5 seconds to avoid
burning out the coil.
1. PERFORM PULL-IN TEST.

(1) Disconnect the field coil lead wire from the terminal M.
(2) Connect battery to the magnetic switch as shown.
(3) Check that the pinion gear moves outward.
SHTS011091200039
2. PERFORMANCE HOLD-IN TEST.

(1) While connected as above with the pinion gear out, disconnect
the negative (-) lead from terminal M.
(2) Check that the pinion gear remains out.
SHTS011091200040
3. INSPECTION PLUNGER RETURN. (SOLENOID COIL BAL-

ANCE CHECK)
(1) Disconnect the positive (+) lead from the terminal C.
(2) Check that the pinion gear returns inward.
SHTS011091200041
4. PERFORM NO-LOAD PERFOMANCE TEST.

(1) 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.
• Using a battery and suitable ammeter.
• Connect the positive lead to the ammeter, "B" and "C" terminal.
• Connect the negative lead to the starter body.
(2) The starter should show smooth and steady rotation immediately
after jumping out of the pinion and should draw less than the
specified current.
Revolution 4,000 r/min or more

Current 100 A or less
SHTS011091200042

EN0110912H300001
Unit: mm {in.}
Measure
If the iron rod does

Armature short circuit
not vibrated,
test (Using a growler — Replace.
the armature is
tester)
good.
Measure
Less than
Armature insulation More than 1 MΩ Replace.
0.5MΩ
Measure
Continuity between the

segments of the com- Continuity — Replace.
mutator
Measure
38
Outside diameter of the 40
{1.496} Replace.
commutator {1.575}
or less
Measure
Depth between the mica 0.2
0.5-0.8
and the commutator {0.0078} Replace or repair.
{0.0197-0.0314}
(Under cut depth) or less
Measure
Continuity between the

brush and the "M" ter- Continuity — Replace.
minal
Measure
Insulation between the

Less than
brush and the yoke More than 1 MΩ Replace.
0.5MΩ
body
Measure
Insulation between the Less than

More than 1 MΩ Replace.
brush and brush holder 0.5MΩ
Measure
21 14
Brush length Replace.
{0.827} {0.551}
Measure
0.02 0.1
Bend of the shaft Replace.
{0.0008} {0.0039}
A: 28 A: 27.90 Measure
{1.102} {1.098}
Outside diameter of the
Replace.
drive shaft
B, C: 17 B, C: 16.92
{0.669} {0.6661}
Measure
Inside diameter of the 17 17.2

Replace the metal.
drive housing bushing {0.669} {0.6772}
Measure

Replace.
center bearing {1.102} {1.1102}
Measure

Replace.
commutator end frame {1.260} {1.2638}
Visual check

Replace.
gear housing {1.850} {1.8543}
Visual check
Replace, if both side

Rotating of pinion — — turn or does not turn
at all.
Visual check
Damage of the pinion

— — Replace.
teeth
Measure
Resistance between the

C terminal and M termi- 0.12-0.15 Ω — Replace.
nal (Pulling Coil)
Measure
Resistance between the

C Terminal and the 0.67-0.83 Ω — Replace.
body (Holding Coil)
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧠㧟ಽ
AIR COMPRESSOR (P11C) EN13–1
AIR COMPRESSOR (P11C)

EN13
EN13-001
AIR COMPRESSOR.................................. EN13-2

DESCRIPTION ................................................ EN13-2
SPECIAL TOOL ............................................... EN13-6
OVERHAUL ..................................................... EN13-7
EN13–2 AIR COMPRESSOR (P11C)
AIR COMPRESSOR
EN0110913I200001
Type Reciprocating, V-type two cylinder
Discharge amount 154 cm3 {9.4 in.3} x 2 cylinders
Bore x stroke 70 mm x 40 mm {2.76 in. x 1.57 in.}
Lubrication system Forced feed lubrication
Cooling system Forced water-circulated
DESCRIPTION
EN0110913C100001
SHTS011091300001
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
TROUBLESHOOTING
EN0110913F300001

Charging efficiency dropped (Valve) Abnormal wear, damage, or poor con- Replace.
tact
Charging efficiency dropped (Pis- Worn piston and cylinder liner Replace.
ton, Cylinder liner and piston rings) Seized piston Replace (piston, piston rings and cylin-
der liner).
Worn or broken piston ring Replace.
Charging efficiency dropped (Air Leakage of high-pressure air Replace or tighten pipe joint.
pipe and joints) Clogged air pipe Replace.
Charging efficiency dropped (Air Clogged element Clean or replace element.
cleaner)
Noisy operation (Piston) Wear of piston pin boss or piston pin Replace.
Seized, damaged or worn connecting Replace.
rod small end
Worn piston or cylinder liner Replace.
Damaged or seized piston Replace.
Foreign particles on the top surface of Clean or replace.
piston
Noisy operation (Bearing) Damaged, or worn ball bearing and/or Replace.
connecting rod bearing
Noisy operation (Valve) Inlet valve is lowered excessively Repair or replace.
Loosen discharge valve holder Tighten it.
Excessive carbon or oil in the com- Worn, sticking or broken piston rings Replace piston rings and/or cylinder
pressor cylinder head or discharge liner.
line (Piston ring) Insufficient piston ring tension Replace piston rings and/or cylinder
liner.
Malfunction of piston rings Replace piston rings and/or cylinder
liner.
Excessive carbon or oil in the com- Worn cylinder liner and piston rings Replace.
pressor cylinder head or discharge
line (Cylinder liner and piston rings)
Malfunction of unloader valve Sticky Clean or replace.
(Unloader valve) Deflection or wear Repair or replace unloader valve
assembly.
Malfunction of unloader valve (Air Air leakage Replace or tighten pipe joints.
pipe and joints)
Malfunction of unloader valve Function Adjust and/or repair pressure regula-
(Pressure regulator) tor.
COMPONENT LOCATOR
EN0110913D100001
SHTS011091300002
1 Air compressor

A 137-147 {1,400-1,500, 102-108} B 44-49 {450-500, 33-36}
SHTS011091300003
1 Cylinder block 18 Delivery valve

2 Ball bearing 19 Valve seat
3 Woodruff key 20 Delivery valve assembly
4 Crankshaft 21 Spacer
5 O-ring 22 Unloader valve
6 Bearing holder 23 Unloader valve holder
7 Connecting rod assembly 24 Unloader valve assembly
8 Connecting rod bolt 25 Cylinder head
9 Connecting rod bearing 26 Cylinder liner
10 Lock washer 27 Gasket
11 Nut 28 Suction valve
12 Piston 29 Suction valve holder
13 Retainer ring 30 Suction valve assembly
14 Piston pin 31 Lock nut
15 Piston ring set 32 Collar
16 Delivery valve holder 33 Drive gear
17 Valve spring

