TRUCK

2002 WORKSHOP MANUAL

FD.FE.FF.SG
CHASSIS
BODY
ELECTRICAL

HINO DIESEL TRUCKS (U.S.A.), INC.

 TRUCK

2002 WORKSHOP MANUAL

FD.FE.FF.SG
ENGINE

HINO DIESEL TRUCKS (U.S.A.), INC.

 FOREWORD

This workshop manual has been prepared to provide information covering repairs on 2002 FD, FE, FF, and
SG 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.
 ■■■■■■■■
1 MENU

GENERAL INTRODUCTION 1
ENGINE 3
CLUTCH 5
WORKSHOP CLUTCH CONTROL 6
TRANSMISSION 7
MANUAL 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
COMPRESSOR 23
TURBOCHARGER 51
SPRING BRAKE 66
© 2002 HINO DIESEL TRUCKS (U.S.A.),INC. POWER STEERING 67
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.
AUTOMATIC TRANSMISSION 75
ANTILOCK BRAKE SYSTEM 77
TOTAL ELECTRONICS SYSTEM 78
SERVICE SPECIFICATIONS S
WIRING DIAGRAMS W
 GENERAL PRECAUTIONS 1-1

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.
● Always wear safety glasses or goggles to protect your eyes.
● Remove rings, watches, ties, Ioose hanging jewelry and loose clothing before start-
ing work on the truck.
● Bind long hair securely behind the head.
● When working on the truck, apply the parking brake firmly, place the transmission
shift lever in neutral or “N”, and block the wheels.
● Be sure to disconnect the cable from the negative (–) terminal of the battery before
servicing.
● 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 truck since fuel and gases from the 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 when using it.
● 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.
● 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.
● 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.
● Run the engine only in a well-ventilated area to avoid inhaling of carbon monoxide.
GENERAL PRECAUTIONS 1-2

● Keep yourself, your clothing and your tools away from moving parts such as the
cooling fan and V-belts when the engine is running.

● Be careful not to damage lines and hoses by stepping or remain standing (holding
your feet) on them.

● 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
automatic 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.
 1 page
INDEX1
Models FD, FE, FF and SG GENERAL INTRODUCTION 1-1

1-218E-05
1

CHAPTER 1
GENERAL INTRODUCTION
Models FD, FE, FF and SG

IDENTIFICATION INFORMATION................................................ 1- 2
 1 page 1
1-2 GENERAL INTRODUCTION Models FD, FE, FF and SG

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.

JHBFF2JM621S10001

SA-QN5

Fig. 1

1) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE on the following page.
2) P.S.CODE AND VEHICLE COMPONENTS
TRANS- REAR REAR PARK-
MODEL P.S. CLUTCH TRANSMISSION RATIO SERVICE
MISSION AXLE AXLE ING
SERIES CODE SIZE 1ST BRAKE
SERIES 2ND 3RD 4TH 5TH 6TH SERIES RATIO BRAKE
SA-HC5 350 MM LF05S 7.46 4.18 2.42 1.42 1.00 - SH13-2 3.36 V C
FA4J
SA-JC5 - AT542 3.45 2.25 1.41 1.00 - - SH13-2 3.36 V C
SA-HC5 350 MM LF05S 7.46 4.18 2.42 1.42 1.00 - SH13-2 3.36 A C
FB4J
SA-JC5 - AT542 3.45 2.25 1.41 1.00 - - SH13-2 3.36 A C
SA-SF5 350 MM LF06S 6.09 3.85 2.34 1.42 1.00 0.76 SH14-1 5.12 A C
FD2J
SA-TF5 - LCT2400 3.51 1.90 1.44 1.00 0.74 - SH14-1 4.33 A C
SA-QF5 350 MM LJ06S 6.89 4.27 2.60 1.56 1.00 0.77 SH14-1 5.12 A C
FE2J
SA-RF5 - LCT2400 3.51 1.90 1.44 1.00 0.74 - SH14-1 5.85 A C
SA-QN5 350 MM LJ06S 6.89 4.27 2.60 1.56 1.00 0.77 SH16-1 5.42 A C
FF2J
SA-RN5 - LCT2000 3.51 1.90 1.49 1.00 0.74 - SH16-1 5.85 A C
SA-PS5 380 MM LJ06S 6.89 4.27 2.60 1.56 1.00 0.77 SH16-1 5.42 F W
SG2J
SA-RS5 - MD3060P 3.49 1.86 1.41 1.00 0.75 - SH16-1 5.42 F W
SA-TS5 380 MM MF06S 7.39 4.75 3.07 1.93 1.34 1.00 SH16-1 4.10 F W
SG1J SA-US5 - MD3060P 3.49 1.86 1.41 1.00 0.75 - SH16-1 5.42 F W
SA-VS5 380 MM RT8709 9.16 6.53 4.80 3.57 2.56 1.83 SH16-1 4.10 F W

