HAJ08CTI ENGINE 12.

01

CONTENTS

GROUP - 12

HAJ08CTI ENGINE

Section Subject Page No.

12.0 General .......................................................................................................................... 12.05
12.0.0 Engine Type and Number ........................................................................................................... 12.05
12.0.1 Design and Operation .................................................................................................................. 12.05
12.0.2 General Data .................................................................................................................................... 12.06
12.0.3 Repair Data ....................................................................................................................................... 12.07
12.0.4 Tightening Torques ........................................................................................................................ 12.12
12.0.5 Crank Shaft Main Journals and Crank Journals Dimensions. ....................................... 12.14
12.0.6 Main and Crank Journals Grinding Sizes .............................................................................. 12.14
12.0.7 Crankcase Parent Bore and Cylinder Liner Outer Dia ................................................. 12.14
12.0.8 Fuel Oil (High Speed Diesel) ..................................................................................................... 12.15
12.0.8.0 Fuel Specifications - as per IS 1460 : 2000 (BS II) ............................................... 12.15
12.0.9 Recommended coolant .................................................................................................................. 12.16
12.0.10 Recommended Lubricants ............................................................................................................ 12.16
12.0.11 Filling Capacity ................................................................................................................................. 12.16
12.0.12 Liquid Gasket Application And Part Assembly Procedure ........................................... 12.17
12.0.13 Description of Leading Engine Components ....................................................................... 12.20
12.0.14 Trouble shooting ............................................................................................................................. 12.21
12.0.14.0 Engine ......................................................................................................................................... 12.21
12.0.14.1 Fuel Injection Pump .............................................................................................................. 12.25
12.0.15 Special Tools ..................................................................................................................................... 12.27

12.1 Engine tuneup .............................................................................................................. 12.29

12.1.0 Valve Clearance Checking And Adjusting Procedures ................................................... 12.29
12.1.0.0 Preparation of Checking and Adjustment .......................................................................................... 12.29
12.1.0.1 Valve Clearance Checking ............................................................................................................................... 12.30
12.1.0.2 Valve Clearance Adjustment ......................................................................................................................... 12.31
12.1.1 Injection Timing Adjusting Procedures .................................................................................. 12.33
12.1.1.0 Inspect The Injection Timing ............................................................................................ 12.33
12.1.1.1 Adjust The Injection Timing ............................................................................................. 12.33
12.1.1.2 Lubrication for the Rocker Arm ..................................................................................... 12.34

12.2 Overhaul Criteria ........................................................................................................ 12.35

12.2.0 Factors to Determine the Engine Overhaul ........................................................................ 12.35
12.2.0.0 Low Compression Pressure ................................................................................................ 12.35
12.2.1 Engine Oil Pressure ....................................................................................................................... 12.36
12.2.2 Other Factors ................................................................................................................................... 12.36

12.3 Dismounting and Mounting ...................................................................................... 12.37

12.3.0 Dismounting ...................................................................................................................................... 12.37
12.3.1 Mounting ............................................................................................................................................. 12.37

12.4 Cylinder head ............................................................................................................... 12.38

12.4.0 Disassembly ........................................................................................................................................ 12.38
12.4.0.0 Disassemble the Cylinder Head ....................................................................................... 12.38
12.4.0.1 Disassemble The Valve System ........................................................................................ 12.39
12.4.0.2 Clean The Cylinder Head. ................................................................................................. 12.39
12.4.1 Replacement ...................................................................................................................................... 12.39
12.4.1.0 Replace The Valve Guide. .................................................................................................. 12.39
12.4.1.1 Replace The Valve Seat ....................................................................................................... 12.40
12.4.1.2 Replace The Valve Stem Seal ........................................................................................... 12.41
12.4.1.3 Replace The Nozzle Seat .................................................................................................... 12.41
12.4.1.4 Assemble The Valve and Valve Spring ......................................................................... 12.42
12.02 HAJ08CTI ENGINE

Section Subject Page No.

12.5 Cylinder Block ............................................................................................................. 12.45
12.5.0 Overhaul ............................................................................................................................................. 12.45
12.5.0.0 Remove the Pistons With Connecting Rods .............................................................. 12.45
12.5.0.1 Remove The Piston Rings .................................................................................................. 12.45
12.5.0.2 Remove The Cylinder Liner .............................................................................................. 12.45
12.5.1 Assembly ............................................................................................................................................. 12.46
12.5.1.0 Inspect and Adjust the Piston Cooling Jet ................................................................. 12.46
12.5.1.1 Install The Cylinder Liner .................................................................................................. 12.47
12.5.1.2 Measure the Protrusion at the Cylinder Liner Flange ........................................... 12.48
12.5.1.3 Measure the Crankshaft ....................................................................................................... 12.48
12.5.1.4 Install The Crankshaft .......................................................................................................... 12.48
12.5.1.5 Install The Main Bearing Cap ........................................................................................... 12.49
12.5.1.6 Replace The Connecting Rod Bushing ......................................................................... 12.50
12.5.1.7 Assemble The Piston And Connecting Rod ............................................................... 12.52
12.5.1.8 Assemble The Piston Ring ................................................................................................. 12.52
12.5.1.9 Install The Piston and Connecting Rod Assembly .................................................. 12.53
12.5.1.10 Tighten the Connecting Rod Bolt ................................................................................... 12.54
12.5.1.11 Install The Oil Pan ............................................................................................................... 12.54

12.6 Cylinder Head .............................................................................................................. 12.56

12.6.0 Install The Cylinder Head Gasket. .......................................................................................... 12.56
12.6.1 Measure The Cylinder Head Bolt ............................................................................................ 12.57
12.6.2 Install The Cylinder Head ........................................................................................................... 12.57
12.6.3 Install The Cam Idle Gear. ......................................................................................................... 12.58
12.6.4 Assemble The Camshaft Gear ................................................................................................... 12.58
12.6.5 Install The Camshaft ...................................................................................................................... 12.61
12.6.6 Install The Rocker Arm Assembly ........................................................................................... 12.62
12.6.7 Install The Head Cover ................................................................................................................ 12.62

12.7 Crankshaft Front End ................................................................................................ 12.65

12.7.0 Remove The Crankshaft Front Oil Seal ................................................................................ 12.65
12.7.1 Install the Crankshaft Front Oil Seal ..................................................................................... 12.65

12.8 Flywheel and Flywheel Housing .............................................................................. 12.67

12.8.0 Remove the Crankshaft Rear Oil Seal ................................................................................... 12.69
12.8.1 Install The Crankshaft Rear Oil Seal ..................................................................................... 12.69
12.8.2 Replace The Flywheel Ring Gear ............................................................................................. 12.70
12.8.3 Flywheel Assembly .......................................................................................................................... 12.71
12.8.3.0 Install The Flywheel .............................................................................................................. 12.71

12.9 Timing Gear ................................................................................................................. 12.72

12.9.0 Remove The Idle Gear Shaft ..................................................................................................... 12.72
12.9.1 Install The Rear End Plate .......................................................................................................... 12.72
12.9.2 Install The Crankshaft Gear ....................................................................................................... 12.72
12.9.3 Install The Idler Gear Shaft And Gear ................................................................................. 12.73
12.9.4 Measurement of Gear Backlash ................................................................................................. 12.73

12.10 Air Intake Manifold .................................................................................................... 12.74

12.10.0 Install The Exhaust Manifold Gasket ...................................................................................... 12.74

12.11 Oil pump and oil strainer ........................................................................................ 12.75

12.11.0 Installing the Oil Pump ................................................................................................................ 12.75
 HAJ08CTI ENGINE 12.03

Section Subject Page No.

12.12 Oil Filter and Oil Cooler ......................................................................................... 12.76
12.12.0 Dismounting ...................................................................................................................................... 12.76
12.12.0.0 Remove The Oil Filter ......................................................................................................... 12.76
12.12.1 Mounting ............................................................................................................................................. 12.76
12.12.1.0 Install The Oil Filter ............................................................................................................. 12.76
12.12.1.1 Install The Oil Cooler And Oil Filter Assembly ...................................................... 12.76
12.12.2 Disassemble The Coolant Pump ............................................................................................... 12.78
12.12.3 Assemble The Coolant Pump .................................................................................................... 12.79

12.13 Thermostat .................................................................................................................... 12.80

12.13.0 Inspect the Thermostat Function ............................................................................................. 12.80
12.13.1 Assembly The Thermostat Case ............................................................................................... 12.80
12.13.2 Install The Thermostat Case Assembly ................................................................................. 12.80

12.14 Cooling Fan .................................................................................................................. 12.81

12.15 Fuel System .................................................................................................................. 12.82

12.15.0 Remove The Fuel Injection Pump ............................................................................................ 12.82
12.15.1 Install The Fuel Injection Pump ................................................................................................ 12.82
12.15.2 Remove The Fuel Filter ................................................................................................................ 12.83
12.15.3 Install The Fuel Filter .................................................................................................................... 12.84
12.15.4 Air Bleeding from Fuel System .................................................................................................. 12.84
12.15.4.0 Bleed Air From The Fuel Filter ....................................................................................... 12.84

12.16 Injection Nozzle (Two-spring Type - Bosch Make) ........................................... 12.85

12.16.0 Dismounting ...................................................................................................................................... 12.85
12.16.0.0 Remove The Fuel Injection Pipe ..................................................................................... 12.85
12.16.0.1 Remove The Nozzle Holder Assembly .......................................................................... 12.85
12.16.1 Inspection ........................................................................................................................................... 12.86
12.16.1.0 Check the Injection Pressure ............................................................................................ 12.86
12.16.1.1 Test The Spray Profile ......................................................................................................... 12.86
12.16.1.2 Test The Fuel Leakage ......................................................................................................... 12.86
12.16.2 Disassembly ........................................................................................................................................ 12.87
12.16.2.0 Remove the Retaining Nut ................................................................................................ 12.87
12.16.2.1 Test The Nozzle Sinking ..................................................................................................... 12.87
12.16.3 Assembly - Nozzle Holder ........................................................................................................... 12.87
12.16.3.0 Adjustment of the First Opening Pressure (Work Step - 1) ............................. 12.88
12.16.3.1 Checking of the Needle Valve Full-Lifts (Work Step 2) ....................................... 12.89
12.16.3.2 Checking of the Pre-lift (Work Step 3) ....................................................................... 12.90
12.16.3.3 Checking of the Second Opening Pressure (Work Step 4) ................................ 12.91
12.16.3.4 Adjusting of the Second Opening Pressure (Work Step 5) ............................... 12.92
12.16.3.5 Replacement of the Retaining Nut (Work Step 6) ................................................. 12.93
12.16.3.6 Final Inspection (Work Step 7) ....................................................................................... 12.93
12.16.4 Mounting ............................................................................................................................................. 12.93

12.17 Turbocharger ................................................................................................................ 12.95

12.17.0 Troubleshooting Procedures Notes ......................................................................................... 12.104
12.17.1 Overhaul Criteria ............................................................................................................................ 12.105
12.04 HAJ08CTI ENGINE

Section Subject Page No.

12.18 Air compressor ............................................................................................................ 12.110
12.18.0 Data and Specifications ................................................................................................................ 12.110
12.18.1 Repair Data ....................................................................................................................................... 12.111
12.18.2 Tightening Torques ........................................................................................................................ 12.111
12.18.3 Trouble Shooting ............................................................................................................................. 12.112
12.18.4 Overhaul ............................................................................................................................................. 12.113
12.18.4.0 Dismounting ............................................................................................................................. 12.113
12.18.4.1 Mounting .................................................................................................................................... 12.113
12.18.4.2 Disassembly .............................................................................................................................. 12.114
12.18.4.3 Assembly .................................................................................................................................... 12.117

12.19 Dry Type Air cleaner ................................................................................................ 12.122

12.19.0 Maintenance and Servicing .......................................................................................................... 12.122

12.20 Aluminium Radiators and charge air cooler ...................................................... 12.123

12.21 Maintenance Programme .......................................................................................... 12.127

IMPORTANT

Experienced personnel should carry out any repair work on the aggregate and utmost cleanliness
must be observed.

A dismantling of the aggregate should only be undertaken for the purpose of replacing or worn
components. After the aggregate has been removed from the vehicle it should be thoroughly
washed with a suitable cleansing liquid before it is opened.

Dismantling and assembly should be carried out on a clean work bench and the special tools,
manufactured for this purpose to be used.

Any old sealing compound adhering to joint surfaces of parts and cover must be removed before
the components are installed. Burrs or similar defects must be removed carefully with a oil stone.

Damaged and badly worn components must be renewed.

Sealing rings with rough, torn or hardened sealing lips must be renewed. Care must be taken that
grease\sludge or other foreign matters do not obstruct oil holes and passages.

The tightening torque and adjustment data, given in the manual must be followed very strictly
during the assembly of the aggregate. Tightening torque’s for bolts and nuts, which are not
contained in the table “ tightening torque and adjustment data” can be obtained from standard
specification tables.
 HAJ08CTI ENGINE 12.05

12.0 GENERAL

12.0.0 Engine Type and Number

The engine number is punched on the

right side front top of the crankcase.

Fig - 2

12.0.1 Design and Operation

6 cylinder, water cooled 4 stroke Diesel Fig. 1

Engine with direct fuel injection into a
optimized combustion chamber arranged in
the crown.

The engine employs a re-entrant combustion

chamber which features a specially shaped
combustion chamber in the piston crown.

Another characteristics is the special shape

and arrangement of the intake ducts in the
cylinder head which allows the air to enter
only from one direction. Upon entering, the Fig. 2
air is given a swirling motion causing the
fuel to mix, which is injected through a
multi hole nozzle into the combustion
chamber. Combustion is ignited at the end
of compression stroke.

The shape of the combustion chamber

allows full use of the energy contained in
the fuel, because the cooling surfaces are
comparatively small in relation to the
volume of the combustion chamber whilst
the air swirls ensures that air and fuel are
mixed uniformly.
12.06 HAJ08CTI ENGINE

12.0.2 General Data

Description HAJ08CTI
Type Diesel four stroke, vertical 6 cylinder, water cooled, direct injection,
in line over head camshaft
Aspiration Turbo charged with Inter cooler.
Max output 191 kW @ 2500 rpm
Max torque 745 Nm @ 1500 rpm
Bore and Stroke 114 mm x 130 mm
Piston displacement 7.961 l
Compression Ratio 18 : 1
Firing order 1-4-2-6-3-5
(Cylinder numbers are counted inorder from crankshaft pulley side)
Direction of rotation Counter clockwise viewed from flywheel
Compression pressure 35 Ã 38 kg/cm² @ 280 rpm (Limit - 28 kg/cm²)
Idling revolution 500 Ã 550 rpm
Max. revolution at full load 2500 rpm
Engine Weight (Dry) 600 kg (approx.)
Valve Timing
Intake opens 14° Before TDC
Intake closes 30° After BDC
Exhaust opens 54° Before BDC
Exhaust closes 13° After TDC
Valve clearance (when cold)
Intake 0.30 mm
Exhaust 0.45 mm
Engine Oil Pump
Type Full forced Pressure feed by gear pump
Drive By gear
Engine oil cooler Multi plate type, water cooled
Fuel Injection Equipment ZEXEL MD - TICS
High Pressure Pipe (OD x ID x Length) 7 x 2 x 560 mm
Injection Nozzle
Type Multi hole nozzle
Nozzle opening pressure 1st - 180 kg/cm², 2nd - 220 kg/cm²
Coolant Pump
Type Forced circulation by volute pump
Drive By V-belt
Impeller dia 120 mm
Thermostat Wax Type, bottom bypass system
Injection timing (Flywheel travel) 6° Before TDC for No. 1 cylinder of the compression stroke
Turbo wastegate Yes
Air compressor Reciprocating, twin cylinder
Electrical
Starter motor Reduction gear type - 24 V - 4.5 kW
Alternator 24 V - 50 A
 HAJ08CTI ENGINE 12.07

12.0.3 Repair Data

SPECIFICATION MEASURING DEVICE

DESCRIPTION
(Measurements in mm) AND REMARKS

Crankcase
Cylinder block flatness 0.05 (limit 0.20) Do not grind for repair, replace.
Crankcase bore inside diameter A - 117.000 - 117.008
B - 117.008 - 117.014
C - 117.014 - 117.022
Cylinder liner outside diameter A - 116.982 - 116.990
B - 116.990 - 116.996
C - 116.996 - 117.004
Clearance between crankcase bore and A - 0.010 - 0.026
liner B - 0.012 - 0.024
C - 0.010 - 0.026
Cylinder liner bore : Size / wear limit 114 (limit 114.15)
Cylinder Liner protrusion 0.01 - 0.08
Block Top Surface to Crankshaft Centre 309
Block Top Surface to sump face height 384
Cylinder block counter bore depth 7.98 - 8.02
Cylinder liner thickness 8
Cylinder counter bore dia 122 + 0.29
Piston and Connecting Rod Assembly
Piston diameter Standard size 113.877
Piston ring Groove Width
Top 2.5 (limit - 2.7)
Second 2.0 (limit - 2.2)
Oil Ring 4.0 (limit 4.1)
Piston ring width
Top 2.5 (limit 2.4)
Second 2.0 (limit 1.9)
Oil Ring 4.0 (limit 3.9)
Piston ring side clearance in groove
Top 0.09 - 0.13
Second 0.04 - 0.08
Oil Ring 0.02 - 0.06
Piston Ring gap
Top 0.30 - 0.40 (limit 1.5)
2nd 0.30 - 0.45 (limit 1.2)
Oil 0.30 - 0.45 (limit 1.2)
Piston pin hole inside diameter 37 (limit 37.05)
Gudgeon pin outside diameter 37 (limit 36.96)
Clearance between Piston pin and Piston 0.013 - 0.014 (limit 0.05)
pin hole
Clearance between piston and cylinder
liner 0.115 - 0.131
12.08 HAJ08CTI ENGINE

Repair Data

SPECIFICATION MEASURING DEVICE

DESCRIPTION
(Measurements in mm) AND REMARKS

Con rod small end bush bore 37 (limit 37.1)

Diametral clearance between gudgeon 0.015- 0.036 (limit 0.08)
pin and con. rod small end bush bore
Interference fit of small end bush in
connecting rod 0.05 - 0.10
Connecting rod centre to centre distance 187.5 ± 0.2
Crankshaft
Crankshaft journals and crankpin grinding Refer Page No. 12.14
dimensions
Surface hardness of journals and crankpins 520 Ã 680
Maximum permissible bend at
4th journal 0.15
Crank pin outside diameter 65 (limit 0.2)
Crank main journal outside diameter 80 (limit 0.2)
Crankshaft Main Bearing Cap roundness 0.005
Main and connecting journal sizes Standard, 0.25 U/S and 0.50 U/S
Crankshaft end play 0.050 - 0.219 (limit 0.5)
Diametral clearance between main 0.051 - 0.102 (limit 0.2)
journal and bearing.
Connecting rod end play 0.20 - 0.52 (limit 1.0)
Diametral clearance between Connecting 0.031 - 0.082 (limit 0.2)
Rod Big End Bearing & Crank pin
Connecting rod Big End parent bore dia 68.985 - 69.000
Connecting rod Big end ovality/taper 0.02
Cylinder Heads and Valves
Cylinder head lower surface flatness 0.06 or less for longitudinal direction Do not grind for repairs.
0.03 or less for lateral direction
(limit 0.20)
Cylinder head height 95 ± 0.05
Nozzle protrusion from cylinder head
surface 2.25 - 2.75
Valve sink (Valve head depth
below cylinder head face)
Inlet 0.55 - 0.85 (limit 1.1)
Exhaust 1.15 - 1.45 (limit 1.7)
Valve stem diameter
Inlet 7.00 (limit 6.92)
Exhaust 7.00 (limit 6.85)
Intake and Exhaust Valve Guide inner dia 7.00 (limit 7.04)
 HAJ08CTI ENGINE 12.09

Repair Data

SPECIFICATION MEASURING DEVICE

DESCRIPTION
(Measurements in mm) AND REMARKS

Diametrical valve stem clearance in guide

Intake 0.023 - 0.058 (limit 0.12)
Exhaust 0.050 - 0.083 (limit 0.15)
Valve seat angle
Intake 30° (limit 30° - 30°35’)
Exhaust 45° (limit 45° - 45°30’)
Valve face angle
Intake 30° (limit 29°30’ - 30°)
Exhaust 45° (limit 44°30’ - 45°)
Valve seat seating depth on cylinder head
Inlet 9.4 -9.6
Exhaust 8.6 - 8.8
Valve seat thickness
Inlet 7 - 7.2
Exhaust 6 - 6.2
Valve seat seating dia on cylinder head
Inlet 41 - 41.016
Exhaust 39 - 39.016
Outer dia of valve seat
Inlet 41.085 - 41.1
Exhaust 39.12 - 39.13
Maximum permissible out of true Inlet - 0.05
head face head to stem Exhaust - 0.03
Interference fit of valve guide in
cylinder head 0.010 - 0.039
Height of valve guide above spring seat 20.1
Valve stem oil seal height 22.5 - 23
Maximum permissible out of true of
valve seat to guide 0.02
Head pin height 42 - 42.5
Outer Valve Spring - Spring load 32 kgf @ 46.8 (limit 29.8 kgf)
- Free length 75.7 (limit 72.7)
- Squareness limit 2.6
Inner Valve Spring - Spring load 13.2 kgf @ 44.8 (limit 12.2 kgf)
- Free length 64.6 (limit 61.6)
- Squareness limit 2.3
Valve lift
Intake 11.2
Exhaust 10.9
12.10 HAJ08CTI ENGINE

