This workshop manual provides information for repairs on 2001 Hino FA and FB series trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on engine overhauls, removing and installing engine components, and tune-ups. Safety precautions are outlined to prevent injury when working on the trucks. The manual aims to help owners maintain their trucks smoothly, safely, and economically.
2001 hino fb series truck service repair manualfujsjefjskekmme
This document provides identification information for Hino FA and FB series trucks from 2001, including:
- The vehicle identification number (VIN) plate located on the driver's side door provides 17 digits describing the vehicle make, model, engine, assembly plant, and other specifications.
- The engine and chassis numbers provide additional identification of the specific engine and frame.
- A vehicle certification label on the driver's side door lists the manufacturer, production year and month, and safety certifications.
2001 hino sg series truck service repair manualfujsjefksekmfm
This document provides information on identifying Hino diesel trucks models FD, FE, FF, and SG from 2001. It discusses locating and interpreting the vehicle identification number (VIN), engine number, chassis number, and vehicle certification label. The VIN is a 17-digit code that includes information on the manufacturer, model, engine, weight rating, and other specifications. The engine and chassis numbers provide additional identification.
2002 hino sg series truck service repair manualjfdjjskekksemm
This document is a workshop manual for 2002 Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these trucks. The manual covers the chassis, body, electrical systems, engine, transmission, brakes and other components. It aims to help owners and technicians service the trucks properly to ensure safe, smooth and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino fb series truck service repair manualjfdjjskfkksmemm
This workshop manual provides information for repairing 2002 FA and FB Hino diesel trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on safely performing inspections and recommended repairs. It also notes that owner maintenance is required. Technicians should take care to avoid injury when working on the trucks.
2005 hino 185 series truck service repair manualfujsjefkskekmme
This workshop manual provides information for repairing Hino Trucks models 145, 165, 185, 238, 268, 338 that are equipped with J05D-TA, J08E-TA and J08E-TB engines. When performing repairs, take safety precautions to avoid injury. The manual includes specifications for torque values and recommended lubricants. It also identifies locations for lifting and supporting the vehicle. Chapters cover various vehicle systems and components.
2014 hino 338 series truck service repair manualfujsjefksekmfm
This document provides information and guidelines for repairing Hino Trucks, including the Hino 238, 258LP, 268, 338, 358 series equipped with J08E-VB and J08E-WU engines. It discusses general precautions for safety when working on vehicles and provides identification information. It also outlines how to use the workshop manual and specifies torque values for bolts and nuts. The document provides recommendations for lubricants and lifting locations when working under the vehicle. It includes an information display and instructions for symptom simulation. Chapter references are also included to direct the user to the appropriate section for their vehicle.
2001 hino sg series truck service repair manualfujsjfjkskkem
This workshop manual provides information for repairing 2001 Hino FD, FE, FF, and SG series trucks. It covers the chassis, body, electrical systems, and engine. The manual instructs technicians on troubleshooting, using special tools, overhaul criteria, removing and installing engine components, and performing tune-ups. Safety precautions are outlined to prevent injury when working on the trucks.
2001 hino ff series truck service repair manualfujsejfkskefmem
This workshop manual provides information for repairing 2001 Hino FD, FE, FF, and SG series trucks. It covers the chassis, body, electrical systems, and engine. The manual instructs technicians on troubleshooting, removing and installing component parts, and tuning the engine. Safety precautions are outlined to prevent injury when working on the trucks.
2001 hino fb series truck service repair manualfujsjefjskekmme
This document provides identification information for Hino FA and FB series trucks from 2001, including:
- The vehicle identification number (VIN) plate located on the driver's side door provides 17 digits describing the vehicle make, model, engine, assembly plant, and other specifications.
- The engine and chassis numbers provide additional identification of the specific engine and frame.
- A vehicle certification label on the driver's side door lists the manufacturer, production year and month, and safety certifications.
