Technical training of New Model N800

Engine
 Objective

1 Understand the characters of N800 (medium body with

independent suspension)

2 Understand the structure of JX4D24A4H engine and the

technical know-how on repair.

JMIE
 Content

1 Model Overview

2 Body Overview

3 Introduction of Engine JX4D24A4H

JMIE
Model Overview
 Model Overview
2750mm wheelbase, single cabin 2750mm wheelbase, king cabin

3360mm wheelbase, single cabin 3360mm wheelbase, king cabin

Page 1
 Model Overview
Vehicle Specification

Wheel
tread

Page 2
 Model Overview
Engine specification
Centrifugal pump forced circulation
Cooling type ,closed cooling, water cooling, pressure cooling,
circulation cooling

Cooling Cooling liquid mixture 45% OAT

Pressure(KPa) 164
Coolant outlet Temperature(°C) 90±5(performance);105±5(durable)
Lubrication type Combined Pressure & Splashing
Oil pump type Gear pump
Lubrication 3500rpm≥0.3MPa
Engine Oil pressure
Idle 800rpm,0.1MPa

Fuel Type BOSCH CP1H

Injection
pump
Type CR12.2
Injector
Rail pressure(bar) 1600
 Model Overview
Auxiliary material
Item Specification Consumption Remark

Brake liquid HZY3 0.68L Same as light truck

Anti-freezing liquid WSS M97B44D 11L For Puma only

Refrigerant R134a 650±20g Same as light truck

Power steering oil PSF1982 1.7L Same as that of light truck

Rear axle gear oil HD80W-90 4L
GL-5
Gearbox oil HD80W-90 3.7L
GL-5
#0 for summer,#10
Diesel for winter 100L/65L
Wiper reservoir 2.2L
additive
Body
Front shield Panel
Panel seal
positioning buckle
Front shield panel ASM

Cross recessed pan

head screw

Front shield grille

Plastic buckle

Front shield grille ASM

2013/5/8
Cross recessed pan head
screw
 On the longitudinal beam of
the frame, the torque is
56±19N.m
Front bumper

On the 1st beam, the torque is

26±5N.m

Front windscreen
Tightening torque

Seal

Support
block
 Rear Windscreen

Tilt Mechanism
 Lock mechanism

Left & Right door glass

Left & right side glass

Rear guard fence

Introduction Engine
JX4D24A4H
 Engine JX4D24A4H
Engine coding

●Engine JX4D24A4H derives from engine PUMA 140PS, some components are the same

with that of JX4D24A4L .

●The front gear train, water pump and vacuum pump are redesigned, and also relevant
cooling, lubrication pipelines changed, the vacuum pump and the alternator integrated
together.
●Renewed variable section turbo charger, exhaust manifold changed.
Renewed flywheel and its connection gear ring.
 Engine JX4D24A4H
Engine specification

,DOHC

mm
 Engine JX4D24A4H
Cylinder block
Fuel injection pump ASM

M8*45 3 bolts, torque: 23+/-3Nm

Cast iron cylinder block without sleeve, aluminum alloys cylinder block skirt rack. 3 fuel
injection pump bolts M8*45, torque 23±3Nm.
 Engine JX4D24A4H
Water pump & Vacuum pump
Alternator& vacuum pump

Water pump
 Engine JX4D24A4H
Crankshaft position sensor bracket

Pin
Bracket bolt;
torque 23+/-
3Nm

Steps of
bracket
assembling:
1. Ensure the flywheel stays 50°before top dead
center
Rear connection ring Crankshaft position
2. Insert the latch to locate timing gap
sensor bracket
3. Tighten the bracket bolt to 23±3Nm
4. Leave the latch in the hole for the usage of
initial rotation and timing.
 Engine JX4D24A4H
Selection of cylinder gasket
#1: 1 gap and 1 hole
Multilayer metal cylinder gasket
#2: 2 gaps and 2 hole
(grouping). Selection of cylinder head #3: 3 gaps and 3 hole
gasket depends on the height of the Gasket group
piston on the surface of cylinder block.
On different height, 3 groups of
cylinder gaskets can be chosen to
guarantee well sealed after
maintenance.

