2.7CTI Engine Workshop Manual PDF

2.
7CTI Engine Workshop Manual

2.7CTI Engine Workshop Manual
Foreward
To help JAC engine authorized professional maintenance technical personnel, and supply effective
proper maintenance for JAC 2.7CTI engine, we compile the engine workshop manual.
To ensure customer’s satisfactory of JAC engine product, warm service and proper operation of
JAC engine professional maintenance technical personnel is very necessary. Therefore, maintenance
technical personnel must fully understand contents in the manual. The manual must be placed to
available places so that can be used for reference at any time.
All contents in the manual, including pictures, technical parameter, are latest, if due to product
improvement effecting maintenance, JAC will supply technical bulletin or ancillary volume. Therefore,
using the manual should notice to obtain latest trends of related information. JAC has the rights of
design change, add or improvement.
Without JAC written authorization, the manual can’t be copied or revised in any form, including
but not limited electronic, paper, tapes, mechanism, and so on.
Finnal interpretation of the manual is owned to JAC customer service department.
When maintaining JAC engine, if using non JAC engine parts or unquanlified oil, it may
damage engine.
JAC Engine Company

2015.12
I
Content
Foreward........................................................................................................................................................ I
Content..........................................................................................................................................................II
Abbreviation Definition.............................................................................................................................VI
Chapter I Engine Introduction.................................................................................................................. 1
I、Engine Identification Code............................................................................................................ 1
1.1 Engine Data Plate Position................................................................................................... 1
1.2 Printed Location of Engine Identification Code and Engine No.......................................1
1.3 Engine Identification Code Instruction................................................................................2
II、Engine Technical Specification Parameter................................................................................. 4
2.1 Main Technical Specification...............................................................................................4
2.2 Main Component Specification............................................................................................5
2.3 Main Inspection and Adjustment Parameter....................................................................... 5
2.4 Oil Specification.................................................................................................................... 5
2.5 Fuel Specification..................................................................................................................6
2.6 Urea........................................................................................................................................ 6
III、Tighten Torque.............................................................................................................................7
IV、Maintenance Limit.....................................................................................................................12
V、Special Tool.................................................................................................................................18
Chapter II Engine Mechanical System..................................................................................................... 20
I、 Maintenance Note.......................................................................................................................20
1.1 General Note........................................................................................................................ 20
1.2 Sealant Note.........................................................................................................................21
1.3 Engine Sealant Use List...................................................................................................... 22
1.4 Engine Sealant Using Detail...............................................................................................23
II、 Front Part Auxiliary Driving System...................................................................................... 24
2.1 System Diagrammatic Sketch.............................................................................................24
2.2 Belt Inspection.....................................................................................................................24
2.3 Removal............................................................................................................................... 25
2.4 Installation............................................................................................................................25
II
2.5 Installation Note.................................................................................................................. 27
2.6 Removal and Installation of Vacuum Pump..................................................................... 28
III、Timing System........................................................................................................................... 30
3.2 Removal............................................................................................................................... 31
3.3 Inspection............................................................................................................................. 31
3.4 Installation............................................................................................................................31
IV、Intake System.............................................................................................................................37
4.2 Removal of Intake System..................................................................................................37
4.3 Installation and Check of Intake System........................................................................... 37
V、Exhaust System........................................................................................................................... 39
5.2 Removal of Exhaust System...............................................................................................39
5.3 Installation and Check of Exhaust System........................................................................ 40
5.4 Fault Judgment of Turbocharger Impeller and Oil Leakage............................................42
VI、Lubricating System....................................................................................................................49
6.2 Replacement Oil and Oil Filter.......................................................................................... 50
6.3 Removal and Check............................................................................................................ 51
6.4 Installation............................................................................................................................52
VII、Valve Mechanism.....................................................................................................................55
7.2 Removal............................................................................................................................... 56
7.3 Check After Removal..........................................................................................................58
7.4 Installation............................................................................................................................62
7.5 Valve Clearance Measurement and Adjustment...............................................................65
VIII、Crankshaft Flywheel Mechanism..........................................................................................68
8.2 Removal............................................................................................................................... 69
8.3 Check and Measurement.....................................................................................................69
8.4 Installation............................................................................................................................73
III
IX、Piston Connecting Rod Assembly............................................................................................79
9.2 Removal............................................................................................................................... 80
9.3 Check and Measurement.....................................................................................................80
9.4 Installation............................................................................................................................83
X、Cooling System........................................................................................................................... 85
10.1 System Diagrammatic Sketch....................................................................................... 85
10.2 System Route Diagram..................................................................................................... 86
10.3 Removal, Installation and Check..................................................................................... 86
XI、SCR System............................................................................................................................... 91
11.1 System Diagrammatic Sketch.......................................................................................... 91
11.2 Connecting Diagrammatic Sketch................................................................................... 92
11.3 Maintenance Note of SCR System.................................................................................. 92
11.4 Removal, Installation and Check..................................................................................... 93
Chapter III Engine Electronic Control System...................................................................................... 102
I、Precaution....................................................................................................................................102
1.1 Maintenance Precaution....................................................................................................102
1.2 Precaution of Engine OBD System..................................................................................103
II、Structure Principle and Maintenance of Engine Control System..........................................105
2.1 Electrical Control System Instruction..............................................................................105
2.2 Electrical Control System Constitution Function........................................................... 107
2.3 OBD System...................................................................................................................... 109
III、Structure Principle and Maintenance of Engine Electronic Component.............................114
3.1 Crankshaft Position Sensor...............................................................................................115
3.2 Camshaft Position Sensor.................................................................................................117
3.3 Intake Pressure Temperature Sensor................................................................................119
3.4 Rail Pressure Sensor..........................................................................................................122
3.5 Coolant Temperature Sensor Ⅱ......................................................................................124
3.6 Exhausting Temperature Sensor...................................................................................... 126
3.7 Differential Pressure Sensor.............................................................................................128
3.8 Environment Temperature Sensor................................................................................... 131
3.9 NO Sensor..........................................................................................................................132
IV
3.10 Urea Level Temperature Sensor.................................................................................... 133
3.11 Intake Heater....................................................................................................................136
3.12 ECU..................................................................................................................................137
3.13 Engine Control Wiring Harness.....................................................................................145
IV、Engine Control System Fault Diagnosis Procedure..............................................................147
4.1 Electrical Control System Common Fault and Main Reason........................................ 147
4.2 Fault Code List.................................................................................................................. 149
4.3 Electrical Control System Common Fault Code Analysis.............................................153
V
Abbreviation Definition
ECU：Engine Control Unit

EGR：Exhaust Gas Re-circulation
WGT：Exhaust Gas Bypass Turbocharger
OBD：On-Vehicle Diagnosis System
PWM：Fuel-air Ratio Signal
IMV：Fuel Metering Valve
DOC：Oxidize Catalyst Converter
PLV：Pressure Limit Valve
IQA：Injector Fuel Quantity Amend
START：Key Start
Key：Key
AC：Air-conditioner compressor
EPC：System Malfunction Light
CAN：Controller Area Network
ROM：Read Only Memorizer
RAM：Read and Write Memorizer
MIL：Engine Malfunction Indicating Light
SCR：Selectivity Catalyst Reduction Technology
Unit：
1MPa=10bar=1000KPa
1bar=100kpa
1V=1000mV
VI
Engine Introduction
Chapter I Engine Introduction
I、Engine Identification Code
1.1 Engine Data Plate Position
Engine data plate is located on cylinder cover hood (intake side) of engine.
1.2 Printed Location of Engine Identification Code and Engine No.
Engine identification code is printed on fuel injector installation flange fixed base of rear part of
cylinder body intake side.
1
Engine Introduction
HFC4DE1-1D
F4400001
1.3 Engine Identification Code Instruction
1、Engine Identification Code

Rear part
Part Front part
Product serial number
Code HFC 4 D E 1 - 1 D
Cylinder Technolog Displac Technolog Emissio
Item Enterprise Type Delimiter
number y platform ement y n
E-type
4 Diesel Lengthwis Turbocharg
Meaning JAC technolog 2.7L Euro V
cylinders engine e mounted ing
y platform
2、Engine No.
Engine No. F 4 123456
Year Engine type Manufacturing

Meaning
（2015 year） (Diesel) number
3、Year Instruction
Year Code Year Code Year Code Year Code
2001 1 2009 9 2017 H 2025 S
2002 2 2010 A 2018 J 2026 T
2003 3 2011 B 2019 K 2027 V
2004 4 2012 C 2020 L 2028 W
2005 5 2013 D 2021 M 2029 X
2
Engine Introduction
2006 6 2014 E 2022 N 2030 Y
2007 7 2015 F 2023 P 2031 1
2008 8 2016 G 2024 R 2032 2
3
Engine Introduction
II、Engine Technical Specification Parameter
2.1 Main Technical Specification
Engine type No. HFC4DE1-1D

Straight type, turbocharging
Engine type
inter-cooling, high pressure common rail
Vehicle equipped type Lengthwise mounted
Emission standard Euro V
Fuel type GB19147 specified Euro Ⅴ diesel
Rated power (kW) 110
Main Rated engine speed (r/min) 3200

function Max torque (N·m) 355
parameter Engine speed of Max torque (r/min) 1800～2600
Idling engine speed (r/min) 750±30
Located type Straight type
Cylinder number 4
Valve number 16
Displacement（ml） 2746
Compression ratio 16.5
Cylinder diameter（mm） 93.5
Main Stroke（mm） 100
structure Crankshaft rotating direction (facing
Anticlockwise
parameter to flywheel side)
Ignition sequence 1-3-4-2
Lubrication method Pressure and splash combined type
Cooling method Coolant cooling
Externality size
772×654×728
(Length×Width×Height)（mm）
Net weight (kg) 284
4
Engine Introduction
2.2 Main Component Specification
Component name Technical characteristic

Oil filter Full flow type, paper core ring tube, replaceable type
Oil pump Rotor type
Coolant pump Centrifugal type
Thermostat Wax type
Generator Alternating generator
Starter Decelerating type low speed big torque starter
High pressure fuel
Electrical control pump
pump
Fuel injector Electrical control fuel injector
Fuel-gas separator Impact type, free maintenance (integrated PCV valve)
Turbocharger Exhaust gas bypass turbocharger (WGT)
Catalyst converter
DOC catalyst converter + SCR catalyst converter
assembly
2.3 Main Inspection and Adjustment Parameter
Parameter Specification
Inlet：（0.25±0.03）mm
Valve clearance (Cool state)
Outlet：（0.5±0.03）mm
Oil pressure (Idling) ≥98kPa
Thermostat opening temperature 82℃
Thermostat totally opening
95℃
temperature
Fuel injector extrusive height （2.85±0.35）㎜
Oil filling capacity（L） New engine fill 7.9L, when maintenance, fill 6.8L
Urea capacity (L) One-time max fill 18L, first time 21L
2.4 Oil Specification
Check engine oil level, and fill in time when oil is not enough. Use diesel oil accord with national
standard GB 11122 shown in below list, according to (environment temperature) season and local air
temperature.
Environment temperature in
Oil type Quality grade
using area
15W/40 -20℃～40℃ Not less than CI-4
5W/30 -30℃～30℃ Not less than CI-4
5
Engine Introduction
2.5 Fuel Specification
HFC4DE1 diesel engine uses national standard GB 19147 specified Euro Ⅴ diesel, for areas with
environment protection requirement must use diesel applicable to environmental regulations, choose
according to the below list according to season and local air temperature.
Environment More than More than More than More than More than
temperature 4℃ -5℃ -14℃ -29℃ -44℃
Diesel brand No.0 light No.-10 light No.-20 light No.-35 light No.-50 light
No. diesel diesel diesel diesel diesel
2.6 Urea
Urea should satisfy the requirement of GB 29518 diesel engine Nox reductant 32.5% urea solution
(AUS 32).
6
Engine Introduction
III、Tighten Torque
Figure No. Name Quantity Specification Tighten torque Remark

Cylinder body
1002
assembly
Coolant discharging
1002106FE010 1 R1 1/4 （20～25）N·m
plug screw
Install piston cooling
Q1840610 Hexagon flange bolt 4 （10～15）N·m
spraying nozzle
（10±1）N•m→
Main bearing cover M12×1.5×11 Final tighten torque is
1002104FE010 10 （60±2）N•m→
bolt 9 (170±40) N•m
（140°±2°）
Crankshaft
1002108FE010 10 M10×1.5×83 （65±5） N·m
connecting bolt
Install high pressure fuel
Q1840835TF61 Hexagon flange bolt 3 （30±3） N·m
pump flange
Q1841275TF61 Hexagon flange bolt 7 （110±5） N·m Install flywheel housing
Q1840830F61 Hexagon flange bolt 7 （23±3） N·m Install flywheel housing
Q1840865TF61 Hexagon flange bolt 3 （30±3） N·m Install flywheel housing
Q1840620 Hexagon flange bolt 4 （10～15）N·m Install gear chamber
Q1840620F61 Hexagon flange bolt 2 （10～15）N·m Install gear chamber
Q1841035 Hexagon flange bolt 4 （28～46）N·m Install gear chamber
Q1841035F61 Hexagon flange bolt 1 （28～46）N·m Install gear chamber
When tighten
manually, tighten
technology is：
(10±1)N•m→
M14×1.5×14 (60±2)N•m+(120 Final tighten torque is
1002041FE010 Cylinder cover bolt 10
0 °±2°+(120°±2°) (290±50) N•m
→reverse(300°±
2°)→(60±2)N•m
+(120°±2°)+(120
°±2°)
Cylinder cover
1003
assembly
Inner hexagon plug
1002103GA screw of right 8 R2 1/16 （10±1） N·m Oil duct plug screw
balance shaft sleeve
Q1200825F61 Stud 2 （23±3） N·m Install intake manifold
Fixed stud of
1003012FE010 2 M8×1.25×55 （23±3） N·m
exhaust manifold
Q1840820F61 Hexagon flange bolt 6 （23±3） N·m Install shackle
Install wiring harness
Q1840816F61 Hexagon flange bolt 1 （23±3） N·m
fixed bracket
1004 Piston connecting
7
Engine Introduction
rod assembly
(5±1) N·m
+(20±2) N·m
1004013FE010 Connecting rod bolt 8 M10×1×42.5
+(60±2) N·m
+(90°±2°)
Crankshaft
1005
flywheel assembly
Crankshaft belt M12×1.25×4
1005014FE010 3 （125±5）N·m
wheel bolt 0
Flywheel tighten M12×1.25×3
1005040FE010 8 （135±5）N·m
bolt assembly 3
1006 Camshaft assembly
Install camshaft locating
Q1840616 Hexagon flange bolt 2 （10±1）N·m
plate
Install rocker arm
1006023FE010 Rocker arm bolt 8 M8×1.25×50 （40±5）N·m
component
1006025FE010 Regulating nut 8 M6×1 （10±1）N·m Regulate valve clearance
1008 Intake system
Q1840825F61 Hexagon flange bolt 1 （23±3） N·m Install intake manifold
Q32008F61 Hexagon flange nut 2 （27±3） N·m Install intake manifold
Q1840620F61 Hexagon flange bolt 3 （10±1）N·m Install intake manifold
1009 Oil sump assembly
Q1840825F61-9.
Hexagon flange bolt 14 （25±3） N·m Install oil sump
8
GB900-8×25-T1
Stud 2 （25±3） N·m
F61
Q32008F61 Hexagon flange nut 2 （25±3） N·m
1009104FE010 Oil discharging bolt 1 M16×1.5 （45±5） N·m Re-tighten torque
Q1840616 Hexagon flange bolt 6 （10±1）N·m Install oil filter assembly
Oil level gauge duct, oil
Q1840612F61 Hexagon flange bolt 2 （10±1）N·m
level gauge connector
1010 Lubricating system
Q1840835F61-9. Install oil pump
Hexagon flange bolt 13 （25±3） N·m
8 component
Q1841030F61-9.
Hexagon flange bolt 4 （50±5） N·m Install oil cooler assembly
8
When sealing
ring contacts,
1010320FE010 Oil filter component 1 M22×1.5
tighten 3/4-1
circle
1010353FA01 Perforated bolt 2 M12×1.5×30 25～31 N·m
Oil return duct connects
to cylinder body
Oil return duct connects
to turbocharger
8
Engine Introduction
Fixed stud of
Fix inlet oil return duct to
1010055FE010 turbocharger oil 1 M8×1.25 （23±3） N·m
exhaust manifold
return duct
Fixed one inlet oil duct,

Q32008F61 Hexagon flange nut 2 （27±3） N·m
fix one oil return duct
Crankcase
1014
ventilation system
Cylinder cover hood Install cylinder cover
1014109FE010 11 M6×1×43 （10±1） N·m
assembling bolt hood
1021 Timing system
GB/T70.1 Inner hexagon
4 （12±1） N·m Install driving chain
M6×16-12.9 cylindrical head bolt
Q1841275TF2 Hexagon flange bolt 1 （125±5） N·m Install idle gear
Chain guide rail
1021060FE010 3 M8×1.25×15 （23±3） N·m
fixed bolt
Inner hexagon Install tensioner back
Q218B0625-9.8 2 （10±1） N·m
cylindrical head bolt cover
(100±5)N·m+(90 Final tighten torque is
1021122FE010 Camshaft chain bolt 1 M14×1.5×52
°±2°) (250±70)N•m.
Front part
1025 auxiliary driving
system
Q1840825F61 Hexagon flange bolt 2 （23±3） N·m Install vacuum pump
Q1840820F61 Hexagon flange bolt 1 （23±3） N·m Install vacuum pump
Q1841040F61-9. Install fan belt wheel
8 bracket component
Q1841050F61-9.
Hexagon flange bolt 2 （50±5） N·m Install compound bracket
8
Q1841080F61-9.
Hexagon flange bolt 2 （50±5） N·m Install compound bracket
8
Q1841035F61-9.
Hexagon flange bolt 1 （50±5） N·m Install generator
8
Q18410120F61-
Hexagon flange bolt 1 （50±5） N·m Install generator
9.8
Q1841030F61-9. Install power steering
8 pump bracket
Q1841023F61-9. Install power steering
8 pump bracket
Install wiring harness
fixed bracket
Install power steering
pump
Install power steering
pump
------------------ Idle wheel Ⅰ 1 M10×1.5 （50±5） N·m
9
Engine Introduction
installation bolt
Idle wheel Ⅱ
----------------- 1 M10×1.5 （50±5） N·m
installation bolt
Q1841075TF61 Hexagon flange bolt 1 （50~54） N·m Tensioner fixed bolt
Q1841030F61 Hexagon flange bolt 4 （45±5） N·m Install fan assembly
Electrical control
1026
system
Install crankshaft position
Inner hexagon sensor, camshaft position
Q218B0616 3 （10±1） N·m
cylindrical head bolt sensor, intake pressure
temperature sensor
1026170FB Oil pressure switch 1 （10±1） N·m
Intake heating
1026041FE010 1 （10±1） N·m
component bolt
GB/T16674.1 Install intake heating
M6×16-9.8 component
Coolant temperature
1026310FA040 1 （23±3） N·m
sensor
1041 Cooling system
8 install coolant pump, 1
install small circulation
water pipe, 1 install
three-way connector, 3
install intake water bend
pipe
Install thermostat valve
base
Install outlet water port
component
1042 Fuel system
pump
Fuel pump gear
1042322FE010 1 M18×1.5 （70±5） N·m
fixed nut
rail
Install fuel injector
pressing plate
Fuel pipe fixed nut Connect fuel rail and fuel
1042112FE010 5 M14×1.5 （30±2） N·m
Ⅰ injector
Fuel pipe fixed nut
1042062FE010 1 M16×1.5 （35±2） N·m Connect with fuel pump
Ⅱ
Bolt spring Connect 2 clamping
1042501FB 1 M5×1×25 （8±1） N·m
subassembly plates of fuel pipe bracket
Q1840612F61 Hexagon flange bolt 1 （10±1） N·m Install fuel pipe bracket
1043 Starter assembly
10
Engine Introduction
Q1841060TF61 Hexagon flange bolt 2 （60±5） N·m Install starter
1044 Exhaust system
6 install exhaust
Exhaust manifold
1044203FE010 9 M8×1.25×45 （27±3） N·m manifold, 3 install
bolt
exhaust bend pipe
2 install exhaust
Exhaust manifold
1044018FB 5 M8×1.25 （27±3） N·m manifold, 3 install
fixed nut
turbocharger
Installed in turbocharger,
Turbocharger
1044104FE010 3 M8×1.25×35 （23±3） N·m connect to exhaust
connecting bolt
manifold
Turbocharger Connect turbocharger and
1044105FE010 1 M8×1.25×25 （27±3） N·m
connecting bolt exhaust manifold
Exhaust bend pipe
1044304FE010 2 M8×1.25×55 （23±3） N·m Install exhaust bend pipe
bolt Ⅱ
Heat shield fixed
1044209FE010 9 M6×1×12 （10±1） N·m Install heat shield
bolt
Turbocharger Install turbocharger
1044012FE010 3 M10×1.5×20 （45±5） N·m
bracket fixed bolt bracket
Installed in exhaust bend
Turbocharger with
1016502GD050 2 M10×1.5 （45±5） N·m pipe, connect to DOC
exhaust pipe stud
assembly
Turbocharger fixed
1044017FB 2 M10×1.5 （50±5） N·m Install DOC assembly
nut
11
Engine Introduction
IV、Maintenance Limit
Coordination Abrasion
No. Diagrammatic sketch/ Content
(mm) limit(mm)
Cylinder body
cylinder hole inner Φ93.5  00 . 015
diameter
1、Cylinder
body cylinder Piston skirt part
Φ93.5  00 ..054
070
hole—Piston outer diameter
skirt part X
Cylinder fitting
0.054~0.085 0.15
clearance
2、Cylinder
0.01mm
cylindricity
Piston pin hole

Φ34.5 00..013
diameter 008
3、Piston pin Piston pin outer 0

轴Φ34.5 0.004
hole-piston pin diameter
Radial clearance 0.008～0.017 0.03
Piston pin outer 0

Φ34.5 0.004
diameter
4、Piston pin
Connecting rod
outer diameter-
small end bushing Φ34.5 00..017
connecting rod 012
hole
small end
bushing hole
Radial clearance 0.012～0.021 0.05
12
Engine Introduction
Connecting rod big

28  00. 10
end wide
5、Connecting
rod big end
Crankshaft
wide-crankshaft
connecting rod
connecting rod 28  00 ..15
20
shaft journal open
shaft journal
gear
open gear
Connecting rod big

0.15～0.30
end axial clearance
1st piston ring

2.097  00..10
groove high 08
6、Piston ring 1st piston ring high 2.097  00 . 029

groove high-
piston ring high
(piston ring side 1st piston ring
clearance) groove-1st piston
0.08～0.129 0.20
ring high fit
clearance
2nd piston ring

2.0  00..06
groove high 04
2nd piston ring high 2.0  00 ..01

03
2nd piston ring

groove-2nd piston
0.05～0.09 0.17
ring high fit
clearance
13
Engine Introduction
3rd piston ring

3.0  00 ..04
02
groove high
3rd piston ring high 3.0  00 ..01

03
3rd piston ring

groove-3rd piston
0.03～0.07 0.15
ring high fit
clearance
1st gas ring 0.25～0.35 0.8

2nd gas ring 0.45～0.65 1.0
7、Piston ring
opening
clearance 3rd oil ring 0.30～0.50 1.0
In Φ93.5  00.01 ring
gauge (or in cylinder

hole)
Crankshaft main
Φ74 (  00 . 016 )
shaft journal
8、Crankshaft Crankshaft main  0 . 018

Φ79 ( )
main shaft shaft bushing hole 0
journal-cranksh
Shaft bushing size 2.5（  00 ..027
033 ）
aft main shaft
bushing hole
Radial clearance 0.054~0.10 0.15
9、Crankshaft Crankshaft
connecting connecting shaft Φ59 ( 00.016 )
shaft journal- journal
connecting
shaft shoe hole Connecting shaft
Φ62.4(  00..003
023 )
bushing hole
14
Engine Introduction
Upper shaft
1.659 00.01
bushing thickness
Lower shaft
1.663 00.006
bushing thickness
Fit clearance 0.039~0.091 0.15
Crankshaft thrust
shaft journal open 32.5  00 . 04
gear
10、Crankshaft Thrust shoe inner
thrust shaft 27.52 0 0 . 05
gear width
journal open
gear-main Thrust shoe outer
32.22 0 0 . 2
bearing thrust gear width
gear
Crankshaft axial
0.1~0.42
clearance
Valve guide pipe

Φ6  00.015
inner diameter
11、Valve guide Intake: Φ6  00 ..030

045
pipe inner Valve rod diameter
diameter-valve Exhaust: Φ6  00..050
065
rod diameter
Intake valve:
0.030～0.060
Fit clearance 0.10
Exhaust valve:
0.050～0.080
12、Exhaust Exhaust valve base

Φ31  00 ..095
075
valve base outer outer diameter
diameter-exhau
st valve base
hole Exhaust valve base
Φ31H7(  00 . 025 )
hole
15
Engine Introduction
Magnitude of
Fit clearance interference
-0.095~-0.05
Intake valve base

Φ33.5  00 ..08
06
outer diameter
13、Intake valve
base outer Intake valve base  0 .025
Φ33.5H7( 0 )
diameter-intake hole
valve base hole
Magnitude of
-0.08~-0.035
Camshaft shaft
Φ43.1(  00 ..035
051 )
journal
14、1-4 Φ43.1H7(  00. 025 )

Camshaft hole
camshaft shaft
journal-camshaf
t hole
Fit clearance 0.035～0.076 0.12
Camshaft shaft
4.0  00 ..18
10
journal open gear
15、Camshaft
Location block
shaft journal 4.0  00 . 03
thickness
open gear-
camshaft
bearing thrust
Camshaft axial
gear width 0.10～0.21 0.4
clearance
16、Camshaft Camshaft bushing

bushing inner inner diameter after Φ39.1H7(  00.025 )
diameter-camsh press fitting
aft shaft journal Camshaft 5th gear
Φ39.1f6(  00 ..025
041 )
shaft journal
16
Engine Introduction
Fit clearance 0.025～0.066 0.15
17、Flywheel
outer Flywheel outer Φ374.5v7(  00..587
530 )
diameter-flywh diameter
eel gear ring
inner diameter
Flywheel gear ring
Φ374.5JS9(  00 ..07
07 )
inner diameter
Magnitude of
-0.46~-0.657
Camshaft bushing Φ43.1H7(  00. 025 )

18、Cylinder installation hole
cover camshaft
bushing bore- Camshaft bushing
camshaft Φ43.1v7(  00 ..106
081 )
outer diameter
bushing outer
diameter Magnitude of
-0.106~-0.056
19、Camshaft
chain wheel Hole Φ21.1(  00 . 021 )
installation
hole-correspond Shaft Φ21.1(  00 ..040
061 )
ing shaft journal

on camshaft Fit clearance 0.04～0.082
20、Cylinder
cover
0.10mm 0.15
flatness-burnt
surface
21、Fuel
injector
2.5-3.2mm
protrusion
amount
22、Flatness of
top surface of 0.04mm 0.15
cylinder body
23、Piston
extruding 0.34～0.26
amount
17
Engine Introduction
V、Special Tool
No. Tool name Outside drawing Use
Used to remove engine valve and

Valve spring
1 related components when don’t
compressor
need to remove
Crankshaft front oil

2 sealing installation Install crankshaft front oil sealing
device
Oil sump removal

3 Used to remove oil sump
device
Crankshaft rear oil

4 sealing installation Install crankshaft rear oil sealing
device
Valve oil sealing

5 Install valve oil sealing
installation device
Fixed flywheel to be convenient to

6 Flywheel fastener
remove
18
Engine Introduction
Fix rear part location groove of

7 Camshaft fixed tool
camshaft
Rotate engine by flywheel housing

8 Barring tool
plugging hole
Urea pump main

Used to assemble and disassemble
9 strainer assembly and
urea pump main strainer
disassembly tool
19
Engine Mechanical System
Chapter II Engine Mechanical System
I、Maintenance Note
1.1 General Note
1、Note for Discharging Engine Coolant

