2 CA4180P66K24E4Z 34C发动机 zj 译文

Jiefang
CA4180P66K24E4Z
Cab Over Engine Diesel Tractor-Truck
Service Manual
Engine
Jan. 2013
Engine Service Manual 2
Content
I. Specifications............................................................................................................................................................. 1
II. Construction ............................................................................................................................................................. 8
III. Operations before Removal and after Installation ................................................................................................... 9
IV. Mounting Units ..................................................................................................................................................... 10
V. Cylinder Block Unit ............................................................................................................................................... 12
VI. Cylinder Head and Cylinder Head Cover Unit ..................................................................................................... 17
VII. Piston-Connecting Rod Unit................................................................................................................................ 19
VIII. Crankshaft-Flywheel Unit .................................................................................................................................. 22
IX. Camshaft and Timing Gear Unit ........................................................................................................................... 24
X. Valve Train ............................................................................................................................................................ 27
XI. Exhaust Manifold and Heat Shield Unit ............................................................................................................... 32
XII. Oil Pan and Oil Dipstick Assembly..................................................................................................................... 33
XIII. Oil Collector Assembly ...................................................................................................................................... 34
XIV. Oil Pump Assembly ........................................................................................................................................... 35
XV. Full-Flow Oil Filter Assembly............................................................................................................................. 36
XVI. Oil Cooler .......................................................................................................................................................... 37
XVII. Positive Crankcase Ventilation System ............................................................................................................ 40
XVIII. Centrifugal Oil Filter Assembly ...................................................................................................................... 41
XIX. Tensioner Unit ................................................................................................................................................... 42
XX. Low Pressure Fuel Pipes ..................................................................................................................................... 44
XXI. High-Pressure Fuel Pump .................................................................................................................................. 45
XXII. Injectors ............................................................................................................................................................ 47
XXIII. Secondary Fuel Filter....................................................................................................................................... 49
XXIV. Turbocharger Unit........................................................................................................................................... 51
XXV. High-Pressure Fuel Rail Unit ........................................................................................................................... 53
XXVI. Drain Cock ...................................................................................................................................................... 54
XXVII. Thermostat ..................................................................................................................................................... 55
XXVIII. Water Pump .................................................................................................................................................. 57
XXIX. Steering Pump Unit ......................................................................................................................................... 58
XXX. Air Compressor Unit ........................................................................................................................................ 59
XXXI. Generator Set .................................................................................................................................................. 60
XXXII. Starter Unit .................................................................................................................................................... 62
XXXIII. Trouble Diagnosis ........................................................................................................................................ 64
XXXIV. Operating Instructions .................................................................................................................................. 79
1
I. Specifications
Main specifications and parameters of the diesel engine
SN Item CA6DM2-42E4
In-line, four-stroke, liquid cooled, four-valve, turbocharged
1 Type
and intercooled
2 Combustion chamber type Direct injection, ω type
3 Number of cylinders 6
4 Cylinder diameter (mm) 123
5 Piston stroke (mm) 155
6 Compression ratio 18.3:1
7 Total piston displacement (L) 11.05
8 Rated power (kW) 312
9 Net power (kW) 309
10 Rated speed (r/min) 1900
11 Maximum torque (N.m) 1900
12 Maximum torque speed (r/min) 1300
13 Fuel supply system Electronically controlled high pressure common rail
14 Exhaust pollutants Compliant with GB 17691-2005 Tier 4
15 Firing order 1-5-3-6-2-4
Intake: 0.30
16 Valve clearance (cold) (mm)
Exhaust: 3.0
17 Idle speed (r/min) 650±50
18 Starting mode Electric start
19 Crankshaft rotation direction (facing flywheel end) Counterclockwise
20 Overall dimensions (L × W × H) (mm) 1365×773×1192 (without fan)
21 Net weight (kg) 1050
Lubrication system parameters

Pressure name Unit Value
Oil pressure at idle speed (permissible minimum pressure) kPa ≥150
Oil pressure at rated speed (permissible minimum pressure) kPa 400
Opening pressure of oil gallery pressure regulating valve kPa 480
Oil temperature (at nominal speed) ℃ 90~110
Oil pan capacity (―LOW‖~―HIGH‖ on oil dipstick) L 31.1~34.1
Caution
★ For a new engine or one that has not been used for a long period, additional 5L oil needs to be added to fill
the filter, etc.
2-1
2 Engine Service Manual
Cooling system parameters
Name Unit Value
Temperature at the beginning of opening of thermostat ℃ 83
Temperature with wide-open thermostat ℃ 95
Coolant capacity (diesel engine only) L 20
Caution
★ To protect the diesel engine, you must know the total capacity of the cooling system which also depends on
the capacity of the radiator on the vehicle. Please refer to related data of the vehicle.
Fuel supply system parameters

Name Unit Value
Maximum outlet pressure of fuel transfer pump kPa 900
Fuel filter resistance (maximum pressure drop of liquid flowing through filter) kPa 120
Max. back pressure at the oil return port of high-pressure oil pump kPa 120
Intake system parameters

Name Unit Value
Maximum permissible intake resistance (with air cleaner element) kPa 7.5
Maximum permissible outlet resistance of turbocharger kPa 10
Maximum permissible pressure drop of intercooler kPa 10
Minimum permissible flow of air cleaner (CA6DM2-42E4) m³/h 1800
Turbocharging under high-altitude conditions: The performance of the diesel engine remains basically unchanged
when the altitude is below 2,000 m. When the diesel engine is running in plateau sections and hilly countries with
altitudes above 2,000 m, its power will drop and fuel consumption will also increase. In areas with altitudes above
2,500 m, a turbocharged diesel engine of special configuration should be used to ensure operational safety of the
machine.
Electrical system parameters

Name Value
Recommended minimum battery capacity 195Ah
Starter 24V, 7.5kW
Alternator 28V, 75A
Alarm pressure (70±7) kPa
Oil pressure sensor (on oil gallery)
Indicated pressure (0~1000) kPa
Alarm temperature (105~107)℃
Coolant temperature sensor (on thermostat body)
Indicated temperature (40~120)℃
A/C compressor (electromagnetic clutch) 24V, 42N
Air heater 24V, 3.6kW
Tightening torques and methods of major threaded parts
 High strength bolts
 The high strength bolts used on the CA6DM2 series diesel engines are tightened using the torque/angle
method.
 The bolts applicable to torque/angle method can only be used for 3 times. Those that have been used
repeatedly for more than 3 times or with lengths exceeding their service limits should be replaced.
2-2
 Service limit length = overall length (including bolt head)
 When using the torque/angle method to tighten a bolt, draw a line on the bolt head and the body of the
connected part with a marker pen to help determine the angle after the bolt has been tightened to the
specified torque in 1st step.
 For high strength bolts to be tightened using the torque/angle method, be sure to lubricate them by applying
engine oil or molybdenum disulfide to their threads and lower ends of flanges during installation.
 See Table 1-1 for the tightening methods and torques of the bolts to be tightened using the torque/angle
method.
Table 1-1 Tightening Methods for the High Strength Bolts Used on the CA6DM2 Series Diesel Engines
Socket Tightening method Service

Name Quantity x size wrench 2nd Free length limit Remark
size 1st step 3rd step length
step
In each step,
Main bearing tighten in the
14×M18×2.5 24 130N·m 210 º 192±0.1 194
bolt sequence shown
in Figure 1-1.
In each step,
Bolt-cylinder tighten in the
26×M16×1.5 18 90N·m 210 º 240º 225.3±0.1 228
head sequence shown
in Figure 1-2.
Tighten on each
Connecting rod
12×M14×1.5 21 60N·m 150 º 82.9±0.1 83.7 connecting rod in
bolt
order.
In each step,
Flywheel bolt 12×M15×1.5 21 75N·m 180 º 104.3±0.1 105.3 tighten diagonally
in pairs.
In each step,
Damper bolt 8×M14×1.5 21 60N·m 210 º 110.8±0.1 112 tighten diagonally
in pairs.
Figure 1-1 Tightening Sequence of Main Bearing Bolts
2-3
Figure 1-2 Tightening Sequence of Cylinder Head Bolts
 Other bolts and nuts
 Exhaust pipe mounting bolt 12×M10 13mm socket wrench
Tighten symmetrically to 60±5N·m.
 Compressed air pump gear nut l×Ml8 27mm socket wrench
Tighten to 155±10N·m at a time.
 Intermediate gland nut-fuel injection pipe adapter 6×M22 24mm socket wrench
Tighten to 50~55 N·m at a time; tighten them and injector plate bolts alternately.
 Piston cooling nozzle adapter bolt 6×M8 13mm socket wrench
Tighten to 27±5 N·m at a time.
 Generic bolts
Table 1-2 Tightening Torques of Generic Bolts

Thread
M6 M8 M10 M12 M14 M16 M18
Strength grade
8.8 8±2.5 22±5 39±7 70±10 115±15 176±20 235±25
10.9 13±2.5 31±5 58±7 100±10 162±15 240±20 330±25
Caution
★ The bolts in this manual having special provisions on torque values are not subject to this table; the values in
the table are based on clean, dry, oilfree threads. When lubricating oils are used, the torque values should be
decreased by 10%; if new coated bolts are used, the torque values should be decreased by 20%; when
aluminum screw holes are used, the torque values should be decreased by 20%.
 Torque provisions
 All bolts (nuts) used on the CA6DM2 series diesel engines are metric bolts (nuts).
 Be sure to note the following during use: Ensure that the bolts on the diesel engine are fitted in their original
positions. When a bolt needs to be exchanged, the bolt and the replacement bolt must have the same size and
strength. Nonconforming bolts may result in damage to the diesel engine.
 The strength grade of a bolt can be identified by the grade number marked on the bolt head or corresponding
nut surface. Larger values mean higher bolt strengths.
 The CA6DM2 series diesel engines mainly use hexagon flange face bolts (automobile standard parts). Bolt
nomenclature:
Bolt length mm
OD of thread mm
Hexagon flange bolt
[36]
Selection of diesel oil
2-4
Sulfur content of diesel oil has a direct impact on emissions from diesel engines; sulfur content of diesel oil used
on diesel engines should be less than 0.05%. The grade of the diesel oil used on the diesel engine should be
determined according to ambient temperature conditions. Diesel oil with low freezing point should be used in cold
winter and on the contrary in summer. Customers can also select diesel oil according to the recommendations in
Table 1-3.
Table 1-3 Relationships between Diesel Oil Grades and Applicable Minimum Air Temperatures
Recommended min. temperature
Oil grade Recommended oil grade when the oil can be used
5# Above 8℃
0# Above 4℃
-10# Above -5℃