Piston Protrusion Gasket

Thickness
height Number
0.310 – 0.400 1.1 #1
0.401 – 0.450 1.15 #2

0.451 – 0.500 1.2 #3

 Engine JX4D24A4H
Piston ring
Piston group A/B/C
Cylinder diameter group No.
Marks of CYL diameter from
left to right is 4-3-2-1
Connecting rod
group H/I/J
Shearing machine & part
No., point to front engine The opening of top Top ring
and second ring
Piston pin should be in the
2nd ring
opposite position
Snap Ring; Piston Pin
Oil ring

Group A:89.84--89.85mm
Group B:89.85--89.86mm
Group C:89.86--89.87mm
 Engine JX4D24A4H
Piston cooling injection pipe

Tighten the piston cooling injection pipe with four M6 bolts

Torque: 9.5±1.5Nm.
 Engine JX4D24A4H
Oil filter
Oil filter on the cylinder surface
should be installed 1mm lower than
the bearing seat.
 Engine JX4D24A4H
Crankshaft bearing
Crankshaft bearing and connecting rod bearing are not designed with position lip,
position tolerance should be ±0.5mm.
 Engine JX4D24A4H
Cylinder block skirt rack gasket

No deformation and
protruded part
cannot be damaged
Cylinder block skirt rack gasket installation steps
1,During installation, ensure the surface of the cylinder bracket & sealing gasket are
clean.
2, As shown in the picture, put the sealing gasket into two locating pins.
3,Stick the two sealing face on the cylinder block.
 Engine JX4D24A4H
Cylinder block skirt rack installation
19 bolts in point A

Cylinder block
skirt rack

1st location pin

3 bolts in position B

Bolts tightening sequence are as shown in the picture, tightening torque: 23±3Nm
Location of cylinder block skirt rack: rear end +0.010/-0.260 mm between bracket and
cylinder, and sideway of bracket and cylinder block. Flatness of A/B point is +/-
0.075mm.
 Engine JX4D24A4H
Crankshaft rear seal
Crankshaft rear seal

Seal ring

Special tool
Crankshaft position number:303-440
sensor bracket
During installation, pay attention to the following matters:
The oil seal lip should face inward after installation, that is the direction shown in the picture.
Ensure concentricity between oil seal and flange plate.(special location installation tool can be used
in assurance).
According to below sequence, tighten the 8 bolts to 9.5+/-1.5Nm in turn.
 Engine JX4D24A4H
Cylinder Head
Valve lock

Valve Spring Seat

Valve spring

Valve Guide pipe Seal

Exhaust Valve

Intake valve

Cylinder head

Aluminum alloy cylinder head, 2 intake valves and 2 exhaust valves, 8 intake 8 exhaust
passages arranged in two sides, combustion chamber and injectors in the middle, glow plug
in the air intake side; Coolant temperature sensor installed.
 Engine JX4D24A4H
Cylinder head installation

Cylinder head bolt tightening procedure:

Bolts No.1-10 pre-tighten with a torque 10Nm,Bolts No. 11-18 with 5Nm.
Bolts No.1-10 pre-tighten with a torque 20Nm,Bolts No. 11-18 with 10Nm.
Bolts No.1-10 re-tighten with 40Nm, then tighten with an angle 180°.
Bolts No. 11-18 re-tighten to 20Nm, then tighten with an angle 180°.
Reuse of bolts must be no more than 4 times, final tightening torque for bolts No.1-10 is 50-147Nm, and that of No.11-18
is 50-60Nm. The bolt needs to retighten or replace while its tightening torque exceeds the standard value much.
 Engine JX4D24A4H
Cylinder head skirt rack seal

Sealant
Sealing instructions
●Gluing surface must stay clean, ensure no oil or dust on it.
●Gluing path as shown in the picture, keep the width of 2.5+/-0.5mm.
●Install the camshaft rocker arm housing seat on the cylinder head and tighten the bolt in ten minutes
after gluing finished.
●Install the fuel injection pump driving gear in 10 minutes after the gluing finished.
 Engine JX4D24A4H
Cylinder head skirt rack installation
1 cylinder head
skirt rack bolt 20 cylinder head
skirt rack bolt
2 cylinder head
skirt rack bolt
1 cylinder head
skirt rack bolt
1 cylinder head
skirt rack bolt

Rocker
housing seat

Cylinder head skirt rack tighten instruction:

Cylinder head skirt rack bolt tightening torque: 23Nm for bolt No.1-22, 10Nm for
bolt No.23-25.
 Engine JX4D24A4H
Valve mechanism
Double overhead hollow camshaft, scientifically
designed, material chosen, which reduces the
movement inertia.