A 98.1-117.7 {1,000-1,200, 73-86} D 24.5-29.4 {250-300, 19-21}
B 68.6-78.4 {700-800, 51-57} E 13.7-17.6 {140-180, 11-13}
C 22.6-25.5 {230-260, 17-18} F 137-147 {1,400-1,500, 102-108}
SPECIAL TOOL
EN0110913K100001
Prior to starting an air compressor overhaul, it is necessary to have these special tools.
S0942-01111 GEAR PULLER
S0948-21580 PISTON PIN PRESS
INLET VALVE HOLDER

S0948-11100
ADAPTER
S0965-01101 BEARING PULLER
S0944-01060 PISTON RING EXPANDER

2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧟㧣ಽ
OVERHAUL
EN0110913H200001
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.
SHTS011091300009
(2) Using the special tool, pull the drive gear from the crankshaft,
then remove the woodruff key.
SST: Gear puller (S0942-01111)
SHTS011091300010
NOTICE
When removing the drive gear, use the special tool in place of the
bolt as shown in the figure.
SHTS011091300011
2. REMOVE THE CYLINDER HEAD, O-RING AND CYLINDER

LINER.
(1) Remove the cylinder head, O-ring and cylinder liner.
NOTICE
Put the aligning mark through the cylinder head to the cylinder
liner.
SHTS011091300012
3. REMOVE THE CONNECTING ROD WITH THE PISTON.

(1) Rotate the crankshaft to the top dead center position.
(2) Spread the staking of the nut completely with a chisel, then
loosen the nut.
(3) Remove the connecting rod with piston.
SHTS011091300013
4. REMOVE THE PISTON RINGS.

(1) Remove the piston rings.
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.
SHTS011091300014
5. REMOVE THE PISTON.

(1) 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 the special tool and a hammer.
SST: Piston pin press (S0948-21580)
NOTICE
Warm up the piston first in hot water, 80-90°C {176-194°F}, for
SHTS011091300015
approximately 5 minutes before removing the piston pin.
6. REMOVE THE CRANKSHAFT.

(1) Remove the bearing holder fitting bolts.
(2) Strike the crankshaft end face with a copper hammer or a mallet
and remove the crankshaft with the bearing holder.
NOTICE
Do not damage the threads at the crankshaft's end.
SHTS011091300016
2A'0HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧟㧤ಽ
7. REMOVE THE BEARING HOLDER.

(1) Strike the circumference of the holder lightly with a plastic ham-
mer or a mallet and remove the holder.
NOTICE
Be careful not to damage the bearing holder.
SHTS011091300017
8. REMOVE THE BALL BEARING.

(1) Using the special tool, remove the ball bearing from the end of the
crankshaft.
SST: Bearing puller (S0965-01101)
SHTS011091300018
9. REMOVE THE SUCTION VALVE ASSEMBLY.

(1) Using the special tool, remove the inlet valve holder.
SST: Inlet valve holder adapter (S0948-11100)
SHTS011091300019
(2) Disassemble the suction valve.
SHTS011091300020
10. REMOVE THE UNLOADER VALVE ASSEMBLY.

(1) Loosen the unloader valve guide and take it out together with the
unloader valve.
SHTS011091300021
(2) Remove the retainer ring and disassemble the unloader valve.
SHTS011091300022
11. REMOVE THE DELIVERY VALVE ASSEMBLY.

(1) Remove the delivery valve holder.
SHTS011091300023
(2) Disassemble the delivery valve.
SHTS011091300024
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.
SHTS011091300025
(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.
SHTS011091300026
(3) Tighten the suction valve holder to the specified torque using a
special tool.
SST: Inlet valve holder adapter (S0948-11100)
(4) Make sure that the suction valve stroke is approximately 2.5 mm
{0.0984 in.}.
SHTS011091300027
(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.)
SHTS011091300028
2. ASSEMBLE THE DELIVERY VALVE ASSEMBLY.

NOTICE
O-ring should be replaced with new one.
(1) 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.
(2) 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.
SHTS011091300029
(3) Tighten the delivery valve holder to the specified torque.

(4) Make sure that the delivery valve stroke is approximately 1 mm
{0.0394 in.}.
SHTS011091300030
3. ASSEMBLE THE UNLOADER VALVE

(1) 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.
(3) Assemble the unloader valve holder from the upper side of the
cylinder head and tighten the unloader valve holder to the speci-
fied torque.
SHTS011091300031
4. INSTALL THE BALL BEARING.

(1) Install the ball bearing on the both end of the crankshaft.
SHTS011091300032
5. INSTALL THE CRANKSHAFT.

(1) Using a copper hammer, install the crankshaft to the bearing
holder.
(2) Install the crankshaft and bearing holder in the crankcase.
(3) Tighten the bearing holder fitting bolt.
SHTS011091300033
6. 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.
SHTS011091300034
(2) Measure the connecting rod end play.

Limit: 0.9 mm {0.0354 in.}
SHTS011091300035
(3) Lock the nut with a lock washer.
SHTS011091300036
7. MEASURE THE END PLAY OF THE CRANKSHAFT.

Limit: 0.8 mm {0.0314 in.}
SHTS011091300037
8. 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 pis-
ton skirt is at the bottom, and use the special tool.
NOTICE
Install the piston rings with the identification mark at the top of the
ring facing up.
SHTS011091300038
NOTICE
The three compression rings are all the same in size and profile.
SHTS011091300039
9. ASSEMBLE THE PISTON AND CONNECTING ROD.

NOTICE
Warm up the piston first in hot water, to 80-90°C {176-194°F}, for
approximately 5 minutes.
(1) Install the retainer ring at one end of the piston 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.
SHTS011091300040
10. 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) Rotate the crankshaft to the top dead center position.
(2) Arrange the piston rings so that their gaps are equally spaced.
(3) Install the cylinder liner and cylinder head.
SHTS011091300041
11. INSTALL THE DRIVE GEAR.