Repair Data

SPECIFICATION MEASURING DEVICE

DESCRIPTION
(Measurements in mm) AND REMARKS

Timing
Rocker arm shaft diameter 22.00 (limit 21.92)
Rocker arm bush inside diameter 22 (limit 22.08)
Diametrical clearance between rocker
arm bush and rocker shaft 0.03 -0.10 (limit 0.15)
Camshaft Bend/Deflection 0.04 (limit 0.1)
Camshaft Cam height - Intake 50.067 (limit 49.987)
Camshaft Cam height - Exhaust 52.104 (limit 52.024)
Camshaft end play 0.100 - 0.178
Camshaft Journal Outside Diameter 40 (limit 39.85)
Camshaft Journal Bearing inside Diameter 40 (limit 40.15)
Diametrical clearance between camshaft
journal and camshaft bearing 0.020 - 0.063
Cam idler gear shaft outer diameter 34.00
Cam idler gear shaft bush inside diameter 34.00
Diametrical clearance between cam Idle
Gear shaft and cam idle gear bush 0.025 - 0.075 (limit 0.2)
Tooth backlash between crank gear 0.030 - 0.167
and main idle gear (limit 0.30)
Tooth Backlash between main Idle gear 0.030 - 0.218
and air compressor gear (limit 0.30)
Tooth backlash between air compressor 0.030 - 0.183
gear and power steering pump (limit 0.30)
Tooth Backlash between cam idle gear 0.030 - 0.253
and camshaft gear (limit 0.30)
Tooth backlash between main idle gear 0.030 - 0.162
and sub idle gear (limit 0.30)
Tooth Backlash between sub idle gear 0.030 - 0.131
and Oil Pump gear (limit 0.30)
Tooth backlash between sub idle gear 0.050 - 0.218
and cam idle gear (limit 0.30)
Main Idle Shaft - Shaft outside diameter 57.00
- Bushing inside diameter 57.00
- Clearance 0.030 - 0.090 (limit 0.20) Replace gear and/or shaft
- Gear width 44
- Shaft length 44
- End play 0.114 -0.160 (limit - 0.30) Replace gear and/or shaft
Sub Idle Shaft - Shaft outside diameter 50.00
- Bushing inside diameter 50.00
- Clearance 0.025 - 0.075 (limit 0.20) Replace gear and/or shaft
- Gear width 22
- Shaft length 22
- End play 0.040 -0.095 (limit - 0.30) Replace gear and/or shaft
 HAJ08CTI ENGINE 12.11

Repair Data

SPECIFICATION MEASURING DEVICE

DESCRIPTION
(Measurements in mm) AND REMARKS

Cam Idle Shaft - Shaft outside dia 34.00

- Bushing inside diameter 34.00
- Clearance 0.025 - 0.075 (limit 0.20) Replace gear and/or shaft
- Gear width 22
- Shaft length 22
- End play 0.040 - 0.095 (limit - 0.30) Replace gear and/or shaft
Flywheel surface deflection limit 0.15
Flywheel flange depth - A Dimension 48.0 Refer page No. 12.71
Flywheel thickness - B Dimension 23.0 (limit - 22.0) Refer page No. 12.71
Engine lubrication
Max. oil pressure: At coolant temperature 80°C or
Full-load 5.0 kg/cm² more.
Idling 0.5 kg/cm²
Minimum oil pressure 0.5 kg/cm²
Oil pump block side pump body inside dia 54
Oil pump gear tip clearance 0.10 - 0.20 (limit 0.30)
Oil pump Gear teeth height 37.5
Oil pump block side pump body inside depth 37.5
Oil pump end play 0.049 - 0.113 (limit 0.15)
Oil flow rate 130 lpm
Oil pump
Valve opening pressure: (Oil filter)
Release valve 5.4 kg/cm²
By-pass valve for paper element 2.0 kg/cm²
By-pass valve for heat exchanger 4.0 kg/cm²
Oil Pump Gear Outer Diameter 54
Oil Pump Gear Backlash(Drive & Driven) 0.073 - 0.207 (limit 0.30)
Drive Gear shaft Diameter 18
Drive shaft Bushing inside Diameter 18
Clearance between Drive Shaft & Bush 0.04 - 0.09
Driven Gear shaft Diameter 18
Driven Gear Bush Inside Diameter 18
Clearance between driven gear and shaft 0.04 - 0.083
Oil Cooler air pressure testing 6 kg/cm²
Cooling System
Permissible maximum cooling temp. 95° C
Thermostat valve opening temp. max. 82°C
Thermostat valve lift 13 mm or more At 95°C
Cooling system capacity 24 l
12.12 HAJ08CTI ENGINE

12.0.4 Tightening Torques Kgm lb.ft Nm

Valve clearance adjusting screw

Lock nut on rocker arm 2.55 18.44 25

Lock nut on cross head 2.55 18.44 25

FIP coupling adjusting bolt 8.97 64.91 88

Engine mounting nut 7.55 54.58 74

Cylinder head cover mounting bolt 2.91 21.02 28.5

Camshaft bearing cap mounting bolt 3.16 22.86 31

Camshaft gear mounting bolt 6.02 + 90° 43.52 + 90° 59 + 90°

Nozzle clamp bolt 2.55 18.44 25

Rocker arm support bolt 6.02 43.52 59

Cam shaft housing mounting bolt 2.35 16.96 23

Cylinder head assembly mounting bolt 6.02+90°+90° 43.52+90°+90° 59+90°+90°

Cam shaft end plug mounting bolt 0.61 4.43 6

Cam idle gear mounting bolt 11.01 79.66 108

Sub idle gear mounting bolt 11.01 79.66 108

Main Idle gear shaft mounting bolt 17.54 126.86 172

Crankshaft pulley mounting bolt 12.03 87.03 118

Torsional damper mounting bolt 11.01 79.66 108

Flywheel mounting bolt 18.97 137.19 186

Stay and crankcase mounting bolt 9.89 71.54 97

Stay and flywheel housing mounting bolt 17.49 126.49 171.5

Flywheel housing mounting bolt

M8 2.91 21.02 28.5

M10 5.61 40.57 55

M16 19.99 144.56 196

Rear end plate mounting bolt 5.61 40.57 55

Piston cooling jet mounting bolt 2.24 16.23 22

Connecting rod cap mounting nut 7.04+90°+45° 50.89+90°+45° 69+90°+45°

Main bearing cap mounting bolt 7.04+90°+45° 50.89+90°+45° 69+90°+45°

Oil pan drain plug 4.18 30.24 41

Oil pan mounting bolt 3.06 22.13 30

 HAJ08CTI ENGINE 12.13

Tightening Torques Kgm lb.ft Nm

Exhaust manifold mounting bolt

Inner 5.40 39.09 53

Outer 6.22 44.99 61

Turbo charger mounting bolt 5.71 41.30 56

Oil pump mounting bolt 2.90 20.95 28.4

Oil strainer mounting bolt 3.16 22.86 31

Oil Cooler

Regulator valve plug 2.51 - 3.50 18.14 - 25.30 24.6 - 34.3

Oil filter safety valve plug 2.45 - 3.50 17.70 - 25.30 24.6 - 34.3

Check valve mounting bolt 1.50 - 1.99 10.84 - 14.38 14.7 - 19.5

Safety valve plug 2.50 - 3.50 18.07 - 25.30 24.5 - 34.3

Oil cooler mounting bolt 2.90 20.95 28.4

Injector pipe nut 3.47 25.08 34.3

Injector leak of pipe banjo bolt 1.48 10.69 14.5

Injector clamp mounting bolt 2.55 18.44 25

Injection pump mounting bolt 2.55 18.44 25

Fuel system bleeding plug 0.50 - 0.91 3.61 - 6.56 4.9 - 8.9

Injector cap nut 4.49 32.45 44

Injector retaining nut 6.99 50.52 68.5

FIP delivery valve holder 11.01 79.66 108

Alternator mounting bolt with mounting bracket 8.46 61.22 83

Alternator mounting bolt with adjuster link 5.20 37.62 51

12.14 HAJ08CTI ENGINE

12.0.5 Crank Shaft Main Journals and Crank Journals Dimensions.

DESCRIPTION mm

1. Std diameter of main journals : 80 (limit 79.3) 79.94 - 79.96

2. Std diameter of conrod journals : 65 (limit 64.3) 64.94 - 64.96

3. Fillet Radius on main journal : 5.0 - 5.5

4. Fillet Radius on crank pin : 5.0 - 5.5

5. Wear limits

Taper (across total width) : 0.004

Ovality : 0.004

Bend : 0.15

Wear limit : 0.2

12.0.6 Main and Crank Journals Grinding Sizes

Under size Crank pin Main Journal
mm mm mm

0.25 64.69 - 64.71 79.69 - 79.71

0.50 64.44 - 64.46 79.44 - 79.46
Width of crank pin - 34 (limit 34.8)
Centre journal width - 36 (limit 37.0)

12.0.7 Crankcase Parent Bore and Cylinder Liner Outer Dia

Crankcase Parent Bore Cylinder Liner Outer Dia

Grade Size (mm) Grade Size (mm)

A 117 + 0.008
+ 0.000
A 117 - 0.010
- 0.018

B 117 + 0.014
+ 0.008
B 117 -0.004
-0.010

C 117 + 0.022
+ 0.014
C 117 + 0.004
- 0.004

Note: Interchangeability is allowed w.r.t. next oversize or undersize liners.

 HAJ08CTI ENGINE 12.15

12.0.8 Fuel Oil (High Speed Diesel)

Users are recommended to obtain their fuel supplies from a source which can be depended upon to
maintain a consistent standard of quality and service.

Fuel should be free from water and dirt, care should be taken by the user to protect fuel from
contamination.

12.0.8.0 Fuel Specifications - as per IS 1460 : 2000 (BS II)

1. Acidity, inorganic ... Nil

2. Acidity, total mg.of KOH/g (Max.) ... 0.20

3. Ash, % by Mass (Max.) ... 0.01

4. Carbon residue (Ramsbottom) on 10 percent residue,

percent by Mass, Max ... 0.30

5. Cetane Number (Minimum) ... 48

or
Cetane index (Minimum) ... 46

6. Pour point (Max.) ... 3°C for Winter &

15ºC for Summer

7. Copper Strip Corrosion for 3 hours @ 100°C ... Not worse than No.1

8. Distillation, percent v/v, recovered:

a) at 350°C, Min ... 85
b) at 370°C, Min ... 95

9. Flash point (Min.)

a) Abel, °C, Min ... 35

10. Kinematic viscosity in centistokes @ 40°C ... 2.0 to 5.0

11. Sediment % by mass (Max.) ... 0.05

12. Density at 15ºC kg/m 3 ... 820 - 860

13. Total Sulphur, % by mass (Max.) ... 0.05

14. Water content % by volume (Max.) ... 0.05

15. Cold Filter Plugging Point (CFPP) max ... 6ºC for Winter and
18ºC for Summer

16. Total Sediments mg per 100 ml. (max) 1.6

 12.16 HAJ08CTI ENGINE

12.0.9 Recommended coolant

Recommended
Change
Name & Address Concentration
Coolant intervals
of the manufacturer For Aluminium
in km
Radiator
Gulf Oil Corporation Limited,
Lubricants Division
Gulf Euro Cool 75,000
IN Centre, 49/50, MIDC, 12th Road,
Andheri (E), Mumbai - 400 093. INDIA
GC 1200 Sunstar-CCI (India) Private Ltd., 60,000
67, Maruthi Industrial Area, Sector 18,
GCL-2000 Gurgaon - 122 015. Haryana. 50% 75,000
Tejon 800 S S Industrial Corporation 75,000
G-10, Udyog Nagar,
Tejon 1200 Delhi - 110 041. 60,000
Bharat Petroleum Corporation Limited,
MAK®
ECE House, 28A Kasturba Gandhi Marg, 75,000
SuperKool
New Delhi - 110 001.

Note: For Sub-zero temperature application use 1 : 1 Ratio.

To Prepare the coolant, it is recommended that only potable drinking water is used.

Caution: Use of any hard water will only increase scale formation in the Engine. Also please note that coolant
does not alter the hardness level of water.

12.0.10 Recommended Lubricants

Use of correct grades of lubrication is most important to prevent the wear and tear of components.
The chart shows the oil grade recommended by AL.
ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Sah
Ambient Indian Oil Hindustan Bharat Elf Karol Pennzoil Meguin
Aggregate Leyland Gulf Oil India IBP Castrol Chemoleums Petroleums
Temp. °C Corporation Petroleum Petroleum Lubricants Lubricants Quaker Oil India
Specification IPOL
Castrol Supreme
Gulf IBP Diesel Meguin
Hino J08C - TI Servo Milcy MAK® Elf Deusol Turbo D IPOL MCF Duty
API CF4 + -15 and Super Turbo Power Diesel
(Turbo charged Premium Power DIAMOND Performance Super Super SAE Diesel Ultra Motor
MB228.1 above Fleet CF4 CF4 Special
after cooled) CF4 15W40 15W40 15W-40 3D 15W40 Euro 15W40 SAE 15W40 Oil
15W40 15W40 15W40 15W40
15W40 15W40

12.0.11 Filling Capacity

Aggregates Qty (l) Change Period (km)

Engine (Including Oil Filter) 13.5 16000

Note: The drain limits indicated are only for plains operation. For Ghat operations drain interval to be
halved.
 HAJ08CTI ENGINE 12.17

12.0.12 Liquid Gasket Application And Part If more than 20 minutes have passed,
Assembly Procedure remove and reapply the liquid gasket.
1. Remove old liquid gasket from each part 5. Wait for at least 15 minutes or more after
and matching parts and wipe off oil, assembly of parts before starting the engine.
moisture or dirt with a rag.
Parts And Positions For Liquid
2. Overlap the liquid gasket at the start and
Gasket.
end of application.
1. Apply liquid gasket to positions and types
3. Be careful of misalignment when assembling
of gasket according to the table shown
parts with liquid gasket. If they are
below.
misaligned, reapply the liquid gasket.
Follow the application pattern at each
4. Assemble parts within 20 minutes of
position shown in the figures.
application.

Part No. Application Position and Pattern Application Gasket to

Width be used
Matching flange face with the block

Oil Seal Retainer 1.5 - 2.5 mm Black

Matching flange face with the block

Coolant Pump 1.5 - 2.5 mm Black

Matching flange face with the block

Oil Cooler 1.5 - 2.5 mm Silver

Matching flange face with the flywheel housing

Dust Cover 1.5 - 2.5 mm Silver

Matching flange face with the cylinder head

Thermostat Case 1.5 - 2.5 mm Silver

Matching face with the rear edge

Flange 1.5 - 2.5 mm Silver

Matching face with the intake manifold

Intake Pipe 1.5 - 2.5 mm Black

12.18 HAJ08CTI ENGINE
Part No. Application Position and Pattern Application Gasket to
Width be used
Matching parts of block upper face rear end, gasket, rear — White
end plate, flywheel housing, cylinder head gasket
Matching parts of oil seal retainer and block lower face
front end.
1.5 - 2.5 mm Black
Matching parts of block lower front end, gasket, rear
end plate and flywheel housing.
1.5 - 2.5 mm Silver

Front and Rear ends of

“Upper / Lower faces of
block

NOTE: Cut the rear end plate gasket with a craft knife
flush with the block upper face.
Matching face of rear end plate

Flywheel Housing 1.5 - 2.5 mm Silver

Matching faces with cam housing and plug. 1.5 - 2.5 mm Black
Matching parts of cam housing, plug, cylinder head (2 locations
cover and gasket at front and
rear ends)

NOTE: Application area of liquid gasket is half

circle of cam housing. Never apply it to
the upper half circle of the plug.
Remove the excessive gasket completely.

Cam Housing

When the cylinder head cover is assembled, reapply

the liquid gasket. (Assembly must be done within
20 minutes.)

NOTE: Figure on the right shows application “pattern” of the liquid gasket. Apply
the liquid gasket to the center of seal flange inside whenever possible.
 HAJ08CTI ENGINE 12.19

Applicator Gun

Fig. 2

Loading Cartridge
Press lever 1 and simultaneously pull lever 2 back completely. Insert the cartridge. The open
cartridge can be dispensed by pressing lever 3.

Unloading Cartridge
Press lever 1 and simultaneously pull lever 2 back completely - Remove cartridge from the gun.
12.20 HAJ08CTI ENGINE

12.0.13 Description of Leading Engine

Components

Cylinder Block - of high grade cast iron.

Cylinders and the crankcase form an
integral casting. The crankcase is enclosed
from below by the oil sump. Oil jets are
provided to cool the pistons.

Cylinder Liners (dry, pre finished, hard,

easy fit type) - made of cast iron. There
are four selectable grades available i.e. A, B,
C based on liner outer diameter.

Cylinder Head - made of high-grade cast

iron, accommodating all cylinders, fitted with
exchangeable, pre finished valve seats and
valve guides.

Crankshaft - an alloy steel forging,

mounted in seven shell bearings with
exchangeable shells. The main journals and
crank-journals are induction hardened.

Vibration Damper - is mounted on the

front end of the crankshaft. Care should
be taken while handling the vibration
damper.

Alfin Pistons - made of special grade

aluminium alloy with cast iron insert to
form the first compression ring seat. The
optimized combustion chamber design type
for better combustion.

Main and Big End Bearing Shells -

thin-walled, with aluminium and tin or lead
bronze linings for sliding surfaces.

Camshaft - made of steel, mounted on

the cylinder head camshaft housing in five
exchangeable shell bearings. Drive is
supplied from the engine crankshaft through
a gear train.

Valves - made of high-grade alloy steel.

Valve stem seals prevent oil leakage into
combustion chamber.

Valve Spring - made of spring steel,

constant pitch coil type, inner and outer
springs.
 HAJ08CTI ENGINE 12.21

12.0.14 Trouble shooting

12.0.14.0 Engine
Symptom Possible Cause Remedy/Prevention
Engine overheating Coolant
* Insufficient coolant Add coolant
* Defective thermostat Replace the thermostat
* Overflow of coolant due to leakage Repair
of exhaust into cooling system
* Coolant leakage from cylinder head gasket Replace gasket.
* Defective coolant pump Repair or replace.

Radiator
* Clogged with rust and scale Clean radiator.
* Clogged with iron oxide due to Clean coolant passage and correct
leakage of exhaust into cooling system exhaust leakage.
* Clogged radiator core due to mud Clean radiator.
or other debris
* Defective radiator cap pressure valve Replace radiator cap
* In correct gap between radiator and fan Correct the gap
* Deration pipes blocked due to mud Clean and use coolant.

Abnormal combustion
* Incorrect injection timing Adjust injection timing.
* Reduced injection pressure Adjust injection pressure.
* Poor fuel Use good quality fuel.
* Poor nozzle spray Adjust or replace nozzle.
* Unsatisfactory automatic timer advance angle Repair or replace timer.

Other problems
* Defective or deteriorated engine oil Change engine oil.
* Unsatisfactory operation of oil pump Replace or repair
* Insufficient oil Add oil.
* Brake drag Repair or adjust.
Excessive oil
consumption Piston, cylinder liners and piston rings
* Wear of piston ring and cylinder liner Replace piston rings and cylinder liner.
* Worn, sticking or broken piston rings Replace piston rings and cylinder liner.
* Insufficient tension on piston rings Replace piston rings and cylinder liner.
* Unsatisfactory break-in of piston rings Replace piston rings and cylinder liner.
* Unsuitable oil (viscosity too low) Change oil as required and replace piston
rings and cylinder liners.
* Incorrectly fitted piston rings (upside down) Replace piston rings.
* Gaps of piston rings in line with each other Reassemble piston rings.

Valve and valve guides

* Worn valve stream Replace valve and valve guide
* Worn valve guide Replace valve guides.
* Incorrectly fitted valve stem seal Replace the stem seal.
* Excessive lubricant on rocker arm Check clearance of rocker arm and shaft.
12.22 HAJ08CTI ENGINE

Symptom Possible Cause Remedy/Prevention

Excessive oil
consumption Excess oil feed
* Defective oil level gauge Replace oil level gauge
* Oil level too high Drain excess oil.

