service repair manual

1. WORKSHOP MANUAL
ENGINE
CHASSIS
BODY
ELECTRICAL
TRUCK
FA.FB
2002
HINO DIESEL TRUCKS (U.S.A.), INC.

2. FOREWORD
This workshop manual has been prepared to provide information covering repairs on 2002 FA and FB series
Hino trucks.
To use Hino trucks for years, smoothly, safely, and economically without trouble, it is important to perform
inspections.
Maintenance required to be performed is the responsibility of the owner. Some recommended repairs of your
truck are mentioned.
When making any repair of your truck, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s and Driver’s Manual.
All information and specifications in this manual are based upon the latest product information available at the
time of printing.
HINO DIESEL TRUCKS (U.S.A.),INC. reserves the right to make changes at any time without prior notice.

3. ©
All rights reserved. This manual may not be
reproduced or copied in whole or in part, without
the written consent of HINO DIESEL TRUCKS
(U.S.A.),INC.
WORKSHOP
MANUAL
GENERAL INTRODUCTION 1
ENGINE 3
CLUTCH 5
CLUTCH CONTROL 6
TRANSMISSION 7
TRANSMISSION CONTROL 8
PROPELLER SHAFT 9
REAR AXLE 10
FRONT AXLE 11
STEERING 12
SERVICE BRAKE 13
PARKING BRAKE 14
EXHAUST BRAKE 15
WHEELS & TIRES 16
SUSPENSION 17
CHASSIS FRAME 18
CAB 19
ELECTRICAL EQUIPMENT 20
ALTERNATOR 21
STARTER 22
AIR COMPRESSOR 23
TURBOCHARGER 51
POWER STEERING 67
AUTOMATIC TRANSMISSION 75
ANTILOCK BRAKE SYSTEM
TOTAL ELECTRONICS SYSTEM 78
SERVICE SPECIFICATIONS S
WIRING DIAGRAMS W
© 2002 HINO DIESEL TRUCKS (U.S.A.),INC.
77
ssssssss1 MENU

4. GENERAL PRECAUTIONS
Some recommended and standard maintenance services for your truck are mentioned in this section.
When performing maintenance on your truck be careful not to get injured by improper work.
Improper or incomplete work can cause a malfunction of the truck which may result in personal injury and/
or property damage. If you have any questions about performing maintenance, please consult your Hino
dealer.
WARNING
When working on your truck, observe the following general precautions to prevent per-
sonal injury and/or property damage in addition to the particular NOTES or WARNINGS.
Most threaded fasteners are metric.
Be careful not to mix the threaded fasteners of the inch type with HINO metric fasteners.
q Always wear safety glasses or goggles to protect your eyes.
q Remove rings, watches, ties, Ioose hanging jewelry and loose clothing before start-
ing work on the truck.
q Bind long hair securely behind the head.
q When working on the truck, apply the parking brake firmly, place the transmission
shift lever in neutral or “N”, and block the wheels.
q Be sure to disconnect the cable from the negative (–) terminal of the battery before
servicing.
q 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.
q To avoid serious burns, keep yourself away from hot metal parts such as the engine,
exhaust manifold, radiator, muffler, exhaust pipe and tail pipe.
q Do not smoke while working on the truck since fuel and gases from the battery are
flammable.
q Take utmost care when working on the battery. It contains corrosive sulfuric acid.
q 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.
q Read carefully and observe the instructions placed on the jack when using it.
q Use safety stands to support the truck whenever you need to work under it. It is
dangerous to work under a truck supported only by a jack.
q When the cab is raised, always lock the cab stopper stay with the safety pin. When
the cab is lowered, always insert and lock the stopper pin.
q If it is necessary to run the engine after the cab is raised (tilted), make sure that the
parking brake is firmly applied, the wheels are blocked, and the transmission shift
lever is in “Neutral” before starting the engine.
q Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.
GENERAL PRECAUTIONS 1-1

5. q Keep yourself, your clothing and your tools away from moving parts such as the cooling
fan and V-belts when the engine is running.
q Be careful not to damage lines and hoses by stepping or remain standing (holding your
feet) on them.
q Be careful not to leave any tool in the engine compartment. The tool may be hit by moving
parts and can cause personal injury.
TOWING
When being towed, always place the transmission shift lever in Neutral and release the parking brake completely.
In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block
under the frame near the No. 1 crossmember when attaching the towing chain. Never lift or tow the vehicle if the
chain is in direct contact with the bumper.
1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground remove the rear axle shafts to
protect the transmission and differential gears from being damaged. The hub openings should be covered
to prevent the loss of axle lubricant or the entry of dirt or foreign matter.
The above-mentioned precautions should be observed for vehicles equipped with either manual or auto-
matic transmission, and even for 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, fasten and secure the steering wheel in a
straight-ahead position.
GENERAL PRECAUTIONS 1-2

