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W04D
Hino Motors W04D User Manual
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Table of Contents
Index: Engine Group
5
General Introduction
7
How to Use this Workship Manual
9
Repair Procedures
9
Timing Gear and Camshaft
9
Engine Serial Numbers
10
Specifications HINO W04D
11
Specifications HINO W04C-T
15
HINO W04C-T Front View
17
HINO W04C-T Left Side View
17
Specifications HINO W04C-TI
19
HINO W04C-TI Front View
21
HINO W04C-TI Left Side View
21
Tightening Torque of Standard Bolt
22
Recommended Lubricants for All Hino Engine
23
W04D, W04C-T, W04C-TI Engines
25
Data and Specifications
27
W04D Pleasure Craft Rating
28
W04D Light Duty Rating
28
W04C-T Light Duty Rating
29
W04C-T Pleasure Craft Rating
29
W04C-TI Light Duty Rating
30
W04C-TI Pleasure Craft Rating
30
Engine: Troubleshooting
31
Engine Overhaul Criteria
37
W04C-TI Engine Moving Parts
39
Engine Overhaul Special Tool
40
Cylinder Head
43
Cylinder Head Disassembly
45
Cylinder Head Assembly
46
Replace the Valve Seat
47
Replace the Valve Guide
48
Replace the Valve Stem Seal
48
Assemble the Rocker Arm
49
Cylinder Head: Inspection and Repair
51
Timing Gear, Camshaft and Oil Pan
54
Remove the Crankshaft Pully
56
Dismount the Fuel Injection Pump
56
Remove the Camshaft/Idler Gear Shaft
56
Assemble the Camshaft Gear and Shaft
57
Install the Idler Gear Shaft
58
Install the Idler Gear
58
Install the Timing Gear Case
58
Install the Oil Strainer
59
Timing Gear, Camshaft and Oil Pan: Inspection and Repair
59
Install the Oil Pan
59
Piston, Crankshaft, Cylinder Block and Flywheel Housing
61
Remove the Pistons with Connecting Rods
63
Remove the Crankshaft
63
Remove the Connecting Rod
63
Remove the Piston Rings
63
Remove the Cylinder Liner
64
Insert the Cylinder Liner into the Cylinder Block
64
Measure the Projection of the Cylinder Liner
65
Install the Crankshaft
66
Replace the Piston Pin Bushing
67
Assemble the Piston and Connecting Rod
69
Install the Piston Ring
70
Install the Piston in the Cylinder Liner
70
Install the Connecting Rod Cap
70
Install the Oil Seal in the Flywheel Housing
71
Install the Flywheel Housing
71
Install the Flywheel
71
Piston, Crankshaft, Cylinder Block and Flywheel Housing: Inspection and Repair
72
Liquid Gasket Application Points and Coating Width
76
Coating Liquid Gasket and Parts Assembly Procedure
77
Coating Liquid Gasket: Removing Parts
78
Timing Gear Plate Gasket
78
Lubrication System Data and Specifications
79
Lubrication System Diagram
79
Oil Pump Description
81
Install the Oil Pump
81
Oil Pump: Inspection and Repair
82
Oil Cooler and Oil Filter Overhaul
83
Install the Oil Cooler
84
Install the Spin-On Type Oil Filter
84
Oil Cooler and Oil Filter: Inspection and Repair
84
Fuel System Data and Specifications
85
Fuel System Diagram
85
Air Bleeding from Fuel System
85
Injection Nozzle Overhaul
86
Adjust the Injection Pressure
87
Test the Spray Profile
87
Test the Fuel Leakage
87
Test the Nozzle Skinking
87
Fuel Filter
88
Install the Spin-On Type Fuel Filter
88
Cooling System Data and Specifications
89
Cooling System Diagram
89
Cooling System Overhaul
90
Coolant Pump Overhaul
91
Coolant Pump Dismounting
91
Coolant Pump Disassembly
91
Coolant Pump Assembly
92
Install the New Coolant Seal
92
Install the Coolant Pump to the Timing Gear Cover
93
Heat Exchanger Description
94
Heat Exchanger Overhaul
94
Heat Exchanger Assembly