(1) Install the woodruff key to the crankshaft.
(2) Install the drive gear.
(3) Install the collar and lock nut.
SHTS011091300042

EN0110913H300001
Unit: mm {in.}
Visual check
Cracks or defects of the con-

— — Replace.
necting rod
14 Measure
Outside diameter of piston pin —
{0.551}
Replace.
Clearance between the piston 0.016-0.042 0.07
pin and connecting rod {0.0006-0.0016} {0.0027}
Inside diameter of the con- Measure

necting rod (without bear- 33
—
ings): A #Tighten the bearing {1.299}
cap to the specified torque
Thickness of the connecting 1.5

—
rod bearing: B, C {0.0591}
Outside diameter of the crank 30

—
pin: D {1.181}
Replace.
Oil clearance between the

connecting rod and the crank
0.017-0.083 0.1
pin: E
{0.0007-0.0032} {0.0039}
# Oil clearance
E= A-(B+C+D)
Measure
Replace con-
0.4-0.7 0.9
Connecting rod end play necting rod or
{0.0158-0.0275} {0.0354}
crankshaft.
Visual check
Damage and scratches of the

— — Replace.
cylinder liner
70 Measure
Outside diameter of the piston —
{2.756}
Inside diameter of the cylinder 70

—
liner {2.756}
A: 0.18-0.24 0.28
{0.0071-0.0094} {0.0110] Replace.
Clearance between the piston

and the cylinder liner B: 0.084-0.144 0.18
{0.0034-0.0056} {0.0071}
Clearance between the piston -0.012-0.014 0.05 Measure

pin hole and the piston pin {-0.0004-0.0005} {0.0020}
Replace.
Outer diameter of the piston 14
—
pin {0.551}
Compression 2.5 Measure

—
Piston ring ring {0.0984}
thickness 4.0
Oil ring —
{0.1575}
Compression 2.5
—
Piston ring ring {0.0984}
Replace.
groove 4.0
Oil ring —
{0.1575}
Clearance between the ring

0.005-0.04 0.07
groove and the compression
{0.0002-0.0015} {0.0027}
ring
Visual check
Worn or damaged bearing — — Replace.

Visual check
Replace
Worn or damaged delivery
— — delivery valve
valve and valve seat
assembly.
Visual check
Replace
Worn or damaged suction
— — suction valve
valve and valve seat
assembly.
Compression 0.1-0.3 Measure

ring {0.0040-0.0118}
Piston
ring gap: 0.8
Replace.
compression 0.1-0.3 {0.0314}
ring, oil ring Oil ring
{0.0040-0.0118}
35.002-35.013 35.0 Measure

Drive side
{1.3781-1.3784} {1.3780}
Outside
diameter of
Replace.
the crank- Opposite 30.002-30.013 30.0
shaft journal drive side {1.1812-1.1816} {1.1811}
79.961-79.991 80.0 Measure

Cylinder block
{3.1481-3.1492} {3.1496}
Inside
diameter
Replace.
of the bearing Bearing 71.961-71.991 72.0
holder holder {2.8332-2.8342} {2.8346}
Measure
Replace
0.10-0.64 0.8
Crankshaft end play crankshaht
{0.0040-0.0251} {0.0314}
bearing
1.67 N
{0.17 kgf, 1.00 N Measure
Suction valve spring setting
0.374 lbf} {0.102 kgf, Replace.
load
at 6.5 mm 0.2248 lbf}
{0.256 in.}
6.35 N
{0.648 kgf, 4.41 N
Delivery valve spring 1.43 lbf} {0.450 kgf, Replace.
at 13 mm 0.992 lbf}
{0.512 in.}
Visual check
Wear or damage of the suc-
tion valve spring and delivery — — Replace.
valve spring
2A'0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧠㧣ಽ
ENGINE P.T.O. (POWER TAKE-OFF) (P11C) EN14–1
ENGINE P.T.O. (POWER TAKE-OFF) (P11C)

EN14
EN14-001
POWER TAKE-OFF ASSEMBLY .............. EN14-2

DESCRIPTION ................................................ EN14-2
SPECIAL TOOL ............................................... EN14-4
OVERHAUL ..................................................... EN14-5
EN14–2 ENGINE P.T.O. (POWER TAKE-OFF) (P11C)
POWER TAKE-OFF ASSEMBLY

DESCRIPTION
EN0110914C100001
SHTS011091400001
1 Case 5 Nut 9 Oil seal

2 Driven gear 6 Coupling 10 Flywheel
3 Driven gear shaft 7 Idle gear shaft 11 Driven gear
4 Cover 8 Idle gear 12 Stay
COMPONENT LOCATOR
EN0110914D100001
SHTS011091400002
1 Gasket 8 Driven gear 15 Idle gear cover

2 O-ring 9 Driven gear shaft 16 Straight Pin
3 Oil jet pipe 10 Pin 17 Drive gear
4 Case 11 Driven gear cover 18 Expansion plug
5 Retainer ring 12 Oil seal 19 Idle gear
6 Collar 13 Stud bolt 20 Woodruff key
7 Ball bearing 14 Coupling 21 Idle gear shaft

A 34-45 {347-458, 26-33} D 23 {230, 16.6}
B 47 {480, 34.7} E 113 {1,150, 83}
C 368 {3,750, 271}
SPECIAL TOOL
EN0110914K100001
Prior to starting a power take-off overhaul, it is necessary to have these special tools.
S0942-01850 OIL SEAL PULLER
S0942-41780 SUPPORT PLATE
S0948-21460 OIL SEAL PRESS (COVER)
S0948-11530 GUIDE BOLT

OVERHAUL
EN0110914H200001

! CAUTION
Do not work on the while it is still hot. This can result in personal
injury.
1. BLOCK THE WHEELS.

(1) Park the vehicle on level ground.
(2) Block the wheels.
NOTICE
Be sure to apply wheel stoppers at the front tires.
SHTS011091400008
2. DRAIN THE ENGINE OIL.
3. DISMOUNT THE TRANSMISSION.
4. DISMOUNT THE CLUTCH COVER ASSEMBLY AND CLUTCH

DISC.
5. REMOVE THE COUPLING.

(1) Secure the flywheel with tire lever, then remove the lock nut.
(2) Remove the coupling.
6. REMOVE THE FLYWHEEL.
7. REMOVE THE FLYWHEEL HOUSING STAY FROM BOTH

SIDES OF THE HOUSING.
8. REMOVE THE OIL PAN.
SHTS011091400009
9. REMOVE THE IDLE GEAR COVER.
10. REMOVE THE CASE WITH DRIVEN GEAR ASSEMBLY AND

IDLE GEAR ASSEMBLY.
(1) Remove the bolts and nuts.
(2) Remove the case with driven gear assembly and idle gear assem-
bly.
NOTICE
• Hold the idle gear assembly to prevent falling.
• If idle gear is not removed with case, remove the idle gear
assembly from the case (cylinder block side).
SHTS011091400010
11. REMOVE THE IDLE GEAR ASSEMBLY.

(1) Using a tapping rod and hammer, remove the idle gear assembly.
SHTS011091400011
12. REMOVE THE DRIVEN GEAR ASSEMBLY.

