HINO Trucks J08E-TA, J08E-TB, J08E-TV, J08E-TW, J08E-VB, J08E-V, J08E-WU, J08C-TI Engines Workshop Manual
Complete repair service manual with electrical wiring diagrams for HINO Trucks J05E Engines, with technical information to maintain, diagnose repair, and service like professional mechanics.
HINO Trucks J08E-TA, J08E-TB, J08E-TV, J08E-TW, J08E-VB, J08E-V, J08E-WU, J08C-TI Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
S5-UJ08E02B - J08E-TA, J08E-TB Engine Workshop Manual (2002).pdf
S5-UJ08E04C - J08E-TV, J08E-TW Engine Workshop Manual (2005).pdf
S5-UJ08E05B - J08E-TV, J08E-TW Engine Workshop Manual (2009).pdf
S5-UJ08E09A - J08E-VB, J08E-VC Engine Workshop Manual (11_12_13 CONVENTIONAL) .pdf
S5-UJ08E10A - J08E-VB, J08E-VC Engine Workshop Manual.pdf
S5-UJ08E10A - J08E-VB, J08E-VC Engine Workshop Manual (2014 CONVENTIONAL).pdf
S5-UJ08E11A - J08E-VB, J08E-VC Engine Workshop Manual.pdf
S5-UJ08E11A - J08E-VB, J08E-VC Engine Workshop Manual (2015 CONVENTIONAL).pdf
S5-UJ08E12A - J08E-VB, J08E-VC Engine Workshop Manual.pdf
S5-UJ08E12A - J08E-VB, J08E-VC Engine Workshop Manual (2016 CONVENTIONAL).pdf
S5-UJ08E13A - J08E-VB, J08E-WU Engine Workshop Manual (2017).pdf
S5-UJ08E14A - J08E-VB, J08E-WU Engine Workshop Manual (2018).pdf
S5-YJ08E29E - J08E-TI Engine Workshop Manual.pdf
S7-UNAE14A - J08E-VB, J08E-WU Engine Workshop Manual (Troubleshooting).pdf
S5-YJ08E17A - J08C-TI Engine Workshop Manual.pdf
Total Pages: 5,902 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
GENERAL INTRODUCTION
ENGINE
HYBRID
WORKSHOP
MANUAL
TRANSMISSION
CLUTCH
PROPELLER SHAFT
AXLE
DIFFERENTIAL
BRAKE
STEERING
SUSPENSION
FRAME AND FRAME ACCESSORY
CAB MOUNTING AND CAB SUSPENSION
BODY CONSTRUCTION
BODY INSIDE ACCESSORY
BODY OUTSIDE ACCESSORY
AIR BAG AND SEAT BELT
HEATER AND AIR CONDITIONER
ELECTRICAL
CONTROL SYSTEM
...
GENERAL INTRODUCTION
ENGINE INTRODUCTION
ENGINE MECHANICAL
AIR INTAKE SYSTEM
EXHAUST SYSTEM
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
TURBOCHARGER
FUEL INJECTION PUMP
EMISSION CONTROL
ALTERNATOR
STARTER
AIR COMPRESSOR
ENGINE PTO (POWER TAKE-OFF)
ENGINE RETARDER
ENGINE CONTROLS
INDEX
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
...
TABLE OF CONTENTS
S5-UJ08E02B - J08E-TA, J08E-TB Engine Workshop Manual (2002).....1
S5-UJ08E04C - J08E-TV, J08E-TW Engine Workshop Manual (2005).....352
S5-UJ08E05B - J08E-TV, J08E-TW Engine Workshop Manual (2009).....774
S5-UJ08E09A - J08E-VB, J08E-VC Engine Workshop Manual (11_12_13 CONVENTIONAL) .....1192
FOREWORD.....1192
CHAPTER.....1193
INDEX.....1194
GENERAL INTRODUCTION.....1195
GENERAL PRECAUTIONS.....1196
GENERAL PRECAUTIONS.....1196
HOW TO USE THIS WORKSHOP MANUAL.....1199
IDENTIFICATION INFORMATION.....1201
PRECAUTIONS.....1202
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....1205
DISMOUNTING AND MOUNTING.....1206
SYMPTOM SIMULATION.....1209
GLOSSARY OF SAE AND HINO TERMS.....1211
ENGINE INTRODUCTION.....1214
ENGINE ASSEMBLY.....1215
DATA AND SPECIFICATIONS.....1215
TROUBLESHOOTING.....1217
TROUBLESHOOTING (COMMON RAIL SYSTEM).....1224
ENGINE TUNEUP.....1225
SPECIAL TOOL.....1231
OVERHAUL CRITERIA.....1232
DISMOUNTING AND MOUNTING.....1233
LIQUID GASKET AND APPLICATIONPOINTS.....1235
ENGINE MECHANICAL.....1240
CYLINDER HEAD.....1241
COMPONENT LOCATOR.....1241
SPECIAL TOOL.....1244
OVERHAUL.....1245
INSPECTION AND REPAIR.....1256
CRANKSHAFT FRONT END.....1260
COMPONENT LOCATOR.....1260
SPECIAL TOOL.....1261
OVERHAUL.....1262
FLYWHEEL AND FLYWHEEL HOUSING.....1264
COMPONENT LOCATOR.....1264
SPECIAL TOOL.....1265
OVERHAUL.....1265
INSPECTION AND REPAIR.....1271
TIMING GEAR.....1272
COMPONENT LOCATOR.....1272
SPECIAL TOOL.....1273
OVERHAUL.....1274
INSPECTION AND REPAIR.....1276
MAIN MOVING PARTS AND CYLINDER BLOCK.....1278
COMPONENT LOCATOR.....1278
SPECIAL TOOL.....1281
OVERHAUL.....1283
INSPECTION AND REPAIR.....1296
AIR INTAKE SYSTEM.....1300
AIR INTAKE MANIFOLD AND PIPE.....1301
COMPONENT LOCATOR.....1301
DISMOUNTING AND MOUNTING.....1302
AIR INTAKE.....1303
COMPONENT LOCATOR.....1303
AIR CLEANER.....1304
DESCRIPTION.....1304
OVERHAUL.....1305
AIR HOSE.....1306
COMPONENT LOCATOR.....1306
OVERHAUL.....1307
AIR FLOW SENSOR.....1308
COMPONENT LOCATOR.....1308
REPLACEMENT.....1309
BOOST PRESSURE SENSOR.....1310
COMPONENT LOCATOR.....1310
REPLACEMENT.....1311
EXHAUST SYSTEM.....1312
EXHAUST MANIFOLD AND PIPE.....1313
COMPONENT LOCATOR.....1313
DISMOUNTING AND MOUNTING.....1314
EXHAUST PIPE AND MUFFLER UNIT.....1315
DESCRIPTION.....1315
COMPONENT LOCATOR.....1316
OVERHAUL.....1322
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....1333
SYSTEM CONFIGURATION.....1333
STRUCTURE OF DPR-CLEANER.....1334
DPR MAINTENANCE.....1335
DPR INSPECTION.....1335
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....1336
INSPECTION BY WAY OF HINO-DX.....1337
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....1340
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO-DX.....1343
CHECKING THE DPR STATE.....1343
REPLACEMENT OF DPR FILTER.....1344
OVERALL OPERATION FLOW.....1348
DIFFERENTIAL PRESSURE SENSOR.....1356
COMPONENT LOCATOR.....1356
DISMOUNTING AND MOUNTING.....1357
EXHAUST CONTROL CYLINDER.....1360
SYSTEM CONFIGURATION.....1360
DPR INSPECTION CHECK SHEET.....1361
LUBRICATING SYSTEM.....1364
LUBRICATING SYSTEM.....1365
DIAGRAM.....1365
OIL PUMP AND OIL STRAINER.....1367
COMPONENT LOCATOR.....1367
OVERHAUL.....1368
INSPECTION AND REPAIR.....1369
OIL FILTER AND OIL COOLER.....1371
COMPONENT LOCATOR.....1371
SPECIAL TOOL.....1372
DISMOUNTING AND MOUNTING.....1373
INSPECTION AND REPAIR.....1374
COOLING SYSTEM.....1375
COOLING SYSTEM.....1376
DIAGRAM.....1376
COOLANT PUMP.....1377
COMPONENT LOCATOR.....1377
THERMOSTAT.....1378
COMPONENT LOCATOR.....1378
OVERHAUL.....1379
RADIATOR AND INTERCOOLER.....1381
COMPONENT LOCATOR.....1381
OVERHAUL.....1381
RADIATOR.....1383
COMPONENT LOCATOR.....1383
SPECIAL TOOL.....1384
OVERHAUL.....1384
INSPECTION AND REPAIR.....1388
COOLING FAN.....1389
COMPONENT LOCATOR.....1389
INSPECTION AND REPAIR.....1390
FUEL SYSTEM .....1391
FUEL SYSTEM.....1392
DIAGRAM.....1392
COMPONENT LOCATOR.....1393
SUPPLY PUMP.....1394
DESCRIPTION.....1394
COMPONENT LOCATOR.....1395
SPECIAL TOOL.....1395
OVERHAUL.....1396
COMMON RAIL.....1404
DESCRIPTION.....1404
INSPECTION.....1404
REPLACEMENT.....1406
INJECTOR.....1410
DESCRIPTION.....1410
REPLACEMENT.....1411
FUEL FILTER.....1419
DESCRIPTION.....1419
SPECIAL TOOL.....1421
AIR BLEEDING.....1421
BUBBLE SEPARATOR.....1423
DESCRIPTION.....1423
FUEL TANK.....1424
COMPONENT LOCATOR.....1424
TURBOCHARGER.....1425
TURBOCHARGER.....1426
DESCRIPTION.....1426
TROUBLESHOOTING.....1427
OVERHAUL CRITERIA.....1436
EMISSION CONTROL.....1438
EGR VALVE AND EGR PIPE.....1439
COMPONENT LOCATOR.....1439
EGR VALVE.....1440
DESCRIPTION.....1440
DISMOUNTING AND MOUNTING.....1441
CLOSED VENTILATOR.....1444
DESCRIPTION.....1444
REPLACEMENT OF CLOSED VENTILATOR.....1444
SELECTIVE CATALYTIC REDUCTION (SCR).....1445
GENERAL DESCRIPTION.....1445
COMPONENT LOCATOR.....1447
DISMOUNTING AND MOUNTING.....1448
INSPECTION AND REPAIR.....1463
BURNER SYSTEM.....1464
COMPONENT LOCATOR.....1464
BURNER SYSTEM WARNING AND CAUTION.....1465
DISMOUNTING AND MOUNTING.....1466
INSPECTION AND REPAIR.....1475
ALTERNATOR.....1476
ALTERNATOR.....1477
DATA AND SPECIFICATIONS.....1477
TROUBLESHOOTING.....1477
COMPONENT LOCATOR.....1478
OVERHAUL.....1479
INSPECTION AND REPAIR.....1482
STARTER.....1483
STARTER.....1484
DATA AND SPECIFICATIONS.....1484
DESCRIPTION.....1484
TROUBLESHOOTING.....1485
COMPONENT LOCATOR.....1486
OVERHAUL.....1487
INSPECTION AND REPAIR.....1491
AIR COMPRESSOR.....1494
AIR COMPRESSOR.....1495
DATA AND SPECIFICATIONS.....1495
DESCRIPTION.....1496
TROUBLESHOOTING.....1497
COMPONENT LOCATOR.....1498
SPECIAL TOOL.....1499
OVERHAUL.....1499
INSPECTION AND REPAIR.....1507
ENGINE CONTROL.....1511
ACCELERATOR PEDAL.....1512