Discharge engine coolant after engine cooling down.
2、Note for Disconnecting Fuel Pipe
1）Release fuel pressure before disconnecting and removing;
2）Plug opening to avoid fuel leaking after disconnecting pipe.
3、Note for Dismantling and Disassembly
1）When illustrating to use special tool, please use special tool. Always pay attention to safety, don’t
force to operate or not follow the instruction.
2）Be careful not to damage fitting surface or sliding surface.
3）If necessary, use tape or equivalent product to plug opening of engine system to avoid inletting
foreign matter.
4）Mark and arrange disassembled components systematically to be convenient for troubleshooting
and assembly.
5）Basic principle of loosening bolt and nut is: first loosen the outermost, and then loosen the
diagonal position, and so on. If specified loosening sequence, please operate according to specified
sequence.
4、Note for Inspection, Maintenance and Replacement
Thoroughly check component before maintaining or replacing; if necessary, please replace.
5、Note for Assembly
1）Use tension wrench to tighten nut and bolt.
2）Basic principle of tightening bolt and nut is in several steps with the same degree of tightness, first
tighten middle, and then tighten the inner and outer diagonal positions. If specify tighten sequence, please
operate according to specified sequence.
3）Replace new gasket, oil seal or “O”-type ring.
4）Thoroughly wash, clean and dry every component. Carefully check whether there is blocking in
engine oil or engine coolant pipe.
20
5）Don’t damage slipping surface or fitting surface. Clear cloth scraps or dust etc. foreign matter
thoroughly. Spread engine oil to sliding surface before assembly.
6）First release air in pipe when re-fill engine coolant after draining engine coolant.
7）After maintain, start engine and increase engine speed to check whether there is leaking in engine
coolant, fuel, engine oil and inlet/outlet.
8）Make sure to spread lubricant before installing all “O”-type ring of lubrication system.
6、Component need to be tighten with fixed angle
1）Use angle wrench to final tighten the following engine components:
1 Cylinder cover bolt
2 Main bearing cover bolt
3 Connecting rod bolt
4 Crankshaft belt wheel fixed bolt
2）Please don’t final tighten according to torque value.
3）Torque values of these components apply to pre-tighten procedure.
4）Ensure screw thread and base surface clean, and spread engine oil.
1.2 Sealant Note
1、Remove Sealant
Use scraper or oil sump separating special tool to separate fitting
surface and clear used sealant after removing fixed nut and bolt.
Note：
■Be careful not to damage fitting surface.
Slid
Knock
■Insert scraper, and then knock side to slip as shown in right
picture.
■Please use plastic hammer to knock component slightly to
remove in the place where can’t use scraper. Scraper
■Please be careful not to damage fitting surface if it has to use
screw-driver etc. tools.
2、Sealant Applying Procedure
1）Use scraper to clear attached used sealant on applied surface
and fitting surface of gasket.
21
Note：
■Clear used sealant thoroughly from sealant applied surface groove, fixed bolt and bolt hole.
2）Clean sealant applied surface and fitting surface, and clear attached water, lubricant and foreign
matter.
3）Place sealant of specified size to specified place.
Note：
■Make sure sealant to be spread to groove.
■Generally place sealant to inside of bolt hole.
■Install combined component according to detailed specified time in this manual after spreading
sealant, generally is 3-10 minutes.
■If there is blot in sealant, please clean immediately.
■Please don’t re-tighten bolt or nut after installing.
■After installing for 30 minutes, fill engine oil and engine coolant.
1.3 Engine Sealant Use List
Sealing part Sealant Sealing strip diameter

Loctite 5182 anaerobic
Cylinder body-lower cylinder box （1.5±0.5）mm
adhesive
Gear wheel chamber-cylinder body, lower
Loctite 900H silica gel （2.5±0.2）mm
cylinder box
Flywheel housing-gear wheel chamber Loctite 5900H silica gel （2.5±0.2）mm
Engine front part-fitting surface of cylinder
Loctite 5900H silica gel 2mm
body and lower cylinder box
Oil sump-oil pump housing, cylinder body,
Loctite 5900H silica gel 2mm
gear wheel chamber
Tonsan 1608 anaerobic
Bowl-type plug-installation hole
adhesive
Coolant drain plug screw- cylinder body
Oil pressure switch screw thread Loctite 516 anaerobic
Coolant temperature sensor screw thread adhesive
Fuel injector installation bolt
Remark: can use other products with similar function to replace, but can’t be less performance than
sealant in the table.
22
1.4 Engine Sealant Using Detail
1）Connecting surface of cylinder body and lower cylinder box: tighten bolt in 3 minutes after
cylinder body and lower cylinder box combined.
2）Connecting surface between gear wheel chamber and

cylinder body, lower cylinder box: install in 10 minutes after
spreading sealant.
3）Connecting surface of flywheel housing and gear wheel

chamber: install in 10 minutes after spreading sealant to flywheel.
4）Engine front part: spread sealant in connecting position of

cylinder body and lower cylinder box, as shown in right figure, and
install in 10 minutes after spreading sealant.
5）Connecting surface of oil sump and oil pump housing,

cylinder body, gear wheel chamber: spread sealant in “T”-shape structure position formed by oil sump,
oil pump housing, cylinder body and oil sump, cylinder body, gear
wheel chamber.
Oil sump Lower Gear wheel
6）Bowl-type plug and installation surface: spread sealant in housing cylinder box chamber
bowl-type plug and installation surface.

7）Coolant draining plug screw: spread sealant to coolant
draining plug screw before installing.
Fly wheel
8）Screw thread of coolant temperature sensor, fixed bolt of high

housing
pressure fuel pump: spread screw thread sealant before installing.
23
II、Front Part Auxiliary Driving System
2.1 System Diagrammatic Sketch
Coolant
8 pump
9 1 2 3 4
Crankshaft belt wheel
1、Engine；2、Idler wheel II；3、Vacuum pump；4、Idler wheel I；5、Power steering pump

bracket；6、Power steering pump；7、Fan belt wheel bracket assembly；8、Automatic tensioner
tension wheel (belong to automatic tensioner)；9、Compressor；10、Automatic tensioner；11、
Belt；12、Compound bracket
2.2 Belt Inspection
1 Mechanical automatic tensioner tension belt, make sure

belt is always in reasonable tension range. It doesn’t need to inspect
belt tension in daily use, and judge whether belt needs to be
replaced according to the relevant position indicating in tensioner.
Indicating line should be between installation position A and limit
tension position C when working normally; if exceeds range C, ABC
replace belt.
2 Visually check extrinsic feature surface of engine belt to check whether there is crack,
24
abrasion and spalling in driving belt surface; if any, please replace. Check belt carefully. If there are
faults as shown below, please replace new belt:
a. Belt crack
b. Belt abrade, wire is exposed
c. Belt arris damaged seriously, and even totally drop
d. Belt aging, lack of flexibility
e. Reverse side rubber hardening, smooth and no flexibility, and hardening to the range that there
is no mark when scratching by nail
3 Check whether automatic tensioner and idler wheel are flexible, and check its clearance and
noise; if needed, please replace automatic tensioner and idler wheel.
2.3 Removal
1 Pull tension arm hole of automatic tensioner clockwise, and

take down belt;
2 Remove automatic tensioner and compound bracket;
3 Remove fan clutch fixed bolt, and take down fan clutch, fan
belt wheel press plate and fan belt wheel;
4 Remove fan belt wheel bracket fixed bolt, and take down fan
belt wheel bracket;
5 Remove generator fixed bolt, and take down generator;

6 Remove power steering pump and power steering pump Fan belt wheel
bracket
bracket;
Fan belt wheel
7 Remove idler wheel I and idler wheel II. Fixed bolt
Fan belt wheel
press plate
Fan assembly
2.4 Installation
1 Install compound bracket component. Check whether

location sleeve dropped before installing, and there are 2 location
sleeve in fitting surface of cylinder body, and 2 location sleeve Location sleeve between with
cylinder body
(compressor location sleeve) in compound bracket;

Location sleeve between with A/C
25
2 Install generator, and tighten generator fixed bolt;

3 Install A/C compressor, and tighten fixed bolt;
4 Check whether location sleeve on power steering pump

bracket dropped before installing, and flat surface in side of location
sleeve should face to anti-rotation convex platform on power steering
pump bracket, and doesn’t connect to anti-rotation convex platform;
5 Install power steering pump, and tighten power steering

pump installation bolt. (At this condition, if bolt can’t be tightened,
tighten bolt according to torque requirement after belt tensioning.)
6 Install fan belt wheel bracket assembly;
7 Install and tighten fan belt wheel stud;
8 Install idler wheel Ⅰ, and tighten fixed bolt; Fan belt wheel
bracket
Fan belt wheel
Fixed bolt Fan belt wheel

press plate
Fan assembly
9 When installing tensioner components, first insert location

pin on tensioner component to pin hole on compound bracket, and
tighten tensioner fixed bolt;
10 Install belt, pull out automatic tensioner belt installation
pin. If not inserting installation pin, pull automatic tensioner tension
arm hole clockwise;
11 Install fan belt wheel, press plate and fan assembly;
26
2.5 Installation Note
1 If there is little lubricant oil on belt, should use dry cloth or paper to clean, and it’s forbidden to
clean belt by cleaning agent.
2 Remember position of driving belt installation passing round to avoid misplacing. When
installing, operate according to the contrary sequence of removal.
3 When installing driving belt to belt wheel, check coordination condition of driving belt and belt
wheel. If driving belt and belt wheel not coordinate well, it will affect using life of driving belt. At last,
after installing driving belt and adjusting, check whether driving belt on belt wheel is running at grade.
If not, it will cause driving belt early damage.
Attachment: Front End Driving System Belt Diagnosis
Condition Possible reason Measure
Belt arris becomes too 1. Foreign matter embedded into belt 1. Clear foreign matter of belt wheel
thick (one or several wheel groove groove
strips separate from belt) 2. Damaged when installing 2. Replace belt
1. Belt wheel not aligned 1. Align belt wheel
2. Environment causes abrasion 2. Clean belt wheel, replace if
3. Belt wheel gets rusty needed
Arris or belt abraded
4. There is sharp angle or bulge on 3. Belt wheel gets rusty
top end of belt wheel groove 4. Replace belt wheel, check belt
5. Belt rubber aging 5. Replace belt
1. Belt trackslip due to belt tension
not enough
1. Check if needed/Replace
2. Belt or pulley exposed in substance
tensioner
that reduce friction (belt oil, oil,
2. Replace belt and clean belt wheel
Belt trackslip ethylene glycol)
3. Replace damaged component or
3. Bearing of driven component
bearing
damage (seizure)
4. Replace belt
4. Be heated and excessive trackslip
make belt abraded and harden
1. Belt not lead in well when getting
into belt groove
1. Replace belt
Belt vertical crack 2. Top edge of belt wheel groove
2. Replace belt
abrades rubber, exposed core rope of
rope
1. Belt tension not right 1. Check if needed/Replace
“Groove jumping” (Belt 2. Belt wheel is not in the range of tensioner
can’t stay in right design common difference 2. Replace belt wheel
position of belt wheel) 3. There is foreign matter in belt 3. Clear foreign matter from groove
wheel groove 4. Align component
27
Condition Possible reason Measure
4. Belt wheel not aligned 5. Replace belt
5. Belt core rope disconnected
1. Replace, check if needed/ replace
1. Belt tension not right
tensioner
Belt crack (Note: install 2. Damage core rope of pulling rope
2. Replace belt
new belt, check and when installing belt
3. Align belt wheel
remove existed fault) 3. Not aligned seriously
4. Replace damaged component and
4. Bracket, belt or bearing damaged
belt
1. Belt tension not right tensioner
Noise (When belt 2. Bearing noise 2. Check and maintain
running, hear or feel 3. Belt not aligned 3. Belt aligned
harsh scream, squeak 4. Belt and belt wheel not matching 4. Install right belt
scream) 5. Driven component causes vibration 5. Find faulted driven component
6. Belt flattening surface separated and maintain
6. Replace belt
1. Tension sheath contacts to fixed
Fault (weaving fiber
object, and overheating cause 1. Check friction condition, replace
outside belt surrounding
weaving fiber aging belt
is damaged or separated
2. Belt sheath connection position 2. Replace belt
from belt)
crack
1. Belt tension not right
Rope edge fault (belt 2. Belt contacts to fixed object
tensioner
edge flexible part 3. Pulley (one or several) is more than
2. Replace belt
exposed or separated common difference
3. Replace pulley
from belt) 4. Adhesive force between flexible
4. Replace belt
part and rubber is not enough
2.6 Removal and Installation of Vacuum Pump
1 Install vacuum pump assembly, ensure its square convex

platform to be inserted into groove of camshaft end, and then tighten
vacuum pump installation bolt;
2 Remove according to the contrary sequence of installation;
3 Ensure connecting surface of vacuum pump is clean before installing.
28
Attachment: Front End Driving System Bolt Tighten Torque
No. Name Quantity Specification Tighten torque Remark

Install vacuum
pump
Install vacuum
pump
Install fan belt
Q1841040F61-9.8 Hexagon flange bolt 4 （50±5） N·m wheel bracket
component
Install compound
Q1841050F61-9.8 Hexagon flange bolt 2 （50±5） N·m
bracket
Install compound
bracket
Q1841035F61-9.8 Hexagon flange bolt 1 （50±5） N·m Install generator
Q18410120F61-9.8 Hexagon flange bolt 1 （50±5） N·m Install generator
Install power
Q1841030F61-9.8 Hexagon flange bolt 2 （50±5） N·m steering pump
bracket
Install power
Q1841023F61-9.8 Hexagon flange bolt 1 （50±5） N·m steering pump
bracket
Install wiring
Q1840816F61 Hexagon flange bolt 1 （23±3） N·m harness fixed
bracket
Install power
steering pump
Install power
steering pump
Idler Ⅰ installation Idler wheel Ⅰ
------------ 1 M10×1.5 （50±5） N·m
bolt installation bolt
Idler Ⅱ installation Idler wheel Ⅱ
------------ 1 M10×1.5 （50±5） N·m
bolt installation bolt
Tensioner
Q1841075TF61 Hexagon flange bolt 1 （50~54） N·m assembly fixed
bolt
Install fan
assembly
29
III、Timing System
1、Gear wheel chamber； 2、Idler gear wheel lower gasket； 3、High pressure fuel pump gear wheel；
4、Idler gear wheel assembly I； 5、Tensioner cover fixed bolt； 6、Tensioner rear cover；
7、Tensioner rear cover sealing ring； 8、Tensioner； 9、Camshaft chain wheel；
10、Camshaft chain wheel press plate； 11、Camshaft chain wheel fixed bolt； 12、Chain；
13、Movable rail； 14、Inner hexagon cylinder head bolt； 15、Driving chain wheel fixed bolt；
16、Inner hexagon cylinder head bolt； 17、Idler gear wheel upper gasket； 18、Driving chain wheel；
19、Idler gear wheel shaft； 20、Idler gear wheel location pin；
21、High pressure fuel pump fixed nut； 22、High pressure fuel pump gear wheel gasket；
23、Fuel pump flange sealing ring； 24、Fuel pump flange； 25、High pressure fuel pump；
26、High pressure fuel pump fixed bolt； 27、Movable rail
30
3.2 Removal
1 Remove all components of front end driving system according to “2.3 Front End Driving
System”;
2 Rotate top dead center mark T of outer annulus of crankshaft
belt wheel to align to base mark of fuel pump housing, which is
convenient to confirm piston upper dead center position, and insert
with pin;
3 Separate engine from transmission;
4 Use flywheel clamp to seize flywheel, remove flywheel fixed
bolt, and take down flywheel and flywheel housing; This side clings to top
side of cylinder head
Camshaft phase
position fixed plate
5 Use special tool to fix rear part of camshaft connecting to

vacuum pump key groove;
Insert into camshaft
position groove
6 Remove camshaft toothed wheel fixed bolt;
7 Remove chain tensioner fixed bolt, and take down tensioner;
8 Loosen fuel injector fixed nut;
9 Loosen camshaft toothed wheel fixed bolt. Remove camshaft bolt bushing and idler gear wheel
shaft;
10 Remove gear wheel chamber fixed bolt.
3.3 Inspection
Check whether there is abrasion, crack and damage in camshaft gear wheel, crankshaft gear wheel,
fuel injector gear wheel and idler wheel; if any, please replace in time.
3.4 Installation
1、Gear Wheel Chamber Installation

1 Clear remained sealant in gear wheel chamber and cylinder
body before installing; check whether there is clash, scratch and
Locating
sealant strip in connecting surface of fuel pump housing and chain sleeve
wheel chamber, and ensure connecting surface clean;
31
2 Check whether fixed bolt and screw thread hole of gear wheel chamber is damaged or stripped;
3 Check/Install gear wheel chamber locating sleeve on cylinder body. Locating sleeve of gear
wheel chamber and cylinder body are interference fit, extrude height: 4.5±0.3mm; Locating sleeve and
gear wheel chamber are clearance fit;
4 Install gear wheel chamber sealing ring to gear wheel
chamber, and check whether sealing ring is damaged before installing,
and ensure sealing ring to be embedded into sealing groove when
installing;
5 Before installing gear wheel chamber, evenly spread sealant
to connecting surface of gear wheel chamber and cylinder body,
complete installation at a time, and ensure it isn’t loosen after
installation. Clear overflowed unnecessary sealant (left/right side and
bottom side) of connecting surface after installing. Sealant type:
Loctite 5900H silica gel; sealant diameter: (2.5±0.2)mm; ensure to
complete installation in 10 minutes after spreading sealant;
6 Tighten gear wheel chamber fixed bolt Ⅰ, Ⅱ, Ⅲ, Ⅳ,
bolt Ⅰ-Q1840620F61/bolt Ⅱ-Q1840620 installation torque:
10±1N•m; bolt Ⅲ-Q1841035F61/bolt Ⅳ-Q1841035 installation
torque: 37±9N•m.
2、Installation of Timing System

1 Ensure upper dead center mark T of outer circle of
crankshaft belt wheel aligned to base mark fuel pump housing, and
to be convenient to ensure position of piston upper dead center, and
insert with pins.
2 Install idler gear wheel assembly, driving chain wheel.
Before installing idler gear wheel assembly, install driving chain
wheel to idler wheel;
3 Install lower heel block (thickness 2.5mm) of idler wheel Idler gear wheel
locating pin
on cylinder body, and install idler gear wheel locating pin (split pin)
on idler gear wheel shaft, locating pin protruding idler gear wheel
end surface height 5mm;
32
4 Install idler gear wheel assembly to idler gear wheel shaft, and should spread proper lubricant
oil to surface of idler gear wheel shaft, and then slightly push idler
gear wheel assembly into idler gear wheel shaft; after installing
upper heel block (thickness 4mm) of idler gear wheel, tighten idler
gear wheel fixed bolt. Oil groove on two shims both face to gear
wheel;
5 Install camshaft according to “7.4 Valve System”, you
Gap upward
should spread proper lubricant oil to all shaft journals and cam
before install camshaft to cylinder head, and then push camshaft into
cylinder head cam bearing hole slightly from front part of cylinder
head, and ensure there is no scratch or damage. Axial positioning
groove faces to rear part of cylinder head, and adjust angle of
camshaft to make key groove of rear part straight up;
This side clings to top Camshaft phase
part of cylinder head position locating plate
6 Fix camshaft by special tool in front part of cylinder head;
7 Camshaft axial locating plate is installed in rear part of
cylinder head, rounded side faces to flywheel end of engine Insert into camshaft
locating groove
(outward), and pay attention to not install reversely, and tighten

camshaft locating plate bolt;
8 Install fixed rail and moveable rail, spread proper lubrication oil to chain side of fixed rail
before installing, and tighten fixing bolt;
9 First install chain to driving chain wheel, mesh camshaft chain and chain, and install it to
camshaft, and at last install camshaft chain wheel pressing plate, and pre-tighten installation bolt;
33
10 Install chain tensioner assembly and tensioner rear cover. Before installing tensioner rear cover,
install sealing ring into sealing groove of tensioner rear cover. Before installing chain tensioner
assembly, first check whether its sliding bushing is sliding flexibly, and there isn’t any clamping
stagnation phenomenon, and then spread proper lubricant oil to shaft journal surface of chain tensioner,
slightly push into installation hole of chain wheel chamber; before chain tensioner assembly is pressing
movable rail, movable rail should move flexibly around chain guide rail fixed bolt, and there is no any
clamping stagnation phenomenon. At the same time, pre-tighten and tighten fixed bolts of two tensioner
rear cover, and avoid rear cover skew when tightening, and causes sealing ring side scrap damaged;
11 Ensure signal gear on camshaft to face to partial upper side of intake side, and tighten camshaft
chain wheel bolt;
12 Tighten camshaft chain wheel bolt, and remove cam phase
position fixed plate for installation;
13 Rotate crankshaft clockwise until top end center mark P of
outer annulus of crankshaft belt wheel aligned to base mark of fuel
pump housing, thus to ensure position of piston top end center, and
insert with pin;
14 Before installing high pressure fuel pump, check high
pressure fuel pump sealing ring, if sealing ring is damaged, it need to be replaced, and spread lubricant
oil to sealing ring; spread anaerobic type screw thread sealant to
installation bolt of high pressure fuel pump before installing. Install
high pressure fuel pump to high pressure fuel pump flange, and align
timing mark on fuel pump to mark on fuel pump installation flange;
34
15 Install high pressure fuel pump gear wheel to fuel pump
shaft, align locating pin groove on gear wheel to locating pin on fuel
pump, pre-tighten fixed nut, and rotate gear wheel until mark Align mark
aligned to mark on fuel pump installation flange, namely fuel pump

is in top dead center;
16 Install fuel pump assembly to front idling wheel gear, and

tighten connecting bolt of flange and cylinder body;
17 Use limit rotation shaft in rear part of crankshaft to get
struck crankshaft by flywheel bolt;
18 Tighten high pressure fuel pump gear wheel nut;
35
Attachment: Bolt Tighten Torque of Timing System
Part Code Name Quantity Specification Tighten torque Remark
GB/T70.1 Inner hexagon Install driving
4 (12±1) N·m
M6×16-12.9 cylindrical head bolt chain wheel
Install idling
Q1841275TF2 Hexagon flange bolt 1 (125±5) N·m
gear wheel
Chain guide rail
1021060FE010 3 M8×1.25×15 (23±3) N·m
fixed bolt
Install
Q218B0625-9. Inner hexagon
2 (10±1) N·m tensioner rear
8 cylindrical head bolt
cover
Camshaft chain (100±5)N·m+(
1021122FE010 1 M14×1.5×52
wheel bolt 90°±2°)
Install high
Q1840835TF61 Hexagon flange bolt 3 (30±3) N·m pressure fuel
pump flange
Install gear
Q1840620 Hexagon flange bolt 4 (10～15) N·m
chamber
Install gear
Q1840620F61 Hexagon flange bolt 2 (10～15) N·m
chamber
Install gear
Q1841035 Hexagon flange bolt 4 (28～46) N·m
chamber
Install gear
Q1841035F61 Hexagon flange bolt 1 (28～46) N·m
chamber
Install high
Q1840830TF61 Hexagon flange bolt 3 (30±3) N·m pressure fuel
pump
High pressure fuel
1042322FE010 pump gear wheel 1 M18×1.5 (70±5) N·m
fixed nut
36
IV、Intake System
1、Intake bending pipe 2、Intake bending pipe sealing ring 3、Intake manifold
4、Fixed nut 5、Intake pipe gasket 6、Hexagon flange bolt 7、Hexagon flange bolt
8、Intake bending pipe fixed bolt 9、Intake heating component
4.2 Removal of Intake System
1、Remove fixed bolt of oil level gauge and intake pipe;

2、Crosswise loosen fixed bolt and nut of intake pipe from two sides to middle. Take down intake
manifold and intake bending pipe assembly, and take down intake manifold sealing ring;
3、Remove intake pressure sensor;
4.3 Installation and Check of Intake System
1 Before installing, clean all components, and there is no scraps in intake manifold and intake
bending pipe;
2 Check all gaskets and ensure there is no damage, scratch or crumple to ensure its sealing function;
37
3 Install intake manifold gasket and intake manifold, surface
of intake manifold gasket should be flat, and there is no scratch or
crumple. Bolt tighten sequence should obey to the principle of from
middle to two sides and tightening crosswise, and tighten torque
should be even to avoid air leakage;
Intake manifold direction
4 Intake heating component installation: First remove

insulation gasket, install intake heating component to intake port of Wiring terminal of
heating component
intake manifold, and install insulation gasket and tighten bolt. When Intake heating
component
installing, 30° chamfering faces to intake manifold side, 45°
chamfering faces to intake bending pipe side (after installing, fixed
bolt is vertical, and wiring terminal is 30°tilting);
5 Install and tighten connecting bolt of heating component and intake pipe;
6 Check state of intake pressure temperature sensor sealing ring, install intake pressure temperature
sensor to intake manifold, and tighten fixed bolt;
7 Install intake bending pipe to intake manifold, and before installing ensure sealing ring is rightly
installed in groove on intake bending pipe, and tighten fixed bolt;
Attachment: Tighten Torque of Intake System Bolt

Part No. Name Quantity Tighten torque Remark
Q1840825F61 Hexagon flange bolt 1 （23±3） N·m Install intake manifold
Q32008F61 Hexagon flange nut 2 （27±3） N·m Install intake manifold
Install intake bending
Q1840620F61 Hexagon flange bolt 3 （10±1）N·m
pipe
Intake heating
1026041FE010 1 （10±1） N·m
component bolt
GB/T16674.1 Install intake heating
M6×16-9.8 component
Inner hexagon stud Install intake pressure
Q218B0616 3 （10±1） N·m
bolt temperature sensor
38
V、Exhaust System
1、Turbocharger 2、Exhaust bending pipe gasket 3、Exhaust bending pipe

4、Catalyst converter gasket 5、Turbocharger bracket 6、Exhaust manifold
7、Turbocharger gasket 8、Exhaust pipe gasket 9、Heat insulation plate I
10、Heat insulation plate II
5.2 Removal of Exhaust System
1、Remove connecting nut of turbocharger and catalyst converter;

