ISLe375 30engine 发动机-En

ISLe375 30 engine
Contents
ISLe375 30 engine..............................................................................................................1
General ...............................................................................................................................1
I. Precautions on engine maintenance..........................................................................................1

II. Assembly identification ..............................................................................................................2
III. Technical parameters .................................................................................................................9
IV. Special tool ..............................................................................................................................11
V. Fault diagnosis.........................................................................................................................35
Engine block ..................................................................................................................117
Precautions ....................................................................................................................117
I. Cleaning essentials of engine ................................................................................................117

II. Repairing essentials of engine ...............................................................................................119
Engine assembly ...........................................................................................................120
I. Removal and refitting of engine assembly .............................................................................120

II. Disassembling and assembling of engine ..............................................................................129
Cylinder head .................................................................................................................217
I. Renewal of jumper plate ........................................................................................................217

II. Renewal of cylinder head.......................................................................................................219
III. Renewal of cylinder head valve guide oil seal .......................................................................233
Cylinder block and flywheel housing...........................................................................240
I. Renewal of cylinder block ......................................................................................................240

II. Renewal of cylinder block reinforcement plate.......................................................................248
III. Renewal of hydraulic pump drive ...........................................................................................250
IV. Renewal of cylinder jacket .....................................................................................................253
V. Renewal of piston and linkage assembly ...............................................................................266
VI. Renewal of piston ..................................................................................................................281
VII. Renewal of piston cooling nozzle...........................................................................................286
VIII. Renewal of linkage.................................................................................................................291
IX. Renewal of linkage bearing....................................................................................................295
Camshaft and timing gear mechanism ........................................................................298

I. Renewal of crankcase breather (external) .............................................................................298
II. Adjustment of clearance of overhead mechanism .................................................................300
III. Renewal of rocker arm...........................................................................................................303
IV. Renewal of rocker chamber ...................................................................................................308
V. Renewal of rocker chamber housing......................................................................................310
VI. Renewal of crankcase breather pipe......................................................................................312
VII. Renewal of front gear housing cover .....................................................................................314
VIII. Renewal of front gear housing ...............................................................................................316
IX. Camshaft................................................................................................................................321
X. Renewal of camshaft bushing ................................................................................................326
XI. Camshaft gear (with the camshaft fitted)................................................................................329
XII. Renewal of camshaft gear (with the camshaft removed) .......................................................333
XIII. Renewal of pushrod. ..............................................................................................................337
XIV. Renewal of tappet ..................................................................................................................340
Crankshaft and piston linkage assembly ....................................................................344
I. Renewal of crankshaft ...........................................................................................................344

II. Renewal of front crankshaft gear (with the crankshaft fitted) .................................................351
III. Renewal of crankshaft front oil seal .......................................................................................354
IV. Renewal of crankshaft rear oil seal ........................................................................................357
V. Renewal of crankshaft front anti-wear bushing ......................................................................360
VI. Renewal of crankshaft rear anti-wear bushing .......................................................................364
VII. Renewal of crankshaft speed indicating ring..........................................................................369
VIII. Renewal of main bearing .......................................................................................................371
IX. Renewal of rubber shock absorber ........................................................................................379
X. Renewal of viscous shock absorber.......................................................................................381
XI. Renewal of oil pan .................................................................................................................384
XII. Engine oil heater ....................................................................................................................387
XIII. Renewal of oil dipstick ...........................................................................................................388
XIV. Oil dipstick pipe......................................................................................................................390
Refitting of engine .........................................................................................................392
I. Renewal of engine front bracket ............................................................................................392

II. Renewal of flexible connecting disc .......................................................................................396
III. Flywheel.................................................................................................................................399
IV. Flywheel housing ...................................................................................................................408
V. Renewal of REPT0 flywheel houing.......................................................................................420
VI. Renewal of flywheel ring gear ................................................................................................437
ISLe375 30 engine
Lubricating system ........................................................................................................439
General ...........................................................................................................................439
I. Lubricating system- general description.................................................................................439
Draining and filling of lubricating system ...................................................................442
I. Draining of lubricating system ................................................................................................442

II. Filling of lubricating system ....................................................................................................443
III. Analysis of oil and filter ..........................................................................................................445
Oil pump and pipeline ...................................................................................................447
I. Renewal of oil pump ..............................................................................................................447

II. Renewal of oil suction pipe (fitted on cylinder block)..............................................................452
Oil filter ...........................................................................................................................454
I. Renewal of oil filter (rotary) ....................................................................................................454

II. Oil filter bypass valve .............................................................................................................456
III. Renewal of oil filter seat.........................................................................................................458
IV. Renewal of oil high pressure reducing valve..........................................................................460
V. Renewal of oil pressure adjuster (main passage) ..................................................................461
Oil cooler ........................................................................................................................463
I. Oil cooler................................................................................................................................463
Fuel system ....................................................................................................................466
I. General description on the fuel system..................................................................................466

II. Fuel injector and fuel pipeline – general description ..............................................................469
III. Fuel consumption...................................................................................................................471
Fuel pump and filter.......................................................................................................475
I. Fuel pump ..............................................................................................................................475

II. Renewal of fuel pump gear pump ..........................................................................................479
III. Timing of fuel pip....................................................................................................................483
IV. Renewal of delivery pump......................................................................................................485
V Renewal of electric fuel heater...............................................................................................488
VI Renewal of fuel pump actuator housing.................................................................................490
VII Renewal of fuel filter (rotary type) ..........................................................................................492
VIII Renewal of fuel filter seat.......................................................................................................495
IX Fuel filter seat bracket............................................................................................................497
Pipe with union and the fuel tank .................................................................................499
I. Renewal of fuel pump head outlet pipe union ........................................................................499

II. Renewal of fuel pump head ...................................................................................................502
III. Air-in-fuel. ..............................................................................................................................509
IV. Renewal of fuel-cooled ECM cooling board ...........................................................................511
V. Measured resistance of fuel return hose ................................................................................514
VI. Renewal of fuel return hose ...................................................................................................516
VII. Measured resistance at the fuel inlet .....................................................................................518
VIII. Renewal of fuel supply pipe ...................................................................................................520
Fuel injector and supply pipe .......................................................................................523
I. Fuel injector ...........................................................................................................................523

II. Renewal of fuel supply pipe of fuel injector (high pressure)...................................................531
III. Renewal of fuel pipe union (seat-mounted) ...........................................................................534
IV. Renewal of fuel rail ................................................................................................................536
V. Renewal of fuel relief valve ....................................................................................................538
Intake and exhaust systems .........................................................................................542
General ...........................................................................................................................542
I. Intake system – general description.......................................................................................542

II. Exhaust system- general description .....................................................................................547
III. Compressed air system-General description .........................................................................549
IV. Leakage of intake and exhaust systems ................................................................................553
V. Measurement of intake resistance .........................................................................................558
VI. Measurement of intake manifold pressure .............................................................................560
VII. Measurement of exhaust resistance ......................................................................................562
Intake pipe and exhaust pipe ........................................................................................564
I. Renewal of air jumper pipe ....................................................................................................564

II. Renewal of intake connector..................................................................................................566
III. Renewal of intake pipe union .................................................................................................568
IV. Renewal of intake manifold hood ...........................................................................................570
V. Renewal of intake pipe union .................................................................................................572
VI. Renewal of turbocharger compressor outlet union.................................................................574
VII. Air-air intercooler....................................................................................................................576
VIII. Renewal of cold starting auxiliaries........................................................................................581
ISLe375 30 engine
IX. Dry exhaust manifold .............................................................................................................583
Turbocharger..................................................................................................................586
I. Turbocharger .........................................................................................................................586
II. Renewal of turbocharger return pipe......................................................................................593
III. Renewal of supply pipe of supercharger................................................................................595
IV. Renewal of turbocharger exhaust bypass valve actuator.......................................................598
Air compressor ..............................................................................................................603
I. Carbon deposit in air compressor ..........................................................................................603

II. Air compressor coolant pipe ..................................................................................................606
III. Renewal of air compressor cylinder head and single cylinder ...............................................608
IV. Air compressor unloading valve and valve body assembly....................................................610
V. Air compressor....................................................................................................................... 611
VI. Air pressure regulator ............................................................................................................616
VII. Leakage of compressed air system .......................................................................................617
VIII. Air compressor oil supply pipe ...............................................................................................618
Cooling system ..............................................................................................................620
General ...........................................................................................................................620
I. Cooling system- general description ......................................................................................620

II. Draining of cooling system and filing of coolant .....................................................................624
III. Diagnosis of cooling system ..................................................................................................627
Radiator and union, coolant filter, expansion tank .....................................................637
I. Renewal of radiator................................................................................................................637
II. Renewal of radiator hose .......................................................................................................639
III. Renewal of radiator pressure cover .......................................................................................640
IV. Coolant filter...........................................................................................................................642
V. Coolant filter seat ...................................................................................................................644
VI. Coolant filter valve .................................................................................................................646
VII. Coolant heater .......................................................................................................................648
Coolant pump and thermostat ......................................................................................650
I. Renewal of coolant pump ......................................................................................................650

II. Renewal of automatic belt tensioner (water pump) ................................................................652
III. Renewal of water inlet joint ....................................................................................................656
IV. Renewal of coolant thermostat...............................................................................................658
ISLe375 30 engine
Fan, fan shroud and combinations ..............................................................................663
I. Renewal of cooling fan drive belt ...........................................................................................663
Connect the split-type fan clutch .................................................................................666
I. Renewal of belt-driven fan hub ..............................................................................................666

II. Renewal of fan shroud assembly ...........................................................................................669
III. Renewal of fan spacer bush and belt pulley...........................................................................671
Electric control system .................................................................................................674
I. General ..................................................................................................................................674
II. Renewal of ECM assembly ....................................................................................................677
III. Renewal of engine cable harness assembly ..........................................................................680
IV. Renewal of coolant temperature sensor ................................................................................684
V. Renewal of pressure sensor of intake manifold .....................................................................686
VI. Renewal of temperature sensor of intake manifold ................................................................688
VII. Renewal of crankshaft speed sensor .....................................................................................691
VIII. Renewal of engine position sensor ........................................................................................693
IX. Renewal of oil pressure sensor..............................................................................................695
ISLe375 30 engine
ISLe375 30 engine
General
I. Precautions on engine maintenance
1. Special recommendations
Give priority to following works.
1. Clean major parts and their immediate areas.
2. Confirm that the power supply is disconnected.
3. If necessary, mark the pipe and wiring harness.
4. Protect all the pipe orifice to avoid the entrance of foreign matters
5. Reduce pressure before removing pressure pipe
6. If the liquid splashes onto the body, immediately use the recommended cleaning product to
clean it.
2. Preparation before assembling

1. Carefully check and clean all the components.
2. The bearing packing is allowed to be opened till mounting. Do not Remove protective
grease on the bearing
3. The old oil seal and lock plate cannot be reused, and must be renewed during assembly
4. When assembling, it is not allowed to be knocked by bar copper but tailor-made driver to
prevent foreign matter entering in the crankcase and bearing.
5. Lubricated parts are always given a priority in the mandatory equipment.
6. Apply the grease on the seal ring lip
7. Heat with hot air for assembly, and heating by flame is forbidden
3. Products for tightening, locking, sealing and sticking

1. Before assembling, carefully clean the product surface, especially the residue of old
product.
2. The threads shall be brushed clean, patted lightly and cleaned by suitable product, if
necessary
4. Use original parts.

Only use the recommended spare parts and pay attention to the label on the product
packing
1. Surface finish
2. Working temperature
3. Valid period of chemical reaction and dry treatment
4. Storage period
5. Follow the mounting method and ensure maintenance quality.
Precautions on engine maintenance 1

General
II. Assembly identification

1. Identification of nameplate
Engine nameplate
Important information on the engine is shown on the engine nameplate. Necessary information on the
ordered parts and service is provided by Engine Serial number (ESN) and Control Parts List (CPL).
Without approval of Dongfeng Cummins Company, nobody is allowed to replace the engine nameplate.
Dongfeng Displacement Series Idle speed Model
Cummins L r/min
Engine No.
Engine Co. , Ltd
Note: if the oil supply/rotation Ignition order: Production date
speed/altitude stipulated for this Clearance of cold valve: intake ■
S. O. No. ①
engine is exceed, the damage exhaust ■
incurred is not within the warranty
Allowable altitude limit: ■ Rated power/rotation speed: kW r/min
scope.
Made by Dongfeng Cummins Engine Co. ,
Number of control performance part: ②
Ltd, Xiangfan, Hubei
Caution: The above information is subject to the product technical documents; if modified,
no further notice will be given.
Caution: Appearance and information arrangement of engine nameplate may be different.
The nameplate is on the top of gear chamber

It is necessary to provide the following data about
the engine when contacting DONGFENG
Cummins Special Maintenance Station.
•ٛ Engine Serial number (ESN)
•ٛ Control parts list (CPL)
•ٛ Model
•ٛ Rated power and speed
Caution: If it is hard to read the engine
nameplate, it is possible to find
out the engine running number
above the flywheel. Additional
engine information is shown on
the ECM plate.
Caution: The above information is subject to the product technical documents; if modified,
no further notice will be given.
2 Assembly identification
ISLe375 30 engine
Name of Dongfeng Cummins engine

The name of Dongfeng Cummins engine involves
the model and rated output of engine
Fuel injector nameplate

The fuel pump nameplate is located on the side
face of high-pressure pump. The nameplate
includes the following information
•ٛ P/N. of Cummins
•ٛ Production serial number of fuel pump
•ٛ Code of manufacturer
ECM plate
The electronic control module (ECM) plate is in the
front of ECM.
The following information can be obtained from
ECM nameplate:
•ٛ ECM part number (PN)
•ٛ ECM production No. (SN)
•ٛ ECM date code (DC)
•ٛ Engine Serial number (ESN)
•ٛ ECM code identification; the software within
the ECM
Air compressor nameplate

The plate for the air compressor in the brand of
Dongfeng Cummins (with the company’s mark) is
usually at the rear side of compressor.
The nameplate includes the helpful information for
repair or replacement
•ٛ P/N. of Cummins
•ٛ Production serial number
•ٛ Date code
Assembly identification 3
General
Turbocharger nameplate
Holset turbocharger plate is located on the intake
compressor housing body. The nameplate
includes the helpful information for repair or
replacement
•ٛ Part number of assembly of Cummins
•ٛ Production serial number
•ٛ Customer’s serial number
•ٛ Model
Engine view
The figure below has indicated key maintenance & service points, including the engine external parts,
filters and so on. The positions of some exterior components may vary with the engine model
Caution: This illustration shows a typical engine which is only for reference.
Engine front view
Front view of engine

1. Air intake union 8. Water pump
2. Fan pulley 9. The turbocharger intake
3. Front gear chamber cover 10. Trubocharger
4. Shock absorber 11. Engine front lifting eye
5. Outlet plug of engine oil sump
6. The front mounting bracket of engine
7. Belt tensioner
ISLe375 30 engine
Side view of engine air exhaust
Side view of engine air exhaust
1. Turbocharger compressor outlet connection 9. Oil pressure adjuster

2. Oil thermostat 10. Oil cleaner
3. Rocker casing 11. Ruler position
4. Coolant outlet union 12. Turbocharger oil return pipe
5. Coolant temperature sensor 13. Oil sump
6. Coolant inlet union 14. Flywheel housing
7. Oil cooler 15. Turbocharger oil supply pipe
8. Coolant drain faucet 16. Exhaust manifold
General
Side view of engine air intake
Side view of engine air intake
1. Air pressure sensor 13. Ruler position

2. Air intake heater 14. Fuel supply pump (behind electronic control module)
3. Fuel rail pressure sensor 15. Electronic control module
4. the temperature and pressure sensor of intake manifold 16. Air compressor
5. High fuel rail reduction valve 17. Air compressor oil pipeline
6. Fuel fuel rail 18. Gear chamber
7. Fuel return manifold 19. Camshaft rotational speed sensor
8. Fuel filter 20 Air compressor coolant return pipe
9. Crankcase breather oil return pipe 21 Coolant supply pipe for air compressor
10. Crankcase wheel speed sensor 22 Engine nameplate
11. Starter motor 23. Fuel pump
12. Oil pressure sensor
ISLe375 30 engine
1. Engine rear lifting eye 5. OEM feed pipe union

2. Injector return union 6. OEM fuel return pipe union
3. Turbocharger exhaust port 7. Crankcase breather tube
4. Flywheel
General
1. Turbocharger air outlet 6. Intake pipe union

2. Crankcase absorber 7. Fuel pump actuator
3. Rocker cover 8. Engine oil filler
4. Crankcase breather oil return pipe 9. Thermostat
5. Crankcase breather tube
ISLe375 30 engine
III. Technical parameters

1. Assembly technical parameter
Manufacturer Dongfeng Cummins Engine Co. , Ltd
Inline six cylinders, water cooled, surcharged intercooler,
Type
electric control diesel engine
Model ISLe375 30
Rated speed 2100(rpm)
Engine idling speed Minimum 600~maximum 800 rpm
Rated output 275kW
Maximum torque 1550N·m/1000~1400(/rpm)
Cylinder bore × stroke 114×145(mm×mm)
Displacement 8. 9L
Working sequence l-5-3-6-2-4
Fuel: use the diesel in compliance with Phase III emission requirements, and select appropriate
designation according to the temperature
Technical parameters 9
General
2. Repair and adjustment data of Cummins engine

Clearance of intake valve 0. 305mm
Clearance of exhaust valve 0. 559mm
Minimum oil pressure when the engine runs with

69kPa
an idle speed
Minimum oil pressure when the engine runs with

207kPa
rated speed
Opening pressure of engine lubricating oil control

352kPa
valve
Pressure difference of oil filter when the bypass

345kPa
valve is opening
Fuel temperature range at fuel pump inlet -30~80℃
Engine idling speed 600~800rpm
Minimum starting engine speed 150rpm
Oil temperature 120℃
Standard adjusting range ofrmostat (coolant) 83~95℃
Allowable maximum working temperature (cooling

100℃
fluid)
Recommended minimum working temperature

71℃
(coolant)
Maximum pressure of coolant 200kPa
Recommended minimum pressure of pressure

50kPa
cover
The maximum temperature of coolant in the top

100℃
radiator
Initial minimum temperature ofrmostat 81℃
Initial maximum temperature ofrmostat 83℃
10 Technical parameters
ISLe375 30 engine
IV. Special tool

The use of following special tools has been listed in corresponding procedures. Please contact
Dongfeng Cummins Market Service Department to purchase these tools
Special tool for engine
Tool No. Tool description Tool illustration
Engine lift
For disassembling and assembling engine.
3162871
Engine support adapter plate

For assembling the engine on heavy-type bracket.
3822607
Engine refitting bracket

Portable tilting engine refitting bracket
3375194 or
3375193
Camshaft gear remover & installer

For removing & refitting camshaft gear.
The gear without thread hole inside can only be
3163054 removed after partial removal of camshaft.
Camshaft gear remover & installer

For disassembling and assembling the camshaft
gear without disassembling of camshaft. Only used
3165093 for the engine whose camshaft has one screw hole.
Used with camshaft gear removing & refitting tools
(P/N. 3163054).
Bowl plug sealant

Mount pipe plug and bowl plug on engine to avoid
the occurrence of leakage.
3375068
Special tool 11
General
Cylinder liner puller

For removing the cylinder liner from the cylinder
block. The cylinder jacket puller plate, with the
3163745 part number of 3822786, is needed.
Cylinder liner puller (common)

For removing the cylinder liner from the cylinder
block. Two puller extra-long legs, with the part
3376015 number of 3376649, are needed.
Handle of expansion plug dismounting device

Use with the expansion plug handling device with
diameter greater than 9. 525mm [0. 75 in].
3164085
Expansion plug dismounting device

For assembling the 25. 4mm expansion plug to the
designated depth. Use with expansion plug
3376816 handling handle (P/N. 3164085).
Cylinder head squeezing tool

For inserting the cylinder liner into its hole on
cylinder block. Two cylinder head bolts which are
3822503 not covered in the hoop component are needed.
Piston ring expander

For assembling the piston ring on piston without any
damage or distortion of piston ring.
3823137
Piston ring compressor

For driving in the piston ring when the piston is
assembled in cylinder.
3164604
12 Special tool
ISLe375 30 engine
Piston ring compressor

For driving in the piston ring when the piston is
assembled in cylinder.
3823290
RTV sealing rubber

For sealing front gear chamber cover and other
joints.
3164067
Depth gauge assembly

For measuring the extrusion length of cylinder liner,
depth of cylinder block counter bore and
3164438 subsidence length and/or extrusion length of valve.
Prepare
Electronic digital indicator.
Camshaft bushing tool

For disassembling and assembling camshaft bush.
3165045

For assembling the 20. 638mm expansion plug to
the designated depth. Use with expansion plug

For assembling the 30. 16 mm expansion plug to
the designated depth. Use with expansion plug

For assembling the 4. 925mm expansion plug to the
designated depth. Use with expansion plug
Special tool 13
General
Main bearing screwing-out tool

For disassembling and assembling main bearing
(with crankshaft mounted on engine).
3823818
Length gauge of bolt

For measuring the free length of bolt.
3823921
Rear wearing bush fitting tools

For assembling the wear liner of crankshaft rear oil
seal.
3824078
Oil seal mounting tool

For mounting the crankshaft front oil seal on the
front cover oil seal bracket.
3824499
Front anti-wear bushing installation tool

For assembling the front wear liner.
3165112
Engine turning gear

For connecting the flywheel ring gear to rotate the
crankshaft.
3824591
Cylinder liner puller

For inserting the cylinder liner into cylinder block.
ST-1229
14 Special tool
ISLe375 30 engine
Inner diameter dial indicator assembly

For measuring the hole with inside diameter of 78. 5
mm~203. 2 mm.
3376619
Nylon lifting sling

Removal and refitting tools for the crankshaft
flywheel and other heavy-duty components having a
3375957 weight of no more than 970kg
Components of dowel puller

For taking the locating pin out of cylinder block.
The subassembly includes SAE and metric
3163720 specifications.
Crack inspection assembly

For checking the crack on component.
3375432
Linkage guide pin

For avoiding the damage of crankshaft when the
piston is mounted on the engine with linkage stud.
3824496
Manual grinding pad

For cleaning the corrosion or carbon deposit.
3823258
Assemble lubricant.
l0 ounce tubular lubricant
3163087
Special tool 15
General
Thread ring assembly

For repairing the cylinder block screw threads.
3822709
Micrometer magnetic base

For connecting with dial gauge (P/N. 3824564
(metric) or 4918289(SAE)).
3377399
Standard puller
For removing the driving belt pulley, impeller and air
compressor bob weight.
ST-647
Assembly guide pin

M12×1. 75
3163934
Assembly guide pin

M10×1. 25
3163935
Assembly guide pin

M8× 1. 0
3163936
Assembly guide pin

M10×1. 5
3376488
16 Special tool
ISLe375 30 engine
Assembly guide pin

M8×1. 25
3164977
Accurate straight ruler

For checking the flatness of cylinder block.
4918219
Valve spring compressor

For disassembling and assembling valve clamp.
3164329
Intake valve spring tester

For testing the spring and tension force.
3375182
Fuel injector hole brush

For cleaning the fuel injector of carbon deposit.
3822509
Length gauge of bolt

For measuring the free length of bolt.
3823921
Depth gauge assembly

For measuring the extrusion length of fuel injector
and subsidence length and/or extrusion length of
3164438 valve. Prepare the electronic digital indicator
Special tool 17
General
Engine turning gear

crankshaft.
3824591
Pliers set
For removing the valve stem oil seal. The dust
cover can be released by pulling and turning and
3163203 the serrated pliers can grasp the dust cover firmly.
Grinding pad
For cleaning the upper cylinder liner of carbon
deposit, rust, corrosion and scratch surface.
3823258
Magnetic flaw detector

For checking the cylinder head around fuel nozzle
and valve seat for crack. The subassembly
ST-1166 includes the powder jet nozzle (P/N. ST-1166-7) for
spraying metal powder (P/N. ST-1166-8).
Valve vacuum tester

Use with vacuum cup (P/N. ST-1257-6). Conduct
vacuum test on the cylinder head to check that the
3824277 valve is seated correctly.
Accurate straight ruler

For checking the flatness of cylinder head firing
level.
4918219
18 Special tool
ISLe375 30 engine
Testing and maintenance tools of engine
Multimeter
C3164488 For measuring the voltage (V), resistacne (ohm)
and current (A).
Digital optical speedometer

3377462
For measuring the rotary speed of engine (RPM).
Engine lift
3162871
For disassembling and assembling engine.
Blow-by testing tool

3822566
For checking the leaked gas of engine crankcase.
Oil filling adapter

For measuring the leaked gas from engine oil filler
3990099 port in rocker chamber cap. Note: not applicable for
oil fillers of all rocker chamber caps. Threaded type,
and the dimension may be different
Compuchek union
3377244 For connecting the diagnostic device. With l/8NPT
connector.
Compuchek union
3824842 For checking the resistance of fuel filter. Connector
with 10 mm O-ring.
Special tool 19
General
Drive system tractometer

3375710
For measuring the engine power.
Engine control
3163890 For starting and controlling the engine rotational
speed.
Wiring harness
4918592
Use with engine controller.
Fuel system special tools
Pressure/vacuum module
For measuring the fuel pressure and resistance.
3164491
Digital multimeter
For measuring the voltage (V), resistacne (ohm) and
current (A).
C3164488
Quick-drying (QD) cleaning agent

For cleaning component and tool safely.
3824510
20 Special tool
ISLe375 30 engine
Measuring cup
For measuring the returned fuel.
3823705
Fuel return hose (M12 injector and fuel pump)

This tool is connected to fuel loop through a special
union for measurement of return volume of injector
C3164618 and fuel pump.
Metering hole for delivery pump performance

test
This tool is connected to diagnosis joint of fuel filer
C3164621 inlet. This tool is for measuring the fuel quantity
through one metering hole of feed pump when the
engine does not operate. This tool includes a 0. 043
in. metering hole and a Compuchek coupler.
Compuchek quick coupling

inlet. It is used to measure the oil feeding
3376859 resistance when the oil transfer pump operates,
exclusive of metering orifice.
Fuel return hose (M14 fuel rail relief valve)

This tool uses a special hollow union, and is used
for connecting fuel circuit, so as to measure return
C3164617 flow rate of rail reducing valve.
Fuel pipe union remover

Disconnect high pressure fuel union from cylinder
head.
C3164025
Torque spanner (fuel injector terminal nut)

This is a torque wrench of 1. 47N·m for fastening
fuel injector solenoid valve end nut.
3823208
Special tool 21
General
Fuel pump drive gear fixer

Fix the fuel pump driving gear when disassembling
or assembling driving gear nut.
3164707
Jigger release tool

For removing the fuel pump gear.
3375326
Return oil volume test components

For checking the quantity of returned oil of fuel
injector and HPCR fuel pump. To 5/8″ and 3/8″
C4918354 pipe union
Return oil hose

Use with 5/16 inch positive joint with quick break
pipe union (including hose in maintenance)
4918433
Return oil hose

Use with 5/16 inch negative joint with quick break
4918434
Fuel pipe plug

For block the high-pressure fuel pipe.
C4918464
Compucheck union
For checking the fuel pressure/resistance. 10mm
O-ring joint
3824842
22 Special tool
ISLe375 30 engine
Fuel pressure gauge adapter toolkit

For checking the fuel pressure/resistance. For
5/16in union.
C4918462
Fuel pump gear pulley

For drawing out the fuel pump gear. Include bolts.
C3163381
Cushion block
Use with the fuel pump gear puller.
4918317
Fuel system leakage tester

It is used to disconnect the oil supply of fuel injector
when diagnosing the leakage or fault of fuel injector.
4918298 (used on fuel rail with 18mm thread)
Fuel return hose (M12)

This tool is connected to fuel circuit via a special
hollow pipe union to measure the amount of
4918679 returned fuel.
Return oil hose

Use with 3/8 inch positive joint with quick break pipe
union (including hose in maintenance)
4918697
Return oil hose

Use with 3/8 inch negative joint with quick break
4918698
Special tool 23
General

For checking the fuel pressure/resistance. For 3/8in
union.
4918696
Torque spanner- fuel injector terminal nut

This is a torque wrench of 13in-lb for fastening fuel
injector end nut.
3823208
Measuring cup
For measuring the returned fuel.
3823705
Fuel return hose (M14 fuel rail relief valve)

This tool uses a special joint for measurement of
return volume of fuel rail reducing valve.
C3164617
Fuel return hose (M12 injector and fuel pump)

This tool is connected to fuel loop through a special
union for measurement of return volume of injector
C3164618 and fuel pump.
Fuel injector hole brush

For cleaning the fuel nozzle.
3822510
Fuel injector puller

For drawing out the fuel injector.
C3823024
24 Special tool
ISLe375 30 engine
Fuel pipe union remover

For drawing out the fuel joint.
C3164025
Use with digital multimeter.
3164491
Digital multimeter
For measuring the voltage (V), resistacne (ohm) and
current (A).
C3164488
Quick-drying (QD) cleaning agent

For cleaning component and tool safely.
3824510
Metering hole for delivery pump performance

test
C316462l inlet. This tool is for measuring the fuel quantity
through one metering hole of feed pump when the
engine does not operate. This tool includes a 0. 043
in. metering hole and a Compuchek coupler.
Compuchek quick coupling

inlet. It is used to measure the oil feeding
3376859 resistance when the oil transfer pump operates,
exclusive of metering orifice.
Fuel system leakage tester

It is used to disconnect the oil supply of fuel injector
when diagnosing the leakage or fault of fuel injector.
4918298 (used on fuel rail with 18mm thread)
Special tool 25
General
Fuel return hose repair kit

For checking the quantity of returned oil of 12mm
hollow pipe union.
C4918295

For checking the fuel pressure/resistance at the
connecting position of 12mm hollow pipe union.
C4918324 (Instruments must be purchased separately).
Return oil volume test components

For checking the quantity of returned oil of fuel
injector and HPCR fuel pump. To 5/16 and 3/8
C4918354 pipe union
Return oil hose

Use with 5/16 positive joint with quick break pipe
4918433
Return oil hose

Use with 5/16 negative joint with quick break pipe
4918434
12mm banjo screw

The 12 mm banjo screw with 1/8NPT pipe plug is
used for checking fuel pressure/resistance.
C4918413

For checking the fuel pressure/resistance. For
5/16in union.
C4918462
26 Special tool
ISLe375 30 engine
Fuel pipe plug

For block the high-pressure fuel pipe.
C4918464
Compucheck union
For checking the fuel pressure/resistance. 10mm
O-ring joint
3824842
M12 fuel return hose

This tool is connected to fuel circuit via a special
hollow joint to measure the amount of returned fuel.
4918679
Return oil hose

Use with 3/8 positive joint with quick break pipe
4918697
Return oil hose

Use with 3/8 negative joint with quick break pipe
4918698

For checking the fuel pressure/resistance. For 3/8in
union.
4918696
Special tool 27
General
Special tools for the lubricating system
Use with multimeter.
3164491
Digital multimeter
For measuring the voltage (V), resistacne (ohm)
and current (A).
C3164488
Oil cooler test kit

For checking whether the engine oil cooler is
leakage.
3823876
Removal/refitting of oil dipstick

For disassembling and assembling engine oil
dipstick.
3823875
Oil filter wrench

For removing the oil filter.
3400158
Magnetic base
It can be used together with the metric dial indicator
or SAE dial indicator
3377399
Pipe cutter (filter)

For cutting the filter and checking the filter element.
3376579
28 Special tool
ISLe375 30 engine
Compucheck union
For measuring the fuel input resistance.
3824824
Black light lamp (12VDC)

The black light lamp with rechargeable battery and
charger and the fluorescent tracer are used
3163338 simultaneously to identify the position where the oil
and/or coolant leaks out. Oil tracer, coolant tracer
agent.
RTV sealing rubber

For many positions applicable to RTV sealant.
3164067
RTV sealing rubber

For sealing the rear gear chamber on cylinder block
(rear gear system), front gear cover on cylinder
3164070 block (rear gear system), oil pan seal gasket and
rear gear chamber on flywheel chamber (rear gear
system).
Dedicated tool for cooling system
Fuel leakage tester

For checking whether there is combustion gas in
cooling system.
3822985
Use with multimeter.
3164491
Special tool 29
General
Multimeter
and current (A).
C3164488
Dial gauge bracket with magnetic base

Use with dial indicator.
3377399
Crack inspection assembly

For checking the crack on engine component.
3375432
Refractometer
Fleetguard refractometer is used to check the
charge of traditional battery.
CC - 2800
Coolant overflow plate/pressure tester

Use the workshop air pressure to build vacuum on
the coolant overflow board to maintain a minimal or
3824319 zero coolant loss.

Use with fluorescent tracer to find out the leakage
point of cooling fluid and/or engine oil. The lamp
3163338 controls and closes the portable rechargeable
battery contained in the vehicle battery or
components. Oil tracer, coolant tracer agent.
30 Special tool
ISLe375 30 engine
Special tools for intake and exhaust systems
Digital multimeter
and current (A).
C3164488
Digital temperature gauge

For measuring the atmospheric temperature. Use
with digital multimeter.
3164499
Flange probe
Adopt the digital thermometer.
3164498
Turbocharger exhaust bypass valve pressure

setting tool kit
For regulating pressure of exhaust gas by-pass
3823799 valve in the process of fault diagnosis and
calibration.

Use with fluorescent tracer to find out the leakage
point of cooling fluid and/or engine oil. The lamp
3163338 controls and closes the portable rechargeable
battery contained in the vehicle battery or
components. Oil tracer, coolant tracer agent.
Pressure gauge
For measuring the pressure difference (0~2. 5kPa)
of pressure and resistance accurately.
ST-1111-3
Depth micrometer
For measuring the axial movement of turbocharger.
ST-537
Special tool 31
General
Dial gauge bracket with magnetic base

Used together with dial gauge.
3377399
Tester of air-air intercooler

For testing the pressure of intercooler.
3824556
RTV sealing rubber

For sealing rear gear chamber and cylinder block,
front gear chamber and cylinder block and intake
3164070 manifold and cylinder head fitting surface.
Pressure gauge
For measuring the exhaust resistance.
ST-1273
For measuring the pressure and degree of vacuum.
Use with digital multimeter.
3164491
Inner diameter dial indicator

For measuring the cylinder diameter.
3376619
Jigger
crankshaft.
C3824591
32 Special tool
ISLe375 30 engine
Other repair tools
Pipe plug sealant

Fit the pipe plug to reduce the possibility of leakage.
3375066
Bowl plug sealant

Fit the bowl plug to avoid the leakage possibility.
3375068
QD synthetic detergent
For cleaning the opening bowl-shaped plug.
3824510
Bowl plug drive (universal handle)

It must be used with the drive head to fit the bowl
plug to the correct depth; in addition, damages of
3164085 bowl plug and its immediate area shall be avoided.
Bowl plug drive (drive head, nominal size of 1in.)

Bowl plug drive (drive head, nominal size of

1-1/4in.)
3376817 plug to the correct depth; in addition, damages of
bowl plug and its immediate area shall be avoided.

11/16in.)
Special tool 33
General

2-1/4in.)
Bowl plug drive

34 Special tool
ISLe375 30 engine
V. Fault diagnosis
1. Procedures and tips for fault diagnosis & troubleshooting
Thorough analysis of customer’s compliant is the key for successive troubleshooting. The more
information from complaints, the more quick and easy settlement to the questions.
The fault symptom table is organized on the basis of first utilizing those easiest and most reasonable
behaviors to find out fault position for troubleshooting. Carry out all the procedures from top to bottom.
It is impossible to include the solutions for all the possible problems in the manual. However, these
designed figures can help to find fault cause and to rectify them.
Please follow basic failure diagnosis and elimination procedures listed below:
•ٛ Collect all information related to the failure.
•ٛ Thoroughly analyze the problems
•ٛ Create a relationship between symptom and basic engine system and component.
•ٛ Consider all the latest maintenance or repair measures related to the fault
•ٛ Recheck before any component part is disassembled.
•ٛ To solve the problem according to the symptom table, set out from the simplest problems.
•ٛ Determine causes to failures and provide thorough repairs.
•ٛ After the repair is completed, operate the engine to ensure the problem has been eliminated.
2. Summary of fault diagnosis & troubleshooting

Procedures of engine noise diagnosis
Note: in case of engine noise diagnosis, make sure not consider the noise from attachments (e. g. , air
compressor, power take-off) as engine noise. Remove driving belt for the accessories to avoid noise
caused by them. The noise will spread onto those components which are not involved with fault.
Therefore, the use of stethoscope will help identify the position where the engine noise appears.
The engine noise generated when crankshaft and engine operate at full speed relates to such
components as crankshaft, linkage, piston, piston pin, etc. The noise generated when the camshaft
operates at full speed and engine operates at half speed relates to valve mechanism. The hand-held
digital speedometer can help to determine whether the noise is related with members which work at the
crankshaft or camshaft speed.
Sometimes, the oil-break test of cylinder can separate the engine noise. If the noise is lessened or
disappears, such noise is correlated with a certain cylinder.
Determine the source of noise, but no fixed rules or testing methods are available.
The engine-driven components and accessories such as gear-driven fan clutch, hydraulic pump,
belt-driven charger, air conditioning compressor and turbocharger may cause engine noise. The
following information can be used to guide the diagnosis on engine noise.
Noise of main bearing
(Too high engine noise – main bearing symptom tree)
The noise is caused by toneless slap generated by loose main bearing when the engine is loaded. If all
main bearings work loose, loud and brief knocks will be heard. This slap will be regularly caused once
every two turns. This noise becomes the most vibrant when the engine runs with increased load and
reduced speed or with heavy load. This slap will be more toneless than the noise generated by linkage.
Low oil pressure may also occur together with this situation.
Although the bearing is not so loose to produce knocking, it can produce the knocking if the oil is too thin
or there is no oil on the bearing
The irregular noise may indicate that the crankshaft thrust bearing is worn.
Fault diagnosis 35
General
The intermittent sharp knocking indicates that the axial clearance of crankshaft is too big. The
repeated release operation of clutch may change the noise.
Noise of linkage bearing
(Refer to “too high engine noise – linkage symptom tree”)
If the clearance of linkage is too big, the knocking sound may be produced when the engine is running at
any speed or under load. When the bearing becomes loose, the noise generated may be confused with
the slap of piston or the noise of loosened piston pin. The volume of noise will increase with increasing of
engine speed. Low oil pressure may also occur together with this situation.
Piston noise
(Too high engine noise – piston symptom tree)
It is different to distinguish piston pin, linkage and piston noises. If the piston pin works loose, double
loud knocks can be often heard in the idle operation of engine. When the fuel supply of this cylinder is
shut off, obvious change of knocking sound appears. However, in certain engines, when the vehicle runs
at a constant speed, such knocks will become more noticeable.
Driving performance
Usually the driving performance is a term used to describe the behavior of vehicle on the road. The
operating performance problem of engine may be caused by several different factors. Some factors are
related to the engine.
Before the fault is eliminated, it is very important to make clear whether the problems related to the
driving performance as complained are true or just caused due to the failure to satisfy drivers’
expectations.
Customer’s opinion form about driving performance/low power contains a series of valuable problems,
and must be used to help the repair technicians to judge the driving performance problem of vehicle
Fault diagnosis table aims at identifying the driving peformance into two symptoms, namely low engine
output, poor engine acceleration or response.
Low output is a term describing some different performances. But in this manual, low output means that
the engine, under given load, slope and wind speed, cannot generate enough power to make the vehicle
travel at required speed. Low output is usually caused by insufficient fuel flow due to any one of following
factors:
•ٛ The full stroke of accelerator pedal is inadequate.
•ٛ The boost pressure sensor is in failure.
•ٛ The resistance of fuel inlet, inlet pipe, drain pipe or return pipe is too high.
•ٛ Looseness of fuel pump suction pipe
Low output does not mean that the vehicle is incapable of speeding up satisfactorily from parking or the
base of slope. Refer to the symptom tree for “Low engine output” for the correct procedure to
troubleshoot the fault of low output. This figure starts from the basic item which may cause low power.
The poor acceleration performance or the lagged response described in the manual means that the
vehicle cannot reach the satisfied acceleration effect when starting from the stationary state or when
staring to climbing. The acceleration lag will be caused when trying to exceed other vehicles at the
speed and load less than rated value. The poor acceleration or response is hard to eliminate because
such fault may be caused by the following reasons:
•ٛ Factors related to engine or pump
•ٛ Driver’s skills
•ٛ Incorrect gear shift
•ٛ The engine model is inapplicable
•ٛ The clutch or its pull rod is worn
36 Fault diagnosis
ISLe375 30 engine
The acceleration or bad respond related to the engine may be caused by following different factors, for
example:
•ٛ The boost pressure sensor is in failure.
•ٛ Return pipe blocking is too serious
•ٛ Dead zone of throttle
Refer to “Poor engine acceleration or response” symptom tre to understand correct procedures and find
the troubleshooting method. For additional information, refer to Diagnosis about Steering Ability Faults.
Fuel consumption
It is difficult to diagnose and correct the causes of fuel consumption for many potential factors. The
real-life fuel consumption problems may be caused by following factors:
•ٛ Engine elements
•ٛ Vehicle factors & technical specifications
•ٛ Environmental factors
•ٛ Driver's skills and operation methods
•ٛ Factors of fuel system
•ٛ Low power/poor drivability
Position the trouble correctly before fault diagnosis. Is the problem really present, or felt, or just caused
due to the failure to satisfy the driver’s expectation?
Following factors must be taken into account in the fuel consumption diagnosis.
1). Results due to low power or poor drivability: the driver can change driving style to compensate for
low power or poor drivability. The measures may be taken by the driver include (a) increasing the
engine speed, or (b) operating under the speed regulating curve upon low gear not operating by
upshifting with partial accelerator. The change of driving style will increase the fuel consumption.
2). Driver’s skills and operation methods：As a general rule, the increase of 1-mph of vehicle speed
means the increase of 0. 1mpg of fuel consumption. For example, after the road vehicle speed
increases from 50mph to 60mph, the unit fuel consumption of lmpg will be consumed
3). Change of environment and seasonal weather: In principle, the difference of running mileage per
gallon fuel oil is 1~1. 5 mile dependent upon the season and climate.
4). Too long idling period: Depending on the specific idle speed, fuel of 0. 5-1. 5gal can be consumed
every hour when the engine runs with an idle speed.
5). Running line and landform of truck: the westward and eastward lines are almost not affected by the
lateral wind or face wind However, the fuel consumption in the south-north traveling route is very
low, as the weather is warm and the wind resistance is low in some areas.
6). Vehicle pneumatic auxiliary units: The maximum power demand of truck is from the power used to
overcome the air resistance. Usually, at every reduction of 10% of air resistance, the running
distance per gallon of fuel will be increased by 5%.
7). Rolling resistance: is the secondary power consumption. The type and tread design of tyre have
great influence on the fuel economy and performance Replace the diagonal-ply tyre with radial
tyre, and in this way, the rolling resistance can be reduced by 36% or so
8). Use the additional equipment of same fuel source: The same fuel tank as the vehicle can be used
for the additional equipment. For example, the excessive use of generator or refrigerator may be
represented by high fuel consumption wrongly
Other vehicle factors, technical specifications and axle location may affect the fuel consumption
Fault diagnosis 37
General
Guideline for Fault Diagnosis for Loss of Coolant

Before troubleshooting, it is very important to find out the leakage position of cooling fluid. The leakage
of coolant is always unobvious
Before troubleshooting, it is very important to talk with driver, examine maintenance history and ECM
information to find out the true problem.
Problems to be discussed with the driver face by face
•ٛ Name of driver:
•ٛ Engine Serial number (ESN):
•ٛ What’s your problem?
•ٛ How has been the engine used?
•ٛ Which type does the load factor belong to?
•ٛ Vehicle drive pattern?
1. Coolant adding frequency
2. How to fill the radiator?
3. Whether it is required to fill it to the high or low scale when the engine is cold (the
temperature is lower than 60℃)?
4. Types of coolant to be added
5. Is there any coolant on the ground under the truck?
6. Whether there is visible green or white striation on engine or about cooling fluid overflow
hose.
7. Check for any specific condition such as special weather, altitude or load under which there
is loss of coolant.
8. Is the engine overheated?
9. Does the alarm lamp flash?
10. What condition?
11. What’s the temperature of coolant usually?
12. Does the cooling fan work normally?
13. Under working temperature, do you see any white smoke or are you informed of white smoke
from exhaust pipe?
14. Whether each engine oil analysis is executed as an integral part of maintenance and
service?
15. Are the contents of sodium and potassium too high?
16. Whether any condensation of wet gas is found on the dipstick or engine oil filler cover or any
wet gas is found in the blowby?
17. The milk white in tube shows the leakage of cooling fluid.
18. Whether there are other notes to provide help in repairing Cummins?
Review of historic repairs
To repair the cylinder head or cylinder head sealing gasket repeatedly show the problem is not caused
on the cylinder head or cylinder head sealing gasket. The repeated problems show the engine has more
problems. The information shall be remembered during fault diagnosis
See the warranty claim history of engine:
•ٛ Who repairs the engine for the last time and what he does?
38 Fault diagnosis
ISLe375 30 engine
•ٛ What is the mileage of this engine?

•ٛ Whether the cylinder head and cylinder head gasket are renewed before?
•ٛ Its maintenance mileage?
•ٛ Do you know where has the coolant flown so far?
If unknown or the coolant loss is not serious, it is recommended to fit a liquid reservoir on the radiator
overflow pipe, used to collect any liquid lost in purging or in operation: Send out the vehicle to collect
more data about the place where the coolant does not reach. If there is a little of coolant in the liquid
reservoir, make reference to the external loss of coolant (overflow) as discussed above.
Fault diagnosis 39
General
3. Fault diagnostic symptom diagram

Caution: Read over the information in every box. Follow the instructions in table to find out
the correct maintenance measure.
Warning: There is risk of equipment damage and human injury through fault diagnosis. The fault
diagnosis and the troubleshooting must be carried out by well-trained technicians.
The air pressure of air compressor increases slowly
The air pressure of air compressor increases slowly
Cause Measure
Renew the air compressor air cleaner (if
Step-1 equipped). Check the intake pipelineIf the
The resistance between intake system …………… compressor inlet has been connected onto
and air compressor is too high the vehicle or equipment intake system,
check the engine intake resistance.
Accepted
Next step
Chock the wheels and check the air system
for any leakage when the spring safety brake
is applied or released. Check whether the air
compressor gasket and the hose, hose union,
Step 2
…………… air reservoir and valve of air system have any
Air system leakage
leakageRefer to “OEM service manual”. For
the engine with selective catalytic reduction
(SCR) exhaust system, check the feed pipe
of dosage control unit.
Accepted
Turn to next step.
Check whether the air regulator works
Step 3
normallyEnsure that the air conditioner keeps
The air pressure regulator is in trouble or ……………
a distance of at least 0. 6M from the
its setting is wrong
compressor.
Accepted
Turn to next step.
Step 4
Check whether there is carbon deposit. If
The carbon deposits in the exhaust pipe,
…………… necessary, replace the air compressor outlet
air valve downstream or compressor
pipe and cylinder head assembly.
cylinder are too many
Accepted
Turn to next step.
Check the performance of check valve,
Step 5 ethanol evaporator, air dryer and air system
……………
The air system component is in trouble components installed by OEM. Refer to the
instructions of manufacturer.
Accepted
Turn to next step.
Step 6 Check the unloading valve and the valve
……………
The unloading valve fails. sealing member
Accepted
Turn to next step.
Check the air compressor cylinder head
Step 7
assembly and replace it, if necessaryIf the
The intake or exhaust valve system of air ……………
compressor cylinder head can’t be repaired,
compressor leaks air
replace the compressor.
40 Fault diagnosis
ISLe375 30 engine
The air compressor is turned on and off frequently

The air compressor is turned on and off frequently
Cause Measure
Step-1
Air system leakage
Accepted
Next step
Step 2
compressor.
Accepted
Next step
Step 3 ethanol evaporator, air dryer and air system
……………
The air system component is in trouble components installed by OEM. Refer to the
instructions of manufacturer.
Accepted
Next step
Step 4
Fit Econ valve, check valve and system hose.
E-type system is not correctly installed ……………
Refer to “OEM service manual”.
vertically
Accepted
Next step
Step 5
assembly and replace it, if necessaryIf the
Accepted
Next step
Renew the desiccant box on the
Turbo/CR2000 air dryer. Refer to “OEM
Step 6
service manual”. Check the work recycle ratio
The air compressor spends a lot of time on ……………
of air compressor. In necessary, a bigger air
gas supply
compressor can be adopted. Refer to “OEM
service manual”.
Accepted
Next step
Step 7 Lubricate or replace the air dryer outlet check
The check valve at the air dryer outlet is …………… valve assembly. Refer to the instructions of
blocked manufacturer.
Fault diagnosis 41
General
The noise of air compressor is too loud

The noise of air compressor is too loud
Cause Measure
Step-1
air valve downstream or compressor
pipe and cylinder head assembly.
cylinder are too many
Accepted
Next step
Check if there is ice at the low points in
Step 2 exhaust pipe, dryer inlet and elbow joint for all
Ice accumulates in the components of air …………… models. For each model of HOLSET®, the
system ECON valve, if any, shall be checked. Refer
to “OEM instructions”.
Accepted
Next step
Step 3
Check the mounting hardware of air
The mounting hardware of air compressor ……………
compressor
gets loose, is worn or broken
Accepted
Next step
Step 4
Mount an impulse pot between air dryer and
The air compressor sends the pulse air ……………
moisture. Refer to “OEM instructions”.
into the air reservoir
Accepted
Next step
Step 5
Spline drive coupler or gear is worn …………… Check whether the coupling is worn
excessively
Accepted
Next step
Check the drive gear and gear train, and
Step 6 repair them, if necessaryRemove air
The air compressor drive gear to engine …………… compressor and check its drive gear. If
gear train is worn or damaged necessary, repair it. If damaged, remove the
flywheel housing and check the gear system.
Accepted
Next step
Renew or overhaul the air compressor.
Step 7
Renew the dryer core on the
The air compressor is worn excessively or ……………
TURBO/CR2000 air dryer (if fitted). Refer to
its interior is damaged
the instructions of manufacturer.
42 Fault diagnosis
ISLe375 30 engine
The air compressor sends too much of oil into the air system
The air compressor sends too much of oil into the air system
Cause Measure
Verify whether oil change interval is correct.
Step-1
…………… Refer to “Operation and maintenance manual”
Too long oil change interval
relevant to the engine being repaired.
Accepted
Next step
Step 2 Refer to the symptom tree for “Contaminated
……………
Oil is strained by coolant or fuel oil”.
Accepted
Next step
Renew the air compressor air cleaner. Check
Step 3 the intake pipelineIf the compressor inlet has
The resistance between intake system …………… been connected onto the vehicle equipment
and air compressor is too high intake system, check the engine intake
resistance.
Accepted
Next step
Empty the air reservoir every dayRefer to “OEM
service manual”. For the engine with selective
Step 4
…………… catalytic reduction (SCR) exhaust system, check
There is deposited dirt in the air reservoir.
if the intake filter on the feed and exhaust pipes
of dosage control unit is polluted.
Accepted
Next step
Step 5
Fit Econ valve, check valve and system hose.
E-type system is not correctly installed ……………
vertically
Accepted
Next step
Renew the desiccant box on the
Turbo/CR2000 air dryer. Refer to “OEM
Step 6
service manual”. Check the work recycle ratio
The air compressor spends a lot of time on ……………
of air compressor, and replace it with a bigger
gas supply
one, if necessaryRefer to “OEM service
manual”.
Accepted
Next step
Step 7
check valve or compressor cylinder are
pipe.
too many
Accepted
Next step
Step 8
The curvature of characteristic curve Refer to “Data table of engine technical
……………
during engine operation exceeds the value specification”.
in the technical specification
Accepted
Next step
Check whether the gas blowby is too
Step 9
…………… muchRefer to the symptom tree for “Too
Overhigh crankcase pressure
much gas in crankcase (blowby)”.
Accepted
(cont’d)
Fault diagnosis 43
General
(cont’d)
Cause Measure
Step 10 Check the oil pressureRefer to the symptom
……………
Oil pressure exceeds symptom range tree for “High oil pressure”.
Accepted
Next step
If the coolant temperature is higher than the
Step 11 normal value, refer to “Coolant overhigh
……………
The air compressor is overheating temperature---gradual overheat symptom
tree”.
Accepted
Next step
Remove air compressor and check the oil
Step 12
…………… return holes in the air compressor and the
Oil return pipe blocking
drive device for the accessories.
Accepted
Next step
Check the drive gear and gear train, and
Step 13
repair them, if necessaryIf damaged, remove
The air compressor drive gear to engine ……………
the flywheel housing and check the gear
gear train is worn or damaged
housing.
Accepted
Next step
Step 14
The gas supply of air compressor is too ……………
normally
high
Accepted
Next step
Step 15
The air compressor is worn excessively or …………… Renew or overhaul the air compressor.
44 Fault diagnosis
ISLe375 30 engine
The air compressor fails to keep the sufficient air pressure (pump the air
continuously)
The air compressor fails to keep the sufficient air pressure (pump the air continuously)
Cause Measure
Step-1
Air system leakage
Accepted
Next step
Step 2
normally
Accepted
Next step
Check the intake and exhaust valve
Step 3
assemblies of air compressor. If necessary,
The intake or exhaust valve of air ……………
replace it. If the compressor cylinder head
can’t be repaired, replace the compressor.
Fault diagnosis 45
General
The air compressor fails to supply the air

The air compressor fails to supply the air
Cause Measure
Step 1
normally and ensure whether the difference
between the air pressure regulator and the air
compressor is less than 0. 6m
Accepted
Next step
Check the unloading valve and the valve
Step 2
…………… sealing memberRefer to “OEM service
The unloading valve fails.
manual”
Accepted
Next step
Check the intake and exhaust valve
Step 3
assemblies of air compressor. If the
The intake or exhaust valve of air ……………
Accepted
Next step
Step 4
The air compressor is worn excessively or …………… Renew or overhaul the air compressor
46 Fault diagnosis
ISLe375 30 engine
The air compressor fails to stop gas supply

The air compressor fails to stop gas supply
Cause Measure
Step 1
Air system leakage
Accepted
Next step
Step 2
compressor.
Accepted
Next step
Check the unloading valve and the valve
Step 3
…………… sealing memberRefer to “OEM service
The unloading valve fails.
manual”
Accepted
Next step
Step 4
Check the signal tube and actuator tubeRefer
The signal pipe or actuation pipe of air ……………
to the instructions of manufacturer.
pressure regulator is blocked
Accepted
Next step
Step 5 ethanol evaporator, air dryer and other air
……………
The air system component is in trouble system components installed by OEM. Refer
to the instructions of manufacturer.
Accepted
Next step
Step 6
assembly and replace it, if necessaryIf it is
not allowed to repair the compressor seat,
Fault diagnosis 47
General
Uncharged or insufficiently charged generator

Uncharged or insufficiently charged generator
Cause Measure
Step-1
…………… Check the vehicle instrument
Vehicle instrument is faulty
Accepted
Next step
Remove the throttle to increase the engine
speed to 1200rpm to charge the generator;
Step 2
for details, refer to Operation and
The engine speed is too low and charging ……………
Maintenance Manual for the engine
fails
concerned, to check whether the engine can
work at both idle and normal speed correctly.
Accepted
Next step
Step 3
…………… Check the tension of generator belt.
The charger belt is loosened
Accepted
Next step
Step 4
Check the fuse, conducting wire and
Open-circuit (fuse blow, disconnected
…………… connectorSee “OEM service manual” and the
cable or loose connector) of electrical
manufacturer's electric wiring diagram.
system
Accepted
Next step
Step 5
The battery cable flexible union is
…………… Check the battery cable and connection
loosened, disconnected or corroded (due
to high resistance).
Accepted
Next step
Step 6 Check the state of battery. If necessary,
……………
Battery failure replace the battery.
Accepted
Next step
Step 7 Tighten the belt pulleyRefer to the
……………
Charger pulley is loosened on the shaft instructions of charger manufacturer or OEM
Accepted
Next step
Step 8
Place the battery far away from the heat
The battery capacity is higher than the ……………
sourceRefer to “OEM service manual”.
required level.
Accepted
Next step
Step 9 Test the charger output. If necessary, replace
……………
Charger or voltage adjuster is faulty the charger or voltage regulator.
Accepted
Next step
(cont’d)
48 Fault diagnosis
ISLe375 30 engine
(cont’d)
Step 10
Charger is overloaded or charger capacity …………… Fit one set charger with large capacity
is lower than the specified value
Accepted
Next step
Step 11 Read the fault code with application software.
The current electronic failure code is Refer to “Fault diagnosis and troubleshooting
……………
activated or the non-current failure code is manual for the electronic control system”
recorded at a high frequency. relevant to the engine being repaired.
Fault diagnosis 49
General
Overcharged generator
Overcharged generator
Cause Measure
Step-1
Accepted
Next step
Check the state of battery. If necessary,
Step 2
…………… replace the battery. Refer to “OEM service
Battery single cell damages (open circuit)
manual”.
Accepted
Next step
Check the voltage regulator. If necessary,
Step 3
…………… replace the regulator. Refer to “OEM service
Fault of voltage regulator
manual”.
Accepted
Next step
Step 4 Read the fault code with application software.
The current electronic failure code is Refer to “Fault diagnosis and troubleshooting
……………
activated or the non-current failure code is manual for the electronic control system”
recorded at a high frequency. relevant to the engine being repaired
50 Fault diagnosis
ISLe375 30 engine
Loss of coolant- exterior

Loss of coolant- exterior
Cause Measure
Step-1
The coolant level is higher than the …………… Check the coolant level
specification
Accepted
Next step
Check the hose, water drain pipe, water
manifold, jumper pipe, expansion plug, pipe
plug, union, radiator core, air compressor and
Step 2 cylinder head gasket, oil cooler, water pump
……………
External coolant leakage seal, cylinder block and components
mounted by OEM (where the coolant passes)
for coolant leakage. If necessary, provide a
pressure test on the cooling system.
Accepted
Next step
Step 3
The radiator cover model is incorrect or …………… Check the radiator pressure cover
fails, or the low-pressure product is used.
Accepted
Next step
Step 4
The cooling system is broken, blocked or …………… Check the radiator hose
has leakage
Accepted
Next step
Step 5
Check whether the exhaust pipe and filling
The filling pipe and exhaust pipe are ……………
pipe are correct or blocked
blocked, or the management is wrong
Accepted
Next step
Step 6
Check the pipeline and confirm that the
Incorrrect OEM pipe distribution will cause
…………… high-pressure coolant cannot backflow in the
the loss of coolant due to the radiator
filling pipeRefer to “OEM service manual”.
overflow.
Accepted
Next step
Refer to the symptom tree for “Coolant level
higher than normal value - gradual
Step 7
…………… overheating” or the symptom tree for “Coolant
Engine overheating
temperature higher than normal value -
sudden overheating”.
Accepted
Next step
Step 8
Check whether there is any air or mixed gas
The air or mixture combustion gas enters ……………
left by combustion in the cooling system
the cooling system
Fault diagnosis 51
General
Loss of coolant- interior

Loss of coolant- interior
Cause Measure
Step-1 Check whether the oil cooler leaks the
……………
Oil cooler leakage coolant
Accepted
Next step
Step 2
There is crack or sand hole on the air Check the air compressor cylinder and
……………
compressor cylinder head or the gasket gasket
leaks
Accepted
Next step
Conduct pressure test on the cooling system,
Step 3
…………… and find out the internal leakage source of
Internal coolant leakage
coolant.
Accepted
Next step
Step 4
…………… Check the cylinder head gasket
The cylinder head gasket is leaky
Accepted
Next step
Step 5
…………… Carry out the cylinder head pressure test
The cylinder head is cracked or broken
Accepted
Next step
Step 6
…………… Check the cylinder block
The cylinder block is cracked or broken
52 Fault diagnosis
ISLe375 30 engine
The coolant temperature is lower than the normal value- gradual overheating
The coolant temperature is lower than the normal value- gradual overheating
Cause Measure
Use the INSITE™ to check and diagnose the
Step-1
failure code. Refer to “Fault diagnosis and
The current electronic failure code is
…………… troubleshooting manual for the electronic
activated or the non-current failure code is
control system” relevant to the engine being
recorded at a high frequency.
repaired.
Accepted
Next step
Step 2 Uncover the radiator cover or cold-proof front
Radiator shield or antifreeze front shield …………… cover used in cold weather. Refer to “OEM
has closed under cold climate instructions”.
Accepted
Next step
Step 3
Check the radiator shutter. If necessary,
The radiator shutter can’t be fully opened
…………… repair or replace it. Check the set opening of
or the shutter openness is not correctly
shutterRefer to “OEM service manual”.
designed.
Accepted
Next step
Step 4
Air-air intercooler fin, radiator fin or A/C Check the air-air intercooler, A/C condenser
……………
condenser fin is damaged or blocked by and radiator fin and clean them if necessary
scrapings
Accepted
Next step
Check the coolant level; check whether there
Step 5
is any exterior leakageTake an oil sample and
The coolant level is lower then the ……………
send it to the laboratory to check for any
specification
coolant (internal leakage)
Accepted
Next step
Verify density of antifreeze fluid in coolant. Fill
Step 6
anti-freezing liquid or water to obtain a correct
The mixing proportion of antifreeze fluid ……………
concentration. Refer to the Cummins coolant
and water in the coolant is incorrect
requirements and maintenance.
Accepted
Next step
Step 7
Check the shield and deflector. If necessary,
The fan shroud or the air deflector is ……………
repair, replace or refit it.
damaged or lost
Accepted
Next step
Step 8 Check the fan drive belt. If necessary, replace
……………
The fan drive belt is fractured or loose the belt.
Accepted
Next step
Step 9
…………… Check the drive and control devices of fan
The fan drive or control device is faulty
Accepted
Next step
(cont’d)
Fault diagnosis 53
General
(cont’d)
Cause Measure
Test the thermometer or the sensor. If
necessary, repair or replace it. Refer to “OEM
service manual” for the instructions about the
Step 10
instrument fault diagnosis. Refer to “Fault
Fault of coolant temperature gauge or ……………
diagnosis and troubleshooting manual for the
sensor
electronic control system” relevant to the engine
being repaired to inspect and test the coolant
temperature sensor.
Accepted
Next step
Step 11
Accepted
Next step
Step 12
Check whether the thermostat has correct
The thermostat model is wrong or in ……………
part number or works normally
trouble
Accepted
Next step
Step 13
has leakage
Accepted
Next step
Step 14 Check whether the exhaust pipe and filling
The filling pipe and exhaust pipe are …………… pipe are correct or blockedRefer to “OEM
blocked, or the management is wrong service manual”.
Accepted
Next step
Step 15 Refer to the symptom tree for “Air
The air temperature of intake manifold is …………… temperature of intake manifold higher than
higher than the specification the value in the technical specification”.
Accepted
Next step
Step 16
Check the oil level. If necessary, fill or
Oil level is lower or higher than technical
Draining engine oil.
specification
Accepted
Next step
Step 17
The cooling system is polluted by dirt, Wash the cooling system.
water fur or oil sludge
Accepted
Next step
Oil is strained by coolant or fuel oil”
Accepted
Next step
Step 19 Refer to the symptom tree for “Coolant mixed
The coolant is polluted by oil with oil or transmission oil”.
Accepted
Next step
(cont’d)
54 Fault diagnosis
ISLe375 30 engine
(cont’d)
Cause Measure
Check whether the water pump works
Step 20
normally. If necessary, replace the water
Water pump failure
pump.
Accepted
Next step
Step 21
Check the radiator fin. If necessary, clean
The radiator cooling fin is damaged or
and repair the cooling fin.
clogged by scraps.
Accepted
Next step
Step 22
Check the torque converter
The torque converter is faulty
Accepted
Next step
Step 23
The cooler for the torque converter or
Remove and check cooler element & O-ring.
something in the cooling area of
hydraulic oil is faulty
Accepted
Next step
Step 24
Verify that engine and vehicle cooling
Vehicle cooling system cannot meet the
systems use correct components
requirements.
Accepted
Next step
Step 25
Check whether there is any air or mixed gas
The air or mixture combustion gas enters
left by combustion in the cooling system
the cooling system
Fault diagnosis 55
General
The coolant temperature is lower than the normal value – sudden overheating
The coolant temperature is lower than the normal value – sudden overheating
Cause Measure
Step-1 Use the INSITE™ to check and diagnose the
The current electronic failure code is failure code. Refer to “Fault diagnosis and
……………
activated or the non-current failure code is troubleshooting manual for the electronic control
recorded at a high frequency. system” relevant to the engine being repaired.
Accepted
Next step
Check the coolant level, and check whether
Step 2 there is the symptom tree of exterior leakage
The coolant level is lower then the …………… of coolantTake an oil sample and send it to
specification the laboratory to check for any coolant
(internal leakage)
Accepted
Next step
Step 3 Check the fan drive belt and replace the belt,
……………
The fan drive belt is fractured or loose if necessary
Accepted
Next step
Step 4
Uncover the radiator cover or cold-proof front
Include a 1. 09mm diagnosis fuel pipe ……………
mask used in cold weather
passing through metering
Accepted
Next step
Step 5
The radiator shutter can’t be fully opened Uncover the radiator cover or cold-proof front
……………
or the shutter openness is not correctly cover used in cold weather.
designed.
Accepted
Next step
Step 6
Air-air intercooler fin, radiator fin or A/C Check the cooling fins of air-air intercooler
……………
condenser fin is damaged or blocked by and radiator. If necessary, clean it.
scrapings
Accepted
Next step
Step 7 Check whether the thermostat has correct
……………
The thermostat model is wrong or in trouble part number or works normally
Step 8 Test the thermometer. If necessary, replace or

……………
Fault of coolant temperature gauge repair the temperature gauge.
Accepted
Next step
Step 9
diagnosis and repair manual for the electronic
sensor
repaired to inspect and test the coolant
temperature sensor.
Accepted
Next step
(cont’d)
56 Fault diagnosis
ISLe375 30 engine
(cont’d)
Cause Measure
Diagnose and eliminate the fault of seawater
Step 10 entering in system. Refer to the symptom tree
……………
Seawater cooling system fault for “Coolant temperature higher than normal
value – sea water cooling system”.
Accepted
Next step
Step 11
has leakage
Accepted
Next step
Step 12
Check whether the exhaust pipe and filling
The filling pipe and exhaust pipe are ……………
pipe are correct or blocked
blocked,or the management is wrong
Accepted
Next step
Check whether the water pump works
Step 13
…………… normally. If necessary, replace the water
Water pump failure
pump.
Accepted
Next step
Step 14
Accepted
Next step
Step 15
…………… Check the drive and control devices of fan
Accepted
Next step
Step 16 Carry out the diagnosis test on the cooling
……………
Component fault of cooling system system
Accepted
Next step
Step 17
The cooler for the torque converter or
…………… Remove and check cooler element & O-ring.
something in the cooling area of hydraulic
oil is faulty
Fault diagnosis 57
General
The coolant temperature is lower than the normal value

The coolant temperature is lower than the normal value
Cause Measure
Check the air under the cold-proof front
Step-1
cover, shutter and engine hoodAir intake
The engine runs under very low ambient ……………
under engine cover is adopted in cold
temperature
climate. Refer to “OEM service manual”.
Accepted
Next step
Step 2 Use the INSITE™ to check and diagnose the
……………
Accepted
Next step
Step 3 Test the thermometer or the sensor. If
……………
Fault of coolant temperature gauge or sensor necessary, provide repairs or replacement.
Accepted
Next step
Step 4
diagnosis and troubleshooting manual for the
sensor
electronic control system” relevant to the
engine being repaired to inspect and test the
coolant temperature sensor.
Accepted
Next step
Close the valve leading to the heater core.
Step 5
Operate the engine. If the engine
Too much coolant flows through OEM ……………
temperature is normal, refer to OEM repair
pipeline and heater element
manual.
Accepted
Next step
Step 6
Check whether the thermostat has correct
The thermostat model is wrong or in ……………
part number or works normally
trouble
Accepted
Next step
Check the drive and control devices of fan if
Step 7
…………… the electrical control is realized by the engine
ECMIf the OEM control is available,
Accepted
Next step
Long time idling may cause too low oil & coolant
temperature (more than 10 min.), and switching off
Step 8 the engine rather than idling for long time. If the
……………
Engine idles for too long period of time long-time operation is required, increase the idle
speed. If the electric control is realized via the engine
ECM, refer to OEM’s manual.
Step 9
…………… Carry out the diagnosis test on the cooling system
Component fault of cooling system
58 Fault diagnosis
ISLe375 30 engine
Some oil enters the coolant

Some oil enters the coolant
Cause Measure
Step-1
…………… Check the oil cooler
Oil cooler fault
Accepted
Next step
Step 2
Check the cylinder head and gasket of air
There is crack or sand hole on the air
…………… compressor. If the compressor cylinder head
compressor cylinder head or the gasket
can’t be repaired, replace the compressor.
leaks
Accepted
Next step
Conduct pressure test on the cooling system,
Step 3
…………… and find out the internal leakage source of
Internal coolant leakage
coolant.
Accepted
Next step
Step 4
Accepted
Next step
Step 5 Carry out the cylinder head pressure test,
……………
The cylinder head is cracked or broken refer to step 002--004
Accepted
Next step
Step 6 Check the cylinder block, and please refer to
……………
The cylinder block is cracked or broken Step 001-026
Fault diagnosis 59
General
Excessive air in the crankcase (blowby)

Excessive air in the crankcase (blowby)
The outflow of residual engine oil of crankcase may contribute to the appearance of symptoms of
excessive air (blowby) in the crankcase. Sub-symptom tree includes all symptoms lick these two.
Cause Measure
Check the oil level and verify whether the
Step-1
calibration of oil dipstick and the capacity of
Oil level is higher than technical ……………
oil pan are correctAdd the oil to the stipulated
specification
level
Accepted
Next step
Step 2
Check and clean the crankshaft case
The crankcase ventilating system is ……………
breather and exhaust pipe
clogged.
Accepted
Next step
Step 3 Refer to “Data table of engine technical
The curvature of characteristic curve specification” related to the technical
……………
during engine operation exceeds the value specification of inclination of engine being
in the technical specification repaired
Accepted
Next step
Renew or overhaul the compressor, and
Step 4
check the blow-by distribution of engine air
The air compressor is worn excessively or ……………
compressor. If the air blowby exceeds the
required limit
Accepted
Next step
Check the turbocharger compressor and the
Step 5 sealing members of turbineCheck whether
……………
Leakage of turbocharger oil seal the turbocharger blows by the gas. If
necessary, replace the turbocharger.
Accepted
Next step
Step 6
Over-large clearance of valve stem or …………… Check the valve stem and seal
damaged seals of valve stem
Accepted
Next step
Step 7
Check whether the valve guide is worn, and
The cylinder head valve guide is worn ……………
replace the cylinder head, if necessary
excessively
Accepted
Next step
Check whether the intake system has
leakageCheck whether the piston and piston
Step 8
…………… ring are worn or damagedAnalyze the oil and
Piston or piston ring is worn or damaged
check the filter to identify the damaged part
and the reason.
60 Fault diagnosis
ISLe375 30 engine
The brake fails to work.