DESCRIPTION.....1512
ENGINE ECU.....1513
COMPONENT LOCATOR.....1513
REPLACEMENT.....1514
S5-UJ08E10A - J08E-VB, J08E-VC Engine Workshop Manual (2014 CONVENTIONAL).....1521
FOREWORD.....1521
CHAPTER REFERENCES.....1522
INDEX.....1523
GENERAL INTRODUCTION (ENGINE).....1525
GENERAL INTRODUCTION (ENGINE).....1526
GENERAL PRECAUTIONS.....1526
HOW TO USE THIS WORKSHOP MANUAL.....1529
IDENTIFICATION INFORMATION.....1531
PRECAUTIONS.....1532
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....1535
DISMOUNTING AND MOUNTING.....1536
SYMPTOM SIMULATION.....1539
GLOSSARY OF SAE AND HINO TERMS.....1541
ENGINE INTRODUCTION (J08E).....1544
ENGINE ASSEMBLY.....1545
DATA AND SPECIFICATIONS.....1545
TROUBLESHOOTING.....1547
TROUBLESHOOTING (COMMON RAIL SYSTEM).....1554
ENGINE TUNEUP.....1555
SPECIAL TOOL.....1561
OVERHAUL CRITERIA.....1562
DISMOUNTING AND MOUNTING.....1563
LIQUID GASKET AND APPLICATION POINTS.....1565
ENGINE MECHANICAL (J08E).....1570
CYLINDER HEAD.....1571
COMPONENT LOCATOR.....1571
SPECIAL TOOL.....1574
OVERHAUL.....1575
INSPECTION AND REPAIR.....1586
CRANKSHAFT FRONT END.....1590
COMPONENT LOCATOR.....1590
SPECIAL TOOL.....1591
OVERHAUL.....1592
FLYWHEEL AND FLYWHEEL HOUSING.....1594
COMPONENT LOCATOR.....1594
SPECIAL TOOL.....1595
OVERHAUL.....1595
INSPECTION AND REPAIR.....1601
TIMING GEAR.....1602
COMPONENT LOCATOR.....1602
SPECIAL TOOL.....1603
OVERHAUL.....1604
INSPECTION AND REPAIR.....1606
MAIN MOVING PARTS AND CYLINDER BLOCK.....1608
COMPONENT LOCATOR.....1608
SPECIAL TOOL.....1611
OVERHAUL.....1613
INSPECTION AND REPAIR.....1626
AIR INTAKE SYSTEM (J08E).....1630
AIR INTAKE MANIFOLD AND PIPE.....1631
COMPONENT LOCATOR.....1631
DISMOUNTING AND MOUNTING.....1632
AIR INTAKE.....1633
COMPONENT LOCATOR.....1633
AIR CLEANER.....1634
DESCRIPTION.....1634
OVERHAUL.....1635
AIR HOSE .....1636
COMPONENT LOCATOR.....1636
OVERHAUL.....1637
AIR FLOW SENSOR.....1638
COMPONENT LOCATOR.....1638
REPLACEMENT.....1639
BOOST PRESSURE SENSOR.....1640
COMPONENT LOCATOR.....1640
REPLACEMENT.....1641
EXHAUST SYSTEM (J08E).....1642
EXHAUST MANIFOLD AND PIPE.....1643
COMPONENT LOCATOR.....1643
DISMOUNTING AND MOUNTING.....1644
EXHAUST PIPE AND MUFFLER UNIT.....1645
DESCRIPTION.....1645
COMPONENT LOCATOR.....1646
OVERHAUL.....1652
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....1663
SYSTEM CONFIGURATION.....1663
STRUCTURE OF DPR-CLEANER.....1664
DPR MAINTENANCE.....1665
DPR INSPECTION.....1665
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....1666
INSPECTION BY WAY OF HINO-DX.....1667
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....1671
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO-DX.....1674
CHECKING THE DPR STATE.....1674
REPLACEMENT OF DPR FILTER.....1675
OVERALL OPERATION FLOW.....1679
DIFFERENTIAL PRESSURE SENSOR.....1687
COMPONENT LOCATOR.....1687
DISMOUNTING AND MOUNTING.....1688
EXHAUST CONTROL CYLINDER.....1691
SYSTEM CONFIGURATION.....1691
DPR INSPECTION CHECK SHEET.....1692
LUBRICATING SYSTEM (J08E).....1695
LUBRICATING SYSTEM.....1696
DIAGRAM.....1696
OIL PUMP AND OIL STRAINER.....1698
COMPONENT LOCATOR.....1698
OVERHAUL.....1699
INSPECTION AND REPAIR.....1700
OIL FILTER AND OIL COOLER.....1702
COMPONENT LOCATOR.....1702
SPECIAL TOOL.....1703
DISMOUNTING AND MOUNTING.....1704
INSPECTION AND REPAIR.....1705
COOLING SYSTEM (J08E).....1706
COOLING SYSTEM.....1707
DIAGRAM.....1707
COOLANT PUMP.....1708
COMPONENT LOCATOR.....1708
THERMOSTAT.....1709
COMPONENT LOCATOR.....1709
OVERHAUL.....1710
RADIATOR AND INTERCOOLER.....1712
COMPONENT LOCATOR.....1712
OVERHAUL.....1712
RADIATOR.....1714
COMPONENT LOCATOR.....1714
SPECIAL TOOL.....1715
OVERHAUL.....1715
INSPECTION AND REPAIR.....1719
COOLING FAN.....1720
COMPONENT LOCATOR.....1720
INSPECTION AND REPAIR.....1721
FUEL SYSTEM (J08E).....1722
FUEL SYSTEM.....1723
DIAGRAM.....1723
COMPONENT LOCATOR.....1724
SUPPLY PUMP.....1725
DESCRIPTION.....1725
COMPONENT LOCATOR.....1726
SPECIAL TOOL.....1726
OVERHAUL.....1727
COMMON RAIL.....1736
DESCRIPTION.....1736
INSPECTION.....1736
REPLACEMENT.....1738
INJECTOR.....1742
DESCRIPTION.....1742
REPLACEMENT.....1743
FUEL FILTER.....1751
DESCRIPTION.....1751
AIR BLEEDING.....1752
BUBBLE SEPARATOR.....1754
DESCRIPTION.....1754
BUBBLE SEPARATOR.....1755
COMPONENT LOCATOR.....1755
TURBOCHARGER (J08E).....1757
TURBOCHARGER.....1758
DESCRIPTION.....1758
TROUBLESHOOTING.....1759
OVERHAUL CRITERIA.....1775
EMISSION CONTROL (J08E).....1777
EGR VALVE AND EGR PIPE.....1778
COMPONENT LOCATOR.....1778
EGR VALVE.....1779
DESCRIPTION.....1779
DISMOUNTING AND MOUNTING.....1780
CLOSED VENTILATOR.....1783
DESCRIPTION.....1783
REPLACEMENT OF CLOSED VENTILATOR.....1783
SELECTIVE CATALYTIC REDUCTION (SCR).....1784
GENERAL DESCRIPTION.....1784
COMPONENT LOCATOR.....1786
INSPECTION.....1787
DISMOUNTING AND MOUNTING.....1788
INSPECTION AND REPAIR.....1803
BURNER SYSTEM.....1804
COMPONENT LOCATOR.....1804
BURNER SYSTEM WARNING AND CAUTION.....1805
DISMOUNTING AND MOUNTING.....1806
INSPECTION AND REPAIR.....1815
ALTERNATOREN1(J08E: REMY 12V-130A,135A,180A).....1816
ALTERNATOR.....1817
DATA AND SPECIFICATIONS.....1817
TROUBLESHOOTING.....1817
COMPONENT LOCATOR.....1818
OVERHAUL.....1819
INSPECTION AND REPAIR.....1822
STARTER (J08E).....1823
STARTER.....1824
DATA AND SPECIFICATIONS.....1824
DESCRIPTION.....1824
TROUBLESHOOTING.....1825
COMPONENT LOCATOR.....1826
OVERHAUL.....1827
INSPECTION AND REPAIR.....1831
AIR COMPRESSOR (J08E: 340 cm3).....1834
AIR COMPRESSOR.....1835
DATA AND SPECIFICATIONS.....1835
DESCRIPTION.....1836
TROUBLESHOOTING.....1837
COMPONENT LOCATOR.....1838
SPECIAL TOOL.....1839
OVERHAUL.....1839
INSPECTION AND REPAIR.....1847
ENGINE CONTROL (J08E).....1850
ACCELERATOR PEDAL.....1851
DESCRIPTION.....1851
ENGINE ECU.....1852
COMPONENT LOCATOR.....1852
REPLACEMENT.....1853
S5-UJ08E10A - J08E-VB, J08E-VC Engine Workshop Manual.....1860
FOREWORD.....1860
CHAPTER REFERENCES.....1861
INDEX.....1862
GENERAL INTRODUCTION (ENGINE).....1864
GENERAL INTRODUCTION (ENGINE).....1865
GENERAL PRECAUTIONS.....1865
HOW TO USE THIS WORKSHOP MANUAL.....1868
IDENTIFICATION INFORMATION.....1870
PRECAUTIONS.....1871
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....1874
DISMOUNTING AND MOUNTING.....1875
SYMPTOM SIMULATION.....1878
GLOSSARY OF SAE AND HINO TERMS.....1880
ENGINE INTRODUCTION (J08E).....1883
ENGINE ASSEMBLY.....1884
DATA AND SPECIFICATIONS.....1884
TROUBLESHOOTING.....1886
TROUBLESHOOTING (COMMON RAIL SYSTEM).....1893
ENGINE TUNEUP.....1894
SPECIAL TOOL.....1900
OVERHAUL CRITERIA.....1901
DISMOUNTING AND MOUNTING.....1902
LIQUID GASKET AND APPLICATION POINTS.....1904
ENGINE MECHANICAL (J08E).....1909
CYLINDER HEAD.....1910
COMPONENT LOCATOR.....1910
SPECIAL TOOL.....1913
OVERHAUL.....1914
INSPECTION AND REPAIR.....1925
CRANKSHAFT FRONT END.....1929
COMPONENT LOCATOR.....1929
SPECIAL TOOL.....1930
OVERHAUL.....1931
FLYWHEEL AND FLYWHEEL HOUSING.....1933
COMPONENT LOCATOR.....1933
SPECIAL TOOL.....1934
OVERHAUL.....1934
INSPECTION AND REPAIR.....1940
TIMING GEAR.....1941
COMPONENT LOCATOR.....1941
SPECIAL TOOL.....1942
OVERHAUL.....1943
INSPECTION AND REPAIR.....1945
MAIN MOVING PARTS AND CYLINDER BLOCK.....1947
COMPONENT LOCATOR.....1947
SPECIAL TOOL.....1950
OVERHAUL.....1952
INSPECTION AND REPAIR.....1965
AIR INTAKE SYSTEM (J08E).....1969
AIR INTAKE MANIFOLD AND PIPE.....1970
COMPONENT LOCATOR.....1970
DISMOUNTING AND MOUNTING.....1971
AIR INTAKE.....1972
COMPONENT LOCATOR.....1972
AIR CLEANER.....1973
DESCRIPTION.....1973
OVERHAUL.....1974
AIR HOSE .....1975
COMPONENT LOCATOR.....1975
OVERHAUL.....1976
AIR FLOW SENSOR.....1977
COMPONENT LOCATOR.....1977
REPLACEMENT.....1978
BOOST PRESSURE SENSOR.....1979
COMPONENT LOCATOR.....1979
REPLACEMENT.....1980
EXHAUST SYSTEM (J08E).....1981
EXHAUST MANIFOLD AND PIPE.....1982
COMPONENT LOCATOR.....1982
DISMOUNTING AND MOUNTING.....1983
