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Hino 700 Series Workshop Manual download

- Quick important note
- Most Hino 700 trucks have diesel engines and use glow plugs, not spark plugs. The procedure below is written for replacing glow plugs. If your vehicle actually has spark plugs (rare on Hino 700), the physical steps are similar but plug type, socket size and some torque values differ — always confirm engine type and manual specs before starting.

- Safety first
- Disconnect battery negative terminal to avoid electrical shorts.
- Work only on a cold engine to avoid burns or snapping a hot glow plug.
- Wear safety glasses, gloves and use good lighting.
- Keep fuel sources away and work in a well-ventilated area.
- Use jack stands if you raise the vehicle — never rely on a jack alone.

- Tools (each tool explained + how to use)
- Ratchet handle (1/2" drive recommended)
- Description: Main turning handle for sockets.
- How to use: Attach sockets and extensions, set direction switch for loosening/tightening.
- Socket set (deep sockets; metric sizes likely 8 mm–14 mm; include 1/2" drive)
- Description: Deep sockets reach recessed glow/spark plugs and fit over insulators.
- How to use: Select correct socket that fits the plug hex snugly; use with extensions to reach down into the head.
- Glow plug socket (insulated or rubber-lined deep socket sized to glow plug hex)
- Description: Special deep socket that grips the plug without crushing the porcelain and often holds the plug when removing.
- How to use: Fit over glow plug and turn with ratchet; rubber insert holds plug for safe removal.
- Extensions and universal (swivel) joint
- Description: Extensions increase reach; swivel joint lets you approach at an angle.
- How to use: Use an extension between ratchet and socket; swivel helps reach awkward angles without stressing plug hex.
- Torque wrench (capable of specified torque, common range 5–100 Nm with 1/2" drive)
- Description: Ensures correct installation torque so plug seals and threads aren’t damaged.
- How to use: Set required torque per manual, tighten until wrench clicks; don’t over-torque.
- Multimeter (digital)
- Description: Measures voltage and resistance to test glow plug and harness.
- How to use: Set to ohms to test plug resistance; set to volts to check power supply when cranking or on ignition.
- Penetrating oil (e.g., PB Blaster)
- Description: Soaks and loosens seized/frozen plugs before removal.
- How to use: Apply to base of plugs and let soak per product instructions (often 10–30 minutes).
- Small wire brush / pick / shop rag
- Description: Cleans carbon/debris from around plug seat before removal and before reinstall.
- How to use: Brush area gently, remove loose debris so nothing falls into the combustion chamber.
- Electrical contact cleaner and dielectric grease
- Description: Cleaner removes corrosion from plug connector; dielectric grease protects electrical connection.
- How to use: Spray connectors, dry, then put a very small amount of dielectric grease on the connector after reinstalling.
- Torque extension or crowfoot adapter (only if space prevents direct torque wrench access)
- Description: Allows accurate torque application in tight spots.
- How to use: Attach to torque wrench and use adapter-specific torque correction procedure if required.
- Optional but recommended: Heat source (propane torch) and stud extractor set
- Why used: If a glow plug breaks or is heavily seized, heat can expand metal for easier removal; a stud extractor may be needed if the plug snaps off.
- How to use: Heat only per safe procedures; use extractor kits as directed and consider professional help if plug breaks flush with the head.
- Thread chaser or helicoil kit (for damaged threads)
- Why used: If glow plug threads are damaged, a thread repair kit restores thread integrity; required when threads are stripped or cross-threaded.
- How to use: Follow kit instructions; this is an advanced repair and may be better handled by a machine shop.

