Tools & consumables
- Basic hand tools: metric sockets, combination wrenches, screwdrivers, pliers.
- Torque wrench (follow Hino torque specs in shop manual).
- Injector puller (appropriate for the injector type).
- Fuel line disconnect tools (if applicable).
- Fuel pressure gauge / diagnostic tool (diesel system pressure reader).
- Portable fuel transfer pump and clean jerry can (for draining tank or transferring diesel).
- Drain pans, rags, absorbent pads.
- Ultrasonic injector cleaner (with heater) OR professional injector flow bench / tester.
- Injector cleaning kit for on-vehicle cleaning (pressurised canister or pump that connects to fuel rail).
- Compressed air or nitrogen source with clean oil/water separator for drying injectors.
- New fuel filters (primary, secondary, water separator element as applicable).
- New injector O-rings, seals, copper crush washers (one per injector line end) — OEM spec.
- Fuel-system-safe cleaning solvent (diesel injector ultrasonic detergent) and bench-flow test solvent.
- Diesel-compatible injector cleaning additive (if doing an on-vehicle chemical flush).
- Gloves (nitrile), safety glasses, face shield, and respirator if solvent vapours present.
- Fire extinguisher rated for flammable liquids.
- Waste containers for contaminated diesel/solvent and used filters.

Safety precautions (must do)
- Work in a well-ventilated area. No open flames, sparks, or smoking.
- Disconnect negative battery terminal before working on fuel system electrical components.
- Relieve fuel pressure before opening fuel lines (consult service manual for pressure-relief procedure).
- Wear eye protection, nitrile gloves, and face protection when cleaning injectors or handling fuel/solvent.
- Contain spills immediately; use absorbent and dispose of waste per local regulations.
- Keep a fire extinguisher close at hand.
- If using compressed air to blow injectors, use regulated low pressure and a blow gun rated for the job. Never point compressed air at personnel.

Overview of procedure (high-level)
1) Prep & safety
2) Drain/inspect fuel tank & water separator
3) Replace primary/secondary fuel filters and drain water separator
4) Bleed system and confirm no fuel starvation/contamination
5) Remove injectors (mark locations)
6) Bench-clean & test injectors (ultrasonic + flow/pattern test) OR perform on-vehicle chemical cleaning
7) Replace seals/washers, reinstall and torque to spec
8) Bleed system, start, check for leaks and road test

Step-by-step detailed procedure

1 — Preparation
- Park on level surface, chock wheels, set parking brake.
- Gather parts and tools; review Hino GH1H shop manual pages for fuel system layout, pressure-relief procedure and torque values.
- Disconnect the negative battery terminal.

2 — Relieve fuel pressure & isolate system
- Follow the manual procedure to relieve rail/line pressure. If no rail relief valve, crank engine with fuel pump fuse removed to relieve pressure and then crank until it stops.
- Place drain pan under filter/water separator.

3 — Drain & inspect tank / water separator
- Drain the water separator; note amount/color of water/debris.
- If tank contamination suspected (sediment, heavy water, odour), drop tank or use a fuel transfer pump to evacuate into clean container and visually inspect. If heavy contamination, tank must be cleaned or replaced.
- Replace water separator element if present.

4 — Replace fuel filters
- Replace primary and secondary filters (use OEM part numbers). Remove old filters, inspect for metal/sediment; note any unusual debris.
- Install new filters with new seals. Torque per manual. Dispose of old filters correctly.

5 — Check fuel supply components
- Inspect fuel lines, clamps, banjos, fuel pump and return lines for leaks, swelling, cracks, or loosened fittings. Replace any damaged components.
- Replace copper crush washers on banjo fittings whenever lines are disturbed.

6 — Decide on cleaning method (on-vehicle chemical flush vs. bench injector service)
- If injectors show only mild deposit symptoms (sluggish idle, slightly poor economy), an on-vehicle cleaning with a diesel-compatible pressurised cleaner can be done first.
- If performance issues persist or if injectors leak/drip/bad spray pattern, pull and bench-test/clean or replace injectors.

7A — On-vehicle cleaning (how to use the cleaning tool)
- Use a reputable diesel on-vehicle cleaning kit that isolates the vehicle’s fuel supply (cleaning canister connected in place of the primary fuel filter or to the supply line) with its own pump and solvent reservoir.
- Connect kit according to its instructions: inlet from cleaning canister to high-pressure pump/feed side, return to tank or waste as specified. Ensure all connections are tight.
- Fill canister with recommended diesel injector cleaning solvent or approved detergent (do not use gasoline-based cleaners in diesel systems).
- Reconnect battery and start engine. Run engine at specified RPM per kit manufacturer instructions (usually idle to light rev range) for the recommended time (commonly 15–30 minutes).
- Monitor for leaks, smoke, or abnormal noises. Stop immediately if concerns arise.
- After cleaning, remove kit and reinstall new fuel filter(s). Prime the system and start engine. Check for improvement.
- Note: On-vehicle cleaning does not replace mechanical cleaning/testing of injectors; it can free carbon and varnish deposits but won’t correct worn nozzle tolerances.