EXHAUST PIPE AND MUFFLER UNIT.....1984
DESCRIPTION.....1984
COMPONENT LOCATOR.....1985
OVERHAUL.....1991
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....2002
SYSTEM CONFIGURATION.....2002
STRUCTURE OF DPR-CLEANER.....2003
DPR MAINTENANCE.....2004
DPR INSPECTION.....2004
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....2005
INSPECTION BY WAY OF HINO-DX.....2006
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....2010
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO-DX.....2013
CHECKING THE DPR STATE.....2013
REPLACEMENT OF DPR FILTER.....2014
OVERALL OPERATION FLOW.....2018
DIFFERENTIAL PRESSURE SENSOR.....2026
COMPONENT LOCATOR.....2026
DISMOUNTING AND MOUNTING.....2027
EXHAUST CONTROL CYLINDER.....2030
SYSTEM CONFIGURATION.....2030
DPR INSPECTION CHECK SHEET.....2031
LUBRICATING SYSTEM (J08E).....2034
LUBRICATING SYSTEM.....2035
DIAGRAM.....2035
OIL PUMP AND OIL STRAINER.....2037
COMPONENT LOCATOR.....2037
OVERHAUL.....2038
INSPECTION AND REPAIR.....2039
OIL FILTER AND OIL COOLER.....2041
COMPONENT LOCATOR.....2041
SPECIAL TOOL.....2042
DISMOUNTING AND MOUNTING.....2043
INSPECTION AND REPAIR.....2044
COOLING SYSTEM (J08E).....2045
COOLING SYSTEM.....2046
DIAGRAM.....2046
COOLANT PUMP.....2047
COMPONENT LOCATOR.....2047
THERMOSTAT.....2048
COMPONENT LOCATOR.....2048
OVERHAUL.....2049
RADIATOR AND INTERCOOLER.....2051
COMPONENT LOCATOR.....2051
OVERHAUL.....2051
RADIATOR.....2053
COMPONENT LOCATOR.....2053
SPECIAL TOOL.....2054
OVERHAUL.....2054
INSPECTION AND REPAIR.....2058
COOLING FAN.....2059
COMPONENT LOCATOR.....2059
INSPECTION AND REPAIR.....2060
FUEL SYSTEM (J08E).....2061
FUEL SYSTEM.....2062
DIAGRAM.....2062
COMPONENT LOCATOR.....2063
SUPPLY PUMP.....2064
DESCRIPTION.....2064
COMPONENT LOCATOR.....2065
SPECIAL TOOL.....2065
OVERHAUL.....2066
COMMON RAIL.....2075
DESCRIPTION.....2075
INSPECTION.....2075
REPLACEMENT.....2077
INJECTOR.....2081
DESCRIPTION.....2081
REPLACEMENT.....2082
FUEL FILTER.....2090
DESCRIPTION.....2090
AIR BLEEDING.....2091
BUBBLE SEPARATOR.....2093
DESCRIPTION.....2093
BUBBLE SEPARATOR.....2094
COMPONENT LOCATOR.....2094
TURBOCHARGER (J08E).....2096
TURBOCHARGER.....2097
DESCRIPTION.....2097
TROUBLESHOOTING.....2098
OVERHAUL CRITERIA.....2114
EMISSION CONTROL (J08E).....2116
EGR VALVE AND EGR PIPE.....2117
COMPONENT LOCATOR.....2117
EGR VALVE.....2118
DESCRIPTION.....2118
DISMOUNTING AND MOUNTING.....2119
CLOSED VENTILATOR.....2122
DESCRIPTION.....2122
REPLACEMENT OF CLOSED VENTILATOR.....2122
SELECTIVE CATALYTIC REDUCTION (SCR).....2123
GENERAL DESCRIPTION.....2123
COMPONENT LOCATOR.....2125
INSPECTION.....2126
DISMOUNTING AND MOUNTING.....2127
INSPECTION AND REPAIR.....2142
BURNER SYSTEM.....2143
COMPONENT LOCATOR.....2143
BURNER SYSTEM WARNING AND CAUTION.....2144
DISMOUNTING AND MOUNTING.....2145
INSPECTION AND REPAIR.....2154
ALTERNATOREN1(J08E: REMY 12V-130A,135A,180A).....2155
ALTERNATOR.....2156
DATA AND SPECIFICATIONS.....2156
TROUBLESHOOTING.....2156
COMPONENT LOCATOR.....2157
OVERHAUL.....2158
INSPECTION AND REPAIR.....2161
STARTER (J08E).....2162
STARTER.....2163
DATA AND SPECIFICATIONS.....2163
DESCRIPTION.....2163
TROUBLESHOOTING.....2164
COMPONENT LOCATOR.....2165
OVERHAUL.....2166
INSPECTION AND REPAIR.....2170
AIR COMPRESSOR (J08E: 340 cm3).....2173
AIR COMPRESSOR.....2174
DATA AND SPECIFICATIONS.....2174
DESCRIPTION.....2175
TROUBLESHOOTING.....2176
COMPONENT LOCATOR.....2177
SPECIAL TOOL.....2178
OVERHAUL.....2178
INSPECTION AND REPAIR.....2186
ENGINE CONTROL (J08E).....2189
ACCELERATOR PEDAL.....2190
DESCRIPTION.....2190
ENGINE ECU.....2191
COMPONENT LOCATOR.....2191
REPLACEMENT.....2192
S5-UJ08E11A - J08E-VB, J08E-VC Engine Workshop Manual (2015 CONVENTIONAL).....2199
FOREWORD.....2199
CHAPTER REFERENCES.....2200
INDEX.....2201
GENERAL INTRODUCTION (ENGINE).....2203
GENERAL INTRODUCTION .....2204
GENERAL PRECAUTIONS.....2204
HOW TO USE THIS WORKSHOP MANUAL.....2207
IDENTIFICATION INFORMATION.....2209
PRECAUTIONS.....2210
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....2213
DISMOUNTING AND MOUNTING.....2214
SYMPTOM SIMULATION.....2217
GLOSSARY OF SAE AND HINO TERMS.....2219
ENGINE INTRODUCTION.....2222
ENGINE ASSEMBLY.....2223
DATA AND SPECIFICATIONS.....2223
TROUBLESHOOTING.....2225
TROUBLESHOOTING (COMMON RAIL SYSTEM).....2232
ENGINE TUNEUP.....2233
SPECIAL TOOL.....2239
OVERHAUL CRITERIA.....2240
DISMOUNTING AND MOUNTING.....2241
LIQUID GASKET AND APPLICATION POINTS.....2243
ENGINE MECHANICAL.....2248
CYLINDER HEAD.....2249
COMPONENT LOCATOR.....2249
SPECIAL TOOL.....2252
OVERHAUL.....2253
INSPECTION AND REPAIR.....2264
CRANKSHAFT FRONT END.....2268
COMPONENT LOCATOR.....2268
SPECIAL TOOL.....2269
OVERHAUL.....2270
FLYWHEEL AND FLYWHEEL HOUSING.....2272
COMPONENT LOCATOR.....2272
SPECIAL TOOL.....2273
OVERHAUL.....2273
INSPECTION AND REPAIR.....2279
TIMING GEAR.....2280
COMPONENT LOCATOR.....2280
SPECIAL TOOL.....2281
OVERHAUL.....2282
INSPECTION AND REPAIR.....2284
MAIN MOVING PARTS AND CYLINDER BLOCK.....2286
COMPONENT LOCATOR.....2286
SPECIAL TOOL.....2289
OVERHAUL.....2291
INSPECTION AND REPAIR.....2304
AIR INTAKE SYSTEM.....2308
AIR INTAKE MANIFOLD AND PIPE.....2309
COMPONENT LOCATOR.....2309
DISMOUNTING AND MOUNTING.....2310
AIR INTAKE.....2311
COMPONENT LOCATOR.....2311
AIR CLEANER.....2312
DESCRIPTION.....2312
OVERHAUL.....2313
AIR HOSE.....2314
COMPONENT LOCATOR.....2314
OVERHAUL.....2316
AIR FLOW SENSOR.....2317
COMPONENT LOCATOR.....2317
REPLACEMENT.....2318
BOOST PRESSURE SENSOR.....2319
COMPONENT LOCATOR.....2319
REPLACEMENT.....2320
EXHAUST SYSTEM.....2321
EXHAUST MANIFOLD AND PIPE.....2322
COMPONENT LOCATOR.....2322
DISMOUNTING AND MOUNTING.....2323
EXHAUST PIPE AND MUFFLER UNIT.....2324
DESCRIPTION.....2324
COMPONENT LOCATOR.....2325
REPLACEMENT OF ATC.....2331
OVERHAUL.....2333
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....2342
SYSTEM CONFIGURATION.....2342
STRUCTURE OF DPR-CLEANER.....2343
DPR MAINTENANCE.....2344
DPR INSPECTION.....2344
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....2345
INSPECTION BY WAY OF HINO DX.....2346
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....2350
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX.....2353
CHECKING THE DPR STATE.....2353
REPLACEMENT OF DPR FILTER.....2354
OVERALL OPERATION FLOW.....2356
DIFFERENTIAL PRESSURE SENSOR.....2364
COMPONENT LOCATOR.....2364
DISMOUNTING AND MOUNTING.....2365
INSPECTION AND REPAIR.....2365
FUEL ADDITION VALVE.....2368
COMPONENT LOCATOR.....2368
OVERHAUL.....2369
EXHAUST CONTROL CYLINDER.....2379
SYSTEM CONFIGURATION.....2379
DPR INSPECTION CHECK SHEET.....2380
ATC UPSTREAM TEMPERATURE SENSOR.....2383
COMPONENT LOCATOR.....2383
OVERHAUL.....2384
LUBRICATING SYSTEM.....2385
LUBRICATING SYSTEM.....2386
DIAGRAM.....2386
OIL PUMP AND OIL STRAINER.....2388
COMPONENT LOCATOR.....2388
OVERHAUL.....2389
INSPECTION AND REPAIR.....2390
OIL FILTER AND OIL COOLER.....2392
COMPONENT LOCATOR.....2392
SPECIAL TOOL.....2393
DISMOUNTING AND MOUNTING.....2394
INSPECTION AND REPAIR.....2395
COOLING SYSTEM.....2396
COOLING SYSTEM.....2397
DIAGRAM.....2397
COOLANT PUMP.....2398
COMPONENT LOCATOR.....2398
THERMOSTAT.....2399
COMPONENT LOCATOR.....2399
OVERHAUL.....2400
RADIATOR AND INTERCOOLER.....2402
COMPONENT LOCATOR.....2402
OVERHAUL.....2402
RADIATOR.....2404
COMPONENT LOCATOR.....2404
SPECIAL TOOL.....2405
OVERHAUL.....2405
INSPECTION AND REPAIR.....2409
COOLING FAN.....2410
COMPONENT LOCATOR.....2410
INSPECTION AND REPAIR.....2411
FUEL SYSTEM.....2412
FUEL SYSTEM.....2413
DIAGRAM.....2413
COMPONENT LOCATOR.....2414
SUPPLY PUMP.....2415
DESCRIPTION.....2415
COMPONENT LOCATOR.....2416
SPECIAL TOOL.....2416
OVERHAUL.....2417
COMMON RAIL.....2426
DESCRIPTION.....2426
INSPECTION.....2426
REPLACEMENT.....2428
INJECTOR.....2432
DESCRIPTION.....2432
REPLACEMENT.....2433
FUEL FILTER.....2441
DESCRIPTION.....2441