Camshaft installation instruction:

●Before camshaft installation, coat it with oil and
insert the bearing into journal.
●Do not turn the camshaft before settlement and
tighten of camshaft rocker seat.
 Engine JX4D24A4H
Rocker Arm ASM
The rocker is designed with roller bearing,
which reduces wear of the surface and
improve the durability as well. The hollow
camshaft and rocker with roller bearing
improves the reliability of the phase
system . The hydraulic adjuster improves
the durability.

During maintenance or repair, we should check the

roller surface to confirm if there is any serious scratches
or block. And we should check hydraulic tappet
mounting hole of rocker seat to see if there is any
scratches in order to ensure a good seal.
 Engine JX4D24A4H
Valve driving mechanism
Torque
 Engine JX4D24A4H
Timing

Camshaft timing

2 timing location pins

Special tool

Crankshaft timing
 Engine JX4D24A4H
Timing chain installation
 Engine JX4D24A4H
Valve timing test

Take down the installation tool and rotate the crankshaft

clockwise twice, insert the 6mm locating pin into the
camshaft chain wheel through the hole once again, check
camshaft timing, then insert the special tool into the
mounting hole of crankshaft position sensor to check timing.
 Engine JX4D24A4H
Fuel injection pump disassembly
 Engine JX4D24A4H
Chain disassembly & maintenance
Dismount the front pulley mechanism

Check and confirm if there is oil leakage front pulley mechanism before removing. Record
the oil quantity. Drain the oil and then repair the front gear chain accessories as the
maintenance manual requested.
 Engine JX4D24A4H
Dismount engine front cover in accordance with the instructions in the
workshop manual
 Engine JX4D24A4H
Timing chain maintenance

9 grooves(8 teeth)
Check the tensioner: If there comes 8 teeth(9 grooves) or more
on the tensioner, it means the chain must be replaced.
•While replacing the timing chain, the relative driving
mechanism needs to be checked.
 Engine JX4D24A4H
Timing chain dismount
1, Insert timing location pin and flywheel gear location pin.
2, Unscrew the fuel injection pump gear bolt and camshaft
gear fixed bolt.
3, Unscrew the tensioner bolt and guiding plate, and then
take out the tensioner guide plate.
4, Dismount the fuel injection pump gear and camshaft gear.
5, Take out the chain.

插入正时定位销
Insert timing
location pin
Unscrew the fuel injection
pump gear fixed bolt
 Engine JX4D24A4H
Maintenance and assembly
Reassemble procedure should be in
accordance with the instructions in the
workshop manual:
•Assemble a new chain (depends);
•(Recommended)Front cover, tensioner and
front oil seal need to be replaced
simultaneously;
•Before assembling, clean the chain gear
train parts;
•Check EGR system.
Assembly procedure:

6.1 Assemble tensioner guide rail

 Engine JX4D24A4H
6.2 Insert timing locating pin and flywheel signal gear locating pin

6.3 Assemble chain and camshaft driving gear

 Engine JX4D24A4H
6.4 Assemble fuel injection pump gear

6.5 Rotate the camshaft gear twice to

check valve timing as requested.

6.6 Pull out tensioner pin

4
 Engine JX4D24A4H
Front cover

Front
cover inner
side

Sealant

Sealant width should be 3±0.5mm, keep the distance of 1±0.5mm from the edge of the
cover, and gluing the bolt hole inside.
 Install the front cover in 5 minutes after the sealant was glued.
 Engine JX4D24A4H
Cooling system
Coolant temperature
sensor Torque: 35+/-5Nm
M8 nut
Cylinder head
coolant outlet pi

M8*25 bolt;
Torque: 23±3Nm
 Engine JX4D24A4H
Cooling system
Make sure the white line of hose is in
a line with the mark of cylinder head
Water pump coolant outlet pipe
Cylinder head
M10*45 Torque: coolant outlet pipe
40Nm