-20# Above -14℃
-35# Above -29℃
-50# Above-44℃
Diesel oil must be kept highly clean and prevented from being contaminated by dust and foreign materials. Before
adding diesel oil into the fuel tank, allow it to settle for more than 72 hours and use the upper layer of oil. This is
extremely important to preventing injection pump plunger from early wear.
Selection of lubricating oil
To ensure normal operation and long life of the diesel engine and improve its emissions, please use the special
―Xichai‖ grade CH-4 lubricating oil. If Xichai lubricating oils are not used, use of CH-4 multigrade lubricating oil
compliant with API requirements is recommended. Appropriate engine oil viscosity grade is determined
according to the minimum outside temperature when the diesel engine is cold and the maximum outside
temperature when the diesel engine is running. Use the data in the ―Minimum‖ temperature column in the
following table to determine the viscosity of the lubricating oil required to start a ―fully cold‖ diesel engine. Use
the data in the ―Maximum‖ temperature column in Table 1-4 to select the viscosity of the lubricating oil for the
expected highest operating temperature.
Table 1-4 Applicable Operating Temperature Ranges of Lubricating Oils

Recommended min. temperature when the oil
Oil grade Recommended oil grade can be used
Diesel – oil API CH-4 SAE 15W-40Diesel- oil Ambient temperature –20℃～40℃
API CH-4 SAE 10W-40Diesel- oil Ambient temperature -25℃～40℃
Selection of coolant
Like fuel and lubricating oil, coolant is also important to the diesel engine. By selecting coolant and maintaining
the cooling system correctly, many troubles related to the system (e.g. diesel engine overheating, water pump
leakage, radiator clogging, and cylinder liner cavitation) can be avoided. Coolant must be used on the CA6DM2
series diesel engines!
 In addition, coolant must be used all year round. Mixing with coolant of other brand during use is prohibited.
Users should select types of the coolants in the table below according to the temperature conditions of the
areas where their vehicles will be used:
2-5
Table 1-5 Types of Coolants Selected under Different Temperature Conditions
Recommended min. Remark
Oil grade temperature when the oil can be
Recommended oil grade used
Engine coolant Freezing point -20℃ -15℃～-28℃ As per the local conditions
Freezing point -35℃ -25℃～-40℃
Freezing point -45℃ -35℃～-50℃
Freezing point -8℃ -15℃以上
 Coolant check and change period: As shown in Table 1-6, the check and change period are based on
kilometrage or term (whichever comes first). Clean the cooling system during coolant change.
Table 1-6 Coolant Check and Change Period

Check and change kilometrage (10,000km) Check and change term (year)
≥10 ≥2
Sealant
 Before assembling the following parts, be sure to apply silicone rubber plane sealant between their sealing
surfaces:
 Upper surfaces of junctions of gear chamber cover plate and cylinder block, gear chamber cover-flywheel
housing and gear chamber cover plate, cylinder block and gear chamber cover-flywheel housing and gear
chamber cover plate with cylinder head gasket, crankshaft front oil seal seat, and cylinder block
 See Figure 1-3 for the method for applying sealant between sealing surfaces of the gear chamber cover plate
and cylinder block.
Cylinder block
Scope of sealant application
between gear chamber cover plate
and cylinder block sealing surface
Gear chamber cover

plate
Figure 1-3
 Be sure to apply a circle of sealant to both upside and underside of the rear end (periphery of gear chamber)
of the cylinder head gasket (see Figure 1-4).
2-6
Figure 1-4
 Before installing the cylinder head cover and its gasket, coat the cylinder head assembly portion in contact
with the arc surface of the semicircular cover and the seams on the upper plane between the cylinder head
assembly and the semicircular cover (total 4 points at front and rear ends) with Tianshan Kesaixin 1596F
silicone rubber plane sealant (see Figure 1-5).
Figure 1-5
 When fitting the gear chamber cover plate, coat threaded portions of the 3 bolts with just enough silicone
rubber. Take care not to allow silicone rubber to fall into the gear chamber.
 Before assembling the following parts, apply anaerobic thread locking sealant between their sealing surfaces:
 Oil filter connecting thread and oil cooler body
 4 studs used to fasten intermediate flange of injection pump
 Bowl plug
2-7
II. Construction
Outside drawing of the CA6DM2 diesel engine
High-pressure fuel Engine harness

Oil filler rail assembly assembly
Water outlet High pressure fuel

injection pump
Air inlet2 assembly
Power steering oil pump

Air heater assembly assembly
Alternator Secondary fuel filter

assembly 1 assembly
A/C compressor
Gear-reduction
assembly starter
Oil-gas separator assembly
Engine control unit assembly (ECU)

[3]
Intake Side View of Diesel Engine
Air pump outlet

Turbocharger assembly
Turbocharger inlet pipe

assembly
Turbocharger return
pipe assembly Oil cooler assembly
Air compressor inlet
Air compressor outlet Full-flow oil filter

assembly
Air compressor
assembly
Water pump inlet
Centrifugal oil filter

assembly
Exhaust Side View of Diesel Engine
2-8
III. Operations before Removal and after Installation

 Operations before removal
 Place chocks.
 Tilt up the cab.
Warning
★ Chocks should be inserted firmly so as to prevent the vehicle from moving.
★ Do not take out chocks until all operations have been finished.
★ After disconnecting the fuel hose, be sure to place it and the fuel return hose so that their ends are above the
fuel tank and seal the hoses with plugs. Otherwise fuel will flow out of the tank thus causing a fire.
★ You must not drain engine coolant until it cools down so as to avoid burns.
 Operations after installation
Follow the reverse order of operations before removal.
2-9
IV. Mounting Units
4
6
[5] T
7
2
[10] 12 T
14 [11]
13 Connected with
Á¬
½engine
· ¢¶ ¯» ú
Ó 15
16
19
20 [21]T
22
Connected with
Á¬½ ³ µ
Ó
frame ¼Ü
18
17
9
T 8
Disassembly sequence
1. Nut 12. Bolt
2. Bottom plate-rear mounting 13. Right front mounting support
3. Bolt 14. Bolt
4. Upper backing plate-engine rear mounting 15. Left front mounting support
5. Bolt 16. Engine front mounting upper cover assembly
6. Engine rear mounting bracket backing plate 17. Nut
7. Rear mounting bracket cushion assembly 18. Shim
8. Nut 19. Bolt
9. Lower backing plate-engine front mounting 20.Engine front mounting cushion assembly
10. Bolt 21. Bolt
11. Bolt 22. Engine front mounting bracket
Assembly sequence
Follow the reverse order of disassembly.
2-10
Tightening torques Unit: N·m

Area Part to be tightened Tightening torque
1 Lock nut 280~320
5 Bolt (engine rear mounting bracket-frame) 145~210
8 Lock nut 240~320
21 Bolt (engine front mounting bracket-frame) 240~320
Inspection method
 All the 4 bolts ([5], [10], [11] and [12]) are precoated with
thread locking sealant and can not be reused.
Operations before removal of engine mounting units
 Before removing mountings, disconnect the engine from related links to vehicle oil circuit, water circuit, air
circuit, and wiring first.
 Dismount the cross member under the transmission, disconnect the transmission from the flywheel housing,
lower the transmission, and then hoist the engine before removing the mountings.
Warning
★ When raising the engine, do not allow it to impact the frame and cab.
2-11
V. Cylinder Block Unit
36
10 9
11
13
12 14
16
15
[32] [31]
5
30 T
7
[8] 6
[19] 3
[24] 20
21 2
1
17
25
26
18
4
29
[33]
[23]
27
28 22 T
35
34
1. Hexagon flange face bolt 19. Gear chamber cover plate
2. Hexagon flange face bolt-thin rod 20. Emblem rivet
3. Rear lug 21. Nameplate
4. Hexagon flange face bolt 22. Bolt-piston cooling nozzle assembly
5. Bolt-timing idler gear shaft 23. Piston cooling nozzle assembly
6. Hexagon flange face bolt 24. Cylinder liner
7. Hexagon flange face bolt 25. O-ring rubber seal
8. Gear chamber cover-flywheel housing 26. O-ring rubber seal
9. Hexagon flange face bolt 27. Hexagon flange face bolt
10. Rubber plug of flywheel housing 28. Crankshaft front oil seal seat
11. Cross recessed pan head screw 29. Cylinder block component
12. Pointer-flywheel housing 30. Main bearing bolt
13. Hexagon flange face bolt 31. Rear bearing cap
14. Stud bolt-flywheel housing 32. Main bearing cap
2-12
15. Hexagon flange face bolt 33. Thrust plate
16. Cover plate-flywheel housing 34. Main bearing shell lower half
17. Hexagon flange face bolt 35. Main bearing shell upper half
18. Hexagon flange face bolt 36. Cylinder block
Assembly sequence
Inspection standard
Standard Limit
Area Maintenance item Method of correction
value value
Tolerance of coaxiality Ø0.20 - -
between inner cylindrical
8 surface of rabbet fitting clutch
housing on flywheel housing
and crankshaft center
Projection of cylinder liner (0.08~0.14) - -
24 boss beyond upper surface of
mm
engine block
Length of main bearing bolt (192±0.1)mm 194 Bolts with lengths exceeding their service limits should be
replaced.
30
Note: Service limit length = overall length (including bolt
head)
Main bearing shell - - In the following cases continued use is allowed:
34,3 In the following cases continued use is not allowed:

5
2-13
Tightening torques
Area Part to be tightened Tightening torque (N.m) Remark
22 Bolt-piston cooling nozzle
Tighten to (27±5)N.m at a time. -
assembly
30 Main bearing bolt Torque/angle method: 1st step: The bolts applicable to torque/angle method can only
130N.m; 2nd step: 210° be used for 3 times; those that have been used
repeatedly for more than 3 times should be replaced.
When using the torque/angle method to tighten a bolt,
draw a line on the bolt head and the connected part
with a marker pen to help determine the angle after the
bolt has been tightened to the specified torque in 1st
step.
Lubricants
Area Location of application Specified lubricant Amount
8 Sealing surface of gear chamber cover-flywheel Silicone rubber plane sealant As needed
housing and gear chamber cover plate
(See ―Inspection method‖
Sealing surfaces between upper surfaces of of this section for the
junctions of cylinder block, gear chamber coating method)
cover-flywheel housing, and gear chamber
cover plate and cylinder head gasket
19 Sealing surface of gear chamber cover plate and Silicone rubber plane sealant As needed
gear chamber cover-flywheel housing
Sealing surface of gear chamber cover plate and of this section for the
cylinder block coating method)
Sealing surfaces between upper surfaces of
junctions of cylinder block, gear chamber
25 Internal and external surfaces of O-ring rubber Clean engine oil As needed
seal
26 Internal and external surfaces of O-ring rubber Clean engine oil As needed
seal
28 Sealing surface of crankshaft front oil seal seat Silicone rubber plane sealant As needed
and cylinder block
30 Bolt thread and lower end face of flange Clean engine oil or molybdenum As needed
disulfide
33 Fitting surface of thrust plate and cylinder block Clean engine oil As needed
34 Internal surface of main bearing shell upper half Clean engine oil As needed
35 Internal surface of main bearing shell lower half Clean engine oil As needed
36 Sealing surface of gear chamber cover plate and Silicone rubber plane sealant As needed
cylinder block
Sealing surfaces between upper surfaces of of this section for the
junctions of cylinder block, gear chamber coating method)
Sealing surface of crankshaft front oil seal seat
and cylinder block
2-14
Special tool
Area Name and shape of tool Part number Purpose
24 Engine cylinder liner extractor Removing engine
cylinder liners
Inspection method
 Installation of gear chamber cover-flywheel housing [8]

[8]
 Put the 2 dowel holes on the flywheel housing on the dowel
pins on the cylinder block.
 Coat the gear chamber cover-flywheel housing [8] and the

gear chamber cover plate [19] with sealant as shown in the
figure at left.
 When installing the flywheel housing, be sure to tighten the

bolts connecting it with the cylinder block diagonally.
Scope of sealant application between

gear chamber cover plate and cylinder  Installation of gear chamber cover plate [19]
block sealing surface
[36]  Coat the sealing surface of the gear chamber cover plate [19]
and the cylinder block [36] with sealant as shown in the
figure at left.
Cover plate
 Installation of piston cooling nozzle [23]
 Before fitting the piston cooling nozzle, assemble the piston

and connecting rod assembly first.
 After the piston cooling nozzle assembly has been installed

into the cylinder block, be sure to check its jet direction.
[23]
2-15
 Removal and installation of cylinder liner [24]
[24]
 The special tool (engine cylinder liner extractor) is required
when removing cylinder liners.
 When installing a cylinder liner, you need to replace both the

seal ring (1 piece) on the cylinder liner and the water
retaining rings (2 pieces) on the cylinder block and apply
engine oil to the replacement parts; when installing the
cylinder liner, you must place the cylinder block upright and
drive the cylinder liner in until a clear sound is heard
indicating that the liner has been installed in place.
：Engine cylinder liner extractor
 Installation of main bearing caps [31] and [32]
 When fitting main bearing caps, pay attention to their pairing

marks. Reversed front and rear of bearing cap is not allowed.
 When fastening main bearing caps, tighten main bearing bolts

sequentially and evenly from neutral position to two ends in 2
steps (as shown in the figure).
 The gaps on the bearing shells on the main bearing caps and
those on the cylinder block should be on the same side, i.e.
shell gaps are corresponding.
 Installation of thrust plate [33]
 When installing thrust plates on main bearing caps, note that

they must be installed so that their oil passages are positioned
correctly (as shown by the red circles in the figure at left) in
order to keep the oil circuit unobstructed.
[33]
2-16
VI. Cylinder Head and Cylinder Head Cover Unit
15
14
6 4
18 8 7 5
2
17
1
3
14
19
10 9
13
11
12
16
1. Gear chamber cover plate bolt 9. Inlet box cover plate bolt 17. Cylinder head bolt
2. Gear chamber cover plate 10. Inlet box cover plate 18. Cylinder head
3. Gear chamber cover plate gasket 11. Inlet box cover plate gasket 19. Cylinder head gasket
4. Camshaft sensor cover plate bolt 12. Front lug bolt
5. Copper washer 13. Front lug
6. Camshaft sensor cover plate 14. Cylinder head cover bolt
7. Camshaft sensor plug 15. Cylinder head cover
8. O-ring rubber seal 16. Semicircular pad
Assembly sequence
Inspection standard
Method of
Area Maintenance item Standard value Limit value
correction
17 Tightening using 90Nm→210°→240°

torque/angle method
19 Replacing cylinder When cylinder head needs

head gasket to be removed each time
you maintain the engine,
be sure to replace cylinder
head gasket.
2-17
Inspection method
 The assembly sequence of cylinder head bolts is shown in the

figure. Follow the reverse order of tightening during
disassembly.
2-18
VII. Piston-Connecting Rod Unit
5 9
4 3
10 2
T
1
T
11 1
1. Connecting rod bolt 5. Piston 9. Spiral expander oil ring assembly
2. Connecting rod cap 6. Connecting rod body 10. Connecting rod bearing shell upper half
3. Piston pin snap ring 7. Top compression ring 11. Connecting rod bearing shell lower half
4. Piston pin 8. Intermediate compression ring
Assembly sequence

7┐
8┤→5→6→4→3→10→11→2→1
9┘
Inspection standard
Standard Limit
value value
The high strength bolts to be tightened using torque/angle
Measuring overall length method can only be used for 3 times. Those that have
1 82.9±0.1mm 83.7mm
(including bolt head) been used repeatedly for more than 3 times or with lengths
exceeding their service limits should be replaced.
Tightening torque
Area Part to be tightened Tightening torque Remark
1 Connecting rod bolt 60Nm+150° —
2-19
Lubricating oil
Threaded portion of connecting rod bolt Wuxi Diesel brand, API Just enough
1
CH-4Multi-grade lubricant
External surface of piston pin Wuxi Diesel brand, API Just enough
4
Internal surface of connecting rod bearing shell Wuxi Diesel brand, API Just enough
10,11
Special tool
Piston clamp Pushing piston and connecting rod
assemblies into cylinder tubes
Inspection method
 Removal and installation of a piston-connecting rod unit
 Turn the crankshaft until piston-connecting rod unit in a

cylinder is at its bottom dead center.
 Loosen the connecting rod bolts, and remove the connecting

rod cap and connecting rod bearing shell upper half.
 Push the piston and connecting rod assembly out of the

cylinder tube with a wooden or rubber hammer.
2-20
 The direction of arrow on the piston top should be the same

as that of the forward mark on the connecting rod and points
to the front end of the engine.
 Piston ring gaps are positioned at a 120° angle with each

other.
 The piston pin surface should be oiled. The pin should be

installed into the piston pin hole and connecting rod small
Gap of top end hole by rotating it gently.
compression ring
Gap of type I steel

oil ring
Gap of second
compression ring
 Install the connecting rod bearing shell upper and lower

halves into the connecting rod cap and connecting rod body
big end hole respectively, place the locating lip in
corresponding locating slot on the bearing shell support, and
force the bearing shell back against the seat surface of the
connecting rod big end hole firmly.
 Coat the internal surface of the bearing shell with just

enough lubricating oil.
 Put the piston-connecting rod unit into the cylinder block

from top of the latter, lock the area where piston rings are
installed with a piston clamp, and guide the piston into the
cylinder block.
：Piston clamp
 Turn the crankshaft until piston-connecting rod unit in a

cylinder is at its bottom dead center.
 Tighten connecting rod bolts according to installation

requirements.
2-21
VIII. Crankshaft-Flywheel Unit
9 10
7 6
8
T
3
4
5
T 2
1
12 13
14
11
1. Damper bolt 8. Poly V-belt pulley
2. Poly V-belt pulley and damper assembly 9. Ring gear
3. Flywheel bolt 10. Flywheel
4. Flywheel 11. Oil pump drive gear
5. Crankshaft assembly 12. Driving gear and flywheel dowel pin
6. Hexagon flange face bolt 13. Crankshaft timing gear
7. Silicon oil damper assembly 14. Crankshaft
Assembly sequence
11┐
14┤ 9┐ 8┐
12┤→5→ ┤→4→3→7┤→2→1
13┘ 10┘ 6┘
Inspection standard
Standard Limit
value value
Measuring overall length method can only be used for 3 times. Those that have been
1 110.8±0.1mm 112mm
(including bolt head) used repeatedly for more than 3 times or with lengths
Measuring overall length method can only be used for 3 times. Those that have been
3 104.3±0.1mm 105mm
(including bolt head) used repeatedly for more than 3 times or with lengths
2-22
Tightening torques
1 Damper bolt 60N·m+210° —
2 Flywheel bolt 75N·m+180° —
Lubricating oil
Wuxi Diesel brand ,API
1 Threaded portion of damper bolt Just enough
Wuxi Diesel brand ,API
3 Threaded portion of flywheel bolt Just enough
Inspection method
 Removal and installation of crankshaft-flywheel unit
 Use a torque wrench to install the poly V-belt pulley and

silicon oil damper assembly. In each step, tighten bolts
diagonally in pairs.
 Removal and installation of crankshaft-flywheel unit
 Use a torque wrench to install the flywheel with ring gear

assembly. In each step, tighten bolts diagonally in pairs.
 Before fitting the crankshaft assembly, carefully clean up

lubricating oil passage holes, and blow clean it. Foreign
materials are not allowed on journals.
 Drip 3-5 drops of lubricating oil on the internal surface of

the installed main bearing shell upper half; hoist the cleaned
crankshaft assembly; put main journals of the crankshaft on
corresponding main bearing seats gently and rotate the
crankshaft 2 turns lightly to allow lubricating oil to disperse
over surfaces of main journals.
2-23
IX. Camshaft and Timing Gear Unit
[5]
4 [17] 18
[6] A
B
7
1
[13] [14]
T 12
2 [11]
9 16T
[10] 8
[15]
1. Steering pump gear 11. Möbius timing idler gear assembly
2. Injection pump drive gear 12. Hexagon socket head cap screw
3. Camshaft and timing gear assembly 13. Timing idler gear shaft (II)
4. Hexagon flange bolt 14. Timing idler gear assembly
5. Timing idler gear shaft (III) 15. Crankshaft timing gear
6. Timing idler gear assembly 16. Fastening bolt-camshaft timing gear
7. Thrust plate-timing idler gear (III) 17. Camshaft timing gear
8. Driven gear of compressed air pump 18. Camshaft
9. Hexagon socket head cap screw A, B: Dowel pin
10. Möbius timing idler gear shaft (I)
Assembly sequence
Inspection standard
Area Maintenance item Standard value Limit value Method of correction