Other problems
* Overcooled engine (low temperature wear) Warm up engine before moving vehicle.
Check cooling system.
* Oil leakage from miscellaneous parts Repair.

Piston seizure Operation

* Abrupt stoppage of engine after running Operate engine properly.
at highspeed
* Hill climbing using unsuitable gear Select suitable gear

Oil
* Insufficient oil Add oil.
* Dirty oil Change oil.
* Poor quality oil Replace with proper engine oil.
* High oil temperature Repair
* Defective oil pump Repair oil pump.
* Reduced performance due to worn oil pump Repair oil pump.
* Suction strainer sucking air Add oil and/or repair strainer.

Abnormal combustion See symptom:”Engine overheating”

Coolant See symptom:”Engine overheating”

Lack of power Intake

* Clogged air cleaner Clean element or replace element.

Fuel and nozzle

* Poor nozzle spray Adjust or replace injection nozzle
* Clogged nozzle with carbon Clean nozzle
* Wear or seizure of nozzle Replace nozzle
* Air in fuel system Repair and bleed air from fuel system.
* Clogged fuel filter Replace element
* Use of poor fuel Use good quality fuel.

Abnormal combustion See symptom:”Piston Seizure”

Wrong injection timing Set as per recommendation.

Throttle not travelling fully. Correct the setting.

Piston, cylinder liners and piston rings See symptom.”Excessive Oil Consumption”

Other problems
* Breakage of turbine or blower Repair
(if so equipped turbocharger)
 HAJ08CTI ENGINE 12.23

Symptom Possible Cause Remedy/Prevention

Difficult starting
engine Electrical system
* Discharged battery Charge battery
* Defective wiring in starter circuit Repair wiring of starter.
* Loose or open-circuit battery cable Tighten battery terminal connections or
replace battery cable.
* Break of glow plug or intake Replace
air heater (if so equipped)

Injection pump Repair

Air cleaner
* Clogged element Clean the element or replace the element.

Fuel system
* No fuel in tank Supply fuel and bleed air from fuel system.
* Clogged fuel line Clean fuel line.
* Air sucked into fuel system through Tighten fuel line connections.
fuel line connections.
* Clogged fuel filter Replace element
* Loose connection in high-pressure line Tighten sleeve nut of high pressure line.
* Water in fuel Drain and clean fuel system

Nozzle
* Seized nozzle Replace nozzle
* Broken or fatigued nozzle spring Replace spring

Oil system
* Oil viscosity too high Use proper viscosity oil, or install an oil
immersion heater and warm up oil.

Other problems
* Seized piston Replace piston, piston rings ,and liner.
* Seized bearing Replace bearing and /or crankshaft
* Reduced compression pressure overhaul engine
* Ring gear damaged or worn Replace the ring gear and/or starter pinion.
* Improperly adjusted or broken accelerator
cable Adjust or replace the accelerator cable
* Arens control struck Correct the cable.
Rough idling Injection pump Repair
Nozzles
* Uneven injection pressure Adjust
* Poor nozzle spray Adjust or replace nozzle.
* Carbon deposit on nozzle tip Remove carbon
* Seized needle valve Replace nozzle
Engine proper
* Improper valve clearance Adjust valve clearance
* Improper contact of valve seat Replace or repair valve and valve seat.
* Idling speed too low Warm up engine.
* Compression pressure of cylinders Overhaul engine
markedly different from one another
12.24 HAJ08CTI ENGINE

Symptom Possible Cause Remedy/Prevention

Leakage of exhaust Cylinder head gasket

* Fatigued gasket (aging) Replace gasket

* Damage Replace gasket

* Improper installation Replace gasket

Cylinder head bolts

* Loose bolts Tighten bolt

* Elongated bolts Replace bolt

* Improper tightening torque of tightening

sequence Tighten properly

Cylinder block

* Cracking Replace cylinder block

* Surface distortion Repair or replace.

* Fretting of cylinder liner insertion portion

(in sufficient projection of cylinder liner) Replace cylinder lines or cylinder block

Cylinder head

* Cracking Replace cylinder head

* Surface distortion Repair or replaces.

Cylinder liners

* Cracking Replace cylinder liner

* Corrosion Replace cylinder liner

* Insufficient projection of cylinder liner Replace cylinder liner

Other problems

* Incorrect injection timing Adjust injection timing.

 HAJ08CTI ENGINE 12.25

12.0.14.1 Fuel Injection Pump

Symptom Possible Cause Remedy/Prevention
Engine does not start Fuel not reaching injection pump
* Fuel lines clogged or damaged Clean or replace fuel lines.
* Fuel filter clogged Clean or replace the filter elements.
* Air in fuel caused by improper connections Repair connections.
of fuel line between fuel tank and feed pump.
* Filter incorporated in inlet side of feed Remove foreign material.
pump clogged
* Faulty feed pump check valve Repair or replace it.
* Feed pump piston spring broken Replace it.
* Feed pump push rod or tappet sticking Repair or replace it.

Fuel reaching injection pump

* Faulty connection of accelerator wire to Repair connection.
pump adjusting lever
* Control rack faulty or sticking Repair it.
* Damaged camshaft bearing Repair it.
* Plunger worn or sticking Correct or replace it
* Faulty connection of engine stop wire to Repair it.
pump stop lever.

Nozzle faulty
* Fuel leakage caused by loosened nozzle Inspect and tighten it.
holder.
* Low opening pressure of nozzle Adjust it.
* Nozzle pressure spring broken Replace it.
* Nozzle needle sticking to nozzle body Correct or replace it.

Pump out of timing

* Improperly retarded injection timing Correct injection timing.
* Incorrect timing caused by improper Check engine timing and correct it.
installation of pump.
* Woodruff key for pump camshaft cut off. Replace it.
* Improper pre-stroke adjustment Correct it to obtain specified injection
timing.
Excessive smoke Black smoke
* Excessive fuel delivery caused by in correct Adjust fuel delivery on test stand.
adjustment of fuel load stopper screw.
* Excessively advanced injection timing. Correct it.
* Large spread in fuel delivery Adjust it.
* Bad nozzle fuel spray characteristics Check and correct them.

White smoke
* Improperly retarded injection timing Advance injection timing.
* Water in fuel Check and clean fuel lines.
12.26 HAJ08CTI ENGINE

Symptom Possible Cause Remedy/Prevention

Low idle speed
irregular Improper adjustment of idle button Correct it.
Bad fuel spray characteristic of nozzles. Check and repair them.
Incorrect injection timing Correct it.
Incorrect initial tension setting of idling spring Adjust or replace it.
or the spring broken.
Control rack not smoothly move Disassemble pump and repair it.
Large spread in fuel delivery Adjust it.
Plunger worn Replace it.
Governor linkage not smoothly move. Correct it.
Defective feed pump Disassemble and repair it.
Engine always runs
at high speed Accelerator cable sticking Check and correct it
Governor linkage sticking Disassemble and repair the governor.
Control rack sticking Check and correct it.
Engine starts and
stops Fuel lines clogged Clean or replace fuel lines.
Air in fuel caused by damaged fuel lines of Repair fuel lines or replace fuel lines and
improper connection of fuel lines. gaskets.
Engine has low
power Pump out of timing
* Excessive advanced timing resulting in loud Check and correct it.
knocking.
* Excessively retarded timing resulting in black Check and correct it.
smoke.
* Defective injection pump overflow valve. Repair or replace it.
* Feed pressure too low Repair the feed pump.
* Improper accelerator cable adjustment Adjust it.
Nozzle faulty
* Fuel leakage from nozzle holder Check and repair nozzle holder.
* Bad nozzle spray characteristic Repair or replace it.
* Loosened adjusting screw in nozzle Adjust it.
holder, resulting in low opening pressure
Pump faulty
* Fuel leakage from delivery valve Retighten the delivery valve holder if it is
holder. loosened or replace O-ring if the O-ring
is defective.
* Defective seat of delivery valve assembly. Repair or replace it.
* Delivery valve spring broken Replace the spring.
* Plunger worn Replace it.
* Large spread in fuel delivery Adjust it.
* Wear of tappet roller Replace the roller.
* Camshaft bearing worn or broken Replace it.
* Improper adjustment of governor fuel load
stopper screw.
Loud knocking Improper injection timing Correct it.
Bad fuel nozzle spray pattern after-dribble. Check and correct it.
High nozzle opening pressure Adjust the opening pressure.
Incorrect fuel deliveries to some nozzles. Readjust the fuel deliveries.
 HAJ08CTI ENGINE 12.27
12.0.15 Special Tools

Special Tool 09552-1090 Special Tool 09552-1030/1060 Special Tool 09433-1070 Special Tool 09491-1010
Compression Gauge Adapter (A) Compression Gauge Adapter (B) Eye Bolt Wire

Special Tool 09470-1170 Special Tool 09431-1020 Special Tool 09472-2100 Special Tool 09472-1210
Valve Spring Press Valve Lapping Tool Valve Stem Seal Press Bar

Special Tool 9800-06100 Special Tool 09471-1520 Special Tool 09420-1742 Special Tool 09407-1040
Steel Ball Guide Rear Oil Seal Puller Oil Seal Press

Special Tool 09481-1340 Special Tool 09420-1100 Special Tool 09420-1442 Special Tool 09411-1300
Guide Bar Sliding Hammer Sliding Hammer Socket Wrench

Special Tool 09442-1011 Special Tool 09420-1720 Special Tool 9001-24262 Special Tool 09472-1620
Piston Ring Expander Puller Connector Bolt Adjusting Bar

Special Tool 09471-1490 Special Tool 09402-1540 Special Tool 09481-1540 Special Tool 9191-08252
Guide Spindle Guide Bolt

Special Tool 09481-1130 Special Tool 09402-1530 Special Tool 9233-10360 Special Tool 09441-1320
Guide Press Sub-Assembly Wing Nut Piston Ring Holder
12.28 HAJ08CTI ENGINE

Special Tools

Special Tool 09444-1630 Special Tool 09503-1090 Special Tool 09420-1810 Special Tool 09420-1820
Gauge Oil Filter Wrench Puller Puller

Special Tool 09503-1040 Special Tool 09511-2500 Special Tool 09512-2470 Special Tool 09420-1442
Fuel Filter Wrench Injection Pump Coupling Wrench Wrench Idle Gear Sliding Hammer
157892-4400

157892-1000
Special Tool 09462-1130 Special Tool 157892-4400 Holder Special Tool 157892-4300 or
Nozzle Holder Adapter Special Tool 157892-1000 Nut 157892-4200 Pin

Special Tool 09444-1130 Special Tool 09420-1830 Special Tool 09420-1670 Special Tool 09482-2220
End Play Gauge Puller Puller Assembly Sleeve Press

Special Tool 09482-2230 Special Tool 09650-1101 Special Tool 09440-1060 Special Tool 09481-1090
Oil Seal Press Bearing Puller Piston Ring Expander Inlet Valve Holder Adapter

Special Tool 9010-10700 Special Tool 9260-10240 Special Tool 09650-1970 Special Tool 09420-1442
Clutch Pressure Plate Fixing Bolt Plain Washer Clutch Pilot Bearing Puller Sliding Hammer

Special Tool 09661-1030 Special Tool 09662-1200

Clutch Release Lever Height Gauge Clutch Aligning Arbor
 HAJ08CTI ENGINE 12.29

12.1 ENGINE TUNEUP

12.1.0 Valve Clearance Checking And

Adjusting Procedures

CAUTION: Valve clearance adjustment is

performed only when the checking
result is not within the specified
value.

12.1.0.0 Preparation of Checking and

Adjustment

1. Positioning the No. 1 or No. 6 piston at

Top Dead Centre of the compression
stroke.

a. Turn the crankshaft counterclockwise

(viewed form the flywheel side) to
align mark 16 on the outer
periphery of the flywheel with the
pointer of the flywheel housing.

Fig - 1
Fig. 1

NOTE: Always turn the crankshaft

counterclockwise (viewed from the
flywheel side).

In this position the No.1 or No.6

piston is at the Top Dead center of
the compression stroke.

b. Confirm whether No.1 or No.6

piston is at the Top Dead center of
the compression stroke by the
following two steps.

- If the timer timing mark is nearly aligned

with the pointer, the No.1 piston is at the
Top Dead Center of the compression
stroke.

Fig - 2

NOTE: When the timing mark of the timer

is at the rear (180 ° opposite), the
No.6 piston is at the Top Dead
Center of the compression stroke. Fig. 2
12.30 HAJ08CTI ENGINE

- Among three drill holes on the camshaft

gear, when two drill holes are on horizontal
position, and the rest of the drill hole is
visible, the No.1 piston is at the Top Dead
Center of the compression stroke.

NOTE: If the rest of drill hole is invisible by

camshaft housing, the No.6 piston is
at the Top Dead Center of the
compression stroke.

Fig - 3 Fig. 3

2. Make sure that the valve stem is correctly

inserted in the cross head.

NOTE: Move the cross head with fingers

right and left to confirm the valve
stem is correctly inserted in the
cross head by listening to the
clicking sound.

Fig - 4

Fig. 4
3. Confirm that there is no foreign particles
or dust between the cross head and the
valve stem.

12.1.0.1 Valve Clearance Checking

1. You can understand which valve to adjust

when No.1 or No.6 piston is at the Top
Dead Center of the compression stroke by
the following chart.
Cylinder 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
With No. 1 Two drill holes and
piston at camshaft
housing is
TDC on horrizontal. The
O O O O O O
compression rest of drill hole is
Camshaft
stroke visible. #1
gear
With No. 6 Two drill holes and
position camshaft
piston at
housing is
TDC on horrizontal. The
O O O O O O
compression rest of drill hole is
stroke invisible. #1

* #1 = View from rear side of camshaft housing

* O mark : Possible to check valve clearance
* Firing order : 1-4-2-6-3-5
* T.D.C : Top Dead Centre
 HAJ08CTI ENGINE 12.31

2. Before checking the valve clearance, make

sure that the roller is on the base circle of
the camshaft.

Fig - 5

3. Insert a feeler gauge of the specified

thickness between the rocker arm and the
cross head to check the valve clearance.

Fig - 6

Valve Clearance (When Cold) Fig. 5

Intake valve - 0.30 mm

Exhaust valve - 0.45 mm

12.1.0.2 Valve Clearance Adjustment

NOTE: Make sure that the cylinder head

bolt, rocker arm support bolt, nozzle
clamp bolt, cam housing bolt and
cam bearing cap bolt are tightened
to the specified torque.

1. Loosen the adjusting screw lock nut A, D Fig. 6

of the rocker arm and cross head fully.

2. The cross head adjusting screw must

protrude 10 mm or more from the cross
head upper face.

Fig - 7

CAUTION: Unless the adjusting screw is

completely loose to the valve stem
head, the following adjustments may
be adversely affected.
Fig. 7
3. Insert a feeler gauge of the specified
thickness shown between the rocker arm
and the cross head, and adjust the valve
clearance with the adjust screw of the
rocker arm.

4. After completion of the adjustment, tighten

the lock nut A securely with the specified
tightening torque (25 Nm / 2.5 kgm / 18
lb. ft.)

Fig - 8

Fig. 8
12.32 HAJ08CTI ENGINE

5. Condition of inserted feeler gauge, loosen

the adjusting screw of the cross head,
make sure that the feeler gauge does not
feel loose.

Fig - 9

NOTE: If the feeling of the feeler gauge

becomes loose, repeat steps from
(1).

6. Tighten the adjusting screw C of the cross

head until the feeler gauge does not move.
Fig. 9
NOTE: In this situation, clearance between
adjusting screw C and valve stem
head is zero.

Fig - 10

7. While loosening the adjusting screw c of

the cross head gradually, adjust the valve
clearance. Tighten the lock nut D of the
cross head securely with the specified
tightening torque (25 Nm/2.5 kgm /18 lb.
ft.) when the feeler gauge feels correct.

Fig - 11 Fig. 10

NOTE: Do not over loosen the adjusting

screw.

Over loosening of the adjusting

screw C will cause the same
condition as in step (3) again. The
feeler gauge may feel correct, but
there may be excessive clearance
between the adjusting screw C of
the cross head and the valve stem
head E. This does not allow for
correct adjustment.
Fig. 11
Fig - 12

8. Position each piston at Top Dead Centre

of compression stroke by turning the
crankshaft counterclockwise view from
flywheel side. Then adjust the valve
clearance for each cylinder as per firing
order.

Fig. 12
 HAJ08CTI ENGINE 12.33

12.1.1 Injection Timing Adjusting Procedures

12.1.1.0 Inspect The Injection Timing

1. Turn the crankshaft clockwise (viewed from

the timing gear side) to align the timing
mark on the outer periphery of the flywheel
at (A°) before Top Dead Center of the No.
1 cylinder compression stroke with the
pointer of the flywheel housing.

Fig - 13

Fig. 13
Injection timing (A °) : Refer section 12.0.2 -
General Data.

2. Check that the injection timing mark on the

automatic timer is aligned with the pointer
of the pump.

Fig - 14

If not, adjust the injection timing as on the

following page.

12.1.1.1 Adjust The Injection Timing

Fig. 14
1. Make sure that the timing mark on the
outer periphery of the flywheel is aligned
with the timing pointer.

2. Loosen two adjusting bolts of the injection

pump coupling. Do not remove the bolts.

Special Tool : Injection pump coupling

wrench (09511-2500)

3. Turn the automatic timer to the left

(counterclockwise viewed from the drive
shaft) to align the automatic timer mark
with the pointer of the pump.

4. Tighten the adjusting bolt to the specified

torque (88 Nm/9 kgm/65 lb.ft).

Special Tool : Injection pump coupling

wrench (09511-2500)

NOTE: No clearance is allowed between thin

plates.
No deformation of the flange is
allowed due to distortion of a thin
plate.
12.34 HAJ08CTI ENGINE

12.1.1.2 Lubrication for the Rocker Arm

1. Remove the head cover.

2. After the engine starts, check that oil is

supplied to the following location of all
rocker arms within approximately 10
seconds.

a. Roller and cam face A

b. Cross head top C and spring upper seat

top face D through adjusting screw B

Fig - 15

NOTE: If the supply of oil is delayed or not

happening, hydraulic pressure may
be low or the oil gallery may be
clogged. Insufficient supply of oil may
lead to seizure, abnormal wear or
abnormal noise. Recheck the
assembly.

Fig. 15
 HAJ08CTI ENGINE 12.35

12.2 OVERHAUL CRITERIA

12.2.0 Factors to Determine the Engine

Overhaul

12.2.0.0 Low Compression Pressure

1. Before measurement
a. Charge the battery completely.
b. Set the valve clearance to the correct
value.
c. Idle the engine (Coolant temperature at
80°C). Fig. 1

d. Remove the air cleaner

e. Remove all nozzle holders.

Fig - 1

2. Measurement

a. Insert the gauge adaptor into the nozzle

holder hole.

Special Tool: Compression gauge adaptor (09552-

1090)
b. Run the engine with the starter and
measure the compression pressure.

Recommended Compression
Standard : 35 - 38 kg/cm²
Limit : 28 kg/cm²
Difference between each
cylinder : 3 kg/cm²
Engine revolution : 280 rpm.

NOTE: Do not operate the starter for more

than 15 seconds.
Do not allow gas leakage from the
seal face.

c. Measure the compression pressure of each

cylinder.

3. Reassemble the removed parts.

12.36 HAJ08CTI ENGINE

12.2.1 Engine Oil Pressure

1. Check the oil pressure warning lamp when

the oil and coolant temperature is hot
(about 80 °C).

a. If the warning lamp is lightens, check the

oil level.

b. Check oil deterioration.

If oil quality is poor, replace with suitable

grade oil.

c. Remove the oil pressure switch and install

the oil pressure gauge.

d. Measure the oil pressure at a coolant

temperature of 80 oC or more.