NmM10*75 Water pump inlet

torque: 40Nm and outlet pipe

Torque 9.5Nm
 Engine JX4D24A4H
Water pump and cooling fan

Water pump
Fan ASM

M10*45
Torque: 40Nm

NmM10*75 Water pump inlet

torque: 40Nm and outlet pipe

Torque 9.5Nm
 Engine JX4D24A4H
Lubrication system

Engine oil: Mobil Delvac Super 1300 5W-40 oil

Tips for lubrication system:
1, Before the mileage 9,000km, the engine should apply oil Fuchs 5W-30 (WSS-M2C943-A);
Fuchs Titan Cargo maxx of API CI – 4 or CI – 4PLUS WSS-M2C943-B;
2, If a new timing chain(part number: 6C1Q-6268-B*) was installed, in the 9,000 km after the
installation, oil 5W-30 (WSS-M2C943-A) must be added;
3, Oil Mobil Delvac Super 1300 5W-40 oil can be applied in the normal service.

Oil capacity: initial filling is 7.25L ; the second filling volume is 5.8L.
 Engine JX4D24A4H
Oil pan installation Oil pan bolt tightening procedure:
1. Tighten all bolts & nuts with a
Sealant width 3mm torque 6.5±1Nm in turn.
2. Tighten all bolts & nuts with
14±1Nm in turn.

The oil pan need to be glued with sealant in a width 3mm before installation, and then
install the oil pan and tighten the bolts and nuts within 5 minutes.
 Engine JX4D24A4H
Oil pump inlet pipe
Bolt M6*20
Torque:9.5±1.5Nm

Oil cooling
thermostat
1 bolt M6*25
Oil pump inlet pipe Torque: 9.5±1.5Nm

Oil cooling thermostat can control on-off of cooling water that through the oil cooler
to ensure the oil normal operation in appropriate temperature.
 Engine JX4D24A4H
Oil pump & cooler
Torque: Oil cooler
23+/-3Nm

Oil pressure alarm

switch
5Torque:15+/-
bolt M8*25
Tensioner lock pin Oil pressure alarm
2.5Nm
Torque:
switch bracket
23±3Nm
Oil pump and cylinder block are fixed with bolt through 4 elliptic bolt holes, during oil
pump installation, do make sure of the flatness between oil pump chain wheel and
crankshaft chain wheel. Or it will lead the oil pump shaken and even the chain fell off,
which will affect the oil pump life span.
 Engine JX4D24A4H
Method to ensure the flatness
Method 1
 Engine JX4D24A4H
Flatness guarantee
Method 2
 Engine JX4D24A4H
Oil dipstick

Torque: 23+/-3Nm

Oil dipstick

Oil dipstick pipe

 Engine JX4D24A4H
Turbo charger, vacuum pump lubrication
Vacuum pump

Turbo charger oil inlet pipe Vacuum pump

oil inlet pipe
Turbo charger oil return pipe
Vacuum pump
Oil dipstick oil return pipe

Inlet /outlet pipes of turbo charger & vacuum are connected to the cylinder
irrespectively. Torque of turbo charger inlet /return pipe bolt is 27±1Nm. Pre-tighten
vacuum pump inlet pipe with a torque 7Nm, final tightening torque is 27+/-1Nm,
and the vacuum return tube joint torque is 23±3Nm.
 Engine JX4D24A4H
Air intake system
Intake Manifold ASM EGR intake pipe 2 bolts
Sensor Torque: 8-11Nm

1 Bolt

EGR pipe gasket

EGR pipe

2 bolts
10 bolts
Torque: 9.5+/-
Torque: 15.5±1.5Nm 1 bolt
1.5Nm
Torque: 23+/-3Nm
 Engine JX4D24A4H
Exhaust system
Exhaust manifold bolt Variable cross-section
torque: 45Nm turbocharger vacuum
control valve

Hex bolt
Torque: 45+/-5Nm
Torque: 45Nm Hex bolt
Torque: 45+/-5Nm
 Engine JX4D24A4H
Turbo charger
 Engine JX4D24A4H
EGR system
EGR cooler
EGR valve
2 bolts EGR cooler bracket
Torque: 9.5+/-1.5Nm