10,11 Fit clearance between Möbius timing 0.035~0.079
idler gear bushing [11] and gear shaft
[10]
10,11 Axial fit clearance between Möbius 0.060~0.120
timing idler gear [11] and gear shaft
[10]
13,14 Fit clearance between timing idler 0.035~0.079
gear bushing [14] and gear shaft (II)
[13]
13,14 Axial fit clearance between timing 0.060~0.120
idler gear [14] and gear shaft (II) [13]
5,6 Fit clearance between timing idler 0.035~0.079
2-24
gear bushing [6] and gear shaft (III)
[5]
5,6 Axial fit clearance between timing 0.060~0.120
idler gear [6] and gear shaft (III) [5]
15,11 Backlash between crankshaft timing 0.030~0.120
gear [15] and Möbius timing idler
wheel [11]
11，14 Backlash between Möbius timing 0.030~0.343
idler pinion [11] and injection pump
timing idler gear [14]
6,17 Backlash between camshaft timing 0.030~0.343
idler gear [6] and camshaft timing
gear [17]
Tightening torques
16 Fastening bolt-camshaft timing gear 60 N·m 120°
Tighten using angle
method. The bolts can
only be used for 3 times.
Those that have been used
repeatedly for more than 3
times or with lengths
exceeding their service
limits should be replaced.
12 Hexagon socket head cap screw (60±5 )N·m —
Special tool
17 Plug pin Ensuring location
holes on camshaft
gear and cylinder
head are aligned
Inspection method
 When installing the Möbius timing idler gear, you must make
sure the tooth on the crankshaft timing gear marked ―1‖
engages with the Möbius timing idler gear between the 2
teeth marked ―1‖.
 At the same time, ensure the mark ―2‖ on the timing idler
gear-injection pump aligns with that on the Möbius timing
idler gear shaft.
2-25
 When No. 1 cylinder is at its TDC position on the
compression stroke, align the location hole on the camshaft
gear with that on the cylinder head, insert the plug pin, and
tighten the timing idler gear-camshaft.
Plug pin
2-26
X. Valve Train
15
19 14
17 20
[3] 18 16
5 22
6 13
[4] 9
[28] [27]
21
[26]
[25]
8 7 24
10 [23]
30 29
[12] [11]
1. Hexagon flange bolt 11. Intake valve 21. Hexagon head plug
2. Rocker gear assembly 12. Exhaust valve 22. Copper washer
3. Intake valve bridge 13. Rocker shaft holddown (III) 23. Exhaust valve rocker assembly
4. Exhaust valve bridge assembly 14. Rocker shaft holddown (II) 24. Axial spacer of rocker
5. Valve cotter 15. Rocker shaft holddown (I) 25. Intake valve rocker assembly
6. Valve spring seat 16. Solenoid valve seat 26. Rocker shaft assemblies (No.
4, No. 5 and No. 6 cylinders)
7. Intake valve spring 17. Hexagon flange bolt 27. Rocker shaft assemblies (No.
1, No. 2 and No. 3 cylinders)
8. Inner spring of exhaust valve 18. Pressure plate of solenoid 28. Valve guide
valve
9. Oil seal assembly of valve guide 19. Brake solenoid valve assembly 29. Intake valve seat
10. Valve spring retainer 20. O-ring rubber seal 10.6X2.64 30. Exhaust valve seat
Assembly sequence
Inspection standard
Area Maintenance item Standard value
3,25 Clearance between intake valve bridge [3] and rocker ball seat [25] 0.3~0.35
4,23 Clearance between exhaust valve bridge assembly [4] and rocker ball 2.82~2.87
seat [23]
11,28 Clearance between intake valve [11] and valve guide [28] 0.023~0.052
12,28 Clearance between exhaust valve [12] and valve guide [28] 0.043~0.072
11 Recess of intake valve [11] on cylinder head bottom surface -0.15~0.15
12 Recess of exhaust valve [12] on cylinder head bottom surface -0.15~0.15
23,26 25,26 Valve rocker bushing [23][25] and rocker shaft [26][27] 0.014~0.099
2-27
23,27 25,27
Special tools
3,25 Feeler gauge Adjusting intake
valve
clearances
4,23 Feeler gauge Adjusting

exhaust valve
clearances
23,25 16mm special socket wrench Loosening and

tightening lock
nuts
5 Cotter remover Removing and

installing valve
cotters
Inspection method
 Install the rocker shaft holddown [15] with an ―F‖ mark onto
the 2 bolt holes on the rocker shaft and close to the front end
of the engine.
 When installing it, leave the direction of arrow facing the

front end of the engine.
 Install the rocker shaft holddown [13] with an ―R‖ mark onto
the 2 bolt holes on the rocker shaft and close to the rear end
of the engine.

2-28
 Install the rocker shaft holddown [14] with an ―M‖ mark onto
the bolt holes in the middle except those on the solenoid
valve seat.

 The rocker shafts [27] with a ―FRONT‖ mark are for No. 1,
No. 2 and No. 3 cylinders. When installing them, leave the
mark facing the front end of the engine.
 When installing the rocker shafts, leave the larger portions of

the bolt holes facing down.
 The rocker shafts [26] with a ―BACK‖ mark are for No. 4,
No. 5 and No. 6 cylinders. When installing them, leave the
mark facing the rear end of the engine.
 When installing the rocker shafts, leave the larger portions of

the bolt holes facing down.
 Tear off the flywheel housing plug and move the flywheel
starting gear to crank the diesel engine slowly. When the
flywheel housing pointer aligns with the ―0‖ scale mark on
the flywheel, the piston in No. 1 cylinder (close to the water
pump) or No. 6 cylinder is at its TDC position.
 Move the exhaust valve rocker of No. 1 cylinder. If loose,

No. 1 cylinder is at its top dead center on the compression
stroke. (At this time, you can see the ―TDC‖ scale mark on
the flywheel.)
 Using a 16mm special socket wrench and a screwdriver,

check or adjust intake valve clearances of No. 1, No. 2 and
No. 4 cylinders with the piston in No. 1 cylinder at its TDC
position on the compression stroke.
 Exhaust valves are driven by the longer rockers with spool;

intake valves are driven by the shorter rockers.
 Tighten lock nuts and recheck valve clearances.
 Intake valve clearance: 0.3mm
 Inspect or adjust valve clearances when the diesel engine is

cold (below 60℃).
2-29
16mm special socket wrench
a
Feeler gauge
Caution
★ The clearance value measured is correct when the feeler

gauge can slide between the intake valve bridge and the
rocker ball seat and an adhesion resistance is felt.
 Turn the flywheel counterclockwise (when viewed from the

rear end) until the valve clearance adjustment position mark
for ―No. 6 and No. 1‖ cylinders are seen on it (turn angle:
approx. 128°).
 Adjust exhaust valve clearance and brake clearance of No. 6

cylinder.
 Exhaust valve clearance: 3mm (with engine brake)
 Then turn 120° crank angle in turn and adjust exhaust valve
clearances of cylinders in the sequence of 6-2-4-1-5-3.
a
Feeler gauge
 Turn the crankshaft until the position of 360° crank angle is

reached (i.e. when the ―TDC‖ mark is seen again), adjust
intake valve clearances of No. 6, No. 3 and No. 5 cylinders.
a
Feeler gauge
2-30
Cotter remover
2-31
XI. Exhaust Manifold and Heat Shield Unit

2
1
6
5
8
3
4
1. Heat shield bolt 4. Exhaust manifold bolt sleeve 7. Middle section of exhaust
manifold
2. Heat shield 5. Front and rear sections of exhaust 8. Gasket-exhaust pipe
manifold
3. Exhaust manifold bolt 6. Exhaust manifold seal ring
Assembly sequence
2-32
XII. Oil Pan and Oil Dipstick Assembly
9
6
5
1
T
3
4 T
2 T
1. Oil dipstick 4. Assembling bolt (M8) 7. Corner plate-oil pan
2. Drain plug 5. Intermediate plate 1-oil pan 8. Oil pan
3. Assembling bolt (M12) 6. Intermediate plate 2-oil pan 9. Oil pan seal gasket
Assembly sequence

2 Drain plug 80
3 Assembling bolt (M12) 70
4 Assembling bolt (M8) 18~34
Lubricant
2 Oil dipstick seal Clean engine oil A little
2-33
XIII. Oil Collector Assembly

5
T
2 4
8 1
T
9
3
1
6 7
1. Hexagon flange face bolt (M10) 4. Shim-oil collector 7. Hexagon flange face bolt (M8)
2. Hexagon socket head cap screw
5. Mounting bracket assembly 8. Oil collector bracket
(M10)
3. Hexagon flange face bolt (M8) 6. Hexagon flange face nut 9. Oil collector assembly
Assembly sequence

