Repair of engine

Fig. 31
540110 Dismantle the engine on the bench
Fig. 30

From the right side of engine:

If the engine harness has not been re-arranged, remove
the electronic connectors connected with the
thermostat temperature sensor, phase position sensor,
engine speed sensor, devices without 3 plungers,
pressure regulator, common rail pressure sensor, air
inlet manifold temperature / pressure sensor.
Take away the side hood, dismantle the electronic
connector of electronic fuel injector and then remove
the harness.
Dismantle the oil return pipe (2) from the engine oil
filling pipe (1).
For installing the engine support 99361029 onto the
engine on the bench, it may be installed from the left
side of engine:
□ Take down the water pipe (3) from the engine oil
filter (4);
□ Take down the water pipe (7) from the rear cover
(5);
□ Dismantle the water pipe assembly (3, 7, 10)
after unscrewing the screws (6 and 9);
□ Dismantle the oil inlet pipe (11) from the
cylinder body;
□ Dismantle the oil return pipe (2) from the engine
oil filling pipe (1);
□ Dismantle the breather (8) and oil pipes (2 and
11).
□ Dismantle the oil inlet pipe (2) of pressure
booster and the engine oil pressure sensor (8)
after unscrewing the fixing screw (6);
□ Dismantle the screw plug cap (7);
□ Dismantle from the cylinder head the assembly
of air outlet manifold (3) of pressure booster (4)
and the oil pipes (2 and 5) after unscrewing the
nut (1);
△ Block the inlet/outlet of air outlet end of pressure
booster to prevent foreign substances from entry into
it.
Install the support 99361029 onto the cylinder body
and fix it; for the engine put on the roll-over bench
99322205, unscrew the oil drain bolt of oil pan to
drain the engine oil.
Fig. 32

Unscrew the hinged joint (8) of cold start-up fuel oil

38
pipe (10) from the five-way pipe connector (9);
dismantle the support fixing nut (11) of cold start-up
fuel oil pipe (10).
After unscrewing the nut (4), dismantle the assembly
of electromagnetic valve (2) with air inlet pipe (6), the
spark heater plug (3) and the cold start-up fuel oil pipe
(10) from the air inlet manifold (1); then, dismantle
the acoustic hood (7).

Fig. 33

Dismantle the fuel oil pipe (2) with the following

method from the HP rail (common rail) (7) of

electronic fuel injector (1):

After clamping it with the special hex wrench (4) for

electronic fuel injector (1), use the wrench 99365160

to screw out the connector (3);

After pressing down the small spring (5) indicated by
the arrow, dismantle the connector of fuel oil
compensation pipe (3) from the electronic fuel injector
(4) and dismantle the HP oil pipe (2) from the HP
pressure (1).
Keep the pressure-limiting valve (7) stopped, and
move away the assembly connector (8) with oil return
pipe (3) of fuel injector, the pipe clamp (6) of oil
return pipe and the five-way oil return pipe connector
(9) of oil inlet pipe (2) of pressure booster.
Fig. 34
Seize the hex nut (6) of pressure-limiting valve, and, if
necessary, unscrew the connector (5), to dismantle the
fuel oil pipe (2);
Dismantle the fixing bolt (8) of support (9) of
electronic fuel injector (1);
Dismantle the electronic injector (1) from the cylinder
head.
△ Only applicable to the 8140.43 engine

Dal motore con n.1 di matricolo 3089322, viene

montato un accumulatore idraulico che , mantenendo

la stessa con figurazine , e` privo di valvola limitatrice

di pressione e limitatori di flusso.

Anche in questo caso occorre osservare le stesse

prescrizioni riportate per il precedente.

Fig. 35

39
 Unscrew the support fixing bolt (2) of warm air water

inlet pipe (4) on the air inlet manifold (5).

Dismantle the war air water inlet pipe (4) from the
Dismantle the HP oil pipe (6) from the HP oil pump (3)
cylinder head
and the HP rail (common rail) (7)
Unscrew the fixing nut (7) of water charging pipe (1)
△ When loosening the oil inlet pipe connector (5),
of water pump (6)
fix it with the special hex wrench (4) for HP pump.
Unscrew the fixing bolt (9) of connecting pipe (8) on
Unscrew the nut (2) and dismantle the hold-down
the lower cylinder body
plate of fuel injector (1).
Fig. 38
Fig. 36

Dismantle the water inlet pipe (4) from the engine oil

Dismantle: HP rail (common rail) (3); HP oil pump (4); cooler (3); unscrew the bolts (1) and (5), and

engine oil stick tube (2); engine oil filling pipe cap (1) dismantle some connecting pipes (2) from the water

Fig. 37 pipe assembly (1 and 8 in Fig. 37) from the lower

cylinder body

Fig. 39

40
Dismantle: air inlet manifold (1), air cylinder head
Lock the crankshaft with the special tool 99360306 (3)
cover (4), revolution speed sensor assembly (2),
(shown in the figure); loosen the fixing bolt (1) of
restoration support (5) and timing gear protection
flywheel (2) and unscrew the bolt (5); dismantle the
cover (3).
joint seat (6) of revolution speed sensor assembly (4).

Fig. 40

Use the special wrench to act on the tightener (2),

loosen the belt and dismantle it

Fig. 42

Fig. 41

Unscrew the fixing bolt of crankshaft pulley (1) and

then dismantle the belt pulley (1) and the flat washer.

Fig. 43

41
Loosen the fixing bolts (1) and (7) of driving gears (1

and 7); insert the special wrench (5) onto the tightener

push rod (3) and its seat; unscrew the nut (2) and

dismantle the lower cover (6) and the toothed belt (8)

Fig. 44

Dismantle the guide wheel support (5) and lower

cover (6)
Dismantle the sensor (2) and (3) and circulating water
pipe (4) in the thermostat housing (1)

42
Fig. 45 Fig. 47

Screw out the cylinder cover (2) bolt (1) and remove
the cylinder cover and its lining
Screw out the small wrench (1) and washer (3) from
△ If there is deformation, inspect the protruding
amount of camshaft according to contents of the water pump shaft (2)
relevant chapters to measure and determine the Take out the belt pulley (9) from the water pump shaft
smoothness of the piston and the cylinder plane.
(2)
Fig. 46
Screw out the nut (7) and take out the electromagnetic

fan clutch joint seat (8)

Dismantle the joint seat (5) of AC generator (4) from

the cylinder body and water pump (2)

Dismantle the water pump (2)

Dismantle the tightener (6)

Dismantle the front cover of crankshaft (10)

As shown in the figure, use suitable washer (1) and

lock the rotation of the belt pulley (2) of the
electromagnetic fan clutch; screw out the hub (4) nut
(3) clockwise to dismantle the hub.
△ Hub nut thread (3) is left threaded

43
Fig. 48

△ Only when the piston of the fourth cylinder is at

the dead point, can the connecting rod cover (1) of this
Screw out the bolt (2) and then dismantle the cylinder be taken out.
hydraulic pump (3), vacuum pump (4), engine oil Fig. 51

filter (6) and engine oil cooler (5) in the accessory

case (1) assembly

Fig. 49

Screw out the tie rod bolt and take out the connecting
rod cover, and then take out the piston (1) from the
upper part of the cylinder body.

△ Maintain each bearing bush. Thus during use,

their installation shall be accomplished as per the
Rotate the engine for 180° and dismantle the oil pan dismantling procedures.
(1)

Dismantle the oil suction pipe (2) on the suction filter

Fig. 50

Dismantle the flywheel locking tool 99360306

Rotate the engine for 90° and loosen the tie rod (1)
bolt (3) with the socket wrench (2)

44
Fig. 52 Screw out the tightening screws (1) of upper/lower

cylinder body with the socket wrench (2).

Fig. 55

Screw out the flywheel (1) bolt (2) with the socket

wrench (3), and then dismantle the flywheel (1).

Fig. 53
Dismantle the lower cylinder body (1) and sealing
gasket.

△ Record the bearing bush piston, for the

installation shall be completed as per the dismantling
position.

Fig. 56

Dismantle the rear oil seal assembly of crankshaft (1)

from the cylinder body.

Fig. 54

Dismantle the crankshaft (1) with the sling.

45
Fig. 57
Install the main bearing bush (2)
Correct the bending degree of washer and dismantle
the piston cooling nozzle (2).
Protective Measures of Cylinder
Inspection and Measurement
Fig. 58
Clean the engine after dismantling it.
Transport the cylinder body with special tool
99365508.
Check carefully if there is crack on the cylinder body.
Inspect all process holes and cover, which shall be
replaced if there is rust or leakage.
Inspect the inner surface of cylinder gasket, which
shall be without napping or scratch or excessive
46
weariness, and the roundness cannot be out of
tolerance.
The inspection of roundness, taper and weariness of
the inside diameter of cylinder gasket shall be carried
out with the cylinder measuring gauge 99395687 (1)
after zero calibration of cylinder diameter gauge.
△ The gauge can be used only after zero
calibration.
According to the above contents, use the cylinder
measuring gauge 99395687 after zero calibration to
check the inside diameter and determine the roundness
weariness.
Fig. 59
The measurement shall be carried out in 3 different
heights of the cylinder gasket and at two directions
perpendicular to each other, among which direction A
is parallel to the longitudinal line of engine, and the
other direction B is perpendicular to it. Usually the
maximal weariness value can be measured at the first
measuring position of direction B.
If there is a certain degree of roundness, deviation
from cylindrical form or weariness, they can be
eliminated through honing. The cylinder gasket boring
must ensure there is regulated assembly clearance
between the cylinder gasket and the piston that is
increased 0.4mm. If the inside diameter after boring is
larger than the increasing grade, the spare parts
installation shall be carried out as per relevant
regulations.
Fig. 60 Fig. 61

Inspect if there is deformation on the cylinder body

plane
Pull out the positioning pin (1) in advance, and inspect
with alignment gauge (2) and feeler gauge (3) overlaid
carbon black
After determining the deformed area, eliminate the
deformation with grinding means.
△ The smoothness on the cylinder body plane can
be judged only after the final process is carried
out. The height that the piston is higher than the
A-B = longitudinal axis
cylinder gasket shall not exceed the regulated
* Surface roughness parameter
value.
R1 = 4∽10μm
RZ = 3∽8μm Installation of spare part cylinder gasket
Ra = 0.3∽0.6μm Fig. 62
W1 < 2μm

The permitted value of cylinder hole surface

roughness after being processed is:
B1 area=The maximal load for the metal part
contacting the piston ring: cannot appear two surfaces
with maximal roughness of 0.5*0.5

B1 area=relevant surface of sliding area of piston ring

cannot permit adjacent surfaces with maximal
roughness of 1*0.8
Inspection of upper surface of cylinder body

B = longitudinal axis
As per regulated means, use the grinding means to
make the main bearing hole reach the numerical value
shown in the figure and obtain the mean of
measurement.

47
Fig. 63
* Upper plane of cylinder body
** Grinding plane
After the upper plane is grinded, the upper edge of
cylinder gasket shall be chamfered again.
The inspection of the main bearing hole shall be
carried out as per the following requirements:
□ Erect the following cylinder body on the upper
cylinder body without bearing bush and sealing
gasket.
□ Tighten bolts as per regulated tightening torque.
□ Inspect the inside diameter of main bearing hole
with the inside diameter gauge.
□ If the inside diameter is not right, the cylinder
body shall be replaced.
48
Fig. 64
Measurement of inside diameter of cylinder gasket
must be carried out in arbitrary four positions, three
different heights perpendicular to each other in the
cylinder gasket hole, among which direction A is
parallel to the longitudinal axis of engine, and the
other direction B is perpendicular to this direction.
Calculate the mean D1 med as per the following formula
A1(10 )  A1( 50 )  A1( 42 )  B1(10 )  B1( 50 )  B1( 42 )
D1 med = 6
The result must be 97.500. in addition, the maximal
deviation between the maximal value and the minimal
value must be Dmax Dmin =≤0.03mm
△ The numerical value inside the bracket: from the
upper plane outline of cylinder body to the measuring
point
□ Installation of cylinder gasket shall adopt the
hydraulic pressure machine and the special pressure
plate as per the following requirements:
□ Inspect whether the inside diameter of cylinder
gasket hole complies with requirements.
□ The engine oil or lubricating grease cannot be
used when the cylinder gasket is being pressed into.
□ During pressing, inspect if the load of pressure
machine is not less than 13000N when the pressed-in
length is 80mm.
□ Continue pressing till complete pressing in and
inspect if the load of pressure machine is not less than
50000N.
Fig. 65 X = Dm cylinder gasket 97.390∽97.450

hole diameter

Y = inside diameter of 97.470∽97.500

cylinder gasket

Z = external diameter of 92.700∽92.900

cylinder gasket

*Cylinder hole diameter 94.402∽94.432

* The above sizes are obtained from the last work

* Upper plane of cylinder body——** grinding
procedure after the cylinder gasket is pressed in.
surface φ111
5408 Crankshaft
□ Ensure the cylinder gasket edge to completely
540810 Measurement of main journal and lateral
insert into the step of the cylinder gasket hole to avoid
damage. The cylinder gasket hole shall not exceed rod journal
0.005 of the upper plane of cylinder body.
Fig. 67
If the above requirement cannot be met, it shall be

replaced.

After the cylinder gasket is pressed in, inspect the

tolerance and roughness value as per the contents in

“Inspection and Measurement”.

Fig. 66

If the main journal and the tie rod journal have scratch,

scoring or excessive out of roundness, they must be

ground. Before that, the micrometer (1) shall be used

to measure the size of journal (2) to determine how

much diameter the journal shall be ground to.

△ It is suggested to refer to relevant tables. See Fig.

68.

 Grinding scope: 0.254—0.508

49
△ The grinding size classes of all main journals and marked with “M”.

tie rod journal shall be the same. The deduction size of the main journal shall be

The deduction amount of the main journal and the tie marked with “B”.

rod journal shall be marked at the lateral side of the The deduction size of the main journal or the tie rod

first sector with special printing device. journal shall be marked with “MB”.

The deduction size of the tie rod journal shall be

Diagram of Measurement Values of Main Journal and Tie rod Journal of Crankshaft Fig. 68

50
 First main journal
After rolling Before After rolling
rolling

Tie rod journal

After rolling
Before After rolling
Before
rolling rolling

Fig. 69 Main Parameters of Main Journal and Tie rod Journal

Therefore, when the sizes of the main journal and the tie rod journal reach the grinding scope, i.e. 0.254 or 0.508,

the rolling part of the notch at two sides of the journal will be reached. The notch shall be turned as shown in the

figure and rolled as per the following.

Rolling pressure:

□ The first main journal 925±25N

□ The second, third, fourth and fifth journals 1850±50 N

□ The first and fourth tie rod journal 1850±50 N

□ The second and third tie rod journal 2040±50 N

□ Rolling: forward 3 circles, rolling 12 circles, backward 3 circles

□ Rolling speed: 56r/min

□ The reduction amount at the round angle of the tie rod journal is 0.15∽0.30 after rolling.

□ The reduction amount at the round angle of the main journal is 0.15∽0.35*mm after rolling.

* Use the measuring instrument to measure with the nominal value of φ2.5 mm.

51
Crankshaft measurement

Fig. 70 Main size of crankshaft

Tolerance Characteristic Value of Tolerance Icon

Roundness ○
Form position
Cylindricity

Bearing Parallelism ∥

Perpendicularity ⊥

Position Circular shaft degree or concentricity ◎

Roundness jumping
Jumping
Total jumping value

key characteristic value important characteristic value minor characteristic value

pressure is below 0.15MPa.
△ After the crankshaft journal is ground, carry out
the tolerance size inspection as per the size shown in
the figure. Fig. 71
Symmetry of the main journal and the tie rod journal
1. Tie rod journal
2. Main journal
3. Nominal position
After the grinding is completed, follow the following
requirements:
□ Inspect whether the cover leaks when the internal

52
 If the timing gear of camshaft is damaged or worn, it
shall be dismantled as per the following means:
□ The gear at the direction pointed by the arrow
can be taken out with special extraction tool
99348001 and puller (3).
When the new gear is installed, heat it ≥200℃ and
then use the special wrench to align the notch on the
gear to the notch of camshaft.
△ The highest heating temperature of the gear is
350℃.

Engine installation
During installation, always use new parts to replace
the spring washer, the flat washer and the sealing
Fig. 71 gasket.
Replace the intermediate bearing
Fig. 72

Fig. 74
Use the sling 99360508 (1) to lift the cylinder body
(2), and fix it on the overturning support through
support 99361029 (3).