(1) Using a press or copper hammer, remove the driven gear assem-
bly.
SHTS011091400012
13. REMOVE THE DRIVEN GEAR COVER ASSEMBLY.

(1) Remove the bolts.
(2) Using a tapping rod and hammer, remove the driven gear cover.
SHTS011091400013
1. REPLACE THE REAR OIL SEAL.

(1) Assemble the special tool as shown in the figure.
SST: Oil seal puller (S0942-01850)
SHTS011091400014
(2) Install the support plate to the end of the drive gear.
SST: Support plate (S0942-41780)
(3) Engage the hook with the oil seal notch and install the hook using
the guide bolt supplied.
SHTS011091400015
2A'0A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧠㧢ಽ
(4) Place the sleeve on the hook.

(5) Tighten the center bolt and remove the oil seal.
SHTS011091400016
(6) Install the new oil seal to the guide.

NOTICE
Pay attention to the orientation of the oil seal (The felt side should
face the outside of the cylinder block).
(7) Apply a little engine oil to the seal portion of the oil seal.
SHTS011091400017
(8) The guide with the new oil seal onto the drive gear end using the
guide bolt.
SST: Guide bolt (S0948-11530)
(9) Attach the press on the guide.
(10) Tighten the center bolt until the press contacts to the guide.
SHTS011091400018
2. REPLACE THE BALL BEARING, DRIVEN GEAR AND DRIVEN

GEAR SHAFT.
(1) Remove the retainer ring.
(2) Support the driven gear and remove the ball bearing and driven
gear from the driven gear shaft using a press.
SHTS011091400019
(3) Press the driven gear shaft into the ball bearing, then install the
collar and retainer ring.
(4) Press the driven gear shaft into the driven gear.
SHTS011091400020
3. REPLACE THE BALL BEARING, IDLE GEAR AND IDLE GEAR

SHAFT.
(1) Remove the retainer ring.
(2) Support the idle gear and remove the idle gear and ball bearing
from the idle gear shaft using a press.
(3) Remove the woodruff key and remove the ball bearing using a
press.
SHTS011091400021
(4) Press the idle gear shaft into the ball bearing.
(5) Install the woodruff key to the idle gear shaft, then press the idle
gear shaft into the idle gear.
SHTS011091400022
4. REPLACE THE BALL BEARING AND OIL SEAL.

(1) Remove the retainer ring and collar.
(2) Using a tapping rod and hammer, remove the ball bearing.
(3) Remove the oil seal.
SHTS011091400023
(4) Using the special tool, press the oil seal into the driven gear
cover.
(5) Press the ball bearing into the driven gear cover and secure the
ball bearing with collar and retainer ring.
SHTS011091400024
1. INSTALL THE OIL JET TO THE CASE.

(1) Press the oil jet with O-ring to the case.
NOTICE
Align the arrow marks as shown in the figure.
SHTS011091400025
2. INSTALL THE EXPANSION PLUG INTO THE DRIVE GEAR.

(1) Coat the outside surface of the expansion plug with adhesive
(THREEBOND 12.5 or equivalent).
SHTS011091400026
3. INSTALL THE IDLE GEAR ASSEMBLY AND DRIVEN GEAR

ASSEMBLY INTO THE CASE (CYLINDER BLOCK SIDE).
SHTS011091400027
4. INSTALL THE CASE (FLYWHEEL SIDE).
5. INSTALL THE BALL BEARING ONTO THE IDLE GEAR SHAFT.

(1) Using a tapping rod and a hammer, press the ball bearing onto
the idle gear shaft.
(2) Install the idle gear cover.
SHTS011091400028
6. INSTALL THE DRIVEN GEAR COVER ASSEMBLY.

(1) Using a tapping rod and a hammer, install the driven gear cover
assembly by tapping the bearing inner race and driven gear
cover.
NOTICE
When installing the driven gear cover assembly, match the oil lead
hole on the driven gear case and case.
7. INSTALL THE FLYWHEEL.

(1) Refer to the chapter “ENGINE MECHANICAL”.
SHTS011091400029
8. INSTALL THE COUPLING ON THE DRIVEN SHAFT.
9. INSTALL THE OIL PAN.
10. INSTALL THE FLYWHEEL HOUSING STAY TO BOTH SIDES

OF THE HOUSING.
11. MOUNT THE CLUTCH DISC AND CLUTCH COVER ASSEM-

BLY.
(1) Refer to the chapter “CLUTCH MAIN UNIT”.
12. MOUNT THE TRANSMISSION.

(1) Refer to the chapter “TRANSMISSION MAIN UNIT”.

EN0110914H300001
Shaft and gear: — — Replace, Visual check

Wear and damage if necessary.
Oil seal lip: — — Replace, Visual check

Wear and damage if necessary.
Bearing improper — — Replace, Visual check

rotation if necessary.
2A&0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧠ಽ
FUEL CONTROL (P11C) DN02–1
FUEL CONTROL (P11C)

DN02
DN02-001
TE SYSTEM ..............................................DN02-2 ECU CHASSIS SIDE CONNECTOR PIN

OVERVIEW ..................................................... DN02-2 ASSIGNMENT ............................................... DN02-33
COMPONENT LOCATOR ............................... DN02-3 DISMOUNTING AND MOUNTING ................ DN02-36
DIAGRAM ........................................................ DN02-8
PRECAUTIONS ............................................. DN02-10
INSPECTION ................................................. DN02-12
DIAGNOSIS USING
THE DIAGNOSIS MONITOR......................... DN02-13
ENGINE SPEED SENSOR NO PULSE
(MALFUNCTION CODE: 2-1) ........................ DN02-16
ABNORMALITY OF
ENGINE SPEED SENSOR
ABNORMALITY OF
COOLANT TEMPERATURE SENSOR
ABNORMALITY OF STARTER SWITCH
ABNORMALITY OF
BOOST PRESSURE SENSOR
ABNORMALITY OF CBCS
(MALFUNCTION CODE: 12-2) ...................... DN02-22
ABNORMALITY OF EXHAUST BRAKE
(MALFANCTION CODE: 13-1) ...................... DN02-24
ABNORMALITY OF RACK SENSOR
ABNORMALITY OF PRE-STROKE SENSOR
ABNORMALITY OF PRE-STROKE F/B
ABNORMALITY OF
PRE-STROKE LEARNING
ABNORMALITY OF PRE-STROKE
POWER SUPPLY
ABNORMALITY OF PRE-STROKE
POWER SUPPLY RELAY
(POWER SUPPLY CUT RELAY)
CONTROL CIRCUIT
ABNORMALITY OF ECU
ENGINE OVERRUN
ENGINE OVERHEAT
2A&0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧡㧝ಽ
DN02–2 FUEL CONTROL (P11C)
TE SYSTEM
OVERVIEW
EN1610902C100001
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" type.
Control of the Intake Air Type
Pre-stroke Pump Type

