2-Engine System CMT 96

Maintenance Manual
Engine System
CMT96 Maintenance Manual for Off-Highway Dump Truck
2 Engine System ................................................................................................................................. 3
21 Overview ........................................................................................................................................... 5
211 Overview on engine function ................................................................................................................. 5
212 Engine performance parameters........................................................................................................... 6
22 Engine block .................................................................................................................................... 7
221 Engine block’s disassembly, inspection, maintenance and assembly .................................................. 7
222 Disassembly and assembly of pre-assembled parts of engine body ................................................... 9
223 Disassembly and assembly of piston nozzle ...................................................................................... 10
224 Disassembly and assembly of thrust collar ......................................................................................... 10
225 Removal and installation of front and rear oil seals ............................................................................ 11
226 Removal and installation of timing gear chamber ............................................................................... 12
227 Disassembly and installation of front end cover ................................................................................. 14
228 Disassembly and assembly of flywheel housing................................................................................. 14
229 Disassembly and assembly of oil sump .............................................................................................. 16
2210 Removal, inspection, maintenance and assembly of cylinder head ................................................. 17
2211 Disassembly, inspection, maintenance and assembly of cylinder head ........................................... 18
2212 Disassembly and assembly of cylinder head cover .......................................................................... 23
2213 Engine lifting and assembly .............................................................................................................. 24
2214 Disassembly and assembly of oil-gas separator .............................................................................. 24
2215 Removal and installation of shock absorber and crankshaft pulley .................................................. 26
2216 Disassembly and installation of flywheel assembly .......................................................................... 26
2217 Removal and installation of crankshaft ............................................................................................. 27
2218 Disassembly and assembly of piston and connecting rod assembly ............................................... 29
2219 Valve mechanism .............................................................................................................................. 32
2220 Removal and installation of camshaft ............................................................................................... 33
2221 Disassembly and assembly of intermediate gear ............................................................................. 34
2222 Removal and installation of tappet and pushrod ............................................................................... 35
2223 Disassembly and assembly of valves ............................................................................................... 36
2224 Removal and installation of rocker and rocker shaft ......................................................................... 37
2225 Intake and exhaust system ............................................................................................................... 38
2226 Removal and installation of supercharger......................................................................................... 39
2227 Removal and installation of intake pipe ............................................................................................ 40
2228 Removal and installation of exhaust pipe ......................................................................................... 41
2229 Fuel system ....................................................................................................................................... 42
2230 Disassembly, inspection, maintenance and assembly of fuel injection pump .................................. 43
2231 Removal and installation of high-pressure fuel pipe ......................................................................... 44
2232 Removal and installation of fuel injector ........................................................................................... 45
2233 Removal and installation of ECU ...................................................................................................... 46
2234 Removal and installation of water pump ........................................................................................... 47
I
2235 Removal and installation of fan ......................................................................................................... 47
2236 Removal and installation of oil pump ................................................................................................ 48
2237 Removal and installation of oil filter .................................................................................................. 49
2238 Removal, inspection and assembly of oil cooler cover ..................................................................... 50
2239 Removal and installation of oil cooler ............................................................................................... 51
2240 Removal and installation of strainer .................................................................................................. 51
2241 Removal and installation of starter .................................................................................................... 52
2242 Installation of vehicle accessory system ........................................................................................... 53
2243 Disassembly, inspection, maintenance and assembly of generator and its bracket ........................ 54
2244 Removal and installation of A/C compressor and engine support .................................................... 55
23 Removal of engine system ........................................................................................................... 55
231 Removal of engine .......................................................................................................................... 55
232 Assembly of engine ............................................................................................................................. 63
233 Removal of radiator ......................................................................................................................... 67
234 Assembly of radiator ........................................................................................................................ 70
235 Removal of fuel tank ........................................................................................................................ 72
236 Assembly of fuel tank .................................................................................................................... 73
237 Removal of exhaust system ............................................................................................................ 75
238 Assembly of exhaust system ........................................................................................................... 78
239 Removal of air filter ......................................................................................................................... 80
2310 Assembly of air filter .......................................................................................................................... 82
Appendix A Common faults, diagnosis and solutions of engine system ........................................... 83
Appendix B Diagnosed fault code table ................................................................................................. 90
Appendix C Fitting clearance among main parts of engine ...............................................................100
II
2 Engine System
3
4
21 Overview
Engine outline
211 Overview on engine function
This engine is of in-line type, 6-cylinder, water-cooled, direct injection, four strokes and turbocharged
diesel engine, and is characterized with high reliability, low fuel consumption and noise, and others.
Beside, this engine meets the China-III emission standards.
Engine ignition sequence
Cylinder is numbered sequentially from the flywheel. Sequence of igniter: 1-5-3-6-2-4. Viewed from the
flywheel, the engine rotates counterclockwise.
Engine cylinder number

Engine principle
As this engine is of four-stroke diesel engine, each work cycle is divided into four processes: intake, compression, power, exhaust.
During the intake, the fresh air is sucked into the engine until the piston reaches the BDC, ending the intake process. Then, piston
moves upward to compress the fresh air that gets hotter and hotter. When the piston is close to the TDC, diesel is injected into the
combustion chamber with the fuel injector in the atomized manner to mix with the high-temperature air, and then the mixture is
rapidly ignited and combusted, pushing the piston downwards to start with the work process. When the piston reaches the BDC,
the power process is completed. After that, the piston moves upwards under the inertial force until the TDC, draining out the
combusted residual exhaust gas and thus completing the exhaust process. Up to now, the diesel engine completes one work
cycle.
5
Engine schematic
212 Engine performance parameters
Definition of diesel model
Variant code
Emission level
Rated power
Displacement
Power
Weichai
Engine Models WP13G530E310

In-line, direct-injection, water-cooling,
Engine type —
supercharger, inter-cooler, electric control
Fuel injector — Electronic-control high-pressure common-rail
Rated power kW 390
Rated rpm r/min 2100
Max. torque N.m 2300
Max. torque speed r/min 1200~1600
Idling ( r/min) 600±50
Emission level — National Ⅲ GB20891-2014
Engine performance parameters
6
22 Engine block
221 Engine block’s disassembly, inspection, maintenance and assembly
Exploded drawing of engine block assembly

1. 26-Cylinder head bolt; 2-Combine washer; 3. 8- Hex. Screw plug; 4- Bowl plug; 5-Rear oil seal; 6-Seal gasket; 7-Screw
plug; 8-Hex. Screw plug; 9-Safety valve spring; 10-Safety valve; 11-Cylinder liner; 12-Socket hex. Cylindrical-head screw;
13- Nozzle assembly; 14-Seal ring; 15-Hollow bolt; 16-Hex. bolt; 17-Pressure-limiting valve of main oil passage;
18-Self-lock washer; 19, 21- thrust collar; 20-Seal ring; 22-Main bearing shell assembly; 23-Cylinder body; 24-Cylindrical
pin; 25-Elastic cylindrical pin
2211 Disassembly process of engine body
1. Take down the dowel pin from cylinder head;
2. Take down the tightening bolts around the crankcase (essential 1);
3. Unbolt the main bearing (essential 2);
4. Take down the crankcase and seal ring;
5. Take down the auxiliary bolt off the cylinder head (essential 3);
6. Take down the screw plug off the main oil passage;
7
7. Take down the cylinder lining (essential 4).
2212 Inspection and maintenance of engine block
Essential 1: assembly
Tightening torque 22 N.m～29N.m Level 8.8
Tightening torque 29 N.m～35N.m Level 10.9
The main bearing bolts shall be tightened up symmetrically according to the following figure. Before
assembly, the load-bearing surface of crankcase and the threads of main bearing bolts should be
brushed with the clean lubricant.
Torque control: at the 1st time, tighten them with a low-torque pneumatic wrench; at the 2nd time, torque
them to 80N·m; at the 3rd time, torque them to 140N·m; at the 4th time, rotate them by 70°in sequence;
at the 5th time, rotate them again by 70° in sequence; at the 6th time, rotate them again by 70° in
sequence.
The auxiliary bolts of cylinder head should be tightened in accordance with the sequence shown in the
following figure and are able to be reused for at most 2 times.
Check the cylinder lining to be mounted carefully for any crack or other detects;
clean the cylinder lining and coat the outside of cylinder lining with the molybdenum powder; then press
it into the cylinder bore with the special tools..
2213 Assembly procedure of engine body
Reverse to the disassembling sequence
8
222 Disassembly and assembly of pre-assembled parts of engine body
Bowl-type plug
(diameter: 60)
Bowl-type plug
(diameter: 60)
Bowl-type plug
(diameter: 40)
Internal thread
cylindrical pin
Camshaft,
Chen Tao
Crankcas
e
Main bearing
bolt
2221 Disassembly procedure of pre-assembled parts of engine body

1. Remove the female-threaded cylindrical pin;
2. Remove the camshaft bushing (essential 1);
3. Remove the main bearing bolts;
4. Remove the crankcase (essential 2)
2222 Inspection and maintenance of pre-assembled parts of engine block
1) Use the special tools to remove the camshaft bushing, during which care must be taken to protect
other bushings.
2) Check if the inside of camshaft bushing is scratched or not before assembly, and replace it if needed.
The oil hole on the camshaft bushing should align the one at the bottom of engine block camshaft.
3) Clean the upper surface of crankcase and the lower surface of cylinder block before assembly.
Besides, the upper surface of crankcase should be coated with the sealant.
4) Before assembly, the load-bearing surface of crankcase and the threads of main bearing bolts
should be brushed with the clean lubricant.
Reverse to the removal procedure
9
2223 Assembly procedure of pre-assembled parts of engine body
223 Disassembly and assembly of piston

nozzle
2231 Removal procedure of cooling nozzle of
piston
Nozzle inspection ring
1. Take down the hollow bolt (essential 1); Nozzle spring
Nozzle oil valve
2. Take down the nozzle assembly; Nozzle inspection ring

Nozzle spring
3. Take down the elastic cylindrical pin (Essential Nozzle oil valve
2).
Disassembly drawing of cooling nozzle of piston
2232 Inspection and maintenance of piston nozzle

Tightening torque of hollow bolt
Tightening torque 20N.m～30N.m
Check if the dowel pin is damaged and replace it if needed. After the dowel pin aligns the engine block
pin hole, use a copper hammer to slightly hit the nozzle block, so as for the dowel pin to completely fit
into the engine block pin hole.
2233 Disassembly procedure of piston nozzle
Reverse to the sequence in assembling of piston cooling nozzle
224 Disassembly and assembly of thrust collar
Crankcase
Lower thrust plate
Upper thrust plate
Cylinder block
Disassembly drawing of upper and lower thrust collars
10
2241 Removal procedure of thrust collar
1. Take down the crankcase (refer to the removal steps of crankcase);
2. Take down the crankcase ( refer to the disassembly procedure of crankshaft);
3. Take down the thrust collar (Essential1).
2242 Inspection and maintenance of thrust collar
The thrust collars should be mounted in pair. Firstly install the crankshaft into the engine block, then
mount the upper thrust collar (no lug); lower thrust collar should be greased and be attached to the
crankcase for together assembly. Oil groove side of thrust collar should face outwards.
2243 Assembly procedure of thrust collar
1. Install the crankshaft;
2. Install the upper thrust collar;
3. Install the lower thrust collar;
225 Removal and installation of front and rear oil seals
Front oil seal Front end cover