1,2 Hexagon flange face bolt (M10) 36~63
3,7 Assembling bolt (M12) 18~34
2-34
XIV. Oil Pump Assembly
3
×
5
6
4
×
5
×
8
7
1
2
1 1
1
1. Hexagon flange face bolt-thin rod 4. Oil pump outlet pipe 7. Oil pump pressure limiting valve
assembly
2. Hexagon flange face 5. Seal ring 8. Seal washer
bolt-threaded rod
3. Oil pump assembly 6. Oil pump outlet pipe joint
Assembly sequence
Lubricant
5,8 Seal ring Clean engine oil Uniform coating on surface
2-35
XV. Full-Flow Oil Filter Assembly
1. Oil filter assembly
Assembly sequence
Lubricant
Seal of oil filter assembly Clean engine oil Uniform coating on surface
Special tool

Special oil filter remover
Inspection method
 Removal and installation of oil filter
 Using the special oil filter remover, loosen the oil filter
assembly. Installation is the reverse order of removal.
[Caution: Before installation, apply a little clean engine oil
around the oil filter seal ring.]
2-36
XVI. Oil Cooler
Operations before removal
 Remove the oil inlet and return pipe assemblies and the centrifugal oil filter assembly of the turbocharger.
 Remove the oil filter body.
1. Hexagon bolt 12. Copper washer 20×28 23. Seal washer

2. Spring washer 13. Spring 24. Bolt
3. Plain washer 14. Bypass valve 25. Bolt
4. Valve cap-oil cooler bypass valve 15. Connecting bolt of full-flow oil filter 26. Bolt
5. O ring-valve cap 16. Copper washer 30×40 27. Bolt
17. Hexagonal socket head plug
6. Valve seat-oil cooler bypass valve M27X1.5 28. Bolt
7. O ring-oil cooler bypass valve 18. Copper washer 27×35 29. Oil cooler body shim
19. Hexagonal socket head plug
8. Spring-oil cooler bypass valve M27X1.5 30. Bolt
9. External circlip 20. Copper washer 27×35 31. Oil cooler assembly
10. Valve-oil cooler bypass valve 21. Pressure regulating valve assembly 32. O ring
11. Valve seat 22. Seal washer
Assembly sequence
Lubricant
2-37
5 Rubber O ring of bypass valve Vaseline As needed
22 O ring rubber seal of pressure regulating valve Vaseline As needed
2-38
Inspection method
 Removal and installation of pressure regulating valve

assembly [21]
 First replace the valve, spring and O ring on the pressure

regulating valve assembly, next apply Vaseline to the O-ring
rubber seal, and finally install the pressure regulating valve
assembly into the oil cooler body.
 Removal and installation of oil cooler bypass valve [4]
 Remove the oil cooler bypass valve cap.
 First remove the oil cooler bypass valve and replace with
new spring, seal ring and valve body, next apply Vaseline to
the seal ring, and finally install the oil cooler bypass valve
assembly into the oil cooler body.
2-39
XVII. Positive Crankcase Ventilation System
10 11
9 2
7
4
3 5
1
1. Hexagon flange bolt 5. Hexagon flange face bolt 9. Connecting bolt
2. Type B worm drive hose clamp 6. Type B worm drive hose clamp 10. Oil-gas separator assembly
3. Oil return pipe support 7. Breather pipe support 11. Shim-breather
4. Oil-gas separator return pipe 8. Breather pipe
Assembly sequence
2-40
XVIII. Centrifugal Oil Filter Assembly
1. Hexagon flange face bolt 2. Centrifugal oil filter assembly 3. Shim-centrifugal oil filter
Assembly sequence
2-41
XIX. Tensioner Unit
5
4
[3]
[1] 6
1. Poly V-belt 3. Automatic tensioner assembly 5. Hexagon flange face bolt
2. Hexagon flange face bolt, spring 4. Idler pulley assembly 6. Front end train bracket
washer and plain washer assembly
Assembly sequence
Inspection standard
1 Tension of poly V-belt During initial installation, -
(340~460) N; after break-in and
during use, maintained at
(340-460) N
Special tool
Area Name and shape of tool Part number/specification Purpose
3 Socket wrench ―17‖17 mm socket head Removing and installing belts
2-42
Inspection method
 Replacing drive belt [1]
 Pull the automatic tensioner hard clockwise until the belt gets
loose, and then remove the belt.
[1]
 Pull the automatic tensioner hard clockwise, install the new
belt, and loosen the wrench to allow the belt to be tensioned
automatically.
：―17‖Socket head wrench
 Replacing automatic tensioner assembly [3]
 Remove the belt.
 Remove the used automatic tensioner and replace it with a

new one (as shown in the figure).
 Install the belt and pull out the plug pin on the automatic
[3] tensioner to allow the belt to be tensioned automatically.
2-43
XX. Low Pressure Fuel Pipes
1. Fuel inlet pipe assembly-fuel 3. Hollow bolt 5. Oil inlet pipe assembly
transfer pump to secondary filter
2. Fuel inlet pipe assembly-fuel 4. Fuel inlet pipe assembly-secondary 6. Hollow bolt
transfer pump to secondary filter filter to high-pressure fuel pump
Assembly sequence
2-44
XXI. High-Pressure Fuel Pump
1. Hexagon flange nut 5. Spring washer 9. Hydraulic and pneumatic rubber
O-ring
2. Dowel pin 6. Injection pump drive gear 10. High-pressure fuel pump
assembly
3. Sleeve 7. Hexagon flange face nut 11. Stud
4. Hexagon head nut 8. Adapting flange of high-pressure
fuel pump
Assembly sequence
11┐
│
9┘→8┐
├→10→6→5→4→3→2→1
7┘
Tightening torque Unit: N·m
3 Hexagon head nut 260~300 —
2-45
Inspection method
 When installing the high-pressure fuel pump assembly [10],

you need to ensure accurate fuel supply timing.
 Before installing the high-pressure fuel pump, set the engine

to top dead center on the compression stroke of No. 1
cylinder first.
 Place the dowel pin [2] between the 2 teeth with a ―△‖ mark
of the injection pump drive gear [6].
 Then install the high-pressure fuel pump.
 After the high-pressure fuel pump is installed, fit the sleeve

[3]; disengage the dowel pin [2] from the injection pump
drive gear [6] to prevent damage to the pin during starting.
2-46
XXII. Injectors
1. Fuel injection pipe 4. Injector plate bolt 7. Injector assembly
2. Intermediate gland nut-fuel 5. Spherical washer
injection pipe adapter
3. Fuel injection pipe adapter 6. Injector plate
assembly
Assembly sequence
4┐
│
5┘→6┐
├→7→3→2→1
3┘
Tightening torques
2 Intermediate gland nut-fuel injection pipe adapter (55~60)N·m
4 Injector plate 5N·m→90º
2-47
Inspection method
 Installing injector assembly [7]
 The adapter of the injector body and fuel injection pipe is

provided with a rubber O ring. Install the injector gasket
into the injector head and apply Vaseline to the rubber seal
of the injector evenly.
 Put the injector in the cylinder head, and install the injector
plate and its bolt.
 Observe from the adapter hole of the fuel injection pipe to

make sure the fuel inlet hole of the injector is at the center
of the adapter hole.
 Install the rubber seal of the fuel injection pipe adapter into
the cylinder head after applying Vaseline to the seal evenly,
and push the connection tube hard axially until it comes into
contact with the contact surface of the fuel inlet hole of the
injector.
 Tighten the injector plate bolt to 5N•m.
 Fix the fuel injection pipe adapter with an open end wrench
to prevent it from rotating when the gland nut of the fuel
injection pipe adapter is tightened, and then pretighten the
nut to 10N•m.
 Turn the injector plate bolt 90°.
 Using the special open end torque wrench, hold down the
gland nut of the fuel injection pipe adapter to (50~55) N•m.
 Tighten the injector terminal bolt to (1.8~2.2) N•m.
2-48
XXIII. Secondary Fuel Filter
[3]
1. Secondary fuel filter assembly 2. Secondary fuel filter bracket 3. Filter element
4. Base
Assembly sequence

3 Filter element 12~15 —
Lubricant
3 O-ring seal of filter element Engine oil Uniform coating on surface
2-49
Special tool
3 Special fuel filter wrench Removing and installing fuel
filter assembly
Inspection method
 Removing filter element [3]
 Using the special wrench, remove the secondary fuel filter

element. Clean the sealing surface of the secondary fuel filter
base.
：Special fuel filter wrench
[3]
 Fill the new secondary fuel filter element with clean diesel
oil, and apply a layer of engine oil to the seal ring evenly.
Caution
★ When installing the secondary fuel filter, use the special

wrench to tighten it after it comes into contact with the seal
ring (tightening torque: 12~15N·m). Excessive tightening
force will cause thread deformation or damage to the seal
ring of the filter.
2-50
XXIV. Turbocharger Unit
1. Hexagon flange face bolt 6. Hollow bolt 11. Hexagon flange
locknut
2. Pressure plate-turbocharger return 7. Shim 12. Turbocharger assembly
pipe
3. Hexagon flange face bolt 8. Hexagon flange face bolt 13. Shim-turbocharger
4. Shim-turbocharger return pipe 9. Inlet pipe flange gasket 14. Stud
5. Turbocharger return pipe assembly 10. Turbocharger inlet pipe assembly
Assembly sequence

1 Hexagon flange face bolt 22±5
6 Hollow bolt 40±5
2-51
11 Hexagon flange locknut 40±5
14 Stud 40±5
Lubricant
12 Oil inlet of turbocharger (50~60)ml
Before starting a new turbocharger, be sure to
add lubricating oil to it beforehand. Add clean
engine oil into the oil inlet connector and turn
the turbine impeller to allow oil to flow into the
bearing housing.
2-52
XXV. High-Pressure Fuel Rail Unit
1
5 1
6
5 1
1
5
1 1
1 1
3
2
1. Fuel injection pipe 3. Shim 5. Hexagon flange bolt
2. Hollow bolt 4. Fuel return pipe assembly 6. High-pressure fuel rail assembly
Assembly sequence
2-53
XXVI. Drain Cock
1. Split pin 2. Lever bracket-drain cock 3. Drain cock assembly
Assembly sequence
2-54
XXVII. Thermostat
11. Hydraulic and pneumatic rubber