The brake fails to work.
Cause Measure
Step-1
The engine brake ON/OFF switch is …………… Switch closed.
disconnected
Accepted
Next step
Use the service software to check
Step 2
programmable parameters and selected
The programmable parameter and ……………
characteristics; if necessary, reset
selected character is incorrect
parameters and characteristics.
Accepted
Next step
Step 3 Refer to the TF section in “CM2150 electronic
The current electronic failure code is control system of ISB, ISE and ISL, ISDe and
……………
activated or the non-current failure code is QSB3. 3 engines” for the fault diagnosis with
recorded at a high frequency. fault code.
Accepted
Next step
Check the ON/OFF switch and circuit of
engine brakeRefer to step 020-012, 020-015
Step 4
or 019-034 and 019-035 in “Fault diagnosis
The engine brake ON/OFF switch or its ……………
and troubleshooting manual of CM2150
circuit is faulty
electronic control system of ISB, ISE and ISL,
ISDe and QSB3. 3 engines”.
Accepted
Next step
Step 5
Check the engine brake wire connectorCheck
Loose or damaged engine brake cable ……………
whether the engine brake wire is connected
harness connector
Accepted
Next step
Check the clutch switch adjustment, switch
Step 6 and circuit, refer to step 019-009 and 019-010
……………
The clutch switch or circuit is in trouble in “CM2150 electronic control system of ISB,
ISE and ISL, ISDe and QSB3. 3 engines”.
Accepted
Next step
Check whether the accelerator pedal is
blocked, and check the accelerator pedal or
Step 7
control lever position sensor and circuitRefer
The accelerator pedal or control lever ……………
to step 019-085 and 019-086 in “CM2150
position sensor or circuit has faults.
electronic control system of ISB, ISE and ISL,
ISDe and QSB3. 3 engines”
Accepted
Next step
Step 8 Check the pressure switch or circuit of
The service brake pressure switch or …………… service brake, and refer to “OEM service
circuit fails. manual”.
(cont’d)
Fault diagnosis 61
General
(cont’d)
Cause Measure
Check the grounding of engine to chassis as
Step 9 well as chassis to negative pole of battery,
……………
Faulty grounding of engine circuit refer to “OEM service manual” and step
013-009.
Accepted
Next step
Step 10 Check the control valve and piston of engine
……………
Oil leakage brakeRefer to step 020-004.
Accepted
Next step
Step 11
Check the control valve and piston of engine
Resistance to engine brake lubricating oil ……………
brake, refer to step 020-004.
passage
Accepted
Next step
Step 12 Adjust the engine brake. Refer to step
……………
The engine brake is adjusted incorrectly 020-004.
62 Fault diagnosis
ISLe375 30 engine
Low deceleration power or slow braking of engine brake

Low deceleration power or slow braking of engine brake
Cause Measure
Refer to the summarized information for the
driveability, “Customer’s comments table for
the driveability/low power” and “Driveability
Step-1
…………… checklist” in step T00-004 at the end of TS
Talk with the operator to verify the faults.
section. Follow the instruction in table to
operate before continuing this fault symptom
tree.
Accepted
Next step
Step 2 Refer to the TF section in “CM2150 electronic
The current electronic failure code is control system of ISB, ISE and ISL, ISDe and
……………
activated or the non-current failure code is QSB3. 3 engines” for the fault diagnosis with
recorded at a high frequency. fault code.
Accepted
Next step
Step 3
characteristics. If necessary, reset
parameters and characteristics.
Accepted
Next step
Preheat the engine to the working
temperature. If the engine can’t reach its
Step 4
…………… working temperature, make reference to the
Engine cooling
symptom tree of lower coolant temperature
than normal value.
Accepted
Next step
Step 5 Adjust the engine brake. Refer to step
……………
The engine brake is adjusted incorrectly 020-004
Accepted
Next step
Step 6
Check the engine brake wire connectorCheck
Loose or damaged engine brake cable ……………
whether the engine brake wire is connected
harness connector
Accepted
Next step
Check the oil levelIf provided with a high
Step 7
…………… level, check whether the suction pipe is
There is air in the lubricating system.
cracked. Refer to step 007-025.
Accepted
Next step
Step 8 Check the control valve and piston of engine
……………
Oil leakage (internal) brakeRefer to step 020-004.
Accepted
Next step
Step 9 Refer to step 020-012 “Engine brake solenoid
……………
The engine brake coil is faulty valve”
(cont’d)
Fault diagnosis 63
General
(cont’d)
Cause Measure
Check the engine brake control valve. If
Step 10
…………… necessary, replace the engine brake control
The engine brake control valve is faulty
valve. Refer to step 020-004
Accepted
Next step
Step 11
Check whether the engine brake assembly
Resistance to engine brake lubricating oil ……………
has resistanceRefer to step 020-004
passage
Accepted
Next step
Check the boost pressure of turbocharger
Step 12 with application software. Refer to the fault
……………
The turbocharger fails. diagnosis tree of engine performance in the
TT section.
64 Fault diagnosis
ISLe375 30 engine
Too much engine noise

Too much engine noise
Ensure that the noise is not caused by the engine accessories (air compressor, fan clutch, A/C
compressor or hydraulic pump) when making fault diagnosis on the noise of engine. Prior to the use of
this failure tree, make reference to the engine noise diagnosis procedure. .
Cause Measure
Step-1 Check the belt tension and tighten the belt if
……………
The fan drive belt is loose necessary
Accepted
Next step
Step 2
…………… Check the fan, refer to OEM repair manual
The fan is loose, damaged or imbalanced
Accepted
Next step
Step 3
Separate each component and check for any
The noise of fan clutch’s hydraulic pump ……………
noise
or refrigerant compressor is too heavy
Accepted
Next step
Step 4 Check whether the intake and exhaust
……………
Intake or exhaust leakage systems leak air
Accepted
Next step
Step 5
Check whether the intake and exhaust
The intake pipe or exhaust pipe shall ……………
systems leak air
touch the chassis or cab
Accepted
Next step
Step 6
Check the oil level and fill or Draining the oil,
Oil level is lower or higher than technical ……………
if necessary
specification
Accepted
Next step
Step 7 If the oil is contaminated, please refer to the
……………
Oil is too thin or is diluted symptom tree for “Contaminated oil”.
Accepted
Next step
Step 8
Check the oil pressure. Refer to the symptom
Oil pressure is lower than technical ……………
tree of low oil pressure if the pressure is low
specification
Accepted
Next step
Step 9
…………… Check the shock absorber
The shock absorber is damaged
Accepted
Next step
Step 10 Refer to the symptom tree for “Coolant
The coolant temperature is higher than the …………… temperature higher than normal value –
specification gradual overheating”
Accepted
Next step
(cont’d)
Fault diagnosis 65
General
(cont’d)
Cause Measure
Disconnect the power train and check the
Step 11
…………… engine for any noise. Refer to “OEM service
Drive system noise is too high
manual”.
Accepted
Next step
Step 12
The engine mounting is worn. Damaged or …………… Check the engine suspension
incorrect
Accepted
Next step
Step 13 Refer to the symptom tree for “Abnormal
……………
The noise of air compressor is too loud noise of air compressor”
Accepted
Next step
Step 14
Measure and adjust the overhead
Incorrect adjustment of overhead ……………
mechanism
mechanism
Accepted
Next step
Step 15
Check the rocker arm, rocker arm shaft and
Damaged overhead mechanism ……………
valve are damaged or worn excessively
components
Accepted
Next step
Step 16 Make the single-cylinder oil-cut test, and
……………
The fuel injector is in trouble replace the injector, if necessary
Accepted
Next step
Step 17
…………… Check the torque converter
The hydraulic converter works loose.
Accepted
Next step
Step 18
Check the flywheel or flexible mounting disc
The flywheel or flexible connecting flange ……………
and mounting bolt
bolt is loose or fractured
Accepted
Next step
Step 19
Gear system side clearance is too wide or …………… Check the gear clearance and gear
gear is damaged
Accepted
Next step
Refer to the symptom tree for “Abnormal
Step 20
…………… engine noise - linkage” or the symptom tree
Noise of main bearing or linkage bearing
for “Abnormal engine noise---main bearing”.
Accepted
Next step
(cont’d)
66 Fault diagnosis
ISLe375 30 engine
(cont’d)
Cause Measure
……………
Turbocharger noise engine noise - turbocharger”

……………
High noise in combustion engine noise - knock during combustion”
Accepted
Next step
Check whether the intake system has any
leakage, and the piston and piston rings are
Step 23
…………… worn or damagedAnalyze the oil and check
the filter to identify the damaged part and the
reason.
Fault diagnosis 67
General
Too much engine noise due to engine knocking

Too much engine noise due to engine knocking
Prior to the use of this symptom tree, make reference to the engine noise diagnosis procedure- general
description.
Cause Measure
Step 1
repaired.
Accepted
Next step
Step 2 Run the engine with high-quality fuel. Refer to
The class of fuel doesn’t agree with the “Operation and maintenance manual”
……………
type of application or the fuel quality is relevant to the engine being repaired for the
poor. fuel technical specification
Accepted
Next step
Step 3 Check whether there is any air in the fuel
……………
Air-in-fuel system. system
Accepted
Next step
Accepted
Next step
Step 5
Incorrect modulation of overhead …………… Test and adjust the overhead mechanism
mechanism
Accepted
Next step
……………
Accepted
Next step
Step 7
…………… Check the timing of gear transmission system
Incorrect timing of camshaft
Accepted
Next step
Remove and check the piston. Know the
Step 8
…………… direction of piston, and remove the piston, if
Piston fitting is not correct
necessary
68 Fault diagnosis
ISLe375 30 engine
Too much engine noise due to the linkage

Too much engine noise due to the linkage
description.
Cause Measure
Step-1
repaired.
Accepted
Next step
Step 2 Check the oil level, and verify whether oil
Oil level is lower than technical …………… dipstick scaling and oil sump volume are
specification correct. Add the oil to the stipulated level
Accepted
Next step
Step 3 Check whether the oil is polluted. Please
……………
Oil is too thin or is diluted refer to the symptom tree of polluted oil
Accepted
Next step
Step 4
specification
Accepted
Next step
Step 5 Remove and check the reinforcement plate of
……………
Oil suction or supply pipe installation error cylinder block
Accepted
Next step
Step 6
Remove and check the reinforcement plate of
The cylinder block reinforcement plate is ……………
cylinder block
fitted falsely
Accepted
Next step
Step 7
The linkage and bearing are damaged or
…………… Check the linkage and bearing
worn or not installed correctly; or the
bearing installed is wrong
Accepted
Next step
Step 8
…………… Remove and check the linkage
The linkage is bent or not aligned
Accepted
Next step
Step 9
Damages or out-of-roundness of …………… Check the crankshaft journal
crankshaft journal
Fault diagnosis 69
General
Too much engine noise due to main bearing

Too much engine noise due to main bearing
description.
Cause Measure
Step-1
repaired.
Accepted
Next step
Step 2 Check the oil level, and verify whether oil
Oil level is lower than technical …………… dipstick scaling and oil sump volume are
Accepted
Next step
……………
Accepted
Next step
Step 4
specification
Accepted
Next step
Step 5
Check the torque of main bearing boltCheck
The main bearing bolt is loose, worn out or ……………
whether the bolt is worn
fails to be fastened correctly.
Accepted
Next step
Step 6
Check whether the main bearing is damaged
The main bearing is worn out or damaged
…………… or worn excessively and the part number is
or assembled incorrectly, or the
correct
assembled bearing is incorrect.
Accepted
Next step
Step 7
Damages or out-of-roundness of …………… Check the crankshaft journal
crankshaft journal
Accepted
Next step
Step 8
Check the flywheel or flexible mounting disc
The flywheel or flexible connecting flange ……………
and mounting bolt
bolt is loose or fractured
70 Fault diagnosis
ISLe375 30 engine
Too much engine noise due to the piston

Too much engine noise due to the piston
description.
Cause Measure
Step-1
repaired.
Accepted
Next step
……………
poor. fuel technical specification
Accepted
Next step
Step 3
Incorrect modulation of overhead …………… Test and adjust the overhead mechanism
mechanism
Accepted
Next step
……………
Accepted
Next step
Remove and check the piston. Know the
Step 5
…………… direction of piston, and remove the piston, if
Piston fitting is not correct
necessary
Accepted
Next step
Step 6
The linkage is bent or not aligned
Accepted
Next step
Step 7
Incorrect assembly of linkage
Accepted
Next step
Step 8 Remove piston and check whether the piston
Piston pin or pin bush is loosened/worn or …………… pin or the pin bush is damaged or worn. And
fitted improperly whether it is correctly fitted;
Fault diagnosis 71
General
Too much engine noise due to turbocharger

Too much engine noise due to turbocharger
description.
Cause Measure
Check the part number of turbocharger, and
Step-1 comparer it with the part number in the
……………
Incorrect model of turbocharger control parts catalogue. If necessary, replace
the turbocharger.
Accepted
Next step
Step 2 Check the resistance of intake system. If
The resistance of intake system exceeds …………… necessary, clean or replace the air filter and
the specification intake pipe.
Accepted
Next step
Step 3 Check whether the intake and exhaust
……………
Intake or exhaust leakage systems leak air
Step 4
Check whether the air pipe and chassis
The intake pipe or exhaust pipe shall ……………
contact the cab
touch the chassis or cab
Accepted
Next step
Step 5
The resistance of exhaust system does …………… Check the resistance of exhaust system
not meet the specifications
Accepted
Next step
……………
Accepted
Next step
Step 7
specification
Accepted
Next step
Check whether the turbocharger is
Step 8
…………… damagedMeasure the clearance between the
The turbocharger is worn or damaged.
turbine wheel and the compressor wheel
72 Fault diagnosis
ISLe375 30 engine
The engine cannot be dragged or is dragged slowly (air starter)

The engine cannot be dragged or is dragged slowly (air starter)
Cause Measure
Step-1 Increase the air pressure by external air
……………
Air pressure inside air reservoir is low source.
Accepted
Next step
Step 2
repaired.
Accepted
Next step
Step 3
…………… Check the starting motor interlock
OEM starting motor hinge unit is engaged
Accepted
Next step
Check whether the oil pressure switch,
Step 4
pressure gauge and pressure sensor work
Oil pressure switch, gauge or sensor is ……………
normally and whether their mounting
faulty or is fitted improperly
positions are correct
Accepted
Next step
Step 5
…………… Disconnect the engine transmission.
Engaged engine transmission
Accepted
Next step
Check the performance of starting motor, and
Step 6
…………… compare the starting motor and generator
Failure or incorrect model of starter motor
with the vehicle specifications
Accepted
Next step
Step 7
Damages of starter motor pinion or ring …………… Remove starter motor and check gear
gear
Accepted
Next step
Step 8 Check the oil levelVerify whether oil dipstick
Oil level is higher than technical …………… scaling and oil sump volume are correct. Add
specification the oil to the stipulated level
Accepted
Next step
Step 9 Renew the oil and filter with reference to the
Oil does not meet technical specification …………… Engine Operation and Maintenance Manual,
with respect to working and understand the oil technical specification
Accepted
Next step
(cont’d)
Fault diagnosis 73
General
Cause Measure
Step 10
…………… Check whether the crankshaft rotates freely
Weakened rotation of crankshaft
Accepted
Next step
Step 11 Remove injector and rotate crank. Check for
……………
Hydraulic lock in the cylinder the source of fluid in the cylinder
Accepted
Next step
Step 12 Analyze the oil and check the filter to identify
……………
Internal damage of engine the damaged part
(cont’d)
74 Fault diagnosis
ISLe375 30 engine
The engine cannot be dragged or is dragged slowly (electric starter)

The engine cannot be dragged or is dragged slowly (electric starter)
Cause Measure
Step-1 Check the battery heater, refer to “OEM
……………
Battery over-cold service manual”
Accepted
Next step
Step 2
repaired.
Accepted
Next step
Step 3 Check battery and the switch-free battery
……………
The battery voltage is low. power circuit
Accepted
Next step
Step 4
Accepted
Next step
Step 5
The battery capacity is lower than the …………… . If necessary, replace the battery.
required level.
Accepted
Next step
Step 6 Replace the batter cable with the larger
The battery cable diameter or length is …………… diameter or shorter cable. Refer to “OEM
incorrect. manual”
Accepted
Next step
Step 7 Check the starting motor interlock, and refer
……………
OEM starting motor hinge unit is engaged to OEM repair manual
Accepted
Next step
Check whether the oil pressure switch,
Step 8
pressure gauge and pressure sensor work
Oil pressure switch, gauge or sensor is ……………
normally and whether their mounting
faulty or is fitted improperly
positions are correct
Accepted
Next step
Step 9
…………… Disconnect the engine transmission.
Engaged engine transmission
Accepted
Next step
Step 10
…………… Check the components of starting circuit
Failure of startup circuit
Accepted
Next step
(cont’d)
Fault diagnosis 75
General
(cont’d)
Cause Measure
Step 11
Damages of starter motor pinion or ring …………… Remove starter motor and check gear
gear
Accepted
Next step
Step 12 Check the oil level, and verify whether oil and
Oil level is higher than technical …………… dipstick scaling and oil sump volume are
Accepted
Next step
Step 13 Renew the oil and filter with reference to the
Oil does not meet technical specification …………… Engine Operation and Maintenance Manual,
with respect to working and understand the oil technical specification.
Accepted
Next step
Step 14
…………… Check whether the crankshaft rotates freely
Weakened rotation of crankshaft
Accepted
Next step
Step 15 Remove injector and rotate crank. Check for
……………
Hydraulic lock in the cylinder the source of fluid in the cylinder
Accepted
Next step
……………
(cont’d)
76 Fault diagnosis
ISLe375 30 engine
The engine cannot stop

The engine cannot stop
Cause Measure
Step-1
repaired.
Accepted
Next step
Step 2 Check the key switch circuit of vehicle,
……………
Key switch circuit fault equipment or ship
Accepted
Next step
Step 3 Check the turbocharger compressor and the
……………
Leakage of turbocharger oil seal sealing members of turbine
Accepted
Next step
Step 4 Check the air intake pipelineCheck for and
The smoke enters into the intake system …………… isolate the fume source and repair, if
during engine operation necessary
Accepted
Next step
Step 5
…………… Renew the ECM
ECM is faulty
Some fuel enters the coolant

Some fuel enters the coolant
Cause Measure
Check the bulk coolant, drain the coolant, fill
Step-1
…………… the clean coolant and replace the coolant
The bulk coolant is contaminated.
filter
Accepted
Next step
Carry out the cylinder head pressure test, and
disconnect the drain connector at the rear of
Step 2
…………… cylinder head. Conduct pressure test on the
cooling system, and find out the internal
leakage source of coolant.
Fault diagnosis 77
General
Fuel is mixed into oil

Fuel is mixed into oil
Cause Measure
Step-1
…………… Check the bulk oil, and renew the oil filter
The bulk engine oil is contaminated.
Accepted
Next step
Step 2
repaired.
Accepted
Next step
Long time idling may cause too low oil &
Step 3 coolant temperature (more than 10 min.). = It
……………
Engine idles for too long period of time is better to shutdown the engine than to
operate it at idle speed for a long term.
Accepted
Next step
Step 4
…………… Check whether the fuel return pipe is blocked
The fuel return hose is clogged.
Accepted
Next step
Step 5 Tighten the bolts in accordance with the
……………
The clamp bolt of fuel injector is loose technical regulations.
Accepted
Next step
Step 6
Remove, clean and check the injector.
Damage or missing of O-ring of fuel ……………
Renew the injector O-ring
injector
Accepted
Next step
Step 7 Make the single-cylinder oil-cut test. If
……………
The fuel injector is in trouble necessary, replace the injector.
Accepted
Next step
Step 8 Remove single cylinder oil shutoff test. If
……………
The fuel injector seal is incorrect necessary, replace the injector.
Accepted
Next step
Carry out the cylinder head pressure
testDisconnect the drain connector at the rear
Step 9
…………… of cylinder head. Conduct pressure test on
the fuel drain passage inside the cylinder
head.
Accepted
Next step
Step 10 Check the output pressure of gear pump. If
……………
Gear pump fault necessary, replace the gear pump.

……………
78 Fault diagnosis
ISLe375 30 engine
The air temperature of intake manifold is higher than the specification

The air temperature of intake manifold is higher than the specification
Cause Measure
Step-1 Check the fan drive belt and replace the belt,
……………
The fan drive belt is broken if necessary
Accepted
Next step
Step 2 Check the belt tension and tighten the belt if
……………
The fan drive belt is loose necessary
Accepted
Next step
Step 3
Uncover the radiator cover or cold-proof front
Radiator shield or antifreeze front shield ……………
mask used in cold weather
has closed under cold climate
Accepted
Next step
Step 4
Check the radiator shutter. If necessary,
The radiator shutter can’t be fully opened
…………… repair or replace it. Check the set opening of
or the shutter openness is not correctly
shutter
designed.
Accepted
Next step
Step 5
Check the cooling fins of air-air intercooler,
Air-air intercooler fin, radiator fin or A/C
…………… radiator or A/C condenser. If necessary, clean
condenser fin is damaged or blocked by
it.
scrapings
Accepted
Next step
Step 6
repaired.
Accepted
Next step
Step 7 Check the intake manifold temperature
The temperature sensor of intake manifold …………… sensor corresponding to the error code. If
has trouble in work range necessary, replace the sensor.
Accepted
Next step
Step 8
characteristics. If necessary, replace the
sensor.
Accepted
Next step
Check the drive and control devices of fanIf
Step 9
…………… the electric control is realized via the engine
ECM, refer to OEM’s manual.
Accepted
Next step
Fault diagnosis 79
General
(cont’d)
Check the fan part number and compare it
Step 10
…………… with OEM part number. If necessary, replace
The fan model is incorrect
the fan, and refer to OEM’s repair manual.
Step 11
Check the shield and deflector, and repair,
The fan shroud or the air deflector is ……………
replace or reinstall them, if necessary
damaged or lost
Accepted
Next step
Step 12
Reduce the engine loadIncrease the engine
Speed is too low, and engine is not cooled ……………
speed via the shift to the low gear.
sufficiently under high load
Accepted
Next step
Step 13
Check whether the exhaust pipeline has
The hot air in the exhaust system is leaked ……………
leakage or broken component
into the engine compartment
Accepted
Next step
Check the boosting pressure sensor and
circuitCompare the reading of intake manifold
pressure sensor with the reading of hand
Step 14
pressure gauge when the INSITE is in
The intake manifold pressure sensor or ……………
detection modeRefer to “Fault diagnosis and
circuit is in trouble
troubleshooting manual for the electronic
repaired
Accepted
Next step
Step 15
Verify that engine and vehicle cooling
Vehicle cooling system cannot meet the ……………
systems use correct components
requirements.
Accepted
Next step
Step 16
…………… Verify whether fan specification is correct
The fan is too small for this type
(cont’d)
80 Fault diagnosis
ISLe375 30 engine
Excessive oil consumption

Excessive oil consumption
Cause Measure
Step-1 Check the ratio of amount of filled oil to the
……………
Verify oil consumption mileage
Accepted
Next step
Check the engine and tighten the bolt, pipe
Step 2
…………… plug and union. If necessary, replace the
Oil leakage (outside)
gasket.
Accepted
Next step
Step 3
Check and clean the crankshaft case
The crankcase ventilating system is ……………
breather and exhaust pipe
clogged.
Accepted
Next step
Step 4 Renew the oil and filter. Refer to “Operation
Oil does not meet technical specification …………… and maintenance manual” for oil technical
with respect to working specification
Accepted
Next step
Verify whether oil change interval is correct,
Step 5 and refer to corresponding Operation and
……………
Too long oil change interval Maintenance Manual for the engine under
repair
Accepted
Next step
Refer to the fault diagnosis and
Step 6
troubleshooting tree for “Excessive oil
The air compressor sends the oil into the ……………
pumped into the air system by the air
air system
compressor”
Accepted
Next step
Check whether the oil cooler leaks the
Step 7 coolantRefer to the symptom tree for “Fault
……………
Oil cooler leakage diagnosis and troubleshooting of loss of inner
coolant” if some oil is detected.
Accepted
Next step
Step 8 Check the oil levelVerify whether oil dipstick
Oil level is higher than technical …………… scaling and oil sump volume are correct, and
specification fill oil to the specified level.
Accepted
Next step
……………
during engine operation exceeds the value specification of inclination of engine be
in the technical specification repairing.
Accepted
Next step
(cont’d)
Fault diagnosis 81
General
(cont’d)
Cause Measure
Step 10 Check the turbocharger compressor and the
……………
Leakage of turbocharger oil seal sealing members of turbine
Accepted
Next step
Check the gas blowbyIf the downward blowby
Step 11
…………… is significant, check whether the piston ring is
Piston ring seat is not correct
correctly seated.
Accepted
Next step
……………
Oil is strained by coolant or fuel oil”.
Accepted
Next step
Step 13
Over-large clearance of valve stem or …………… Check the valve stem and seal
damaged seals of valve stem
Accepted
Next step
Step 14
Check whether the valve guide is worn. If
The cylinder head valve causes excessive ……………
necessary, replace the cylinder head.
wear
Accepted
Next step
Check whether the intake system has
leakageCheck whether the piston and piston
Step 15
…………… ring are worn or damagedAnalyze the oil and
check the filter to identify the damaged part
and the reason.
Accepted
Next step
……………
Internal damage of engine the damaged part.
82 Fault diagnosis
ISLe375 30 engine
Oil stain
Oil stain
Cause Measure
Step-1 Analyze the oil to define the pollutants in the
……………
Check whether the oil is polluted oil
Accepted
Next step
Step 2 Refer to the symptom tree for “Oil mixed with
……………
Fuel exists in oil fuel”.
Accepted
Next step
Step 3 Refer to the symptom tree for “Loss of inner
……………
Internal coolant leakage coolant”.
Accepted
Next step
Step 4 Renew the oil and filter. Crankcase overmuch
……………
Excessive oil sludge oil sludge symptom tree
Accepted
Next step
Step 5 Check the bulk oil, drain the oil and add the
……………
The bulk engine oil is contaminated. clean oil, and renew the oil filter.
Fault diagnosis 83
General
High oil pressure

High oil pressure
Cause Measure
Step-1
repaired.
Accepted
Next step
Step 2
Refer to the symptom tree for “Coolant
The coolant temperature is lower than the ……………
temperature lower than normal value”.
specification
Accepted
Next step
Renew the oil and filter. Refer to “Operation
Step 3
and maintenance manual” relevant to the
Existing technical regulations inconsistent ……………
engine being repaired for the oil technical
with the working conditions
specification.
Accepted
Next step
Step 4 Measure the oil pressure, operate the engine
OEM installed oil pressure switch, and compare the reading with that of vehicle
pressure meter or the fault happens to the …………… OEM instrument or the oil pressure
senor or the mounting position is not sensor/switch. Refer to “OEM service
correct manual”.
Accepted
Next step
Measure the oil pressure, operate the engine
Step 5
and compare the reading with that of vehicle
Faults happens to the oil pressure
…………… OEM instrument or oil pressure
sensor/switch on the engine or electic
sensor/switch. Refer to “OEM service
circuit
manual”.
Accepted
Next step
Step 6 Verify whether oil filter pipeline layout is
……………
Oil filter pipeline layout is not correct correct
Accepted
Next step
Step 7
Check the oil pressure regulator assembly for
The main oil passage engine pressure ……………
main oil passage
regulator is in failure.
Accepted
Next step
Check whether the part number of installed
oil pump is correct.
<for example, use the oil pump for 6-cylinder
Step 8
…………… engine in the 4-cyliner engine >refer to the
Fit incorrect oil pump
suitable parts mobile phone and/or
QuickServe®Online website. If necessary,
change the engine oil.
84 Fault diagnosis
ISLe375 30 engine
Low oil pressure

Low oil pressure
Cause Measure
Step-1 Use the INSITE™ to check and diagnose the
……………
Accepted
Next step
Step 2
Measure the oil pressure, operate the engine
OEM installed oil pressure switch,
and compare the reading with that of
pressure meter or the fault happens to the ……………
instrument installed by the vehicle OEM.
senor or the mounting position is not
correct
Accepted
Next step
Measure the oil pressure. If the engine oil
pressure sensor is fitted, use the INSITE to test
Step 3 the engine oil pressure, operate the engine and
Faults happens to the oil pressure compare the readings. If necessary, replace the
……………
sensor/switch on the engine or electic engine oil pressure sensor switch. Refer to
circuit (electronic control fuel system) “Fault diagnosis and troubleshooting for the
electronic control system” relevant to the
engine being repaired for
Accepted
Next step
Step 4 Remove front gear chamber to check
The oil pressure sensor/switch or pipe is …………… whether pressure sensor / switch port is
blocked blocked by coolant.
Accepted
Next step
Step 5
Check the oil level. If necessary, fill or
Oil level is lower or higher than technical ……………
Draining engine oil.
specification
Accepted
Next step
Check whether the exterior of engine leaks
Step 6
…………… oilTighten the bolt, pipe plug and union. If
Oil leakage (external)
necessary, replace the gasket.
Accepted
Next step
Renew the oil and filter. Refer to “Operation
Step 7
and maintenance manual” relevant to the
Oil does not meet technical specification ……………
engine being repaired for the oil technical
with respect to working
specification.
Accepted
Next step
……………
Accepted
Next step
(cont’d)
Fault diagnosis 85
General
(cont’d)
Cause Measure
……………
during engine operation exceeds the value specification of inclination of engine be
in the technical specification repairing
Accepted
Next step
Accepted
Next step
Step 11 Verify whether oil filter pipeline layout is
……………
Oil filter pipeline layout is not correct correct
Accepted
Next step
Step 12
Check the oil pressure regulator assembly for
The main oil passage engine pressure ……………
main oil passage
regulator is in failure.
Accepted
Next step
Step 13
Remove and check the oil sump or the
Oil suction pipe or supply pipe is loosened ……………
suction pipe
or cracked; gasket or O-ring has leakage
Accepted
Next step
Step 14
…………… Check the oil pump
Oil pump is faulty
Accepted
Next step
Check whether the part number of installed
oil pump is correct. (e. g., 4-cylinder pump
Step 15
…………… inside 6-cylidner engine) refer to relevant part
Fit incorrect oil pump
catalogue and/or website, and renew oil
pump, if necessary.
Accepted
Next step
Step 16
Oil cooler blocking
Accepted
Next step
Step 17
Refer to the symptom tree for “Oil
Oil temperature exceeds technical ……………
temperature higher than the standard value”
specification
Accepted
Next step
Step 18
Check whether the piston cooling nozzle is damaged
Piston cooling nozzle is damaged or fitted ……………
or installed correctly
improperly
Accepted
Next step
Analyze the oil. Check the oil filter, and the possible
Step 19 damage. The parts that may be damaged include the
……………
Internal damage of engine or internal oil leakage internal circular plug, main bearing, linkage bearing,
cam lining and rocker arm
86 Fault diagnosis
ISLe375 30 engine
Overmuch sludge in the crankcase

Overmuch sludge in the crankcase
Cause Measure
Step-1 Check the bulk oil, drain the oil and add the
……………
The bulk engine oil is contaminated. clean oil, and renew the oil filter.
Accepted
Next step
Step 2 Renew the oil and filter. Refer to “Operation
Oil does not meet technical specification …………… and maintenance manual” relevant to the
with respect to working engine being repaired for the oil specification.
Accepted
Next step
Verify whether oil change interval is correct.
Step 3 Refer to “Operation and maintenance
……………
Too long oil change interval manual” of engine being repaired. Know the
oil draining specifications
Accepted
Next step
……………
poor. fuel technical specification.
Accepted
Next step
Step 5
Refer to the symptom tree for “Coolant
The coolant temperature is lower than the ……………
temperature lower than normal value”
specification
Accepted
Next step
……………
Accepted
Next step
Step 7
Oil temperature exceeds technical …………… . If necessary, replace the engine oil cooler.
specification
Accepted
Next step
Step 8
…………… Check whether the gas blowby is too much.
Overhigh crankcase pressure
Accepted
Next step
Step 9
Check whether the exhaust system is
The resistance of exhaust system is ……………
blocked
higher or lower than the specification
Fault diagnosis 87
General
Some engine oil or gearbox oil enters the coolant

Some engine oil or gearbox oil enters the coolant
Cause Measure
Check the bulk coolantDraining the coolant,
Step-1
…………… fill the clean coolant, and renew the coolant
The bulk coolant is contaminated.
filter.
Accepted
Next step
Step 2
Oil cooler fault
Accepted
Next step
Step 3
Remove and check cooler element & O-ring.
The cooler for the torque converter or the ……………
cooler for the hydraulic axle is faulty
Accepted
Next step
Step 4
Accepted
Next step
Carry out the cylinder head pressure test,
Step 5 conduct pressure test on the cooling system,
……………
The cylinder head is cracked or broken and find out the internal leakage source of
coolant.
Accepted
Next step
Step 6
Check the cylinder head and gasket of air
There is crack or sand hole on the air
…………… compressor. If the air compressor can’t be
compressor cylinder head or the gasket
repaired, replace it.
leaks
Accepted
Next step
Step 7
…………… Check the cylinder block
The cylinder block is cracked or broken
88 Fault diagnosis
ISLe375 30 engine
Leakage of engine oil or fuel in the turbocharger

Leakage of engine oil or fuel in the turbocharger
Cause Measure
Review the Operation and Maintenance Instructions
or corresponding Driver’s Manual; long idling can
Step-1 cause too low oil and coolant temperature (more than
The engine runs with a small load or without load …………… 10min). It is better to shutdown the engine than to
for a long period of time operate it at idle speed for a long term. If the
long-time idling operation is required, increase the
engine operation at idle speed.
Accepted
Next step
Step 2
…………… Refer to the symptom tree for “Engine performance”
White smoke appears
Accepted
Next step
Check all the pipelines and unions for
Step 3
…………… leakageTighten the loose pipe union, and replace the
Oil pipe has oil leakage
oil pipe with leakage, if necessary
Accepted
Next step
Remove turbocharger oil return pipe, and check
Step 4
…………… whether it is blocked. Clean or renew the oil return
Turbocharger return pipe blocking
pipe.
Accepted
Next step
Step 5 Check and clean the crankshaft case breather and
……………
The crankcase ventilating system is clogged. exhaust pipe
Accepted
Next step
Step 6
…………… Remove intake/exhaust pipe, and check for oil or fuel
Oil or fuel enters turbocharger
Accepted
Next step
Step 7
The resistance of intake system exceeds the …………… Check the resistance of intake system
technical range
Accepted
Next step
Step 8
The resistance of exhaust system does not meet …………… Check the resistance of exhaust system
the specifications
Accepted
Next step
Step 9 Check the turbocharger compressor and the sealing
……………
Leakage of turbocharger oil seal members of turbine
Accepted
Next step
Step 10 Check the radial and axial clearances of bearing,
The turbocharger impeller clearance exceeds the …………… check the turbocharger, and repair or replace the
required limit. turbocharger, if necessary
Accepted
Next step
Step 11
Over-large clearance of valve stem or damaged …………… Check the valve stem and seal
seals of valve stem
Fault diagnosis 89
General
4. Engine performance troubleshooting tree

The troubleshooting procedures are applicable for the following phenomenon:
•ٛ Poor acceleration or low acceleration response of engine
•ٛ Low starting fuel pressure
•ٛ The fuel pressure is low
•ٛ The engine speeds down slowly
•ٛ The engine starts difficultly or fails to start (exhaust smoke)
•ٛ The engine starts difficultly or fails to start (no exhaust smoke)
•ٛ Engine output is low
•ٛ The engine runs sharply with an idle speed
•ٛ The engine operates sharply or misfires
•ٛ The engine hunts at low or high idle speed
•ٛ The engine hunts with a load or within the working range
•ٛ A great deal of black smoke
•ٛ A great deal of white smoke
•ٛ The engine stops or shuts down accidentally during deceleration
•ٛ The engine can start but cannot keep running
•ٛ The engine cannot reach the rated speed (RPM)
•ٛ The (boosting) pressure of intake manifold is lower than the normal value
How to use this failure diagnosis and solution procedure:
This symptom tree is used for diagnosis and troubleshooting of all engine performance fault symptoms
mentioned above. Carry out fault diagnosis and troubleshooting starting from step 1. Some questions
will be asked in Step 2, and some fault diagnosis procedure will be provided according to the symptoms.
Perform the fault diagnosis according to the sequence described in "Technical specification/repair" in the
symptom tree.
Notes for overhaul:
Usually the driving performance is a term used to describe the behavior of vehicle on the road The
operating performance problem of engine may be caused by several different factors. Some factors are
related to the engine. Before fault diagnosis, it is important to define the complaint correctly, and make
sure if the engine has driving performance problem or it only fails to meet the driver’s expectation.
Low output is a term describing some different performances. Low power means that the engine output
is not enough for driving with reliable speed under given load, slope and wind speed.
The poor acceleration or slow response indicates that the vehicle fails to realize the satisfying
acceleration performance when it is static or at the foot of slope. The acceleration lag will be caused
when trying to exceed other vehicles at the speed and load less than rated value. The poor
acceleration or response is hard to eliminate because such fault may be caused by many reasons:
90 Fault diagnosis
ISLe375 30 engine
Troubleshooting summary
Step 1: Exercise the troubleshooting.
Step 1A: Check whether the existing error code or non-existing error code is recorded at high frequency
Step 1B: Exercise the troubleshooting.
Step 2: Determine symptoms of engine.
Step 2A: Low power, poor acceleration or low acceleration response
Step 2B: The engine misfires, hunts or has unstable speed.
Step 2C: A great deal of white or black smoke.
Step 2D: The intake manifold pressure is lower
Step 2E: The engine fails to start or starts difficultly, or shuts down accidentally.
Step 3: Fault diagnosis and troubleshooting without staring.
Step 3A: Verify the working status of starting auxiliary unit under cold climate.
Step 3B: Verify that low pressure fuel pipe layout is correct.
Step 3C: Check the ECM key switch voltage
Step 3D: Check the power voltage of ECM battery.
Step 3E: Check the engine speed in motoring operation.
Step 3F: Verify fuel rail pressure sensor accuracy.
Step 3G: Check the fuel rail pressure in the motoring operation.
Step 3G-1: Check the fuel gear pump pressure
Step 3G-2: Check the fuel supply pump pressure
Step 3H: Check whether there is other error code that can explain the starting failure
Step 4: Fuel system diagnosis procedure
Step 4A: Check whether there is any error code about the fuel system
Step 4B: Check whether there is any air in the fuel supplied by the high-pressure pump
Step 4C: Measure the pressure of gear fuel pump.
Step 4C-1: Measure the intake resistance.
Step 4D: Make the single-cylinder oil-cut test
Step 4E: Diagnose and test the balancing of cylinder
Step 4F: Measure the resistance of fuel return pipe.
Step 4G: Monitor the fuel pressure during idle running
Step 5: Fault diagnosis procedure for air processor system
Step 5A: Check whether the turbocharger vane is damaged
Step 5B: Check the axial and radial clearances of turbocharger
Step 5C: Renew the exhaust gas by-pass actuator.
Step 5D: Check whether the actuator rod of exhaust bypass valve moves
Step 5G-1: Check whether the actuator rod of exhaust bypass valve moves
Step 6: Fault diagnostic procedures for electrical features.
Step 6A: Verify accelerator pedal range.
Step 6B: Check the precision of air pressure sensor
Fault diagnosis 91
General
Step 6C: Check the precision of intake manifold pressure sensor

Step 6D: Verify that electronic characteristic setting is correct.
Step 7: Procedures for basic engine fault diagnosis.
Step 7A: Verify that overhead mechanism adjustment is correct.
Step 7B: Verify that engine brake & adjustment device.
Step 7C: Check the air-air intercooler
Step 7D: Check the air inlet resistance
Step 7E: Check the exhaust resistance
Step 7F: Verify that engine blow-by gas meets technical specification.
Step 7F-1: Verify the effect of turbocharger on engine blow-by gas.
92 Fault diagnosis
ISLe375 30 engine
Troubleshooting procedures
Step 1: Exercise the troubleshooting.
Step 1A: Check whether the existing error code or non-existing error code is recorded at high frequency
Prerequisites:
• Rotate the key switch to “ON” position
• Connect the fault diagnosis device
Take actions Technical regulations/ maintenance Next step
Check whether there is any existing error Whether there is any high-frequency Applicable
code occurrence of current failure codes or failure code
• Use the failure diagnoser to read the non-current failure codes? diagnosis
failure code. Yes tree
Repairs:
Operate according to the applicable fault
diagnostic procedure in the electronic fault
code tree.
Whether there is any high-frequency lB

occurrence of current failure codes or
non-current failure codes?
No
Step 1B: Exercise the troubleshooting.
Prerequisites:
Before next step, be sure to check and Whether all procedures are verified? 2A
verify following items: Yes
• Verify oil level in fuel tank.
• Verify that CPL components on engine Whether all procedures are verified? Repairs
have no change. No completed
• Verify that fuel grade meets Repairs:
application type. Eliminate the failure, and verify the
• Verify that engine runs within the reoccurrence of problem as complained.
recommended altitude.
• Verify that engine oil level is correct.
• Verify that engine additional power
has no change.
• Verify that engine working cycle has
no change.
• Verify that engine start speed is above
150rpm.
• Verify that battery voltage is sufficient.
Fault diagnosis 93
General
Step 2: Determine symptoms of engine.

Step 2A: Low power, poor acceleration or low acceleration response
Prerequisites:
Take with the driver to verify the Does the engine problem lies in low Exercise the
complaints. output, poor acceleration or low troubleshooting
acceleration response? recommended
Yes in maintenance
Repairs: procedures.
Carry out the diagnosing and
troubleshooting procedure according to
the following recommended sequence:
• Step 4-Check of fuel system
• Step 5- Check of air handling system
• Step 6-Check of electronic
equipments
• Step 7-Basic engine check.
Does the engine problem lies in low 2B

output, poor acceleration or low
acceleration response?
No
Step 2B: The engine misfires, hunts or has unstable speed
Prerequisites:
Take with the driver to verify the Does the engine problem lies in misfiring, Exercise the
complaints. hunting or unstable speed? troubleshooting
Yes recommended
Repairs: in maintenance
Carry out the diagnosing and procedures.
• Step 6- Check of electronic
equipments.
Does the engine problem lies in misfiring, 2C

hunting or unstable speed?
No
94 Fault diagnosis
ISLe375 30 engine
Step 2C: A great deal of white or black smoke
Prerequisites:
Take with the driver to verify the Whether a great deal of white smoke or Exercise the
complaints. black smoke comes out of engine? troubleshooting
Yes recommended
• Step 4-Check of fuel system.
Whether a great deal of white smoke or 2D

black smoke comes out of engine?
No
Step 2D: The intake manifold pressure is lower
Prerequisites:
Take with the driver to verify the Does the engine problem lies in low Exercise the
complaints. supercharging pressure? troubleshooting
Yes recommended
• Step 7-Basic engine check.
Does the engine problem lies in low 2E

supercharging pressure?
No
Fault diagnosis 95
General
Step 2EThe engine fails to start or starts difficultly, or shuts down accidentally
Prerequisites:
Take with the driver to verify the Whether the symptom is start failure or Exercise the
complaints. accidental shutdown of engine? troubleshooting
Yes recommended
• Step 3 –Check for failure to start
• Step 4 –Check of fuel system
• Step 5 –Check of air handling
system
• Step 6 –Check of electronic
equipments.
Whether the symptom is start failure or Refer to the

accidental shutdown of engine? proper
No symptom tree
Step 3: Fault diagnosis and troubleshooting without staring.

Step 3A: Verify the working status of starting auxiliary unit under cold climate.
Prerequisites:
Ensure that the intake heater and other If the necessary auxiliary starter, which 3B
cold-start aids can work normally. works under cold weather, operates
• normally?
Yes
If the necessary auxiliary starter, which Repairs

works under cold weather, operates completed
normally?
No
Repairs:
Fit ro maintain the starter auxiliary unit in
cold weather.
96 Fault diagnosis
ISLe375 30 engine
Step 3B: Verify that low pressure fuel pipe layout is correct.
Prerequisites:
Sometimes, the low-pressure fuel pipe is Whether the low pressure pipe is 3C
connected to the incorrectly-mounted ECM connected properly to the ECM cooling
cooling plate. The inlet end is on the top of plate or not?
ECM cooling plate and the bottom Yes
connector is the outlet.
•If the low-pressure fuel pipe is removed Whether the low pressure pipe is Repairs
and refitted on the engine, verify the connected properly to the ECM cooling completed
correct connection. plate or not?
No
Repairs:
Correctly connect the low-pressure fuel
pipe to ECM cooling plate. The fuel inlet is
the top union.
Step 3C: Check the ECM key switch voltage
Prerequisites:
• Disconnect OEM harness from ECM.
Measure the voltage between the input Whether the voltage of key switch is equal 3D
signal conductor of key switch of OEM to that of battery?
harness and the ground of engine block. Yes
• When the key switch is at “ON”
position and “Cranking” position, Whether the voltage of key switch is equal Repairs
measure its voltage. to that of battery? completed
For the identification of joint contact pin, No
refer to electrical wiring diagram. Repairs:
Repair or replace OEM power wire, key
switch or check the battery connection.
Fault diagnosis 97
General
Step 3D: Check the power voltage of ECM battery.
Prerequisites:
• Rotate the key switch to “OFF” position
• Disconnect ECM power wiring harness.
Measure the voltage between the (-) power Is the ECM battery power voltage equal to 3E
contact pin and the (+) power contact pin of the battery voltage?
ECM battery in the ECM power harness Yes
connector.
•When the key switch is at “ON” position Is the ECM battery power voltage equal to Repairs
and “Cranking” position, measure its the battery voltage? completed
voltage. No
For the identification of joint contact pin, Repairs:
refer to electrical wiring diagram. Repair or replace ECM power wire. Check
the battery connector
Fuse terminal.
Step 3E: Check the engine speed in motoring operation.
Prerequisites:
Use INSITE™ service software to monitor Check whether the engine speed is higher 3F
the engine speed in motoring operation. than 150 in the motoring operation: rpm?
Yes
Check whether the engine speed is higher Repairs

than 150rpm in the motoring operation. completed
No
Repairs:
Find out and eliminate the reason of low
cranking speed. Check the loads of
battery, engine starting motor and
accessories
98 Fault diagnosis
ISLe375 30 engine
Step 3F: Verify fuel rail pressure sensor accuracy.
Prerequisites:
• Connect the INSITE™ service software
When the key switch is turned to “ON” Whether the value (measured value) of fuel 3G
position and engine operates, adopt rail fuel pressure sensor is less than
INSITE™ software to monitor the fuel 30bar?
pressure sensor of fuel rail. Yes
Whether the value (measured value) of fuel Repairs

rail fuel pressure sensor is less than completed
30bar?
No
Repairs:
Renew the fuel rail pressure sensor.
Step 3G: Check the fuel rail pressure in the motoring operation.
Prerequisites:
Try to start the engine by running the Does the fault code 559 act when the 3G-1
starter motor for at least 30s. attempt to start fails?
•Use the failure diagnoser to monitor the Yes
fuel rail pressure (measured value and
command value). Does the fault code 559 act when the 3H
•Use the failure diagnoser to read the attempt to start fails?
failure code. No
Attempt to start the engine for continuous
10s, and then reserve logic time necessary
for fault code operation. If the failure code
559 works, the fuel rail will not build up the
pressure.
Note: If the engine starts for this attempt, it
is possibly loss of fuel injected into high
pressure pump previously. Check for any
loose fuel pipe or filter which may cause
loss of fuel during filling.
Fault diagnosis 99
General
Step 3G-1: Check the fuel gear pump pressure
Prerequisites:
• Mount a pressure gauge at the pressure side of fuel filter seat.
At starting the engine, measure the fuel Does the gear pump pressure exceed the Repairs
gear pump output pressure. required limit in the motoring operation? completed
• The motoring speed shall exceed Yes
150rpm. Repairs:
Operate according to the fault diagnostic
tree for the fault code 559.
Does the gear pump pressure exceed the 3G-2

required limit in the motoring operation?
No
Step 3G-2: Check the fuel supply pump pressure
Prerequisites:
• Mount the pressure gauge on the inlet of high-pressure gear pump
Measure the output pressure of feed pump. Is the fuel supply pump pressure higher Repairs
• The feed pump will operate for 30 than the generally required value? completed
seconds and then stops after the key Yes
switch is turned on at the first time. Repairs:
Renew the gear pump.
Is the fuel supply pump pressure higher Repairs

than the required value? completed
No
Repairs:
Ensure that the OEM fuel filter is filled up
with fuel and that the air has been removed
from the low-pressure fuel pipe to verify the
fueling. If necessary, cancel the delivery
pump test via the INSIETM software. .
If the low-pressure fuel system is filled up
with fuel, replace the supply pump.
100 Fault diagnosis

ISLe375 30 engine
Step 3H: Check whether there is other error code that can explain the starting failure
Prerequisites:
• Mount the pressure gauge on the inlet of high-pressure gear pump
Use the INSITE™ service software to read Whether there is fault code which causes Applicable
the failure code. the start failure but is still active in cranking failure code
• Check for the fault code which is process. diagnosis
activated when the attempt to start Yes tree
fails and causes that the engine Repairs:
cannot start. Operate according to the applicable fault
code tree.
Whether there is fault code which causes 4A

the start failure but is still active in cranking
process.
No
Step 4: Fuel system diagnosis procedure

Step 4A: Check whether there is fault code of fuel system
Prerequisites:
Use the failure diagnoser to read the failure Whether there is fault code which causes Applicable
code. the start failure but is still active in cranking failure code
• Determine whether any current failure process. diagnosis
codes for the fuel system as Yes tree
complained are available. Repairs:
Operate according to the applicable fault
code tree.
Does the fuel system failure code work? 4B

No
Fault diagnosis 101

General
Step 4B: Check whether there is any air in the fuel supplied by the high-pressure pump
Check whether there is any air in the fuel Is there any air in the fuel? Repairs
• Yes completed
Repairs:
Check for and rectify the fault that causes
the fuel supply system to intake air. The
reasons for air intake include loose fuel
filter, loose fuel pipe union, loose or
cracked fuel tank suction pipe, or seriously
clogged feed pipe and filter.
Is there any air in the fuel? 4C

No
Step 4C-1: Measure the intake resistance
Prerequisites:
• Measure the inlet resistance of fuel pump.
Check the fuel intake resistance Whether the fuel inlet resistance is higher Repairs
• than the required value? completed
Yes
Repairs:
Find out and eliminate the reason of large
inlet resistance. Check whether the OEM
fuel filter or strainer, the ECM cooler, the
bypass check valve of feed pump (in the
ECM cooler) or the vertical pipe of OEM
fuel tank is clogged, or if the OEM fuel pipe
is bended.
Whether the fuel inlet resistance is higher Repairs

than the required value? completed
102 Fault diagnosis

ISLe375 30 engine
Step 4D: Make the single-cylinder oil-cut test
Prerequisites:
• Rune the engine at low idle speed.
Run the engine with a load. Does the single cylinder misfires or gives Repairs
• Use the failure diagnoser to carry out off a great deal of smoke? completed
the single cylinder fuel cutoff test to Yes
stop any individual injector. Repairs:
Check for the reasons for claims, including
the symptoms such as too large valve
clearance and crankcase pressure
indicating the cylinder wear or the
camshaft wear. If no other damages are
found, replace the injector identified via the
individual cylinder fuel cutoff test. Make the
single-cylinder oil-cut test
Does the single cylinder misfires or gives 4E

off a great deal of smoke?
No
Step 4E: Diagnose and test the balancing of cylinder
Prerequisites:
Use the failure diagnoser to execute the Whether is it possible to find out the Repairs
cylinder performance test to determine cylinder which causes unstable power via completed
whether the engine symptom is caused by the cylinder performance test?
a certain cylinder. Yes
Repairs:
Check for the reasons for unstable power,
including the symptoms such as too large
valve clearance and crankcase pressure
indicating the cylinder wear or the
camshaft wear. If no other damages are
found, replace the injector of cylinder with
unstable power output.
Whether is it possible to find out the 4F

cylinder which causes unstable power via
the cylinder performance test?
No
Fault diagnosis 103

General
Step 4F: Measure the resistance of fuel return pipe.
Check the resistance of fuel return pipe Whether return pipe resistance is lower 4G
• than technical specification?
Yes
Whether return pipe resistance is lower Repairs

than technical specification? completed
No
Repairs:
Check the cause of high resistance of oil
return pipe, for example, the fuel pipe is
twisted or blocked
Step 4G: Monitor the fuel pressure during idle running
Prerequisites:
• Start the engine.
Run the engine at idle speed for at least Does the deviation between the measured Repairs
one minute to Draining the air absorbed in fuel rail pressure and the command completed
the previous step. pressure exceed 200 bar and is the engine
• Use the INSITE™ service software to hunting during idling, or does the engine
monitor the fuel rail pressure. start and then stop?
• Force and measured fuel rail pressure Yes
shall continue for 10s at least Repairs:
• To verify your results, repeat this Renew the fuel pump actuator.
procedure with the INSITE™ software
to carry out the fuel system leakage Does the deviation between the measured 7A
test. fuel rail pressure and the command
pressure exceed 200 bar and is the engine
hunting during idling, or does the engine
start and then stop?
No
104 Fault diagnosis

ISLe375 30 engine
Step 5: Fault diagnosis procedure for air processor system

Step 5A: Check whether the turbocharger vane is damaged
Prerequisites:
• Remove the intake hose and exhaust hose from the turbocharger.
Check whether the compressor and turbine Whether the turbocharger blade is Repairs
vane are damaged or worn damaged? completed
Yes
Repairs:
Renew the turbocharger assembly.
Whether the turbocharger blade is 5B

damaged?
No
Step 5B: Check the axial and radial clearances of turbocharger
Prerequisites:
Check whether the axial and radial Whether the turbocharger axial and radial 5C
clearances of turbocharger are correct bearing clearances are controlled within
the required range?
Yes
Whether the turbocharger axial and radial Repairs

bearing clearances are controlled within completed
the required range?
No
Repairs:
Renew the turbocharger.
Fault diagnosis 105

General
Step 5C: Renew the exhaust gas by-pass actuator
Prerequisites:
• If it is not allowed to approach the exhaust gas bypass valve actuator, remove the turbocharger.
Check whether there is any crack or hole Whether there is sand hole or crack in the Repairs
on the actuator hose of integral exhaust exhaust gas by-pass valve actuator hose? completed
bypass valve Yes
Repairs:
Renew the exhaust gas by-pass actuator
hose.
Whether there is sand hole or crack in the 5D

exhaust gas by-pass valve actuator hose?
No
Step 5D: Check whether the actuator rod of exhaust bypass valve moves
Prerequisites:
• Remove integral supercharging pipe from exhaust bypass valve actuator.
Connect the 138kPa regulating air source Whether the exhaust gas by-pass valve Repairs
with the actuator and check whether the actuate lever moves or not? completed
actuator moves Yes
Whether the exhaust gas by-pass valve 5D-1

actuate lever moves or not?
No
106 Fault diagnosis

ISLe375 30 engine
Step 5D-1: Check whether the actuator rod of exhaust bypass valve moves
Prerequisites:
• Remove integral supercharging pipe from exhaust bypass valve actuator.
Connect the 138kPa regulating air source Whether the exhaust gas by-pass valve Repairs
with the actuator and check whether the actuate lever moves or not? completed
actuator moves Yes
Repairs:
Move the exhaust gas bypass valve control
lever on the turbocharger.
And check whether the operation can be
carried out smoothly.
If the exhaust gas bypass valve is seized,
replace the turbocharger assembly.
Whether the exhaust gas by-pass valve Repairs

actuate lever moves or not? completed
No
Repairs:
Renew the exhaust gas by-pass actuator.
Step 6: Fault diagnostic procedures for electrical features.

Step 6A: Verify accelerator pedal range.
Prerequisites:
Use the INSITE™ service software to Whether the reading of throttle position is 0 6B
monitor the throttle position when the when the throttle is released; whether the
accelerator pedal is fully depressed or reading is 100% when the throttle is
released. stepped down.
Yes
Whether the reading of throttle position is 0 Repairs

when the throttle is released; whether the completed
reading is 100% when the throttle is
stepped down.
No
Repairs:
Determine and eliminate causes to block
the accelerator pedal.
Fault diagnosis 107

General
Step 6B: Check the precision of air pressure sensor
Prerequisites:
Start INSITE™ service software data Is the difference for reading of INSITE™ 6C
monitoring/recorder, and compare with the service soft and that of local air pressure is
atmospheric pressure indicated by within 102mm-Hg?
INSITE™ software and the local Yes
atmospheric pressure in terms of following
data: Is the difference for reading of INSITE™ Repairs
Altitude 0 m seal level): Pressure of service soft and that of local air pressure is completed
759mm-Hg within 102mm-Hg?
Altitude 915 m: Pressure of 683mm-Hg No
Altitude 1830 m: Pressure of 864 mm-Hg
Altitude 2744 m: Pressure of 544mm-Hg
Altitude 3659 m: Pressure of 483mm-Hg
Step 6C: Check the precision of intake manifold pressure sensor
Prerequisites:
When the engine fails to operate, use If the reading of intake manifold pressure is 6D
INSITE™ software to monitor the pressure lower than 102mmHg
of intake manifold. Yes
If the reading of intake manifold pressure is Repairs

lower than 102mmHg completed
No
Repairs:
Renew the intake manifold pressure
sensor.
108 Fault diagnosis

ISLe375 30 engine
Step 6D: Verify that electronic characteristic setting is correct.
Prerequisites:
Use the failure diagnoser to verify the Whether the electrical features have been 2A
correctness of following adjustable set correctly?
parameters: Yes
• Maximum vehicle speed
• Drive system protection Whether the electrical features have been Repairs
• Rear axle drive ratio set correctly? completed
• Number of tail shaft teeth No
Repairs:
• Revolution per mileage
Use the failure diagnoser to recover the
• Down-shifting protection
programmable characteristics.
• Setting of cruise control speed
• Maximum cruise control speed
Step 7: Procedures for basic engine fault diagnosis.

Step 7A: Verify that overhead mechanism adjustment is correct.
Prerequisites:
• Remove rocker chamber cover.
Measure the setting of overhead Is the mechanism set within the adjusting 7B
mechanism. range?
Yes
Whether the overhead mechanism is within Repairs

the adjustment limit? completed
No
Repairs:
Adjust the overhead mechanism.
Fault diagnosis 109

General
Step 7B: Verify that engine brake & adjustment device.
Prerequisites:
• Remove rocker chamber cover.
Measure the setting of overhead Is the mechanism set within the adjusting 7B
mechanism. range?
Yes
Whether the overhead mechanism is within Repairs

the adjustment limit? completed
No
Repairs:
Adjust the overhead mechanism.
Step 7C: Check the air-air intercooler
Check whether the air-air intercooler has Is the air-air intercooler cracked or 7D
any crack, hole or damage damaged?
Yes
Is the air-air intercooler cracked or Repairs

damaged? completed
No
Repairs:
Repair the air-air intercooler assembly.
Step 7D: Check the air inlet resistance
Mount vacuum gauge in air intake system Is the intake resistance within the technical Repairs
to check the system resistance. range? completed
• Yes
Repairs:
Eliminate the cause resulting in high intake
resistance
Check whether the air filter or intake pipe is
blocked
Is the intake resistance within the technical 7E

range?
No
110 Fault diagnosis

ISLe375 30 engine
Step 7E: Check the exhaust resistance
Mount the pressure gauge at the outlet Is the exhaust pressure within the 7F
adjacent to turbocharger of exhaust system specifications
to check the exhaust back pressure. Yes
•
Is the exhaust pressure within the Repairs
specifications completed
No
Repairs:
Check the reason why the exhaust system
resistance is too high
Step 7F: Verify that engine blow-by gas meets technical specification
Measure the blowby value of engine. Whether the measured engine blow-by 7F
value meets the technical specification?
Yes
Whether the measured engine blow-by 7F-1

value meets the technical specification?
No
Step 7F-1: Verify the effect of turbocharger on engine blow-by gas
Prerequisites:
• Connect the proper metering hole with one end of upper exhaust (blowby) guide pipe
• Remove turbocharger oil drain pipe from cylinder block, and drain oil into the barrel.
• Start the engine.
Measure the blowby value of engine. Does the total blow-by quantity of engine Repairs
drops more than 30%? completed
Yes
Repairs:
Renew the turbocharger assembly.
Does the total blow-by quantity of engine Repairs

drops more than 30%? completed
No
Repairs:
It may be necessary to refit the engine.
See “Technical specification for refitting the
engine”.
Fault diagnosis 111

General
5. Fuel economy diagnosis & solution tree

The troubleshooting procedures are applicable for the following phenomenon:
• Overhigh fuel consumption
How to use this failure diagnosis and solution procedure:
This symptom tree is used for fuel economy diagnosis. This table “Symptom tree & fuel consumption –
use comments” should be used together with the table “Inspection of low power/too high fuel
consumption regarding driving performance”, so as to determine the problems of engine, chassis or
driving as a result of too high fuel consumption.
Notes for overhaul:
Refer to the Fuel Consumption-General section in this manual and the Troubleshooting Instructions for
Excessive Fuel Consumption before making any fault diagnosis on the engine purchased by the
customer.
It is difficult to diagnose and correct the causes of fuel consumption for many potential factors. The
real-life fuel consumption problems may be caused by following factors:
• Engine elements
• Vehicle factors & technical specifications
• Environmental factors
• Driver's skills and operation methods
• Factors of fuel system
• Low power/poor drivability.
Position the trouble correctly before fault diagnosis. Is the problem really present, or felt, or just caused
due to the failure to satisfy the driver’s expectation? Valuable problems are listed in the fuel
consumption-Form for User’s Opinions, which can be used by the repairman to find out causes. Be sure
to fill in this table before troubleshooting. Following factors must be taken into account in the fuel
consumption diagnosis.
• Too long idling period: Depending on the specific idle speed, fuel of 0. 5-1. 5gal can be consumed
every hour when the engine runs with an idle speed.
• Vehicle pneumatic auxiliary units: The maximum power demand of truck is from the power used to
overcome the air resistanceUsually, at every reduction of 10% of air resistance, the running
distance per gallon of fuel will be increased by 5%.
• Rolling resistance: Rolling resistance is the secondary power consumption for a truck. The type and
tread design of tyre have great influence on the fuel economy and performanceReplace the
diagonal-ply tyre with radial tyre, and in this way, the rolling resistance can be reduced by 36% or so
• Change of environment and seasonal weather: The difference of mileage by every gallon of fuel can
be up to 1 to 1. 5 miles, depending on the season and climate conditions.
• Running line and landform of truckThe traveling route in the east-west direction is affected by the
cross wind and free wind almost all the time. However, the fuel consumption in the south-north
traveling route is very low, as the weather is warm and the wind resistance is low in some areas.
• Driver’s skills and operation methodsThe fuel consumption increases 0. 1 mile/gallon when the
vehicle speed rises by 1 mile/hour on the road. This shows 1mpg (amount of fuel used per unit
distance) will be lost when the vehicle speed increases from 50mph to 60mph.
• Results due to low power or poor drivability: The driver can change the driving style to compensate
the low power or bad driving performance. The measures may be taken by the driver include (a)
increasing the engine speed, or (b) operating under the speed regulating curve upon low gear not
operating by upshifting with partial accelerator. The change of driving style will increase the fuel
consumption.
112 Fault diagnosis

ISLe375 30 engine
Other vehicle factors, technical specifications and axle location may affect the fuel consumptionFor the
additional information on fault diagnosis of fuel consumption; refer to high fuel consumption fault
diagnosis and troubleshooting manual.
Troubleshooting summary
Step 1: Verify fault
Step 1A: Fill in with fuel consumption-Form of User’ Opinions
Step 1B: Operate VE/VMS.
Step 2: Use the failure diagnoser for electronic system check.
Step 2A: Check whether there is error code
Step 2B: Confirm characteristics and parameters.
Step 2C: Check the calibration of ECM
Step 2D: Check the vehicle speed
Step 2D-1: Check the grounding of engine and chassis
Step 3: Engine performance
Step 3A: Fault diagnosis of engine performance.
Troubleshooting procedures
Step 1: Verify fault
Step 1A: Fill in with fuel consumption-Form of User’ Opinions
Prerequisites:
Fill in with fuel consumption-Form of User’ Is the problem caused by the vehicle Repairs
Opinions factors, environmental factors or the completed
driver’s competence?
Yes
Is the problem caused by the vehicle 1B

factors, environmental factors or the
driver’s competence?
No
Fault diagnosis 113

General
Step 1B: Operate VE/VMS.
Prerequisites:
Fill in with driving performance/low If with consideration to unfavorable 2A

power/high fuel consumption-Inspection influences of environmental conditions, is
sheet the VE/VMS fuel economy in line with the
•Use the collected data to run VE/VMS or current fuel efficiency of user?
provide the data to the proper operator to Yes
run VE/VMS.
If with consideration to unfavorable Repairs
influences of environmental conditions, is completed
the VE/VMS fuel economy in line with the
current fuel efficiency of user?
No
Repairs:
Explain to users the influence of driving
habits on the fuel consumption
Step 2: Use the INSITE™ service software to carry out electronic system check.
Step 2A: Check whether there is error code
Prerequisites:
Use the INSITE™ service software to read Whether there is any high-frequency Fault code
the failure code. occurrence of current failure codes or diagnosis
Yes
Whether there is any high-frequency 2B

occurrence of current failure codes or
No
114 Fault diagnosis

ISLe375 30 engine
Step 2B: Confirm characteristics and parameters.
Prerequisites:
Confirm that the programmable Whether characteristics and parameters 2C

characteristics and parameters are are correctly set?
correctly set. Yes
Whether characteristics and parameters Repairs

are correctly set? completed
No
Repairs:
Reset the characteristics and parameters
to correct value
Step 2C: Check the calibration of ECM
Prerequisites:
Compare ECM code with engine Is the calibration correct? 2D

specifications and CPL Yes
• Verify whether the calibration is
correct. Is the calibration correct? Repairs
No completed
Repairs:
Calibrate ECM with correct ECM code.
Step 2D: Check the vehicle speed
Prerequisites:
Use INSITE™ software to monitor vehicle Speed reading is 0 when vehicle is 3A

speed when vehicle is stationary. stationary?
Yes
Speed reading is 0 when vehicle is 2D-1

stationary?
No
Fault diagnosis 115

General
Step 2D-1: Check the grounding of engine and chassis
Prerequisites:
Check the grounding connection of engine, Whether all earthings are present, correctly Repairs
chassis or battery is loose or eroded performed and reliably connected without completed
• Check the grounding connection of corrosion?
engine Yes
• Check the grounding connection of Repairs:
chassis Check the VSS and VSS circuit
• Check the terminal connection of
battery Whether all earthings are present, correctly Repairs
performed and reliably connected without completed
corrosion?
No
Repairs:
Renew, clean or tighten the earth terminal.
Step 3: Engine performance

Step 3A: Fault diagnosis of engine performance.
Prerequisites:
Carry out the fuel system inspection, A/C Does the problem of poor fuel economy Repairs
adjusting inspection and basic engine remain there? completed
inspection in the engine performance fault Yes
diagnosis Repairs:
Carry out the fuel system inspection, A/C
adjusting inspection and basic engine
inspection in the engine performance fault
diagnosis
Does the problem of poor fuel economy Repairs

remain there? completed
No
116 Fault diagnosis

ISLe375 30 engine
Engine block
Precautions
I. Cleaning essentials of engine
1. Solvent and pickling
The engine components and parts can be cleaned with many solvents and acid cleansers. It is
recommended by Dongfeng Cummins Engine Co., Ltd that any special cleaning fluid should not be used.
Use the cleanser with the instructions of manufacturer.
The test shows that the effect of cleaning agent heated to 90~95℃ is the bestIn the washing operation,
mixing the cleaning solvent at a certain proportion and filtering it can largely improve cleaning effects.
Before mounting the part in the cleaning cabinet, remove all the gaskets, O-rings, deposited sludge or
carbon deposit by iron wire brush or shovel
Caution: Do not damage any surface which is in conjunction with the pad. If possible, use the
steam to clean parts before they are put into the cleaning cabinet.
Warning: The acid is a very hazardous substance, which may damage the machine. Therefore,
a box of dense soda water shall be always prepared to be used as the neutralizing
agent.
After the pickling, rinse all parts with hot water, and fully dry them with compressed air. Blow out the
residual washings from all screw holes and oil passages.
If the parts are not immediately used after they are cleaned, apply the anti-rust oil onto them. The
antirust oil must be removed before these parts are installed on the engine
2. Steam cleaning
A variety of dirt which may pollute the cleaning cabinet can be removed by steam cleaning mean. It is a
good way to clean the oil passage with steam.
Warning: To avoid human injuries due to high pressure and high temperature, wear protecting
clothes.
Do not use steam to clean the following parts:
• Electrical components
• Electric circuit
• Fuel injector
• Fuel pump
• Belt and hose
• Bearing
Glass or plastic shot blasting
The glass or plastic shot blasting can used to remove many kinds of carbon deposit on the engine
components. The size of glass or plastic shot peen, working pressure and duration have a direct
bearing on the cleaning effects.
Caution: Do not use the glass or plastic shot blasting to clean the aluminum piston skirt. Do
not employ the shot peening method to clean the aluminum piston ring groove. The
particles of glass will embed into the aluminum parts and cause the early wear of
parts. The intake valve, turbocharger shaft etc may be also damaged in shot peening.
Please observe requirements in the shot peening as specified in the following
procedure.
Cleaning essentials of engine 117

Engine block
Caution: The plastic shot peen medium can be used to clean the aluminum ring groove. Do
not use any shot blasting medium to clean the pine hole or the aluminum skirt.
Please observe following guidance on cleaning provided by the equipment manufacturer.
1. Dimension of shot
• Use the America No. 16-20 plastic medium shot peens to clean the piston.
• Use the America No. 70 glass medium shot peens to clean the piston crown.
• Use the America No. 60 glass medium shot peens to clean ordinary parts.
2. Working pressure:
• Glass: In ordinary washing operation, adopt a pressure of 620kPa.
• Plastic: Clean the piston at 270kPa.
3. After blast cleaning, clean the component of residual glass shot blast and impurity with the
steam mixed with cleanser. Wash with hot water again. And dry it with compressed air.
4. Do not let the glass or plastic shot blasting contaminate the cleaning cabinet.
118 Cleaning essentials of engine

ISLe375 30 engine
II. Repairing essentials of engine

The engine reflects the latest technology for the time it was manufactured: However, the quality
requirements can be satisfied even if ordinary repair methods are adopted.
• Except the items described on Dongfeng Cummins Service Bulletin, the company does not
recommend or authorize any modification or repair towards Cummins engine or parts. Especially,
for the components related to safety, the unapproved reconstruction may cause personal injury and
even casualty. Following parts are related to the safety:
Air compressor Fan mounting screw Lifting device

Air control mechanism Fan hub spindle Throttle control mechanism
Air cut valve assembly Flywheel Turbocharger air compressor
casing
Bogie Flywheel crankshaft connecting Turbocharger return pipeline
flange
Cooling fan Flywheel mounting screw Turbocharger supply pipeline
Fan hub assembly Fuel cutoff valve assembly Turbocharger turbine casing
Fan mounting bracket Fuel supply pipe Mounting screw of torsion and
vibration absorber
• Follow the safety regulations mentioned in this procedure.