Rear oil seal Flywheel housing
Disassembly drawing of oil seal

2251 Removal steps of front and rear oil seals
1. Take down the gear chamber (refer to the disassembly procedure of gear chamber);
2. Take down the front oil seal (Essential1);
3. Take down the crankshaft case (refer to the disassembly procedure of crankcase)
4. Take down the rear oil seal (Essential1):
2252 Inspection and maintenance of front and rear oil seals
Before installation of the oil seals, clean the mounting holes and oil seals to be free from any dirt. The oil
seals should be steadily fit in with the special tools. The oil seals and the press-fitting tools before use
should be applied with the lubricant.
11
Disassembly
Any removed oil seals cannot be reused.
2253 Assembly procedure of front and rear oil seals
1. Install the crankcase;
2. Install the rear oil seal;
3. Install the gear chamber;
4. Install the front oil seal.
226 Removal and installation of timing gear chamber
9
Exploded drawing of timing gear chamber
2261 Removal procedure of timing gear chamber
1. Unbolt the gear chamber; (Essential1)
2. Take down the screw plug and combine washer;
3. Take down the middle gear shaft (refer to the disassembly procedure of middle gear);
4. Take down the middle gear shaft off the oil pump, and unbolt the middle gear off the oil pump (refer to
the removal procedure of middle gear in oil pump);
5. Take down the gear chamber; (Essential3 )
6. Take down the seal ring; (essential2 )
2262 Inspection and maintenance of timing gear chamber
Symmetrically and crosswise bolt the gear chamber in the figure shown below
12
Tightening sequence of timing gear chamber bolts

Tightening torque 44 N.m～58N.m
Check if the seal ring to the assembled is scratched or has other defects, and replace it with a new one if
needed. The seal ring shall be greased and then completely pressed into the groove, during which care
must be taken to protect the seal ring from being scratched by the groove.
Essential 3: disassembly
For disassembly of gear chamber, firstly unbolt the gear chamber to take down the middle gear shaft and
the one off the oil pump. The removed gear chamber shall be put in a clean environment.
Assembly
Firstly the middle gear shaft is mounted with the middle gear; then they are put into the gear chamber.
The water inlet and outlet of cylinder body shall be coated with sealant and then mounted with seal ring.
2263 Assembly procedure of gear chamber
Reverse to the disassembly procedure
13
227 Disassembly and installation of front end cover
Exploded drawing of front end cover

1. Cylindrical pin 2. Front end cover 3, 4. Hex. Flange bolt 5. Front oil seal
2271 Disassembly procedure of front end cover
1. Unbolt the front end cover to take it down;
2. Take down the dowel pin off the front end cover;
3. Take down the front oil seal.
2272 Inspection and maintenance of front end cover
Essential 1: The tightening bolt of front end cover shall be of pre-gluing bolt.
Essential 2: the interface between cylinder block and front end cover shall be coated with sealant.
Besides, care must be taken to protect the interface between front end cover and engine body and oil
sump from the impacted or scratched.
2273 Disassembly procedure of front end cover
Reverse to the sequence of removing the signal generator.
228 Disassembly and assembly of flywheel housing
14
Hexagon head bolt

Rear power take-off cover plate
Hexagon flange O-ring
bolt
Cylindrical pin
Flywheel housing
Rear oil seal

Elastic washer
Hexagonal nut
Double end studs
Waveform elastic Access plate

washer
Hexagon head bolt
Installation drawing of flywheel housing

2281 Disassembly procedure of flywheel housing
1. Unbolt the rear PTO cover to take it down.
2. Unbolt the slight glass cover on flywheel housing to take this cover down;
3. Take down the stud of the outer edge of flywheel housing;
4. Crosswise unbolt the flywheel housing;
3. Remove the flywheel housing, cylindrical pin and rear oil seal.
2282 Inspection and maintenance of flywheel housing
The flywheel housing bolts should be applied with sealant on their flanges and then tightened crosswise
for two times at most.
Tightening torque 110N.m～140N.m
The interface between cylinder block and flywheel housing shall be evenly coated with sealant. In
addition, while being lifted, the flywheel housing shall be strictly protected against any impact or damage.
2283 Assembly procedure of flywheel housing
Reverse to the disassembly procedure
15
229 Disassembly and assembly of oil sump
Gasket
Oil pan
Oil pan support

block
Plug support
Sealing washer
Hexagon flange
bolt Magnetic plug
Disassembly drawing of oil sump

2291 Disassembly procedure of oil sump
1. Turn over the diesel engine to have the oil sump face upwards (Essential1);
2. Unbolt the oil sump (Essential2);
3. Take down the support of oil sump;
4. Take down the oil sump and gasket.
5. Remove the magnetic screw plug, seal washer and screw plug supports.
2292 Inspection and maintenance of oil sump
Essential 1: removal
Before removal of the oil sump, completely drain out the oil Put an oil collector under the drain plug of oil
sump, and loosen the drain plug with a wrench, draining oil out of oil sump.
The tightening bolts of oil sump should be tightened to 22N.m～29N.m in sequence shown below:
16
Tightening sequence of oil sump bolts

2293 Assembly procedure of oil sump
Reverse to the sequence in removal of oil sump assembly
2210 Removal, inspection, maintenance and assembly of cylinder head
Exploded drawing of cylinder head

1. Cylinder head gasket 2. Valve 3. Oil-gas separator 4. Intake pipe 5. Fuel injector 6. High-pressure oil
pipe 7. Cylinder head cover
8. Main bolt of cylinder head 9. Rocker base and spring 10. Sealing bushing of valve rod 11. Nut 12.
Hoisting ring 13. Clamping block 14. Bleeder pipe
15. Exhaust pipe 16. Engine block 17. Fuel return pipe
22101 Removal procedure of cylinder head assembly
① Remove the exhaust pipe. For details, see the removal instruction of exhaust system
② Remove the intake manifold. For details, see the removal instruction of intake & exhaust system.
③ Remove the oil-gas separator.;
17
④ Remove the bleeder pipe;
⑤ Remove the front and rear lug clamps;
⑥ Take down the fuel injector harness, fuel return pipe and high-pressure oil pipe. For more, see the
disassembly illustration of fuel system;
⑦ Remove the cylinder head cover and its gasket;
⑧ Take down the fuel injector. For more, see the removal illustration of fuel system;
⑨ Remove the rocker arm assembly and pushrod. For details, see the removal instructions of valve
mechanism.
⑩ Remove the cylinder head sub-assembly and the cylinder head gasket;
⑪ Remove the inside and outside springs of valves, upper and lower seats of springs off intake and
exhaust valves, valve clips and valves. For details, see the removal instruction of valve mechanism.
⑫ Remove the seal cartridge of valve rod.
22102 Installation procedure of cylinder head assembly
2211 Disassembly, inspection, maintenance and assembly of cylinder head
22111 Disassembly procedure of cylinder head
For removal of cylinder head, firstly take down the parts off the cylinder head, as well as the intake pipe,
exhaust pipe (refer to the disassembly illustration on enter and exhaust system), fuel pipeline and
harness (refer to the disassembly illustration on fuel system), cylinder head cover, oil-gas separator,
water outlet pipe and lifting plate (refer to the disassembly illustration on cylinder head). Disassembly
procedure shown below:
① Loosen the bolts and nuts off cylinder head to take down the clamps that have two structures: one is
mounted between the two cylinder heads and the other is mounted on the front and rear cylinder
heads. .
② Loosen the main bolts attached to the cylinder head.
③ Removal of fuel injector: as the fuel injector nozzle protrudes the bottom surface of cylinder head,
ensure the spark plug has been taken down before removal of cylinder head. Otherwise, the cylinder
head is liable to impact the head of spark plug during the installation.
④ Removal of cylinder head: put the removed cylinder head onto the paperboard so as not to rub the
upper surface of combustion chamber and other sealing surface. More than one cylinder heads, if to be
removed, should be marked with cylinder number for further solution to the problem.
⑤ Removal of cylinder head gasket: more than one cylinder head gasket, if to be removed, should be
marked with the cylinder number for further solution to the problem;
⑥ The auxiliary bolts of cylinder head could be removed for the purpose of its replacement or inspection.
⑦ Remove the valve mechanism such as the rocker arm seat and intake/exhaust valve (refer to the
disassembly illustration on valve mechanism).
⑧ For the purpose of its replacement or inspection, the seal cartridge of valve rod could be removed
with the special tools or by using the pliers to clip the wall of this seal cartridge to be replaced and to
rotationally lift it. The removed seal cartridge of valve rod should be discarded and not be reused.
22112 Inspection and maintenance of cylinder head
① Check if there are leakages of both water, oil and gas or other abnormalities at the matching face
between cylinder head and the engine block before removal of cylinder head. If so, try replacing with a
new cylinder head gasket for the solution to the above problem. For the method to remove and install the
cylinder head gasket, see this section.
18
② Check if the cylinder head appearance is discolored or cracked. In case it is cracked, perform the dye
penetration test on it.
③ Check for the valve sinkage before removal of valve mechanism. The valve sinkage refers to the
vertical distance from the bottom surface of valve to the bottom surface of cylinder head. In addition, the
difference between the measured valve sinkage and the required one could indirectly reflect the wearing
of both valve and valve seat. This sinkage can be measured with a depth micrometer. If the measured
value exceeds the allowable range, check the valve and valve base for wear by the means of installing
the unused valve for the measurement of valve sinkage again. If this problem still exists, replace the
cylinder head so as to guarantee the reliability of diesel engine. If the valve sinkage does not exceed the
allowable value, remove the valve to check the sealing face between the valve and valve base ring for
obvious abrasion or abnormal damage.
Depth micrometer
Required valve sinkage value
(mm)
Air intake ±0.2
Top of cylinder ±0.2
④ After the valve mechanism is removed, check whether the inside of intake and exhaust passages on
the cylinder head leaks or not; if so, perform the dye penetration test to locate the leakage, and replace
with a new one if needed.
⑤ Clean the cylinder head, especially the surface of combustion chamber, valve seat, intake and
exhaust valves, intake and exhaust passages, so as to make sure there is no carbon accumulation and
adhesive. Besides, check the cylinder surface state.
⑥ Check the inside diameter of valve guide. As the inside diameter of valve guide is the friction face
between the valve guide and valve, if the valve guide is so worn that the inside diameter exceeds the
allowable value, the valve guiding effect will be impacted and the reliability of diesel engine will decrease.
The inside diameter of valve guide could be measured with an inside micrometer, with measured value
ranging from 11mm to 11.018mm. Otherwise, replace the cylinder head so as to guarantee the reliability
of diesel engine.
Inside micrometer
⑦ Remove the cylinder head gasket to check if it’s damaged; if so, find out the causes and replace with
a new gasket regardless of the cylinder head gasket being good.
⑧ Before removal, check if the rubber lip of valve rod seal cartridge is damaged and if the spring fails or
has other problems. In addition, the removed valve rod seal cartridge must be discarded.
22113 Assembly procedure of cylinder head
1. Assembly of auxiliary bolt of cylinder head
19
Secondary bolts of cylinder head

① The auxiliary bolt of cylinder head could be mounted for 3 times and then replaced with a new one
after that.
② The screwing-in end (with shorter thread) of auxiliary bolt should be coated with anaerobic thread
locking agent 262.
③ Clean the thread hole in the cylinder block.
④ Tighten the bolt to (20+10)N.m.
2. Assembly of cylinder head gasket
Cylinder head gasket

① The cylinder head gasket is disposable and thus should be replaced with a new one after repair.
② Clean the inside of cylinder liner and coat it with clean lubricant; clean the upper surface of engine
block and mount the cylinder head gasket by aligning the corresponding pin holes.
③ Make sure the holes on cylinder head gasket aligns the corresponding ones in cylinder block for the
proper assembly of cylinder head gasket.
3. Assembly of seal cartridge of valve rod
Spring
Seal cartridge of valve rod