2001 hino sg series truck service repair manualfujsjefksekmfm
This document provides information on identifying Hino diesel trucks models FD, FE, FF, and SG from 2001. It discusses locating and interpreting the vehicle identification number (VIN), engine number, chassis number, and vehicle certification label. The VIN is a 17-digit code that includes information on the manufacturer, model, engine, weight rating, and other specifications. The engine and chassis numbers provide additional identification.
2002 hino sg series truck service repair manualjfdjjskekksemm
This document is a workshop manual for 2002 Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these trucks. The manual covers the chassis, body, electrical systems, engine, transmission, brakes and other components. It aims to help owners and technicians service the trucks properly to ensure safe, smooth and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino fb series truck service repair manualjfdjjskfkksmemm
This workshop manual provides information for repairing 2002 FA and FB Hino diesel trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on safely performing inspections and recommended repairs. It also notes that owner maintenance is required. Technicians should take care to avoid injury when working on the trucks.
2005 hino 185 series truck service repair manualfujsjefkskekmme
This workshop manual provides information for repairing Hino Trucks models 145, 165, 185, 238, 268, 338 that are equipped with J05D-TA, J08E-TA and J08E-TB engines. When performing repairs, take safety precautions to avoid injury. The manual includes specifications for torque values and recommended lubricants. It also identifies locations for lifting and supporting the vehicle. Chapters cover various vehicle systems and components.
2014 hino 338 series truck service repair manualfujsjefksekmfm
This document provides information and guidelines for repairing Hino Trucks, including the Hino 238, 258LP, 268, 338, 358 series equipped with J08E-VB and J08E-WU engines. It discusses general precautions for safety when working on vehicles and provides identification information. It also outlines how to use the workshop manual and specifies torque values for bolts and nuts. The document provides recommendations for lubricants and lifting locations when working under the vehicle. It includes an information display and instructions for symptom simulation. Chapter references are also included to direct the user to the appropriate section for their vehicle.
2001 hino sg series truck service repair manualfujsjfjkskkem
This workshop manual provides information for repairing 2001 Hino FD, FE, FF, and SG series trucks. It covers the chassis, body, electrical systems, and engine. The manual instructs technicians on troubleshooting, using special tools, overhaul criteria, removing and installing engine components, and performing tune-ups. Safety precautions are outlined to prevent injury when working on the trucks.
2001 hino ff series truck service repair manualfujsejfkskefmem
This workshop manual provides information for repairing 2001 Hino FD, FE, FF, and SG series trucks. It covers the chassis, body, electrical systems, and engine. The manual instructs technicians on troubleshooting, removing and installing component parts, and tuning the engine. Safety precautions are outlined to prevent injury when working on the trucks.
2001 hino fe series truck service repair manualfusjejfkskeme
This workshop manual provides information for repairing 2001 Hino FD, FE, FF, and SG series trucks. It covers the chassis, body, electrical systems, and engine. The manual instructs technicians on troubleshooting, using special tools, overhaul criteria, removing and installing engine components, and performing tune-ups. Safety precautions are outlined to prevent injury when working on the trucks.
2001 hino fd series truck service repair manualfusjejfkskeme
This document provides information on identifying Hino diesel trucks models FD, FE, FF, and SG from 2001. It discusses locating and interpreting the vehicle identification number (VIN), engine number, chassis number, and vehicle certification label. The VIN is composed of 17 digits that provide information on the manufacturer, model, engine, weight rating, and other specifications. The engine and chassis numbers provide additional identification.
2001 hino sg series truck service repair manualfjskekxswesemm
This document provides information on identifying Hino diesel trucks models FD, FE, FF, and SG from 2001. It discusses identifying the vehicle using the Vehicle Identification Number (VIN), which is a 17-digit code providing information on the manufacturer, model, engine, weight rating, and other specifications. It also provides the location and meanings of the engine and chassis numbers stamped on the vehicle components. Instructions are given on general precautions for maintenance and towing the vehicles.