Fig. 75

Replace the driving gear of camshaft

Fig. 73

Turn over the cylinder body; install the piston cooling

nozzle (2) with lock washer; then use the torque
wrench (1) to tighten the bolt as per regulated torque
and bend the lock washer.

53
Install main bearing bush Fig. 78
Fig. 76

Fig. 78
△ If the bearing bushes do not need replacing, they □ Erect the rubber liner (1) and the main bearing
shall be installed correspondingly to the bush (2).
dismantling positions. Fig. 79
The inside diameter of this thrust bearing bush is
0.254∽0.508mm.
△ No adjustment operation shall be done to the
bearing bush.
The seat must be lubricated before the thrust bearing
bush (1) is erected.

540811 Adjustment of installation clearance of

main journal
Fig. 77

□ Erect the lower cylinder body; inspect if the mark

(1) is corresponding, for the fittings of the upper and
lower cylinder body cannot be replaced mutually.
Fig. 80

Installation of crankshaft (1)

Inspection of the coordination clearance between the
crankshaft main journal and the main bearing bush is
implemented as follows:
□ Clean the journal thoroughly.
□ Use the measuring line to check the journal. □ Install the screw (2) and tighten them in two
steps.
□ Step I, use the torque wrench (1) to tighten them
with 50±5Nm torque.

54
□ Step II, retighten them with 90°±5° turn angle as
shown in the following figure.
Fig. 81
Diagram of Tightening Sequence of Fixed Bolts of
Upper and Lower Cylinder Bodies
Fig. 82
□ Dismantle the lower cylinder body.
Inspection of axial clearance of crankshaft
Fig. 83
55
Use the dial gauge with magnetic gauge stand (1) to
inspect the axial clearance of the crankshaft (2) (as
shown in the figure). The regulated clearance shall be
between 0.06 to 0.310mm. If the measuring value
exceeds this scope, replace the thrust bearing bush and
re-measure the clearance till it is qualified.
Inspection of straightness of crankshaft belt pulley
Fig. 84
Push the crankshaft to the flywheel side to make the
crankshaft touch the thrust bearing. At this time,
measure the distance from the end of cylinder body to
the gear end to be X, whose value is between
53.82-54.55. Thus an adjusting washer shall be
inserted between the gear (2) and the belt pulley (4) or
(6). If the value is between 54.56-55.12, no
adjustment is needed.
Install the belt pulley (4) (engine without air
conditioner compressor) or belt pulley (6) (engine
with air conditioner compressor), and measure the
distance from the belt pulley (4) or (6) end to the fixed bolts with regulated torque and dismantle the
cylinder body end to be Y or Y1. retainer (2).
Y=89.67-91.03 540440 Front oil seal assembly of crankshaft
Y1=107.17-108.53 Fig. 86

Rear oil seal assembly of crankshaft

Fig. 85 The surplus sealing gasket at the position pointed by
the arrow shall be eradicated.
Lubricate the shaft timing gear and install the front
cover(1); tighten the fixed bolt (3) with regulated
torque and dismantle the retainer (2).
△ The oil seal fixed bolt indicated on the diagram
shall be re-installed after the timing toothed belt with
protection hood is erected.

540850 flywheel
Fig. 87

△ The rear oil seal of crankshaft (3) and the front

oil seal of crankshaft (1) are equipped with the sealing
gasket and the retainer (2) marked with “ROTOSTAT”.
The retainer can be taken out only after the oil seal
installation is completed.
Moreover, the oil seal thickness is different from
initial installation.
When the oil seal is installed, pay attention to install
the lip of the oil seal on the external circle of rear end
flange of crankshaft. If the oil seal is not installed at Inspect whether there is crack or damage of the
the appointed position, it may cause oil leakage. flywheel gear ring and at the position pointed by the
The surplus sealing gasket at the position pointed by arrow. If there is, the flywheel shall be replaced.
the arrow shall be eradicated after the installation is Inspect the positioning pin of the clutch. If there is
completed. damage, it shall be processed.
Lubricate the exterior margin of crankshaft flange (1) △ The nominal thickness of the flywheel is 53mm.
and install the rear oil seal assembly (3); tighten the

56
540853 Replacement of flywheel gear ring
Check if there is serious breakage or weariness of the
flywheel gear ring. If there is, dismantle it from the
flywheel with the press machine. Heat 15-20s before
assembly to raise the temperature to 100°, and make
its end with chamfer towards the flywheel device.
Fig. 88
Refer to “flywheel installation and adjustment”
When the flywheel bolt is used again, any point of the
exterior diameter of thread measured by the dial gauge
cannot be less than 10.8mm, or it shall be replaced.
Install the flywheel (1) but don’t tighten it. Tightening
torque of flywheel bolt
Refer to the chapter of “flywheel installation and
adjustment”
5408 piston tie rod assembly
Fig. 89
Fig. 92
57
1. piston — 2. piston pin circlip — 3. piston pin — 4.
air ring — 5. oil ring — 6. oil ring with groove and
lining — 7. tie rod — 8. tie rod bush — 9. tie rod
cover — 10. tie rod bolt
Inspect the piston and there shall be no scratch,
abrasion, crack and serious weariness, or it shall be
replaced.
Fig. 90
Use the piston ring caliper 99360183 (3) to dismantle
the piston ring (1)
Fig. 91 Dismantle the piston (1) and take out the
piston pin circlip (3), and then dismantle the piston
pin.
 Main parameters of 8140.43S engine piston ring and pin
Data of size with “*” measured from diameter of 91.4mm
Fig. 93

Main parameters of 8140.43S engine piston ring and pin

Data of size with “*” measured from diameter of 91.4mm

Fig. 94

Main parameters of 8140.43N engine piston ring and pin

* Data of size with “*” measured from diameter of 91.4mm

540840 piston diameter measurement Use the dial gauge (2) to measure the diameter of
Fig. 95 piston (1) to determine the assembly clearance. The
measured value can refer to the data in relevant tables
of the main technical parameters of engine (P31).
△ The diameters of all pistons as spare parts are
standard, and the increasing level of the circlip, the

58
piston pin and the sealing spring is 0.4mm.
Fig. 96

Lubricate the piston pin (1) and the piston pin hole (2)
with engine oil. The piston pin shall be lubricated
As shown in the figure, use the feeler gauge to under pressure of thumb.
measure the installation clearance between the piston
and the cylinder gasket.
540842 air spring
Fig. 99
540841 piston pin
Fig. 97

“TOP” characters are marked on the first and second

Use the dial gauge (2) to measure the diameter of the
piston (1) air rings. The character shall be upward during

installing.
Coordination of the piston pin and the piston pin
hole Fig. 100
Fig. 98

59
Use the dial gauge (1) to inspect the thickness of

piston ring (2).

Fig. 101

Use the feeler gauge (1) to inspect the coordination

clearance between the first air ring (2) and the ring
groove. According to the following requirement, when
pressing the piston into the cylinder gasket, about half
of the piston ring (2) shall be outside the cylinder
gasket.

60
Fig. 102

Fig. 104

Diagram of measurement of coordination clearance Install the piston in the cylinder gasket and use the
between the first piston ring and the ladder ring feeler gauge to inspect the open clearance of the
piston ring.
groove

1. ring groove — 2. first ring — 3. cylinder gasket 540830 tie rod

Use the feeler gauge (1) to inspect the coordination

clearance X between the ladder groove (1) and the
first ring (2), and the value shall comply with relevant
requirement.

Fig. 103

Use the feeler gauge (1) to inspect the coordination
clearance between the ladder groove and the second
ring and oil ring.
Fig. 105
Main sizes of tie rod, tie rod liner, piston pin and tie
rod bush
* Size of the tie rod liner after the tie rod is pressed
in
** Size measured from the tie rod which has erected
fittings
* Diameter of spare parts of tie rod
△ Each tie rod shall be marked with the following
contents:
□ Matching No. marked on the tie rod and the tie

61
rod cover
□ Diameter level marked by “0” or “X” on the tie
rod cover
□ Weight level marked on the tie rod cover
When it needs replacing, the tie rod with the same
level No. must be selected for assembly.
The tie rod No. shall be marked beside the notch
opposite to the thrust bearing bush.
Use “0” to represent the tie rod head diameter to be
60.341-60.348, and the code “33” to represent the
weight level.
which is carried out as per the following contents:
□ Install the tie rod (1) on the special tool
99395363 (5) and tighten it with the bolt (4).
□ Insert the special core rod (3) into “V” block and
use the shaft (2) to support the tie rod (1).
Inspection of parallelism at horizontal direction
Fig. 107

540834 Liner
Inspect if it is loose in the tie rod liner, and there shall
be no abrasion or scratch on the inner surface of liner,
or it shall be replaced.
Appropriate press machine shall be selected for the
disassembly of liner.
The liner hole and the small end oil hole of tie rod
shall be ensured to overlap when it is pressed into the
liner. Then use the reamer to cut the inside diameter of
liner to 32.010-32.020.

Inspection of tie rod

Fig. 106 Fig. 107
On the plane parallel to the tie rod axis, select Point A
and B on the piston pin (3) to inspect the twisted
amount of tie rod.
Install the dial gauge (2) and its support (1), and at
Point A of the piston pin (3), set the dial gauge (2) to
zero after the gauge head contracts 0.5mm; remove
the core rod (4) with tie rod (5) and compare “B”
value opposite to the piston pin; the deviation between
A and B shall not exceed 0.08mm.

Use the special tool (5) 99395363 to inspect the

parallelism of the central line of small end of tie rod,

62
Inspection of parallelism at vertical direction
Fig. 108

As for the marks on the piston top, 1 represents engine

model and supplier level; 2 represents the direction of
installing the piston in the cylinder gasket; 3
represents the adhesive force of the first ring groove; 4
represents the engine model and the bar code of
grouping level.
On the plane perpendicular to the tie rod axis, carry
out the inspection to original Point C and D on the Fig. 110
piston pin to determine the twisted degree of the tie
rod.
Install the gauge support (1) at the position
perpendicular to the dial gauge (2) to support the dial
gauge on the piston pin C; swing the tie rod forward
and backward at the position higher than the piston
pin; when the dial gauge is set to zero, remove the
core rod with the tie rod (5); make repeat
measurement on Point D opposite to the piston pin,
and the deviation between C and D cannot exceed
0.08mm.

Installation and matching of the piston tie rod

components and the tie rod and piston
Fig. 109
Determine the piston installation datum after
connecting the piston (1) and the tie rod (2) assembly;
pay attention to the matching of the rod body and the
rod cover.
Fig. 111

63

Install the piston (1) on the tie rod; insert the piston
pin (2) and fix with the piston ring (3).
Components of piston tie rod
Fig. 112
After the components of piston tie rod are erected, use
the special tool 99395363 to inspect its average
support area as per the following contents.
□ Put the components of piston (7) tie rod (7) on
the special tool 99395363 with special tool and then
tighten it with bolt;
□ Lean the tie rod (7) against the core shaft (6);
□ After installing the dial gauge (2) and its support
(1), contract 0.5 of the gauge head on piston Point A
64
and then set the dial gauge to zero;
□ Remove the core rod (4) to make the dial gauge
at the piston Point B, and inspect its swinging
deviation.
Installation of piston ring
Fig. 113
The piston ring can be installed with the piston ring
caliper 99360183.
△ “TOP” characters are marked on the first and
second rings. The character shall be upward during
installing.
Installation of components of piston tie rod
Fig. 114
Lubricate the piston, including the piston ring and the
inner surface of cylinder gasket.
Use the special clamp 99360605 (2) to put the piston
tie rod components (1) into the cylinder gasket, and
inspect:
□ The serial Nos. on each (tie) rod body and rod
cover shall be identical.
Fig. 115

The assembly diagram of the piston tie rod assembly
in the cylinder 1. piston 2. accessory case 3. marking
position of matching No.
□ The openings of the three piston rings shall be
120° different from each other;
□ All pistons shall belong to the same quality team;
□ The mark on the top of the piston shall be toward
the flywheel or the notch of piston skirt, and is at
the same side of the engine oil nozzle.
△ If the tie rod bush does not need replacing,
reinstall it as per the same sequence with reference to
the dismantling process.
540831 tie rod journal installation clearance
Fig. 116
As to the installation clearance, the following
operations are followed:
□ Clean parts thoroughly and eliminate oil sludge
(stain).
□ Put a section of measuring line (3) on the tie rod
journal (4).
Fig. 117
65
□ Install the tie rod cover (2) and the tie rod bush.
△ The tie rod cover can be installed only when the
piston is at the end point.
□ After using UTDM lubricating oil to lubricate the
tie rod screws, tighten the screws with 50Nm
torque and 63°±3°turn angle.
△ Use the special tool 99395216 to retighten the
turn angle.
□ Dismantle the tie rod cover (2), and compare the
width of the measuring line being pressed flat
(Fig. 116, 3) with the scales on the package of the
same measuring line (Fig. 116, 2), thus to
determine the coordination clearance between the
tie rod bush and the tie rod journal. If it does not
comply with the requirement, it shall be replaced
and inspected again. If it is correct, lubricate the
tie rod and carry out the final assembly, and
tighten the tie rod bolt as required.
△ The tie rod screw must be replaced in the final
assembly.
Inspect the lateral clearance on the crankshaft tie rod
manually.
Inspection of protrusion amount of piston
Fig. 118
After the piston tie rod assembly is assembled, use the
feeler gauge (3) and the alignment gauge (2) to inspect
the protrusion height of the piston (1) out of the upper
plane of cylinder body at the end point.
The piston amount can be adjusted through the Ensure the flywheel both (4) is at loose condition.
thickness of the cylinder cover washer. Refer to the
following table for specific data. Place the special measuring tool 99395214 on the
Average Thickness of Cylinder Cover cylinder body.
Protrusion Washer*
Amount of Not Having Been Rotate the crankshaft to make the first cylinder piston
Piston Assembled Assembled at the end point.
0.61∽0.80 1.48∽1.62 ∽1.40
Then rotate it reversely for 90°
0.40∽0.60 1.23∽1.35 ∽1.20
Use the special dial gauge (2) to measure the
△ The selection of the thickness* of cylinder cover
equilibrium point of the pistons of cylinders 1 and 2.
washer depends on the one with the largest
protrusion amount in the 4 pistons. Set the dial gauge on the piston of cylinder 1 to zero
△ The difference between the maximal value and
and move it to the cylinder 2 to determine the
the minimal value of the protrusion amount of
the 4 pistons shall not exceed 0.2mm. deviation of the two cylinders.
△ During engine overhaul, the overhaul package
If there is no deviation, the two cylinders are
shall include the cylinder cover washer, whose
thickness shall be the maximal. equilibrium, or rotate the crankshaft to decrease half

of the deviation.
Installation and adjustment of flywheel
For instance:
Fig. 119
If the deviation is 0.2mm, rotate the crankshaft

reversely to decrease the deviation to be 0.1mm.

If the deviation is 0.2mm after zero setting, rotate the

crankshaft positively for 45° to restore the clearance.

Thus rotate reversely till the deviation reduces to be

66
half, i.e. 0.1mm.

After the piston equilibrium point is determined, there

is no need to rotate the crankshaft. Position the

flywheel so that the special tool 99395244 (3) pin can

be inserted into the flywheel milling groove.

Tighten bolt (4) slightly.

Get rid of the special tool 99395214.

Tighten the flywheel bolt (4) as per the contents

indicated in the following diagram. Rotate the engine and install the oil suction pipe of

Fig. 120 suction filter (1) and the sealing gasket, and then erect

the oil pan.

560610 cylinder cover

541210 dismantling of camshaft

Fig. 122

Use the special tool 99360306 (3) to tighten the

flywheel (1) bolt (2) in two steps.

Step I: use the torque wrench to tighten it with

30±3Nm torque. Fix the special tool 99361004 on the supporting seat,

Step II: retighten it with 90°±2° turn angle. and then fix it on the cylinder cover.

△ Use the special tool 99395216 (4) to retighten the After taking off the rear cover (3) and unscrewing the

turn angle. fixed nut of camshaft (1), dismantle the camshaft

Fig. 121 cover and take off the camshaft.

△ To avoid excessive twisting of the camshaft, the

unscrewing must be carried out in steps and in

sequence to release the spring force evenly.

67
Inspection

The supporting seat surface of the camshaft and the

cam surface shall be smooth. If there is napping or

damage, it must be replaced.