1. Hexagon flange face bolt 6. Seal ring-thermostat O-ring
2. Hexagon head tapered plug 7. Hexagon head tapered plug O-ring
3. Hexagon flange face bolt 8. Bolt-thermostat 13. Minor cycle connection tube
4. Upper cover of thermostat 9. Bolt-thermostat O-ring
5. Thermostat assembly 10. Thermostat seat
Assembly sequence
Lubricant
11 O-ring rubber seal Vaseline As needed
13 Minor cycle connection tube Vaseline As needed
Removal and installation of thermostat assembly
 Removing thermostat assembly
 Remove radiator inlet hose.
 Remove steel return pipe of expansion tank.
 Remove heater connector.
 Remove coolant temperature sensor.
2-55
 Installing thermostat assembly
 Install in the reverse order of removal.
2-56
XXVIII. Water Pump
1. Hexagon flange bolt with fit

neck 7. Assembling bolt 13. Water pump housing
2. Water pump pulley 8. Water pump bracket 14. Water seal
3. Internal circlip 9. Assembling bolt 15. Water pump impeller assembly
4. Double sealed shaft pivot bearing 10. Bolt-water pump 16. Water pump shim
5. Water pump pulley flange 11. Hexagon head tapered plug 17. Rear cover of water pump
6. Assembling bolt 12. Hexagon head tapered plug O-ring
Assembly sequence
Lubricant
17 In O-groove on rear cover of water pump Vaseline As needed
Removal and installation of water pump assembly
 Removing water pump assembly
 Remove belt.
 Remove thermostat.
 Dismount intermediate adapter.
 Remove water pump inlet pipe adapter.
 Installing water pump assembly
Install in the reverse order of removal.
2-57
XXIX. Steering Pump Unit
1. Gasket-power steering oil pump 2. Power steering oil pump 3. Hexagon flange bolt
assembly
Assembly sequence
Assemble in the sequence of SNs. Disassembly is the reverse order of assembly.
2-58
XXX. Air Compressor Unit
5
12 10
6
11
13
2
6
1
5
7
4T
3
1. Hexagon flange face bolt 6. Copper washer 10×16 11. Copper washer 18×24
2. Hexagon flange face bolt 7. Oil inlet pipe assembly-air 12. Water inlet pipe assembly of air
compressor compressor
3. O-ring 8. Worm drive hose clamp 13. Water outlet pipe assembly of
air compressor
4. Air compressor assembly 9. Intake hose
5. Hollow bolt 10. Hollow bolt
Assembly sequence

4 Air compressor gear nut Tighten to 155±10 N·m at a time. -
2-59
XXXI. Generator Set
1. Nut 3. Nut 5. Generator
2. Bolt 4. Bolt
Assembly sequence
Inspection method
IC regulator
Schematic Circuit Diagram of Generator
2-60
Connection Definitions of Generator

Location Name Connection definition
1 B+ terminal To battery (+)
2 Harness socket To harness
3 N end Neutral point of generator
4 D+ end To charge indicator light
5 W end Speed sampling end
Precautions for removal of generator harness
 Disconnect B+ terminal [1] of generator.
Tightening torque for nut of B+ terminal: (6~7) N·m
Caution
★ When loosening the outer nut of the terminal, you need to

use a wrench to fix the inner nut of the terminal screw.
 Remove harness connector [2].
Caution
★ When removing the harness connector [2], first press the clip
on the lower part of the connector, and then remove the
connector.
2-61
XXXII. Starter Unit
1. #30 terminal 3. Bolt 5. Bolt 7. Starter
2. #50c terminal 4. Bolt 6. Nut
Assembly sequence
Inspection method
Control relay Solenoid switch Motor
Schematic Circuit Diagram of Starter
2-62
Connection Definitions of Starter

Location Terminal Specification Connection definition
1 #30 terminal M12 To battery (+)
2 #50c terminal M5 To start control end
Precautions for disconnecting the starter
◆ Disconnect #30[1] and #50[2] terminals of the starter.
Caution
★ When loosening the outer nut of the terminal, you need to use
a wrench to fix the inner nut of the terminal screw.
◆ Dismount starter mounting bolt [3], and remove engine

ground wire.
Caution
★ During assembly, remove foreign materials such as oil stain

from the fastening bolt so as to ensure reliable earthing of the
engine ground wire.
Engine ground wire
2-63
XXXIII. Trouble Diagnosis

System Diagram of Diesel Engine
The following sectional views are used to represent system flows of the diesel engine. Though parts vary a little
with applications and installations, the flows remain unchanged. The systems include:
Lubrication system
Cooling system
Intake and exhaust systems
Fuel system
Having a good knowledge of systems of the diesel engine will be of help to you in troubleshooting, use, and
maintenance.
2-64
Lubrication system
Oil gallery
Opening
pressure
Cylinder head
Pressure regulating valve of
Crankshaft main journal

oil gallery
Piston cooling nozzle

Full-flow oil filter
Bypass valve
Rocker shaft
Oil cooler
Injection pump
Compressed air
Rear end train

Turbocharger
Cam journal
pump
Rocker bushing
Rocker roller
Opening
Engine brake
Connecting rod
pressure
journal
Centrifugal oil filter
Pressure limiting valve of oil pump
Opening
pressure
Oil pan
Schematic Diagram of Lubrication System
1. Oil collector 2. Pressure limiting valve of oil pump 7. Inlet of oil cooler body
2. Oil pump 5. Return port of centrifugal oil filter 8. Inlet of oil gallery
3. Inlet of centrifugal oil filter 6. Upper oil passage on engine block 9. Drainage passage of pressure
regulating valve of oil gallery
2-65
Connection diagram of oil cooler assembly and Oil cooler bypass valve closed Oil cooler bypass valve
full-flow oil filter open
(Opening pressure: 3bar)
Oil circuit in oil cooler when oil cooler bypass valve is Oil circuit in oil cooler when oil cooler bypass valve is
closed wide open
Pressure regulating valve of oil gallery closed Pressure regulating valve of oil gallery open (opening
pressure: 4.8bar)
10. Oil cooler body 17. Oil cooler core

11. Full-flow oil filter 18. Oil passage after oil cooler core cools down
12. Pressure regulating valve of oil gallery 19. Outlet of full-flow oil filter
13. Bypass valve of oil cooler 20. Oil passage to inlet of oil gallery
14. Inlet of oil cooler core 21. Inlet of oil gallery
15. Oil passage after bypass valve is opened 22. Drainage passage port of pressure limiting valve of oil gallery
16. Inlet of full-flow oil filter
2-66
 Lubrication of turbocharger
1. Turbocharger inlet pipe 2. Turbocharger return pipe 3. Oil cooler body
 Lubrication of moving parts
Rear end face of engine block Front end face of engine block
1. Oil gallery of engine block 4. Oil passage for lubricating 7. Upper oil passage of cylinder
injection pump head at front end of engine block
2. Oil passage for lubricating 5. Upper oil passage of cylinder 8. Oil passage to piston cooling
crankshaft main journal (7) head at rear end of engine block nozzle (1 per cylinder)
3. Oil inlet for lubricating gear shaft 6. Lateral oil passage at front end
of engine block
2-67
Oil Passages on Crankshaft
 Lubrication of rocker gear
1. Upper oil passage in cylinder 5. Oil passage in exhaust valve 9. Oil passage in intake valve rocker
head rocker for lubricating roller for lubricating roller
2. Upper bearing shell cover of 6. Rocker shaft 10. Oil passage in intake valve
camshaft rocker
3. Hold-down bolt of rocker shaft 7. Oil passage in exhaust valve 11. Adjusting bolt of intake valve
rocker rocker
4. Oil gallery in rocker shaft 8. Adjusting bolt-exhaust valve
rocker
2-68
Cooling system
Water pump
Water pump inlet pipe

Oil cooler chamber on engine block
Radiator
Water distribution passage on
exhaust side Minor cycle connection
tube
Thermostat assembly
Outlet water
Minor cycle
Water jacket of engine temperature
block
Outlet water
Major cycle
Fully closed temperature
Wide
open
Cooling jacket of cylinder head Thermostat
Schematic Diagram of Cooling System
Water circuit in cylinder block Water circuit at connection of cylinder block and cylinder
head
1. Water pump outlet 3. Water distribution passage on exhaust 5. Refill port on exhaust side of No. 6
side cylinder
2. Oil cooler chamber 4. Main inlet passage of water jacket 6. Water passage on cylinder head (1 per
cylinder)
2-69
 Working process of thermostat
Closed (minor cycle) Half open Wide open (major cycle)
Thermostat
1. Thermostat 3. Flow back to water pump (minor cycle) 5. Flow into radiator (major cycle)
2. From cylinder head 4. Partial flow back to radiator 6. Partial flow back to water pump
Intake and exhaust systems
FAW Aoshen
Intake System (Figure I)
1. From intercooler 2Intake manifold (Integrated

with cylinder head )
2-70
Exhaust System (Figure II)