EGR valve
gasket

EGR pipe
Torque: 23+/-3Nm
Bolt:9Nm washer

Nut torque:
23+/-3Nm M8*20 bolt
M8*20 bolt
EGR cooler EGR cooler gasket EGR valve cooler bolt
Torque: 23+/-3Nm
 Engine JX4D24A4H
Glow Plug
4 glow plugs Glow plugs junction plate
Torque: 13+/-1Nm Torque: 9.5+/-1.5Nm

Glow plugs nut

Torque: 2.5+/-0.5Nm

Operating Voltage 12V, the longest preheat time is 8 seconds in -20°C or lower. Over 80°C, no
preheat section. Preheat after the engine starts, the longest post preheat time is 30 seconds
when the rotation speed is less than 2500r/min and temperature below -20°C. Post preheat
will help to improve operative condition and reduce hydrocarbon emissions .
 Engine JX4D24A4H
Transmission accessories
 Engine JX4D24A4H
POC
Function of DOC (Diesel Oxidation Catalyst)
 Reduce HC & CO effectively
 Remove partial VOF from PM
 Reduce PM, Efficiency up to 10-30% DOC+POC system
Function of POC（Particle Oxidation Catalyst）
 Trap particulates, regenerate through oxidation-combustion.
 Reduce PM, efficiency up to 30-80%
No obvious back exhaust pressure increase
Feature of POC
a, POC is open filtration, it traps particulates of LD & HD diesel exhaust .
b, The picture is metal carrier, and special chemical coating is on the carrier.
c, DOC and POC work together as one.
d, Special carrier structure design is required to make wide contact area and free-
flowing exhaust fluid. Ensure to capture part of particulate matter(PM) and
regenerate while back pressure.
e, Thermal durability and good mechanical properties is required.
 Engine JX4D24A4H
POC
Engine

Differential pressure sensor

DOC+POC系统

Front exhaust pipe DOC and POC ASM Silencer

Principal of POC regenerative combustion to erase the particle matter.

By the oxidation of DOC catalysts, NO+O2—〉NO2, and combustion inside the cylinder of
diesel vehicle, a certain amount of NO2 is produced and enters into POC. Then under the
catalysis of special chemical coating with noble metal, NO2 molecular bond can be fracture
while at low temperature(250-500 ℃) , then PM can be removed effectively.
 Engine JX4D24A4H
Common Rail System

The fuel injection pump pressurizes the fuel and transfers it to common The pressure of the
fuel injection pressure varies between 230 bar and 1600 bar. according to different kind of
engine operate condition. ECU controls the fuel injection both in time and quantity according
to different variable signal input. Quantitative fuel will be injected into the corresponding
combustion chamber through a solenoid valve of the fuel injector. Excessive fuel would flow
back to the fuel tank through the fuel return pipe.
 Engine JX4D24A4H
Common rail system

BOSCH CRI2.2 fuel injection common rail system consists of ECU(EDC17C55), fuel
injection pump (CP1H), common rail, injectors, various sensors monitoring engine
status, actuator, relay and EOBD, etc.
 Engine JX4D24A4H
High pressure fuel pump
3 cylinder radial plunger
Fuel transfer Integrated ZP26 gear transfer pump,
pump rotating speed no more than Fuel return
3000r/min
IMV Normally Closed metering valve

Lubrication Fuel Lubrication

form
Seal Double shaft seal, O-ring flange, axial
force not allowed

Flow rate 843mm³/Rev

Direction of Right-hand rotation (Driving end) Plunger
rotation
Rated pressure 1600bar/ 3000r/min
/rotating speed
Triangle
Min. inlet fuel -25
temperature(FT
Gear pump
MP) Seal
Max. inlet 70
FTMP Eccentric shaft
Operating 8~32V
voltage
Operating -25~120 Bearing bush
ambient
temperature
 Engine JX4D24A4H
Common rail

Rail pressure
sensor RDS4

Rail body
Embedded orifice; 1 Rail pressure
Rail
for each injector) sensor RDS4
nameplate

Model HFR+RDS4.2
Max. rail pressure 1700+50 bar
Operating ambient temperature -40～120℃
 Engine JX4D24A4H
Injector