Fig. 123

Use the dial gauge to measure the camshaft journal

size; use the dial gauge of inside diameter to measure

the inside diameter of corresponding supporting seat

hole. The difference of the two is coordination

clearance, and the value is 0.035-0.081mm. If the

deviation is exceeded, relevant parts shall be replaced.

If the cover at the end of camshaft needs replacing,

special tool shall be used for the operation.

Main sizes and parameters of cam and camshaft
△ Before the cover is assembled, the installation
supporting seats
piston shall be applied to glue.
*Nominal size

**Increasing size
541211 inspection of camshaft lift range and

journal straightness

Put the camshaft on the parallel V-form support and

place the dial gauge on the central position of the

support. Inspect the straightness which shall not

exceed 0.04, or it shall be replaced. In addition,

inspect the air outlet cam stroke to be 10.5, and the air
Fig. 124
inlet stroke to be 9.5, or it shall be replaced.

541224 cam chamber cover

68
Fig. 125

Use the dial gauge (2) to inspect the tappet diameter

and use the dial gauge of inside diameter to check

corresponding inside diameter of tappet seat. All of

them shall comply with the regulations in Fig. 125.

The maximal clearance shall be 0.03-0.075.

When replacing the tappet, if the clearance is too large,

adopt suitable tool to process corresponding seat, and

Fig. 125 Main size of cam chamber cover of
then put into the tappet.
cylinder gasket

540662 dismantling of air valve

Fig. 126
Fig. 128

Pull out the tappets with adjusting washer as per

dismantling sequence and place them in sequence.

The lateral face of tappet shall be smooth without Use the special tool 99360268 (1) to apply pressure to

scratch. If there is slight hurt, it can be eliminated the spring seat of upper air valve (3) so as to make the

through grinding with fine grinder. inner and outside springs (4 and 5) at the compaction

condition, and then take out the air valve lock blade

Fig. 127 (2); dismantle the spring seat of upper and lower air

69
valves (3), the air valve springs (4 and 5) and the Fig. 131 Inspection of Lower Plane of Cylinder
Cover
spring seat of lower air valve (6).

Repeat the operation.

Rotate the cylinder cover and take out the air valve

(7).

Fig. 129

Use the alignment gauge 2 and the feeler gauge 3 to

inspect the flatness of the working plane of cylinder
cover 1. If there is deformation, it must be ground to
be flat. The total maximal grinding amount is 0.4mm,
and the cylinder cover height is 150± 0.1mm, or it
shall be replaced.

Fig. 132 540662 Air valve

Use the special caliper (1) to dismantle the sealing

ring (2).

Fig. 130 Tightness Inspection of Cylinder Cover

Main size parameters of air inlet and outlet valves and

guide pipe of air valve

Use tools 1, 2, 3 and 4 to inspect the tightness of

cylinder cover water jacket. Fill in about 90°C hot
water under 2-3 barometric pressure. There shall no
leakage at this time, or it must be replaced. (Special
tools shall be used to assembly and disassembly of the
cylinder cover.)
△ Before installing the cover, special glue must be
applied to the sealing plane.

70
Fig. 133
Remove the carbon deposit on the air valve with metal
brush. There shall be no crack or scratch on the air
valve, or it shall be replaced. To trim the head cone
face of air valve, the air valve rod shall be inserted
into the air valve grinder 99301014.
Fig. 134
Use the dial gauge 2 to measure the diameter of air
valve rod 1, which shall be 7.985---8.000mm;
71
Fig. 135 Installation clearance of the air
valve seat ring and the air valve
Use the dial gauge 1 of magnetic gauge stand 1
(position as shown in the figure) to check if the
installation clearance is 0.023mm∽0.053mm. Take out
the air valve 2 and inspect if the central error of air
valve seat sing is over 0.03mm.
540667 Guide pipe of air valve
Fig. 136 Replacement of guide pipe of air valve
Use the punch tool 1 (99360288) to dismantle the
guide pipe of the air valve.
Fig. 137
Place the cylinder cover under the environment of
80°∽100°. Use the punch tool 1 (99360288) and the
limit sleeve 2 (99360291); install correctly the guide
pipe of air valve 3 cooled in the nitrogen solution.
Fig. 138
Assembly size of guide pipe of air valve
Fig. 139 Processing of guide pipe of air valve
After the guide pipe of air valve is installed, use the
rimer 1 (99390310) to ream holes.
540661 Air valve seat ring
Repair--replacement of air valve seat ring
Fig. 140
Inspect the air valve seat ring 2 and use the tool
72
99360419 (1) to grind the slight scratch on the surface
according to relevant parameters of Fig. 141. Or,
replace with the same tool and pay attention that the
punching head cannot hit and injure the cylinder
cover.
Fig. 141
Fig. 142
Place the cylinder cover under the environment of
80°∽100°. Use the punch tool 1 (99360288); install
correctly the guide pipe of air valve 3 cooled in the
nitrogen solution. 99360419 air valve grinder can be
used for grinding as per the size in Fig. 141.
Fig. 143
 Fig. 146

Use the tool 99394083 (1) to eliminate the dirt of the

fuel injector seat. Use the special tool 99305047 to inspect the elasticity
of air valve spring before installation. Compare the
Fig. 144 elasticity of the new and old springs under regulated
load as required by the diagram.
Fig. 147

Main parameters for detection of air inlet and outlet

Install the air valve and the fuel injector, and use the air valve springs
special tools 1 and 2 to inspect the tightness of the air External Spring Internal Spring
valve. Height Height
Pressure (N)
(mm) (mm)
Fig. 145 52 Free 45.5
38.5 429.24±24.5 160.72±9.8 33.5
28.5 758.52±39.2 294±14.7 23.5

Use the dial gauge 1 to check if the protrusion height

of the fuel injector 2 complies with the requirement.
540665 Air valve spring Installation of cylinder cover

73
Fig. 148 springs (4 and 5) and the spring seat 6 of lower air
valve; use the air valve lock blade to complete the air
valve installation.

Tappet installation
Fig. 151

When dismantling (or erecting) the rear oil seal (1)

from/on the cylinder cover (3), add the sealing gasket
and then tighten nut as per regulated torque.

Fig. 149

Lubricate the tappet seat and then install the tappet (1)
and the clearance adjusting shim of air valve as per
the sequence reverse to the dismantling.

Fig. 152

Lubricate the air valve seat ring and use the special
tool 99360292 (1) to install the oil seal (2) on the
guide pipe of the air inlet and out air valves.
Fig. 150

Camshaft installation

Lubricate the bearing seat of camshaft (1) and then

install.
After installing the camshaft cover (2), check if the
cover No. is identical to its position.

Use the special tool 1 (99360268) to apply pressure to

the external and internal springs (4 and 5) of air valve;
install the spring seat 3 of upper air valve, the air Fig. 153

74
 Fig. 155

Loosen the fixed nut (1) of camshaft cover (2) and

take off the camshaft cover with the same means, and
tighten the nut (1) with regulated torque.

Fig. 154 The adjustment of air valve clearance shall be

conscientious and meticulous. In fact, too big
clearance will cause noise and delay the opening of air
valve and advance the closing, while too small
clearance will advance the opening but delay the
closing. If the clearance is zero, the air valve will
always at the state of slight opening, which will result
in serious damage of the service life of relevant parts.

Fig. 156

Use the guide tool 99374336 (2) and the punching

head 99370006 (1) to install the oil seal (3) with
retainer on the front cover (4).
After lubricating the front end of camshaft and
applying IVECO LOCTITE 1905685, install the oil
seal on the cylinder cover, and tighten the nut as per
regulated torque (5).
△ The retainer of oil seal cannot be taken off from
the oil seal before installation.

The adjustment of air valve clearance shall be carried

out as per the following means:
□ Erect the special wrench 2 (99350114) on the
tightening screw of the camshaft gear 3 (Fig.
Adjustment of air valve clearance 2-134), and use it to rotate the camshaft to make

75
 the air valve is at the complete closing position.
□ Use the feeler gauge 1 (99395113) to check the
air valve clearance, i.e. the clearance between the
air inlet and outlet cam and the tappet. The valve
shall be 0.5±0.05mm.
Fig. 157
To get the regulated working clearance, the clearance
adjusting shim of air valve shall be replaced as per the
following means:
□ Rotate the tappet 3 to make the notch on its edge
towards one side of the air inlet and outlet
manifold.
□ Insert the special tool 1 (99360309) between the
air inlet and out tappets, and use it to press the
tappets to the lowest position;
Fig. 158
□ Use the air compression gun 3 to inject
compressed air to the tappet notch 2 to make the
clearance adjusting shim of air valve 1 float.
□ Use the caliper 99380701 to dismantle the
76
adjusting shim.
Fig. 159
The thickness of the clearance adjusting shim of air
valve 1 is marked on one surface of the shim. If the
print cannot be recognized, use the dial gauge 2 to
measure. When installing the clearance adjusting shim
of air valve, the surface marked with the thickness
shall be toward the tappet.
△ Note: the thickness of the clearance adjusting
shim of air valve is:
3.25 3.30 3.35 3.40 3.45 3.50 3.55
3.60 3.65 3.70 3.75 3.80 3.85 3.90
3.95 4.00 4.05 4.10 4.15 4.20 4.25
4.30 4.35 4.40 4.45 4.50 4.55
△ If the air valve clearance must be adjustment
when the cylinder cover is installed on the engine,
the engine must be rotated with appropriate tool
to make the air valve cam at the upward position.
At this time, the piston is 10-13mm away from
the end point, so the interference of the piston
and the air valve can be avoided.
Fig. 160

Place the piston at the upper end point and maintain
the condition; lock the rotation of crankshaft (4) and
place the special tool 99392214 (3) on the cylinder
body. Under such condition, installation and
adjustment of camshaft can be carried out.
Inspect if the contact surface of the cylinder body and
the cylinder cover is clean. The sealing gasket cannot
be stained. Arrange the sealing gasket of cylinder
cover and select the thickness of the sealing gasket
according to the contents in “protrusion amount of
piston”, and the face marked with “ALTO” shall be
upward.
△ The tightness of the sealing gasket in its package
must be ensured completely, and it can be taken
out only in short time before installation.
Fig. 161
Rotate the crankshaft (2) to shut off the first cylinder
air valve, and then install the cylinder cover (3).
77
△ Before using the cylinder cover bolt again, use
the dial gauge to measure and inspect the thread
outside diameter. The measuring value of any
point cannot be lower than 11.5mm, or it must be
replaced.
Screw on the fixed bolt and tighten the bolt as per the
following sequence in three steps.
△ Use the tool 99395216 to tighten turn angle.
Fig. 162
Tightening sequence drawing of cylinder cover bolt
□ Step I: use the torque-indicating wrench to
pre-tighten the bolt with 60±5Nm torque;
□ Step II: re-tight it with 60±5Nm torque;
□ Step III: tighten turn angle with 180°±10°.
Fig. 163
Apply Silastic 732RT to the four corners of the
cylinder head cover at Point “A” between the rear
cover (6) and the cylinder cover (5). Install the sealing
gasket (2) on the cylinder head cover (1); after
applying SILASTIC732RTV LOCTITE glue to
several corners, install the cylinder head cover (1),
and tighten nut as per regulated torque (7).
Install the oil return pipe support (8) and harness and Fig. 166
tighten the nut (5) as per regulated torque. Install the
sensor (4) on the cylinder head cover; after inspecting
its air clearance as per contents in relevant chapters,
install the air inlet manifold (3).

503050 Accessory case

Fig. 164

Dismantle the connector 3 with the Allen wrench. The

connector fixes the engine oil cooler on the accessory
5.

Fig. 167

The accessory case, as an integral, is installed at the

lateral side of the cylinder body, and is driven by the
timing gear belt which also drives the camshaft. There
is lubricating oil way processed on the accessory case
to lubricate each part. The accessory case includes the
following parts: high pressure pump, engine oil pump
and engine oil pressure valve, engine oil cooler with
double filtering function and vacuum pump.
Dismantle the vacuum pump 1 (with shaft coupling 2)
Dismantling of accessory case and sealing gasket.
Fig. 165 Dismantle the rear cover (3) of engine oil pump and
the pressure regulator valve of engine oil.

Fig. 168

78
Dismantle the hydraulic pump (5); unscrew the bolt
(3); pull out the transmission gear of high-pressure 503010 Engine oil pump
pump (4); dismantle the screw (1) and take off the Fig. 171
upper cover (2).

543075 Pressure regulator valve of engine

oil

Fig. 169

Use the straight rule 2 and the feeler gauge 1 to

inspect the clearance between the end face of gear 3
and the rear cover of accessory case, which shall be
0.065—0.131mm, or the parts with excessive
weariness shall be replaced.

Unscrew the plug screw (5); take out the spring (4) Fig. 172
and the pressure regulator valve composed of the
plunger (3) and the sleeve 92) on the rear cover (1).
Check if the plunger (3) can slide freely, and if there is
scratch, and if the spring 2 is damaged.
When the engine oil temperature reaches 100℃, its
pressure regulation is:
1. Idle speed: 0.08MPa
2. Maximal rotational speed: 0.38
MPa
Fig. 170

Take out the driven gear shaft 1 of the engine oil

pump.

Fig. 173

Main size of elasticity of spring in the pressure

regulator valve of engine oil

79
Loosen the screw and dismantle the front cover 1 of
the accessory case.
Fig. 174
Take out the driven gear shaft (1) of the high-pressure
oil pump.
Fig. 175
If the driven gear of engine oil pump (1) and the
driving gear of engine oil pump (2) are worn
excessively, they shall be replaced. The operation
shall be completed with the hydraulic machine (2).
Fig. 176 Installation of accessory case
80
The assembly of the accessory case shall be carried
out as per the sequence reverse to the dismantling. Pay
attention to the following:
As for installing the driven gear of engine oil pump on
its shaft (3), First, heat the driven gear (2) and cool its
shaft at the same time. When the temperature
difference of the two is 270°, use the hydraulic
machine (1) to assemble it. Then check if the outer
end faces of two sides are 88 ±0.2mm away from each
other.
Fig. 177
Inspect the coordination strength of the gear and its
shaft as per the following means:
□ Install the special tool 2 (99360607) to lock the
gear rotation.
□ Draw a straight line as the reference mark 3 on
shaft 4 and gear 4 respectively;
□ Use the torque wrench 1 and the special tool 6
(99360607) to apply 64Nm torque to the gear at
the other end;
□ Inspect the reference mark, which shall still be a
straight line.
Fig. 178

Install the front cover (2) with sealing gasket and

tighten the screw (3) with regulated torque.
Install the driven gear shaft (1) of the engine oil pump. Fig. 182
Fig. 179

Install the driven gear shaft (1) of the high-pressure oil

pump.
Clean the contact face (1) of the rear cover and the
Fig. 180 accessory case proper, and the proper surface.
Apply LOCTITE IVECO 1905685 to the sealing face
of the rear cover (1) (in the black area as shown in the
figure) with the same method, and pay attention to the
evenness of application.

Fig. 183

Use the tool 2 (99374336) and the punching head

99370006 (1) to replace the oil seal (3) on the front
cover of the accessory case.
Fig. 181

81
 Fill the compressor air of 0.1Mpa into the heat
exchanger 1 and inspect if there is leakage in its oil
Fig. 183 way and water way 2.
Install the rear cover (2) and tighten the bolt (3) and Test conditions:
nut as per regulated torque. Oil product model: SAE 30
Installation of the rear cover shall be completed within Oil temperature at cooler inlet 115℃
10min after the glue is applied. Oil amount 30 l/min
Install the vacuum pump. Water temperature at cooler inlet 85℃
Flow amount 20 l/min
Performance
Capacity: 4.0kw
Oil pressure 0.085MPa
Fig. 184 Safety valve (2)
Opening pressure 0.082∽0.103 MPa

Fig. 186

Install the upper cover (2) with sealing gasket and

tighten the bolt (1) with regulated torque.
Install the transmission gear of high-pressure oil pump
(1) and tighten the screw (3) as per regulated torque.
Install the hydraulic pump (5).
Clean thoroughly the engine oil filter seat (2), the
543110 Engine oil cooler engine oil cooler (4) and the engine oil filter connector
Fig. 185 (5), especially the water way and the oil way.
Replace the O-form seal ring (1 and 3).