6. Models FA and FB GENERAL INTRODUCTION 1-1
1 page 1
GENERAL INTRODUCTION
Models FA and FB
CHAPTER 1
1
IDENTIFICATION INFORMATION................................................1- 2
1-217E-05
1 INDEX

7. Models FA and FB1-2 GENERAL INTRODUCTION
1 page 1
Fig. 1
IDENTIFICATION INFORMATION
1. VEHICLE IDENTIFICATION NUMBER
VEHICLE IDENTIFICATION NUMBER (VIN) is comprised of 17 digits and letters. The VIN plate, as
shown in Fig. 1, is affixed to the left-side door step of the cab.
The following is an explanation of the items that are listed on the VIN plate.
1) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.
2) P.S.CODE AND VEHICLE COMPONENTS
CODE
SERVICE BRAKE CONTROL CODE PARKING BRAKE CONTROL CODE
V : VACUUM SERVO C : ACTING ON TRANSMISSION OUTPUT SHAFT
A : AIR OVER HYDRAULIC W: ACTING ON REAR WHEEL
F : FULL AIR
J H B F B 4 J G 4 2 1 S 1 0 0 0 1
SA-HC5
MODEL
SERIES
FB4J
FD2J
FE2J
FF2J
SG2J
SG1J
P.S.
CODE
CLUTCH
SIZE
TRANS-
MISSION
SERIES
350 MM
380 MM
380 MM
350 MM
350 MM
350 MM
-
-
-
-
-
-
LF05S
MF06S
LJ06S
LJ06S
LJ06S
LCT2400
LF06S
AT542
TRANSMISSION RATIO
1ST 6TH5TH4TH3RD2ND
7.46
3.45
6.09
3.51
6.89
3.51
6.89
3.51
6.89
3.49
7.39
3.49
4.18
2.25
3.85
1.90
4.27
1.90
4.27
1.90
4.27
1.86
4.75
1.86
2.42
1.41
2.34
1.44
2.60
1.44
2.60
1.49
2.60
1.41
3.07
1.41
1.42
1.00
1.42
1.00
1.56
1.00
1.56
1.00
1.56
1.00
1.93
1.00
1.00
-
1.00
0.74
1.00
0.74
1.00
0.74
1.00
0.75
1.34
0.75
-
-
0.76
-
0.77
-
0.77
-
0.77
-
1.00
-
SH13-2
SH16-1
SH16-1
SH16-1
SH16-1
SH16-1
SH16-1
SH14-1
SH14-1
SH14-1
SH14-1
SH13-2
3.36
3.36
5.12
4.33
5.12
5.85
5.42
5.85
5.42
5.42
4.10
5.42
A
A
A
A
A
A
A
A
F
F
F
REAR
AXLE
SERIES
PARK-
ING
BRAKE
REAR
AXLE
RATIO
SERVICE
BRAKE
F
C
C
C
C
C
C
C
W
W
W
C
W
FA4J
350 MM
-
LF05S
AT542
7.46
3.45
4.18
2.25
2.42
1.41
1.42
1.00
1.00
-
-
-
SH13-2
SH13-2
3.36
3.36
V
V
C
C
SA-HC5
SA-RN5
SA-QN5
SA-US5
SA-TS5
SA-RS5
SA-PS5
SA-RF5
SA-QF5
SA-TF5
SA-SF5
SA-JC5
SA-HC5
SA-JC5
RT8709 9.16 6.53 4.80 3.57 2.56 1.83 SH16-1 4.10 F WSA-VS5 380 MM
LCT2400
LCT2000
MD3060P
MD3060P