- Use the cleaning solvent and other material suggested by the engine manufacturer during repairing.
The government agency has proved that some solvents and used engine oil are poisonous or
carcinogenic. Avoid the excessive inspiration or contact of such substance. The tools and
equipments must be used safely and correctly.
• Provide a clean environment and follow guidance on cleaning as stipulated.
- It is important to keep the mechanical parts clean. Any pollutant on the engine or engine
components will cause premature wear.
• Exercise the inspection as required.
• Renew all components or assemblies which do not meet the specification due to damage or wear
• Use original Dongfeng Cummins parts and assemblies.
- The key points for assembling have been provided in written form to make it applicable to as more
as possible components and assemblies. The renewing procedure of component or assembly is
written on the precondition that new and genuine Dongfeng Cummins parts are used. All the repair
services described in the manual are provided by Dongfeng Cummins Maintenance Station.
• Operating according to the specified dismantling and assembling procedures can avoid damaging
components
As for key points in the overhaul, refer to Overhual Manual. The overhaul manual is available in
designated service centers by Dongfeng Cummins Engine Co. , Ltd
Repairing essentials of engine 119

Engine block
Engine assembly
I. Removal and refitting of engine assembly
1. Recommended tools and consumables
Tool and auxiliary material Name and model
Sockets S8/S10/S13/S16/S18/S21/S27
Common tools
Offset ring spanner S10/S13/S16/S22, slip joint pliers
Special tool Engine hook
Testing tools Torque spanner (40~200N·m)
Auxiliary material Oil pan, lubricant, refrigerant, cooling fluid and steering fluid
2. Procedure
Removal
1. Disconnect the main power

2. Draining the engine coolant
3. Wash the engine.

Clean the engine with steam.
120 Removal and refitting of engine assembly

ISLe375 30 engine
Warning: The fuel is flammable. Make sure

to put the cigar, open flame,
indicator lamp, electric arc
equipment and switch away from
the working area, and install
ventilation in the working area
during the operation of fuel
system, so as to reduce potential
severe human injury or even
death.
4. Disconnect the OEM fuel pipe and return
pipe
1). Remove fuel feed pipe and the return pipe,
and then block with caps.
2). Attach a label to indicate their positions when

disassembling all the hoses, hard tube,
linkage and electrical joint.
Warning: To minimize personal injuries,

avoid the direct contact with hot
engine oil.
5. Draining the oil
6. Disconnect the pipeline, cable harness and
cable connecting the engine, cab and
chassis
7. Disconnect the intake and exhaust pipes

1). Disconnect the intake hose and exhaust hose
from the turbocharger end.
8. Remove all the engine-driven accessories
installed on the chassis
Removal and refitting of engine assembly 121

Engine block
9. Disconnect the drive unit of flywheel

housing
10. Remove all the related parts
11. Seal all the openings of engine

1). Seal the opening with clean blanking cover to
avoid the entry into engine of dirt and chip.
Warning: The engine lift must be capable of

lifting safely the engine and
gearbox as a whole so as to avoid
human injury. Know the general
specifications of engine, engine
weight and gearbox weight
Warning: If the gearbox is not removed,
place a support beneath the
gearbox prior to the removal of
engine, to prevent the gearbox
from falling.
Refer to the related procedure for the technical
specification of engine weight.
Connect the crane of correct rated power and the engine lifter onto the engine lug to remove the engine.

ISLe375 30 engine
Caution: Pay attention to the position of

any shim or spacer bush during
the removal of engine rear
mounting fasteners.
12. Remove fastener for the engine
suspension
Caution: If the engine rear mounting is

connected with the gearbox,
generally it is required to remove
the engine and gearbox as an
integral part.
13. Lift the engine assembly
Caution: To repair the engine, fit the engine

bracket connecting board onto the
exhaust side of engine. Before the
engine support connecting plate
is installed, the turbocharger shall
be dismountedMount the
connecting board of engine
support on the moveable tilting
engine bracket
Caution: To replace the engine, mount the
engine onto a proper shipping
pallet

Engine block
Caution: To replace the engine, remove all

remaining accessories, brackets
and drives.
Refitting
Caution: To repair the engine, lift the
engine and its regenerating
bracket connecting board from the
engine
1. Remove connecting plate of engine
support
Caution: 1. The provision of a turbocharger

may be required after removing
engine bracket connecting board.
2. In case of engine replacement,
lift the engine to be replaced on
the pallet.
3. If the rear suspension of engine
is connected with the
transmission, usually Fit the
engine and transmission as an
assembly.

ISLe375 30 engine
2. Remove all the sealing plugs
3. Fix the engine front/rear suspension

(1). Align the engine and screw up its mounting
bolts.
4. Connect all the accessories removed from
engine and chassis
Caution: 1. Ensure that all pipelines, hoses

and metal pipes are arranged and
fixed properly, so as to prevent
any damage. Ensure that the
intake pipe and exhaust pipe are
closely connected without any
leakage.
2. If not installed together with
engine, connect drive unit to
flywheel shell. For the relevant
specifications, refer to OEM
maintenance manual.
5. Add the engine oil

1). Fill the engine with clean 15W-40# engine oil.

Engine block
Caution: The total volume of engine coolant

can change.
6. Add the coolant
Refer to “Technical specification of cooling
system”.
Caution: It is of vital importance for

installation of cooling system
pressure cover to correctly bleed
the air inside. If the air is not
Drainingd from the cooling system
correctly, the engine may be
damaged due to overheating
7. Full inspection
Ensure that all hoses, leads, connectors and parts
are correctly fitted and fastened.
Warning: The battery may give off explosive

gas. To minimize personal
injuries, keep the engine
compartment well-ventilated prior
to the repairs of battery. To avoid
the generation of electric arcs,
firstly remove and finally refit the
negative (-) cable.
8. Connect the battery
9. Disconnect 4-pin power plug from

electronic control module (ECM)
Prevent the engine from starting.

ISLe375 30 engine
Caution: Make sure to fill the oil before

operating the engine which has
undergone maintenance or
overhaul, so as to avoid the
damage of internal components.
10. Mount pressure gauge in main oil way at
the air feed side of engine.
Caution: If the port on the main oil passage
is unavailable, fit a pressure
gauge onto the top of engine oil
filter seat.
Caution: Do not let the starter motor

engage longer than 30 s. To
minimize engine damages, wait for
2min. in the engine engagement
period to cool down the starter
motor.
11. Measure the oil pressure
1). Drive the engine with motor till the pressure
indicated on engine oil pressure gauge is
normal.
12. Disconnect the 4-pin power connector of

ECM
13. Remove manometer
14. Add the fuel

Engine block
Warning: Do not open the pressure cap of

radiator on the hot engine. Open
the pressure cover after the
coolant temperature is reduced to
below 50℃. Otherwise, the
high-temperature coolant or steam
may eject to cause human injury.
15. Run the engine with low idle speed
1). Operate for 2~3 min.
2). Stop the engine and wait 5 to 7 min to allow
the oil to flow into the oil sump.
16. Recheck the engine oil level and cooling

fluid level.
1). If necessary, fill engine oil or coolant into the
engine till the correct level is reached.
17. Check whether the engine runs normally

1). Run the engine at the speed of 1,000 to
1,200rpm for 8 to 10 min.
2). Check whether the rotation is normal, there is
abnormal noise or leakage of coolant, fuel or
oil
3). Repair all parts with leakage and other
failures.
Caution: Use the failure diagnoser to read

and clear all failure codes.

ISLe375 30 engine
II. Disassembling and assembling of engine

Sockets S13/S16/S18/S21/S27, double offset ring & open-end wrenches

Common tools S21, slotted screwdriver
Jack and rigid bracket
Special tool - -
Auxiliary material Lubricating grease
2. Procedure
Disassemble
1. Remove oil filter (rotary)
1). Clean the immediate area of engine oil filter
base
2). Use the engine oil filter spanner to remove the
filter.
3). Clean the sealing surface of filter seat with
clean lint-free cloth.
2. Remove coolant filter

Warning: 1. Repair of coolant filter should
be done when cut-off valve is at
“OFF” position, and little coolant
may leak. To minimize personal
injuries, avoid the contact with hot
coolant.
1). Remove and discard coolant cleaner.
Disassembling and assembling of engine 129

Engine block
3. Remove fuel filter (screw-in)

Warning: Fuel flammability depends on the
environment. During inspection or
maintenance or repair of fuel
system, smoking or use of open
flame (e. g. identification lamp,
electrical switch or welding
equipment) in the working area is
forbidden in order to reduce
potential fire and serious human
injury or death or property loss.
1). If fitted, disconnect the lead wire from the
water-in-fuel sensor.
2). If fitted, disconnect the lead wire from the fuel heater.
3). Undo and remove the fuel filter, and ensure that the seal ring is seized in the filter seat.
4). . If necessary, use the special tool to remove the O-shaped ring.
4. Remove drive belt of cooling fan

Caution: 1. Belt tensioner is spring-loaded,
and must be screwed down from
drive belt. The incorrect rotating
direction may cause the damage
on belt tensioner.
2. The application of too high
force in reverse direction of spring
bending or after spring is turned
to stopper will give rise to crack or
breaking of tensioner arm.
3. We no not recommend to use
long sleeve, because in this case,
the belt tensioner will be damaged
due to the deformation of shaft
direction.
1). Prepare a belt arrangement plan before disassembling the driving belt. This is for the convenience
of installation and to ensure the correct arrangement of cooling fan driving belt.
2). Lift tensioner when removing drive belt.
Caution: If it is necessary to use any extension socket, use one hand to support the ratchet
spanner head to prevent any accidental loading of belt tensioner arm.
130 Disassembling and assembling of engine

ISLe375 30 engine
5. Remove front engine support

1). Remove 4 mounting bolts.
2). Remove front engine support.
6. Remove fan spacer bush and the belt

pulley
Caution: Some engines have no cooling fan
or the cooling fan is not at the
engine.
1). If fitted, remove the cooling fan.
2). For engine fitted with startup cooling fan,

fasten the pulley and spacer bush in place.
Remove fan pulley & spacer ring.
2. If the engine is not equipped with cooling
fan, remove fan pulley mounting bolt and fan
pulley.
7. Remove belt drive fan hub

1). Remove mounting bolts for the fan hub.
2). Remove fan hub.

Engine block
8. Remove automatic belt tensioner (water

pump)
1). Remove the bolt and belt tensioner from the
bracket.
9. Remove charger
1). Remove bolt for the linkage of charger.
2). Remove mounting bolt for the charger.
3). Remove charger.
10. Remove charger bracket

1). Remove charger bracket mounting bolt &
bracket.
11. Remove coolant filter seat

1). Undo these four filter seat bolts.
2). Remove filter seat and the sealing gasket.

ISLe375 30 engine
12. Remove coolant thermostat

1). Remove water outlet joint bolt & outlet joint.
2). Remove thermostat.
13. Remove coolant heater

1). Disconnect the electrical cable of coolant
heater.
2). Undo the coolant heater, and remove it from

the cylinder block.
14. Remove water pump

1). Remove water pump bolts and water pump

Engine block
15. Remove water inlet pipe union

1). Remove water inlet joint bolt.
16. Remove rear engine support

1). Remove 4 bolts and rear bracket.
17. Remove starter motor

1). Attach a label to each conducting wire to
indicate their positions on starting motor.
2). Remove electric terminal on the starter motor.
3). Remove 3 bolts and the starter motor.
4). If the starter motor spacer ring is fitted,
remove the ring and use the steel wire brush
to clean the surface between the starter
motor, motor spacer ring and the flywheel
housing.
18. Remove flexible connecting disc

1). Remove flexible coupling disc bolt & flexible
coupling disc.
Caution: Certain flexible connecting discs
require the use of installation disc
and/or snap ring. It may be
required to remove all mounting
discs and/or adapters at or prior to
the use of flexible connecting
disc. Ensure that all mounting
positions of installing disc and/or
adapter are recorded to facilitate
the installation in future.

ISLe375 30 engine
19. Remove flywheel

Caution: Use the turning gear to fix the
flywheel to prevent it from
rotating.
1). Remove 2 bolts fitted at angle of 180 degrees.
2). Fit 2 M12×1. 25×90mm guide pins
Caution: If the clutch is used, the threaded
hole for the clutch pressure plate
mounting bolt can be either metric
or standard. Ensure that the
correct bolt is used.
3). Determine the pattern and specifications of bolt threads, and fit two T-shaped handles at points (1)
and (2) on the flywheel.
4). Remove rest 6 mounting bolts for the flywheel.
Warning: The weight of this component is

up to or more than 23 kg. To
minimize personal injuries, use
this component with a lifting
device or under the assistance of
others.
5). Remove flywheel from guide pin.
20. Remove rear oil seal of crankshaft

1). Drill two (2) holes at two positions on oil seal
support which have an included angle of 180°.
2). Use the screwdriver and slide hammer to

remove the rear oil seal.

Engine block
21. Remove flywheel housing

1). When the flywheel housing is supported,
disassemble mounting bolts.
2). First support the flywheel housing and then

loosen the flywheel housing with rubber
hammer.
3). Remove flywheel shell.
Caution: When removing flywheel shell,
record the positions of all locating
pins on flywheel shell.
22. Remove oil dipstick tube

1). Take out the dipstick from the oil dipstick pipe.
2). Remove dipstick pipe from cylinder block.
(1). Use the groove puller and M8×1. 25×21mm
self-tapping bolt. Screw the bolt into the oil
dipstick and then remove the oil dipstick
23. Remove outlet connector of turbocharger

compressor
1). Remove the turbocharger outlet elbow, the
V-band clamp and O-ring from the
turbocharger compressor outlet.

ISLe375 30 engine
24. Remove oil return pipe of turbocharger

1). Clean the surroundings of oil return pipe of
cylinder block with clean cloth.
2). Remove two bolts fixing return pipe &
turbocharger.
3). Pull the oil return pipe out from the cylinder
block
25. Remove oil feed pipe of turbocharger

1). Remove the feed pipe from the connector of
oil filter retainer.
Caution: Use the wrench to fix the pipe
union in the engine oil filter to
prevent unintentional looseness.
2). Remove the feed pipe from the turbocharger

bearing housing connector.
26. Remove turbocharger

1). Remove 4 mounting nuts for the turbocharger.
2). Remove turbocharger and the sealing gasket.

Engine block
27. Remove dry-type exhaust manifold

1). Remove bolt, the exhaust manifold and the
gasket.
2). Apply a thin coat of nickel base high
temperature complex grease onto coarse
thread of manifold bolt.
28. Remove oil cooler

1). Remove oil cooler cover, the sealing gasket
and the oil cooler core.
29. Remove pipe of ventilating device for the

crankcase
1). Remove the crankcase ventilation pipe from
the ventilation assembly.
2). Remove the crankcase return pipe from the
ventilation assembly.
3). Remove ventilation return pipe, cap & gasket

from cylinder block.

ISLe375 30 engine
30. Remove intake pipe union

1). Remove V clamp fixing intake joint adapter &
intake joint.
2). Remove intake pipe union adaptor.

1). Remove mounting bolt.
2). Remove intake pipe union.
32. Remove cold start auxiliary device

1). Remove intake heater.
33. Remove fuel feed pipe

1). For fast-acting fuel pipe, remove the clamp
from the pipe bracket. This makes pipe
movable for the convenience of disconnection.

Engine block
2). Loosen all fast-acting tubes from the carrier.

3). Before removing gear pump outlet pipe, make
sure to remove gear pump outlet pipe.
4). Press in the latches at both sides of quick

disconnect coupling and remove quick
disconnect fuel pipe.
Caution: To facilitate the removal, insert the
screwdriver into the space
between the fuel pipe end and
quick-break external threaded
pipe. After pushing down the lock
plates at two sides, rotate the flat
head of screwdriver to
disassemble fuel pipe.
34. Remove fuel return pipe

death.
Warning: Do not bleed the fuel system when
the engine is hot, or, the fuel may
splash onto the exhaust manifold
to cause the fire.
Caution: There are three return pipes on the engine:

1. Fuel pump’s return pipe connects fuel pump and fuel return manifold.
2. Fuel rail reducing valve return pipe is connected with reducing valve and fuel
return manifold.
3. The return pipe of injector connects the rear part of cylinder head with the fuel
return manifold.
1). The pipelines can be removed after the removal of hollow bolt and the sealing washer

ISLe375 30 engine
35. Remove fuel filter seat bracket

1). Remove cleaner bracket from engine.
36. Remove fuel feed pipe of injector (high

pressure)
1). Undo the fuel pipe and its union on the fuel rail
as well as the high-pressure fuel pump outlet
pipe union.
2). Undo the shock-absorbing pad bolt of
high-pressure fuel rail pipe bracket.
3). Remove high pressure fuel pipe.
37. Remove intake manifold cover

1). Remove mounting bolt and the intake
manifold cap.
2). Seal the opening of intake manifold with
adhesive tape to avoid the entry into air intake
system of chips.
Caution: Ensure that the manifold edge is
not fully covered by the adhesive
tape to facilitate the surface
cleaning.
38. Remove fuel pipe union (if fitted)

1). Remove fuel joint fixing nut.
2). Use the fuel pipe union puller to remove the
union from the cylinder head.

Engine block
39. Remove rail

1). Remove bolts fixing fuel rail & cylinder head.
2). Remove fuel rail assembly.
40. Remove fuel pump

1). Undo bolts (1) and (2) to remove the fuel
pump upper bracket.
2). Slowly move the engine, until the scale on fuel

pump gear flushes with the scale on front gear
chamber, thus determining top dead point on
1# cylinder.
3). Remove fuel pump gear nut & washer

4). Use the fuel pump gear puller to pull the
injector pump drive gear to disengage from
the pump transmission shaft.

ISLe375 30 engine
5). Remove four mounting nuts fitting fuel pump

onto gear chamber.
6). Remove fuel pump.
41. Remove coolant pipe of air compressor

1). Remove air compressor cylinder head and the
cylinder body coolant pipe.
42. Remove oil feed pipe of air compressor

1). Remove air compressor & cylinder block’s air
compressor supply pipe.
43. Remove air compressor

1). Remove air compressor bracket & bolt.
2). Remove 2 bolts and the air compressor.

Engine block
44. Remove fuel-cooled ECM cooling plate

1). Remove ECM cooling plate bolts &ECM
cooling plate from engine cylinder block.
Caution: The electric fuel filling pump and
its fuel pipe should be connected
onto the ECM cooling plate during
the removal of cooling plate.
45. Remove ventilating device for the

crankcase (outer)
1). Remove mounting bolt.
2). On respirator assembly, pull upwards the
respirator vertically and remove it from the
rocker arm cover.
46. Remove rocker chamber cover

1). Remove bolt.
2). Remove rocker chamber cover and the
sealing gasket.
Caution: If the engine is equipped with a
brake, the rocker arm
compartment cover may be
higher.
47. Remove engine brake assembly

1). Disconnect the cable and cable harness from
the electrical connector of rocker housing

ISLe375 30 engine
2). Disconnect the cable from the brake solenoid.

Caution: After removing brake, it is more
convenient to remove cables from
rocker chamber shell.
3). Remove as required 6 mounting bolts and

plain washers from one or two engine brake
assemblies.
4). Remove as required one or more brake

assemblies.
48. Remove rocker arm

1). Remove the bolt from the rocker shaft support.
2). Remove shaft seat and rocker assembly, and
mark the position after every removal.
3). The rocker arm assembly must be fitted as per
its original position and direction.

Engine block
49. Remove bridge plate

Caution: Record the position and direction
of jumper plateIf the jumper
pressure plates are used again,
they must be refitted as per their
original positions and directions.
1). Remove jump pressure plate.
2). Mark the ejector sleeves for reassembling

3). Remove ejector sleeve.
50. Remove injector (Cummins common rail

fuel system)
1). Disconnect the cable and cable harness from
the injector.
2). Remove 2 injector holding-down bolts and the
clamps.
3). Use a small pry bar to pry out the injector
hoop pressing flange (a portion of injector
body is just an integral part of cylinder head
casting).
51. Remove rocker chamber housing

1). Remove mounting bolts for the rocker
chamber.
2). Remove rocker chamber shell & gasket from
cylinder head.

ISLe375 30 engine
52. Remove cylinder head

1). Remove cylinder head bolt.
53. Remove rubber damper

Caution: Some engines use four shock
absorber bolts but other engines
use five shock absorber bolts
1). Remove vibration insulator.
54. Remove viscous vibration insulator

1). Remove vibration insulator.
55. Remove front oil seal of crankshaft

1). Remove bracket for the front oil seal of
crankshaft.

Engine block
2). Remove the oil seal from the carrier. Push the
oil seal from bracket rear to its front when
supporting the bracket.
56. Remove front gear chamber cover

1). Remove front gear chamber cover
57. Remove oil pump

1). Remove 4 mounting bolts.
2). Remove oil pump from the hole of cylinder
block.
58. Remove engine oil heater

1). Disconnect the electrical cable of oil heater.
2). Remove heater element.

ISLe375 30 engine
59. Remove oil sump

1). Remove oil sump and the washer.
60. Remove oil suction pipe (fitted on the

cylinder block)
1). Remove oil suction pipe.
61. Remove tappet

1). Remove camshaft, and then pass through
engine bottom to remove tappet.
2). Mark the position where the tappet is
removed. If the repeated use is desired, refit it
onto its original position.
3). Fit the tappet at the same position on the
engine.
62. Remove camshaft

1). Rotate the crankshaft to align the crankshaft
with the camshaft timing mark.

Engine block
Caution: As the thrust bar surrounds the

camshaft by more than 180°, it is
only allowed to remove the thrust
plate from the camshaft after the
camshaft gear is removed from
the camshaft.
2). Remove the bolt from the thrust plate.
3). Dismount the camshaft and thrust plate
63. Remove front gear chamber

1). Remove gear chamber bolt and the gear
chamber.
64. Remove piston cooling nozzle

1). Remove piston cooling nozzle bolt and the
nozzle.
Caution: The crankshaft must be turned to
remove nozzle.
Caution: It is allowed to remove 6# piston
cooling nozzle only after
separating the linkage from
crankshaft and taking the piston
out. Additionally, the bolt can only
be reached by the single-opening
socket

ISLe375 30 engine
65. Remove piston & linkage assembly

1). Rotate the crankshaft till the piston is lower
than the carbon deposit on the piston ring
stroke zone.
2). Remove the carbon deposit with fine fibre
grinding pad or equivalent and solvent.
3). Mark each piston according to the position of

cylinder.
4). Rotate the crankshaft to make the linkage

cover at bottom dead center for the
convenience of disassembling.
5). Mark each linkage and linkage cover
according with the position mark of cylinder
number.
6). Engine fitted with horizontal angle-split linkage

7). Remove nut, the linkage cap and the lower
linkage bearing.
8). Mark cylinder number and letter “L” (lower) on
bearing locating tongue surface.

Engine block
9). Push the linkage and cylinder assembly out

from the cylinder boreAlways pay attention not
to damage the linkage or the bearing.
10). Remove upper bearing for the linkage.

11). Mark cylinder number and letter “U” (upper) on
12). Take out the piston and linkage assembly by

hand.
13). If such parts are desired to be used again, refit
the piston and linkage assembly into the same
cylinder and ensure that the worn mating
surface is corrected fitted.
14). Label the position of piston and linkage
assembly in the removal operation.
15). Place the linkage and piston in the container
for safety
16). Engine fitted with angle-split linkage

17). Rotate the crankshaft till the piston is lower
than the carbon deposit on the zone of piston
ring stroke.
18). Remove the carbon deposit with fine fibre

ISLe375 30 engine
19). Mark each piston according to the position of

cylinder.
20). Rotate the crankshaft to make the linkage

cover at bottom dead center for the
convenience of disassembling.
21). Mark each linkage and linkage cover
according with the position mark of cylinder.
22). Undo the linkage cover bolt.

Caution: Do not remove bolts from the
linkage.
23). Use the rubber hammer to knock the linkage
bolt to separate the linkage cover from the
positioning pin.
Caution: When disassembling the linkage

cover, do not damage the broken
surface of linkage or linkage
cover. If the fissured surface of
section is damaged, replace the
linkage and its cover, which may
help to reduce potential damages
of engine. False mounting may
damage the linkage.
24). Remove linkage bolt.
25). Remove linkage cap.
26). Remove lower bearing for the linkage.
27). Mark cylinder number and letter “L” (lower) on

Engine block
28). Push the linkage and cylinder assembly out

from the cylinder bore
Caution: Do not damage the linkage or the
bearing.
29). Remove upper bearing for the linkage.

30). Mark cylinder number and letter “U” (upper) on
31). Take out the piston and linkage assembly by

hand.
Caution: If such parts are desired to be
used again, refit the piston and
linkage assembly into the same
cylinder and ensure that the worn
mating surface is corrected fitted.
32). Label the position of piston and linkage
33). Place the linkage and piston in the container
for safety
66. Remove cylinder liner

1). Initial inspection
Caution: Before removing cylinder liner,
check its status to determine
further use or not.
(1). Check whether the cylinder liner bore has any
crack, scrape or score
(2). Check the longitudinal scuffing depth on the
inner diameter can be felt by finger
Caution: If the scratch can be felt by the
fingernail, replace the cylinder
jacket.

ISLe375 30 engine
(3). Visually check the inner diameter to determine

the polishing of cylinder liner hole
A bright mirror face can be produced on the worn
zone via polishing, with the original grinding mark
or corrosion pattern.
The thorough polishing will produce a bright mirror
surface at abrasion area but the original grinding
crack or corrosion pattern is eliminated.
Caution: Do not continue to use the
severely worn cylinder liner or
those embedded with particles
due to some defectives.
A seriously worn cylinder jacket will hump at the

jacket top.
If the wear indicates that the cylinder jacket is not
straight or round, use a micrometer of internal
diameter to measure the internal diameter of
cylinder at four 4 positions 90°apart on both the top
and bottom of piston travel zone.
Specification of cylinder liner (mm)
Taper 0. 04 Maximum
Out-of-roundness 0. 04 Maximum
Diameter of hole 114. 04 Maximum
Caution: If the cylinder jacket doesn’t

permit any further use, it must be
replaced. The damaged cylinder
jacket shall not be ground or
polished. This will damage the
grid chart required by engine oil
control.
Caution: Do not remove or interfere the oil
seal of cylinder liner which meets
the inspection standards.
The projection of cylinder liner means the distance

projecting above the surface of cylinder block.
Check the projection when the clamp is not fitted
before removing the cylinder liner. Use the jacket
projection gauge to measure the projection.
Projection of cylinder liner (mm)
0. 026 Minimum
0. 122 Maximum

Engine block
If the cylinder head is correctly fitted but the projection exceeds the limit, machine the countersunk hole
and add shims till the technical requirements are met.
2). Remove
(1). Cover the crankshaft with a piece of clean
repair cloth, to avoid the fall of any scraps onto
the main journal zone or into the linkage
journal oil hole.
(2). The cylinder liner puller must be assembled

and used as illustrated to avoid damage the
cylinder block. The puller must not touch the
Point (1), (2), (3) and (4) on the cast member
of cylinder block
(3). Universal jacket puller method
(4). Insert the cylinder liner puller into the cylinder
block top
Caution: The cylinder liner must be

centered on the top of cylinder
block.
(5). Rotate the puller screw clockwise to undo the
cylinder jacket from the cylinder block.
(6). Remove the cylinder liner by hand.
Caution: The cylinder liner puller must be

assembled and used as illustrated
to avoid damage the cylinder
block. The puller disc must be
parallel with the main bearing
saddle and not cover the outer
diameter of cylinder liner
Standard liner puller method
The universal puller can be alternatively used with
the standard puller. The universal puller must be
used with the remover board.
(7). Insert the cylinder liner puller into the cylinder
block top

ISLe375 30 engine

block.
(8). Rotate the puller screw clockwise to undo the
(9). Remove the cylinder liner by hand.
(10).Mark the cylinder number on each cylinder

liner.
67. Remove main bearing

1). Before removing main bearing cap, determine
that the cap has been clearly marked with the
position on oil cooler side of main bearing. 1#
bearing cap, at engine front
Caution: Do not pry the main bearing cap

from the cylinder block. This will
damage the main shaft bearing
and cylinder block.
2). Fully undo the main bearing bolt, but do not
remove it.
3). Use two main bearing bolts to work loose the
main bearing cover, and note that bolt threads
shall not be damaged.
4). Remove main bearing cap.

Engine block
(1). When removing main bearing, mark their

positions and numbers.
5). Mark the bearing position in the range of
locating tongue with awl.
Caution: Mark the bearing position for
future identification or fault
analysis.
Remove crankshaft
Caution: Lift the crankshaft upright to avoid
damaging the crankshaft and
cylinder block.
1). Wrap #3 and #4 linkage bearing journals by
the nylon sling
2). Connect the sling with the crane, and then
dismount the camshaft
3). Remove upper main bearing.

4). Mark the bearing position in the range of
locating tongue with awl.
Caution: The bearing position is marked for
analysis.
68. Remove camshaft bush

1). Use the camshaft lining remover kit to remove
the camshaft lining. Slide the thrust bar
through the centering guide sleeve, and then
insert it into the camshaft hole from behind the
cylinder block.
2). Insert the removing and fitting tool for the
camshaft bush and push out the front
camshaft bush from the cylinder block.
3). Take out puller & pushrod from cylinder block.
4). Insert pushrod, camshaft bush puller &
centering sleeve in the front of cylinder block.
5). Starting 2# camshaft bush, push out the rest
camshaft bushes from cylinder block in turns.
6). Take out pushrod, puller & sleeve in the front of cylinder block.

ISLe375 30 engine
Assembly
1. Fit crankshat bush
1). Mark on camshaft bush and cylinder block for
the convenience of aligning the engine oil port
on cylinder block with the large engine oil port
on bush.
2). Have the camshaft lining slide on the remover

& installer. Align the marks on the camshaft
bush and cylinder block.
3). Push the front camshaft lining to the correct
mounting depthThe correct mounting depth is
to align the engine oil hole of camshaft bush
with that of cylinder block.
4). Starting from the rear of cylinder block, fit the
rest camshaft bush towards in turns. Remove
pushrod, puller & guide sleeve from cylinder
block.
5). Remove pushrod, puller & guide sleeve from
cylinder block.
6). Ensure that the larger engine oil hole in the

camshaft lining is aligned with that beneath
the camshaft hole.
7). Oil filler must allow the passing of a lever with
diameter of 3. 2mm. Ensure that the smaller
engine oil hole in the camshaft lining is aligned
with that above the camshaft hole.
2. Fit crankshaft
Caution: To locate the positioning bearing
to avoid engine damages, the
bearing positioning tongue (1)
must be located within the bearing
saddle groove (2).
1). Fit upper main bearing
Caution: Do not lubricate the main bearing
side towards the cylinder block.
(1). Apply a coat of fitted lubricant or equivalent on
upper main bearing facing crankshaft.
Caution: Ensure that the dimensions of new main bearing are the same with that of removed
one. Specification is marked on back of main bearing.

Engine block
Caution: The crankshaft thrust bearing must be fitted at the position No. 4.
Caution: The upper and lower main bearings of some engines cannot be replaced. If
necessary, mark out the correct direction on the backside of main bearing.
Caution: To fit the main bearing housing, fit the main bearing housing on the original position
marked in the removal operation.
2). Use the crane and nylon lifting rope. Wrap the
sling around the bearing journals of No. 3 and
No. 4 linkages
3). Fit crankshaft.
3. Fit main bearing

1). Fit the lower main bearing.
Caution: The bearing back must be clean
without chips.
(1). Mount the lower main bearing into the main
bearing cap
(2). Align the bearing locating tongue with the one
on the main bearing cover
2). Apply a coat of fitted lubricant or equivalent on
main bearing facing crankshaft.
3). When fitting cover, the No. must face one side
of engine oil cooler.
Caution: The main bearing cap surface
between main bearing cap and
housing body must be clean
without chips.
4). After fitting every upper main bearing, Fit main
bearing cap in order to keep the position of
bearing correct when fitting other main
bearing.
5). Use the clean 15W-40 engine oil to lubricate
the bolt beneath the main bearing cover and
the main bearing bolt thread.

ISLe375 30 engine
6). Slightly knock the main bearing cap in place

with plastic or rubber hammer.
7). After dropping, mount and tighten the main
bearing bolt
Tightening torque 50N·m
Caution: Do not tighten to final torque.
Apply the final torque after all
main bearing covers are fitted.
8). After the main bearing cover is fitted, use the

turning gear to check whether the crankshaft
can rotate freely.
When applying the final torque on main bearing
bolt, it is required to frequently check whether the
crankshaft rotates freely.
If the crankshaft can’t rotate freely:
1). It is proved that the crankshaft doesn’t contact
a linkage.
2). Check whether the main bearing cap is
mounted correctly.
3). It is proved that the annular locating pin or
mounting surface of main bearing cap is not
damaged during assembling.
4). It is proved that the main bearing is mounted
correctly.
Tighten main bearing bolts evenly in sequence.

Tightening torque Step 1 170 N·m
Step 2 Loosen all the
bolts.
Step 3 50 N·m
Step 4 Turn by 120
degree
If the crankshaft can’t rotate freely, check mounting
conditions and specifications of main bearing.
The size of thrush bearing and crankshaft journal

decides the axial clearance.
Use the micrometer and magnetic base to
measure the crankshaft axial clearance.
Extreme axial clearance of crankshaft (mm)
Minimum 0. 085
Maximum 0. 385

Engine block
If the axial clearance of crankshaft doesn’t meet

technical requirements:
1). If the crankshaft axial clearance is lower than the required limit, check whether the crankshaft is
obstructed (engine oil pump, linkage etc.).
2). If the crankshaft axial clearance is higher than the required limit, check the crankshaft thrust bearing
surface. It is also necessary to check whether a correct thrust bearing has been fitted.
Caution: If the bearing clearance doesn’t meet technical requirements, use thrust bearings of
larger sizes. See the corresponding list of parts.
4. Fit the cylinder liner

1). Clean off all deposits and crumbs on sealing
surfaces A, B and C. Use the grinding pad or
its equivalent and the detergent to polish the
surface. In view of strict mismachining
tolerance, be careful not to remove the
additional materials.
2). If the sealing surface C is cracked or
abnormally worn, the countersunk hole must
be provided to fit the shim thus to obtain a
correct cylinder jacket projection.
3). Use the hole cutter to process the

countersunk hole to a proper depth.
Caution: The cutter and cutter head must
be used together with the counter
bore machining tool.
Use the gasket blade or grinding pad or the

equivalent and diesel oil or solvent to clean the
combustion surface.

ISLe375 30 engine
4). Use the mineral oil or detergent to thoroughly

flush the cylinder.
5). Remove the overhaul cleaning cloth and clean
the crankshaft with detergent.
6). Dry cylinder hole and crank, and clean with lint
free cloth.
7). Use 15W-40 engine oil to lubricate the sealing

surfaces A and B.

the O-shaped seal ring of cylinder jacket.
9). Mount the new O-ring on the cylinder liner
10). Put the cylinder liner to be used continuously

into the same cylinder as the removed, and
rotate it 45° (1/8 turn) from the original
position. When the assembly is correct, the
cylinder sleeve cave corrosion position must
be as illustrated by the picture and the cave
corrosion must turn the direction eccentrate
the cave corrosion position.

Engine block
11). Use the cylinder jacket remover & installer to

fit the jacket into the cylinder hole.
12). As shown in the figure, two (2) cylinder head

bolts are used to fix these two (2) cylinder
jacket hoops.
13). Tighten the bolt
14). Remove pressure plate for the cylinder liner
and repeat the step until all the cylinder liners
have been pressed tight and released.
Measure
1). Use the micrometer to measure the cylinder
jacket internal diameter at four positions
90°apart on the top and bottom of piston travel
zone.
Projection of cylinder liner (mm)
Minimum 0. 026
Maximum 0. 122
Caution: If the change of cylinder jacket

projection within 180°exceeds 0.
025mm,
• Reassemble and fasten cylinder liner clip.

ISLe375 30 engine
• Measure the extrusion length of cylinder liner

again.
Caution: If the projection change exceeds

0. 025mm again,
• Remove cylinder liner
• Check whether the seal lip of cylinder liner has
burrs, dirt or damage
• If the cylinder jacket is damaged, replace it.
• Reassemble cylinder liner.
• Measure the projection of cylinder liner.
Repair skillsIf a minimal exceedance exists, fit

another new cylinder jacket in the cylinder hole
with exceedance, to add the error to within the
extreme limit of projection.
Caution: If the cylinder jacket projection

remains unqualified, use following
tools to machine the jacket holes
on the cylinder block to
accommodate shims.
• Drive
• Cutter
• Cutter head

Engine block
Use the thickness gauge to check the gap between

the cylinder jacket and the cylinder block at four
casting points on the cylinder block.
Clearance between the cylinder liner and

cylinder block (mm)
Minimum 0. 229
Caution: If the gap is less than 0. 229mm

• Remove cylinder liner.
• Check whether the cylinder liner and block

have any dirt or damage
• If the cylinder jacket is damaged, replace it.

• Reassemble cylinder liner.

ISLe375 30 engine
Measure the out of roundness of cylinder liner hole

at points “C”, “D”, “E”, “F” and “G”. Measure
various points along directions “AA” and “BB” . The
out of roundness of cylinder liner hole must be no
more than 0. 04 mm.
Caution: If the out-of-roundness of jacket

exceeds 0. 04mm
• Remove cylinder liner in order to measure the
liner hole of cylinder block.
5. Fit pistion and linkage assembly

1). Use a piece of clean non-burr cloth to clean
the linkage and bush.
Caution: If no new bearing is used, the old

one must be refitted onto the
original linkage and position.
2). Mount the upper bearing on the linkage
3). The locating tongue of bearing bush must be
in locating slot of linkage. The end face of
bearing bush must be flush with mounting
surface of linkage cover.
Caution: For split-angle type linkage, the
upper and lower bearing shells of
linkage cannot be exchanged. The
bearing back has UPR or LWR
mark to indicate its position.

Engine block
4). Apply the mounting lubricant or its equivalent

onto the bush internal surface.
5). Apply a coat of clean 15W-40# engine oil on
cylinder liner.
6). Use the clean engine oil to lubricate the piston

ring and piston apron.
7). Turn and adjust the position of opening of

piston ring as illustrated.
Caution: The opening of each piston ring
shall not be aligned with the
piston pin or the opening of other
piston ringIf the piston ring is
opened at the incorrect position,
the ring will not be sealed
properly.
8). Use the piston ring compressor to compress

the piston ring.

ISLe375 30 engine
9). Rotate the crankshaft to make the journal of

linkage to be assembled at bottom dead
center.
Caution: If the operation is not carried out

according to the procedure, the
engine will be damaged severely.
10). Align the piston valve sleeve with the exhaust
side of engine
11). Insert the linkage into the cylinder liner till the
piston ring compressor touches the cylinder
liner top
12). The angle split of linkage shall be toward the
intake side
13). Support the cylinder liner by piston ring

compressor
14). Push the piston into the cylinder lining through
the piston ring compressor
15). Push the piston till its crown is fully engaged in
the cylinder jacket.
Caution: If the piston can’t move freely,
remove the piston and check
whether the piston ring is broken
or damaged.
16). Push the piston into the cylinder bore

carefully, and guide the linkage to the
crankshaft journal.
Caution: The linkage guider can be used to
mount the linkage stub on the
engine

Engine block

original linkage cover.
17). Mount the bearing on the linkage cover
18). The bearing (2) locating tongue must be in
locating slot of linkage cover (1).
19). Use the mounting lubricant or its equivalent to
lubricate the bush internal surface.
20). Lubricate the screw thread of linkage with
clean 15W-40# engine oil.
Caution: 1. When removing linkage cap, do

not damage the linkage or the
cap’s cracking surface. If the
fissured surface of section is
damaged, replace the linkage and
its cover, which may help to
reduce potential damages of
engine.
2. The linkage and its cap must
have the same number, and must
be fitted into correct cylinder. The
serial numbers of linkage cap and
linkage must be on the same side
of linkage to prevent the engine
from damage when the engine is
running
21). Fit linkage cover and nut.

22). Use the marked socket wrench and torque
wrench to tighten the connecting bolt.
23). Use the torque + angle method to tighten the
linkage bolt in an alternative sequence.
Step 2 Loosen the bolt
Step 3 70 N·m
Step 4 Advance by 60
degree
Caution: Do not measure the side play

between the linkage cap and the
crankshaft.
24). Measure the clearance between the linkage
body and the crankshaft.
Lateral clearance of linkage and crankshaft

(mm)
Minimum 0. 10
Maximum 0. 30

ISLe375 30 engine
25). Check whether the linkage cover can rotate

freely when it is fittedIf the crankshaft can’t
rotate freely, check the mounting and sizes of
linkage bearing.
6. Fit the pistion cooling nozzle

1). Fit the pistion cooling nozzle and bolt
Tighten the bolt
assemble the nozzle.
7. Fit front gear chamber

1). Place the gear chamber gasket on the locating
pin
2). Use the guide pin (M8×1. 25×50) to help to
align the gasket and gear chamber.
3). Ensure that the guide pin can be removed
after alignment.
4). Fit the gear chamber


Engine block
8. Fit crankshaft
1). Apply a coat of fitted lubricant or equivalent
onto front camshaft hole.
2). Lubricate the camshaft cam, journal and thrust

plate with fitted lubricant or equivalent.
Caution: Do not fit camshaft into the

camshaft hole by force, or the
camshaft bush will be damaged.
3). Fit crankshaft.
(1). Rotate the camshaft whist pushing it inside, to
have the camshaft thread through its sleeve.
When every camshaft journal goes through
the bush, the camshaft sinks slightly and then
the cam is fixed into the bush. Rotate the
camshaft to disengage the cam from the
bushing, thus to fit the camshaft.
4). Before the camshaft gear engages with

crankshaft gear, check whether the camshaft
rotates easily. If fitted correctly, the camshaft
can rotate freely.

ISLe375 30 engine
5). Align to the timing mark as illustrated to

complete the installation of camshaft.
6). Fit bolt of thrust plate.

7). Use the gauge and magnetic base to verify

the correctness of camshaft lateral clearance
and axial clearance.
Camshaft axial clearance (A) (mm)
Minimum 0. 12
Maximum 0. 50
Extreme backlash of camshaft (B)
Minimum 0. 08
Maximum 0. 33
9. Fit lifter
1). Use the mounting lubricant or its equivalent to
lubricate the tappet.
2). Pass the bottom of engine to mount tappet
before the camshaft is assembled.
Caution: If this tappet is to be used again,
refit it onto its original position.

Engine block
10. Fit oil suction pipe (installed on the

cylinder)
1). Fit oil suction pipe and new washer.
2). Fit and tighten all the bolts and check whether
alignment is correct.
3). Fix the oil suction pipe on the cylinder block
4). Fasten the oil suction pipe bracket on the
engine cylinder block
Tightening torque 10 N. m
5). Fix the oil suction pipe on the bracket
11. Fit the oil sump

1). Fill up the gap between the oil pan guide rail,
gear chamber and rear oil seal housing with
RTV sealant or its equivalent.
2). Fit sealing gasket and oi sump.

3). Fit oil sump gusset, if equipped.
Caution: The sound-insulating pad must be
used with the oil pan fitted with an
independent gasket system.
4). Fit the washer and bolt to fix the oil pan as
shown in the figure.
5). Tighten all the bolts according to the illustrated
order.

ISLe375 30 engine
12. Fit the engine oil heater

1). Fit heater core.
13. Fit oil pump

Caution: If the pump is not filled with oil
when assembly, the fault may be
caused to oil pump and heavily
damage the engine.
the engine oil pump.
Caution: Ensure that the idler pin is fitted in

the positioning hole of cylinder
block.
2). Fit oil pump
3). Tighten bolts crosswise, starting from right

upper bolts.
Caution: If a new engine oil pump is fitted,
ensure the side gap of gear is
correct.

Engine block
4). Measure the backlash of gear.
Oil pump gear side clearance limit value (fitted)
Minimum 0. 0762mm
A
Maximum 0. 3302mm
Minimum 0. 0762mm
B
Maximum 0. 3302mm
Caution: The reading will be incorrect if the

adjacent gear moves during the
measurement of backlash.
5). Lubricate the front gear system with clean

15W-40# engine oil.
14. Fit front gear chamber cover

1). Apply only a thin coat of RTV sealant or
equivalent on engine front cover.
2). Mount the front cover on engine within 10 min.
Caution: Apply the sealant inside the bolt
hole
3). Tighten bolts of front cover according to the

illustrated sequence.

ISLe375 30 engine
15. Fit crankshaft front oil seal

1). Leave the plate guide tool in the oil seal
2). Place the oil seal on the repair tool with the oil
seal dust tip outward
Caution: Correctly support the bracket

engine oil seal flange to avoid the
damage on engine oil seal and
bracket.
3). Press the oil seal into the bracket from back to
front
4). Press in the oil seal till the oil seal keeps flush
on the carrier front.
5). Apply a coat of sealant (4mm thick, 4mm

wide) between mounting hole and oil seal
around oil seal support interior.
wide) onto all the stud bolts on front cover.
7). Mount the oil seal bracket on the front cover
8). Remove plastic installation tool.
9). Screw up the mounting nut for the carrier in
accordance with the astroid sequence,
starting with the stud at the upper left part as
illustrated in the figure.
16. Fit adhesive shock absorber

1). Fit the shock absorber.

Engine block
2). Tighten bolts diagonally.

Torque value200N·m
17. Fit the rubber shock absorber

use
1). Adopt five vibration isolator bolts.
2). Fit the shock absorber.
18. Fit cylinder head

1). Ensure that the cylinder head gasket is
aligned with the hole on the cylinder block. If
not aligned, the engine may be damaged.
Caution: Do not try to repeatedly use the
sealing gasket of cylinder head.
2). Place the new cylinder head gasket on the
locating pin
3). Put the cylinder head onto the cylinder block

carefully, and seat it into the positioning pin.

ISLe375 30 engine
Caution: If any new bolt is used, grind the

bolt thread. When polishing the
new bolt, mount the tightening
bolt described in the
followingUndo bolts and then
retighten them in the required
sequence.
the cylinder head bolt thread and screw.
5). Tighten bolts of cylinder head according to the

illustrated sequence。
Step 2 150 N·m
bolts
Step 4 115 N·m
Step 5 115 N·m
Step 6 Advance by
120 degree.
19. Fit the rocker chamber housing

Caution: A new gasket must be used after
the rocker housing is removed. Do
not continue to use the old sealing
gasket.
1). Fit the rocker chamber housing and new
sealing gasket of rocker chamber housing
(1). Press the forged gaskets in each corner of
rocker chamber housing
(2). Press the rest gasket into the housing
2). Fit and tighten the bolt. Start from the center
bolt and then face outwards.
20. Fit oil injector

1). Ensure that the fuel injector hole is clean and
that the nozzle is equipped with one (1)
washer.
2). Use the clean engine oil to lubricate the
injector O-shaped ring.
3). Mount the injector in the cylinder head along
correct direction (the fuel inlet shall be toward
the high-pressure fuel connector)
4). Use the injector transportation socket to
ensure that the injector is seated into its hole.

Engine block
Caution: To fit a new injector, the new fuel

pipe union must be used.
5). Install but not tighten the clamp bolts of oil
injectors
6). Fit the high pressure fule connector and make
sure the connector end in oil injector inlet end.
7). Install the fixing nuts of high-pressure fuel
connector and then tighten them partially
Caution: This is not the final fastening
torque of high-pressure fuel joint
fixing nut.
8). Tighten the hold-down bolt of oil injector

Caution: Ensure that the pressure bolts are
tightened crosswise. Check and
ensure that the clearance between
pressing clamp and fuel injector is
equal to the clearance around the
fuel injector
9). Tighten the fixing nut of high-pressure fuel

connector
Caution: Do not over tighten harness of

injector. If excessively fastened, the
injector terminal will be damaged.
10). Connect the injector conducting wire with the
injector
Tightening torque 1. 25N·m
Caution: Sort the injector lead wires such
that they will interfere with the
rocker arm or the engine brake
housing. If the rocker arm can
reach the injector wire, it may
chafe the lead wire insulation and
give rise to the generation of
injector circuit failure codes.

ISLe375 30 engine
11). Mount the push tube at its original position

12). Mount the push tube into the valve tappet hole
13). Lubricate the push pipe ball socket with clean
15W-40# engine oil.
21. Fit the jump pressing plate

Caution: There is a round and elliptic hole
on the jumper plateIf a new jumper
pressure plate is fitted, it is not
necessary to locate the hole on a
specific position.
Caution: Make sure to fit the jump pressure
plate to be used continuously in
the original position and direction.
1). Install the jumper pressure plate on the valve
stem
2). When mounting crossover pressure plate at
the engine with engine support, the pin on
crossover pressure plate shall face exhaust
manifold.
22. Fit the rocker

1). Fix the rocker arm on the rocker arm shaft
seat
2). Mount the rocker arm assembly and shaft seat

to original position

Engine block
3). Lubricate the screw thread with clean engine

oil.
4). Fit and tighten the shaft seat bolt
5). Fix the rocker arm on the rocker arm shaft

seat(with engine brake)
6). Mount the rocker arm assembly and shaft seat

to original positionAnd ensure that the lock nut
for longer adjusting screw is installed on the
exhaust rocker arm.

oil.
8). Mount the bolt of engine brake oil supply pipe
on the intake rocker arm of Cylinder 1 and 4

ISLe375 30 engine

oil.
10). Mount the exhaust rocker arm bolts on all the
exhaust rocker arms

oil.
12). Mount the shaft holder bolts on the intake
rocker arm shaft holder of Cylinder 2, 3, 5 and
6

oil.
14). Mount six threaded washers on the cylinder
head
23. Fit the engine brake assembly

Assembly
1). On stub bolt of inlet valve (1# cylinder and/or
4# cylinder), lubricate the engine oil joint and
O-ring with engine oil.
2). Fit the assembly of engnine brake overhead
mechanism.
Caution: Ensure that the engine oil supply
adapter on the intake manifold
stud is fitted on the engine oil
supply hole in the brake assembly.
3). Install six 10mm mounting bolts on the brake
spacer and tighten them (on the exhaust side
of engine)

Engine block
Caution: Do not tighten bolts to final torque

specified.
4). Rotate the sleeve regulator (pre-fitted in

engine brake) at the mounting position of
exhaust to contact the stud bolt of engine
brake and then fasten it.
5). Undo these three 10mm external mounting

bolts
6). Mount three 10mm mounting bolts with plain
washer at the mounting position of exhaust
valve rocker.
7). Tighten six 10mm mounting bolts
Caution: It is not required to tighten
according to certain sequence,
but may be possible to tighten
bolts diagonally.
Tightening torque 32 N·m
8). Install the conducting wire on the terminal

near the spacer
Caution: The longer conducing wire must
be connected with the front brake
solenoid valve of engine. If the
lead is fitted in the wrong
direction, it may interfere with the
rocker arm.

ISLe375 30 engine
9). Connect the conducting wires on the terminals

on the side of spacer with the solenoid valve
Adjust
1). Use the turning gear or its equivalent to rotate
the crankshaft to align the mark on the fuel
pump gear with the top dead center mark on
the gear housing cover.
2). The brake clearance of No. 1, 3 and 5

cylinders can be set when the engine is at the
top dead center.
3). Use two spanners to fix the adjusting nut and
undo lock nuts on brakes of cylinders Nos. 1,
3 and 5.
4). Adjustment of brake clearance

Using method of thickness gauge
Insert the proper brake clearance feeler between
the brake slave piston and exhaust jumper plate of
Cylinder 1
Brake clearance - clearance gauge method
Technical requirements on
2. 286mm
the valve clearance
Caution: If the right thickness gauge is unavailable, the alternative micrometer method can
be applied in this step to set the brake gap.

Engine block
(1). Use the torque wrench to tighten the adjusting

nut.
(2). Till the toque wrench gives a sound of click or
the resistance can be felt on clearance gauge.
(3). Remove the thickness gauge. Use two

spanners to fix the adjusting nut and tighten
the lock nut.
(4). Repeat this step for No. 3 and 5 cylinders.
(5). Use the engine turning gear to rotate the

crankshaft by 360° to align the mark on the
fuel pump gear with the mark 180°apart from
the top dead center on the gear housing
cover.
(6). The brake clearance of No. 2, 4 and 6
cylinders can be set when the engine is in this
position.
(7). Insert the proper brake clearance feeler

between the brake bushing piston and
exhaust jumper plate of Cylinder 2
Brake clearance - clearance gauge method
Technical requirements on the

2. 286mm
valve clearance

ISLe375 30 engine
(8). Use the torque wrench to tighten the adjusting

nut till the torque wrench clatters or till the
resistance can be felt on the thickness gauge.
(9). Remove the thickness gauge. Use two

spanners to fix the adjusting nut and tighten
the lock nut.
Repeat this step for No. 4 and 6 cylinders.
If the right thickness gauge is unavailable, use the

following method instead.
Use the turning gear or its equivalent to rotate the
crankshaft to align the mark on the fuel pump gear
with the top dead center mark on the gear housing
cover.
Mounting method of micrometer

(1). Tighten the clearance adjusting nut on
Cylinder 1 till the resistance can be feltPlace
the dial indicator tip on the adjusting nut, and
reset it to zeroRotate the clearance adjusting
nut counterclockwise to the proper clearance
Technical specification of brake clearance: 2. 286
mm

Engine block
(2). Use two spanners to fix the adjusting nut and

tighten the lock nut.
(3). Repeat this step for No. 3 & 5 cylinders.
(4). Use the engine turning gear to rotate the

crankshaft by 360° to align the mark on the
fuel pump gear with the mark 180° apart from
the top dead center on the gear housing
cover.
(5). The brake clearance of No. 2, 4 and 6
cylinders can be set when the engine is in this
position.
(6). Tighten the clearance adjusting nut on

Cylinder 2 till the resistance can be feltPlace
the dial indicator tip on the adjusting nut, and
reset it to zeroRotate the clearance adjusting
nut counterclockwise to the proper clearance
Technical specification of brake clearance: 2. 286
mm
(7). Use two spanners to fix the adjusting nut and

tighten the lock nut.
(8). Repeat this step for No. 4 & 6 cylinders.

ISLe375 30 engine
5). Fit the plastic fuel dirve cover of engine front

cover.
24. Fit the rocker chamber cover

Caution: If the gasket has been removed
from the rocker arm compartment
cover, fit a new one.
1). The gasket must be fitted in accordance with
the following procedures.
(1). Press the forged gaskets in each corner of
rocker chamber cover
(2). Press the gasket in around the bolt mounting
hole
(3). Press the reset gaskets into the rocker
chamber cover
2). Fit the rocker chamber cover and bolt

3). Tighten all the bolts according to the illustrated
sequence.
25. Fit the overhead mechanism

the crankshaft
2). Align the gear housing cover and the top dead
center mark on the fuel pump gear.

Engine block
3). Valve clearance check can be conducted for

the following rockers when the engine is at
this position:
1I, 1E, 2I, 3E, 4I & 5E.
4). Raise the rocker arm end, and insert the feeler
between the jumper plate, rocker arm ball joint
and seat to measure the clearanceIf the
measured gap exceeds the required value,
loosen the lock nut and adjust the gap to the
normal value.
Reset the specifications of clearance (mm)
Intake valve 0. 305 Nominal
Exhaust valve 0. 559 Nominal
5). Tighten the locknut and then make adjustment


the crankshaft by 360°, and measure the
rocker arm clearances 2E, 3I, 4E, 5I, 6I and
6E. If the gap exceeds the required value,
reset the gap.
26. Fit crankcase breather (external)

1). Mount the new O-ring on the solenoid valve
2). Lubricate the O-ring and valve with engine oil.
3). Mount the ventilator on the rocker chamber
cover

ISLe375 30 engine
27. Fit the fuel cooling ECM cooling plate

1). Install the ECM cooling plate assembly on the
engine blockTighten the bolt
28. Fit the air compressor

1). Timing of air compressor (only for the
single-cylinder air compressor)
2). Rotate the engine to locate the cylinder No. 1
at the top dead center of compression stroke.
To arrive at this, align the timing mark on fuel
pump gear with TDC mark.
Caution: There are two similar marks on the

air compressor gear (look like [1]
and 1)Use the timing mark “I” to
set the timing of air compressor
and engine.
Cummins single-cylinder air compressor

When viewing the compressor (it is in the vertical
position) from the gear end, rotate the gear to
make the “1” timing mark stay at the 3 o’clock
position. On the Cummins single-cylinder air
compressor, there is a small plate at the 3 o’clock
position on its casing to set the timing of
compressorOnce the timing mark is located at the
3 O’clock position, this may set the compression
stroke of compressor at 60°in front of top dead
center.

Engine block
Timing of air compressor (only for the

single-cylinder air compressor other than
Cummins)
1). Remove unloading valve or cylinder head, so
as to find top dead point of compressor crank.
Refer to the related air compressor manual.
TDC is not needed to be very correct. A
certain angle error is allowed in the system.
2). Mark the TDC position (12: 00 o'clock position

seen from the front) of air compressor gear
face with ink or dykem.
3). Rotate the TDC mark of compressor to 60°

before TDC or ahead by 6 teeth on 36-tooth
gearThis is about 10: 00 o’clock position seen
from the front of air compressor.
4). Install the air compressor and new gasket on

the gear chamber

ISLe375 30 engine
5). Mount the bracket on the air compressor

7). Mount the spacer on the bracket bolt, and

then tighten it by hand
8). Ensure that there is no gap between the
spacer ring and the carrier and between the
spacer ring and the cylinder block.
10). Assemle and tighten the bolt which connects

spacer ring and cylinder body.
11). Ensure that there is no gap between the
spacer ring and the carrier and between the
spacer ring and the cylinder block.
29. Air compressor oil supply pipe

1). Fit air compressor and feed pipe of air
compressor for the cylinder

Engine block
30. Fit air compressor coolant pipe 1212

1). Fit the air compressor cylinder head and
coolant pipe of cylinder
31. Fit fuel pump

1). Ensure that the engine cylinder No. 1 is
located at the top dead center. The fuel ump
gear timing mark shall be aligned with the top
dead center on the front cover.
2). Ensure that the engine oil filler gauge hole (A)
and guiding ring (B) O-shaped rings are
correctly fitted.
3). Use the clean engine oil to lubricate the
guiding O-shaped ring.
4). Clean the drive shaft end and fuel pump inner
gear ring with contact cleanser or equivalent.
5). The oil pump drive gear internal diameter and
propeller shaft external diameter must be
cleaned and dried after installing the gear
6). Slide the fuel injection pump into the drive
gear, and mount the pump flange on the
mounting stub
7). Ensure that the drive shaft positioning pin is

aligned with the keyway on the fuel injection
pump gear.

ISLe375 30 engine
8). Fit cylinder head

(1). Fit the cylinder (1) bolt and install bolt into the
supporing bracket and through the pump
flange
(2). Pass through pump flange (2) to tighten bolts.
(3). Tighten the bolt inside the cylinder head (1)
9). Tighten the nut of drive gear of fuel injection

pump
32. Fit fuel rail

Fit the fule rail assemblu. Follow the correct order
and ensure the high-pressure fuel pipe is aligned
correctly.
1). Fit and tighten the bolts of assembly of fuel rail
munually.
2). Fit and tighten the high pressure fuel pipe.
3). Tighten the bolt of fuel rail assembly
33. Fit the fuel connector (seat mounting)

Caution: If a new injector is fitted, the fuel
pipe union must be renewed.
1). Lubricate the fuel pipe union O-shaped ring
and the lock nut threads.
2). Insert the fuel pipe union carefully, and align
the guide pin with the cylinder head slot.
Located at the 12: 00 position;
3). Tighten the fixing nut of fuel connector

Engine block
34. Fit the intake manifold cover

1). Fit intake manifold cover and new gasket
Caution: On some engines, some bolts are
shared by fuel pipe support.
35. Fit feed pipe of oil injector (high pressure)

1). Before Fitting the oil injector oil pipe , make
sure the fuel connector correct and seat oil
injector completely. Ensure that the
high-pressure union nut is fastened.
2). Fit fuel line in reverse order to the removal.

3). Tighten the fuel rail connector
4). Tighten the fuel pipe of fuel pump onto the fuel
rail at the end
5). Locate fuel pipe between fuel pump and fuel
rail.
6). Fasten the bolts of vibration isolating pad of
fuel pipe and bracket by hand.
7). Tighten the fuel pump connector
8). Damping gasket bolt of torque tightening
bracket
9). Tighten the cylinder head connector

ISLe375 30 engine
36. Fit the fuel filter seat bracket

1). Fit the fuel filter seat bracket.
2). Tighten the fixing nut
37. Fit fuel return pipe

Mount three oil return pipes on the engine
1). Fuel return of high pressure pump;
(1). Fit p-type clamp bracket
(2). Mount hole bolt on fuel return manifold.
(3). Mount hole bolt on fuel pump
2). Return pipe of fuel relief valve
(1). Mount hole bolt on fuel return manifold.
(2). Mount hole bolt on pressure reducing valve.
Fix the pipeline to avoid distortion and wear
due to friction with the bottom of cylinder
head.
3). Fuel return pipe of fuel injector
Tightening torque M12 banjo bolt 24N. m
M16 banjo bolt 43 N·m
P-type clamping bolt
24N·m
38. Fit fuel feed pipe

1). Fit quick break pipe union.
2). Fit quick break pipe union.
Ensure that the quick-break fuel pipe is fastened

on the pipe union.
Ensure that the pipeline is correctly arranged and
connected. If the pipeline is incorrectly connected,
the engine will not run.
Arrange fuel pipes in the following sequence:

1). OEM connector to the connector of ECM cooling plate

Engine block
2). The lower ECM cooling board pipe union is connected to the upper gear pump pipe union.
3). The lower gear pump pipe union is connected to the 2μm fuel filter inlet.
4). 2µm fuel cleaner outlet to fuel pump control actuator shell.
Fix the fuel pipes onto the carrier in following sequence:

1). The inner pipeline connects the upper pipe union of gear pump and the lower pipe union of ECM
cooling panel
2). The intermediate pipe connects 2µm filter outlet and fuel pump oil control actuator housing
3). The external pipeline is connected with the gear pump lower pipe union and 2μm filter inlet.
If necessary, fit the fuel pipe carrier hoop (only limited to the quick-break fuel pipe) and carrier.
Tightening torque Fuel pipe carrier 24 N·m
Fuel pipe carrier clip 24 N·m
39. Fit cold strat auxiliary unit

1). Fit intake heater.
Caution: The intake heater will keep loose
till it is installed in the intake
connector
40. Fit intake pipe union

1). Fit intake pipe union and new sealing gasket.
Caution: The intake pipe union is installed
on the top of grid heater and
shares the bolts

Fit intake pipe union adapter, O-ring and V-belt clip
of intake pipe union.
Tighten the clamp

ISLe375 30 engine
42. Fit crankcase breather

Caution: Ensure that the crankcase
ventilator or return pipe are not in
contact with any high-pressure
fuel pipe.
1). Mount the ventilator pipe of crankshaft case
on the crankshaft case ventilator assembly
2). Mount the return pipe of crankshaft case on its
ventilator assembly
3). Mount the ventilator oil return pipe cover,

gasket and pipe on the cylinder block
43. Fit oil cooler

Caution: Ensure that the shipping plug on
the new engine oil cooler core is
removed.
1). Assemble engine oil cooler sealing gasket,
core and cover.
2). If the engine oil cooler cover is not dented,

tighten the bolt in the sequence as indicated.