Fig. 187

82
Install the engine oil filter seat (3) on the accessory
case (5). After aligning the base hole to the center
shaft (4), install the engine oil cooler (2) on its seat (3);
then align them with the engine oil filter connector (1)
and tighten the connector (1) with regulated torque.
△ Before installing the engine oil filter connector
(1), apply LOCTITE IVECO 1905683 to the thread.
Fig. 188
Lubricate the seal ring with engine oil and install it on
the engine oil filter 2; install the engine oil filter (Fig.
187, 1) and use the special tool 2 (9936091) to tighten
it with 25Nm torque.
Fig. 189
83
Install the accessory case (2) with sealing gasket and
tighten the bolt with torque-indicating wrench of
regulated torque.
△ Apply LOCTITE 506 to the thread end of screw
(1); if it is used again, the thread shall be cleaned
thoroughly (as shown in the figure), and be
applied with LOCTITE IVECO 1905683.
5450 lubrication system
General
The lubrication system of engine is a type of forced
circuit circulation system, which is composed of the
following accessories.
Gear-type engine oil pump and a pressure regulator
valve
One Modine engine oil cooler with safety valve
Single-core and double-core component function with
safety valve (see Fig. 191)
After the engine oil enters the oil suction pipe (9) of
oil pan through the engine oil pump (8), it flows into
the engine oil cooler (4) for cooling under a certain
pressure.
The engine oil is conveyed to each lubricating part
through the engine oil filter (5) and the oil transfer
pipe.
After the lubrication is completed, the engine oil flows
back to the oil pan. If there is blockage, it can flow
back from the safety valve.
If the engine oil cooler is blocked at this time, no
filtering is needed, and the engine oil enters from the
safety valve.
△ Refer to relevant contents in the “accessory case”
for the dismantling inspection and installation of the
engine oil pump and the engine oil pressure regulator
valve.

54048 Crankcase ventilation system

Fig. 190

Diagram of crankcase ventilation system

When the engine runs normally and the engine oil
flows in from the filling port, it is collected in the oil
gas pipe (2) and the breather (4) in the oil pan and
exhausted from the oil pan through the oil return pipe
(5). Thus the circulation work completes.
If the oil gas is too much, it can be exhausted from the
ventilation pipe (3).

84
 Fig. 191
Diagram of Lubrication System of Engine
1-camshaft oil way 2-main oil way 3-accessory case with engine oil pump 4-engine oil cooler
5-engine oil filter 6-vacuum pump 7-engine oil pressure regulator 8-engine oil pump gear
9-engine oil suction filter 10-piston cooling nozzle 11-oil inlet pipe of booster 12-engine oil pressure
sensor

5432 Cooling system

Fig. 192

85
 Fig. 192
Diagram of cooling system
A. warm air inlet device B. warm air outlet device opening of water return
valve
The cooling system is the closed type forced circulation system.
Description
□ There is a water injection valve (1) and a water utilization valve (2) in the expansion tank. They can adjust
the internal pressure of the system.
□ The coolant level sensor is installed at the bottom of the expansion tank.
□ The heat exchanger can cool the lubrication oil.
Temperature of coolant
□ The one with the electromagnetic fan clutch is 94℃±2℃.
□ The one without the electromagnetic fan clutch is 80℃±2℃.

86
□ The three-way thermostat can adjust the circulation of coolant.
Function
The water pump running is driven by the V-ribbed belt. It sends small part of coolant to the cylinder body, while
most coolant is pumped to the cylinder cover.
When the coolant reaches a certain temperature, the thermostat opens and the coolant is sent to the water tank for
heat dissipation with fan.
The internal pressure of the system depends on the variation of the temperature and the water amount, which can
be adjusted by the expansion tank.
The water return valve has double functions:
□ Keep the system at small pressure to increase the boiling point of the coolant.
□ If the coolant temperature rises, surplus pressure will be emitted.
The injection valve permits filling of coolant from the expansion tank to the radiator. When negative pressure is
produced inside the system due to decrease of coolant capacity, it can control through reducing temperature.
The opening pressure of the water return valve is 1±0.1kg/cm2, while the opening pressure of the water injection
valve is 0.005∽0.02 kg/cm2.

543212 electromagnetic fan clutch belt pulley

Fig. 193

Characteristics of sectional drawing of electromagnetic fan clutch belt pulley

Bonding torque under 20℃ and 1000r/min 23Nm
Transmission torque under 20℃ and separation condition 43 Nm
Voltage 12V
Consumption power 24W
When the coolant temperature reaches 94℃±2℃, the temperature control switch makes the electromagnet (1)
start exciting, and attracts the movable blade (2) to make the hub (4) absorb the electromagnetic joint seat (3).

87
543210 water pump
Fig. 194 Longitudinal section of water pump

1. Water pump casing 2. Bearing set screw 3. Water pump shaft (with bearing)
4. Water pump seat ring 5. Water pump impeller
A = 0.56~1.08mm; the installation clearance between the water pump impeller and the water pump seat ring

Fig. 195

Use the feeler gauge 3 to inspect the clearance between the impeller 1 and the water pump seat ring 2, which shall
be 0.56—1.08mm. Inspect if there is crack on the water pump casing. If there is, replace the water pump
assembly.

Fig. 196

The thermostat 1 is the by-pass type and installed in its bearer 2 which is fixed on the cylinder cover. The
thermostat needs no adjustment. If there is problem, it shall be replaced. The temperature sensor and the water

88
temperature sensor are installed on the thermostat casing.
Fig. 197

A． Start stroke is at 82.℃±2℃

B． Stroke is at 97℃≥7mm
C． Stroke is at 110℃≤10.5 mm
The stroke not reaching 60″ is 7mm.
The water leakage amount of the thermostat and the valve≤2 L/h.

Fig. 198

Install new sealing rings (2 and 3) on the connecting pipe (4) and install it on the thermostat (1).
Fig. 199

After installing the thermostat (1) with the connecting pipe (2) on the water pump (3), install the water pump
assembly on the cylinder body and the cylinder cover.
Apply LOCTITE5065 to the thread end of the bolt. If it is used again, the thread shall be cleaned thoroughly and

89
be applied glue again.
Fig. 200 Timing mechanism

Install the tightener push rod )2) into the water pump seat (1) and install the guide wheel support (3) and the guide
wheel (4).

Fig. 201

Install the belt but don’t tighten the nut (5) of the tension pulley (4).
Insert the special wrench (3) between the push rod seat (1) and the push rod (2) to ease the tightness of the tension
pulley (3)

90
Fig. 202 Phase adjustment of timing mechanism

Inspect if the first cylinder piston is at the end point.

Under this condition, use the pin (2) of the special tool 99395214 (1) to insert in the milling groove of the
flywheel (3). The hole (5) of camshaft driving gear shall be downward.
Fig. 203

Make the inner margin mark of the camshaft gear (1) align the mark (2) in the cam chamber cover.

91
Fig. 204

□ Install the gear-type belt (1)

□ Install the lower cover (4) and tighten the fixed nut and screw as per regulated torque.
□ Take off the tool (3) to make push rod (2) act on the tension pulley (5) so that the belt is under tensioning
condition.

Fig. 205

□ Pull out the pin of the special tool 99395214 (1) from the milling groove of the flywheel (3).
□ Rotate slowly the crankshaft ring in positive direction. When the gear belt is under tensioning condition,
inspect if the hole (5) on the camshaft driving gear (4) faces downward, and if the pin (2) of the special tool
(1) is in the milling groove of the flywheel (3), and if the marks align each other.

92
Fig. 206

□ Tighten the fixed nut with 37-45 torque to tighten the tightener (2).
Use the special device 99395849 to inspect the tension of the belt and if the vibration frequency at Point “A” is
90-118HZ.

Fig. 207

Install the upper cover (1)

93
Fig. 208

Adjustment of belt pulley is carried out as per relevant contents of the dismantling or “belt straightness”. Lock the
flywheel with the special tool 99360306 first, and tighten its support bolt with the torque-indicating wrench as per
regulated torque.
Fig. 209

Install the electromagnetic fan clutch seat (2) on the water pump shaft (3) and tighten the nut (1) with regulated
torque.
Inspect and rectify the electromagnetic fan clutch joint seat

94
Install the small wrench (5) and the belt pulley (4) and inspect if the “Y” direction distance is 88.9-90.1mm.

Fig. 210

Install the hub (1) and the fixed nut (3) washer (2); lock the hub rotation and tighten the nut (3) in two steps.
△ The fixed nut thread of the hub (2) is left-handed, and the nut shall be replaced for every dismantling.
Step I: tighten the torque-indicating wrench with 40Nm torque.
Step II: retighten it with 110°±10° turn angle.
△ Tighten with special tool 99365216.

Fig. 211

Use the feeler gauge (1) to inspect if the clearance is 0.25-0.45mm.

95
Fig. 212

Install the AC generator (1) assembly seat (2) on the lower cylinder body, or
Install the tightener (5) but don't tighten the screw (4) or (7).
Install the belt (9) after the belt gear is corresponded to the corresponding belt trough.
Act on the bolt (1). Tighten the belt (9) and rotate the crankshaft for 1 circle. Use the device 99395849 to inspect
if the frequency of the Point “B” of the crankshaft compressor belt under 500±50Nm load is 160±10Hz.
If it is opposite, act on the bolt (11) correctly.
Tighten the bolts (4) and (7) with 25NM torque.
Unscrew the bolt (11) for 2 circles and tighten the nut (10(6) with 25Nm torque.
□ The seat (2) can be connected to the air conditioner compressor.
□ The seat (6) is without the air conditioner compressor.
Tighten the bolt (3) with 80-90Nm.
Tighten the bolt (4) with 40-50Nm.
Alignment inspection of AC generator belt pulley
Inspect if the “X” direction distance between the cylinder body and the belt pulley (5) is 88.7-90.1mm.

96
Fig. 213

Install the compressor (2) and tighten the fixed bolt with 25Nm torque.

Alignment inspection of compressor belt pulley

Inspect if the Y direction distance between the cylinder body and the belt pulley (3) is 106.96-108.56.

544012 Adjustment of belt tension of water pump—AC generator

Fig. 214

97
Adjustment of belt pulley tension of water pump—AC generator
Act on the bolt (3) and eliminate the tension pressure of the automatic tightener.
Install the belt (1) after the belt gear is corresponded to the corresponding belt trough.
Loosen the tightener (2) and rotate the crankshaft bearing ring to assemble the belt.
Use the device 99393849 to measure the tension of belt (1). Inspect if the frequency at Point “A” of the water
pump-AC generator belt is 140±5Hz.
544035 Adjustment of air conditioner compressor belt tension (Fig. 214)
Install the compressor (6) and tighten the fixed bolt (8) with 25Nm torque.

Fig. 215

△ When re-stall the dismantled water pump seat (5), new sealing gasket shall be used and install the seat (5)
well to make “A” downward.
Install the high-pressure oil pump (4), the engine oil stick tube (2) and the high pressure rail (2).
When fixing the fixed nut of the high pressure oil pump, the HP pump joint seat shall be replaced. Use the tool
99365143 to lock its rotation and take out the joint seat with the special tool 99342138. When new parts are
installed, tighten the fixed nut with regulated torque.

98
Fig. 216

The HP oil pipe (5) connecting the HP pump (6) and the HP rail (1)
△ Use the special wrench and the torque-indicating wrench 99389833 to tighten the oil inlet connector (4) of
the HP oil pipe (5) with 20Nm torque.
Tighten the oil inlet connector (4) while locking the hex nut (8) of HP pump.
During each dismantling, the HP oil pipe (5) shall be replaced.
According to the record card 3089322, the installation of the HP rail shall try to ensure the identical
appearance, and be equipped with the pressure-limiting valve and the flow valve, or it shall be carried out as
per the same requirement as the previous one.
△ Only applicable to 8140.43S
According to the contents of record card 3089322, the installation of the HP rail shall be accomplished
completely as per the diagram, and no pressure-limiting valve or flow valve is equipped with for the time
being, or it shall be carried out as per the same requirement as the previous one.

Fig. 217

Install the electric nozzle (1) and the oil injection support (3) and tighten the fixed nut (2) as per regulated torque.

99
Fig. 218

The HP oil pipe (2) connecting the electric nozzle (1) and the HP common rail (4)
△ Use the wrench 99317951 and the torque-indicating wrench 99389833 to tighten the connector (3) of the HP
oil pipe (2) with 20Nm torque.
Use the special wrench to lock the hex nut (6) of electric nozzle and the hex nut (8) of flow valve (if
necessary), and tighten the connector (3).
During each dismantling, the HP oil pipe (2) shall be replaced.
Fig. 219

Erect the common rail (6) and the protection hood (1); tighten the fixed nut (2) with regulated torque; connect the
fuel return connector (8) with the three-way connector (5); connect the oil return pipe (4) of the HP oil pump (3).

100
Fig. 220

After dismantling the small spring (2) indicated by the arrow, connect the connector of fuel compensation pipe (3)
of the electronic fuel injector (3); erect the oil return pipe clamp on the common rail protection hood (5), and
connect the oil return pipe (6) to the five-way connector (7).

Fig. 221

Connect the water inlet pipe (1 and 4) assembly to the engine oil cooler (3), and connect the water inlet pipe (4) to
the lower cylinder body with screws (1 and 5).

101
Fig. 222

Use the screw (9) to fix the connecting pipe (8) on the lower cylinder body; use the screw (7) to fix the warm air
water inlet pipe (1) on the water pump (6); connect the water pipe connecting pipe (4) on the cylinder cover
connector; connect the support (3) and the warm air water inlet pipe assembly 1-4 to the air inlet manifold, and
tighten the screw (2) with regulated torque.

Fig. 223

Erect the acoustic hood (7), and re-install the air inlet pipe (6) and the air inlet manifold (1), the electromagnetic
valve (2), the spark heater plug (3) and the air inlet manifold (1); tighten the nut (4) with regulated torque.
Connect the cold start-up fuel oil pipe (10) to the three-way connector (10) with the hinged joint (8). Fix the cold
start-up fuel oil pipe (10) with the screw (5) and the nut (1).
If necessary, connect the engine harness to the fuel injector (with lateral hood), the air temperature and pressure
sensor, the common rail pressure, the 3rd pump oil cut-off valve, the rotational speed sensor, the phase sensor, and
the thermostat temperature sensor.
Connect the fan to the electromagnetic fan clutch joint seat; cultivate the upper sling 99360549, and lift the engine
from the roll-over bench; dismantle the support 99361029.

102
Fig. 224

Complete engine installation: after erecting the new sealing gasket (1) on the cylinder cover, install the booster (4),
the exhaust manifold (3) assembly and the oil pipes (2) and (5); use the screw to fix the connector (8) on the lower
cylinder body; use the screw and the engine oil pressure sensor assembly connector (7) to fix the oil pipe (2).

Fig. 225

Erect the breather (8) and oil pipes (2 and 11) assembly; connect the engine oil filling cover (1) to the oil return
pipe of breather (2); connect the lateral hood (7) connecting pipe (5); connect the engine oil cooler (4) connecting
pipe (3); fix the connecting pipes on the cylinder body and cover with screws (9 and 6). Convey the lubrication oil
again as per regulated quantity and quality.

103
764264 Rational speed sensor of camshaft
764266 Engine speed sensor
Fig. 226

Inspect if the clearance at sensor position is 0.8-1.5mm.

The clearance between the camshaft belt pulley (1) and the sensor shall be 0.8-1.5mm.
Loosen the nut (3) and act on the seat (4), and then compare the values.
The clearance between the flywheel (5) and the sensor (6) shall be 0.8-1.5MM.
If it is not correct, loosen the screw (7) and act on the seat (8).