① The seal cartridge of valve rod is disposable and thus should be replaced with a new one after repair.
20
② Check if the seal cartridge of valve rod or its spring is damaged.
③ Mount the seal cartridge of valve rod onto the valve guide.
④ Apply the lubricant to the lip of seal cartridge of valve rod.
⑤ Mount the seal cartridge of valve rod with the special tools and a rubber hammer.
Guide rod sealing installation
tool
Valve rod sealing sleeve
Valve guide
Cylinder
head
Installation of seal cartridge of valve rod

4. Assembly of cylinder head
① Carefully clean the cylinder head free of dust, debris or sand, and then wipe the lower surface of
cylinder head clean.
② Check if there is foreign material in the air and coolant passages in cylinder head, as well as inside of
the cylinder the cylinder head gasket; clean the lower surface of cylinder head;
Cleaning;
③ Adopt the pin-plane location for cylinder head before tightening the cylinder head bolts.
④ Assemble the cylinder head.
5. Installation of clamp
① Wipe the clamp.
② Lubricated on its load-bearing surface, the clamps should be sequentially mounted onto the cylinder
head. In addition, the clamp shall be so proper that it does not flow into the space between the cylinder
heads,
③ Mounting of the clamp should be such that the direction of groove is same as that of clearance
between the cylinder heads.
④ Manfully tighten the auxiliary bolts and nuts onto the cylinder head.
6. Installation of cylinder head bolts
Main bolts of cylinder head
21
① It is allowed to use the main bolts of cylinder head for three times at most.
② Sequentially center the cylinder heads. After coated with proper clean lubricant, the main bolt threads,
the shoulder bearing surface and the nuts should be respectively mounted onto the cylinder head, its
auxiliary bolts and clamps. In addition, the auxiliary bolts shall be glued: a. At the bottom hole of auxiliary
bolt, the part to be glued must be cleaned, free of any residual oil film; b. Bottom hole of auxiliary bolt
shall be manually coated with Weichai 243 thread-locking adhesive by 1/4-1/2 cycle in peripheral
direction at the depth of 5mm at least ; The gluing position shown in the following figure; c. It is required
to tighten the nut in 10min after the auxiliary bolt of cylinder head is tightened; d. Check if the glue is
small in amount or gets damp on site, and if any, the bolt cannot be used.
Gluing of bottom hole in auxiliary bolt

③ Tightening process of main and auxiliary bolts:
a. Tighten the main bolts to (60±6)N.m;
b. Tighten the auxiliary bolts to (25±3)N.m;
c. Tighten the auxiliary nut with angle of 120°±5°, of which position is marked with a color point.
d. Tighten the main bolt by 90°±5°, of which position is marked with a color point.
e. Rotate the auxiliary nut again by 90°±5°, of which position is marked with a color point.
f Tighten the main bolt again by 90°±5°, of which position is marked with a color point.
Tightening sequence of main bolts of cylinder head

Bolt number in figure: 1～14 of tightening bolt refers to M12×1.5 of auxiliary bolt (stud); 15～38 of
tightening bolts refers to the main bolts.
22
2212 Disassembly and assembly of cylinder head cover
Exploded drawing of cylinder head cover

Cylinder head cover is mainly composed of 1 cylinder head bolt, 2 cylinder head cover and 3 cylinder
head cover gasket.
22121 Disassembly procedure of cylinder head cover
Sequentially loosen the bolts off the cylinder head cover and vertically lift out the cylinder head cover and
the cylinder head cover gasket.
22122 Inspection and maintenance of cylinder head cover
① Check the cylinder head cover for the crack or excessive wear, and replace with a new one if needed.
② If there is oil leakage from the cylinder head cover gasket, check if cylinder head gasket fails and if the
sealing face between the upper surface of cylinder head and the lower surface of cylinder head cover is
worn, and replace the cylinder head cover gasket if needed for solution to oil leakage.
22123 Assembly procedure of cylinder head cover
① The cylinder head cover gasket is disposable and thus should be replaced after repair. The new
cylinder head cover gasket to be mounted should be inspected to be free of manufacturing or usable
defect or damage.
② Wipe the upper surface of cylinder head, and then sequentially and correctly mount the cylinder head
cover gasket.
③ Clean the cylinder head cover, and then sequentially and correctly mount them onto the cylinder
head.
④ Mount and tighten up the bolts of cylinder head cover.
23
2213 Engine lifting and assembly
1-Hoisting ring 2-Hoisting ring clamp

22131 Disassembly procedure of engine hoisting ring
The hoisting ring is threaded on onto its clamp for lifting of engine. For disassembly, loosen the thread to
take down the hoisting ring.
22132 inspection and maintenance of engine hoisting ring
After the disassembly, check if the front and rear hoisting rings and clamps are not cracked or deformed
severely, and if the hex. Bolt fails.
If so, replace with a new one for prevention against any safety accidents
22133 Assembly procedure of engine hoisting ring
Reverse to the disassembly sequence Tightening torque of shoulder nut: 120N.m~160N.m.
2214 Disassembly and assembly of oil-gas separator
Oil-gas separator is mainly composed of oil-gas separator, oil-return pipe, gas-bleeder pipe, fixing bolt,
intake pipe joint and clamp.
24
Oil and gas separator
support Fixing bolt for oil-gas separator
support
Connecting hose
Oil and gas separator
Pre-separator
Lifting ring Fixing bolt for oil-gas

clamping block Clamp separator
Clamp
Air intake pipe
Return pipe
Pre-separator return
pipe
Metal oil tank
Clamp
Escape pipe
Pipe clamp
Oil cooler cover bolts
Cover plate bolt
Oil return cover plate
Oil cooler cover
Disassembly drawing of oil-gas separator

22141 Disassembly procedure of oil-gas separator
① Remove the two fixing bolts off the oil-gas separator supports.
② Remove the rubber hose clamps between the oil-gas separator and pre-separator;
③ Unclamp the oil-return pipe and gas-bleeder pipe of oil-gas separator;
22142 Inspection and maintenance of oil-gas separator
① Check if each part is damaged or cracked and if the rubber hose is hardened or fragmented; replace
the proper parts if needed.
② Check whether the oil-gas separator is smooth or not by inflating the air inlet pipe of pre-separator. If
not, blow the pressurized air into each pipe of the oil-gas separator so as to remove the foreign material
and oil contamination away from the oil-gas separator. Replace with a new pre-separator if it is still not
smooth.
③ Check whether the oil-gas separator is smooth or not by the means of inflating the air inlet pipe of
pre-separator. If not, blow the pressurized air into each pipe of the oil-gas separator so as to remove the
foreign material and oil contamination away from the oil-gas separator. Replace with a new oil-gas
separator if problem is not yet solved after that.
22143 Assembly procedure of oil-gas separator
The steps to assemble oil-gas separator is reverse to the sequence in dismantling it. Refer to the
disassembly drawing to make sure that each rubber pipe fits each port and that the rotation angle of
rubber hose and the fixing position match the diesel engine during installation
25
2215 Removal and installation of shock absorber and crankshaft pulley
Torsional vibration
damper
Pulley bolt
Crankshaft
Crankshaft pulley Hexagon head
bolt Oil pump gear
Disassembly drawing of shock absorber and crankshaft pulley

1. Removal
Sequentially take down the pulley bolts, pulley and damper assembly, hex. bolts and crankshaft pulley,
and torsional vibration damper.
2. Assembly
After installation of the oil pump gears, firstly secure the torsional vibration damper onto the crankshaft
pulley by using the hex. bolts, and then fix the torsional vibration damper and the crankshaft pulley onto
the crankshaft flange by using the pulley bolts.
3. Maintenance essential
1) Check if the damper is impacted or deformed or has other defects.
2) Check if the pulley is damaged or if the part where the bolt is tightened is crushed.
3) Check if the pulley bolts are damaged.
2216 Disassembly and installation of flywheel assembly
Disassembly drawing of flywheel

1. Crankshaft 2. Crankshaft timing gear 3. Radial ball bearing 4. Cylindrical pin 5. Flywheel gear ring 6.
26
Flywheel
7. Flywheel bolt 8. Hex. bolt 9. Stud10. Circlip for hole
1. Preparation for disassembly
Equipment condition: Universal socket, wrench, press-fitting tool and torque wrench;
2. Disassembly procedure is reversed to the assembly steps.
3. Installation
1) Fix the flywheel gear ring (5) onto the flywheel (6) by using the hex. bolts.
2) Mount the rear oil seal of crankshaft onto the crankshaft gears, and then press the rear oil seal in with
the special tools.
3) Hit the cylindrical pin into the timing gear of crankshaft in place.
4) After inserting the flywheel guide rod into the crankshaft bolt hole, mount the flywheel components
and tighten the bolts in the diagonal way.
5) Tighten the flywheel bolt to M14×1.5 (9 PCs). Manual tightening: Lubricated at their threads and
pressure surfaces, flywheel bolts should be inserted into the threaded holes, diagonally tightened up to
N·m and then rotated by 270°±5°each.
6) Unable to reach the torque after rotated, the flywheel bolts should be replaced.
4. Maintenance essential
1) Check if the flywheel bolt threads fail.
2) Check if the flywheel surface is crushed.
3) Check if the flywheel gear ring is damaged.
2217 Removal and installation of crankshaft
22171 Disassembly procedure of crankshaft
Piston connecting rod

combination group Cylinder block
Crankshaft timing Flywheel housing

gear
Pulley bolt
Flywheel assembly
Pulley Absorber
Flywheel bolt
Gasket
Oil pump gear
Cranksha
ft Main bearing bush
Connecting rod
big cap
Crankcase
Main bearing
bolt
Disassembly drawing of crankshaft

1. With crankcase facing upward, remove the main bearing bolts and put them away in sequence.
27
2. Sequentially take down the following items: bolts, flywheel assembly, bearing at flywheel, front and
rear thrust collars, oil seals, bolts of the front pulley, pulley and shock absorber. Put the crankshaft onto
the supports (if it lasts for a long time, the crankshaft should be vertically placed.)
3. All parts taken down should be sorted out and put away.
22172 Inspection and maintenance of crankshaft
1. Check if the fillets of main bearing journal and connecting rod journal are cracked; as for the interface
between the crankshaft and the bearing, make sure the oil galley is smooth and free of crack.
2. Check if the main bearing journal and the connecting rod journal wear, peel off, strip or crack.
3. Check if the front and rear oil seals are worn.
4. Check if the main bearing bolts have any the damaged threads or other failure mode.
5. Check whether the bolt hole of crankshaft flange is cracked or not.
6. Check if the crankshaft journal is worn and if the crankshaft is bent or twisted.
22173 Assembly procedure of crankshaft
1. Hoist the crankshaft onto the support, during which care must be taken not to impact it.
2. Hit the cylindrical pin into the rear pin hole of crankshaft.
3. Heat the oil pump gear for 10s and then press it to the front end of crankshaft. Meanwhile, make sure
the distance from the outer end of gears to the front end of crankshaft is (26.5±0.3)mm.
(4) Make sure all interfaces of crankshaft should be cleaned and free of any impact; remove any dirt or
replace it if needed. Besides, the inside of oil passage should be cleaned with the compressed air to be
unobstructed.
5. Ground the lower surface of cylinder block, deoil it with a cleaning agent and then clean it with a towel.
Therefore, the cylinder block interface shall be kept clean, free of any burr.
6. The holes at bottom of the main bearing should be cleaned with detergent and then with a towel. After
that, the upper shell of main bearing should be pressed into the bottom holes.
7. With the crankshaft components up in air, use the compressed air to blow the oil passage clean and
towel the main shaft journal and the connecting rod journal. Then lightly lower the crankshaft
components into the cylinder block, with main shaft journal touching the bearing shell.
① Before installation of crankshaft, the upper bearing shell should be lubricated.
② Before the hoisting, carefully check if each friction pair of crankshaft is impacted and resolve it if
needed.
③. Avoid any possibility of impact during the hoisting.
④ Before installation, make sure each oil passage hole and friction pair are clean.
8. Mount two upper thrust collars, with its oil groove facing outwards (crankshaft). Thrust collar to be
installed shall be lubricated at its interface with the bearing cover.
9. Each main journal shall be coated with clean lubricant.
10. The lower surface of cylinder block should be applied with the sealant, with the sealant line
continuous and uniform. On the basis that the oil seal is uniform and free of torsion or other deformation,
the oil seal is evenly fitted into its groove in the lower surface of cylinder block by using a special tools.
11. Press the lower main bearing shell and the lower thrust collar (oil groove faces crankshaft) into the
crankcase, assembling the crankshaft.
12. Lubricate the bearing surface of crankcase bolts and the threads of main bearing bolts, then loosely
install the main bearing bolts and then tighten them in sequence shown below: Loosely fit them, tighten
them firstly to (80±5)N.m and then to (140±5)N.m, then rotate them by (70±5)°for 3 times, finishing the
crankshaft assembly.
28
Tightening sequence of main bearing bolts