Engine block
3). If the engine oil cooler cover is not dented,

tighten the bolt in the sequence as indicated.
The arrow (A) points at the position of pit
Step 2 32 N·m
44. Fit dry type exhaust manifold

1). Use new gaskets to fit the exhaust manifold of
cylinder head.
2). Tighten according to the illustrated sequence.
45. Fit the turbocharger

1). Apply a coat of high-temperature anti-sticking
compound onto stud bolt of turbocharger.
2). Fit new sealing gasket and turbocharger.
3). Fit and tighten the installed 4 nuts.
Caution: The given torque value is based
on taking the antiseize compound
as lubricant.
46. Fit the oil feed pipe of turbocharger

1). Apply a thin coat of engine oil on O-ring of oil
supply pipe.
2). Fit and tighten the turbocharger and feed pipe
of oil filter seat manually.
3). Tighten the oil supply pipe on the turbocharger
bearing casing

ISLe375 30 engine
Caution: Retain 10mm at least of clearance

between the turbocharger oil
supply pipe and its turbine
housing and exhaust manifold.
4). Tighten the oil supply pipe on the oil filter seat
connector
Caution: Tighten the oil supply pipe, and at
the same moment, fix the threaded
pipe union on the oil filter seat by
spanner to prevent the oil filter
seat connector from excessive
tightness

1). Apply a thin coat of clean engine oil on O-ring
of oil return pipe.
2). Push the oil return pipe into the lug
bossEnsure that both O-shaped rings are fully
fitted into the hole.
3). Mount a new sealing gasket on oil return pipe.
4). Fit and tighten the mounting bolt of
turbocharger retun pipe
48. Fit the turbocharger compressor outlet

connector
1). Mount the turbocharger compressor outlet
bend, V-shaped strap and new O-ring on the
exhaust outlet of turbocharger compressor
2). Tighten the clamp
49. Fit oil dipstick pipe

1). Apply a round of bush fixing compound or
equivalent around the bottom of pipe groove
end.

Engine block
2). Insert the slotted end of pipe into the oil

dipstick hole of cylinder block
3). Use the plain washer and hexagon head bolt
to extend the pipe into the cylinder block.
4). Slightly insert the oil dipstick pipe till it torches
the cylinder block casting.
5). Remove plain washer and the hexagon bolt.
6). Install the oil dipstick in its tube
50. Fit the flywheel housing

Application of wet type flywheel
1). Continuously apply a round of sealant or
equivalent around bolt holes on mounting
surface of flywheel housing.
Caution: Before fitting flywheel housing,

make sure all the dowels at the
same position when flywheel
housing is removed.
2). Mount a new rectangle seal on seal rear
support and apply the fitted lubricant.

ISLe375 30 engine
3). If provided, fit a new camshaft journal hole

rectangular seal ring behind the flywheel
housing.
4). Apply a little of sealant, and fix the seal ring in
place till the flywheel is fitted.
5). Check whether the rear end surface of

cylinder block and the mounting surface of
flywheel are clean, or have projecting scores
or burrs.
6). Fit two dowels.
7). Assemble the flywheel housing above guide
pin. Ensure that the flywheel housing is
located on the positioning pin.
Caution: Ensure that the sealing ring is not
damaged in the refitting operation.
8). Remove guide pin.

9). Install the mounting bolt
10). Tighten mounting bolts of flywheel housing

according to the illustrated sequence.

Engine block
51. Fit rear oil seal of crankshaft

Caution: When fitting oil seal, the neutral
soap should be applied on the oil
bracket external diameterMount
the oil seal guider (including the
dismounting tool kit) in the
crankshaftPush the oil seal to the
guider and crankshaft
1). Remove the oil seal guiding device.
2). Use the aligner to fit the oil seal into the
housing to a correct depth. Use the hammer to
press the oil seal into the housing till the
aligning tool supports the housing.
3). Knock the tool at its positions 12, 3, 6 and 9
and uniformly mount the oil seal to prevent the
oil seal support bending.
52. Fit the flywheel

1). Mount the two M12×1. 25×90mm guide pins
on the crankshaft flange with a distance of
180°
2). Determine the pattern and specifications of `
bolt threads, and fit two T-shaped handles at
points (1) and (2) on the flywheel.
3). Check whether the rear end surface of

crankshaft and the mounting flange of
flywheel are clean and scored or have burrs
4). Mount the flywheel on the guide pin

ISLe375 30 engine
5). Lubricate the screw thread and washer

surface with clean engine oil.
6). Fit 6 bolts

7). Remove T-handle & guide pin.
8). Mount the rest bolts on the vacant guide pin
holes
9). Use barring gear to fix the camshaft when

tightening the flywheel bolt.

Engine block
Measure
• Play of hole
1). Use the micrometer (1) or similar tools and
micrometer accessory (2) to check the runout
of flywheel hole (3) and end face (4).
2). Mount the accessories on the flywheel
housing
3). Install the dial indicator on the accessories
4). Support the inner diameter of flywheel hole by
dial indicator tip, and reset its finger to zero
5). Use the turning gear to rotate the crankshaft

by one circle.
Total reading of flywheel indicator (mm)
Maximum 0. 127
If the total indicator reading of micrometer (TIR)

exceeds the required value, follow the procedures
described below:
6). Thereafter, remove the flywheel.
7). Check whether there is any dirt or damage on

the flywheel mounting surface
8). Check whether the crankshaft is dirty or

damaged

ISLe375 30 engine
9). Fit the flywheel

10). Measure the hole run-out。
If the runout exceeds the extreme limit again,

replace the flywheel.
• Runout of end face

1). Fit the contact of dial gauge against the
flywheel housing end face.
2). When locating the contact, look over the table
of total reading of dial gauge for the runout of
flywheel housing end face introduced later in
this step. Locate the contact to make its radius
correspond to the value in the table. And its
radius is also required to be close to the
outside diameter of flywheel as far as
possible, so as to check the runout of end face
(1) of flywheel housing.
3). Push the flywheel forward to eliminate the
crankshaft axial clearance. Adjust the dial
gauge until its pointer returns to zero.
by one circle. Measure and record the jerk
value of four equally spaced points on the
flywheel.
5). For every measurement, the flywheel shall be
pushed to the front end of engine to eliminate
the axial clearance of crankshaft
6). Determine the total reading on the micrometer
(TIR).
7). Through the difference between the maximum
measurement and the minimum measurement
calculated at four measured positions, TIR
can be determined.

Engine block
8). Measure the distance (A) between the center

of flywheel and the contact of dial gauge. Use
this measurement to determine which one of
specifications in the following is used
The total reading of dial gauge is not allowed to
exceed the value in the following technical
specification:
Flywheel surface,
Radius of flywheel (A)
maximum (reading of
(mm)
dial gauge) (mm)
203 0. 203
254 0. 254
305 0. 305
356 0. 356
406 0. 406
If the flywheel end face runout doesn’t meet

technical requirements, remove the flywheel.
Check whether there is any score, burr or dirt
between the flywheel mounting surface and the
crankshaft flange
53. Fit flexible connecting pan

required to fit all mounting discs
and/or snap rings by following
instructions on the removal at or
prior to the use of flexible
connecting disc.
1). Fit and tighten flexible connecting pan and
flexible connecting pan

ISLe375 30 engine
54. Fit starter motor

1). For the engine equipped with wet flywheel,
apply sealant on the mounting flange of
flywheel housing starter motor with a width of
1. 5 mm to 2. 0mm.
Caution: If any starter motor pad is needed,
ensure that the sealant is applied
onto the side where the pad is in
contact with the motor.
2). Fit 3 bolts, the starting motor and the starter

motor cushion block (if used)
55. Fit the engine rear bracket

1). Fit lifting bracket and bolt.
56. Fit the water inlet joint

1). Fit the sealing gasket of inlet union.
2). Fit the water inlet joint and mounting bolt

Engine block
57. Fit water pump

1). Mount the new O-ring in the slot on the water
pump housing
2). Fit water pump.

58. Fit coolant heater

1). Use the clean engine oil to lubricate the new
coolant heater thread.
2). Fit coolant heater


ISLe375 30 engine
3). Connect the coolant heater wire
59. Fit coolant thermostat

1). Mount the new thermostat into the water outlet
unionEnsure that the O-shaped rings at the
top and bottom are fitted in place.
2). Fit the mounting bolt of outlet pipe union
60. Fit coolant filter seat

1). Fit new sealing gasket and fliter seat.
2). Tighten four bolts
61. Fit the charger bracket

1). Fit bracket and mounting bolt of bracket.

Engine block
62. Fit the charger

1). Fit charger and it's bolts in reverse order to the
removal
2). Fit the charger ejector rod bolt.

63. Fit automatic belt tensioner (water pump)

1). Fit the belt tensioner and bolt.
64. Fit the belt drive fan hub

1). Fit the fan hub and bolt.

ISLe375 30 engine
65. Fit the fan spacer sleeve and belt pulley

1). If the engine is not equipped with a cooling
fan, the fan pulley mounting bolt and fan
pulley must be fitted.
2). Fasten the holddown bolts by hand.
3). After Fitting the drive belt, tighten the
mounting bolt to the final torque and use the
tension force of belt to avoid the rotation of fan
belt wheel.
Tightening torque M6 10 N·m
M10 43 N·m
M12 77 N·m
For the engine equipped with engine-driven

cooling fan, fix in place the fan belt pulley and
spacer bush. Fit the belt pulley and spacer sleeve
1). If removed, refit the cooling fan.
(1). For the relevant specifications, refer to OEM
maintenance manual.
2). Fasten the holddown bolts by hand.
3). After fitting the drive belt, tighten the mounting
bolt to the final torque and use the tension
force of belt to avoid the rotation of fan belt
wheel.
Caution: Do not constrain the fan blades so
as to keep the fan belt pulley or
the cooling fan can rotate freely.
Tightening torque M6 10 N·m
M10 43 N·m
M12 77 N·m
66. Fit the engine front bracket

1). Fit the front bracket and mounting bolt.

Engine block
67. Fit cooling fan drive belt

1). Arrange the drive belt on the engine by the
belt arrangement diagram made during the
disassembly procedureDo not fit the belt on
water pump pulley.
2). Turn the tension pulley according to the

direction of spring latch and install the driving
belt, finally make the belt slip onto the belt
pulley of water pump.
3). Release the belt tensioner to tension the drive
belt.
Caution: If it is necessary to use any
extension socket, use one hand to
support the ratchet spanner head
to prevent any accidental loading
of belt tensioner arm.
4). Check whether the belt and tensioner are
aligned with the front accessories drive device
68. Fit fuel filter (rotary)

Caution: If the filter is too tight, the threads
will become deformed, and the
filter core gasket or filter tank may
be damaged
1). The 10 µmwater separator (suction side) must
be filled with fuel.
2). Do not fill the 3 micrometer (pressure side)
fuel filter but use the feed pump to fill up the
fuel system.
3). Ensure that the central seal ring is fitted on the
filter positioning pin.
4). Fit filter according to the manufacturer’s
requirements.
5). Connect the water-in-fuel sensor and fuel
heater
Caution: 1. Fuel system can detect whether a correct water-in-fuel sensor has been provided.
2. If water-in-fuel sensor is not applicable or disconnected, engine alarm indicator
lamp will light up.

ISLe375 30 engine
69. Fit coolant filter

Caution: Do not let the oil enter into the
filter. Otherwise, the oil can
damage DCA.
Caution: Over-tightening of filter may give
rise to thread distortion, or
damage the seat.
1). Apply thin oil on the surface of sealing gasket
before Fitting new coolant filter.
2). Mount the coolant filter on the filter
seatTighten the filter till the gasket touches the
filter seat surface
3). Tighten the coolant filter for another 1/2 to 3/4
of a circle or as per the technical
specifications provided by the filter
manufacturer
Refer to the suggestions for the coolant filter.
Caution: The cutoff valve must be turned to

ON to avoid damaging the engine.
4). Open the stop valve by turning the knob from
the horizontal position to the vertical position
according to the illustrated direction.
70. Fit oil filter (rotary)

Caution: Fill the engine oil filter with engine
oil at starting to avoid the damage
on engine.
1). Apply a layer of clean 15W-40 engine oil onto
the oil filter gasket surface.
2). Fill the filter with clean 15W-40# engine oil.
Caution: Oil filter must have a filter bypass
valve. If the filter is clogged, the
use of engine oil filter without
bypass valve may lead to low oil
pressure.
For the suggestions of engine oil filter, refer to the
relevant chapter and section.

Engine block
3). Mount the filter on the filter seatTighten the

filter till the gasket touches the filter seat
surface
4). Use the engine oil filter spanner to fasten the
filter.
Refer to the instructions provided by filter
manufacturers.

ISLe375 30 engine
Cylinder head
I. Renewal of jumper plate
Common tools Sockets S10/S13/S16/S21, ratchet spanner
Special tool - -
Testing tools - -
Auxiliary material Detergent
2. Procedure
Preparatory step
1. Disconnect the battery
2. Remove pipe of ventilating device for the crankcase and the oil return hose
4. Remove engine brake assembly (if fitted)
5. Remove rocker arm assembly
Removal
Caution: Record the position and direction

of jumper plateIf the jumper
pressure plates are used again,
they must be refitted as per their
original positions and directions.
1. Remove jump pressure plate
Renewal of jumper plate 217

Engine block
After cleaning, check whether any further

use is possible.
1. Use the detergent to clean the jumper

pressure plate.
2. Blow-dry with compressed air.
3. Check whether the jumper plate is cracked
or is excessively worn on the joint with
rocker arm and valve tip
4. Check whether the pad has any crack or
other damage
Refitting
Caution: There is a round and elliptic hole

on the jumper plateIf a new jumper
pressure plate is fitted, it is not
necessary to locate the hole on a
specific position.
Caution: Make sure to fit the jump pressure
plate to be used continuously in
the original position and direction.
1). Install the jumper pressure plate on the valve
stem
Last step
1. Fit rocker assembly
2. Adjust the overhead mechanism
3. Fit the engine brake assembly (if equipped)
5. Fit crankshaft venlitation unit pipe and
return hose
7. Operate the engine.
8. Check whether there is any leakage
218 Renewal of jumper plate

ISLe375 30 engine
II. Renewal of cylinder head

Common tools Sockets S16/S18, pliers set, grinding pad
Cylinder header fixer, valve spring compressor, injector nozzle brush,

Special tool
crack tester, bolt length gauge
Testing tools Valve vacuum tester, gage block, and torque wrench （0~80N·m）
Auxiliary material - -
2. Procedure
Preparatory step
Caution: If the cylinder head fitted with an injector is removed, do take care not to damage the
injector tip. Do not place upside down the cylinder head equipped with the injectors
onto the combustion front. Otherwise, the injector end can be damaged.
2. Draining the coolant
3. Remove jumper air pipe
4. Remove intake pipe union adaptor
6. Remove injector supply pipeline
7. Remove intake manifold
8. Remove fuel rail
9. Remove fuel filter seat bracket
10. Remove fuel pump upper bracket
11. Remove connecting fuel pipe
12. Remove crankcase ventilation pipe and return hose
17. Remove jump pressure plate
18. Remove ejector sleeve
19. Remove fuel return pipe
21. Remove exhaust manifold
Renewal of cylinder head 219

Engine block
Caution: Do not remove fuel injector in this

time. Remove cylinder head fitted
with injector, so as to check
injector projection.
Removal
1. Remove cylinder head bolt
2. Vacuum test
Caution: If it is doubted that the intake
valve has leakage, use a valve
vacuum tester and cup to test the
valve and its seat. 5. The
descending speed of vacuum
within s can not exceed 25. 4 mm
Hg.
Vacuum of valve and valve seat
Old 457 mm Hg
New 635 mm Hg
3. Place the cylinder head in its holder
4. Use the gage block to measure the injector

projection.
5. Measure the highest point of injector
1). Place the injector protrusion measurer on the
top of cylinder headMeasure the highest point
of injector to obtain its projection. The
projection shall meet following technical
requirements:
Protrusion of fuel injector
220 Renewal of cylinder head

ISLe375 30 engine
Maximum 2. 80mm
6. Remove injector
7. Check the thickness of oil injector gasket
(if the protection of oil injector exceeds the
specifications)
8. Check the oil injector hole (if the thickness
of gasket is correct)
1). Check and ensure that the fuel injector hole is
clean and free of scrapingsIt is also necessary
to ensure that gasket does not stay inside
injector hole.
9. Remove valve stem lock clamp

1). Use the valve spring compressor to compress
the spring.
10. Release the valve spring.
11. Remove spring seat and the spring
12. Remove oil seal for the valve stem

13. Remove and discard the oil seal for the
valve stem
Caution: 1. When measuring, place the

valve on the bracket with number,
so as to correspond with the
seats.
2. Mark the valves to facilitate the
determination ofir positions. If the
valve is to be used again, refit the
valve to its original position, and
any numbering method can be
adopted.
14. Remove valve

Engine block
15. After cleaning, check whether any further

use is possible.
16. Use the injector hole brush to remove the
carbon deposit on the injector nozzle seat.
17. Eliminate sealing materials on all sealing
surfaces of cylinder block & cylinder head
18. Remove expansion plug

19. Remove deposits in the coolant passage.
1). Clean the excess deposits in acid solution
tank.
20. Use the grinding pad or the equivalent
cleaning pad and the diesel oil or solvent
to clean the cylinder head combustion
surface.
21. Clean the valve cover of carbon deposit
with best quality wire wheel mounted on
drill bit or die grinding machine.
Caution: If any poor-quality steel wire wheel
is used, the steel wire may be left
to cause additional pollution.
22. Clean the cylinder head with hot soapy
water.
24. Use the ruler and thickness gauge to

measure the overall planeness of cylinder
block.
25. Complete planeness
Caution: From the front end to the rear end
and from the left side to the right
side, the clearance shall not
exceed 0. 075mm.
26. Measure the flatness of part of combustion
surface of cylinder block
1). Use a 2in. ruler and a 0. 001in. thickness
gauge to measure the local planeness of
cylinder head combustion surface. Check
between cylinder holes and between cooling
fluid passages. If an 0. 001in. thickness gauge
can be inserted beneath a 2in. ruler, or the
cylinder block is cavitated, dented or
otherwise damaged, it must be renewed.

ISLe375 30 engine
Cracked cylinder head-guide for continuous

use
If the crack on the cylinder head extends from the
injector to the intake valve seat, follow the
guidance provided below:
• If the crack doesn’t extend into the valve seat,
the cylinder head can be used again.
• If the crack extends to or threads through the

valve seat hole, replace the cylinder head.
27. Identification of cylinder head cracks
1). Use the crack testing kit to identify the cylinder
head crack.
28. Check the flatness of combustion surface

of cylinder head
1). Use the ruler and thickness gauge to check
the planeness of cylinder head combustion
surface.
The planeness of cylinder head
From the front Maximum 0. 203mm

end to the rear
end
From left side to Maximum 0. 075mm

right side
29. Measure the flatness of part of combustion surface of cylinder head

Use a 2in. ruler and a 0. 001in. thickness gauge to measure the local planeness of cylinder head
combustion surface. Check between cylinder holes and between cooling fluid passages. If an 0. 001in.
thickness gauge can be inserted beneath a 2in. ruler, or the cylinder head is cavitated, dented or
otherwise damaged, it must be renewed.

Engine block
30. Use the gasoline-based solvent to clean

the bolt.
31. Clean the bolt.
1). Use the steel wire brush and soft steel wire
brush to thoroughly clean the bolt, or use
non-abrasive shot peen to remove deposits on
the screw and thread.
32. Visually check whether the cylinder head

bolt has damaged thread, eroded surface
or decreased diameter (because the bolt is
prolonged)
33. Judge if the cylinder head bolt can be

continued to use
1). It is not allowed to use continuously the
cylinder head bolt with the following problems:
(1). The area of obvious erosion or pitting exceeds
1sqcm. For example:
• 9. 525 ×9. 525 can be acceptable.
• 12. 12. 700 x 12. 700 mm is not allowed.
(2). The depth of visible corrosion or pitting
exceeds 0. 12mm
(3). The visible corrosion or pitting is 3. 2mm to the
beveling or thread
(4). Pull the bolt till it exceeds the max. free
lengthSee the following measurement
procedure.

ISLe375 30 engine
34. Measure the free length of bolt

1). Use the bolt length gauge to measure the free
length.
Caution: As long as the bolt is not damaged
and doesn’t exceed its specified
“free length”, it is allowed to be
used in the useful life of engine.
2). When checking the free length of bolt, place
the bolt head in the corresponding slot to
make the bolt flange close to the slot bottom
3). If the bolt tail contacts the bottom of measure,

this bolt is too long, and thus must be
discarded. The maximum free length of bolt is
162. 6 mm
Free length of cylinder head bolt
Maximum 162. 6mm
Pressure test
The cylinder head tester can be made by a steel or
aluminum plate. Refer to the following table for the
size of test unit.
Dimension of test equipment
Thickness 16 mm
Length 749 mm
Width: 193 mm
1. Use the cylinder gasket as the bolt boring

template.
2. Fit the cylinder head water test unit
1). Fit new cylinder head sealing gasket.
2). Fit test board
3). Fit the following parts
• 26 - 180 mm long cylinder head bolt
• 6 - M12 x 1. 75 hexagon flange nut
• 52-12 mm washer
3. Fit washer
1). Mount a washer between each bolt and
cylinder head and between each nut and test

Engine block
plate. This can avoid the damage on cylinder

head surface.
4. Tighten 26 nuts according to the illustrated

order
5. Connect one gas source hose with the test

fixing panel
6. Apply the air pressure.
• Air pressure 276 kPa
7. Lift the cylinder head in hot radiator with
nylon tape and lifting device.
• Water temperature 60°C
8. Immerse the cylinder head in the water
completely
9. Check the cylinder head

1). The air bubble shows air leakage. If the
cylinder head has leakage, replace it.
10. Remove test unit

11. Blow-dry the cylinder head with
compressed air.

ISLe375 30 engine
12. Clean the valve head.

1). Use the soft steel wire wheel to clean the
valve head.
Caution: Place the valve on the numbered
rack to avoid mixing up before
measuring.
13. The valve stem is worn out
1). Use the grinding pad or its equivalent and the
diesel oil or solvent to polish the valve stem.
14. Clean the valve guide pipe hole.

1). Use the brush to clean the inside of valve
guide pipe hole, and purge out foreign matters
via the compressed air.
15. Check whether the valve guide is scraped

or scuffed
16. Measure the inner diameter (I. D.) of valve
guide
Valve guide pipe inner diameter (I. D.)
Minimum 8. 019mm
Maximum 8. 071mm
If the valve guide pipe hole is worn to its maximum

limit, replace the cylinder head.
17. Measure the mounting height of valve

guide
1). Use the depth micrometer to measure the
mounting height of valve guide pipe. Measure
the distance from the top of valve guide to the
bottom of groove.
Valve guide pipe height (fitted)
Minimum 13. 15mm
Maximum 13. 65mm
If the valve guide pipe height exceeds the required

value, replace the cylinder head.

Engine block
18. Check whether the valve seat is cracked or

burnt
If the valve seat is cracked or burnt, replace the
cylinder head.
19. Verify whether valve sealing zone is at

center of valve seat insert
If the sealed zone reaches the top or bottom of
valve seat ring, replace the valve.
20. Recheck the valve sealing area after
renewing the valve
If the sealed zone reaches the top or bottom of
valve seat ring, replace the cylinder head
21. Adjust the angle of valve seat

• The intake valve holder is at 30°
• The exhaust valve is at 45°
22. Check whether the valve head and valve

stem are worn abnormally
23. Measure the diameter of valve stem
Diameter of valve stem
Minimum 7. 96mm
Maximum 7. 98mm
Renew any valve with size not in conformance with

the specification.

ISLe375 30 engine
24. Check whether the valve head is straight

and flat
25. Check whether there is any bent valve
26. Measure the thickness of edge
If the valve thickness goes beyond the limited
range, change the valve.
Valve head edge thickness
Exhaust valve Minimum 1. 83mm
Intake valve Minimum 2. 20mm
27. Check the valve spring

28. Measure the valve spring
• Approximate free length: 59. 18mm
29. Measure the spring force

1). To compress the sprint to 30. 6mm, the load of
906N to 1007N is neededUse the spring
compressor to measure the spring force.
If the load needed by the compression spring has
exceeded the required limit, replace the valve
spring.
30. The valve to be reused must be installed at

the position where it is removed.
31. Use SAE 90W or 15W-40 engine oil to
lubricate the valve stem.
32. Fit valve

Engine block
33. Install the black valve oil seal on the

exhaust valve guide
34. Mount the blue valve oil seal on the intake
valve guide pipe
35. Fit valve spring seat and valve spring

36. Use the valve spring compressor to
compress the spring.
37. Fit the new valve collar and release the
spring tension force
38. Knock the valve stem with plastic hammer.

39. Measure the deflection of valve
Sinkage of valve in the cylinder head
Minimum 0. 84mm
Maximum 1. 32mm
If the valve sinkage exceeds the required value,

replace the valve. If the valve sinkage exceeds the
required value again, replace the cylinder head.
40. Conduct vacuum test on the cylinder head.

Refer to “Vacuum test” in the procedure

ISLe375 30 engine
41. Check the cylinder liner projection before

Fitting the cylinder head
Caution: Ensure that the cylinder head

gasket is aligned with the hole on
the cylinder block. If not aligned,
the engine may be damaged.
Caution: Do not try to repeatedly use the
sealing gasket of cylinder head.
42. Place the new cylinder head gasket on the
locating pin
43. Place the cylinder heat on the cylinder

block and in the locating pin
44. Fastening bolt

If any new bolt is used, grind the bolt thread. When
polishing the new bolt, mount the tightening bolt
described in the followingUndo bolts and then
retighten them in the required sequence.
45. Use the clean 15W-40 engine oil to
lubricate the cylinder head bolt thread and
screw.

Engine block
46. Tighten bolts of cylinder head according to

the illustrated sequence
Tightening torque Step 1 50N·m
Step 2 150N·m
bolts
Step 4 115N·m
Step 5 115N·m
Step 6 Advance by
120 degree.
47. Fit the exhaust manifold

48. Fit the turbocharger
49. Fit fuel return pipe
50. Fit the push pipe
57. Fit crankshaft venlitation unit pipe and return hose
58. Fit fuel conncting pipe
59. Fit upper fuel pump bracket
60. Fit the fuel filter seat bracket
61. Fit the fuel rail
62. Fit feed pipeline of oil injector
64. Fit intake pipe union adapter
65. Fit the air jump pipe
66. Fill the cooling system
68. Operate the engine to check whether there is leakage of engine oil.

ISLe375 30 engine
III. Renewal of cylinder head valve guide oil seal

Sockets S10/S13/S16/S18/S22/S24, double offset ring & open-end

Common tools wrenches S16S18/S22/S24
Slotted screwdriver, lifting rope
Special tool Jigger, offset ring socket 3910-Z-BD-21/3910-Z-BD-18
Testing tools Feeler gauge, torque wrench (0~400N·m), dial gauge and magnetic stand
Auxiliary material Lubricating oil
2. Procedure
The following procedure is used for the removal of seal for valve tappet fitted with cylinder head. For the
removal of valve tappet seal when the cylinder head has been removed.
Caution: The procedure also applies the removal of valve spring, the valve spring seat and
the valve key assembled with the cylinder head.
Preparatory step
3. Remove engine brake assembly (. If necessary)
5. Remove bridge plate
6. Remove all the injectors
Removal
Caution: To remove the valve spring fitted

with the cylinder head, the piston
in operation must be located at
TDC to support the valve.
1. Align the gear housing cover and the top
dead center mark on the fuel pump gear
to align top dead center marks on the gear
housing cover and fuel pump gear.
Renewal of cylinder head valve guide oil seal 233

Engine block
2. Mark the shock absorber

1). Mark the vibration insulator when the top dead
center mark of No. 1 cylinder is aligned, so as
to identify the positions of top dead center of
other cylinders.
(1). Every 120°, draw marks on the shock
absorber by the marker on it or stick the seal
straps around the shock absorber
Repair skillsIndex gauge, camshaft dividing wheel
or angle/plane indicator can be used for finding out
the increment of 120° around the vibration
insulator.
(2). As shown in the figure, use TDC pointer to mark out the shock absorber of each cylinder block. The
two cylinder blocks correspond to each pipe of 120°
3. Compress the valve spring

1). Use the valve spring compressor repair tool to
compress the spring.
4. Fix the puller
1). Fix the puller screw (4) on the injector nozzle,
and fit two bolts (5) inside the cylinder head
whose compression clamp screw is removed.
Caution: Uneven clearance between the

valve and the fuel injector holeIt is
very important to align the groove
on the valve spring compressor
plate wit the spring.
5. Apply the release grease on the threads of
puller screw (4)
1). Always read and follow preventive measures
written on the label.
6. Fix the valve spring compressor plate
1). Fix the valve spring compressor plate (1) on
the puller screw (4), and align the slot on the
valve spring compressor plate with the valve
spring
7. Mount the washer (3) and nut (2) on the

puller screw (4)
234 Renewal of cylinder head valve guide oil seal

ISLe375 30 engine
Warning: The valve spring is tensioned; if

released, it may be ejected. To
prevent eye injuries, wear goggles
with side shields.
8. Rotate the nut (2) clockwise to compress
the valve spring.
9. Remove valve key
1). Keep on turning the nut (2) clockwise till the
valve lock plate is removed by magnetic tool,
such as the tip of magnetic screw driver.
Caution: Because there is clearance
between piston top and valve
surface, this may require the
second magnet to support the
valve tappet so as to remove the
valve lock plate.
10. Remove valve key and the repair tool for

the valve spring compressor
Caution: After the valve locking plate,
spring and its seat are removed,
do not run the engine. To rotate
the engine will drop the valve into
cylinder, which requires
disassembling cylinder head or
may damage the engine.
11. Remove 4 valve spring seats and valve
springs
12. Remove the valve stem oil seal with pliers.

Caution: Type and position of seal, and
then abandon the old seal

Engine block

use is possible.
1. Clean the sealing tower and valve tappet
with contact cleanser.
2. Check whether the exposed valve tappet is

cracked or worn out severely.
3. Check whether the slot on the valve lock
plate is worn
If the valve tappet is damaged, remove the cylinder
head and replace the valve.
4. Check whether the valve spring seat or

valve lock plate is damaged or worn
5. Dispose and renew any damaged or worn
part
Refitting
Caution: When removing, make sure to fit

valve stem of same color at a
position. The improper sealing of
valve stem may lead to excessive
engine oil consumption and
damages of interior members of
engine.
Caution: Use the SAE 15W-40 engine oil to
lubricate all valve guide pipe holes
and valve stem. If there is
lubrication valve guide and valve
stem, the valve guide will be worn
early
1. Mount a same color of new valve stem seal
at the same position as disassembling.
Caution: Black valve stem sealing is used

ISLe375 30 engine
for exhaust valve, and black for

intake valve.
2. Lubricate the valve stem.

1). Use 15W-40 engine oil to lubricate the valve
stem.
3. Fit valve spring and spring seat
4. Use the valve spring compressor repair

tool to compress the spring.
5. Fix the puller screw (4) on the injector
nozzle
6. Install 2 bolts (5) in the cylinder head with
the bolt for the clamp removed
7. Tighten the bolts
Caution: Uneven clearance between the

valve and the fuel injector holeIt is
very important to align the groove
on the valve spring compressor
plate wit the spring.
8. Apply the release grease on the threads of
puller screw (4)
Always read and follow preventive measures
written on the label.
9. Fix the valve spring compressor plate (1)
on the puller screw (4), and align the slot
on the valve spring compressor plate with
the valve spring
10. Mount the washer (3) and nut (2) on the
puller screw (4)

Engine block
Warning: The valve spring is tensioned; if

released, it may be ejected. To
prevent eye injuries, wear goggles
with side shields.
Caution: Because there is clearance
between piston top and valve
surface, this may require the
second magnet upwards to
absorb the valve tappet so as to
remove the valve lock plate.
11. Compress the valve spring
1). Compress the valve spring till the valve lock
plate can be fitted.
12. Fit valve collar

Repair skillsApply the fitted lubricant or equivalent on valve lock plate to fix these lock plates in plate till
the valve spring compressor is released.
13. Remove repair tool for the valve spring

compressor
14. Fit valve lifter seal
1). Based on the mark previously made on the
shock absorber, turn the engine to the next
mark to replace the valve guide pipe seals on
the next cylinder block pairs.
Caution: Before knocking the valve tappet

of cylinder of previous operation,
rotate the engine to the next
cylinder in firing order. This can
avoid the occurrence of valve
bending and engine interior
damage because the valve
contacts piston.
2). After rotating engine to next cylinder in firing
order, first knock at the valve tappet of
cylinder of previous operation to ensure the
lock plate is in place.
15. Repeat the previous procedures till all the valve tappet seal is replaced.

ISLe375 30 engine
Last step
1. Fit oil injector
8. Operate the engine to check whether there is leakage.

Engine block
Cylinder block and flywheel housing

I. Renewal of cylinder block
Common tools Sockets S8/S10/S13/S16/S18/S21/S27, ratchet spanner
Special tool Engine bracket, non-metallic brush, steam washer
Testing tools - -
2. Procedure
Preparatory step
1. Remove engine and place it on the engine stand
See “Disassembling of engine”.
2. Disassemble the engine
See “Disassembling of engine”.
Initial inspection
1. Visual inspection
Before cleaning or further disassembling cylinder
block, visually check whether there is any damage,
crack or abrasion which may affect the use. Notice
the following regions of cylinder block:
· Main bearing cap & hole
· Camshaft hole
· Cylinder hole
· Tappet hole
· Cylinder block combustion surface
· Fitting surface of oil sump
· Fitting area of oil pump
· Fitting area of water pump
· Front and rear of cylinder block sealing
surface
240 Renewal of cylinder block

ISLe375 30 engine

use is possible.
1. Check whether all the pipe plugs,
expansion plugs and straight thread plugs
are damaged or have leakage
If it is required to thoroughly clean the cylinder
block for further use due to overmuch scraps or
pollutants, remove all pipe plugs, expansion plugs
and straight thread plugs as the case may be.
Ensure that all engine oil and coolant pipelines are
clean.
2. Use the detergent and non-metal brush to

clean the cylinder block engine oil
passage.
3. Thoroughly clean all gasket residues on

sealing surfaces.
4. Dismount the cylinder block from engine

support
Renewal of cylinder block 241

Engine block
Caution: If the camshaft bushing is not

removed, ensure that the
detergent which will not damage
the camshaft bushing is used.
For the tank cleaning, refer to manufacturer’s
instruction.
Follow the manufacturer’s instruction in the use of
detergents.
Caution: Any special-purpose cleaning
agent is not recommended by
Cummins CompanyThe test
shows that the effect of cleaning
agent heated to 80~95℃ is the
bestThe cleaning tank capable to
mixed and filter the cleaning agent
is the best.
5. Clean the cylinder block in cleaning

container.
Caution: In order to minimize engine
damages, ensure that all scraps in
the bolt hole and engine oil
passage are removed.
6. Take out the cylinder block from the wash
tank
7. Thoroughly clean the cylinder block with
steam.
8. Blow-dry the cylinder block with
compressed air.
9. Recheck whether the cylinder block has

crack, corrosion and discolouration which
may affect the continued use.
To identify any crack in the cylinder block, employ
the crack tester kit.
Notice the following regions of cylinder block:
· Main bearing cap & hole
· Camshaft hole
· Cylinder hole
· Tappet hole
· Cylinder block combustion surface
· Fitting surface of oil sump
· Fitting area of oil pump
· Fitting area of water pump
· Front and rear of cylinder block sealing
surface

ISLe375 30 engine
· Oil cooler cavity.
10. Check whether the main bearing cover and

saddle zone is cracked, worn or faded.
If any crack is visible, replace the cylinder block.
11. Check whether any screw hole has

damaged thread
1). If any, use a spiral threaded ring carrier to
repair all damaged threads.
Caution: The thread ring shall not be used
to repair the threaded bolt hole on
the main bearing saddleIf
damaged, replace the cylinder
block.
12. Check whether the camshaft hole is

scored, scraped or worn excessively
If the camshaft hole is damaged, replace the
cylinder block. No larger cam lining is available
13. Check whether the counter holes are worn

or cracked
If the sealing surface C is cracked or abnormally
worn, the countersunk hole must be provided to fit
the shim thus to obtain a correct cylinder jacket
projection. See “Repair” in the procedure.

Engine block
Measure
All cylinder measurements must be performed with
the cylinder fitted with the main bearing cover and
located on a level ground.
If the cylinder block is fitted on the engine support,
and/or the main bearing cover is not fitted, the
measurement may be inaccurate due to the
distortion of cylinder hole, main bearing hole and
camshaft hole.
1. Check whether the cylinder head top is

damaged
2. Check the flatness of cylinder head top
between each cylinders
Technical specification of cylinder block plane
mm
From the front end to

0. 075
the rear end
From left side to right

0. 075
side
Check whether there is local tilting or defectIf any

damage is detected or the planeness doesn’t meet
technical requirements, replace the cylinder block.
3. Measure the bore of liner in the cylinder
block
Bore of cylinder liner inside the cylinder block

(press fit)
Minimum 130. 900mm
Maximum 130. 950mm
Caution: If any jacket hole can’t satisfy

technical requirements, replace
the cylinder block.

ISLe375 30 engine
4. Measure the depth of countersink of

cylinder liner
Depth to the cylinder block hole on the cylinder

head top surface
Minimum 122. 930mm
Maximum 123. 000mm
Caution: If the depth of any countersunk

hole on the cylinder jacket
exceeds the required limit,
machine the hole and fit shims.
Refer to “Repair” in the procedure.
Camshaft bore (without bushing)
Maximum 64. 01mm
5. Measure the camshaft bore when the

camshaft bush is not installed
Caution: If any camshaft bore doesn’t meet
the cylinder block.
6. Check whether the tappet hole is scored or

worn excessively
7. Measure the tappet hole
Tappet bore
Minimum 31. 295mm
Maximum 31. 325mm
Caution: If the tappet hole can’t satisfy

the cylinder block.

Engine block
8. Fit the main bearing cap without the main

bearingAbout the fitting of main bearing
cap
1). Tighten the main bearing cap bolt
Diameter of main bearing hole
Minimum 104. 982mm
Maximum 105. 018mm
Measure the main bearing hole after the removal

of bearing.
The maximum deflection of bore is 0. 0127mm
Repairs
If the countersunk hole requires machining, use
the cutter to process the hole to a proper depth.
Thickness of cylinder liner shim
mm In
0. 25 0. 010
0. 38 0. 015
0. 51 0. 020
0. 76 0. 030
1. 00 0. 040

ISLe375 30 engine
The cylinder liner pad with following thickness.

If the cylinder block is not used immediately, coat
the machined surface with the antirusting agent.
Ensure that the cylinder block is covered to
prevent the ingress of dust or scraps on inside and
outside surface of block.
New cylinder block

Prior to the use of any new or stored cylinder
block, do remove all engine oil/anti-rusting agent in
the cylinder hole, on the gasket sealing zone and
in the main bearing hole.
Last step
1. Assemble engine.
See “Assembling of engine”.
2. Remove engine support
3. Fit engine

Engine block
II. Renewal of cylinder block reinforcement plate

Sockets S8/S10/S13/S16/S18/S21/S27, internal hexagon socket S6

Common tools
Offset ring spanner S10/S13/S16/S22, slip joint pliers, circlip pliers
Engine hook, front oil seal puller, barring tool

Special tool
Engine rollover stand, flywheel clamp plate
Torque spanner (40~200N·m), inside gauge, outer diameter micrometer

Testing tools
Feeler gauge, dial gauge and magnetic stand
Auxiliary material Sealant, flat chisel
2. Procedure
General
Only partial engines are provided with reinforced panel of cylinder block
Preparatory step
1. Draining the oil
2. Remove oil sump
3. Remove oil suction pipe
Removal
1. Remove reinforcement plate of cylinder
block
Caution: The plate will become loose after
the oil pan bolts are removed.
248 Renewal of cylinder block reinforcement plate

ISLe375 30 engine

use is possible.
1. Clean off all materials on the surface of
gasket
2. Check whether the reinforced board of
cylinder block has any crack or other
damage
Refitting
1. Fit the cylinder reinforeced version and
seling gasket
Caution: The cylinder block reinforcement
plate must be fitted in place during
the assembling of oil suction pipe.
Use a few of oil pan bolts or lead
wire strips to fulfill this work.
Last step
1. Fit oil suction pipe
2. Fit the oil sump
3. Fill engine oil into the engine.
Renewal of cylinder block reinforcement plate 249

Engine block
III. Renewal of hydraulic pump drive


Common tools

Special tool

Testing tools
2. Procedure
Removal
1. Disconnect all hydraulic pipes from pump
2. Remove hydraulic pump and the gear

assembly
3. Disassembling of related components
250 Renewal of hydraulic pump drive

ISLe375 30 engine
Cleaning
1. Clean the hydraulic pump gasket.
2. Use the detergent to clean the hydraulic

pump gear.
Check whether it can be reused

1. Check whether the drive gear of hydraulic
pump is damaged
Refitting
1. Use new gaskets to fit the hydraulic pump.
Renewal of hydraulic pump drive 251

Engine block
2. Connect all the hydraulic pipes to the

pump
3. Tighten the mounting bolt

252 Renewal of hydraulic pump drive

ISLe375 30 engine
IV. Renewal of cylinder jacket

Common tools Sockets S8/S10/S13/S16/S18/S21/S27
Cylinder liner puller, countersunk cutter, cylinder liner removing and fitting
Special tool
tool
Testing tools Inner diameter dial indicator
Auxiliary material Working cloth, non-burr tissue, 15W-40 engine oil
2. Procedure
General
The cylinder block is equipped with a renewable
cylinder liner. The intermediate stop design is used
for locating the cylinder liner in cylinder block. The
press fit between the cylinder liner and cylinder
block provides tightness of coolant on the top of
cylinder liner. The rectangular seal ring (cylinder
linger seal ring) is used to seal the thrust
Caution: If the internal diameter of cylinder

jacket stays in the required range
in this step, Cummins doesn’t
recommend to remove the jacket
to solve the problem of engine oil
consumption. Carefully analyze
the condition of cylinder liner
hole, piston ring and piston and
eliminate the sealing problem of
cylinder by the minimum Renewal
of component.
Preparatory step
5. Draining the oil
6. Remove oil sump
8. Remove piston & linkage assembly
Renewal of cylinder jacket 253

Engine block
Initial inspection
Caution: Before removing cylinder liner,
check its status to determine
further use or not. Check whether
the cylinder liner bore has any
crack, scrape or scoreCheck
whether the longitudinal scuffing
depth on the inner diameter can
be felt by fingers, and whether the
scuffing can be felt by finger nail,
replace the cylinder liner
1. Visually check the inner diameter to

determine the polishing of cylinder liner
hole
Do not continue to use the severely worn cylinder
liner or those embedded with particles due to some
defectives.
A seriously worn cylinder jacket will hump at the
jacket top
If the wear indicates that the cylinder jacket is not

straight or round, use a micrometer of internal
diameter to measure the internal diameter of
cylinder at four 4 positions 90°apart on both the top
and bottom of piston travel zone.
Specification of cylinder liner
Specification of cylinder liner
Taper Maximum 0. 04mm
Out-of-roundness Maximum 0. 04mm
Diameter of hole Maximum 114. 04mm
254 Renewal of cylinder jacket

ISLe375 30 engine
Caution: If the cylinder jacket doesn’t

permit any further use, it must be
replaced. The damaged cylinder
jacket shall not be ground or
polished. This will damage the
grid chart required by engine oil
control.
Caution: Do not remove or interfere the oil
seal of cylinder liner which meets
the inspection standards.

Check the projection when the clamp is not fitted
before removing the cylinder liner. Use the jacket
projection gauge to measure the projection.
Projection of cylinder liner
Lowest 0. 026mm
Maximum 0. 122mm
If the cylinder head is correctly fitted but the projection exceeds the limit, machine the countersunk hole
and add shims till the technical requirements are met.
Removal
Universal jacket puller method
1. Cover the crankshaft with a piece of clean
repair cloth.
Cover the crankshaft with a piece of clean repair
cloth, to avoid the fall of any scraps onto the main
journal zone or into the linkage journal oil hole.

block. The puller must not touch
the Point (1), (2), (3) and (4) on the
cast member of cylinder block
2. Insert the cylinder liner puller into the
cylinder block top

Engine block
Caution: The cylinder liner puller must be at

the center of cylinder block top.
3. Undo the cylinder jacket.
1). Rotate the puller screw clockwise to undo the
4. Remove the cylinder liner by hand.
5. Mark the cylinder number on each cylinder

liner.

block. The puller disc must be
parallel with the main bearing
saddle and not cover the outer
diameter of cylinder liner
Standard liner puller method
The universal puller can be alternatively used with
the standard puller. The universal puller must be
used with the remover board.
1. Insert the cylinder liner puller into the
cylinder block top

block.
2. Undo the cylinder jacket.
Rotate the puller screw clockwise to undo the
3. Remove the cylinder liner by hand.
4. Mark the cylinder number on each cylinder
liner.

ISLe375 30 engine

use is possible.
Caution: Do not use abrasive in the stroke
range of piston ring of cylinder
liner. Otherwise, the cylinder liner
can be damaged.
1. Use the soft steel wire brush or fine fiber
grinding pad or its equivalent to clean the
flange support zone.
2. Use the detergent or steam too clean the

cylinder jacket and dry it with the
compressed air.
lubricate the inside of cylinder jacket.
4. Wet the cylinder jacket with engine oil for 5
to 10min.
Caution: Use the non-burr tissue to remove

the engine oil on the inside
surface of cylinder jacket.
5. Keep on lubricating the inner bore of
cylinder lining
1). Keep on lubricating the inner bore of cylinder
lining, and wipe it clean till there is no dust or
black residue on the paper
6. Check whether the inner and outer

diameters of cylinder liner have any crack

Engine block
7. Check whether there is any crack below

the flange
8. Check whether the outer diameter and

carrier is eroded or pitted excessively
Caution: The cavitation depth shall be no
more than 1. 6mm.
If the cavitation erosion extends deep or it is not
allowed to remove the erosion with fine sand cloth,
replace the cylinder jacket.
9. Check the longitudinal scuffing depth on

the inner diameter can be felt by finger
Caution: If the scratch can be felt by the
fingernail, replace the cylinder
jacket.
10. Check whether the inner diameter is
scraped or scored
11. Visually check the inner diameter

Determine the polishing conditions of cylinder
jacket holes.

ISLe375 30 engine

The cylinder jacket shall be replaced in following
circumstances:
· Serious polishing goes beyond 20% of piston
ring travel area.
· Intermediate and serious polishing goes
beyond 30% of piston ring travel area, half of
which is serious polishing.
12. Accurately measure with inside

micrometer.
1). Respectively measure the inside diameter of
cylinder liner at four positions which form an
angle of 90° at the top and bottom in the range
of piston stroke.
Inside diameter of cylinder liner
Minimum 114. 000mm
Maximum 114. 040mm
2). Measure the outer diameter of matching area at

top of cylinder lining.
Outside diameter of cylinder liner (press fit on

the top)
Minimum 130. 938mm
Maximum 130. 958mm
3). Measure the bore of liner in the cylinder block.

Engine block
Refitting
Caution: Clean off all deposits and crumbs
on sealing surfaces A, B and C.
Use the grinding pad or its
equivalent and the detergent to
polish the surface. In view of strict
mismachining tolerance, be
careful not to remove the
additional materials.
If the sealing surface C is cracked or abnormally
worn, the countersunk hole must be provided to fit
the shim thus to obtain a correct cylinder jacket
projection.
1. Machine the counter hole (if needed)

Use the hole cutter to process the countersunk
hole to a proper depth.
Caution: The cutter and cutter head must
be used together with the counter
bore machining tool.
2. Wash the combustion surface.

Use the gasket blade or grinding pad or the
equivalent and diesel oil or solvent to clean the
combustion surface.
3. Wash the cylinder and crankshaft.

1). Use the mineral oil or detergent to thoroughly
flush the cylinder.
2). Remove the overhaul cleaning cloth and clean
the crankshaft with detergent.
3). Dry cylinder hole and crank, and clean with lint
free cloth.

ISLe375 30 engine
4). Use 15W-40 engine oil to lubricate the sealing

surfaces A and B.
4. Lubricate the cylinder jacket.

Use the clean 15W-40 engine oil to lubricate the
O-shaped seal ring of cylinder jacket.
5. Fit O-ring
Mount the new O-ring on the cylinder liner
6. Fit the cylinder liner

1). Put the cylinder liner to be used continuously
into the same cylinder as the removed, and
rotate it 45° (1/8 turn) from the original
position. When the assembly is correct, the
cylinder sleeve cave corrosion position must
be as illustrated by the picture and the cave
corrosion must turn the direction eccentrate
the cave corrosion position.
2). Use the cylinder jacket remover & installer to

fit the jacket into the cylinder hole.

Engine block
3). As shown in the figure, two (2) cylinder head

bolts are used to fix these two (2) cylinder
jacket hoops.
Tighten the bolt
4). Remove pressure plate for the cylinder liner
and repeat the step until all the cylinder liners
have been pressed tight and released.
7. Measure the projection of cylinder liner

1). Use the micrometer to measure the cylinder
jacket internal diameter at four positions
90°apart on the top and bottom of piston travel
zone.
Minimum 0. 026mm
Maximum 0. 122mm
2). If the change of cylinder jacket projection

within 180°exceeds 0. 025,
(1). Reassemble and fasten cylinder liner clip.
3). Measure the extrusion length of cylinder liner

again.
If the projection change exceeds 0. 025mm again:
4). Remove cylinder liner.
5). Check whether the seal lip of cylinder liner has
burrs, dirt or damage
6). If the cylinder jacket is damaged, replace it.
7). Reassemble cylinder liner.
8). Measure the projection of cylinder liner.

ISLe375 30 engine
Repair skillsIf a minimal exceedance exists, fit

another new cylinder jacket in the cylinder hole
with exceedance, to add the error to within the
extreme limit of projection.
9). If the cylinder jacket projection remains

unqualified, use following tools to machine the
jacket holes on the cylinder block to
accommodate shims.
Drive
Cutter
Cutter head
10). Use the thickness gauge to check the gap

between the cylinder jacket and the cylinder
block at four casting points on the cylinder
block.
Clearance between the cylinder liner and

cylinder block
Minimum 0. 229mm
11). If the gap is less than 0. 229mm

12). Remove cylinder liner.

Engine block
13). Check whether the cylinder liner and block

have any dirt or damage
14). If the cylinder jacket is damaged, replace it.

15). Reassemble cylinder liner.
Measure the out of roundness of cylinder liner hole

at points “C”, “D”, “E”, “F” and “G”. Measure
various points along directions “AA” and “BB” . The
out of roundness of cylinder liner hole must be no
more than 0. 04 mm.
Caution: If the out-of-roundness of jacket

exceeds 0. 04mm
16). Remove cylinder liner in order to measure the
liner hole of cylinder block.
Last step
1. Fit the pistion and linkage

ISLe375 30 engine
3. Fit the oil sump

7. Fill the lubrication system

Engine block
V. Renewal of piston and linkage assembly


Common tools

Special tool

Testing tools
2. Procedure
Preparatory step
2. Draining the oil
4. Remove oil sump
6. Remove piston cooling nozzle (if required)
Removal
1. Rotate the crankshaft till the piston is
lower than the carbon deposit on the
piston ring stroke zone.
2. Remove the carbon deposit with fine fibre
266 Renewal of piston and linkage assembly

ISLe375 30 engine
3. Mark each piston according to the position

of cylinder
4. Rotate the crankshaft to make the linkage

cover at bottom dead center.
5. Mark each linkage and linkage cover
according with the position mark of
cylinder number
Engine fitted with horizontal angle-split linkage

1. Remove nut, the linkage cap and the lower
linkage bearing
2. Mark cylinder number and letter “L”
(lower) on bearing locating tongue surface.
3. Push the linkage and cylinder assembly

out from the cylinder bore
Always pay attention not to damage the linkage or
the bearing.
Renewal of piston and linkage assembly 267

Engine block
4. Remove upper bearing for the linkage

5. Mark cylinder number and letter “U”
(upper) on bearing locating tongue
surface.
6. Take out the piston and linkage assembly

by hand.
If such parts are desired to be used again, refit the
piston and linkage assembly into the same cylinder
and ensure that the worn mating surface is
corrected fitted.
7. Label the position of piston and linkage
8. Place the linkage and piston in the
container
Engine fitted with angle-split linkage

1. Rotate the crankshaft till the piston is
lower than the carbon deposit on the
piston ring stroke zone.
2. Remove the carbon deposit with fine fibre
3. Mark each piston according to the position

of cylinder

ISLe375 30 engine
4. Rotate the crankshaft to make the linkage

cover at bottom dead center.
5. Mark each linkage and linkage cover
according with the position mark of
cylinder
6. Undo the linkage cover bolt.

Caution: Do not remove bolts from the
linkage.
7. Undo the linkage cover.
(1). Use the rubber hammer to knock the linkage
bolt to separate the linkage cover from the
positioning pin.

surface of linkage or linkage cover
section. If the fissured surface of
of engine. False mounting may
damage the linkage.
8. Remove linkage bolt
9. Remove linkage cap
10. Remove lower bearing for the linkage
11. Mark cylinder number and letter “L”
(lower) on bearing locating tongue surface.
12. Push the linkage and cylinder assembly

out from the cylinder bore
Always pay attention not to damage the linkage or
the bearing.

Engine block
13. Remove upper bearing for the linkage

14. Mark cylinder number and letter “U”
(upper) on bearing locating tongue
surface.
15. Take out the piston and linkage assembly

by hand.
If such parts are desired to be used again, refit the
piston and linkage assembly into the same cylinder
and ensure that the worn mating surface is
corrected fitted.
16. Label the position of piston and linkage
17. Place the linkage and piston in the
container for safety
Disassemble
1. Remove piston ring
1). Use the piston ring expander to remove the
piston ring.
2). Disassemble the snap rings at the two sides of

snapring plier.

ISLe375 30 engine
2. Remove piston pin

Caution: No need to heat the piston.
Caution: The piston skirt should be

detached from the piston crown
when the piston pin is removed
from the articulated piston. Care
should be taken not to damage the
piston.
3. Mark their cylinder numbers on
disassembled piston, piston crown, piston
skirt and piston pin.
Ensure that the cylinder is correctly refitted.

use is possible.
1. Clean the piston.
2. Check the piston

Engine block
3. Check the linkage
Assemble
Single-piece piston
1. Install the clip ring on the piston pin slot
on the side of piston
2. Lubricate the contact pin and its hole with

engine oil.
3. Thread the piston pin through the piston

and linkage
Caution: The piston does not need to be
heated when assemle the pistion
pin, but the operation must be
made at indoor temperature or
upper temperature.

ISLe375 30 engine
4. Fit the second piston pin clamp ring
Caution: Discrepancies exist between most

of pistons which appear the same.
Ensure that the correct piston ring
is used as per the engine part
number.
The top faces of upper ring and intermediate ring
can be identified by the mark “TOP” or the
supplier’s trademark (for example, a round point).
When assembling, make the character of “TOP” or
supplier’s identification mark upwards.
The bottom ring or oil control ring can be fitted both
sides.
Caution: When fitting these 2-piece type oil

control rings, the opening of
bushing ring must be at the 180
degree of oil control ring.
5. Use the piston ring expander to refit the

piston ring onto the piston.

Engine block
6. Place the oil ring expander in the oil

control ring slot
Hinged piston
Caution: If the piston is used again, the
piston crown, skirt and pin must
be refitted to restore their original
status.
1. Install the piston apron on the piston
crown
Caution: The hinged piston pin needs no
heating before assemblyPiston
pin is engaged through sliding.
2. Install the clip ring on the piston pin slot
on the side of piston
Caution: Do not use hammers to fit piston

pin. Piston is distorted, thus being
clipped into cylinder liner.
Caution: The lock tongue on the linkage
must be opposite to the deep
valve sleeve on piston crown
3. Lubricate the contact pin and its hole with
engine oil.
4. Align the piston pin hole on the linkage
with that on the piston crown, and then
install the piston pin
Caution: The clip ring must be placed in the

piston slot completely to protect
the running engine
5. Fit the second piston pin clamp ring

ISLe375 30 engine
Caution: Discrepancies exist between most

of pistons which appear the same.
Ensure that the correct piston ring
is used as per the engine part
number.
The top faces of upper ring and intermediate ring
can be identified by the mark “TOP” or the
supplier’s trademark (for example, a round point).
When assembling, make the character of “TOP” or
supplier’s identification mark upwards.
The bottom ring or oil control ring can be fitted both
sides.
Caution: When fitting these 2-piece type oil

control rings, the opening of
bushing ring must be at the 180
degree of oil control ring.
6. Use the piston ring expander to refit the

piston ring onto the piston.
7. Place the oil ring expander in the oil

control ring slot

Engine block
Refitting
Caution: Before assembling, keep cylinder
block and components clean.
1. Check whether the cylinder liner can be
used again
2. Use a piece of clean non-burr cloth to
clean the linkage and bush.
3. Fit bearing
If no new bearing is used, the old one must be
refitted onto the original linkage and position.
4. Mount the upper bearing on the linkage
The locating tongue of bearing bush must be in
locating slot of linkage. The end face of bearing
bush must be flush with mounting surface of
linkage cover.
Caution: For split-angle type linkage, the
upper and lower bearing shells of
linkage cannot be exchanged. The
bearing back has UPR or LWR
mark to indicate its position.
5. Apply the mounting lubricant or its

equivalent onto the bush internal surface.
6. Apply a coat of clean 15W-40# engine oil
on cylinder liner.
7. Use the clean engine oil to lubricate the

piston ring and piston apron.

ISLe375 30 engine
8. Undo the piston ring and adjust its

opening position.
Turn as illustrated
Caution: The opening of each piston ring
shall not be aligned with the
piston pin or the opening of other
piston ringIf the piston ring is
opened at the incorrect position,
the ring will not be sealed
properly.
9. Use the piston ring compressor to

compress the piston ring.
10. Rotate the crankshaft to make the journal

of linkage to be assembled at bottom dead
center.
Caution: If the operation is not carried out

according to the procedure, the
engine will be damaged severely.
Engine fitted with angle-split linkage
1. Align the piston valve sleeve with the
exhaust side of engine
2. Insert the linkage into the cylinder liner till
the piston ring compressor touches the
cylinder liner top
3. The angle split of linkage shall be toward
the intake side

Engine block
4. Support the cylinder liner by piston ring

compressor
5. Push the piston into the cylinder lining
through the piston ring compressor
6. Push the piston till its crown is fully
engaged in the cylinder jacket.
Caution: If the piston can’t move freely,
remove the piston and check
whether the piston ring is broken
or damaged.
7. Push the piston into the cylinder bore

carefully, and guide the linkage to the
crankshaft journal.
Caution: The linkage guider can be used to
mount the linkage stub on the
engine

original linkage cover.
8. Mount the bearing on the linkage cover
The bearing (2) locating tongue must be in locating
slot of linkage cover (1).
9. Use the mounting lubricant or its
equivalent to lubricate the bush internal
surface.
10. Lubricate the screw thread of linkage with

surface of linkage or linkage cover
section. If the fissured surface of
of engine.
11. Fit the linkage and lick rod cover
The serial numbers of linkage and connecting cap
must be the same, and must be installed in the
correct cylinderThe serial numbers of linkage cap

ISLe375 30 engine
and linkage must be on the same side of linkage to

prevent the engine from damage when the engine
is running
12. Fit linkage cover and bolt or nut
Engine with connection rod stud and nut
Fit linkage cover and nut.
Engine with linkage bolt
Fit linkage cover and bolt
13. Use the marked socket wrench and torque

wrench to tighten the connecting bolt.
Use the torque + angle method to tighten the
linkage bolt in an alternative sequence.
Tightening torque
Step 1 60 N·m
Step 2 Loosen the bolt
Step 3 70 N·m
Step 4 Advance by 60 degree
Caution: Do not measure the side play

between the linkage cap and the
crankshaft.
14. Measure the clearance between the linkage
body and the crankshaft
Lateral clearance of linkage and crankshaft
Minimum 0. 10mm
Maximum 0. 30mm
15. Check whether the linkage cover can

rotate freely when it is fitted
If the crankshaft can’t rotate freely, check the
mounting and sizes of linkage bearing.
Last step
1. Fit the pistion cooling nozzle (if removed)
3. Fit the oil sump

Engine block


ISLe375 30 engine
VI. Renewal of piston

Common tools - -
Special tool - -
Testing tools 0. 15mm feeler gauge, inside gauge
Auxiliary material Detergent, non-metal brush
2. Procedure
General
Some engines are equipped with the articulated
piston. The hinged piston is a two-piece piston,
including one forged steel piston crown and one
aluminum piston apronThere is an oil passage at
lower part of piston crest, which enables larger
contact area between piston and oil, thus providing
better cooling effect.

use is possible.
1. Wash the piston.
1). Immerse the piston in the clean steel and
aluminum tank for 30min at least
Caution: Do not use the wire brush. The

steel brush can damage the piston
ring groove.
2). Use the mixture of high-concentration
detergent and hot water to clean the piston
and linkage. Use the non-metal brush to
remove the carbon deposit.
Renewal of piston 281

Engine block
Caution: Do not use the cleaning agent for

ring slot to clean the ring slot. Do
not scratch the sealing surface of
piston ring in the piston groove.
3). Use the square end of broken piston to
remove remaining deposits in the ring trough.
4). Clean the piston again in cleanser solution or

solvent.
5). After washing, it shall be blown clean by
compressed air
2. Fault analysis and check

1). Check whether the piston is damaged and
worn excessively, and check whether the top,
ring slot, apron and pin hole of piston have
any crack or damage
Caution: If the piston is seriously damaged,
check whether the turbocharger
and other exhaust components
are damaged due to any scraps.
Abrasion due to grinding and/or scraps

The possible reason for scratch on piston skirt of
insert material:
1. Grinding material is sucked.
2. Cleaning is not done thoroughly in earlier
service.
3. The particle which inserts the cylinder holes
4. The maintenance of lubrication system is
improper
5. The oil system produces debris due to the
fault again.
6. Scratch and strain
282 Renewal of piston

ISLe375 30 engine
Scratch and strain

The fault may be caused by the following reasons:
1. Engine overheating
2. Oil is diluted
improper
4. The fault of piston cooling nozzle
5. The oil ring is jammed by the sediment
6. The injector suppliese excessive oil/the
engine consumes alternative fuel to operate,
for example, the engine oil in the intake
system.
Caution: Scratch on piston ring indicates
oil film on cylinder hole wall is
damaged, thus resulting in foreign
matter’s entry into the wall.
Other types of piston failures

Hydraulic lock
The hydraulic lock (engine oil, fuel or water) may
divide the piston into two halves or damage the
ring groove, or bend the linkage.
Dust-free
Pay special attention to the worn pattern of
immediate (second) ring, to facilitate the diagnosis
of scratches on the dust-free piston.
This piston ring is polished at whole ear surface of
middle ring, and the dimming zone becomes
glossier.
The wear starts from the bottom of piston ring and then spread upwards along the conical ring.
Sometimes, the edges of piston ring shall be polished with razor and the cylinder block hole will protrude
by about 1-1/2 in below the top surface.
Piston top melting down
Piston top is likely to melt down, and this fault is similar to excessive oil supply, for example, injector is
sticky. The clogged cooling nozzle of piston has the similar fault.

Engine block
Measure
Caution: The piston ring groove must be
checked with a new piston ring
and a feeler gauge.
1. Place the new piston ring in the circular
slot and keep it flush with the outer
diameter of piston
2. Fit 0. 15mm feeler
1). If the thickness gauge can be easily inserted
into the ring trough, it is seriously worn.
Renew the piston.
Hinged piston
Measure the inner diameters of piston pin
holes on the piston crown and skirt.
Inner diameter of hinged piston pin hole
Minimum 45. 016mm

Piston crest
Maximum 45. 036mm
Piston skirt Minimum 45. 012mm
Simple piston
Measure the diameter of piston pin hole when
the piston temperature is 20 ℃.
Diameter of piston pin hole
Minimum 45. 006mm
Maximum 45. 012mm
Caution: The aperture increases 0. 013 mm

accordingly when the temperature
rises by 5 ℃ after reaching 32 ℃.
3. Check whether the piston pin is scored,
chiseled or worn excessively
284 Renewal of piston

ISLe375 30 engine
4. Measure the outer diameter of piston pin
Piston pin diameter
Minimum 44. 997mm
Maximum 45. 003mm
If the out-of-roundness of piston exceeds 0.

003mm, replace the piston pin.

Engine block
VII. Renewal of piston cooling nozzle

Sockets S13/S16, double offset ring & open-end wrenches

Common tools
S10/S13/S16/S22, snapring pliers

Special tool

Testing tools
2. Procedure
Preparatory step
2. Draining the oil
3. Remove oil sump
Removal
1. Remove piston cooling nozzle bolt and the
nozzle
remove nozzle.
Caution: It is allowed to remove 6# piston
cooling nozzle only after
separating the linkage from
crankshaft and taking the piston
out. Additionally, the bolt can only
be reached by the single-opening
socket
286 Renewal of piston cooling nozzle

ISLe375 30 engine

use is possible.
1. Use the detergent to clean the piston
cooling nozzle and bolt.
3. Check whether the piston cooling nozzle

has any flow resistance or any other
damage
If necessary, replace it.
Refitting
Fit the pistion cooling nozzle and bolt
Tighten the bolt
assemble the nozzle.
Last step
2. Fit the oil sump
Renewal of piston cooling nozzle 287

Engine block
3. Piston ring
Fault analysis and check
1. Check whether the piston ring is worn by
abrasive grains
Caution: Black grinding material on face of
piston ring reduces rapidly, not
visible sometimes (A), indicating
that grain wearing exists in middle
ring. This is often regarded as
thorough abrasion of ring surface.
The abrupt decrease of adhesive
will usually leave a sharp edge on
the middle ring bottom. The
vertical scrape accumulated on
the top ring (B) also indicates the
abrasive wear.
Following causes may give rise to the particle
abrasion:
1. Grinding material is sucked.
2. Cleaning is not done thoroughly in earlier
service.
3. The particle which inserts the cylinder holes
4. If the interval of oil draining is prolonged, the
dust contents will be increased.
5. Scratch and strain
Caution: Scratch can be reflected by

serious scratch, metal color
change or pitting (B).
The scratch and strain may caused by the
following factors:
1. Engine overheating
2. Oil is diluted
improper
4. The fault of piston cooling nozzle
5. The oil ring is jammed by the sediment.