1. Exhaust valve 4. Air pump inlet 7. Seal ring of exhaust pipe
2. Exhaust manifold 5. Air pump outlet 8. Turbocharger turbine outlet
3. Turbocharger 6. Two routes into turbocharger
Fuel system
1 Fine fuel filter assembly 6High-pressure fuel pipe 11Fuel injector
assembly-high-pressure fuel pipe to
high-pressure fuel rail
2Fuel inlet pipe assembly- fuel delivery 7High-pressure fuel rail assembly 12Connection pipe of
pump to fine filter high-pressure fuel pipe
3Fuel inlet pipe assembly-filter to 8High-pressure fuel pipe assembly 13 Fuel passage connected to the
high-pressure fuel injection pump assembly (high-pressure fuel rail-connection pipe of fuel return pipe
high-pressure fuel rail )
2-71
4Fuel delivery pump 9Fuel return pipe assembly
5High-pressure fuel injection pump 10 Fuel return passage of fuel injector
assembly
2-72
Common troubles
Symptom Cause analysis Remedy
Hard starting or start failure of diesel (1) No fuel in fuel tank (1) Refuel.
engine
(2) Air in fuel system (2) Bleed system and check it for air
leak.
(3) Clogging in fuel system
(3) Remove and clean.
(4) Mounting angle of injection pump
gear incorrect (4) Check and adjust.
(5) Injection pump spray NG or injector (5) Replace injector.
pressure too low
(6) Replace piston ring and cylinder
(6) Serious blowby due to piston ring liner.
and cylinder liner badly worn
(7) Clean or replace piston ring.
(7) Loose seal due to piston ring sticking,
(3) Check wear on sealing cone between
loss of elasticity, fracture, etc.
valve and valve seat; regrind sealing
(8) Valve blowby surface of valve after repair; readjust
valve clearance.
(9) Low air temperature in winter
(9) Warm up by means of electrical
(10) Low battery voltage causing diesel
resistance air heater.
engine to fail to reach minimum
starting speed (10) Recharge until requirement is met.
(11) Electric circuit connector coming off (11) Check that wiring is firm.
(12) Starter gear’s failure to embed in (12) Check and repair magnetic
flywheel ring gear mechanism of starter.
(13) Brake solenoid valve failure (13) Check brake solenoid valve.
(14) Starting relay malfunction (14) Replace starting relay.
(15) Auxiliary shutdown switch of engine (15) Disconnect auxiliary shutdown
closed switch.
(16) Sensor fault (16) Examine related blink codes, and
then replace involved sensors.
(17) Out of neutral gear
(17) Shift into neutral position.
Diesel engine underpower (1) Insufficient air intake due to air (1) Dedust or replace filter element.
cleaner clogging
(2) Clean fuel line or replace filter
(2) Insufficient fuel supply due to fuel element.
line or fuel filter clogging
(3) Adjust.
(3) Valve clearance incorrect
(4) Check, clean or replace injector.
(4) Injector spray NG, nozzle clogging, or
(5) Check injector.
needle valve seizure
(6) Check cooling system and remove
(5) Fuel supply to injector insufficient
water scale and carbon deposit.
(6) Engine overheating
(7) Remove carbon deposit.
(7) Heavy carbon deposits in exhaust pipe
(8) Check sealing of valve and valve seat
or muffler
surface; check wear on piston ring
(8) Cylinder compression pressure and rubbing between cylinder liner
insufficient and piston ring; when necessary,
grind sealing cone of valve or replace
(9) Inferior fuel
cylinder liner, piston ring, and piston.
(10) Too high ambient temperature or
(9) Replace with fuel in compliance with
running in high-altitude areas
service specification requirement.
(11) Brake solenoid valve failure
(10) The actual power of the diesel engine
will drop when it is used in
high-altitude areas or places where
ambient temperatures are too high.
Therefore, customers should then
reduce load of the diesel engine
during use.
(11) Check brake solenoid valve.
2-73
Continued
Sudden shutdown of diesel engine (1) Entry of air into fuel system (1) Bleed fuel system.
(2) Fuel line or fuel filter clogging (2) Clean blocked parts or replace filter
element.
(3) High pressure fuel injection pump
assembly failure (3) Repair or replace high pressure fuel
injection pump assembly.
(4) Lock between crankshaft and bearing
shell (can be determined by rotating (4) If the problem is caused by
crankshaft) insufficient oil pressure or oil break,
repair grind journals and bearing
(5) Piston stuck in cylinder liner or
shells; when necessary, replace
scuffing of cylinder bore
involved parts.
(5) In the case of water pump failure or
exhaust temperature rise due to
combustion deterioration, check
water pump and belt; replace piston,
piston ring and cylinder liner; and
check and adjust injection pump and
injectors.
Abnormal sound is heard when diesel (1) Excessive clearance between valve (1) Check and adjust valve clearance
engine is running. and rocker causing valve gear to
(2) Check and modify.
make metal slaps.
(3) Replace worn piston, piston ring and
(2) Broken valve spring
cylinder liner.
(3) Slaps made between piston and
(4) Replace piston pin and connecting
cylinder and reduced as diesel engine
rod small end bush to ensure
warms up gradually
specified clearance.
(4) Light and sharp sound (particularly
(5) Replace main bearing shell and
clearer at idle) made due to excessive
connecting rod bearing shell to
clearance between piston pin and
ensure clearance.
connecting rod small end hole
(6) Replace complete set of gears.
(5) Metal slaps (heavy and powerful at
low speed) heard due to excessive (7) Replace crankshaft or camshaft thrust
clearances of main bearing shell and plate to ensure specified clearance.
connecting rod bearing shell when (8) Replace bearing, water pump or
diesel engine speed drops suddenly generator assembly
(6) Metal slaps heard at gear chamber (9) Check and replace.
when speed drops suddenly and
caused by excessive clearance of gear
due to wear
(7) Longitudinally moving slaps heard at
idle due to excessive axial clearance
of crankshaft or camshaft
(8) Continuous sound heard due to water
pump bearing or generator bearing
damage
(9) Rubbing between impeller and spiral
case due to bent turbocharger shaft or
deformed impeller
Diesel engine stumbling (1) Air in fuel system (1) Bleed fuel system.
(2) Excessive moisture entrained in (2) Check water content in fuel; replace
diesel oil with approved diesel oil.
(3) Injector malfunction (3) Check, clean or replace injector.
(4) Fuel line sealing NG (4) Check sealing of fuel lines from fuel
tank to injectors.
2-74
Continued
Diesel engine overheating (1) Black smoke
① Diesel engine overloaded ① Reduce load.
② Oil cooler core and oil passage ② Clean or replace cooler core; check
sticking and clogging or bypass valve and clean bypass valve.
failure
(2) Too high cooling water temperature
① Excessive dust on radiator fins ① Clean radiator fins.
② Coolant shortage ② Add coolant.
③ Thermostat failure leading to minor ③ Replace thermostat.
cycle of cooling water
④ Overhaul water pump; replace water
④ Water pump malfunction or loose pump pulley and adjust its tension.
water pump belt
⑤ Clean up blocked part.
⑤ Cooling water line clogged with dirt
⑥ Reduce load and vehicle speed.
⑥ Hot weather or too heavy load
Abnormal exhaust smoke of diesel Black smoke
engine
① Individual cylinders inoperative ① Locate inoperative cylinder; find out
causes of the problem and repair.
② Junction between fuel injection pipe
adapter and injector body not sealed ② Reinstall.
③ Overloading operation ③ Remove excess load.
④ Injector spray NG ④ Clean injector and replace it when
necessary.
⑤ Injection quality too poor
⑤ Replace with fuel of specified grade.
⑥ Insufficient air supply due to air
cleaner element clogging ⑥ Remove dust on air filter element or
replace element; in the case of a
⑦ Incorrect valve clearance, valve stem
turbocharged diesel engine, check if
stuck in guide due to scaling, or valve
rotor of turbocharger rotates smartly.
sealing cone blowby
⑦ Check valve clearance; clean valve
and valve guide hole; check and
grind sealing cone of valve.
Blue smoke
① Piston ring gaps located on the same ① Reassemble piston rings so that their
side. gaps are staggered 120° as required.
② Piston ring stuck or excessively worn ② Check and troubleshoot.
③ Valve stem oil seal coming off or ③ Replace valve guide oil seal
damaged
④ Repair turbocharger and keep good
④ Turbocharger lubricating oil seal sealing.
failure
⑤ Check brake solenoid valve.
⑤ Brake solenoid valve failure
White smoke
① Water seepage in cylinder liner ① Check sealing of cylinder head
② Excessive moisture in fuel gasket; check cylinder head for
cracks; check cylinder liner for
cavitation, perforation or cracks.
② Replace with fuel of specified grade.
2-75
Continued
Diluted lubricating oil (1) Piston ring sticking or wear out of (1) Clean sticking piston ring; replace
limit worn piston ring.
(2) Use of engine oil or diesel oil of (2) Replace with approved oil.
out-of-specification grade
(3) Check or replace fuel injector.
(3) Fuel entry into oil pan, too low
injection pressure of injector, or fuel
atomization failure
Too low oil pressure (1) Low oil in oil pan (1) Add oil.
(2) Indication of oil pressure gauge or (2) Replace oil pressure gauge or
sensor inaccurate pressure sensor.
(3) Excessive clearances between (3) Replace worn bearing shell or
crankshaft journals and main bearing crankshaft.
shells and connecting rod bearing
(4) Replace oil pump.
shells
(5) Clean pressure regulating valve or
(4) Oil pump gear, bearing and housing
replace spring.
plane worn
(6) Replace with oil of specified grade.
(5) Pressure limiting valve or pressure
adjusting spring broken (7) Replace oil filter assembly and oil
cooler assembly.
(6) Low oil viscosity
(8) Clean.
(7) Oil filter or oil cooler clogged
(8) Oil collector clogged
Engine oil and cooling water are mixed. (1) Lubricating oil level in oil pan rises
and oil whitens.
Replace water seal ring.
Water seal ring of cylinder liner
Replace cylinder head or engine block.
damaged
Replace cylinder head gasket.
Cylinder head or engine block cracked
Cylinder head gasket ablated
Engine oil and cooling water are mixed. (1) Engine oil in cooling water tank
Oil leak due to cracked cooler Replace oil cooler assembly.
assembly
Replace seal gasket.
Cooler seal gasket damaged
Turbocharger malfunction (1) Black smoke

① Air leak in intake and exhaust lines ① Check intake and exhaust pipes for
cracking and gaskets for good
② Turbocharger bearing damaged
sealing.
② Replace turbocharger assembly.
Turbocharger malfunction (2) Abnormal sound from and vibration

of turbocharger
① Exhaust turbine or air pump blade ① Replace turbocharger assembly.
deformed or damaged
② Replace turbocharger assembly.
② Shaft seizure due to poor lubrication
③ Replace turbocharger assembly.
of turbocharger bearing
③ Entry of foreign materials into
turbocharger impeller
Engine trouble (1) Starter does not rotate. Replace starter assembly.
2-76
Continued
Engine trouble (2) Starter rotates weakly.