2、Remove fixed bolt and gasket of turbocharger inlet/return oil steel pipe;
3、Remove fixed bolt of turbocharger bracket and cylinder body;
4、Remove fixed bolt of exhaust manifold, and take down exhaust manifold and turbocharger
assembly;
39
5.3 Installation and Check of Exhaust System
1 Check whether surface of turbocharger impeller is flat,

whether there is damage or scratch and abrasion due to foreign
matter getting in, and check whether turbocharger is rubbing housing,
check whether axial clearance of turbocharger is too large and
rotating flexibly. If there is any fault above, replace turbocharger,
and at the same time check whether there is leakage in all
components of intake system and pipe, thus to avoid turbocharger
being damaged too early again;
2 Check gaskets, and there is no damage, scratch, crumple,
and ensure its sealing function;
3 Install exhaust manifold gasket to stud of cylinder head
exhaust side;
4 Install exhaust manifold, and tighten fixed bolt and nut;
5 Before installing turbocharger, tighten stud to turbocharger. Install turbocharger and
turbocharger gasket to exhaust manifold, and tighten fixed bolt and
nut;
6 When installing turbocharger inlet oil pipe assembly, check
whether two ends of banana-shape connector not installed grommet.
Copper gasket is disposable component, replace new after removing;
7 Install turbocharger return oil steel pipe assembly, and
check the condition of sealing gasket when installing;
8 Fix turbocharger return oil pipe fixed stud to joint under
exhaust manifold, and after respectively fixing inlet/return oil pipe to
stud by respective clamp, tighten with fixed nut;
9 Install exhaust bending pipe and gasket;
10 Connect catalyst converter and exhaust bending pipe, and
tighten fixed nut;
11 Install exhaust pipe heating insulation cover and exhaust
bending pipe heating insulation cover;
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Attachment: Tighten Torque of Fixed Bolt of Exhaust System
Part No. Name Quantity Specification Tighten torque Remark
6 install exhaust
Exhaust manifold manifold, 3 install
1044203FE010 9 M8×1.25×45 （27±3）N·m
bolt exhaust bending
pipe
2 install exhaust
Exhaust manifold
1044018FB 5 M8×1.25 （27±3）N·m manifold, 3 install
fixed nut
turbocharger
Installed on
Turbocharger
turbocharger,
1044104FE010 connecting 3 M8×1.25×35 （23±3）N·m
connecting to
double-screw bolt
exhaust manifold
Connect
Turbocharger
1044105FE010 1 M8×1.25×25 （27±3）N·m turbocharger and
connecting bolt
exhaust manifold
Exhausting bending Install exhaust
1044304FE010 2 M8×1.25×55 （23±3）N·m
pipe bolt Ⅱ bending pipe
Heat insulation Install heat
1044209FE010 9 M6×1×12 （10±1）N·m
plate fixed bolt insulation plate
Install
Turbocharger
1044012FE010 3 M10×1.5×20 （45±5）N·m turbocharger
bracket fixed bolt
bracket
Turbocharger Installed on
connecting to exhaust bending
1016502GD050 2 M10×1.5 （45±5）N·m
exhaust pipe pipe, connecting
double-screw bolt DOC assembly
Turbocharger fixed Install DOC
1044017FB 2 M10×1.5 （50±5）N·m
nut assembly
1010353FA01 Crossing hole bolt 2 M12×1.5×30 25～31 N·m
Connecting return
Hexagon flange
Q1840820F61 2 （23±3）N·m oil pipe and
bolt
cylinder body
Connecting return
Hexagon flange
Q1840616F61 2 （10±1）N·m oil pipe and
bolt
turbocharger
Turbocharger return Fix inlet/return oil
1010055FE010 oil pipe fixed 1 M8×1.25 （23±3）N·m pipe to exhaust
double-screw bolt pipe
1 fixes inlet oil
Q32008F61 Hexagon flange nut 2 （27±3）N·m pipe, 1 fixes return
oil pipe
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5.4 Fault Judgment of Turbocharger Impeller and Oil Leakage
When there is fault in turbocharger, no matter oil leakage or abnormal noise, first check state of
turbocharger impeller, and ensure whether state of turbocharger impeller is normal. If impeller is
normal, troubleshoot relevant oil leakage of booster end of turbocharger, oil leakage of turbine end
of turbocharger, abnormal noise fault of turbocharger according to different fault mode.
1、Check Method of Turbocharger Two Wheels Damaged by Foreign Matter
Remove malfunction turbocharger from engine, and check damage condition of turbine and impeller,
and whether there is knock mark of foreign matter, whether there is foreign matter in turbocharger inlet/
outlet pipe.
Normal impeller Impeller damaged by hard object
Impeller damaged by particulate matter Impeller damaged by particulate matter

Responsibility Judgment:
All turbocharger impeller damage faults are not damaged by turbocharger quality problems, are all
caused by users or improper maintenance and usage of intake system.
Possible reasons:
(1) Turbocharger is not maintained for a long time
(2) Use inferior filter
(3) Pull out pipe between fuel-gas separator and intake pipe, air without filtering gets into
turbocharger through connector, and dust will abrade impeller.
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2、Check Method of Oil Leakage Fault of Booster side of Turbocharger
① Turbocharger itself causes booster side oil leakage

A：Booster impeller damaged;
B：Booster impeller clamped or turbocharger abraded;
② Other reasons cause booster side oil leakage
Oil leakage of turbocharger booster side is related to many factors, sometimes oil leakage of
turbocharger booster side is not because of turbocharger, but due to other factor causing oil leakage of
turbocharger booster side, and affect factors are shown below:
A：There is oil getting into turbocharger intake pipe in crankcase respiratory system;
B：There is blockage in turbocharger intake system;
C：There is air leakage between pipe of turbocharger booster to engine intake pipe;
D：Turbocharger returns oil not smoothly;
E：Engine is in idling working condition for a long time;
③ Check method of oil leakage of booster side of turbocharger
A：Check Condition of Turbocharger Impeller
Judge the condition of impeller by visually check appearance of booster impeller (methods of
impeller damage and judging whether impeller is damaged are the same), and at the same time can judge
intake condition: normal impeller angel is about 90°right angle, there is no any round angle. If impeller
angle becomes round, it indicates turbocharger intake is fairly dirty, and there is a little tiny particle, as
shown in below picture. Due to turbocharger impeller is high speed rotating component, when there is
tiny particle in intake system, it will cause high speed friction with impeller, and impeller angle will
become round because of abrasion. And some tiny particle may get into interior component of
turbocharger, accelerate abrasion of turbocharger and leading to oil leakage of turbocharger.
When impeller leaking oil due to round angle phenomenon, it can judge that turbocharger damage
due to worse intake quality, it’s user’s responsibility, not turbocharger quality problem.
Possible reasons:
(1) Air filter element isn’t maintained for a long time or filter element damaged causing air get into
turbocharger directly;
(2) Use inferior filter element;
(3) Pull out pipe between fuel-gas separator and intake pipe, air without filtering gets into
turbocharger through connector, and dust will abrade impeller.
Note: If turbocharger impeller angle is slight round and slightly leaking oil, it doesn’t need to
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replace turbocharger, but should check intake system before engine turbocharging to ensure whether air
filter and intake pipe are clean; if not, replace air filter and clean intake pipe. As such, if turbocharge
impeller angle is round, check intake system before engine turbocharging to ensure whether air filter and
intake pipe are clean; if not, replace air filter and clean intake pipe.
B：Check Whether Turbocharger Impeller is Clamped (Scrub Housing)
After ensuring turbocharge impeller is normal, please check whether there is interfere phenomenon
between turbocharger impeller and turbocharger housing, namely scrubbing housing, as shown in below
pictures. When there is scrubbing housing phenomenon of turbocharger, impeller speed will drop
rapidly and even stop running, turbocharger booster will not compress air, namely turbocharging; and at
this time, due to engine continuous intake air, it will become from normal positive pressure (more than
atmosphere pressure) to negative pressure (less than atmosphere pressure) in booster, and it will cause
oil in turbocharger be absorbed from opening sealing ring of rotor shaft.
Impeller scrubbing housing Impeller scrubbing housing leading to serious abrasion

Rotate impeller to observe whether there is phenomenon of clamping or scrubbing housing; if there
is, hold two sides of impeller to shake up and down, if impeller shaking very strongly, it indicates
abrasion has already exceeded standard value, namely, turbocharger is damaged already. Or hold two
sides of impeller to shake up and down, if impeller could touch turbocharger housing, it indicates
abrasion has already exceeded standard value, namely, turbocharger is damaged already.
When turbocharger impeller shaft abraded, axial and radial clearance of impeller shaft will become
large, at the same time turbocharger leaking oil amount will be very large; certainly leaking oil amount
depends on its abrasion amount (except for abrasion causing impeller shaft locked). Due to more
abrasion amount, axial and radial clearance of impeller shaft will be more larger, leaking oil amount will
be more larger.
If turbocharger impeller gets stuck and not interfere to housing, it indicates impeller shaft is locked
already.
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Impeller scrubbing housing but impeller shaft clearance is normal, it’s turbocharger’s quality
problem.
If impeller scrubbing housing but impeller shaft clearance is larger than standard value, it indicates
impeller shaft abraded too much, thus shaft clearance too large causes impeller scrubbing housing when
rotating, but oil quality and turbocharger maintenance are important factors, they are user’s
responsibility and have nothing to do with turbocharger quality.
Impeller shaft locked is also closely related to oil quality and turbocharger maintenance, which is
user’s responsibility and has nothing to do with turbocharger quality.
Turbocharger shaft rotation speed is very fast; if oil quality is bad or there is impurity, shaft
abrasion speed will be also very fast. Therefore during the procedure, shaft clearance will become big or
shaft will be locked.
C、Check Whether There is Oil Getting into Turbocharger Intake Pipe From Crankcase
Breath System
Remove intake pipe of turbocharger booster intake port, and check whether there is oil in intake pipe
and turbocharger booster intake port; if there is oil both in intake pipe and booster intake port, it indicates
there is remained oil in crankcase breath system getting into turbocharger, thus causes that there is oil in
turbocharging inter-cooling system, and causes the false phenomenon of turbocharger leaking oil. Due to
one side of crankcase ventilation hose connects to engine cylinder hood, crank exhaust gas will be
discharged from the pipe when engine running, and as the same it will take out some oil; but the other
side of crankcase ventilation hose is connected to intake pipe of turbocharger, oil gets into turbocharger,
causing the false phenomenon of leaking oil.
If also can’t conform problem by above check, remove connected part of breath hose of engine
cylinder hood and cylinder hood, block hose with cork, and clean turbocharger and all pipes, connect
well to test run; if there is no oil leaking in inter-cooling system any more, it indicates oil in breath
system getting into turbocharger; if there is more oil leaking again, it indicates it’s not related to breath
system, and it needs further check.
Oil in crankcase ventilation hose getting into turbocharger causes turbocharger false phenomenon of
leaking oil, in this condition, turbocharger is normal, and there is no need to replace turbocharger, and
only need to remove the related problem of crankcase pressure too large.
D、Check Whether There is Blockage Phenomenon in Turbocharger Intake System
When turbocharging system is blocked seriously, it may affect engine power performance, but
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slight blockage may not affect engine power performance. When find engine bad power performance
and turbocharger leaking oil at the same time, intake system may be blocked. Slight blockage doesn’t
affect engine power, but either serious blockage or slight blockage will cause turbocharger leak oil.
Because when turbocharger intake is blocked, intake vacuum degree increases, booster outtake pressure
decreases, and oil will be sucked out by too low intake pressure from turbocharger impeller shaft
opening ring.
When intake system blockage causes turbocharger leak oil, turbocharger is normal and not
damaged, there is no need to replace turbocharger, and should check intake blockage position prior.
Check whether air filter is too dirty or there is blockage.
Check pipe between air filter and turbocharger intake port, and can remove the pipe length by
length to check; if there is blockage, please clear.
Note: Intake system blockage generally is air filter too dirty.
E、There is Leaking Air Phenomenon between Pipes of Turbocharger Booster and Engine
Intake Pipe
When there is leaking air phenomenon in engine boosting inter-cooling pipe, pressure in
turbocharger booster will decrease, pressure in turbine and booster will lose balance, causing booster
leak oil; at the same time, there is compressed air leaking in position of pipe leaking air, and there is oil
in leaked compressed air, which will be attached to leakage point, and appearance will be ugly.
There are some engines due to not installing gasket in combining intake pipe and outtake pipe leads
to the position leak oil seriously, and intake pressure decreasing greatly leads to turbocharger leaking oil
more seriously.
Observe all connecting points of turbocharging inter-cooling pipe, if connecting point attached oil,
it indicates there is leakage in the connecting point, and should deal with it.
If there is no obvious leaking point, check whether there is damage in pipe and inter-cooler
concealment position; handle pipe to check in order to feel leaking position. Installation position of
inter-cooler may affect inspection of leaking position, and remove inter-cooler from vehicle to check if
necessary. Use water to check leakage, namely, stuff up one port of inter-cooler, fill water, and observe
its change condition of water level; if water level decreases, it indicates there is leakage. And also can
observe whether there is water leaking to judge whether there is leakage.
When due to leakage air of engine turbocharging inter-cooling pipe causing turbocharger leak oil,
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it’s not related to turbocharger itself quality, turbocharger is normal and there is no need to replace. Deal
with leakage air position to ensure all turbocharging inter-cooling pipe not leak, therefore remove the
leakage oil fault.
F、Turbocharger Return Oil not Smoothly
When turbocharger return oil not smoothly, oil pressure in turbocharger will rise up, thus oil will
leak from opening ring of turbine and booster; if oil leakage too much when the fault happens, oil in oil
sump will decrease obviously.
1、Ensure whether pressure in engine crankcase is too large. Because turbocharger is gravity return
oil, when crankcase pressure is too large, return oil will get stuck. After engine running for a long time,
you can pull out oil level gauge to check whether there is gas injecting fuel; if there is the phenomenon, it
indicates crankcase pressure is too large.
2、Check whether there is blockage in turbocharger return oil pipe. Observe whether return oil hose
is bending; if bending, it will affect oil return; if normal, remove return oil pipe to check.
When turbocharger return oil not smoothly causing turbocharger leak oil, turbocharger is normal and
there is no fault, as long as deal with return oil pipe blockage problem, and then is OK. Of course, return
oil pipe blockage will cause turbocharger leak oil seriously, therefore clean oil in turbocharger and
inter-cooler pipe.
G：Engine is In Idling Working Condition For A Long Time
When engine idling running for a long time, gas pressure in turbocharger booster is lower, but oil
pressure in middle of turbocharger is higher, thus oil in middle of turbocharger will leak from opening
ring of impeller side. As the same, if engine idling running for a long time, turbine side may leak oil.
When check items above and there is no problem, pay attention to user’s using habit, user possibly
idling running for a long time causes the fault. Inquiry user’s using condition carefully, and inform user
that can’t idle running for a long time.
When engine idling running for a long time causing turbocharger leak oil, it doesn’t need to replace
turbocharger, because turbocharger is normal and there is no fault.
3、Check Method of Turbocharger Turbine Side Leaking Oil Fault
① Turbocharger itself reason causes turbine side leaking oil

A：Turbine impeller damaged;
B：Turbine impeller clamped;
C：Turbocharger shaft abraded;
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② Other reasons cause turbine side leaking oil
Oil leakage of turbocharger turbine side is related to many factors, sometimes oil leakage of
turbocharger turbine side is not because of turbocharger, but due to other factor causing oil leakage of
turbocharger turbine side, and affect factors are shown below:
A：Engine is in idling working condition for a long time;
B：Turbocharger returns oil not smoothly;
C：Engine leaking oil seriously leads to oil get into turbocharger turbine from exhaust pipe;
③ Check method of oil leakage of turbocharger turbine side
A：Turbine impeller damaged;
B：Turbine impeller clamped;
C：Turbocharger shaft abraded;
D：Engine is in idling working condition for a long time;
E：Turbocharger returns oil not smoothly;
Fault modes shown above are similar to fault modes of turbocharger booster leaking oil, and please
refer to troubleshooting method of related fault of turbocharger booster leaking oil to remove these
faults.
Fault leaking oil seriously leads to oil get into turbocharger turbine from exhaust pipe.
When engine leaking oil seriously, maybe there is redundant oil getting into turbocharger turbine
from exhaust pipe, causing the false phenomenon of turbine leaking oil. At this time, exactly judge
whether oil is leaking from turbocharger turbine side or other places; when removing turbocharger,
carefully observe turbocharger turbine condition, and observe whether there is oil in inlet port of
turbocharger turbine at the same time; if there is oil, it indicates oil gets into turbine from engine exhaust
pipe; or else, it indicates there is no oil in engine exhaust pipe or don’t affect turbocharger.
Note: When checking the fault, pay attention to that whether there is oil leaking in turbocharger
booster side. When booster side is leaking oil seriously, more oil gets into cylinder from engine exhaust
pipe, but redundant oil can’t be totally burnt and discharging from exhaust pipe. There is amount of oil
in engine exhaust pipe, which indicating engine leaking oil and oil discharged from exhaust pipe. Inlet
port of turbocharger turbine is clean and there is no oil, which indicating there is no oil in engine exhaust
pipe.
There is oil leaking in exhaust pipe, which is not directly linked to turbocharger, therefore there is
no need to replace turbocharger.
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VI、Lubricating System
1、Oil sump； 2、Oil discharging plug screw & gasket； 3、Oil sump sealing ring；
4、Oil level gauge； 5、Turbocharger oil return pipe； 6、Turbocharger oil inlet pipe；
7、Oil pump； 8、Oil cooler； 9、Oil filter； 10、Oil strainer
Oil pump is crankshaft direct-drive pump, its housing is front part cover plate.
Oil pump atmospheric valve opening pressure: 400-500Kpa
Oil filter by-pass valve opening pressure: 80-120Kpa
Oil cooler by-pass valve opening pressure: 100-140Kpa
Below figure is 2.7CTI lubricating system related diagrammatic sketch and route diagram.
49
Cylinder head
Tensioner
Rocker arm
Camshaft bearing
Cylinder body
Vacuum Crankshaft Connecting
pump Cylinder cover main journal rod journal
oil duct
Piston cooling Piston
spraying nozzle
Timing gear Auxiliary Turbocharger

Cylinder body main oil duct oil duct
wheel bearing
Cylinder head oil One-way safety valve
return hole Oil filter
return pipe
Turbocharger oil
Splash
Oil cooler One-way safety valve
Chain wheel
chamber idler
wheel Oil pump
Limit pressure valve
Oil strainer
Oil sump
6.2 Replacement Oil and Oil Filter
After long time usage, there will be impurity, dust and dirt in oil. And due to some unburned
fuel mixed in oil, which makes oil thin, and some exhaust gas along with acid anhydride gets into
oil, which makes oil go bad and corrode engine components. Therefore, after using oil for a period
of time (such as vehicle running 15000km), discharge all oil and replace new oil. And should use
oil not less than CI-4 and accord with the regulation of GB 11122.
1 Clean oil filling port cover on cylinder head hood with cloth, and pay attention to not mix
external sundries. Remove oil filling port cover;
2 Remove oil discharging plug screw on oil sump to discharge oil, and pay attention to oil
temperature may be very high;
3 Use special tool to remove engine oil filter;
4 Clean installation surface of oil filter0;
5 Before connecting oil filter and oil cooler central screw arbor, tighten central screw arbor,
tighten torque is 50-60N.m;
6 Spread a little oil to O-type ring of new oil filter;
7 Once O-type ring of oil filter connects installation surface of oil filter, please use special
tool to tighten according to specified tightening process;
8 Replace new oil discharging plug screw gasket, and install oil discharging plug screw
gasket on oil sump;
9 Fill oil from oil filling port on cylinder head hood;
50
10 Wait for 10min to make oil flow back to oil sump;
11 Pull out oil level gauge from engine, and check whether oil level is between upper and
lower graduation;
12 Install oil filling port cover;
13 Run engine 2～3min, and check installation surface of oil filter, and it should not seep oil;
14 Check oil level again;
Note:
■ Be careful to avoid oil scald, and deal with used oil appropriately to protect environment. After
filling oil, tighten oil discharging plug screw according to specified tighten torque, fill new oil, and oil
level.
Note:
■ When filling oil in oil filling port on cylinder head cover, should clean oil filling port to avoid
impurity and dust mixed in. Cover oil filling cover well after filling.
6.3 Removal and Check
1 Discharge all oil in engine according to “6.2 Replace Oil and Oil Filter”;
2 Remove fixed bolts of oil level gauge, and take down oil level gauge assembly;
3 Loosen fixed bolts and nuts of engine oil sump according to the principle of “from two sides to
middle, cross tighten”. Use drawknife or oil sump separating special tool to separate fitting surface and
clear used sealant. Remove oil sump;
4 Use flywheel clamp to fix flywheel, remove crankshaft belt wheel fixed bolt, and take down
crankshaft belt wheel;
5 Refer to “10.3 Removal and Installation of Cooling System” to remove coolant pump;
6 Refer to “Exhaust System” to remove turbocharger oil intake pipe;
7 Remove oil pump fixed bolt, and take down oil pump. Clear oil pump gasket;
8 Remove oil cooler fixed bolt, and remove oil cooler;
Check after Removal:
1 Check whether all oil holes of oil pump housing are blocked, and clean oil hole if necessary;
2 Check whether there is crack or other damage in oil pump housing, and replace if necessary;
3 Check whether there is scratch, damage or aging in crankshaft front sealing, and replace if any;
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6.4 Installation
1 Clean up sealant on cylinder body and oil pump assembly;

Note:
■ Ensure there is no oil contamination, scratch and foreign matter in fitting surface of cylinder
body and oil pump assembly.
2 Install or check oil pump positioning sleeve on lower part of
cylinder body. Positioning sleeve hole of front part surface of lower
part of cylinder body and positioning sleeve is interference fit, height
of positioning sleeve protruding front part surface of lower part of
cylinder body is 6mm; positioning sleeve and oil pump housing is
clearance fit;
3 Before installing oil pump component and its gasket, spread
sealant to fitting surface of front part surface cylinder body and lower
part of cylinder body. Sealant type: Loctite 5900H silica gel; sealant
diameter: 2mm; ensure to complete installation in 10 minutes after
spreading sealant;
4 Install oil pump positioning hole to align to positioning
sleeve, install oil pump to cylinder body, and tighten oil pump fixed
bolts according to the principle of cross tightening, tighten torque:
25±3N.m;
Note:
■ After installation, inner and outer rotor can rotate smoothly, and there is no clamping
stagnation phenomenon.
5 After installing oil pump housing, spread proper engine oil to
installation hole, and use special tool to install crankshaft front oil
sealing to oil pump housing, press front oil sealing to dead port
position of installation hole of oil pump housing, in which flat side
outward when installing, and spread proper oil to labial part. Front oil
sealing press to dead port position of installation hole of oil pump housing;
6 After spread sealant to fitting surface of oil pump component and cylinder body, install oil
pump component to oil sump. Before spreading sealant, check that oil pump housing gasket should not
52
be higher than bottom of lower part of cylinder body; if gasket protrudes bottom of lower part of
cylinder body, replace gasket. After installation, clean up redundant sealant;
7 Install gear wheel chamber and front part timing system according to “3.3 Installation of
Timing System”;
8 Install flywheel housing and flywheel according to “8.4 Cylinder Body Crankshaft Flywheel
Mechanism”;
9 After spread sealant to fitting surface of oil pump component and cylinder body, install oil
pump component to oil sump. Before spreading sealant, check that oil pump housing gasket should not
be higher than bottom of lower part of cylinder body; if gasket protrudes bottom of lower part of
cylinder body, replace gasket. After installation, clean up redundant sealant. And pre-spread sealant
according to figure as shown below. Sealant should be even and continuous to avoid to affecting sealant
function. Sealant type: Loctite 5900H silica gel; sealant diameter: 2mm; ensure to complete installation
Oil sump Lower part of Gear wheel chamber Fly wheel housing
sealing ring cylinder body
Oil pump
housing
in 10 minutes after spreading sealant;

10 Before installing oil sump, install 2 studs on bottom of
middle part of cylinder body, and after installing oil sump, fix
correspondent position with 2 nuts, and fix others with bolt;
11 Before installing oil sump, install filter assembly to oil sump.
Check whether sealing ring on filter is good before installing, insert filter to installation hole of oil sump,
and fasten with filter pipe clamp, tighten bracket bolt at the same time;
12 Put oil sump sealing gasket to sealing groove of oil sump, when installing, press sealing gasket
tightly to make sealing gasket deformation and stick closely to cylinder body and oil pump housing, and
ensure sealing of oil sump with cylinder body and oil pump;
Spreading sealant position with oil sump
53 fitting surface (4 positions)
13 Tighten oil sump bolt according to the principle of first pre-tighten, and then tighten from
middle to two sides, and cross tighten. Re-tighten oil discharging plug screw after installing oil sump;
14 Install oil level gauge assembly, and tighten oil level gauge guide pipe fixed bolt and oil level
gauge guide pipe connector installation bolt. It should be smooth when installing oil level gauge to oil
level gauge guide pipe, and there is no clamping stagnation phenomenon. Check whether sealing ring on
oil level gauge handle and oil level gauge guide pipe is good;
15 Install turbocharger inlet oil pipe refer to “5.3 Check and Installation of Exhaust System”;
16 Before installing oil cooler component, check whether sealing ring of oil cooler seat is good.
Tighten oil cooler fixed bolt;
17 Spread anaerobic type screw thread sealant to screw thread of oil pressure switch, and then
install oil pressure switch to oil cooler seat;
18 Before installing oil filter, tighten oil cooler with oil filter central screw arbor, tighten torque is
50-60N.m;
19 Before installing oil filter assembly, spread proper oil to fitting surface of gasket in oil filter
and oil filter O-type sealing ring. Install oil filter component to oil cooler seat, when sealing ring
connects, tighten 3/4-1 cycle;
Attachment: Tighten Torque of Lubricating System Fixed Bolt

Install oil pump
component
Install oil cooler
assembly
--------------- Central screw arbor 1 （50±5） N·m

When sealing ring
1010320FE010 Oil filter component 1 M22×1.5 connects, tighten
3/4 -1 cycle
54
VII、Valve Mechanism
1、Cylinder head； 2、Bowl-shape plug； 3、Valve lock clamp； 4、Valve spring upper seat；
5、Valve spring； 6、Valve spring lower seat； 7、Fixed bolt of wiring harness fixed bracket；
8、Wiring harness fixed bracket； 9、Oil duct screw plug；10、Lifting lug (front and rear are the same)；
11、Fixed bolt of lifting lug； 12、Stud； 13、Intake valve； 14、Exhaust valve；
15、Rocker arm of intake valve； 16、Rocker arm of exhaust valve； 17、Camshaft；
18、Fixed bolt of camshaft axial positioning plate； 19、Camshaft axial positioning plate；
20、Valve press plate； 21、Rocker arm bracket
55
7.2 Removal
1 Remove vacuum pump assembly refer to “Removal and Installation of Front Part Driving
System”;
2 Remove all high pressure oil pipes and all connector installation protection sleeves;
3 Pull out fuel injector oil return pipe connector, and remove fuel injector oil return pipe and oil
pressure guide rail fuel pump oil return pipe assembly;
4 Remove fixed bolt of oil pressure guide rail, and take down oil pressure guide rail and all
connector installation protection sleeves;
5 Remove fixed bolt of fuel injector press plate, and take down fuel injector and fuel injector
press plate;
6 Remove fixed bolts of cylinder head hood from two sides to middle, and take down cylinder
head hood;
7 Remove crankshaft chain wheel and gear wheel chamber refer to “Removal and Installation of
Timing System”;
8 Remove fixed bolts of all rocker arms, and take down rocker arm and rocker arm shaft
assembly, and mark sequence of all rocker arms in detail;
9 Take down all valve press plates, and mark sequence of rocker arms and valve press plates;
10 Remove fixed bolt of camshaft positioning plate, and take down positioning plate;
11 Rotate and push out camshaft assembly from camshaft bearing hole;
12 Remove fixed bolt of rocker arm shaft bracket, and take down rocker arm shaft bracket;
13 Loosen cylinder head bolt from middle to two sides, take
out cylinder head bolt, and remove cylinder head and cylinder head
gasket;
14 Remove fixed bolts of front and rear lifting lug, and take
down front and rear lifting lug;
15 Use valve spring compressor to compress valve spring, and
remove valve locking plate, valve spring and valve spring seat;
Note:
■Position of piston upper dead point. Mark on removed valve,
valve spring and other components, and record cylinder number
56
and position. Place components reliably.
16 Remove valve oil sealing by pliers;
Note:
■ Please don’t reuse valve oil sealing.
57
7.3 Check After Removal
1、Cylinder Head Check

1 Carefully check whether there is crack, damage or leakage in cylinder head; if any, please
replace new cylinder head;
2 After totally clearing dust, sealant residue, carbon deposition and clearing oil duct, use
compressed air to ensure oil duct is not blocked;
3 Check the flatness of bottom surface of cylinder head: place
flatness measuring instrument to burnt surface to observe displayed
reading; and also can place ruler to flat surface, and then measure
clearance of ruler and flat surface by clearance gauge;
Cylinder Head Flatness:
■ Standard common difference——less than 0.05mm
■ Maintenance limit—— 0.15mm
If exceed technical specification, ensure whether can maintain cylinder head surface, or
replace cylinder head.
If valve deepness and protruding quantity of fuel injector can’t keep in the range of technical
specification, please replace cylinder head.
2、Check of Protruding Quantity of Fuel Injection:
Install deepness gauge assembly on cylinder head burnt surface
and reset it. Rotate deepness gauge, measure fuel injector protruding
quantity at the highest point of fuel injector. Record protruding
quantity of each fuel injector.
Standard Value: 2.5-3.2mm
Note:
■ Don’t use thickening or double-layer-type fuel injector gasket to adjust protruding quantity of
fuel injector. This will cause outer connector of fuel injector can’t be aligned and can’t be installed.
If protruding quantity of fuel injector exceeds technical specification, check whether fuel injector
gasket is installed well; check and ensure fuel injector hole is clean and there is no scrap. And also
should ensure fuel injector gaskets are not “piled up” in fuel injector hole. Use clean oil to lubricate fuel
injector O-type ring. Install fuel injector press plate to fuel injector, and then install fuel injector into
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hole. Check again, if also can’t ensure fuel injector is installed rightly, check and replace cylinder head.
3、Valve Check
Valve external diameter check (at least measure at front / middle
/rear part of valve rod)
Valve
 0 . 030  0 .050 guide pipe
Standard Value: Intake: Φ6  0 . 045 , Exhaust: Φ6  0 .065
If valve is damaged or valve rod is abraded less than min

specification value, must replace valve. Inner diameter of valve guide pipe
Outer diameter of valve rod
4、Valve Guide Pipe

Inner Diameter Standard Value of Valve Guide Pipe Hole: 6.000-6.015mm.
If exceed limit, replace cylinder head.
5、Clearance of Valve and Valve Guide Pipe
Check clearance between valve rod and valve guide pipe; if exceed limit, replace cylinder.
Clearance of valve rod and valve guide pipe:
Standard Valve:
■ Intake valve: 0.030~0.060mm
■ Exhaust valve: 0.050~0.080mm
Maintenance Limit:
■ Intake valve: 0.1mm
■ Exhaust valve: 0.1mm
If not within range, replace cylinder head.
6、Valve Seat Ring Maintenance:
1 Use valve seat guide rod and reamer to revise valve seat.
Hobbing
Guide rod
Intake valve seat is 60°, Exhaust valve seat is 45°;
2 After revising, valve and valve seat should be ground
carefully by grinding paste;
7、Replacement of Valve Seat Ring:
1 Use punching machine or special tool to install intake valve and exhaust valve seat ring to
counterbore;
2 After installing new valve seat ring, make sure to check valve deepness and test whether valve
is leaking;
3 If there is abnormality that can’t grind seat ring, spread a thin layer of fine grinding agent or
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equivalent evenly to valve, electrical power or manually pump grinding tool to press valve center; and
rotate valve back and forth and grind continuously until valve seat ring and grinding agent on valve both
displaying even contact vein;
4 If need to grind valve, measure head edge thickness to check whether edge material is enough;
Min Limit Value of Valve Edge Thickness: 1.9mm (Exhaust); 1.1mm(Intake). If valve thickness is not
within limit value, make sure to use new valve.
Make sure to test valve leakage after grinding to ensure normal sealing.
9、Cylinder Cover Bolt Check
Check whether there is damage or corrosion on screw thread of cylinder head bolt. Cylinder head
bolt only can be used twice, replace new bolt after using twice.
10、Camshaft Check
Measure Diameter of Camshaft Journal：
Use micrometer to measure diameter of camshaft 1-5 gear shaft
journal.
Diameter of 1-4 Gear Shaft Journal: 43.049-43.065mm
5 Gear Shaft Journal: 39.059-39.075mm
Measure Camshaft Lift:

Checkout of camshaft lift: Use micrometer to measure cam
height at the direction of cam peach tip, measure cam base circle
diameter at the direction of cam base circle, and the difference value
of two values is cam lift.
Intake Cam Lift: 35.07-35.09mm
Exhaust Cam Lift: 34.05-34.07mm
11、Check Whether Cylinder Head Gasket is Burnt, Slugging Cylinder or Damaged; If Any,
Please Replace.
Note:
■ Cylinder head gasket must be replaced with manufacturer original cylinder head gasket, or
else may cause air-fuel ratio not actual fault.
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12、Rocker Arm Removal Check:
1 Check whether rocker arm trolley wheel and ball-head seat
are abraded or damaged; if any, replace rocker arm.
2 Remove rocker arm shaft from rocker arm.
3 Don’t remove sleeve in pointed part of rocker arm. The

component can’t be repaired. If find sleeve damaged, must replace
rocker arm.
4 Remove lock tighten nut and regulating bolt.