104
Fig. 227 Boosting system (8140.43S)
Fig. 227
Diagram of 8140.43S engine boosting
Description
The boosting system is composed of the air filter, the
turbocharger and the intercooler.
There is filtering core in the middle section of the air
filter and the dry-type filter that can be replaced
periodically.
The turbocharger has the function of reutilize the
waster gas resource to make the air enter the cylinder
under certain pressure.
The intercooler is composed of the radiator in the
105
engine cooling radiator and can reduce the
temperature of the exhausted air before sending it to
the cylinder.
542410 Turbocharger with the model of
MITSUBISHI TD04
Equipped with the turbocharger of 8140.43S engine
with the pressure-limiting valve
It is composed of the following parts:
□ The turbine and the pressure reference point
mechanism are at the end position of the case.
□ The boost pressure-limiting valve is installed on
the turbine. When the boost pressure is lower
than the pressure reference point mechanism and
reaches the adjustment value, it can discharge
part of the waste gas.
54249 pressure-limiting valve
Detection and adjustment of the
pressure-limiting valve
Inspect the GARRETT turbocharger as per the
diagram
Fig. 228
Seal up the inlet and outlet of waste gas.
Use anticorrosion liquid to clean the inside of the
turbocharger strictly.
Dismantle the oil return pipe (2) from the
pressure-limiting valve base and erect the hose of
99367121 device on the position of the oil return pipe.
Fig. 229
Support the magnetic dial gauge (1) on the booster tie
rod (2) and set it to zero through 99367121 equipment
106
(5). Inject the compressed air as per a certain pressure
into the air release valve body (6) and ensure the air
release valve to maintain the self-inspection condition
for a long time. Moreover, adjust the tie rod to finish
the regulated stroke. Compare different data; loosen
the nuts (3 and 4) and rotate the adjusting tie rod
correctly.
Fig. 230
As for MITSUBISHI booster, loosen the nut (3) and
rotate the booster tie rod (4) correctly.
Replacement of air release valve
As for MITSUBISHI booster, adjust the opening pin
(2) of adjusting arm (1) tie rod and dismantle it
completely; dismantle the fixed bolt and then
dismantle the pressure-limiting valve (5). The
installation sequence of the air release valve is just the
same as the reverse dismantling sequence. Adjust the
tie rod stroke as per requirements of relevant chapters
and sections.
Fig. 231
The dismantling process of the turbocharger is as
follows:
Dismantle the opening pin (1); dismount the nut (2)
and then disassemble the fixing support (3) of the air
release valve (4).
The installation sequence of the valve shall be reverse
to its dismantling sequence, and it shall be adjusted as
per the following means.
Tighten the nut (6) on the diaphragm (5) (to the thread
bottom); erect the adjusting arm (7); use the special
tool 99367121 (Fig. 229, 5) to press the compressed
air into the pressure-limiting valve body 4 with
regulated pressure; then tighten the nut (2) till the
adjusting arm is at correct position. Loosen the nut (6)
till it touches the adjusting arm. Insert the nuts (2 and Fig. 233
6) and adjust the air release valve as per relevant
requirements.
Fit in the nut and apply safety paint. After installing
the opening pin, fix the connecting pipe with suitable
clamp (Fig. 228, 2).
△ Before installing the turbocharger, fill in
lubricating liquid.

542410 VGT variable nozzle-type booster

(8140.43N)
General
The variable nozzle-type booster is composed of the
following parts:
□ One centrifugal compressor (1)
□ One turbine (2)
□ A group of movable blades (3)
□ EDC MS6.3. one pneumatic operation Fig. 234 Function at high rotational speed
mechanism (4) controlling the movable blades,
whose pressure is controlled by the geometric
ratio electric valve controlled by MS6.3 EDC
electric control center.
Advantages of the variable nozzle-type booster:
□ Accelerate the return waste gas speed in the
turbine at low rotational speed of the generator.
□ Continue adjusting the waste gas speed in the
turbine under every rotational speed.
The aim is to obtain maximal capacity efficiency of
the low rational speed engine.
Fig. 232 Function at low rational speed

1 Turbine
2 Movable blade
3 Pneumatic operation mechanism

107
4 Circular hoop
When the engine works at low speed, the waste gas
kinetic energy is week. Under this condition, the
traditional turbine rotates slowly and provides limited
boost pressure.
However, when the movable blades (2) of the variable
nozzle-type turbine (1) are closed to the maximal
position, the channel section among blades is small, to
the air inlet speed increases. The larger the inlet speed
is, the quicker the circular velocity of turbine is, i.e.
the turbocharger speed is quicker.
The engine speed increases, i.e. the waste gas kinetic
energy increases. The turbine (1) speed accelerates,
and the boost pressure increases.
Control electric valve of pneumatic
operation mechanism
See Fig. 235 and 236
The electric valve can adjust the opening of the
booster blades and use the vacuum degree in the brake
system to control the engine speed.
The control valve of MS6.3 electric control center
opens to adjust the pressure control pneumatic
operation mechanism.
The resistance of electric valve coil is: 16±40hm.
Operation mechanism section

The electric control center controls the geometric ratio

electric valve through the operation mechanism to
adjust the vacuum degree acting on the diaphragm.
The operation mechanism (3) pulls the tie rod tightly
to make the movable blades (2) open slowly till it
opens completely. The channel section among the
blades increases, which causes that the waste gas
injecting to the turbine (1) flows slowly with the speed
equal to or less than the low rotational speed working
condition.
The speed of turbine (1) is stable, so a correct value is Fig. 235
obtained during the high speed working condition of
the engine.

Fig. 236

Working principle diagram 237

108
1. Nozzle-type booster- 2. Pneumatic operation mechanism- 3. Electric valve- 4. Air filter- 5. MS6.3 electric
control center- 6. servo brake (vacuum booster)- 7. Vacuum pump 8. Oil injection pump-

Protective measures

Inspect and adjust the air release valve

Use anticorrosion liquid to clean the inside of the Use the vise to clamp the booster tightly, and connect
turbocharger strictly, and then execute the following the connecting pipe of vacuum meter (1) 99367121 to
inspection. See Fig. 238. the case.
Connect the dial gauge (2) with electromagnetic base to
the booster flange; put the gauge head on the booster tie
rod 3; set the gauge to zero and inspect the valve stroke
as per the following requirements:
Vacuum degree 0mmHg Valve open
Vacuum degree 150mmHg Valve stroke 2.3—2.7mm
Vacuum degree 400mmHg Valve stroke 9.7—10.7mm
Valve closed Valve stroke 11—12.4mm
If it is incorrect, loosen the nut 5 and adjust the hoop 4.
During inspection, there is no need to inspect the
reduction of vacuum degree. If other parameters are not
qualified, the operation mechanism shall be replaced.

109
Replacement
See Fig. 239.
Dismantle the open pin 4 and dismount the
turbocharger tie rod 3 from the adjusting arm 5.
Dismantle the air release valve 1 after unscrewing the
nut 2.
The installation sequence of the value is verse to its
dismantling sequence, and the torque for tightening the
nut is 5.6—6.8Nm.

Finally, apply the safety paint on the nut 5 (Fig. 238).

Before installing the turbocharger, fill in lubricating oil.

110
HP electromagnetic injection supply system (common rail MS6.3)

Fig. 240
Diagram of parts distribution of HP electromagnetic injection supply system
1. Engine speed sensor 2. Air pressure and temperature sensor 3. Hot-start flame glow plug 4. Electromagnetic
valve 5. Phase sensor 6. Electric nozzle
7. Common rail 8. Coolant temperature sensor 9. Electromagnetic fan 10. Common rail fuel pressure sensor 11.
Compressor (if there is ) 12. EGR valve (if there is)
13. HP oil pump 14. the 3rd pump oil cut-off valve 15. Pressure regulator 16. Fuel filter 17. Radiator 18. Fuel
temperature sensor 19. Oil transfer pump 20. Fuel pre-filtering 21. Oil tank 22. Battery 23. Electric control center
with barometric pressure sensor 24. Fuel tank with measuring hole 25. Common rail pressure-limiting valve 26.
Accelerator pedal sensor 27. Clutch pedal sensor 28. Brake pedal sensor 29. Engine tachometer 30. Odometer 31.
Hot-start indicator

General
To reduce the particle discharge, the injection ability of the fuel must be improved.
The fuel injection system provides the injection pressure as high as 135MPa. The precise control of the electronic
management system optimizes the engine performance and controls the emission and oil consumption.
In other diesel engine systems, the HP pressure is only produced when each cylinder injects (oil injection pump
and pump nozzle).
In the common rail system, a special pump can maintain the fuel in the common pipe at high pressure but not
depending on the injection cylinder and phase of the engine.
There is always the fuel with the injection pressure computed by the electric control center at the inlet of the fuel
injector.

111
When the electromagnetic valve of the electronic fuel injector starts under the effect of the electric control center,
the fuel with high pressure is injected into corresponding cylinder from the common oil pipe.

Caution: As there is high pressure in this hydraulic system, the following contents must be
complied with strictly for safety reason:

 Avoid not tightening the HP pipe connector.

 Avoid dismantling HP pipe when the engine is running (prohibit trying to release air from HP pipe
because it is absolutely useless and is much danger!)

The completeness of LP pipeline is also very important, so adjustment and alteration shall be avoided.
Repair it immediately if there is leakage.

Electric Control of Injection System

1 58918 Speedometer
2 58918 Engine tachometer
3 42374 Clutch pedal sensor
4 53565 Clutch pedal sensor
5 85152 Acceleration pedal position sensor
Idle switch
6 47106 Fuel temperature sensor
Fuel filter blockage sensor
7 47035 Coolant temperature sensor
8 85156 Air flow amount sensor
9 48042 Phase sensor
10 48035 Flywheel sensor
11 85157 Fuel pressure sensor
12 78247 Electronic fuel injector
13 19005 Hot start
Hot-start electromagnetic valve
14 85151 Electric fuel pump
15 78013 Pressure regulator
16 78015 Electromagnetic valve
17 12012 Air conditioner compressor
18 58701 EDC indicator
19 58702 Hot-start indicator
20 Cruising/power output control
21 85130 None
22 72027 Diagnosis interface
23 VGT control electromagnetic valve (8140.43N engine)
The electric control center calculates out the injection mode as per the following parameters:
- Engine speed
- Accelerator pedal position

112
- Inlet air flow amount
- Temperature of coolant
- Storage battery voltage
- Fuel oil pressure
The fuel oil pressure is regulated from 25 to 135MPa according to the spontaneous working condition of engine
(rotational speed and load etc).
The lower fuel pressure is compensated with lengthening of oil injection time; on the contrary, the value under the
required load is always kept.
Keep pre-injection till 2800rpm to reduce the specific noise of direct injection.
The advance angle of pre-injection, the interval of the pre-injection and the main injection, and the advance angle
of the main injection are varied according to the spontaneous working condition of engine.

Control Strategy
Control of Electric Fuel Pump
Electric control center:
- The power is supplied to the electric pump when the start key is at the running position.
- If the engine cannot be started within 9s, cancel power supply to the electric pump.
Hot-start Control
When one of the air temperature sensor or the fuel temperature sensor indicates the temperature below 0°C, the
preheating device functions.
Phase Identification
Inject fuel to corresponding cylinder through the sensor signal on the camshaft and the flywheel.

Injection Control
According to the information obtained from each sensor, the electric control controls the pressure regulator and
alters the pre-injection mode and the main injection mode.

Closed-loop Control of Injection Pressure

According to the engine load information obtained from each sensor, the electric control controls
the pressure regulator to obtain optimal pressure.
Control of Advance Angles of Pre-injection and Main Injection
The electric control center calculates the optimal injection point as per the information provided by each sensor
and the stored MAP.

Control of Booster with Variable Nozzle (8140.43N Engine)

The electric control center controls the variable nozzle of booster. The electric control center changes geometry to
successively adjust the speed of booster turbine according to the rotational speed and load of the engine.

Idle Speed Control

The electric control center collects information from each sensor and adjusts the fuel injection amount.

113
Control the pressure regulator and change the injection time of the electromagnetic fuel injector.
Keep the battery voltage within a certain range.
Equilibrium of Each Cylinder at Low Speed
According to the information collected from each sensor, the electric control center controls the rotational speed at
low speed and idle speed through the injection time of each electromagnetic fuel injector.

Anti-toothing Control
Ensure the smooth transition under various conditions through controlling the start time of the pressure regulator
and the electromagnetic fuel injector.
Limitation of Maximal Rotational Speed
At 4250rpm, the electric control center controls the fuel flow through decreasing the start time of electromagnetic
fuel injector.

When 5000rpm is exceeded, the electromagnetic fuel injector will not work

Cut Off Control

When the accelerator is released, the cut-off of fuel is controlled by the electric control center as per the following
logic:

t cut off the fuel supply to the electromagnetic fuel injector

Re-supply fuel to the electromagnetic fuel injector a little before the engine reaches the lowest rotational speed.

Control the fuel pressure regulator.

Control Acceleration Smoke

When the load is required to be increased, the electric control center controls the pressure regulator and changes
the fuel injection time of fuel injector to reduce the emission smoke, according to the air inlet flow and the signal
of engine speed sensor.

Fuel Temperature Control

When the fuel temperature exceeds 75℃ (measured by the sensor in the fuel filter), the electric control center
will reduce the injection pressure.

When the fuel temperature exceeds 90℃, the power will reduce to 60%.

Description

The fuel temperature largely depends on the completeness of the LP pipeline system.

The system function can be damaged under such conditions as not complying with standards, not using the
parts of original factory or arbitrary alteration.

Cooling Fan Control

When the coolant temperature exceeds 98℃, the electric control center will make the fan work.

114
 Work Control of Air Conditioner Compressor
The electric control center will control the bonding or separation of the electromagnetic clutch of air conditioner
compressor according to the coolant temperature.

-If the coolant temperature reaches ~ 105℃, then it shall be separated (for about 6s).

After Running
After turning off with the key, the electric control center is still supplied power by a special relay for several
seconds. That is to permit the microprocessor to store relevant data into EEPROM. Therefore, in the next start, the
stored fault information and theft prevention information can be obtained from EEPROM.

Run Up
Put through all keys and these data are copied on RAM memory.

Functional Diagram of Common Rail System

Fig. 241
1. Pressure sensor 2. engine speed sensor 3. HP pump 4. HP regulator 5. other operation mechanisms (spark plug,
heating filter, fan control, AC control etc.) 6. the electric control center with mixed gases pressure sensor 7. other
sensors (accelerator pedal, brake, clutch, speed, water temperature, and air temperature) 8. common rail pressure
sensor 9. fuel tank 10. pre-filter 11. electric pump 12. fuel filter 13. booster filter 14. fuel tank with measuring hole
15. common rail pressure-limiting valve 16. air flow meter 17. common rail 18. electromagnetic fuel injector 19.
cam phase sensor

115
Hydraulic System Fig. 242

Fig. 242
1. Fuel tank
2. Electric fuel pump
3. Filter
4. Temperature sensor
5. High-pressure oil pump
6. Pressure regulator
7. Fuel return connector with 3.5mm measuring hole
8. Common rail
9. Fuel oil pressure sensor inside the common rail
10 Electronic fuel injector
11. Fuel return pipe with measuring hole.

Electric Pump

The measurable pump with bypass rotary type is outside the oil tank. Fig. 243

It is installed in the reachable area at the left side of the vehicle frame.

Fuel supply devices do not need cleaning.

The pipeline has quick slot.

116
Connect to the A7/A8 terminal phase of the electric control center.

Characteristics

Input voltage: 2,5 bar

Flow amount: > 155 liter/h

Power supply: 13,5 V - < 5 A

Coil resistance at 20℃: 28.5 Ohm

Fig. 243

Fuel filter

Installed at the front left part of the engine compartment. Fig. 244

Filter paper density: 5 micrometer

Erected on the support: one fuel temperature sensor, one blockage sensor, and durability preheater.

Working pressure poor (blockage annunciator): 0.6bar

Signal sensor of fuel accumulated water at the bottom of filter element.

The fuel temperature signal transmitted to the electric control center managing the electronically-controlled fuel
injector through relevant sensor concerns the careful calculation of the fuel amount injected into the cylinder.

117
 Fig. 244

1. Filter blocking sensor – 2. Fuel temperature sensor – 3. Accumulated water sensor –

4. Heating – 5. Bypass valve
Caution:
The common rail oil injection system requires that the fuel oil must be very clean without
accumulated water.
Carry out the repair of fuel oil feeding system correctly.
HP oil pump (radial injection)
1. Three radial piston pumps (total amount 0.7cc) are driven by the timing gear belt. The phase does not need
adjusting.
2. Each pump unit includes:
3. - The eccentric wheel (2) is floated on the eccentric part of the shaft (6). Thus, when the shaft rotates, the
eccentric wheel does not rotate together but moves horizontally along a circumference with bigger radius,
which results in alterative rising of three plungers.
4. - Plate air inlet valve (3)
5. Spherical air inlet valve (4)
6. The pressure entering the common rail is between 250bar and 1350bar, which is controlled by the electric
control center through the pressure regulator on the electric valve.
7. The pump is lubricated and cooled through the fuel system.
8. The function of the third cut-off valve (78015) is to increase the diesel flow amount lubricating the radial

118
 pump, which functions above 4200r/min (when no power is needed), i.e. when the piston rises, corresponding
air inlet valve of small pump also keeps open. The 1/3 flow amount of the HP oil pump returns to the LP
chamber inside the pump to ensure the liner lubrication.
9. The opening-closing time of the radial injection pump on the engine reduces obviously as compared with
traditional oil injection pump. The phase does not need adjusting.
10. The control electric valve (78015) is connected to the A20/A21 terminal phase of the electric control center.