2001 hino fd series truck service repair manualfjsefksemmm
This document provides information on identifying Hino diesel trucks models FD, FE, FF, and SG from 2001. It discusses identifying the vehicle using the Vehicle Identification Number (VIN), which is a 17-digit code providing information on the manufacturer, model, engine, weight rating, and other specifications. It also provides the location and meanings of the engine and chassis numbers stamped on the vehicle. Instructions are given for vehicle towing and general maintenance precautions.
2001 hino fe series truck service repair manualfjsefksemmm
This document provides information on identifying Hino diesel trucks models FD, FE, FF, and SG from 2001. It discusses identifying the vehicle using the vehicle identification number (VIN), vehicle certification label, engine number, and chassis number. The VIN is a 17-digit code that includes information on the manufacturer, model, engine, weight rating, and other specifications. The vehicle certification label also provides the manufacturer name and is affixed to the driver's side door. The engine and chassis numbers provide additional identifying information located on the engine block and frame, respectively.
2002 hino fd series truck service repair manualjfdjjskfkksmemm
This document is a workshop manual for 2002 Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these trucks. The manual covers the chassis, body, electrical systems, engine, transmission, brakes and other components. It aims to help owners and technicians service the trucks properly to ensure safe, economical and smooth operation for many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino fe series truck service repair manualjfdjjskfkksmemm
This document provides information on identifying Hino diesel truck models FD, FE, FF, and SG from 2002, including:
- The vehicle identification number plate contains 17 digits and letters that identify the manufacturer, model, engine, assembly plant, and other details.
- The engine and chassis numbers provide additional identification information found on specific parts of the vehicle.
- Specifications such as wheelbase, gross vehicle weight rating, brake systems, and transmission components are identified by codes within the VIN.
2002 hino ff series truck service repair manualjfjskeksemm
This document is a workshop manual for 2002 Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these trucks. The manual covers the chassis, body, electrical systems, engine, transmission, brakes and other components. It aims to help owners and technicians service the trucks properly to ensure safe, economical and smooth operation for many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino fe series truck service repair manualfjsjekksemm
This document provides information on identifying Hino trucks models FD, FE, FF and SG from 2002. It discusses identifying the vehicle using the vehicle identification number (VIN), which is a 17-digit code providing information on the manufacturer, model, engine, assembly plant and more. It also provides the engine and chassis numbers' locations to further identify the specific vehicle. The document aims to clearly identify Hino truck models and components for maintenance and repair work.
2002 hino fe series truck service repair manualfjskekmsemmwe
This document provides information on identifying Hino trucks models FD, FE, FF, and SG from 2002. It discusses identifying the vehicle using the vehicle identification number (VIN), which is a 17-digit code providing information on the manufacturer, model, engine, assembly plant, and other details. It also provides the engine identification number and chassis number locations to further identify components.
2002 hino fd series truck service repair manualfjskekmsemmwe
This document is a workshop manual from 2002 for Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these truck models. The manual covers the chassis, body, electrical systems, engine, transmission, brakes, suspension, and other components. It aims to help owners and technicians service the trucks properly to ensure safe and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino ff series truck service repair manualfjskefksemer
This document is a workshop manual from 2002 for Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these truck models. The manual covers the chassis, body, electrical systems, engine, transmission, brakes, suspension, and other components. It aims to help owners and technicians service the trucks properly to ensure safe and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino fd series truck service repair manualfjsjekksemm
This document is a workshop manual from 2002 for Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these truck models. The manual covers the chassis, body, electrical systems, engine, transmission, brakes, suspension, and other components. It aims to help owners and technicians service the trucks properly to ensure safe and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino sg series truck service repair manualfujsekfkksemm
This document is a workshop manual from 2002 for Hino FD, FE, FF, and SG series trucks. It provides information for repairs and maintenance of these truck models. The manual covers the chassis, body, electrical systems, engine, transmission, brakes, suspension, and other components. It aims to help owners and technicians service the trucks properly to ensure safe and economical operation over many years. Cautions are provided regarding safety when working on the vehicles.