Recommended oil pressure:

Standard : 0.5 - 5.0 kg/cm²

Max. : 5.0 kg/cm²

Limit : More than 0.5 kg/cm²

12.2.2 Other Factors

1. Excess blowby gas

2. Defective engine start

3. Low engine output

4. Excess fuel consumption

5. Abnormal engine noise

6. Excess engine oil consumption

 HAJ08CTI ENGINE 12.37

12.3 DISMOUNTING AND MOUNTING

12.3.0 Dismounting
Dismount the Engine Assembly
1. Park the vehicle on level ground and then
block the wheels.
2. Drain coolant from the radiator and cylinder
block, and engine oil from the oil pan.
CAUTION: To avoid the danger of burns, do not
drain the coolant and engine oil while
the engine and radiator are still hot.
3. Disconnect the power steering pump.
4. Disconnect the engine stop cable.
Fig - 1
5. Disconnect the electric lines, fuel lines, air
lines, speedometer cable and accelerator
control cable.
NOTE: Disconnect the battery cable from the
negative terminal (-) of the battery
and disconnect the electric lines.
Cover open ends of the pipes, hoses
and pumps to prevent entry of dirt.
6. Disconnect the hoses (coolant, heater and Fig. 1
air intake) and remove the radiator.
7. Disconnect the air intake and exhaust lines.
8. Disconnect the transmission control and
transmission with clutch housing from the
flywheel housing.
9. Connect a cable from an engine hanger to
the hanger bracket (1 point) on the front of
the engine, and to the hanger bracket (1
point) on the flywheel housing at the rear of
the engine. Using a hoist, raise the hanger
until there is a bit of slack in the cables.
Fig - 2
10. Remove the engine mounting fitting nuts
(front and rear, both sides).
11. Lift the engine hanger so that the cables are
fully tightened, then, after checking that the
cables are securely, lift gently and remove
the engine from the vehicle.

12.3.1 Mounting
1. Mount The Engine Assembly
1. Mount the engine assemble in the reverse
order of dismounting.
Engine mounting fitting nuts tightening Torque
(74 Nm / 7.5 kgm / 54 lb.ft.) Fig. 2
NOTE: Check to see that there are no oil leaks,
fuel leaks, coolant leaks, or air leaks.
12.38 HAJ08CTI ENGINE

12.4 CYLINDER HEAD

12.4.0 DISASSEMBLY

12.4.0.0 Disassemble the Cylinder Head

1. Clean parts around the nozzle holder and

fuel system connections.

2. Remove the nozzle holder assembly.

NOTE: Refer to Fuel System

Fig. 1

3. Remove the rocker arm assembly.

a. Loosen the lock nut at the end of the

rocker arm and turn the adjusting
screw counterclockwise completely.

Fig - 1

NOTE: Not untightening the adjusting screw

may result in a bent rocker shaft.

b. Loosen the nozzle clamp bolt.

c. Loosen the rocker arm support bolt.

Sequence as shown.
Fig. 2

Fig - 2

NOTE: If the cross head is removed from the

valve during disassembly of the rocker
arm assembly, reassemble the cross
head as it was.

4. Remove the cylinder head bolts.

a. Gradually loosen bolts three times in

the order shown in the figure.

Fig. 3
Fig - 3

5. Lift and remove the cylinder head using the

special tool and hoist.

Special Tool : Eye bolt (09433-1070)

Wire (09491-1010)

Fig - 4

NOTE: Do not damage the cylinder head

lower surface or cylinder block upper
surface during removal of the cylinder
head. Fig. 4
 HAJ08CTI ENGINE 12.39

12.4.0.1 Disassemble The Valve System

1. Remove the valve spring retainer using the

special tool.

Special Tool - Valve spring press (09470-

1170)

Fig - 5

2. Remove the intake and exhaust valve.

NOTE: Attaching tags to the valves (giving Fig. 5

corresponding cylinder nos.) will
eliminate time required for lapping the
valve seats on reassembly.

Fig - 5A

12.4.0.2 Clean The Cylinder Head.

1. Clean the cylinder head and remove carbon

deposits or foreign particles.

NOTE: Be careful not to damage the cylinder

head lower surface when removing
Fig. 5A
carbon deposits or foreign particles.

Fig - 6

12.4.1 Replacement

12.4.1.0 Replace The Valve Guide.

1. Remove the valve stem seal.

2. For removal, strike the valve guide with a

brass bar and hammer carefully.

3. When installing a new valve guide, do not Fig. 6

twist the end. Press fit the valve guide using
the special tool.

Special Tool - Guide (09471-1520)

Fig - 7

NOTE: Be careful not to damage the upper

or lower end of the guide during
press-fitting.

Be sure to apply engine oil around

the valve guide during press-fitting.
Fig. 7
12.40 HAJ08CTI ENGINE

12.4.1.1 Replace The Valve Seat

1. When replacing the valve seat, cut three

places on the circumference of an unwanted
valve and weld it to the valve seat.

NOTE: To protect the lower surface of the

cylinder head from welding spatter,
be sure to apply grease before
welding.

2. Place a (brass) back plate at the top of Fig. 8

the valve and strike it with a hammer to
remove the valve seat.

Fig - 8

3. Valve seat dimension

Intake Exhaust
(mm) (mm)
41.000 - 39.000 -
A
Cylinder Head 41.016 39.016
Side
B 9.4 - 9.6 8.6 - 8.8 Fig. 9

41.085 - 39.120 -
C
41.100 39.135
Valve Seat Side
D 7.0 - 7.2 6.0 - 6.2

Fig - 9

4. Heat the cylinder head to 80° – 100 °C in

hot water. After cooling the valve seat,
insert it into the cylinder head.

Fig. 10
Fig - 10

5. Apply a small amount of lapping compound

to the contact surfaces of the valve and
valve seat. Turn the valve using the special
tool and tap it lightly to lap.

Special Tool - Valve lapping tool (09431-

1020).

Fig - 11

Fig. 11
 HAJ08CTI ENGINE 12.41

12.4.1.2 Replace The Valve Stem Seal

1. After removing the valve stem seal,

assemble the spring lower seat and apply
engine oil to the stem seal lip. Punch it into
the valve guide using the special tool.

Special Tool - Valve stem seal press (09472

–2100)

NOTE: After assembly of the stem seal,

check for deformation or cracking of
Fig. 12
the rubber or incline.

Fig - 12

12.4.1.3 Replace The Nozzle Seat

1. Tap the nozzle seat from the cylinder head

lower surface. Then, screw in a suitable bolt
and strike the bolt head with a hammer to
remove the nozzle seat from the cylinder
head.

Fig - 13 Fig. 13

NOTE: After removing the nozzle seat,

remove the rest of liquid gasket or
the adhesion such as dust completely.

2. After inserting the new O-ring into the

nozzle seat insertion hole of the cylinder
head, apply liquid gasket to the lower part
of the new nozzle seat and assemble it
onto the cylinder head.

Fig - 14
Fig. 14

NOTE: Be sure to replace the O-ring with a

new one. Reuse of the O-ring may
cause water or gas leakage, resulting
in overheating or cracking of the
cylinder head.

3. Caulk the nozzle seat with the special tools.

Special Tool - Bar (09472-1210)

Steel ball (9800-06100)

Fig - 15
Fig. 15
12.42 HAJ08CTI ENGINE

12.4.1.4 Assemble The Valve and Valve

Spring

Clean the cylinder head lower surface

Apply engine oil to the valves.

Install the valve intake and exhaust

Fig - 16

Fig. 16

Install the valve lower seat.

Fig - 17

Fig. 17

Drive the head pin into the cylinder head

with special tool.

Fig - 18

Fig. 18

Measure the head pin height (42.00 -

42.50 mm).

Fig - 19

Fig. 19
 HAJ08CTI ENGINE 12.43

Measure the head pin squareness (Less

then 0.02 mm).

Fig - 20

Fig. 20

Apply engine oil to the valve stem.

Install the valve stem oil seal using the

special tool.

Stop striking of tool when it contacts the

cylinder head upper surface.

Fig - 21

Fig. 21

Measure the valve stem oil seal height

(22.5 - 23.0 mm).

Fig - 22

Fig. 22

Install the valve spring inner and outer.

Fig - 23

Fig. 23
12.44 HAJ08CTI ENGINE

Install the valve upper seat.

Fig - 24

Fig. 24

Install the valve spring lock

- Compress the spring with special

tool - valve spring press (09470-
1170), then fit the stem lock into
the upper seat.

Fig - 25

Fig. 25

Apply engine oil to the head pins.

Install the crosshead to the head pins.

The side without the adjust screw shall be

at the camshaft side.

Fig - 26

Fig. 26

15. Measure the crosshead horizontally (0.02

mm).

Fig - 27

Fig. 27
 HAJ08CTI ENGINE 12.45

12.5 CYLINDER BLOCK

12.5.0 Overhaul

12.5.0.0 Remove the Pistons With

Connecting Rods

1. Remove the pistons and connecting rods

from the cylinder block upper side.

NOTE: Remove carbon deposits from the

end inside the cylinder liner with a
scraper or emery paper Fig. 1
(recommended: No. 150) in a
circular direction.

Fig - 1

Arrange the removed pistons and

connecting rod caps in the order of
cylinder Numbers. Be careful not to
change the combination of the
connecting rod and cap.

Fig - 2
Fig. 2
12.5.0.1 Remove The Piston Rings

1. Remove the piston ring using the special

tool.

SST: Piston ring expander (09442-1011)

NOTE: Handle the piston rings carefully

because they are made of a special
casting which is easily broken.

Keep the piston rings for each

cylinder separately. Fig. 3

Fig - 3

12.5.0.2 Remove The Cylinder Liner

1. Before removing the cylinder liner, put

alignment marks on the cylinder block and
liner flange.

Fig - 4

NOTE: Do not make alignment marks with

a punch. Fig. 4
12.46 HAJ08CTI ENGINE

2. Pull the cylinder liner from the cylinder

block using the special tool.

Special Tool - Puller (09420-1720)

Fig - 5

NOTE: Carefully set the special tool to

prevent touching to the piston
cooling jet.

After removing the cylinder liners, Fig. 5

arrange them in sequence

12.5.1 Assembly

12.5.1.0 Inspect and Adjust the Piston

Cooling Jet

1. Install the piston cooling jet on the

cylinder block using the special tool.

Special Tool - Connector bolt (9001-

24262) Fig. 6

Fig - 6

2. For the jet test, connect the oil hose to

the connector bolt from the cylinder block
lower side.

Fig - 7

NOTE: Use clean engine oil for jet flow.

3. Set the special tool on the cylinder block

Fig. 7
upper surface against the dowel pin.

Special Tool - Gauge (09444-1630)

Fig - 8

4. Test jet oil flow the piston cooling jet

nozzle at a hydraulic pressure of 2 kg/cm².

Fig. 8
 HAJ08CTI ENGINE 12.47

5. If the center of the jet flow is within the

target circle (7 mm diameter), the test is
acceptable.

Fig - 9

CAUTION: Engine oil is flammable. Carry out this

test in a well ventilated room and do
not use naked lights in the room.

6. If the center of the jet flow is out of the

target circle, realign the nozzle using the
special tool.
Fig. 9
Special Tool - Adjusting bar (09472-1620)

Fig - 10

12.5.1.1 Install The Cylinder Liner

NOTE: When assembling the cylinder liner

with the cylinder block, clearance can
be set to three levels.

The upper surface and side surface of the

cylinder block are stamped A, B or C
depending on the inside diameter. Insert a
matching cylinder liner having the same
Fig. 10
symbol.

Fig - 11 & 12

1. Apply engine oil to the inner surface of the

block bore and insert the cylinder liner
using the special tool.
Special Tool - Guide (09471-1490)

Fig - 13

NOTE: Handle the cylinder liner carefully

because it is thin.
Fig. 11

Fig. 13 Fig. 12
12.48 HAJ08CTI ENGINE

12.5.1.2 Measure the Protrusion at the

Cylinder Liner Flange
Special Tool : Puller (09420-1720)
Tightening Torque : 9.8 Nm/1 kgm/7 lb.ft.
Liner protrusion : 0.01 - 0.08 mm

Fig - 14

12.5.1.3 Measure the Crankshaft

1. If necessary, grind the crankshaft and use an

undersize bearing.
Fig. 14
Bearing
Outside Diameter (mm)
Size
Crankpin Journal
Standard
64.94 - 64.96 79.94 - 79.96

0.25 US 64.69 - 64.71 79.69- 79.71

0.50 US 64.44 - 64.46 79.44 - 79.46

2. Dimension of fillet “R”

Crank pin - 5.0 - 5.5 mm
Journal - 5.0 - 5.5 mm
Fig. 15
Fig - 15

12.5.1.4 Install The Crankshaft

1. Install the main bearing onto the bearing

caps and the cylinder block.

NOTE: Install the bearing with the oil hole

on the block side and the bearing
without the oil hole on the cap side.

Apply clean engine oil to inner surfaces of

the bearings.

2. Install the thrust bearing with the groove

side (front) toward the crank arm and with
the part No. stamp (back) toward the main
bearing cap or cylinder block.

Fig - 16

NOTE: Apply engine oil or grease to the

back of the bearing to prevent
loosening during installation.

Fig. 16
3. Install the crankshaft onto the cylinder block.
 HAJ08CTI ENGINE 12.49

12.5.1.5 Install The Main Bearing Cap

1. Install the main bearing cap onto the

cylinder block.

NOTE: Check the number stamped on the cap.

2. Measure the length below the head of the

bearing cap bolt and replace any bolts not
meeting the limit with new ones.

Dimension A : 108 mm

3. Apply clean engine oil to the bolt seat and

bolt threads. Fig. 17

Fig - 17

4. Tighten the bolts in the order as shown in

the figure to the specified torque (69 Nm/7
Kgm/51 lb. ft.)

Fig - 18

5. Loosen all bolts, tap the front and back

ends of the crankshaft using a plastic
hammer.

6. Again, tighten the bolts as in step (4)

7. Mark the bolt heads with marker. Fig. 18

8. Further tighten the bolts 90° (1/4 turn) in

the same order as in step (4)

9. Retighten the bolts 45° (1/8 turn) as in step

(8)

10. Make sure that all marker marks face the

same direction.

NOTE: When adding torque, never untighten the

bolt, even it they have been overtightened.

Fig - 19
Fig. 19
Measure the crankshaft end play

Set the dial gauge on the crank shaft end

face to measure the play.

Standard : 0.05 - 0.219 mm

Rotate the crankshaft for smooth movement

of the crankshaft.

Fig - 20

Fig. 20
12.50 HAJ08CTI ENGINE

12.5.1.6 Replace The Connecting Rod

Bushing

1. Prepare the special tools.

a. Assembly the guide and press Sub-assembly

inserting its pin into the guide then secure
them with the wing nut.

Fig - 21

Special Tool - Guide (09481-1130) Fig. 21

Press sub-assembly (09402-1530)

Wing nut (9233-10360)

NOTE: Bring lever “H” punched on the

guide above the pin.

Making sure to align both supporting

surfaces of the guide and press sub-
assembly flush on a flat plane.
Fig. 22
2. Using a special tool, remove the
connecting rod bushing

a. Set the connecting rod assembled without

connecting rod bearing on the guide and
press sub-assembly.

Fig - 22

b. Install the spindle into the bushing.

Special Tool - Spindle (09402-1540)

Fig. 23

Fig - 23

NOTE: Align the groove of the spindle with

the groove of the press subassembly.

c. Using a hydraulic press, remove the

bushing.

Fig - 24

NOTE: Always operate the press slowly and

Fig. 24
smoothly.
 HAJ08CTI ENGINE 12.51

3. Chamfer one edge of the bushing hole at

the small end of the connecting rod
uniformly by 0.5 - 1.0 mm.

Fig - 25

NOTE: Irregular chamfering can cause out-

of-roundness of the pressed bushing,
which may result in jamming during
insertion.

Remove dust from the inner surface

of the small-end hole. Fig. 25

4. Mount the bushing on the spindle.

a. Set the bushing and guide on the

spindle as shown in the figure, then
secure them with the bolt.

Special Tool : Spindle (09402-1540)

Guide (09481-1540)
Bolt (9191-08252)

Fig - 26
Fig. 26

Bolt tightening Torque:

5.0 - 6.8 Nm / 0.5 - 0.7 kgm / 3.62 -
5.06 lb. ft.

NOTE: Align the groove of the spindle with

the groove of the press sub
assembly.

Make sure that the contact surfaces

of the bushing seats firmly against
the contact surfaces of the spindle
and guide.

b. Apply the fresh engine oil around

the bushing and guide.

5. Align the oil hole of the bushing with the

oil hole of the connecting rod.

Fig - 27

NOTE: Put the connecting rod to the press

sub assembly that chamfer side of
the small end to the bushing side.

Apply the fresh engine oil to the Fig. 27

bore of the connecting rod.
12.52 HAJ08CTI ENGINE

6. Using a press, install the bushing in the

connecting rod.

7. Inspect the bushing positioning after

installation.
a. Make sure that the oil hole of the
bushing and the oil path of the
connecting rod are suitably aligned
allowing a 6 mm diameter rod to
penetrate.

Fig - 28

Fig. 28
NOTE: Misalignment can lead to insufficient
lubrication, which may result in
seizure.
b. Insert a new piston pin. When it is
turned gently, make sure that there is
no catch or rough movement.

12.5.1.7 Assemble The Piston And Connecting

Rod

1. Heat the piston to 50°C.

Apply engine oil to the piston pin,

connecting rod small end. Fig. 29

2. Assemble the piston O-mark to be opposite

to the connecting rod match mark.

Fig - 29

Install the snap rings, using snap ring plier.

Fig - 30

12.5.1.8 Assemble The Piston Ring

1. Install in the order of oil ring, second ring

and top ring using the special tool. Fig. 30
Special Tool : Piston ring expander (09442-
1011)

NOTE: Install the second ring that turn the

identification print on the piston ring
to upper surface.

2. Connect the joint of the coil expander for

the oil ring and install it inside the piston
ring. Assemble the ring with the joint 180°
opposite to the matching point.

Fig - 31
Fig. 31
 HAJ08CTI ENGINE 12.53

3. Position the matching points of the piston ring

at a even distance as shown in the figure.

Fig - 32

Install the connecting rod bearings.

- Locate the oil hole in correct position.

Fig - 33

12.5.1.9 Install The Piston and Connecting

Rod Assembly

1. Apply engine oil to the piston, cylinder liner

and connecting rod bearing. Then compress Fig. 32
the piston ring using the special tool.

Special Tool - Piston ring holder (09441-

1320)

NOTE: When installing the piston, be careful

that the cooling jet is not struck by
the connecting rod.

Fig - 34

Make sure that the 0-mark on the

piston is at the exhaust side.

Insert the piston and the connecting rod Fig. 33

assembly into the cylinder liner, using special
tool and push it inside.

Fig - 35

Apply engine oil to the piston rings,

crankshaft pin and connecting rod bearings.

Install the connecting rod cap. When

installing the caps to the connecting rods.
Ensure the match marks of the caps and
the connecting rods are located at the
injection pump side.

Fig - 36 Fig. 34

Fig. 36 Fig. 35
12.54 HAJ08CTI ENGINE

12.5.1.10 Tighten the Connecting Rod Bolt

1. Measure the length of the bolts, if the length
is A or more, replace with new bolts.
Dimension A - 82.5 mm
Fig - 37
2. Apply clean engine oil to the bolt thread
and the nut seat surface of the connecting
rod cap.
3. Tighten the connecting rod nut to the
specified torque (69 Nm/7 kgm/51 lb.ft).
4. Mark the nut heads in the same direction
with marker. Fig. 37
5. Tighten the connecting rod nut 90° (1/4 turn).
6. Tighten the connecting rod nut 45° (1/8 turn).
7. Make sure that the marker marks face the
same direction.
Fig - 38
CAUTION: When adding torque, never untighten
the nuts, even if they have been
overtightened.
Check the con. rod end play.
Gently tap the connecting rod cap.
Insert the thickness gauge while pushing the
cap to the right or left. Fig. 38

Standard end play : 0.20 - 0.52 mm

Fig - 39

12.5.1.11 Install The Oil Pan

Install the ‘O’ ring to the strainer.

Fig - 40

Tighten the bolts to torque - 31 Nm.

Fig - 41

Fig. 39

Fig. 41 Fig. 40
 HAJ08CTI ENGINE 12.55

1. Make sure that there is no deformation,

impact marks or foreign particles on the
cylinder block, oil pan or flange surface.
Apply liquid gasket to the front and back
ends of the cylinder block lower surface.

2. Install the gasket, so that the protrusion is

at the flywheel housing side and the intake
side. (the print seal surface is at the cylinder
block side)

3. Place a guide pin of 70 mm or more in the

cylinder block and assemble the oil pan
against the guide.

4. Tighten oil pan fitting bolts in the order 1-

2–3–4.

Tightening Torque:
19.7 - 24.5 Nm/2.0 - 2.5 kgm, 15 - 18 lb.ft.)

5. Finish tightening the bolts with a torque

wrench to the specified torque. Tighten the
bolts according to the arrow in the figure.
Fig. 42

Fig - 42

NOTE: Make sure that the washer is not on

the flange.

Install the drain plug with soft washer and

torque tighten to 41 Nm.

Fig - 43

Install the housing stay and tighten the bolts

to torque. Fig. 43

Fig - 44

Fig. 44
12.56 HAJ08CTI ENGINE

12.6 CYLINDER HEAD

12.6.0 Install The Cylinder Head Gasket.

Cut the lengthy part of the flywheel housing

gasket.