Model CRI2.2
Working pressure 250～1450 bar
Fuel return pressure 0.3-0.8(Relative environmental pressure)bar
Fuel temperature -30 -115
Fuel return temperature Below 125
Working ambient temperature -40~ 120
Fuel-water separator filter rating 93%(2% emulsion included)
Operation (constant) current 11.5～12.5
Injection Min. Hydraulic interval 200μS
 Engine JX4D24A4H
ECU
ECU Model EDC 17C55
Rail pressure control Max. fuel injection pressure 160Mpa
Discretionary control can be achieved
Injection Timing & quantitative control by solenoid valve conduction time of
injector
Flywheel target wheel circumference
Phase and the injection timing control uniform distributed on 60-2 gear

CKP/CMP

Mass air flow meter; intake manifold

Air inlet flow control
temperature sensor
Coolant temperature sensor; air intake
Corrective Controls
pressure sensor
Emission
DOC +POC
post processing
Emission standard EURO Ⅳ
10~16V(Note: 10V is the normal Min.
Operating voltage
operating voltage)
 Engine JX4D24A4H
Sensor
Name Function description

Crankshaft position Crankshaft position sensor used to calculate fuel injection time and quantity and
sensor rotation speed
Camshaft position
Identify the cylinder
sensor
Calculate the air inflow in order to provide basic parameters check air intake system,
Air Flow Meter
control combustion and emission
Air intake temperature Check the intake tube temperature, calculate the change of intake air density , and
sensor amend the fuel injection quantity.
Measure temperature of coolant, used for cold starting and target idle calculation,
Coolant temperature
meanwhile it is used for modify fuel injection advance angle and Max. power
sensor
protection

Rail pressure sensor Measure the fuel pressure in common rail pipe to ensure stable of rail pressure control

Throttle position sensor

Transfer the drivers intension to ECU
(TOCOS)

Water level sensor Monitoring and warning for the water level of fuel filter
 Engine JX4D24A4H
Crankshaft position sensor
crankshaft position
sensor

Crankshaft position sensor detection

A, Multimeter detect the resistance: turn off the ignition system, measure resistance
between the two sensor pins, coil resistance under 20℃ is 780~950Ω
B, Measure voltage waveform with oscilloscope(OSC): measure between the signal terminal
and ground wire, and observe the starting speed, idling speed and improved rotating speed
wave signal. Uss must rise up(signals is not interfered) while the engine rotating speed
increased.
 Engine JX4D24A4H
Camshaft position sensor

Camshaft position sensor

Camshaft position sensor detection:

A, Detect reference voltage: disconnect the joint of camshaft sensor, measure it between
one side of the harness(+) and ground wire.
Ignition Switch lie in “II”，check whether the voltage t is 5V.
B, Check the signal waveform by the oscilloscope: measure it between signal terminal and
ground wire, and observe the waveform. Amplitude is 5V, low voltage shows the position
of gear.
 Engine JX4D24A4H
Coolant Temperature sensor

Sensor

Coolant temperature sensor

Coolant temperature sensor detection:

Voltage metering: disconnect the plug of coolant temperature sensor, ignition
switch lies in “II”, signal voltage should be 5V. Connect sensor plug, signal voltage
reduces with the rise of temperature, voltage variation range is 0-5V.
Resistance metering: disconnect the plug joint of coolant temperature sensor,
ignition switch lies in “0”. Measure the resistance value under different temperature.
 Engine JX4D24A4H
Air intake temperature sensor

Air intake pressure & temperature sensor

Installation:
● Installation direction: down from pressure port;
●Deviating angle in the vertical direction should be within 60°;
●Installation bolt: M6
Function:
Air intake temperature sensor is to detect the air temperature of engine intake pipe,
and calculate the change of intake density , and amend the fuel injection quantity. Air
intake temperature sensor installed on the intake pipe.
 Engine JX4D24A4H
Air Flow Meter
Air flow meter