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
 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

WMI VDS C/D VIS

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)

J H B F F 2 J M 6 2 1 S 1 0 0 0 1

CHECK DIGIT SEQUENTIAL NUMBER

MANUFACTURER LINE & CAB/BODY TYPE,
MAKE,MODEL SERIES, BRAKE SYSTEM MODEL ASSEMBLY
ENGINE MODEL WHEEL BASE
YEAR PLANT

MODIFICATION CODE DESCRIPTION

S
CODE YEAR CODE YEAR T A NEW LETTER
U WILL BE ALLOTED
W 1998 4 2004
AT EVERY MAJOR
...

CODE MANUFACTURER MAKE TYPE X 1999 5 2005 MODIFICATION

Z
Y 2000 6 2006
JHA HINO MOTORS, LTD. HINO TRUCK 1 2001 7 2007
2 2002 8 2008
JHB HINO MOTORS, LTD. HINO INCOMPLETE VEHICLE
3 2003 9 2009

JHC HINO MOTORS, LTD. HINO BUS

INCOMPLETE VEHICLE ASSEMBLED BY CODE LENGTH (mm)

JH8 HINO MOTORS, LTD. HINO CODE ASSEMBLY PLANT
BURNS PHILP (SOUTH SEA) CO., LTD.
C 2,920
1 page 1

HINO MOTORS, LTD.

E 3,420 1
HINO PLANT, JAPAN
3,780 (for FD,FE)
G MITSUI SEIKI KOGYO CO., LTD
3,860 (for FA,FB) 2
KAWASHIMA PLANT, JAPAN
Models FD, FE, FF and SG

H 4,190 HINO AUTO BODY, LTD.

3
J 4,280 YOKOHAMA PLANT, JAPAN
BRAKE K 4,600 HINO AUTO BODY, LTD.
SERIES 4
CODE LINE & CAB/BODY TYPE SYSTEMS KANAZAWA PLANT, JAPAN
GVWR OR OVERALL LENGTH M 5,050
6,350 kg-7,030kg BURNS PHILP (SOUTH SEA) CO.,
FORWARD CONTROL TYPE P 5,530 B
FA HYDRAULIC LTD., AMERICAN SAMOA
TRUCK [14,001-15,500 (lbs.) ] (CLASS 4) R 5,800
FORWARD CONTROL TYPE 7,258 kg-8,165kg AIR OVER S 6,220
FB TRUCK [16,001-18,000 (lbs.) ] (CLASS 5) HYDRAULIC
FORWARD CONTROL TYPE 8,845 kg-10,433kg AIR OVER
FD TRUCK [19,501-23,000 (lbs.) ] (CLASS 6) HYDRAULIC
CODE MANUFACTURER MODEL DESCRIPTION
FORWARD CONTROL TYPE 10,434 kg-11,793kg AIR OVER
FE TRUCK [23,001-26,000 (lbs.) ] (CLASS 6) HYDRAULIC 4J HINO MOTORS, LTD. J05C-TD 5.3 LITERS, DIESEL 168 HP
FORWARD CONTROL TYPE 11,794 kg-13,608kg AIR OVER
FF TRUCK [26,001-30,000 (lbs.) ] (CLASS 7) HYDRAULIC
2J HINO MOTORS, LTD. J08C-TP 8.0 LITERS, DIESEL 200 HP
FORWARD CONTROL TYPE 13,609 kg-14,968kg
SG TRUCK [30,001-33,000 (lbs.) ] (CLASS 7) FULL AIR
1J HINO MOTORS, LTD. J08C-TR 8.0 LITERS, DIESEL 252 HP
GENERAL INTRODUCTION 1-3
 1 page 1
1-4 GENERAL INTRODUCTION Models FD, FE, FF and SG

2. VEHICLE CERTIFICATION LABEL

– EXAMPLE – 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 SM1-060B
ENGINE MODEL: J-SERIES 3. ENGINE NUMBER
ENGINE The Engine Number, as shown in Fig. 3 is on the right
NUMBER
side of the engine block.

Fig. 3 SM1-J014
4. CHASSIS NUMBER
The Chassis Number is displayed on the left siderail of
the frame near the front axle, as shown in Fig. 4.