Fig - 1

Install the guide pin on the cylinder block

top surface.

Fig - 2
Fig. 1
CAUTION: Never reuse the gasket as it may
cause engine damage.

The twelve water hole seal rings

between the bores are easily
damaged. Do not touch them with
your hands or other objects make
sure that the seal rings are not loose
or damaged.

Since silicon material is used for the

gear case print seal, make sure that
there is no peeling before assembly.
Fig. 2
Fig - 3

1. Install the cylinder head gasket on the

cylinder block and flywheel housing.

2. Fill the hole at the back of the cylinder head

gasket with liquid gasket.

NOTE: Make sure that the liquid gasket

surface is flush with the cylinder head
gasket upper surface.

Fig - 4 & 5
Fig. 3

Fig. 5 Fig. 4
 HAJ08CTI ENGINE 12.57

12.6.1 Measure The Cylinder Head Bolt

1. Measure the length of the M12 head bolts,

if the length is A or more, replace with
new bolts.

Dimension A - 126.5 mm

Fig - 6

12.6.2 Install The Cylinder Head

1. Using the special tool and hoist, put the

Fig. 6
cylinder head and align the guide pin.
Special Tool : Eye bolt (09433-1070)
Wire (09491-1010)

CAUTION: When installing the cylinder head,

attention to cam idle gear and sub
idle gear engagement.

Fig - 7

2. Apply clean engine oil to the bolt surface

and bolt threads of the M10 and M12 bolts.

Fig. 7
3. Clean the bolt seats completely on the
cylinder head upper surface.

4. Tighten No.1 – No.26 (M12 bolts) in the

order shown in the figure to the specified
torque (59 Nm/6.0 kgm/43 lb. ft.).

Fig - 8

5. Mark the M12 bolts with marker to indicate

the same directions as shown in the figure.

6. Turn No.1 – No. 26 (M12 bolts ) 90o (1/4

turn) in the same order as in (4) Fig. 8

7. Retighten them 90 ° (1/4 turn) as step (6).

8. Make sure that all marker marks face the

same direction.

Fig - 9

NOTE: When adding torque, never untighten

the bolts, even if they have been
overtightened.

Fig. 9
12.58 HAJ08CTI ENGINE

9. Tighten No.27 – No.29 (M10 bolts) in the

order shown in the figure to the specified
torque (59 Nm/6.0 kgm/43 lb.ft.)

Fig - 10

12.6.3 Install The Cam Idle Gear.

Apply engine oil to the idle gear.

Insert the idle gear with the thrust washer

into the cylinder head, and align the gear
bush bore and the hole of the cylinder
head rear side.

Insert the idle gear shaft from the cylinder Fig. 10

head rear side through the gear bush.

Fig - 11

CAUTION: Install the cam idle gear shaft through

the thrust plate as shown in the
figure so that the lubrication hole is
downward.

Fig - 12

Apply clean engine oil to the bolt

seat and bolt threads.

12.6.4 Assemble The Camshaft Gear

Fig. 11
1. Measure the length of the camshaft gear
bolts, if the length is A or more, replace
with new bolts.
Dimension A - 51 mm.

Fig - 13

2. Make sure that there is neither damage to the

camshaft gear or camshaft nor dirt on them.

3. Apply clean engine oil to the bolt surface

and bolt threads and tighten them to the
specified torque (59 Nm/6.0 kgm/43 lb.ft.).

Fig - 14 Fig. 12

Fig. 14 Fig. 13
 HAJ08CTI ENGINE 12.59

4. Turn bolt an additional 90° (1/4 turn).

NOTE: When adding torque never untighten

the bolt, even if it has been
overtightened.

Fig - 15

Fig. 15

Assemble the camshaft housing

assembly.

Install the camshaft housing gasket and apply

engine oil to the gasket.

Fig - 16

Fig. 16

Set the camshaft housing bolts. Fig. 17

Fig 17 & 18

Fig. 18
12.60 HAJ08CTI ENGINE

Install the camshaft housing plug.

Apply bond to the front and rear half circle Fig. 19

of the camshaft housing.

Fig - 19 & 20

Install the camshaft housing plug to the

housing with torx bolt and torque tighten to
6 Nm. Fig. 20

Fig - 21 & 22

Install the camshaft bearings.

Install the bearings in the caps and camshaft

housing.

Fig - 23

Fig. 21

Fig. 23 Fig. 22
 HAJ08CTI ENGINE 12.61

12.6.5 Install The Camshaft

1. Align the mark on the flywheel with the

flywheel housing pointer to set the No.1
piston to top dead center of the
compression stroke.

2. Install the camshaft into the cam housing.

NOTE: Two drill holes on the camshaft gear

should be located at left side and
lower drill hole should match with
the camshaft housing upper surface. Fig. 24

Fig - 24

Install the camshaft caps, aligning the guide

pins, tighten the bolts to torque. confirm
that the camshaft shell turns smoothly.

Fig - 25

Measure the backlash between the camshaft

gear and idle gear with dial gauge.

Nominal backlash - 0.030 - 0.253 mm. Fig. 25

Fig - 26

Install the injection pipe oil seal for the

injection nozzle and flange to the camshaft
housing and tighten the bolts.

Fig - 27

Installation direction of the injection pipe oil

seal.

Fig - 28
Fig. 26

Fig. 28 Fig. 27
12.62 HAJ08CTI ENGINE

12.6.6 Install The Rocker Arm Assembly

1. Make sure that the cross head is on each

valve.

NOTE: If the cross head is assembled whilst

off the valve, the upper seat will be
pressed, resulting in a loose valve.

2. Make sure that the adjusting screw at the

end of the rocker arm is completely
screwed in.

Fig. 29
3. Tighten the rocker arm support bolt as
shown in the figure to the specified torque
(59 Nm/6.0 kgm/43 lb.ft.).

Fig - 29

4. Tighten the nozzle clamp bolt to the

specified torque (25 Nm/2.5 kgm/18 lb.ft.).

5. Make sure that the rocker arm moves

smoothly.

NOTE: When assembling the rocker arm

assembly, fix the arm and nozzle Fig. 30
clamp with an O-ring as shown in the
figure to facilitate installation/avoid its
rotation.

Fig - 30

6. Make sure the Oil hole is placed

below.

Fig - 31

Adjust the valve clearance (Refer Engine

Tuneup).
Fig. 31

12.6.7 Install The Head Cover

1. Remove the camshaft housing plugs at the

front and rear ends of the camshaft housing.

NOTE: Do not remove the plug except there

is no oil leakage from plug.

2. Remove the liquid gasket from camshaft

housing plugs and camshaft housing
completely.

Fig - 32 Fig. 32
 HAJ08CTI ENGINE 12.63

3. Install the camshaft housing plug to camshaft

housing with torx bolt.

Fig - 33

NOTE: Make sure that the camshaft housing

plug installed with no tilt.

4. Apply liquid gasket to the front and rear

half circles of the camshaft housing.

Fig. 33

NOTE: Wipe out excess liquid gasket

completely.

Fig - 34

Fig. 34

5. Install the cover gasket into the gasket

groove at the head cover lower surface.

Fig - 35

NOTE: Make sure that there are no foreign

particles (including liquid gasket), or
oil on the gasket grooves of the
head cover, gasket or cam housing
upper surface nor damage to them.

Fig. 35

6. Apply liquid gasket to plug corner at the

front and rear ends of the cam housing
before installing the head cover.

Fig - 36

Fig. 36
12.64 HAJ08CTI ENGINE

7. Insert the silent block from the head cover

upper surface.

Fig - 37

Fig. 37

8. Tighten the bolt through the silent block to

the specified torque (25 Nm/2.5 kgm/18
lb.ft.) and fix the head cover on the cam
housing.

Fig - 38

Fig. 38
 HAJ08CTI ENGINE 12.65

12.7 CRANKSHAFT FRONT END

12.7.0 Remove The Crankshaft Front Oil

Seal
Special Tool : Oil seal puller (09420-1731)
1. Place the plate at the crankshaft end using
the crankshaft pulley bolts.

Fig - 1

2. Engage the hook with the oil seal notch and

install the hook using the bolt supplied.
Fig. 1
3. Remove the installed bolt in step (1).

Fig - 2

4. Install the centre bolt and tighten it to

remove the oil seal.

Fig - 3

12.7.1 Install the Crankshaft Front Oil Seal

Special Tool : Oil seal press (09407-1030)

1. Clean the edges and surface of the Fig. 2

crankshaft and the special tools.

2. Insert a new crankshaft oil seal into the

guide of the oil seal press.

Fig - 4

NOTE: Pay attention to the orientation of

the crankshaft oil seal ( The felt side
should face the outside of the
cylinder block)

Fig - 5
Fig. 3

Fig. 5 Fig. 4
12.66 HAJ08CTI ENGINE

3. Apply a little engine oil to the seal portion

of the crankshaft oil seal.

4. Attach the oil seal press guide with the new

crankshaft oil seal onto the crankshaft using
the attached guide bolt.

Fig - 6

5. Insert the oil seal press by adjusting the oil

seal press hole to the guide bolt.
Fig. 6
6. Press the crankshaft oil seal inside by
attaching the accompanying center bolt
onto the oil seal press and tightening it
until it stops.

Fig - 7

Fig. 7
 HAJ08CTI ENGINE 12.67

12.8 FLYWHEEL AND FLYWHEEL HOUSING

Install the dust cover. Fig. 1

Fig - 1 & 2

Fig. 2

Install the stud bolt.

Fig - 3

Fig. 3

Apply liquid gasket to flywheel housing.

Fig - 4

Fig. 4
12.68 HAJ08CTI ENGINE
INSTALL THE FLYWHEEL HOUSING

Fig. 5

Fig. 6

Fig. 7

Fig. 8
 HAJ08CTI ENGINE 12.69

12.8.0 Remove the Crankshaft Rear Oil Seal

Special Tool : Oil seal pulled (09420-1742)
1. Place the plate at the crankshaft end using
the flywheel bolts.
NOTE: Match the plate hole to the crankshaft collar
knock part.

Fig - 9

2. Engage the hook with the oil seal notch and

install the hook using the bolt supplied.

3. Remove the installed flywheel bolts in step (1). Fig. 9

Fig - 10

4. Install the center bolt and tighten it to

remove the oil seal.

Fig - 11

12.8.1 Install The Crankshaft Rear Oil Seal

Special Tool - Oil seal press (09407-1040).

1. Clean the edges and surface of the

Fig. 10
crankshaft and the special tools

2. Insert a new crankshaft oil seal into the

guide of the oil seal press.

Fig - 12

NOTE: Attention to the orientation of the

crankshaft oil seal (The Felt side should face
the outside of the cylinder block).

Fig - 13

Fig. 11

Fig. 13 Fig. 12
12.70 HAJ08CTI ENGINE

3. Apply a little engine oil to the seal portion

of the crankshaft oil seal.

4. Attach the oil seal press guide with the

new crankshaft oil seal onto the crankshaft
using the attached guide bolt.

Fig - 14

5. Insert the oil seal press by adjusting the oil

seal press hole to the guide bolt.
Fig. 14
6. Press the crankshaft oil seal inside by
attaching the accompanying center bolt
onto the oil seal press and tightening it
until it stops.

Fig - 15

Fig. 15

12.8.2 Replace The Flywheel Ring Gear

1. Heat the ring gear evenly to about 200 °C

with a torch. Tap the ring gear periphery
lightly using a cushion bar to remove the
gear.

Fig - 16

Fig. 16

2. Heat the ring gear evenly to about 200°C

with a torch Insert the ring gear into the
flywheel so that the chamfered side is
upward.

Fig - 17

Fig. 17
 HAJ08CTI ENGINE 12.71

12.8.3 Flywheel Assembly

Inspection

Flywheel flange depth ‘A’ - 48 mm

(limit 48 mm)
Flywheel thickness ‘B’ - 23.00 mm
(limit 22.00 mm)

Fig - 18

Face out - Std. - 0 - 0.1 mm

(limit 0.15 mm)
Fig. 18

Fig - 19

Check for flywheel friction surface scoring or

check on heat spots, if necessary regrind
friction surface or replace.

12.8.3.0 Install The Flywheel

1. Make sure that there are no burns or dirt

on the contact surface or in the threaded
holes of the crankshaft or flywheel. Install the
special tool onto the crankshaft.

Fig. 19
Special Tool - Guide bar (09481-1340)

NOTE: Place one guide bar at the collar

knock and another at the opposite
side of the collar knock.

2. Insert the flywheel slowly until it contacts the

collar knock to prevent impact on the guide
bar. Adjust the position, then insert the
flywheel completely.

Fig - 20

3. Apply clean engine oil to the threads of the

Fig. 20
flywheel bolt and the flywheel bolt seat. Be
sure to tighten the flywheel bolts.

Pull out the guide bar and tighten the

remaining two flywheel bolts as in step (3).

4. Tighten the flywheel in the order shown in

the figure to the specified torque (186 Nm/
19 kgm/137 lb. ft).

Fig - 21

5. Loosen all bolts and tighten them again to

the specified torque.
Fig. 21
12.72 HAJ08CTI ENGINE

12.9 TIMING GEAR

12.9.0 Remove The Idle Gear Shaft
1. Remove the idle gear shaft using the special
tool - Sliding hammer (for main idle gear)
(09420-1100).
Fig - 1
Sliding hammer (for sub and cam idle gear)
(09420-1442)
Fig - 2

12.9.1 Install The Rear End Plate

Fig. 1
Position the rear end plate gasket.
Ensure that the gasket is properly positioned.
Install the rear end plate.
Fig - 3
1. Apply lock sealant (Nut Lock Super 5M or
equivalent) to the threads of the torx bolts
in the side of the air compressor fitting (2
places) and tighten to the specified torque
(55 Nm/560 kgm/41 lb.ft) using special tool.
Fig - 4

12.9.2 Install The Crankshaft Gear Fig. 2

1. Heat the crankshaft gear in oil heated to

100°C –150°C.
CAUTION: Never touch the heated gear with
your bare hand. This can result in
personal injury.
2. Align the crankshaft gear groove with
crankshaft pin.
3. Install the crankshaft gear onto the
crankshaft as shown in the figure.
Dimension A : 22 ± 0.3 mm.
Fig - 5
Fig. 3

Fig. 5 Fig. 4
 HAJ08CTI ENGINE 12.73

Fig. 6

12.9.3Install The Idler Gear Shaft And

Gear
NOTE: Install each idle gear shaft through the
thrust plate as shown in the figure so
that the lubrication hole is downward.

Adjust the timing of the main idle

gear to align with the air compressor
gear as shown in the figure.

Fig - 6

12.9.4 Measurement of Gear Backlash

1. Measure the backlash between the gears

with a dial gauge as per recommendation.
Refer page 12.10.

Fig - 7

NOTE: After measurement of the backlash,

apply engine oil to each gear surface.

Fig. 7
12.74 HAJ08CTI ENGINE

12.10 AIR INTAKE MANIFOLD

Install the intake manifold gasket so that the

protrusion is positioned at the stud bolt side
of the cylinder head rear end.

Install the intake manifold, tighten the bolts

and nuts to torque (22 Nm).

Fig - 1

12.10.0 Install The Exhaust Manifold Gasket Fig. 1

NOTE: Since the exhaust manifold gasket

must be installed in one way, install
the gasket with the black side facing
toward the exhaust manifold.

Fig - 2

2. Install The Exhaust Manifold

1. Install the exhaust manifold onto the

cylinder head and tighten the inner
Fig. 2
mounting nut in the order shown in the
figure to the specified torque (53 Nm/5.4
kgm/39 lb.ft.).

2. Tighten the same nuts according to the

same procedure again.

3. Tighten the outer mounting nut, while in the

order shown in the figure to the specified
torque (61 Nm/6.2 kgm/45 lb.ft.).

NOTE: Be sure to hold the inner nut when

tightening the outer nut. Fig. 3

Fig - 3
 HAJ08CTI ENGINE 12.75

1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump safety valve
5. Oil cooler and oil filter
6. Oil cooler safety valve
7. Oil filter (full flow)
8. Oil filter (by-pass)
9. Pressure switch
10. Oil filter safety valve
11. Regulator valve
12. Main oil hole
13. Piston cooling jet
14. Crankshaft
15. Piston
16. Valve rocker shaft
17. Camshaft
18. Valve
19. Rocker arm
20. Cross head
21. Fuel injection pump
22. Air compressor
23. Main idle gear
24. Cam idle gear
25. Sub idle gear
26. Check valve
27. Check valve for turbocharger
28. Turbocharger
A. To oil pan

Fig. 1 Lubricating System

12.11 OIL PUMP AND OIL STRAINER

12.11.0 Installing the Oil Pump

NOTE: Apply oil to the pump case and bearings

of the block before installing the oil pump.

2. To prevent misalignment of the gasket,

apply grease to the gasket matching face of
the block. Then, place and fix the gasket.

Install the oil pump.

Fig - 2
Fig. 2
3. Tighten the oil pump mounting bolts
provisionally in the order as shown in the
figure. Tighten them to the specified
torque (28.4 Nm/2.9 kgm/21 lb. ft.).

Fig - 3

After tightening the bolts, ensure that the

oil pump is rotating smoothly.

Fig. 2
12.76 HAJ08CTI ENGINE

12.12 OIL FILTER AND OIL COOLER

12.12.0 Dismounting

12.12.0.0 Remove The Oil Filter

1. Remove the drain plug from bottom of the

oil filter and drain the engine oil.

Fig - 1

2. Using the special tool - oil filter wrench

(09503-1090) remove the oil filter.
Fig. 1
NOTE: Make sure that 0-ring are not on
the oil cooler case side.

12.12.1 Mounting

12.12.1.0 Install The Oil Filter

1. Remove the dust on installation surface of

oil cooler case side.

2. Apply the engine oil to the O-ring on new

filter.

3. Install the oil filter by turning it lightly to Fig. 2

the right by hand until it comes in contact
with the surface of the oil cooler. Then
using the special tool, tighten the oil filter
about 270° -360° (3/4-1 turn).
Special Tool - Oil filter wrench (09503-
1090)

Fig - 2

NOTE: Do not reuse the O-ring.

12.12.1.1 Install The Oil Cooler And Oil Filter

Assembly

1. Insert the O-ring into the O-ring groove of

the oil cooler.

NOTE: Face the flat area of the O-ring

toward the oil cooler for installation.

2. Apply liquid gasket to the oil cooler case

and install it onto the cylinder block, then
tighten the bolt to the specified torque
(28.4 Nm/2.9 kgm/21 lb. ft.).

Fig - 3

Fig. 3
 HAJ08CTI ENGINE 12.77

1. Reservoir tank
2. Radiator cap
3. Radiator
4. Coolant temperature gauge
5. Thermostat case
6. Thermostat
7. Coolant pump
8. Air compressor
9. Turbocharger
10. Cylinder head
11. Cylinder block
12. Oil cooler
13. Drain plug

Fig. 4 Cooling System

12.78 HAJ08CTI ENGINE

12.12.2 Disassemble The Coolant Pump

1. Remove the vane from the shaft using the

special tool - Puller (09420 –1820).

Fig - 5

2. Remove the pulley center from the shaft

using the special tool - Puller (09420 –
1810)

Fig - 6 Fig. 5

3. Remove the retainer ring from the pump

case using snap ring pliers.

Fig - 7

4. Push the shaft from the vane side using a

hydraulic press, and remove the coolant
shaft from the pump case.

Fig - 8
Fig. 6
5. Remove the coolant seal from the pump
case using a hammer and brass bar.

Fig - 9

NOTE: Replace the removed coolant seal

with a new one. Never reuse it.