Hino TE System
Electronic Governer Type
Common Rail Fuel Injection Type
PRE-STROKE PUMP SYSTEM

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 Control of the Injection

Injection Timing
Control of the Exhaust

Brake Control of the Injection
Pre-stroke Type Rate
Fuel Injection System CBCS (Computer Boost
Control System)
Function of Diagnosis
Function of Tachometer
Driver
COMPONENT LOCATOR
EN1610902F200001
SHTS161090200003
1 ECU main relay 5 Speed sensor

2 Actuator power supply relay 6 Pressure sensor
3 Control unit (ECU) 7 Pre-stroke actuator and pre-stroke sensor
4 Coolant temperature sensor 8 Rack sensor
SHTS161090200004
1 Straight pin 17 Tappet roller

2 Control rack 18 Adapter
3 Housing 19 Tappet sub assembly
4 Element block 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 Gasket
16 Woodruff key

A 132 {1,350, 98}
SHTS161090200005
1 Boost compensator cover 14 Screw 27 Start spring

2 Gasket 15 Screw plug 28 Spring seat
3 Stroke adjust screw 16 Pin 29 Adapter
4 Diaphragm 17 Shaft 30 Flyweight sleeve
5 Governor spring 18 Cam plate 31 Round nut
6 Nut 19 Load lever 32 Flyweight
7 Bushing 20 Spring plate 33 Governor housing
8 Spring plate 21 Tension lever 34 Load control lever
9 Return spring 22 Guide lever 35 Stop lever
10 Speed control lever 23 Floating lever 36 Collar
11 Oil seal 24 Link 37 Plain washer
12 Governor cover 25 Load control lever 38 Joint bolt
13 Shim 26 Spring plate 39 Rack position sensor
SHTS161090200006
1 Joint bolt 8 Priming pump

2 Gasket 9 Piston rod
3 Feed pump housing 10 Piston
4 Check valve 11 Push spring
5 Check valve spring 12 Tappet
6 O-ring 13 Snap ring
7 Plug
SHTS161090200007
1 Pre-stroke actuator and pre-stroke sensor

DIAGRAM
EN1610902J100001
FUEL SYSTEM
SHTS161090200008
ELECTRICAL SYSTEM
+24V
CONTROL UNIT
ACTUATOR POWER
ENGINE SPEED SUPPLY RELAY
SENSOR (N.C)
COOLANT PRE-STROKE
TEMPERATURE ACTUATOR
SENSOR
CBCS MAGNETIC
VALVE (WASTE
RACK SENSOR GATE CONTROL
MAGNETIC VALVE)
PRE-STROKE EXHAUST BRAKE
SENSOR MAGNETIC VALVE
BOOST EXHAUST BRAKE

ECU
PRESSURE SWITCH
SENSOR BOOST ALARM
LIGHT
TACHOMETER
CHECK ENGINE
LIGHT
ECU
MAIN RELAY EXHAUST BRAKE
(N.O) INDICATOR LIGHT
STARTER
DIAG
SWITCH
KEY SWITCH
N.O: Normal Open N.C: Normal Close

SHTS161090200009
PRECAUTIONS
EN1610902C100002
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. HARNESS WIRE CONNECTOR.

(1) 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 twist-
ing 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.
• Do not let water, oil or dust get on the connector when it is discon-
nected, 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 PERFORM-
ING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
5. AFTER COMPLETING THE MALFUNCTION ANALYSIS,

ERASE THE MALFUNCTION MEMORY STORED IN THE PAST.
OTHERWISE, THE MALFUNCTION LIGHT 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
• There is a danger that the control unit might malfunction if a high
output radio transmitter (over 50W) is installed in the vehicle.
9. USING A QUICK CHARGER

• Disconnect both battery terminal before using a quick charger.
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 discon-
necting 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
EN1610902H300001
CHECK ENGINE LIGHT STATUS
1. INSPECTION PROCEDURE
(1) Turn the starter switch to the ON position (do not start the engine)
and confirm that the check engine light in the indicator area lights
up.
(2) Start the engine.
(3) If the engine is normal, the check engine light goes out.
(4) If the check engine warning light does not light up or if it blinks,
there is trouble in the system. Check the system according to the
following chart.
SHTS161090200011 .
CHECK ENGINE LIGHT ILLUMINATION PATTERN
ON Major
BLINKING OFF
0.5 sec 0.5 sec 0.5 sec 0.5 sec 0.5 sec
Degree
ON of
trouble
ON (1)
OFF
ON
Minor
ON (2) OFF
Light up 30 seconds after engine started
The light ON/OFF status and illumination pattern as well as the corre-
sponding conditions they indicate and the measures to be taken-are
shown in the following table.
Light ON/OFF
STATUS
This indicates that the engine has stopped or it will not start.
Turn the starter switch to the [LOCK] position and wait few seconds.
Blinking
If the engine does not start and the light 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.
This indicates that the engine has insufficient force and irregular idling occurred due to a sys-
ON (1) tem damage.
This condition must be inspected at a Hino service dealer as soon as possible.
This indicates that a light damage has occurred in the system.

ON (2) Driving is possible, but this condition must be inspected at a Hino service dealer as soon as
possible.
DIAGNOSIS USING THE DIAGNOSIS MONITOR

EN1610902F200002
1. CONNECT THE DIAGNOSIS MONITOR.

SST: Diagnosis (S0963-01370)
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".
SHTS161090200013
(2) Connect the harness to the diagnosis connector.

SST: Harness (S0963-02300)
SHTS161090200014
(3) Connect the diagnosis monitor to the connector which tagged a

"STD-ENG" label.
SHTS161090200015
2. READ OUT THE MALFUNCTION CODE.

(1) Turn on the exhaust brake switch.
SHTS161090200016
(2) Check engine light and exhaust brake indicator light 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 pro-
gressing upward, with no distinction between present and past
malfunction codes.
SHTS161090200017
MALFUNCTION CODE DISPLAY PATTERN
Malfunction Code 9 - 2
Check Engine
Code 9 Light
Turn ON
Turn OFF
Exhaust Brake
2.0s 1.5s a a a a a a a a a 2.0s
Indicator Light
Turn ON
Turn OFF
a a a a 2.0s
a = about 0.2 seconds
Code 2
Check Engine
Malfunction Code 3 - 1 and 6 - 1 Light
Exhaust Brake
2s 2s Indicator Light
Code 3 - 1 Code 6 - 1 Code 3 - 1 Code 6 - 1

SHTS161090200018
3. ERASE THE MALFUNCTION CODE MEMORY.