8. Models FA and FB GENERAL INTRODUCTION 1-3
1 page 1
CODEDESCRIPTION
ANEWLETTER
WILLBEALLOTED
ATEVERYMAJOR
MODIFICATION
CODE
1
2
3
4
B
ASSEMBLYPLANT
HINOMOTORS,LTD.
HINOPLANT,JAPAN
HINOAUTOBODY,LTD.
YOKOHAMAPLANT,JAPAN
HINOAUTOBODY,LTD.
KANAZAWAPLANT,JAPAN
BURNSPHILP(SOUTHSEA)CO.,
LTD.,AMERICANSAMOA
S
T
U
Z
...
CODEMANUFACTURERMODELDESCRIPTION
4JHINOMOTORS,LTD.J05C-TD5.3LITERS,DIESEL168HP
8.0LITERS,DIESEL200HP
8.0LITERS,DIESEL252HP
J08C-TP
J08C-TR
HINOMOTORS,LTD.
HINOMOTORS,LTD.
2J
1J
CODELENGTH(mm)
C2,920
D
E
G
H
J
P
K
M
R
S
3,200
3,420
3,860(forFA,FB)
4,600
5,050
4,280
4,190
5,800
6,220
5,530
CODEYEARCODEYEAR
W1998
Y
2
1
3
X
4
6
5
8
7
9
2001
2000
2002
1999
2003
2005
2007
2004
2006
2009
2008
CODEMANUFACTURERMAKETYPE
JHAHINOMOTORS,LTD.HINO
JHB
JHC
JH8
HINO
HINO
HINO
HINOMOTORS,LTD.
HINOMOTORS,LTD.
HINOMOTORS,LTD.
TRUCK
INCOMPLETEVEHICLE
BUS
INCOMPLETEVEHICLEASSEMBLEDBY
BURNSPHILP(SOUTHSEA)CO.,LTD.
CODE
FA
FB
FD
FE
FF
SG
LINE&CAB/BODYTYPE
SERIES
GVWROROVERALLLENGTH
BRAKE
SYSTEMS
FORWARDCONTROLTYPE
TRUCK
6,350kg-7,030kg
[14,001-15,500(lbs.)](CLASS4)
HYDRAULIC
AIROVER
HYDRAULIC
AIROVER
HYDRAULIC
AIROVER
HYDRAULIC
FULLAIR
(CLASS6)
(CLASS6)
(CLASS7)
(CLASS7)
(CLASS5)
7,258kg-8,165kg
[16,001-18,000(lbs.)]
11,794kg-13,608kg
[26,001-30,000(lbs.)]
13,609kg-14,968kg
[30,001-33,000(lbs.)]
FORWARDCONTROLTYPE
TRUCK
FORWARDCONTROLTYPE
TRUCK
FORWARDCONTROLTYPE
TRUCK
FORWARDCONTROLTYPE
TRUCK
FORWARDCONTROLTYPE
TRUCK
MANUFACTURER
MAKE,MODEL
LINE&CAB/BODYTYPE,
SERIES,BRAKESYSTEMENGINEMODELWHEELBASE
CHECKDIGIT
MODEL
YEAR
ASSEMBLY
PLANT
MODIFICATION
SEQUENTIALNUMBER
10001S1GJ4BFBHJ
WMIVDSC/D
(17)(16)(15)(14)(13)(12)(11)(10)(9)(8)(6)(5)(4)(3)(2)(1)
VEHICLEIDENTIFICATIONNUMBER(VIN)STRUCTURE
(7)
VIS
MITSUISEIKIKOGYOCO.,LTD
KAWASHIMAPLANT,JAPAN
AIROVER
HYDRAULIC
24
8,845kg-10,433kg
[19,501-23,000(lbs.)]
10,434kg-11,793kg
[23,001-26,000(lbs.)]
3,780(forFD,FE)

9. Models FA and FB1-4 GENERAL INTRODUCTION
1 page 1
Fig. 4
Fig. 3 SM1-J014
3. ENGINE NUMBER
The Engine Number, as shown in Fig. 3 is on the right
side of the engine block.
ENGINE MODEL: J-SERIES
ENGINE
NUMBER
CHASSIS NUMBER
4. CHASSIS NUMBER
The Chassis Number is displayed on the left siderail of
the frame near the front axle, as shown in Fig. 4.
2. VEHICLE CERTIFICATION LABEL
The Vehicle Certification Label, as shown in Fig. 2, is
affixed to the left hand side door of the cab. The name of
manufacturer, production year and month, and verifica-
tion of items which are in conformity with Federal Motor
Vehicle Safety Standards are displayed.
Fig. 2 SM1-060
– EXAMPLE –

10. 3
3-229E-04
ENGINE
Model: J05C-TD
CHAPTER 3
ENGINE 3-1-1ModelJ05C-TD
TROUBLESHOOTING...............................................................3- 1-3
SPECIAL TOOLS ......................................................................3- 2-1
ENGINE OVERHAUL CRITERIA ..............................................3- 3-1
DISMOUNTING THE ENGINE ASSEMBLY ..............................3- 4-1
REMOVAL OF THE ENGINE COMPONENT PARTS ...............3- 5-1
CAMSHAFT HOUSING AND CYLINDER HEAD ......................3- 6-1
CRANKSHAFT FRONT END, OIL PAN, FLYWHEEL AND
FLYWHEEL HOUSING ..............................................................3- 7-1
TIMING GEAR ...........................................................................3- 8-1
PISTON, CRANKSHAFT AND CYLINDER BLOCK .................3- 9-1
LUBRICATING SYSTEM ...........................................................3-10-1
COOLING SYSTEM...................................................................3- 11-1
FUEL SYSTEM ..........................................................................3-12-1
AIR INTAKE AND EXHAUST SYSTEM ....................................3-13-1
ENGINE CONTROL SYSTEM ...................................................3-14-1
ELECTRICAL PARTS................................................................3-15-1
INJECTION PUMP SHAFT ASSEMBLY(FA), AIR
COMPRESSOR(FB) AND POWER STEERING PUMP ............3-16-1
INSTALLATION OF THE ENGINE COMPONENT PARTS .......3-17-1
ENGINE TUNE-UP ....................................................................3-18-1
MOUNTING THE ENGINE ASSEMBLY ....................................3-19-1
LIQUID GASKET AND APPLICATION POINTS .......................3-20-1
1 INDEX