5 Check whether there is crack or over abrasion in hole.
Sleeve can move flexibly on rocker arm, and plastic sleeve limiting
stopper should locate accurately. Check whether sleeve end part is
abraded.
6 Use clean engine oil to lubricate rocker arm shaft. Install

rocker arm shaft into rocker arm, rotate rocker arm 180°around rocker arm shaft. Rocker arm can rotate
flexibly and there is no retardarce. If rocker arm can’t rotate flexibly, replace rocker arm shaft and
rocker arm.
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7.4 Installation
1 Spread lubricant oil to each inner installation paring component;

2 Clean component before installing, there is no rag, burr, oxide coating, corrosion, cuttings, oil
contamination, colorant and dust, and there is no knock, touch or scratch when installing;
3 Check/Install cylinder head each bowl-shape plug and oil duct screw plug. Install 11 bowl-type
plug ①, 3 bowl-type plug ⑥, 8 oil duct blocking plug ⑦. Spread bowl-type plug sealant before
pressing all bowl-type plugs, and end surface distance from hole end 1mm after bowl-type plug pressing
in. Spread sealant to seal when installing oil duct screw plug and cylinder head. When tightening 4
rocker arm oil supplying hole blocking plugs, sink cylinder head intake side 2mm;
Note:
■ New cylinder head each bowl-type plug is already installed.
4 Use special tool to press and install valve oil sealing to specified position, and spread a little oil
to lip part;
5 Spread oil to each valve, insert guide pipe to valve, and check whether valve can move
smoothly after installation. Install valve spring;
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6 Use special tool or proper tool to compress spring and install lock clamp. After installing valve,
slight knock end part of valve rod by wooden hammer or plastic hammer to ensure valve lock clamp is
installed in place;
Valve lock clamp
7 Check valve sealing of ground valve seat and valve by Valve spring upper seat
Valve spring
special device: use leakage detector or coal oil leakage detection Valve oil sealing
method to detect leakage amount of valve. If sealing is no good, grind

Valve
and repair valve seat ring refer to “Valve System-Cylinder Head guide pipe
Check”;
8 Check/Install cylinder head positioning sleeve of upper
Valve seat ring
surface of cylinder body. Positioning sleeve protruding height: Valve
4.5±0.3mm;
9 Install cylinder head gasket, and part NO. side upward. Pay attention to intake side oil return
hole position when installing cylinder gasket, and don’t install reversely. After installing cylinder gasket,
check whether each water duct and oil duct hole is unblocked between cylinder body and cylinder head;
10 Install cylinder head to cylinder body steadily;
11 Spread proper clean lubrication oil to head of cylinder head
bolt, pre-tighten cylinder head bolt. Tighten for several steps+angle
tighten method: 10N.m→60N.m+240°→Reverse 300°→60N.m+
240°. Monitor final tighten torque, and control to the range of (290±
50)N.m. Tighten according to the method of “from middle to two
sides, cross tighten” when tighten manually;
12 Install camshaft, spread proper lubrication oil to each shaft
journal and cam before installing camshaft to cylinder head, and
slightly push camshaft from front part of cylinder head to camshaft Round
angle
bearing hole of cylinder head, and there is no knock, touch or scratch.
Axial positioning sleeve faces to rear part of cylinder head;
13 Face round angel side to flywheel side of engine (outward)
when installing camshaft axial positioning plate, and pay attention to
not install reversely;
14 Check axial clearance, and there is no clamping or
stagnation phenomenon when camshaft rotating. Use dialgauge to
measure axial clearance when moving camshaft axially at the same
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time.
Note:
■ Camshaft axial clearance standard value: 0.10~0.21mm
■ If axial clearance is too large, replace cylinder head. If camshaft thrust surface is damaged,
replace camshaft.
15 Check/Install rocker arm shaft bracket positioning sleeve. Ensure its protruding to installation
surface 3mm after installing rocker arm shaft bracket positioning sleeve. Positioning sleeve and cylinder
head is interference fit, positioning sleeve protruding to cylinder head height is 3mm; positioning sleeve
and rocker arm shaft bracket is clearance fit;
16 Install rocker arm shaft bracket, and tighten bracket fixed
bolt;
17 Install valve pressing plate, and should pay attention to valve
pressing plate long hole facing to exhaust side; Rocker arm shaft bracket positioning pin
18 Before installing intake/exhaust rocker arm, check rocker

arm components. After installing ball-head seat of intake/exhaust
rocker arm and ball-head seat connecting sleeve, ball-head seat can’t
drop, ball-head seat and ball-head seat connecting sleeve can rotate
flexibly as valve clearance adjusting bolt ball-head;
19 Install adjusting bolt until can’t move, and install lock tighten nut;
20 When installing intake/exhaust rocker arm, first spread Lock tighten nut Rocker arm bolt
Rocker arm
proper lubrication oil to rocker arm trolley wheel, trolley wheel shaft, cylinder
Valve clearance
rocker arm shaft journal surface and valve clearance adjusting bolt adjusting bolt
Ball-head seat
ball-head. Tighten rocker arm bolt according to required torque. After connecting
sleeve
Trolley
installing, rocker arm can rotate flexibly, and there is no clamping Ball-head seat
Rocker arm shaft wheel
Trolley
wheel shaft
stagnation phenomenon.
21 Install front and rear lifting lug, and tighten fixed bolt;
22 Install intake/exhaust pipe cylinder head stud;
23 Adjust valve clearance refer to “7.5 Measurement and Adjustment of Valve Clearance”;
24 Check state of camshaft position sensor sealing ring, install sensor to cylinder head, and tighten
fixed bolt. Ensure sensor and signal gear installation clearance is 0.35-1.65mm;
25 Install PCV exhaust hose to cylinder head hood, and fasten with clamp, and don’t drop;
26 Install oil filling port sealing ring to oil filling port cover, and then spread proper lubrication oil
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to oil filling port sealing ring surface, install oil filling port to cylinder cover hood, and it can open and
close flexibly, and there is no clamping stagnation phenomenon;
27 Check whether sealing ring in cylinder head hood sealing groove is installed smoothly,
whether there is tensioning or blockage, and after installing turn cylinder head hood, cylinder head hood
sealing ring can’t drop partly. Check whether fuel injector sealing ring on cylinder head hood and
sealing ring of pressing plate bolt is damaged;
28 Check whether gasket on fuel injector component drops, whether sealing ring is damaged;
29 Install cylinder head hood, before pre-tightening fixed bolt
of cylinder head hood, insert all cylinder fuel injector to installation
hole (don’t install fuel injector pressing plate and pressing plate bolt),
and initially position cylinder head cover;
30 Tighten fixed bolt of cylinder head hood according to sequence;
31 Install high pressure oil rail to cylinder head, and tighten fixed bolt;
32 Press two pressing finger of fuel injector pressing plate to fuel injector, and pre-tighten fixed
bolt of fuel injector pressing plate;
33 Install all high pressure oil pipes, first pre-tighten all nuts, and then tighten;
34 Tighten fixed bolt of fuel injector pressing plate;
35 Install high pressure oil pipe clamps and oil pump outlet oil pipe fixed bracket;
36 Install all fuel system inlet/return oil pipe;
Note:
■ Ensure clean when installing each fuel system component, and ensure un-installed connector
to install protection sleeve.
7.5 Valve Clearance Measurement and Adjustment
1 Rotate crankshaft belt wheel T point to correspond with mark point of oil pump, place to 1st
-4th cylinder upper dead point position. Pre-tighten crankshaft belt wheel according to need;
2 Measure cooling state valve clearance between rocker arm
ball-head seat and valve pressing plate by clearance gauge. Measure
1&2&3&6 set valve clearance or 4&5&7& set valve clearance
according to compressing stroke upper dead point corresponding
condition;
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3 Adjust if needed: loosen adjusting bolt lock tighten nut,
ensure valve clearance by clearance gauge is: intake valve
(0.25±0.03)mm, exhaust valve: (0.50±0.03)mm, and then tighten
valve clearance adjusting bolt lock tighten nut according to required
torque;
4 Rotate crankshaft a round, and measure or adjust remained
valve set clearance;
5 After adjusting valve clearance, rotate crankshaft two
rounds, and check whether valve clearance accord with requirement.
If exceed requirement, adjust valve clearance again.;
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Attachment: Tighten Torque of Cylinder Head Assembly Bolt
Part No. Name Quantity Specification Tighten Torque Remark
Right balance
shaft sleeve inner Oil duct is
1002103GA 8 R2 1/16 （10±1） N·m
hexagon screw blocked
plug
Install intake
Q1200825F61 Stud 2 （23±3） N·m
manifold
Exhaust pipe
1003012FE010 2 M8×1.25×55 （23±3） N·m
fixed stud
Hexagon flange
Q1840820F61 6 （23±3） N·m Install lifting lug
bolt
Install wiring
Hexagon flange
Q1840816F61 1 （23±3） N·m harness fixed
bolt
bracket
(10±1)N•m→(60±
2)N•m+(120°±2°)+
Final tighten
Cylinder head M14×1.5×14 (120°±2°)→Revers
1002041FE010 10 torque is
bolt 0 e (300°±2°)→(60±
(290±50) N•m.
2)N•m+(120°±2°)+
(120°±2°)
Hexagon flange Install camshaft
Q1840616 2 （10±1）N·m
bolt positioning plate
Install rocker
1006023FE010 Rocker arm bolt 8 M8×1.25×50 （40±5）N·m
arm component
Adjust valve
1006025FE010 Adjusting nut 8 M6×1 （10±1）N·m
clearance
Hexagon flange Install high
Q1840825F61 2 （23±3） N·m
bolt pressure oil rail
Install fuel
Hexagon flange
Q18410130TF2 4 （60±5） N·m injector pressing
bolt
plate
Connect with
Oil pipe fixed nut
1042112FE010 5 M14×1.5 （30±2） N·m fuel rail and fuel
Ⅰ
injector
Oil pipe fixed nut Connect with oil
1042062FE010 1 M16×1.5 （35±2） N·m
Ⅱ pump
Connect two
Bolt spring
1042501FB 1 M5×1×25 （8±1） N·m clamping plate of
assembly
oil pipe bracket
Hexagon flange Install oil pipe
Q1840612F61 1 （10±1） N·m
bolt bracket
Cylinder head
Install cylinder
1014109FE010 hood combined 11 M6×1×43 （10±1） N·m
head hood
bolt
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VIII、Crankshaft Flywheel Mechanism
1、Cylinder head bolt； 2、Cylinder head gasket； 3、Φ18 positioning sleeve； 4、Cylinder body；
5、Thrust gear main bearing bushing assembly； 6、Upper bushing of main bearing bushing；
7、Crankshaft belt wheel；8、Bolt of crankshaft belt wheel；9、Lower bushing of main bearing bushing；
10、Φ13 positioning sleeve； 11、Connecting bolt of upper and lower cylinder body；
12、Bolt of main bearing head； 13、Crankshaft； 14、Fixed bolt of flywheel；
15、Flywheel positioning pin； 16、Flywheel assembly； 17、Flywheel housing；
18、Crankshaft rear oil sealing； 19、Sealing ring of flywheel housing cover；
20、Flywheel housing cover； 21、Positioning pin of gear wheel chamber
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8.2 Removal
1 Clamp flywheel by flywheel clamp, loosen fixed bolt of flywheel and crankshaft belt wheel,
and remove flywheel assembly;
2 Remove crankshaft rear oil sealing and crankshaft rear oil sealing bracket;
3 Remove cylinder head system, refer to “Valve Mechanism”;
4 Remove fixed bolt of crankshaft belt wheel, and take down crankshaft belt wheel;
5 Remove oil pump refer to “6.2 Lubricating System”;
6 Remove fixed bolt of flywheel housing;
7 Remove fixed bolt of gear wheel chamber, and take down gear wheel chamber;
8 Remove connecting rod bolt, take down piston connecting rod, and place piston connecting rod
well in order;
Note:
■ The same cylinder piston connecting rod assembly should be installed to original cylinder hole
when installing, thus mark or place well in order; there is mark on connecting rod body and
connecting rod cover to avoid to be mistaken installed.
9 Remove bolt of crankshaft main bearing cover according to “from two sides to middle and
cross loosen”;
10 Remove crankcase connecting bolt according to “from two sides to middle and cross loosen”;
11 Take down crankshaft, and push out main bearing bushing;
12 Loosen fixed bolt of piston cooling fuel injector; remove piston cooling fuel injector;
8.3 Check and Measurement
1．Crankshaft
Carefully sash crankshaft and clean, and then use compressed air to
dry oil hole.
Measure main bearing journal and connecting bearing journal.
Standard Value:
■ Diameter of main bearing journal: 73.984-74mm
■ Diameter of Connecting rod bearing journal: 58.984-59mm
Calculate clearance of crankshaft main bearing journal-crankshaft main bearing bushing hole:
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difference of diameter of main bearing journal and diameter of crankshaft main bearing bushing hole
measured above, is its fit clearance.
2、Standard Value of Main Bearing Hole Size
■ Diameter of main bearing hole: 79-79.018mm
If main bearing hole size is not in standard range, first check whether
not remove bearing bushing; and then check whether main bearing bolt or
upper/lower cylinder body is installed in place, bolt torque is normal. If
above-mentioned is normal, directly replace cylinder body (including
upper/lower cylinder body).
3、Standard Value of Main Bearing Fit Clearance
Standard fit clearance is 0.054~0.1mm, abrasion limit is not over 0.15mm.
Note:
■ When measuring diameter of crankshaft main bearing bushing hole, should install bearing
cover and bearing bushing to bearing seat, and tighten bolt by specified torque. Use internal
micrometer to measure hole diameter. Diameter value of using internal diameter-outer diameter
value of crankshaft main bearing journal is fit clearance.
4、Bearing Bushing
There is no scratch or impurity in antifriction material of bearing bushing surface; there is no
phenomenon of bearing bushing blocked or antifriction material drop due to bad lubrication; pay more
attention to keep clean when installing.
Measure clearance of oil membrane:
Clearance of oil membrane is difference of outer diameter of measured crankshaft main bearing
journal and inner diameter of bearing bushing.
Standard Value:
■ Crankshaft main bearing bushing: 0.054～0.1mm
■ Connecting rod bearing bushing: 0.039~0.091mm
■ Limit value: 0.15mm
Usage of Plastic Measure Gauge
Generally, use plastic measure gauge to measure clearance of oil
membrane. First clean oil, lubrication oil and other impurity on bearing
bushing and main bearing journal, put plastic measure gauge, which has the
same width of main bearing bushing, and make it parallel to bearing journal,
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and keep away from oil hole. Install crankshaft, main bearing bushing and main bearing cover, and
tighten to specified torque. Don’t turn crankshaft during this procedure. Remove main bearing cover,
measure its width at the widest position according to mark remained on plastic measure gauge. If
measured oil membrane exceeds limit value, replace bearing bushing or choose small size bearing
bushing.
5、Check Cylinder Hole:

When engine cylinder hole abraded to a certain extent, technical function of engine becomes bad,
power decreases, fuel and oil consumption increases obviously. Judge abrasion degree of cylinder hole
by detecting cylindricity and roundness after cylinder abraded.
Detect method of roundness and cylindricity of cylinder:
① According to diameter size of cylinder hole, choose proper
connecting rod, fix to lower part of cylinder gauge;
② Revise cylinder gauge size, measure at
3 cross sections and 2 directions of distance from cylinder top 10mm,
80mm, 150mm by cylinder gauge, and get average value;
Note:
■ When measuring by cylinder gauge, it should be vertical between
measured rod and cylinder axial line, or else measurement is not
accurate.
 Calculate deviation of roundness and cylindricity according
measured result. Roundness deviation is half of difference value of
measured max diameter value and min diameter value of the same cross
section; cylindricity deviation is half of difference value of measured max
diameter value and min diameter value of any direction of measured
cylinder surface.
Cylinder hole Piston outer Standard value of matching
diameter diameter cylinder clearance
φ93.5  00 . 015 φ93.5  00 ..054

070 0.054~0.085
■ Clearance between piston and cylinder hole: 0.054～0.085mm. Limit value is 0.15mm.
6、Check Flatness of Top Surface of Cylinder Body:
■ Standard value: Cylinder body max flatness is 0.04mm
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If exceeds limit value, machining to min limit or replace.
If flatness of nearby area of burnt chamber is abnormal and can’t be processed, replace cylinder
body. To repair of burnt surface, special sealing gasket without thickness adding is available. If
can’t repair burnt surface to get right piston protruding amount, must replace cylinder body.
Note:
■ Measure cylinder body after upper and lower cylinder body being installed, tightening main
bearing cover bolt and connecting bolt, and being replaced in flat. If install cylinder body in engine
platform or without installed main bearing cover, measured value will be not right due to warping.
7、Cylinder Hole Check
Check whether cylinder hole is pulled damaged.
Check whether cylinder hole is burnished. There is reticulate pattern appearance in not burnished
surface, and lines and top part of cylinder hole shapes a 40～
50°angle.
8、Crankshaft Belt Wheel Check
Clean crankshaft belt wheel and signal wheel, and dry belt
wheel by compressed air.
If there is damage or crack in crankshaft belt wheel and

signal tooth, replace belt wheel.
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8.4 Installation
1、Cylinder Body Blocked Confirmation

Check or install 6 bowl-type plugs①, 2 bowl-type plugs ②, 2
bowl-type plugs ⑤, 1 oil duct diameter changed valve ③, and
install 1 coolant discharging bolt ④. Before pressing and installing
bowl-type plug, firstly spread sealant evenly to inwall circle of
installation hole or flange outer round on bowl-type plug, and after
bowl-type plug being pressed into cylinder body, end surface is
(1±0.5)mm height from hole end. Coolant discharging bolt has screw
thread sealant, directly tighten according to required tighten torque. Before installing, check whether
screw thread sealant is well, to avoid affect sealing function. After pressing and installing oil duct
diameter changing valve, end surface is (1±0.5)mm height from hole end.
Note:
■ Overhaul engine cylinder body and before installing, check whether all blockage sealing is
normal.
■ Other blocking plugs of new cylinder body are installed except 2 bowl-type plugs ② and 1 oil
duct diameter changed valve ③.
2、Installation of Cylinder Body Assembly
1 Install piston cooling fuel injector assembly: install piston cooling fuel injector assembly to
cylinder body;
2 Install upper main bearing bushing: align seam allowance

on upper main bearing bushing to clamping bushing groove of
cylinder body main bearing seat hole, and push and install 5 upper
main bearing bushings in place;
Note:
■ When installing upper and lower bushing of main bearing
bushing and anti-thrust main bearing bushing assembly, ensure
there is no dust in bearing bushing and main bearing hole, and bearing bushing locating lip must in
locating groove of main bearing hole. When installing main bearing bushing, check all oil grooves
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and oil holes of upper bushing of main bearing bushing, and must align to cylinder body.
■ Install main bearing bushing assembly with anti-thrust plate on 4th main bearing seat which
bears crankshaft axial load.
3 Install lower main bearing bushing: align seam allowance on lower main bearing bushing to
clamping bushing groove on main bearing cover, and push and install 5 lower main bearing bushings in
place;
4 Spread proper clean engine oil to upper bearing bushing; lift and place crankshaft to cylinder
body main bearing hole;
5 Spread sealant to fitting surface of cylinder body and lower
cylinder body, the sealant line must be even, and there is no broken
sealant line. Sealant type: Loctite 5182; sealant diameter of anaerobic
adhesive: 1.5±0.5mm; and must complete installation in 3 minutes after spreading sealant;
6 Fill oil: Fill clean engine oil to crankshaft main bearing journal, main bearing bushing,
anti-thrust plate. Rotate crankshaft to check whether crankshaft can rotate flexibly; install 5 main
bearing cover to cylinder body in order and direction; slightly knock main bearing cover to install in
place;
7 Spread proper clean engine oil to main bearing journal, install lower cylinder body to cylinder
body steadily, and ensure complete installation in one time, and don’t be loosened after installation;
8 Install fixed bolt of lower cylinder body, and spread proper engine oil to main bearing bolt
screw thread before installing;
9 Main bearing bolt tighten torque is 10N•m→60N.m→140°. Final tighten torque is in the range
of (170±40)N.m;
10 Tighten connecting bolt of crankcase in order, and tighten torque of crankcase connecting bolt
is (65±5)N.m;
Note:
■ Make sure that tighten crankcase connecting bolt after tightening all main bearing bolts.
11 Check crankshaft axial float;
■ Axial clearance is 0.10~0.42mm
When crankshaft moving forward and backward to the end
along with graduation indicator, measure clearance between middle
main bearing bushing and crankshaft arm. If measured value exceed
limit value, please replace anti-thrust bearing bushing assembly, and measure again. If still exceed limit
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value, please replace crankshaft until axial float amount is qualified.
12 Check and install crankshaft position sensor, crankshaft position sensor sealing ring must be
good, and tighten fixed bolt. Ensure clearance of crankshaft position sensor and crankshaft belt wheel
signal teeth is 0.5-1.2mm;
13 Install piston connecting rod assembly refer to “9.4 Piston Connecting Rod Mechanism”;
14 Rotate cylinder body to horizontal state, rotate crankshaft to make 1st and 4th cylinder
connecting rod bearing journal be in lower dead center; overlap installed piston connecting rod using
piston slipping sleeve; push and install piston connecting rod assembly in place;
Note:
■ When assembling piston connecting rod assembly on
cylinder body, use special tool to guide to avoid knock piston
cooling fuel injector.
■ Piston top arrow points to front part of cylinder body, and
piston connecting rod assembly should move flexibly before and
after installing cylinder body: forward mark of connecting rod
big-head (round bulge) and forward mark of piston are in the same side, and pay attention that
connecting rod round bulge side faces to front part of engine when assembling engine.
15 Before installing connecting rod bolt, spread proper engine oil to bolt head flange and screw
thread, and install connecting rod big-head cover. Before installing connecting rod big-head cover, dry
and clean connecting rod broken surface by high pressure air, ensure there is no oil, metal cutting in
connecting surface, and ensure broken surface fitting is good, and there is no clearance. It’s forbidden to
mix install or install connecting rod big-head cover reversely;
Note:
■ Ensure broken surface clean, fitting is good, and avoid damage.
16 Cross tighten by six steps according to the method of “5N.m→10N.m→20N.m→60N.m→
Rotate 45°→Rotate 45° again”. Connecting rod bolt only can be used once;
17 Check connecting rod side clearance;
Check: shake to check connecting rod big-head clearance along axial direction (There is no
clamping stagnation phenomenon when rotating crankshaft).
■ Standard value: 0.15～0.30mm
If connecting rod side clearance exceeds limit value, must replace connecting rod. If still not within
limit value after replacing connecting rod, must replace crankshaft.
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18 Measure piston protruding amount:
■ Standard value: 0.34～0.26mm
If exceed range, check whether piston is right, cylinder body
is processed properly.
19 Rotate engine for on circle, and install 2nd and 3rd cylinder
piston connecting rod assembly according to the method above;
20 Detect crankshaft rotation torque: rotate crankshaft at least 360°, detected rotation torque
should be not more than 20N.m;
21 Install timing system and gear wheel chamber refer to “3.3 Timing System”;
22 Check and install flywheel housing locating sleeve.
Locating sleeve of flywheel housing and flywheel housing is
Locating
interference fit, protruding height is 4mm; locating sleeve and gear sleeve
wheel chamber is clearance fit;