Fig. 245
1. The third pump oil cut-off valve 2. Push rod 3. Plate air inlet valve 4. Cylinder 5. Piston 6. Pump shaft
7. LP fuel inlet 8. Spherical air inlet valve 9. HP fuel inlet 10. Fuel oil return 11. Trivalve eccentric wheel

Pressure regulator

Fig. 246
1. Valve 2. Spherical sealer 3. Pin 4. Valve body 5. Coil 6. Pre-pressing spring 7. Armature

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It is on the HP oil pump to adjust the fuel pressure of the common rail (electronic fuel injector) under the control
of electric control center.

Major parts of composition:

- One spherical (1) sealer
- One pin (2) controlled by valve (3)
- One preload spring (4)
- One coil (5)
The electric valve is open constantly when there is no control signal.
The electric control center adjusting PWM control signal can partly increase or reduce the fuel leakage to the air
exhaust direction.
The pressure adjustment can be inspected by the electric control center through the pressure sensor on the
common rail. If needed, the control signal intensity can be altered to reach the required value.
 The control electric valve (78013) is connected to the A9/A20 phase of the electric control center.
As introduced above, this component cannot be replaced separately, so it cannot be dismantled absolutely.

Common rail (only applicable to 8140.43S)

001039t

1 Common rail 4 Fixed fuel oil return connector

2 Fuel injector 5 HP oil pump fuel inlet
3 Pressure sensor
Fig. 247
The common rail capacity is not large.

The pressure can be increased quickly under low rotational speed and large flow amount for quick start.

Anyhow, the capacity of common rail capacity must be sufficient to minimize the pressure fluctuation caused by
the fuel injector on/off and the work of HP oil pump. When the HP oil pump appears a trough, a measuring hole is

120
also helpful for this function.

The fuel oil pressure sensor is on the common rail. The start of common rail is passed to the electric control center
through the signal of fuel pressure sensor. One feedback information is obtained to control the pressure on
common rail, which can be rectified if necessary.

Flow amount valve (Fig. 248)

Fig. 248

If the engine leaks oil, it can be used to prevent fire and ensure normal operation of engine. The small piston 1 is
at the spring 2 to control its start position with fuel pressure control. If the oil leakage pressure at the outlet end of
the pressure-limiting valve is too high, the small piston can block the fuel outlet end.

Pressure-limiting valve (Fig. 249)

When the fuel oil pressure exceeds 135MPa, the small piston will overcome the pressure motion of the spring 2 to
make the fuel return the LP pipe, so the common rail fuel pressure becomes stable.
Fig. 249

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 Fuel supply system (Fig. 250)

Fig. 250
Diagram of fuel supply system
1. Hot-start spark plug 2. Hot-start electromagnetic valve 3. Electromagnetic fuel injector 4. HP rail (common
rail) 5. The third pump oil cut-off valve 6. HP pump 7. Fuel filter 8. Electromagnetic pump 9. Pre-filter 10. Oil
tank 11. Pressure regulator 12. Socket 13. Pressure-limiting valve 14. Flow amount valve
This fuel supply system is divided into two types of low pressure and high pressure rails.
The LP rail is composed of the prefilter, the oil return pipe, the fuel filter, the electromagnetic pump, the fuel
outlet pipe, the hot-start spark plug and the hot-start electromagnetic valve. If the HP pump fuel is excessive and
can be supplied to lubrication and cooling device of this pump, the excessive fuel of the electromagnetic fuel
injector can flow into the hot starter. There is a measuring hole at the fixed joint seat of oil outlet connector and
the pressure-limiting valve of HP rail, whose function is to maintain the inner pressure of the hot starter to be
0.05MPa. This system shall not leak air.
The LP pipe (except the oil return pipe) is under quick closing condition.

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Electronically-controlled fuel injector (Fig. 251)
The electric control valve controls the rising of the needle valve of jet nozzle.
The filter erected on the fuel inlet connector protects the fuel injector inlet from foreign substances. The structure
of oil nozzle is similar to the traditional oil nozzle, only different in plunger spring.
To get close to the fuel injector, the acoustic hood at the lateral side of cylinder cover must be dismantled. The fuel
oil return pipe is the quick connecting type.
The composition of electronically-controlled fuel injector can be regarded as the following two parts:
- Injector consisting of the tappet (1), plunger (2) and nozzle (3);
- Electronic control valve consisting of the coil (4) and pilot valve (5).

123
 Fig. 251

1. Tappet- 2, Plunger- - 3. Nozzle- 4. Coil- 5. Pilot valve- 6. Spherical sealer- 7. Control area- 8. Pressure
chamber- 9. Control capacity- 10. Oil return pipeline- 11. Control pipeline- 12. Input pipeline- 13. Circuit
connection- 14. HP fuel inlet- 15. Spring

Function:
The electronically-controlled fuel injector works in three steps.
Step 1: Rest position Fig. 252

124
The coil (4) does not excite and the sealer (6) is at closing position.
The fuel pressure is the same no matter in the control area (7) or in the pressure chamber (8). And at this time, the
sealer (6) closes, and the plunger (2) cannot rise.

Fig. 252

Step: Starting injecting (Fig. 253)

The coil (4) excites to make the sealer (6) move upward.
The fuel in the control capacity (9) flows to the oil return pipeline (10), and the inner pressure of the control area

(7) reduces.

125
Meanwhile, the fuel oil pressure in the pressure chamber (8) makes the plunger (2) rise, and the fuel oil in the
cylinder starts injecting.

Fig. 253

Step: End of injection (Fig. 254)

The coil (4) does not excite, and the sealer (6) returns to the close position. Force returns equilibrium, so the
plunger (2) returns to the close position, and the injection ends.

126
Fig. 254

127
 Main Description of Storage/Package and Assembly of Common Rail Injection

System

Description overview:
All parts and components in the common rail system shall ensure conformance to the humidity requirement, and

the package can only be removed before assembly.

The cleanliness of each part shall also be ensured, especially during repair and assembly (when replacing the filter
and the pre-filter).
Finally, the protection plug lid of the hydraulic part and the sensor can only be removed before assembly
positioning.
All circuit connections shall pay attention to the assembly direction.
All thread connections shall be tightened to the regulated torque value.
All pipe connections shall be tightened to bottom.

Electronic fuel injector:

The connector/pipe connector/nut on the fuel injector body cannot be dismantled.
Don’t dismantle the injector body and the electromagnet.

High-pressure oil pump

The HP regulator and the third oil cut-off pump are not permitted to be repaired.

High-pressure oil pipe

Each HP oil pipe shall be replaced every time after being dismantled.

128
Electric control center MS 6.3

Fig. 255

The electric control center is installed at the left side of the engine compartment and is connected to the engine
harness through two 43-foot slot.
Slot A: connecting the engine
Slot B: connecting the complete vehicle.

Sensor
Engine flywheel and rotational speed sensor
There are 58 holes on the flywheel in total to sense the occurrence of the sensor signal. The same as that on
the camshaft, the sensor is positioned on the cylinder body and receives the stroke variation signal of 58
holes and the signal of the two vacant holes on the flywheel.
The variation (A, synchronous position) of the signal sent by the two vacant holes detected by each rotation
of the engine is the datum signal for the electric control center to identify the dead point position on the
piston.
Moreover, the signal is also used by the electric control center to learn the engine speed to realize
calculation of the advance angles of the main injection and the pre-injection and the oil injection time and
the control of tachometer.
Assembly of sensor:
- Use the feeler gauge to ensure the size marked in the diagram.
- The perpendicularity of the sensor to the wheel must be ensured when tightening the bolt.

Characteristics of flywheel rotational speed sensor and timing sensor

Both of the two are inductive sensors.
 The flywheel sensor is connected to A29/A37 terminal of the electric control center.
It is also used to control the electric tachometer on the dashboard. Therefore, if there is no such signal, the
tachometer does not work.
 The timing sensor is connected to A4/A31 terminal of the electric control center.
 The electric resistance is ~ 860 Ohm under 20℃.

Air flow amount sensor

It includes the assembly parts and components of the temperature sensor and the pressure sensor.
It is assembled on the air inlet manifold of the engine to measure the maximal flow amount of the inlet air, thus to
calculate the fuel amount from the fuel injector into each circulation.
 It is connected to the electric control center terminals A2/A3/A19/A34.
Pin 1 sensor - Pin A19 ECU - Ground wire-
Pin 2 sensor - Pin A2 ECU - Temperature signal-
Pin 3 sensor - Pin A3 ECU - 5V power supply
Pin 4 sensor - Pin A34 ECU - 0~5V voltage signal

Atmospheric pressure sensor

It is inside the electric control center.

115
Provide correct flow amount according to the atmospheric pressure measured as per height above sea-level.

Coolant temperature sensor

 It is NTC sensor and is installed on the thermostat.
Measure the coolant temperature to provide thermal state signal of the engine to the electric control center.
 It is connected to the electric control center terminal A1/A30.
 The temperature requirement during sensor working:

Fuel temperature sensor

 It is NTC sensor and is installed on the fuel filter.
Measure fuel temperature and provide the diesel thermal state signal to the electric control center.
 It is connected to the electric control center terminal A15/A30.

Acceleration pedal position sensor

The sensor is installed on the accelerator pedal and is the embedded type NA smallest switch accelerator.
Provide parts of numerical values of the electric control center and supply fuel operation pedal.
 Input voltage is 5V.
 Electric resistance of accelerator is about 1Kohm.
 It is connected to the electric control center slots B2/B13/B27/B29/B35.

116
Diagnosis

117
 Diagnosis of EDC MS 6.3

Identification of electric control center

Through the operation of reading the identification reading of the electric control center, the following inherent
information of the complete vehicle/electric control center can be extracted (divided into 3 areas: plant/workshop
data—repair data—working data):

- Input time of program

- Hardware and software versions of the electric control center
- Complete vehicle identification code (VIN)
- List of equipment and optional fittings

The program input in EDC system by the electric control center is based on the engine performance and the
equipment of the complete vehicle: vibration damper, cruising control and air conditioner etc.

Fault reading
The electric control center can read over 60 pieces of faults (engine and system).
Each fault can be divided into “present” (the fault exists when the fault reading appears) or “intermittent”
(the fault has been detected when it occurred, but does not exist when the fault is red).

Type of Fault
Each fault has its type, representing the signal fault or the parts and components fault of the system.
- Short circuit of battery/power supply
- Short circuit of ground wire
- Opening of line/pipeline
- Inefficiency of signal
- The physical value of signal exceeding the high level
- The physical value of signal exceeding the low level
- Input/power supply of sensor being too high
- Input/power supply of sensor being too low

Counter
Each fault passes through a fault process timer, a specific fault counter and a down counter.
The reading of the fault process timer increases progressively only when the fault is “present” (calculated in
seconds); when the fault is “intermittent”, the reading keeps unchanged (the faults of sensor and parts and
components are not in the system).
The specific fault counter increases successively when the fault exists in the system (calculated as per unit).
The down counter is according to the specific fault variation figure of each time; the key contacts the start, and the
formerly existed fault disappears or keeps at “intermittent” state.
When the value is zero, the fault will be deleted from the fault record, just as it never happens.

Environmental condition
Each fault includes 10 environmental conditions: 2 fixed ones (engine speed and existing time of fault) and 8
variable ones (from one fault to another).
The aim is to remain a fault outline/general impression.
The environmental condition will be maintained in the fault recordings, and the parts and components are
classified as per faults.
When reading, each single fault displays 10 environmental conditions. Compare the 10 environmental conditions
memorized when the fault is finally detected with those when the first fault occurs.

118
If the fault does not occur once, it displays the environmental conditions of the first importance and covers the
previous record at the same time.

Parameters
The continuous readings of the condition parameters and the measurement parameters can be executed.

Condition parameters:
Key 15
The 1st brake switch
The 2nd brake switch
Smallest accelerator switch
Condition of preheating indicator
Condition of EDC indicator
…
Measurement parameters:
- Engine speed
- Accelerator pedal position
- Fuel oil temperature
- Coolant temperature
- Pressure in the common rail system
- …

Effective diagnosis
The following can be realized through the diagnostic unit and the diagnostic facilities of the electric control
center:

Bench test of operation/execution mechanism

Operation of the following parts and components is directly controlled by the electric control center:
- Execution mechanism of common rail pressure regulation and operation
- VGT operation execution mechanism (if there is)
- EDC indicator
- The 3rd pump oil cut-off valve

The following parts and components are controlled by the relay:

- Hot start
- Hot-start electric valve
- Preheating indicator
- Electric fuel pump
- Filtering preheater
- Fan relay

Engine bench test

The compression pressure test: detecting the deviation of cylinder compression pressure

Trial run test: detecting the deviation of each fuel injector performance

HP system test: determining the functional problems that may occur in the HP system
Booster test: detecting the turbine performance or variable nozzle booster.

EDC MS6 electric control center has a memory area to rescue the data of the first engine bench test. The
new vehicle data of the plant can be red out from Modus.

119
Management of recorded data (memory)

The name is the recorded data, including parameters relating to the engine-complete vehicle-electric control
center operation conditions.
The parameters are divided into two groups:

- Timer: loss operation time information.

For example: the duration of coolant temperature over 90℃.

- Counter: information required by loss.

For instance: the times for over-speed use of the engine.

Blink-Code EDC Fault Decrease Level

Indicator
Complete vehicle
1.1 Lit Complete vehicle speed
1.3 Out Cruising/stroke control
1.4 One lit, one Accelerator pedal X
out
1.5 Out Clutch switch
1.6 Lit Brake switch
1.7 Out Step down brake/accelerator simultaneously Minimal speed
1.8 Out Diagnosis indicator /EDC indicator
1.9 Out Relay controlling air conditioner
Engine 1
2.1 One lit, one Water temperature sensor X
out
2.2 Out Air temperature sensor
2.3 Lit Diesel temperature sensor
2.4 One lit, one Pressure-boosting pressure sensor X
out
2.5 Out Atmospheric pressure sensor
2.7 One lit, one Relay controlling electric fuel pump
out
2.8 Out Relay controlling fuel filtering preheater
2.9 Lit Relay controlling fan
Engine 2
3.1 One lit, one Cylinder 1 equilibrium
out
3.2 One lit, one Cylinder 2 equilibrium
out
3.3 One lit, one Cylinder 3 equilibrium
out
3.4 One lit, one Cylinder 4 equilibrium
out
3.5 Out Battery/power supply voltage
3.6 Out Hot-start indicator
3.7 Out Relay controlling hot start
3.8 Out Electric valve relay controlling hot start
3.9 Out Preheating monitor
Booster
4.4 One lit, one VGT monitor
out
4.5 Lit VGT electric valve
Fuel injector

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 5.1 One lit, one Cylinder 1 fuel injector
out
5.2 One lit, one Cylinder 2 fuel injector
out
5.3 One lit, one Cylinder 3 fuel injector
out
5.4 One lit, one Cylinder 4 fuel injector
out
5.7 Lit Working condition (cylinder 1-4)
5.8 Lit Working condition 2 (cylinder 2-3)
X=power decrease

Blink-Code EDC Fault Decrease Level

Indicator
Engine speed
6.1 One lit, one Engine rotation speed sensor X
out
6.2 One lit, one Timing speed sensor X
out
6.4 One lit, one Engine over-speed
out
Connection harness
7.1 Out PWM signal
7.2 Out Vehicle CAN nonreactivity
7.3 Out Vehicle CAN control
7.4 Out CAN information control
Fuel oil pressure/EGR
One lit, one X or engine
8.1 Fuel pressure control
out flameout
8.2 One lit, one Fuel pressure sensor X
out
8.3 One lit, one Pressure regulator electric valve
out
8.4 Out Electric valve for three small pumps
8.5 Lit EGR monitor
8.6 Lit EGR electric valve
8.7 Lit Debimetro X
8.8 Out EGR atmospheric pressure sensor
Electric control center
One lit, one X or engine
9.1 Electric control center fault
out flameout
9.2 Lit Electric control center EEPROM fault
9.3 One lit, one Fixed information-EDC
out
9.4 Lit Main relay
9.5 Out After bench test of trial run
9.6 One lit, one Completion of engine bench test (ECU)
out
One lit, one X or engine
9.7 Input/power supply of sensor
out flameout
9.8 One lit, one Electric control center fault Start impossible
out
9.9 One lit, one ECU operation system Engine flameout
out
X=power decrease

121
The program of deleting the fault record through Blink Code button:
 Break off the ignition switch with key.
 Press down Blink Code switch and maintain 4-8s, and get through the ignition switch with key.