ISLe375 30 engine
Caution: Scratch on piston ring indicates

oil film on cylinder hole wall is
damaged, thus resulting in foreign
matter’s entry into the hole.
Caution: The deposit on oil ring groove (B)
shows that the oil ring is blocked.
The possible reason for oil ring blocking:
1. Low engine working temperature – long time
idling or cooling system fault
2. Oil change interval is prolonged
3. Use the engine oil with wrong class
4. Use the engine oil of poor quality.
Caution: The oil return block of oil ring

limits the return of engine oil so
that the engine oil is filled with the
region of piston ring and causes
the bad control of engine oil.
Caution: Following measures are used to
check a new piston ring.
Caution: Before completing this test,
ensure the cylinder liner conforms
to technical specification.
Measure the piston ring clearance by fitting the
piston into the cylinder bore concerned.
Place each piston ring 89mm under the cylinder
block top (A), make the ring under the ring rotation
region, and match the piston with its hole
Piston ring type and position can be determined by

the shape.
1. Top piston ring
2. Middle piston ring
3. Oil control ring
Renewal of piston cooling nozzle 289

Engine block
Piston ring clearance
Minimum 0. 30mm
Top ring
Maximum 0. 45mm
Intermediate Minimum 0. 85mm

ring
Maximum 1. 15mm
Minimum 0. 30mm
Oil ring
Maximum 0. 73mm
Use the thickness gauge to measure the gap.

If the piston ring gap doesn’t meet the technical
requirements:
1. Comfirm the all used piston ring types and
part number is correct.
2. Confirm that cylinder liner is consistent with
technical specification.
3. Confirm that the piston ring gap is measured
under the cylinder surface less than 89mm.
4. Try to use another set of piston ring

ISLe375 30 engine
VIII. Renewal of linkage

Common tools Socket S16
Special tool - -
Testing tools Linkage inspection clamp, mandrel assembly
2. Procedure
General
The configuration of linkage may vary with the

configuration of engineSome engines use the
line-split linkage, and the other engines use the
angle-split linkageThe section of linkage may be
split or serrate
Always handle the split section linkage or the split
tooth face linkage with great care. The two
sections of linkage shall not rub with each other;
otherwise, the joint may be damagedTake care to
avoid the fall of any linkage section.
1. C linkage is in line with a smooth machining surface.

2. Split linkage L section has certain angle with crank end section.
3. Serrated linkage is at some angle to the serrated machined surface on the crankshaft end
These linkages are not allowed to be used in an engine.
Preparatory step
2. Empty the cooling system
3. Draining the oil
5. Remove oil sump
7. Remove piston cooling nozzle
8. Remove and disconnect the piston from the linkage
Renewal of linkage 291

Engine block

use is possible.
1. Use the nylon brush to clean the engine oil
passage.
2. Clean the linkage with steam or solvent.
4. Check whether the linkage and linkage

cover are damaged
If the I-beam is scratched or damaged, replace the
linkage.
5. Check whether the piston pin hole is

damaged or the oil passage and lining are
aligned
If damaged, replace the linkage.
6. Check the bend and twist of linkage

The linkage inspection clamp and mandrel
assembly can be used to check the bend and twist
of linkage
292 Renewal of linkage

ISLe375 30 engine
7. Measure the inner diameter of piston pin

bush of linkage
Diameter of linkage piston pin sleeve
Minimum 45. 023mm
Maximum 45. 035mm
If the internal diameter of linkage piston pin lining

doesn’t meet technical requirements, replace the
linkage.
8. Measure the crankshaft bore on the

linkage
To measure the bore diameter of linkage
crankshaft, first remove shaft bush and fasten
linkage cover.
Refer to the related procedure for the torque value.
Diameter of linkage crankshaft hole (the bearing

is removed)
Minimum 80. 987mm
Maximum 81. 013mm
If the diameter of linkage crankshaft exceeds the

required value, replace the rod.
9. Measure the diameter of linkage journal on

the crankshaft
Bearing clearance
Minimum 0. 038mm
Maximum 0. 116mm
Renewal of linkage 293

Engine block
Bearing clearanceThe inner diameter of linkage

(with bearing) reduces the diameter of crankshaft
journal
The bearing clearance may also be determined by
plastic line clearance gauge at assembling engine.
Caution: If the gap exceeds the required
value, replace the linkage bearing
or try another set of linkage
bearings.
Refitting
1. Fit the pistion cooling nozzle
2. Assemble and mount piston and linkage assembly.
4. Fit the oil sump
6. Fill the oil pan
294 Renewal of linkage

ISLe375 30 engine
IX. Renewal of linkage bearing

Common tools - -
Special tool Grinding pad
Testing tools Micrometer
2. Procedure
Preparatory step
2. Draining the oil
3. Remove oil sump
Removal
Caution: If the linkage bearing is checked

or replaced, it is unnecessary to
remove the cylinder head.
1. Remove linkage cap
2. Remove upper bearing bush and mark it

with “U” (upper) and the corresponding
cylinder number
Renewal of linkage bearing 295

Engine block

use is possible.
1. Wash the bearing and linkage cover.
3. Check whether there is any score, crack,
burr, scuffing or wear on the linkage cover,
connecting bearing saddle and bolt
4. Check whether the bearing is damaged

Renew the bearing with the following damages:
· Cavitation
· Stripping
· Corrosion
· Latch damage
· Scratch.
5. Check whether the bushing saddle joint is

scored or has burrs
If it is impossible to remove the scratch or burrs
with he grinding pad or its equivalent, replace the
bearing.
Caution: If the bearing is damaged, replace
the complete set of bearings.
Caution: For the details about bearing
damage, refer to Analysis and
Prevention of Bearing Faults.
6. Use the external diameter micrometer with

a ball end to measure the linkage bush
thickness.
Dimension of linkage bearing
Minimum 2. 457mm
Maximum 2. 469mm
If the bush thickness is lower than the required

minimum value, discard the bush.
296 Renewal of linkage bearing

ISLe375 30 engine
Caution: The linkage bearing is identified

by the
Determine the specifications of removed linkage
bearing, and use a set of bearings of same
specifications.
The larger linkage bearing for repair can be used
together with the crankshaft which becomes
smaller after repairSee the corresponding list of
parts.
Refitting
For the assembling instruction of linkage bearing,
refer to the relevant procedures.
Last step
2. Fit the oil sump
3. Fill the oil pan
Renewal of linkage bearing 297

Engine block
Camshaft and timing gear mechanism

I. Renewal of crankcase breather (external)
Common tools Socket S10, ratchet spanner
Special tool Soft brush
Testing tools Torque spanner (7N·m)
Auxiliary material Hot soap water
2. Procedure
Preparatory step
Removal
1. Remove mounting bolt

2. Remove ventilating device
1). On respirator assembly, pull upwards the
respirator vertically and remove it from the
rocker arm cover.

use is possible.
1. Clean the crankshaft ventilator.
1). Use the hot soap water and soft brush to clean
the crankshaft box ventilator.
2. Dry crankcase ventilation unit
1). Blow-dry with compressed air.
298 Renewal of crankcase breather (external)

ISLe375 30 engine
3. Check whether the ventilator has crack or

other damage
Refitting
1. Mount the new O-ring on the solenoid
valve
2. Lubricate the O-ring and valve with engine
oil.
3. Mount the ventilator on the rocker
chamber cover
Last step
Renewal of crankcase breather (external) 299

Engine block
II. Adjustment of clearance of overhead mechanism

Common tools
Special tool Jigger
Testing tools Thickness gauge and torque wrench （75~400N·m）
Auxiliary material
2. Procedure
Preparatory step
3. Remove drive cover plastic of fuel pump on the front end of engine
Adjustment
Caution: The engine coolant temperature

should be less than 60℃.
1. Align the gear housing cover and the top
dead center mark on the fuel pump gear
the crankshaft to align top dead center marks
on the gear housing cover and fuel pump
gear.
300 Adjustment of clearance of overhead mechanism

ISLe375 30 engine
2. Check the valve clearance

1). Valve clearance check can be conducted for
the following rockers when the engine is at
this position: 1I, 1E, 2I, 3E, 4I & 5E.
Clearance limit
Minimum 0. 152mm
Intake valve
Maximum 0. 559mm
Exhaust valve Minimum 0. 381mm
3. Measure the clearances between the

bridge plate and the ball head of rocker
arm lever/the bearing
1). Raise the rocker arm end, and insert the feeler
between the jumper plate, rocker arm ball joint
and seat to measure the clearanceIf the
measured gap exceeds the required value,
loosen the lock nut and adjust the gap to the
normal value.
Reset the specifications of clearance
Intake valve 0. 305mm
Exhaust valve 0. 559mm
Caution: Only when measuring and finding that the clearance exceeds the stipulations, or
when the rocker arm is dismounted due to engine repair and/or the adjusting screw
becomes loose, the clearance shall be reset in accordance with the proper user’s
manual or the interval stipulated in the operation and maintenance manual
4. Tighten the locknut and then make

adjustment
the crankshaft by 360°, and measure the
rocker arm clearances 2E, 3I, 4E, 5I, 6I and
6E. If the gap exceeds the required value,
reset the gap.
Adjustment of clearance of overhead mechanism 301

Engine block
Last step
4. Fit the plastic fuel dirve cover of engine front cover
302 Adjustment of clearance of overhead mechanism

ISLe375 30 engine
III. Renewal of rocker arm

Common tools
Special tool - -
Testing tools Inner diameter gauge, torque spanner (75-400N·M)
2. Procedure
Preparatory step
Removal
1. Remove the bolt from the rocker shaft

support
2. Remove shaft seat and rocker arm
assembly, and mark the position
respectively
Caution: The rocker arm assembly must be
fitted as per its original position
and direction.

use is possible.
1. Use the mixture of high-concentration
detergent and hot water to clean all parts.
Renewal of rocker arm 303

Engine block

The bearing seat is made from metal powder and it
looks wet relatively after cleaned and dried.
3. Ensure that the oil passage between the
rocker arm and rocker arm shaft is not
clogged.
4. Check whether there is any crack and

excessive wear inside the hole
The socket shall be able to move freely on the
rocker arm, and the plastic socket limiter shall be
correctly oriented free from any crack.
5. Check whether the sleeve end is worn
6. Measure the rocker arm bore
Rocker arm hole
Minimum 24. 987mm
Maximum 25. 013mm
7. Check the rocker arm shaft and its seat

8. Measure the diameter of rocker arm shaft
Rocker arm shaft
Minimum 24. 950mm
Maximum 24. 962mm
304 Renewal of rocker arm

ISLe375 30 engine
Refitting
Without the engine brake
1. Fix the rocker arm on the rocker arm shaft
seat
2. Mount the rocker arm assembly and shaft

seat to original position
3. Lubricate the screw thread with clean

engine oil.
4. Fit and tighten the shaft seat bolt
With engine brake

1. Fix the rocker arm on the rocker arm shaft
seat

Engine block
2. Install the jumper pressure plate on the

original position
3. Fit the matched engine brake exhaust jump
pressing plate
Make the pin towards the exhaust manifold, and
then mound the exhaust jumper plate matching
with the engine brake
4. Mount the rocker arm assembly and shaft

seat to original position
Ensure that the exhaust rocker arm is fitted with
longer adjusting screw nut.

engine oil.
6. Mount the bolt of engine brake oil supply
pipe on the intake rocker arm of Cylinder 1
and 4

engine oil.
8. Mount the exhaust rocker arm bolts on all
the exhaust rocker arms
306 Renewal of rocker arm

ISLe375 30 engine

engine oil.
10. Mount the shaft holder bolts on the intake
rocker arm shaft holder of Cylinder 2, 3, 5
and 6

engine oil.
12. Mount six threaded washers on the
cylinder head
Last step

Engine block
IV. Renewal of rocker chamber

Common tools
Offset ring spanner S10/S13/S16/S22
Special tool - -
2. Procedure
Preparatory step
Removal
1. Remove rocker chamber cover and the

sealing gasket
Caution: If the engine is equipped with a
brake, the rocker arm
compartment cover may be
higher.

use is possible.
1. Check whether the damping block is
cracked, broken or embrittled
If damaged, replace the spacer.
308 Renewal of rocker chamber

ISLe375 30 engine
2. Check whether the silicone coating of

gasket has any crack
1). If damaged, replace the gasket.
Caution: If the gasket is removed from the
rocker arm compartment, replace
it.
Refitting
Caution: If the gasket has been removed
from the rocker arm compartment
cover, fit a new one.
1. Fit the pressed matched sealing gasket
1). Press the forged gaskets in each corner of
rocker chamber cover
2). Press the gasket in around the bolt mounting
hole
3). Press the reset gaskets into the rocker
chamber cover

3. Tighten all the bolts according to the
illustrated sequence
Last step
Renewal of rocker chamber 309

Engine block
V. Renewal of rocker chamber housing

Common tools
Special tool - -
2. Procedure
Preparatory step
4. Disconnect the through connector for injector cable harness
6. Disconnect the cable and cable harness from the injector
Removal
1. Remove rocker chamber shell & gasket

from cylinder head
1). Remove mounting bolts for the rocker
chamber.
310 Renewal of rocker chamber housing

ISLe375 30 engine

use is possible.
1. Use the detergent to clean the rocker
chamber housing.
3. Check the rocker chamber casing

Check whether the rocker chamber casing has any
crack or other damage, especially on the cylinder
head mounting surface,
4. Check whether the new coupling region
inside the rocker chamber casing is
cracked
5. Renew the rocker housing gasket
Refitting
Caution: A new gasket must be used after
the rocker housing is removed. Do
not continue to use the old sealing
gasket.
1. Fit the rocker chamber housing and new
sealing gasket of rocker chamber housing
1). Press the forged gaskets in each corner of
rocker chamber housing
2). Press the rest gasket into the housing
2. Fit and tighten the bolt
Start from the center bolt and then face outwards.
Last step
1. Connect the injector conducting wire with the injector
2. Connect the through connect of oil injector wire
Renewal of rocker chamber housing 311

Engine block
VI. Renewal of crankcase breather pipe

Common tools
Special tool - -
Auxiliary material Detergent, soft brush
2. Procedure
Preparatory step
Removal
1. Remove the crankcase ventilation pipe

from the ventilation assembly
2. Remove the crankcase return pipe from
the ventilation assembly
3. Remove ventilation return pipe, cap &

gasket from cylinder block
312 Renewal of crankcase breather pipe

ISLe375 30 engine

use is possible.
1. Check the interior pipe and pipeline are
blocked or has accumulative oil and dirt
2. Use the hot soap water and soft brush to
clean the pipe and pipeline.
3. Blow-dry the pipe and pipeline with
compressed air.
4. Check whether the check valve of

ventilator return pipe works normally
A little of air can be blown out from the pipeline
(less than 34kPa) so as to inspect the check valve
Refitting
Caution: Ensure that the crankcase
ventilator or return pipe are not in
contact with any high-pressure
fuel pipe.
1. Mount the ventilator pipe of crankshaft
case on the crankshaft case ventilator
assembly
2. Mount the return pipe of crankshaft case
on its ventilator assembly
3. Mount the ventilator oil return pipe cover,

gasket and pipe on the cylinder block
Last step
Renewal of crankcase breather pipe 313

Engine block
VII. Renewal of front gear housing cover

Common tools
Special tool - -
Auxiliary material RTV sealing rubber or similar materials
2. Procedure
Preparatory step
2. Remove drive belt
3. Remove vibration insulator
Removal
1. Remove front gear chamber cover

use is possible.
1. Remove the sealant on the surface of gear
housing cover and gasket.
314 Renewal of front gear housing cover

ISLe375 30 engine
2. Check whether the gear chamber cover

cracks or is damaged
Refitting
1. Apply a thin coat of RTV sealant or
equivalent on front cover of engine.
Mount the front cover on engine within 10 min.
Caution: Apply the sealant inside the bolt
hole
Tighten bolts of front cover according to the

illustrated sequence.
Last step
1. Fit front crankshaft oil seal
2. Fit shock absorber
3. Fit drive belt
Renewal of front gear housing cover 315

Engine block
VIII. Renewal of front gear housing

Common tools
Special tool - -
Testing tools Thickness gauge and torque wrench （75~400N·m）
2. Procedure
Preparatory step
3. Remove fuel pump
4. Remove air compressor (if fitted)
6. Remove gear chamber cover
7. Remove camshaft gear
Removal
1. Remove four (4) front oil sump bolts
316 Renewal of front gear housing

ISLe375 30 engine
2. Separate the oil sump gasket

Use the thickness gauge to separate the oil pan
gasket from the gear house.
3. Remove gear chamber

use is possible.
1. Clean the gasket on the cylinder block.
2. Check whether the oil pan gasket is

cracked or damaged
If the gasket is damaged, refer to the refitting
section in this step.
3. Check whether the fuel pump stubs are

damaged
To fit or remove the fuel pump stud, use two nuts
locked together on the stud.
Renewal of front gear housing 317

Engine block
4. Check whether the gear chamber has

cracks or the sealing joint is damaged
If damaged, replace the gear housing.
Refitting
If the oil pan gasket is damaged, repair it.
1. Cut the gasket to make it flush with the
front of cylinder block
2. Cut the new seal

1). Use the old gasket as template, and cut the
front of new gasket to the same shape
Caution: The gear chamber must be

installed within 10 min after the
sealant is applied.
3. Clean the sealing surface.
4. Apply RTV sealant or equivalent at two
sides of new sealing gasket.
Ensure that the intersection of cylinder block, oil
pan and gear housing is coated with sealant.

ISLe375 30 engine
5. Use ordinary wire or fine metal wire to fix

the new gasket in place (as shown in the
figure).
6. Place the gear chamber gasket on the

locating pin
Use the guide pin (M8×1. 25×50) to help to align
the gasket and gear chamber. Ensure that the
guide pin can be removed after alignment.
7. Fit the gear chamber

8. Fit the oil sump sealing gasket

1). Mount the oil pan casing bolt from the unused
hole, and mount the gasket to proper position
Renewal of front gear housing 319

Engine block
2). Remove wire or steel wire fixing the sealing

gasket in place.
3). Fit and tighten the left 2 bolts (2).
Last step
1. Fit crankshaft gear
2. Fit the gear chamber cover
5. Fit drive belt
6. Fit the air compressor (if equipped)
7. Fit fuel pump

ISLe375 30 engine
IX. Camshaft
Common tools
Special tool - -
Testing tools Gauge, magnetic base, torque spanner (75~400N·m)
2. Procedure
Preparatory step
3. Remove engine brake (if fitted)
6. Remove push rod
10. Rising tappet
Removal
1. Rotate the crankshaft.
Align the crankshaft and camshaft timing marks.
Camshaft 321
Engine block

only allowed to remove the thrust
plate from the camshaft after the
camshaft gear is removed from
the camshaft.
2. Remove the bolt from the thrust plate
3. Dismount the camshaft and thrust plate

use is possible.
1. Check the valve cam and bearing journal
are cracked, eroded or scored
Know the recycle guideline of roller tappet and
camshaft system
2. Check the camshaft gear

. If necessary, replace it.
322 Camshaft
ISLe375 30 engine
3. Measure the seven bush journals of

camshaft
Camshaft bushing journal diameter
Minimum 59. 962mm
Maximum 60. 013mm
Caution: If the external diameter of any

bearing surface is lower than 59.
962mm, replace the camshaft.
Caution: It is necessary to disassemble the

camshaft gear for measuring the
thickness of thrust plate.
4. Measure the thickness of thrust plate of
camshaft
Camshaft thrust plate
Minimum 9. 40mm
Maximum 9. 60mm
Refitting
1. Apply a coat of fitted lubricant or
equivalent onto front camshaft hole.
2. Lubricate the camshaft cam, journal and

thrust plate with fitted lubricant or
equivalent.
Camshaft 323
Engine block
Caution: Do not fit camshaft into the

camshaft hole by force, or the
camshaft bush will be damaged.
3. Fit crankshaft
Rotate the camshaft whist pushing it inside, to
have the camshaft thread through its sleeve. When
every camshaft journal goes through the bush, the
camshaft sinks slightly and then the cam is fixed
into the bush. Rotate the camshaft to disengage
the cam from the bushing, thus to fit the camshaft.
4. Check whether the camshaft is easy to

rotate
If fitted correctly, the camshaft can rotate freely.
5. Align to the timing mark as illustrated
6. Fit bolt of thrust plate

324 Camshaft
ISLe375 30 engine
7. Use the gauge and magnetic base to verify

the correctness of camshaft lateral
clearance and axial clearance.
Camshaft axial clearance (A)
Minimum 0. 12mm
Maximum 0. 50mm
Minimum 0. 08mm
Maximum 0. 33mm
Last step
3. Fit drive belt
4. Release the tappet.
5. Fit the pushrod
6. Fit the rocker
8. Adjust the valve clearance
9. Fit engine brake (if equipped)
Camshaft 325
Engine block
X. Renewal of camshaft bushing

Common tools
Special tool Camshaft bushing remover, 3. 2mm dia rod
2. Procedure
General
The engine covered in the manual has 7 camshaft bushes arranging from the bush 1 on the front of
engine.
Replace camshaft bushings 1 to 6 by driving the bushing toward the engine rear end and putting through
the engine front end.
In order to facilitate the renewal of camshaft bush 7 requiring flywheel housing, the bowl plug at the rear
of camshaft should be removed so as to drive the camshaft bush 7 forwards.
Preparatory step
2. Draining the oil
3. Remove oil sump
5. Remove flywheel or the flexible connecting disc
6. Remove flywheel housing
7. Remove camshaft
8. Remove rear bowl plug of camshaft
Removal
1. Remove camshaft bush
1). Use the camshaft lining remover kit to remove
the camshaft lining.
2). Slide the thrust bar through the centering
guide sleeve, and then insert it into the
camshaft hole from behind the cylinder block.
3). Insert the removing and fitting tool for the
camshaft bush and push out the front
camshaft bush from the cylinder block.
4). Take out puller & pushrod from cylinder block.
326 Renewal of camshaft bushing

ISLe375 30 engine
5). Take out pushrod, camshaft bush puller & centering sleeve in the front of cylinder block.
2. Starting 2# camshaft bush, push out the rest camshaft bushes from cylinder block in
turns.

use is possible.
1. Check whether the camshaft hole is
damaged and worn excessively
2. Measure the camshaft hole
Camshaft bore (max.)
Bushing-free 64. 013mm
There is bush. 60. 120mm
Refitting
1. Make a mark.
1). Mark on camshaft bush and cylinder block for
the convenience of aligning the engine oil port
on cylinder block with the large engine oil port
on bush.
Renewal of camshaft bushing 327

Engine block
2). Have the camshaft lining slide on the remover

& installer. Align the marks on the camshaft
bush and cylinder block.
2. Push the front camshaft lining to the
correct mounting depth
The correct mounting depth is to align the engine
oil hole of camshaft bush with that of cylinder
block.
3. Starting from the rear of cylinder block, fit
the rest camshaft bush towards in turns
4. Remove pushrod, puller & guide sleeve
from cylinder block
5. Ensure that the larger engine oil hole in the

camshaft lining is aligned with that
beneath the camshaft hole.
Oil filler must allow the passing of a lever with
diameter of 3. 2mm.
6. Ensure that the smaller engine oil hole in
the camshaft lining is aligned with that
above the camshaft hole.
Last step
1. Fit the rear bowl plug of crankshaft
2. Fit crankshaft
4. Fit the flywheel and the flexible connecting pan
6. Fit the oil sump
328 Renewal of camshaft bushing

ISLe375 30 engine
XI. Camshaft gear (with the camshaft fitted)

Common tools Socket S16
Special tool Camshaft gear remover, installer and puller assembly
Testing tools Gauge, magnetic base, torque spanner (0~100N·m)
Auxiliary material Assemble lubricant or equivalent.
2. Procedure
Preparatory step
6. Undo the rocker arm assembly.
Removal
1. Remove camshaft gear
Use the camshaft gear removing & refitting tools
and puller assembly to remove the camshaft gear
from the camshaft.
Camshaft gear (with the camshaft fitted) 329

Engine block

use is possible.
1. Check whether the camshaft gear has any
cracked, eroded or broken tooth
2. Check whether the camshaft hole has
abrasion or burr
Caution: If it is impossible to remove any
corrosion, burrs or projection with
the grinding pad or its equivalent,
replace the gear.
3. Check whether the gear key slot on the

camshaft has any burr
Use the grinding pad or its equivalent to remove
the burrs.
Caution: If the keyway is damaged or burrs
can’t be removed, replace the
camshaft gear.
4. Check whether the camshaft tip has

abrasion or burr
abrasion or burrs with the
grinding pad or its equivalent,
replace the camshaft.
Refitting
equivalent to lubricate the camshaft
surface.
330 Camshaft gear (with the camshaft fitted)

ISLe375 30 engine
2. Install the key on the camshaft tip

3. Tighten the thrust plate bolt
Caution: If overheated, the camshaft gear

will be permanently deformed. The
furnace temperature must not
exceed 204℃.
4. Heat the camshaft gear for 45min
Furnace temperature
Use the camshaft gear removing & refitting tools
and puller assembly to refit the camshaft gear onto
the camshaft.
Caution: Ensure that the gear is located on
the camshaft shoulder.
6. Verify that camshaft side clearance and

axial clearance are correct
Use the gauge and magnetic base to verify the
correctness of camshaft lateral clearance and axial
clearance.
Camshaft axial clearance (A)
Minimum 0. 12mm
Maximum 0. 50mm
Minimum 0. 08mm
Maximum 0. 33mm
Camshaft gear (with the camshaft fitted) 331

Engine block
Last step
3. Fit drive belt
4. Tighten the rocker arm assembly
332 Camshaft gear (with the camshaft fitted)

ISLe375 30 engine
XII. Renewal of camshaft gear (with the camshaft

removed)
Common tools
Special tool Pressing machine and grinding pad
Testing tools 0. 02mm feeler gauge, torque spanner (0~100N·m)
2. Procedure
Preparatory step
1. Remove camshaft
Removal
1. Remove gear
Use the pressing machine to remove the gear.
2. Remove thrust plate
3. Remove camshaft spline
Renewal of camshaft gear (with the camshaft removed) 333

Engine block

use is possible.
1. Check whether the camshaft gear has any
cracked, eroded or broken tooth
2. Check whether the camshaft hole has
abrasion or burr
corrosion, burrs or projection with
the grinding pad or its equivalent,
replace the gear.
3. Check whether the gear key slot on the

camshaft has any burr
Use the grinding pad or its equivalent to remove
the burrs.
Caution: If the keyway is damaged or burrs
can’t be removed, replace the
camshaft gear.
4. Check the camshaft gear and speed

sensor target
If damaged, replace the gear.
5. Check whether the camshaft tip has

abrasion or burr
abrasion or burrs with the
grinding pad or its equivalent,
replace the camshaft.
334 Renewal of camshaft gear (with the camshaft removed)

ISLe375 30 engine
Refitting
equivalent to lubricate the camshaft
surface.
2. Fit the spline

3. Fit thrust plate
required to fit the thrust plate prior
to the installation of camshaft gear
onto the camshaft.
Caution: If overheated, the camshaft gear

will be permanently deformed. The
furnace temperature must not
exceed 204℃.
4. Heat the camshaft gear for 45min
Furnace temperature
Warning: Wear protective gloves to handle

the heated parts so as to avoid
injury.
Fit ctankshaft gear and make the timing sign faces
side.
Renewal of camshaft gear (with the camshaft removed) 335

Engine block
Caution: Ensure that the gear is located on

the camshaft shoulder.
6. Check the clearance between camshaft
gear and camshaft shoulder
Use the 0. 02mm thickness gauge to check
whether it can be inserted between the camshaft
gear and camshaft shoulder. If a thickness gauge
can be inserted, the camshaft gear is not correctly
fitted.
Last step
1. Fit crankshaft
2. Operate the engine to check whether there
is leakage.
336 Renewal of camshaft gear (with the camshaft removed)

ISLe375 30 engine
XIII. Renewal of pushrod.

Common tools
Special tool - -
Auxiliary material Compressed air and hot soap water
2. Procedure
Preparatory step
Removal
1. Mark the ejector sleeves
To identify their positions;

use is possible.
1. Clean the push pipe with hot soapy water.
Renewal of pushrod. 337

Engine block
3. Check whether the push pipe ball joint and

socket are scored
4. Check whether there is any crack between
the ball joint and the push rod where the
ball socket is welded
5. Check whether the push pipe is straight
Refitting
1. Mount the push tube at its original position
2. Mount the push tube into the valve tappet
hole
3. Lubricate the push pipe ball socket with
338 Renewal of pushrod.

ISLe375 30 engine
Last step
1. Fit the rocker
Renewal of pushrod. 339

Engine block
XIV. Renewal of tappet

Common tools
Special tool Tappet remover kit and puller
2. Procedure
Preparatory step
Removal
1. Remove tappet
Use the tappet remover kit to remove the tappet.
2. Fit lifter pulling tools
1). Insert the tappet puller (2) into the tappet
holeGrasp the bottom knob, and rotate the top
knob counterclockwise to unfold the tool and
fix it in the tappet.
2). Raise the tappet puller till it can’t be moved.
Push the metal lock plate toward the cylinder
head surface to fix the tool and keep the
tappet upright.
3). Repeat the same step for the remaining
tappets.
340 Renewal of tappet

ISLe375 30 engine
3. Remove camshaft
4. Ensure that the tappet hole keeps upright.

5. Insert the tappet fixture into the whole
camshaft hole completely
6. Remove the puller and tappet.

1). Lower the tappet puller to place the tappet in
the camshaftGrasp the bottom knob, and
rotate the top knob clockwise to disengage the
puller and tappet. Repeat this step for the
remaining tappets.
7. Pull out the tappet fixer and the tappet

from the camshaft hole.
To use tappets again, record their original
positions. Do not refit tappet on a different
position.
Renewal of tappet 341

Engine block

use is possible.
1. Check whether the tappet body has crack
or other damage
2. Check whether the roller has rubdown
point or pitting
Refer to “Manual for continuing to use camshaft”. If
the tappet is excessively worn, replace it and
check the camshaft.
3. Roller column must rotate easily
If the rotation is not allowed, replace the tappet.
Refitting
equivalent to lubricate the tappet.
2. Ensure that the pin groove faces to the

outside of cylinder block in the installation
of tappet.
3. Insert the tappet into the tappet fixture
Caution: To use tappets again, ensure that
they are refitted onto their original
positions.
4. Insert the tappet fixture into the whole
camshaft hole completely
5. Fit lifter pulling tools

1). Insert the tappet puller (2) into the tappet
holeRotate the top knob counterclockwise to
open the tool and fix the tool in the tappet
2). Raise the tappet puller till it can’t be moved.
Push the metal lock plate toward the cylinder
head surface to fix the tool and keep the
tappet upright.
Caution: Some operations may be needed
to make tappet enter its holeTry to
rotate the puller and apply a little
pressure on it when the tappet
enters into the hole.
342 Renewal of tappet

ISLe375 30 engine
3). If the tool can’t rotate, the tappet has been

engaged with the guide pin. If the tool can
rotate, turn it till the tappet is engaged with the
guide pin.
6. Repeat the same step for the remaining
tappets
7. Remove tappet fixator
8. Fit crankshaft
9. Remove puller
Lower the tappet puller to place the tappet in the
camshaftGrasp the bottom knob, and rotate the top
knob clockwise to disengage the puller and tappet.
Repeat this step for the remaining tappets.
Last step
3. Fit drive belt
4. Fit the push pipe
5. Fit the rocker
6. Adjust the valve
Renewal of tappet 343

Engine block
Crankshaft and piston linkage assembly

I. Renewal of crankshaft
Common tools
Special tool - -
2. Procedure
General
This crankshaft uses forged counterweight.
At repair, it is allowed to extra-large main bearing,
thrust bearing and linkage bearing. It is
recommended by Cummins company that all main
bearing or connection rod bearing journals should
be ground again when one journal is ground. See
the corresponding list of parts.
Removal
Caution: Lift the crankshaft upright to avoid
damaging the crankshaft and
cylinder block.
1. Remove camshaft
1). Wrap #3 and #4 linkage bearing journals by
the nylon sling
2). Connect the sling with the crane, and then
dismount the camshaft
344 Renewal of crankshaft

ISLe375 30 engine
2. Remove upper main bearing

Mark the bearing position in the range of locating
tongue with awl.
Caution: The bearing position is marked for
analysis.

use is possible.
1. Finish the machine finished surface with
polishing cloth.
2. Clean the engine oil passage with banister
brush.
3. Clean the crankshaft with steam.

Ensure that air is purged from the threaded hole at
each end of crankshaft and the engine oil passage.
5. Check whether the screw hole is damaged

Repair the screw hole in one of following methods:
Carve the thread.
Use the threaded ring carrier component.
Caution: It can repair one front crankshaft
screwed hole and three rear
screwed holes at best. If more
than one front crankshaft
threaded holes or three rear
crankshaft threaded holes need to
be repaired, the crankshaft may
not be recycled.
Renewal of crankshaft 345

Engine block
6. Check whether there are rub grooves in the

contacting area of front and rear oil seal
Crankshaft front & rear oil seal rub groove
Maximum 0. 25mm
Use front and rear wear bushings for excessively

worn crankshaft
Refer to the related procedure for the wear bush of
front crankshaft.
Refer to the related procedure for the wear bush of
rear crankshaft.
7. Check whether there are deep scores on

the linkage and main journal
Minor scratches are tolerable.
8. Use the micrometer to measure the linkage

journal.
Diameter of crankshaft linkage journal
Minimum 76. 000mm
Maximum 76. 026mm
Incompleteness of crankshaft linkage
Maximum 0. 050mm
Taperness of crankshaft linkage journal
Maximum 0. 013mm
If the crankshaft linkage journal can’t satisfy the given technical requirements, ground the crankshaft
again. All journals should be always ground once one ofm does not meet the technical specification. The
larger linkage bearing can be usedRefer to the appropriate parts list.

ISLe375 30 engine
9. Use the micrometer to measure the

crankshaft main bearing journal.
Diameter of crankshaft main bearing journal
Minimum 98. 006mm
Maximum 98. 032mm
Incompleteness of crankshaft main bearing

journal
Maximum 0. 050mm
Tapeness of crankshaft main bearing journal
Maximum 0. 013mm
Caution: If the crankshaft main journal fails to satisfy the given technical requirements,
ground the crankshaft again. All journals should be always ground once one ofm
does not meet the technical specification. The larger linkage bearing can be used;
refer to the proper parts catalogue
10. Measure the width of thrust surface

11. Finish the finished surface with polishing
cloth.
Width of crankshaft thrust surface (normal)
Minimum 42. 98mm
Maximum 43. 08mm
12. Measure the outer diameter of flange of

rear oil seal
Crankshaft rear oil seal flange external diameter
Minimum 129. 98mm
Maximum 130. 03mm

Engine block
13. Measure the outer diameter of guiding

device of vibration insulator
Crankshaft absorber guiding device external

diameter
Minimum 23. 92mm
Maximum 24. 00mm
14. Measure the outer diameter of crankshaft

gear journal
Crankshaft gear journal external diameter
Minimum 75. 987mm
Maximum 76. 006mm
15. Apply a thin layer of anti-corrosion oil on

the crankshaft to prevent dust.
Caution: If the crankshaft is not to be used
immediately, protect it with a
plastic cover to prevent the
adhesion of dirt onto the oil.
Refitting
Caution: To locate the positioning bearing
to avoid engine damages, the
bearing positioning tongue (1)
must be located within the bearing
saddle groove (2).
1. Upper main bearing
Do not lubricate the main bearing side towards the
cylinder block.
2. Apply a coat of fitted lubricant or
equivalent on upper main bearing facing
crankshaft.
Caution: Ensure that the dimensions of new
main bearing are the same with
that of removed one. Specification

ISLe375 30 engine
is marked on back of main

bearing.
Caution: The crankshaft thrust bearing must be fitted at the position No. 4.
Caution: The upper and lower main bearings of some engines cannot be replaced. If
necessary, mark out the correct direction on the backside of main bearing.
Caution: To fit the main bearing housing, fit the main bearing housing on the original position
marked in the removal operation.
3. Use the crane and nylon lifting rope.

Wrap the sling around the bearing journals of No. 3
and No. 4 linkages
4. Fit crankshaft
Last step
1. Fit main bearing cap
2. Fit linkage cover
3. Fit bracket of rear oil seal for crankshaft
4. Fit front gear chamber housing
6. Fit fuel pump
7. Fit the air compressor
9. Fit the oil sump
11. Fit the flywheel and the flexible connecting
pan
12. Fit front cover
14. Fit drive belt

Engine block
Rotation and inspection

1. Check whether the engine could run freely
1). Insert the jigger into the flywheel housing, and
engage the flywheel/flexible connecting disc
gear ringThereafter, use the 1/2in. ratchet
spanner or pry bar to rotate the crankshaft by
hand.
2). If the engine can’t rotate freely, check whether
there is any external obstacle
(flywheel/flexible connecting disc, accessories
driven by the engine etc.). If unobstructed,
remove the oil pan and check whether its
inside is damaged.
2. Fit engine
is leakage.

ISLe375 30 engine
II. Renewal of front crankshaft gear (with the crankshaft

fitted)
Common tools
Special tool Constant temperature heating box
2. Procedure
Preparatory step
1. Remove crank
Removal
1. Remove crankshaft gear
As shown in the figure, use the heavy-load bearing
separator or gear remover to remove the
crankshaft gear.

use is possible.
1. Check whether the gear has cracks or
broken or gapped gear.
If the gear is damaged, it must be renewed.
Renewal of front crankshaft gear (with the crankshaft fitted) 351

Engine block
2. Check whether the gear and key slot are

scored or have burrs
Use the fine sand cloth to remove the pull mark
and burrs.
3. Check whether the crankshaft gear journal

and gar locating pin hole have burrs or
damage
Use the fine sand cloth to remove burrs.
4. Measure the inner diameter of crankshaft

gear hole
Crankshaft gear hole internal diameter
Minimum 75. 898mm
Maximum 75. 923mm
5. Measure the outer diameter of crankshaft

gear journal
352 Renewal of front crankshaft gear (with the crankshaft fitted)

ISLe375 30 engine
Refitting
Caution: Not longer than the specified
heating time or higher than
specified temperature. The
crankshaft gear tooth may be
damaged
1. Use the soft-head hammer to fit the gear
positioning kin into the crankshaft.
The dowel must be positioned 1. 02mm above the
surface of crankshaft.
2. Heat the gear in furnace for 45 min.
Not longer than 2 h.
Temperature
Steel gear 177℃
equivalent to lubricate the crankshaft gear
journal external surface.

injury.
Caution: After installing the gear, the timing
sign (1) and part number (2) must
face external side of crankshaft. If
the gear is installed backward, it
may cause engine damages.
Caution: Do not use water or oil to shorten
the cooling time. Gear may
produce crack. Have the gear cool
down in the air.
4. Take out the gear from the thermostat.

5. Fit gear
Align the key slot on the gear with the locating pin on the crankshaft, and then install the gear within 30s
If the gear is cooled down and keeps a difference on the crankshaft before it is fully fitted, use a
screwdriver to fulfill the fitting operation.
Last step
1. Fit crankshaft
Renewal of front crankshaft gear (with the crankshaft fitted) 353

Engine block
III. Renewal of crankshaft front oil seal

Common tools
Special tool - -
Auxiliary material Sealant
2. Procedure
Preparatory step
Removal
1. Remove bracket for the front oil seal of
crankshaft
2. Remove the oil seal from the carrier
3. Push the oil seal out from back to front of
bracket
354 Renewal of crankshaft front oil seal

ISLe375 30 engine

use is possible.
1. Clean the gear housing oil seal hole, and
remove all engine oil and seal residues on
the crankshaft surface.
2. Check whether the crankshaft is worn

excessively
Caution: If the crankshaft is excessively
worn, use the anti-wear bushing
for repair purpose.
Refitting
1. Fit oil seal
1). Leave the plate guide tool in the oil seal
2). Place the oil seal on the repair tool with the oil
seal dust tip outward
Correctly support the bracket engine oil seal flange

to avoid the damage on engine oil seal and
bracket.
3). Press the oil seal into the bracket from back to
front
4). Press in the oil seal till the oil seal keeps flush
on the carrier front.
Renewal of crankshaft front oil seal 355

Engine block

wide) between mounting hole and oil seal
around oil seal support interior.
6). Apply a coat of sealant (4mm (0. 16 in) thick,
4mm (0. 16 in) wide) onto all the stud bolts on
front cover.
2. Mount the oil seal bracket on the front
cover
3. Remove plastic installation tool
Screw up the mounting nut for the carrier in
accordance with the astroid sequence, starting
with the stud at the upper left part as illustrated in
the figure.
Last step
2. Fit drive belt
356 Renewal of crankshaft front oil seal

ISLe375 30 engine
IV. Renewal of crankshaft rear oil seal

Common tools
Special tool - -
2. Procedure
Preparatory step
2. Remove clutch & gearbox
4. Remove flywheel or flexible coupling disc
Removal
1. Drill two (2) holes at two positions on oil
seal support which have an included angle
of 180°.
2. Use the screwdriver and slide hammer to

remove the rear oil seal.
Renewal of crankshaft rear oil seal 357

Engine block

use is possible.
1. Clean the rear crankshaft seal.
1). The crankshaft seal lip and surface shall bear
no residual engine oil to avoid the leakage.
2). Clean the rear crankshaft sealing surface and
dry it.
2. Check whether the crankshaft is worn

excessively
Caution: If the crankshaft is excessively
worn, use the anti-wear bushing
for repair purpose.
Refitting
Caution: When fitting oil seal, the neutral
soap should be applied on the oil
bracket external diameter
1. Fit oil seal guide device
Mount the oil seal guider (including the
dismounting tool kit) in the crankshaft
2. Assemle oil seal
Push the oil seal to the guider and crankshaft
3. Remove the oil seal guiding device.
4. Adjust the oil seal

1). Use the aligner to fit the oil seal into the
housing to a correct depth. Use the hammer to
press the oil seal into the housing till the
aligning tool supports the housing.
2). Knock the tool at its positions 12, 3, 6 and 9
and uniformly mount the oil seal to prevent the
oil seal support bending.
358 Renewal of crankshaft rear oil seal

ISLe375 30 engine
Last step
3. Fit clutch and transmission
Renewal of crankshaft rear oil seal 359

Engine block
V. Renewal of crankshaft front anti-wear bushing

Common tools
Special tool Dismantling device, cushion block
2. Procedure
Preparatory step
4. Remove the front gear house cover.
Removal
Caution: Do not let the chisel scratch or
gouge the crankshaft. If the
crankshaft is seriously damaged,
replace it.
1. Remove wear bush
It is only allowed to use the chisel and hammer
with the width same as wear liner. Cross one or
two chisel marks over the anti-wear bushing. This
will expand the wear liner for the convenience of
disassembling.

use is possible.
1. Use the fine sand cloth to Remove rust or
other deposit on the flange of crankshaft
2. Use a piece of clean cloth to clean the
crankshaft flange.
360 Renewal of crankshaft front anti-wear bushing

ISLe375 30 engine
3. Check whether the joint between the oil

seal and the crankshaft is worn to a slot
If the rub groove depth of oil seal can be felt by a
sharp object or the fingernail, an anti-wear bushing
must be fitted to prevent the oil leakage.
Oil seal for wearing bush has larger inner diameter
than standard oil seal. The two kinds of oil seals
cannot be interchangedFor the correct part
number, refer to the relevant parts catalog.
Refitting
1. Use the anti-wear bushing installation kit
to fit the anti-wear bushing onto the
correct position on the crankshaft.
Include the following tools:
Reference
Description Quantity
number
Dismantling
1 1
device
2 Cushion block 2
Bolt M14x1.
3 3
5x60mm
2. Apply a thin coat of clean 15W- 40# engine

oil onto inside diameter of driver and
screw thread of bolt.
3. Apply a thin coat of clean 15W-40# engine
oil onto crankshaft flange.
4. Place the beveling end of lining on the
crankshaft end
Renewal of crankshaft front anti-wear bushing 361

Engine block
5. Place the sunk end of puller on the

anti-wear lining
1). Pass through driver, and fit bolts (without

washer), thus fitting it into crank bolt hole.
Align the lining with the loader and
crankshaftFasten the bolts by hand.
1. Dismantling device 3. Crankshaft

2. Wear bushing 4. Bolt
Caution: To avoid damaging the anti-wear

bushing, rotate each bolt by no
more than half a circle.
2). Alternatively tighten the nuts till the mounting
depth of lining reaches 16mm or so
Tightening torque 20 N·M
6. Remove bolts and fit filling block for each

bolt
7. Fit bolts
362 Renewal of crankshaft front anti-wear bushing

ISLe375 30 engine
1). Tighten bolts alternately until the bottom of

removing & refitting tool gets in touch with the
crankshaft.
8. Remove puller
Last step
4. Fit drive belt
Renewal of crankshaft front anti-wear bushing 363

Engine block
VI. Renewal of crankshaft rear anti-wear bushing

Common tools
Special tool - -
2. Procedure
Initial inspection
If the crankshaft oil seal shows a rub groove on the
crankshaft flange, fit an anti-wear bushing to
prevent the engine oil leakage.
Preparatory step
2. Disconnect the power train and remove the
gearbox (if equipped)
4. Remove flywheel shell
Removal
Caution: Undo the oil pan washer on the
rear cover and avoid damaging it.
If the washer is damaged, remove
the oil pan and replace the
washer.
1. Undo the oil pan at rear end.
1). Remove 4 oil sump mounting bolts fixing the
oil sump on the rear cover
2). Insert the clearance gauge or pad between
rear cover and oil pan. Move the thickness
gauge or pad to loosen the washer of rear
cover.
364 Renewal of crankshaft rear anti-wear bushing

ISLe375 30 engine
2. Remove rear cover

Remove bolts of rear cover and the rear cover from
the crankshaft flange.
3. Remove the oil seal from the rear cover
Caution: Do not let the chisel scratch or

gouge the crankshaft. If the
crankshaft is damaged, replace it.
It is only allowed to use the blunt chisel with the
width same as wear liner.
1). Slightly knock the wear liner by 1~2 times to
leave a chisel mark on the liner. This will
expand the wear liner for the convenience of
disassembling.

use is possible.
1. Wash gaskets of cylinder block and rear
cover.
2. Use the fine sand cloth to Remove rust or
other deposit on the flange of crankshaft
crankshaft flange.
4. Check whether the crankshaft flange is

dirty or scored
Renewal of crankshaft rear anti-wear bushing 365

Engine block
5. Check whether the rear cover has any

crack or other damage
Refitting
Caution: Do not use any lubricant to fit oil
seal. Always assemble the oil seal
with the sealing lip of oil seal and
the crankshaft clean and dry so as
to ensure a normal oil-sealing
state.
1. Remove all lubricants on the oil seal lip.
The crankshaft oil seal (A) anti-wear bushing and

(B) repair kit are fitted on the crankshaft as an
assembly. Do not remove rear oil seal of
crankshaft from the wear bush of rear oil seal of
crankshaft.
Caution: If the oil pan is fitted, undo the pan

bolt to reserve a gap for the rear
cover and washer.
2. Fit rear cover and washer
1). The oil seal mounted shall align with the rear
cover correctly. Do not push or press on the
rear cover in any direction to avoid the
position of sealing lip after the oil seal is
assembled is incorrect.

ISLe375 30 engine
2). The oil seal of wet type flywheel housing

needs to be applied with soap liquid along its
external diameter. For dry flywheel housing, it
is unnecessary to apply any substance at the
outside diameter of oil seal holder.
3. Use the repair kit to fit the oil

seal/anti-wear bushing assembly.
4. Mount the two stubs in the crankshaft bolt
holes
5. Apply a few of clean 15W-40# engine oil
onto inside diameter of mounting tool of
crankshaft, stud bolt and crankshaft rear
oil seal/wear liner.
6. Tighten the stub screw

1). Place the slot end (A) of lining on the
crankshaft end (B)Place the open hole of
mounting tool (C) on the stub, align it with the
lining and make it vertical to the crankshaft
endMount the washer (D) and nut (E) on the
stub.
2). Alternatively tighten the nuts till the installation

tool touches the crankshaft top
Caution: Each nut shall not be tightened by
more than a half of a circle so as
to prevent the anti-wear lining
from sticking or disordered
extension
7. Remove mounting tool and the stud
Renewal of crankshaft rear anti-wear bushing 367

Engine block
8. Align the rear cover with the both sides of

oil pan guide rail on the cylinder block
9. Tighten the rear cover bolts

10. Mount the four rear oil pan mounting bolts

on the oil pan
Refer to step 007-025 for the correct torque value.
Last step
3. Fit transmission and connect drivetrain system (if equipped)

ISLe375 30 engine
VII. Renewal of crankshaft speed indicating ring

Common tools
Special tool - -
Auxiliary material Degreased solvent
2. Procedure
Preparatory step
1. Remove crank
Removal
1. Remove and discard 4 mounting bolts for
the crankshaft speed indicating ring
Caution: The bolt can only be used onceDo
not repeatedly use them.

use is possible.
1. Remove the engine oil on the engine speed
indicating ring.
2. Clean the crankshaft bolt hole.
Use the degreased solvent, such as the contact
cleaner.
Renewal of crankshaft speed indicating ring 369

Engine block
3. Check whether the speed indicator ring

has missed, bent or damaged tooth
4. Check whether there is any cracked or
damaged surface
If damages are visible, replace the speed
indicating ring.
Refitting
1. Fit the rotation speed indication ring
2. Fit new bolt
Tighten the bolts in an alternative sequence.
Last step
1. Fit crankshaft
370 Renewal of crankshaft speed indicating ring

ISLe375 30 engine
VIII. Renewal of main bearing

Common tools
Special tool - -
2. Procedure
Preparatory step
1. Draining the oil
2. Remove oil sump
Initial inspection
1. Use the micrometer and magnetic base to
Extreme axial clearance of crankshaft
Minimum 0. 085mm
Maximum 0. 385mm
If the crankshaft axial clearance goes beyond the required range, check whether the crankshaft and
thrust bearing surface is damaged.
Renewal of main bearing 371

Engine block
Removal
Before removing main bearing cap, determine that
the cap has been clearly marked with the position
on oil cooler side of main bearing.
1# bearing cap, at engine front
When replacing the bearing on chassis, if the 1st

and 7th bearing caps support the crankshaft,
replace the 2nd~6th bearings. After the 2nd~6th
bearings are replaced, replace the 1st and 7th
bearings.
1. Remove all the main bearing caps except
the No. 1 and 7 main bearing caps.
Caution: Do not pry the main bearing cap

from the cylinder block. This will
damage the main shaft bearing
and cylinder block.
1). Fully undo the main bearing bolt, but do not
remove it.
2). Use two main bearing bolts to work loose the
main bearing cover, and note that bolt threads
shall not be damaged.
3). Remove main bearing cap.
2. Mark their positions and numbers

Mark the bearing position in the range of locating
tongue with awl.
Caution: Mark the bearing position for
analysis.
372 Renewal of main bearing

ISLe375 30 engine
1. Remove main bearing

1). Mount the main bearing puller in the oil hole
on the crankshaft main bearing journal so as
to remove the upper main bearing
2). Rotate the crankshaft to contact the
dismantling device with the upper main
bearing side justly opposite to locating tongue.
3). Continue to turn the crankshaft in the direction
in which the locating tongue side (1) of upper
main bearing can be removed first.
4). Remove bearing.
5). Remove all the main bearings except the No. 1
front main bearing according to the procedure.
Caution: Take much care in the operation to

avoid damaging the crankshaft or
cylinder block with the
screwdriver.
Caution: There is no hole on the front main
bearing (No. 1) journal; therefore,
it is not allowed to replace the
bearing via tools.
6). Use the slotted screwdriver to lightly knock the
bearing end to remove it from the cylinder
block. Thereafter, hold the main bearing bush
with fingers and rotate the crankshaft to undo
the main bearing.

use is possible.
1. Clean the main bearing cap with steam.

Engine block
3. Check whether all the main bearing caps

and main bearing crankshaft journals have
deep scores or overheat
Renew all damaged components. If the main
bearing cover is damaged, replace the cylinder
block.
4. Check whether the main bearing journal of

crankshaft is damaged or worn
excessively
If the crankshaft axial clearance measured in the
initial inspection exceeds the required value, do
visually check whether the crankshaft thrust
surface is excessively worn or damaged. Minor
scratches are tolerable.
If damaged, remove the crankshaft. .
Refer to the related procedure for the inspection
procedure of crankshaft or for the renewal of
crankshaft when it is damaged.
5. Check whether the thrust bearing surface
is worn excessively
If any excessive wear is found, replace the thrust
bearing.
6. Check whether the bearing is damaged

Renew the bearing with the following damages:
· Cavitation
· Stripping
· Corrosion
· Latch damage
· Scratch.

ISLe375 30 engine
7. Check whether the bushing saddle joint is

scored or has burrs
If it is impossible to remove the scratch or burrs
with he grinding pad or its equivalent, replace the
bearing.
If the bearing is damaged, replace the complete
set of bearings.
For the details about bearing damage, refer to
Analysis and Prevention of Bearing Faults.
8. Use the external diameter micrometer with

a ball head to measure the main bearing
bush thickness.
Size of main bearing
Minimum 3. 446mm
Maximum 3. 454mm
If the bush thickness is lower than the required minimum value, discard the bush.
Caution: The main bearing can be identified

by the part number and size
pressed on the back
To replace the bearing, determine the size of main
bearings and adopt new products of same size.
The larger main bearing can be used together with
the crankshaft that is machined to a smaller
sizeSee the corresponding list of parts.
Refitting
1. Fit main bearing
Do not lubricate the side towards the cylinder
block.
Caution: Ensure that the dimensions of new
main bearing are the same with
that of removed one. Specification
is marked on back of main
bearing.
1). Apply a coat of fitted lubricant or equivalent on
Caution: The crankshaft thrust bearing
must be fitted at the position No.

Engine block
4.
Caution: The upper and lower main
bearings of some engines cannot
be replaced. If necessary, mark
out the correct direction on the
backside of main bearing.
2). Insert the reverse side of locating plate of

main bearing and install by hand whenever
possible.
3). To mount thrust bearing on 4# journal, it is
possible to push crankshaft to the position in
front of or behind cylinder block.
4). Install all the upper main bearings except the

No. 1 front main bearing according to the
procedure.
Ensure that the positioning pin doesn’t slide
beneath the bearing.
5). Use the main bearing remover & installer and
rotate the crankshaft to refit the main bearing.
6). Use the turning gear to rotate the crankshaft.
7). Ensure that the positioning tongue (1) of main
bearing is located in the gap (2) on the
cylinder block.
8). Finally, push the main bearing in place.
Caution: There is no hole on the front main

bearing (No. 1) journal; therefore,
it is not allowed to replace the
bearing via tools.
Lubricate and fit the main bearing No. 1.
Firstly, insert the reverse side of positioning tongue
of main bearing. It is better to mount it by hand
Push the main bearing in place with screwdriver
when rotating crankshaft.

ISLe375 30 engine
Lower main bearing

The bearing back must be clean without chips.
Mount the lower main bearing into the main
bearing cap
Align the bearing locating tongue with the one on
the main bearing cover
Apply a coat of fitted lubricant or equivalent on
When fitting cover, the No. must face one side of

engine oil cooler.
The main bearing cap surface between main
bearing cap and housing body must be clean
without chips.
After Fitting every upper main bearing, Fit main
bearing cap in order to keep the position of bearing
correct when fitting other main bearing.
Use the clean 15W-40 engine oil to lubricate the
bolt beneath the main bearing cover and the main
bearing bolt thread.
Slightly knock the main bearing cap in place with

plastic or rubber hammer.
After dropping, mount and tighten the main bearing
bolt
Do not tighten to final torque. Apply the final torque
after all main bearing covers are fitted.
After the main bearing cover is fitted, use the

turning gear to check whether the crankshaft can
rotate freely.
When applying the final torque on main bearing
bolt, it is required to frequently check whether the
crankshaft rotates freely.
If the crankshaft can’t rotate freely:
1. Prove that crankshaft doe not contact any
linkage.
2. Prove whether main bearing cap is fitted
properly.
3. Confirm that the main bearing ring dowel or
the installing surface is not damaged during
the installation.

Engine block
4. Prove the installation of main bearing is

correct.
Tighten main bearing bolts evenly in sequence.

Tightening torque
Step 1 170 N·m
Step 2 Loosen all the bolts.
Step 3 50 N·m
Step 4 Turn by 120 degree
If the crankshaft can’t rotate freely, check mounting
conditions and specifications of main bearing.

Use the micrometer and magnetic base to
Extreme axial clearance of crankshaft
Minimum 0. 085mm
Maximum 0. 385mm
If the axial clearance of crankshaft doesn’t meet technical requirements: ，

1. Check for any obstacles hindering crankshaft motion, such as oil pump, linkage, etc. if crankshaft
axial clearance is less than the specified value.
2. If crank axial clearance is higher than the specified value, check crank thrust bearing surface. It is
also necessary to check whether a correct thrust bearing has been fitted.
Last step
2. Fit the oil sump
3. Fill the oil pan

ISLe375 30 engine
IX. Renewal of rubber shock absorber


Inner hexagonal socket S18, slotted screwdriver, sling
Jigger, offset ring socket 3910-Z-BD-21/3910-Z-BD-18, oil seal pliers,

Special tool
valve spring compressor, cylinder liner presser
Feeler gauge, torque wrench (0~400N·m), dial gauge and magnetic stand
Testing tools
Vernier caliper, inside caliper and outside micrometer
2. Procedure
Preparatory step
Removal
Renewal of rubber shock absorber 379

Engine block

1. Check the marks on the shock absorber
hub (B) and inertia member (C)
If the deviation between two lines exceed 1.
59mm, replace the shock absorber.
2. Check whether there is any crack on the
shock absorber hub (B)
If the hub is cracked, replace the shock absorber.
3. Check whether the rubber members are

aged
If the rubber pad is missing or the elastic
component locates more than 3. 18mm beneath
the metal surface, replace the shock absorber.
Caution: It is also necessary to check
whether shock absorber ring
moves forward. If any forward
movement is found, replace the
shock absorber.
Refitting
Tighten bolts diagonally.
Last step
1. Fit drive belt
380 Renewal of rubber shock absorber

ISLe375 30 engine
X. Renewal of viscous shock absorber

Common tools Sockets S10/S13/S16/S18/S22/S24, ratchet spanner
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
Removal

use is possible.
mounting panel
2. Check whether there is any pit or
projection on the housing surface
If problems are found via the above-mentioned
procedures, replace the shock-absorber.
Renewal of viscous shock absorber 381

Engine block
3. Check whether the thickness of shock

absorber is correct
1). Remove the paint from the four positions at
the side of vibration isolator.
2). Measure and record the thicknesses of four
positions of vibration insulator.
3). Check whether the thickness of vibration
insulator is 3. 175mm.
4). If the thickness change exceeds 0. 25mm,
replace the shock absorber.
4. Check whether the shock absorber has

any leakage
1). Spray SKD- NF or the equivalent sampling
Color-developing agent onto the shock
absorber.
2). Heat the shock absorber (with edge rolling
surface downwards) in furnace for 45 min.
Temperature 93℃

injury. Take out the vibration
damper from the thermostat, and
check it for any leakage of liquid.
3). If any leakage is found, replace the shock
absorber.
Refitting
use five shock absorber boltsFit
the shock absorber.
382 Renewal of viscous shock absorber

ISLe375 30 engine
1. Tighten bolts diagonally

Last step
1. Fit drive belt
Renewal of viscous shock absorber 383

Engine block
XI. Renewal of oil pan

Common tools Sockets S13/S16/S18/S22/S24
Special tool - -
Testing tools - -
Auxiliary material Steam, compressed air
2. Procedure
Preparatory step
2. Draining the oil
Removal
1. Remove oil sump and the washer

use is possible.
1. Remove all materials on cylinder block and
oil sump
2. Clean the oil pan with steam.
384 Renewal of oil pan

ISLe375 30 engine
4. Check whether the oil pan, oil suction pipe

and pipe bracket are damaged
Caution: If any crack is visible, replace the
damaged part. Do not try to repair
the oil sump by welding.
Only limited to the composite oil pan

5. Ensure that the transverse spacer pipe
union is tight.
If any looseness is detected, replace the O-shaped
ring and tighten the cross spacer.
Refitting
1. Fill up the gap between the oil pan guide
rail, gear chamber and rear oil seal
housing with RTV sealant or its equivalent.
2. Fit sealing gasket and oi sump

3. Fit oil sump gusset (if equipped)
Caution: The sound-insulating pad must be
used with the oil pan fitted with an
independent gasket system.
Renewal of oil pan 385

Engine block
4. Fit the washer and bolt to fix the oil pan as

shown in the figure.
5. Tighten all the bolts according to the illustrated
order
Last step
386 Renewal of oil pan

ISLe375 30 engine
XII. Engine oil heater

Common tools Adjustable wrench
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
1. Draining the oil
Removal
1. Disconnect the electrical cable of oil heater
2. Remove heater element
Refitting
1. Fit heater core
Last step
1. Connect the oil heater wire
Engine oil heater 387

Engine block
XIII. Renewal of oil dipstick

Common tools Sockets S10/S13/S16/S18/S22/S24
Special tool - -
Testing tools - -
2. Procedure
Calibration
1. Draining the oil
2. Install the oil dipstick in its tube housing
3. Add engine oil.
Fill the clean 15W- 40 oil to the oil pan till the
stipulated Low level
Caution: Take care when marking the oil

dipstick. If marked too deep, the
engine oil dipstick may be broken.
4. Remove oil dipstick and mark the oil level
on the dipstick
Mark “L” at marking position to indicate the “low” oil
level.
Caution: If a new blank gauge is used, cut
off the portion about 38mm below
the “LOW” mark.
5. Wipe the dipstick clean and then mount it

in the dipstick housing
6. Fill the oil to the stipulated HIGH oil level in
the oil pan
388 Renewal of oil dipstick

ISLe375 30 engine
Caution: Take care when marking the oil

dipstick. If marked too deep, the
engine oil dipstick may be broken.
7. Remove oil dipstick and mark the oil level
on the dipstick
Mark “H” at marking position to indicate the “H” oil
level.
389
Engine block
XIV. Oil dipstick pipe

Common tools Socket S8, slotted screwdriver
Special tool Groove puller
Testing tools - -
2. Procedure
Preparatory step
1. Clean the immediate area of dipstick pipe.
1). Before removing, clean the area around dipstick, so as to prevent debris from entry into oil system
Removal
1. Take out the dipstick from the oil dipstick
pipe
2. Remove dipstick pipe from cylinder block
Repair skillsUse the groove puller and M8×1.
25×21mm self-tapping bolt. Screw the bolt into the
oil dipstick and then remove the oil dipstick
Refitting
1. Apply a round of bush fixing compound or
equivalent around the bottom of pipe
groove end.
390 Oil dipstick pipe

ISLe375 30 engine
2. Insert the slotted end of pipe into the oil

dipstick hole of cylinder block
3. Use the plain washer and hexagon head
bolt to extend the pipe into the cylinder
block.
4. Slightly insert the oil dipstick pipe till it
touches the cylinder block casting.
5. Remove plain washer and the hexagon bolt
6. Install the oil dipstick in its tube
Oil dipstick pipe 391

Engine block
Refitting of engine
I. Renewal of engine front bracket
Special tool Lifting device
Testing tools - -
Auxiliary material Steam or solvent, compressed air
2. Procedure
Removal
1. Support the front part of engine with lifting
equipment or tool.
2. Remove bolts for the front engine
suspension
Caution: Do store all removed pads or
spacers properly and record their
positions.
3. Remove 4 mounting bolts and the front

engine support
392 Renewal of engine front bracket

ISLe375 30 engine

use is possible.
1. Use the steam or solvent to clean the
engine front bracket.
3. Check whether the bracket is cracked or

damaged
If the bracket is cracked, it must be replaced.
Refitting
1. Fit the front bracket and mounting bolt
2. Lower down the front part of engine

Caution: Ensure that all shims or spacers
are refitted on the original
positions.
3. Assemle the engine front suspension bolt
4. Tighten bolts according to the technical
specification of manufacturer
5. Take away lifting tools or equipments in
the front of engine
Renewal of engine front bracket 393

Engine block
3. Engine rear bracket



Special tool
Feeler gauge, torque wrench (0~400N·m), dial gauge and magnetic stand
Testing tools
Vernier caliper, inside caliper and outside micrometer
2. Procedure
Removal

human injury.
1. Support the rear part of engine with lifting
equipment or tool.
2. Remove bolts for the rear engine
suspension
3. Remove 4 bolts and rear bracket
394 Renewal of engine front bracket

ISLe375 30 engine

use is possible.
1. Use the steam or solvent to clean the
engine rear bracket.
3. Check whether the bracket is cracked or
damaged
If the bracket is cracked, it must be replaced.
Refitting
1. Fit lifting bracket and bolt
2. Lower down the rear part of engine

3. Fit the bolts of engine rear suspendion
4. Tighten bolts according to the
manufacturer’s technical specification
the rear of engine
positions.
395
Engine block
II. Renewal of flexible connecting disc

Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Remove gearbox & relevant components
Initial inspection
1. Check whether the gear ring tooth of
flexible connecting plate is damaged
If the flexible connecting disc ring gear is
damaged, check against following potential causes
prior to the Renewal of disc:
Mechanic
Generally, as for the 6-cylinder engine, if flexible
connecting disc ring gears at three different
positions (generally called 120°milling) are
damaged, the mechanic failure can be identified.
The possible reasons for mechanic fault:
1. Fit flexible connecting pan
When fitting the fexible connecting, you should
make sure that there is no unsuitable clearance for
starting motor.
2. Check whether the gear ring slot interferes
with the motor pinion.
396 Renewal of flexible connecting disc

ISLe375 30 engine
The starter motor installed may be wrong

3. Potential damages of starter motor pinion
Check whether the pinion is scored or has burrs. If necessary, replace the starter motor.
4. The torque converter/transmission is damaged/installed incorrectly
5. Improper matching between the starter motor pinion and the flexible connecting disc ring
gear tooth clearance/gear tooth
Electric
Generally, if the flexible connecting disc in the
360°circle of gear ring (generally called
360°milling) is damaged, the electric failure can be
identified. Possible reasons of electrical fault are
as follows:
1. The driver tries to start the engine which
has been in operation
Check the motor locking characteristics via OEM
(started by the failure diagnoser) or the starter
motor manufacturer.
2. The key switch makes the starter motor
engage intermittently during engine
operation
3. Check the key switch

4. Locate the starter motor relay
Have the pull contact located in the moving direction of vehicle.
5. This will cause intermittent engagement of starting motor when engine operates.
6. Relocate the starting motor relay.
7. Interval lead failure of starter motor
Removal
1. Remove flexible coupling disc bolt &
flexible coupling disc
required to remove all mounting
discs and/or adapters at or prior to
the use of flexible connecting
disc. Ensure that all mounting
positions of installing disc and/or
adapter are recorded to facilitate
the installation in future.
Renewal of flexible connecting disc 397

Engine block

1. Check whether the gear ring tooth has
scrapings or is worn unevenly
2. Check whether the flexible connecting
plate has any crack
If damaged, replace the flexible connecting disc.
3. Check whether the mounting hole of

flexible connecting plate, drive spline and
internal drive disc have any crack
If damaged, replace the flexible connecting disc.
Refitting
required to fit all mounting discs
and/or snap rings by following
instructions on the removal at or
prior to the use of flexible
connecting disc.
1. Fit the bolt of flexible connecting pan and
flexible connecting pan
Last step
2. Fit transmission and related parts
is noise or vibration.
398
ISLe375 30 engine
III. Flywheel


Special tool
Testing tools
2. Procedure
Preparatory step
2. If the wet type flywheel housing is fitted,
remove the plug at the flywheel bottom to
drain the oil from the housing.
Caution: Use a vessel which can
accommodate at least 28. 4L
engine oil.
3. Remove transmission and all the related
components (if fitted)
Initial inspection
1. Check whether the flywheel gear ring is
damaged
If the flywheel ring gear is damaged, check against
following causes prior to the Renewal of flexible
connecting disc.
Flywheel 399
Engine block
Mechanic
Generally, as for the 6-cylinder engine, if flexible
connecting disc ring gears at three different
positions (generally called 120°milling) are
damaged, the mechanic failure can be identified.
The possible reasons for mechanic fault:
1. When fitting the flywheel, check whether
the starter motor has suitable clearance.
2. Intervene exists between gear ring groove
and starter motor pinion.
3. The starter motor installed may be
wrongRefer to the technical specification
of OEM.
4. Potential damages of starter motor pinionCheck whether the pinion is scored or has burrs
5. Gear ring may be fitted improperly or is damaged.
6. The flywheel end face runout may exceed the value in the technical specification. See
“Measurement” in the procedure.
7. Improper matching between the starter motor pinion and flywheel ring gear tooth
clearance/gear tooth
Electric
Generally, if the flexible connecting disc in the
360°circle of gear ring (generally called
360°milling) is damaged, the electric failure can be
identified. Possible reasons of electrical fault are
as follows:
1. The driver tries to start the engine which
has been in operation. Check the motor
locking characteristics via OEM (started by
the failure diagnoser) or the starter motor
manufacturer.
2. The key switch makes the starter motor
engage intermittently during engine
operation. Check the key switch
3. Locate the starter motor relay to enable the pulling direction of contact to correspond with
the vehicle’s traveling direction. This will cause intermittent engagement of starting motor
when engine operates. Relocate the starting motor relay.
4. Interval lead failure of starter motor
400 Flywheel
ISLe375 30 engine
Removal
Caution: Use the turning gear to fix the
flywheel to prevent it from
rotating.
1. Remove 2 bolts fitted at angle of 180
degree
2. Fit 2 M12×1. 25×90mm guide pins
3. Determine the pattern and specifications of bolt threads, and fit two T-shaped handles at
points (1) and (2) on the flywheel.
4. Remove remaining 3 flywheel mounting bolts
1. Remove flywheel from guide pin
Disassemble
Caution: The guide bearing should be
renewed only when it is damaged
or after the new clutch or repaired
clutch is installed.
1. Remove guide bearing (if equipped)
2. Use a spindle and hammer to remove the
guiding bearing.
3. Use the grinding pad or its equivalent to
clean the guiding hole.
Flywheel 401
Engine block

use is possible.
1. It is required to clean crankshaft guide
hole with wire brush (if guide bearing has
been disassembled).
2. Clean the flywheel with steam or solvent.
4. Check whether there is any score or burr

on the flywheel
5. Use the grinding pad or its equivalent to
remove minor pull marks and burrs.
Warning: Do not use the flywheel with

cracks or with its surface be
reprocessed. These flywheels may
break and cause severe personal
injury or property loss.
6. Use the crack testing kit to check whether
there is any crack on the flywheel.
Operate according to the instructions in the tool kit.
7. Check whether there is any crack or gap

on the flywheel gear ring tooth
Caution: If the ring gear tooth is cracked or
broken, it must be replaced.
402 Flywheel
ISLe375 30 engine
Assemble
1. Fit new guide bearing (if removed)
2. Use a spindle and hammer to fit the
guiding bearing.
When make the assembly, the guide bearing must
be in the same level with guide hole.
Refitting
1. Fit the guide pin
Mount the two M12×1. 25×90mm guide pins on the
crankshaft flange with a spacing of 180°
2. Fit two T-type hanles
Determine the pattern and specifications of bolt
threads, and fit two T-shaped handles at points (1)
and (2) on the flywheel.
3. Check whether the rear end surface of

crankshaft and the mounting flange of
flywheel are clean and scored or have
burrs
4. Mount the flywheel on the guide pin
5. Lubricate the screw thread and washer

surface with clean engine oil.
Flywheel 403
Engine block
6. Fit 6 bolts
7. Remove T-handle & guide pin
8. Mount the rest bolts on the vacant guide
pin holes
9. Use the turning gear to fix the crankshaft.