AIR BLEEDING.....2442
FUEL FILTER (BUBBLE SEPARATOR).....2444
DESCRIPTION.....2444
OVERHAUL.....2445
FUEL TANK.....2448
COMPONENT LOCATOR.....2448
FUEL CUTOFF VALVE.....2450
COMPONENT LOCATOR.....2450
OVERHAUL.....2451
TURBOCHARGER.....2452
TURBOCHARGER.....2453
DESCRIPTION.....2453
TROUBLESHOOTING.....2454
REPLACEMENT.....2463
INSPECTION AFTER MOUNTING.....2469
EMISSION CONTROL.....2470
EGR VALVE AND EGR PIPE.....2471
COMPONENT LOCATOR.....2471
EGR VALVE.....2472
DESCRIPTION.....2472
DISMOUNTING AND MOUNTING.....2473
CLOSED VENTILATOR.....2476
DESCRIPTION.....2476
REPLACEMENT OF CLOSED VENTILATOR.....2476
REPLACING THE ELEMENT.....2477
SELECTIVE CATALYTIC REDUCTION (SCR).....2478
GENERAL DESCRIPTION.....2478
COMPONENT LOCATOR.....2480
INSPECTION.....2481
SPECIAL TOOL.....2482
DISMOUNTING AND MOUNTING.....2483
INSPECTION AND REPAIR.....2498
ALTERNATOR.....2499
ALTERNATOR.....2500
DATA AND SPECIFICATIONS.....2500
TROUBLESHOOTING.....2500
COMPONENT LOCATOR.....2501
OVERHAUL.....2502
INSPECTION AND REPAIR.....2505
STARTER.....2506
STARTER.....2507
DATA AND SPECIFICATIONS.....2507
DESCRIPTION.....2507
TROUBLESHOOTING.....2508
COMPONENT LOCATOR.....2509
OVERHAUL.....2510
INSPECTION AND REPAIR.....2514
AIR.....2517
AIR COMPRESSOR.....2518
DATA AND SPECIFICATIONS.....2518
DESCRIPTION.....2519
TROUBLESHOOTING.....2520
COMPONENT LOCATOR.....2521
SPECIAL TOOL.....2522
OVERHAUL.....2522
INSPECTION AND REPAIR.....2530
ENGINE CONTROL.....2533
ACCELERATOR PEDAL.....2534
DESCRIPTION.....2534
ENGINE ECU.....2535
COMPONENT LOCATOR.....2535
REPLACEMENT.....2536
S5-UJ08E11A - J08E-VB, J08E-VC Engine Workshop Manual.....2543
FOREWORD.....2543
CHAPTER REFERENCES.....2544
INDEX.....2545
GENERAL INTRODUCTION (ENGINE).....2547
GENERAL INTRODUCTION .....2548
GENERAL PRECAUTIONS.....2548
HOW TO USE THIS WORKSHOP MANUAL.....2551
IDENTIFICATION INFORMATION.....2553
PRECAUTIONS.....2554
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....2557
DISMOUNTING AND MOUNTING.....2558
SYMPTOM SIMULATION.....2561
GLOSSARY OF SAE AND HINO TERMS.....2563
ENGINE INTRODUCTION.....2566
ENGINE ASSEMBLY.....2567
DATA AND SPECIFICATIONS.....2567
TROUBLESHOOTING.....2569
TROUBLESHOOTING (COMMON RAIL SYSTEM).....2576
ENGINE TUNEUP.....2577
SPECIAL TOOL.....2583
OVERHAUL CRITERIA.....2584
DISMOUNTING AND MOUNTING.....2585
LIQUID GASKET AND APPLICATION POINTS.....2587
ENGINE MECHANICAL.....2592
CYLINDER HEAD.....2593
COMPONENT LOCATOR.....2593
SPECIAL TOOL.....2596
OVERHAUL.....2597
INSPECTION AND REPAIR.....2608
CRANKSHAFT FRONT END.....2612
COMPONENT LOCATOR.....2612
SPECIAL TOOL.....2613
OVERHAUL.....2614
FLYWHEEL AND FLYWHEEL HOUSING.....2616
COMPONENT LOCATOR.....2616
SPECIAL TOOL.....2617
OVERHAUL.....2617
INSPECTION AND REPAIR.....2623
TIMING GEAR.....2624
COMPONENT LOCATOR.....2624
SPECIAL TOOL.....2625
OVERHAUL.....2626
INSPECTION AND REPAIR.....2628
MAIN MOVING PARTS AND CYLINDER BLOCK.....2630
COMPONENT LOCATOR.....2630
SPECIAL TOOL.....2633
OVERHAUL.....2635
INSPECTION AND REPAIR.....2648
AIR INTAKE SYSTEM.....2652
AIR INTAKE MANIFOLD AND PIPE.....2653
COMPONENT LOCATOR.....2653
DISMOUNTING AND MOUNTING.....2654
AIR INTAKE.....2655
COMPONENT LOCATOR.....2655
AIR CLEANER.....2656
DESCRIPTION.....2656
OVERHAUL.....2657
AIR HOSE.....2658
COMPONENT LOCATOR.....2658
OVERHAUL.....2660
AIR FLOW SENSOR.....2661
COMPONENT LOCATOR.....2661
REPLACEMENT.....2662
BOOST PRESSURE SENSOR.....2663
COMPONENT LOCATOR.....2663
REPLACEMENT.....2664
EXHAUST SYSTEM.....2665
EXHAUST MANIFOLD AND PIPE.....2666
COMPONENT LOCATOR.....2666
DISMOUNTING AND MOUNTING.....2667
EXHAUST PIPE AND MUFFLER UNIT.....2668
DESCRIPTION.....2668
COMPONENT LOCATOR.....2669
REPLACEMENT OF ATC.....2675
OVERHAUL.....2677
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....2686
SYSTEM CONFIGURATION.....2686
STRUCTURE OF DPR-CLEANER.....2687
DPR MAINTENANCE.....2688
DPR INSPECTION.....2688
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....2689
INSPECTION BY WAY OF HINO DX.....2690
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....2694
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX.....2697
CHECKING THE DPR STATE.....2697
REPLACEMENT OF DPR FILTER.....2698
OVERALL OPERATION FLOW.....2700
DIFFERENTIAL PRESSURE SENSOR.....2708
COMPONENT LOCATOR.....2708
DISMOUNTING AND MOUNTING.....2709
INSPECTION AND REPAIR.....2709
FUEL ADDITION VALVE.....2712
COMPONENT LOCATOR.....2712
OVERHAUL.....2713
EXHAUST CONTROL CYLINDER.....2723
SYSTEM CONFIGURATION.....2723
DPR INSPECTION CHECK SHEET.....2724
ATC UPSTREAM TEMPERATURE SENSOR.....2727
COMPONENT LOCATOR.....2727
OVERHAUL.....2728
LUBRICATING SYSTEM.....2729
LUBRICATING SYSTEM.....2730
DIAGRAM.....2730
OIL PUMP AND OIL STRAINER.....2732
COMPONENT LOCATOR.....2732
OVERHAUL.....2733
INSPECTION AND REPAIR.....2734
OIL FILTER AND OIL COOLER.....2736
COMPONENT LOCATOR.....2736
SPECIAL TOOL.....2737
DISMOUNTING AND MOUNTING.....2738
INSPECTION AND REPAIR.....2739
COOLING SYSTEM.....2740
COOLING SYSTEM.....2741
DIAGRAM.....2741
COOLANT PUMP.....2742
COMPONENT LOCATOR.....2742
THERMOSTAT.....2743
COMPONENT LOCATOR.....2743
OVERHAUL.....2744
RADIATOR AND INTERCOOLER.....2746
COMPONENT LOCATOR.....2746
OVERHAUL.....2746
RADIATOR.....2748
COMPONENT LOCATOR.....2748
SPECIAL TOOL.....2749
OVERHAUL.....2749
INSPECTION AND REPAIR.....2753
COOLING FAN.....2754
COMPONENT LOCATOR.....2754
INSPECTION AND REPAIR.....2755
FUEL SYSTEM.....2756
FUEL SYSTEM.....2757
DIAGRAM.....2757
COMPONENT LOCATOR.....2758
SUPPLY PUMP.....2759
DESCRIPTION.....2759
COMPONENT LOCATOR.....2760
SPECIAL TOOL.....2760
OVERHAUL.....2761
COMMON RAIL.....2770
DESCRIPTION.....2770
INSPECTION.....2770
REPLACEMENT.....2772
INJECTOR.....2776
DESCRIPTION.....2776
REPLACEMENT.....2777
FUEL FILTER.....2785
DESCRIPTION.....2785
AIR BLEEDING.....2786
FUEL FILTER (BUBBLE SEPARATOR).....2788
DESCRIPTION.....2788
OVERHAUL.....2789
FUEL TANK.....2792
COMPONENT LOCATOR.....2792
FUEL CUTOFF VALVE.....2794
COMPONENT LOCATOR.....2794
OVERHAUL.....2795
TURBOCHARGER.....2796
TURBOCHARGER.....2797
DESCRIPTION.....2797
TROUBLESHOOTING.....2798
REPLACEMENT.....2807
INSPECTION AFTER MOUNTING.....2813
EMISSION CONTROL.....2814
EGR VALVE AND EGR PIPE.....2815
COMPONENT LOCATOR.....2815
EGR VALVE.....2816
DESCRIPTION.....2816
DISMOUNTING AND MOUNTING.....2817
CLOSED VENTILATOR.....2820
DESCRIPTION.....2820
REPLACEMENT OF CLOSED VENTILATOR.....2820
REPLACING THE ELEMENT.....2821
SELECTIVE CATALYTIC REDUCTION (SCR).....2822
GENERAL DESCRIPTION.....2822
COMPONENT LOCATOR.....2824
INSPECTION.....2825
SPECIAL TOOL.....2826
DISMOUNTING AND MOUNTING.....2827
INSPECTION AND REPAIR.....2842
ALTERNATOR.....2843
ALTERNATOR.....2844
DATA AND SPECIFICATIONS.....2844
TROUBLESHOOTING.....2844
COMPONENT LOCATOR.....2845
OVERHAUL.....2846
INSPECTION AND REPAIR.....2849
STARTER.....2850
STARTER.....2851
DATA AND SPECIFICATIONS.....2851
DESCRIPTION.....2851
TROUBLESHOOTING.....2852
COMPONENT LOCATOR.....2853
OVERHAUL.....2854
INSPECTION AND REPAIR.....2858
AIR.....2861
AIR COMPRESSOR.....2862
DATA AND SPECIFICATIONS.....2862
DESCRIPTION.....2863
TROUBLESHOOTING.....2864
COMPONENT LOCATOR.....2865
SPECIAL TOOL.....2866
OVERHAUL.....2866
INSPECTION AND REPAIR.....2874
ENGINE CONTROL.....2877
ACCELERATOR PEDAL.....2878
DESCRIPTION.....2878
ENGINE ECU.....2879
COMPONENT LOCATOR.....2879
REPLACEMENT.....2880
S5-UJ08E12A - J08E-VB, J08E-VC Engine Workshop Manual (2016 CONVENTIONAL).....2887
FO REWORD.....2887
CHAPTER REFERENCES.....2888
INDEX.....2889
GENERAL INTRODUCTION (ENGINE).....2891
GENERAL INTRODUCTION (ENGINE) .....2892
GENERAL PRECAUTIONS.....2892
HOW TO USE THIS WORKSHOP MANUAL.....2895
IDENTIFICATION INFORMATION.....2897
PRECAUTIONS.....2898
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....2901
DISMOUNTING AND MOUNTING.....2902
SYMPTOM SIMULATION.....2905
GLOSSARY OF SAE AND HINO TERMS.....2907