CHASSIS NUMBER

Fig. 4
 1 INDEX
Models J08C-TP and J08C-TR ENGINE 3-1-1

3-228E-05

3
CHAPTER 3
ENGINE
Models: J08C-TP and J08C-TR

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

AIR COMPRESSOR 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
POWER TAKE-OFF (IF FITTED) .............................................. 3- 21-1
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-3-1

GENERAL

WARNING
The following items should be observed to prevent
injury to yourself and others when servicing the
engine or vehicle;
● Stop the engine and keep the engine off during
checks and adjustments.
● Place the starter key in the “LOCK” position.
● Leave the engine stop knob pulled out fully.
(For model equipped with manual engine stop
control)
● Place the transmission shift lever in “NEUTRAL”.
● Apply the parking brake firmly.
● Block the wheels.

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 3-18-4.
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.
SM3-J580 NOTE: Refer to page 3-6-3.
Fig. 1 6. Remove the air cleaner hose.
 1 page 1
3-3-2 ENGINE Models J08C-TP and J08C-TR

(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.
SM3-J581
NOTE: Do not operate the starter for more than 15 sec-
Fig. 2
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
SM3-J580 engine stop motor and the engine stop lever of the
Fig. 3 fuel injection pump will move, resulting in your
fingers caught by the lever.
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-3-3

2. DECREASED OIL PRESSURE

Check the oil pressure warning lap when the oil and cool-
ant temperature is hot [about 80°C (176°F)].
a. If the warning lamp is lit, check the oil level.
b. Check oil deterioration.
OIL If oil quality is poor, replace with a suitable grade oil.
c. Remove the oil pressure switch and install the oil
pressure gauge.
SM3-J024
d. Measure the oil pressure at oil temperature 100°C
Fig. 4
ATMOSPHERIC TEMPERATURE
(212°F).
S.A.E.
-10 0 32 50 70 90 100 ˚F Standard oil Pressure:
GRADE
-23 -18 0 10 21 32 39 ˚C At 2,500 (rpm) 5.7 kg/cm2 (81.05 lb/sq.in.)
40

30
Service Limit:
20W/20
At idle speed 0.5 kg/cm2 (7.11 lb/sq.in.)
15W/40

10W/30

Fig. 5
3. OTHER FACTORS
a. Blow-by gas increases.
b. Engine does not start easily.
c. Engine output decreases.
d. Fuel consumption increases.
e. Engine makes greater noise.
f. Excessive oil consumption.
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-4-1

DISMOUNTING THE ENGINE ASSEMBLY

1. BLOCK THE WHEELS OF THE VEHICLE.
1. Park the vehicle on level ground.
2. Block the wheels.

SM3-J500
Fig. 1
2. DISCONNECT THE ENGINE CONTROL AND 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.

SM3-J580
Fig. 2
4. Tilt up the cab.
5. Disconnect the engine control and the stop cable at
the injection pump.

SM3-J582A
Fig. 3

3. DISCONNECT THE NEGATIVE TERMINAL OF THE

BATTERY.

WARNING
Always disconnect the battery cable when servic-
ing the engine.

SM3-J583
Fig. 4
4. DISCONNECT THE PARKING BRAKE CABLE (1).
1. Remove the center console.
2. Disconnect the parking brake cable at the lever.

SM3-J584
Fig. 5
 1 page 1
3-4-2 ENGINE Models J08C-TP and J08C-TR

OVER-TILTING NORMAL POSITION 5. OVER-TILT THE CAB

POSITION NOTE: Refer to CAB in CHAPTER 19.

SM3-J585
Fig. 6
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
OPEN CLOSE are still hot.
DRAINING PLUG
DRAINING PLUG 1. Drain the coolant from the radiator. (Fig. 7)
NOTE: The coolant can be drained more easily by
SM3-J705B
removing the filler cap.
Fig. 7 Fig. 8

2. Drain the coolant from the cylinder block. (Fig. 8)

Coolant capacity: 21 L (22.19 US qt)
23 L (24.30 US qt)
(with transmission oil cooler only)

DRAINING PLUG 3. Drain the engine oil through the drain plug.
Engine oil capacity: 13.5 L (14.27 US qt)
SM3-J791
Fig. 9
7. DISCONNECT THE POWER STEERING LINES AT THE
GEAR UNIT.
NOTE: Place a container under the gear unit.

SM3-J587
Fig. 10

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.

SM3-J589
Fig. 11
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-4-3

9. DISCONNECT THE SPEEDOMETER CABLE AT THE

TRANSMISSION.

SM3-J590
Fig. 12
10. REMOVE THE TRANSMISSION CONTROL ROD
TOGETHER WITH THE BRACKET AT THE TRANSMIS-
SION.

SM3-J796
Fig. 13
11. 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.