Fig. 7

Fig. 9 Fig. 8
 HAJ08CTI ENGINE 12.79

12.12.3 Assemble The Coolant Pump

1. Install the coolant shaft onto the pump case
using a hydraulic press.
Assembly standard (A) - 5.9 - 6.1 mm.
NOTE: Press until the bearing upper end surface
comes into contact with the retainer ring
groove lower end surface.
Fig - 10
2. Install the retainer ring onto the pump case
using snap ring pliers.
Fig - 11
Tightness of shaft and pulley center - 0.017
- 0.051 mm. Fig. 10
3. Install the pulley center onto the shaft using
a hydraulic press.
Standard - 129.0 – 129.8 mm from the
pulley center mounting surface to the pump
case end surface.
Fig - 12
4. Install the new coolant seal.
a. Apply liquid gasket to the seal outer
circumference and case bore.
b. Install the slinger and seal to the case
using a press.
Fig - 13
c. Install the seal to the vane. Fig. 11 Fig. 12
NOTE: Replace the coolant seal with new one.
Fig - 14
5. Install the vane onto the shaft using a
hydraulic press.
Tightness of shaft and vane - 0.017 - 0.048 mm.
Assembly standard (B) - 0.6-1.2 mm.
NOTE: Press until the vane end face comes into
contact with the shaft end surface.
6. After assembly, turn the shaft by hand and
make sure that there is no noise, catching
or rough movement in the shaft direction
and that it rotates smoothly.
Fig - 15 Fig. 13

Fig. 15 Fig. 14
12.80 HAJ08CTI ENGINE

12.13 THERMOSTAT
12.13.0 Inspect the Thermostat Function
1. Place the thermostat in hot water and check
the valve opening temperature and the valve
lift.
Thermostat valve opening temperature:
Thermostat valve
Opening temperature (T1) - 82°C
Service standard - 80° - 84°C
NOTE: Check that the thermostat valve
opening temperature (T 1) is engraved
on the thermostat.
Thermostat valve lift:
Thermostat valve
opening temp. (T ) : 82°C
1

Measuring temp. (T ) : 95°C

2

Valve lift (L - L ) : 13 mm or more

2 1

2. Immerse the opened thermostat in water at

normal temperature. If it completely closes
within 5 minutes, it is satisfactory. If it
remains slightly open, it is defective and
must be replaced.
12.13.1 Assembly The Thermostat Case Fig. 1

NOTE: Remove water or dirt adhering to the

thermostat case.
Be sure to replace the gasket if it is
corroded, damaged or flattened.
Before installing the hose, apply liquid gasket
to the hose installation part of the
thermostat case cover.
To prevent clogging of the radiator, do not
use a large amount of liquid gasket.
Be sure that the jiggle valve faces upward
when installing it.
Fig. 2
Fig - 1
12.13.2 Install The Thermostat Case
Assembly
1. Apply liquid gasket to the thermostat case.
2. Install the O-ring into the groove of the
coolant pump.
Fig - 2
3. Temporarily tighten the bolts “1” and bolts
“2” in that order, and securely contact the
fitting surface.
4. Tighten the bolts in numeral order.
Fig. 3
Fig - 3
 HAJ08CTI ENGINE 12.81

12.14 COOLING FAN

NOTE: Shock to the fan clutch and fan.

During maintenance and inspection, be careful

not to drop or strike the fan clutch or fan
itself. The resulting damage may lower the
performance of the fan. Also, note that the fan
is made of plastic and may become damaged
or deformed if force is applied to it.

Replace the fan.

Do not replace the fan unless it is faulty.

When replacing the fan, replace with the
Fig. 1
same type. If the fan is replaced with one of
a larger capacity because of overheating or,
conversely is replaced with one of a smaller
capacity due to overcooling, the performance
may in fact be reduced and durability may
be jeopardized.

Other items.

Check the bimetal to see if there is any

mud or dust on it. If the bimetal is covered
with mud or dust, the fan performance will
be erratic, and may result in overheating or
overcooling. In such case, carefully remove
mud and dust adhering to the surface of the
bimetal, using a wire brush, or the like.

Do not paint the fan or fan clutch. Do not

place any paint or other reagents which are
likely to dissolve plastic in contact with the fan.

Adjust the alternator V-Belt

Deflection

Fig - 2

- Loosen the through bolt and the fixing nut.

- Apply a load of about 98 N (10 kgf) by

pressing the measuring point A.

- Turn the adjusting bolt, and adjust the

deflection of the belt at measuring point A,
so that it comes within the standard value.
Standard : 8 - 10 mm

NOTE: When installing a new V-belt, be sure to

repeat the adjustment two or three times,
after running the engine.
When adjusting the V - belt, do not apply
the lever directly against the alternator.

- After adjusting the deflection, tighten the

through bolt and then securely tighten the
fixing nut.
Fig. 2
- Retighten the adjusting bolt.
12.82 HAJ08CTI ENGINE

12.15 FUEL SYSTEM

1. Return Pipe
2. Injection nozzle
3. Through feed pipe
4. Fuel Tank
5. Feed pump
6. Fuel Filter
7. Injection pipe

Fig. 1

12.15.0 Remove The Fuel Injection Pump

1. Disconnect the fuel lines, oil lines and engine

control lines.

2. Remove the through bolt of the coupling and

loosen the adjusting bolt using the special tool
- Injection pump coupling wrench (09511-
2500).

3. Remove the injection pump mounting bolt

and dismount the pump.

Fig - 2

Special Tool - Wrench (09512-2470)

Fig. 2
12.15.1 Install The Fuel Injection Pump

1. To adjust the injection timing, turn the

flywheel in the rotation direction
(counterclockwise viewed from the flywheel
side). Align the pointer at the inspection
side on the flywheel housing to injection
timing before top dead center for No.1
cylinder compression stroke.

Fig - 3

Fig. 3
 HAJ08CTI ENGINE 12.83

2. Turn the timer counterclockwise slowly

viewed from the coupling (normal direction
of engine) and align the mark on the timer
with the mark on the injection pump
pointer.

Fig - 4

Fig. 4

3. Tighten the injection pump mounting bolt

evenly to the torque (25 Nm/2.5 kgm/18
lb.ft.).

Special Tool : Wrench (09512-2470)

Fig - 5

Fig. 5

4. Tighten the adjusting bolt using the special

tool to torque (88 Nm/9.0 kgm/65 lb.ft.).

Special Tool - Injection pump coupling

wrench (09511-2500)

5. Tighten the through bolt at the flange to

torque (88 Nm/9.0 kgm/65 lb.ft.).

6. Install pipes and engine control cables.

Fig - 6

NOTE: Cylinder numbers are stamped on the Fig. 6

flare nuts at the pump side of the
injection pipe.

12.15.2 Remove The Fuel Filter

1. Remove the fuel filter using the special tool

- Fuel filter wrench (09503-1040).

Fig - 7

Fig. 7
12.84 HAJ08CTI ENGINE

12.15.3 Install The Fuel Filter

1. Remove the dust on installation surface.

2. Apply light oil to gasket of new fuel filter

3. Install the fuel filter by turning it lightly to

the right by hand until it comes in contact
with the surface of the fuel filter cover.
Then using the special tool, tighten the fuel
filter about 240° (2/3 turn).
Special Tool : Fuel filter wrench (09503-
1040).
Fig. 8

Fig - 8

12.15.4 Air Bleeding from Fuel System

12.15.4.0 Bleed Air From The Fuel Filter

1. Bleed air from the fuel filter.

2. Loosen the bleeder plug on the fuel filter.

3. Operate the priming pump knob until the

air will not come out from the bleeder plug.

4. Tighten the bleeder plug.

Torque: 4.9-8.9 Nm/0.5-0.9 kgm/3.6-6.6 lb.ft. Fig. 9

Fig - 9

NOTE: The bleeder plug should be tightened while

the priming pump knob is operated.

5. Once again, operate the priming pump knob

several times.

6. Push back the priming pump knob and

tighten it
 HAJ08CTI ENGINE 12.85

12.16 INJECTION NOZZLE (TWO-SPRING

TYPE - BOSCH MAKE)

Fig - 1

12.16.0 Dismounting

Clean off surrounding area of the nozzle

and the fuel line connectors

12.16.0.0 Remove The Fuel Injection Pipe

1. Remove the return pipe.

2. Loosen the injection pipe nut.

3. Remove the bolt of the injection pipe seal

1. Joint bolt 9. Second pressure adjusting shim
and pull it with the injection pipe from the 2. Gasket 10. Second pressure spring
3. Cap nut 11. Second pressure spring seat
camshaft housing. 4. Gasket 12. Lift piece
5. Adjusting screw 13. Spacer
6. First Pressure Spring 14. Nozzle assembly
NOTE: Cover open ends of the pipes and 7. Push Rod 15. Retaining Nut
fuel injection pump to prevent entry 8. Nozzle holder 16. Pre Lift (L1)
17. Valve Lift (L)
of dirt.
Fig. 1

Fig - 2

12.16.0.1 Remove The Nozzle Holder Assembly

1. Remove the nozzle clamp bolt.

2. Pull out the nozzle holder assembly taking

care not to contact other parts. If it is
difficult to remove the assembly, use of the
special tool (Sliding hammer - 09420-1442
and Adapter - 09462-1130)
Fig. 2

3. Remove the O-ring.

Fig - 3

Fig. 3
12.86 HAJ08CTI ENGINE

12.16.1 Inspection

12.16.1.0 Check the Injection Pressure

1. Install the nozzle holder assembly to the

nozzle tester.

Fig - 4

2. Operate the lever at the rate of 50 to 60

strokes per minute. If the injection pressure
is not within specified value, adjust the
injection pressure with adjusting screw.
Fig. 4

First opening pressure

With new parts : 185-195 kg/cm²
With reused parts : 180-188 kg/cm²

Fig - 5

12.16.1.1 Test The Spray Profile

1. In the case of a new nozzle, operate the

lever at the rate of 30 to 60 strokes per
minute, and for a used nozzle, operate the
Fig. 5
lever at the rate of 15 to 16 strokes per
minute. If spray is coarse, replace or clean
the nozzle.

Fig - 6

12.16.1.2 Test The Fuel Leakage

1. When checking for fuel leakage from the

nozzle, apply a pressure about 10 - 20 kg/
cm² lower than the correct injection
pressure to the nozzle using a nozzle tester.
Fig. 6

If faulty, replace or clean the nozzle.

Fig - 7

Fig. 7
 HAJ08CTI ENGINE 12.87

12.16.2 Disassembly

12.16.2.0 Remove the Retaining Nut

NOTE: To prevent dropping parts, face the nozzle

holder toward the retaining nut side.

Fig - 8

12.16.2.1 Test The Nozzle Sinking

1. Wash the nozzle proper with diesel fuel oil,

them immerse it in diesel fuel oil.

Next slide the needle inside the nozzle Fig. 8

proper and ensure that it moves smoothly.
The needle valve should fall under its own
weight when withdrawn vertically about 1/3
its length and released. If its motion is
sluggish, replace the nozzle with a new one.

Fig - 9

NOTE: When assembling, you must reinstall the

same parts in the same nozzle holder. Do
not mix them up.

12.16.3 Assembly - Nozzle Holder

NOTE: - The steps below for adjustment are

Fig. 9
made during parts assembly.
- Because the nozzle holder is adjusted
1/100 mm units, it must be thoroughly
washed to remove all dirt and foreign
objects.

WORK STEPS

1. Adjustment of first opening pressure Adjust first opening pressure with the adjusting screw.

2. Checking of needle valve full-lifts Check with nozzle cover method.

3. Checking of pre-lift Check with nozzle cover method.

NOTE: If pre-lift is not within specified value, replace pins, lift

piece, spacer and nozzle assembly with the nozzle
service kit.

4. Checking of second opening pressure Check with nozzle cover method.

5. Adjusting of second opening pressure Adjust second opening pressure with adjusting shim.

6. Replacement of the retaining nut Replace adjustable retaining nut with normal retaining nut.

7. Final inspection Check condition of the fuel spray with the nozzle and nozzle
holder assembly.
12.88 HAJ08CTI ENGINE

12.16.3.0 Adjustment of the First Opening

Pressure (Work Step - 1)

1. Install the adjusting shim, second pressure

spring and spring seat into the nozzle
holder.

NOTE: The second pressure spring is the same

as the first pressure spring.

2. Install the pins, lift piece, spacer and

nozzle onto the nozzle holder. Fig. 10

Fig - 10

3. Put the special tool - Gasket (157892-

1500) onto the nozzle, then use the
special tool - Adjustable retaining nut
(157892-4000) to hold the nozzle in
place on the nozzle holder.

NOTE: Make sure that the pin is all the way in

the nozzle and then tighten adjustable
retaining nut. Fig. 11

Finger-tighten the adjustable retaining nut

until it no longer turns and tighten the
nut to specified torque (68.5 Nm/7 kgm/
51 lb.ft).

Fig - 11

4. Install the push rod, first pressure spring

and first pressure adjusting screw into the
nozzle holder.

Fig. 12
5. Install the gasket and cap nut onto the
first pressure adjusting screw.

Fig - 12

6. Attach the nozzle holder assembly to the

nozzle tester.

Fig - 13

Fig. 13
 HAJ08CTI ENGINE 12.89

7. Adjusting the first opening pressure to the

specified value with the first pressure
adjusting screw.
First opening pressure
With new parts : 185-193 kgf/cm²
With reused parts : 180-188 kgf/cm²

Fig - 14

8. Holder the nozzle body using a adjustable

wrench, then tighten the cap nut to the
specified torque (44 Nm/4.5 kgm/33 lb.ft)

Fig - 15 Fig. 14

12.16.3.1 Checking of the Needle Valve Full-

Lifts (Work Step 2)

1. Attach the Gasket (Special Tool -

026508-1140) and the plug (Special Tool
- 157892-1600) onto the adjustable
retaining nut.

Fig - 16

2. Turn the nozzle holder body so that the

cap side facing upward.

3. Attach the holder (Special Tool - 157892- Fig. 15

4400) to the cap nut.

4. Temporarily tighten the attachment nut

(Special Tool - 157892-1000) onto the
holder.

Fig - 17

5. Screw the pin (Special Tool - 157892-

4200 or 157892-4300) into the dial
gauge.

Fig - 18

Fig. 16

Fig. 18 Fig. 17
12.90 HAJ08CTI ENGINE

6. Tighten the nut so that it holds the dial

gauge in place in the nozzle holder
assembly and so that the pin is in contact
with the push rod upper surface.

NOTE: Attach the dial gauge into place so that it

can measure a stroke of approx. 2 mm
Do not tighten the nut too much, or the
dial gauge shaft will be stuck.

Fig - 19
Fig. 19
7. Attach the nozzle holder assembly to the
nozzle tester and adjust the dial gauge to
zero.

8. Operate the nozzle tester to bleed air in

the adjustable retaining nut. Make sure
that there are no fuel leaks.

Fig - 20

9. Operate the nozzle tester to raise

pressure to 350-450 kgf/cm² and check
Fig. 20
the needle valve lift fully. At this time,
record the dimensions of full-lifts as “L”.

NOTE: This check is made to determine whether

the nozzle seat is abnormally worn or not
and whether the nozzle is correctly
assembled or not.

12.16.3.2 Checking of the Pre-lift (Work

Step 3)

1. When the needle value is full-lifted, release

the nozzle tester handle to lower pressure
inside the tube so that decrease the
needle valve lift value (Value indicated on
dial gauge).

Fig - 21

Fig. 21
 HAJ08CTI ENGINE 12.91

2. When the second pressure spring stop to

action and the needle valve drop ends
(the needle valve lift dimension “L1”) read
the dial gauge indication, make sure it is
within specified values.
Fig - 22
Pre-lift measuring points:
Read the dial gauge at (First opening
pressure + approx. 10 kgf/cm²).
NOTE: Watch the pressure decrease to find the
point.
Pre-lift (L1) : 0.07 mm
Fig. 22
Fig - 23

3. If pre-lift is not within the specified value.

replace the pins, the lift piece, the spacer
and the nozzle assembly with the nozzle
service kit.
Fig - 24

12.16.3.3 Checking of the Second Opening

Pressure (Work Step 4)
1. Check the pre-lift, then operate the nozzle
tester to raise pressure to 350-450 kgf/
cm² and lift the needle valve fully.
2. Release the nozzle tester handle to lower Fig. 23

pressure inside the tube, all the while

watch the dial gauge indicate.
Fig - 25
3. Read the value indicated on the pressure
gauge at the instant the dial gauge needle
indicates the specified needle valve lift
value (pre-lift “L1”+ 0.05 mm)
Second opening pressure
With new parts : 225-235 kgf/cm²
With reused parts : 220-230 kgf/cm²

Fig - 26
Fig. 24

Fig. 26 Fig. 25
12.92 HAJ08CTI ENGINE

12.16.3.4 Adjusting of the Second Opening

Pressure (Work Step 5)

1. If the second opening pressure deviates

from the specified value and the amount
of that deviation is small, readjust the first
opening pressure within the specified
value.

NOTE: If the second opening pressure is

lower than the specified value,
readjust the first opening pressure
to maximum specified value, then Fig. 27
measure the second opening
pressure.

If the second opening pressure is

higher than the specified value,
readjust the first opening pressure
to minimum specified value.

Fig - 27

2. If the first opening pressure has been

readjusted and the second opening
pressure still deviates from the specified
value, disassemble the nozzle side of the
nozzle holder and remove the adjusting
shim.

3. If the second opening pressure is higher

than the specified value. replace the
adjusting shim with a thinner one.

4. After replacing the adjusting shim,

remeasure the second opening pressure,
and adjust the pressure until it comes to
the specified value.

Second opening pressure adjusting shims

as follows.
Parts number Shim thickness (mm)
22882-2850 0.40
22882-2860 0.50
22882-2870 0.52
22882-2880 0.54
22882-2890 0.56
22882-2900 0.58
22882-2910 0.60
22882-2920 0.70

Fig. 28
Fig - 28
 HAJ08CTI ENGINE 12.93

12.16.3.5 Replacement of the Retaining Nut

(Work Step 6)

1. Remove the dial gauge, the nut, the

holder and the gasket from the cap nut.

2. Remove the adjustable retaining nut and

the gasket, and attach a normal retaining
nut to torque (68.5 Nm / 7 kgm / 51
lb.ft)

Fig - 29 Fig. 29

12.16.3.6 Final Inspection (Work Step 7)

1. Attach the nozzle holder to the nozzle

tester and check the first opening
pressure, the spray condition, the seat’s
fuel seal, and whether are any fuel leaks
from any part.

Fig - 30

2. To replace the nozzle, the lift piece, and

Fig. 30
the spacer, which are all in one set, with
the nozzle service kit.

NOTE: Replacing only the nozzle will cause the

amount of pre-lift deviate from the
specified value.

Fig - 31

12.16.4 Mounting

1. Install the Nozzle Holder Assembly.

Fig. 31

1. Install a new O-ring into the groove of

the cylinder head.

2. Make sure that there is no dirt or foreign

particles at the sealing part between the
nozzle holder and related parts (O-ring,
nozzle seat and injection pipe seal), and
connecting part between the nozzle
holder and nut of the injection pipe.
12.94 HAJ08CTI ENGINE

3. Insert the nozzle holder taking care not to

contact the valve spring as shown.

NOTE: Apply clean engine oil to the O-ring and

be careful that the O-ring is not damage.

4. Put the end of the injection pipe seal on

the nozzle holder as shown and tighten
the bolts to fasten the injection pipe seal
to the camshaft housing.

5. Tighten the nut of the injection pipe

provisionally.

6. Tighten the nozzle clamp bolt to the

specified torque (24.5 Nm/2.5 kgm/18.1
lb.ft).

NOTE: After tightening the bolt, make

sure that the rocker arm moves
smoothly.

7. Tighten the nut of the injection pipe to

Fig. 32
the specified torque (34.3 Nm/3.5 kgm/
2.3 lb.ft).