ENGINE INTRODUCTION (J08E).....2910
ENGINE ASSEMBLY.....2911
DATA AND SPECIFICATIONS.....2911
TROUBLESHOOTING.....2913
TROUBLESHOOTING (COMMON RAIL SYSTEM).....2920
ENGINE TUNEUP.....2921
SPECIAL TOOL.....2927
OVERHAUL CRITERIA.....2928
DISMOUNTING AND MOUNTING.....2929
LIQUID GASKET AND APPLICATION POINTS.....2931
ENGINE MECHANICAL (J08E).....2936
CYLINDER HEAD.....2937
COMPONENT LOCATOR.....2937
SPECIAL TOOL.....2940
OVERHAUL.....2941
INSPECTION AND REPAIR.....2952
CRANKSHAFT FRONT END.....2956
COMPONENT LOCATOR.....2956
SPECIAL TOOL.....2957
OVERHAUL.....2958
FLYWHEEL AND FLYWHEEL HOUSING.....2960
COMPONENT LOCATOR.....2960
SPECIAL TOOL.....2961
OVERHAUL.....2961
INSPECTION AND REPAIR.....2967
TIMING GEAR.....2968
COMPONENT LOCATOR.....2968
SPECIAL TOOL.....2969
OVERHAUL.....2970
INSPECTION AND REPAIR.....2972
MAIN MOVING PARTS AND CYLINDER BLOCK.....2974
COMPONENT LOCATOR.....2974
SPECIAL TOOL.....2977
OVERHAUL.....2979
INSPECTION AND REPAIR.....2992
AIR INTAKE SYSTEM (J08E).....2996
AIR INTAKE MANIFOLD AND PIPE.....2997
COMPONENT LOCATOR.....2997
DISMOUNTING AND MOUNTING.....2998
AIR INTAKE.....2999
COMPONENT LOCATOR.....2999
AIR CLEANER.....3000
DESCRIPTION.....3000
OVERHAUL.....3001
AIR HOSE.....3002
COMPONENT LOCATOR.....3002
OVERHAUL.....3003
AIR FLOW SENSOR.....3004
COMPONENT LOCATOR.....3004
REPLACEMENT.....3005
BOOST PRESSURE SENSOR.....3006
COMPONENT LOCATOR.....3006
REPLACEMENT.....3007
EXHAUST SYSTEM (J08E).....3008
EXHAUST MANIFOLD AND PIPE.....3009
COMPONENT LOCATOR.....3009
DISMOUNTING AND MOUNTING.....3010
EXHAUST PIPE AND MUFFLER UNIT.....3011
DESCRIPTION.....3011
COMPONENT LOCATOR.....3012
REPLACEMENT OF ATC.....3018
OVERHAUL.....3020
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....3029
SYSTEM CONFIGURATION.....3029
STRUCTURE OF DPR-CLEANER.....3030
DPR MAINTENANCE.....3031
DPR INSPECTION.....3031
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....3032
INSPECTION BY WAY OF HINO DX.....3033
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....3037
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX.....3040
CHECKING THE DPR STATE.....3040
REPLACEMENT OF DPR FILTER.....3041
OVERALL OPERATION FLOW.....3043
DIFFERENTIAL PRESSURE SENSOR.....3051
COMPONENT LOCATOR.....3051
DISMOUNTING AND MOUNTING.....3052
INSPECTION AND REPAIR.....3052
FUEL ADDITION VALVE.....3055
COMPONENT LOCATOR.....3055
OVERHAUL.....3056
EXHAUST CONTROL CYLINDER.....3066
SYSTEM CONFIGURATION.....3066
DPR INSPECTION CHECK SHEET.....3067
ATC UPSTREAM TEMPERATURE SENSOR.....3070
COMPONENT LOCATOR.....3070
OVERHAUL.....3071
LUBRICATING SYSTEM (J08E).....3072
LUBRICATING SYSTEM.....3073
DIAGRAM.....3073
OIL PUMP AND OIL STRAINER.....3075
COMPONENT LOCATOR.....3075
OVERHAUL.....3076
INSPECTION AND REPAIR.....3077
OIL FILTER AND OIL COOLER.....3079
COMPONENT LOCATOR.....3079
SPECIAL TOOL.....3080
DISMOUNTING AND MOUNTING.....3081
INSPECTION AND REPAIR.....3082
COOLING SYSTEM (J08E).....3083
COOLING SYSTEM.....3084
DIAGRAM.....3084
COOLANT PUMP.....3085
COMPONENT LOCATOR.....3085
THERMOSTAT.....3086
COMPONENT LOCATOR.....3086
OVERHAUL.....3087
RADIATOR AND INTERCOOLER.....3089
COMPONENT LOCATOR.....3089
OVERHAUL.....3089
RADIATOR.....3091
COMPONENT LOCATOR.....3091
SPECIAL TOOL.....3092
OVERHAUL.....3092
INSPECTION AND REPAIR.....3096
COOLING FAN.....3097
COMPONENT LOCATOR.....3097
INSPECTION AND REPAIR.....3098
FUEL SYSTEM (J08E).....3099
FUEL SYSTEM.....3100
DIAGRAM.....3100
COMPONENT LOCATOR.....3101
SUPPLY PUMP.....3102
DESCRIPTION.....3102
COMPONENT LOCATOR.....3103
SPECIAL TOOL.....3103
OVERHAUL.....3104
COMMON RAIL.....3113
DESCRIPTION.....3113
INSPENTION.....3114
REPLACEMENT.....3115
INJECTOR.....3119
DESCRIPTION.....3119
REPLACEMENT.....3120
PRE FUEL FILTER.....3128
DESCRIPTION.....3128
AIR BLEEDING.....3129
FUEL FILTER.....3131
DESCRIPTION.....3131
OVERHAUL.....3132
FUEL TANK.....3135
COMPONENT LOCATOR.....3135
FUEL CUTOFF VALVE.....3137
COMPONENT LOCATOR.....3137
OVERHAUL.....3138
TURBOCHARGER (J08E).....3139
TURBOCHARGER.....3140
DESCRIPTION.....3140
TROUBLESHOOTING.....3141
REPLACEMENT.....3150
INSPECTION AFTER MOUNTING.....3156
EMISSION CONTROL (J08E).....3157
EGR VALVE AND EGR PIPE.....3158
COMPONENT LOCATOR.....3158
EGR VALVE.....3159
DESCRIPTION.....3159
DISMOUNTING AND MOUNTING.....3160
CLOSED VENTILATOR.....3163
DESCRIPTION.....3163
REPLACEMENT OF CLOSED VENTILATOR.....3163
SELECTIVE CATALYTIC REDUCTION (SCR).....3165
GENERAL DESCRIPTION.....3165
COMPONENT LOCATOR.....3167
INSPECTION.....3168
SPECIAL TOOL.....3169
DISMOUNTING AND MOUNTING.....3170
INSPECTION AND REPAIR.....3185
ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A).....3186
ALTERNATOR.....3187
DATA AND SPECIFICATIONS.....3187
TROUBLESHOOTING.....3187
COMPONENT LOCATOR.....3188
OVERHAUL.....3189
INSPECTION AND REPAIR.....3192
STARTER (J08E).....3193
STARTER.....3194
DATA AND SPECIFICATIONS.....3194
DESCRIPTION.....3194
TROUBLESHOOTING.....3195
COMPONENT LOCATOR.....3196
OVERHAUL.....3197
INSPECTION AND REPAIR.....3201
AIR COMPRESSOR (J08E: 340 cm3).....3204
AIR COMPRESSOR.....3205
DATA AND SPECIFICATIONS.....3205
DESCRIPTION.....3206
TROUBLESHOOTING.....3207
COMPONENT LOCATOR.....3208
SPECIAL TOOL.....3209
OVERHAUL.....3209
INSPECTION AND REPAIR.....3217
ENGINE CONTROL (J08E).....3220
ACCELERATOR PEDAL.....3221
DESCRIPTION.....3221
ENGINE ECU.....3222
COMPONENT LOCATOR.....3222
REPLACEMENT.....3223
S5-UJ08E12A - J08E-VB, J08E-VC Engine Workshop Manual.....3230
FO REWORD.....3230
CHAPTER REFERENCES.....3231
INDEX.....3232
GENERAL INTRODUCTION (ENGINE).....3234
GENERAL INTRODUCTION (ENGINE) .....3235
GENERAL PRECAUTIONS.....3235
HOW TO USE THIS WORKSHOP MANUAL.....3238
IDENTIFICATION INFORMATION.....3240
PRECAUTIONS.....3241
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....3244
DISMOUNTING AND MOUNTING.....3245
SYMPTOM SIMULATION.....3248
GLOSSARY OF SAE AND HINO TERMS.....3250
ENGINE INTRODUCTION (J08E).....3253
ENGINE ASSEMBLY.....3254
DATA AND SPECIFICATIONS.....3254
TROUBLESHOOTING.....3256
TROUBLESHOOTING (COMMON RAIL SYSTEM).....3263
ENGINE TUNEUP.....3264
SPECIAL TOOL.....3270
OVERHAUL CRITERIA.....3271
DISMOUNTING AND MOUNTING.....3272
LIQUID GASKET AND APPLICATION POINTS.....3274
ENGINE MECHANICAL (J08E).....3279
CYLINDER HEAD.....3280
COMPONENT LOCATOR.....3280
SPECIAL TOOL.....3283
OVERHAUL.....3284
INSPECTION AND REPAIR.....3295
CRANKSHAFT FRONT END.....3299
COMPONENT LOCATOR.....3299
SPECIAL TOOL.....3300
OVERHAUL.....3301
FLYWHEEL AND FLYWHEEL HOUSING.....3303
COMPONENT LOCATOR.....3303
SPECIAL TOOL.....3304
OVERHAUL.....3304
INSPECTION AND REPAIR.....3310
TIMING GEAR.....3311
COMPONENT LOCATOR.....3311
SPECIAL TOOL.....3312
OVERHAUL.....3313
INSPECTION AND REPAIR.....3315
MAIN MOVING PARTS AND CYLINDER BLOCK.....3317
COMPONENT LOCATOR.....3317
SPECIAL TOOL.....3320
OVERHAUL.....3322
INSPECTION AND REPAIR.....3335
AIR INTAKE SYSTEM (J08E).....3339
AIR INTAKE MANIFOLD AND PIPE.....3340
COMPONENT LOCATOR.....3340
DISMOUNTING AND MOUNTING.....3341
AIR INTAKE.....3342
COMPONENT LOCATOR.....3342
AIR CLEANER.....3343
DESCRIPTION.....3343
OVERHAUL.....3344
AIR HOSE.....3345
COMPONENT LOCATOR.....3345
OVERHAUL.....3346
AIR FLOW SENSOR.....3347
COMPONENT LOCATOR.....3347
REPLACEMENT.....3348
BOOST PRESSURE SENSOR.....3349
COMPONENT LOCATOR.....3349
REPLACEMENT.....3350
EXHAUST SYSTEM (J08E).....3351
EXHAUST MANIFOLD AND PIPE.....3352
COMPONENT LOCATOR.....3352
DISMOUNTING AND MOUNTING.....3353
EXHAUST PIPE AND MUFFLER UNIT.....3354
DESCRIPTION.....3354
COMPONENT LOCATOR.....3355
REPLACEMENT OF ATC.....3361
OVERHAUL.....3363
DPR (DIESEL PARTICULATE REDUCTION SYSTEM).....3372
SYSTEM CONFIGURATION.....3372
STRUCTURE OF DPR-CLEANER.....3373
DPR MAINTENANCE.....3374
DPR INSPECTION.....3374
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....3375
INSPECTION BY WAY OF HINO DX.....3376
