Hino N04C Engine Complete Workshop Service Repair Manual

NAME SECTION GENERAL 0 TROUBLESHOOTING 1 ENGINE OVERHAUL 2 FUEL SYSTEM 3 COOLING SYSTEM 4 LUBRICATION SYSTEM 5 STARTING SYSTEM 6 CHARGING SYSTEM 7 TURBOCHARGER SYSTEM 8 APPENDIX 9 12 12 13 14 15 16 17 18 19 20 21 E SECTION INDEX

0-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E GENERAL Page 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

0-2 0-2 SPECIFICATIONS Engine model N04C Type Diesel Cycle 4 cycle Number and arrangement of cylinders In-line 4 cylinder, longitudinally mounted Combustion chamber type Direct injection Valve mechanism OHV gear drive Bore × stroke mm (in.) 104.0 × 118.0 (4.09 × 4.65) Total displacement cm 3 (in 3 .) 4009 (244.6) Compression ratio 18.0 Minimum fuel Consumption when fully loaded g/kw·h (g/ps·h)/rpm 217 (160)/1600 No-load maximum speed rpm 2290 to 2390 Idle speed rpm 800 to 850 Engine dimensions (Length × width × height) mm (in.) 887 × 716 × 751 (34 × 21 × 29) Weight (Oil included) kg (lb) 396 (873) Intake valve open/close interval Open BTDC 14° Close ABDC 42° Exhaust valve open/close interval Open BBDC 53° Close ATDC 17°

0-3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E ENGINE EXTERIOR VIEWS

0-4 0-4 ENGINE PERFORMANCE CURVES

0-5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operating procedure (1) Operating procedures are described using either pattern A or pattern B. Pattern A: Each step of the operation is explained with its own illustration. Pattern B: The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and "Point Operations". Example of pattern B DISASSEMBLY·INSPECTION·REASSEMBLY Tightening torque unit → T = N·m (kgf·cm) [ft·lbf] Disassembly·Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure. Point Operations [Point 1] Inspection: Measure the backlash. Standard: 0.05 mm (0.0020 in.) [Point 2] Reassembly: Install the rotor in the position shown in the illustration. No. Item Disassembly Inspection Reassembly 1 Crank pulley W/ set bolt 2 Timing gear cover 3 Idle gear No.1 [Point 1] 4 Oil pump ASSY [Point 2] • The numbers may partially be omitted in the illustration. • In the case where a part for which the tightening torque is specified is not shown in the illustration, the name of the part will be listed inside the illustration frame. T = 274.59 ~ 370.69 (2800 ~ 3780) [202.6 ~ 273.5] 1 2 4 3 Explanation of operation point with illustration Operations that have a following explanation

0-6 0-6 1. How to read component figures (1) The component figures use the illustration in the parts catalog for the vehicle model. Please refer to the catalog to check the part name. 2. Matters omitted from this manual (1) This manual omits descriptions of the following jobs, but perform them in actual operation: (a) Cleaning and washing of removed parts as required (b) Visual inspection (partially described) TERMINOLOGY Warning: Items that may lead to an injury to either the operator or another person, and items and operation point switch, if not followed, may lead to an injury or accident. Caution: Items that must not be performed because doing so will result in damage to the vehicle or it's components, and items in the operation to which special attention should be paid. Note: Supplemental explanations for performing the operation easily. Standard: Value showing the allowable range in inspection or adjustment. Limit: The maximum or minimum value allowed in inspection or adjustment. (Example) Parts catalog FIG number 3201

0-7 ABBREVIATIONS Reference symbol Original word Meaning RH Right Hand Right hand side LH Left Hand Left hand side FR Front Front RR Rear Rear STD Standard This refers to the part size used by the maker at the time of assembly being the standard size. O/S Over Size For parts that do not engage well anymore due to wear from long use, or repeated disassembly, by replacing the part that is engaged by a part of slightly larger dimensions, it's corresponding part can be reused. These parts that have larger dimensions than STD, and are referred to as O/S. U/S Under Size As with the O/S parts, by replacing the engaging part with one that has a smaller hole, it's corresponding part can be reused. These parts that have smaller dimensions than STD, and are referred to as U/S. ATDC After Top Dead Center After the top dead center point of the piston in the cylinder. BTDC Before Top Dead Center Before the top dead center point of the piston in the cylinder. IN Intake Refers to the intake system. EX Exhaust Refers to the exhaust system. SST Special Service Tool Special service tool T Torque Tightening torque ASSY Assembly A part that consists of two or more single parts or sub-assembled parts that have been assembled together into an integrated whole. SUB/ASSY Sub Assembly A part in which two or more parts are joined together by welding, casting, riveting etc. W/ With/ The following items are attached. (Example: W/ washer ... With a washer attached) LWR Lower Lower

0-8 0-8 OPERATING TIPS POINTS FOR WHICH SPECIAL CARE MUST BE TAKEN 1. Always set the engine on an engine stand for carrying out assembly and disassembly of an engine. Never operate on a workbench or on the floor as this is dangerous. 2. When handling and moving the cylinder head ASSY or the cylinder block, always wear gloves and do not use your bare hands. GENERAL INSTRUCTIONS 1. For safe operation (1) Wear the correct safety gear (cap, safety goggles, gloves, safety shoes). (2) To prevent burns, do not touch the radiator, muffler or exhaust pipe directly after stopping the engine. (3) Do not put your clothing or tools near to the rotating part when the engine is turning. (4) When the engine is not on, always have the engine switch OFF, and remove the starter key. 2. Preparation for disassembly (1) Prepare general tools, SSTs, measuring instruments, lubricant and parts that cannot be reused. (2) When disassembling a complex part, put imprints and match marks in places that will not effect the function of the part in order to facilitate easy reassembly. 3. Prevention of entry of foreign bodies Foreign bodies such as dust, sand and metal pieces inside the engine cause faults to occur. (1) Thoroughly remove sand and mud etc. sticking to the engine exterior. (2) Protect disassembled parts from dust with a plastic cover or similar.

Hino N04C Engine Complete Workshop Service Repair Manual

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