(1) 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) Wait 5 seconds and connect the diagnosis monitor.
(3) This time, only the present malfunction codes are displayed.
(4) Compare the two sets of codes you get to determine which are
the present codes and which are the past one's.
SHTS161090200019
MALFUNCTION CODE TABLE
CODE MALFUNCTION CONTENTS PROBABLE CAUSE
1 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
Abnormality of coolant temperature

4-1 Harness disconnection, short circuit or abnormality of sensor
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
12-2 Abnormality of CBCS Harness disconnection, short circuit or abnormality of magnetic

13-1 Abnormality of exhaust brake valve
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 Harness disconnection, short circuit or abnormality of sensor
16-3 Abnormality of pre-stroke learning
Abnormality of pre-stroke power sup-

16-4 Harness disconnection, short circuit
ply
Abnormality of pre-stroke power sup-

16-6 Harness disconnection, short circuit or abnormality of relay
ply relay control circuit
22-1 Abnormality of ECU Abnormality of ECU
Engine speed is 2,990 r/min or more or abnormality of engine

23-1 Engine overrun
speed sensor
Engine coolant temperature is 115°C {239°F} or abnormality of

24-1 Engine over heat
coolant temperature sensor
.
2A&0A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧟ᤨ㧡ಽ
ENGINE SPEED SENSOR NO PULSE (MALFUNCTION CODE: 2-1)

EN1610902F200003
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:
.
ABNORMALITY OF ENGINE SPEED SENSOR

(MALFUNCTION CODE: 3-1)
EN1610902F200004
1. CHECK THE CONTINUITY BETWEEN TERMINALS.

(1) Set the starter switch to "LOCK" and disconnect the 26 pin con-
NE+
nector of ECU.
(2) Measure the resistance between NE+ and NE- terminals of 26 pin
connector (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11 12 13 Standard: APPROX. 1.8kΩ at 20°C {68°F}
14 15 16 17 18 19 20 21 22 23 24 25 26
NE-
SHTS161090200020
.
NO
Proceed to 3
YES
2. RECHECK THE MALFUNCTION CODE.

(1) Connect the 26 pin connector and erase the past malfunction
code.
(2) Check the malfunction code with the diagnosis monitor.
Standard: code 1 (Normal function)
.
NO
• Bad contact of ECU connectors
• Abnormality of ECU
YES • Abnormality of harness (Short circuit)
Normal
3. CHECK THE ENGINE SPEED SENSOR.

(1) Disconnect the connectors of engine speed sensor.
NE- NE+ (2) Measure the resistance between NE+ and NE- terminals of sen-
sor connector (Sensor harness side).
Standard: APPROX. 1.8kΩ at 20°C {68°F}
SHTS161090200021
.
NO
Abnormality of sensor
YES
• Harness disconnection or short circuit

• Bad contact of connectors
ABNORMALITY OF COOLANT TEMPERATURE SENSOR

EN1610902F200005
1. CHECK THE RESISTANCE BETWEEN TERMINALS.

(1) Set the starter switch to "LOCK".
THW+
(2) Disconnect the 16 pin connector of ECU.
(3) Measure the resistance between THW+ and THW- terminals of
16 pin connector (Chassis harness side).
1 2 3 4 5 6 7 8
HINT
9 10 11 12 13 14 15 16
Measure the resistance under any condition of the following.
Standard:
THW- APPROX. 2.4kΩ at 20°C {68°F}
APPROX. 1.5kΩ at 40°C {104°F}
APPROX. 870Ω at 60°C {140°F}
SHTS161090200022
APPROX. 530Ω at 80°C {176°F}
.
NO
Proceed to 2
YES
• Abnormality of ECU connectors
2. CHECK THE COOLANT TEMPERATURE SENSOR.

(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals (Sensor side).
HINT
Standard:
APPROX. 2.4KΩ at 20°C {68°F}
APPROX. 870Ω at 60°C {140°F}
APPROX. 530Ω at 80°C {176°F}
SHTS161090200023
NO
Abnormality of coolant temperature sensor
YES

• Abnormality of connectors
.
ABNORMALITY OF STARTER SWITCH (MALFUNCTION CODE: 6-1)

EN1610902F200006
! CAUTION
Make sure that transmission is in neutral position.
1. CHECK THE VOLTAGE BETWEEN TERMINALS.

(1) Set the starter switch to "LOCK" and disconnect the 16 pin and 22
pin connectors of ECU.
(2) Measure the voltage between ST and MGD1 terminals of 22 pin
connector, between ST terminal of 22 pin connector and CGD1
one of 16 pin one (Chassis harness side)
ST
Standard:
Starter switch "LOCK": 0V
1 2 3 4 5 6 7 8 9 10 11 Starter switch "START": 24V
12 13 14 15 16 17 18 19 20 21 22
+ -
MGD1
CGD1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
SHTS161090200024
.
NO
Abnormality of harness
YES
.
ABNORMALITY OF BOOST PRESSURE SENSOR

EN1610902F200007

(1) Set the stater switch to "ON" (ECU connectors remain connected
PIM and the engine is stopped).
(2) Measure the voltage between PIM and PIM- terminals of 16 pin
8 7 6 5 4 3 2 1
connector.
+ - Standard: 0.2-4.8V
16 15 14 13 12 11 10 9
PIM-
ECU VIEW
SHTS161090200025
.
NO
Proceed to (3)
YES
(3) Set the starter switch to "LOCK" and disconnect the connector of
boost pressure sensor.
GND VCC
(4) Set the starter switch to"ON" and measure the voltage between
VCC and GND Terminals (Chassis harness side).
Standard: 4.5V or more
SHTS161090200026
.
NO
Proceed to 2 - (4)
YES

(1) Set the stater switch to "LOCK".
PIM 1 2 3 4 5 6 7 8
(2) Disconnect the 16 pin connector of ECU and connector of boost
9 10 11 12 13 14 15 16
pressure sensor.
(3) Measure the resistance between PIM terminal of 16 pin connector
SIG and SIG connector of boost pressure sensor (Chassis harness
side).
Standard: 2Ω or less
SHTS161090200027
.
NO
YES
• Abnormality of boost pressure sensor


(5) Disconnect the 16 pin connector of ECU and connector of boost
PIM+ 1 2 3 4 5 6 7 8
pressure sensor.
9 10 11 12 13 14 15 16
(6) Measure the resistance between PIM+ terminal of 16 pin connec-
tor and VCC terminal of boost pressure sensor (Chassis harness
VCC side), PIM- terminal of 16 pin connector and GND terminal of
boost pressure sensor (Chassis harness side).
SHTS161090200028
PIM- 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
GND
SHTS161090200029
.
NO
YES
.
ABNORMALITY OF CBCS (MALFUNCTION CODE: 12-2)