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....3380
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DX.....3383
CHECKING THE DPR STATE.....3383
REPLACEMENT OF DPR FILTER.....3384
OVERALL OPERATION FLOW.....3386
DIFFERENTIAL PRESSURE SENSOR.....3394
COMPONENT LOCATOR.....3394
DISMOUNTING AND MOUNTING.....3395
INSPECTION AND REPAIR.....3395
FUEL ADDITION VALVE.....3398
COMPONENT LOCATOR.....3398
OVERHAUL.....3399
EXHAUST CONTROL CYLINDER.....3409
SYSTEM CONFIGURATION.....3409
DPR INSPECTION CHECK SHEET.....3410
ATC UPSTREAM TEMPERATURE SENSOR.....3413
COMPONENT LOCATOR.....3413
OVERHAUL.....3414
LUBRICATING SYSTEM (J08E).....3415
LUBRICATING SYSTEM.....3416
DIAGRAM.....3416
OIL PUMP AND OIL STRAINER.....3418
COMPONENT LOCATOR.....3418
OVERHAUL.....3419
INSPECTION AND REPAIR.....3420
OIL FILTER AND OIL COOLER.....3422
COMPONENT LOCATOR.....3422
SPECIAL TOOL.....3423
DISMOUNTING AND MOUNTING.....3424
INSPECTION AND REPAIR.....3425
COOLING SYSTEM (J08E).....3426
COOLING SYSTEM.....3427
DIAGRAM.....3427
COOLANT PUMP.....3428
COMPONENT LOCATOR.....3428
THERMOSTAT.....3429
COMPONENT LOCATOR.....3429
OVERHAUL.....3430
RADIATOR AND INTERCOOLER.....3432
COMPONENT LOCATOR.....3432
OVERHAUL.....3432
RADIATOR.....3434
COMPONENT LOCATOR.....3434
SPECIAL TOOL.....3435
OVERHAUL.....3435
INSPECTION AND REPAIR.....3439
COOLING FAN.....3440
COMPONENT LOCATOR.....3440
INSPECTION AND REPAIR.....3441
FUEL SYSTEM (J08E).....3442
FUEL SYSTEM.....3443
DIAGRAM.....3443
COMPONENT LOCATOR.....3444
SUPPLY PUMP.....3445
DESCRIPTION.....3445
COMPONENT LOCATOR.....3446
SPECIAL TOOL.....3446
OVERHAUL.....3447
COMMON RAIL.....3456
DESCRIPTION.....3456
INSPENTION.....3457
REPLACEMENT.....3458
INJECTOR.....3462
DESCRIPTION.....3462
REPLACEMENT.....3463
PRE FUEL FILTER.....3471
DESCRIPTION.....3471
AIR BLEEDING.....3472
FUEL FILTER.....3474
DESCRIPTION.....3474
OVERHAUL.....3475
FUEL TANK.....3478
COMPONENT LOCATOR.....3478
FUEL CUTOFF VALVE.....3480
COMPONENT LOCATOR.....3480
OVERHAUL.....3481
TURBOCHARGER (J08E).....3482
TURBOCHARGER.....3483
DESCRIPTION.....3483
TROUBLESHOOTING.....3484
REPLACEMENT.....3493
INSPECTION AFTER MOUNTING.....3499
EMISSION CONTROL (J08E).....3500
EGR VALVE AND EGR PIPE.....3501
COMPONENT LOCATOR.....3501
EGR VALVE.....3502
DESCRIPTION.....3502
DISMOUNTING AND MOUNTING.....3503
CLOSED VENTILATOR.....3506
DESCRIPTION.....3506
REPLACEMENT OF CLOSED VENTILATOR.....3506
SELECTIVE CATALYTIC REDUCTION (SCR).....3508
GENERAL DESCRIPTION.....3508
COMPONENT LOCATOR.....3510
INSPECTION.....3511
SPECIAL TOOL.....3512
DISMOUNTING AND MOUNTING.....3513
INSPECTION AND REPAIR.....3528
ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A).....3529
ALTERNATOR.....3530
DATA AND SPECIFICATIONS.....3530
TROUBLESHOOTING.....3530
COMPONENT LOCATOR.....3531
OVERHAUL.....3532
INSPECTION AND REPAIR.....3535
STARTER (J08E).....3536
STARTER.....3537
DATA AND SPECIFICATIONS.....3537
DESCRIPTION.....3537
TROUBLESHOOTING.....3538
COMPONENT LOCATOR.....3539
OVERHAUL.....3540
INSPECTION AND REPAIR.....3544
AIR COMPRESSOR (J08E: 340 cm3).....3547
AIR COMPRESSOR.....3548
DATA AND SPECIFICATIONS.....3548
DESCRIPTION.....3549
TROUBLESHOOTING.....3550
COMPONENT LOCATOR.....3551
SPECIAL TOOL.....3552
OVERHAUL.....3552
INSPECTION AND REPAIR.....3560
ENGINE CONTROL (J08E).....3563
ACCELERATOR PEDAL.....3564
DESCRIPTION.....3564
ENGINE ECU.....3565
COMPONENT LOCATOR.....3565
REPLACEMENT.....3566
S5-UJ08E13A - J08E-VB, J08E-WU Engine Workshop Manual (2017).....3573
S5-UJ08E14A - J08E-VB, J08E-WU Engine Workshop Manual (2018).....3927
FOREWORD.....3927
CHAPTER REFERENCES.....3928
INDEX.....3929
GENERAL INTRODUCTION (ENGINE).....3931
GENERAL INTRODUCTION (ENGINE).....3932
GENERAL PRECAUTIONS.....3932
HOW TO USE THIS WORKSHOP MANUAL.....3935
IDENTIFICATION INFORMATION.....3937
PRECAUTIONS.....3938
SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS.....3941
DISMOUNTING AND MOUNTING.....3942
SYMPTOM SIMULATION.....3945
GLOSSARY OF SAE AND HINO TERMS.....3947
ENGINE INTRODUCTION (J08E).....3950
ENGINE ASSEMBLY.....3951
DATA AND SPECIFICATIONS.....3951
TROUBLESHOOTING.....3953
TROUBLESHOOTING (COMMON RAIL SYSTEM).....3960
ENGINE TUNEUP.....3961
SPECIAL TOOL.....3967
OVERHAUL CRITERIA.....3968
DISMOUNTING AND MOUNTING.....3969
LIQUID GASKET AND APPLICATION POINTS.....3971
ENGINE MECHANICAL (J08E).....3976
CYLINDER HEAD.....3977
COMPONENT LOCATOR.....3977
SPECIAL TOOL.....3980
OVERHAUL.....3981
INSPECTION AND REPAIR.....3992
CRANKSHAFT FRONT END.....3996
COMPONENT LOCATOR.....3996
SPECIAL TOOL.....3997
OVERHAUL.....3998
FLYWHEEL AND FLYWHEEL HOUSING.....4000
COMPONENT LOCATOR.....4000
SPECIAL TOOL.....4001
OVERHAUL.....4001
INSPECTION AND REPAIR.....4007
TIMING GEAR.....4008
COMPONENT LOCATOR.....4008
SPECIAL TOOL.....4009
OVERHAUL.....4010
INSPECTION AND REPAIR.....4012
MAIN MOVING PARTS AND CYLINDER BLOCK.....4014
COMPONENT LOCATOR.....4014
SPECIAL TOOL.....4017
OVERHAUL.....4019
INSPECTION AND REPAIR.....4032
AIR INTAKE SYSTEM (J08E).....4036
AIR INTAKE MANIFOLD AND PIPE.....4037
COMPONENT LOCATOR.....4037
DISMOUNTING AND MOUNTING.....4038
AIR INTAKE.....4039
COMPONENT LOCATOR.....4039
AIR CLEANER.....4040
DESCRIPTION.....4040
OVERHAUL.....4041
AIR HOSE.....4042
COMPONENT LOCATOR.....4042
OVERHAUL.....4043
AIR FLOW SENSOR.....4044
COMPONENT LOCATOR.....4044
REPLACEMENT.....4045
BOOST PRESSURE SENSOR.....4046
COMPONENT LOCATOR.....4046
REPLACEMENT.....4047
EXHAUST SYSTEM (J08E).....4048
EXHAUST MANIFOLD AND PIPE.....4049
COMPONENT LOCATOR.....4049
DISMOUNTING AND MOUNTING.....4050
EXHAUST PIPE AND MUFFLER UNIT.....4051
DESCRIPTION.....4051
COMPONENT LOCATOR.....4052
REPLACEMENT OF ATC.....4058
OVERHAUL.....4060
DPR (DIESEL PARTICULATE ACTIVE REDUCTION SYSTEM).....4076
SYSTEM CONFIGURATION.....4076
STRUCTURE OF DPR-CLEANER.....4077
DPR INSPECTION.....4078
INSPECTION PROCEDURE FOLLOWED WHEN "DPR MAINTENANCE" IS DISPLAYED ON THE INFORMATION DISPLAY.....4079
INSPECTION BY WAY OF HINO DXU.....4080
INSPECTION PROCEDURE FOLLOWED WHEN CHECK ENGINE LIGHT ILLUMINATES (ABNORMAL).....4084
DETERMINATION BY WAY OF DPR STATE DETERMINATION MONITOR OF HINO DXU.....4087
CHECKING THE DPR STATE.....4087
REPLACEMENT OF DPR FILTER.....4088
OVERALL OPERATION FLOW.....4092
DIFFERENTIAL PRESSURE SENSOR.....4100
COMPONENT LOCATOR.....4100
DISMOUNTING AND MOUNTING.....4101
INSPECTION AND REPAIR.....4101
AFTERTREATMENT FUEL INJECTOR.....4104
COMPONENT LOCATOR.....4104
OVERHAUL.....4105
EXHAUST CONTROL CYLINDER.....4115
SYSTEM CONFIGURATION.....4115
DPR INSPECTION CHECK SHEET.....4116
EXHAUST GAS TEMPERATURE SENSOR 1.....4119
COMPONENT LOCATOR.....4119
OVERHAUL.....4120
LUBRICATING SYSTEM (J08E).....4121
LUBRICATING SYSTEM.....4122
DIAGRAM.....4122
OIL PUMP AND OIL STRAINER.....4124
COMPONENT LOCATOR.....4124
OVERHAUL.....4125
INSPECTION AND REPAIR.....4126
OIL FILTER AND OIL COOLER.....4128
COMPONENT LOCATOR.....4128
SPECIAL TOOL.....4129
DISMOUNTING AND MOUNTING.....4130
INSPECTION AND REPAIR.....4131
COOLING SYSTEM (J08E).....4132
COOLING SYSTEM.....4133
DIAGRAM.....4133
COOLANT PUMP.....4134
COMPONENT LOCATOR.....4134
THERMOSTAT.....4135
COMPONENT LOCATOR.....4135
OVERHAUL.....4136
RADIATOR AND INTERCOOLER.....4138
COMPONENT LOCATOR.....4138
OVERHAUL.....4138
RADIATOR.....4140
COMPONENT LOCATOR.....4140
SPECIAL TOOL.....4141
OVERHAUL.....4141
INSPECTION AND REPAIR.....4145
COOLING FAN.....4146
COMPONENT LOCATOR.....4146
INSPECTION AND REPAIR.....4147
FUEL SYSTEM (J08E).....4148
FUEL SYSTEM.....4149
DIAGRAM.....4149
COMPONENT LOCATOR.....4150
SUPPLY PUMP.....4151
DESCRIPTION.....4151
COMPONENT LOCATOR.....4152
SPECIAL TOOL.....4152
OVERHAUL.....4153
COMMON RAIL.....4162
DESCRIPTION.....4162
INSPECTION.....4163
REPLACEMENT.....4164
INJECTOR.....4168
DESCRIPTION.....4168
REPLACEMENT.....4169
PRE FUEL FILTER.....4177
DESCRIPTION.....4177
AIR BLEEDING.....4178
FUEL FILTER.....4180