11. Model J05C-TD ENGINE 3-3-1
1 page 1
SM3-J580
Fig. 1
GENERAL
WARNING
The following items should be observed to prevent
injury to yourself and others when servicing the
engine or vehicle;
q Stop the engine and keep the engine off during
checks and adjustments.
q Place the starter key in the “LOCK” position.
q Leave the engine stop knob pulled out fully.
(For model equipped with manual engine stop
control)
q Place the transmission shift lever in “NEUTRAL”.
q Apply the parking brake firmly.
q Block the wheels.
ENGINE OVERHAUL CRITERIA
FACTORS TO DETERMINE THE ENGINE
OVERHAUL
1. LOW COMPRESSION PRESSURE
(1) Before measurement
1. Charge the battery completely.
2. Set the valve clearance to the correct value.
Intake : 0.30 mm (0.0118 in.)
Exhaust : 0.45 mm (0.0177 in.)
(when engine is cold)
NOTE: Refer to page 3-18-2.
3. Idle the engine (to 80 °C {176°F}).
4. While the starter switch is at the LOCK position, dis-
connect the engine stop motor.
5. Remove all nozzle holders.
NOTE: Refer to page 3-6-3.
6. Remove the air cleaner hose.

12. Model J05C-TD3-3-2 ENGINE
1 page 1
Fig. 3
SM3-J580
SM3-J581
Fig. 2
(2) Measurement
1. Insert the gauge adaptor into the nozzle holder hole.
Special tool: Compression gauge adaptor
(09552 - 1090)
(09552 - 1060)
(09552 - 1030)
2. Run the engine with the starter and measure the
compression pressure.
NOTE: Do not operate the starter for more than 15 sec-
onds.
3. Measure the compression pressure of each cylinder.
NOTE: Do not allow gas leakage from the seal face.
Unit: kg/cm2
(lb/sq.in.)
Assembly standard Assembly limit
Difference among Engine speed
individual cylinders (rpm)
35 - 38 (498 - 540) 28 (398) Less than 3 (43) 180 - 220
(3) After measurement
1. Install the removed parts.
WARNING
Do not connect the electric harness with the en-
gine stop motor while the engine starter key is at
ON position as this may operate the engine stop
motor instantaneously and the link lever of the
engine stop motor and the engine stop lever of the
fuel injection pump will move, resulting in your
fingers caught by the lever.

13. Model J05C-TD ENGINE 3-3-3
1 page 1
SM3-J024
OIL
Fig. 4
Fig. 5
2. DECREASED OIL PRESSURE
Check the oil pressure warning lamp when the oil and
coolant temperature is hot (about 80 °C {176 °F})
a. If the warning lamp is lit, 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.
d. Measure the oil pressure at oil temperature 103°C
(217°F).
Standard oil pressure:
At 2,500 (rpm) 5.6 kg/cm2
(79.63 lb/sq.in.)
Service limit: At idle speed 0.5 kg/cm2
(7.11 lb/sq.in.)
3. OTHER FACTORS
a. Blow-by gas increases.
b. Engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.
S.A.E.
ATMOSPHERIC TEMPERATURE
GRADE
-10 0 32 50 70 90 100 ˚F
-23 -18 0 10 21 32 39 ˚C
40
30
20W/20
15W/40
10W/30

14. Model J05C-TD ENGINE 3-4-1
1 page 1
4. DISCONNECT THE PARKING BRAKE CABLE (1).
1. Remove the center console.
2. Disconnect the parking brake cable at the lever.
SM3-J500
Fig. 1
SM3-J580
Fig. 2
SM3-J582
Fig. 3
SM3-J583
Fig. 4
Fig. 5
SM3-J584
DISMOUNTING THE ENGINE ASSEMBLY
1. BLOCK THE WHEELS OF THE VEHICLE.
1. Park the vehicle on level ground.
2. Block the wheels.
2. DISCONNECT THE ENGINE CONTROLAND THE STOP
CABLE.
1. Set the starter switch to the ON position.
2. Disconnect the wires of the engine stop motor at the
connector.
3. Set the starter switch to the LOCK position.
4. Tilt up the cab.
5. Disconnect the engine control and the stop cable at
the injection pump.
3. DISCONNECT THE NEGATIVE TERMINAL OF THE
BATTERY.
WARNING
Always disconnect the battery cable when servic-
ing the engine.