13. Measure the axial clearance of crankshaft, with (0.06-0.25)mm as the standard range.
2218 Disassembly and assembly of piston and connecting rod assembly
Exploded drawing of piston and connecting rod assembly

1. Second gas ring 2. Piston pin 3. Connecting rod body 4. Connecting rod cap 5. Connecting rod bolt 6.
Lower shell of connecting rod
7. Upper shell of connecting rod 8. Piston pin retainer 9. Piston 10. Oil ring 11. First gas ring
29
22181 Disassembly procedure of piston and connecting rod assembly
Trapezoidal barrel faced ring
Twisted conical ring

Helical spring oil ring
Piston pin
Piston
Piston pin retaining ring
Piston pin retaining

ring
Connecting rod bushing

Connecting rod body
Connecting rod lower

half bearing
Connecting rod upper half
bearing
Connecting rod bolt
Connecting rod cap
Disassembly drawing of piston and connecting rod mechanism

1. Inspection before removal Check the axial clearance of connecting rod and the tightening torque of
connecting rod bolt; tilt the engine and crank the piston to be removed to BDC so as to take down the
bolts and cover off the connecting rod; crank the piston to TDC to hammer the piston out with a wood
hammer, during which care must be taken to prevent the large end of connecting rod from be stuck on
cylinder body. Similarly, take down the rest piston and connecting rod assemblies. After that, the pistons,
bolts and covers of connecting rod shall be numbered separately and put in order.
2. Use the internal circlip pliers to carefully remove the circlips at both sides of piston, and then push out
the piston pin to take down the connecting rod block. The piston pins and connecting rods are separately
numbered and put in order.
3. Use the piston ring pliers to respectively remove the 1st ring, 2nd ring and oil ring, and then mark
them.
3. Take down the upper and lower shells off the lower connecting rod, number them on their backs and
then put them in order.
22182 Inspection and maintenance of piston and connecting rod assembly
1. Check if there are cracks on the fillet of combustion chamber throat and piston pin base; check if the
piston skirt and head are scratched; check if the piston pin hole is worn normally.
2. Check if the piston ring is stuck in the piston ring groove.
3. Check if the excircle of piston ring and upper and lower end faces of piston ring are worn normally.
4. Check if the excircle of piston ring is worn normally.
5. As for the connecting rod, check if the large-end bottom hole, rod body and small-end oil hole are
cracked; check if the alloy layer of connecting rod bushing is worn normally or peels out; check if the
connecting rod side is worn abnormally; check if the connecting rod body is bent.
6. Check if the connecting rod bearing wears normally, and if the alloy layer discolors, peels off or slips.
7. For the same machine, the connection rod and piston shall be in the same mass group and be used
together.
30
22183 Assembly procedure of piston and connecting rod assembly
1. Mount the internal circlip into the piston circlip groove by using its special tool, and then rotate the
circlip in place. The angular side of retainer shall face inwards and the cotter opening shall offset the
piston center line by 30°. As shown in the figure below:
The opening of the retaining ring is offset

by 30°from the center line of the piston.
Assembly schematic of piston pin retainer

2. Put the small end of connecting rod into the piston, making this small end align the piston pin hole.
Then install the piston pin and the circlip at other side of piston pin. Before assembly, the small-end hole
of connecting rod and piston pin shall be coated with proper clean lubricant. Besides, the oblique incision
of connecting rod shall be in the same direction as the coolant inlet hole (large bore) of piston. As shown
in the figure below:
The oblique cutting direction of the connecting rod
body is the same as that of the oil inlet hole of the
piston cooling oil passage.
Schematic of assembly relation between piston and connecting rod

3. Arrange the assembled piston and connecting rod in the same order as the cylinder numbers, and
then sequentially put the oil ring, 2nd gas ring and 1st gas ring into the piston ring groove by using the
piston ring pliers, with the “TOP” of piston ring facing upwards. Besides, the rings shall rotate freely in
groove.
4. Wipe the inner wall of cylinder, connecting lever of crankshaft and piston and connecting rod; apply
the clean lubricant to each moving pair.
5. Adjust the direction of each ring opening: the 1st ring opening should offset the piston pin centerline by
30°; the 2nd ring opening should shift from the 1st ring opening by 120°; the oil ring opening should
respectively stagger the 1st gas ring and the 2nd gas ring by 120°and be on the perpendicular bisector
of piston pin centerline.
31
First gas ring Second gas

ring
Horizontal direction of
piston pin
Oil ring
Schematic of piston ring opening angle

6. Crank the crankshaft to have the cylinders 1 and 6 at BDC to install the piston and connecting rod
assembly onto the cylinders 1 and 6. The connecting rod bolts shall be loosely mounted. The arrow on
top of piston shall face the free end. Besides , the piston cylinder number is same as cylinder number
and the connecting rod cover matches the connecting rod block. Furthermore, the connecting rod bolts
to be mounted should be applied with the clean lubricant.
7. Tightening of connecting rod bolts: Tighten them manually and then to 115N•m symmetrically, at last,
turn each bolt by 90°±5°. Other cylinders are installed in the same way.
2219 Valve mechanism
Wire harness support

WCBS bracket hex head bolt WCBS adjusting nut
Exhaust rocker arm
assembly Intake rocker arm assembly
Rocker arm shaft Rocker arm support
combination group
WCBS adjustment screw Valve bridge
Valve lock clamp
Cylindrical pin
Valve spring upper seat
WCBS support
Valve spring
WCBS valve bridge
combination group
Valve spring lower seat
Valve spring upper seat
Intake valve
Valve spring lower seat Air intake and exhaust push rod
Gear chamber cover

Exhaust valve
Intermediate gear assembly

Tappet Camshaft timing gear
Camshaft
Positioning pin
Hexagon head bolt
Hexagon-head bolt of thrust

plate
Thrust disc
Hexagon head bolt
Exploded drawing of valve mechanism

22191 Disassembly procedure of valve mechanism
1 Remove the rocker and rocker shaft. For details, see their disassembly procedure;
2 Remove the intake and exhaust valves. For details, see their disassembly procedure;
3 Remove the tappet and pushrod. For details, see their disassembly procedure;
4 Remove camshaft and camshaft timing gear. For details, see their disassembly procedure;
5. Remove the intermediate gear. For details, see its disassembly procedure;
32
22192 Disassembly procedure of valve mechanism
1 Mount the intermediate gear. For details, see its assembly procedure;
2 Mount the camshaft and camshaft timing gear. For details, see their assembly procedure;
3 Mount the tappet and pushrod. For details, see their assembly procedure;
4 Mount the intake and exhaust valves. For details, see their assembly procedure;
5. Mount the rocker and rocker shaft. For details, see their assembly procedure;
2220 Removal and installation of camshaft
Flywheel housing connecting
plate
Intermediate gear assembly
Camshaft timing gear

Camshaft
Positioning pin
Hexagon head bolt
Hexagon-head bolt of thrust plate
Thrust plate
Hexagon head bolt
22201 Disassembly procedure of camshaft

1 Rotate the camshaft to check if it moves freely and does not interfere with the timing gear;
2 Check if the camshaft axially plays with a dial gauge.
3 Check the backlash of timing gear;
4. Rotate the crankshaft on the engine workbench until the camshaft timing gear is at the TDC of 1st
cylinder. Check if the hex. Bolts of camshaft are loosened. Sequentially remove the hex. bolt of camshaft
timing gear, timing gear and dowel pin.
5. Remove the hex. bolt of camshaft thrust collar, thrust collar and camshaft in sequence.
22202 Inspection and maintenance of camshaft
1. After removal, check the camshaft and timing gear for wear or considerable deviation of other
parameters, and replace or repair the camshaft if needed.
2. Check if the cam surface touching the tappet is worn and if the main journal is stuck or worn.
3. Check if the hex. bolts of timing gear is bent or deformed and if the camshaft timing gear is impacted
or severely worn.
22203 Assembly procedure of camshaft
After removal, check the camshaft and timing gear for wear or considerable deviation of other
parameters, and replace or repair the camshaft if needed.
1. Towel the camshaft hole so as to check it for impact; then apply the proper lubricant to the inner circle
of camshaft bushing by using a oil pot. The hole-impacted camshaft should be not repaired but
discarded.
2. Put the camshaft guide tool and camshaft lubrication bushing into the camshaft hole; clean the
camshaft and check if it is impacted; insert the camshaft into the its hole, finishing its installation. At last,
remove the camshaft guide tool and camshaft bushing. While inserting the camshaft, do not impact the
camshaft bushing.
3. Mount the camshaft thrust collar, of which both sides should be coated with clean lubricant so proper
that the camshaft could rotate freely. Coated with 242 sealant at its threads, the thrust collar bolts should
be tightened to (35 ±3)N.m.
4. Grind, deoil and clean the rear end surface of cylinder, so as to keep the fitting face level and clean.
33
Hammer the cylindrical pins into the rear end of crankshaft, and then mount and tighten the connecting
plate of flywheel housing with four bolts;
5. Apply the special sealant to the connecting plate, with the sealant line continuous and even.
6. The camshaft thrust collar and the timing gear should be bolted onto the camshaft. The counterbore
on the connecting plate must align the marked teeth on the camshaft timing gear.
2221 Disassembly and assembly of intermediate gear
Exploded drawing of intermediate gear

1. Bolt 2. Shim 3. Intermediate gear shaft 4. Bushing 5. Intermediate gear
22211 Disassembly procedure of intermediate gear
1. Take down the air compressor. For more, see the disassembly illustration on vehicle accessory
system;
2. Take down the fuel injector. For more, see the removal illustration of fuel system;
3. Take down the camshaft timing gear. For more, see the removal illustration of valve system.
4. Check if the bolt rotates according to the marker of intermediate gear bolt. Take down the 4 M10 hex.
Bolts from the intermediate gear and then the gaskets. Screw one M8 bolt into shaft at the middle of gear
to pull out the shaft, during which care must be taken not to drop the intermediate gear;
5. The intermediate gear assembly and its shaft shall be taken down together with gear chamber and
removed out from the gear chamber opening.
22212 Disassembly procedure of intermediate gear
1. Check if the mounting bolt threads are good;
2. Check if each gear has tooth broken or peeled off at the top, if the bolt bearing surface is crushed, and
if the threaded hole or through hole in gear is deformed;
3. Check if the intermediate gear and its bushing are worn normally, and if each oil hole is blocked due to
dirt or foreign material.
22213 Assembly procedure of intermediate gear
1. Assemble the oil pump, crankshaft and intermediate gear of oil pump in order.
2. Installation of gear chamber Before installing the gear chamber, put the intermediate gear shaft into its
34
assembly (intermediate gear and bushing ), with “V” side facing outwards (“V” cannot be shielded with
the intermediate gear shaft). Put the intermediate gear assembly and its shaft onto the position where
the intermediate gear should be, and meanwhile the diesel engine shall be installed upside down;
otherwise, the intermediate gear assembly and intermediate gear shaft may drop.
2222 Removal and installation of tappet and pushrod
Exploded drawing of tappet and pushrod