23 Before installing flywheel housing, spread even sealant to
connecting surface of flywheel housing and cylinder body, complete
installation in one time, and ensure that it’s not loosened after
installation. After installing, clear unnecessary sealant overflowed by
connecting surface (left and right side surface and lower side surface).
Sealant type: Loctite 5900H gal sealant; sealant diameter: (2.5±0.2)
mm; make sure to complete installation in 10 minutes;
24 Tighten fixed bolt of flywheel housing;
25 After installing flywheel housing, spread proper engine oil
to rear oil sealing installation hole, and use special tool to press and
install crankshaft rear oil sealing to flywheel housing, and the height
of rear oil sealing flat surface end distant from dead center of
installation hole on flywheel housing is 2mm; when installing, pay attention that flat surface end faces
outward, and spread proper engine oil to lip;
26 Check/Install flywheel housing blocking plug, pay attention
to spread oil to sealing ring;
27 Install flywheel. Install fixed bolt of flywheel. First
pre-tighten across angle and then tighten across angle;
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28 Check/Install locating pin of flywheel;
29 Check/Install flywheel bearing, make sure to press and
install in place;
30 Use flywheel clamp to fix flywheel, and install oil pump
refer to “6.4 Lubricating System”;
31 Align locating pin on belt wheel to locating pin on
crankshaft, and before installing, spread proper engine oil to belt wheel bolt screw thread. Install
crankshaft belt wheel, and tighten fixed bolt of belt wheel;
Attachment: Tighten Torque of Cylinder Body Assembly Bolt
Coolant
（20～25）
1002106FE010 discharging screw 1 R1 1/4
N·m
plug
Install piston
Hexagon flange （10～15）
Q1840610 4 cooling spraying
bolt N·m
nozzle
(10±1)N•m(Tig When tightening
htener 100r/ manually, don’t
min)→(60±2) need to control
Main bearing M12×1.5×11 N•m tighten speed, only
1002104FE010 10
cover bolt 9 (Tightener) need to tighten in
20r/min）→ constant speed,
(140°±2°)(Tigh final tighten torque
tener 20r/min) is (170±40)N•m。
Connecting bolt
1002108FE010 10 M10×1.5×83 （65±5） N·m
of crankcase
Install high
Q1840835TF6 Hexagon flange
3 （30±3） N·m pressure oil pump
1 bolt
flange
Q1841275TF6 Hexagon flange （110±5） Install flywheel
7
1 bolt N·m housing
Hexagon flange Install flywheel
Q1840830F61 7 （23±3） N·m
bolt housing
Q1840865TF6 Hexagon flange Install flywheel
3 （30±3） N·m
1 bolt housing
Hexagon flange （10～15） Install gear
Q1840620 4
bolt N·m chamber
Q1840620F61 2
bolt N·m chamber
Q1841035 4
bolt N·m chamber
Q1841035F61 Hexagon flange 1 （28～46） Install gear
77
bolt N·m chamber
(5±1) N·m (5±1) N·m+(10±1)
Connecting rod +(20±2) N·m N·m + (20±2)N·m
1004013FE010 8 M10×1×42.5
bolt +(60±2) N·m + (60±2) N·m+
+(90°±2°) (45°±2°)+(45°±2°)
Crankshaft belt M12×1.25×4
1005014FE010 3 （125±5）N·m
wheel bolt 0
Flywheel tighten M12×1.25×3
1005040FE010 8 （135±5）N·m
bolt assembly 3
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IX、Piston Connecting Rod Assembly
1、Connecting rod assembly piston；2、Piston pin clamp ring；3、Combination oil ring；4、2nd air ring；
5、1st air ring；6、Piston pin；7、Piston pin；8、Upper bushing of connecting rod bearing bushing；
9、Lower bushing of connecting rod
79
9.2 Removal
1 Pry piston pin lock ring by screwdriver;

Note:
■ When prying out by screwdriver, press piston pin lock ring by
hands to avoid popup and damage person.
2 Take out piston ring by special tool or hands;
3 Take out piston pin and connecting rod;
9.3 Check and Measurement
1、Measure piston diameter:

Standard value is:
Outer diameter of piston skirt part: 93.43-93.446mm
2、Check scratch, abrasion and other fault of each piston, if any, please replace piston, piston
ring and piston are replaced together. Check installation of piston pin in pin hole, in room
temperature, piston pin can move smoothly in pin hole by hands.
3、Measure piston ring
① Measure piston ring side clearance
Check end surface clearance between piston ring and all grooves on piston by thickness gauge. If
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measured value exceeds limit value, replace new piston ring, and then measure its side clearance. If side
clearance still exceeds limit value, replace piston and piston ring at the same time. If side clearance is
less than limit value, only replace piston ring.
Piston ring side clearance standard value:
■ First piston ring end surface clearance: 0.08~0.129, abrasion limit: 0.20mm
■ Second piston ring end surface clearance: 0.05~0.09, abrasion limit: 0.17mm
■ Oil ring end surface clearance: 0.03~0.07, abrasion limit: 0.15mm
② Piston ring opening clearance

Place piston ring to cylinder body hole, slightly push piston downward
to right position (distance from upper surface of cylinder hole is more than
50mm). Measure opening clearance by gauge.
If piston ring clearance is not in the range of technical specification:
a) Ensure used piston ring type and component No. are right;
b) Ensure cylinder hole is in the range of technical specification;
c) Ensure piston ring clearance is measured below 50mm of upper
surface of cylinder body;
d) Replace piston ring;
■ First piston ring opening clearance: 0.25~0.35, abrasion limit: 0.80mm
■ Second piston ring opening clearance: 0.45~0.65, abrasion limit: 1.0mm
■ Oil ring opening clearance: 0.30~0.50, abrasion limit: 1.0mm
4、Measure piston pin diameter:

■ Standard value of piston pin outer diameter: 34.496-34.5mm
5、Check piston pin hole size

■ Standard value of piston pin hole inner diameter:
34.508-34.513mm
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6、Measure connecting rod small-head:
■ Connecting rod small-head bushing hole: φ34.5 00..017

012
■ Clearance fitting of piston pin outer diameter and connecting rod small-head sleeve is
0.012~0.021mm.
7、Measure connecting rod big-head:
■ Connecting rod big-head bearing bushing hole:
62.377-62.403mm
Note:
■ When measuring connecting rod big-head bearing bushing hole,
install bearing bushing and bearing cover to corresponding connecting
rod, and tighten fixed bolt of bearing cover according to specified torque.
Measure inner diameter of connecting rod bearing hole by inner diameter
micrometer.
8、Check connecting rod bearing bushing:
There should not be scratch or imbedded impurity in antifriction material of bearing bushing
surface; and there should not be any phenomenon of bearing bushing struck or antifriction material
dropped due to bad lubrication; and should pay attention to keep clean when installing again.
82
9.4 Installation
1 Before installing piston pin, spread proper oil to piston pin outer
round and pin hole. Install piston pin lock ring by pressing and installing
piston pin lock ring device (Generally, when removing, only remove one
piston pin lock ring; if there is still one lock ring at the same time, then
there is no this step).
Note:
■ Install piston pin lock ring opening position in place, and avoid
main thrust surface.
2 Put connecting rod assembly to piston, pay attention to connecting
rod position, when piston top part mark faces forward, clamping bushing
groove is in intake side, and press piston pin into piston pin and connecting
rod small-head hole.
Note:
■ When installing connecting rod component and piston, forward
mark of connecting rod big-head (round bulge) and forward mark of
piston are in the same side, and pay attention that connecting rod round
bulge side faces to front part of engine when assembling engine.
3 Install second piston pin lock ring by pressing and installing piston
pin lock ring device, if there is no special tool, carefully use
screwdriver to install second piston pin lock ring into piston retaining
ring groove; pay attention to avoid piston pin lock ring popup to hurt
person when installing.
4 Use piston ring caliper to install oil ring and 2 air rings in
piston ring groove, and air ring with letter side should be upward.
5 Fill proper oil to all fitting surfaces, and rotate piston ring to
make oil spread to piston ring groove fully.
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6 When installing piston ring, make ring surface mark to be
Opening direction Opening direction
of coil loaded spring of first air ring
upward, and make openings of 3 rings mutually staggered, and don’t
face to the direction of piston pin hole. When installing oil ring, make
Front part
cushion spring joining port of combination oil ring be in opposite of engine
position of oil ring steel belt opening. After installing 3 piston ring,
Opening direction Opening direction
there is no clamping stagnation phenomenon in ring groove. of second air ring of oil ring body
7 Install connecting rod bushing to connecting rod body. Upper bushing of connecting rod is
rufous, lower bushing is metallic color.
8 Install lower bushing of connecting rod bushing to connecting rod big-head cover.
9 Install piston connecting rod assembly refer to “8.3 Crankshaft Flywheel Assembly”.
Attachment: Tighten Torque of Piston Connecting Rod Assembly Bolt

(5±1) N·m+(20±2)
Connecting Fix connecting
1004013FE010 8 M10×1×42.5 N·m +(60±2) N·m
rod bolt rod head cover
+(90°±2°)
84
X、Cooling System
1、Water outlet port；2、Warm air intake hose； 3、Three-way connector (warm air device, SCR system
intake)；4、Small circulation water pipe；5、Water pump assembly；6、Water intake port；7、Oil cooler
intake pipe；8、Oil cooler return water hose.
85
10.2 System Route Diagram
Coolant pot
Thermostat
Cylinder cover
Radiator
Warm
air
blower
Coolan
t pump Cylinder body
Oil cooler
10.3 Removal, Installation and Check
1、Removal
1 Remove fixed bolt of fan clutch, and take down fan clutch;
2 Remove water outlet port connecting hose;
3 Remove fixed bolt of water outlet port;
4 Take down thermostat;
5 Remove three-way connector (connecting SCR and warm air
device);
6 Remove warm air water inlet hose;
7 Remove vacuum pump refer to “2.4 Removal and Installation of Vacuum Pump ”;
8 Remove fixed bolt of small circulation water pipe, and take down small circulation water pipe;
9 Remove fixed bolt of thermostat valve seat, and take down thermostat valve seat. Remove
coolant temperature sensor;
10 Remove SCR return water hose, warm air device return water hose and oil cooler intake and
outlet hose;
2、Check thermostat:
① Hang closed thermostat to container with water, and don’t let thermostat contact to bottom of
86
container. Heat thermostat, and check water temperature in container
at the same time. Thermostat Thermometer
② Check whether valve works normally according to

temperature. Check thermostat opening degree in corresponding
temperature.
Standard: Water
■ Open valve temperature: 80～84°C, totally open

temperature: 93～97°C. (Totally open stroke is more than 8mm). Thermostat closed temperature
is more than 77°C.
3、Check:
① Check whether there is crack, aging or damage phenomenon in belt;
② Check whether water pump impeller rotates normally, whether there is clamping stagnation and
bearing dropping out phenomenon;
③ Check whether water pump bearing is damaged, sends out abnormal noise or rotates slowly,
and replace water pump assembly if necessary;
④ Check whether sealing component is leaking, and replace water pump component if necessary;
⑤ Check whether engine coolant is leaking, if leaking, replace water pump sealing component;
4、Installation
1 Install coolant temperature sensor: spread anaerobic type screw thread sealant to coolant
temperature sensor screw thread, and install it to thermostat valve seat;
2 Install water pump. Before installing water pump, check
whether water pump housing sealing ring in sealing groove is good.
After installing water pump, there is no axial endplay in bearing and
belt wheel, and there is no clamping stagnation, rub touch or noise
when rotating by hands; there is no abnormal noise when running;
3 Check sealing ring of small circulation water pipe, and
pre-install thermostat valve seat and small circulation water pipe;
4 Pre-tighten thermostat valve seat sealing ring. Install

thermostat valve seat and small circulation water pipe;
87
5 Install thermostat component and water outlet port, when installing, pay attention that whether
sealing ring of thermostat component is good. Water outlet port should face to exhaust side of engine;
6 Install warm air water inlet hose and three-way connector,
and tighten fixed bolt;
7 Install water intake port, and tighten fixed bolt;
8 Connect related pipe of warm air, SCR heating, oil cooler,
and water pump;
9 Install other components according to the contrary sequence
of removal, and fill coolant according to requirement finally. After exhausting, fill coolant again to
standard range;
Note:
■ After installing, tighten all fixed bolts, and don’t be loosened;
water pump should rotate flexibly, and there is no touching
scrubbing and clamping stagnation phenomenon; coolant pipe all
connecting positions should not be leaking.
Attachment: Tighten Torque of Cooling System Tighten Bolt

8 install water pump, 1
installs small circulation
water pipe, 1 installs
three-way connector, 3
install intake bending
water pipe
Install thermostat valve
seat
Install outlet water port
component
88
Attachment: Cooling System Diagnosis List
Condition Possible reason
1. Whether coolant temperature sensor is connected;
2. Whether coolant temperature gauge works normally;
Coolant temperature gauge
3. In cool environment temperature, coolant level is low, and warm effect is
reading is low
bad at the same time;
4. Inside air door or controller of warm air heater works abnormally;
1. Tow trailer normally, vehicle crawls in abrupt rampway, runs in slow
moving traffic or open A/C when engine in high temperature environment
(outside). Higher height will exacerbate these conditions.
2. Whether coolant temperature gauge reading is right?
3. Whether coolant temperature warning is unnecessary on?
4. Whether liquid level is low in coolant recycle/overflow tank and radiator?
5. Radiator pressure cover is not installed well. If pressure cover is loosened,
boiling point of coolant will reduce. Please refer to step 6 below at the same
time.
6. Radiator cover sealing is not good.
reading is high or coolant
7. Radiator liquid level is low, but liquid level of coolant recycling overflow
warning light is on. There
tank is not low. It indicates radiator doesn’t pump coolant in
may be or not coolant
recycling/overflow tank when engine cooling.
reducing or leaking in
8. Incorrect coolant thickness.
cooling system.
9. Coolant doesn’t flow through system.
10. Cooling plate of radiator or A/C condenser is too dirty or blocked.
11. Radiator core is already corroded or blocked.
12. Brake is dragging.
13. Use shielding plate or paper plate, thus reduce air flow.
14. Thermostat is partly or totally closed.
15. Cooling fan works abnormally.
16. Cylinder gasket leaks.
17. Warm air heater core leaks.
1. When working in cold weather, warm air blower is in high hot state,
coolant temperature gauge may drop a little.
2. Coolant temperature gauge or coolant temperature sensor installed in
engine loses efficacy or is short circuit. Or wires in the circuit are corroded or
loosen.
3. When vehicle stops after heavy loaded (engine still running), coolant
temperature gauge reading will rise up.
4. Heated engine starts again, coolant temperature gauge reading is high.
reading is not steady
5. Liquid level is low in radiator (It will gather air in cooling system, causing
(wave, circulate or no rule)
thermostat delayed open).
6. Cylinder gasket leaking causes fuel-air get into cooling system, causing
thermostat delayed open.
7. It’s loosened between coolant pump impeller and shaft.
8. Attachment driving belt is loosened. (Coolant pump is slipped)
9. Intake part of coolant pump leaks air, causing air gather in cooling system,
and leading to thermostat delayed open.
Radiator pressure cover Pressure releasing valve on radiator cover loses efficacy
89
Condition Possible reason
sprays vapour and/or
coolant gets into overflow
tank.
may exceed normal value,
but not very high, coolant
recycling/liquid level of
overflow tank may be high
There is coolant leaking in
ground, and there is no
steam spraying out in
radiator pressure cover.
1. There is coolant leaking in radiator, coolant system hose, coolant pump or
engine.
is high (HIGH) or hot
2. Engine too hot
(HOT).
3. Coolant freezing point is not right. Mixed liquid may be too dense or too
Explode liquid or early
thin.
burnt (not caused by
ignition system). Coolant
temperature gauge may be
high or not.
When engine running,
When engine cooling, vacuum produced by cooling system doesn’t get
oneor several hoses are
compensation through coolant recycling/overflow system.
shrunken
1. Fan impeller is loosen
Coolant fan noise 2. Impeller knock surrounding objects
3. Air blockage of radiator or A/C condenser
1. Whether there is DTC
2. Coolant level is low
3. Warm air hose/connecting gets blocked
Warm air effect not 4. Warm air hose is twisted
enough, lose efficacy when 5. Coolant pump does/doesn’t pump coolant through warm air heating core.
thermostat in open position After engine fully warming, 2 warm air hose of heater will be hot. If only one
hose is hot, coolant pump may work abnormally or heater core may get
blocked. Attachment driving belt may be trackslipped, causing coolant pump
work not well.
In damp weather, engine In damp weather, (snow, ice or mis-condensed rain) when thermostat opens,
already gets warm and moisture around radiator will be evaporated. Thermostat opening makes hot
keeps running. Coolant water get into radiator. After moisture contacting hot radiator, it will be
temperature gauge is in evaporated to vapour. This generally happens in cold day, when there is no
normal value range. fan or airflow blows vapour.
Coolant color is not the necessary indicating of its corrosion state and
Coolant color
antifreezing function. Don’t ensure its state according to coolant color.
Coolant recycle/Liquid Coolant volume changes along with engine temperature, so liquid level of
level of overflow tank overflow tank changes. If tank liquid level is between FULL and ADD in
changes. Coolant normal temperature, after high temperature working, liquid level will return
temperature is normal to the range.
90
XI、SCR System
1、SCR catalytic converter；2、Urea injector；3、Differential pressure sensor gas sampling steel pipe I；
4、Differential pressure sensor；5、Differential pressure sensor gas sampling steel pipe II；6、Differential
pressure sensor connecting hose assembly；
7、DOC catalytic converter assembly；8、Urea tank assembly；
9、Urea pump；10、Electrical heating urea pipe I；11、Electrical heating urea pipe II；12、Electrical
heating urea pipe III.
91
11.2 Connecting Diagrammatic Sketch
Urea pump
SCR catalytic DOC catalytic
converter assembly converter assembly
Injector
Air flow
direction
Temperature sensor
installation seat
Differential pressure sensor
connecting steel pipe hose
NOX sensor installation seat
Urea level temperature sensor
Electrical
heating urea pipe Urea tank assembly
11.3 Maintenance Note of SCR System
There may be explosibility gas escaping out from battery. To avoid personal damage as far as
possible, before maintaining battery, must keep engine compartment ventilation well. To avoid
producing electric arc, should first remove battery negative electrode wiring harness, and connect
battery negative electrode wiring harness at last.
There is diesel engine exhausting treatment liquid in SCR injection system. Don’t make the matter
get into eyes. If getting into eyes, use a large number water to wash at least 15 minutes immediately.
Avoid long time contact with skin. If contacting, please use soap and water to clean skin immediately.
Don’t drink it. If absorbing diesel engine exhausting treatment liquid by accident, please go to see a
doctor immediately.
During maintaining, make sure to check whether there is leaking or white deposition in diesel
engine exhausting treatment liquid injection valve and input/output pipe of quick-connector-pipe, around
urea pump filter cover.
92
11.4 Removal, Installation and Check
1 Install urea injector to welding connector of SCR catalytic

converter. Don’t be install reversely, and make sure to keep heat
insulation plate side of SCR injector next to catalytic converter pipe;
2 Pre-tighten injector bolt until sealing gasket is pressed flat.

1. Injection valve seat
Tighten fixed bolt;

2. Coolant connector
3. Heat insulation
plate
4. Heat insulation
Note: plate
5. Injection valve
■ Sealing gasket is disposable sealing component, don’t permit 6. Coolant housing
to install and use again. 7. Sealing gasket
3 Install DOC catalytic converter assembly and sealing gasket

according to the marked direction on catalytic converter. Tighten
fixed bolt and nut;
4 Install gas sampling steel pipe and connecting hose. Tighten
fixed bracket bolt of gas sampling steel pipe. Pipe connected
differential pressure sensor must be upward, to avoid water gathered
in pipe and affect pressure measurement;
5 Install DOC differential pressure sensor, H mark direction
pipe of differential pressure sensor must be connected to front part
high pressure gas sampling pipe of DOC catalytic converter, and don’t be installed reversely;
6 Install upper gas flow arrow direction of SCR catalytic
converter to connect SCR catalytic converter assembly and DOC
catalytic converter assembly, install gasket, and tighten fixed bolt
and nut;
7 Install exhausting temperature sensor to temperature sensor
installation seat of SCR catalytic converter assembly, and tighten
93
fixed bolt;
8 Install NOx sensor to temperature sensor installation seat of SCR catalytic converter assembly.
Sensor controller is fixed in vehicle beam, controller must be installed horizontally, and tighten fixed bolt;
9 Install urea pump, and tighten fixed bolt;

Urea pump
10 Install urea tank assembly: slightly push urea tank to installation bolt
required state along direction in left below firgure (urea tank next to
urea bracket beam), after being pushed to preseted postion, urea tank
ventilation pipe must be in outside of urea tank crossbeam. Before
installing, check and ensure ventilation hole and ventilation pipe is
not damaged or blocked;
11 Install urea tank clamping belt, tighten fixed bolt, and pay attention that whether clamping belt
is installed in clamping groove on urea tank;
Clamping belt
Urea tank
installation bolt
ventilation pipe
Urea tank bracket

clamping belt
Urea tank bracket
crossbeam
12 Install electrical heating urea pipe (liquid absorbing pipe,

return liquid pipe, pressure pipe): connect electrical heating urea pipe to urea
tank and urea pump, urea pump and urea injector. Pressure pipe respectively is
fixed in two sides of urea tank bracket by single pipe clamp.
Connect related pipe according to urea pump connector mark:
INLET: Inlet liquid port——Urea pipe outlet (Electrical heating urea pipe I)
OUTLET: Outlet liquid port——Urea injector (Electrical heating urea pipe III)
94
BACKFLOW: Backflow port——Urea inlet port (Electrical heating urea pipe II)
a. Connect electrical heating urea pipe III and urea injector;
b. Install urea pipe I and urea pipe II according to the inlet/outlet urea pipe arrow direction of urea
pipe;
Liquid absorbing pipe

Backflow pipe
Pipe clamp
fixed bolt
Single pipe
Pressure pipe clamp
13 Install urea tank heating water pipe according to electromagnetic valve direction;
14 Connect urea injector coolant pipe;
Note:
■ Don’t remove protection cover when installing all pipe connectors.
■ After installing, tightly seal all sealing surface, and there should not be any urea or exhausting
gas leaking; all connectors are connected well, and there should not be loosened or dropped.
■ All urea solution mechanism must be clean, to avoid pollution causing component damage.
Removal: operate according to the contrary sequence of installation.
Check whether there is leaking in inlet and outlet pipe of urea pump. Diesel engine exhausting
treatment liquid will remain white deposition around leaking connector. If find deposition, should check
whether diesel engine exhausting treatment liquid pipe connector is damaged.
95
11.4 Maintenance Operation of SCR System

Generally, every time fill three times fuel, fill once urea solution, disposable maximum filling
volume is 18L, first filling volume is 21L; there is indicating light displaying urea level in vehicle
dashboard, when level is lower than warning level, it needs to add urea solution. Urea solution must be
satisfied with GB 29518 or the same class vehicle urea solution, don’t add agricultural urea or water, or
else will cause OBD warning or limit torque, even damage rear treatment device. If mistake filling fuel
or other solution to urea tank by accident, should stop engine immediately, emptying urea tank and wash
with water immediately; after washing, fill urea solution, if don’t handle it, it may damage rear treatment
device. When filling urea solution by hands, should loosen urea tank cover, guide urea solution getting
into urea tank; when urea solution level already reaching to filling port, it indicates it’s full. During
filling, should avoid urea solution spattering or being remained in tank surface; if there is urea solution
remained in tank surface, please clean with wet cloth; if don’t deal with it, it will appear white mark,
which is normal phenomenon. When filling with filling device, it will automatically stop when level
reaching to full level.
1、Maintenance Requirement and Note:
1 When in daily engine maintenance, there should not be oil or fuel getting into catalytic
converter assembly;
2 Urea pump main strainer replaces every year or 100000km, which comes first;
3 Urea tank assembly should empty and clean at least every year;
4 Urea filling port strainer should remove and clean at least every year;
5 Urea tank ventilation valve assembly should replace every year;
2、Maintenance Operation Method of Urea Pump Main Strainer and Urea Tank:
1 Replace urea pump main strainer
1) Open bottom cover of main strainer;
2) Take out adjustment component;
96
3) Insert special tool into bottom of main strainer along guiding groove;
4) After inserting in place, rotate special tool along the direction shown in the figure above, and
rotate to the state in below figure;
5) Pull out special tool directly, and take out urea pump main strainer;
6) Replace new strainer, keep the direction of original main strainer, and push main strainer to
bottom part of urea pump main strainer installation hole;
7) Install adjustment component;
8) Tighten main strainer seat, tighten torque is 15~25N.m;
Note:
■ Keep strainer and urea pump strainer installation hole clean
during the whole procedure.
2 Clean urea tank assembly
97
1) Remove urea pipe, water pipe and electrical connector on urea tank;
2) Fix urea tank body, and rotate sensor until to relax state;
3) Slightly raise up sensor;
4) Place a pot to bottom part of urea tank, remove liquid discharging port bolt in bottom part of
urea tank;
5) Discharge remained urea solution in urea tank into pot;

6) Loosen clamping belt bolt of urea tank bracket;
7) Take out urea tank, and clean the inside of tank;
98
3 Clean urea filling port strainer;

1) Open urea tank cover;
2) Pry 2 buckles of filling port by screwdriver, and popup buckles out of safety position;
3) Take out filling port assembly;
4) Take out filling port strainer;
99
5) Clean filling port strainer;
4 Replace urea tank ventilation valve assembly

1) Remove ventilation valve assembly, take out ventilation valve guide pipe from fixed
clamping groove, and anticlockwise rotate ventilation valve assembly until removable state;
2) Take out ventilation valve assembly;
3) Replace new ventilation valve assembly;
Attachment: Tighten Torque of SCR System Tighten Bolt