8. Install the return pipe.

Fig - 32
 HAJ08CTI ENGINE 12.95

12.17 TURBOCHARGER

Fig. 1

1. Turbine housing 13. Hexagon Nut

2. Compressor housing 14. Piston Ring
3. Center housing 15. Journal Bearing
4. Clamp 16. Spacer
5. Bolt 17. Thrust Bearing
6. Actuator bracket 18. Thrust Collar
7. Actuator Assembly 19. Seal Ring
8. Hexagon Nut 20. Backplate
9. Hose 21. Compressor Wheel
10. Hose Clamp 22. O Ring
11. Rod End 23. Turbine Wheel Assembly
12. Retaining Ring 24. Wheel Shroud
12.96 HAJ08CTI ENGINE

TROUBLESHOOTING

Table 1 - 1

Engine Exhaust Lacks Power or Engine Exhaust Emits Black Smoke

ENGINE
ENGINE
SYMPTOM OR EXHAUST
LACKS OR
TROUBLE EMITS BLACK
POWER
SMOKE

(See Notes A and H*) (See Notes A*) (See Notes B and C*) (See Notes A*)

Dirty air cleaner

Viscosity of oil in oil Loose compressor to Leakage at engine
element or inlet NO bath air cleaner too NO intake manifold duct NO intake manifold NO
screen restricted in oil
high connections
bath air cleaner

YES YES YES YES

Service air cleaner in

Replace air cleaner Tighten duct Refer to engine
accordance with
element or clean inlet connections as manufacturer’s
engine
screen in bath air required service manual
manufacturer’s
cleaner
service manual

(See Notes D, F and G *) (See Notes D and F*) (See Notes K *) (See Notes A*)

Dirty air cleaner

Viscosity of oil in oil Loose compressor to Leakage at engine
element or inlet
NO bath air cleaner too NO intake manifold duct NO intake manifold NO
screen restricted in oil
high connections
bath air cleaner

YES YES YES YES

Refer to engine Check condition of

Perform trouble- Remove restriction
manufacturer’s gasket at turbocharger
shooting procedures or replace damaged
service manual mounting flange and
outlined in Table1-7 parts as necessary
tighten loose bolts

(See Note H*)

Restricted duct Engine malfunction

Restricted engine Restricted engine (fuel system
between compressor
NO exhaust system NO intake or exhaust NO component, valves
and engine intake
(after turbocharged) manifold valve timing, rings,
manifold
pistons, etc)

YES YES YES YES

Remove restriction or Remove restriction or

Refer to engine Refer to engine
replace damaged replace damaged parts
manufacturer’s manufacturer’s
parts as necessary as necessary
service manual service manual

* - Refer section 12.17.0

 HAJ08CTI ENGINE 12.97

Table 1 - 2

Troubleshooting - Engine Exhaust Emits Blue Smoke

ENGINE
SYMPTOM OR EXHAUST
TROUBLE LIMITS BLUE
SMOKE
Possible Causes and Remedies

(See Notes A and H *) (See Notes A*) (See Notes B and C *) (See Notes F*)

Dirty air cleaner

Viscosity of oil in oil Loose compressor to Leakage at engine
element or inlet
NO bath air cleaner too NO intake manifold duct NO intake manifold
screen restricted in oil NO
high connections
bath air cleaner

YES YES YES YES

Replace air cleaner Service air cleaner in

Tighten duct Refer to engine
element or cleaner accordance with engine
connections as manufacturer’s
inlet screen in oil bath manufacturer’s service
required service manual
air cleaner manual

(See Note H*)

Restricted duct
Plugged engine oil between air cleaner Seal leakage at Engine malfunction
filter NO and turbocharger NO compressor end of NO rings, pistons, valves
compressor turbocharger etc)

YES YES YES YES

Service oil filter in Remove restriction or Perform

accordance with Refer to engine
replace damaged parts troubleshooting
engine manufacturer’s manufacturer’s
as necessary procedure outlined in
service manual service manual
Table 1-6

* - Refer section 12.17.0

12.98 HAJ08CTI ENGINE

Table 1 - 3

Troubleshooting - Engine Oil Consumption Excessive

ENGINE OIL
SYMPTOM OR CONSUMPTION
TROUBLE EXCESSIVE

Possible Causes and Remedies

Seal leakage at Seal leakage at

Wrong type or Oil in engine exhaust
compressor end of turbine end of
viscosity of engine manifold (indicating
NO turbocharger NO turbocharger
NO malfunction of rings,
lubricating oil (indicated by oil in
(indicated by oil in pistons, valves, etc)
housing or on wheel) housing or on wheel)

YES YES YES YES

Service engine lube
system in accordance Perform Perform
Refer to engine
with engine troubleshooting troubleshooting
manufacturer’s
manufacturer’s service procedure outlined in procedure outlined in
service manual
manual Table 1-6 Table 1-7
 HAJ08CTI ENGINE 12.99

Table 1-4

Troubleshooting - Noisy Turbocharger

SYMPTOM OR TURBOCHARGER
TROUBLE NOISY

Possible Causes and Remedies

(See Notes A and H*) (See Notes H*)

Dirty air cleaner Foreign object or Foreign object or

element or inlet material in compressor material in Foreign object in
screen restricted in oil
NO inlet ducting or NO compressor to intake NO engine exhaust NO
bath air cleaner compressor housing manifold ducting system

YES YES YES YES

Replace air cleaner Remove foreign object. Remove foreign object. Remove foreign object.
element or clean inlet Repair air intake system Repair air intake system Repair air intake system
screen in oil bath air and overhaul and overhaul and overhaul
cleaner turbocharger as turbocharger as turbocharger as
necessary necessary necessary

Turbocharger rotating
Carbon build-up in assembly binding or
turbine housing NO
dragging

YES YES

Clean housing or Perform

overhaul turbocharger troubleshooting
as required. Check procedures outlined in
engine operating Table 1-5
procedures

* - Refer section 12.17.0

12.100 HAJ08CTI ENGINE

Table 1-5

Troubleshooting - Turbocharger Rotating Assembly Binding or Dragging

TURBOCHARGER
SYMPTOM OR ROTATING ASSEMBLY
TROUBLE BINDING OR
DRAGGING
Possible Causes and Remedies

(See Notes J*)

Damaged turbine Excessive dirt build-

Damaged compressor Compressor wheel or up in compressor
wheel due to foreign NO wheel due to foreign
NO turbine wheel NO (on housing or
NO
object impact object impact
rubbing on housing wheel)

YES YES YES YES

Clean and repair air Clean and repair air

Clean and repair air Worn bearing, shaft
intake system as intake system as
intake system as journals, or bearing
necessary. Overhaul necessary. Clean
necessary. Overhaul bores. Troubleshoot as
turbocharger compressor or
turbocharger outlined in Table 1-8 overhaul turbocharger

(See Notes I*)

Excessive carbon Sludged or coked

build-up behind NO center housing
turbine wheel

YES YES

Coked oil combustion

Service engine
deposits. Overhaul
lubrication system.
turbocharger
Overhaul turbocharger

* - Refer section 12.17.0

 HAJ08CTI ENGINE 12.101

Table 1-6

Troubleshooting - Seal Leakage at Compressor End of Turbocharger

SEAL LEAKAGE AT
SYMPTOM OR COMPRESSOR END OF
TROUBLE TURBOCHARGER

Dirty air cleaner

Viscosity of oil in oil Restricted duct Loose compressor
element or inlet NO bath air cleaner too NO between air cleaner NO to intake manifold NO
screen restricted in oil
high and turbocharger duct connection
bath air cleaner
compressor

YES YES YES YES

Replace air cleaner Service air cleaner in

element or clean accordance with Remove restriction Tighten duct
inlet screen in oil engine or replace damaged connections as
bath air cleaner manufacturer’s parts as necessary required
service manual

Dirty air cleaner

element or inlet Restricted Plugged engine crank
NO Worn or damaged
screen restricted in oil turbocharger oil NO case breather NO compressor wheel NO
bath air cleaner drain line

YES YES YES YES

Clean and remove Clean and repair air

Leakage at engine restriction or replace Refer to engine
manufacturer’s intake system as
intake manifold oil drain line as
service manual necessary. Overhaul
required turbocharger

Engine malfunction
Turbocharger (excessive piston
bearings, bearing NO blowby or high
bores, or shaft internal crankcase
journals worn pressure

YES YES

Perform trouble- Refer to engine

shooting procedures manufacturer’s
outlined in Table1-6 service manual
12.102 HAJ08CTI ENGINE

Table 1-7

Troubleshooting - Seal leakage at Turbine End of Turbocharger

SEAL LEAKAGE AT
SYMPTOM OR TURBINE END OF
TROUBLE TURBOCHARGER

Possible Causes and Remedies

Plugged engine crank Restricted

Sludged or coked NO
Excessive pre-oiling NO case breather
NO turbocharger oil
NO
drain line center housing

YES YES YES YES

Oil will burn Clean and remove Service engine

Refer to engine
away. No action restriction or replace oil lubrication system.
manufacturer’s
required drain line as required Overhaul
service manual
turbocharger

(See Notes I*)

Turbocharger Engine malfunction

bearings, bearing (excessive piston
bores, or shaft
NO blowby or high
journals worn internal crankcase
pressure

YES YES

Perform trouble- Refer to engine

shooting procedures manufacturer’s
outlined in Table1-6 service manual
 HAJ08CTI ENGINE 12.103

Table 1-8

Troubleshooting - Turbocharger Bearings, Bores, or Journals are Worn

TURBOCHARGER
SYMPTOM OR BEARINGS, BORES,
TROUBLE OR SHAFT
JOURNAL WORN*
Possible Causes and Remedies

Contaminated or
Inadequate pre-oiling improper grade or type Insufficient engine oil
Restricted
following turbocharger NO of engine lubricating oil NO supplied to
NO turbocharger oil feed NO
installation or engine used in engine turbocharger due
line
lube system servicing “to lag”

YES YES YES YES

Service engine lube

system in accordance Remove restriction or
Follow pre-oiling Follow proper engine
with engine replace damaged parts
instructions operating procedures
manufacturer’s service as necessary
manual

Abrasive wear due to Insufficient lube oil

flaking of coked supplied to
Plugged engine oil NO
filter
NO particles from center turbocharger due to
housing interior engine oil pump
surfaces malfunction

YES YES YES

Service engine lube

Refer to engine system in accordance Refer to engine
manufacturer’s with engine manufacturer’s service
service manual manufacturer’s service manual
manual

* - Overhaul turbocharger, then use this table to determine cause of failure.

12.104 HAJ08CTI ENGINE

12.17.0 Troubleshooting Procedures Notes i. Internal inspection of the center housing

can be accomplished by removing the oil
a. Refer to engine manufacturer’s service drain line and looking through the oil
manual for inspection requirements and drain opening. When a slugged or coked
replacement specifications. condition exists, a heavy sludge build-up
will be seen on the shaft between the
b. With engine stopped, check duct clamping bearing journals and in the center
devices for tightness. housing from the oil drain opening back
to the turbine end.
c. With engine running at idle speed, lightly
spray duct connections with starting fluid.
j. Thorough cleaning of the air intake
Leaks at connections will be indicated by
system is essential following compressor
an increase in engine speed due to the
wheel damage due to foreign object
starting fluid being drawn into the
impact. In many cases, metal pieces from
compressor and pumped into the engine
the wheel become imbedded in the air
combustion chambers.
cleaner element. If the element is not
changed , these metal pieces can be
d. With engine running at idle speed, check
drawn into the replacement turbocharger
duct connections for leaks by applying
and cause it to fail in the same manner
lightweight oil or liquid soap to areas of
possible leakage and checking for bubbles. as the original unit.
Exhaust gas leakage between the engine
block and the turbocharger inlet will also k. With the air inlet and exhaust gas
create a noise level change. ducting removed from the turbocharger,
examine both the compressor and
e. With engine running at idle speed, check turbine wheels for blade damage.
for unusual noise and vibration. If either Examine the outer blade tip edges for
condition is noted, shut down the engine evidence of rubbing on housing surfaces.
immediately to protect the turbocharger
and engine from further damage. With - Turn the rotating assembly by hand and
the engine stopped, check the feel for dragging or binding. Push the
turbocharger shaft wheel assembly for rotating assembly side-ways while rotating
damage. to feel for wheel rub. If there is any
indication of rubbing, perform the bearing
f. With engine running, a change in the clearance inspection procedure. If the
noise level to a higher pitch can indicate rotating assembly rotates freely and there
air leakage between the air cleaner and is no evidence of binding or rubbing, it
the engine or a gas leak between the can be assumed that the turbocharger is
engine block and the turbocharger inlet. serviceable.

g. Exhaust gas leakage may be indicated by

hat discoloration in the area of the leak.

h. With the engine running. Noise level

cycling from one level to another can
indicate a plugged air cleaner, a restriction
in the air-cleaner to compressor duct, or
a heavy build-up of dirt in the
compressor housing or on the
compressor wheel.
 HAJ08CTI ENGINE 12.105

12.17.1 Overhaul Criteria

1. Condition Which Determine When

A Turbocharger Overhaul May Be
Needed On Engine Troubleshooting

The most common symptoms of

turbocharger failure are related to engine
performance.

- Lack of power

- Excessive exhaust smoke

- Unusual noise

- Excessive oil or fuel consumption.

NOTE: Any of these symptoms could be the

result of an internal engine problem, and
might not involve the turbocharger at all.

2. Examine The Turbocharger Exterior

And Installation.

CAUTION: Do not work on the turbocharger

while it is still hot. This can result
personal injury.

Visually check for:

- Missing or loose nuts and bolts.

- Loose or damaged intake and exhaust

pipe.

- Damaged oil supply and drain lines.

- Cracked or deteriorating turbocharger

housings.

- External oil or coolant leakage.

Correct any installation problems. If

turbocharger parts are damaged, the unit
should be overhauled after completion of
the remainder of this troubleshooting
procedure.
12.106 HAJ08CTI ENGINE

3. Inspection Turbine Wheel And

Housing.

Remove the duct from the turbine outlet.

Using a flash-light, check the turbine for
wheel to housing rub, evidence of oil
leakage or foreign object damage. Foreign
object damage to the turbine is not
usually visible through the turbine outlet
unless the damage is severe.

Wheel to housing rub

If wheel rub is found, and the housing

attaching hardware is secure, then the
turbocharger is probably damaged
internally and must be overhauled.

Oil leakage

If oil deposits are found, determine

whether the oil has come from the
engine exhaust or from the turbocharger
center housing.

If the oil has come from the engine, refer

Engine manual and correct the problem.
If oil deposits on the wheel are heavy the
turbocharger should be disassembled,
cleaned, and overhauled if necessary.

Foreign object damage

If foreign object damage to the turbine is

visible, the turbocharger must be
overhauled. Such damage destroys the
wheel’s balance and causes internal
damage to the seal bores and journal
bearings. Be sure to find the source of
the foreign object. In many cases, the
object has come out of the engine, and
there may be engine damage as well.

Fig - 2

Fig. 2
 HAJ08CTI ENGINE 12.107

4. Examine Compressor Wheel And

Housing.

Remove the ducting from the compressor

inlet. Using a flashlight, check the
compressor for wheel to housing rub,
evidence of oil leakage, or foreign object
damage.

Wheel to housing rub

If wheel rub is found, and the housing

attaching hardware is secure, then the
turbocharger is probably damaged
internally and must be overhauled.

Oil leakage

Oil leakage into the compressor can be

caused by:

- Long periods of idling on restricted

oil drain line.

- Oil leakage into the compressor can

also be caused by a restricted air
intake system.

- Oil leakage into the compressor can

be caused by frequent use of the
engine as a brake. In this case,
nothing is wrong with either the
engine or the turbocharger, but
frequent compressor wheel and
housing clean-up is recommended.

Foreign object damage

If the compressor wheel has been

damaged by a foreign object, the
turbocharger must be overhauled.

Fig - 3

Fig. 3
12.108 HAJ08CTI ENGINE

5. Check Rotating Assembly for Noise

or Excessive Play

If no damage is visible in the turbine and

compressor areas, spin the rotating
assembly by hand. It should spin freely
with no drag or grinding noises.

Fig - 4

6. Check Axial Bearing Clearances

Fig. 4
Check the turbine rotor (Exhaust Side) for
axial play using the end play gauge
(Special Tool - 09444-1130) and dial
gauge.

Service limit : 0.045 - 0.090 mm

If the measurement is out of service limit,

the turbocharger is worn or damaged
internally and must be overhauled.

Fig - 5
Fig. 5

7. Check Wastegate Performance

Remove hose clamps and hose from

wastegate sensing port.

Attach a dial gauge, set to the

turbocharger so that the dial gauge rests
on the end of the actuator rod in the
plane of the rod, as applicable.

Set the dial indicator to zero.

While gently tapping the turbine housing

with a soft mallet, apply air pressure until
the rod movement shown 0.38 mm on
the dial gauge. Make sure that this
pressure is within the specified value.

Specified air pressure : 975 - 1025 mmHg

Fig - 6

Fig. 6
 HAJ08CTI ENGINE 12.109

Release the air pressure at the sensing

port. Note that the dial gauge pointer
returns exactly to zero.

Repeat steps (4) through (5) several

times to make sure that wastegate valve
or rod movement has been accurately
measured.

If the specified value or rod movement

cannot be obtained within the specified air
pressure range. The turbine housing
assembly or actuator assembly must be
replaced.

NOTE: Operation of the engine with the

wastegate calibrated to some value other
than that specified can result in reduced
performance or severe engine damage.

If wastegate performance is within

specification, install the hose onto the
wastegate sensing port.
12.110 HAJ08CTI ENGINE

12.18 AIR COMPRESSOR

12.18.0 Data and Specifications

Type - Reciprocating, two cylinder

Discharge amount - 271 cm3 x 2 cylinders

Bore x Stroke - 80 mm x 54 mm

Lubrication System - Forced Feed Lubrication

Cooling System - Forced Water-circulated

Fig. 1 - Air Compressor - Exploded View

1 Cylinder block 16 Connecting rod nut 31 Bolt
2 Crank shaft 17 Connecting rod washer 32 Bolt
3 Oil seal sleeve 18 Piston 33 Through bolt
4 O-ring 19 Piston pin 34 Lock washer
5 Suction valve assembly 20 Retainer ring 35 Bearing
6 Bearing holder assembly 21 Bolt 36 Bearing
7 Bearing holder 22 Straight pin 37 Piston ring set
8 Oil seal 23 Cylinder liner gasket 38 Unloader valve assembly
9 O-ring 24 Cylinder liner 39 Unloader valve holder
10 Bearing retainer 25 Cylinder liner gasket 40 Unloader valve spring
11 Bolt 26 Cylinder head assembly 41 Unloader valve
12 Woodruff key 27 Cylinder head 42 O-ring
13 Connecting rod assembly 28 O-ring 43 Spacer
14 Connecting rod bearing 29 Delivery valve assembly 44 Retainer ring
15 Connecting rod bolt 30 Delivery valve holder
 HAJ08CTI ENGINE 12.111

12.18.1 Repair Data

SPECIFICATION MEASURING DEVICE

DESCRIPTION
(Measurements in mm) AND REMARKS

Air Compressor
Outside dia of the piston pin 16
Clearance between piston pin and 0.02 - 0.04
connecting rod (limit 0.07)
inside dia of the connecting rod 37
Thickness of the connecting rod bearing 1.5
Outside dia of the crank pin 34
Oil clearance between the connecting 0.02 - 0.09
rod bearing and crank pin (limit 0.10)
Connecting rod end play 0.2 - 0.4 (limit 0.5)
Outside dia of the piston 80
Inside dia of the cylinder liner 80
Clearance between piston and cylinder liner 0.07 - 0.13 (limit 0.18)
Clearance between hole and piston pin 0 - 0.026 (limit 0.08)
Piston ring gap
1st ring 0.3 - 0.5 (limit 1.0)
2nd ring 0.3 - 0.5 (limit 1.0)
3rd ring 0.1 - 0.3 (limit 1.0)
Oil ring 0.2 - 0.8 (limit 1.0)
Piston ring thickness
Compression ring 3.0
Oil ring 4.0
Piston ring groove
Compression ring 3.0
Oil ring 4.0
Clearance between the ring groove and 0.02 - 0.05
the compression ring (limit 0.08)
Outside dia of the crank shaft journal
At drive end 34.99 - 35.00 (limit 34.985)
At rear end 35.002 - 35.013 (limit 34.997)
Inside diameter of the bearing holder
Cylinder block 80 (limit 79.996)
Bearing holder 72 (limit 71.996)
Crankshaft end play 0 - 0.3 (limit 0.4)
Section valve spring setting load 4.41 N @ 7.0 mm (limit 3.63 N)
Deliver valve spring setting load 4.5 N @ 9.5 mm (limit 3.6 N)

12.18.2 Tightening Torques Kgm lb.ft Nm

Air compressor
Drive gear mounting nut 36.00 260.36 353
Suction valve assembly 9.99 - 11.93 72.28 - 86.29 98 - 117
Delivery valve holder 9.99 - 11.93 72.28 - 86.29 98 - 117
Unloader valve holder 9.99 - 11.93 72.28 - 86.29 98 - 117
Cylinder head mounting bolt 3.98 - 5.00 28.76 - 36.14 39 - 49
Connecting rod nut 2.29 - 2.60 16.60 - 18.81 22.5 - 25.5
Cylinder liner mounting bolt 2.50 - 3.01 18.07 - 21.76 24.5 - 29.5
Bearing holder mounting bolt 1.40 - 1.79 10.10 - 12.98 13.7 - 17.6
12.112 HAJ08CTI ENGINE

12.18.3 Trouble Shooting

Symptom Possible Cause Remedy/Prevention
Charging efficiency dropped (Valve) Abnormal wear, damage, or Replace.
poor contact
Charging efficiency dropped (Piston, Worn piston and cylinder liner Replace.
Cylinder liner and piston rings)
Seized piston Replace (piston, piston rings and
cylinder liner).
Worn or broken piston ring Replace.
Charging efficiency dropped (Air pipe Leakage of high-pressure air Replace or tighten pipe joint.
and joints)
Clogged air pipe Replace.
Charging efficiency dropped Clogged element Clean or replace element.
(Air cleaner)
Noisy operation (Piston) Wear of piston bin boss or piston Replace.
pin
Seized, damage or worn connecting Replace.
rod small end
Worn piston or cylinder liner Replace.
Damaged or seized piston Replace.
Foreign particles on the top surface Clean or replace.
of piston.
Noisy operation (Bearing) Damaged, or worn ball bearing and/ Replace.
or connecting rod bearing
Noisy operation (Valve) Inlet valve is lowered excessively Repair or replace.
Loosen discharge valve holder Tighten it.
Excessive carbon or oil in the Worn, sticking or broken piston rings Replace piston rings and/or cylinder
compressor cylinder head or liner.
discharge line (Piston ring)
Insufficient piston ring tension Replace piston rings and/or cylinder
liner.
Malfunction of piston rings Replace piston rings and/or cylinder
liner.
Excessive carbon or oil in the Worn cylinder liner and piston rings Replace.
compressor cylinder head or
discharge line (Cylinder liner and
piston rings)
Malfunction of unloader valve Sticky Clean or replace.
(Unloader valve)
Deflection or wear Repair or replace unloader valve
assembly.
Malfunction of unloader valve Air leakage Replace or tighten pipe joints.
(Air pipe and joints)
Malfunction of unloader valve Function Adjust and/or repair pressure
(Pressure regulator) regulator.
 HAJ08CTI ENGINE 12.113

12.18.4 Overhaul

12.18.4.0 Dismounting
Remove the five air compressor mounting
bolts and remove the air compressor
without applying excessive force.