Air flow meter is used to measure air volume enters the cylinder, generally installed on
the intake pipe behind the air filter. The hot film air flow meter is an air quantity sensor with
logic output. Inherited the atmosphere temperature sensor inside as well. ECU gets accurate
intake volume through the monitoring and managing the two signals, and then control fuel
injection quantity accurately.
Output of air flow in HFM is high frequency pulse signal. Output of temperature is
occupied space ratio signal. Change of these two signals is small while the intake volume and
temperature changes.
 Engine JX4D24A4H
Oil pressure sensor

Plug ASM

Spring
Ejector rob
Rotor contact
Static contact

Diaphragm Sealing ring

Body

Normally closed oil pressure sensor

When the oil pressure is lower than the default value, diaphragm has no acting
force to push the spring, contact spot closes and the alarm light will be lightened.
When the oil pressure is higher than the default value, diaphragm overcomes
spring force, contact spot separates and the alarm light will be turned off.
 Engine JX4D24A4H
Common rail pressure
sensor

Adjusting
Mounting interface circuit Electric appliance inter
Sensitive element
Common rail pressure sensor detection: High pressure fuel passage
Check reference voltage of common rail pressure sensor: ignition switch stays in “II”, signal
voltage should be 5V. If no voltage detected, check the harness.
Check signal voltage: step the acceleration pedal, check if the signal voltage value rises up with
the rotation speed rises up, if not, there might be a failure on common rail pressure sensor .
When the rail pressure is 0, the sensor signal voltage should be 0.5V. The sensor outputs 4.5V
while it reaches max rail pressure.
 Engine JX4D24A4H
Electronic acceleration pedal
Simple circuit inside the acceleration pedal

Power supply of pedal 1

Power supply of pedal 2
Output voltage from pedal 1
Output voltage from pedal 2

Acceleration pedal position sensor detection:

Disconnect all, measure the resistance value between pin 2 and 3, the normal value should be
1.2KΩ±0.4 KΩ.
Reconnect all connectors, voltage of pin 1 and 2 should be 5V; pin 3 and 5 are earth grounding.
Measure the voltage of pin 4(u1) and pin 6(u2), normally u1 =0.4V，u2≈u1/2; When step the
acceleration pedal, see variation of u1&u2 on pedal characteristic curve, the greater the opening, the
higher the voltage, the faster to step the pedal, the faster the voltage rises.
Ignition switch stays in “II”, check the acceleration pedal to see if the reference voltage is 5V. Detect
the voltage value lies in idle position and full throttle position.
 Engine JX4D24A4H
Principle of ECU
 Engine JX4D24A4H
Principle of ECU
 Engine JX4D24A4H
Schematic diagram for vacuum EGR control
Power supply: 12V

Schematic diagram for vacuum EGR valve

 Engine JX4D24A4H
Schematic diagram Electronic control EGR
 Engine JX4D24A4H
1,Poor power output(in engine aspect)
Read DTC from engine diagnostic equipment, then check from tips of DTC. At present, reasons
why the lack of power caused by engine part failure are as follows:
A. Vacuum solenoid valve failure. (Vacuum solenoid valve failure makes turbo charger fails
providing enough intake air, boost pressure is obviously low. Thus, ECU limits the torque through
limiting the fuel injection quantity, which causes poor engine power output).The vacuum
solenoid valve should be replaced to solve the problem.
B.EGR valve failure(mainly because the electrical machine is damaged while EGR valve is on
long term operation under large pressure difference. The EGR valve cannot open or close in time
or cannot be closed at all. Thus, the EGR ratio is excessive, thus, ECU limits the torque through
limiting the fuel injection quantity, which cause poor engine power output. The EGR valve should
be replaced to solve the problem.
C. Serious injector leakage.(Currently, foreign material intrudes into the injector leads to
abnormal wearing of injector and inadequate fuel supply, finally the power cannot meet the
requirements) The injectors should be replaced to solve the problem( fuel filter is suggested to
be replaced at the same time).
D. Looseness on electric connector plug. Reconnect the plugs to solve the problem.
2. Guide bearing of crankshaft fails.
Because the clutch driven plate center is not coaxial with the engine during the mounting, thus
leading to bearing premature wear. This failure may cause abnormal shift or abnormal noise
from the back of engine. To solve this problem, the gearbox needs to be dismounted, dismount
the failure bearing with special tool and replace it with a new one.
THANK YOU