95
Heat Exchanger: Inspection and Repair
95
Install the Thermostat
96
Install the Thermostat Case
96
Thermostat: Inspection and Repair
96
Air Intake and Exhaust System Model W04D Overhaul
97
Air Intake and Exhaust System Model W04C-T Overhaul
98
Air Intake and Exhaust System Model W04C-TI Overhaul
99
Install the Exhaust Pipes
100
Engine Component and Parts Dismounting and Mounting
103
Remove the Fuel Injection Pump
103
Install the Injection Pump
104
Install the Generator on the Engine
105
Remove the Starter from the Engine
106
Install the Starter on the Engine
106
Engine Tune-Up
107
Inspection and Adjustment of the Valve Clearance
107
Method for Determining if the No.1 or No.4 Piston Is at the Top Dead Center on Compression Stroke
107
Inspect the Injection Timing
108
Inspect the Thermostat Function
109
Inspect the Filler Cap Function
109
Adjust the Solenoid (Engine Stop) Link Rod
110
Adjust the Engine Idling Speed
110
Engine Tune-Up on Test Bench
111
Set the Engine Assembly on a Test Bench
111
Start the Engine
112
Procedure for Installing Joints and Gaskets of Engine Pipes
113
Gasket Seal Type
113
Tightening Torque Chart
113
Metal Seal Type
113
Marine Transmission Dismounting and Mounting Overhaul
115
Marine Transmission Dismounting and Mounting Operation
115
Pumping out Marine Transmission Fluid
116
Remove the Marine Transmission
116
Install the Torsion-Elastic Coupling
117
Install the Intermediate Flange
118
Install the Marine Transmission
118
Fill with Automatic Transmission Fluid
119
Electrical Equipment
121
Electrical Equipment: Data and Specifications
122
Location of Electrical Equipment
122
Electrical Equipment: Troubleshooting
123
Electrical Equipment: General Instruction
125
Wiring Code
125
Connector
125
Fuse
125
Conversion Formula for Specific Gravity
126
Battery Charging
126
Cleaning the Battery
126
Connecting the Battery Cables
126
Engine Starting Circuit
127
Check the Continuity of the Starter Switch
127
Check the Operation of Battery Relay
127
Check the Operation of the Starter Block Relay
127
Pre-Heat Circuit
128
Check the Operation of the Intake Air Heater
128
Check the Continuity of the Heater Plug
128
Engine Stop and Warning Lamp Circuit
128
Check the Operation of the Water Temperature Switch
129
Check the Operation of the Pressure Switch
129
Meter and Gauge Circuit
129
Check the Operation of the Tachometer
129
Check the Operation of the Fuel Receiver Gauge
130
Check the Operation of the Fuel Sender Gauge
130
Check the Operation of the Water Temperature Sender Gauge
130
Check the Operation of the Oil Pressure Receiver Gauge
130
Check the Operation of the Oil Pressure Sender Gauge
131
Check the Operation of the Vaoltmeter
131
Check the Operation of the Generally Use Switch (Illumination Lamp Switch)
131
Turbocharger
133
Turbocharger: Data and Specifications
134
Turbocharger: Description
134
Turbocharger: Overhaul Criteria
136
Turbocharger: Special Tool
137
Turbocharger: Overhaul
138
Turbocharger: before Disassembly
138
Turbocharger: Disassembly
139
Remove the Blower Impeller
139
Remove the Bearing
140
Turbocharger: Assembly
140
Assemble the Journal Bearings
141
Assemble the Thrust Bearing
141
Install the Seal Plate
141
Assemble the Turbine Rotor
142
Assemble the Blower Case
142
Assembly Test
142
Turbocharger: Inspection and Repair
143
Fuel Injection Pump
145
Fuel Injection Pump: Description
146
Fuel Injection Pump: Troubleshooting