10. Tighten bolts diagonally
Measurement
Play of hole
1. Use the micrometer (1) or similar tools and
micrometer accessory (2) to check the
runout of flywheel hole (3) and end face (4).
2. Mount the accessories on the flywheel
housing
3. Install the dial indicator on the accessories
4. Support the inner diameter of flywheel hole
by dial indicator tip, and reset its finger to
zero
5. Use the turning gear to rotate the

crankshaft by one circle.
Total reading of flywheel indicator
Maximum 0. 127mm
404 Flywheel
ISLe375 30 engine
If the total reading of micrometer exceeds the

required value, follow the procedures described
below:
6. Remove the flywheel.
7. Check whether there is any dirt or damage

on the flywheel mounting surface
8. Check whether the crankshaft is dirty or

damaged
9. Fit the flywheel

10. Measure the hole run-out
Flywheel 405
Engine block

Runout of end face

1. Fit the contact of dial gauge against the
flywheel housing end face
When locating the contact, look over the table of
total reading of dial gauge for the runout of
flywheel housing end face introduced later in this
step. Locate the contact to make its radius
correspond to the value in the table. And its radius
is also required to be close to the outside diameter
of flywheel as far as possible, so as to check the
runout of end face (1) of flywheel housing.
2. Push the flywheel forward
3. Adjust the dial gauge
4. Till the pointer returns to zero.
5. Rotate the crankshaft by one turn with

hand turning tool.
6. Measure and record the jerk value of four
equally spaced points on the flywheel
For every measurement, the flywheel shall be
pushed to the front end of engine to eliminate the
axial clearance of crankshaft
7. Determine the total reading on the
micrometer.
8. The difference between the maximum
measurement and the minimum.
measurement calculated at four
measurement positions can be
determined.
406 Flywheel
ISLe375 30 engine
9. Measure the distance (A) between the

center of flywheel and the contact of dial
gauge
10. Use this measurement to determine which
one of specifications in the following is
used
The total reading of micrometer shall not exceed
following maximum values:
Flywheel surface,
Radius of
maximum
flywheel
(total reading of dial gauge)
203mm 0. 103mm
254mm 0. 254mm
305mm 0. 305mm
356mm 0. 356mm
406mm 0. 406mm
11. If the flywheel end face runout doesn’t

meet technical requirements,
12. Remove flywheel
13. Check whether there is any score, burr or
dirt between the flywheel mounting surface
and the crankshaft flange
14. If the runout exceeds the extreme limit
again, replace the flywheel.
Last step
1. Fit transmission and all related parts (if
equipped)
2. Fill engine oil into the flywheel housing (if
a wet type flywheel housing is fitted)
5. Check whether there is noise or vibration
407
Engine block
IV. Flywheel housing

Special tool - -
Testing tools - -
Auxiliary material Steam or solvent
2. Procedure
Preparatory step
2. Remove screw plug at the bottom of flywheel housing (if the wet-type flywheel housing is
fitted)
Drain oil from flywheel shell, and use a container at least for 16L oil.
4. Remove transmission, the clutch and all the related components (if fitted)
6. Remove all the components installed by OEM on the flywheel housing (the silencer, the gear
shift mechanism, the air filter and etc.)
Removal
human injury.
1. Support the rear part of engine with lifting
equipment or tool.
408 Flywheel housing

ISLe375 30 engine
Caution: When removing engine rear

mounting fasteners, note the
position of any gasket or spacer
ring used.
2. Remove engine mounting fasteners
3. Remove rear support bolts & bracket
4. Remove support flywheel shell mounting

bolt
5. Support wheel housing

6. Use the rubber hammer to undo the
flywheel housing.
7. Remove flywheel shell
Caution: When removing flywheel shell,
record the positions of all locating
pins on flywheel shell.
Flywheel housing 409

Engine block
Disassemble
1. Remove all plugs on flywheel shell, and
record their positions.
2. Remove inspection cover plate and gasket

(if equipped)
3. Remove the screw plug from the turning

gear hole

use is possible.
1. Clean the flywheel housing with steam or
solvent.

ISLe375 30 engine

flywheel housing
Especially the zone on the cylinder block or the
rear gear house used to accommodate the
flywheel housing

mounting surface of transmission/drive
unit of flywheel housing
5. Check whether any thread is damaged
because of using slip-thread bolt or wrong
bolt
Caution: The damaged threads can be
repaired by the spiral tap
Measure
Calibration of end face
Caution: The micrometer probe shall not be
inserted into the screw hole;
otherwise the micrometer may be
damaged.
1. The position of end face is determined by
the calculated total reading of dial gauge
2. Connect the dial indicator with crankshaft
As shown in the figure, mounting tools are used to
connect the micrometer onto the crankshaft.
Caution: The micrometer can be installed in
many ways, and the meter
extension bar shall keep rigid. If
the extension bar works loose or
the micrometer slides, the
accurate readings will not be
obtained.
3. Set the dial indicator at the position of 12 o’clock and reset it to zero
Caution: For every measurement, it is needed to push the crankshaft to the front end of
engine to eliminate the axial clearance of crankshaft

Engine block
4. Use the turning gear to slowly rotate the

crankshaft.
5. Record the readings A, B and C at the
positions of 3 o’clock (A), 6 o’clock (B) and
9 o’clock (C), which can be positive or
negative
6. Keep on rotating the crankshaft till the dial

indicator points at the position of 12
o’clock.
7. Check the dial indicator and confirm the
finger points to zero
If the rotation is not allowed, the reading is
incorrect. At this moment, repeat this procedure.
8. Determine the total reading on the

micrometer.
9. The difference between the maximum
measurement and the minimum.
measurement calculated at four
measurement positions can be
determined.
10. Among examples indicated in following
drawing, it shall be:
+0. 08 mm-(-0. 05 mm)=0. 13 mm
For example
12 O’clock 0. 00mm
3 O’clock +0. 08mm
6 O’clock -0. 05mm
9 O’clock +0. 08mm
Equal to 0. 13mm

ISLe375 30 engine
11. The maximum allowable dial indicator

readings (TIR) are decided by flywheel
housing bore diameter.
If the technical requirements can’t be satisfied,
replace the flywheel housing.
Flywheel housing hole and end face runout
Maximum total
Diameter of
SEA reading on the
hole
micrometer
Quantity mm mm
784. 15 to 784.
00 0. 25
65
657. 45 to 647.
0 0. 28
95
584. 00 to 584.
1/2 0. 30
40
510. 98 to 511.
1 0. 36
38
447. 55 to 447.
2 0. 41
81
409. 5 to 409.
3 0. 48
71
Calibration of flywheel housing hole

1. Connect the dial indicator with crankshaft
As shown in the figure, mounting tools are used to
connect the micrometer onto the crankshaft.
Caution: The micrometer can be installed in
many ways, and the meter
extension bar shall keep rigid. If
the extension bar works loose or
the micrometer slides, the
accurate readings will not be
obtained.
2. Place the gauge at the position of 6 o'clock
and reset the gauge

Engine block
3. Slowly rotate the crankshaft

Record the readings at the positions of 9 o’clock,
12 o’clock and 3 o’clock, and record them in the
concentricity worksheet as A, B and C
4. Recheck the zero position of 6 O’clock
position
If the rotation is not allowed, the reading is
incorrect.
Repeat this step.
5. The value for A, B, C can be positive or
negtive
When recording these values, please refer to the
correct coordinate determined by the attached
drawing
Caution: Do not let the crankshaft go

beyond the position not including
the bearing clearance. Do not pry
the flywheel housing. These
operations may cause the
incorrect reading of bearing
clearance and the damage of
engine.
6. Rotate the crankshaft till the dial indicator
is at its position of 12: 00 o’clock and
returns to zero.
7. Use the pry bar to elevate the crankshaft
rear end to the highest position.
Record this value as D in concentricity working
table. This value is the bearing’s vertical clearance
adjustment, and is positive always.
8. Create a worksheet of concentricity as

specified to identify the “total verticality”
and “total horizontality”
Caution: Values listed in the concentricility
worksheet are only used as
examples, expressed in inch.
Measured values may be different.
9. Enter the recorded values of A, B, C and D
in concentricity working table.
10. The overall levelness is the value obtained
by subtracting the reading (C) at 3: 00
o’clock position from the reading (A) at 9:
00 o’clock position.
11. The overall verticality is the sum of reading (B) at 12: 00 o’clock position and bearing
clearance (D).
For example:

ISLe375 30 engine
• 6 O’clock position=reference value=0

• 9 O’clock position=[a]=0. 004
• 12 O’clock position =(b)=0. 003
• 3 O’clock=(c)=(-0. 002)
Use values listed in the worksheet and this example, total horizontal component=0. 006, vertical
component=0. 005.
Caution: Use the flywheel housing gauges

SAE1, 2 and 3 to measure the
flywheel housing.
Mark as illustrated the total horizontality
horizontally on the table, and mark the total
verticality vertically.
Use the ruler to find out the intersection between
the total horizontal component and total vertical
component. The cross point must be in the shadow
to ensure the concentricity of flywheel housing
meets the technical specifications
Use the total horizontal component and vertical
component as mentioned in the previous example,
with the intersection located in the shade zone.
Therefore, the wheel house concentricity meets
technical requirements.
Caution: Ensure to use the correct technical specifications for the total reading of dial gauge
measuring the flywheel housing when comparing the measurements.
SEA2 flywheel houding meter.
SAE3 flywheel houding meter.

Engine block
12. If the hole is not aligned as required.

1). The dowel must be removed and the flywheel
housing be relocated.
2). Use the positioning pin puller to remove the
pin from the cylinder block.
Caution: Circular positioning pin is not
necessarily kept concentrically by
the same shell.
After disposing the dowel, fit the flywheel housing

on the engine in accordance with the assembly
part covered by this step, but not tighten up the
bolt. Tighten the bolt to fix the flywheel housing,
and there shall be a little of moving space left for
knocking by hammer
13. Recheck the hole positioning.
After the lock is located in accordance with the
specifications, tighten the bolt to the stipulated
torque stipulated in the section of installation of this
step
Assemble
1. Apply the pipe sealant onto all the
disassembled screw plugs (for wet type
flywheel housing).
2. Fit and tighten screw plug
3. Fit the inspection cover and new sealing

gasket
4. Fit and tighten the bolt
Caution: If no gasket is fitted, apply the
sealant onto the immediate area of
inspection cover plate.

ISLe375 30 engine
5. Use the new O-shaped ring to fit the

turning gear hole plug.
Refitting
Application of wet type flywheel
1. Continuously apply a round of sealant or
equivalent around bolt holes on mounting
surface of flywheel housing.
Caution: Before fitting flywheel housing,

make sure all the dowels at the
same position when flywheel
housing is removed.
2. Mount a new rectangle seal on seal rear
support and apply the fitted lubricant.
3. Mount the new camshaft journal/hole

rectangle seal ring behind flywheel
housing (if fitted).
4. Apply a little of sealant.
5. Fix the washer to correct position till
mount the flywheel housing

Engine block

flywheel are clean, or have projecting
scores or burrs.
7. Fit two dowels
8. Assemble the flywheel housing above
guide pin.
Caution: Ensure that the flywheel housing
is located on the positioning pin
and that the seal ring is not
damaged in refitting operation.
9. Remove guide pin

10. Install the mounting bolt
11. Tighten mounting bolts of flywheel

housing according to the illustrated
sequence
12. Fit the rear bracket and bolt of engine

ISLe375 30 engine

positions.
13. Lower down the rear part of engine
14. Fit the fasteners of engine rear suspension
the rear of engine
Last step
3. Fit transmission and related parts (if equipped)
4. Fill engine oil into the flywheel housing (if a wet type flywheel housing is fitted)
5. Mount the components provided by OEM (such as muffler, gear shift mechanism, air filter,
etc.) on flywheel housing.
8. Check whether there is any leakage or vibration

Engine block
V. Renewal of REPT0 flywheel houing

Exploded view
1. Flywheel housing 11. Bolt 21. Idler shaft 31. Hexagon head screw
2. Inspection hatch 12. Plain washer 22. O-ring 32. Hexagon head screw
3. Sealing gasket, cover 13. Oil seal (output shaft) 23. Hexagon screw 33. Expansion plug
plate
14. Gasket 24. Crankshaft gear 34. Flexible feed hose
4. Drain screw plug
15. Plain washer 25. Hexagon head screw 35. The paired feed union
5. Attachment drive output
shaft 16. Plain washer (PTO 26. Plain washer 36. Retaining ring
flange)
6. Power output flange 27. Support gasket 37. Dust cover seal
17. Hexagon head screw
7. Roller (big) bearing 28. Sealing tool kit
18. Shaft retainer ring
8. Roller (middle) bearing 29. Cap washer cap screw
19. Idler gear
9. Rectangular sealing ring 30. Hexagon head screw
(tetra) 2. Bearing & seat insert
assembly
10. Cover plate (ribbed)
420 Renewal of REPT0 flywheel houing

ISLe375 30 engine
Note: There are seven washers provided for use. The specific REPTO can be used to group these shims
in any way.
Reference number Description mm
14 Shim 0. 127
14 Shim 0. 254
14 Shim 0. 381
14 Shim 0. 051
14 Shim 0. 076
14 Shim 0. 508
14 Shim 1. 016

Common tools
wrenches S16S18/S22/S24
Special tool - -
Testing tools - -
Auxiliary material Lubricant
2. Procedure
Preparatory step
2. Remove gearbox, clutch & all relevant components (if equipped)
4. Support the engine properly.
6. Remove two engine rear mountings
Renewal of REPT0 flywheel houing 421

Engine block
Removal
1. Remove REPTO oil supply pipe
2. Remove oil seal bolt, oil seal and gasket
3. Use the punch to directly knock the bowl

plug into the housing to remove the screw
from it.
Do not try to pull out or screw out the bowl-shaped
plug in reverse direction from the housing.
Otherwise, the bowl plug hole can be damaged
and cause oil leakage.
4. Mount the two locating stubs of crankshaft

on the mounting flange of crankshaft
flywheel with a spacing of 180°
5. Remove crankshaft drive gear

ISLe375 30 engine
Caution: If the shaft is removed, the idler

gear will drop.
6. Use the idler gear puller to remove the gear
shaft.
7. Remove idle gear so as to be accessible to

the remaining housing bolts
8. Remove two bolts

9. Mount the guide pin on the support
housing
10. Use the angle wrench to remove those
invisible bolts.
11. Remove rest bolts

12. Use the rubber hammer to undo the
flywheel housing.
13. Remove casing

Engine block
Disassemble
1. Remove output shaft bolt
1). Use gear lock to prevent the first axle from
rotating during the removal of bolt.
2). Remove bolts & washers fixing output flange
onto output shaft.
3). Use the cowskin hammer to remove the
output shaft flange and plain washer from the
output shaft.
2. Take off the sealing element with groove

puller.
Caution: Do not damage the housing
surface of hole of oil seal.
3. Remove four cover plate bolts and cover

plates
The bearing can come off when the housing is
rotated reversely. Do not damage the bearing.
1). Rotate the casing reversely to remove and fit
the four cover bolts. Be careful not to damage
output shaft.
2). Remove bolts & edged cover plates from
output shaft chamber.
4. Remove and discard square O-ring
5. Keep the original gaskets for reinstallation

Use them to set the correct axial clearance of input
shaft and bearing assembly
6. Remove output axle subassembly
Rotate the casing reversely, and use a rawhide
hammer to hit the end of second axle and remove
the second axle pair assembly from the REPTO
housing.

ISLe375 30 engine
7. Remove outer bearing seat

When the mating face of housing with the cylinder
block faces downwards, use a hammer and copper
punch head to push the bearing outer race out of
first axle housing hole.
8. Remove idler shaft bush

1). Use the machine press to support the housing
with its fitting surface downward.
2). Use the longer spindle to press out the idler
shaft lining.
9. Remove and discard the O-ring
10. Remove two outer bearing seat and

discard outer seat ring
Use the hammer and copper punch to remove both
bearing outer races from the idler gear hole, and
discard the outer ring.
11. Remove big spacer ring from middle gear
groove and discard spacer ring

use is possible.
1. Use the steam cleaner to clean all zones on
the idler gear.
2. Check whether the output shaft and
bearing are worn
3. Check whether the output gear is damaged
4. Check whether the output flange is
damaged or whether the oil seal slot is
worn

Engine block
5. Check whether there are cracks on the rear

mounting surface of engine and the
REPTO casing on the flywheel hole
6. If cracked, replace the housing.
7. Check whether the idler gear shaft sleeve
is worn
If worn, replace the bushing.
8. Check the gear hole and the tooth of lateral

and idler gear
If there is any cracking or deformation or other
damages due to overheating, replace the gear.
Assemble
1. Mount the new O-ring on the idler pulley
bushing
equivalent to lubricate the O-shaped ring.
3. Fit new bearing bushing

1). The casing is supported stably to make the
cylinder block joint downward
2). Press the new lining into the housing till it is
lower than the cylinder block matching surface

ISLe375 30 engine

equivalent to lubricate the larger bearing
race
5. Use the larger end of remover & installer to
press the bearing race into the housing
shoulder.
6. Rotate the casing reversely

7. Support the pressing machine stably.
equivalent to lubricate the smaller bearing
race.
9. Use the smaller end of drive to press the
bearing race into the housing shoulder.

equivalent to lubricate the output shaft and
the larger bearing.
11. Install the big bearing on the output shaft
12. Place the housing joint upside on the table

13. Mount the output shaft assembly on the
housing

Engine block
14. Check the inter-axle clearance

The correct axial clearance (rolling resistance) is
dependent on the number and thickness of used
shim.
When the shim thickness is increased, the axial
clearance becomes larger and the rolling
resistance becomes smaller.
When the shim thickness is reduced, the axial
clearance lessens and the rolling resistance
becomes larger.
15. Rotate the housing to face the cylinder

block mating surface downward.
16. Fix the second axle and gear
17. Fit originally thick gasket
If the original shim can’t be used again, use 1.
47mm shims as a minimum.

equivalent to lubricate the smaller bearing
race.
19. Mount the small bearing on the output
shaft
20. Mount input flange temporarily.

lubricate the spline.

ISLe375 30 engine
22. Fit plain washer and bolt

When tightening the bolt, use the gear lock tool to
fix the output shaft
Axial clearance
Minimum 0. 0mm
Maximum 0. 03mm
23. Measure the shaft end clearance
24. Check the rotation resistance of output

shaft with torque wrench.
Rolling resistance ranges from 0. 6 to 1. 1N·m
25. Remove output flange & small bearing ( if

rolling resistance does not meet technical
specification)
26. To obtain correct rolling resistance,
increase or decrease shim.
The increase of shim will reduce resistance;
contrarily, the decrease of shim will increase
resistance. The gaskets can be combined for use
27. Remove output flange and fit new oil seal

(once correct rolling resistance is
obtained)
28. Press the oil seal into the housing, and
make it flush with the surface

Engine block
29. Apply the pipe sealant on the output flange

bolt and below the washer
30. Fit input flange plain washer and bolt
32. Mount the new O-ring on the bearing seat

cover
33. Use the vegetable oil to lubricate the
O-shaped ring.
34. Fit the cap and tighten 4 bolts

35. Insert the new spacer ring into the idler

gear hole
36. Push the spacer till it is seized in the
central groove.

ISLe375 30 engine

equivalent to lubricate the bearing outer
race.
38. Press the two new bearing outer rings into
the idler pulley gear holes
The larger taper side must face the exterior of
gear.
Caution: Do not exchange between any two

single parts which forms the idle
pulley bearing assembly. Use
bearings from the same package
to refit the idler gear.
Caution: Attach both roller bearing
assemblies to the spacer ring and
idler gear.
Refitting
1. Fit rectangle seal on the sealing rear
bracket
2. Lubricate with fitted lubricant or
equivalent.
3. Continuously apply a round of RTV sealant

or equivalent around pin holes on
mounting surface of flywheel housing.

Engine block

flywheel are clean, or have scores or burrs.
5. Mount the flywheel housing on the two
circular locating pins
Ensure that the sealing ring is not damaged in the
refitting operation.
6. Fit bolts and tighten it based on the

pictorial sequence
7. Use the spanner to remove those invisible
bolts.
8. Measure the flywheel housing hole and

align the end face
9. Bearing outer ring of new gear

10. Apply a thin coat of fitted lubricant or
equivalent onto outer seat ring and
bearing.
11. Mount the bearing and water in the idler
gear
When fitting the idler gear assembly, use the
plastic bushing to fix the bearing assembly
together.

ISLe375 30 engine
12. Apply a thin coat of fitted lubricant or

equivalent on the idler shaft hole on
housing body and the idler shaft.
13. Install the idler gear assembly into the
flywheel housing
Fit idler gear and the bearing in place before
removing the plastic bush.
14. Use the clean mounting lubricant or its

equivalent to lubricate the idler hub
O-shaped ring and fit the O-shaped ring
into the shaft.
15. Fit the gear assembly
16. Insert the idler gear shaft into the housing
and idler gear bearing
It is necessary to use a hammer during the
assembling of idler gear shaft and bolt to avoid the
damage of parts.
17. Apply the fitted lubricant or equivalent

below the bolt head of idler shaft.
18. Insert the bolt in the shaft of idler pulley
and tighten mounting bolt with a torque
wrench
The torque used to pull the idler pulley shaft shall
not exceed 88N·m. If the mounting torque is higher
than this value, it may be not allowed to align the
shaft hole and the shaft. Remove idler shaft and
then refit it.
19. Remove bolt

Remove the bolt after the idler shaft is fitted in
place.
20. Apply the pipe sealant onto the screw
thread of idler shaft.
21. Apply the lubricant or equivalent under the
bolt head
22. Tighten according to the final torque value

Engine block
23. Apply a coat of cup plug sealant onto bowl

plug outside diameter.
24. Use the remover & installer to fit the bowl
plug into the housing.
As shown in the figure, in the fitting operation of
bowl plugs, ensure that they keep flush with the
hole plane on the flywheel housing.
25. Apply the pipe sealant on oil drain plug of

flywheel housing.
26. And install it into the hole at the bottom of
flywheel housing
27. Tighten the screw plug
Refer to the torque values of pipe plugs in the
related the procedure for various pipe plug
dimensions.
28. Rotate the input shaft flange disc to make

the straight edge at top and bottom.
This is used to avoid interference when
assembling transmission on housing body.
29. Mount the two locating stubs of crankshaft

on the mounting flange of crankshaft
flywheel with a spacing of 180°
30. Ensure that the crankshaft and its gear are
clean.
31. Mount the crankshaft gear on the locating
stub

ISLe375 30 engine
32. Assemle oil seal

1). Do not use any lubricant to fit oil seal. Always
assemble the oil seal with the sealing contact
surface of crankshaft gear and the sealing lip
of oil seal clean and dry so as to ensure a
normal oil-sealing state.
2). Mount the new gasket (1) into the flywheel
housing
3). Mount a new oil seal on contacting surface of

crankshaft gear oil seal.
33. Apply the sealant on fixing bolt for sealing

purpose.
34. Fit and tighten the cap screw by the star
sequence
Step 2 19 N·m
35. Fit REPTO oil feed pipe


Engine block
Last step
2. Fit two rear suspensions of engine
4. Fit transmission, clutch and all related parts (if equipped)
Refer to “OEM service manual”

ISLe375 30 engine
VI. Renewal of flywheel ring gear


Special tool - -
Testing tools - -
2. Procedure
Preparatory step
1. Check whether the gear ring is dismountable or changeable.
2. Check the existing gear ring used for change
3. Check whether it is needed to replace the whole flywheel assembly
Caution: The ring gear on the flexible connecting disc shall not be replaced. If the flexible
connecting disc ring gear is damaged, replace the disc assembly.
Disassemble
1. Remove the copper punch to remove the
ring gear from the flywheel.
Assemble
1. Heat the new gear ring for 20 min in
thermostatic oven which has been
preheated to 127℃.
Renewal of flywheel ring gear 437

Engine block
Warning: To minimize serious injuries due

to high temperature, refit a heated
gear with protecting gloves.
2. Fit the ring gear
When fitting the gear ring, the taper surface nust
face the flywheel shaft.
438 Renewal of flywheel ring gear

ISLe375 30 engine
Lubricating system
General
I. Lubricating system- general description
Oil filter
LF9009 the oil filter is applicable to all the engines.
This filter is composed of one rotary filter element
and one interior Venturi tube which makes the filter
bypath engine oil flow into filter laminated
segment. Oil filter must be Venturi tube type. The
use of any venture-free engine oil filter may lead to
the premature wear of engine.
Oil system flow chart

Oil cooler flow chart
1. Gear type oil pump 5. The filter bypass valve

2. Oil cooler 6. From the oil filter to main passage
3. Bypass oil to oil sump 7. Oil thermostat
4. Full-flow oil cleaner
Lubricating system- general description 439

Lubricating system
Lubrication of power units
1. From oil cleaner 4. to piston cooling nozzle

2. Main oil passage 5. From main passage
3. To camshaft 6. To the linkage bearing
440 Lubricating system- general description

ISLe375 30 engine
Lubrication of turbocharger
1. Oil supply from oil cleaner 3. Oil drain, turbocharger

2. Turbocharger oil supply
Lubrication of overhead system
Lubrication of overhead system
1. Camshaft liner 4Rocker arm shaft

2. Oil channel 5. Rocker hole
3. Rocker bracket 6. Rocker
Lubricating system- general description 441

Lubricating system
Draining and filling of lubricating system

I. Draining of lubricating system
Common tools Offset ring spanner S16
Special tool - -
Testing tools Oil sump
2. Procedure
Caution: Use a vessel which can
accommodate at least 28. 4L
engine oil.
Caution: For compound oil sump, use
another spanner to keep the
external cap nut in the original
place during removing the drain
plug. This can prevent cross slab
loosening in the course of
disassembling oil drain plug.
1. Till the temperature of cooling fluid
reaches 60℃.
1. Stop the engine
2. Remove drain plug

3. Draining the oil immediately
Ensure that the engine oil and floating dirt in the engine are fully removed.
4. Remove and renew the oil filter (if the oil change is carried out between each maintenance)
442 Draining of lubricating system

ISLe375 30 engine
II. Filling of lubricating system

Common tools Offset ring spanner S16
Special tool - -
Testing tools - -
Auxiliary material Oil
2. Procedure
Caution: For compound oil sump, always
use new sealing washer for the oil
drain plug. When tightening the oil
drain plug, fix the external locknut
to correct position
1. Clean and check the thread and sealing
surface of oil drain plug.
2. Fit the outlet screw plug of oil sump
Torque value
Steel oil sump 80N·m
Cast aluminum oil pan 60N·m
Compound oil sump 60N·m
3. Fill clean engine oil into the engine till the

correct level is reached.
Caution: When filling the oil pan, use the oil
filling pipe on the side of engine
instead of one on the rocker
chamber cover top.
Filling of lubricating system 443

Lubricating system
Caution: If the engine oil pressure is not

indicated within 15s after the
engine startup, shut down the
engine to minimize damages.
4. Run the engine at idle speed.
5. Check whether the oil drain plug has
leakage
6. Stop the engine

7. Wait about ten min
8. Recheck the oil level.
9. Add the oil to the high oil mark (H) on the
oil dipstick (. If necessary)
444 Filling of lubricating system

ISLe375 30 engine
III. Analysis of oil and filter


Common tools
Special tool Pipe cutter
Testing tools - -
2. Procedure
Check
Analyzing the used oil can help make diagnosis on
the internal damage of engine and identify if the
damage is caused by the following factors:
• The intake air filter is in trouble
• Coolant leakage
• Oil is diluted by fuel
• Cause the abrasion by granular metal.
To obtain more information on engine oil analysis,

refer to Recommendations on Engine oil for
Cummins Engines.
Never decompose the engine for repairs by merely
depending on results of engine oil analysis. Check
the oil filterIf the oil filter has internal damages,
investigate the cause and then provide repair
service. Refer to the following corresponding
procedure base on the inspection of oil filter:
Analysis of oil and filter 445

Lubricating system
Warning: Fix the full-flow oil filter and cut

the filter (top of combined filter)
with care. The filter core spring is
compressed or it may hurt people.
1. Use the pipe cutter to open the full-flow

type engine oil filter (upper portion of
bypass filter).
2. Check whether the filter element has water
marks or metal scrapings
Metal Possible source
Copper Bearing and bush
Chrome Piston ring
Iron Cylinder liner
Lead Material of bearing

bush coverage
Aluminum Piston is worn or

scratched
446 Analysis of oil and filter

ISLe375 30 engine
Oil pump and pipeline

I. Renewal of oil pump
Special tool - -
Testing tools Thickness gauge
Auxiliary material Marker pen, cleaning agent, compressed air, 15W-40 oil
2. Procedure
Preparatory step
4. Remove the front gear house cover.
Removal
1. Remove 4 mounting bolts
2. Remove oil pump from the hole of cylinder
block
Disassemble
1. Check whether the oil pump gear has
peeling, crack or is worn excessively
Renewal of oil pump 447

Lubricating system
2. Remove back plate
3. Mark TOP on planet gear.
4. Remove planetary gear of inner gear oil

pump

use is possible.
1. Use the detergent to clean all parts.
3. Check whether the oil pump casing and the
drive and itself of inner-gear oil pump are
damaged or worn excessively
448 Renewal of oil pump

ISLe375 30 engine
Measure
Caution: Ensure that the gear oil pump
planetary gear is fitted at the
original position.
1. Fit inner gear pump planetaty gear
2. Measure the top clearance
Top end clearance
Minimum 0. 0254mm
Maximum 0. 1778mm
If the top gap exceeds the required value, replace

the engine oil pump.
3. Measure the clearance between the gerotor

drive/planetary gear and the valve plate
Clearance between the internal gear oil pump

drive/planet gear and the flow distributor
Minimum 0. 0254mm
Maximum 0. 1270mm
If the clearance between the internal gear oil pump drive/internal gear pump planetary gear and the flow
distribution disc exceeds the required value, replace the engine oil pump.
4. Measure the clearance between the

planetary gear of gerotor and the pump
body hole
Clearance between the internal gear oil pump

planet gear and the pump body hole
Minimum 0. 1778mm
Maximum 0. 3810mm
If the clearance between the internal gear oil pump

planetary gear and the pump hole exceeds the
required value, replace the engine oil pump.

Lubricating system
5. Measure the backlash
Oil pump gear side clearance limit value (old)
Minimum 0. 0762 mm
Maximum 0. 3302 mm
Caution: To check the gear backlash, draw

the adjacent gear and do not let it
move. Otherwise, the readings will
be the sum of two gears.
If the side clearance of gear exceeds the required
value, replace the engine oil pump.
Assemble
1. Fit back plate
Refitting
Caution: If the pump is not filled with oil
when assembly, the fault may be
caused to oil pump and heavily
damage the engine.
lubricate the engine oil pump.
Caution: Ensure that the idler pin is fitted in

the positioning hole of cylinder
block.
2. Fit oil pump
450 Renewal of oil pump

ISLe375 30 engine
3. Tighten bolts crosswise, starting from

right upper bolts.
Caution: If a new engine oil pump is fitted,

ensure the side gap of gear is
correct.
4. Measure the backlash of gear
Oil pump gear side clearance limit value (fitted)
Minimum 0. 0762mm
A
Maximum 0. 3302mm
B Minimum 0. 0762mm
Caution: The reading will be incorrect if the adjacent gear moves during the measurement of
backlash.
5. Lubricate the front gear system with clean

15W-40# engine oil.
Last step
1. Fit front cover
3. Fit drive belt

Lubricating system
II. Renewal of oil suction pipe (fitted on cylinder block)

Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Draining the oil
3. Remove oil sump
Removal

use is possible.
1. Clean the gasket surface.
452 Renewal of oil suction pipe (fitted on cylinder block)

ISLe375 30 engine
2. Check whether the oil suction pipe is

cracked
Refitting
1. Fit oil suction pipe and new washer
2. Fit and tighten all the bolts
3. Check the alignment
4. Fix the oil suction pipe on the cylinder
block
5. Fasten the oil suction pipe bracket on the
engine cylinder block
6. Fix the oil suction pipe on the bracket

Last step
1. Fit the oil sump
Renewal of oil suction pipe (fitted on cylinder block) 453

Lubricating system
Oil filter
I. Renewal of oil filter (rotary)

Common tools
Special tool Oil filter wrench
Testing tools - -
Auxiliary material Clean and phozy fabric, 15W-40 oil
2. Procedure
Removal
1. Clean the immediate area of engine oil
filter base.
2. Use the engine oil filter spanner to remove
the filter.
3. Clean the sealing surface of filter seat with
clean lint-free cloth.
Refitting
Caution: Fill the engine oil filter with engine
oil at starting to avoid the damage
on engine.
1. Apply a layer of clean 15W-40 engine oil
onto the oil filter gasket surface.
2. Fill the filter with clean 15W-40# engine oil.
Caution: Oil filter must have a filter bypass
valve. If the filter is clogged, the
use of engine oil filter without
bypass valve may lead to low oil
pressure.
454 Renewal of oil filter (rotary)

ISLe375 30 engine
Caution: Over-tightening of filter may give

rise to thread distortion, or
damage the filter element sealing.
3. Mount the filter on the filter seat
Tighten the filter till the gasket touches the filter
seat surface
4. Use the engine oil filter spanner to fasten
the filter.
Caution: If the engine oil pressure is not

indicated within 15s after the
engine startup, shut down the
engine to minimize damages.
7. Stop the engine
8. Recheck the engine oil level.
455
Lubricating system
II. Oil filter bypass valve


Slotted screwdriver
Special tool - -
Testing tools - -
Auxiliary material Solvent and compressed air
2. Procedure
General
If the engine oil filter pressure drop exceeds the
preset point, the bypass valve of filter will be turned
on to enable the oil to pass by the filter.
It can happen when the engine is started in a cold
weather (the oil temperature is too low).
The provision of a bypass valve aims to maintain
the engine oil flow to avoid damaging the oil filter.
Preparatory step
2. Remove oil filter
3. Remove oil filter seat
Removal
1. Remove the 3/4 in. pipe plug from the end
of oil filter retainer
2. Use the screwdriver to slightly press the
bypass valve top downward to remove it
from the hole.
456 Oil filter bypass valve

ISLe375 30 engine

use is possible.
1. Use the detergent to clean the bypass
valve.
3. Check whether the bypass valve is
damaged
4. Ensure that the valve is fully closed.
Refitting
5. Insert the bypass valve into the hole
The spring should be put into the hole and faces
upwards.
6. Slightly push the bypass valve into the
hole till it is fixed.
7. Mount the 3/4″pipe plug on the oil filer seat
end
Last step
1. Fit oil filter seat
2. Fit oil filter
Oil filter bypass valve 457

Lubricating system
III. Renewal of oil filter seat


Common tools
Special tool - -
Testing tools - -
Auxiliary material Solvent
2. Procedure
Preparatory step
Removal
1. Remove oil filter seat adapter bolts, filter
seat & gasket

use is possible.
1. Clean the filter seat adapter with solvent.
458 Renewal of oil filter seat

ISLe375 30 engine
2. Check whether the filter seat adapter has

any crack and other damage
Refitting
1. Fit sealing gaket, oil filter seat adapter and
bolt
Last step
1. Fit oil filter
Renewal of oil filter seat 459

Lubricating system
IV. Renewal of oil high pressure reducing valve


Special tool - -
Testing tools - -
2. Procedure
Removal
1. Remove bypass valve of oil cooler

1. Check whether there is any damaged
O-ring, broken spring or other damage
Refitting
1. Fit oil cooler bypass valve
460 Renewal of oil high pressure reducing valve

ISLe375 30 engine
V. Renewal of oil pressure adjuster (main passage)


Common tools
Special tool - -
Testing tools - -
Auxiliary material Detergent, compressed air
2. Procedure
Removal
1. Wash the pressure regulator plug.
Use the detergent to thoroughly clean the
immediate area of pressure regulator plug to avoid
the entry of scraps into the plunger hole.
2. Remove screw plug, the spring and the

plunger
Repair skillsWhen removing plunger, you may
insert one of your fingers into the hole and pull it off
when feeling tight. If the plunger can’t be removed
in such way, it may have been seized, and the
housing shall be removed to undo and clean the
plunger.
Renewal of oil pressure adjuster (main passage) 461

Lubricating system
After cleaning, check whether any further use is possible.
Caution: If the plunger hole needs to be

washed, remove the housing and
avoid the entry of scraps into the
engine.
1. Use the detergent to thoroughly clean all
parts.
3. Check the plunger and plunger hole

It is acceptable that there is polishing zone on
plunger and plunger hole.
4. Verify whether plunger can move easily in

the hole
Refitting
1. Install the new O-ring on the screw plug
and use the clean oil for lubricating
2. Fit the pressure regulator assembly
462 Renewal of oil pressure adjuster (main passage)

ISLe375 30 engine
Oil cooler
I. Oil cooler

Common tools
Special tool - -
Testing tools Air pressure tester
2. Procedure
Preparatory step
3. Clean the immediate area of engine oil cooler cover.
5. Clean the exhaust manifold with steam and dry it with compressed air.
Removal
1. Remove oil cooler cover, the sealing
gasket and the oil cooler core
Cleaning
1. Clean the sealing surface of cylinder block
and the engine oil cooler cover.
Oil cooler 463

Lubricating system
Leakage test
1. Conduct pressure test on the cooler core
If any leakage is detected, replace the cooler.
Air pressure test
Minimum 449KPa
Maximum 518KPa
Refitting
Caution: Ensure that the shipping plug on
the new engine oil cooler core is
removed.
1. Assemble engine oil cooler sealing gasket,
core and cover.
2. Tighten bolts according to the illustrated

sequence (if no dent on the oil cooler
cover)
3. Finally tighten bolts according to the

illustrated sequence (if no dent on the oil
cooler cover)
The arrow (A) points at the position of pit
Last step
2. Fit oil filter
464 Oil cooler

ISLe375 30 engine

Oil cooler 465

Fuel system
Fuel system
I. General description on the fuel system
1. General
This fuel system is a high pressure common rail
injection system. The fuel rail is used to store the
boosted fuel to be injected. Four components
provide or receive the input of electronic control
module (ECM). When the key switch is gotten
through, ECM supplies electricity for the electric
fuel feed pump (at rear of ECM) for 30 s to ensure
the filling of fuel system. Normally opened fuel
pump actuator receives pulse width modulation
(PWM) signal from ECM to execute OFF/ON
operation, so as to respond the signal from fuel rail
pressure sensor. The fuel injector is fitted with
independent solenoid valveEMC provides
electricity for every injector to provide oil for each
cylinder.
The high pressure fuel pump can be divided into 4

independent assemblies. They are fuel gear pump,
fuel pump actuator housing, camshaft housing and
high-pressure fuel pump head.
The fuel passes through the gear pump and
reaches a 3μm filter on the pressure side. After the
filter on the side of pressure, the fuel enters the
fuel pump actuator housingThe fuel pump actuator
housing includes the air Draining pipe union and
fuel pump actuator. Some fuel returns constantly
via the air bleeding gauge hole union. The
metering fuel enters the end of high-pressure fuel
pump through the fuel actuator, and at this
position, the fuel is boosted to the fuel rail pressure
and then flows out from the high-pressure outlet
pipe union.
The delivery pump is used to fill the gear pump at

the startup. The oil transfer pump will operates for
about 30s after the key switch is connected. Once
the engine is started, the gear pump keeps filling
oil even without the oil delivery pump.
The feed pump and its fuel pipe can only be
accessible after the ECM and ECM cooling plate
are removed. it can be realized by disconnecting
the engine wire and quick-cut fuel pipeThe ECM,
the cooling plate, the feed pump and the feed
pump pipeline can be removed as an assembly
after the removal of ECM cooling plate bolt.
Fuel from gear pump enters 2µm fuel filter. The filtered fuel returns to fuel pump actuator shell.
466 General description on the fuel system

ISLe375 30 engine
The high pressure pump is driven by the engine

camshaft. Gear pump is driven by pump camshaft
through internal coupler.
The two plungers are driven by 3-blade

camshaftThe camshaft is fitted in the camshaft
housing module via the taper roller bearing. The
bearing, tappet, truckle and camshaft of support
camshaft are lubricated by engine oil. These are
only components in pump which are lubricated by
engine oil.
The engine oil is transmitted into the high pressure
pump via the engine gear housing. Oil flow from
engine gear chamber into high pressure pump cam
shell. Seal this passage by the small O-ring at the
recess at the back of engine gear chamber.
The boosted fuel is supplied to the fuel pump

actuator from the gear pumpECM controls the fuel
pump actuator to open/close to keep the suitable
fuel fuel rail pressure.
The air bleeding hole on the fuel pump actuator
housing can be used to Draining the air in the fuel
supply. With the provision of a air bleeding hole
union, part of fuel supplied by the gear pump will
always return into the return pipe.
The metering fuel enters the fuel passage of

high-pressure fuel pump inlet through the fuel
pump actuator, flows through the check valve at
the inlet, presses the plunger down and enters the
fuel booster chamber. When the plunger is pushed
upwards by the camshaft, the fuel rail pressure is
reached and the check valve at the outlet is lifted.
And then the fuel enters into the outlet passage of
fuel pump and flows out of high pressure pipe into
the rail.
General description on the fuel system 467

Fuel system
Fuel system flow chart
1. Oil supply for oil reservoir 12. High pressure fuel pump
2. Fuel cleaner & water separator 13. High pressure pump fuel outlet
3. OEM fuel supply connector 14. High pressure return union
4. Fuel supply ECM installed fuel feed pump 15. Fuel rail
5. ECM cooling plate 16. High pressure injector oil pipeline
6. ECM the installed fuel feed pump 17. High pressure fuel connection
7. ECM installed outlet of fuel feed pump 18. Fuel injector
8. Fuel gear pump 19. Fuel reduction valve
9. Fuel folws from the gear pump to the fuel filter 2. Fuel injector return pipe
10. Primary fuel filter 21. Fuel returns to the fuel tank
11. Fuel inlet through fuel pump actuator
468 General description on the fuel system

ISLe375 30 engine
II. Fuel injector and fuel pipeline – general description

Solenoid-driven injector is used for the high
pressure common rail fuel system. High pressure
fuel flows at the side of injector. When the solenoid
is activated, the internal needle valve is lifted and
the fuel is ejected. The clearance of fuel nozzle is
too small, and the fuel injector is blocked by any
dirt or pollutant
This is the reason why it is very important to clean
the area about fuel joint before repairing fuel
system. Before repairing fuel system, cover the
opened fuel joint.
Caution: To avoid damaging the engine,

always use the correct torque and
tightening sequence of
high-pressure pipe nut.
High pressure fuel flows from the fuel rail into the
injector via injector feed pipe and connecting pipe.
When tightening the fuel connector nut, the fuel
connector shall press the fuel injector body.
Thereafter, connect the injector supply pipe to the
fuel pipe union.
Torque and tightening sequence here is very
important. If the nut or pipe is not tightened, the
sealing surface will fail to be sealed to cause
high-pressure fuel leakage. If the nut is excessively
tightened, the union and injector may be deformed
to give rise to the leakage of high-pressure fuel.
The leakage exists inside cylinder head, and will
not be seen. The error code, low power or starting
failure may occur
If the injector is not fully located prior to the

installation of high-pressure pipe union, the
connection will not be sealed.
The fuel pipe union incorporates a streamline filter
which can smash any small-sized particles
entering into the fuel system.
In the repair process, the provision of any
streamline type filter does not exempt the cleaning
and covering of all fuel system unions.
Confirm that all fuel pipe unions and ports are
covered or masked.
Fuel injector and fuel pipeline – general description 469

Fuel system
All injectors will return the fuel into a common

return hole in the cylinder head. All redundant fuel
will return to the tank via this passage and the
return pipe connected with the cylinder head rear
end. The back pressure valve is located the
connection position for the oil return pipe to the
back of cylinder head.
ECM operates the injector solenoid so as to control
the fuel supply and timing of engine. The electronic
pulse is transmitted to the solenoid so as to lift the
needle vale and start the injector. Via the
electronic injector, the volume and timing are
controlled in a more accurate manner. The
multi-point injection is allowed with the electronic
injector.
Fuel filter
For the engine covered in the manual, it is required
for the OEM to install a 10 µm filter at suction side
before the connector of OEM fuel feed pipe at the
rear of cylinder block. 10µm filter can eliminate
water, and also include water-in-fuel sensor. The
water-in-fuel sensor must be installed. Otherwise,
the fault code alarm indicator lamp will light up.
The engine covered in the manual also has a 2 µm
fuel filter at the pressure side. The pressure side
filter is located downstream from the gear pump,
while upstream from the high-pressure fuel pump
inlet. If there is water in fuel, Draining the water
separator and replace the fuel filter on the
pressure side.
470 Fuel injector and fuel pipeline – general description

ISLe375 30 engine
III. Fuel consumption


Common tools
Special tool - -
Testing tools Balance
2. Procedure
Measure
Caution: Check the fuel consumption, and
the most precise method is to
weigh the consumed fuelWeigh
the fuel tank with the balance with
precision of less than 0. 045. Use a
long-distance fuel tank which
allows the vehicle to run for 80km.
1. Fully fill the fuel tank
1. Weighing fuel tank
2# diesel nominal specific gravity is 0. 844 kg/L.
2. Fit long-distance oil tank (1)

3. Mount the fuel return pipe on the test fuel
tank
Fuel consumption 471

Fuel system
4. Measure the running distance with an

accurate odometer.
5. Run by a certain distance

6. Remove fuel tank and weight the
remaining fuel
7. Calculate the consumed amount of fuel in
liter as required
To calculate the fuel consumption, expressed in
km/L.
Kilometer/Liter=KPL
In addition to metering fuel consumption, the
following factors also have significance on the
tests similar with the approved “SAE 2-catergory
fuel test”.
These procedures are helpful to determine the fuel
consumption difference of two vehicles under
same environment, road and test condition.
8. Use one tested vehicle and one controlled

vehicle in the test.
The control vehicle is used to offset the change of
traffic conditions
The distance between vehicles must be very near,
thus they has the same passing traffic and weather
conditions; however, too near distance may affect
the driving or wind resistance.
472 Fuel consumption

ISLe375 30 engine
9. The test mileage must be 65-80 km
The test rout and the truck weight must not be

changed during the testing.
10. Compare the fuel quantity of test truck with

that of control truck to get all test results
11. Driver the truck after the heater operates

12. Test as much as possible
To obtain:
The difference of time between trial runs must be
within 0. 55. At the speed of at 97 km/h, a
difference of 15s will be caused within 80km
mileage.
The difference between the fuel volumes
consumed by the tested truck during every two
times of test driving must be within the range of
2%, for example: 2. 55 and 2. 60 km/L.
The control on the consumption difference of truck
during each driving is also applicable to the same
range, the differences in traffic conditions and
driving operations may be the difference between
Fuel consumption 473

Fuel system
test driving +2%
To make the test effective, at least 3 satisfying test

driving operations are needed. One test may not
produce reliable results.
Caution: All the tests shall be completed by

an experienced driver and the
vehicle speed must be the typical
representation of working status.
1). Record the following data in the process of

test:
• Ambient temperature
• Humidity
• Atmospheric pressure
• Wind speed
• Wind direction
Caution: Avoid testing under the extreme
operating conditions.
474 Fuel consumption

ISLe375 30 engine
Fuel pump and filter

I. Fuel pump

Common tools
Special tool Fuel pump gear remover
Testing tools - -
Auxiliary material Oil
2. Procedure
Preparatory step
2. Remove fuel pump supply pipe
3. Remove return pipe on fuel pump
4. Disconnect the engine cable harness from the fuel pump actuator
5. Remove fuel pump gear inspection hatch
Before repairing any component of fuel system

such as fuel pipe, fuel pump, fuel injector, etc. ,
clean the area around pipe union, hardware and
component part to be disassembled because the
repair will pollute the fuel system or internal
components of engine before disassembling. If the
immediate area is not cleaned, the fuel system and
engine inside may be contaminated, thus to
damage the fuel system and engine.
Fuel pump 475

Fuel system
Removal
1. Undo bolts (1) and (2) to remove the fuel
pump upper bracket.
2. Ensure that the cylinder No. 1 is located at

the top dead center.
Slowly move the engine, until the scale on fuel
pump gear flushes with the scale on front gear
chamber, thus determining top dead point on 1#
cylinder.
3. Remove fuel pump gear nut & washer

4. Remove fuel injection pump drive gear
Use the fuel pump gear puller to pull the injector
pump drive gear to disengage from the pump
transmission shaft.
5. Remove four mounting nuts fitting fuel

pump onto gear chamber
6. Remove fuel pump
476 Fuel pump

ISLe375 30 engine

1. The fuel pump driven shaft positioning
shaft shall not be cut.
If the positioning pin is cut, replace the cam
housing or fuel pump, and renew the drive gear.
2. Ensure that the O-shaped ring is not

broken or damaged.
3. Ensure that the fuel pump supply pipe
O-shaped ring is not damaged.
Refitting
1. Ensure that the engine cylinder No. 1 is
located at the top dead center.
The fuel ump gear timing mark shall be aligned
with the top dead center on the front cover.
2. Ensure that the engine oil filler gauge hole
(A) and guiding ring (B) O-shaped rings
are correctly fitted.
guiding O-shaped ring.
4. Clean the drive shaft end and fuel pump
inner gear ring with contact cleanser or
equivalent.
5. The oil pump drive gear internal diameter
and propeller shaft external diameter must
be cleaned and dried after installing the
gear
6. Slide the fuel injection pump into the drive
gear, and mount the pump flange on the
mounting stub
7. Ensure that the drive shaft positioning pin
is aligned with the keyway on the fuel
injection pump gear.
Fuel pump 477

Fuel system
8. The assembly sequence:

1). Fit the cylinder (1) bolt and install bolt into the
supporing bracket and through the pump
flange
2). Pass through pump flange (2) to tighten bolts.
3). Tighten the bolt inside the cylinder head (1)
9. Tighten the nut of drive gear of fuel

injection pump
Last step
battery negative (-) cable.
1. Install the access cover on the front cover
2. Mount the fuel supply pipe on the fuel
pump
3. Mount the fuel supply pipe with the fuel pump

4. Install the conducting wire with the furl pump actuator
478 Fuel pump

ISLe375 30 engine
II. Renewal of fuel pump gear pump


Common tools
Special tool Ml0 × 1. 5 Compuchek pipe union
Testing tools Pressure gauge
2. Procedure
Initial inspection
Gear pump shaft has two sealings. Oil in the first
layer of sealed fuel pump camshaft housing; fuel in
the second layer of sealed gear pump. If two layers
of seals are disabled, the leakage may occur in the
weep hole. The leakage hole is inside (towards the
engine cylinder block), and near the mounting
flange of gear pump
Gear pump gasket can seal the oil at interface of
gear pump & camshaft shell.
1. Measure the gear pump pressure when the

engine is at cranking state (it is very useful
when the engine fails to start.).
2. Mount the pressure gauge on the engine
fuel filter seat (Ml0 x 1. 5 Compuchek
union)
3. Monitor the gear pump pressure in the
motoring operation.
1). Gear pump pressure in the motoring
operation: 69kpa (minimum)
2). If the gear pump pressure is lower than 69kPa
in the motoring operation, verify that the
starting speed of engine is no lower than
150rpm. The delivery pump pressure shall be
at least kept at 35kPa in the motoring
operation.
Renewal of fuel pump gear pump 479

Fuel system
4. Measure the pressure of gear pump under

the rated condition
1). Mount the Ml0 x 1. 5 Compuchek pipe union
on the diagnosis end of fuel filter seat outlet
2). Use a quick-break union and two 1/8in. NPT
Compucheck pipe unions to constitute a
T-shaped adapter pipe union.
3). Mount a diagnosis fuel pipe with the length of
0. 043 inch on fuel filter seat outlet. Have the
fuel hose return to the fuel tank.
4). Mount the press gauge with a range of
0-1034kPa on the T-shaped adapter union.
5. Run the engine at high idle speed.

6. Observe the gear pump pressure
• Minimum gear pump pressure: 483 kPa
If the gear pump pressure is low, check whether
the inlet vacuum is too high.
Preparatory step

death.
Warning: Do not bleed the fuel system when the engine is hot, or, the fuel may splash onto the
exhaust manifold to cause the fire.
2. Remove the fuel, engine oil and scraps in the gear pump.
3. Remove gear pump supply pipe
480 Renewal of fuel pump gear pump

ISLe375 30 engine
Warning: Wear suitable goggles and face

mask in the operation of
compressed air. Flying crumb and
dirt can cause human injury.
Warning: In the use of steam cleaner, wear
safety glasses or face mask, and
protecting clothes. Hot steam may
cause serious personal injuries.
Caution: Clean all the pipe connectors before disassemblyThe dirt or impurity may damage
the fuel system.
Before repairing any component of fuel system such as fuel pipe, fuel pump, fuel injector, etc. , clean the
area around pipe union, hardware and component part to be disassembled because the repair will
pollute the fuel system or internal components of engine before disassembling. If the immediate area is
not cleaned, the fuel system and engine inside may be contaminated, thus to damage the fuel system
and engine.
Removal
1. Remove 4 bolts fixing the gear onto the
fuel pump
2. Remove drive coupling (if the drive
coupling is always connected to the rear
part of fuel pump camshaft)
3. Remove sealing gasket for the gear pump

use is possible.
1. Check whether the drive coupling is worn
If worn, replace the transmission coupler.
Renewal of fuel pump gear pump 481

Fuel system
Refitting
1. Install the drive coupling on the back of
high-pressure pump camshaft
2. Insert the mounting bolt into the gear
pump flange
3. Mount the new gasket on the bolt
4. Fit gear pump
Engage the gear pump input shaft with the
transmission coupler, and then fit the gear pump.
5. Fit and tighten 4 gear pump bolts
Last step

482 Renewal of fuel pump gear pump

ISLe375 30 engine
III. Timing of fuel pip


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
Warning: The battery may give off explosive gas. To minimize personal injuries, keep the
engine compartment well-ventilated prior to the repairs of battery. To avoid the
generation of electric arcs, firstly remove and finally refit the battery negative (-)
cable.
3. Remove fuel pump camshaft nut
Warning: Wear suitable goggles and face

mask in the operation of
compressed air. Flying crumb and
dirt can cause human injury.
Warning: In the use of steam cleaner, wear
safety glasses or face mask, and
protecting clothes. Hot steam may
cause serious personal injuries.
Caution: Clean all the pipe connectors
before disassemblyThe dirt or
impurity may damage the fuel
system.
Before repairing any component of fuel system such as fuel pipe, fuel pump, fuel injector, etc. , clean the
area around pipe union, hardware and component part to be disassembled because the repair will
pollute the fuel system or internal components of engine before disassembling. If the immediate area is
not cleaned, the fuel system and engine inside may be contaminated, thus to damage the fuel system
and engine.
Timing of fuel pip 483

Fuel system

1. Check whether the fuel pump camshaft
locating pin is in the drive gear key slot of
fuel pump
If the positioning pin is invisible, remove the
injector pump and find out the cause of angle error,
and repair or renew any damaged member.
• Fuel pump gear small keyway
• Positioning pin for fuel pipe timing
• Fuel pump camshaft
• Fuel gear pump
If this check is conducted due to

performance-related problems and failures firstly
occur after the gear system is removed and
replaced, check the timing between the camshaft
gear and crankshaft gear and that between the
camshaft gear and the fuel pump drive gear.
Last step

2. Fit and tighten fuel injection pump camshaft nut
3. Fit front gear chamber cover
484 Timing of fuel pip

ISLe375 30 engine
IV. Renewal of delivery pump


Common tools
Special tool - -
2. Procedure
Initial inspection
Faulty electric fuel feed pump may cause slow
engine start or failure to start. Clean and repair the
fuel supply pump in the limit range
The feed pump can operate for 30s to 60s after the
key switch is connected. The feed pump can
operate when the engine is dragged.
The delivery pump is fitted on the backside of ECM

cooling board.
The bypass check valve in the ECM cooling plate
ensures that the feed pump fill the system. . Once
the engine is started, this check valve will be
started with the vacuum in the gear pump. The
high vacuum measured between electric oil
transfer pump and gear pump may show the check
valve has been blocked.
The EMC cooling plate check valve and the
cooling plate lower piper union (outlet) is as a
whole part.
Renewal of delivery pump 485

Fuel system
Check working conditions of fuel delivery pump via

following tests:
1. Use the pipe union to fit the repair tool at
the high-pressure pump gear pump inlet.
1. Measure the output pressure of feed pump
Caution: Quick connector passing through
fuel pump inlet must be replaced
by pipe union, so as to bring
service tool 4918324.
2. Turn on the key switch

3. Use the pressure gauge to measure the
fuel delivery pump pressure at the gear
pump inlet.
Caution: The feed pump will operate for 30
seconds and then stops after the
key switch is turned on at the first
time.
• Minimum pressure: 34 kPa
If the fuel supply pump has a low pressure in the
operation, ensure that the ECM cooling board
check valve is not seized at the “ON” position.
If the fuel supply pump has a low pressure in the operation, ensure that the fuel is filled. For example,
after the fuel filter is replaced, it is required to run the fuel supply pump repeatedly for 3 to 4 times to
Draining the air
Preparatory step
2. Disconnect electrical fuel filling pump from engine cable harness
Caution: Before disassembling, thoroughly clean all the pipe unions and components.
Ensure that no scraps, water, steam or detergent enters into the fuel system.
3. Remove fuel feed pipeline
4. Remove ECM cooling plate
Removal
1. Remove electric feed pump from ECM
cooling plate
486 Renewal of delivery pump

ISLe375 30 engine
Refitting
1. Mount the electric fuel supply pump on the
ECM cooling panel
Caution: There must be no chipping on the
ECM cooling plate single valve
and the check valve must be
installed on the end (outlet end);
fix the fuel pipe as illustrated by
the figure and in that case, they
can not touch each other or the
engine cylinder body.
Last step
1. Mount the ECM cooling panel on the engine block
2. Fit all the fuel feed pipes
Renewal of delivery pump 487

Fuel system
V Renewal of electric fuel heater


Common tools
Special tool - -
Testing tools Multimeter
2. Procedure
Initial inspection
The fuel heater is an optional device fitted on the
fuel filter seat. It is fixed onto the filter seat via the
threaded filter pin.
Caution: The fuel heater is beyond the
control by the electronic control
module (ECM). The dual-metal
switch on the filter seat is used as
a thermostatThe fuel heater will be
activated at about 1°C and
deactivated at about 18°C.
Record the switch as disconnection at 18℃above,
and record the connection at 1℃ below.
1. Remove the 2-pin connector from the fuel

heater
2. Check whether the voltage of input fuel
heater is correct
Caution: When the key switch is switched
on, the minimum voltage is 2 VDC
(A separate 24V heater is adopted
on the vehicle with 24V charging
system).
If the voltage doesn’t meet technical requirements,
please refer to OEM failure diagnosis and solution
manual.
Preparatory step
2. Disconnect OEM power connection from the fuel heater
3. Disconnect the engine cable harness connector from the water-in-fuel sensor
4. Draining small quantity of fuel from the filter drain pipe
5. Remove rotary fuel cleaner
488 Renewal of electric fuel heater

ISLe375 30 engine
6. Clean the pipe union and the immediate area for parts to be fitted or removed.
Removal
1. Remove filter thread pin & fuel heater
Refitting
1. Mount a new sealing gasket on fuel heater.
2. Place the fuel heater on the filter seat with
the gasket upward, and electrical
connector opposite to the engine block
3. On filter pin screw thread, apply the screw

thread locking adhesive on the screw
thread engaged with filter seat.
4. Fit the fuel filter pin
Last step
1. Fit fuel filter
2. Connect the fuel heater
3. Connect the water-in-fuel sensor
Renewal of electric fuel heater 489

Fuel system
VI Renewal of fuel pump actuator housing


Common tools
Special tool - -
Testing tools - -
Auxiliary material Contact point cleaning agent
2. Procedure
Preparatory step
1. Disconnect the cable and cable harness from the fuel pump actuator
2. Disconnect the feed pipe from the fuel pump actuator housing
3. Disconnect the high pressure pipe from the fuel pump actuator housing
4. Disconnect the return pipe from the fuel pump actuator housing
Removal
1. Remove 3 bolts fixing the fuel pump
actuator shell on the high pressure fuel
pump head
2. Remove fuel pump actuator shell & gasket

use is possible.
1. Check the fuel pump actuator casing
gasket
If the gasket is damaged, cracked or torn, never
use it again.
2. Use the contact detergent to clean the
high-pressure pump head and fuel control
valve adapter.
Ensure that the mounting surface of high-pressure
pump head and the fuel control valve adapter is
clean.
490 Renewal of fuel pump actuator housing

ISLe375 30 engine
Refitting
1. Insert the three mounting bolts into the
fuel pump actuator housing
2. Mount the gasket on the bolt
The sealing gasket must be kept dry when
assembly.
3. Fit actuator housing
5. Installation of upper bracket
1). Pass through fuel pump actuator shell, and fit
bolts onto upper support bracket (loosened)
2). Pass through upper support bracket, and fit bolts onto cylinder head (loosened)
3). Tighten two bolts
Last step
1. Connect the high-pressure fuel pipe with the fuel pump
2. Connect the fuel supply pipe with the fuel pump
3. Connect the fuel return pipe with the fuel pump
4. Install the conducting wire with the furl pump actuator
Renewal of fuel pump actuator housing 491

Fuel system
VII Renewal of fuel filter (rotary type)


Common tools
Special tool M10 Compuchek pipe union
2. Procedure
Measure
Measure the pressure drop via the fuel filter in
accordance with the following procedures to check
the resistance of fuel filter.
Caution: Mark the fuel inlet/outlet on fuel
filter seat with character or arrow.
It is unnecessary to indicate the
real-life direction of fuel filter inlet
or outlet in the drawing.
1. Mount a M10 Compuchek pipe union on diagnosis port at the side of fuel filter inlet.
Caution: It may be needed to loosen the mounting bolt of fuel filter seat so as to make the test
port attached to Compuchek pipe union in the center
2. To run the engine at high idle speed;

3. Record the fuel pressure at the fuel filter
inlet and outlet
4. Reduce the outlet reading by inlet degree
to determine the resistance
Max. pressure drop at both ends of fuel filter
Maximum 138KPa
If the pressure drop exceeds the required value, replace the fuel filter.
5. Remove Compuchek union
6. Install the screw plug on the diagnosis port
Preparatory step
492 Renewal of fuel filter (rotary type)

ISLe375 30 engine
Removal
1. Disconnect the cable and cable harness
from the water-in-fuel sensor (if equipped)
from the fuel heater (if equipped)
3. Undo and remove the fuel filter.
4. Ensure that the seal ring is not seized in
the filter seat.
. If necessary, use the special tool to remove the
O-shaped ring.
Refitting
1. Fill the fuel into the 10μm dewatering fuel
filter (absorption side).
Do not fill the 3 micrometer (pressure side) fuel
filter but use the feed pump to fill up the fuel
system.
2. Ensure that the central seal ring is fitted on
the filter positioning pin.
3. Fit filter according to the manufacturer’s
requirements
If fitted, connect the water-in-fuel sensor and the fuel heater.