15. Model J05C-TD3-4-2 ENGINE
1 page 1
SM3-J585
Fig. 6
SM3-J586
Fig. 7
SM3-J587
Fig. 10
SM3-J589
Fig. 11
SM3-J791
Fig.9
Fig.8
CLOSE
5. OVER-TILT THE CAB
NOTE: Refer to CAB in CHAPTER 19.
6. DRAIN THE COOLANT AND ENGINE OIL.
WARNING
To avoid the danger of burns, do not drain the en-
gine oil and coolant while the engine and radiator
are still hot.
1. Drain the coolant from the radiator. (Fig. 7)
NOTE: The coolant can be drained more easily by remov-
ing the filler cap.
2. Drain the coolant from the cylinder block. (Fig. 8)
Coolant capacity: 15 L (15.85 US qt)
17 L (17.96 US qt)
(with transmission oil cooler only)
3. Drain the engine oil through the drain plug.
Engine oil capacity: 10.0 L (10.57 US qt)
7. DISCONNECT THE POWER STEERING LINES AT THE
GEAR UNIT.
NOTE: Place a container under the gear unit.
8. DISCONNECT THE PARKING BRAKE CABLE (2)
1. Remove the bracket behind the cab, then pull out
the parking brake cable.
NOTE: Pull out the cable straight and slowly. If pulled out
forcefully, the gasket will crack. Cracked cables
must be replaced with new ones.
DRAINING PLUG
DRAINING PLUG
OVER-TILTING
POSITION
NORMAL POSITION
DRAINING PLUG
OPEN

16. Model J05C-TD ENGINE 3-4-3
1 page 1
SM3-J591
Fig. 13
SM3-J592A
Fig. 14
SM3-J593
Fig. 15
SM3-J590
Fig. 12
SM3-J594
Fig. 16
9. DISCONNECT THE SPEEDOMETER CABLE AT THE
TRANSMISSION.
10. REMOVE THE TRANSMISSION CONTROL CABLE
TOGETHER WITH THE BRACKET AT THE TRANSMIS-
SION.
11. DISCONNECT THE VACUUM PUMP LINES.
12. REMOVE THE CLUTCH SLAVE CYLINDER.
1. Remove the connecting clip of the clutch hose.
2. Remove the return spring and the clevis of the lever.
3. Remove the slave cylinder together with the lines.
13. DISCONNECT THE POWER STEERING LINES AT THE
PUMP.
NOTE: Be careful of oil leakage from the removed lines
at the gear unit.

17. ModelJ05C-TD3-4-4ENGINE
1 page 1
SM3-J596
Fig. 18
Fig. 19
SM3-J598
Fig. 20
SM3-J595
Fig. 17
SM3-J597
14. DISCONNECT THE AIR HOSES WHICH CONNECT THE
AIR CLEANER AND ENGINE.
15. REMOVE THE SPLASH BOARD.
16. REMOVE THE AIR CLEANER TOGETHER WITH THE
BRACKET.
17. DISCONNECT THE ELECTRICAL WIRES (1).
1. Engine speed sensor
2. Glow plug
3. Rack sensor, pre-stroke actuator
4. Starter terminals B and C and grounding (frame end)
18. REMOVE THE REAR CAB MOUNTING BRACKET.
19. DISCONNECT THE ELECTRICAL WIRES (2).
1. Water temperature sensor (2 parts)
2. Alternator
3. Magnetic clutch of the air conditioner
20. DISCONNECT THE HEATER HOSES.
SM3-J599
Fig. 21
21. DISCONNECT THE GAS LINES OF THE AIR CONDI-
TIONER.
1. Use the refrigerant collector to discharge refriger-
ant.
2. Disconnect the gas lines of the air conditioner at the
compressor.