Urea tank clamping belt fixed
1 2 19±3.8N·m
bolt
2 Urea pump fixed bolt 4 19±3.8N·m
3 NOX sensor 1 50±10 N·m Install water outlet
100
port component
4 Fuel injector fixed bolt 3 ` 8±2 N·m
5 Exhausting temperature sensor 1 45±7 N·m。
Installed on
Turbocharger connecting to exhausting bending
6 2 M10×1.5 （45±5） N·m
exhaust pipe stud pipe, connect to
DOC assembly
Install DOC
7 Turbocharger tighten nut 2 M10×1.5 （50±5） N·m
assembly
101
Engine Electrical Control System
Chapter III Engine Electronic Control System
I、Precaution
1.1 Maintenance Precaution
Fault of sensor, actuator, control circuit, ECU or any component in electrical control system will
cause a certain effect to engine running. Due to fault self-diagnosis function of ECU, when maintaining,
connect computer detector to ECU to read fault code and data scream and find fault reason of electrical
control system. But in most conditions, the method only can judge approximate fault range, to ensure
specific fault position, you should troubleshoot further according to relevant technical data of circuit
diagram, detection method, detection step and standard value in “Workshop Manual”.
To improve reliability of engine electrical control system, most components of the system are
designed to be sealed and nondecomposable, and can’t be repaired after damaged. Maintenance of
electrical control system is to find out fault component in system, and replace.
When maintaining electrical control system, must pay attention to the following items to avoid
damage of ECU or controlled component.
1、Only allow to use vehicle special diagnosis tool to detect electrical control system (such as
digital multimeter, vehicle oscilloscope, vehicle diagnosis device and so on);
2、Please use JAC genuine parts when maintaining, or else can’t ensure system work normally.
3、Please obey to regulatory maintenance diagnosis procedure to maintain;
4、It’s forbidden to disassemble system components when maintaining;
5、When maintaining, be careful to take and place electronic component (electronic control module,
sensor, and so on), and please don’t drop them;
6、Set up environmental protection consciousness, and effectively deal with rejected material
produced in maintenance procedure;
7、When turning ignition switch to “ON”, it’s forbidden to connect or disconnect ECU wiring
harness connector to avoid inductive components of electrical control system producing induce voltage
and cause ECU damage;
8、Connect ECU wiring harness connector reliably, or else it may damage ECU;
9、When removing battery or using external battery connected to start, must first turn ignition
102
switch to “OFF”, and then remove or crossover connecting battery. Must especially pay attention that
battery positive and negative electrode can’t be connected reversed;
10、Don’t start engine when not tightening battery electrode. And don’t remove battery electrode
when engine running, or else it will cause engine charging voltage too big, and damage components in
electrical control system;
11、When rotating engine to check cylinder compressing pressure, cut off power supply of fuel
injector or disconnect all wiring harness connectors of fuel injector to avoid injected fuel getting into
exhaust pipe without burnt, and cause three-way catalytic converter damaged.
12、When imitating thermal state working condition of fault and other maintenance that may cause
temperature rising, don’t make ECU temperature over 80℃;
13、Fuel supplying pressure of electrical control injection system is high to 1800bar, thus all fuel
pipes should use high pressure fuel pipes. Even though engine is not running, there is very high fuel
pressure in fuel line, therefore don’t remove fuel pipe when maintaining, and when maintaining fuel
system, release pressure of fuel system before removing fuel pipe;
14、It’s forbidden to detect component input/output signal by the method of piercing wire epiderm;
1.2 Precaution of Engine OBD System
There is a OBD system in ECU, when exhausting system failure due to ageing, fault indicating light
will be on.
■ Before any maintenance or check, turn ignition switch to “OFF”, and disconnect battery negative
electrode wire. Open circuit or short circuit of related switch, sensor and electromagnetic valve will cause
fault indicating light on.
■ After maintaining, must connect and lock connector reliably. Loosen (unlocked) connector may
cause open circuit, thus causing fault indicating light on. (Ensure there is no water, lubrication on
connector, there is no bending or broken in connector pins.)
■ After maintaining, rightly arrange wiring harness and fix. If bracket and wiring harness are
interfered, it may cause short circuit or open circuit, thus causing fault indicating light on.
■ Before handing vehicle to customer, clear history fault information in ECU (after maintaining).
■ Make sure to use 12V battery as power supply.
■ Please don’t disconnect battery wire when engine running.
■ Before connecting or disconnecting ECU wiring harness connector, turn ignition switch to “OFF”,
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and disconnect battery negative electrode wire. Or else, it may damage ECU. Because even though turn
ignition switch to “OFF”, battery still supplies power to ECU.
■ Before removing component, turn ignition switch to “OFF”, and disconnect battery negative
electrode wire.
■ Please don’t disassemble ECU.
■ When connecting ECU wiring harness connector, push button pole to the end to be convenient to
lock ECU reliably.
■ When inserting contact pin connector into ECU or pulling out from ECU, be careful not to damage
contact pin port (bended or broken). Before connecting contact pin connector, first ensure ECU connector
is not bended or broken.
■ Connect ECU wiring harness connector firmly. Bad connect will cause coil and condenser to
produce very high (fluctuant) voltage, thus cause ECU damaged.
■ Keep engine electronic control system component and wiring harness dry.
■ In intake system, even little leakage may cause serious fault, therefore don’t replace intake pressure
sensor easily.
■ It’s forbidden to shake or knock camshaft position sensor and crankshaft position sensor.
■ Read fault code, and ensure there is no fault code after maintaining.
■ When measuring ECU by circuit tester, it’s forbidden to contact two tester probes (Contact of
probes will cause short circuit and damage ECU power transistor).
■ Ensure fuel pipe is installed in place according to the standard.
■ It’s forbidden to step accelerator pedal when starting.
■ It’s forbidden to increase engine speed immediately after starting.
■ Please don’t accelerate before closing engine (Avoid turbocharger damaged due to can’t continue
to lubricate).
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II、Structure Principle and Maintenance of Engine Control System
2.1 Electrical Control System Instruction
Intake Intake pressure

heater temperature sensor Urea pump
Urea tank
Camshaft Oil pressure switch (intergrated level
position sensor temperature sensor)
WGT
Crankshaft turbocharger
position sensor
High pressure
fuel rail
Coolant
temperature sensor Environment
temperature
Fuel injector Differential Engine CAN sensor
pressure Diagnosis CAN
sensor Urea injector Electromagnetic
valve
Exhausting Nox sensor

temperature
sensor
1 Intake heater 10 ECU

2 Intake pressure temperature sensor 11 Differential pressure sensor
3 Camshaft position sensor 12 Urea injector
4 Oil pressure switch 13 Exhausting temperature sensor
5 High pressure fuel rail 14 Nox sensor
6 Fuel injector 15 Electromagnetic valve
7 Crankshaft position sensor 16 Environment temperature sensor
8 Coolant temperature sensor 17 Urea pump
9 WGT turbocharger 18 Urea tank (intergrated level temperature
sensor)
Note:
■ The figure is control system diagrammatic sketch, if sensor position is not accord with the
vehicle sensor position, please refer to the vehicle.
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106
2.2 Electrical Control System Constitution Function
Engine electrical control system is generic terms of all electronic control device installed in engine
(or connected to engine), its function is to control running of all engine systems, to make engine have
good power performance, fuel economical efficiency and emission efficiency.
Engine electrical control system can be divided into 3 parts according to its component, namely
sensor, ECU and actuator. ECU is the control center of engine electrical control system, all sensors in
engine electrical control system measure parameter of engine speed, coolant temperature, intake
pressure temperature, and so on; analyze, judge and calculate according to setting program in ECU, and
transmit instruction signal to actuator of high pressure fuel pump, fuel injector, and so on, according to
calculated result, and control all engine system working.
Control range of control system has already expanded to engine fuel injection system, exhausting
system, and so on.
Sensor Input signal to ECU ECU function Actuator
Crankshaft position sensor
(position) Engine speed
Camshaft position sensor (phase Piston position High pressure
position) fuel pump flow
Intake pipe pressure and Fuel injection control valve
Intake pressure temperature sensor
temperature and mixing Fuel injector
Battery voltage Battery voltage ratio control Fault indicating
Rail pressure sensor Fuel system rail pressure light
A/C switch A/C pressure A/C relay
Wheel speed sensor Vehicle speed

Engine coolant temperature sensor Engine coolant temperature
1、Fuel Injection Control System

Common rail fuel injection system is a fuel direct injection system applied to internal combustion
engine. In common rail fuel injection system, producing of system pressure is divided from fuel
injection function, producing of system pressure is affected by engine speed and fuel injection amount.
Electronic diesel control system (ECU) controls every component of common rail system.
2.7CTI applies BOSCH high pressure common rail system, fuel gets into high pressure fuel pump
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through two-stage filtration, produce high pressure fuel (200~1800bar) and cause high pressure fuel-way,
injected through high pressure fuel injector. ECU controls fuel injection amount according to
requirement, revise fuel quantity according to air-fuel ratio, to accurately control fuel injection pressure,
fuel injection pressure and fuel injection phase position. Single cylinder can complete 4-6 times fuel
injection according to requirement in each working circulation.
Fuel capacity
metering unit
Rail pressure Rail pressure
control valve sensor
Common rail pipe
High pressure
fuel pump
Accelerator
pedal
Fuel injector
Other
Crankshaft
actuator
sensor
Fuel Filter
Camshaft
Electronic fuel
input pump sensor
Low pressure
Other sensor High pressure

Fuel tank
Primary filter Fuel backflow
Electrical circuit
2、Exhausting Control System

To reduce exhausting pollution of engine, use DOC+SCR rear treatment system. DOC oxidation
catalytic converter effectively deals with HC and CO, and transforms HC and CO into CO2 and H2O.
SCR rear treatment system deoxidizes NOx to N2 and H2O through urea solution in specified condition,
thus effectively reduce NOx in exhausting gas.
ECU calculates urea injection amount, controls system deicing and realizes OBD function
according to sampling and treatment of engine related data and all sensors data of rear treatment system.
System control procedure is: obtain engine running state data by CAN bus, sample front and rear
temperature signal of catalytic converter at the same time, calculate urea injection amount of SCR
system in engine actual working condition according to all pulse spectrum calibrated in advance, thus
make NOx in engine exhausting gas be accurately deoxidized. It needs vehicle or engine supplies
environment temperature signal through CAN line in system icing function, and system will judge
whether to open urea pipe heating through environment temperature feedback from the signal. Therefore,
when it needs to heat pipe in SCR system, vehicle or engine should install environment temperature
sensor.
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Urea pump
SCR catalytic DOC catalytic converter assembly

converter assembly
Fuel injector
Airflow direction
Temperature sensor
installation seat
Nox sensor connecting steel pipe hose
installation seat
Electrical heating urea pipe
Urea tank assembly
2.3 OBD System
1、Instruction
OBD system is a diagnosis system, which is integrated in engine control system, and it can monitor
fault component that affects exhausting gas discharging and monitor main function state of engine.
The system applies CAN communication, which is equipped with 16 pins fault diagnosis connector
(shown as figure below), and read related data according to related standard design by decompiler.
Standard diagnosis connector

There are four pins in fault diagnosis connector connecting to engine ECU, in which 5th pin is
grounding;
16th pin connects to battery positive electrode, 6th and 14th pin are data transmitting pin, which
partly is CAN High and CAN Low of high speed CAN bus.
2、Function Introduction
Functions of diagnosis system mainly are monitoring, fault code storage and warning, lose efficacy
protection and data output.
1）Monitoring Function
Objects diagnosis system monitored mainly are all sensors, actuators in engine electrical control
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system and control procedure of electrical control system. Fault self-diagnosis system monitors related
signal of electrical control system continuously when vehicle running, when some signal exceed
presetting range value and the phenomenon doesn’t disappear in some time, fault self-diagnosis system
will judge there is fault in the signal corresponding circuit or component.
■ Used to diagnose component which has input or output relationship with controller (sensor and
driver), mainly test component circuit, and including reasonable judgment of sensor input value at the
same time.
■ System detection is used to diagnose system fault, such as misfire, catalytic converter degradation,
cooling system fault and so on.
■ Detection of control component is used to diagnose hardware fault, communication fault and
internal storage memorizing state, which is related to data of control component.
2）Fault Code Storage and Warning Function
Once fault self-diagnosis system finds there is fault in electrical control system, fault warning light
on dashboard will be on immediately, which warns driver to maintain vehicle to avoid more damage.
Fault self-diagnosis system will also detect fault content and stored in ECU memorizer as fault
code. As long as not remove vehicle battery, detected fault code will always be stored in ECU. When
maintaining, testing personal can apply some method to read fault code stored in ECU, and supply actual
foundation for finding fault component.
No. Name Graphic Remark
1 Engine fault light Yellow
2 EPC fault light Yellow
3 Fuel-water separator Red
4 Pre-heating Yellow
5 Urea level warning light Yellow
6 Low pressure oil indicating light Red
7 Brake fault indicating light Red
8 Coolant temperature high Red
3）Lose Efficacy Protection Function

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According to different monitoring objects, fault self-diagnosis system will take different lose
efficacy protection measures.
4）Data Storage Output Function
Data storage unit in ECU is divided into ROM and RAM. Memorizer ROM stores program that is
based on accurate calculation and data from a large number of experiment; when engine running, the
intrinsic program compares and calculates with all sensors signals, to control engine.
There is a special diagnosis connector in vehicle electrical control system circuit, as long as connect
vehicle ECU decompiler to the diagnosis connector, it can visit vehicle ECU storage unit, and read
stored fault code.
Besides, fault self-diagnosis system also can output data flow that reflect working condition of
vehicle electrical control system through diagnosis connector.
3、Fault Light Instruction and Its Control Strategy
1）Engine fault indicating light (MIL): indicating for emission related component or system lose
efficacy, generally, MIL is a indicating light that can be displayed in dashboard.
2）Activation of MIL indicating light obey to the following principle:
① Ignition switch is “ON” (not start), MIL will be always on;
② After engine starting 3s, if there is not fault request that needs to lit MIL, MIL will be off;
③ There is fault request that needs to lit MIL, or there is lightening MIL request outside ECU,
MIL will be on;
④ When there is twinkling MIL request outside ECU, or there is twinkling MIL request due to
misfire, or there is twinkling MIL request in fault internal storage, MIL will twinkle in the frequency of
1HZ;
3）EPC fault indicating light: used to indicating vehicle related fault.
4）In different mode, EPC light working condition has:
① In normal mode, and fault internal storage is vain. Turn ignition switch to “ON”, ECU will be
initialized immediately, from initialization, EPC light will be on for 4s and then off. If start in the 4s,
after finding engine speed, EPC light will be off;
② In normal mode, and there is fault in internal storage. Turn ignition switch to “ON”, EPC light
will be on continuously. After starting, if in fault internal storage fault request EPC light on in fault
mode, EPC light will be on in the following driving circulation; if in fault internal storage fault don’t
request EPC light on in fault mode, EPC light will be off after finding engine speed;
③ In twinkling mode, and fault internal storage is vain. If ECU monitoring EPC light is in
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twinkling mode, EPC light will twinkle and display fault corresponding fault code in fault internal
storage. From turning ignition switch to “ON”, EPC light will be on for 4s continuously, and then after
1s, EPC light will twinkle in the frequency of 2HZ, which indicates there is no fault until engine starting
and finding engine speed. (Mainly used to related fault indicating of ECU anti-theft).
4、Fault Maintenance Step
1）To vehicle with OBD function, fault maintenance generally obey to the following steps:
OBD Troubleshooting Step
1. Connect diagnosis test device to diagnosis connector, and turn on

diagnosis test device;
2. Turn on “ignition switch”;
3. Read fault related information (fault code, freeze frame data and
so on); inquiry workshop manual to ensure fault component and
type; formulate maintenance scheme according to fault related
information and experience;
4. Remove fault;
5. Clear fault memorizer; run vehicle properly, running mode should

satisfy corresponding fault diagnosis condition; read fault
information, and ensure fault is removed.
2）Common use diagnosis device for fault diagnosis

Compare vehicle electrical control system to mechanism system, their maintenance method is basic
different, depending on electronic device and using information of self-diagnosis system to diagnose is a
necessary method of vehicle electrical control system. Common use device of electrical control system
includes vehicle computer testing device, multimeter, and so on.
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Connect data connecting wire of computer testing device to diagnosis connector on vehicle, which
can build connection with vehicle ECU, visit related fault diagnosis data stored in ECU, including fault
code, data flow, and so on, thus learn monitoring result of vehicle fault self-diagnosis system and
working condition of electrical control system, and supply foundation for removing fault rapidly.
Besides, it can also test move, and so on.
① Read and clear fault code
Connect vehicle computer testing device to electrical control system, which can be convenient to
read fault code stored in ECU. By reading fault code, maintenance personal can find short circuit and
open circuit of most sensors and their control circuit in vehicle electrical control system. After removing
fault, also can send instruction to vehicle electrical control system through computer testing device, and
clear fault code stored in ECU to make fault warning light off.
② Read data flow
Connect vehicle computer testing device to electrical control system, and read ECU working
condition and instant data of all input/output signals (such as all sensors signals, ECU calculated result,
control mode, control signal sent to all actuators, and so on). Computer testing device can display these
values on testing device screen as data list, which can make working condition of control system
absolutely clear. Maintenance personal can judge whether system works normally according to change
condition of all data, or compare all signal values in special working condition to standard value, thus to
judge fault type and fault component accurately.
③ Move test
Move test sends working instruction to ECU of vehicle electrical control system through computer
testing device, drive or stop some actuators working to detect the working condition of the actuator, and
find faulted actuator or control circuit.
Besides the basic function mentioned above, vehicle computer testing device also can read vehicle
computer, carry out basic settings, and so on.
④ IQA code written in
Write all fuel injectors IQA code to ECU through computer testing device.
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III、Structure Principle and Maintenance of Engine Electronic

Component
The electronic components involved in this chapter mainly include sensor, actuator and ECU.
Below mainly introduce working principle, structure, circuit and related maintenance of all electronic
components.
Generally, there are 3 wires in basic circuit of sensor, namely power supply, signal and grounding.
Some sensors don’t need power supply, or build-in power supply in ECU, therefore there are only signal
and grounding two wires; if uses housing grounding, there may be one signal wire connecting ECU, thus
make circuit very simple; but circuit of some sensors are very complicated. Complicated degree of
sensor circuit depends on sensor’s type and structure principle, sensors in engine electrical control
system mainly have switch type, resistance type, pulse type, voltage type, and so on.
Switch type sensor is the most simple structure, generally has 2 connecting terminals, its circuit has
grounding type and power supply type, in which grounding type is one terminal of switch is grounding
pin, one terminal of power supply type circuit is connected to power supply.
Resistance type sensor is mostly applied in electrical control system. Its structure has resistance
variable type, potentiometer type, and so on; generally produces signal by the principle of direct circuit
distributing voltage, and to ensure signal precision, ECU supplies a constant basic voltage as working
voltage (generally is 5V).
Resistance variable type sensor has 2 connecting terminals, generally applies grounding type circuit,
one terminal is signal, the other is grounding; potentiometer type sensor has 3 connecting terminals,
namely power supply, signal and grounding.
Pulse type sensor has different principle and structure type, such as electromagnetic type using
electromagnetic induction principle, photoelectricity type using photoelectricity principle, hall type
using hall effect, magnetic resistance type using magnetic resistance principle, and so on; and its circuit
is fairly complicated.
Voltage type sensor generally uses electrochemistry principle and piezoelectric effect to transform
change of detected data into change of voltage. Most voltage type sensors don’t need working power
supply.
Actuators of electrical control system mainly have electromagnetic valve, electrical power motor,
relay, triode switch circuit, indicating light, and so on. Actuator circuit generally is very simple,
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generally only has power supply and grounding two wires. ECU uses grounding control method to most
actuators, power supply of these actuators comes from battery, and grounding wire is connected to ECU.
3.1 Crankshaft Position Sensor
Sensor signal +
Crankshaft position sensor
Sensor signal -
Crankshaft position
sensor shielding
1、Summary
Crankshaft position sensor is magnetoelectricity type sensor; piston position in burnt chamber
decides starting time of fuel injection, engine piston connects to crankshaft by connecting rod,
crankshaft position sensor can supply all data of piston position, and engine speed ensure crankshaft
round per minute.
2、Working Principle
Crankshaft is connected to a ferromagnetic trigger wheel with 60 gears. There are 2 gears missing
in actual used trigger wheel, which corresponding to some specified crankshaft position of 1st cylinder.
Crankshaft position sensor records gear sequence of trigger gear, and it consists of permanent magnet
and soft iron core with copper coil. Magnetic flux in sensor changes along with passed gear and
clearance, produce sine AC voltage, and its amplitude increases rapidly along with engine (crankshaft)
engine, and it also can achieve adequate amplitude even though engine speed is 50 r/min.
3、Installation Position
Crankshaft position sensor is installed in exhausting side of engine, and in front part of crankshaft.
4、Technical Parameter and Terminal Definition
Wiring terminal:
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1—Crankshaft position sensor signal terminal
2—Crankshaft position sensor grounding terminal
Resistance: 860Ω;
Clearance between sensor and signal gear top : 0.5~1.5mm.
Temperature range:
Storage temperature: -20~50℃;
Working temperature: -40~120℃.
5、Installation Note
Sensor can only be opened before assembly;
Installing sensor must be pressed to install (It’s forbidden to knock);
Installation bolt tighten torque: 8±2 N.m;
6、Fault Phenomenon and Judging Method
 General Fault Reason:
① Sensor inner component is damaged or inner circuit open circuit, short circuit, can’t produce
signal;
② External circuit of sensor open circuit or short circuit;
③ Installation position of sensor is not right, clearance between rotor is too large, causing output
signal abnormal;
 Fault Phenomenon: power not enough, can’t start;
 Detect Method:
1）Appearance Check
Check whether sensor installation is well, wiring harness connector is connected well and firmly;
check whether distance of hall component and signal wheel accord with standard requirement, and there
is no dirt or iron scurf between them; if any, please clear.
2）Resistance Measurement
Check sensor resistance, if resistance is too large or too small, sensor is damaged.
3）Circuit Detect
① Turn off ignition switch, and measure connecting condition of all wiring harness connectors;
② Measure resistance between ECU control wiring harness and connector, resistance is less than
3Ω;
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3.2 Camshaft Position Sensor
1 2 3
+5Vpower supply
Camshaft position sensor

Signal
GND
1、Summary
Camshaft position sensor can timely and truely induces relative rotating angle position of engine
camshaft during engine running, supplies electrical signal to engine electronic control module (ECU), so
that ECU rightly judges working phase position of engine each cylinder at the moment according to
camshaft position signal inputed by camshaft position sensor, and make system control fuel injection
and ignition sequence according to specified engine working sequence, thus to more accurately control
engine combustion procedure and reduce harmful combustion emissions. Applicance of camshaft
position sensor is useful to realize optimum control of engine each cylinder ignition and fuel injection
timing.
Camshaft position sensor is hall-type sensor, which uses Hall effect to
ensure position of camshaft, trigger wheel of one ferromagnet rotates along
with camshaft, integrated circuit of Hall effect is installed between trigger
wheel and permanent magnet, and permanent magnet produces magnetic
field which perpendicular to Hall-component. If one of the trigger wheels
getting through streamlined sensor component (semiconductor chip), it
changes intensity of magnetic field of perpendicular Hall-component, which
will cause driving electron in long axis direction voltage deviate to direction
that perpendicular to current, and produces instant signal voltage
(Hall-voltage), and calculating circuit integrated with sensor Hall integrated circuit handle the signal and
output with square wave signal.
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Camshaft position sensor is installed in intake side of cylinder cover and below high pressure fuel
rail.
4、Technical Parameter and Terminal Definition
Working voltage: 5V
Signal gear addendum sensor output voltage: +0.5V
Signal gear dedendum sensor output voltage: -0.5V
Wiring terminal:
1— +5V power supply
2—Signal output
3—Grounding
Clearance between sensor induction terminal and camshaft signal wheel is: 0.35~1.65mm.
Sensor surface is clean, and there is no crack;
Tighten torque of sensor installation bolt: 10±2 N.m.
 General Fault Reason:
① Sensor inner component is damaged, or inner circuit is open circuit, short circuit, can’t produce
signal;
② Sensor outer circuit is open circuit or short circuit;
③ Installation position of sensor is not right, clearance with rotor is too large, causing output
signal abnormal.
 Fault Phenomenon:
If camshaft position sensor input signal is wrong, it can’t inject fuel in order, which is easy to cause
engine misfire, idling unsteadily, accelerating weakly, and so on.
Detect Method:
 Appearance Check
Check whether installation of sensor is firmly, wiring harness connector is connected well and
firmly, distance between Hall-component and signal wheel is accord with requirement, there is dust or
iron scurf; if any, please clear.
 Circuit Check
Hall sensor can produce signal only in the condition of power supply grounding is normal, thus first
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check its power supply circuit and grounding circuit.
① Close ignition switch, and disconnect wiring harness connector of sensor.
② Open ignition switch, use multimeter to respectively measure all terminals of sensor wiring
harness connector.
Measure sensor power supply terminal, it should be 4.5～5V reference voltage. If voltage value is
not accord with, it indicates there is fault in control circuit or ECU, and should detect further.
Measure sensor grounding terminal, and resistance between it and battery negative electrode should
be less than 3Ω; if abnormal, should maintain grounding circuit.
③ If check above is abnormal, close ignition switch, disconnect ECU wiring harness connector,
and check whether there is open circuit or short circuit between sensor connecting terminal and ECU
connecting terminal.
3.3 Intake Pressure Temperature Sensor
Power supply
Pressure signal
Grounding
Intake pressure
temperature sensor Temperature signal
1、Summary
Intake pressure temperature sensor characterizes engine actual intake state when engine running,
thus it is one of the main components of characterizing engine running working condition and load state.
Intake pressure temperature sensor integrates the function of pressure sensor and temperature
sensor.
Pressure sensor part (MAP) is designed by principle of piezoelectricity technical, when induced
pressure, it produces output signal which is proportional to input pressure. Pressure level directly
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indicates engine current load and working state. It has conclusive effect to engine management system
output control state.
Core temperature sensor component of temperature sensor consists of semiconductor thermal
resistor of negative temperature coefficient. Its temperature characteristic is negative temperature
coefficient (NTC) thermal resistor, when temperature increases, output resistance value of thermal
resistor decreases; when temperature decreases, resistance value of thermal resistor increases.
ECU supplies 5V direct current signal for engine intake temperature sensor and measure its voltage
drop according to itself circuit, and engine management system will judge engine actual working state
according to the voltage signal.
Intake pressure temperature sensor is installed intake manifold, and pressure measurement function
is prior.
4、Technical Parameter and Pin Definition
Working voltage: +5V
Working temperature: -40~130℃
Pressure measuring range: 50~400Kpa, highest is 600Kpa
Pressure measuring response time: ＜1.8ms
Temperature measuring response time: ≤10s
Temperature/℃ Maximum resistance value/Ω Minimum resistance value/Ω

-20 14055 16970
0 5420 6403
20 2323 2690
40 1100 1254
120
60 561 631
80 306 339
85 265 297
90 231 255
95 202 223
100 178 195
105 156 171
110 137 151
115 121 133
120 107 118
Pin definition:
1—Grounding
2—Temperature signal
3—Power supply +5V
4—Pressure signal
When installing, ensure pressure port faces downward, and angle between it and vertical direction
is less than 60°;
Installation bolt tighten torque: 6±2 N.m;
 General fault reason: sensor inner circuit open circuit, or dirt piled up, intake pipe leaking
causes signal incorrect.
 Fault phenomenon: when fault appears, it will cause fuel injection function of engine ECU
abnormal, and appears the phenomenon of mixed gas too dense or too thin, engine abnormal idling
running or bad accelerating, exhausting pipe giving off black smoke, and so on.
 Maintenance Note: it’s forbidden to disassemble sensor.
 Detect Method:
1）Appearance Check
Check whether sensor wiring harness connector is connected well and firmly. Check whether
sensor installation is loosen or dropped. Check whether extrinsic feature is good, and ensure there is no
knock mark. Check whether sensor check hole is blocked.
2）Circuit Check
① Turn off ignition switch, disconnect sensor wiring harness connector;
② Turn on ignition switch, use multimeter to respectively measure all terminals of sensor wiring
harness connector;
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a、Measure power supply terminal of sensor, and it should be 5V reference voltage. If voltage value
is not accord with, it indicates there is fault in control circuit or ECU, and check further.
b、Measure sensor grounding terminal, and resistance between it and battery negative electrode
should be less than 3Ω; if abnormal, should maintain grounding circuit.
If check above is abnormal, turn off ignition switch, disconnect wiring harness ECU connector, and
check whether there is phenomenon of open circuit or short circuit in wiring harness between sensor
connector and ECU connector.
3.4 Rail Pressure Sensor
Rail pressure sensor Power supply