1. Pushrod; 2. Cylinder head; 3. Tappet;
22221 Disassembly procedure of tappet and pushrod
1. After the rocker and rocker shaft are dismounted, directly take out the pushrods and put them in order;
2. After dismounting the cylinder head (see the removal procedure of cylinder head), take out the tappets
and put them in order.
22222 Inspection and maintenance of tappet and pushrod
1. Clean the pushrod and tappet;
2. Check if the oil passage of tappet and pushrod is smooth;
3. Check if the pushrod is bent or if its outer surface is worn severely;
4. Check if the pushrod ball head or concave is worn;
5. Check if the surface and bottom of tappet are worn;
6. Check if the concave inside of tappet is worn.
22223 Assembly procedure of tappet and pushrod
1. Check if the tappet and pushrod have any problem, and correct it if needed. It is a must that the tappet
to be mounted shall be blown clean with compressed air and the oil hole shall be unblocked;
2. Apply the clean lubricant to the valve tappet;
3. Put the valve tappet into its hole;
4. After the cylinder head is assembled in place (For more, see the assembly procedure of cylinder
head), blow the pushrod clean with compressed air and make sure the oil hoke is unblocked.
5. Apply the clean lubricant to the pushrod and make sure there is sufficient lubricant between ball head
and concave;
6. Install the pushrod in place.
35
2223 Disassembly and assembly of valves
Exploded drawing of valves

1. Inlet valve; 2. Cylinder head; 3. Lower seat of valve spring; 4. Upper seat of valve spring; 5. Valve clip;
6. Valve spring; 7 Exhaust valve;
22231 Disassembly procedure of valves
1.Press down the valve spring by using its special compressor, valve pliers or other tool, so as to take
out the valve clip, upper seat of valve spring and inner and outer springs of valve;
2. Take the valve out of its base.
22232 Inspection and maintenance of valve
1. Check if the valve rod and its end are worn;
2. Check if the valve cone is worn or damaged;
3. Check if the valve cone has accumulated soot;
4. Check if the valve disc end has accumulated soot or is sintered.
22233 Assembly procedure of valves
If worn, sooted or sintered severely, the valve shall be replaced with a new one.
1. Evenly apply the molybdenum disulfide paste onto the intake and exhaust valve rods, and then install
the intake and exhaust valves onto the cylinder head to make sure the intake & exhaust valves could
move freely in the guide, free of any stuck phenomenon;
2. The lower base bottom of exhaust valve spring is evenly coated with thread-locking sealant, and then
this exhaust valve is put on the cylinder head in place. If the lower base of exhaust valve spring cannot
sit in place, replace or repair it, and do not forcefully knock it in.
3. Install the lower base of intake valve spring; put the upper valve rod protector onto the intake and
exhaust valve guides; then, install the sealing sleeve of valve rod;
Note: Before assembly, it is a must to check if the spring inside of valve rod sealing sleeve is intact.
4. Install the inner and outer springs of valve. Note that the two springs are in the opposite direction.
5. Install the upper seat of valve spring, and press the valve spring to install the valve clip.
6. After put in, the valve clip shall be tapped into the exhaust valve in place with a rubber hammer. If the
valve clip or upper seat cannot be installed in place, find out the root reasons and solve them.
36
2224 Removal and installation of rocker and rocker shaft
Hexagon head bolt

WCBS adjusting nut Cylindrical pin
Wire harness support

Rocker arm shaft assembly
Intake rocker arm assembly

Exhaust rocker arm assembly
WCBS adjustment screw
Rocker arm support Valve bridge
WCBS valve bridge

combination group WCBS support
Cylinder head
Exploded drawing of rocker and rocker shaft

22241 Disassembly procedure of rocker and rocker shaft (included into WCBS part)
1) Check if the rocker rotates freely.
2) Check if the valve clearance changes by measuring it.
3) If the rocker rotates inflexibly or the valve clearance changes considerably, loosen the hex. bolts to
remove the WCBS bracket, rocker shaft assembly, intake and exhaust rockers and rocker supports, and
then mark them to sort out rockers of each cylinder.
22242 Inspection and maintenance of rocker and rocker shaft
1. Clean the rocker and check the appearance of rocker for crack or other defects.
2. Check the inside hole of rocker for abrasion and wear and then measure its diameter.
3. Check if the ball pin and rocker shaft are worn normally.
4. Check if each oil passage is smooth.
5. Measure the rocker hole and the rocker shaft diameters so as to calculate the fit clearance.
6. Check if adjusting screw of WCBS is worn normally and if the WCBS support is cracked or worn.
22243 Assembly procedure of rocker and rocker shaft
1. Put the rocker onto the workbench, then turn the adjusting screw into the rocker and loosely fit the nut.
2. Insert the cylindrical pin into its hole in the lower surface of rocker shaft by tapping it. After that, this pin
cannot be cracked.
3. Tighten the two hex. screws respectively into the M5 threaded holes at both sides of crankshaft.
Besides, if not coated in advance, the screws shall be coated with the 271 sealant. After turned to the
end, screw head should recess the side of rocker shaft by (0~1)mm.
4. The rocker shaft should be assembled on to rocker supports; after lubricated a little, the rocker should
be mounted on the rocker shaft assembly; after that, the rocker assembly shall rotate flexibly, and then
the two hex. bolts shall be inserted into the rocker shaft supports.
5. Drive the cylindrical pin into the plane pin hole on WCBS bracket until to the end; screw the adjusting
nut into WCBS bracket and loosely install the WCBS adjusting nut.
6. The injector harness bracket is mounted on the WCBS bracket, then located with a cylindrical pin and
tightened with the hex. Bolts.
37
7. Mount the valve pushrod (for more information, see the assembly instruction on valve pushrod), and
individually put the valve bridge and WCBS valve bridge assembly onto the intake and exhaust valves.
8. Mount and tighten the rocker components: the dowel pin on the upper surface of cylinder head should
align and fit the pin hole in the lower rocker support; rocker ball pin shall perfectly sit into the round hole
in the valve pushrod.
9. Install and pre-tighten the WCBS bracket support. The pin hole at lower side of WCBS bracket shall
align and completely sit into the dowel pin on the upper surface of cylinder head
10. Tighten the rocker base bolt and hold-down bolt of WCBS bracket.
11. Check and adjust the clearance of intake and exhaust valves.
1) Crank the engine to TDC of one cylinder. Namely flywheel marker aligns the one on flywheel housing,
so as to determine the compression TDC of one cylinder.
2) Adjust the intake valve clearances of 1st, 2nd and 4th cylinders to be (0.38±0.03)mm respectively; the
exhaust valve clearances of 1st, 3rd and 5th cylinders to be (0.58±0.03)mm respectively and WCBS
clearance to be (0.38±0.03)mm. Tightening torque of adjusting nuts of intake and exhaust valves: (45±5)
N•m; WCBS tightening-nut torque: (50~65) N•m.
3) Measure to adjust the exhaust valve clearance:
Completely loosen the WCBS adjusting screw to adjust the exhaust clearance locknut and adjusting
screw, so that the exhaust valve clearance could be (0.58±0.03)mm. Insert a feeler gauge at the bottom
of WCBS adjusting screw to adjust the WCBS clearance to be (0.38±0.3)mm. At this time, the piston
inside of WCBS valve bridge shall be completely compressed.
(4) Mount the engine-cranking device onto the flywheel housing, then tighten the outside two hex. nuts
and crank the engine to TDC of 6th cylinder.
5) Adjust the intake valve clearance of 3, 5 and 6 cylinders and the exhaust valve clearance of 2, 4 and 6
cylinders The 6th cylinder piston is at the TDC of combustion. Intake valve clearance: (0.38±0.03)mm;
exhaust valve clearance: (0.58±0.03)mm; WCBS clearance: (0.38±0.03)mm;
6) At the ambient temperature, check the valve phase of the 1st cylinder. Intake valve opens by (20±5)°
angle from the TDC and exhaust valve opens by (21±5)°angle from the TDC.
2225 Intake and exhaust system
22251 Disassembly procedure of intake and exhaust system
1. Take down the supercharger lubricant pipe.
2. Remove supercharger.
3. Remove the exhaust pipe.
4. Remove the intake pipe.
22252 Assembly procedure of intake and exhaust system
38
Exploded drawing of intake and exhaust system

1. Intake pipe 2. Exhaust pipe 3. Supercharger lubricant pipe 4. Supercharger
2226 Removal and installation of supercharger
Supercharger includes: turbocharger, oil pipe of supercharger, oil return pipe of supercharger, nut,
supercharger gasket and stud, as shown in the figure.
Supercharger
inlet pipe
Stud
Superchar
ger gasket
Nut
Turbocharger
Supercharger
oil pipe
Exploded drawing of supercharger

22261 Assembly procedure of supercharger system
1. Take down the oil return pipe assembly of supercharger.
2. Take down the oil inlet pipe assembly of supercharger.
3. Take down the turbocharger.
39
22262 Disassembly procedure of supercharger
Reverse to the assembly procedure
22263 Inspection and maintenance of supercharger system
1. Make sure the supercharger is tightly connected to the engine pipeline.
2. Check the supercharger for leakage of gas and oil and timely solve it if needed.
3. Check if the screws of supercharger are loosened and tighten them if needed.
4. Check if the air filter is dusty and clean it if needed.
5. If there is the unsolved failure or the disassembly and assembly conditions are not met during removal
or installation of the supercharger, submit it to the production or repair departments.
① Remove the fixing screws off the air compressor volute, and lightly rock this volute along the impeller
periphery and hit it evenly outwards with rubber hammer. The housing cannot impact the vanes, and the
nut at the shaft end cannot be loosened.
② Remove the oil contamination away from both the vane passage and the inside of housing by using
the gasoline.
③ The fixing screws should be tightened to 15N.m to fix the compressor housing.
④ Removal of any shafts should be carried out by the professional or the entrusted manufacturer.
2227 Removal and installation of intake pipe
Double
end Gasket
studs
Intake
Intake
heater
pipe
Intake pipe
bolt
Intake pipe
Pressure
temperature sensor
Disassembly drawing of intake pipe

22271 Disassembly procedure of intake pipe
1. Take down the intake pipe at the joint
2. Take down the intake heater.
3. Unbolt the intake pipe.
4. Remove the intake pipe.
5. Remove the intake pipe gasket.
22272 Inspection and maintenance of intake pipe
1. Inspection of intake pressure and temperature sensor: Check if the intake pressure and temperature
sensor and its harness are normal, free of damage.
40
ECU Pins
2. Inspection on intake pipeline: Check if the engine intake pipe is smooth and free of crack, and tighten
them if needed to ensure the airtightness of intake system. Besides, check if the intake heater is intact.
22273 Assembly procedure of exhaust pipe
2228 Removal and installation of exhaust pipe
Exhaust
pipe
gasket
Sealing ring
Sleeve
Bolt
Exhaust manifold
Exploded drawing of exhaust pipe