EN1610902F200008

(2) Disconnect the 26 pin connector and 16 pin connector of ECU.
(3) Set the starter switch to "ON" (The engine is stopped).
(4) Measure the resistance between WGV1 terminal of 26 pin con-
WGV1
nector and CGD1 one of 16 pin one (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11 12 13 Standard: 19V or more
14 15 16 17 18 19 20 21 22 23 24 25 26
CGD1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
SHTS161090200030
.
NO
Proceed to 2
YES

(2) Disconnect the 16 pin connector of ECU and the connector of
waste gate valve.
(3) Measure the resistance between WGV1 terminal of 16 pin con-
nector and WGV- terminal of waste gate valve connector (Chas-
WGV- sis harness side).
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
WGV1
SHTS161090200031
.
NO
YES
Proceed to 3
3. CHECK THE WASTE GATE MAGNETIC VALVE.

(2) Disconnect the connector of waste gate magnetic valve.
(3) Measure the resistance between terminals (Magnetic valve side).
Standard: 35-45Ω
SHTS161090200032
.
NO
Abnormality of waste gate magnetic valve
YES
• Abnormality of FUSE
• Abnormality of harness between waste gate valve and FUSE
.
ABNORMALITY OF EXHAUST BRAKE (MALFANCTION CODE: 13-1)

EN1610902F200009

(2) Disconnect the 26 pin and 16 pin connectors of ECU.
(3) Set the starter switch and exhaust brake switch to "ON". (The
engine is stopped.)
EBMV
(4) Measure the voltage between EBMV terminal of 26 pin connector
1 2 3 4 5 6 7 8 9 10 11 12 13 and CGD1 one of 16 pin one (Chassis harness side).
14 15 16 17 18 19 20 21 22 23 24 25 26 Standard: 19V or more
CGD1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
SHTS161090200033
.
NO
Proceed to 2
YES
2. CHECK THE EXHAUST BRAKE MAGNETIC VALVE.

(2) Disconnect the connector of exhaust brake magnetic valve.
(3) Measure the resistance between terminals (magnetic valve side).
Standard: 35-45Ω
SHTS161090200032
.
NO
Abnormality of exhaust brake magnetic valve
YES
• Abnormality of harness
ABNORMALITY OF RACK SENSOR (MALFUNCTION CODE: 14-1)

EN1610902F200010

(2) Disconnect the 26 pin connector of ECU and 4 pin connector of
injection pump.
(3) Measure the resistance between terminals of 26 pin connector
RWML
and 4 pin connector of injection pump (Chassis harness side).
NOTICE
1 2 3 4 5 6 7 8 9 10 11 12 13
Combinations of terminals (26 pin connector-4 pin connector):
14 15 16 17 18 19 20 21 22 23 24 25 26
RWGD-GND, RWML-MDL, RWOC-OSC.
RWOC
RWGD
MDL
1 2
3 4
GND
OSC
SHTS161090200034
.
NO
Abnormality of harness and connectors
YES
• Abnormality of injection pump

.
ABNORMALITY OF PRE-STROKE SENSOR

EN1610902F200011

(3) Measure the resistance between PMDL and PGND, PMDL and
POSC terminals of 26 pin connector (Chassis harness side).
Standard: 4-9Ω
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
SHTS161090200035
.
NO
Proceed to 2
YES
2. CHECK THE PRE-STROKE SENSOR.

(1) Disconnect the connector of pre-stroke sensor.
PGND (2) Measure the resistance between PMDL and PGND, PMDL and
PMDL POSC terminals of sensor connector (Sensor side).
Standard: 4-9Ω
POSC
SHTS161090200036
.
NO
Abnormality of pre-stroke sensor
(Injection pump)
YES

ABNORMALITY OF PRE-STROKE F/B (MALFUNCTION CODE: 16-2)

EN1610902F200012

PS+
(3) Measure the resistance between PS+ and PS- terminals of 26 pin
connector (Chassis harness side).
1 2 3 4 5 6 7 8 9 10 11 12 13 Standard: 2-4Ω
14 15 16 17 18 19 20 21 22 23 24 25 26
PS-
SHTS161090200037
.
NO
Proceed to 2
YES
• Malfunction of pre-stroke actuator

• Malfunction of injection pump link mediations
2. CHECK THE PRE-STROKE ACTUATOR.

(1) Disconnect the connector of pre-stroke actuator.
PS- PS+ (2) Measure the resistance between PS+ and PS- terminals of actua-
tor connector (Actuator side).
Standard: 2-4Ω
SHTS161090200038
.
NO
Abnormality of pre-stroke actuator
(Injection pump)
YES

ABNORMALITY OF PRE-STROKE LEARNING

EN1610902F200013
1. Check that the malfunction code 16-1 is being displayed

together with 16-3 in the order at the same time.
SHTS161090200039
.
NO
Abnormal adjustment of pre-stroke sensor
(Injection pump)
YES
Make sure to inspect it in accordance with the contents of mal-

function code 16-1.
.
ABNORMALITY OF PRE-STROKE POWER SUPPLY

EN1610902F200014

PSP+
(3) Set the starter switch to "ON"(The engine is stopped).
(4) Measure the voltage between PSP+ and PSGD terminals of 26
1 2 3 4 5 6 7 8 9 10 11 12 13 pin connector (Chassis harness side).
+ -
14 15 16 17 18 19 20 21 22 23 24 25 26 Standard:
Starter switch "ON": 24V
PSGD
SHTS161090200040
.
NO
Proceed to 2
YES
2. CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER

SUPPLY CUT RELAY).
(2) Disconnect the pre-stroke power supply relay.
S- B (3) Measure the resistance between B and NC terminals.
NC
S+
SHTS161090200041
.
NO
Abnormality of pre-stroke power supply relay
YES

.
ABNORMALITY OF PRE-STROKE POWER SUPPLY RELAY

(POWER SUPPLY CUT RELAY) CONTROL CIRCUIT
EN1610902F200015

PSRY (2) Disconnect the 26 pin connector of ECU.
(3) Set the starter switch to "ON" (The engine is stopped).
(4) Measure the voltage between PSRY and PSGD terminals of 26
1 2 3 4 5 6 7 8 9 10 11 12 13
+ -
pin connector (Chassis harness side).
14 15 16 17 18 19 20 21 22 23 24 25 26
Standard:
Starter switch "ON": 24V
PSGD
SHTS161090200042
.
NO
Proceed to 2
YES
2. CHECK THE PRE-STROKE POWER SUPPLY RELAY (POWER