147
Fuel Injection Pump: Special Tool
150
Injection Pump Overhaul
151
Injection Pump: Disassembly
152
Measure the Camshaft End Play
152
Remove the Tappet Assembly
153
Remove the Plungers, Springs and Control Sleeve
154
Remove the Taper Bearing from the Camshaft
154
Injection Pump: Assembly
155
Install the Plunger Barrels
155
Install the Delivery Valves, Springs and Holders
155
Install the Plunger and Tappet
156
Fuel Injection Pump: Inspection and Repair
158
SCZ-Type Timer Overhaul
159
SCZ-Type Timer Dismounting
159
SCZ-Type Timer Disassembly
159
SCZ-Type Timer: Assembly
160
Install the Timer Flange with Drive Gear
160
SCZ-Type Timer: Mounting
160
Adjustment of the Timer
160
FP/KS-Type Overhaul
161
FP/KS-Type: Inspection and Repair
162
Fuel Injection Pump: Adjustment Preparation
163
Adjusting the Injection Timing
163
Adjust the Injection Interval
164
Check the Tappet Top Clearance
165
Measure and Adjusting the Injection Volume
165
Injection Pump Governor Model RSV
167
Injection Pump Governor: Description
168
Injection Pump Governor: Special Tool
170
Injection Pump Governor: Disassembly
170
Injection Pump Governor: Assembly
171
Install the Adjusting Lever
171
Adjustment of the Governor
172
Governor External Lead Seals and Crimp Caps
173
Injection Pump Governor Model RSV with Boost Compensator
175
Injection Pump Governor Model RSV with Boost Compensator: Overhaul
176
Governor Model RSV with Boost Compensator: Special Tool
177
Governor Model RSV with Boost Compensator: Disassembly
177
Governor Model RSV with Boost Compensator: Assembly
178
Governor Model RSV with Boost Compensator: Installing the Adjusting Lever
178
Adjusting of the Governor (Model RSV with Boost Compensator)
179
Boost Compensator Overhaul
181
Adjustment of Boost Compensator
181
Adjustment of Boost Compensator Stroke
182
Adjustment of Boost Compensator Spring
182
Generator
185
Generator: Data and Specifications
186
Generator: Description
186
Generator: Troubleshooting
187
Generator: Overhaul
188
Generator: Disassembly
189
Remove the I.C. Regulator and Brush Holder
189
Remove the Front Ball Bearing
189
Remove the Stator and Rectifier
189
Generator: Testing
190
Generator: Assembly
191
Install the Stator and Rectifier
191
Install the Front Ball Bearing
191
Install the I.C. Regulator and Brush Holder
191
Generator Performace Test
192
Voltage Regulation Test
192
Generator: Inspection and Repair
193
Starter
195
Starter: Data and Specifications
196
Starter: Description
196
Starter: Troubleshooting
197
Starter: Overhaul
199
Starter: Disassembly
200
Remove the Yoke from the Magnetic Switch
200
Remove the Armature from the Yoke
200
Remove the Overrunning Clutch/Idle Gear
200
Starter: Assembly
201
Install the Brush Holder on the Yoke
202
Install the Steel Plate on the Magnetic Switch
202
Starter: Magnetic Switch Test
203
Starter: Performance Test
203
Starter: Inspection and Repair
205
Injection Pump Calibration
207
Injection Pump Number: 22030-2070B and 22030-2071A
209
Injection Pump Number: 22020-3462A and 22020-3463A
211
Injection Pump Number: 22020-2731A and 22020-3590A
213
Governor Characteristic Diaphragm
214
4
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Hino Motors W04D Specifications
General
Engine Model
W04D
Number of cylinders
4
Displacement
4.009 L
Bore x Stroke
104 mm x 118 mm
Fuel System
Direct Injection
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