Signal
Grounding
1、Summary
Rail pressure sensor is to measure actual pressure in high pressure fuel rail in high pressure
common rail system. Rail pressure sensor transforms pressure signal into voltage signal and transmits to
ECU, thus to realize closed loop control of fuel pressure.
Rail pressure sensor must measure instant pressure in rail, and has adequate precision and fast
response ability.
High pressure fuel flows into rail pressure sensor through a hole in common rail, and there is a
sensor membrane sealing in end part of the hole. Fuel in high pressure reaches to sensor membrane
through a blind hole. There is sensor component (semiconductor assembly) on the membrane, and the
pressure is transformed into electrical signal by the component. The produced signal is transmitted to
calculated circuit by wire, and it will amplify signal and be transmitted to ECU.
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Resistance of sensor will change accordingly along with the shape changing of sensor metal layer
installed in membrane. Shape change produced by established system pressure will make resistance
change and cause voltage of 5V conducting bridge consisted by resistance component change. The
voltage change range is 0~70mV (depends on applied pressure), and is amplified to 0.5~4.5V by
calculated circuit.
Accurate measurement of rail pressure is crucial to effective running of system. This is one of the
reasons that common difference of rail pressure sensor is very strict during pressure measurement.
Within main working condition, measurement precision is about ±2％ of full scale reading.
Rail pressure sensor is installed in end part of high pressure fuel rail.
Fuel pressure signal range: 0.5V~4.5V
Maximum working rail pressure: 2000bar
Pin definition:
1—Grounding
2—Signal
3— +5V power supply
Rail pressure sensor is forbidden to disassemble.
6、Fault Phenomenon and Diagnosis Method
 General fault reason: rail pressure sensor connector fault or sensor damaged.
 Fault phenomenon: engine fault light is on, power not engough, hard to start.
 Detect Method:
① Wiring harness connector check: after disconnected, signal terminal voltage is about 5V, power
supply voltage is 5V, grounding wire is normal;
② When working, signal wire output voltage check: in not starting state, voltage output is about
5V; in idling state, voltage output is about 1V; in normal working state, voltage is 0.5-4V.
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3.5 Coolant Temperature Sensor Ⅱ
1 2
Signal
Grounding
Coolant temperature sensor Ⅱ
1、Summary
Engine coolant temperature sensor detects engine coolant temperature, and transmits signal to ECU
to control starting, idling, fuel injection timing when running normally, fuel injection pulse width, and
supply coolant temperature signal to combination meter to display coolant temperature in combination
meter.
Coolant temperature sensor is used to detect engine working temperature, and ECU supplies
optimal control program for engine according to different temperature. There is a negative temperature
coefficient (NTC) thermal resistor in coolant temperature sensor, and the thermal resistor is connected in
voltage division circuit of 5V power supply. Voltage drop on resistor inputs to ECU by analog-to-digital
converter (ADC), and it’s a standard to measure temperature. There is a characteristic curve in ECU
microprocessor, and it sets temperature as function of given voltage value.
Coolant temperature sensor Ⅱ is installed on thermostat valve seat of front part of cylinder cover.
Heat response time: ≤10S
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Resistance/kΩ Resistance/kΩ
Temper Temper
ature/℃ Standard Minimu Maximu ature/℃ Standard MinimuMaximu
value m value m value value m valuem value
Pin definition:
1—Signal terminal
2—Grounding terminal
When installing coolant temperature, must spread screw thread sealant;
Installation tighten torque: 25 N.m.
 General fault reason: short circuit and open circuit, input signal voltage is not accord with
standard value.
 Fault phenomenon: when there is fault in coolant temperature sensor, it will affect dense of
mixed gas. When coolant temperature signal that coolant temperature sensor sends to ECU is lower than
actual coolant temperature, it will cause mixed gas too dense, and appear fault of exhausting pipe giving
out black smoke, idling not steadily when heating vehicle, and so on. When there is short circuit or open
circuit in coolant temperature sensor, fault self-diagnosis circuit of ECU will detect the fault, make
engine fault warning light on, and ECU will start lose efficacy protection function. Coolant temperature
fault causes coolant temperature deviated, which will affect pre-heating plug not working, and cause
engine start difficultly.
 Maintenance Note: after installation, idling run to check whether there is leakage.
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 Check Method:
1）Appearance check
Check whether sensor wiring harness connector is connected well and firmly; whether sensor
installation is loosen or dropped; whether extrinsic feature is good, and ensure there is no knock mark.
2）Circuit check
① Turn off ignition switch, disconnect sensor wiring harness connector;
② Turn on ignition switch, use multimeter to respectively measure all terminals of coolant
temperature sensor wiring harness connector.
a、Measure sensor power supply terminal, it should be 5V reference voltage. If voltage value is not
accord with, it indicates there is fault in control circuit or ECU, check further.
b、Measure sensor grounding terminal, resistance between it and battery negative electrode should
be less than 3Ω; if abnormal, should maintain grounding circuit.
3）Function detect
Disconnect coolant temperature sensor wiring harness connector, remove coolant temperature
sensor, and place coolant temperature sensor to water, heat and measure resistance of coolant
temperature sensor terminals in different temperatures at the same time, corresponding to standard value;
if not accord with, should replace sensor.
3.6 Exhausting Temperature Sensor
1 2
Signal
Exhausting temperature sensor Grounding
1、Summary
There is a temperature sensor installed in front of SCR catalytic converter, and it is used to detect
starting combustion temperature of SCR, SCR controller judges urea injection amount according to the
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temperature.
Exhausting temperature sensor applies PT200 membrane platinum thermal electronic technology,
and sensor resistance increases along with exhausting temperature increasing. ECU calculates
exhausting temperature by voltage resistance change affected on resistance circuit, and can ensure fast
response time and high precision.
Exhausting temperature sensor is installed on exhausting pipe in front of SCR catalytic converter.
Working voltage: +5V
Response time:
When gas speed is 11m/s, temperature is 300℃, less than 11s
When gas speed is 70m/s, temperature is 300℃, less than 5s
Pin definition:
1—Signal terminal
Temperature/℃ Resistance/Ω Voltage/V Resistance error/Ω
-20 185.6 0.783 ±1.9
0 201.0 0.837 ±1.9
50 239.0 0.964 ±1.9
200 349.5 1.295 ±1.9
300 420.2 1.479 ±3.1
400 488.6 1.641 ±4.0
500 554.6 1.784 ±4.9
600 618.3 1.910 ±5.6
700 679.7 2.023 ±6.3
Ensure to be in middle and be installed with head-part of inducing face downward;
Installation tighten torque: 40~50 N.m;
It’s forbidden to let engine exhausted deposition carbon, silicon oil, lead, paint or other organics
pollute sensor.
It’s forbidden to pull and drag wire when installing.
It’s forbidden to knot, break or do other operations that damage sensor wiring harness wire.
It’s forbidden to use oil lubricant, cleaner or other impurity on connectors.
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 Appearance Check
Check whether sensor wiring harness connector is connected well and firmly; whether sensor
installation is loosen or dropped. Check whether extrinsic feature is good, and ensure there is no knock
mark.
 Circuit Check
① Turn off ignition switch, and disconnect sensor wiring harness connector;
② Turn on ignition switch, use multimeter to respectively measure all terminals of coolant
temperature sensor wiring harness connector;
a、Measure power supply terminal of sensor, it should be 5V reference voltage. If voltage value is
not accord with, detect further.
b、Measure grounding terminal of sensor, resistance between it and battery negative electrode
should be less than 3Ω; if abnormal, should maintain grounding circuit.
 Function detect
Disconnect sensor wiring harness connector, measure resistance between two terminals; if
resistance too large or too small, it indicates sensor is damaged.
3.7 Differential Pressure Sensor
1 2 3
1 Power supply
2 Signal
3 Grounding
1、Summary
The function of differential pressure sensor is monitoring differential pressure between DOC in real
time to ensure whether rear treatment system works normally, draw forth pressure between DOC by two
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pressure port on sensor, and sensor transforms the measured result into voltage value to feed back to
control unit, thus it can ensure full oxidation of particle and avoid blocking of catalytic converter.
Connect differential pressure sensor to DOC by stainless steel pipe (gas sampling steel pipe) and
high temperature rubber pipe, draw forth pressure from DOC by stainless steel pipe, and then connect
differential pressure sensor by high temperature rubber pipe, rubber pipe can bear temperature more than
150℃. Once differential pressure between DOC two ends is too large or too small, fault light will be on
after ECU receiving feedback voltage, which judges catalytic converter blocked or short circuit.
It’s installed on gas sampling steel pipe of DOC two sides.
Minimum Normal Maximu

Sensor characteristic parameter value m value
value
Measureable differential
pressure range kPa
Working temperature ℃
Power supply voltage V
Storage temperature ℃
Highest bearable pressure of

sensor single input end kPa
Bearable pressure range of

sensor kPa
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Output voltage
Differential pressure value (kPa)
Pin definition:
1—Power supply terminal
2—Signal terminal
Pipe connected to differential pressure sensor only can be upward, and avoids gathering water in
pipe and influence pressure measurement.
 Fault phenomenon: Fault light/System light is always on
 General fault reason: differential pressure sensor is damaged or not connected well, DOC is
blocked or brokenover
 Detect method
1）Whether sensor extrinsic feature is damaged, check whether connector is loosen, wiring harness
is broken, whethere there is liquid in connector;
2）Check whether pipe is normal, there is the phenomenon of leaking gas;
3）Fault code diagnosis: use diagnosis device to diagnose fault, judge fault possible reason by fault
code, including whether power supply or grounding is normal;
4）Function test: disconnect two connecting pipe, detect output voltage when working, it should be
about 1V, or else sensor is damaged.
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3.8 Environment Temperature Sensor
Environment
temperature sensor 1 Signal
2 GND
1、Summary
Urea of SCR system will be frozen in low temperature environment, and it needs to heat to
unfreeze urea when working, and environment temperature sensor is used to measure temperature of
surrounding environment. ECU controls urea heating according to the temperature signal.
There is a temperature sensitive resistance in environment temperature sensor, which changes along
with the change of surrounding environment temperature, causing division voltage change of
temperature sensitive resistance. ECU calculates surrounding environment temperature according to the
voltage signal.
It’s installed below engine front bumper.
Resistance between 1st and 2nd pin/kΩ Environment temperature/℃
3.0~3.6 0
1.1~1.4 20
0.5~0.6 40
Pin definition:
1—Signal
2—Grounding
Prevent bending wiring harness when installing.
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 Fault phenomenon: system light/fault light is always on.
 General fault reason: wiring harness connecting fault, sensor inner fault.
 Detect Method:
1）Whether there is damage in sensor extrinsic feature, check whether connector is loosen,
wiringharness is broken, and whether there is liquid in connector;
3）Measure resistance between 1st pin and 2nd pin of sensor, compare to standard value, and judge
whether there is fault in environment temperature sensor.
3.9 NO Sensor
CAN-L
NO sensor
CAN-H
1、Summary
NO sensor can detect NOx thickness in exhausting gas (after through SCR catalytic converter), thus
to realize closed loop control of SCR system, and also can act on OBD diagnosis.
It’s installed on exhausting pipe behind SCR catalytic converter.
Working voltage: 12V
NOx measuring range: 0~1650ppm
Response time: ＜2000ms（10~90℃）
Pin definition:
1—Empty
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2—CAN-H (K86)
3—CAN-L (K64)
4—Grounding
5—Power supply (Main relay)
Installation tighten torque: 50±10 N.m;
It’s forbidden to let engine discharged deposition carbon, silic oil, lead, paint or other organics
pollute sensor.
It’s forbidden to pull wire when installing.
It’s forbidden to do operation of knoting, bending or other operations that damage sensor wiring
harness wire.
It’s forbidden to use oil lubricant, cleaner or other impurity on connector.
 Fault phenomenon: engine limit torque, system light/fault light is always on.
 General fault reason: sensor connecting wiring harness fault, sensor inner circuit damage
 Check method:
1）Whether sensor extrinsic feature is damaged, check whether connector is loosen, whether wiring
harness is broken, whether there is liquid in connector;
3.10 Urea Level Temperature Sensor
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1 Signal
2 Grounding
3 Signal
Urea temperature sensor
4 Grounding
1、Summary
Urea level temperature sensor can detect urea temperature and level height in urea tank, and urea
temperature supplies foundation for urea heating. When urea level is low, meter indicating light will be
on to remind user to fill in time.
Urea temperature sensor and urea level sensor are integrated together and are installed in urea tank.
Both of them are based on division voltage change of variable resistance to measure.
It’s installed in urea tank.
Electrical device function parameter:
Rated voltage: U=48VDC
Rated current: I=300mA
Rated power: P=125mW
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Temperature resistance Level resistance
corresponding list corresponding list
Pin definition:
1—Urea level signal
2—Urea level grounding
3—Urea temperature signal
4—Urea temperature grounding
When installing, avoid bending sensor wiring harness.
6、Fault Phenomenon and Detec Method
 Fault phenomenon: engine limit torque, system light/fault light is always on
 General fault reason: sensor fault, wiring harness fault
 Detect method:
1）Whether sensor extrinsic feature is damaged, check whether connector is loosen, whether wiring
harness is broken, whether there is liquid in connector;
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3.11 Intake Heater
Intake heating relay
Control terminal Main relay output
1、Summary
When engine starts in cold, due to low intake temperature, it’s not easily to be burnt when injecting
fuel at the end of compression stroke, causing cold starting is difficult. Intake heater heats intake gas
when engine starting in cold to ensure engine starting smoothly.
Intake heater consists of 3 parts, namely, heating slice, ceramic body and outer housing. Its
working principle is using ohm’s law, connect heating component to power supply to achieve needed
power, and supply enough heat for engine to safisfy cooling starting requirement. Intake heater takes
power from vehicle wiring harness, and is controlled by intake heating relay. ECU K07 pin outputs low
voltage to control intake heating relay working, thus controls heater working.
It’s installed in intake manifold.
4、Technical Parameter
Power: 1.5±0.15kw
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Component temperature, current characteristic curve graph
Temperature
Current
s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s
5、Note
There should be crack in metal component and insulation shim of intake heater; there is no gear
missing, deformation or other fault that influences product function in screw thread.
Continuous heating time can’t be more than 1min, if first starting fails, second starting time should
be 2 min interval.
3.12 ECU
1、Summary
Electronic control system of diesel engine can accurately adjust fuel injection parameter in different
working condition, which is the only reason that current diesel engine can be applied to all occasions.
ECU collects engine current working information through all sensors and switches, analyzes and
calculates to control fuel injection amount, fuel injection time and fuel injection pressure according to
pre-calibrated optimum parameter, thus adjust engine working state to reach the purpose of saving fuel,
high efficiency, low emission, safety, comfortable and so on.
ECU can be divided into 3 modules:
① The function of sensor is transforming physical signal to electrical signal to make ECU learn
current engine working condition (such as engine speed) and setting value (such as switch position).
② ECU handles signal achieved from sensor basing on given open loop or closed loop control
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arithmetic, and outputs electronic control signal to actuator. Besides, ECU is also connector of vehicle
other system and OBD system.
③ Actuator transforms electrical signal to mechanical move (such as, open electromagnetic valve
in fuel injection system).
ECU will always monitor whether all sensors and actuators are in normal range. At the same time,
it will detect connector void connecting, short circuit, open circuit and rationality with other signal.
When there is fault, ECU will store corresponding fault code of the fault and start safe mode.
There are 2 wiring harness connectors in ECU, including 94 pins vehicle wiring harness connector
and 60 pins engine wiring harness connector.
Working environment temperature: -40~105℃
2、ECU Pin Definition

A connector
A01 3rd fuel injector high voltage terminal A31 2nd fuel injector low voltage terminal
A02 2nd fuel injector high voltage terminal A32
A03 A33 4th fuel injector low voltage terminal
A04 A34
Camshaft position sensor grounding
A05 Starter relay control terminal A35
terminal
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A06 Rail pressure sensor +5V A36
Intake pressure temperature sensor Coolant temperature sensor Ⅱ signal
A07 A37
+5V terminal
Differential pressure sensor signal

A08 Camshaft position sensor +5V A38
terminal
A09 A39
Rail pressure sensor grounding
A10 A40
terminal
A11 A41
A12 A42
Crankshaft position sensor signal
A13 A43
terminal
Crankshaft position sensor grounding
A14 A44 Electromagnetic valve control terminal
terminal
A15 A45 Pressure control valve control terminal
A16 1st fuel injector high voltage terminal A46 3rd fuel injector low voltage terminal
A17 4th fuel injector high voltage terminal A47 1st fuel injector low voltage terminal
Electronic fuel pump relay control
A18 A48
terminal
A19 A49
Coolant temperature sensorⅡ
A20 Urea injector low voltage terminal A50
grounding terminal
Fuel temperature sensor grounding
A21 A51
terminal
A22 A/C relay control terminal A52 Rail pressure sensor signal terminal
Intake pressure temperature sensor
A23 SCR main relay control terminal A53
temperature signal terminal
Pressure temperature sensor pressure
A24 Urea injector high voltage terminal A54
signal terminal
Heater high terminal relay control
A25 A55
terminal
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Differential pressure sensor grounding
A26 A56 Crankshaft position sensor shielding
terminal
Camshaft position sensor signal
A27 A57
terminal
Intake pressure temperature sensor Fuel temperature sensor signal
A28 A58
grounding terminal terminal
Exhausting brake relay control
A29 A59
terminal
A30 A60 Fuel quantity gauge control terminal
K connector
K01 Battery positive electrode K48 Starter request grounding
K02 Battery negative electrode K49
K03 Battery positive electrode K50 Engine brake switch signal terminal
K04 Battery negative electrode K51
K05 Battery positive electrode K52 Cruise off
K06 Battery negative electrode K53 Cruise decelerating
K07 Intake pre-heating (heating grid) K54 Starting request signal
Environment temperature sensor
K08 K55 Clutch switch signal terminal
grounding terminal
Urea temperature sensor signal
K09 K56
terminal
K10 Intake pipe heating relay feedback K57
Exhausting temperature sensor 2 signal Accelerator position sensor 2
K11 K58
terminal grounding terminal
K12 K59
2nd accelerator position sensor signal
K13 K60
terminal
K14 K61
K15 Urea level sensor signal terminal K62
K16 K63
K17 K64 CAN commnunication 2 low voltage
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signal
K18 Urea level sensor grounding terminal K65 Urea pump heating relay feedback
CAN communication 1 high voltage
K19 K66
signal
Accelerator position sensor 1
K20 K67
grounding terminal
K21 K68 Backflow pipe heating relay
Accelerator position sensor 2 power
K22 K69 Urea pump heating
supply terminal
K23 K70
K24 Urea pressure sensor K71
K25 K72 Urea pump
K26 K73 Urea pump motor grounding
K27 K74 Cruise reset
Accelerator position sensor 1 power
K28 K75 Fan switch signal
supply
K29 Intake pipe heating relay K76
Environment temperature sensor signal
K30 K77 Fuel-water separator signal
terminal
Urea pump relay 3 (pressure pipe
K31 K78 Auxiliary brake switch signal
heating)
K32 K79
Intake temperature sensor 1 grounding
K33 K80
terminal
Accelerator position sensor 1 signal
K34 K81
terminal
K35 K82 Urea pressure sensor signal terminal
Exhausting temperature sensor 1 signal
K36 K83
terminal
K37 A/C request signal K84
K38 Main brake switch signal K85 Urea tank temperature sensor
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grounding terminal
Urea pressure sensor grounding CAN communication 2 high voltage
K39 K86
terminal signal
CAN communication 1 low voltage

K40 Cruise accelerating K87
signal
K41 K88 Backflow pipe heating relay feedback
K42 K89 Neutral position switch
K43 Engine speed signal output K90 Urea pump motor
K44 K line communication K91
K45 Pressure pipe heating relay K92 Fan relay 1 control
K46 Ignition switch ON K93 Fan relay 2 control
K47 Main relay control K94
3、Circuit Diagram and Vehicle Related Circuit Component
1）Power supply and grounding
Grounding 1、2、3
Ignition switch
ECU power supply
Main relay
ECU power supply
Key_on signal
Start signal
Turn ignition switch to “ON”, ECU K46 pin receives Key_on signal, K47 pin outputs low voltage
control signal, main relay starts to supply power to ECU (K01, K03, K05); at the same time, main relay
87th pin is output power supply of other electrical control components, including main/auxiliary brake
switch, clutch switch, A/C switch, urea injector, urea level temperature sensor, urea pressure sensor,
electrical heating urea pipe, intake heating, fuel-water separator and so on.
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Start signal
Starting relay
Turn ignition switch to “START”, ECU K54 pin receives “Start” signal, A05 pin outputs low
voltage control signal, starting relay starts working, and starter works.
2）A/C related control
A/C compressor relay
A/C request signal
After A/C switch being connected, ECU K75 pin receives signal, ECU outputs low voltage control
signal (A22) according to engine working condition to control A/C compressor relay working.
3）Accelerator pedal, brake pedal, clutch pedal
Main brake switch

Auxiliary brake switch
Main brake switch is normally open type, auxiliary brake switch is normally closed type. Brake
switch detect brake pedal move, and transmits detected signal to engine ECU; when ECU detecting the
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two signals, it judges whether brake switch is normal. When stepping brake pedal and accelerator pedal
at the same time, power will get limited.
Clutch switch is normally closed type switch, and ECU related pin is grounding actual time. When
stepping clutch, clutch switch is disconnected, ECU ensure driver steps clutch; further optimize engine
working state and idling speed to promote vehicle driving function. At the same time, clutch switch
indicating switch indicates clutch is stepped, at this time, only turn ignition switch to “START”, starter
can work, which is the necessary condition of starting.
Sensor 1 power supply
Sensor 1 signal
Sensor 1 grounding
Sensor 2 power supply
Sensor 2 signal
Sensor 2 grounding
1 Sensor 1 signal
2 Sensor 1 grounding
3 Sensor 1 power supply
4 Sensor 2 power supply
5 Sensor 2 grounding
6 Sensor 2 signal
Accelerator pedal position sensor is installed on accelerator pedal, accelerator pedal position sensor
supplies a signal voltage changing along with accelerator pedal position, and ECU supplies independent
5V reference voltage circuit and low voltage reference voltage circuit for each accelerator pedal position
sensor. After stepping pedal, signal voltage of accelerator pedal position sensor 1 increases, namely,
increases from about 0.75V when pedal in free position to more than 4V when pedal is totally stepped.
After stepping pedal, signal voltage of accelerator pedal position sensor 2 increases, namely, increases
from about 0.375V when pedal in free position to about 2V when pedal is totally stepped. 2 data mutual
monitor by control system.
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4）Water in fuel level sensor
Signal
Main relay output 12V
Water in fuel level position sensor is used to detect water content in fuel filter, and it is installed in
bottom of fuel filter. When water content reaches to some degree, ECU will control engine working.
Once water level exceeds limit, water level sensor sends high voltage signal (11.3-12V) to ECU K77 pin,
and ECU will warn to indicate discharging water.
Note: Make sure to discharge water in water in fuel level sensor in time; and make sure to replace
fuel filter element in regular time according to requirement.
5）Pre-heating relay
Control terminal Pre-heating relay
Main relay output 12V
Pre-heating relay is connected on vehicle chassis wiring harness, controls its working by ECU K07
pin. When ECU K07 pin outputs low voltage control signal, pre-heating relay starts working, and controls
heater intake and heating.
Note: Continuous heating time can’t be more than 1 minute, if first starting fails, second starting
time needs 2 minutes interval.
3.13 Engine Control Wiring Harness
1、Summary
Engine control wiring harness is on engine, and connects all sensors and actuators of engine to ECU
and vehicle wiring harness (chassis wiring harness). Control wiring harness mainly includes all sensors
installed on engine, actuator connectors, ECU connector and chassis wiring harness connector.
2、Connector Pin Definition
A connector wiring harness pin definition
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Chassis wiring harness
E is power supply terminal, and the others refer to ECU A connector pin definition.
Note: Crankshaft position sensor, camshaft position sensor, rail pressure sensor, flow control valve,
coolant temperature sensor, fuel injector, pressure control valve, intake pressure temperature sensor are
directly connected to engine control wiring harness; starting relay, differential pressure sensor,
electronic fuel pump relay, urea sensor, fuel temperature sensor, A/C relay, SCR main relay, urea
injector, exhausting temperature sensor are connected to engine control wiring harness through vehicle
chassis wiring harness.
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IV、Engine Control System Fault Diagnosis Procedure
4.1 Electrical Control System Common Fault and Main Reason
1、ECU Fault
In common condition, ECU reliability is fairly well and it doesn’t appear fault in normal usage,
most of ECU faults are due to abnormal use or improper. Main reasons causing ECU fault are the
followings:
1）There is fault in ECU power supply circuit, causing ECU not work;
2）Remove and install ECU wiring harness connector when power is on, because instant high
voltage will cause ECU damaged;
3）Due to water inlet or damp when using, cause ECU inner circuit short circuit or electronic
component damaged, or wire connecting terminal in connector oxidized, and lead to bad contact;
4）If there is partly damage or some input/output circuit damage in ECU control program, it will
cause partial function of electrical control sytem abnormal, such as some cylinder doesn’t inject fuel,
idling automatic control losing efficacy, and so on.
2、Sensor Fault
There are the following types to sensor fault.
1）Sensor inner fault, such as inner circuit open circuit, short circuit or inner component aging,
damage, and so on;
2）Sensor outer control circuit fault, such as short circuit or open circuit of sensor power supply
circuit, grounding circuit, signal circuit, and so on;
3）Accidental fault of sensor inner or outer, such as inner component or connector bad contact,
occasionally appear fault when working;
When there is open circuit or short circuit fault in inner or outer circuit of sensor, signal value of
sensor will exceed normal range, which is easy to be detected by ECU self-diagnosis system. ECU will
lit engine fault warning light on dashboard immediately, and record the fault code in memorizer, and
start losing efficacy protection control to keep engine running.
When sensor inner component aging or other damage, though its signal value doesn’t exceed
normal range, the signal value is not accord with detected actual parameter. The fault sometimes can’t
be detected by ECU self-diagnosis system, therefore it can’t start losing efficacy protection control, thus
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it may cause engine running abnormally.
3、Actuator Fault
There are electronic component and mechanical component in actuator, which are the easiest
faulted components. When some actuator is faulted, it can’t carry out ECU control instruction accurately,
causing engine running abnormally. Common fault reason are the followings:
1）Hardware fault that electronic component in actuator damage or inner circuit short circuit or
open circuit, and so on;
2）Mechanical component in actuator can’t work normally due to aborasion, clamping stagnation
and blockage;
3）Electronic component or mechanical component in actuator due to aging cause actuator work
slowly, function reduced; though work basicly normally, it’s about to damage limit;
4）There is void connecting in electronic component of actuator or there is abnormal fit clearance in
mechanical component, when working due to temperature or other external factors cause actuator fault
occasionally;
4、Control Circuit Fault
Control circuit between Engine ECU and sensor, actuator, power supply, grounding is abnormal,
which will cause sensor, actuator, ECU of electrical control system can’t work normally, and cause
engine fault. Common fault reasons for control circuit mainly are the followings:
1）Power supply fuse due to bad contact and overload fused cause system power supply circuit
fault;
2）Bad grounding of sensor, actuator or ECU grounding wire causes sensor, actuator or ECU work
abnormally;
3）Due to several removal and installation of connector in control circuit, causes connector or
terminal loosen or due to terminal oxidized causes connector bad contact;
4）Connected wire aging, inner broken or outer leather broken, causes short circuit or open circuit
fault.
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4.2 Fault Code List
Fault code Fault code definition OBD light EPC light

Accelerator pedal position sensor 1 voltage signal lower than lower
P0122 OFF ON
limit value
Accelerator pedal position sensor 1 voltage signal higher than upper
P0123 OFF ON
limit value
P0219 Engine overspeed indicating OFF OFF
Accelerator pedal position sensor 2 voltage signal lower than lower
P0222 OFF ON
limit value
Accelerator pedal position sensor 2 voltage signal higher than upper
P0223 OFF ON
limit value
SCR catalytic converter upper temperature sensor dynamic reliability
P0426 ON_3DC ON
detection upper temperature too high fault
SCR catalytic converter upper temperature sensor dynamic reliability
P0426 ON_3DC ON
detection upper temperature too low fault
SCR catalytic converter upper temperature sensor statics reliability
P0426 ON_3DC ON
detection fault
SCR catalytic converter upper temperature sensor signal voltage too
P042C ON ON
low
SCR catalytic converter upper temperature sensor signal voltage too
P042D ON ON
high
P04D4 Exhausting brake control relay driving circuit open circuit OFF OFF
P04D4 Exhausting brake control relay driving chip in ECU overheating OFF OFF
Exhasusting brake control relay driving circuit short circuit to power
P04D4 OFF OFF
supply
Exhasusting brake control relay driving circuit short circuit to
P04D4 OFF OFF
grounding
Brake signal unlikelihood, main brake signal and auxiliary brake signal
P0504 OFF OFF
change when different
P0562 Battery voltage too low causes related component stop working OFF OFF
P0563 Battery voltage too high causes related component stop working OFF OFF
P0575 Cruise control button signal unreasonable OFF OFF
P05EE Urea suppling unit motor speed deviation permanent fault ON_3DC ON
P05EE Urea suppling unit driving circuit open circuit fault ON ON
P05EE Urea suppling unit driving chip in ECU overheating fault ON ON
P05EE Urea suppling unit driving circuit short circuit to power supply fault ON ON
P05EE Urea suppling unit driving circuit short circuit to grounding fault ON ON
P05F8 When SCR system heating, heating component faulted causes SCR ON ON
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system stop working
P0607 ECU inner chip Cy327 communication fault OFF OFF
P060B ECU inner software/hardware bottom monitoring error (MoC) OFF OFF
P060C ECU inner software/hardware bottom monitoring error (MoC) OFF OFF
P0615 Starter relay control terminal open circuit OFF OFF
P062C Vehicle speed from CAN bus inaccurate OFF ON_3DC
P062F ECU software fault indicating when reading/writing OFF OFF
P0645 A/C compressor circuit open circuit OFF OFF
P0645 ECU inner A/C compressor driving chip overheating OFF OFF
P0646 A/C compressor driving circuit short circuit to grounding OFF OFF
P0647 A/C compressor driving circuit short circuit to power supply OFF OFF
ECU inner temperature sensor voltage signal value lower than lower
P0668 OFF ON
limit
ECU inner temperature sensor voltage signal value higher than upper
P0669 OFF ON
limit
P068A Main relay cut-off too early fault OFF OFF
P068B Main relay clamping stagnation fault OFF OFF
P0697 Sensor power supply module 3 voltage exceeds upper limit ON ON