Caution: after the operation is completed, don’t break off the key and get through
immediately, but maintain ten seconds or so before inserting the ON
position.

122
 Troubleshooting (Part I)
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement
CODE Indicator
1.1 Lit Vehicle speed sensor—signal No vehicle speed displayed on the Use IT2000 for road test
unable to be received or no odometer.
signal Slight toothing form/vibration at Read parameters
high-gear position.
Check harness, converter and
relevant parts and components

1.1 Lit Short circuit of the positive Cruising control/power output Use IT2000 for road test
pole or ground wire of vehicle not working. Inspect the information
speed sensor (between the acceptance between the odometer
odometer and the electric Slight toothing form/vibration at display and the vehicle speed
control center) high-gear position. through IT2000 readings. Inspect
harness and the connector among
the odometer, the electric control
center and relevant parts and
components.
1.3 Out Unable to receive the control Cruising control/power output Distinguish fault key through
of cruising control/power not working IT2000 readings
output button/key Inspect the cab and the harness,
connector and control key of the
electric control center
1.4 One lit, one Short circuit of the positive Power decrease. Inspect the harness, the adapter
out pole or ground wire of the Minimal acceleration 1500r/min. and the parts and components
accelerator pedal or the power through IT2000 readings.

123
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
supply voltage of the the vehicle speed sensor.
accelerator pedal being too
high or the accelerator sensor
failing
1.5 Out Clutch switch: signal unable to Cruising control/power output Step down the clutch pedal to the If the result is different after
be received or no signal not working bottom and read out the inspection, the fault may be the clutch
Or, connecting the clutch pedal parameters on IT2000. not being stepped down to the bottom
with cruising control/power If there is still fault, inspect if the (shifting gear after disconnecting the
output, engine accelerating to assembly of the harness, the switch)
maximal speed. adapter and the switch is correct. If there is no clutch signal, there will
Slight toothing form during gear be no result for the engine test.
shifting
1.6 Lit Brake switch: the signal The stop indicator may not work. Parameters of harness, connector Inspect if the pedal switch is
between the first and the Cruising control/power output and switch condition assembled correctly (shall be
second unable to be received. not working operated simultaneously)
1.7 Out Step down brake/accelerator Engine speed reducing to the Inspect the signal of accelerator If the brake and the accelerator pedal
pedal simultaneously lowest pedal sensor and if the are stepped down simultaneously, the
accelerator pedal is not stepped, engine reduces to the lowest speed till
or the driver steps down the the brake pedal is released; the aim is
brake and the accelerator pedal to turn off the vehicle and engaging
simultaneously. the accelerator pedal steadily at the
intermediate position. The pedal shall
be released with consideration of
safety issue.
1.9 Out Short circuit or broken circuit Adjust 2.7-2.8-2.9 under the broken Measurement parameters of relay
of the coil ground oil of the circuit of slot PIN 8a.

124
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
relay controlling compressor Air conditioner compressor not Inspect harness, connector and
working relay
2.1 One lit, one Broken circuit, short circuit of Cold start difficult Inspect the connection of the Fuel temperature of fan=20℃
out ground wire or positive pole of Cooling fan of engine always under harness of the water temperature If the water temperature and the
the water temperature sensor, the working condition sensor through IT2000 readings; diesel temperature is the same, the
using the fuel temperature Power reducing (noise increasing replace the sensor. crossing-over value is effective.
sensor because of inefficiency of
pre-injection)
2.1 One lit, one Refer to Part II of Refer to Part II of troubleshooting: Refer to Part II of Refer to Part II of troubleshooting:
out troubleshooting: “Engine Not “Engine Not Starting” troubleshooting: “Engine Not “Engine Not Starting”
Starting” Starting”
2.2 Out Short circuit or broken circuit Performance reduces slightly at IT2000 readings Te air temperature crossing-over
of the positive pole or the cold state; the smoke intensity Inspect harness and parts and value is stable at 40℃. When the air
ground wire of the air reduces slightly during hot start, components. temperature works, the hot start
temperature sensor on the air and the start smoke signal is 3.9. controls not working.
inlet manifold Smoke intensity of start and When the temperature signal of the
high-speed start, hot water temperature sensor or the fuel
temperature sensor is less than 0℃ or
reduced to ℃, preheating works.
2.3 Lit Short circuit or broken circuit If it is the circuit problem, correct IT2000 readings Obtain the water temperature of
of the positive pole or the the slot PIN 30 and 2.1 Inspect harness, connector and crossing-over value. If there is no
ground wire of the fuel Cold start difficult parts and components. such signal, adjust to the stable value
temperature sensor 40℃.
2.4 One lit, one Short circuit or broken circuit Spraying smoke when starting IT2000 readings
out of the ground wire of the air VGT: reducing power Inspect harness and parts and
pressure sensor on the air inlet There is smoke during start components.

125
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
manifold, or the positive pole
short circuit or the input
current exceeding the limit
amount
2.5 Out Short circuit of the ground wire The vehicle with EGR emits black IT2000 readings The exchanging use of the pressure
of the environment/external smoke. valve is good for the adjustment of
pressure sensor in ECU, the electric control center.
positive pole short circuit or Note: the environmental pressure
broken circuit sensor in EDC electric control center
cannot be replaced separately.
2.7 One lit, one Short circuit of the positive The battery is out of power. Pass through IT 2000 diagnosis Hear the sound of continuous work of
out pole of the electric pump relay The electric pump is damaged in Inspect harness, connector and the pump, even when the key/ignition
advance. parts and components. switch is turned off.
The electric fuel pump is always at
working condition, even when the
engine is off.
2.7 One lit, one Short circuit or broken circuit The engine is off or cannot be Pass through IT 2000 diagnosis
out of the coil ground wire of the started. Inspect harness, connector and
electric pump relay parts and components.
2.8 Out Short circuit of positive pole of The battery is out of power. Pass through IT 2000 diagnosis
the filtering preheater Inspect harness, connector and
relay—the preheater is always parts and components.
under working condition when
the fuel temperature>5℃
2.9 Lit Short circuit of positive pole of Add fuel consumption Pass through IT 2000 diagnosis The fan clutch is always at working
the electromagnetic fan clutch Inspect harness, connector and condition (engine working)

126
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
parts and components.
2.9 Lit Short circuit or broken circuit Overheating of engine limits Pass through IT 2000 diagnosis
of the coil ground wire of the power. Inspect harness, connector and
relay Cooling fan of engine does not parts and components.
work.
2.9 Lit Short circuit of the positive Add fuel consumption Pass through IT 2000 diagnosis
pole of the fan relay The cooling fan of engine is always Inspect harness, connector and
under the working condition, even parts and components.
when the engine is at cold state.
3.1 One lit, one Fuel injector unbalance It may be due to irregular running Carry out the engine bench test The electric control center shall alter
3.2 out and smoke. EDC indicator is one lit through IT2000. the fuel injector signal beyond the
3.3 and one out when the speed is Replace the fault fuel injector. normal regulated value.
3.4 lower than 1300r/min. If the engine bench test result is good
and the problem does not occur again,
leg go the vehicle.
3.5 Out Too low battery voltage Step down the pedal and start to Inspect the pressure regulator, the When the battery voltage <6.5V, the
1300r/min battery, the AC generator, the engine is off.
The engine is off or cannot be connector and the harness.
started.
3.6 Out Short circuit or broken circuit The indicator is always out. Cold Pass through IT 2000 diagnosis The driver does not preheat; when the
of the preheating indicator start difficult Inspect harness and parts and ambient temperature is low, the
components. indicator does not display.
3.6 Out Short circuit of the ground wire The preheating indicator is always Diagnosis. Inspect harness, The preheating works. It does not
of indicator on. connector and parts and display for cold start because the
components. indicator is always on.
3.7 Out Short circuit of the ground wire It may be because overheating of Diagnosis

127
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
of the hot start spark plug relay. the hot-start distributor because it Inspect harness, connector and
works constantly. parts and components.
The battery is out of power.
3.8 Out Short circuit of the coil ground 3.9, The battery consumes quickly. Diagnosis The electric valve is always at
wire of the hot-start electric Cold start difficult Inspect harness, connector and working state. The fuel oil flows into
valve relay. There is smoke during start parts and components. the air inlet manifold through the
spark plug.
3.8 Out Short circuit or broken circuit If the positive pole is short circuit Relay diagnosis. Inspect harness
of the coil positive pole of the 3.9, there is smoke. and parts and components.
hot-start electric valve relay 1.5-1.6-1.3-2.1-2.2-2.3-3.6, if it is
circuit fault, correct the ground
wire of relevant parts and
components.
Cold start difficult
3.9 Out Short circuit of the ground wire There is smoke, noise and Diagnosis The electric valve is always on. The
of the hot-start electric valve. abnormal smell of fuel oil; it is Inspect harness, connector and key is at ON position, and the fuel
working fault of engine. parts and components. continues flowing into the air inlet
Add fuel consumption manifold.
4.4 One lit, one The boosting pressure is too 4.5 VGT bench test Mechanical equipment is
out high or too low or does not The exhaust back pressure IT2000 readings partly/wholly engaged steadily,
conform to the regulating value consumption may be increased. Inspect the mechanical closed or opened.
(mechanical part engaged The booster is damaged in advance. equipment motion of VGT Or short circuit of the positive pole of
steadily) Power decreases. Inspect VGT operation VGT electric valve, or short circuit of
There is smoke during starting (air mechanism ground wire.
quality poor). Inspect harness.
Inspect VGT control pneumatic

128
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
pipeline.
4.5 Lit Short circuit of positive pole of 4.4 Reduce power (there is noise VGT bench test If the positive pole connecting the
Only VGT operation mechanism, or because pre-injection does not Inspect harness, connector and harness slot PIN 8a is short circuit
VGT short circuit or broken circuit work efficiently) parts and components. and breaks, there is fault of:
of ground wire There is smoke during starting (air - Fan control
quality poor). - VGT control
- The third oil cut-off pump
- Pressure regulation
- Air compression
- Electric fuel pump
5.1 One lit, one Short circuit of positive pole of 3.1-3.2-3.3-3.4 Engine bench test Only double-cylinder of engine
5.2 out the cylinder fuel injector Cylinder 3 of engine works, or Harness-connector-relevant fuel works (2 and 3 or 1 and 4).
5.3 connection cylinder 3 works first, and then injector circuit parts Cylinder 3 of engine works after
5.4 cylinder 2 works. turning off and restarting
5.7 One lit, one Power amplifier stage fault of 3.1-3.4 or 3.2-3.3 Delete fault record and test again. It is possible that the electric control
5.8 out cylinders 1 and 4 or cylinders 2 5.1-5.4 or 5.2-5.3 Note: The input power meter of center appearance is under short
and 3 (in the electric control Cylinder 2 of engine works. the electronic fuel injector is in circuit + battery (connecting the key
center). EDC electric control center and or other parts by accident).
cannot be replaced separately.
6.1 One lit, one Flywheel sensor: without The hot-start of engine is difficult; Inspect the assembly of harness, If there is no flywheel signal, use the
out signal or signal unable to be the cold-start of engine is connector and sensor. speed signal of camshaft sensor.
received impossible.
Power reduces (there is noise
because the pre-injection work is
inefficient).
6.2 One lit, one Camshaft sensor: no signal or The hot-start of engine is difficult; Inspect the assembly of harness, If there is no camshaft signal, use the

129
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
out signal unable to be received the cold-start of engine is connector and sensor. phase signal of flywheel sensor.
impossible.
Power decrease.
8.1 One lit, one Too high current of If the voltage is lower than the Observe visually if the HP oil If the pressure obtained by the
out regulator—fuel injector objective pressure value, the engine pipe and the common rail leaks electric control center is too low as
leaking; regulator engaged is off. diesel. compared with the calculated value.
steadily; the 3rd oil cut-off Power decreases. Inspect the electric resistance of The engine goes off.
pump working constantly; HP Increase noise because the harness and regulator coil. If it
oil pump failing; common rail preinjection work is inefficient. also occurs, 8.4 or eliminate the
being damaged or the pipeline fuel injector fault. Inspect the
from the oil injection pump to connector between the harness
the common rail being and the 3rd oil cut-off pump.
destroyed; LP pipeline failing Replace HP oil pump. Use the
measuring meter/gauge to
measure the pressure of LP
circulation.
8.1 One lit, one Pressure regulator engaged 8.3-8.4 If 8.3 blink code does not appear,
out steadily and closed Power decreases. replace the pressure sensor on the
Increase noise because the common rail. If there is, check
preinjection work is inefficient. the regulator resistance. Replace
the regulator, if necessary.
8.2 One lit, one Short circuit of positive pole of Power decreases. IT2000 readings
out the common rail pressure Increase noise because the Inspect harness and replace
sensor, short circuit or broken preinjection work is inefficient. sensor
circuit of ground wire.
8.3 One lit, one Short circuit of ground wire of 8.1-8.4 possible Inspect harness, connector and Impossible to restart.

130
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
out pressure regulator, or short The engine is off or cannot be regulator. Replace the pressure
circuit or broken circuit of started. regulator
positive pole
8.4 Out Short circuit or broken circuit 8.1 Engine bench test to inspect The work of the 3rd oil cut-off pump
of the ground wire of the 3rd oil There is fault record in the electric pump. is abnormal, and the pump lubrication
cut-off pump of the control control center. Inspect harness, connector and is ineffective.
electric valve parts and components.
9.1 One lit, one Internal fault of the electric The engine is off or cannot be Eliminate fault and test again. If there is fault, replace the electric
out control center started. It may not turn off under control center.
Turn-off at the beginning, then some circumstances, but the power
replacing new electric control decreases.
center; don’t use the key (+15);
disconnecting the positive pole
of the battery when the engine
works.
9.4 Lit Relay unable to be 3.5 Condition parameters The electric control center always has
disconnected The battery is out of power. Inspect harness, connector and power supply and ECD indicator is
parts and components. lit, even if the key is at OFF position.
9.7 One lit, one Internal fault of the electric It is possible to display faults 1.4 - Eliminate fault and test again. If there is fault, replace the electric
out control center of the input line 2.4 - 8.2 - 8.7 simultaneously. control center.
of the sensor Power reduces (there is noise
because the pre-injection work is
inefficient).
9.8 One lit, one Fault of internal software of The engine is off or cannot be Eliminate fault and test again. If there is fault, replace the electric
out electric control center due to started. control center.
trying to open the electric

131
BLINK EDC
Possible Causes Possible Faults Test or Suggested Improvement Remarks
CODE Indicator
control center illegally
9.9 One lit, one Fault of internal software of It may interrupt injection quickly, Eliminate fault and test again. If there is fault, replace the electric
out electric control center, or trying environmental parameters, and control center.
to open the electric control other fault signals. The engine is
center illegally impossible to be restarted.
Slight toothing form during gear
shifting

132
 Troubleshooting (Part II)
Displaying BLINK EDC Test or Suggested
Possible Causes Possible Faults Remarks
Fault CODE indicator Improvement
Engine — — Poor contact of ground The internal printed circuit Inspect the ground wire fuse, The electric control center is good in
unable to be wire of the electric control center under the battery. Inspect if the appearance. Warn that there is
started melts. welding is correct. Ensure there abnormal smell of burning in the
is no paint traces of vehicle body. engine chamber.
Retighten the nut correctly.
Replace the electric control The electric control center still
center. communicates with the diagnostic
— — unit. There is till the fault record of
Engine There is air in the “water temperature sensor” and some
unable to be pipeline after repair. other intermittent faults in the fault
started Insist the start operation. record.
immediately
The air is discharged automatically
from the hydraulic circulation in the
common rail system.
Engine — — Blockage of prefilter Analyze the prefilter visually,
unable to be which shall be replaced if there is
started or sediment.
going off
under low
speed
Engine Electric pump without Check the harness and the fuse of Electric input maintains 9s operation
unable to be power supply electric pump power supply. through the starting key. There is
started or alternating-current hum during

