Hino N04C engine Workshop Manual

Hino N04C engine workshop. This is ther factory manual. Index below.

0 GENERAL
SPECIFICATIONS ..................................................0-2
ENGINE EXTERIOR VIEWS ..................................0-3
ENGINE PERFORMANCE CURVES .....................0-4
HOW TO USE THIS MANUAL ...............................0-5
EXPLANATION METHOD .........................................0-5
TERMINOLOGY.......................................................0-6
ABBREVIATIONS ....................................................0-7
OPERATING TIPS ..................................................0-8
POINTS FOR WHICH SPECIAL CARE
MUST BE TAKEN...................................................0-8
GENERAL INSTRUCTIONS ......................................0-8
ELECTRICAL PARTS INSPECTION.........................0-11
BOLT & NUT TIGHTENING TORQUES...............0-13
BOLT STRENGTH CLASS IDENTIFICATION
METHOD AND TIGHTENING TORQUE ..................0-13
PRECOATED BOLTS (BOLTS WITH SEAL
LOCK AGENT COATING ON THREADS) .........0-16
SI UNITS ...............................................................0-16
HANDLING FIPG (LIQUID GASKETS)................0-17

1 TROUBLESHOOTING
TROUBLESHOOTING............................................1-2

2 ENGINE OVERHAUL
USED SSTs ............................................................2-2
ENGINE ACCESSORIES .......................................2-4
REMOVAL AND INSTALLATION................................2-4
CYLINDER HEAD...................................................2-9
DISASSEMBLY, INSPECTION AND REASSEMBLY .....2-9
TIMING GEAR......................................................2-22
DISASSEMBLY, INSPECTION AND REASSEMBLY ...2-22
CYLINDER BLOCK..............................................2-33
DISASSEMBLY, INSPECTION AND REASSEMBLY ...2-33
ENGINE TURN-UP ...............................................2-47
COOLANT INSPECTION.........................................2-47
ENGINE OIL INSPECTION......................................2-47
BATTERY ELECTROLYTE INSPECTION..................2-47
V BELT INSPECTION AND ADJUSTMENT ...............2-47
IDLE SPEED INSPECTION .....................................2-48
NO-LOAD MAXIMUM GOVERNED SPEED
INSPECTION .......................................................2-48
COMPRESSION PRESSURE INSPECTION ..............2-48
DIESEL SMOKE DENSITY INSPECTION..................2-49
VALVE CLEARANCE INSPECTION .........................2-49
EGR VALVE ASSY INSPECTION.............................2-49

3 FUEL SYSTEM
FUEL SYSTEM.......................................................3-2
PRECAUTION .........................................................3-2
FUEL FILTER .........................................................3-3
REMOVAL, INSPECTION AND INSTALLATION...........3-3
INJECTION (SUPPLY) PUMP ................................3-6
REMOVAL, INSPECTION AND INSTALLATION...........3-6
COMMON RAIL ....................................................3-12
REMOVAL, INSPECTION AND INSTALLATION.........3-12
FUEL INJECTOR..................................................3-16
REMOVAL, INSPECTION AND INSTALLATION.........3-16
VENTURI ASSY....................................................3-22
REMOVAL, INSPECTION AND INSTALLATION.........3-22

4 COOLING SYSTEM
COOLING SYSTEM................................................4-2
INSPECTION OF FUNCTIONS...................................4-2
COOLANT ..............................................................4-3
REPLACEMENT ......................................................4-3
WATER PUMP ASSY .............................................4-4
REMOVAL AND INSTALLATION................................4-4
THERMOSTAT........................................................4-6
REMOVAL, INSPECTION AND INSTALLATION...........4-6

5 LUBRICATION SYSTEM
USED SSTs ............................................................5-2
LUBLICATION SYSTEM ........................................5-3
INSPECTION OF FUNCTIONS...................................5-3
OIL PUMP...............................................................5-5
REPLACEMENT ......................................................5-5
OIL FILTER.............................................................5-6
REPLACEMENT ......................................................5-6
OIL COOLER ASSY...............................................5-7
REPLACEMENT ......................................................5-7

6 STARTING SYSTEM
STATER MOTOR ASSY .........................................6-2
REMOVAL, INSPECTION AND INSTALLATION...........6-2
PREHEATING SYSTEM.........................................6-4
INSPECTION OF PREHEATING TIMER......................6-4
REPLACEMENT OF GLOW PLUG.............................6-6
INSPECTION OF GLOW PLUG .................................6-7

7 CHARGING SYSTEM
CHARGING SYSTEM.............................................7-2
INSPECTION OF FUNCTIONS...................................7-2
ALTERNATOR ASSY .............................................7-4
REMOVAL AND INSTALLATION................................7-4

8 TURBOCHARGER SYSTEM
TURBOCHARGER ASSY ......................................8-2
REMOVAL AND INSTALLATION................................8-2
9 APPENDIX
SST LIST ................................................................9-2
SERVICE STANDARDS .........................................9-4
TIGHTENING TORQUE FOR EACH PART ...........9-8