① Bearing bush worn ① Replace starter assembly.
② Poor brush contact ② Replace starter assembly.
③ Commutator dirty or singeing ③ Replace starter assembly.
④ Segment coming off ④ Replace starter assembly.
⑤ Friction clutch slipping ⑤ Replace starter assembly.
⑥ Battery undercharge or too low ⑥ Charge or replace battery.
capacity
Engine trouble (3) Difficult gear retraction due to switch Replace starter assembly.
contact piece burning out and
sticking
Injector malfunction (1) Less or no injection

① Needle valve stuck with valve body ① Replace injector.
② Needle valve and valve body ② Replace injector.
seriously worn
③ Replace injector.
③ Solenoid valve coil burned out
Injector malfunction (1) Serious fuel leak

① Return spring broken ① Replace injector.
② Needle valve and valve seat surface ② Replace injector.
damaged.
Injection pump malfunction (1) Insufficient or no fuel supply

① Air in fuel supply system ① Bleed.
② Pumping gear in fuel transfer pump ② Replace fuel pump.
worn
③ Overhaul, clean or replace spring.
③ Delivery valve stuck or spring broken
④ Replace fuel pump.
④ Delivery valve rod body and sealing
⑤ Replace fuel pump.
surface worn
⑥ Replace diesel filter element.
⑤ Fuel pump plunger worn or spring
broken ⑦ Replace fuel pump.
⑥ Low inlet pressure
⑦ Fuel quantity control unit damaged
Injection pump malfunction (1) Internal leakage of injection pump Replace fuel pump.
plunger core housing or oil pan level
rise
High-pressure fuel rail malfunction (1) Sensor failure Replace high-pressure fuel rail.
(2) Spill valve failure Replace high-pressure fuel rail.
Compressed air pump malfunction (1) Insufficient air pumping due to (1) Remove scaling and replace damaged
exhaust valve scaling, broken air parts.
valve spring, broken piston ring or
(2) Overhaul and replace parts.
cylinder liner wear
(3) Overhaul and replace parts.
(2) Excessive engine oil outflow due to
stuck or broken piston ring, cylinder
liner wear or return line clogging
(3) Abnormal sound made due to serious
wear of air pump crankshaft and
bearing or piston hitting cylinder
head
2-77
Continued
Fuel consumption increase (1) Resistance in intake system increased (1) Check air cleaner element.
(2) Serious leakage in fuel system (2) Service fuel system and inspect lines
for good sealing.
(3) Injector out of order
(3) Overhaul injector; repair or replace.
(4) Serious wear inside diesel engine
(4) Check wear of cylinder liner, piston
and piston ring, sealing of valve and
valve seat, and wear of moving parts
and repair.
Oil consumption increase (1) Serious external oil leakage (1) Check oil leaks on exterior of diesel
engine and front and rear oil seals of
(2) Air cleaner element clogging, high
crankshaft, etc.; replace damaged
intake vacuum of compressed air
parts.
pump , or reverse oil blowby
(2) Clean or replace air cleaner element.
(3) Valve guide excessively worn
(3) Replace valve guide.
(4) Excessive oil blowby of compressed
air pump (4) Service compressed air pump.
(5) Turbocharger seal ring failure (5) Replace turbocharger seal ring.
(6) Diesel engine cylinder liner, piston, (6) Repair diesel engine; replace
piston ring and valve sealing cone, damaged parts.
etc. seriously worn
2-78
XXXIV. Operating Instructions

Abbreviations in this manual
APl……American Petroleum Institute h……Hour
℃……Degree Celsius mm……Millimeter
GVW……Gross Vehicle Weight MPa……Megapascal
Hg……Mercury Column N.m……Newton·Meter
Ps……Horsepower ppm……Part per Million
H 2 0……Water r/min……Revolutions per Minute
kg……Kilogram S.A.E……Society of Automotive Engineers (U.S.A.)
km……Kilometer L……Liter
kPa……Kilopascal min……Minute
How to identify the meaning of your diesel engine code
Emissions compliant with EU Stage III regulations
Representing 1/10 rated power (HP)
Serial number
M series
Diesel engine
Number of cylinders
Product code of FAW Group
Notices for users of new diesel engines
 For a new diesel engine used on a vehicle, its speed should be limited within 80% of nominal value within
the first 2,000 km (approx. 40h).
 Perform routine maintenance according to Chapter 3.
 For a new engine, be sure to check its oil pressure gauge, temperature gauge, warning indicator light and
other meters after use so as to ensure their normal operation.
 If the oil pan is not filled with lubricating oil, do the job as required.
 If the cooling system has been filled up with coolant, check properties of the liquid as per the requirements in
Chapter 1. If unsatisfactory, drain it and refill with approved coolant.
Diesel engine starting
 Disengage the diesel engine from its drive or set the transmission to the neutral position.
 Turn the start button to start the diesel engine.
 To prevent damage to the starting motor and protect the battery, the engaging time of the motor should not
exceed 30 seconds at each start attempt and the interval between 2 consecutive attempts should at least be 2
2-79
minutes.
 The oil pressure gauge must display a reading within 15 seconds after the engine is started.
 After a diesel engine cold start, rev up slowly to ensure that bearings are lubricated adequately and that the
oil pressure is stable.
 Before running the engine under load, idle it at 700-800r/min for 3~5 minutes first.
Starting at low temperature
At temperatures above -5℃, the diesel engine generally can start up smoothly without requiring any preheating
measure, but starting will become difficult as the air temperature drops in cold winter. Therefore, as an intake
heating measure for diesel engine starting in winter, we have selected the air heater among various types of intake
preheaters according to matching requirements of different types of vehicle.
The air heater uses a varistor to heat air entering cylinders so as to ensure that the engine can start up smoothly at
-5~-25℃ in winter. This heater (consumed power: 3.6kW) is a resistance wire. A 40-second continuous heating
process is allowed before starting. (Extended heating can cause the resistance wire to be burned out easily.)Press
the preheat button and the indicator light will come on, indicating that the air heater is energized and starts heating.
After about 40 seconds (not exceeding 50 seconds), the air heater has heated air to above 1,000℃. Then turn off
the preheat button and depress the start button rapidly to power on the starter thus allowing the diesel engine to
start smoothly.
Diesel engine running
At a speed below the maximum torque speed, the diesel engine should not run continuously for more than 1
minute at WOT (accelerator pedal is fully depressed).
Always observe the oil pressure gauge and coolant temperature gauge (refer to recommended working pressure
and temperature in Chapter 1 ―Main specifications and parameters of the diesel engine‖); if any abnormality is
found, stop the vehicle for inspection.
Caution
★ If the diesel engine runs continuously with the temperature of its coolant below 60℃ or above 100℃, damage
to the engine will result.
★ If the diesel engine is too hot, rev down or shift down or perform the both at the same time until the
temperature of the engine restores to within the normal working range; otherwise, service the engine
referring to ―Troubleshooting‖.
★ When the vehicle goes down a steep slope, you must use a transmission gear and brake to control vehicle
speed and diesel engine speed at the same time; when dashing up a slope with a transmission gear engaged,
the gear must correspond to the speed at which the vehicle is about to dash up the slope; if above speed is
high, you should shift the transmission into a higher gear so as to prevent the vehicle from reversely dragging
the diesel engine in this process thus causing engine overspeeding.
★ Diesel engine overspeeding (speed exceeds permissible maximum no load speed) will cause damage to the
engine.
Precautions for diesel engine shutdown
Before shutting down the diesel engine, remove load and run the engine at medium and low speeds for 3~5
minutes to allow turbocharger speed to significantly drop first. This helps protect the diesel engine and
turbocharger.
It is strictly forbidden to operate the diesel engine by means of ―acceleration-stalling-coasting in neutral‖.
If the diesel engine needs to be put out of service for a period of time, you need to clean it properly and take
2-80
necessary oilproof measures to prevent rusting.
2-81

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Jiefang

Lubrication system parameters

Oil pressure at idle speed (permissible minimum pressure) kPa ≥150

Oil pressure at rated speed (permissible minimum pressure) kPa 400

Opening pressure of oil gallery pressure regulating valve kPa 480

Oil temperature (at nominal speed) ℃ 90~110

Oil pan capacity (―LOW‖~―HIGH‖ on oil dipstick) L 31.1~34.1

Fuel supply system parameters

Intake system parameters

Electrical system parameters

Tightening torques and methods of major threaded parts

 High strength bolts

Socket Tightening method Service

Figure 1-1 Tightening Sequence of Main Bearing Bolts

 Other bolts and nuts

 Exhaust pipe mounting bolt 12×M10 13mm socket wrench

Tighten symmetrically to 60±5N·m.

 Compressed air pump gear nut l×Ml8 27mm socket wrench

Tighten to 155±10N·m at a time.

 Piston cooling nozzle adapter bolt 6×M8 13mm socket wrench

Tighten to 27±5 N·m at a time.

Table 1-2 Tightening Torques of Generic Bolts

-10# Above -5℃

Selection of lubricating oil

Table 1-4 Applicable Operating Temperature Ranges of Lubricating Oils

Table 1-6 Coolant Check and Change Period

Gear chamber cover

 Oil filter connecting thread and oil cooler body

 4 studs used to fasten intermediate flange of injection pump

High-pressure fuel Engine harness

Water outlet High pressure fuel

Power steering oil pump

Alternator Secondary fuel filter

Oil-gas separator assembly

Engine control unit assembly (ECU)

Intake Side View of Diesel Engine

Air pump outlet

Turbocharger inlet pipe

Air compressor inlet

Air compressor outlet Full-flow oil filter

Water pump inlet

Centrifugal oil filter

Exhaust Side View of Diesel Engine

III. Operations before Removal and after Installation

 Tilt up the cab.

★ Chocks should be inserted firmly so as to prevent the vehicle from moving.

 Operations after installation

Follow the reverse order of operations before removal.

IV. Mounting Units

Follow the reverse order of disassembly.

Tightening torques Unit: N·m

Operations before removal of engine mounting units

V. Cylinder Block Unit

Follow the reverse order of disassembly.

34,3 In the following cases continued use is not allowed:

 Installation of gear chamber cover-flywheel housing [8]

 Coat the gear chamber cover-flywheel housing [8] and the

 When installing the flywheel housing, be sure to tighten the

Scope of sealant application between

 Installation of piston cooling nozzle [23]

 Before fitting the piston cooling nozzle, assemble the piston

 After the piston cooling nozzle assembly has been installed

 When installing a cylinder liner, you need to replace both the