18. ModelJ05C-TD ENGINE3-4-5
1 page 1
SM3-J600A
Fig. 22
SM3-J601B
Fig. 23
SM3-J602
Fig. 24
SM3-J502
Fig. 25
22. DISCONNECT THE RADIATOR FROM THE FRAME.
1. Disconnect the reservoir hose.
2. Remove the radiator mounting.
23. REMOVE THE EXHAUST PIPE AND MUFFLER.
24. REMOVE THE PROPELLER SHAFT.
1. Remove the center bearing support.
NOTE: Attach a hoist to the propeller shaft.
2. Loosen the flange, then remove the propeller shaft.
25. REMOVE THE TRANSMISSION.
1. Place a jack under the bottom of the flywheel hous-
ing.
2. Place a transmission jack under the transmission.
WARNING
The engine must be suspended with a hoist until
completion of disassembly of the transmission
assembly.
3. Remove the mounting bolt of the mounting rubber
behind the transmission.
4. Remove the mounting bolt of the transmission at the
clutch housing, then remove the transmission.
NOTE: Jack up and align the transmission with the en-
gine, then pull the transmission straight out.

19. ModelJ05C-TD3-4-6ENGINE
1 page 1
SM3-J503
Fig. 26
SM3-J604
Fig. 27
Fig. 28
SM3-J746
26. REMOVE THE ENGINE ASSEMBLY.
1. Attach hoists to the engine hangers at the front and
rear ends of the engine, and lift slightly.
2. Remove the engine mounting at the frame.
3. Remove the engine assembly together with the ra-
diator and inter cooler.
4. Mount the engine assembly on a work stand.
27. REMOVE THE RADIATOR AND INTER COOLER.
1. Loosen the tightening band of the fan shroud.
2. Disconnect the radiator hoses and inter cooler hoses
at the engine.
3. Remove the radiator and inter cooler.
NOTE: Attach a hoist to the radiator.
28. REMOVE THE CLUTCH COVER AND CLUTCH DISC.
NOTE: Refer to CLUTCH in CHAPTER 5.
29. REMOVE THE AIR CONDITIONER COMPRESSOR.
1. Loosen the tension pulley, then remove the V-belt.
2. Remove the air conditioner compressor.

20. Model J05C-TD ENGINE 3-5-1
1 page 1
SM3-J606
Fig. 1
SM3-J504
Fig. 2
SM3-J607A
Fig. 3
SM3-J608
Fig. 4
SM3-J609
Fig. 5
REMOVAL OF THE ENGINE COMPONENT
PARTS
1. PREPARATION
1. Loosen the coolant drain cock of the oil cooler, then
discharge coolant.
2. Loosen the oil drain plug of the oil filter, then dis-
charge oil.
3. Clean the engine assembly.
a. Cover openings with tape.
b. Clean the engine assembly with a steam cleaner.
NOTE: Do not apply steam directly to the electrical com-
ponents. (Alternator, starter, etc.)
4. Mount the engine assembly on a work stand.
2. REMOVE THE POWER STEERING OIL PUMP.
3. REMOVE THE STARTER.
1. Put alignment marks on the harness and the starter
terminal, then remove the harness.
2. Remove the starter from the engine.
4. REMOVE THE FUEL FILTER AND FUEL LINES.
Remove the fuel lines, oil lines and fuel leakage lines.
NOTE:
q Cover openings to prevent foreign matter from enter-
ing.
q Refer to page 3-12-1.

21. Model J05C-TD3-5-2 ENGINE
1 page 1
SM3-J613
Fig. 7
SM3-J610B
Fig. 8
SM3-J612
Fig. 9
SM3-J613
Fig. 6
SM3-J614B
Fig. 10
SM3-J611C
5. REMOVE THE INTAKE MANIFOLD
6. REMOVE THE INJECTION PUMP
1. Remove the through bolt of the coupling.
2. Use the following special tool and loosen the adjust-
ing bolt.
Special tool: Injection pump coupling wrench
(09511 - 2500)
3. Remove the mounting bolt of the injection pump, then
remove the pump assembly.
NOTE: Cover openings to prevent foreign matter from
entering.
7. REMOVE THE INJECTION PUMP SHAFT ASSEMBLY.
(For model FA4J)
1. Remove the oil lines, refrigerant lines and air lines.
2. Remove the mounting bolt of the injection pump shaft
assembly then remove the injection pump shaft as-
sembly.
NOTE: Do not remove the injection pump shaft assem-
bly forcefully. The spigot may be damaged, or oil
leakage may occur due to removal of liquid gas-
ket between the flywheel housing and the rear end
plate.
FA4J FB4J

22. Model J05C-TD ENGINE 3-5-3
1 page 1
Fig. 11
Fig. 12
Fig. 13
Fig. 14
SM3-J614
8. REMOVE THE AIR COMPRESSOR.
(For model FB4J)
1. Remove the oil lines, refrigerant lines and air lines.
2. Remove the air compressor.
3. Remove the mounting bolt of the air compressor, then
remove the air compressor.
NOTE: Do not remove the air compressor forcefully. The
spigot may be damaged, or oil leakage may oc-
cur due to removal of liquid gasket between the
flywheel housing and the rear end plate.
SM3-J615
SM3-J616
ASM3-J617
9. REMOVE THE TURBOCHARGER.
NOTE: Refer to TURBOCHARGER in CHAPTER 51.
10. REMOVE THE OIL FILTER AND OIL COOLER.
1. Remove the oil lines.
2. Remove the oil filter.
Special tool: Oil filter wrench (09553 - 1021)
3. Remove the oil cooler.
11. REMOVE THE EXHAUST MANIFOLD.