- Parts you will likely need (what, why)
- Replacement glow plugs (one per cylinder) — OEM or approved aftermarket
- Why: Glow plugs wear out, open circuit, or fail to heat. Replace the bad ones or all at once for consistent performance.
- What to buy: Match engine model and plug length/hex size; buy exact OEM part numbers or reputable equivalent.
- Glow plug seals/O-rings (if fitted)
- Why: Seals prevent oil or combustion gas leaks around plug; reusing old torn seals can leak.
- What to buy: Replacement seals specific to glow plug type.
- Replacement connector(s) or harness segments
- Why: Corroded connectors or broken harness wiring can mimic plug failure.
- What to buy: OEM connectors or pigtail repair kits to restore good electrical contact.
- Glow plug relay/resistor pack (if multiple plugs fail or old)
- Why: A faulty relay or control unit can prevent all plugs from heating; replace if voltage/power supply tests bad.
- What to buy: OEM relay or recommended replacement for your model.

- Basic pre-checks and testing
- Visually inspect connectors for corrosion, melting or broken wires.
- With battery connected, measure coil/harness voltage at the connector when glow is active (follow truck’s glow sequence or ignition cycle). Expect battery voltage at the connector during glow activation; no voltage means relay/wiring issue.
- Remove one connector and measure glow plug resistance across its two terminals (or between tip and terminal if 2-wire). A functioning glow plug usually shows low resistance (typically a few ohms); an open/infinite reading means failed plug.

- Removal procedure (general — follow workshop manual for your engine)
- Disconnect battery negative.
- Remove obstruction components to reach plugs (engine cover, intake pipe, valve cover, cable trays) as needed and set aside labeled.
- Clean around glow plug base thoroughly to keep debris out of combustion chamber.
- Unplug electrical connector from glow plug; label wiring if necessary.
- Apply penetrating oil at plug base if they look corroded; wait as recommended.
- Fit the correct deep glow-plug socket over the plug; use extension and ratchet. Turn counter-clockwise to loosen slowly—if it resists, don’t force; apply more penetrating oil and wait or apply heat carefully.
- Remove glow plug straight out; keep plugs upright to avoid dropping carbon into the head.
- Inspect removed plugs: broken tip, heavy carbon, or open circuit → replace.
- If a plug breaks, stop and consider using a stud extractor or seek professional machine shop help; do not drive bits into the cylinder.

- Installation procedure
- Clean the plug hole with a brush and rag; remove debris.
- Fit new glow plug (with any new seal/O-ring). Check manufacturer’s instructions about anti-seize — many manufacturers advise against anti-seize on glow plugs because it alters torque readings.
- Hand-thread the plug first to avoid cross-threading.
- Use torque wrench to tighten to the specified torque from the workshop manual. If you don’t have the manual, tighten snugly but avoid over-torquing — better to get the exact spec before final torquing.
- Reconnect electrical connector (use dielectric grease sparingly inside connector).
- Reinstall any removed components in reverse order.
- Reconnect battery negative.

- Post-install testing
- Turn ignition to glow on and verify voltage at each plug connector if possible.
- Start engine; engine should start more readily when glow plugs are functioning, especially when cold.
- Check for leaks, unusual noises, or fault codes. If warning lights remain, scan for trouble codes or consult workshop manual.

- Troubleshooting notes and when to get professional help
- If a glow plug is seized or breaks below the head surface: stop and consult a workshop or machinist — removal without proper tools can damage the cylinder head.
- If multiple plugs fail quickly after replacement: investigate relay, wiring harness, or control module.
- If threads are stripped: use a thread repair kit or have a machine shop retap/insert Helicoil.
- If unsure about torque values, injector proximity, or disassembly of major components, get professional mechanical help.

- Final practical tips
- Replace all glow plugs in a bank if one is bad and mileage is high — it’s common and avoids repeat labor.
- Buy one or two spare glow plugs to keep in the tool box if you travel in remote areas.
- Keep the workshop manual or a repair sheet handy for exact socket sizes, torque specs and wiring diagrams.

- Important: consult your Hino 700 workshop manual for engine-specific socket sizes, torque specifications and wiring diagrams before final torquing or ordering parts.
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