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P0697 Sensor power supply module 3 short circuit to grounding ON ON
P0697 Sensor power supply module 3 voltage exceeds lower limit ON ON
P0699 Sensor power supply module 3 fault ON ON

P0704
Clutch signal unlikelihood OFF OFF
(0704)
P1012 ECU inner software/hardware bottom monitoring error (MoF) OFF OFF
P101A ECU inner software/hardware bottom monitoring error (MoF) OFF OFF
P101B ECU inner software/hardware bottom monitoring error (MoF) OFF OFF
P101C ECU inner software/hardware bottom monitoring error (MoF) OFF OFF
P101D ECU inner software/hardware bottom monitoring error (MoF) OFF OFF
P101E ECU inner software/hardware bottom monitoring error (Mon) OFF OFF
P101F ECU inner software/hardware bottom monitoring error (Mon) OFF OFF
P1020 ECU inner software/hardware bottom monitoring error (Mon) OFF OFF
P110A Vehicle function limit 0 activated OFF ON
P110B Vehicle function limit 1 activated OFF ON
P110C Vehicle function limit 2 activated OFF ON
P110D Vehicle function limit 3 activated OFF ON
P1608 ECU software reset_0 OFF OFF
P16E6 ICM communication interrupted OFF OFF
P203B Urea tank temperature sensor unlikelihood fault ON_3DC ON
P203F Urea tank level too low fault ON_1DC ON
P2043 Urea tank temperature too high fault ON_3DC ON

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P2047 Injection valve of urea injection unit fault (clamping stagnation) ON_3DC ON
P2047 When in low voltage, Dosing valve fault ON_3DC ON
P2047 Injection valve of urea injection unit fault ON ON
P2047 Urea injection unit short circuit to battery fault ON ON
P2047 High terminal of urea injection unit short circuit to battery fault ON ON
P2047 Urea injection unit short circuit to grounding fault ON ON
P2047 High terminal of urea injection unit short circuit to grounding fault ON ON
P2047 ECU inner urea injection unit driving chip overheating fault OFF OFF
P204A Measured value exceeds upper limit value ON_3DC ON
P204A Measured value lower than lower limit value ON_3DC ON

Urea tank temperature sensor signal rationality fault (detected
P205B ON_3DC ON
measured value too low)
P208A Urea pump control fuel-air ratio higher than effective range ON ON
P208A Urea pump control fuel-air ratio lower than effective range ON ON
P208A Urea pump motor speed fuel-air ratio higher than upper limit value ON ON
P208A Urea pump motor speed fuel-air ratio lower than lower limit value ON ON
P20A0 SCR system urea backflow pipe blocked fault ON_3DC ON
P20A0 Urea backflow pump PWM output module open circuit fault ON ON
P20A0 Urea backflow pump PWM output module temperature too high fault ON ON
Urea backflow pump PWM output module short circuit to power
P20A0 ON ON
supply fault
Urea backflow pump PWM output module short circuit to grounding
P20A0 ON ON
fault
P20A6 Pressure reducing fault ON_3DC ON
P20E9 SCR system pressure too high fault ON_3DC ON
P20FE When SCR system injecting, pressure too high fault ON_3DC ON
P20FE When SCR system injecting, pressure too low fault ON_3DC ON
P2135 Accelerator pedal 1 and accelerator 2 signal rationality fault OFF ON
P215A Vehicle speed signal fault from CAN bus OFF ON
P21C7 DNOX relay gets struck in closed position ON_3DC ON
P21C7 DNOX relay gets struck in open position ON_3DC ON
P21C7 Outer relay open circuit fault ON ON
152
P21C7 Outer relay overheating fault ON ON
P21C7 Outer relay short circuit to battery fault ON ON
P21C7 Outer relay short circuit to grounding fault ON ON
P2214 Lower Nox sensor rationality check fault (peak value check) ON_3DC ON
P2214 Lower Nox sensor rationality check fault (increment check) ON_3DC ON
P2264 Water in fuel level sensor self-check fault (sensor damage) OFF ON
P2299 Accelerator pedal and brake pedal signal irrationality fault OFF OFF
P249D Urea injection too low fault diagnosis check ON_3DC ON
P249E Urea injection too high fault diagnosis check ON_3DC ON
P249E Urea tank level sensor voltage signal higher than upper limit ON_3DC ON
P249E Urea tank level sensor voltage signal lower than lower limit ON_3DC ON
Starter relay control terminal lower terminal driving chip in ECU
P26E4 OFF OFF
overheating
Starter relay control terminal lower terminal short circuit to power
P26E4 OFF OFF
supply
P26E4 Starter relay control terminal lower terminal short circuit to grounding OFF OFF
P2BAE Engine Nox discharging more than 5.0g/kW.h fault ON_3DC ON
P2BAE Engine Nox discharging more than 7.0g/kW.h fault ON_3DC ON
P3040 SCR system pressure build-up failure fault ON_3DC ON
P3053 SCR system urea pressure pipe or urea injection unit blocked fault ON_3DC ON
P3054 SCR system pressure wave too much fault ON_3DC ON
U0073 Can A communication interrupted OFF OFF
U0080 CAN C communication interrupted ON ON
U0100 CAN communication between ECU and Nox sensor interrupted ON ON
U010E Urea suppling unit CAN communication fault ON ON

Lower Nox sensor CAN signal receiving overtime (namely signal
U0113 ON ON
missing)
4.3 Electrical Control System Common Fault Code Analysis
1、Instruction
1）Only when in current steady state fault can you maintain, or else it will cause wrong diagnosis;
2）”Multimeter” mentioned below is digital multimeter, and it’s forbidden to check electrical
153
control system by indicator-type multimeter;
3）If fault code indicates that some circuit voltage is too low, it indicates there is short circuit or
open circuit to grounding in the circuit; if fault code indicates that some circuit fault, it indicates there is
open circuit or several circuits fault in the circuit.
2、Diagnosis Help
1）If fault code can’t be erased, the fault is steady state fault; if it’s occasional fault, firstly check
whether there is loosen phenomenon in wiring harness connector;
2）When maintaining, don’t ignore influence of vehicle maintenance condition, cylinder pressure,
battery power to system.
3、Losing Efficacy Strategy
According to fault state of electrical control system, running strategy is divided into 4 classes:
① First class: default value ② Second class: reduce torque (limit torque) ③ Third class: go
home laming (electronic accelerator lose efficacy, engine speed gets limited) ④ Fourth class: stop
engine
4、Fault Code Diagnosis
1）Fault code-Main relay
Whether is not erased
Fault code Fault description
fault code?
P068A Main relay interrupted too early fault No
P068B Main relay clamping stagnation fault No
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine can’t
start; 3. Missfire when engine running.
General fault reason: 1. Main relay damage; 2. ECU damage; 3. Related connecting
wiring harness, connector fault.
Battery-
Battery+
Grounding1 Power supply input 1

Grounding2 Power supply input 2 Main relay
Grounding3 Power supply input 3
Main relay control signal
2）Fault code—Battery
fault code?
P0562 ECU inner battery voltage signal too low No
Battery voltage too low causing related
P0562 No
component stop working
154
Battery voltage too high causing related
P0563 No
component stop working
P0563 ECU inner battery voltage signal too high No
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine start
difficultly; 3. Engine can’t start.
General fault reason: 1. Battery power not enough; 2. Engine fault; 3. Relay or fuse
damaged; 4. Related wiring harness, connector damaged.
Battery+
Battery -
Grounding 1 Power supply input 1 Ignition switch
Grounding 2 Power supply input 2 Main relay
Grounding 3 Power supply input 3
Power on signal
3）Fault code—Brake switch

fault code?
Brake signal unlikelihood, change when main
P0504 brake signal andauxiliary brake signal are No
difference
Possible fault phenomenon: 1. System light/Fault light is always on.
General fault reason: 1. Brake switch fault; 2. Related wiring harness, connector open
circuit or short circuit.
Battery+
Power supply input 1
Main relay
Main brake
signal Main brake switch
Auxiliary brake switch

Auxiliary
brake signal
4）Fault code—Water in fuel level sensor

fault code?
Water in fuel level sensor self-check fault (sensor
P2264 No
damaged)
P2269 Water in fuel fault No
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not
enough.
General fault reason: 1. Water in fuel level sensor damaged; 2. Related circuit, connector
open circuit or short circuit.
155
Battery+
Main relay
Water in
fuel signal
Water in fuel
level sensor
5）Fault code—Starter relay

fault code?
P0615 Starter relay control terminal open circuit No
Starter relay control terminal low terminal driving
P26E4 No
chip in ECU overheating
Starter relay control terminal low terminal short
P26E4 No
circuit to power supply
Starter relay control terminal short circuit to
P26E4 No
grounding
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine can’t
start.
General fault reason: 1. Relay damaged; 2. ECU damaged; 3. Related connecting wiring
harness, connector damaged, open circuit or short circuit.
Battery+
Ignition switch
Starting relay
Starting relay
control signal
Starter
To battery positive
electrode
6）Fault code—Compressor relay

fault code?
P0645 A/C compressor circuit open circuit No
P0645 A/C compressor driving chip in ECU overheating No
A/C compressor driving circuit short circuit to
P0647 No
power supply
A/C compressor driving circuit short circuit to
P0646 No
grounding
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Idling shaking; 3.
Engine power not enough.
156
General fault reason: 1. Compressor relay damaged; 2. Related connecting wiring
Note: The fault code only is compressor relay fault, not involved compressor.
Battery+
Main relay
Compressor relay
Compressor relay power supply
control signal 2
Compressor relay
7）Fault code—Exhausting brake relay

fault code?
Exhausting brake control relay driving circuit
P04D4 No
open circuit
Exhausting brake control relay driving chip in
P04D4 No
ECU overheating
P04D4 No
short circuit to power supply
P04D4 No
short circuit to grounding
Possible fault phenomenon: 1. System light/Fault light is always on; 2 、 Engine can’t
start.
General fault reason: 1. Exhausting brake relay damaged; 2. ECU damaged; 3. Related
connecting wiring harness, connector damaged, open circuit or short circuit.
Note: The fault code only is exhausting brake relay fault, not involved exhausting brake valve.
Battery+

Power supply input 2 Main relay
Exhausting brake Exhausting brake

relay control signal 1 relay power supply
Exhausting brake relay
8）Fault code—Rail pressure control valve

fault code?
(Rail pressure) pressure control valve (PCV)
P009B No
driving circuit open circuit
P009B No
driving chip in ECU overheating
157
P009B No
driving circuit short circuit to power supply
P009B No
driving circuit short circuit to grounding
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine idling
shaking; 3. Engine hard to start; 4. Engine power not enough; 5.Engine can’t start.
General fault reason: 1. Pressure control valve damage; 2. ECU damage; 3. Related

Main relay Battery
+
Rail pressure
control valve
Rail pressure control
valve control signal 1
9）Fault code—Fuel quantity metering unit

fault code?
High pressure pump fuel quantity metering unit
P0251 No
(MeUn) connector loosen
High pressure pump fuel quantity metering unit
P0251 No
(MeUn) driving circuit open circuit
Fuel quantity metering unit (MeUn) driving
P0251 No
circuit short circuit to power supply
Fuel quantity metering unit (MeUn) driving
P0251 No
circuit short circuit to grounding
Fuel quantity metering unit (MeUn) driving chip
P0252 No
in ECU overheating
Possible fault phenomenon: 1.System light/Fault light is always on or twinkling; 2.
Engine idling shaking; 3. Engine sends out black smoke; 4. Engine power not enough; 5.
Engine can’t start.
General fault reason: 1. Fuel quantity metering unit damaged; 2. ECU damaged; 3.
Related connecting wiring harness, connector damaged, open circuit or short circuit.
Battery+
Main relay
Control
signal Fuel quantity metering
unit (MeUn)
158
10）Fault code—Fuel injector

fault code?
Ignition sequence 1st cylinder fuel injector driving
P0201 No
circuit open circuit
Ignition sequence 2nd cylinder fuel injector driving
P0203 No
Ignition sequence 3rd cylinder fuel injector driving
P0204 No
Ignition sequence 4th cylinder fuel injector driving
P0202 No
Fuel injection control module 0 (wiring harness)
P062D No
short circuit fault
Fuel injection control module 1 (wiring harness)
P062E No
short circuit fault
Ignition sequence 1st cylinder fuel injector wiring
harness short circuit (high terminal or low
P0262 No
terminal short circuit to power supply or
grounding)
Ignition sequence 2nd cylinder fuel injector wiring
P0268 No
grounding)
Ignition sequence 3rd cylinder fuel injector wiring
P0271 No
grounding)
Ignition sequence 4th cylinder fuel injector wiring
P0265 No
grounding)
Ignition sequence 1st cylinder wiring harness
P0261 No
lower terminal short circuit to high terminal
Ignition sequence 2nd cylinder wiring harness
P0267 No
Ignition sequence 3rd cylinder wiring harness
P0270 No
Ignition sequence 4th cylinder wiring harness
P0264 No
shaking; 3. Engine sends out black smoke; 4. Engine power not enough; 5. Engine can’t
start; 6. Engine hard to start.
General fault reason: 1. Fuel injector damaged; 2. Related connecting wiring harness,
connector damaged, open circuit or short circuit.
159
1st cylinder fuel
injector high terminal
1st cylinder fuel 1st cylinder
injector low terminal fuel injector
4th cylinder fuel
4th cylinder fuel 4th cylinder
3rd cylinder fuel
3rd cylinder fuel 3rd cylinder
2nd cylinder fuel
2nd cylinder fuel 2nd cylinder
11）Fault code—Coolant temperature sensor

fault code?
Coolant temperature sensor absolute value
P0116 rationality check fault (coolant temperature No
doesn’t reach to threshold value in some time)
Coolant temperature sensor dynamic value
P0116 rationality check fault (coolant temperature No
doesn’t rise to threshold value in some time)
Coolant temperature sensor voltage higher than
P0117 No
upper limit value
Coolant temperature sensor voltage lower than
P0118 No
lower limit value
enough; 3. Engine sends out black smoke.
General fault reason: 1. Coolant temperature sensor damaged; 2. Related connecting
wiring harness, connector damaged, open circuit or short circuit.
Coolant
temperature signal
Coolant
temperature sensor
Coolant temperature
signal grounding
12）Fault code—Rail pressure sensor

fault code?
160
Rail pressure sensor signal drifting fault (voltage
P0191 No
too high)
Rail pressure sensor signal drifting fault (voltage
P0191 No
too low)
Rail pressure sensor voltage signal higher than
P0193 No
upper limit
Rail pressure sensor voltage signal lower than
P0192 No
lower limit
P018F Switch to CPC working mode times exceed limit No
enough; 3. Engine can’t start; 4. Engine misfire when running.
General fault reason: 1. Rail pressure sensor damaged; 2. Related connecting wiring
Rail pressure
sensor power
suply
Rail pressure Rail pressure signal

sensor
Rail pressure
signal grounding
13）Fault code—Intake pressure temperature sensor

fault code?
Turbocharging pressure ssensor signal higher than
P0235 No
upper limit
Turbocharging pressure sensor voltage signal
P0235 No
lower than lower limit
Intake temperature sensor voltage signal lower
P0097
than lower limit after turbocharging inter-cooling
Intake temperature sensor voltage signal higher
P0098
than upper limit
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power
not enough; 3. Engine sends out smoke.
General fault reason: 1. Intake pressure temperature sensor damaged; 2. Related
161
Sensor
power supply
Turbocharging
pressure signal
Turbocharging Signal grounding
pressure sensor
Intake temperature
signal
14）Fault code—Camshaft position sensor

fault code?
P0340 Not detect camshaft signal No
There is disturbing or signal missing fault in
P0341 No
camshaft signal
P0340 Camshaft signal and crankshaft deviates too much No
enough; 3. Engine hard to start; 4. Engine can’t start; 5. Engine misfire when running.
General fault reason: 1. Camshaft position sensor damaged; 2. Related connecting wiring
harness, connector damaged, open circuit or short circuit; 3. Camshaft position sensor
installation fault; 4. Signal panel fault; 5. Clearance between camshaft and signal panel is
not reasonable.
Sensor power
supply
Camshaft Camshaft signal

sensor Camshaft signal
grounding
15）Fault code—Crankshaft position sensor

fault code?
P0335 Not detect crankshaft signal No
There is disturbing or signal missing fault in
P0336 No
crankshaft signal
Clearance between camshaft signal and crankshaft
P0340 No
signal deviates too much
enough; 3. Engine hard to start; 4. Engine can’t start; 5. Engine misfire when running.
General fault reason: 1. Crankshaft position sensor damaged; 2. Related connecting
162
wiring harness damaged, open circuit or short circuit; 3. Crankshaft position sensor
installation fault; 4. Signal panel fault; 5. Clearance between crankshaft and signal panel
is not reasonable.
Crankshaft
signal +
Crankshaft Crankshaft
sensor signal -
Shielding wire
grounding
16）Fault code—Fuel pump relay

fault code?
Fuel pre-supplying pump (PSP) driving circuit
P0627 No
open circuit
Fuel pre-supplying pump (PSP) driving chip in
P0627 No
ECU overheating
P0627 No
short circuit to power supply
P0627 No
short circuit to grounding
Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power
notenough; 3. Engine can’t start; 4. Engine idling shaking.
General fault reason: 1. Fuel pump relay damaged; 2. Related connecting wiring harness,
Note: The fault code is only fuel pump relay fault, not involved electronic fuel pump.
Grounding
Fuel pump relay

control signal
Fuel pump relay
17）Fault code—Environment temperature sensor

fault code?
P0072 Enviroment temperature sensor voltage signal No
163
lower than lower limit
Environment temperature sensor voltage signal
P0073 No
higher than upper limit
General fault reason: 1. Environment temperature sensor damaged; 2. Related
Environment temperature
Environment sensor signal
temperature
sensor
Environment temperature
sensor grounding
18）Fault code—DOC differential pressure sensor

fault code?
Forbid probability monitoring of differential
P2002 No
pressure sensor
P2002 DOC removal No
When DOC differential pressure voltage signal
P2453 No
AfterRun, higher than upper limit
DOC differential pressure voltage signal higher
P2455 No
than upper limit
DOC differential pressure voltage signal lower
P2454 No
than lower limit
General fault reason: 1. DOC differential pressure sensor damaged; 2. Related
connecting wiring harness, connector damaged, open circuit or short circuit; 3. DOC
damaged or removed; 5. Gas sampling steel pipe connecting fault; 6. Gas sampling pipe
leaking or blocked.
Differential pressure
sensor power supply
Differential pressure sensor signal
DOC differential
pressure sensor
Differential pressure
sensor grounding
19）Fault code—Accelerator pedal sensor

Fault code Fault description Whether is not erased
164
fault code?
Accelerator pedal sensor 1 voltage signal lower
P0122 No
than lower limit value
Accelerator pedal sensor 1 voltage signal higher
P0123 No
than upper limit value
Accelerator pedal sensor 2 voltage signal lower
P0222 No
than lower limit value
Accelerator pedal sensor 2 voltage signal higher
P0223 No
than upper limit value
Accelerator pedal sensor 1 and accelerator pedal
P2135 No
sensor 2 signal rationality fault
Accelerator pedal and brake pedal signal
P2299 No
irrationality fault
increases; 3. Engine power not enough; 4. There is no response when engine running to
accelerate.
General fault reason: 1. Accelerator pedal sensor damaged; 2. Related connecting wiring
harness, connector damaged, open circuit or short circuit; 3. Pin connecting fault.
Note: Inquiry and check driver’s driving habbit. Accelerator pedal and brake pedal can’t be stepped at
the same time.
Accelerator pedal
1 power supply
Accelerator pedal
1 signal
Accelerator pedal
1 signal grounding
Accelerator Accelerator pedal
pedal sensor 2 power supply
Accelerator pedal
2 signal
Accelerator pedal
2 signal grounding
20）Fault code—Clutch switch

fault code?
P0704 Clutch switch unlikelihood No
General fault reason: 1. Clutch switch damaged; 2. Related connecting wiring harness,
165
Battery negative
electrode
Clutch switch
Grounding Clutch signal
21）Fault code—CAN bus communication module fault

fault code?
U0073 CAN A communication interrupted No
U0046 CAN C unactive fault No
U0046 CAN C communication interrupted No
CAN signal from EMS1 receiving overtime
U1402 No
(namely signal missing)
U1403 No
U1404 No
U1405 CAN signal from ICM2 frame length fault No
CAN signal from ICM2 receiving overtime
U1406 No
Communication between ECU and CAN meter
U1103 No
interrupted
P16E6 ICM communication interrupted No
P062C Vehicle speed from CAN bus not accurate
P215A Vehicle signal from CAN bus fault No
enough.
General fault reason: 1. Related connecting wiring harness, connector damaged, open
circuit or short circuit; 2. ECU damaged; 3. ABS/ESP fault; 4. SAS fault; 5. GW fault; 6.
TCU fault; 7. Nox sensor fault.
166
CAN_L
CAN bus
communication CAN_H
module 1
CAN_L
CAN bus
communication CAN_H
module 1
21）Fault code—Nox sensor

fault code?
U0113 Lower Nox sensor CAN signal frame length fault No
Lower Nox sensor CAN signal receiving overtime
U0113 Yes
CAN communication between ECU and Nox
U0100 Yes
interrupted
NOxNoCat2Ds CAN information content exceeds
U0113 No
SAE set reasonable range
SensNOxStabNoCat2Ds CAN information
U0113 No
content exceeds SAE set reasonable range
Getting into heating mode when NOx sensor 2
P22A3 diagnosis released, but in given heating time, fault No
appears
P229E No Yes
P229E No Yes
P229E No No
P229E No No
P22A6 Nox sensor 2 signal in ready state No
P2201 No Yes
Lower Nox sensor rationality check fault (peak
P2214 Yes
value check)
Lower Nox sensor rationality check fault
P2214 Yes
(increment check)
enough.
General fault reason: 1. Nox sensor installation fault (position fault); 2. Nox sensor
167
damaged; 3. Related connecting wiring harness, connector damaged, open circuit or
short circuit.
22）Fault code—Catalytic converter upper temperature sensor (Exhausting temperature sensor)

fault code?
SCR catalytic converter upper temperature sensor
P0426 dynamic reliability check upper temperature too Yes
high fault
P0426 dynamic reliability check upper temperature too Yes
low fault
P0426 Yes
statics reliability check fault
P0435 Yes
signal voltage too high
P2435 Yes
signal voltage too low
enough; 3. Urea consumption too high.
General fault reason: 1. Catalytic converter upper temperature sensor damaged; 2.
Related connecting wiring harness, connector damaged, open circuit or short circuit.
Catalytic converter upper

temperature sensor signal
Catalytic converter
upper temperature
sensor Catalytic converter upper
temperature sensor
grounding
23）Fault code—Urea injection unit

fault code?
Injection valve fault of urea injection unit
P2047 Yes
(clamping stagnation)
P2047 When low voltage, Dosing valve fault Yes
P2047 Injection valve fault of urea injection unit Yes
Urea injection unit driving chip in ECU
P2047 Yes
overheating fault
P2047 Urea injection unit short circuit to battery fault Yes
High terminal of urea injection unit short circuit
P2047 Yes
to battery fault
P2047 Urea injection unit short circuit to grounding fault Yes
P2047 High terminal of urea injection unit short circuit Yes
168
to grounding fault
enough; 3. Urea consumption too high.
General fault reason: 1. Urea injection unit fault (blocking, clamping stagnation, abrasion,
leaking); 2. Related connecting wiring harness, connector damaged, open circuit or short
circuit; 3. ECU fault; 4. There ia impurity in urea solution.
Urea injection unit control

signal high terminal
Urea Urea injection unit control
injection unit signal low terminal
24）Fault code—Urea level temperature sensor

fault code?
Urea tank level sensor voltage signal higher than
P203D Yes
upper limit
Urea tank level sensor voltage signal lower than
P203C Yes
lower limit
P203B Urea tank temperature sensor unlikelihood fault Yes
P2043 Urea tank temperature too high fault Yes
Urea tank temperature sensor signal voltage too
P205D No
high
Urea tank temperature sensor signal voltage too
P205C No
low
Urea tank temperature sensor signal rationality
P205B No
fault (measured value too high)
Urea tank temperature sensor signal rationality
P205B Yes
fault (measured value too low)
enough.
General fault reason: 1. Urea level temperature sensor damaged; 2. Related connecting
wiring harness, connector damaged, open circuit or short circuit; 3. Urea leaking.
Note: Urea temperature sensor and urea level sensor are integrated together and are installed in urea tank.
169
Urea level signal

Urea tank level Signal grounding
sensor
Urea temperature
Urea tank signal
temperature sensor Signal grounding
25）Fault code—Urea tank

fault code?
P203F Urea tank level too low fault Yes
enough.
General fault reason: 1. Urea level temperature sensor damaged; 2. Urea solution too
little (fill urea solution); 3. Urea tank damaged to leak.
170

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2.

7CTI Engine Workshop Manual

JAC Engine Company

ECU：Engine Control Unit

Chapter I Engine Introduction

I、Engine Identification Code

1.1 Engine Data Plate Position

1.2 Printed Location of Engine Identification Code and Engine No.

1.3 Engine Identification Code Instruction

1、Engine Identification Code

Engine No. F 4 123456

Year Engine type Manufacturing

II、Engine Technical Specification Parameter

2.1 Main Technical Specification

Engine type No. HFC4DE1-1D

Main Rated engine speed (r/min) 3200

2.2 Main Component Specification

Component name Technical characteristic

2.3 Main Inspection and Adjustment Parameter

2.4 Oil Specification

2.5 Fuel Specification

Figure No. Name Quantity Specification Tighten torque Remark

Fixed one inlet oil duct,

Piston pin hole

3、Piston pin Piston pin outer 0

Radial clearance 0.008～0.017 0.03

Piston pin outer 0

Radial clearance 0.012～0.021 0.05

Connecting rod big

Connecting rod big

1st piston ring

6、Piston ring 1st piston ring high 2.097  00 . 029

2nd piston ring

2nd piston ring high 2.0  00 ..01

2nd piston ring

3rd piston ring

3rd piston ring high 3.0  00 ..01

3rd piston ring

1st gas ring 0.25～0.35 0.8

gauge (or in cylinder

8、Crankshaft Crankshaft main  0 . 018

Radial clearance 0.054~0.10 0.15

Fit clearance 0.039~0.091 0.15

Valve guide pipe

11、Valve guide Intake: Φ6  00 ..030

12、Exhaust Exhaust valve base

Intake valve base

14、1-4 Φ43.1H7(  00. 025 )

Fit clearance 0.035～0.076 0.12

16、Camshaft Camshaft bushing

Fit clearance 0.025～0.066 0.15

Camshaft bushing Φ43.1H7(  00. 025 )

ing shaft journal

No. Tool name Outside drawing Use

Used to remove engine valve and

Crankshaft front oil

Oil sump removal

Crankshaft rear oil

Valve oil sealing

Fixed flywheel to be convenient to

Fix rear part location groove of

Rotate engine by flywheel housing

Urea pump main