7B — Injector removal, ultrasonic cleaning & bench testing (how to use tools)
- Mark each injector/cylinder location to ensure return to original position.
- Disconnect electrical connectors carefully; cap them to prevent contamination.
- Remove fuel lines carefully and cap open lines to avoid contamination/air ingress.
- Use injector puller per tool instructions if injectors are tight. Protect cylinder head surfaces.
- Inspect injectors visually: carbon on tips, oil or fuel leaks, broken insulators, cracked bodies.
- Replace injector O-rings and seals before reinstall if damaged (but final replacement after cleaning).
- Ultrasonic cleaning:
- Place injectors in the ultrasonic tank with diesel-compatible cleaning solution or OEM-recommended detergent. Ensure the solution does not contact electrical connectors (remove them if necessary).
- Run ultrasonic cycles per machine instructions (typical: 15–30 minutes). Agitate and rinse with clean solvent or diesel.
- Dry injectors with low-pressure, filtered compressed air from the pintle/nozzle side and from body passages. Do not exceed safe pressure for internal parts.
- Bench flow/pattern testing:
- Mount injectors on a flow bench/tester. Use the correct test fuel/solvent and set pressure to the engine’s operating rail pressure (or per injector spec).
- Check spray pattern, quantity, leak-by (drip), and response time. Compare to OEM tolerance charts.
- If injector balance or spray pattern out of spec, either have them serviced by a professional reconditioner or replace injectors.
- Replacing failed injectors: use OEM or remanufactured injectors meeting Hino specs. Fit new injector seals and crush washers.

8 — Reinstallation
- Install new O-rings/seals on injectors (lubricate lightly with clean diesel or assembly lubricant specified). Replace copper crush washers on fuel lines.
- Insert injectors carefully and torque hold-downs to OEM torque.
- Reconnect fuel lines and electrical connectors. Replace any line fittings that show damage.
- Install new fuel filters (again) after bench-cleaning or as required and prime the system using the manual primer or electro pump.
- Reconnect battery negative.

9 — Bleed, start-up & testing
- Prime the fuel system until a steady stream free of air comes from the filter housing bleed screw or follow Hino bleed procedure.
- Start engine. Monitor for leaks, rough running, smoke or codes.
- Let engine reach normal operating temperature. Re-check torque on injectors after initial heat cycle if required by manual.
- Road test under load. Verify improved idle, throttle response, smoke level and fuel economy.

10 — Final checks & disposal
- Re-inspect all fittings for leaks after road test.
- Dispose of contaminated fuel, solvent and filters per regulations.

Common pitfalls to avoid
- Not relieving fuel pressure before opening lines — risk of injury and mess.
- Reusing old injector O-rings and crush washers — almost always replace them.
- Using inappropriate cleaning solvents (gasoline additives or harsh solvents that damage seals) — use diesel-safe products.
- Not marking injector positions — if the injectors are matched and balanced, keep them in the same cylinders unless rebalanced.
- Not bench-testing injectors — on-vehicle cleaning can mask a worn injector that needs replacement.
- Over-torquing injector clamps or banjo fittings — causes thread damage or distorted seating; use specified torque values.
- Allowing dirt or water into open lines or injector bores — always cap open fittings immediately.
- Skipping air bleed — air in the system causes hard starts/rough running.
- Not checking the fuel tank or supply for contamination — contaminated tank will re-contaminate a cleaned system.

Replacement parts commonly required
- Primary and secondary fuel filters and water separator element.
- Injector O-rings, seals, copper crush washers.
- Injector return lines or banjo bolts if damaged.
- Injectors (if flow/pattern tests fail or if mechanically damaged).
- Fuel tank cleaning or replacement if heavy contamination found.
- Fuel pump (rare, but required if contaminated with abrasive debris).

Estimated time
- On-vehicle chemical clean and filter change: 1–3 hours.
- Full injector removal, ultrasonic clean and bench test (per injector bank): 4–8 hours depending on engine layout and bench availability; longer if injectors require reconditioning or replacement.

Notes
- Always use the Hino Super F Series GH1H workshop manual for torque values, specific pressure-relief steps, injector types and system diagrams.
- If unsure about bench testing or injector calibration, send injectors to a professional injector service/reconditioner.

End.
rteeqp73

Introducing the New Hino 300 Series 4x4 Here's what the New Hino 300 Series 4x4 all is about.

2021 Hino XL8 Crew Cab A09 Turbo Diesel Truck Hino Semi.

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