DESCRIPTION.....4180
OVERHAUL.....4181
FUEL TANK.....4184
COMPONENT LOCATOR.....4184
FUEL CUTOFF VALVE.....4186
COMPONENT LOCATOR.....4186
OVERHAUL.....4187
TURBOCHARGER (J08E).....4188
TURBOCHARGER.....4189
DESCRIPTION.....4189
TROUBLESHOOTING.....4190
REPLACEMENT.....4199
INSPECTION AFTER MOUNTING.....4205
EMISSION CONTROL (J08E).....4206
EGR VALVE AND EGR PIPE.....4207
COMPONENT LOCATOR.....4207
EGR VALVE.....4208
DESCRIPTION.....4208
DISMOUNTING AND MOUNTING.....4209
CLOSED VENTILATOR.....4212
DESCRIPTION.....4212
REPLACEMENT OF CLOSED VENTILATOR.....4212
REPLACEMENT.....4213
REPLACING THE ELEMENT.....4213
SELECTIVE CATALYTIC REDUCTION (SCR).....4214
GENERAL DESCRIPTION.....4214
COMPONENT LOCATOR.....4216
INSPECTION.....4217
SPECIAL TOOL.....4218
DISMOUNTING AND MOUNTING.....4219
INSPECTION AND REPAIR.....4235
ALTERNATOR (J08E: REMY 12V-130A,135A,180A,200A).....4236
ALTERNATOR.....4237
DATA AND SPECIFICATIONS.....4237
TROUBLESHOOTING.....4237
COMPONENT LOCATOR.....4238
OVERHAUL.....4239
INSPECTION AND REPAIR.....4242
STARTER (J08E).....4243
STARTER.....4244
DATA AND SPECIFICATIONS.....4244
DESCRIPTION.....4244
TROUBLESHOOTING.....4245
COMPONENT LOCATOR.....4246
OVERHAUL.....4247
INSPECTION AND REPAIR.....4251
AIR COMPRESSOR (J08E: 340 cm3).....4254
AIR COMPRESSOR.....4255
DATA AND SPECIFICATIONS.....4255
DESCRIPTION.....4256
TROUBLESHOOTING.....4257
COMPONENT LOCATOR.....4258
SPECIAL TOOL.....4259
OVERHAUL.....4259
INSPECTION AND REPAIR.....4267
ENGINE CONTROL (J08E).....4270
ACCELERATOR PEDAL.....4271
DESCRIPTION.....4271
ENGINE ECU.....4272
COMPONENT LOCATOR.....4272
REPLACEMENT.....4273
S5-YJ08E17A - J08C-TI Engine Workshop Manual.....4280
FOREWORD.....4280
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL.....4281
INDEX.....4282
GENERAL INTRODUCTION (ENGINE).....4284
GENERAL INTRODUCTION (ENGINE).....4285
ENGINE INTRODUCTION (J08C).....4292
ENGINE ASSEMBLY.....4293
ENGINE MECHANICAL (J08C).....4311
CYLINDER HEAD.....4312
CRANKSHAFT FRONT END.....4329
FLYWHEEL AND FLYWHEEL HOUSING.....4332
TIMING GEAR.....4337
MAIN MOVING PARTS AND CYLINDER BLOCK.....4342
AIR INTAKE SYSTEM (J08C).....4359
AIR INTAKE MANIFOLD AND PIPE.....4360
EXHAUST SYSTEM (J08C).....4361
EXHAUST MANIFOLD AND PIPE.....4362
LUBRICATING SYSTEM (J08C).....4364
LUBRICATING SYSTEM.....4365
OIL PUMP AND OIL STRAINER.....4367
OIL FILTER AND OIL COOLER.....4369
COOLING SYSTEM (J08C).....4372
COOLING SYSTEM.....4373
COOLANT PUMP.....4374
THERMOSTAT.....4379
RADIATOR.....4381
COOLING FAN.....4386
FUEL SYSTEM (J08C).....4388
FUEL SYSTEM.....4389
INJECTION NOZZLE(TWO-SPRING TYPE - BOSCH MAKE).....4394
TURBOCHARGER (J08C).....4407
TURBOCHARGER.....4408
ALTERNATOR (J08C: 24V-50A).....4421
ALTERNATOR.....4422
ALTERNATOR (J08C: 24V-80A).....4436
ALTERNATOR.....4437
STARTER (J08C).....4452
STARTER.....4453
AIR COMPRESSOR (J08C: 1-CYLINDER TYPE).....4466
AIR COMPRESSOR.....4467
AIR COMPRESSOR (J08C: 2-CYLINDER TYPE).....4482
AIR COMPRESSOR.....4483
ENGINE P.T.O. (POWER TAKE-OFF) (J08C).....4502
POWER TAKE-OFF ASSEMBLY.....4503
FUEL CONTROL (J08C: PRE-STROKE PUMP).....4511
TE SYSTEM.....4512
FUEL CONTROL (J08C: ELECTRONIC GOVERNOR).....4542
TE SYSTEM.....4543
S5-YJ08E29E - J08E-TI Engine Workshop Manual.....4599
FOREWORD.....4599
CHAPTER.....4600
INDEX.....4601
GENERAL INTRODUCTION (J08E).....4603
GENERAL INTRODUCTION.....4604
WARNING.....4604
HOW TO USE THIS MANUAL.....4605
PRECAUTIONS FOR WORK.....4610
TIGHTENING OF BOLTS AND NUTS FOR ENGINE.....4615
TIGHTENING OF BOLTS AND NUTS FOR CHASSIS.....4617
TIGHTENING OF FLARE NUTS AND HOSES.....4619
SEALANT ON THE TAPERED SCREW FOR PIPING.....4620
NYLON TUBE.....4621
ASSEMBLY OF JOINT/GASKET FOR PIPING.....4625
HANDLING OF LIQUID GASKET.....4627
TROUBLESHOOTING USING THE TROUBLE LIST.....4628
TROUBLESHOOTING USING A DIAGNOSIS MONITOR.....4629
DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS TOOL WITH INTERFACE.....4633
CHASSIS SERIAL NUMBER, VEHICLE IDENTIFICATION NUMBER AND ENGINE SERIAL NUMBER.....4636
RECOMMENDED LUBRICANTS.....4637
ENGINE INTRODUCTION (J08E).....4639
ENGINE ASSEMBLY.....4640
DATA AND SPECIFICATIONS.....4640
TROUBLESHOOTING.....4643
TROUBLESHOOTING (COMMON RAIL SYSTEM).....4651
ENGINE TUNEUP.....4652
SPECIAL TOOL.....4658
OVERHAUL CRITERIA.....4659
DISMOUNTING AND MOUNTING.....4660
LIQUID GASKET AND APPLICATION POINTS.....4662
ENGINE MECHANICAL (J08E).....4667
CYLINDER HEAD.....4668
COMPONENT LOCATOR.....4668
SPECIAL TOOL.....4674
OVERHAUL.....4675
INSPECTION AND REPAIR.....4686
CRANKSHAFT FRONT END.....4690
COMPONENT LOCATOR.....4690
SPECIAL TOOL.....4691
OVERHAUL.....4691
FLYWHEEL AND FLYWHEEL HOUSING.....4693
COMPONENT LOCATOR.....4693
SPECIAL TOOL.....4694
OVERHAUL.....4695
INSPECTION AND REPAIR.....4699
TIMING GEAR.....4700
COMPONENT LOCATOR.....4700
SPECIAL TOOL.....4702
OVERHAUL.....4702
INSPECTION AND REPAIR.....4705
MAIN MOVING PARTS AND CYLINDER BLOCK.....4709
COMPONENT LOCATOR.....4709
SPECIAL TOOL.....4711
OVERHAUL.....4713
INSPECTION AND REPAIR.....4723
AIR INTAKE SYSTEM (J08E).....4727
AIR INTAKE MANIFOLD AND PIPE.....4728
COMPONENT LOCATOR.....4728
DISMOUNTING AND MOUNTING.....4729
AIR INTAKE.....4730
COMPONENT LOCATOR.....4730
OVERHAUL.....4732
AIR CLEANER.....4737
COMPONENT LOCATOR.....4737
OVERHAUL.....4737
EXHAUST SYSTEM (J08E).....4738
EXHAUST MANIFOLD AND PIPE.....4739
COMPONENT LOCATOR.....4739
DISMOUNTING AND MOUNTING.....4741
EXHAUST PIPE AND MUFFLER.....4742
COMPONENT LOCATOR.....4742
OVERHAUL.....4744
LUBRICATING SYSTEM (J08E).....4745
LUBRICATING SYSTEM.....4746
DIAGRAM.....4746
OIL PUMP AND OIL STRAINER.....4748
COMPONENT LOCATOR.....4748
OVERHAUL.....4749
INSPECTION AND REPAIR.....4750
OIL FILTER AND OIL COOLER.....4751
COMPONENT LOCATOR.....4751
SPECIAL TOOL.....4753
DISMOUNTING AND MOUNTING.....4753
INSPECTION AND REPAIR.....4754
COOLING SYSTEM (J08E).....4755
COOLING SYSTEM.....4756
DIAGRAM.....4756
COOLANT PUMP.....4758
COMPONENT LOCATOR.....4758
SPECIAL TOOL.....4759
OVERHAUL.....4759
INSPECTION AND REPAIR.....4762
THERMOSTAT.....4763
COMPONENT LOCATOR.....4763
OVERHAUL.....4764
RADIATOR.....4766
COMPONENT LOCATOR.....4766
SPECIAL TOOL.....4766
OVERHAUL.....4767
INSPECTION AND REPAIR.....4770
COOLING FAN.....4771
COMPONENT LOCATOR.....4771
INSPECTION AND REPAIR.....4771
FUEL SYSTEM (J08E).....4772
FUEL SYSTEM (EXCEPT J08E-UF, UG).....4773
DIAGRAM.....4773
COMPONENT LOCATOR.....4774
FUEL SYSTEM (J08E-UF, UG).....4775
DIAGRAM.....4775
COMPONENT LOCATOR.....4776
SPECIAL TOOL.....4777
OVERHAUL.....4777
SUPPLY PUMP (EXCEPT J08E-UF, UG).....4780
DESCRIPTION.....4780
COMPONENT LOCATOR.....4781
SPECIAL TOOL.....4781
OVERHAUL.....4782
COMMON RAIL.....4786
DESCRIPTION.....4786
OVERHAUL.....4787
INJECTOR (EXCEPT J08E-UF, UG).....4792
DESCRIPTION.....4792
OVERHAUL.....4793
INJECTION NOZZLE (TWO-SPRING TYPE - DENSO MAKE) (J08E-UF, UG).....4796
DESCRIPTION.....4796
COMPONENT LOCATOR.....4797
SPECIAL TOOL.....4798
OVERHAUL.....4799
FUEL FILTER.....4805
DESCRIPTION.....4805
COMPONENT LOCATOR.....4806
FUEL TANK.....4807
COMPONENT LOCATOR.....4807
TURBOCHARGER (J08E: VARIABLE NOZZLE TURBINE TYPE).....4809
TURBOCHARGER.....4810
DESCRIPTION.....4810
TROUBLESHOOTING.....4811
SPECIAL TOOL.....4819
OVERHAUL CRITERIA.....4820
TURBOCHARGER (J08E: WASTE GATE VALVE TYPE).....4822
TURBOCHARGER.....4823
DESCRIPTION.....4823
TROUBLESHOOTING.....4824
COMPONENT LOCATOR.....4833
SPECIAL TOOL.....4833
OVERHAUL CRITERIA.....4834
FUEL INJECTION PUMP (J08E).....4837
FUEL INJECTION PUMP.....4838
DATA AND SPECIFICATIONS.....4838
DESCRIPTION (NB-TYPE).....4846
TROUBLESHOOTING.....4847
COMPONENT LOCATOR (NB-TYPE).....4850
SPECIAL TOOL.....4851
OVERHAUL.....4853
INSPECTION AND REPAIR.....4863
ADJUSTMENT (NB-TYPE).....4864
TIMER (SA2 TYPE).....4868
COMPONENT LOCATOR.....4868
SPECIAL TOOL.....4869
OVERHAUL.....4870
FEED PUMP (KD-TYPE).....4874
COMPONENT LOCATOR.....4874