SM3-J593
Fig. 14
12. DISCONNECT THE POWER STEERING LINES AT THE
PUMP.
NOTE: Be careful of oil leakage from the removed lines
at the gear unit

SM3-J594
Fig. 15
13. DISCONNECT THE AIR HOSES WHICH CONNECT THE
AIR CLEANER AND ENGINE.
14. REMOVE THE SPLASH BOARD.
15. REMOVE THE AIR CLEANER TOGETHER WITH THE
BRACKET.

SM3-J595
Fig. 16
 1 page 1
3-4-4 ENGINE Models J08C-TP and J08C-TR

16. 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)

SM3-J596A
Fig. 17
17. REMOVE THE REAR CAB MOUNTING BRACKET.

SM3-J597
Fig. 18
18. DISCONNECT THE ELECTRICAL WIRES (2).
1. Water temperature sensor (2 parts)
2. Alternator
3. Magnetic clutch of the air conditioner
19. DISCONNECT THE HEATER HOSES.

SM3-J598
Fig. 19
20. 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.

SM3-J599
Fig. 20

21. DISCONNECT THE RADIATOR FROM THE FRAME.

1. Disconnect the reservoir hose.
2. Remove the radiator mounting.

SM3-J600A
Fig. 21
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-4-5

22. REMOVE THE EXHAUST PIPE AND MUFFLER.

SM3-J601A
Fig. 22
23. 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.

SM3-J602
Fig. 23
24. 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
SM3-J502 assembly.
Fig. 24
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.
 1 page 1
3-4-6 ENGINE Models J08C-TP and J08C-TR

25. 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.

SM3-J503
Fig. 25
26. 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.

SM3-J604
Fig. 26
27. REMOVE THE CLUTCH COVER AND CLUTCH DISC.
NOTE: Refer to CLUTCH in CHAPTER 5.

SM3-J746
Fig. 27
28. REMOVE THE AIR CONDITIONER COMPRESSOR.
1. Loosen the tension pulley, then remove the V-belt.
2. Remove the air conditioner compressor.
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-5-1

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.
SM3-J606
Fig. 1
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.

SM3-J504
Fig. 2
2. REMOVE THE POWER STEERING OIL PUMP.

SM3-J607
Fig. 3
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.

SM3-J608
Fig. 4
4. REMOVE THE FUEL FILTER AND FUEL LINES.
Remove the fuel lines, oil lines and fuel leakage lines.
NOTE:
● Cover openings to prevent foreign matter from enter-
ing.
● Refer to page 3-12-1.

SM3-J609
Fig. 5
 1 page 1
3-5-2 ENGINE Models J08C-TP and J08C-TR

5. REMOVE THE INTAKE MANIFOLD.

SM3-J613
Fig. 6
6. REMOVE THE INJECTION PUMP.
1. Remove the through bolt of the coupling.

SM3-J610A
Fig. 7
2. Use the following special tool and loosen the adjust-
ing bolt.
Special tool: Injection pump coupling wrench
(09511 - 2500)

SM3-J611C
Fig. 8
3.
Remove the mounting bolt of the injection pump, then
remove the pump assembly.
NOTE: Cover openings to prevent foreign matter from
entering.

SM3-J612
Fig. 9
7. REMOVE THE AIR COMPRESSOR.
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
SM3-J614 flywheel housing and the rear end plate.
Fig. 10
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-5-3

8. REMOVE THE TURBOCHARGER.

NOTE: Refer to TURBOCHARGER in CHAPTER 51.

SM3-J615
Fig. 11
9. 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.

SM3-J616
Fig. 12
10. REMOVE THE EXHAUST MANIFOLD.

SM3-J617
Fig. 13
11. 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.

SM3-J619A
Fig. 14
12. REMOVE THE FAN CLUTCH TOGETHER WITH THE
COOLING FAN.

SM3-J620
Fig. 15
 1 page 1
3-5-4 ENGINE Models J08C-TP and J08C-TR

13. REMOVE THE THERMOSTAT CASE.

SM3-J621
Fig. 16
14. REMOVE THE COOLANT PUMP.