1. Exhaust pipe gasket 2. Exhaust manifold 3. Tightening bolt of exhaust pipe 4. Exhaust pipe bolt 5.
Bushing 6. Exhaust manifold 7. Sealing ring of exhaust pipe
22281 Disassembly procedure of exhaust pipe
1. Take down the exhaust pipe bolts.
2. Take down the socket.
3. Remove the exhaust pipe.
4. Take down the exhaust pipe gaskets.
5. Take down the seal ring of exhaust pipe.
22282 Inspection and maintenance of exhaust pipe
Check if the exhaust pipe is smooth, if the exhaust pipe bolts (heatproof bolts) are loosened or if the
exhaust pipe is cracked or leaked.
22283 Assembly procedure of pipe
Reverse to the disassembly procedure. Openings of two seal rings for installation shall stagger by 180°.
41
2229 Fuel system
Exploded drawing of fuel system

22291 Disassembly procedure of fuel system
1.Take down the harness.
2. Take down the low-pressure fuel pipe.
3. Take down the high-pressure fuel pipe.
4. Take down the high-pressure connector.
5. Take down the fuel injector.
6. Take down the ECU.
7. Take down the fuel filter.
8. Take down the high-pressure fuel pump.
22292 Assembly procedure of fuel system
42
2230 Disassembly, inspection, maintenance and assembly of fuel injection pump
Exploded drawing of fuel injection pump

1. Fuel injection pump gear 2. Silicon seal 3. Flange of fuel injection pump 4. Hex. Bolt 5. Stud
6. Nut 7. Fuel injection pump 8. Hollow bolt 9. Seal gasket 10. Lubricant pipe of fuel injection pump
22301 Disassembly procedure of fuel injection pump
1. Take down the hex. Nut between the flange of fuel injection pump and gear chamber.
2. Take down the fuel injection pump and gear assembly off the engine.
3. Take down the locknut off the fuel injection pump.
4. Take down the hex. Bolt between the fuel injection pump and flange.
5. Take down the flange off the fuel injection pump.
22302 Inspection and maintenance of fuel injection pump
Fuel injection pump structure shown below Rotate the flywheel to the compression DTC of the 1st
cylinder, and the fuel injection pump gear marker should be aligned with the gear chamber marker.
Fuel injection pump structures
43
Fuel injection pump timing

22303 Assembly procedure of fuel injection pump
1. Install the flange of fuel injection pump, and apply a little of lubricant to the silicon seal of fuel injection
pump.
2. Install the hex. Bolt between the fuel injection pump and flange.
3. Bolt the fuel injection, and tighten the locknut M24×1.5 of fuel injection pump gear to (250~300)N·m at
one time.
4. Rotate the flywheel until the compression TDC of the 1st cylinder; then rotate the fuel injection pump
gear until fuel injection pump gear marker is aligned with the one on fuel injection pump flange; install the
fuel injection pump assembly. Viewing from the sight glass at the front end of gear chamber, the marker
on fuel injection pump gear shall be aligned with the one on the gear chamber.
5. Install the hex. Nut between fuel injection pump and gear chamber.
6. Install the hex. Nut between fuel injection pump and gear chamber.
2231 Removal and installation of high-pressure fuel pipe
Rail to injector high pressure
oil pipe
Pump to rail high

Pipe clamp
pressure oil pipe
Exploded drawing of high-pressure fuel pipe

22311 Disassembly procedure of high-pressure fuel pipe
1. Take down the fixing bracket of high-pressure fuel pipe.
2. Take down the high-pressure fuel pipe.
22312 Inspection and maintenance of high-pressure fuel pipe
1. Check if high-pressure fuel pipe joint cap is loosened, and tighten it if needed.
2. If there is air in high-pressure fuel pipe: Loosen the high-pressure fuel pipe on some cylinder, and use
the starter to drive the diesel engine to rotate until the fuel continuously comes out of high-pressure fuel
44
pipe! (It is suggested not to frequently take down the joint off the high-pressure fuel pipe！).
22313 Assembly procedure of high-pressure fuel pipe
Note: Tightening torques of high-pressure fuel pipe: (30~40)N·m at the fuel injector; (30~40)N·m at the
rail end and fuel injection pump.
2232 Removal and installation of fuel injector
Screw
sleeve High voltage connector Hexagon head bolt
Ball washer
Injector block
Fuel injector
Exploded drawing of fuel injector assembly

22321 Disassembly procedure of fuel injector
1. Take down the two hex. Bolts off the fuel injector clamp.
2. Take down the fuel injector clamp and anchor block.
3. Take fuel injector assembly out of the cylinder head.
22322 Inspection and maintenance of fuel injector
Replacement of fuel injector nozzle shall be carried out by the Special service station of Bosch.
Engraving of fuel injector nameplate:
Engraving position: at solenoid valve at top of fuel injector
Engraving specifications: first row: fuel injector model
Second row: Weichai part number
Third row: Bosch part number
Note: fuel injectors with different part numbers cannot be exchanged.
45
Fuel injector engraving specifications

22323 Assembly procedure of fuel injector
Note: Two tightening bolts M8 of fuel injector (different lengths): tighten them symmetrically to (13~15)
N·m, with the consistent clearance.
2233 Removal and installation of ECU
Spring washer Hexagon head bolt
Hexagon socket head cap

screws
ECU support
ECU support
ECU cover
Exploded drawing of ECU

1. Disassembly procedure of ECU
(1) Take down the four bolts off the ECU.
(2) Take down the ECU.
(3) Take down the two screws off the ECU bracket.
2.Inspection and maintenance of ECU
(1) Check the bolts and screws of ECU are reliably connected and tighten them with a wrench if needed.
(2) Check if the ECU pins are intact.
3 Assembly procedure of ECU
46
2234 Removal and installation of water pump
Hexagon head bolt
Water pipe head

O-ring
Temperature sensor
Thermostat cover
Hexagon head
bolt
O-ring
Exploded drawing of water pump

22341 Disassembly procedure of water pump
Remove the five bolts and then water pump; remove the four bolts and then thermostat cover.
22342 Inspection and maintenance of water pump
1. Check if the water pump rotates freely or if the seal ring is damaged, and replace them if needed.
22343 Assembly procedure of water pump
(1) Grind the interface between the front end of cylinder and the rear cover of water pump, and then wipe
it to apply the adhesive. The interface between the rear end of water pump and the cylinder should be
applied with 518 flange sealant.
(2) Insert the proper O-ring into the interface of rear end of water pump.
(3) Mount and bolt the water pump assembly. Before installation, the water pump pulley should rotate
freely.
2235 Removal and installation of fan
Fan
Fan drive shaft

Hexagon head bolt
Hexagon head bolt
Nut
Fan bracket
Gasket
Fan clutch
Disassembly drawing of fan
47
22351 Disassembly procedure of an
1) Take down the four hex. Bolts off the fan.
2) Take down the six bolts off the fan drive shaft.
22352 Inspection and maintenance of fan
1) Check if the fan vane does not crack, but rotates smoothly, and replace it if needed.
2) Check if the fan drive shaft is cracked and replace it if needed. Check if the drive shaft fails, and
replace it if needed.
22353 Assembly procedure of fan
1. Mount and secure the fan drive shaft onto the fan bracket by using six hex. bolts.
2. Mount and secure the fan onto the fan drive shaft by using four bolts.
2236 Removal and installation of oil pump
Hexagon head bolt
Oil pump
Exploded drawing of oil pump

22361 Disassembly procedure of oil pump
1) Loosen the hex. Bolt.
2) Take down the oil pump.
22362 Inspection and maintenance of oil pump
Check if the oil pump does not crack, and if the drive gear of oil pump rotates freely, and replace with a
new one if needed.
22363 Assembly procedure of oil pump
1. Before installation, check the oil pump and hex. bolts are free of any manufacturing or service defects
or damages.
2. Clean the interface between oil pump and crankshaft.
3. Install the oil pump gasket.
4. Install the oil pump.
5. Install the hex. bolt and tighten it.
48
2237 Removal and installation of oil filter
Hexagon flange bolt
Oil filter base
Oil filter
Exploded drawing of oil filter

22371 Disassembly procedure of oil filter
Remove the oil filter with special tools, and loosen the four bolts attaching the oil filter seat to unbolt it
and then take down the oil filter.
22372 Inspection and maintenance of oil filter
1. Check if the oil filter is impacted and if the fitting face between the oil filter seat and the oil filter leaks,
and replace them if needed.
2. Check if the bolt threads are deformed. Replace bolts if needed.
22373 Assembly procedure of oil filter
1. Grind the interface between the oil filter seat assembly and the engine block, and then use the
compressed air to purge the inside of chamber.
2. Take the spin-on oil filter element out to loosely fit it onto the oil filter seat.
49
2238 Removal, inspection and assembly of oil cooler cover
Oil cooler cover
Flange bolt
O-ring
Sealing washer
Water outlet joint

Hollow bolt
Exploded drawing of oil cooler cover

22381 Disassembly procedure of oil cooler cover
Before removal, drain the coolant out of the engine and loosen the hollow bolts of oil cooler cover in
sequence so as to remove the oil cooler cover and O-ring.
22382 Inspection and maintenance of oil cooler cover
1. Check the oil cooler cover for crack or other defects, and replace it if needed.
2 Check the seal ring of oil cooler cover for damage, leakage or other failures, and replace it if needed.
22383 Assembly procedure of oil cooler cover
1. Before installation, check the oil cooler cover and its seal rings to make sure there is no manufacturing
or applicable defect or damage.
2. Clean the interface between the oil cooler cover and the engine block, and then mount the oil cooler
cover.
3. Bolt and tighten the oil cooler cover.
4. Mount the coolant outlet pipe joints of which should be sealed with the seal rings and then tightened
with the hollow bolts.
50
2239 Removal and installation of oil cooler
Oil cooler
Hexagon head bolt
O-ring
Exploded drawing of oil cooler

22391Disassembly procedure of oil cooler
Unbolt oil cooler sequentially to take down the oil cooler and O-ring.
22392 Inspection and maintenance of oil cooler
1. Check the oil cooler for crack or other defects, and replace it if needed.
2. Check the seal ring of oil cooler for damage, leakage or other failure, and replace it if needed.
22393 Installation procedure of main oil cooler
1. Before installation, check the oil cooler and its seal rings to make sure there is no manufacturing or
applicable defect or damage.
2. Clean the interface between the oil cooler and the engine block, and then mount the oil cooler.
3. Bolt and tighten the oil cooler.
2240 Removal and installation of strainer
Gasket Gasket seal
Hexagon head bolt
Collector filter
Exploded drawing of strainer

22401 Disassembly procedure of strainer
Loosen the two hex. bolts off strainer to take down the strainer and its gasket.
51
22402 Inspection and maintenance of strainer
1. Check if the strainer is cracked and if the inside chamber is smooth, and replace it if needed.
2. Check the strainer gasket leaks oil, and replace it if needed. Check if the strainer gasket fails, and
replace the strainer if needed.
22403 Assembly procedure of strainer
1. Before installation, check the strainer and its gasket for manufacturing or applicable defects or
damages.
2. Before installation, check if its welding seam is cracked or opened.
3. The strainer bolt threads should be coated with the Loctite 242 sealant and should be screwed up
together with the wave washer.
4. Assembly sequence is reversed to the disassembly steps.
2241 Removal and installation of starter
Exploded drawing of starter

1. Stud 2. Starter 3. Hex. locknut
22411 Disassembly procedure of starter
1. Take down the hex. Nut (3) and then the starter (2).
2. Take down the stud (1).
22412 Inspection and maintenance of starter
1. The starter shall be protected against the sprayed water, road mud and oil, and the protection board
shall be mounted if needed.
2. The starter shall be protected against high temperature. The allowable temperature of starter housing
is not higher than 100℃.
3. The starter relay must be installed in order to protect the starter and to prevent against teeth collision
when the driver cannot monitor the starting (for example, the engine is located at the tail of commercial
vehicle.). The starter relay should have the current capability of higher than 80A and be able to cut off the
starter circuit soon after the diesel engine starts to run normally. The axial line of starter relay should be
parallel to the ground and be perpendicular to the vehicle traveling direction so as to prevent the starter
from being unexpectedly engaged due to vibration or impact or other causes.
52
22413 Assembly procedure of starter
Before installation, the starter gear shall be coated with lithium grease for vehicle. Reverse to the
disassembly procedure
2242 Installation of vehicle accessory system
Exploded drawing of vehicle accessory system - 1