2002 hino fa series truck service repair manualfjjskksekmemm
This workshop manual provides information for repairing 2002 FA and FB Hino diesel trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on safely performing inspections and recommended repairs. It also details specifications and wiring diagrams to aid in maintenance and repairs. Hino may make changes to their vehicles without notice, so technicians should always refer to the latest information available.
2002 hino fb series truck service repair manualfjskekmsemmwe
This workshop manual provides information for repairing 2002 FA and FB series Hino trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on repairs, maintenance responsibilities, and general safety precautions when working on the trucks. It also includes specifications, diagrams, and a troubleshooting guide to aid repairs.
2002 hino fa series truck service repair manualfjsjekksemm
This workshop manual provides information for repairing 2002 FA and FB series Hino trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on safely performing inspections and recommended repairs. It also includes specifications and wiring diagrams as references for maintenance and repairs. Technicians should take safety precautions when working on the trucks to avoid injury.
2002 hino fb series truck service repair manualfjsjekksemm
This workshop manual provides information for repairing 2002 FA and FB series Hino trucks. It covers the engine, chassis, body, electrical systems, and truck components. The manual instructs technicians on safely performing inspections and recommended repairs. It also includes specifications and wiring diagrams as references for maintenance and repairs. Technicians are advised to follow general precautions for safety when working on the trucks.
Caterpillar cat 345 b series ii excavator (prefix dcw) service repair manual ...fujsekfkksemm
This document provides instructions for removing and installing the cylinder head on a 345B Series II Excavator with a 3176 engine. The removal procedure involves removing components like the valve mechanism cover, rocker shaft, and pushrods. Sensors and tubes must be disconnected from the cylinder head before removing bolts and lifting the head off. For installation, the mating surfaces are cleaned and the correct gasket is installed before lowering the head onto the cylinder block and installing bolts.
Caterpillar cat 345 b series ii excavator (prefix ald) service repair manual ...fujsekfkksemm
This document provides instructions for installing a cylinder head on a 3176C engine. It involves cleaning surfaces, installing gaskets and seals, lifting the cylinder head into place using guide bolts, and tightening head bolts in a specific sequence to the correct torque specifications. Sensors and wiring are then reconnected, coolant is added to the system, and remaining components like the rocker shaft and pushrods are reinstalled to complete the job.
Caterpillar cat 345 b series ii excavator (prefix ccc) service repair manual ...fujsekfkksemm
This document provides instructions for removing and installing the cylinder head on a 345B Series II Excavator with a 3176C engine. The removal procedure involves removing various components like sensors, tubes, and manifolds. The cylinder head bolts are then removed and the head lifted off using a suitable lifting device. For installation, the mating surfaces are cleaned and new gaskets installed before positioning the cylinder head on the block and installing the bolts.
Caterpillar cat 345 c excavator (prefix dhp) service repair manual (dhp00001 ...fujsekfkksemm
The document provides instructions for disassembling and assembling the travel motor of a 345C excavator. It lists 31 steps to disassemble the travel motor by removing components like the head, plates, seals, pins, and piston assemblies. It notes to mark parts for reinstallation and clean components to prevent contamination. Reassembly follows the reverse order of disassembly.
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Caterpillar cat 345 b series ii excavator (prefix dcw) service repair manual ...fujsekfkksemm
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The document provides assembly instructions for a travel motor in 3 steps:
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The document provides assembly instructions for a travel motor in 3 steps:
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3) It outlines attaching the head, installing valves and plugs, and filling the travel motor with oil before operation.
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The document provides instructions for disassembling and assembling the travel motor of a 345B Excavator. It lists 32 steps for disassembly, including removing covers, springs, seals, gears, and housing components. It then lists 15 steps for assembly, reversing the disassembly process and including inspecting parts and ensuring cleanliness to prevent contamination. The overall document provides detailed technical instructions for servicing the excavator's travel motor.