133
 Displaying BLINK EDC Test or Suggested
Possible Causes Possible Faults Remarks
Fault CODE indicator Improvement
going off starting.
under low
speed
Engine — — Blockage or damage Analyze visually and eliminate
unable to be of the connecting leakage or blockage.
started or pipeline of the oil
going off injection pump
under low
speed
Engine — — Blockage of oil return Analyze visually and eliminate
unable to be pipe of oil tank blockage.
started or
going off
under low
speed
Engine — — Starting electric valve There is abnormal noise and Block the fuel inlet pipe of the
unable to be engaged steadily, and smoke intensity during hot-start electric valve, and
started or cold start breaking off starting; the air inlet restart.
going off manifold is wetted by fuel. If the engine starts, inspect the
under low power supply and replace the
speed electric valve.
Engine — — The oil return pipe of Assemble a measuring gauge on Electric input maintains 9s operation
unable to be oil tank on the fuel oil the hot-start valve: the pressure through the starting key. There is
started or drainage system leaks reading on the gauge shall be alternating-current hum during
going off or the oil drainage over 0.4bar. If the reading is starting.
under low system is not incorrect, inspect the circulation Read out the pressure on the

134
 Displaying BLINK EDC Test or Suggested
Possible Causes Possible Faults Remarks
Fault CODE indicator Improvement
speed tightened. nozzle and the leakage condition measuring gauge within 9s.
relating to oil return of oil tank
and the tightening torque.
Engine — — Blockage of fuel oil Assemble a measuring gauge on Electric input maintains 9s operation
unable to be drainage system the hot-start valve: the pressure through the starting key. There is
started or circulation reading on the gauge shall be less alternating-current hum during
going off than 0.9bar. If the reading is starting.
under low incorrect, dismantle the Read out the pressure on the
speed circulation nozzle and blow and measuring gauge within 9s.
wash it.
Engine Blockage of fuel filter Sensor is blocked and filter Assemble a measuring gauge The possible cause is that the ambient
unable to be does not work. between the filter and the direct temperature is too low.
started or injection pump: the pressure Caution
going off reading on the gauge shall be Ensure the cleanliness of the filter
under low over 1.8bar. Or, replace the filter during operation.
speed screen and measure again.
Engine — — Blockage or no Assemble a measuring gauge Electric input maintains 9s operation
unable to be adjustment of bypass between the filter and the direct through the starting key. There is
started or valve of the filter injection pump: the pressure alternating-current hum during
going off reading on the gauge shall be starting.
under low over 1.8bar. Or, replace the filter Read out the pressure on the
speed and measure again. measuring gauge within 9s.
Caution
Ensure the cleanliness of the filter
during operation.
Engine — — Failure of electric Assemble a measuring gauge Electric input maintains 9s operation

135
 Displaying BLINK EDC Test or Suggested
Possible Causes Possible Faults Remarks
Fault CODE indicator Improvement
unable to be pump work between the electric pump and through the starting key. There is
started or the filter: the pressure reading on alternating-current hum during
going off the gauge shall be less than 2bar. starting.
under low Or, replace the electric pump. Read out the pressure on the
speed measuring gauge within 9s.
Engine — — Excessive flow If the common rail pressure is Doing this test needs to release the
unable to be amount of electric still lower than 150bar after the circuit connection and the fuel
started or injection above tests, release the circuit injector circulation pipe. Prevent fuel
going off connection and the circulation overflowing when the electric pump
under low pipe of fuel injector, block the works through blocking the pipe.
speed pipe and inspect if there is flow
fault of the rotational handle.
Replace the fault fuel injector.
Engine — — Blockage of direct If the common rail pressure is
unable to be injection pump or still lower than 150bar after the
started or blockage of pressure above tests, replace the regulator
going off regulator pump.
under low
speed
Engine — — Accelerator signal Measure parameters and inspect
unable to be unable to be received pedal tightening and harness.
started or 100% Replacement
vehicle
unable to be
accelerated
to the

136
 Displaying BLINK EDC Test or Suggested
Possible Causes Possible Faults Remarks
Fault CODE indicator Improvement
maximal
speed
Engine — — Waste-gate work The smoke intensity is large Inspect functions of parts and
unable to be failure or booster during high rotational speed components.
started or and high loads
vehicle
unable to be
accelerated
to the
maximal
speed
Dense smoke — — Waste-gate work Engine cannot be started or Inspect functions of parts and
with deep failure or booster vehicle cannot reach the components.
color under maximal speed.
any
condition
Dense smoke — — Hot-start electric valve Engine cannot be started or The fuel input of electric valve is
with deep engaged steadily goes off during low-speed blocked and restart.
color under cold start; the air inlet If the result is qualified and
any manifold is wetted by fuel. effective, dismantle parts and
condition components; inspect visually and
replace.
White or — — Incorrect linear of the Possible start difficulty, fuel Inspect if the assembly is correct Effect, engine function, comparing
black dense flywheel sensor noise. and the tightening torque of the the sensor position with the sensor on
smoke under fixed support bolt and the sensor. traditional oil injection pump,
any different phases.

137
 Displaying BLINK EDC Test or Suggested
Possible Causes Possible Faults Remarks
Fault CODE indicator Improvement
condition
Fuel noise — — Incorrect linear of the Start may be difficult; there Inspect if the assembly is correct Effect, engine function, comparing
flywheel sensor is smoke during starting. and the tightening torque of the the sensor position with the sensor on
fixed support bolt and the sensor. traditional oil injection pump,
different phases.

138
Using Measuring Gauge for Measurement on Low-pressure Circulation Pipeline
During overhaul, the low-pressure (LP) pipeline needs measuring. There is standard for the precision of measuring

gauge. Fig. 256

To read out the pressure value correctly, the precision of the measuring gauges A and B shall not exceed

0.4—0.5MPa, and the precision of the measuring gauge C shall not exceed 2—2.5MPa.

The measuring gauges A and B are connected with a three-way connector. The measuring gauge C is connected

the common connector if the oil drainage system is connected to the hot-start direction, or connected to the

three-way connector if the oil way from the fuel filter is connected to the oil drainage system.

Fig. 256

139
 Fault Diagnosis

Major functional faults of engine

1- Engine unable to be started 6- engine emitting blue smoke
2- Over-heat of engine 7- engine emitting white smoke or black smoke
3- Insufficient power of engine 8- abnormal collision of engine
4- Engine emitting black smoke or dark grey smoke 9- engine being off
5- Engine emitting light grey smoke 10- too high fuel consumption
11. engine oil pressure being too high or insufficient

The engine cannot be

1
started or is off.

Inspect if the battering wiring is - No Clear up, inspect and tighten the wiring nut or replace

effective
Yes ↓

Inspect if the battery is effective - No Inspect as per the "electric apparatus” description in

the service manual

Yes ↓

Inspect if the starter is effective - No Inspect as per the "electric apparatus” description in

the service manual

Yes ↓

Inspect if the oil transfer pipe leaks air - No Prolong the starting procedure, automatic air exhaust

under low pressure device

Yes ↓

Inspect if there is accumulated water in - No Eliminate the cause for water leakage and clean up the

the oil transfer pipe accumulated water in the oil transfer pipe and the fuel

tank
Yes ↓

Inspect if the fuel pre-injection is - No Analyze and replace when necessary.

effective

140
 Yes ↓

Inspect if the pre-heating system is - Yes Fault diagnostic unit IT2000-IWT

effective
Yes ↓

Inspect if the HP oil pump is effective - Yes Fault diagnostic unit IT2000-IWT
Yes ↓

Inspect if the fuel injector is effective - No Fault diagnostic unit IT2000-IWT, detect the tightness

of “O” form sealing ring

Yes ↓

Inspect if the compression pressure is No Inspect relevant parts (air valve, piston ring etc.)

normal
Yes ↓

Inspect if the electromagnetic pump is No Pump does not work

Inspect harness and hose

effective
If there is alternating-current hum
Yes ↓

Inspect if the electromagnetic pump is No The pressure displayed on the pressure gauge between
the electromagnetic pump and the filter shall not be
effective lower than 0.2MPa, or the electromagnetic pump shall
be replaced.
Yes ↓

Inspect if the LP pipeline is normal No Observe visually to eliminate leakage and blockage
Yes ↓

Inspect if the oil return pipeline of oil tank No Observe visually to eliminate leakage and blockage

is normal
Yes ↓

Inspect if the fuel filter is effective No The pressure displayed on the pressure gauge between

the LP oil pump and the filter shall be over 0.18MPa,

or the filter core shall be replaced.

Yes ↓

Inspect if the sensor in the fuel filter is No The pressure displayed on the pressure gauge between

effective the LP oil pump and the filter shall be over 0.18MPa,

141
 or the filter core shall be replaced.
Yes ↓

Inspect if the hot-start electromagnetic No Block the fuel oil pipe and restart; if the engine runs,

valve is effective detect its condition, or replace the electromagnetic

valve
Yes ↓

Inspect if the oil return pipeline of oil tank No Insert the pressure gauge on the magnetic valve of the

is normal hot starter and the pressure displayed shall not be over

0.04MPa; if there is leakage, tighten the connector.

Yes ↓

Inspect if the oil return pipeline of oil tank No Insert the pressure gauge on the magnetic valve of the

is normal hot starter and the pressure displayed shall be less than

0.09MPa, or dismantle and clean the nozzle.

Yes ↓

Inspect if the bypass valve of fuel filter is No The pressure displayed on the pressure gauge between

effective the LP oil pump and the filter shall be over 0.18MPa,

or the filter core shall be replaced.

Yes ↓

Inspect if the pressure increasing valve of No Insert the pressure gauge on the HP pump, and the

HP common rail is normal displayed pressure shall be at least 0.18MPa; the

pressure displayed on the pressure gauge on the

hot-start electromagnetic valve shall be over 0.09MPa;

use the fault diagnostic unit IT2000-IWT for detection

Yes ↓

Inspect if the pressure increasing valve is No If the common rail pressure is less than 15MPa,

normal dismantle the HP common rail and seal up the sealing

gasket; inspect if the pressure increasing valve leaks;

if there is scratch, the valve body shall be replaced;

and use the diagnostic unit IT2000-IWT for detection

142
 Yes ↓

Inspect if the electromagnetic fuel injector No If the common rail pressure is still less than 15MPa

is normal after the above test, the fuel injector shall be replaced
Yes ↓

Inspect if the HP pump and the SHUT-OFF No If the common rail pressure is still less than 15MPa

valve are normal after the above test, the HP pump-regulation device

shall be replaced
Yes ↓

Inspect if the flywheel is equilibrium No Inspect its flatness; re-install and adjust if necessary
Yes ↓

Inspect if the flywheel phase sensor is No Inspect if the sensor is installed to its position

normal
Yes ↓

Inspect if the EDC electric control center is No Replace EDC electric control center.

normal

2 Over-heat of engine

Inspect if the coolant liquid is correct - No Inspect possible leakage and supplement coolant
Yes ↓

Inspect if the tightness of the driving belt - No Replace the tightener

of water pump is correct

Yes ↓

Inspect if the water pump works - No Repair or replace the assembly

normally
Yes ↓

Inspect if the thermostat works normally - No Replace

Yes ↓

143
Inspect if the radiator works normally - No Clean carefully; inspect if there is leakage; replace

parts.
Yes ↓

Inspect if the air filter, connecting pipe - No Clean up or replace defected parts

or pipeline is normal
Yes ↓

Inspect if the cylinder cover washer is - No Replace

normal
Yes ↓

Inspect if the electromagnetic fan - No Inspect the line, sensor and joint seat of

clutch is normal electromagnetic fan clutch

Insufficient power of
3
engine

Inspect if the air filter is normal - No Replace

Yes ↓

Inspect if the LP and HP oil ways of - No Inspect the tightness

fuel pipes are normal

Yes ↓

Inspect if the thermostat is normal - No Replace

Yes ↓

Inspect if there is fuel oil in the oil tank - No Inspect the fuel oil amount
Yes ↓

Inspect if the oil suction pipe of oil - No Inspect the fuel supply and clean the oil suction pipe

tank is normal
Yes ↓

144
 Inspect if the HP oil pump is normal - No Use the fault diagnostic unit IT2000-IWT for

detection, or replace
Yes ↓

Inspect if the fuel injector and the - No Use the fault diagnostic unit IT2000-IWT for

pressure-limiting valve (if there is) are detection, and inspect if the “O” form ring is sealed

normal
Yes ↓

Inspect if the pressure increasing valve is No Dismantle the fuel oil return pipe from the HP

normal common rail and inspect if there is scratch

Yes ↓

Inspect if the air valve clearance - No Inspect and adjust

complies with the regulation

Yes ↓

Inspect if the cylinder compression - No Use the fault diagnostic unit IT2000-IWT for

pressure complies with the regulation detection

Yes ↓

Inspect if the booster (blade - No Repair or replace the assembly

completeness, bearing, execution

elements etc) is normal

Yes ↓

Inspect if the acceleration pedal sensor is - No Inspect the harness and tighten the pedal seat, or

normal replace

145
 Engine emitting black smoke
4
or dark grey smoke

Inspect if the air filter is normal - No Replace

Yes ↓

Inspect if the fuel injector is normal - No Use the fault diagnostic unit IT2000-IWT for

detection, and inspect if the “O” form ring is sealed

Yes ↓

Inspect if the cylinder compression - No Use the fault diagnostic unit IT2000-IWT for

pressure is normal detection

Yes ↓

Inspect if the hot-start electromagnetic - No Block the fuel oil pipe and restart; if the engine runs,

valve is correct detect its condition, or replace the electromagnetic

valve
Yes ↓

Inspect if the turbine booster is normal - No Inspect and carry out necessary repair or replacement

Engine emitting light grey

5
smoke

Inspect if the fuel injector is normal - No Use the fault diagnostic unit IT2000-IWT for

detection
Yes ↓

Inspect if the cooling oil level is normal - No It is possible that the coolant enters the combustion

chamber and causes knocking. Replace the cylinder

washer or inspect and repair the engine.

146
 Engine emitting blue
6
smoke

There is engine oil in the cylinder - Yes Too high consumption of engine oil

Leakage of turbine engine oil

Gas blowby of air valve guide pipe

Engine emitting white

7
smoke or black smoke

If the flywheel phase sensor is normal - No Check if the sensor position is correct

Yes ↓

Inspect if the flywheel is equilibrium No Inspect its flatness; re-install and adjust if necessary

8 Abnormal collision of engine

If it comes from the crankshaft - Yes Inspect: main journal clearance and ellipticity, tie rod

bolt and flywheel bolt, and engine oil pressure.

Replace parts or overhaul engine

No ↓

If it comes from the tie rod - Yes Inspect: tie rod journal clearance and ellipticity, and

tie rod bolt. Replace parts or overhaul engine

No ↓

If it comes from the piston - Yes Inspect the clearance between the piston and the

cylinder, the piston ring completeness, and the

147
 clearance between the piston and the pin hole. Replace

parts or overhaul engine

No ↓

If it comes from the cylinder cover - Yes Inspect: air valve clearance; adjust oil injection pump

phase, and the timing phase of camshaft. Adjust.

No ↓

If it comes from the camshaft - Yes Overhaul or replace gears

No ↓

If it comes from the vacuum pump - Yes Overhaul or replace the vacuum pump
No ↓

If it comes from the fuel injector - Yes Inspect and adjust or replace as per relevant

regulations
No ↓

If the hot-start electromagnetic valve is - No Block the fuel oil pipe and restart; if the engine runs,

effective detect its condition, or replace the electromagnetic

valve
Yes ↓

If the flywheel phase sensor is normal - No Check if the sensor position is correct

Yes ↓

Inspect if the flywheel is equilibrium No Inspect its flatness; re-install and adjust if necessary

9 Engine flameout

Inspect if there is fuel oil in the fuel oil - No Fill in fuel oil, and exhaust air if necessary

tank
Yes ↓

148
 Inspect if the fuel filter is normal - No Replace
Yes ↓

Inspect if the fuel oil transfer pipeline - No Inspect the pipeline and exhaust air

is normal

Too high consumption of

10
fuel oil

If the fuel oil tank and the fuel oil - No Eliminate possible leakage and replace damaged parts

pipeline are normal

Yes ↓

Inspect if the air filter is normal - No Replace

Engine oil pressure being

11
too high or insufficient

Inspect if the engine oil - No Inspect and replace as required

pressure-limiting valve is normal

Yes ↓

If the engine oil pump and the engine - No Inspect and replace as required

oil pipeline are normal

Yes ↓

If the main bearing bush and the tie rod - No Replace the bearing bush and rectify the crankshaft as

are normal required

Yes ↓

If the engine oil viscosity is correct - No Replace the engine oil with suitable viscosity

149