4. It is allowed to check whether a correct water-in-fuel sensor is fitted via the fuel system.
If the water-in-fuel sensor is disabled or disconnected, the engine warning lamp will be lit.
Normal load
Warning: Do not open the high-pressure
fuel system with the engine
running. High fuel pressure
occurs when the engine is in
operation. Any ejected high
pressure fuel may cause serious
injury or even death.
Renewal of fuel filter (rotary type) 493

Fuel system
2. Open and close repeatedly the key switch

to make the feed pump operate
3. Run the delivery pump for 30s.
4. Turn off the key switch, and then turn on it
again to allow the feed pump to operate
again
Prior to the startup of engine, run the fuel delivery
pump for three or four 30s cycles.
Last step
1. Start of engine
1. Increase slowly the engine speed when the air Drainings from the fuel tank
494 Renewal of fuel filter (rotary type)

ISLe375 30 engine
VIII Renewal of fuel filter seat


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Remove fuel filter
3. Disconnect the feed pipe and return pipe union
Removal
1. Remove mounting bracket for the lower
fuel filter seat
Disassemble
1. Remove fuel heater (if equipped)
Renewal of fuel filter seat 495

Fuel system

1. Check whether the fuel filter seat is
cracked, the passage is blocked and the
sealing surface has any dirt or scrap
Assemble
1. Apply only the thread sealant or equivalent
on filter adapter screw thread engaged
with fuel filter seat.
Caution: Ensure that an O-shaped ring is
provided between the fuel filter
and the heater.
Refitting
1. Fit the fuel filter seat
2. Tighten the fixing nut
Last step
1. Connect the fuel supply pipe and return pipe
2. Fit fuel filter
496 Renewal of fuel filter seat

ISLe375 30 engine
IX Fuel filter seat bracket


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Remove fuel filter
3. Remove the fuel feed pipe from the filter retainer
4. Remove fuel filter seat
Removal
1. Remove cleaner bracket from engine

fuel filter seat bracket
Fuel filter seat bracket 497

Fuel system
Refitting
1. Fit filter bracket
2. Tighten the fixing nut
Last step
1. Fit the fuel filter seat
2. Fit fuel filter
498 Fuel filter seat bracket

ISLe375 30 engine
Pipe with union and the fuel tank

I. Renewal of fuel pump head outlet pipe union

Wire brush
Special tool - -
Testing tools - -
Auxiliary material Steam, compressed air, contact cleanser
2. Procedure
Preparatory step
Warning: Do not bleed the fuel system when the engine is hot, or, the fuel may splash onto the
exhaust manifold to cause the fire.
Caution: When disconnecting or disassembling fuel pipe, replacing filter and filling fuel to
fuel system, be careful not to let the fuel overflow or Draining the fuel to cabin. Do
not let the filter element drop out or throw it in the cabin. The used fuel and the fuel
filters must be scrapped according to the local environmental laws.
2. Thoroughly clean the fuel pump with steam.
3. Blow-dry the fuel pump with compressed air.
4. Turn off the fuel supply valve.
5. Remove the high pressure pipe from the fuel pump actuator housing
6. Remove the return pipe from the actuator housing
7. Remove the feed pipe from the fuel pump actuator housing
8. Remove fuel pump actuator shell from high pressure fuel pump
Renewal of fuel pump head outlet pipe union 499

Fuel system
Removal
1. Remove fuel pump outlet pipe union &
gasket from thread hole on back of high
pressure pump head
Caution: The sealing washer must be
removed with a conical punch.
Insert the taped punch head into
the center of washer, and make
the washer out from the hole on
the back of high-pressure pump
head

use is possible.
1. Use the contact detergent or its equivalent
to clean the threaded hole in the
high-pressure pump head.
2. Check whether the threads and cavities of
high-pressure pump head have any burr or
scraping.
3. Check the seal washer of outlet union.
4. Check whether the top has any score or
dirt
If the crown is damaged or flattened, replace the
external threaded pipe union.
5. Use the steel wire brush to remove all
burrs.
6. Wash the pipe hole clean
Refitting
Caution: The designed sealing capability of
this joint is above 179,264 kPa. Do
not continue to use the sealing
washer.
1. Mount the new washer on the outlet pipe
union
The washer shall be placed in the outlet pipe union
as per correct directionUse a little of clean grease,
for example, mounting grease, to help to adhere
the seal into the outlet pipe union.
Tightening torque 13. 6 N·m
Rotate by 90°.
Last step
1. Mount the fuel pump actuator housing on the high-pressure fuel pump
2. Mount the high-pressure fuel pipe on the fuel pump actuator casing
500 Renewal of fuel pump head outlet pipe union

ISLe375 30 engine
3. Mount the fuel return pipe on the actuator housing

4. Mount the fuel supply pipe on the fuel pump actuator housing
5. Open the fuel feed valve
Renewal of fuel pump head outlet pipe union 501

Fuel system
II. Renewal of fuel pump head


Common tools
Special tool Fault diagnostic instrument
Testing tools Hollow flow adapter union
2. Procedure
Initial inspection
Warning: Fuel flammability depends on the
environment. During inspection or
maintenance or repair of fuel
system, smoking or use of open
flame (e. g. identification lamp,
electrical switch or welding
equipment) in the working area is
forbidden in order to reduce
potential fire and serious human
injury or death or property loss.
The test adopts the union for the flow adapter. The
flow adapter union is only used to guide the return
fuel of fuel pump to the collector so as to monitor
the leakage
Test configuration
1. Remove hollow bolt on the fuel return pipe
of fuel pump for the fuel return manifold
2. Install the hollow adapter union on the fuel
return manifold
3. Lead a hose from adapter to a barrel or
vehicle fuel tank.
4. Connect the pump return pipe to the
central connection point of fuel return
manifold
502 Renewal of fuel pump head

ISLe375 30 engine
Alternative test configuration

If it is hard to approach the return manifold,
connect a M14 hollow union onto the pump head
return port, and fit a fuel hose onto this union to
guide the fuel into the collecting vessel.
In this configuration, a bolt, nut and washer are
required to returned oil back flowing and leaking
out of unused oil return pipe.
Caution: The high pressure leakage test by

the fault diagnostic instrument will
improve the working pressure of
engine which runs with an idle
speed. If the fuel injection
pressure is higher during this test,
the sound of engine will
changeWear the safety glass
when being close to the running
engineNever adjust the fuel pipe
during this test
In this test, close the engine hood.
Test (without starting the engine)

1. Rotate the key switch to “ON” position
1. Have the fuel delivery pump fulfill this
cycle.
1. Start to drag the engine
1. Till the fuel flows out of oil return pipe.
2. Guide the return oil into the graduated
flask and drag the engine for 30s
Max. fuel volume in motoring operation
30 s 200cc
If the fuel flow reaches 200CC within 30s at the

startup, the pump head is disabled and shall be
replaced.
Renewal of fuel pump head 503

Fuel system
Test (with the engine started)

If the engine is started, use Cummins failure
diagnoser software to carry out the high-pressure
leakage test.
1. Connect the fault diagnosis device
2. Start the engine
3. Keep the engine idling
4. Have the fuel flow into the collector.
5. Use the failure diagnoser to conduct the
high-pressure leakage test.
6. Measure the time for 300 cc fuel to flow out
of fuel return pipe at the head of fuel pump
7. Use a graduated cylinder when measuring
Maximum fuel quantity for the high pressure

leakage test
30 s 300cc
If the fuel flow of pump head within 30s exceeds

300cc, the pump head is in trouble and must be
replaced.
This technical specification is for diesel engine.
The leakage rate will rise if the fuel viscosity is low;
for example, excessive leakage of kerosene or
aviation fuel. Make sure to verify the fuel type
before renewing the excessively leaky fuel pump
head.
Preparatory step
2. Close the feed valve and return valve
3. Remove high pressure fuel pipeline from high pressure pump
4. Remove return pipe on fuel pump actuator shell
5. Remove the feed pipe from the fuel pump actuator housing
6. Disconnect the cable and cable harness from the fuel pump actuator
7. Remove fuel pump actuator shell

ISLe375 30 engine
Removal
1. Remove fuel pump drive gear cap
2. Determine the top dead center of cylinder
No. 1.
Slowly move the engine, until the scale on pump
gear flushes with the scale on front gear chamber,
thus determining top dead point on 1# cylinder.
3. Remove two final bolts

Alternatively loosen the bolts to avoid
jammingEvery time loosen each bolt by about one
circle
4. Remove fuel pump head
Pull up the fuel pump head from the camshaft
housing carefully, and note the connection
between the tappet spring and pump head;
thereafter, put the pump head on a clean surface.

use is possible.
1. Remove spring and spring seat of plunger
seat
2. Make a mark.
Distinguish front and rear springs. The same
mounting sequence is proposed for those parts
although the new high-pressure pump head is
installed
Caution: Do not remove plunger sleeve

seat. Otherwise, the pump head
and plunger sleeve seat can be
damaged.

Fuel system
If the plunger is fully pressed upward, the liquid

above the plunger and the inlet check valve seal
will fix it in place.
If these parts are removed, pay special attention to
keep them absolutely clean. When removing pump
head, use a clean towel to cover the camshaft.
Do not adopt the cleanser other than contact
cleanser at pump parts.
Caution: Each plunger must be installed in

the original plunger sleeve along
the original direction; otherwise,
the engine may be damagedMark
the plunger at its bottom for
correctly positioning purpose.
If the plunger is removed, check it. Even minor
fading is noticeable. There must not be visible
deep scrapes. If any pull or scratch is felt, the fuel
pump head must be replaced.
1. After removing fuel head

2. Check the camshaft casing
The tappet can be removed with the O-shaped ring
remover.
3. Check whether the tappet guide pin and its

slot are worn excessively
If the guide pin or groove is worn by 25%, replace
the fuel pump.

ISLe375 30 engine
4. After removing cam shell tappet

5. Check whether the camshaft is worn
If any excessive cavitation is found on the
camshaft tip, replace the fuel pump.
6. Check whether the tappet roller is worn

If excessive cavitation is found on the roller,
replace the tappet.
7. Check whether the camshaft, tappet or

camshaft casing is damaged
If damaged, the fuel pump may have an insufficient
supply.
8. During the renewal of fuel pump
9. Check the gear chamber to ensure that the
fuel supply of fuel pump is not blocked.
Refitting
1. Mount the tappet into the original tappet
hole
2. Ensure that the tappet is fitted at the
original position.
3. Ensure that the tappet guiding pin is
engaged with its groove.

Fuel system
4. Mount the new O-ring of fuel pump head

on the camshaft casing
5. Fit new lifter spring and seat ring provided
with the bump head at the same time
6. Place the high-pressure pump head on the
high-pressure pump camshaft casing
7. Alternatively tighten the four
high-pressure pump holder bolts till the
pump head touches the camshaft casing to
press down the high-pressure pump head
8. Tighten four high-pressure pump head
bolts to the final torque
Last step
1. Fit fuel pump actuator housing
2. Connect the fuel supply pipe of high-pressure fuel
3. Connect the fuel supply pipe on the fuel pump actuator housing
4. Connect the fuel supply pipe on the fuel pump actuator housing
5. Open the fuel feed valve and drain valve
6. Connect the engine wires with the fuel pump actuator

ISLe375 30 engine
III. Air-in-fuel.

Common tools
Compucheck pipe union, 1. 09mm fuel diagnosis fuel pipe, container of 19

Special tool
liters
Testing tools - -
2. Procedure
Setting
Include a 1. 09mm diagnosis fuel pipe passing
through metering.
0. 043 in. bore diagnosis fuel pipe is used to
produce the rated flow passing through low
pressure fuel system, and the engine can work
without load.
Obtain one vessel (a 19L vessel is recommended)
suitable to collect the fuel from the diagnosis fuel
pipe.
Measure
Caution: The water in fuel of engine fitted
with common rail fuel system is
represented by the change of fuel
system pressure (because there is
air in fuel) and the audible
wobbling.
The testing method below can simulate the rated
fuel flow in the simulation system, so as to
investigate the air in fuel.
1. Mount the Compuchek pipe union on the 2
micron fuel filter inlet
1. Connect the 1. 09mm diagnosis fuel pipe
Air-in-fuel. 509
Fuel system
1. Place the 0. 043″diagnosis fuel pipe outlet

in the container with proper size (19L
barrel is recommended)
Start the engine, and run it from idle speed to high
speed for several times to eliminate the air
entering at the fitting of diagnosis fuel pipe.
1. Observe the fuel flow out of diagnostic fuel

pipe when the engine runs with an idle
speed
Little bubble inside pipeline is normal. The
appearance of bubbles indicates that there is
leakage due to the air ingress, which gives rises to
extremely high inlet resistance for cavitation, or
that the system is not filled with fuel. If the fuel inlet
resistance is not high, prevent the air from entering
into following components:
· Fuel suction pipe
· ECM cooling plate assembly
· OEM fuel pipe
· Fuel cleaner holder on suction side
· Vertical pipe in fuel tank.
Last step
1. Remove all the fuel pipes
510 Air-in-fuel.
ISLe375 30 engine
IV. Renewal of fuel-cooled ECM cooling board


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
ECM cooling plate system provides a vibration isolation mounting position. The cooling plate also cools
the ECM, including the fuel supply pumpThe check valve on the ECM cooling outlet end ensures that the
oil has beem filled in fuel system when the fuel feed bump runs.
1. Check whether the ECM cooling panel has damaged damping gasket, loose bolt or leaked
fuel.
2. Ensure that the earthing bus is correctly

fitted.
1). The intermittent engine performance failure
may be caused if the grounding bus wire is
missing or not connected properly
2). The grounding bus wire must be connected
between ECM mounting bolt head and ECM
3). The grounding bus wire must be connected to
the unpainted and un-corrosive surface of
cylinder block
Preparatory step
2. Disconnect harness connector from ECM
3. Disconnect ECM ground bus
4. Disconnect engine harness from electric fuel filling pump
5. Disconnect the feed pipe
6. Remove ECM from the cooling plate
Renewal of fuel-cooled ECM cooling board 511

Fuel system
Removal
1. Remove ECM cooling plate bolts &ECM
cooling plate from engine cylinder block
Caution: The electric fuel filling pump and
its fuel pipe should be connected
onto the ECM cooling plate during
the removal of cooling plate.
Disassemble
2. Remove positive hollow quick joint,
positive hollow one-way valve joint, fuel
pump supply pipe, fuel pump bracket and
fuel pump from ECM cooling plate

1. Check whether the ECM cooling panel has
leakage (notice the fuel passage, including
the cast pipe on the cooling panel)
2. Renew all damaged insulation
3. Check whether the filling circuit of electric
fuel supply pump has leakage
4. Check for any cracked fuel pipe, damaged
O-ring or sealing washer
5. Check whether the check valve has
scrapings or is damaged.
Assemble
1. Fit the electic fuel filling pump and fill the
fuel pipe
Ensure that the pipe is supported firmly when
tightening the banjo screw. Fuel pipes shall not be
bent.
2. Ensure that the ECM check valve is fitted
on the pipe union of ECM cooling plate
bottom (outlet).
512 Renewal of fuel-cooled ECM cooling board

ISLe375 30 engine
Refitting
1. Mount the ECM cooling panel assembly on
the engine block
Last step
Tightening torque Ensure that the shock-absorbing pad is correctly fitted, which can
be only fitted into the chamfer positioner only one direction.
1. Mount ECM on the ECM cooling panel
2. Connect the fuel supply pipe
3. Connect the engine wires with the electric fuel filling pump
4. Connect the ECM grounding bus wire
5. Connect the wire connector with ECM
7. Open and close repeatedly the key switch to make the feed pump operate
8. Run the delivery pump for 30s.
9. Turn off the key switch, and then turn on it again to allow the feed pump to operate again
10. Have the fuel delivery pump fulfill three or four 30s cycles.
Renewal of fuel-cooled ECM cooling board 513

Fuel system
V. Measured resistance of fuel return hose


Common tools
Special tool Compucheck pipe union
Testing tools Hollow pressure gauge adapter
2. Procedure
Preparatory step
Obtain one M12 hollow pressure gauge adapter.
The hollow pressure gauge adapter can be used to
measure the pressure or vacuum at any point of
low-pressure fuel system, and the fuel pipe is
provided with hollow bolt
M12×1. 5 banjo bolt connector is used for the
engine. The tool, 4918413 can be used to measure
the resistance (pressure) of oil return pipe on the
fuel return manifold
1. Assemble hollow pressure gauge adapter.

1). Mount the Compuchek pipe union or other
union with the hexagonal surface of hollow
bolt
2). Connect the hose or pressure gauge with the
hollow pressure adapter
3). Install the M12 hollow pressure gauge adapter

on the hollow bolt of injection return pipe of
fuel return manifold
4). Install the pressure gauge of 0~762mm Hg on
the M12 hollow pressure gauge adapter
514 Measured resistance of fuel return hose

ISLe375 30 engine
Measure
1. Run the engine at rated speed and zero
load.
2. Observe the reading of pressure gauge
Maximum pressure of fuel return pipe
Maximum 254mm Hg
If the return pipe pressure exceeds the required

value, check whether the pipe is bent or twisted.
Check the OEM fuel pipe for the part that may be
flattened by the cable tie or P clamp. Check
whether the fuel tank exhaust port is blocked
Last step
1. Remove all test unions
2. Fit the return pipe
Measured resistance of fuel return hose 515

Fuel system
VI. Renewal of fuel return hose


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Check whether the oil return pipe has any
leakage, crack, scrape or is loose, or the
bracket is broken
Preparatory step
Removal
There are three return pipes on the engine:
1). Connect the fuel pump return pipe with the
pump and return manifold.
2). The fuel rail relief valve return pipe is
connected with the relief valve and return
manifold.
3). Rear part of connecting cylinder head of fuel
injector return pipe and fuel return manifold
1. Remove hollow bolt and the sealing
washer
1. Remove three return pipes
516 Renewal of fuel return hose

ISLe375 30 engine

1. Check whether the pipeline is damaged
2. Check whether the hollow washer is
damaged
Refitting
1. Mount three oil return pipes on the engine
· Oil return of high pressure fuel pump:
Fit p-type clamp bracket.
Mount hole bolt on fuel return manifold.
Mount hole bolt on fuel pump
· Oil return pipe of fuel reduction valve:
Mount hole bolt on fuel return manifold.
Mount hole bolt on pressure reducing valve. Fix the pipeline to avoid distortion and wear due to friction
with the bottom of cylinder head.
· Injector’s oil return pipe.
Tightening torque M12 banjo bolt 24N. m
Tightening torque M16 holloe bolt 43 N·m
Tightening torque P-type clamping bolt 24N·m
Last step
Renewal of fuel return hose 517

Fuel system
VII. Measured resistance at the fuel inlet


Common tools
Special tool 1. 09mm fuel pipe, 20L container, M10 Compuchek union
Testing tools Pressure gauge adaptor, 0-762mm vacuum gauge
Auxiliary material Steam
2. Procedure
Preparatory step
1. Include a 1. 09mm diagnosis fuel pipe passing through metering
2. Obtain one vessel suitable to collect the fuel from the diagnosis fuel pipe.
The shaft with a capacity of 20L is recommended
3. Use the fuel pipe union to fit one pressure

gauge adaptor onto the gear pump inlet.
Caution: Quick connector passing through
fuel pump inlet must be replaced
by fuel union so as to bring
pressure gauge into use.
4. Install the M10 Compuchek pipe union on
the fuel filter seat
5. Connect the 1. 09mm diagnosis fuel pipe
with the fuel filter seat Compuchek pipe
union
6. Place this hose in the collector or oil tank
Caution: It is necessary to connect 1. 09mm measuring and diagnostic fuel pipe to make the
fuel pump reach its rated flow rate. If the nominal flow is not reached, the test result
may be incorrect
7. Install the pressure gauge of 0~762mm Hg on the M12 hollow pressure gauge adapter
8. Mount a M10 Compuchek pipe union at OEM oil feed joint.
9. Mount a 0~762mmHg vacuum gauge at OEM oil feed joint.
518 Measured resistance at the fuel inlet

ISLe375 30 engine
Measure
1. Run the engine at idle speed.
2. Measure the inlet vacuum
Maximum fuel resistance
On OEM joint (dirty filter),

mm-Hg
loading state
203. 2
On fuel pump gear inlet (dirty

304. 8
filter), loading state
If the inlet resistance is high, investigate the

causes.
The fuel filter on the absorption side is clogged.
The fuel heater valve is clogged.
ECM cooling plate plug
ECM cooling plate single direction valve plug
OEM fuel pipe is depressed or plugged
The vertical pipe of fuel tank is clogged.
Last step
1. Disconnect all the diagnostic test pipe unions
2. Fit the removed parts during test period
Measured resistance at the fuel inlet 519

Fuel system
VIII. Renewal of fuel supply pipe


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Check all the fuel supply pipes and unions
Find out the pipe crack or pipe union with leakage.
2. Check the quick-release pipe union for the
damaged O-ring or broken lock plate
Preparatory step
2. Clean the pipe union and the immediate

area for parts to be fitted or removed.
Removal
1. Remove the clamp from the fuel pipe
carrier
For fast-acting fuel pipe, remove the clamp from
the pipe bracket. This makes pipe movable for the
convenience of disconnection.
520 Renewal of fuel supply pipe

ISLe375 30 engine
2. Loosen all fast-acting tubes from the

carrier
3. Remove gear pump outlet pipe
4. Remove gear pump outlet pipe
5. Remove quick fuel pipe

To facilitate the removal, insert the screwdriver into
the space between the fuel pipe end and
quick-break external threaded pipe. After pushing
down the lock plates at two sides, rotate the flat
head of screwdriver to disassemble fuel pipe.
6. Remove fuel hose or quick release union

(if it is suspected that fuel has leakage or
air enters on suction side)

1. Check whether the metal connecting has
any burr or scraping that may result in
leakage
2. Ensure that the quick-break pipe union
O-shaped ring is not worn or cut and that
its lock tongue is not damaged.
Renewal of fuel supply pipe 521

Fuel system
Refitting
1. Fit quick break pipe union
2. Fit quick break pipe union
3. Ensure that the quick-break fuel pipe is
fastened on the pipe union.
4. Ensure that the pipeline is correctly
arranged and connected.
If the pipeline is incorrectly connected, the engine
will not run.
5. Arrange fuel pipes in the following sequence:

1. OEM joint through ECM cooling plate upper union
2. Lower ECM cooling plate joint through upper gear pump union
3. The gear pump is connected to the fuel filter intake of 2 microns.
4. The outlet of fuel filter of 2 microns to the control actuator housing of fuel pump.
6. Fix the fuel pipes onto the carrier in following sequence:
1. Internal pipeline connects gear pump upper union and ECM cooling plate lower union.
2. Middle pipeline connects 2 µm cleaner outlet and fuel pump control actuator shell
3. External pipeline connect the lower union under the pliers with gears and the filter intake of 2 microns.
. If necessary, fit the fuel pipe carrier hoop (only limited to the quick-break fuel pipe) and carrier.
Tightening torque Fuel pipe carrier 24 N·m
Tightening torque Fuel pipe carrier clip 24 N·m
Last step
522 Renewal of fuel supply pipe

ISLe375 30 engine
Fuel injector and supply pipe

I. Fuel injector

Common tools
wrenches S16S18/S22/S24, clean cloth
Special tool - -
Testing tools - -
Auxiliary material Safety solvent
2. Procedure
Initial inspection
Cummins common-rail fuel system
Caution: if the hollow adapter is installed outside the fuel return manifold, the components of
high-pressure fuel system may be damaged
Return fuel comes back by way of three different

pipes in injector, fuel rail reducing valve and fuel
pump head.
The fuel return hose needs to be used during the
measurement of leakage of injector.
This tool is used for isolating injector leakage, so
that it can flow into the drum for easy
measurement.
. If necessary, fabricate this tool as per following

procedures.
1. Make a hole bolt flow adapter tool.
Drill and tap on the hexagon surface of M12X1. 5
hole bolt or equivalent to make a hole bolt flow
adaptor tool.
Drill and tap on the hexagon surface of hole bolt to
conform to the specification of used external
screwed pipe union (or other hose joint). For
example,1/8 inch NPT hose barb pipe union).
Fuel injector 523

Fuel system
2. Drill and tap at the open end of hole bolt.

To facilitate the installation of 5/16-24 adjusting
screws;
Caution: if the hollow adapter is installed

outside the fuel return manifold,
the components of high-pressure
fuel system may be damaged
3. Assemble hollow flowmeter adapter.
1). Mount the male-threaded union on the
hexagonal surface of hollow bolt
2). Connect a pieces of hose with sufficient length
(which must be connected with engine
compartment from exterior container) with the
male-threaded pipe union or other pipe union
3). Mount the 5/16-24 adjusting screw on the
opening of hollow bolt
4. Remove M12 hollow bolt connecting the

fuel return pipe of injector and the fuel
return manifold
5. Mount the M12 fuel return hose on the fuel
return manifold
6. Place the fuel return hose in the container
7. Prepare a graduated flask (cm3).
For example: Measuring cup or equivalentThe
household measuring cup with a scale of cubic
centimeter can also be adopted
8. Start the engine and have it run at idle

speed.
9. Till the fuel flows in the collection vessel
from oil return pipe of fuel injector.
524 Fuel injector

ISLe375 30 engine
1). If the engine can’t be started, these

procedures still work. However, different
qualification/disqualification criteria are
provided.
2). If the engine can’t be started, engage the
starter motor for 30s each time to measure the
fuel return volume.
Technical requirements on leakage in the case of engine startup failure
Max. leakage in 30s of startup 100 cc
3). If the injector has an excessive leakage and

the engine can’t be started in the motoring
operation, check against following items:
· Fitting of high pressure fuel connection;
· Damage of high pressure fuel connection;
· Use a leakage tester to separate the injector
on fuel rail, one by one.
Caution: During this test, the fuel shall be

under high pressureAfter the test
pipe union is connected, close the
engine hood and be away from
high-pressure fuel pipe.
4). If the engine can be started, determine
whether the injector return volume is
excessively high via following procedures.
(1). When the engine runs with an idle speed,
enable the generation of high fuel rail pressure
by using the fault diagnostic instrument to
conduct High Pressure Leakage Test. During
this test, the fault diagnostic device requires
the fuel fuel rail pressure of 1500 bar when the
engine operates at idle speed.
Fuel injector 525

Fuel system
(2). During high-pressure leakage test by fault

diagnosis device, record the time spent by the
fuel flowing out from the injector return pipe to
reach 300cc
Technical specification on the leakage during engine operation
The maximum leakage within 45 s 300 cc
(3). If the duration is less than 45s, the high-pressure fuel pipe union or injector is loosened or damaged.
Caution: The measurement may be influenced by the fuel temperature and type. For example:
The leakage rate will rise when the engine is heated and the injector temperature is
very high. Additionally, the low-viscidity fuel, such as coal oil can worsen the
leakageThe above-mentioned technical requirements are applicable for the highway
diesel oil, with the inlet temperature of lower than 49℃.
(4). After recording the leakage rate of fuel, stop the high-pressure leakage test of fault diagnostic
device and switch off the key switch.
5). If the injector has a overhigh return flow,

isolate the possibly damaged or worn injector
or fuel pipe union.
6). If the fuel pipe union nut works loose, the
contact surface between the pipe union and
injector may be improperly sealed. This
loosing state will cause the leakage of
high-pressure fuel of fuel injector oil return
pipe.
(1). Firstly, check whether the fuel pipe union is
correctly tightened.
(2). If any nut is loose, tighten the nut and conduct
the leakage test again.
Caution: Do not fit separating tool on the

outlet pipe union of high-pressure
pump. May cause serious engine
damage. To isolate the
high-pressure fuel supply of any
individual injector, this tool shall
be only fitted on the fuel rail.
Caution: Ensure that the key switch is at
the OFF position (the engine is not
in operation) when disconnecting
or tightening the high pressure
526 Fuel injector

ISLe375 30 engine
pipe.
11. Use the separator for leakage test to
isolate the excessive fuel return from the
injector or fuel pipe union.
1). Mount the isolator on the fuel rail, instead of

the high-pressure fuel pipe of fuel connector
so as to isolate the fuel injector and fuel
connector of each cylinder
2). Record the time needed for the fuel flowing

out from the injector return pipe to reach
300cc when the engine is running. Use the
failure diagnoser to conduct the high-pressure
leakage test and repeat this step for six (6)
times where each time one fuel pipe is
isolated.
3). If the isolation of any individual injector and
high-pressure fuel pipe union causes a
noticeably longer duration of leakage than
other injectors and unions, the injection and
union must be checked.
12. Check the doubtable fuel connector
If the fuel pipe union is not damaged, replace both
the injector and union.
13. Remove M12 diagnostic mass flow adapter

from the fuel return manifold and fit M12
banjo bolt
14. Fit the high pressure fuel pipe
Preparatory step
Caution: The trial removal of injector prior to the dismounting of fuel pipe union will damage
the injector body and /or the union.
Fuel injector 527
Fuel system
3. Remove high pressure fuel pipe

4. Remove engine brake (if fitted)
5. Remove fuel pipe union
6. Remove exhaust rocker arm assembly
Removal
from the injector
2. Remove 2 injector holding-down bolts and
the clamps.
3. Use a small pry bar to pry out the injector
hoop pressing flange (a portion of injector
body is just an integral part of cylinder
head casting).

use is possible.
1. Verify whether injector gasket thickness is
correct
If the wrong gasket is used, the injector projection
may be incorrect, thus to give rise to the
high-pressure fuel leakage and/or performance
problems.
2. Verify injector part number to obtain
correct sealing washer/gasket thickness
Caution: Do not use wire brushes or glass

shot blasting to clean the injector.
This will damage the nozzle hole
and reduce engine performance.
3. Clean the end and main part of fuel injector
with safety solvent and clean soft cloth.
528 Fuel injector

ISLe375 30 engine
4. Check whether the O-ring is damaged

5. Check whether there are burrs on the
injector inlet
6. Check whether the nozzle is eroded or
blocked or subject to other damage
Spay the safety solution onto the fuel injector,
check the fuel inlet passage has any crack which
may leak the high-pressure fuel into the fuel
injector return oil passage
Refitting
1. Ensure that the fuel injector hole is clean
and that the nozzle is equipped with one
(1) washer.
injector O-shaped ring.
3. Mount the injector in the cylinder head
along correct direction (the fuel inlet shall
be toward the high-pressure fuel
connector)
4. Use the injector transportation socket to
ensure that the injector is seated into its
hole.
Caution: To fit a new injector, the new fuel

pipe union must be used.
5. Install but not tighten the clamp bolts of oil
injectors
6. Fit the high pressure fule connector and
make sure the connector end in oil injector
inlet end.
7. Install the fixing nuts of high-pressure fuel
connector and then tighten them partially
Caution: This is not the final fastening
torque of high-pressure fuel joint
fixing nut.
Fuel injector 529

Fuel system
8. Tighten the hold-down bolt of oil injector

Ensure that the pressure bolts are tightened
crosswise. Check and ensure that the clearance
between pressing clamp and fuel injector is equal
to the clearance around the fuel injector
Torque value10 N·m
9. Tighten the fixing nut of high-pressure fuel

connector
Caution: Do not over tighten harness of

injector. If excessively fastened,
the injector terminal will be
damaged.
10. Connect the injector conducting wire with
the injector
Caution: Sort the injector lead wires such
that they will interfere with the
rocker arm or the engine brake
housing. If the rocker arm can
reach the injector wire, it may
chafe the lead wire insulation and
give rise to the generation of
injector circuit failure codes.
Last step
1. Fit exhaust rocker assembly
2. Fit engine brake (if equipped)
3. Fit the high pressure fuel pipe
530 Fuel injector
ISLe375 30 engine
II. Renewal of fuel supply pipe of fuel injector (high

pressure)

Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Check the fuel pump connector
2. Check the cylinder head connector
3. Check the fuel rail connector
4. Check the bolt of bracket supporting the

high-pressure fuel rail supply pipe
Tightening torque High pressure feed pipe
bracket bolt (1) 24 N·m
5. Check the bolt of damping gasket of
bracket
Tightening torque Bracket vibration
isolating pad bolt (2)
Preparatory step
2. Clean the immediate area of fuel pipe.
3. Remove intake pipe union (. If necessary)
Renewal of fuel supply pipe of fuel injector (high pressure) 531

Fuel system
Removal
1. Undo the fuel pipe and its union on the fuel
rail as well as the high-pressure fuel pump
outlet pipe union.
2. Undo the shock-absorbing pad bolt of
high-pressure fuel rail pipe bracket.
3. Remove high pressure fuel pipe

use is possible.
1. Check whether the high-pressure fuel
supply pipe bushing has any burr, dirt,
beveling or crack
Renew, if necessary.
2. Check whether there is any cracked, worn
or pressed part
Renew, if necessary.
3. Check whether the sealing surfaces on the
both ends of high-pressure oil pipe are
damaged
Refitting
1. Ensure that the fuel pipe union is correctly
and fully fitted into the injector.
2. Ensure that the high-pressure union nut is
fastened.
Fit fuel line in reverse order to the removal.

4. Tighten the fuel rail connector
Tightening torque 38 Nm
5. Tighten the fuel pipe of fuel pump onto the
fuel rail at the end
6. Locate fuel pipe between fuel pump and
fuel rail.
7. Fasten the bolts of vibration isolating pad
of fuel pipe and bracket by hand.
8. Tighten the fuel pump connector
532 Renewal of fuel supply pipe of fuel injector (high pressure)

ISLe375 30 engine
Tightening torque 38Nm

9. Tighten the bracket damping gasket bolt
10. Tighten the cylinder head connector

Last step
1. Fit intake pipe union (if removed)
Renewal of fuel supply pipe of fuel injector (high pressure) 533

Fuel system
III. Renewal of fuel pipe union (seat-mounted)


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Remove high pressure fuel supply pipe.
Removal
1. Remove fuel joint fixing nut
2. Use the fuel pipe union puller to remove
the union from the cylinder head.

1. A new high pressure connector must be
installed (if a new injector is installed)
2. Check the fuel connector
Check whether there are burrs or deformation at
the inlet and outlet sides of connector.
3. Check whether the streamline filter is
blocked or its materials are polluted
Do not continue to use the high-pressure fuel pipe
union with scraps.
4. Check whether the O-ring has crack or
deformation
534 Renewal of fuel pipe union (seat-mounted)

ISLe375 30 engine
5. Check whether the seal of high-pressure

union outlet is worn and whether the
carrier surface is uneven or has leakage
If there is high-pressure fuel leakage, the small
pipe or cut in the union will be corroded and project
into the seat surface. .
The high pressure union and injector must be
renewed when this fault is found out.
Refitting
Caution: If a new injector is fitted, the fuel
pipe union must be renewed.
1. Lubricate the fuel pipe union O-shaped
ring and the lock nut threads.
Insert the fuel pipe union carefully, and align the
guide pin with the cylinder head slot, located at the
12 O’ clock position.
Caution: If the injector is removed together
with the high-pressure fuel pipe
union, follow the refitting
procedure as specified in the step
006-026.
Tighten the fixing nut of fuel connector

Last step
1. Fit the high-pressure fuel feed pipe
Renewal of fuel pipe union (seat-mounted) 535

Fuel system
IV. Renewal of fuel rail


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
Warning: The pressure in fuel rail is very
high. High pressure fuel can
penetrate into the skin. Be sure to
stand away from the engine during
the operation of engine.
Warning: The fuel in the pump
high-pressure pipeline and rail
has a very high pressure. To avoid
personal injuries and property
loss, never undo any pipe union
when the engine is running.
1. Check whether the fuel pressure sensor, high-pressure fuel pipe union and male union have
any leakage
Preparatory step
2. Clean the immediate area of fuel rail.
3. Disconnect fuel pressure sensor from engine cable harness
4. Remove the high pressure pipe from the fuel rail
5. Disconnect the return pipe from the fuel pressure reducing valve
536 Renewal of fuel rail

ISLe375 30 engine
Removal
1. Remove bolts fixing fuel rail & cylinder
head
2. Remove fuel rail assembly
Refitting
1. Fit the fuel rail assembly
Follow the correct order and ensure the
high-pressure fuel pipe is aligned correctly.
2. Fit and tighten the bolts of assembly of
fuel rail munually
3. Fit and tighten the high pressure fuel pipe
4. Tighten the bolt of fuel rail assembly
Last step
1. Tighten the high-pressure fuel pipe
2. Mount the fuel return pipe on the fuel relief valve
3. Mount the fuel pressure sensor on the engine conducting wire
Renewal of fuel rail 537

Fuel system
V. Renewal of fuel relief valve


Common tools
Special tool - -
Testing tools - -
Auxiliary material Lubricant, detergent
2. Procedure
Initial inspection
2. Check whether there is any exterior
leakage
3. Check whether the fuel relief valve leaks

too much fuel into the fuel return pipe
4. The fuel return hose needs to be used
during the measurement of leakage of fuel
pressure reduction valve
This tool is used for isolating fuel reducing valve
leakage, so as to facilitate the measurement of fuel
feed drum.
Caution: If the failure code 449 or 2311
works, do not replace the fuel
relief valve without determining
the failure status and causes.
Refer to the corresponding fault
diagnosis tree.
5. Remove M12 hollow bolt connecting the fuel return pipe of fuel pressure reduction valve and
the fuel return manifold
6. Mount the fuel return hose on the fuel return manifold
7. Place the fuel return hose in the container
538 Renewal of fuel relief valve

ISLe375 30 engine
Or fit a leakage measuring tool on fuel reducing

valve.
Test
1. Start the engine, and have it run at idle
speed.
2. Measure leakage
Technical regulations:
When the engine runs with an idle speed, the fuel
drained from the fuel rail pressure reducing valve
every minute must be no less than 30 drops.
Caution: During this test, the fuel shall be

under high pressureAfter the test
pipe union is connected, close the
engine hood and be away from
high-pressure fuel pipe.
3. When the engine runs with an idle speed,
enable the generation of high fuel rail
pressure by using the fault diagnostic
instrument to conduct High Pressure
Leakage Test
During this test, the fault diagnostic device requires
the fuel fuel rail pressure of 1500 bar when the
engine operates at idle speed.
Technical regulations:
The quantity of fuel drained from the fuel pressure reduction valve every minute must be less than 30
drops.
If the fuel relief valve has a significant leakage, replace it. However, to ensure that the failure code 449 or
2311 will not work means that the fuel relief valve is opened with the system failure.
Renewal of fuel relief valve 539

Fuel system
4. Remove fuel return hose

5. Fit the banjo bolt of fuel return pipe
Preparatory step
2. Close the feed valve and return valve
3. Remove the return pipe from the fuel rail
pressure reduction valve
4. Remove fuel pressure reducing valve
adapter & copper gasket
Removal
1. Remove fuel pressure reducing valve

If the too much fuel leaks into the return pipe via
the fuel relief valve, no further use is allowed.
1. Check whether the high-pressure sealing
surface of fuel relief valve and the interior
of fuel rail are damaged
If the high-pressure sealed union is damaged,
never further use the part concerned.
2. Check whether the copper washer and
adapter union are damaged
Refitting
1. Fit the fuel reducing valve
2. Apply the fitted lubricant or equivalent on
screw thread.
If the reductor has been removed from the fuel rail
relief valve, use a new copper seal ring to fit the
reductor.
540 Renewal of fuel relief valve

ISLe375 30 engine
Last step
1. Mount the fuel return pipe on the fuel relief valve
Renewal of fuel relief valve 541

Intake and exhaust systems

General
I. Intake system – general description
The fuel system on the engine includes the air
filter, intake pipe, turbocharger, air-air intercooler
pipe, air-air charge air cooler (CAC) and intake
heater.
The air is suck into the compressor side (1) of
turbocharger from air filterThereafter, the air
reaches CAC and intake heater (if applicable) via
CAC pipe (2) and is pressed into the intake
manifold. The air is suck into the cylinder (5) for
burning by intake manifold
The turbocharger utilizes the exhaust energy to

rotate the turbine impeller. The turbine impeller
drives the compressor impeller to supply burning
pressurized air to the engine. With an additional air
supply from the turbocharger, more fuel can be
injected thus to improve the engine output power.
The turbine, compressor impeller and wheel shaft

are supported by two rotating bearings in the
bearing seat. The passage in bearing seat will be
led into bearing and thrust bearing via the filtered
and pressurized engine oil. Oil is used for
lubricating and cooling of rotary components.
Thereafter, the engine oil will return to the oil sump
through the return pipe from the bearing carrier.
Adequate, filtered high quality oil is very important
for service life of turbocharger. Ensure that the
high-quality engine oil is used and that the oil and
filter are changed as scheduled.
542 Intake system – general description

ISLe375 30 engine
Adopt bypass-type turbocharger to optimize the

performance. The exhaust gas by-pass valve is
designed to generate the largest supercharging
pressure quickly, and ensure that the turbocharger
will not overspeed when the engine speed is high.
The exhaust gas by-pass valve is controlled by the
actuator which senses the pressure of gas
compressor and keeps balance with the preset
spring load. The exhaust gas by-pass valve is
located at the intake passage of turbine. When
opening, it bypasses some waste gas bypass from
the turbine impeller, and controls the wheel shaft
rotating speed and boosting pressure in this way
When the turbocharger fails, its working efficiency

will be impaired, with the emission of a lot of
smoke to cause the power reduction. The bearing
fault may cause friction so as to reduce the rotation
speed of rotor assembly. The bearing fault may
cause the friction between rotor assembly vane
and housing so as to reduce the rotation speed of
rotor assembly.
The turbocharger exhaust bypass valve failure or
the bypass valve calibration error may give rise to
high or low boosting pressure. The low pressure
charging may generate a large numbers of smokes
and reduce power. The high pressure charging
may cause the severe damage of engine.
The engine oil is used for lubricating the bearing

and cooling the turbocharger to a certain extent.
The oil supplied to the turbocharger through oil
supply pipe is lower than the working pressure of
engineTo the oil return pipe at bottom of
turbocharger so as to return the oil to the engine oil
pan
The oil seal ring is adopted for each end of rotor

assembly. The oil seal is mainly used to prevent
the exhaust gas and compressed air entering in
the turbocharger housing. The engine oil leakage
from oil seal is infrequent, but possible.
An over-high crankcase pressure may prevent the
engine oil from returning to the oil pan. This will
increase the load on bearing seat and make
engine oil flow into compressor oil seal and engine.
Intake system – general description 543

Oil return pipe blocking or damage may give rise to

pressure increase inside turbocharger shell, thus
resulting in leakage at oil seal.
In addition, high intake or exhaust resistance may

give rise to vacuum between compressor and
turbocharger, thus causing oil leakage from seal.
If the engine oil enters into the oil seal of
compressor housing, it is required to flush the
air-air intercooler to remove the engine oil in the
intake system.
In normal case, the turbocharger will generate the

sound of purr and the volume will vary with the
rotation speed and load of engine. The sound is
caused by the rotor assembly rotating at a very
high speed and also by the rotor assembly balance
method adopted in the production. Therefore, the
sound at full speed will be louder.
If possible, run the engine at full speed to verify the
level of noise.
The leakage of intake and/or exhaust component

of air system may result in loud engine noiseThe
leakage noise is generally the high-frequency
purrs or inspiration sounds.
Check whether the intake and exhaust system
have leakageCheck and ensure that all the hose
clamps are tightened

ISLe375 30 engine
A murmur or snap when the engine speed is low

may indicate that there is crumb in the system or
the rotor assembly rubs with the housing.
Remove turbocharger inlet, and check for foreign
matter.
If doubtful, check whether the turbocharger blade
is damaged or whether there is any gap in the
bearing.
If there is leakage, vane damage or abnormal gap,
replace the turbocharger.
With the intercooler (CAC) fitted on the chassis,

the engine performance and emission are
improved. The system also uses the large
diameter pipeline to convey the air from the engine
turbocharger to the CAC, and then return the air
from the CAC to the engine intake manifold.
Ensure that the permanent completeness of air-air
intercooler system remains the responsibility of
vehicle and parts manufacturers.
Intake system – general description 545

Intake system flow chart

Air-air inter-cooled engine
空-空中冷式发动机
Air-air inter-cooled engine
1. To turbocharger air inlet 4. Intake manifold (as a whole of cylinder head)

2. Turbocharger air to air-air intercooler 5. Intake valve
3. Air-air intercooler

ISLe375 30 engine
II. Exhaust system- general description

This exhaust gas by-pass valve turbocharger is in
Holset Model HX40 type. It includes the
turbocharger, exhaust bypass valve actuator and
the bypass valve in the turbocharger housing. The
exhaust gas by-pass turbocharger improves the
engine response at low speed,
But no compromise should be made on the
endurance of turbocharger at high speed. It
enables the exhaust to pass by the turbine impeller
under a certain working mode of engine thus to
realize this. In the course of rotation at low speed,
the turbocharger will operate as a close system to
transmit the exhaust gas energy to the compressor
impeller for compressing the incoming gas. In the
course of rotation at high speed, the turbocharger
will change to an open system to allow the exhaust
gas to pass by the turbine. As the exhaust bypass
valve passes the turbine blade, only a little of heat
is transferred to the compressor via the turbine to
reduce the intake manifold pressure and turbine
speed.
Fit the bypass valve actuator beside turbocharger,

including pressure fliter tank, diaphragm and
actuator lever. With pressure changes in the filter
canister (controlled via the exhaust bypass valve
controller), the actuator lever will correspondingly
adjust the valve.
The exhaust gas by-pass valve is fitted on the
turbocharger inside the turbine housing. The
bypass valve opens, and the waste gas bypasses
the turbine blade, reducing the turbine speed and
adjusting the pressure of intake manifold
Exhaust system- general description 547

Flow charge of exhaust system
548 Exhaust system- general description

ISLe375 30 engine
III. Compressed air system-General description

General
The compressed air system is generally composed
of air compressor driven by the engine/gear, air
pressure regulator, air reservoir and necessary
pipelines.
Following parts are usually used in the
compression system:
• Air pressure regulator
• Exhaust pipe
• Air dryer
• Fuel tank
• Check valve
• Main oil tank
• Auxiliary fuel tank:
• Check valve
• Air compressor
The engine is only equipped with air compressor and relevant intake pipe and coolant pipe. Vehicle
manufacturer will be responsible for removing the residues inside air compression system
Air compressor
Different air compressors can be used for the
engine covered by this manual. For both
single-cylinder (1) and double-cylinder (2) module.
The air compressor can be turbocharged type or
naturally-aspirated type, dependent on its
configuration
The air compressor can be low output torque type

or high output type, dependent on its use
There is one SAE A rear flange (1) for the low-yield
torque model.
There is one SAE B rear flange (2) for the
high-yield torque model.
Compressed air system-General description 549

To ensure that the air compressor will not cause

engine vibration, the compressor must be correctly
timed on the engine in the refitting operation.
The key factor determining the reliability and

durability of air compressor is that if the air
compressor spends a lot time on gas supply when
the vehicle/machine is operating, and its is called
as load cycle of air compressor
The air compressor is not designed to supply the
gas continuously, and a lot of heat will produce
during gas supply, and those heat will dispel when
the air compressor stops gas supply
The maintenance/repair of air compressor system

can minimize its load cycle and ensure its reliability
and durabilityMaintenance & service parts include
(but not limited to):
1). Check for and stop all the leakage in the
system. The air leakage may increase the
work load cycle to two or three timesIt is vital
to pay attention to correct the leakage off air
system
2). Check whether the exhaust port, exhaust pipe
and connector of air compressor have any
carbon depositIf the carbon deposit is thicker
than 1. 6mm, clean or renew it as the case
may be.
3). Check whether there is any water or oil in the air pipe and pipe union between the air dryer outlet
and the first oil tank after the air dryerThe fuel tank shall keep dry. If the engine oil is visible, replace
the dryer desiccant and clean the downstream system and components as the case may be.
See “OEM service manual” for the maintenance and repair information of vehicle compressed air system.
For the maintenance of air compressor, refer to the Engine Operation and Maintenance Manual.
550 Compressed air system-General description

ISLe375 30 engine
Air compressor cylinder head

The air compressor cylinder head is cooled by
engine coolantThe cylinder is fitted with the inlet
and outlet valves used to regulate the cylinder
head air flow.
Most of air compressor cylinder head can be
repaired when the compressor is not dismounted
from the engineThis manual covers the repair of
cylinder head of engine equipped with a
compressor.
If the compressor has internal damages, replace it.
Be sure to check the replaced parts for workability
before the air compressor cylinder is
disassembled.
It is possible that some air compressor cylinder
head cannot be separated from the air compressor
for repairing purpose.
The air compressor runs continuously under the

Loaded or Unloaded modeThe operation mode is
controlled by pressure-driven air transformer and
air compressor. The air pressure regulator can be
on the air compressor or the far end of vehicle
When the preset pressure of air system is reached,
the pressure regulator sends out an air signal to
the relief valve assembly and makes it open or
close the compressor intake valve. Thus the
compressed air stops flowing into the system.
The pressure drops when the system is used.
Under set pressure, the pressure regulator will
send an air signal to compressor unloading valve
assembly to allow the compressor to pump the
compressed air to air system again.
Compressed air system-General description 551

Flow chart of compressed air system
1. Coolant 3. Lubricating oil

2. Air
552 Compressed air system-General description

ISLe375 30 engine
IV. Leakage of intake and exhaust systems


Common tools
Special tool - -
Testing tools - -
Auxiliary material Soapy water solution, cleaning agent
2. Procedure
Initial inspection
1. Judge if the intake system has gas leakage
1). Check whether the pipeline has any crack or
the clamp is loose
2). Apply the soapy water onto the questionable
zone and check whether there is air bubble.
3). Listen to the doubted part to check whether it
purrs or makes aspiratory sound at high
frequency.
Caution: The engine air intake must be

equipped with a filter so as to
avoid any dirt and crumb to enter
into the engine. If the intake pipe
is damaged or loosened, the
unfiltered air will enter into the
engine to cause premature wear of
engine.
2. Check whether the intake hose has any

crack or the clamp is damaged or gets
loose
3. Run the engine with a high idle speed and
find out the position of leakage using
soapy water
If there is any leakage, soap bubbles will appear.
Leakage of intake and exhaust systems 553

4. Renew the damaged pipe and screw up the

loose clamp
Ensure that the intake system has no leakage.
5. Check whether the intake pipe under the
clamp and hose are eroded
Rust and dirt can enter into the intake system due
to corrosion.
6. Disassemble and clean (if needed)
Intake system on the pressure side

The leakage of intake system will reduce the
amount of air entering the cylinder and decrease
the engine performance when the engine is
running
1. At the rated speed of rotation and

maximum load, operate the engine when
full throttle.
2. Listen to the turbocharger, adjacent pipe
and union to check whether they whistle at
high frequency.
3. Apply the soapy water onto sealing
surface.
4. Check whether the bubble exsits
The bubble can be detected easily
5. The leakage may be also found at the

turbocharger compressor outlet union.
6. Check the damage
Renew the O-ring and tighten the loose clamp.
554 Leakage of intake and exhaust systems

ISLe375 30 engine
Air-air intercooler pipe or connecting

hose
1. Check whether the hose and tube are
damaged
2. Tighten the loose clamp
Intake connector
1. Check whether there is any damage
2. Renew the gasket or screw up the loose
clamp, if necessary
Intake manifold
2. Renew the gasket, if necessary
Exhaust gas by-pass valve bellows/pipe


Compressor housing sealing surface

surface.
Exhaust system
The leakage of exhaust system will make the
turbine rotate at low speed, and reduce the air
entering the cylinder when the engine is rotating

full throttle.
2. Identify the leakage through the
discoloring caused by noise, soap water or
hot air.
3. Check whether the exhaust manifold

gasket has any leakage
556 Leakage of intake and exhaust systems

ISLe375 30 engine
4. Check whether the mounting gasket of

turbocharger has any leakage
5. Check whether the sealing surface of

turbine casing has leakage

full throttle.
7. Recheck whether there is leakage.

V. Measurement of intake resistance


Common tools
Special tool - -
Testing tools - -
2. Procedure
Measure
1. Mount vacuum gauge or differential water
pressure gauge in air inlet pipe.
The instrument union must form a 90°angle with
the air flow direction and be fitted at about one pipe
diameter from the turbocharger front straight pipe
section.

full throttle.
3. Record the reading of instrument or
pressure gauge
• Maximum intake resistance: 63. 5 cm H2O
4. If the resistance exceeds the required limit

5. Renew or clean the air filter cartridge
558 Measurement of intake resistance

ISLe375 30 engine
6. Check whether the intake pipeline is

damaged
7. Remove test equipment
Measurement of intake resistance 559

VI. Measurement of intake manifold pressure


Common tools
Special tool - -
Testing tools Fault diagnostic instrument, pressure gauge
2. Procedure
Measure
Caution: Do not try to fit threaded pipe
union on the plastic or rubber
pipe. This will cause damage on
pipe.
1). Monitor the pressure of intake manifold by
application software of fault diagnostic tool.
8. If the failure diagnoser is unavailable,
Exercise the following procedures:
1). Remove air-air intercooler pipe connecting the
outlet of air-air intercooler and the intake
manifold connector.
2). Drill and tap on crossunder pipe to form 1/8
inch pipe threaded hole.
3). Remove all metal scraps on inside or outside
surface of pipe.
4). Fit sensor pipe.
9. Fit the pressure meter

10. Run the engine at rated speed and full
load.
11. Record the reading of booster
12. Remove manometer after testing
13. Mount plug at test port.
560 Measurement of intake manifold pressure

ISLe375 30 engine
Caution: The temperature of torque

converter oil must not higher than
120℃. The overheating may occur
or the torque converter be
damaged
14. Alternative loading method (if automatic
gearbox is equipped)
1). If the chassis dynameter is unavailable, use
other methods to load the engine.
2). Stall the engine with the vehicle torque
converter to establish full load conditions.
3). Stall the vehicle till the engine speed stabilizes
at the full openness of throttle.
4). Record the stall and the reading of booster
5). Remove manometer and install plug in the test
port after testing.
Measurement of intake manifold pressure 561

VII. Measurement of exhaust resistance


Common tools
Special tool - -
2. Procedure
Measure
1. Mount the pressure gauge on the pressure
gauge interface on the front exhaust pipe
or muffler inlet
2. To run the engine at rated speed and load;
3. Record the exhaust resistance
Exhaust resistance- muffler
Maximum 76 mmHg
1. If the exhaust resistance exceeds the

required value,
2. Check whether the exhaust pipe is

damaged
562 Measurement of exhaust resistance

ISLe375 30 engine
3. Remove test equipment

4. Fit and tighten pipe plug
Measurement of exhaust resistance 563

Intake pipe and exhaust pipe

I. Renewal of air jumper pipe

Common tools
Special tool - -
Testing tools - -
2. Procedure
Removal
1. Undo the hose hoop.
1. Adjust the position of jumper tube until it
can be removed
2. Remove hose

use is possible.
1. Check whether any part of jumper pipe is
cracked, punctured or worn
2. Check whether the seal between hose and
pipe is good
3. Check whether the clamp is worn out
4. Renew it with a new hose and clamp, if
necessary
564 Renewal of air jumper pipe

ISLe375 30 engine
Refitting
1. Fit jumper pipe and the clamp in reverse
order to the removal
2. Tighten the clamp
565
II. Renewal of intake connector


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
1. Remove air-air intercooler pipe or hose connecting air intake joint
Removal
1. Remove V-clamp, intake joint & bearing

use is possible.
1. Check whether the intake union and seal
are cut or cracked or have hole or wear.
2. Replace (. If necessary)
566 Renewal of intake connector

ISLe375 30 engine
Refitting
1. Fit sealing intake connector and V-type
belt clip
2. Tighten the V-belt clamp
Last step
1. Fit the air-air charge cooler pipe or hose
Renewal of intake connector 567

III. Renewal of intake pipe union


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Remove intake jumper tube
3. Remove as required the intake pipe union
4. Remove injector supply pipe (, if necessary)
Removal
1. Remove mounting bolt
3. Seal the opening of intake manifold with
adhesive tape.
To avoid the entry of scraps into the intake system;
cleaning.
Caution: The grille heater becomes loose
now.

use is possible.
Caution: Do not let the sealing material and
any other foreign substance enter
into the air inlet pipe.
2. Check whether the intake pipe union has
any crack or other damage
568 Renewal of intake pipe union

ISLe375 30 engine
Refitting
1. Fit intake pipe union and new sealing
gasket
Caution: The intake pipe union is installed
on the top of grid heater and
shares the bolts
Last step
1. Fit feed pipe of oil injector (if removed)
2. Fit intake pipe union adapter (if removed)
Renewal of intake pipe union 569

IV. Renewal of intake manifold hood


Common tools
Special tool - -
Testing tools - -
2. Procedure
2. Disconnect the cold start auxiliary device
3. Remove jumper air pipe
5. Remove cold start auxiliary unit
6. Remove injector supply pipe (, if necessary)
Removal
1. Remove bolt and the intake manifold cap
2. Seal the opening of intake manifold with
adhesive tape.
To avoid the entry of scraps into the intake system;
cleaning.

use is possible.
Caution: The sealant and other material
must not enter air inlet
2. Remove the adhesive tape.
3. Check whether the intake manifold has any
crack or other damage
Caution: It is required to check whether
there is engine oil and chips when
checking whether there is engine
oil or chips from defective air
system in intake manifold.
570 Renewal of intake manifold hood

ISLe375 30 engine
Refitting
1. Fit intake manifold cover and new gasket
Last step
1. Fit cold strat auxiliary unit
2. Fit feed pipe of oil injector (if removed)
3. Assemble gas-type fitting.
5. Connect the cold starting accessories
Renewal of intake manifold hood 571

V. Renewal of intake pipe union


Common tools
Special tool - -
Testing tools Intake pipe union adapter
2. Procedure
Preparatory step
2. Remove air-air intercooler pipe connected to the inlet connector adaptor
Removal
1. Remove V clamp fixing intake joint adapter
& intake joint
2. Remove intake pipe union adaptor

use is possible.
1. Clean the air inlet adapter with solvent.
2. Check whether the intake pipe union has
any crack, scraping or other damage
572 Renewal of intake pipe union

ISLe375 30 engine
3. Check whether the O-ring inside the air

intake pipe union is cut or damaged
4. Check whether the V-belt is drawn
excessively or has damaged thread.
5. If the intake pipe union is not sealed, the
union or air-air intercooler must be
replaced.
Refitting
1. Fit intake pipe union adapter, O-ring and
V-belt clip of intake pipe union
Last step
1. Fit air-air charge cooler pipe of air-air cooler and tighten the hose clip
4. Check whether there is boosting leakage
Renewal of intake pipe union 573

VI. Renewal of turbocharger compressor outlet union


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Disconnect air-air intercooler pipe
Removal
1. Remove the turbocharger outlet elbow, the
V-band clamp and O-ring from the
turbocharger compressor outlet

use is possible.
1. Clean the turbocharger outlet joint with
solvent.
1. Blow-dry with compressed air again.
2. Check whether the turbocharger
compressor outlet union is cracked,
damaged or worn abnormally
3. Dispose the O-ring
Do not repeatedly use.
574 Renewal of turbocharger compressor outlet union

ISLe375 30 engine
Refitting
1. Mount the turbocharger compressor outlet
bend, V-shaped strap and new O-ring on
the exhaust outlet of turbocharger
compressor
Last step
1. Connect the air-air intercooler pipe
Renewal of turbocharger compressor outlet union 575

VII. Air-air intercooler


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Check whether the air-air intercooler has
any crack, hole or damage
2. Check whether the pipeline, vane and weld
joint has any crack, breakage or other
damage
If there is any failure which causes the air-air
intercooler to fail the air leakage test, replace the
intercooler.
3. Check whether the air-air intercooler
pipeline is cracked or damaged
Leakage test
Warning: To prevent any plug from
separation in the test, connect the
protection chain on the plug onto
the radiator bolt reliably. This test
must be conducted when
protection chain is fastened
solidly.
1. Check whether the air-air intercooler pipe
or gas collecting tube is cracked.
2. Remove the intake hose and exhaust hose from the air-air intercooler
No need to remove air-air intercooler from the chassis.
576 Air-air intercooler

ISLe375 30 engine
3. Apply air pressure onto the intercooler till

the pressure indicated on the pressure
gauge is stabilized at 207kPa.
4. Cut off the air supply to the intercooler.
5. Meanwhile, start to count the time with a
stopwatch.
Record the leakage of 15s
If the pressure drop within 15s is 48kPa, the
intercooler works normally.
If the pressure drop within 15s exceeds 48kPa,
re-check all unions.
6. Check whether the pressure drop is

caused by the leakage in the air-air
intercooler or by the leakage at the union.
1). Spray the soapy water onto all the hose joints
with the sprinkler filled with soapy water,
check whether there is air bubble and find out
the leaked position.
2). If the pressure drop is caused by the leakage
from the union, repeat the test after the union
is repaired. If any leakage is found in the
air-air intercooler, repeat the test and verify
the accurate measurement of drop pressure.
The reading of pressure drop can only be
regarded accurate when it is approximated
from at least three times successive
measurements
Caution: If the pressure drop due to the leakage in the air-air intercooler within 15s exceeds
48kPa, there is massive leakage in the air chamber.
3). If the pressure drop within 15s exceeds

48kPa, replace the air-air intercooler.
The design of air-air intercooler cannot ensure no
leakageIf the pressure drop within 15s is lower
than 48kPa, it is unnecessary to replace the air-air
intercooler.
Air-air intercooler 577

Pressure test
1. Obtain two pressure gauges.
1. Check the same pressure of two gauges
under 206kPa
2. Place one pressure gauge into the 1/8″pipe
union in the outlet bend of turbocharger
compressor
3. Mount another pressure gauge on the
intake manifold
4. Run the engine at the rated speed and

load.
5. Record the readings of two pressure
gauges
6. Check whether the air-air intercooler and
corresponding pipeline are jammed,
blocked or damaged (if the pressure
difference is more than 20. 6kPa)
7. Clean or replace (. If necessary)
Temperature difference test

1. Check whether the cooling fins of air-air
intercooler obstruct the air flow
1. Eliminate failures of anti-cold front cover,
and remove scraps or other problems;
1. Lock the shutter (if fitted)at the opened
position by hand.
2. Lock the fan drive at the “ON” (connected)
position
3. Fit thermocouple bead probe

4. Connect the dial indicator and temperature
adapter with the thermocouple probe to
get the intake temperature
5. The other choice is to use the monitoring
mode in the fault diagnosis meter
6. Mount an additional thermocouple at air
inlet of air filter to measure the ambient air
temperature.