23. Model J05C-TD3-5-4 ENGINE
1 page 1
Fig. 15
Fig. 16
Fig. 17
SM3-J618
Fig. 18
SM3-J619
Fig. 19
SM3-J620
SM3-J621
16. REMOVE THE COOLANT PUMP.
SM3-J622
12. REMOVE THE FAN SHROUD TOGETHER WITH THE
BRACKET.
13. REMOVE THE V-BELT AND THE ALTERNATOR.
1. Loosen the V-belt adjustment bolt.
2. Loosen the through bolt.
3. Remove the V-belt, then remove the alternator.
14. REMOVE THE FAN CLUTCH TOGETHER WITH THE
COOLING FAN.
15. REMOVE THE THERMOSTAT CASE.

24. Model J05C-TD ENGINE 3-6-1
1 page 1
CAMSHAFT HOUSING AND CYLINDER HEAD
SM3-J046
Fig. 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
18
20
21
22
23
24
25
26
27
28
29
30
31
32
33

25. Model J05C-TD3-6-2 ENGINE
1 page 1
SM3-J047
Fig. 2
34
35
1. Oil filler cap
2. Cylinder head cover
3. Silent block
4. Spacer
5. Head cover gasket
6. Valve rocker shaft
7. Lock nut
8. Valve rocker arm
9. Adjusting screw
10. Nozzle clamp
11. Valve rocker support
12. Camshaft bearing
13. Camshaft bearing cap
14. Camshaft
15. Camshaft drive gear
16. Camshaft housing
17. Camshaft housing gasket
18. Idler gear thrust plate
19. Camshaft idler gear
20. Idler gear shaft
21. Cross head
22. Valve spring retainer
23. Valve spring seat upper
24. Valve spring outer
25. Valve spring inner
26. Valve stem seal
27. Valve spring seat lower
28. Cross head adjusting screw
29. Lock nut
30. Cylinder head
31. Cylinder head gasket
32. Valve seat
33. Valve
34. Valve stem guide
35. Nozzle seat

26. Model J05C-TD ENGINE 3-6-3
1 page 1
SM3-J178
SM3-J623
Fig. 3
Fig. 4
SM3-J624
Fig. 5
DISMOUNTING
1. REMOVE THE CYLINDER HEAD COVER.
NOTE: Clean all dust from around the cylinder head
cover before removing it to prevent foreign parti-
cles from getting in.
5. Pull out the nozzle holder assembly, avoiding any
interference.
NOTE: If difficult, use a special tool, sliding hammer
(09420 - 1442), for easier removal.
6. Remove the O-ring.
NOTE: Replace the O-ring with a new one.
2. REMOVE THE INJECTION NOZZLE.
1. Remove the leakage pipe.
2. Loosen the injection pipe nut.
3. Remove the injection pipe seal mounting bolts. Re-
move the injection pipe seal together with the injec-
tion pipe out of the cam housing.
4. Remove the nozzle clamp bolt.
NOZZLE CLAMP BOLT
LEAKAGE PIPE
CAM HOUSING
O-RING
NOZZLE HOLDER
ASSEMBLY

27. Model J05C-TD3-6-4 ENGINE
1 page 1
SM3-J056
SM3-J057
Fig. 7
Fig. 6
SM3-J625
Fig. 8
SM3-J626
Fig. 9
SM3-J058B
Fig. 10
3. LOOSEN THE VALVE CLEARANCE ADJUSTING
SCREW.
1. Loosen the lock nut at the top of the rocker arm, then
wind up the adjusting screw completely.
NOTE: If the adjusting screw is left unwound, the rocker
shaft may bend when the rocker arm support is
loosened.
4. REMOVE THE ROCKER ARM ASSEMBLY.
1. Remove the rocker arm support bolt in the order as
shown in the figure.
NOTE: When the rocker arm assembly is removed, the
rocker arm and rocker arm support tend to come
off the rocker shaft. Be careful in handling.
5. REMOVE THE CAMSHAFT.
1. Remove the cam bearing cap bolt.
2. Remove the camshaft together with the gear.
NOTE: Be extremely careful not to drop any part into the
interior of the engine.
6. REMOVE THE CAM HOUSING.
1. Remove the cam housing bolts.
2. Tap and remove the cam housing with a plastic ham-
mer.
7. REMOVE THE CYLINDER HEAD BOLTS.
Remove the cylinder head bolts in the or-
der as shown in the figure.
ROCKER ARM SUPPORT
LOCK NUT
ADJUSTING
SCREW
1 2 435