1. Water return pipe of air compressor 2. Air outlet pipe of air compressor 3. Water inlet pipe 4. Hollow
bolt 5. Lubricant pipe 6. Air compressor 7, 15. Bolt
8, 14. Seal ring 9, 13. Gear 10. Pipe joint 11. Ferrule 12. Nut 16. Hydraulic pump
Exploded drawing of vehicle accessory system - 2
53
1, 15. Gasket 2, 3, 4, 7, 8, 13, 16, 17. Bolt 5. Generator 6. Adjusting nut 9. A/C compressor 10. Nut
11. Engine support 12. Pad 14. Dowel pin 18. Bushing 19. Engine mounting bracket
22421 Disassembly procedure of vehicle accessories system
1) Remove the generator and its supports.
2) Remove the A/C compressor and the engine supports.
3) Remove the air compressor.
4) Remove the hydraulic pump.
2243 Disassembly, inspection, maintenance and assembly of generator and its bracket
Exploded drawing of generator and its bracket

1. Bolt 2. Gasket 3. Generator 4. Mounting bracket of generator 5. Bushing 6. Adjusting nut
22431 Disassembly procedure of generator and its bracket
Firstly remove the two bolts off the generator to take the generator down; then remove the three bolts off
the generator bracket to take it down.
22432 Inspection and maintenance of generator and its bracket
1) Check if the generator rotates freely and if the bushing and bolts are cracked; and replace them if
needed and find out the causes.
2) Check if the generator bracket is cracked, if the bushing is loosened and if the bolt torque meets the
requirements. For installation and wiring of the generator, pay attention to: ◆It shall cool down
completely ◆it shall be protected against any dust, splash or oil ◆ check if motor belt is tensioned
properly◆ it has to work together with the voltage regulator and battery.
22433 Assembly procedure of generator and its bracket
1) Mount the locating bush onto the engine block, then use the hex. bolt to fix the generator bracket onto
the diesel engine.
2) Use two hex. bolts and one hex. nut to loosely fit the generator onto its bracket and then tighten it.
54
2244 Removal and installation of A/C compressor and engine support
Bolt
Gasket
Positioning
pin
Cushion
block
Bolt
Bolt Air Nut Engine

conditioning support
compressor
Exploded drawing of A/C compressor and engine support

22441 Disassembly procedure of A/C compressor and engine support
(1) Unbolt the A/C compressor to take it down.
(2) Remove the four bolts off the engine block to take down the engine support.
22442 Inspection and maintenance of A/C compressor and engine support
Check if the A/C compressor sheave wears or has any attached foreign material and if the engine
support is damaged, and replace them if needed.
22443 Assembly procedure of A/C compressor and engine support
(1) Install the engine support onto the engine block.
(2) Use the hex. bolts and hex. nuts to loosely fit the A/C compressor onto its bracket and then tighten
them.
23 Removal of engine system

231 Removal of engine
1. Drive the vehicle to the maintenance site;

tension up the parking brake; shut down the
engine; power off the complete vehicle; wedge the
tires.
After the vehicle cools down, perform the

following operations. During the removal, each
pipe joint shall be properly protected against
any foreign material from getting in..
2 Draining-out of coolant
55
1 Drain valve
2 Disconnection of engine circuits

2.1 Disconnect the engine harness from the cab
harness.
1. Engine harness
2.2 Disconnect the generator harness.
1 Generator harness
2.3 Disconnect the grounding wire from the

compressor bracket
1 Grounding wire
56
3 Disconnect the water inlet pipe from the

engine
1 Water inlet pipe of engine
4 Disconnect the air inlet pipe of intercooler,

bleeder pipe, .water outlet pipe of engine, air outlet
pipe of engine and air outlet pipe of intercooler.
1 Air inlet pipe of intercooler 2 Bleeder pipe 3

Water outlet pipe of engine 4 Air outlet pipe of
engine 5 Air outlet pipe of intercooler
5 Disconnect the blocking alarm sensor
1 Air filter sensor
57
6 Disconnect the pipe from the compressor.
1 Pipe between compressor and cooler 2 Pipe

between compressor and evaporator
7 Engine fuel pipe
7.1 Disconnect the fuel inlet pipe from engine

(cold-weather fuel assist is connected to engine)
7.2 Disconnect the fuel return pipe from engine
(engine is connected to fuel tank)
2
1
1 Fuel inlet pipe 2 Fuel return pipe
8 Disconnect the steel wire hose from the

engine.
1 Steel wire hose
58
9 Unclamp the oil dipstick.
1 Dipstick 2 Clamp
10 Disconnect the connection pipe from the

butterfly valve of exhaust brake.
1、Connection pipe 2. Butterfly valve of exhaust

pipe 3. Bolt and nut 4. Exhaust pipe
11 Disconnect the transmission mounting

assembly
1 Adjusting shim 2 Shock absorber 3. Cross beam

4. Bolt and nut 5. Bolt and nut
12 Disconnect the transmission pipeline
59
12.1 Disconnect the oil inlet and return ports

from the transmission.
1. Oil inlet port 2. Oil inlet port
13 Disconnect the transmission wires.
13.1 Disconnect the engine harness from the

transmission.
1. Engine harness
60
14 Disconnect the drive shaft from the

transmission.
1. Drive shaft 2. Bolt and nut 3. Transmission
15 Disconnect the engine from the frame.

15.1 Disconnect the front bracket of engine
from the buffer block.
1. Front bracket of engine 2. Buffer block 3. Bolt
15.2 Disconnect the rear bracket of engine from the

buffer block.
1. Rear bracket of engine 2. Buffer block 3. Bolt
61
16 Crane the engine onto the tooling.
Engine assembly
1. Engine assembly 2. Sling
17 Sling the transmission to separate the

transmission
from the engine..
Gearbox assembly
1. Engine 2. Bolt 3. Transmission
18. Removal of compressor from its bracket.
18.1. Loosen the adjusting bolt to take down

the compressor
1 2
1. Adjusting screw 2. Compressor
62
18.2. Take down the compressor bracket
1 Compressor bracket 2 Bolt
19 Removal of engine support

19.1 Take down the rear bracket of engine
1 Rear bracket of engine 2 Bolt

232 Assembly of engine
1 Assembly of engine bracket
Bolt the left/right-rear bracket of engine.
Torque: 355±35Nm
For the installation of bracket, the engine

shall be lifted up.
1 Rear bracket of engine 2 Bolt
63
2 Assembly of compressor
Bolt the compressor bracket, adjust the adjusting
bolt of compressor, and then tighten the nut.
Tighten the bracket
After connected to engine, the compressor

belt shall be measured with a dynamometer for its
tension. The tension shall be controlled within
110±5 pound. After that, tighten all bolts of
compressor.
1 2
1 Compressor bracket 2 Bolt
3 Connect the water inlet pipe to the engine.
4 Lay the engine cable onto the engine and

clamp it tightly.
1 Engine cable assembly
64
1
5 After connected to the butterfly valve of

exhaust brake, this connection pipe shall be then
connected to engine with nuts..
1 2 3
1 Nut 2 Connection pipe 3 Butterfly valve of
exhaust brake
6 Installation of engine bracket

6.1 Left-/right-front bracket shall be fixed on the
engine with bolts and nuts.
Torque: 355±35N.m
Apply 262 locking agent to threads
1 Right-front bracket of engine 2 Bolt and nut
6.2 Bolt the rear bracket of engine
Torque: 355±35N.m
1 Right-rear bracket of engine 2 Bolt and nut
65
7 Lowering of engine
7.1 Crane the engine assembly onto the frame.
Engine assembly
1. Engine assembly 2. Sling
7.2 Fix the front support of engine and buffer

block
onto the front bracket of engine, and then tighten
the bolts attaching the buffer block to the bracket.
Torque:
685±68 N.m
1 Front bracket of engine 2 Front support of engine

3 buffer block 4. Bolt
7.3 Connect the rear support of engine to the

buffer block.
Torque: 750±75 N. m
1. Rear bracket of engine 2. Buffer block 3. Rear

bracket of engine 4 Bolt and washer
66
8 Clip the oil dipstick onto the workbench

support.
1 Dipstick 2 Clamp
233 Removal of radiator
1. Drive the vehicle to the maintenance site;

tension up the parking brake; shut down the
engine; power off the complete vehicle; wedge the
tires.
After the vehicle cools down, perform the

following operations. During the removal, each
pipe joint shall be properly protected against
any foreign material from getting in.
2 Draining-out of coolant
1 Drain valve
3 Disconnect the radiator pipeline.

3.1 Disconnect the water inlet pipe from the
engine.
1
67
3.2 Disconnect the air inlet pipe of intercooler,

bleeder pipe, water outlet pipe of engine, air outlet
pipe of engine and air outlet pipe of intercooler.
.water outlet pipe of engine, air outlet pipe of
engine and air outlet pipe of intercooler.

engine 5 Air outlet pipe of intercooler
3.3 Disconnect the water supply pipe from the

surge tank.
1 Water supply pipe of surge tank 2 Clamp 3

Radiator
3.4 Disconnect the water outlet pipe from the

heater.
1 2
1 Water outlet pipe of heater 2 Clamp
68
4 Unclamp the oil dipstick.
1 Dipstick 2 Clamp
5 Disconnect the radiator bracket from the pad.
1 Pad 2 Nut and gasket 3 Bracket
6 Crane the radiator onto the tooling.
Radiator assembly
1 Radiator assembly
69
7 Disconnect the pipe from the surge tank to

take this tank down.
1 Bleeder pipe 2 Surge tank 3 Water supply pipe of

surge tank 4 Clamp
234 Assembly of radiator
1 Fix the radiator assembly onto its

bracket and pad.
Torque: 48±5N.m
1 Nut and washer 2 Bracket 3 Pad
2 Connect the radiator pipeline.

2.1 Connect the water inlet pipe of engine.
1
70
2.2 Connect the air inlet pipe of intercooler,

bleeder pipe, water outlet pipe of engine, air outlet
pipe of engine, air outlet pipe of intercooler and
water inlet pipe of heater, and then clamp them
respectively.

engine 5 Air outlet pipe of intercooler 6 Water inlet
pipe of heater
2.3 Connect the water supply pipe of surge tank to

the radiator.
1 2 3
1 Water supply pipe of surge tank 2 Clamp 3

Radiator
2.4 Connect the water outlet pipe of heater to the

radiator.
1 2
1 Water outlet pipe of heater 2 Clamp
71
3 Install the surge tank and connect its

pipeline.
1 Bleeder pipe 2 Surge tank 3 Water supply pipe of

surge tank 4 Clamp
4 Add the coolant
Add the about 50L of -35 # antifreeze to the

level between upper and lower scales.
1 Filler
235 Removal of fuel tank
1 Disconnect the fuel tank pipeline from the

cable terminal.
1 2 3 4
1 Fuel tank 2 Fuel outlet port of fuel tank 3 Frame
cable 4 Fuel return pipe of fuel tank
72
2 Take down the fuel tank.