SUPPLY CUT RELAY).
(2) Disconnect the pre-stroke power supply relay.
S- (3) Measure the resistance between S+ and S- terminals.
Standard: 390-490Ω
S+
SHTS161090200043
.
NO
Abnormality of pre-stroke power supply relay
YES

(1) Set the starter switch "LOCK".
(2) Disconnect the pre-stroke power supply relay and 26 pin connec-
tor of ECU.
(3) Measure the resistance between PSRY terminal of 26 pin con-
nector (Chassis harness side) and S- terminal of relay connector
(Relay panel side).
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
SHTS161090200044
.
NO
• Harness disconnection
YES
Bad contact of connectors
ABNORMALITY OF ECU (MALFUNCTION CODE: 22-1)

EN1610902F200016
1. After the starter switch is positioned on the 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.
SHTS161090200039
.
NO
The same code is being shown up: Malfunction
of ECU.
YES
Normal (Temporary malfunction because of radio interference

noise)
.
ENGINE OVERRUN (MALFUNCTION CODE: 23-1)

EN1610902F200017
1. The malfunction code will be displayed, once detected over

2,990 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 2,790 r/min.
NOTICE
The malfunction code is aimed not for detecting the engine over-
run 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)

EN1610902F200018
1. CHECK THE COOLANT TEMPERATURE SENSOR.

(1) Disconnect the connector of coolant temperature sensor.
(2) Measure the resistance between terminals.
HINT
Standard:
APPROX. 870Ω at 60°C {140°F}
APPROX. 530Ω at 80°C {176°F}
SHTS161090200023
NO
Abnormality of coolant temperature sensor
YES
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 nor-
mal control volume when it descends less than 105°C {221°F}.
.
ECU CHASSIS SIDE CONNECTOR PIN ASSIGNMENT

EN1610902F200019
26 PIN CONNECTOR
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 CHASSIS HARNESS
No. SIGNAL CONNECTING DESTINETION No. SIGNAL CONNECTING DESTINETION
1 — 14 WGV1 Waste gate magnetic valve
2 — 15 EBMV Exhaust brake magnetic valve
3 — 16 —
4 MVB Power source VB 17 EBLP Exhaust brake indicator light
5 RWML Rack sensor (Signal) 18 —
6 RWOC Rack sensor (Power source) 19 RWGD Rack sensor ground
7 PMDL Pre-stroke sensor (Signal) 20 PSLD Pre-stroke sensor shield
8 PGND Pre-stroke sensor ground 21 POSC Pre-stroke sensor
9 — 22 —
10 NE+ Engine speed sensor + 23 NE- Engine speed sensor -
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 actuator-

22 PIN CONNECTOR
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
1 — 12 —
2 VB1 Power source (ECU main relay) 13 MGD1 Ground
3 MRL1 ECU main relay control 14 —
4 DGSW Diagnosis monitor 15 IDLE Exhaust brake accelerator switch
5 — 16 —
6 — 17 EBSW Exhaust brake switch
7 ST Power source (Starter switch) 18 —
8 — 19 BALP Boost pressure warning light
9 CE/G Check engine light 20 —
10 SSWS Power source (Fuse E/G2) 21 —
11 — 22 —
16 PIN CONNECTOR
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 PIM- Boost pressure sensor - 9 —
2 PIM Boost pressure sensor (signal) 10 —
3 PIM+ Boost pressure sensor + 11 —
4 — 12 —
5 — 13 —
6 THW+ Coolant temperature sensor + 14 THW- Coolant temperature sensor -
7 — 15 —
8 CGD1 Magnetic valve ground 16 —
12 PIN CONNECTOR
1 2 3 4 5 6
7 8 9 10 11 12
1 — 7 —
2 — 8 —
3 — 9 —
4 — 10 —
5 — 11 CASE ECU case ground
6 TACH Tachometer 12 —

EN1610902H100001
1. REMOVE THE SPEED SENSOR.

(1) Disconnect the connector (Black), loosen the lock nut using two
wrenches.
(2) Remove the speed sensor from the timing gear case cover.
1. INSTALL THE SPEED SENSOR.

(1) 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 opera-
tion if these adjustments are neglected.
SHTS161090200049 (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 sen-
sor 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.}).
(5) 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⋅in.}
SHTS161090200050
%1.12*10HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧡㧤ಽ
Pub. No. S5-YP11E07A ’03-5

S5-YP11E07B ’06-11
%1.12*10HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧡㧤ಽ

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(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧡㧞ಽ

Applicable for P11C engine

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MANUAL NO. S5-YP11E07B

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

AIR COMPRESSOR EN13-001

ENGINE P.T.O. (POWER TAKE-OFF) EN14-001

FUEL CONTROL DN02-001

INDEX: ENGINE GROUP 1/2

WORKSHOP AIR INTAKE SYSTEM

MANUAL EXHAUST SYSTEM

FUEL INJECTION PUMP

ENGINE P.T.O. (POWER TAKE-OFF)

All rights reserved. This manual may not be

INDEX: ENGINE GROUP 2/2

CAB EQUIPMENT CONTROL

GENERAL INTRODUCTION (ENGINE) GN01–1

GENERAL INTRODUCTION (ENGINE)

GENERAL INTRODUCTION (ENGINE) ...GN01-2

GN01–2 GENERAL INTRODUCTION (ENGINE)

GENERAL INTRODUCTION (ENGINE)

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

GENERAL INTRODUCTION (ENGINE) GN01–3

2. If the engine of the towed vehicle is defective, make sure that

GN01–4 GENERAL INTRODUCTION (ENGINE)

This workshop manual is designed as a guide for servicing the vehi-

TROUBLESHOOTING is dealt with in each chapter.

SPECIAL TOOL are dealt with in each chapter.

TIMING GEAR AND CAMSHAFT

GENERAL INTRODUCTION (ENGINE) GN01–5

1 Gasket 8 Main idle gear

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

• ENGINE SERIAL NUMBERS.

GN01–6 GENERAL INTRODUCTION (ENGINE)

SPECIFIED TORQUE FOR

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

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

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

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

M12 x 1.25 108 {1,100, 79.6} 136 {1.390, 100.5}

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

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

M14 x 2 154 {1,570, 113.6} 199 {2.030, 146.8}

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

Diameter x Pitch No Mark

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

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

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

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

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

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

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

(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧜᦬㧟㧝ᣣ‫ޓ‬Ἣᦐᣣ‫ޓ‬ඦᓟ㧞ᤨ㧡㧞ಽ