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29. Model J05C-TD ENGINE 3-6-5
1 page 1
SM3-J627A
Fig. 11
8. LIFT AND REMOVE THE CYLINDER HEAD FROM THE
CYLINDER BLOCK.
Special tool: Eye bolt (09433 - 1070)
NOTE:
q Place a piece of wood between the cylinder head and
table.
q When removing the cylinder head together with the
injection nozzle, avoid contact between the injection
nozzle and a piece of wood.
q Check that there is no oil, water or gas leakage in the
cylinder head gasket if overheated or not.

30. Model J05C-TD3-6-6 ENGINE
1 page 1
SM3-J060
SM3-J628
Fig. 12
SM3-J629
Fig. 13
Fig. 14
SM3-J061
Fig. 15
IN
EX
1 2 3 4
DISASSEMBLING
REMOVE THE CAM IDLER GEAR.
1. Remove the cam idler gear.
2. Using the special tool, remove the cam idler gear.
Special tool: Sliding hammer (09420 - 1830)
DISASSEMBLE THE VALVE SYSTEM.
1. Using the special tool, press fit the valve spring seat
upper, then remove the valve spring retainer.
Special tool: Valve spring press (09470 - 1170)
2. Remove the valve spring seat upper, valve spring
outer and inner.
3. Remove the intake and exhaust valves from the cyl-
inder head.
NOTE:
q Do not remove the valve guide and valve spring seat
lower unless they need to be replaced.
q Align the removed parts in the order of the cylinder
No.

31. Model J05C-TD ENGINE 3-6-7
1 page 1
SM3-J062
SM3-J103
SM3-J630A
Fig. 18
SM3-J505
Fig. 19
ASM3-J506
Fig. 20
Fig. 17
Fig. 16
INSPECTION AND REPAIR
CYLINDER HEAD
NOTE:
q Clean the cylinder head thoroughly with a commercial
cleaning agent before inspection.
q Do not damage the lower surface of the cylinder head.
INSPECT THE CYLINDER HEAD FOR CRACKS.
Check the head surface and intake and exhaust valve
seats, for cracks, using a dye penetrant. If cracks are found,
replace the cylinder head.
CHECK THE CYLINDER HEAD FLATNESS.
1. Check the cylinder head surface for flatness with a
straight edge and a thickness gauge. If the meas-
urements exceed specified limits, replace the cylin-
der head.
Standard: 0.06 mm (0.0024 in.) or less for longitudinal di-
rection
0.03 mm (0.0012 in.) or less for lateral direction
Repair limit: 0.20 mm (0.0079 in.)
2. Check the flatness of the intake and exhaust mani-
folds mounting surfaces.
Standard: 0.06 mm (0.0024 in.) or less for longitudinal di-
rection
0.03 mm (0.0012 in.) or less for lateral direction
Repair limit: 0.20 mm (0.0079 in.)
E’
B
C
D
A
E
F’ G’
A’
C’
D’
B’GF

32. Model J05C-TD3-6-8 ENGINE
1 page 1
SM3-J104
SM3-J631
Fig. 21
Fig. 22
SM3-J632A
Fig. 23
SM3-J507
Fig. 24
SM3-J507A
INSPECT THE VALVE CONTACT SURFACES FOR PROPER
CONTACT.
1. Visually check valves for damage, burn marks, car-
bon accumulation, warpage, or cracks in valve heads,
valve stems, and valve stem grooves. Replace valves
which are excessively worn, burnt, warped or
cracked.
2. Check the valve seating condition.
Lightly apply red lead marking compound to the valve
face. Install the valve with a special tool, tap and
rotate the valve against the seat. Check the valve
face and valve seat for seating. When the red lead
mark is not concentric or even all around the valve
face or seat, correct the valve face or the valve seat.
Special tool: Valve lapping tool (09431 - 1020)
HAND-LAP THE VALVE AND VALVE SEAT.
Lightly apply lapping compound to the valve face. Install
the valve with a special tool, tap and rotate the valve against
the seat.
NOTE:
q Following completion of hand-lapping, clean off any
lapping compound which has adhered to the valves
and valve seats.
q Following hand-lapping, always recheck the seating
condition.
Special tool: Valve lapping tool (09431 - 1020)
GRIND VALVES
NOTE:
q Grinding of valves should only be performed when
hand-lapping does not result in proper seating.
q Following hand-lapping, always recheck the seating
condition.
WARNING
When grinding, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.