OVERHAUL.....4875
GOVERNOR (R901).....4877
DESCRIPTION.....4877
COMPONENT LOCATOR.....4878
SPECIAL TOOL.....4880
OVERHAUL.....4881
ADJUSTMENT.....4885
BOOST COMPENSATOR.....4891
COMPONENT LOCATOR.....4891
ADJUSTMENT.....4892
EMISSION CONTROL (J08E).....4894
EGR VALVE AND EGR PIPE.....4895
COMPONENT LOCATOR.....4895
EGR VALVE.....4896
DESCRIPTION.....4896
DISMOUNTING AND MOUNTING.....4897
ALTERNATOR (J08E: 24V-50A).....4900
ALTERNATOR.....4901
DATA AND SPECIFICATIONS.....4901
DESCRIPTION.....4901
TROUBLESHOOTING.....4903
COMPONENT LOCATOR.....4904
SPECIAL TOOL.....4906
OVERHAUL.....4906
INSPECTION AND REPAIR.....4916
ALTERNATOR (J08E: 24V-60A).....4918
ALTERNATOR.....4919
DATA AND SPECIFICATIONS.....4919
DESCRIPTION.....4919
TROUBLESHOOTING.....4921
COMPONENT LOCATOR.....4922
OVERHAUL.....4924
INSPECTION AND REPAIR.....4933
ALTERNATOR (J08E: 24V-90A).....4935
ALTERNATOR.....4936
DATA AND SPECIFICATIONS.....4936
DESCRIPTION.....4936
TROUBLESHOOTING.....4938
COMPONENT LOCATOR.....4939
OVERHAUL.....4941
INSPECTION AND REPAIR.....4951
STARTER (J08E: 24V, 4.5 kW).....4953
STARTER.....4954
DATA AND SPECIFICATIONS.....4954
DESCRIPTION.....4954
TROUBLESHOOTING.....4955
COMPONENT LOCATOR.....4956
OVERHAUL.....4958
INSPECTION AND REPAIR.....4966
STARTER (J08E: 24V, 5.0 kW).....4969
STARTER.....4970
DATA AND SPECIFICATIONS.....4970
DESCRIPTION.....4970
TROUBLESHOOTING.....4971
COMPONENT LOCATOR.....4972
OVERHAUL.....4973
INSPECTION AND REPAIR.....4982
AIR COMPRESSOR (J08E: 154 cm3).....4985
AIR COMPRESSOR.....4986
DATA AND SPECIFICATIONS.....4986
DESCRIPTION.....4986
TROUBLESHOOTING.....4987
COMPONENT LOCATOR.....4988
SPECIAL TOOL.....4990
OVERHAUL.....4991
INSPECTION AND REPAIR.....4999
AIR COMPRESSOR (J08E: 227 cm3).....5002
AIR COMPRESSOR.....5003
DATA AND SPECIFICATIONS.....5003
DESCRIPTION.....5003
TROUBLESHOOTING.....5004
COMPONENT LOCATOR.....5005
SPECIAL TOOL.....5007
OVERHAUL.....5008
INSPECTION AND REPAIR.....5016
AIR COMPRESSOR (J08E: 271 cm3).....5019
AIR COMPRESSOR.....5020
DATA AND SPECIFICATIONS.....5020
DESCRIPTION.....5020
TROUBLESHOOTING.....5021
COMPONENT LOCATOR.....5022
SPECIAL TOOL.....5024
OVERHAUL.....5025
INSPECTION AND REPAIR.....5032
AIR COMPRESSOR (J08E: 271 cm3 x 2 CYLINDERS).....5035
AIR COMPRESSOR.....5036
DATA AND SPECIFICATIONS.....5036
DESCRIPTION.....5036
TROUBLESHOOTING.....5037
COMPONENT LOCATOR.....5038
SPECIAL TOOL.....5040
OVERHAUL.....5041
INSPECTION AND REPAIR.....5053
ENGINE P.T.O. (POWER TAKE-OFF) (J08E).....5057
POWER TAKE-OFF ASSEMBLY.....5058
DESCRIPTION.....5058
COMPONENT LOCATOR.....5059
OVERHAUL.....5060
INSPECTION AND REPAIR.....5065
ENGINE CONTROL (J08E).....5066
ACCELERATOR PEDAL.....5067
DESCRIPTION.....5067
ADJUSTMENT.....5067
FUEL CONTROL (J08E: COMMON RAIL).....5068
COMMON RAIL FUEL INJECTION SYSTEM.....5069
OVERVIEW.....5069
COMPONENT LOCATOR.....5070
DIAGRAM.....5072
ELECTRICAL.....5073
PRECAUTIONS.....5076
INSPECTION.....5085
DIAGNOSIS USING THE DIAGNOSIS MONITOR.....5086
DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS TOOL WITH INTERFACE.....5088
DTC CHECK / CLEAR (WITH HINO-DX).....5089
DTC CHECK / CLEAR (NOT USING Hino-DX).....5090
DIAGNOSIS TROUBLE CODE TABLE (EXCEPT FOR HONG KONG, IRELAND AND SINGAPORE).....5091
DIAGNOSIS TROUBLE CODE TABLE (FOR HONG KONG, IRELAND AND SINGAPORE).....5095
INSPECTION OF AIR FLOW SENSOR (CHECK/ADJUSTMENT OF AIR INTAKE VOLUME BY HINO-DX).....5099
CHECK THE ECU POWER SUPPLY VOLTAGE.....5100
CHECK THE GROUND.....5100
ENGINE SPEED MAIN SENSOR (CIRCUIT).....5101
ENGINE SPEED MAIN SENSOR (PULSE).....5103
ENGINE SPEED SUB SENSOR (CIRCUIT).....5105
ENGINE SPEED SUB SENSOR (PULSE).....5107
ENGINE SPEED MAIN AND SUB SENSOR.....5108
COOLANT TEMPERATURE SENSOR.....5109
ENGINE OVERHEAT.....5110
ENGINE OVERRUN.....5110
FUEL TEMPERATURE SENSOR.....5111
BOOST PRESSURE SENSOR.....5112
BOOST PRESSURE SENSOR (CHECK BY HINO-DX).....5114
TURBOCHARGER OVER BOOST.....5116
AIR FLOW SENSOR.....5117
AIR FLOW SENSOR (CHECK BY HINO-DX).....5119
INTAKE AIR TEMPERATURE SENSOR.....5120
COMMON RAIL EXCESSIVE PRESSURE, CONTROL SYSTEM.....5121
COMMON RAIL PRESSURE AND SUPPLY PUMP.....5122
COMMON RAIL PRESSURE SENSOR STICKING.....5123
COMMON RAIL PRESSURE SENSOR MALFUNCTION.....5124
ACCELERATOR SENSOR 1 (VOLTAGE).....5126
ACCELERATOR SENSOR 1.....5128
ACCELERATOR SENSOR 2 (VOLTAGE).....5129
ACCELERATOR SENSOR 2.....5131
ACCELERATOR SENSOR 1 & 2.....5131
ACCELERATOR SENSOR (FOR OPERATION OF P.T.O.).....5132
VEHICLE SPEED SENSOR.....5134
ECU.....5135
INJECTOR SOLENOID VALVE DRIVING SYSTEM SHORT-CIRCUIT (GND).....5136
INJECTOR SOLENOID VALVE DRIVING SYSTEM SHORT-CIRCUIT (24V).....5138
INJECTOR SOLENOID VALVE SYSTEM DISCONNECTION.....5140
CYLINDER CONTRIBUTION/BALANCE.....5143
SUPPLY PUMP SUCTION CONTROL VALVE (SCV).....5145
SUPPLY PUMP.....5146
EGR SOLENOID VALVE 1.....5147
EGR SOLENOID VALVE 2.....5148
EGR.....5150
EGR VALVE 1.....5151
EGR VALVE 2.....5151
EGR LIFT SENSOR 1.....5152
EGR LIFT SENSOR 2.....5154
VNT (VARIABLE NOZZLE TURBINE) TURBOCHARGER CONTROLLER.....5156
VNT (VARIABLE NOZZLE TURBINE).....5157
EXHAUST BRAKE MAGNETIC VALVE.....5158
INJECTOR CORRECTION DATA.....5158
MAIN RELAY.....5159
IDLE SET CONTROLLER.....5160
ACCELERATOR SWITCH.....5162
STARTER SWITCH.....5163
CLUTCH SWITCH.....5164
NEUTRAL SWITCH.....5165
INTAKE MANIFOLD GAS TEMPERATURE SENSOR.....5166
EGR LOW FLOW.....5168
CAN (COMMUNICATION AREA NETWORK).....5169
S7-UNAE14A - J08E-VB, J08E-WU Engine Workshop Manual (Troubleshooting).....5171
FOREWORD.....5171
CHAPTER REFERENCES.....5172
INDEX.....5173
ENGINE CONTROL SYSTEM.....5174
ENGINE CONTROL SYSTEM.....5177
DTC: P1133.....5177
DTC: P119F.....5183
DTC: P1426.....5188
DTC: P1427.....5194
DTC: P1428.....5200
DTC: P1458.....5206
DTC: P1459.....5211
DTC: P14B0.....5216
DTC: P14B2.....5220
DTC: P14B3 and P14B4.....5224
DTC: P14B7 and P14B8.....5230
DTC: P14BC and P14BD.....5236
DTC: P14BF.....5242
DTC: P1515.....5247
DTC: P1530.....5252
DTC: P2002.....5256
DTC: P200C.....5276
DTC: P2032 and P2033.....5282
DTC: P203F.....5290
DTC: P204F.....5294
DTC: P206B.....5296
DTC: P207F.....5319
DTC: P2080.....5342
DTC: P2084.....5351
DTC: P20CD.....5359
DTC: P20CE.....5363
DTC: P20CF.....5367
DTC: P20D8.....5372
DTC: P20DE.....5377
DTC: P20DF.....5381
DTC: P20E0.....5387
DTC: P20EE.....5393
DTC: P2100.....5418
DTC: P2101.....5424
DTC: P2103.....5430
DTC: P2120.....5436
DTC: P2122 and P2123.....5440
DTC: P2127 and P2128.....5448
DTC: P2135.....5457
DTC: P2138.....5462
DTC: P2146.....5467
DTC: P2147 and P2148.....5474
DTC: P2149.....5482
DTC: P2150 and P2151.....5488
DTC: P2184 and P2185.....5496
DTC: P2201.....5504
DTC: P2227.....5543
DTC: P2228 and P2229.....5547
DTC: P2269.....5552
DTC: P226C.....5556
DTC: P229F.....5564
DTC: P22D3.....5604
DTC: P240F.....5608
DTC: P2428.....5617
DTC: P242B.....5621
DTC: P242C and P242D.....5629
DTC: P244A.....5637
DTC: P244B.....5654
DTC: P2457.....5674
DTC: P2458.....5688
DTC: P2459.....5697
DTC: P2463.....5699
DTC: P246F.....5704
DTC: P2470 and P2471.....5712
DTC: P2481 and P2482.....5720
DTC: P2483.....5728
DTC: P24A0.....5736
DTC: P24A1.....5739
DTC: P24A2.....5741
DTC: P24A3.....5751
DTC: P24AE.....5756
DTC: P24AF.....5764
DTC: P24B0.....5769
DTC: P24B1.....5774
DTC: P24B4.....5777
DTC: P24B6.....5787
DTC: P24B7.....5792
DTC: P24C7.....5795
DTC: P24D1.....5799
DTC: P24DA.....5804
DTC: P2563.....5809
DTC: P2564 and P2565.....5814
DTC: P259E.....5821
DTC: P259F.....5826
DTC: P2635.....5831
DTC: P268A and P2696.....5840
DTC: P2A00.....5846
DTC: P2A01.....5855
DTC: P2BA9.....5864
DTC: U0073.....5869
DTC: U010A.....5872
DTC: U010C.....5875
DTC: U010E.....5878
DTC: U029D.....5881
DTC: U029E.....5884
DTC: U02A2.....5887
DTC: U02A3 .....5890
DTC: U0301.....5893
DTC: U1001.....5896
DTC: U110A.....5899
HINO Trucks J08E-TA, J08E-TB, J08E-TV, J08E-TW, J08E-VB, J08E-V, J08E-WU, J08C-TI Engines Workshop Manual