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The document provides disassembly instructions for a swing drive on a 340F excavator model. It begins by having the technician remove the swing drive and mark parts for reassembly. Several internal components of the swing drive are then removed, including planetary gears, shafts, rings, and housings. Precision tools are required and technicians should be careful due to the weights of parts removed. Cleanliness is emphasized to prevent contamination of hydraulic systems during repair.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Expanding Access to Affordable At-Home EV Charging by Vanessa WarheitForth
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Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
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Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
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2. FOREWORD
This workshop manual has been prepared to provide information covering repairs on 2001 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.
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
GENERAL INTRODUCTION
Models FA and FB
CHAPTER 1
1
IDENTIFICATION INFORMATION................................................1- 2
1-217E-04
1 INDEX
7. Models FA and FB1-2 GENERAL INTRODUCTION
1 page 1
Fig. 1
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
MT643
MF06S
MT643
LJ06S
AT545
LJ06S
AT545
LJ06S
AT542
LF06S
AT542
TRANSMISSION RATIO
1ST 6TH5TH4TH3RD2ND
7.46
3.45
6.09
3.45
6.89
3.45
6.89
3.45
6.89
3.58
7.39
3.58
4.18
2.25
3.85
2.25
4.27
2.25
4.27
2.25
4.27
2.09
4.75
2.09
2.42
1.41
2.34
1.41
2.60
1.41
2.60
1.41
2.60
1.39
3.07
1.39
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
-
1.00
-
1.00
-
1.00
-
1.34
-
-
-
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
3.63
3.63
5.12
3.90
5.12
4.33
5.42
4.62
5.42
4.10
4.10
4.10
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
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
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
3.63
3.63
V
V
C
C
SA-HC4
SA-RN4
SA-QN4
SA-US4
SA-TS4
SA-RS4
SA-PS4
SA-RF4
SA-QF4
SA-TF4
SA-SF4
SA-JC4
SA-HC4
SA-JC4
J H B F B 4 J G 6 1 1 S 1 0 0 0 1
SA-HC4
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
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
16
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-03
ENGINE
Model: J05C-TD
CHAPTER 3
ENGINE 3-1-1Model J05C-TD
TROUBLESHOOTING...............................................................3- 1-2
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. Model J05C-TD3-4-4 ENGINE
1 page 1
Fig. 18
SM3-J596
Fig. 19
Fig. 20
SM3-J598
Fig. 21
SM3-J790
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. REMOVE THE NOISE COVER FROM THE REAR CAB
MOUNTING.
18. 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)
19. REMOVE THE REAR CAB MOUNTING BRACKET.
20. DISCONNECT THE ELECTRICAL WIRES (2).
1. Water temperature sensor (2 parts)
2. Alternator
3. Magnetic clutch of the air conditioner
21. DISCONNECT THE HEATER HOSES.
NOISE COVER
REAR CAB MOUNTING
18. Model J05C-TD ENGINE 3-4-5
1 page 1
SM3-J600A
Fig. 23
SM3-J601B
Fig. 24
SM3-J602
Fig. 25
SM3-J502
Fig. 26
SM3-J599
Fig. 22
22. 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.
23. DISCONNECT THE RADIATOR FROM THE FRAME.
1. Disconnect the reservoir hose.
2. Remove the radiator mounting.
24. REMOVE THE EXHAUST PIPE AND MUFFLER.
25. 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.
26. 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.
19. Model J05C-TD3-4-6 ENGINE
1 page 1
SM3-J503
Fig. 27
SM3-J604
Fig. 28
Fig. 29
SM3-J746
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.
27. 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.
28. 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.
29. REMOVE THE CLUTCH COVER AND CLUTCH DISC.
NOTE: Refer to CLUTCH in CHAPTER 5.
30. 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.
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. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
28. 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
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.