SM3-J622
Fig. 17
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-6-1

CAMSHAFT HOUSING AND CYLINDER HEAD

2
7

3
11
8 10
4 9
5

15
13
14
12

16

28
17 29

21
22
23
24
25
26
27

30
18
31 20

32
18 19
33
SM3-J264A
Fig. 1
 1 page 1
3-6-2 ENGINE Models J08C-TP and J08C-TR

35

34

1. Oil filler cap

2. Cylinder head cover 20. Idler gear shaft
3. Silent block 21. Cross head
4. Spacer 22. Valve spring retainer
5. Head cover gasket 23. Valve spring seat upper
6. Valve rocker shaft 24. Valve spring outer
7. Lock nut 25. Valve spring inner
8. Valve rocker arm 26. Valve stem seal
9. Adjusting screw 27. Valve spring seat lower
10. Nozzle clamp 28. Cross head adjusting screw
11. Valve rocker support 29. Lock nut
12. Camshaft bearing 30. Cylinder head
13. Camshaft bearing cap 31. Cylinder head gasket
14. Camshaft 32. Valve seat
15. Camshaft drive gear 33. Valve
16. Camshaft housing 34. Valve stem guide
17. Camshaft housing gasket 35. Nozzle seat
18. Idler gear thrust plate
19. Camshaft idler gear
SM3-J265
Fig. 2
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.
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-6-3

DISMOUNTING
1. REMOVE THE CYLINDER HEAD COVER.
NOTE: Clean all dust from around the cylinder head
cover before removing it to prevent foreign parti-
cles from getting in.

SM3-J623
Fig. 3
2. REMOVE THE INJECTION NOZZLE.
1. Remove the leakage pipe.
NOZZLE CLAMP BOLT 2. Loosen the injection pipe nut.
LEAKAGE PIPE 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.

CAM HOUSING

O-RING

NOZZLE HOLDER
ASSEMBLY

SM3-J178
Fig. 4
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.

SM3-J624
Fig. 5
 1 page 1
3-6-4 ENGINE Models J08C-TP and J08C-TR

3. LOOSEN THE VALVE CLEARANCE ADJUSTING

LOCK NUT 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.
ADJUSTING
SCREW
SM3-J056
Fig. 6
4. REMOVE THE ROCKER ARM ASSEMBLY.
1. Remove the rocker arm support bolt in the order as
ROCKER ARM SUPPORT shown in the figure.
NOTE: When the rocker arm assembly is removed, the
rocker arm and rocker arm support tend to come
7 5 3 1 2 4 6 off the rocker shaft. Be careful in handling.

SM3-J266
Fig. 7
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.

SM3-J625
Fig. 8
6. REMOVE THE CAM HOUSING.
1. Remove the cam housing bolts.
2. Tap and remove the cam housing with a plastic ham-
mer.

SM3-J626
Fig. 9
7. REMOVE THE CYLINDER HEAD BOLTS.
Remove the cylinder head bolts in the or-
der as shown in the figure.

SM3-J276B
Fig. 10
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-6-5

8. LIFT AND REMOVE THE CYLINDER HEAD FROM THE

CYLINDER BLOCK.
Special tool: Eye bolt (09433 - 1070)
NOTE:
● Place a piece of wood between the cylinder head and
table.
● When removing the cylinder head together with the
injection nozzle, avoid contact between the injection
SM3-J627 nozzle and a piece of wood.
Fig. 11
● Check that there is no oil, water or gas leakage in the
cylinder head gasket if overheated or not.
 1 page 1
3-6-6 ENGINE Models J08C-TP and J08C-TR

DISASSEMBLING
REMOVE THE CAM IDLER GEAR.
1. Remove the cam idler gear.

SM3-J628
Fig. 12
2. Using the special tool, remove the cam idler gear.
Special tool: Sliding hammer (09420 - 1830)

SM3-J629
Fig. 13
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)

SM3-J060
Fig. 14
2. Remove the valve spring seat upper, valve spring
outer and inner.
IN 3. Remove the intake and exhaust valves from the cyl-
inder head.
NOTE:
EX ● Do not remove the valve guide and valve spring seat
lower unless they need to be replaced.
● Align the removed parts in the order of the cylinder
SM3-J061A
No.
Fig. 15
 1 page 1
Models J08C-TP and J08C-TR ENGINE 3-6-7

INSPECTION AND REPAIR

CYLINDER HEAD
NOTE:
● Clean the cylinder head thoroughly with a commercial
cleaning agent before inspection.
● Do not damage the lower surface of the cylinder head.

SM3-J062
Fig. 16
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.

SM3-J103
Fig. 17
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 service limits, replace the cylinder
head.
Standard: 0.06 mm (0.0024 in.) or less for longitudinal di-
rection
0.03 mm (0.0012 in.) or less for lateral direc-
SM3-J630 tion
Fig. 18 Service limit: 0.20 mm (0.0079 in.)

E’ F’ G’
B A’
C C’

D D’
A G B’
E F
SM3-J505
Fig. 19
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 direc-
tion
Service limit: 0.20 mm (0.0079 in.)

SM3-J506
Fig. 20