ISLe375 30 engine
7. Carry out once road test

8. Have the engine work at its maximum
power and adjust the vehicle speed to be
equal to or higher than 48kph.
9. Record the temperature of intake manifold
and ambient air
10. Calculate the temperature difference.
• Temperature difference = intake manifold
temperature - atmospheric temperature
If the temperature difference exceeds the required

value, check whether the air-air intercooler cooling
fin is contaminated, and clean it, if necessary. If the
problem remains there, check whether there are
any scraps between the air-air intercooler cooling
fan or air-air intercooler and the radiator.
11. Confirm that the fan is fully connected.
Preparatory step
1. Use the compressed air to remove external scraps of air-air intercooler.
2. Remove air-air intercooler pipe
Removal
1. Remove air-air intercooler
Air-air intercooler 579

Cleaning
Caution: Do not use the corrosive cleaning
agent to clean the air-air
intercooler. Otherwise, the air-air
intercooler can be damaged.
If the engine turbocharger once fails, or the engine
oil or scraps have entered into the air-air
intercooler, clean the intercooler.
1. Use the solvent to flush the air-air
intercooler inside along the direction
opposite to the normal air flow.
1. Shake air-air intercooler and slightly hit air end box with a rubber hammer.
1. Water flush to clean all debris or oil (until clean water flows out)
Caution: Ensure that the intercooler pipeline keeps vertical in the washing operation.
If it is not allowed to fully remove scraps in the air-air intercooler, replace it.
2. Clean the intercooler of engine oil and

chips with solvent.
3. Clean the intercooler inside with soapy
water.
4. Thoroughly clean it with water.
5. Dry the air-air intercooler with the
compressed air.
Refitting
1. Fit air-air charge cooler
Last step
1. Fit air-air charge cooler pipe

ISLe375 30 engine
VIII. Renewal of cold starting auxiliaries


Common tools
Special tool - -
Testing tools - -
2. Procedure
Test
2. Select “Cancel grille heater” from the list
of ECM diagnosis test
3. Follow the instructions about filter screen
to determine whether the starting assistor
works normally.
Preparatory step
2. Disconnect the cable of intake heater
3. Remove air-air intercooler pipe
4. Remove intake pipe union adaptor (if fitted)
6. Remove injector supply pipeline
Removal
1. Remove intake heater
Caution: . If necessary, remove the intake
heater, and no matter how the time
is long, seal the pipe nozzle with
adhesive tape to prevent the entry
of scraps into the intake pipe.
Renewal of cold starting auxiliaries 581


use is possible.
1. Clean the intake heater sealing surface.
2. Clean the intake manifold cover sealing
surface.
3. Clean the intake pipe union sealing
surface.
Caution: Do not let the sealing material and
any other foreign substance enter
into the intake manifold of cylinder
head.
Refitting
1. Fit intake heater
Caution: The intake heater will keep loose
till it is installed in the intake
connector
Last step
3. Fit intake pipe union adapter
4. Connect the intake heater wire
5. Fit air-air charge cooler pipe
582 Renewal of cold starting auxiliaries

ISLe375 30 engine
IX. Dry exhaust manifold


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Remove air jump pipe & air-air intercooler hose
3. Disconnect the intake and exhaust pipes
Removal
1. Remove bolt, the exhaust manifold and the
gasket
Caution: Apply a thin coat of nickel base
high temperature complex grease
onto coarse thread of manifold
bolt.

use is possible.
1. Clean the sealing surface of cylinder head
and exhaust manifold.
2. Clean the seal surface of carbon deposit
with 240# coarse emery cloth.
Dry exhaust manifold 583

3. Clean the union with multiple seals.

4. Clean the seal surface of carbon deposit
with 240# coarse emery cloth.
5. Clean the exhaust manifold with steam and

dry it with compressed air.
6. Check whether the exhaust manifold has

any crack, smoke trace, or leakage or is
burnt
Caution: If the exhaust manifold is
damaged, check the air-air
intercooler. The failure of air-air
intercooler may damage the
exhaust manifold
7. Check whether the gasket surface is

chiseled, scraped or burnt.
8. Measure the flatness of manifold surface.
584 Dry exhaust manifold

ISLe375 30 engine
Place the straight ruler on the exhaust portUse the

thickness gauge to measure the gap between the
port surface and the ruler.
Flatness of exhaust manifold
Maximum 0. 20mm
If the measured value at any port exceeds the

required value, replace the manifold.
9. Check the matching degree of manifold

with cylinder head
If the manifold mounting bolt hole is not aligned
with the cylinder head threaded hole, replace the
exhaust manifold.
Refitting
1. Use new gaskets to fit the exhaust
manifold of cylinder head.
2. Tighten according to the illustrated sequence
Last step
1. Fit the turbocharger.
2. Connect the intake pipe and exhaust pipe
3. Connect the air-air intercooler hose and
jumper pipe
is leakage.
Dry exhaust manifold 585

Turbocharger
I. Turbocharger

Common tools
Special tool - -
Testing tools Micrometer, thermometer, high-intensity black light lamp
2. Procedure
Initial inspection
1. Remove the intake pipe from the
turbocharger
See “Removal” in the procedure.
2. Check whether the turbocharger
compressor impeller vane is damaged
If damaged, replace the turbocharger. See
“Removal and installation” in the procedure.
3. Check whether the air intake pipe and filter
element are damaged (if the compressor
impeller is damaged)
4. Repair all the damaged components before
the engine operates.
5. Remove the exhaust pipe from the

turbocharger
6. Check whether the turbine impeller is
damaged
If damaged, replace the turbocharger. See
“Removal and installation” in the procedure.
586 Turbocharger
ISLe375 30 engine
Inspection of axial clearance

1. Use the depth micrometer.
2. Push the rotor assembly away from the
dial indicator
3. Set the dial indicator at 0
Push the rotor assembly towards the dial indicator

and record the reading
Axial clearance
Minimum 0. 025mm
Maximum 0. 127mm
If the gap doesn’t meet technical requirements,

Check the radial clearance

1. Use the wire type thickness gauge to
measure the gap between the turbocharger
compressor impeller and the housing.
2. Push the compressor impeller lightly to the
compressor housing and feeler
3. Record this clearance
Locate the thickness gauge at the same position,

slightly push the compressor impeller from the
compressor housing and measure the gap
between them.
Subtract the smaller clearance from the larger
clearance. This is radial clearance of bearing.
Radial clearance of exhaust gas by-pass valve

bearing
Minimum 0. 330mm
Maximum 0. 508mm
4. Repeat this step for the turbocharger

turbine wheel
Turbocharger 587
If the bearing radial clearance can’t meet technical requirements, replace the turbocharger.
Leakage test
1. Check whether the inlet and outlet of
turbocharger has oil
If the compressor inlet and outlet are contaminated
by the engine oil, check the upstream section of
turbocharger to find out the source.
If the engine oil is only found on the exhaust side,

fit the intake pipe and air-air intercooler.
2. Check the intake resistance
If the intake resistance meets the technical
requirements, replace the turbocharger.
oil has entered into the air-air intercooler, check
and clean the intercooler.
Add one unit of fluorescent tracer to every 38L

engine oil.
3. Run the engine at low idle speed for 10min.
4. Stop the engine

5. Cool down the turbocharger.
6. Remove the exhaust pipe from the turbine
housing
588 Turbocharger
ISLe375 30 engine
7. Check whether the turbine outlet has any

leakage
1). Use the high-intensity black light lamp.
2). Yellow indicates oil leakage. If the dark blue
light is visible, there is fuel in the engine oil.
3). If there is engine oil on the turbocharger

housing, remove the return pipe and check
whether it is clogged.
4). Remove any clogging.
5). Fit the return pipe of turbocharger.
9. Check whether the turbine inlet has any

leakage
1). Use the high-intensity black light lamp.
2). Yellow flash indicates engine oil leakage.
3). If no yellow flash is found at the turbocharger
inlet, replace the turbocharger.
Turbocharger 589
4). Mount the exhaust pipe on the turbocharger

outlet and tighten the clamp
5). Install the intake pipe on the turbocharger
compressor inlet and tighten the clamp
Preparatory step
1. Remove turbocharger compressor outlet
joint
2. Remove the feed pipe from the
turbocharger
3. Remove the return pipe from the
turbocharger
Removal
1. Remove exhaust pipe
2. Remove air inlet pipe of turbocharger
compressor
3. Remove 4 mounting nuts for the

turbocharger
4. Remove turbocharger and the sealing
gasket

use is possible.
1. Clean the turbocharger exhaust manifold
gasket surface.
2. Check whether the sealing surfaces of
turbocharger and exhaust manifold and
the mounting stubs are cracked or
damaged
1). If the flange mounting surface is cracked,
2). If the flange mounting surface is cracked,
replace the exhaust manifold.
590 Turbocharger
ISLe375 30 engine
3. Remove the carbon deposit and seal on

the surface.
4. Use the detergent or steam to clean the
outside surface of turbocharger.
6. Check the turbine and compressor casing

If the crack extends through the outer wall, replace
the turbocharger.
The air-air intercooler may damage the turbine
casingIf the turbine housing is damaged, check the
air-air intercooler.

oil or scraps have entered into the air-air
intercooler, check and clean the intercooler.
Refitting
1. Apply a coat of high-temperature
anti-sticking compound onto stud bolt of
turbocharger.
2. Fit new sealing gasket and turbocharger
3. Fit and tighten the installed 4 nuts.
The given torque value is based on taking the
antiseize compound as lubricant.
Turbocharger 591
4. Install the intake pipe on the turbocharger

compressor inlet and tighten the clamp
5. Mount the exhaust pipe on the
turbocharger outlet and tighten the clamp
Refitting
1. Fit the return pipe of turbocharger
2. Pour 58 to 89ml clean 15W-40 engine oil

into the turbocharger supply pipe union to
lubricate the bearing.
3. Rotate the turbine impeller to make the
engine oil flow into bearing seat.
Last step
2. Fit the turbocharger compressor outlet
connector
592 Turbocharger
ISLe375 30 engine
II. Renewal of turbocharger return pipe


Common tools
Special tool - -
Testing tools - -
Auxiliary material Compressed air
2. Procedure
Preparatory step
Removal
1. Clean the surroundings of oil return pipe of
cylinder block with clean cloth.
2. Remove two bolts fixing return pipe &
turbocharger
3. Pull the oil return pipe out from the
cylinder block

use is possible.
1. Clean the gasket sealing surface of oil
return pipe and turbocharger.
2. Clean the O-shaped sealing ring in the
cylinder block.
Take care to avoid the entry of any dirt or scraps
into the cylinder block.
Renewal of turbocharger return pipe 593

3. Clean the oil return pipe of turbocharger

with solvent and blow it dry with
compressed air.
oil coking or blockage
5. Check whether there is any charring or
clogging of engine oil in the oil return pipe.

crack, wear, leakage or other damage
If such symptoms exist, replace the return pipe.
7. Check whether the O-ring of oil return pipe
is cracked, worn or eroded.
Refitting
1. Apply a thin coat of clean engine oil on
O-ring of oil return pipe.
2. Push the oil return pipe into the lug boss
3. Ensure that both O-shaped rings are fully
fitted into the hole.
4. Mount the new sealing gasket on oil return
pipe.
5. Fit and tighten the mounting bolt of
turbocharger retun pipe
Last step
594 Renewal of turbocharger return pipe

ISLe375 30 engine
III. Renewal of supply pipe of supercharger


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Clean the surroundings of fuel pipe union with clean cloth.
Removal
1. Remove the feed pipe from the connector
of oil filter retainer
Caution: To avoid loosening accidentally,
fix the pipe union in engine oil
filter seat with wrench.
2. Remove the feed pipe from the

turbocharger bearing housing connector
Renewal of supply pipe of supercharger 595


use is possible.
1. Clean the oil pipe with solvent.
3. Check whether the oil supply pipe has any

crack or may result in oil leakage
4. Check whether the O-ring is worn or
eroded
Refitting
1. Apply a thin coat of engine oil on O-ring of
oil supply pipe.
2. Fit and tighten the turbocharger and feed
pipe of oil filter seat manually
3. Tighten the oil supply pipe on the
turbocharger bearing casing
Caution: Retain 10mm at least of clearance

between the turbocharger oil
supply pipe and its turbine
housing and exhaust manifold.
4. Tighten the oil supply pipe on the oil filter
seat connector
Caution: Tighten the oil supply pipe, and at
the same moment, fix the threaded
pipe union on the oil filter seat by
spanner to prevent the oil filter
seat connector from excessive
tightness
596 Renewal of supply pipe of supercharger

ISLe375 30 engine
Last step
Renewal of supply pipe of supercharger 597

IV. Renewal of turbocharger exhaust bypass valve

actuator

Common tools
Special tool - -
Testing tools Micrometer, pressure gauge
2. Procedure
Initial inspection
Caution: All exhaust bypass valves have
been calibrated in advance, and
shall be not regulated on the field.
The trial adjustment of exhaust
gas bypass valve may damage the
engine.
The integral exhaust gas by-pass valve transfers
the pressurization from turbocharger compressor
outlet to exhaust gas by-pass valve sylphon.
3. Check whether there is any crack or hole

on the actuator hose of integral exhaust
bypass valve
If damaged, replace the hose.
598 Renewal of turbocharger exhaust bypass valve actuator

ISLe375 30 engine
4. Check whether the mounting bracket,

actuator and control rod of exhaust bypass
valve are damaged
Any curved exhaust gas by-pass valve mounting
bracket, actuator lever or control lever may work
abnormally.
If the exhaust bypasss valve bracket, actuator
lever or control lever is bent, it shall be replaced.
Test
2. Disconnect integral supercharging pipe

from exhaust bypass valve bellows
3. Fit dial gauge
Fit the micrometer (1) as shown in the figure to
bring its shaft in a line with the exhaust gas bypass
valve actuator rod. Rest the dial indicator to zero
4. Connect the regulated clean air pressure
source with the pressure gauge and
diaphragm box
5. Apply a pressure of 200kPa

1). Ensure that the exhaust gas bypass valve works normally.
2). If there is no block or air leakage, the actuator rod must move for about 5m.
3). It must not be heard that, for example, the air is leaking from the working waste-gate sylphon.
4). Slight displacement is normal when the air pressure is applied at the start. There is no tolerance for
this system.
Renewal of turbocharger exhaust bypass valve actuator 599

5). If the actuator rod doesn’t move, separate the

actuator control lever from the exhaust gas
bypass valve control lever pin.
6). Check whether the shaft can move freely and
is not blocked by hand.
7). If the exhaust gas bypass valve control lever
can’t be moved by hand, replace the
turbocharger.
8). If the exhaust gas bypass valve control lever
can be freely moved by hand, replace the
bypass valve actuator.
Removal
2. Record the position length of control rod in

the boosting film box casing, and the
direction of hose union of boosting film
box against the mounting bracket
3. Remove the retaining clip from the control

lever
4. Remove integral supercharging pipe from
exhaust bypass valve bellows

ISLe375 30 engine
Caution: Take care to not bend the control

lever; otherwise the engine may
be damaged.
5. Remove the supercharger bellows actuator
lever end from the turbocharger exhaust
gas bypass valve control lever
To arrive at this, slowly supply adjusting air into the
pressurizing membrane box till the control lever
moves.
6. Remove the control lever from the
turbocharger exhaust gas bypass valve
lever pin
1). If the membrane of pressurizing box is burst

and can’t resist the air pressure, pull the
control lever by hand to overcome the spring
tension of pressurizing membrane box thus to
remove the control lever from the
turbocharger exhaust gas bypass valve stem
pin.
7. Undo the pressurizing membrane box
mounting bolt.
8. Remove air supply hose
9. Remove the assembly from the carrier

use is possible.
1. Check whether the actuator hose of
exhaust bypass valve has any crack or
hole
If damaged, replace the hose.
2. Check whether the mounting bracket,

actuator and control rod of exhaust bypass
valve are damaged
Any curved exhaust gas by-pass valve mounting
bracket, actuator lever or control lever may work
abnormally.
If the exhaust bypasss valve bracket, actuator
lever or control lever is bent, it shall be replaced.
Renewal of turbocharger exhaust bypass valve actuator 601

Refitting
1. Mount the mounting stubs of actuator in
the bracket hole
2. Fit the mouting bolts of two actuator
3. Re-install the end linkage on the
crankshaft pin
4. Fit the control lever fixing clip
5. Cut off the binding strip, and then remove
the strip and pad.
6. Use the provided new hose clamp to

connect the gas supply hose with the
actuator again
7. Fit the turbocharger (if removed)

ISLe375 30 engine
Air compressor
I. Carbon deposit in air compressor

Nonmetallic brush
Special tool - -
Testing tools - -
Auxiliary material Compressed air, detergent
2. Procedure
Initial inspection
1. Stop the engine
2. Turn on the air Draining cock on the wet air
reservoir
3. Release the compressed air in the system.
Warning: The temperature of gas supply

pipeline is extremely high. It is
allowed to contact the pipe only
after the pipe becomes cool to
avoid the personal injury.
4. Remove the connectors at the intake port
and exhaust port from the air compressor
Carbon deposit in air compressor 603

5. Measure the total thickness of carbon

deposit in the air outlet pipe
Caution: Carbon deposit thickness should
not exceed 1. 6mm.
Warning: The exhaust must be capable to

bear the high temperature and
high voltage to as to avoid
personnel injury and property loss
Caution: If the carbon deposit thickness
exceeds the required limit, remove
and clean the exhaust pipe or
replace it.
6. Check whether there is any carbon deposit
from gas supply pipe union to first
connector or wet-type gas reservoir
7. Wash or renew all pipes and unions with
the carbon deposit thickness of higher
than 1. 6mm.
604 Carbon deposit in air compressor

ISLe375 30 engine
Cleaning
Caution: 1. Do not use sharp tools to clear
carbon deposit, otherwise the
sealing surface will be damaged.
2. Avoid the entry of debris and
solvent into the gap between
piston and cylinder hole.
8. Remove air compressor cylinder head &
valve assembly
9. Clean the air compressor cylinder head

and valve assembly with solvent and
nonmetallic brush.
10. Use the compressed air to dry the
passage.
11. Clean the compressor cylinder.

1). Rotate the crankshaft till the piston reaches
the top point of cylinder hole.
2). Use the detergent to remove the carbon
deposit and oil sludge.
12. Fit the air compressor zyliner cover and

valve assembly
Carbon deposit in air compressor 605

II. Air compressor coolant pipe


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
Removal
1. Remove air compressor cylinder head and
the cylinder body coolant pipe

1. Check whether the clamp or connector has
damaged thread
2. Check whether the flowing of coolant is
affected in the coolant hose and pipeline
606 Air compressor coolant pipe

ISLe375 30 engine
Refitting
1. Fit the air compressor cylinder head and
coolant pipe of cylinder
Last step
Air compressor coolant pipe 607

III. Renewal of air compressor cylinder head and single

cylinder

Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
3. Remove air regulator or signal line
4. Remove air compressor coolant pipe
Removal
1. Remove 4 pieces of 8mm bolts
2. Remove air compressor cylinder head and
the sealing gasket
Refitting
1. Use new gaskets to fit the air compressor.
2. Fit the cylinder head and sealing gasket
3. Fit 4 bolts of 8 mm
4. Tighten all the bolts according to the
illustrated sequence
Use the torque + angle method.
Tightening torque
Step 1 25 N·m
Step 2 Turn the bolt 1, 2 and 3
by 90 degree
Step 3 Turn the bolt 4 by 60
degree
608 Renewal of air compressor cylinder head and single cylinder

ISLe375 30 engine
Caution: If a new cylinder head assembly is fitted, fasten these five small bolts of head.
5. Tighten five little bolts of cylinder head

according to the illustrated sequence (if a
new cylinder head assembly is installed)
Step 2 Turn by 90
degree.
Last step
1. Assemble air intake and exhaust joint of air compressor.
2. Assemble air pressure regulator or air pressure regulator signal line (. If necessary).
3. Fit air compressor coolant pipe
Renewal of air compressor cylinder head and single cylinder 609

IV. Air compressor unloading valve and valve body

assembly

Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Remove the air pressure regulator or air
pressure regulator signal line from the air
compressor
If the compressor doesn’t work, replace its cylinder

head.
610 Air compressor unloading valve and valve body assembly

ISLe375 30 engine
V. Air compressor

Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
2. Empty the engine cooling system
3. Remove any attachment at rear end of air compressor
4. Remove the coolant pipe from the air compressor
5. Remove air regulator or signal line
6. Remove the connectors at the intake port and exhaust port from the air compressor
7. Remove air compressor supply pipe
Removal
1. Remove air compressor bracket & bolt
2. Remove 2 bolts and the air compressor
Air compressor 611


use is possible.
1. Check whether the air compressor casing
is cracked or damaged
2. Check whether the drive gear is cracked or
damaged
3. Ensure that the front gear housing and air

compressor gasket surface are clean and
undamaged.
4. Check the adapter behind the air

compressor
If worn, replace the adapter. Use the air
compressor puller for the 11-tooth adapter. Use
the air compressor puller for the 13-tooth adapter.
Refitting
1. Timing of air compressor (only for the
single-cylinder air compressor)
Rotate the engine to locate the cylinder No. 1 at
the top dead center of compression stroke. To
arrive at this, align the timing mark on fuel pump
gear with TDC mark.
612 Air compressor

ISLe375 30 engine
Caution: The air compressor gear bears

two similar marks (looking like
“[1]” and “1”). Use the timing mark
“I” to set the timing of air
compressor and engine.
Cummins single-cylinder air compressor

1). When viewing the compressor (it is in the
vertical position) from the gear end, rotate the
gear to make the “1” timing mark stay at the 3
o’clock position. On the Cummins
single-cylinder air compressor, there is a small
plate at the 3 o’clock position on its casing to
set the timing of compressorOnce the timing
mark is located at the 3 O’clock position, this
may set the compression stroke of
compressor at 60°in front of top dead center.
2). Timing of air compressor (only for the

single-cylinder air compressor other than
Cummins)
3). Remove unloading valve or cylinder head, so
as to find top dead point of compressor crank.
Refer to the related air compressor manual.
TDC is not needed to be very correct. A
certain angle error is allowed in the system.
4). Mark the TDC position (12: 00 o'clock position

seen from the front) of air compressor gear
face with ink or dykem.
Air compressor 613

5). Rotate the TDC mark of compressor to 60°

before TDC or ahead by 6 teeth on 36-tooth
gearThis is about 10: 00 o’clock position seen
from the front of air compressor.
2. Install the air compressor and new gasket

on the gear chamber
3. Mount the bracket on the air compressor

Tighten the bolt
4. Mount the spacer on the bracket bolt, and

then tighten it by hand
Ensure that there is no gap between the spacer
ring and the carrier and between the spacer ring
and the cylinder block.
Tighten the bolt
614 Air compressor

ISLe375 30 engine
5. Assemle and tighten the bolt which

connects spacer ring and cylinder body
Ensure that there is no gap between the spacer
ring and the carrier and between the spacer ring
and the cylinder block.
Last step
1. Connect the oil supply pipe of air compressor
2. Install the unions of intake and exhaust pipes on the air compressor
3. Fit the air conditioner compressor or air pressure adjuster signal wire (. If necessary)
4. Fit air compressor coolant pipe
5. Mount any accessory behind air compressor.
6. Fill the engine cooling system
Air compressor 615

VI. Air pressure regulator


Common tools
Special tool - -
2. Procedure
Measure
The position of speed regulator of air compressor
is quite differentThe air pressure regulator can be
installed on the air compressor or chassis
If the air pressure is higher or lower than the limit
specified by the manufacturer, connect the
adjusted overhaul air pressure pipe to the air
signal port of air compressor governor.
Before checking air pressure, be sure that the
barometer is accurate and the working state of air
supply pipe and pipe union is good. Check the
barometer with standard pressure with known
precision.
Ensure that the air system pressure does not exceed the maximum allowable pressure by the
manufacturer during testing.
Operate the engine and increase the pressure of signal sent to air regulator to check when the air
compressor stops the pumping operation (the system pressure stops increasing at this time.).
Reduce the signal pressure, to ensure when the system pressure re-enables the air compressor to
supply the air (at this moment, the system pressure increases again)
Compare these pressure values with the technical specifications provided by the manufacturerIf such
pressures can’t satisfy technical requirements, the governor is in trouble, and requires repairs,
replacement or adjustment.
616 Air pressure regulator

ISLe375 30 engine
VII. Leakage of compressed air system


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Stop the engine
2. Open the air Draining cock on the wet air
reservoir
3. Release the compressed air in the system.
4. Close the bleeding cock

Use soapy water to check for any air leakage at
the following parts when the pumping pressure of
air compressor is between 550 kPa and 690 kPa:
• Air compressor cylinder head gasket
• Air compressor cover gasket
• Leakage of hose and union
If any air leakage is detected, check whether the
air compressor cover and bolt are fastened
correctly. Ensure that the hose and pipe union are
tightened. If necessary, replace it.
Leakage of compressed air system 617

VIII. Air compressor oil supply pipe


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
Removal
2. Remove air compressor & cylinder block’s
air compressor supply pipe

use is possible.
1. Check whether the oil supply pipe of air
compressor has any crack, or is worn or
damaged
If damaged, replace it.
2. Check whether the oil supply pipe and
union of air compressor have any
blockage that may result in wrong oil flow
3. Clear away any blockage and renew the air
compressor feed pipe or union as required
618 Air compressor oil supply pipe

ISLe375 30 engine
Refitting
1. Fit air compressor and feed pipe of air
compressor for the cylinder
Last step
Air compressor oil supply pipe 619

Cooling system
Cooling system
General
I. Cooling system- general description
The cooling system is used to keep the specific
working temperature of engineThe coolant flows
through the coolant passage on the cylinder block
and head, absorbing some of heat produced by the
engineThereafter, when the coolant passes
through the radiator, the heat in the liquid is carried
away.
The engine fitted with automatic gearbox and using

the traditional cooling method usually uses the
cooler of oil-water gearbox torque converter. The
cooler is connected between the radiator and the
engine water pump
The cooling system of torque converter fitted with
remote bypass valve enables the coolant to flow
though the torque converter when the thermostat is
closed (when the engine is cold)
Following publications have provided the cooling

system installation suggestions and technical
requirements approved by Dongfeng Cummins.
• Installation suggestions for vehicle (cooling
system)
• Installation suggestions for construction,
mining, lumbering & farming (cooling system)
• Database of specific engine model
• Operation of diesel engine in cold weather
• Heavy-duty coolant/SCA maintenance
requirements
620 Cooling system- general description

ISLe375 30 engine
Open the screw plug at the bottom of radiator and

oil cooler housingRemove lower hose of radiator. A
20L oil pan is necessary to contain the coolant for
most application.
Please note the following points when making a

fault diagnosis on overheating: If there is overmuch
oil in the oil pan, the frictional heat may be
produced when the linkage journal is soaked in the
engine oil. Too much oil filling causes temperature
increase, and transfers heat in oil cooler to cooling
system.
The amount of coolant in the cooling system shall

be specific; if the coolant level is too low, the
engine will overheat.
If it is required to frequently add the coolant, there
may be a leakage in the engine or system. Check
for and repair leakage.
The intake air will mix with the coolant and causes
cavitation and dropping of heat transfer efficiency
when the engine is in operation. Too much air in
the coolant may overheat the cylinder head and
block locally, crack the cylinder head, damage the
cylinder liner or make the cylinder head gasket
leaking
Cooling system- general description 621

Cooling system
The blockage of coolant passage may reduce the

coolant flow and result in overheating
The cylinder head gasket is especially easy to be
clogged. There size is critical. Do not ream the
holes. This will disturb the flow of cooling fluid but
cannot eliminate overheating problem.
Water may cause rusting to reduce the coolant

flow at the narrow passage.
Additionally, if the cold water is used as coolant,
the expansion plug will be rusted, resulting in
coolant leakage in a short period
Sudden shutoff of coolant supply to the engine
which runs with high load can cause serious
damage of piston and cylinder port.
Excessive fuel supply and overload

Excessive fuel supply can cause engine
overheating. Ensure that the engine electronic
control module (ECM) is correctly calibrated.
Continuous overload will result in engine

overheating.
622 Cooling system- general description

ISLe375 30 engine
Flow rate of internal engine coolant
发动机内部冷却液流量
Flow rate of internal engine coolant
1. Coolant flowing from radiator 5. Outlet of coolant filter (optional)

2. Water pump suction pipe 6. The outlet of coolant filter (optional)
3. Coolant flows through the oil cooler 7. Coolant to the cylinder head
4. Cylinder body lower part water manifold (to the cylinder) 8. Coolant that flows out the cylinder head
Cooling system- general description 623

Cooling system
II. Draining of cooling system and filing of coolant


Common tools
Special tool - -
Testing tools - -
2. Procedure
Draining
Warning: Do not open the pressure cap of
radiator on the hot engine. Open
the pressure cover after the
coolant temperature is reduced to
below 50 ℃ . Otherwise, the
high-temperature coolant or steam
may eject to cause human injury.
1. Remove pressure cap
2. Open the exhaust valve on the radiator and

the exhaust valve at the bottom of engine
oil cooler housing
A 19L oil pan is enough for most application.
4. Remove pressure cap to drain the coolant
5. Draining of cooling system
6. Close the exhaust valve
7. Check whether there is any damaged hose
and loose or broken hose clamp
624 Draining of cooling system and filing of coolant

ISLe375 30 engine

8. Check whether the radiator has any
leakage, damage or dirt
. If necessary, clean or replace it.
Flushing
The Fleetguard Restore heavy-duty cooling
system detergent can remove the corrosion, silica
ans other sediment. The performance of
Fleetguard Restore is determined by time,
temperature and concentration. For example, the
scaled or blocked system may use thicker cooling
agent, higher temperature or longer cleaning
period or use Restore PlusThe Retore with
concentration up to two times more than the
recommended value can be used safely. Restore
Plus only can be used based on the recommended
concentration. The system which is polluted or
blocked severely may be cleaned for many times.
Caution: Fleetguard Restore does not

include antifreeze. Never froze the
cooling system during cleaning
Caution: The system must be correctly
refilled to avoid air lock. During
filling, it is necessary to dispel the
air from the engine coolant
passageFor intercooled engine,
make sure to open the cock on the
intercooler. Wait for two to three
min to enable the air to Draining,
and then fill the mixture till the top.
Add immediately 3. 8 L Fleetguard Restore, Restore Plus or equivalent for every 38-57 L coolant.
1. Fill clean water into the system.
2. Adjust the cab heater temperature switch to high level
It is allowed to let the cooling fluid pass the heater core at its maximum flow rate. No need to switch on
the blower.
Draining of cooling system and filing of coolant 625

Cooling system
3. Operate the engine for 1~1. 5 hours under

normal working temperature (85 ℃ at
lease).
4. Stop the engine
5. Cool the coolant to 50℃

7. Fill clean water into the cooling system.
8. Run the engine at high idle speed for 5min

with the coolant temperature higher than
85℃.
9. Stop the engine
10. Cool the coolant to 50℃, and then Draining
the cooling system
If the Drainingd water is still very dirty, flush the
system again till the clean water is Drainingd.
Filling
Caution: The system must be correctly
refilled to avoid air lock. During
filling, it is necessary to dispel the
air from the engine coolant
passageFor intercooled engine,
make sure to open the cock on the
intercooler. Wait for two to three
min to enable the air to Draining,
and then fill the mixture till the top.
Caution: Do not only use water as coolant.
Otherwise, corrosion can occur
and damage the engine.
1. The designed filling speed of cooling system 19L/min

2. Fill a mixture made up of 50% water and 50% glycol anti-freezing liquid into the cooling system.
626 Draining of cooling system and filing of coolant

ISLe375 30 engine
III. Diagnosis of cooling system


Common tools
Special tool - -
Testing tools - -
2. Procedure
General
Following procedures include common failure

diagnosis procedures for identification:
Reasons for engine overheating. See “Initial
check” in the procedure.
A work list is attached to the latter end of this step
for recording the measured value during
troubleshooting. This work sheet is helpful for data
collection and analysis.
Leakage/loss of external and internal coolantSee
“Pressure test” in the procedure.
Initial inspection
1. Connect the service software with the
communication interface of vehicle
2. Rotate the key switch to “ON” position
3. Monitor the temperature of cooling fluid
with application software.
4. Check the coolant temperature recorded
when the shutter is opened.
Diagnosis of cooling system 627

Cooling system
Compare this value with the finger marked on the

shutter controller
Cummins Company suggests to ensure that the
temperature curtain be opened at the temperature
of 85℃
when the fan is engaged

fan controller
Cummins Company suggest that the fan shall be
started at the temperature of 96℃
6. Monitor the temperature of cooling fluid
with application software.
Compare with the thermometer readings of driver
cab.
If the manufacturer’s technical requirements on the

correct reading can’t be satisfied, replace the cab
temperature gauge.
If the manufacturer’s technical requirements are
unavailable and the reading is beyond the correct
range by more than ±3. 9 ℃ , replace the
instrument.
7. Measure the coolant pressure at the

coolant cock at the exhaust side of
cylinder head
628 Diagnosis of cooling system

ISLe375 30 engine
Pressure test
1. Check the coolant level
1). . If necessary, provide a refilling operation.
2). To identify the coolant leakage, it may be

required to add certain fluorescent tracer into
the coolant.
3). Add a unit of fluorescent tracer in every 38L of
coolant
4). Make the fluorescent tracer circulate through
the lubricating system when the engine runs at
an idle speed for five to ten min or when the
normal operating temperature is reached.
2. Use the high-intensity black light lamp or

its equivalent to illuminate the dye.
Caution: The pressure applied on the

cooling system should be no more
than 138 kPa, otherwise the
tightness of water pump can be
damaged.
3. Mount plug on overflow pipe (1) (if there is
pressure reducing valve on radiator).
4. Mount the pressure tester on the radiator
filler neck or supplement the radiator (if
any) and increase the pressure
• Air pressure 138kPa
5. The repair tools for coolant Dam/pressure
tester boost the cooling system

Cooling system
The coolant Dam/pressure tester uses the

compressed air instead of hand air pump
For external leakage of coolant
1. Check whether the exterior of engine leaks
coolant
. If necessary, repair it.

Please pay special attention to immediate areas of
following parts:
• Oil cooler
• Water pump
• Air compressor cylinder head gasket
• Bowl plug and pipe plug
• Variable-section turbocharger and coolant
tube
For internal leakage of coolant
1. Check the interior of engine

To find the coolant leakage, the following
components may be dismounted
• Rocker chamber cover
• Oil pan
If it is doubted that there is a mixture of coolant
and fuel,
1. Disconnect the return pipe union at the

rear of cylinder head

ISLe375 30 engine
Test
All cab heaters and air conditioners shall be shut
down, and the engine fan control shall be turned to
AUTOMATIC (if applicable).
1. Remove radiator cover
Never install it during the following test s
2. Fuel leakage test

1). Use the gas tester or its equivalent to check
whether there is any fuel gas in the cooling
system.
2). To check whether there is leakage of fuel gas,
it is advisable to adopt the cooling system
mixed by 50% of antifreezing fluid and 50% of
water. Using only water during testing will
cause the color of test fluid turn from blue to
turquoise or light green。But this does not
indicate leakage of gas.
3). Draining the coolant to drop the coolant level

to 76mm under the pressure cover seal in the
radiator filler
4). If the coolant level is higher than this point, it
may pollute the testing liquid to invalid the
test.
5). Pour the test fluid into the gas leakage tester
till this fluid is filled to the yellow mark on the
instrument

Cooling system
6). Insert the rubber end of gas leakage tester

into the radiator water filling journal, fix the
instrument downward firmly and rotate it back
and forth, ensure a tight gas seal between the
tester and radiator water filling neck
7). Start the engine, and have it run at high idle

speed for about 30min. During the operation
of engine, monitor the engine temperature and
color of testing liquid. Do not let the
temperature of engine exceed 100℃ during
testing.
8). When the tested fluid changes its color from

blue to yellow or green during the test, this
shows the leaked fuel gas enters in the
cooling system. If the testing liquid turns to be
yellow or green from blue, interrupt the test.
9). If the testing liquid doesn’t turn to yellow or

green from blue within the test duration of
30min. , run the engine at low idle speed.

ISLe375 30 engine
10). Check the tester and ensure that is firmly

sealed on the water filling neck of radiator
11). Insert the rubber ball tip into the hole on the
top of tester, press the rubber ball for 2-3min,
and suck out the air in the radiator through test
fluid
12). If the testing liquid remains blue, the fuel gas
has not entered into the cooling system. If the
testing liquid turns to yellow or green from
blue, the fuel gas has entered into the cooling
system, and another test is required to
determine the position of gas leakage.
13). When the cooling system is preheated to the

operating temperature, the air will Draining in
the form of bubble via the gas tester, which is
caused by normal expansion of coolant. Do
not wrongly take the appearance of bubbles in
the tester as the leakage of fuel or air into the
cooling system. The color changing of test
fluid from blue to yellow or green is the only
sign indicating that there is fuel in the cooling
system.
14). If the fuel gas tester indicates positive results,

the cylinder head gasket or casting has
leakage.
Caution: If the testing liquid turns to be
positive, discard it.

Cooling system
15). Negative results indicated by the fuel leakage

test or continuous bubbling in the previous test
shows following conditions:
• The fan, louvre or heater air control valve is
faulty
• The air compressor cylinder head or its gasket
has leakage
• The air is mixed due to the damage of radiator
check valve or incorrect filling.
Overflow method
1. Cool the engine.
1. And remove radiator cap
2. Fit the removed spring and the pressure cover of evaporator of pressure reduction valve
Have the liquid flow through the overflow pipe

freely.
3. Connect one rubber hose with the overflow
connector of radiator
4. Place the free end of hose under the water
surface in the water container
The pressure valve must be tightly sealed on the
radiator filler neck top.
5. Operate the engine at the rated speed of
rotation.
6. Till the temperature reaches 82℃.

7. Check whether the hose in the water
container emits air bubbles
During this test, the engine coolant temperature
must be stableThe rising of coolant temperature
will expand the coolant in the system, resulting in
wrong air reading
Data analysis
1. In mixed gas leakage test after burning, check the color of liquid.

ISLe375 30 engine
The case, together with results from sight hole, will

be helpful for isolating air source (if any) inside
cooling system.
If the post-combustion mixture leakage test
indicates no leakage, the potential leakage can’t
be precluded. The test component is not sensitive
enough to detect the minute leakage of gas
mixture after combustion.

when the shutter is opened.
shutter controllerCummins Company suggests to
ensure that the temperature curtain be opened at
the temperature of 85℃

when the fan is engaged
Cummins Company suggest that the fan shall be
started at the temperature of 96℃
4. Compare the reading of cab temperature

gauge with the cylinder block temperature
If the manufacturer’s technical requirements on the
correct reading can’t be satisfied, replace the cab
temperature gauge. If the manufacturer’s technical
requirements are unavailable and the reading is
beyond the correct range by more than ±3. 9℃,
replace the instrument.

Cooling system
5. Read the recorded pressure of cylinder

block at 60℃.
If no pressure cover is fitted in the operation at
high idle speed, the cylinder block pressure shall
be lower than 138kPa. Check the following items:
1). Remove water pump.
2). Check the completeness of impeller and
whether it slides on the shaft
3). Check the tension and state of belt
If the cylinder block pressure drop exceeds 34kPa,

check against following items:
1). There is air in the system.
2). The initial filling of cooling system is incorrect
3). Check whether the percentage of
antifreeze-mixed fluid is lower than 50/50, or if
the engine runs at high altitude.
6. Check the color of fluid in the gas leakage

tester
Yellow or green indicates fuel leakage. Blue
indicates no leakageThis information is helpful for
isolating air source of cooling system, if any.
The test component is not sensitive enough to
detect the minute leakage of gas mixture after
combustion.
If the post-combustion mixture leakage test
indicates no leakage, the potential leakage can’t
be precluded.

ISLe375 30 engine
Radiator and union, coolant filter, expansion

tank
I. Renewal of radiator

Common tools
Special tool - -
Testing tools - -
Auxiliary material Compressed air
2. Procedure
General
The air inductive in fan flows into the radiator fin
and cools the cooling fluid pumped in radiator.
Environmental debris (e. g. , paper scrap, wheat
straw, floss, dirt) can block the radiator fin and
hinder the air flow, thus worsening the cooling
effect.
Initial inspection
1. Check whether the radiator fin is blocked
2. Use the compressed air to purge out the
dirt and scraps.
• Air pressure: 552kPa
Renewal of radiator 637

Cooling system
3. Check whether the radiator fin is bent or

broken
4. Check whether the radiator core and

gasket have any leakage
. If necessary, replace the radiator.
638 Renewal of radiator

ISLe375 30 engine
II. Renewal of radiator hose


Common tools
Special tool - -
Testing tools - -
2. Procedure
1. Check whether all the hoses have cracks,
notches or sink
Caution: Due to its elasticity, the silicone
hose for the engine coolant can
expand.
Renewal of radiator hose 639

Cooling system
III. Renewal of radiator pressure cover


Common tools
Special tool - -
2. Procedure
General
This system uses pressure cap to prevent the
coolant from boiling.
Different pressure covers are used in these two
recommended systems.
Radiator cover pressure test
System Cover
A (normal 104℃ 103kPa

load)
B (light-duty) 99℃ 48kPa
The improper use or failure of pressure cover may

lead to coolant loss and engine overheat.
640 Renewal of radiator pressure cover

ISLe375 30 engine
When the coolant containing air is heated, the air

expands and makes the coolant spill out and
cause loss. After the air expands due to heat, the
system pressure will increase and open the
pressure cover
Similarly, if the compressed air leaks into the
cooling system via the cylinder head gasket, it may
give rise to the loss of coolant.
If there is any leakage between the cylinder head

gasket and the engine oil cooler etc, the engine oil
will be mixed with the coolant under the working
pressure of cooling system and lubricating system.
The gearbox oil may also leak into the coolant via
the gearbox oil cooler fitted in the water tank on the
radiator bottom.

1. Ensure that the correct pressure cover is
used.
2. Check whether the rubber seals of
pressure cover are damaged
3. Visually check whether there is any crack
or other damage on the radiator filling neck
If the filler neck is damaged, make reference to the
related instruction in the repair manual of
equipment manufacturer.
4. Conduct pressure test on the radiator

pressure cap
The pressure valve must be properly sealed within
the zone marked with the 14kPa pressure value;
otherwise it must be replaced.
641
Cooling system
IV. Coolant filter


Common tools
Special tool - -
Testing tools - -
2. Procedure
Removal
The engine of some model does not need the
coolant filter
1. Remove pressure cap of cooling system
2. Close the shut-off valve
Close the stop valve by turning the knob from the
vertical position to the horizontal position
Warning: A few coolants may leak out when

the coolant filter is repaired with
the shut-off valve at the OFF
position. To minimize personal
injuries, avoid the contact with hot
coolant.
3. Remove and discard coolant cleaner
642 Coolant filter

ISLe375 30 engine
Refitting
1. Apply a thin coat of engine oil on sealing
gasket surface.
2. Mount the coolant filter on the filter seat
Tighten the filter till the gasket touches the filter
seat surface
3. Tighten the coolant filter for another 1/2 to
3/4 of a circle
Caution: The cutoff valve must be turned to

ON to avoid damaging the engine.
4. Open the shut-off valve
Open the stop valve by turning the knob from the
horizontal position to the vertical position
5. Fit cooling system pressure cover

7. Check whether the coolant leaks
8. After the air in the system is Drainingd
9. Check the coolant level
643
Cooling system
V. Coolant filter seat


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
3. Remove coolant cleaner
Removal
1. Undo these four filter seat bolts.
2. Remove filter seat and the sealing gasket

use is possible.
1. Clean the mating surface.
644 Coolant filter seat

ISLe375 30 engine
2. Check whether the filter seat has any

crack, burr or other damage
If the filter seat is damaged, replace it.
Refitting
1. Fit new sealing gasket and filter seat
2. Tighten four bolts
Wearing limit
Last step
1. Fit coolant filter
Coolant filter seat 645

Cooling system
VI. Coolant filter valve


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
3. Remove coolant cleaner
4. Remove coolant filter seat
Removal
1. Loosen cutting-off valve screw from valve
end
2. Remove cutting-off valve’s double pieces

on both sides of hole
646 Coolant filter valve

ISLe375 30 engine
Refitting
1. Renew the shut-off valve O-ring
2. Lubricate the O-shaped ring.
3. Install the valve member into the valve hole
4. Tighten the screw of cut-off valve

And tighten both valve pieces together;
Last step
1. Mount the coolant filter seat on the engine
2. Fit coolant filter.
Coolant filter valve 647

Cooling system
VII. Coolant heater


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
Removal
1. Disconnect the electrical cable of coolant
heater
2. Undo the coolant heater, and remove it

from the cylinder block.
648 Coolant heater

ISLe375 30 engine
Cleaning
1. Thoroughly clean coolant heater & cylinder
block thread
Refitting
new coolant heater thread.
2. Fit coolant heater

3. Connect the coolant heater wire

Last step
Coolant heater 649

Cooling system
Coolant pump and thermostat

I. Renewal of coolant pump

Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Check whether the water pump casing has
any crack and/or is damaged
2. Check whether the water pump leak hole
keeps on leakage
Caution: The strips or chemical deposit at
the leakage hole shall not be used
as the reference of Renewal of
water pumpIf the coolant flows
stably, replace the water pump.
Preparatory step
Removal
1. Remove water pump bolts and water pump
650 Renewal of coolant pump

ISLe375 30 engine

use is possible.
1. Clean the water pump housing and
cylinder block O-shaped ring sealing
surface.
2. Check whether vane has cracked or

missed blade
3. Check whether the shaft slides or has
other damage
4. Check whether the water pump casing is
cracked and damaged
5. If damaged
6. Renew the water pump
Refitting
1. Mount the new O-ring in the slot on the
water pump housing
2. Fit water pump

Last step
1. Fit drive belt
651
Cooling system
II. Renewal of automatic belt tensioner (water pump)


Common tools
Special tool - -
Testing tools - -
2. Procedure
Initial inspection
1. Check belt deflection under longest belt
pan.
The deflection inspection must be made at the
center point (1) of span.
The permissible maximum belt flexibility is 9. 5mm
to 12. 7mm.
2. Use the belt tension gauge to measure the

tension of transmission belt.
This shall be in the range of 360~480N·m.
652 Renewal of automatic belt tensioner (water pump)

ISLe375 30 engine
3. Check whether the tensioner arm, pulley

and limit block have any crack
If any crack is visible, replace the tensioner.
4. Verify that tensioner arm stopper is not in

contact with spring shell stopper (fitted
with a belt)
If the stopper is contacted, replace the drive belt.
After the belt is replaced, if the tensioner arm
stopper still contacts with the spring housing
stopper, replace the tensioner.
Preparatory step
Removal
1. Remove the bolt and belt tensioner from
the bracket
Renewal of automatic belt tensioner (water pump) 653

Cooling system

1. Check the position of drive belt on the belt
tensioner pulley
The belt is in the middle of or near the center of
belt pulleyThe unaligned belt, either close to the
front or to the rear, will be subject to premature
abrasion, rolling failure or worsened uneven
abrasion of tensioner bushing.
2. Check whether the belt is damaged

3. Transverse (width) crack is acceptable.
4. The longitudinal crack (along the length of
belt) crossed with the transverse crack is
unacceptable.
If the belt is worn or any part is missing, the belt
shall be rejected and replaced.
5. Verify that tensioner arm stopper is in

contact with spring shell stopper (belt
removed)
If there is no contact between both, replace the
tensioner.
6. Measure the clearance between the spring

housing of tensioner and the tensioner
arm
If the gap at any point exceeds 3mm, the tensioner
is disabled and the whole assembly must be
replaced.
The test shows that the tensioner usually has
larger clearance difference near the underpart of
spring casing, resulting that the upper part rubs
with the tensioner shoulderMake sure to renew the
belt when renewing the tensioner.
1). Tensioner cap
2). Tensioner arm
3). Spring housing
654 Renewal of automatic belt tensioner (water pump)

ISLe375 30 engine
4). Tensioner belt pulley
5). Clearance difference

7. Check whether the tensioner arm contacts
the tensioner cap
If these two parts contact each other, the pivot
sleeve bushing is disabled, and the tensioner must
be replaced.
Refitting
1. Fit the belt tensioner and bolt
Last step
1. Fit drive belt
4. Check whether the rotation is correct
655
Cooling system
III. Renewal of water inlet joint


Common tools
Special tool - -
Testing tools - -
2. Procedure
Preparatory step
3. Disconnect the coolant hose from the inlet pipe union
Removal
1. Remove water inlet joint bolt

use is possible.
1. Clean all mating surfaces.
656 Renewal of water inlet joint

ISLe375 30 engine
Refitting
1. Fit the sealing gasket of inlet union
2. Fit the water inlet joint and mounting bolt
Last step
1. Connect the coolant hose of inlet pipe union
2. Add the coolant
Renewal of water inlet joint 657

Cooling system
IV. Renewal of coolant thermostat


Common tools
Special tool - -
Testing tools Temperature gauge
2. Procedure
General
Control coolant temperature ofrmostatWhen the
coolant temperature is lower than the operating
temperature, the coolant flows into the pump inlet
via the bypass. When the coolant temperature is
within the operating range, the thermostat is turned
on to close the bypass and force the coolant to
flow into the radiator. The thermostat starts to open
at 82℃
Caution: Never run the engine without

thermostatWithout thermostat, the
passage where the coolant
resistance is minim is through
bypass to water pump inletThis
will cause engine overheating.
The incorrect specification or failure ofrmostat may
result in overheating or over-cold of running engine
658 Renewal of coolant thermostat

ISLe375 30 engine
Leakage test
The engine thermostat and thermostat seal must
work normally so as to ensure that the engine
operates within the most effective temperature
range. Too hot or cold may shorten the service life
of engine.

2. Remove radiator hose from water outlet
joint
3. Mount applicable temperature gauge in
cylinder block at one side of engine
calorstat.
4. Mount the hose with the size same with the
water outlet on the water outlet.
This hose should be long enough to connect a dry

container far away, so as to gather the
coolant.
5. Assemble and fasten the clip at housing
outlet.
6. Place one end of hose in the dry container
Renewal of coolant thermostat 659

Cooling system
This test must be conducted only when the engine

coolant temperature is lower than the temperature
when the thermostat is turned on.
8. Run the engine at the rated speed for one
minute.
9. Stop the engine and measure the coolant
gathered in the container
10. The volume of collected coolant shall not
exceed 100cc.
If the volume of collected coolant is more than

100cc, there is leakage in the thermostat which
shall be replaced.
11. Fulfill following on-board tests to

determine the thermostat opening
temperature.
12. Start the engine, and monitor the water
temperature via the diagnoser or the
instrument.
Keep engine operating at 1500 rpm below during
the test.
Initial opening temperature ofrmostat
Minimum 81℃
Maximum 83℃

ISLe375 30 engine
13. When the coolant starts flow, turn off the

engine
If the coolant doesn’t start to flow into the vessel
within the initial opening temperature range,
replace the thermostat.
Preparatory step
3. Remove radiator hose from water outlet joint
Removal
1. Remove water outlet joint bolt & outlet
joint
2. Remove thermostat

use is possible.
1. Clean all mating surfaces.
Caution: At washing the surface, avoid the
entry of any scraps into the
thermostat chamber.
Renewal of coolant thermostat 661

Cooling system
2. Check whether the thermostat is damaged
Caution: Do not let the thermostat or the

thermometer in contact with the
container.
1). Heat the water and check the thermostat by
the following sequence
2). Suspend the thermostat and a temperature
gauge with a range of 100℃ in the water
container
3). There is nominal working temperature on

calorstat. The thermostat must meet the
following standard:
• The thermostat must open at nominal
temperature±1℃
• The fully-opening temperature ofrmostat must
within 12℃ to this nominal temperature
4). When the calorstat is open fullyThe distance
between thermostat flange and cashing is 9.
4mm
Refitting
1. Mount the new thermostat into the water
outlet union
Ensure that the O-shaped rings at the top and
bottom are fitted in place.
2. Fit the mounting bolt of outlet pipe union
Last step

ISLe375 30 engine
Fan, fan shroud and combinations

I. Renewal of cooling fan drive belt
Special tool - -
Testing tools - -
2. Procedure
General
In view of many layouts of driving belt, this step is

not applicable to all the arrangements of cooling
fan driving belt.
To ensure the correct layout of cooling fan drive
belt, draw a map for cooling fan belt layout prior to
the removal of belts.
The arrangement of cooling fan belt usually
includes the following components, but not all of
those components.
• Crankshaft pulley/shock absorber
• Fan belt pulley
• Water pump pulley

• Refrigerant compressor belt pulley
• Charger pulley
• Belt tensioner pulley
Renewal of cooling fan drive belt 663

Cooling system
The driving belt of some engines shall be

assembled/supplied by vehicle OEM. See the
removal and installation instructions in “OEM
service manual”.
The worn belt tensioner or the un-calibrated belt
pulley can make the belt off
To check the pulley calibration, use the pulley
calibrating tools. If this tool is unavailable, use the
ruler and inclinometer for measurement.
The maximum deflection of belt pulley is 3
degrees. If necessary, repair, adjust or replace
affected parts.
Preparatory step
1. Disconnect the battery.
Removal
Caution: Prepare a belt arrangement plan before disassembling the driving belt. This is for
the convenience of installation and to ensure the correct arrangement of cooling fan
driving belt.
1. Lift tensioner when removing drive belt
If it is necessary to use any extension socket, use one hand to support the ratchet spanner head to
prevent any accidental loading of belt tensioner arm.

use is possible.
1. Check whether the belt is cracked, worn,
torn, cut, hardened or worn out
If damaged, replace the starter motor.
2. Check whether the idler pulley is worn or

cracked
• The plastic pulley may be covered by the road
mud and belt material, and the confusion with
the wear shall be avoided.
• Remove the dirt with applicable tool and check
for abrasion.
• Clean away the accumulated dirt on the idler
shaft, and check and reuse the idler shaft.
664 Renewal of cooling fan drive belt

ISLe375 30 engine
3. Check whether the drive belt pulley and

idler pulley have any crack or broken slot
If the pulley or idler is damaged, make reference to
following procedures:
1). Check the fan pulley
2). Check the crankshaft pulley
3). Check the belt tensioner pulley
Refitting
1. Fit drive belt
1). Arrange the drive belt on the engine by the
belt arrangement diagram made during the
disassembly procedureDo not fit the belt on
water pump pulley.
2). Turn the tension pulley according to the
direction of spring latch and install the driving
belt, finally make the belt slip onto the belt
pulley of water pump.
3). Release the belt tensioner to tension the drive
belt.
If it is necessary to use any extension socket, use one hand to support the ratchet spanner head to
prevent any accidental loading of belt tensioner arm.
4). Check whether the belt and tensioner are aligned with the front accessories drive device
Last step
2. Operate the engine to check whether the belt generates the noise of groan.
The excessive wear of belt slides the belt. If the belt screams, check the belt layout and ensure that the
belt is correct fitted on each pulley.
Renewal of cooling fan drive belt 665

Cooling system
Connect the split-type fan clutch

General
Many fan clutches can be controlled by engine

electronic control module (ECM). ECM monitors
the coolane temperature and intake manifold
temperature to confirm when to connect the
cooling fan. Some applications use the additional
sensor, the sensor is monitored by ECM to control
the fan (for example, the air conditioner pressure
and gearbox temperature)These are different
clutch fan types, such as: Air-connected,
air-disconnected, electric, sticking and ON/OFF
typeRefer to the service manual provided by the
equipment manufacturer to find out the type of fan
clutch.
ECM can use the 0-VDC or 12-VDC signal to

connect the fan clutch. The startup logic is
contained in ECM calibration, and can be
programmed by the failure diangoser.
I. Renewal of belt-driven fan hub

Special tool - -
Testing tools - -
Auxiliary material Steam, compressed air
2. Procedure
General
There are several different fan hub mounting positions and fan hub optional parts. The figure in the
procedure is for general purpose and may not represent the hardware on all engines
Preparatory step
2. Remove cooling fan(. If necessary)
666 Renewal of belt-driven fan hub

ISLe375 30 engine

4. Remove fan pulley & spacer ring
Removal
1. Remove mounting bolts for the fan hub
2. Remove fan hub

use is possible.
1. Clean the outside of fan hub with steam.
3. Check whether the oil seal of fan hub leaks

oil
4. Check whether the fan hub is cracked or
damaged
If damaged, replace the fan hub.
5. Check whether it can rotate feely

1). Rotate the fan hub by hand.
2). Any swing or excessive axial clearance is
forbidden when the fan hub rotates.
Renewal of belt-driven fan hub 667

Cooling system
6. Check whether the fan hub bearing is worn

7. The bearing must have minimum radial
and axial clearance.
If the fan hub axial clearance is higher than 0.
15mm, replace the fan hub.
Axial clearance of fan hub
Maximum 0. 15mm
Some fan hub assemblies can be refitted via new

bearings and relevant parts. Check the
components for workability before the fan hub is
disassembled.
Refitting
1. Fit the fan hub and bolt
Last step
1. Fit the belt pulley and spacer sleeve
2. Fit drive belt
3. Fit cooling fan (if removed)
668 Renewal of belt-driven fan hub

ISLe375 30 engine
II. Renewal of fan shroud assembly


Common tools
Special tool - -
Testing tools - -
2. Procedure
General
The radiator or fan cowl is used to guide the air
flow to pass through the radiator cooling fin other
than the radiator edge.
Any incorrect or clogged fan shroud can reduce
the air flow and cause engine overheating.
Check and confirm that the air is not
recycledCheck whether the baffle is missing.
Initial inspection
Caution: The fan shroud must be fitted
correctly and is in good condition.
And the clearance between the
shroud and fan must be in
accordance with the
manufacturer’s technical
specification, so as to ensure
correct air flow passing through
the radiator and full cooling of
engine.
1. Check whether the clearance between the
fan hood and the fan is correct, and
whether there is any crack, gas leakage or
damage on the fan hood
Renewal of fan shroud assembly 669

Cooling system
2. The proposed clearance between fan and

radiator is 5. 08cm to 10. 16cm
670 Renewal of fan shroud assembly

ISLe375 30 engine
III. Renewal of fan spacer bush and belt pulley

Special tool - -
Testing tools - -
2. Procedure
Preparatory step
Caution: Before removing drive belt, loosen fan pulley & cooling fan (if equipped) mounting
bolt.
2. Remove driving belt for the fan
Removal
Caution: Some engines have no cooling fan
or the cooling fan is not at the
engine.
1. Remove cooling fan(if equipped)
2. Remove fan pulley & spacer ring
3. Remove fan pulley mounting bolt & fan

pulley
Renewal of fan spacer bush and belt pulley 671

Cooling system

use is possible.
1. Use the detergent to clean the fan pulley.
3. Check whether the fan pulley has cracks

around the bolt hole and the joint with the
drive belt is damaged
If damaged, replace the pulley.
Refitting
1. Fit tht mounting bolt of belt pulley and belt
pulley
2. Fasten the holddown bolts by hand.
After Fitting the drive belt, tighten the mounting bolt
to the final torque and use the tension force of belt
to avoid the rotation of fan belt wheel.
Tightening torque M6 10N·m
M10 43N·m
M12 77N·m
For the engine equipped with engine-driven
cooling fan, fix in place the fan belt pulley and
spacer bush.
3. Fit the belt pulley and spacer sleeve

4. Fit cooling fan (if removed)
5. Assemble the bolts by hand.
After Fitting the drive belt, tighten the mounting bolt
to the final torque and use the tension force of belt
to avoid the rotation of fan belt wheel.
Do not constrain the fan blades so as to keep the
fan belt pulley or the cooling fan can rotate freely.
Tightening torque M6 10N·m
M10 43N·m
M12 77N·m
672 Renewal of fan spacer bush and belt pulley

ISLe375 30 engine
Last step
Caution: Tighten the mounting bolts of fan belt pulley and cooling fan (if fitted)
1. Fit drive belt
Renewal of fan spacer bush and belt pulley 673

Cooling system
Electric control system

I. General
1. Introduction to engine electronic control system
Cummins electric-control engine is a new engine with partial improvement on the original engineIt is
additionally provided with an engine control module (ECM) and electric devices under its control, like the
sensor and actuator. The electronic equipment adjusts the engine’s fuel quantity, advance angle and
other parameters in accordance with environmental conditions such as atmospheric pressure and
vehicle load, and optimizes the engine condition in order to meet the requirements on output, fuel
consumption and emission.
2. Working principle of electronic control system of Cummins

electric-control engine
674 General
ISLe375 30 engine
Operating principle of engine electronic control system

Input Output
Sensor on the engine Engine
● Temperature: ● Injector
Coolant, air intake, ● Actuator
fuel ● Electronic feed
● Pressure: Air pump
intake, oil, fuel and Computation
atmospheric ● Speed of Vehicle
pressure rotation ● Indicator lamp
● Rotational speed: ● Torque ● Electronic fan
Crankshaft and ● Emission ● Relay
camshaft ● Other functions ● Electronic
Vehicle signal communication
● Ignition
● Electronic throttle
● Speed signal
● Switch
● Temperature
● Pressure
3. Precautions in the repair service

1. Do not plug or unplug the ECM connector from the live circuit;
2. ECM insert has the plug frequency limit and dot not plug frequently;
3. When the welding operation is conducted on vehicle, be sure to disconnect the main power
source.
4. Fault diagnosis
Table of fault diagnosis for the engine electronic control system
Table 13-1 Common faults and troubleshooting
Serial
Fault phenomenon Cause analysis Solving methods
number
1 The signal of one Sensor damaged Renew relevant sensor

sensor is missing or
2 the fault of one Sensor harness cracked Renew relevant sensor cable harness
sensor is alarmed
Pull out the plugs of engine

harness and the harnesses
Report the ECM
3 of whole vehicle, and if the Renew the ECM
internal fault
fault still exist, the ECM is
damaged
On the instrument
panel, words “No
Poor contact of engine cable
4 ECM report is Check and replace the corresponding wire
harness
received” are
indicated.
There are many fault It is generally caused by

5 Renew the ECM
codes flashing in internal damage of ECM in
General 675
Cooling system
Table 13-1 Common faults and troubleshooting
ECM on instrument accordance with experience

panel.
Emit smoke by
6 ECM the nomnal data error Recalibrate ECM data.
sudden acceleration
676 General
ISLe375 30 engine
II. Renewal of ECM assembly

Diagnosis: If the engine reports any ECM internal failure, remove the engine wiring harness connector
from the vehicle. If this failure is eliminated, the ECM itself works normally; if the failure
remains there, the ECM is in trouble, and requires a replacement.
Common tools Sockets S8/S10/S13, slotted screwdriver
Special tool - -
Testing tools Multimeter, INSITE software
2. Procedure
Removal
1. Turn off the power master switch
2. Disconnect power plug from electronic
control module (ECM)
3. Disconnect ECM wiring harness
Renewal of ECM assembly 677

Cooling system
4. Remove ECM assembly

1). Remove 4 ECM fixing bolts.
2). Remove the ECM assembly.
Check
1. Check the ECM assembly
1). The connector is loose
2). Feeler is corroded.
3). Feeler is bent or broken
4). Feeler contracts or extends
5). The inner surface of connector is damp
6). The connector seal is missing or damaged
7). There is any dirt or scrapping inside or on the
connector pin
8). Damaged cable insulation

9). The connector casing is broken
10). All damaged unions
Caution: If possible, repair the damaged union and needle.
Refitting
1. Fit ECM assembly

1). Fix ECM assembly on its back plate with four
bolts.
2. Connect the ECM wire connector
678 Renewal of ECM assembly

ISLe375 30 engine
3. Turn on the power master switch

4. Inspection on vehicle
1). Start the engine.

2). Remove the failure code.
3). Read the other fault codes of engine for
troubleshooting.
4). If no failure code is available, shut down the
engine.
Renewal of ECM assembly 679

Cooling system
III. Renewal of engine cable harness assembly

Diagnosis: If a certain engine sensor loses its signal or a certain electric device is in trouble, check
ECM, sensor or electric element, and if the problem remains there, check or replace the
corresponding wiring harness.
Common tools Sockets S5/S6/S8/S10/S13
Special tool - -
2. Procedure
Removal
2. Remove engine harness connector.
3. Disconnect the cable harness of coolant

temperature sensor
680 Renewal of engine cable harness assembly

ISLe375 30 engine
4. Remove injector harness

1). Remove rocker chamber cover.
See “Renewal of rocker chamber cover”
2). Screw off the oil injector wire
5. Disconnect the cable harness of speed

sensor
1). Disconnect the cable harness connector from
the wheel speed sensor.
6. Disconnect the cable harness of

supercharging pressure sensor
the supercharging pressure sensor.
7. Disconnect the cable harness of engine

position sensor
1). Pull out the harness connector of position
sensor.
Renewal of engine cable harness assembly 681

Cooling system
8. Disconnect the cable harness of oil

pressure sensor
the oil pressure sensor.
9. Disconnect the cable harness of rail

pressure sensor
the rail pressure sensor.
10. Remove engine harness assembly

1). Remove clamp bolt and take down the
harness assembly from the engine.
Check
1. Check the engine wire assembly
connector pin
682 Renewal of engine cable harness assembly

ISLe375 30 engine
Refitting
1. Fit the engine wiring harness assembly in

the sequence opposite to the removal.
troubleshooting.
engine.
Renewal of engine cable harness assembly 683

Cooling system
IV. Renewal of coolant temperature sensor

Diagnosis: When the ECM reports that the coolant temperature sensor is faulty, if the ECM and the
cable harness of sensor are sound, it is required to check and renew the coolant
temperature sensor.
Common tools Sockets S8/S10/S13/S19
Special tool - -
2. Procedure
Removal
2. Disconnect the cable harness connector of

coolant temperature sensor and then
remove the sensor
Check
1. Check whether the engine wire and sensor

connector pin have following cases:
connector pin
684 Renewal of coolant temperature sensor

ISLe375 30 engine

Caution: If possible, repair the damaged wiring harness, union and needle.
2. Check the resistance of coolant temperature sensor
Use the multimeter to measure the resistance between the coolant sensor signal contact pin and the
circuit contact pin.
Resistance range: 180-160 k. ohm
Caution: If the measured resistance is beyond the required range, renew the coolant
temperature sensor.
Refitting
1. Fit coolant temperature sensor
2. Connect the coolant temperature sensor
wire
troubleshooting.
engine.
Renewal of coolant temperature sensor 685

Cooling system
V. Renewal of pressure sensor of intake manifold

Diagnosis: When the ECM reports that the intake manifold pressure sensor is faulty, if the
ECM and cable harness are sound, it is required to check and renew the intake
manifold pressure sensor.
Common tools Sockets S5S6//S8/S10
Special tool - -
Testing tools Multimeter, INSITE software, mechanic intake pressure gauge
2. Procedure
Check the precision of sensor
1. Rotate the key switch to “ON” position, and the engine does not run
2. Connect the INSITE service software, and monitor the pressure of intake manifold
Caution: If the intake manifold pressure is lower than 203mm Hg (8in Hg), replace the intake
manifold pressure sensor.
3. Verify sensor accuracy
1). Rotate the key switch to “ON” position
2). Connect the INSITE service software
3). Connect the mechanical intake manifold pressure gauge with the engine
4). Start the engine, and compare the intake manifold pressure indicated on the service software
monitor screen with the reading on the mechanic intake manifold pressure gauge.
Caution: Before the pressure reading can be used for comparing purpose, the engine may
need loading.
Caution: If sensor reading difference falls outside 127mm Hg (5 in Hg), renew intake manifold
pressure sensor.
686 Renewal of pressure sensor of intake manifold

ISLe375 30 engine
Removal
2. Disconnect the cable harness of intake manifold pressure sensor
3. Remove pressure sensor for the intake

manifold
Check
1. Check the intake manifold pressure sensor
connector pin
Refitting
1. Fit turbocharger sensor
2. Connect boosting pressure sensor wire
troubleshooting.
engine.
Renewal of pressure sensor of intake manifold 687

Cooling system
VI. Renewal of temperature sensor of intake manifold

Diagnosis: When the ECM reports that the intake manifold temperature sensor is faulty, if the
ECM and cable harness are sound, it is required to check and renew the intake
manifold temperature sensor.
Common tools Sockets S5S6//S8/S10
Special tool - -
2. Procedure
Removal
2. Disconnect the cable harness of intake manifold temperature sensor
3. Remove temperature sensor for the intake

manifold
688 Renewal of temperature sensor of intake manifold

ISLe375 30 engine
Check
1. Check the intake manifold temperature
sensor
connector pin
Caution: If possible, repair the damaged
union and needle.
2. Check the resistance of intake manifold

temperature sensor
1). Use the multimeter to measure the resistance
between the intake manifold temperature
sensor signal contact pin and the circuit
contact pin.
Caution: The following resistance technical specification relative to temperature should be

applied during the measurement of sensor resistance:
Temperature / ℃ Resistance/Ω
15 3100
20 2450
25 2010
30 1670
Caution: If the measured resistance is beyond the required range, renew the intake manifold
temperature sensor.
Renewal of temperature sensor of intake manifold 689

Cooling system
Refitting
1. Fit the intake manifold temperature sensor
2. Connect the intake manifold temperature
sensor wire
troubleshooting.
engine.
690 Renewal of temperature sensor of intake manifold

ISLe375 30 engine
VII. Renewal of crankshaft speed sensor

Diagnosis: When the ECM reports that the crankshaft speed sensor is faulty, if the ECM and
cable harness are sound, it is required to check and renew the crankshaft speed
sensor.
Special tool - -
2. Procedure
Removal
2. Disconnect the cable harness of speed sensor
3. Remove crankshaft speed sensor
Check

connector pin
Renewal of crankshaft speed sensor 691

Cooling system

1. Check the rotation speed sensor

between the speed sensor lead pins.
Standard value: 650-1000 ohm
Caution: If the measured resistance is
beyond the required range, renew
the engine speed sensor.
Refitting
1. Fit the rotation speed sensor
2. Connect the speed sensor wire
troubleshooting.
engine.
692 Renewal of crankshaft speed sensor

ISLe375 30 engine
VIII. Renewal of engine position sensor

Diagnosis: When the ECM reports that the phase sensor is faulty, if the ECM and cable
harness are sound, it is required to check and renew the position sensor.
Common tools Sockets S5/S6/S8/S10, slotted screwdriver
Special tool - -
2. Procedure
Removal
2. Remove air compressor assembly
See “Renewal of air compressor”
3. Disconnect the cable harness of phase

sensor
Renewal of engine position sensor 693

Cooling system
4. Remove engine position sensor

1). Remove 1 bolt and take down the engine position sensor.
Check
1. Check the rotation speed sensor

between the speed sensor lead pins.
Standard value: 650-1000 ohm
Caution: If the measured resistance is
beyond the required range, renew
the engine speed sensor.
Refitting
1. Fit engine position sensor
1). Fix the engine position sensor with one bolt.

2. Connect the engine position sensor wire
troubleshooting.
engine.
694 Renewal of engine position sensor

ISLe375 30 engine
IX. Renewal of oil pressure sensor

Diagnosis: Check the oil pressure sensor and cable harness when the ECM reports that the oil
pressure sensor is faulty.
Special tool - -
2. Procedure
Check
1. Check the oil pressure sensor and circuit
1). Rotate the key switch to “OFF” position
2). Disconnect oil pressure sensor from engine harness
2. Check the sensor and wire connector

connector pin
Caution: If possible, repair the damaged
union and needle.
3. Check the power voltage and circuit

1). Connect the oil pressure sensor
Renewal of oil pressure sensor 695

Cooling system
3). Use the multimeter to measure the voltage

between the +5V power contact pin for the
engine oil pressure in the union of engine
wiring harness sensor and the engine oil
pressure circuit contact pin.
If the voltage stays in the range of 4. 75-5. 25 VDC,
check the responsivity of circuit.
4). Rotate the key switch to “OFF” position
5). Disconnect oil pressure sensor from engine
harness
7). Connect a jumper wire between power supply
contact pin and signal pin at engine oil
pressure +5V, wait for 30s, and check whether
the circuit response is correct.
8). Read the fault code which indicates that the sensor is faulty, and then renew the oil pressure
sensor.
If the voltage ranges from 4.75 VDC to 5.25 VDC, check ECM and engine wiring harness with reference
to ECM and engine wiring harness testing.
Removal
2. Disconnect the cable harness of oil pressure sensor
3. Remove oil pressure sensor
696 Renewal of oil pressure sensor

ISLe375 30 engine
Refitting
1. Fit oil pressure sensor
2. Connect the oil pressure sensor wire
troubleshooting.
engine.
Renewal of oil pressure sensor 697

ISLe375 30engine 发动机-En

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ISLe375 30 engine

I. Precautions on engine maintenance..........................................................................................1

Engine block ..................................................................................................................117

I. Cleaning essentials of engine ................................................................................................117

Engine assembly ...........................................................................................................120

I. Removal and refitting of engine assembly .............................................................................120

Cylinder head .................................................................................................................217

I. Renewal of jumper plate ........................................................................................................217

Cylinder block and flywheel housing...........................................................................240

I. Renewal of cylinder block ......................................................................................................240

Camshaft and timing gear mechanism ........................................................................298

Crankshaft and piston linkage assembly ....................................................................344

I. Renewal of crankshaft ...........................................................................................................344

Refitting of engine .........................................................................................................392

I. Renewal of engine front bracket ............................................................................................392

Lubricating system ........................................................................................................439

I. Lubricating system- general description.................................................................................439

Draining and filling of lubricating system ...................................................................442

I. Draining of lubricating system ................................................................................................442

Oil pump and pipeline ...................................................................................................447

I. Renewal of oil pump ..............................................................................................................447

Oil filter ...........................................................................................................................454

I. Renewal of oil filter (rotary) ....................................................................................................454

Oil cooler ........................................................................................................................463

Fuel system ....................................................................................................................466

I. General description on the fuel system..................................................................................466

Fuel pump and filter.......................................................................................................475

I. Fuel pump ..............................................................................................................................475

Pipe with union and the fuel tank .................................................................................499

I. Renewal of fuel pump head outlet pipe union ........................................................................499

Fuel injector and supply pipe .......................................................................................523

I. Fuel injector ...........................................................................................................................523

Intake and exhaust systems .........................................................................................542

I. Intake system – general description.......................................................................................542

Intake pipe and exhaust pipe ........................................................................................564

I. Renewal of air jumper pipe ....................................................................................................564

IX. Dry exhaust manifold .............................................................................................................583

Air compressor ..............................................................................................................603

I. Carbon deposit in air compressor ..........................................................................................603

Cooling system ..............................................................................................................620

I. Cooling system- general description ......................................................................................620

Radiator and union, coolant filter, expansion tank .....................................................637

Coolant pump and thermostat ......................................................................................650

I. Renewal of coolant pump ......................................................................................................650

Fan, fan shroud and combinations ..............................................................................663

I. Renewal of cooling fan drive belt ...........................................................................................663

Connect the split-type fan clutch .................................................................................666

I. Renewal of belt-driven fan hub ..............................................................................................666

Electric control system .................................................................................................674

2. Preparation before assembling

3. Products for tightening, locking, sealing and sticking

4. Use original parts.

5. Follow the mounting method and ensure maintenance quality.

Precautions on engine maintenance 1

II. Assembly identification

The nameplate is on the top of gear chamber

Name of Dongfeng Cummins engine

Fuel injector nameplate

Air compressor nameplate

Front view of engine

Side view of engine air exhaust

Side view of engine air exhaust

1. Turbocharger compressor outlet connection 9. Oil pressure adjuster