33. Model J05C-TD ENGINE 3-6-9
1 page 1
Assembly standard:
Valve seat (Intake): 30°00' - 30°35'
Valve face (Intake): 29°30' - 30°00'
Valve seat (Exhaust): 45°00' - 45°30'
Valve face (Exhaust): 44°30' - 45°00'
EXHAUST
30˚
SM3-J097
VALVE
VALVE SEAT
BLOCK BRASS
ELECTRIC WELDING
APPLIED
GRIND THIS POINT
WITH A GRINDER
SM3-J064
SM3-J065
IF NECESSARY, REPLACE THE VALVE SEAT.
1. Cut three places on the circumference of an un-
wanted valve and weld it to the valve seat.
NOTE: To protect the lower surface of the cylinder head
from welding spatter, be sure to apply grease
before welding.
2. Place a back plate at the top of the valve stem and
strike it with a hammer to remove the valve seat.
NOTE: When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
3. Machine the valve seat according to the specified
valve seat dimensions.
Dimensions of the valve seat machining:
45˚
HAMMER
EXHAUST INTAKE
4. Heat the cylinder head to approx. 80°C (176°F) -
90°C (194°F) with hot water. Cool the valve seat with
dry ice for approx. 30 minutes. Hold the seat with
pincers and place it into the heated cylinder head.
The valve seat can be easily made to fit by lightly
hitting it.
WARNING
q Never touch the cooled valve seat with your bear
hands.
q When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
q Following valve grinding, always recheck the
seating condition.
SM3-J066
Fig. 25
Fig. 26
Fig. 27
INTAKE
Fig. 28
Unit:mm Unit:in. Unit:mm Unit:in.
A 41
+0.0016
1.6141
+0.0001
39
+0.0016
1.5354
+0.0001
-0 -0 -0 -0
B 9.4
+0.2
0.3700
+0.0078
8.6
+0.2
0.3385
+0.0078
-0 -0 -0 -0
C 41
+0.1
1.6141
+0.0039
39
+0.135
1.5354
+0.0053
+0.085 +0.0033 +0.12 +0.0047
D 7
+0.2
0.2756
+0.0078
6
+0.2
0.2362
+0.0078
-0 -0 -0 -0
Clynder head
dimension
Valve seat
dimension
Intake Exhaust
C C
34. Model J05C-TD3-6-10 ENGINE
1 page 1
SM3-J508
Fig. 29
SM3-J509
Fig. 30
SM3-J510
Fig. 31
SM3-J511
Fig. 32
MEASURE THE VALVE SINK.
Assembly standard:
Intake: 0.55 - 0.85 mm (0.0217 - 0.0334 in.)
Exhaust: 1.05 - 1.35 mm (0.0414 - 0.0531 in.)
Service limit:
Intake: 1.1 mm (0.0433 in.)
Exhaust: 1.6 mm (0.0630 in.)
NOTE:
q If the valve heads are protruding from cylinder head
surface, the valve heads may hit against the pistons
while the engine is running.
q Following replacement of valve and valve seat, always
recheck the seating condition.
MEASURE THE CLEARANCE BETWEEN THE VALVE STEM
AND VALVE GUIDE
1. Measure the outside diameter of the valve stem with
a micrometer. If the value exceeds the service limit,
replace the valve.
Nominal dimension: 7.0 mm (0.2756 in.)
Service limit: Intake 6.92 mm (0.2724 in.)
Exhaust 6.84 mm (0.2693 in.)
2. Calculate the clearance between the valve stem and
valve guide. If the clearance exceeds the service
limit, replace the valve or valve guide.
Nominal dimension:
Intake: 0.023 - 0.058 mm (0.0010 - 0.0022 in.)
Exhaust: 0.037 - 0.067 mm (0.0015 - 0.0026 in.)
Service limit:
Intake: 0.10 mm (0.0039 in.)
Exhaust: 0.12 mm (0.0047 in.)
IF NECESSARY, REPLACE THE VALVE GUIDE
1. Remove the valve stem seal.
2. Strike the valve guide out with a brass bar and a
hammer.
WARNING
When striking, a metal tip may fly off on impact.
Wear safety glasses to protect your eyes.
VALVE
SINK
DIMENSION VALVECYLINDER
HEAD
90°
VALVE SEAT