12.18.4.1 Mounting
1. Installation Procedures

1. Fit the No.1 Cylinder to the Top Dead

Center.

Fig - 2 Fig. 2

2. Align the aligning mark (two drill hole) on

the side of gear teeth with protrusion on
the compressor housing.

Fig - 3

3. Place a guide stud bolt (M8 x 1.25,

length: 50 mm or more) in the flywheel
housing as shown in the figure and insert
the compressor onto the stud bolt.

4. Tighten the mounting bolts (other than

the stud bolt) then remove the stud bolt.
Insert a bolt in the place of the stud bolt. Fig. 3

Fig - 4

5. Make sure that the compressor crankshaft

key is aligned with aligning mark (J) on
the bearing holder.

Fig - 5

NOTE: When installing the injection pump, make

sure that the coupling phase adjusting
bolt is at the center of the slot.

Fig - 6
Fig. 4

Fig. 6 Fig. 5
12.114 HAJ08CTI ENGINE

12.18.4.2 Disassembly

1. Remove the Drive Gear

- Remove the lock nut from the

compressor drive gear.

Fig - 7

- Pull the drive gear from the crankshaft,

then remove the woodruff key.
Fig. 7
Use Special Tool - Puller (09420-1830)

Fig - 8

2. Remove The Cylinder Head, O-ring

and Cylinder Liner

1. Remove the cylinder head, O-ring and

cylinder liner.

NOTE: Put the aligning mark through the cylinder

head to the cylinder liner.
Fig. 8

Fig - 9

3. Remove the Piston

- Remove the retainer rings installed on

both ends of the piston, using retainer
ring pliers.

- Strike out the piston pin, using a tapping

rod and a hammer.

NOTE: Warm up the piston first in hot water, Fig. 9

80-90°C for approximately 5 minutes

before removing the piston pin.

Fig - 10

Fig. 10
 HAJ08CTI ENGINE 12.115

4. Remove the Connecting Rod

- Rotate the crankshaft to the top dead
center position.
- Spread the staking of the nut completely
with a chisel, then loosen the nut.
- Remove the connecting rod.
Fig - 11

5. Remove the Piston Rings

Remove the piston rings using special tool

Fig. 11
- Piston ring expander (09440-1060)

Fig - 12

6. Remove the Crankshaft

- Remove the bearing retainer

Fig - 13

- Press the crankshaft end face and remove

the crankshaft with the bearing holder.

Fig - 14 Fig. 12

7. Remove the Bearing Holder

- Strike the circumference of the holder
lightly with a plastic hammer or a mallet
and remove the holder.

Fig - 15

Fig. 13

Fig. 15 Fig. 14
12.116 HAJ08CTI ENGINE

8. Remove the Oil Seal Sleeve

1. Using the special tool - Puller assembly

(09420-1670), remove the oil seal sleeve.

Fig - 16

9. Remove The Ball Bearing

- Using the special tool Bearing Puller

(09650-1101), remove the ball bearing
from the end of the crankshaft.
Fig. 16
Fig - 17

10. Remove The Suction Valve

Assembly

- Using the special tool Adapter (09482-

1090), remove the suction valve holder.

- Disassemble the suction valve.

Fig - 18

11. Remove The Unloader Valve

Assembly Fig. 17

- Loosen the unloader valve guide and take

it out together with the unloader valve.

Fig - 19

2. Remove the retainer ring and disassemble

the unloader valve.

Fig - 20

Fig. 18

Fig. 20 Fig. 19
 HAJ08CTI ENGINE 12.117

12. Remove The Delivery Valve Assembly

1. Remove the delivery valve holder.
Fig - 21

2. Disassemble the delivery valve.

Fig - 22

12.18.4.3 Assembly

1. Assemble The Suction Valve

Assembly
Fig. 21

- Assemble the gasket with new one, valve

seat, suction valve and valve spring in that
order from the lower side of the cylinder
head, then install the suction valve holder
and tighten provisionally.

Fig - 23

- Before completely tightening the suction

valve holder, push in the suction valve
with a finger or bar from the upper side
of cylinder head (Unloader valve side),
and check that the suction valve and Fig. 22
valve spring moves smoothly.

Fig - 24

- Tighten the suction valve holder to the

specified torque using a special tool
(Adapter - 09481-1090).

- Make sure that the suction valve stroke is

approximately 2.5 mm.

Fig - 25
Fig. 23

Fig. 25 Fig. 24
12.118 HAJ08CTI ENGINE

- Caulk three places on the outer periphery

of the suction valve holder.
NOTE: In this case be sure that the lower face
of the valve holder is not protruding from
the head lower face. (The faces should be
flush or the lower face of the valve
holder should be recessed from the head
lower face.)

Fig - 26

2. Assemble the Delivery Valve

Assembly Fig. 26

- Assemble the valve seat, delivery valve,

valve spring and new O-ring from the
upper side of cylinder head, then install the
delivery valve holder and tighten
provisionally.

- Push in the delivery valve with a finger or

bar from the lower side of the cylinder
head, and check that the delivery valve
and valve spring move smoothly.

Fig - 27 Fig. 27

- Tighten the delivery valve holder to the

specified torque.

- Make sure that the delivery valve stroke

is approximately 1 mm.

Fig - 28

3. Assemble The Unloader Valve

- Assemble the valve spring, unloader valve

with O-ring and spacer in the unloader
Fig. 28
valve holder, and secure them with the
retainer ring.

- Push the unloader valve from the upper

side with a finger or bar, and check that
the unloader valve and valve spring move
smoothly.

- Assemble the unloader valve holder from

the upper side of the cylinder head and
tighten the unloader valve holder to the
specified torque.

Fig - 29 Fig. 29
 HAJ08CTI ENGINE 12.119

4. Install the Ball Bearing.

1. Install the ball bearing on the both end of

the crankshaft.

Fig - 30

5. Install the Oil Seal Sleeve

Using the special tool - Sleeve Press

(09482-2220). Install the oil sleeve onto
the crankshaft. Fig. 30

Fig - 31

6. Install the Oil Seal

- Using the special tool oil seal press

(09482-2230), install the oil seal into the
bearing holder.

Fig - 32

7. Install the Crankshaft

Fig. 31

- Using a copper hammer, install the

crankshaft to the bearing holder.

Fig - 33

- Install the crankshaft and bearing holder

in the crankcase.

- Tighten the bearing holder fitting bolt.

Fig - 34
Fig. 32

Fig. 34 Fig. 33
12.120 HAJ08CTI ENGINE

8. Install the Connecting Rod and

Measure the End Play
NOTE: Be sure to align the aligning mark.
Apply engine oil to the bearing.
- Apply engine oil to the thread before
installing the connecting rod bolt.
Fig - 35
- Measure the connecting rod end play.
Assembly Standard : 0.2 - 0.4 mm
Limit : 0.5 mm
Fig. 35
Fig - 36
- Lock the nut with a lock washer.
Fig - 37

9. Measure the End Play of the

Crankshaft
Assembly standard : 0 - 0.3 mm
Limit : 0.4 mm

Fig - 38

10. Assemble the Piston Fig. 36

NOTE: Assemble the various parts after applying

engine oil to the sliding parts.
- When installing the piston rings on the
piston, ensure that the piston skirt is at
the bottom, and use the special tool
Piston ring expander (09440-1060).
NOTE: Install the piston rings with the
identification mark at the top of the ring
facing up.
Fig - 39

Fig. 37

Fig. 39 Fig. 38
 HAJ08CTI ENGINE 12.121

11. Assemble the Piston and

Connecting Rod

NOTE: Warm up the piston first in hot water, to

80 - 90°C, for approximately 5 minutes.

- Install the retainer ring at one end of the

piston holes.

- Apply engine oil to the piston pin.

- Fix the piston and connecting rod by Fig. 40

inserting the pin.

- Fit the new retainer ring at the other

end.

Fig - 40

12. Install the Cylinder Liner and

Cylinder Head

1. Arrange the piston rings so that their

gaps are equally spaced.
Fig. 41

Fig - 41

2. Install the cylinder liner and cylinder head.

Fig - 42

13. Install The Drive Gear

- Install the woodruff key to the crankshaft

- Install the drive gear.

Fig. 42

- Install the collar and lock nut.

Fig - 43

Fig. 43
 12.122 HAJ08CTI ENGINE

12.19 DRY TYPE AIR CLEANER

12.19.0 Maintenance and Servicing

* Remove dust deposit weekly by squeezing the

dust evacuator valve. Fig - 1

* Replace dust evacuator valve immediately if it is

torn, cracked, remains open or missing.

* Never operate the engine, if the restriction

indicator is either broken or missing.

* If red band appear in restriction indicator, clean

the primary element immediately and reset the
restriction indicator by pressing the top button. Fig. 1

CAUTION: It is recommended that the primary

filter element should not be cleaned
till the red band appears. Good
cleaning practice can increase the life
of the filter element.

* Check for proper adhesion between end plate

of the element and the sealing ring. Fig - 2

* Always clean the primary element with

pressurised air. Keep a distance between the
nozzle and the element. Use the pressurised air
from inside to outside of the primary element.

* Don't tap on the element and never try to clean Fig. 2

it with compressed air, flowing from outside to
inside of the primary element. Fig - 3

* Glow an electric bulb inside the primary element.

Check for any holes. If light comes out through
any hole, replace the element. Fig - 4 ✔
* Change the air filter primary element only if

- due for cleaning after two consecutive

cleaning

- primary element get punctured (refer

electric bulb test) OR

- red band appears in restriction indicator Fig. 3

with engine stopped condition, even after
cleaning the primary element.

* Replace the safety element after third

replacement of the primary element. Safety
element should never be cleaned but
always replaced.
NOTE: The wing bolt should be tightened
with hand alone, excessive tightening
would damage the air cleaner.
CAUTION: Frequent cleaning of the air filter element
leads to drop in the dust holding
capacity, weakening of the air filter
media and ruptures. This, in turn, could
result in serious damage to the engine
because of entry of dust in the system. Fig. 4
 HAJ08CTI ENGINE 12.123

12.20 ALUMINIUM RADIATORS AND

CHARGE AIR COOLER

Service Instruction

Introduction
This manual explains the procedure for
servicing (specifically, the sealing of leakages)
of aluminium radiators fitted with plastic
tanks that may damage in actual usage due
to improper handling before installation on
the vehicle.

The procedure covers the following aspects

of servicing :- Fig. 1 Construction of Aluminium Radiators

* Leakage spot detection

* Sealing Techniques and the tools

required

* Confirmation of proper sealing

Details of Radiator

A typical radiator is shown in Fig - 2 for

reference.

CAUTION: Users are requested to get themselves

familiar with all the parts and the
Fig. 2
assembly of radiator before
undertaking the servicing.

Servicing Kit

The radiator servicing kit consists of

following items:-

* Screw Driver

* Monkey Plier

* Sealant resin and hardener containers

(Araldite Standard of M/s Ciba Geigy
make)

* Alumaseal container

* Araldite applicator

* Brush

NOTE: Araldite rapid may be used in place of

Araldite standard for faster drying and curing
of seal.
12.124 HAJ08CTI ENGINE

Procedure for Servicing

Removal of radiator from vehicle -
* Allow the coolant in the radiator to
reach to the room temperature.
* Drain the coolant from radiator
completely by unscrewing the drain
cock.
* Remove all the mounting fasteners,
attachments like shroud, hoses etc.
* Take out the radiator from the vehicle
carefully without damaging the core.
CAUTION: Radiator core and plastic tanks are
susceptible to cracking due to impact
and deformation.

Detection of Leakage Spot –

* Connect the inlet of the radiator to
air supply at the gauge pressure of
1.5 bar.
* Seal all other outlet points.
* Dip the radiator completely in a clean
water tank.
* Tilt the radiator and shake it
vigorously to let the air bubbles
trapped at the clinching area to
escape.
* Observe carefully for one minute and
locate the source of air leakage on
the radiator from the direction of air
bubbles that are coming out of the
radiator.
CAUTION: Do not use the water tank that is
used for copper radiators.

Sealing the leakage spot –

Following procedures shall be adopted for
arresting leakages at different locations of
the radiator.

Replacement of Plastic tank –

Fig. 3
* Take out the member supports using
13 size spanner
* Release the clinch projections of
header plate using screw driver.
Fig - 3
* After making all the clinching
projections up, take out the tank from
its seat in header plate while grasping
the outlet.
* In case, it takes more effort, pat the
tank with rubber or plastic hammer
lightly.
Fig - 4 Fig. 4
 HAJ08CTI ENGINE 12.125

* Take off the tank packing.

* Clean the area of the header plate
where the tank sits, thoroughly.
* Insert new tank packing in the place
without twisting.

* Insert new tank (top or bottom) as

applicable.

NOTE: If the source of leakage is at the base

of the tank, i.e. area between header
plate and tank there is no need to
replace the tank.
Fig. 5
CAUTION: Tank packing shall be replaced, every
time, the tank is taken off for
servicing.

* If gap is found between the clinching

projections of header plate and tank,
softly hammer the projections.

Fig - 5

* Clinch the header plate projections

with monkey plier.

* The sequence of clinching should be

followed as illustrated in the figure.
Fig. 6

Fig - 6

* After clinching, confirm the dimension.

Fig - 7

CAUTION: If any of the clinching projections is

broken during the clinching or releasing
process, discontinue the servicing and
replace the entire radiator by a new
one.

* Fix the member supports and tighten

the bolts properly wherever applicable.
Fig. 7
Bottom Type pipe, Drain Cock and
Pressure Cap –

Bottom Type pipe -

* Take out the Bottom Type pipe using
10 size spanner.
* Remove the ‘O’ ring.
* Clean the seat of Bottom Type pipe
and the ‘O’ ring groove.
* Insert a new ‘O’ ring.
* Fit the Bottom Type pipe back,
ensuring proper tightness of the bolts.
12.126 HAJ08CTI ENGINE

Drain Cock * Silver colour paint may be used for

* Unscrew the drain cock. touching up the araldite spots and
impart the aluminium type appearance.
* Remove the ‘O’ ring.
* Clean the ‘O’ ring groove. CAUTION: * Do not damage the fins during
the process.
* Insert a new ‘O’ ring.
* Confirm that fins are set properly,
* Screw the drain cock back.
if disturbed during the process.
Pressure Cap – * As the Araldite is inflammable, do
not dry it by heating.
* Replace the pressure cap with a new
one, if leakage is through if after * Proper cleaning of radiator core
cleaning the filler neck. is must for proper setting of
Araldite or else it will come off.
CAUTION: Always use recommended radiator
pressure cap. Confirmation of Proper Sealing

Radiator Core – * After the sealing work is over,

Different procedure of sealing shall be assemble the radiator properly.
followed for minor and major leaks in the * Subject the assembled radiator to
radiator core. leakage test as shown in point 4.2.
Minor Leaks : Leak spots which are very NOTE: If the problem of leakage persists, it is
minute, are to be sealed in following manner. advisable to replace the radiator with new
* Install the radiator onto the vehicle. one.

* Pour the contents of alumaseal in the Radiator Installation

radiator.
* Ensure that all the openings of the
* Fill proper quantity of coolant liquid. radiator are closed properly except
* Run the engine in idling for more than the inlet.
20 minutes to detect leakage, if any. * Install the radiator on the vehicle
Major Leaks: Procedure of sealing major ensuring proper alignment, damping
leaks in the radiator is as follows : etc. as applicable.
* Wash the core with clean water and * Connect the inlet and outlet pipes
brush provided in the kit to remove and clamp them.
dirt, dust etc. * Fit the fan shroud.
* To remove the greasy spot on the Fill the radiator with proper quantity of
core, apply thinner with cotton swab fresh coolant as recommended.
and take off the grease.
* Dry the core using a dryer. Do's and Don'ts
CAUTION: Drying by heating must be avoided. Do's
Always use the clinching tool for removing
* Mix adequate quantity of Araldite
and refitting the radiator tanks.
resin and hardener in the ratio of 1:1
and stir it thoroughly. Always drain the radiator fully before
removing it from vehicle.,
* Apply the mixture immediately at the
leakage spot with the applicator. Always refill the radiator with coolant
recommended by the manufacturer.
* If required, apply the mixture to dry
and harden under the shade at room Always check tank packing before
temperature for 10-12 hour. reassembly of tank to core.

* Allow the mixture to dry and harden Don'ts

under the shade at room temperature
for 10-12 hour. Never open the pressure cap when the
radiator is hot.
NOTE: * Araldite Rapid of M/s Ciba Geigy
Don't use acid for cleaning the tubes and
dries and hardens within one hour and
tanks.
hence users may use it to minimize
the down time. Don't use manual force for cleaning clogged
tubes.
 HAJ08CTI ENGINE 12.127

12.21 MAINTENANCE PROGRAMME

km x 1000
Lubricant

16000 km
8000 km
Weekly
Remarks

No. of
points

Every

Every
Every
Daily
PDI
I. ENGINE
A. General
1. Check and adjust valve clearance on cold engine ✓ 60
2. Check and tighten front and rear engine
mounting / other peripheral bolts ✓ ✓
3. Check compression pressure 60
4. Check and tighten cylinder head nut / bolts
for correct torque in correct sequence ✓ 80
5. Check for proper functioning of Engine
Check Lamp ✓
B. Lubrication system
1. Check and top up engine oil O 1 ✓
2. Change engine oil and oil filter element ✓ ✓
3. Clean oil cooler During
engine
overhauling.
4. Check engine oil pressure (min. 1 kg/cm² at
idling and 80°C engine temperature ✓ ✓
5. Check oil leakages, if any ✓
C. Cooling System
1. Check and tight fan mounting bolts ✓ ✓
2. Check coolant level and top up if necessary ✓
3. Check radiator hoses and clamps for
leakages and tightness ✓ ✓
4. Check fan belt tension and adjust If necessary ✓ ✓
5. Check radiator stay rod & radiator mounting
bolts ✓ ✓
6. Drain cooling system and fill recommended
coolant. Refer Page 12.16 80
7. Replace cooling system hoses and radiator 80 Every 2
rubber pads for radiator mounting & stay rod Years
D. Fuel System
1. Replace fuel filter element
a. Primary element* ✓
b. Secondary element* ✓ First
24000 kms
& thereafter
every
16000 kms
c. Engine Mounted Filter (Hino Supply) ✓
2. Check water separator and drain if necessary ✓ ✓
3. Clean fuel feed pump stainer ✓
4. Lubricate accelerator link pedal shaft O 1 ✓
5. Check FIP control lever return spring ✓
6. Check and tighten F.I.P. mountings 40
* Both the fuel filter elements must not be changed at the same time
12.128 HAJ08CTI ENGINE

MAINTENANCE PROGRAMME

km x 1000
Lubricant

16000 km
8000 km
Weekly
Remarks

No. of
points

Every

Every
Every
Daily
PDI
7. Check injection timing 40
8. Clean Fuel tank and suction strainer 80
9. Adjust Fuel Injector Nozzle opening Pressure 60
10. Recalibrate fuel pump 120
11. Check and replace fuel hoses, if necessary 60
E. Air Intake and Exhaust
1. Check and clean air cleaner - primary element Refer page
(If restriction indicator shows red band) no. 12.122
2. Replace air cleaner primary element (After Refer page
2 consecutive cleaning). no. 12.122
3. Replace air cleaner safety element (At the Refer page
time of third replacement of primary element no. 12.122
or once in a year - whichever earlier).
4. Check restriction indicator, if necessary clean Refer page
the element ✓ no. 12.122
5. Check air inlet hose for any puncture/
damage, replace ✓
6. Check for any blockage / breakage at ✓
rainhood assembly
7. Check Turbocharger mounting ✓ 60
8. Check charge air cooler for any blockage of
fins and clean the cooler if necessary ✓ 32
9. Check charge air cooler hoses for any damage ✓
10. Check exhaust manifold and silencer for
leaks and tightness ✓ ✓