2.1 Remove the fixing nuts off the fuel tank strap
Fuel tank to crank the fuel tank onto the

tooling.
Fuel tank shall be protected against any impact
or damage Fuel tank.
1 Strap 2 Nut and washer 3 Bracket 4 Fuel tank
2.2 Remove the strap from the bracket.
1 Cotter pin 2 Pivot 3 Strap 4 Bracket
2.3 Take down the bracket from the frame.
1 2
1 Pad 2 Bolt and nut
236 Assembly of fuel tank
73
1 Installation of fuel tank assembly

1.1 The bracket is fixed onto the frame with bolts
and nuts.
Torque: 330±30N.m
The threads are coated with 262 sealant
1 Pad 2 Bolt and nut
1.2 Connect the strap onto the bracket.
1 Cotter pin 2 Pivot 3 Strap 4 Bracket
1.3 The rubber pad is glued to the bracket.
Adhesive 801
1 2
1 Bracket 2 Rubber pad
74
1.4 Crane the fuel tank onto the bracket and then
strap it onto the bracket.
Fuel tank
The rubber pad must be smoothly

attached to the strap.
1 Rubber pad 2 Strap 3 Nut and washer 4 Bracket

5 Fuel tank
2 Connect the fuel pipeline and cable terminal

Respectively install the fuel outlet pipe, fuel return
pipe and fuel level sensor onto the fuel tank.
1 Fuel tank 2 Fuel outlet pipe of fuel tank 3 Fuel

level sensor 4 Fuel return pipe of fuel tank
3 Adding of fuel
0# light diesel for ambient temperature ≥4℃;
-10# light diesel for ambient temperature ≥-5℃;
1
1 Fuel filling gun
237 Removal of exhaust system
75
1 Disconnect the exhaust pipe from the butterfly

valve of exhaust brake.
1 Exhaust gas pipe
2 Disconnect the butterfly valve of exhaust

brake from the connection pipe.
1.Engine 2.Connection pipe 3.Butterfly valve of

exhaust brake 4.Bolt
3 Disconnect the butterfly valve from the upper

exhaust pipe.
1 Bolt 2 Upper exhaust pipe
76
4 Disconnect the flexible hose from the upper

and lower exhaust pipes.
1 Bolt and nut 2 Flexible hose assembly
5 Disconnect the lower exhaust pipe from the

exhaust converter
1 Lower exhaust pipe 2 Clamp 3 Exhaust

converter
6 Disconnect the exhaust converter from the

bracket
1 Buffer box 2 Exhaust converter 3 Bolt and nut 4

Bracket
77
7 Take down the frame from the bracket
1 Bracket 2 Bolt and nut 3 Frame
238 Assembly of exhaust system
1 Fix the bracket onto the frame, with the front

bracket notch facing forward and rear bracket
facing backwards.
1 Bracket 2 Bolt and nut 3 Frame
2 Put the butter box onto the bracket, tighten the

support and bolt the sleeve.
1 Bracket and sleeve 2 Buffer case 3 Bolt and nut

4 Bracket
78
3 Connect the lower exhaust pipe to the exhaust

converter.
1 Lower exhaust pipe 2 Clamp 3 Exhaust

converter
4 Connect the flexible hose in straight state to

the upper and lower exhaust pipes.
1 Bolt and nut 2 Flexible hose assembly
5 Connect the butterfly valve to the upper

exhaust pipe.
1 2
1 Bolt 2 Upper exhaust pipe
79
6 Connect the butterfly valve of exhaust brake to

the connection pipe.
1 Engine 2 Connection pipe 3 Butterfly valve of

exhaust brake 4 Bolt
239 Removal of air filter
1 Disconnect the air filter from the engine.
1 Connection rubber hose 2 Engine
2 Disconnect the connection rubber hose from

the air filter.
1 Air filter assembly 2 Connection rubber hose
80
3 Disconnect the air filter
1 Air filter sensor
4 Disconnect the connection rubber hose from

the filter.
1 High-position intake system 2 Clamp 3

Connection rubber hose 4 Donaldson desert filter
5 Separate the air filter assembly from the

bracket.
1 Air filter assembly 2 Bracket 3 Bolt
81
6 Take the bracket down from the workbench.
1 Workbench 2 Support 3 Bolt
2310 Assembly of air filter
1 Connect the high-position intake system to the

rubber hose of Donaldson desert filter.
1 High-position intake system 2 Clamp 3 Rubber

hose 4 Bracket 5 Donaldson desert filter
2 Fix the bracket onto the workbench.
1 Workbench 2 Support 3 Bolt
82
3 Connect the rubber hose to the engine.
1 Connection rubber hose 2 Engine
4 Connect the rubber hose to the air filter.
1 Air filter assembly 2 Connection rubber hose
5 Connect the air filter sensor.
1 Air filter sensor
Appendix A Common faults, diagnosis and solutions of engine system

A1 Diesel engine cannot be started.
Cause Troubleshooting
Drain air out and check if the joint is airtight, and repair it if
1. There is air in the fuel system.
needed.
2. Fuel injection pump fails. Check the plunger and oil-outlet valve, and repair or
83
replace any damaged part.
3. Fuel injector fails Check if the fuel injector gives out good atomization.
4. Valve mechanism or fuel supply pipe is
Check and adjust it.
damaged or leaks oil.
5. High-pressure fuel pipe is damaged or
Repair or replace it.
leaks oil.
Check if valves and cylinder gaskets are airtight and if the
6. Compression pressure in cylinder is
piston rings are worn, and repair or replace any damaged
insufficient.
one if needed.
7. The temperature is excessively low. Add the starter assist.
A2 As soon as it is started, the engine stops running.
Take down the filter body to remove the dirt and water out, and
1. Fuel filter is blocked.
replace the filter element if needed.
Check if the fuel pipe and joint are airtight and if the bleeder
2. Air entrainment in fuel oil system screw is tightened. In addition, it is needed to drain the residual
air.
3. Fuel is inferior due to excessive
Clean the filter and change the fuel.
water content.
4. Idling speed is excessively low. Readjust it.
A3 Engine powerless
1. Intake system is clogged (air filter is Check the air filter and intake pipe, and clean or replace
clogged). the filter element if needed.
2. Back pressure of exhaust gas is Check if the valve timing is proper and if the exhaust pipe
excessively high is blocked, and adjust or repair it if needed.
3. Supercharger system has insufficient
Check it to solve the leakage of pipe joint.
pressure.
4. Supercharger works abnormally Replace it.
4.1 Air compressor and turbine runner are
Clean or replace
blocked.
4.2 The floating bearing fails. Replace
4.3 There is accumulated soot and sludge
at the clearance between the turbine and Clean it
compressor back.
Check if the fuel pipe and joint are airtight and if the filter
5. Fuel pipe leaks or is blocked. is contaminated, and repair or clean the fuel pipeline and
replace the filter element.
Clean the fuel tank, filter and pipeline, and change the
6. Fuel is inferior.
fuel.
7. Fuel injection pump or speed regulator is
Repair or replace it
worn severely.
8. Fuel injector nozzle cannot give the good Check the fuel injection pressure and accumulated soot at
atomization. fuel injector nozzle; adjust or repair it.
9. The valve mechanism or fuel-supply Check and adjust it.
84
timing is wrong.
10. For the speed regulator, the high speed
Check the speed-regulating characteristics and adjust it.
is adjusted excessively low.
11. Oil level in oil sump is excessively high. Check the oil dipstick to drain out the excessive oil.
With engine still hot, check the compression pressure and
12. Cylinder gasket leaks
replace the damaged cylinder gasket.
13. Piston ring is worn or broken; the
Replace the worn parts or overhaul the engine.
bearing shell clearance is widened.
14. Cylinder lining or piston is worn or
Replace the worn parts or overhaul the engine.
scratches the inside of cylinder.
A4 Fuel consumption is excessively high.
1. Intake system is blocked. Check the air filter and intake pipe, and clean them.
2. Back pressure of exhaust gas is
Check the exhaust pipeline and brake valve, and clean them.
excessively high
3. Fuel is inferior. Change the fuel as stipulated.
4. Fuel pipe is blocked. Check and repair it.
5. Fuel pipe leaks Check and repair it.
6. Fuel injector gives out poor
Check, adjust or repair it.
atomization
7. The valve mechanism or fuel-supply Adjust the valve clearance and advance angle of fuel supply
timing is wrong. according to the specifications.
8. Cylinder gasket leaks Check the compression pressure.
9. As the bearing shell clearance is
widened, engine needs to be Check and overhaul it.
overhauled.
10. Piston swells Replace the cylinder liner, piston and piston ring.
11. Supercharger system has
Solve the leakage at pipeline and joints.
insufficient pressure.
12. Supercharger works abnormally Check and replace it.
A5 Exhaust system emits black smoke.
1. Intake pipe is clogged or back
Clean it
pressure of exhaust gas is high.
2. Fuel is inferior. Clean or replace it.
3. The valve mechanism or fuel-supply
Adjust in accordance with the regulations
timing is wrong.
4. Fuel injection nozzle has poor
Check, repair or replace it.
atomization.
5. Fuel injection pump has too much
fuel.
6. Supercharger system has insufficient
Solve the leakage at pipeline and joints.
pressure.
7. Supercharger works abnormally Check and replace the assembly.
85
A6 Exhaust system emits white smoke and blue smoke.
1. Fuel is inferior due to excessive water
Change the fuel
content.
2. Coolant temperature is excessively Check the thermostat work temperature, and replace it if
low. needed.
timing is wrong.
4. Fuel injector nozzle cannot give the
Check and repair it.
good atomization.
5. Compression pressure is low,
Check the piston ring, cylinder liner and cylinder gasket, and
combustion is incomplete and piston
repair them if needed.
swells.
6. Piston ring and cylinder line have the
Continuously perform the running-in
poor running-in.
7. Piston ring openings do not stagger. Reinstall and adjustment them.
8. Oil ring of piston fails. Replace
9. Fitting clearance of piston liner is
Repair or replace it.
widened.
10. Seal ring of supercharger is worn. Check or replace it.
11. Thrust bearing of supercharger is
Check or replace it.
worn.
12. Return pipe of supercharger is
Clean or repair it
blocked.
A7 There is excessively engine oil at the air inlet and pipe of supercharger.
1. Supercharger seal fails. Repair or replace the supercharger.
2. Oil-gas separator fails. Replace it.
3. Oil level in sump is excessively high
Drain the proper amount of oil out.
due to too much oil.
A8 Unsteady RPM
1. Fuel is inferior due to water or wax
Change the fuel
content.
Check if the fuel pipe and joint are airtight, and drain the air
2. Air enters the fuel pickup pipe.
out.
3. Regulator weight or spring works
Check and adjust it (by the professional manufacturer)
abnormally.
4. Fuel supply is uneven. Check and adjust it (by the professional manufacturer)
5. Fuel injector nozzle has unsteady
Check and repair it.
atomization effect.
Check and clean the compressor runner and exhaust gas
6. Supercharger surges
passage, and remove any blocking.
7. Supercharger bearing is damaged. Replace
86
A9 Oil pressure is too low.
1. Oil sump has low oil level or is in lack Check the oil level and find out the oil leakage; solve the
of oil. problem and then replenish the oil.
2. Pressure valve of primary oil passage
Check, clean and repair the valve.
fail.
3. Check if the strainer, oil pipeline and Check and clean the compressor runner and exhaust gas
joint gasket are clogged or cracked. passage, and remove any blocking.
4. Engine oil grade is unsatisfied. Change the oil with the one with stipulated grade.
5. Oil inlet pipe of oil pump leaks Check the oil pipe and joint, and repair or replace it.
6. In the cooling system, the coolant
Check the cooling system to find out the root causes, and
temperature is high, so is the engine oil
solve them.
temperature.
7. Oil filter resistance is excessively high. Replace with a new filter element.
8. Oil cooler is blocked. Check and clean it.
9. Main oil passage is blocked. Check and clean it.
10. Bearing shell has widened clearance
Check and replace it.
or is damaged.
11. Some component is so worn as to Check the work parameters and engine and perform the
need to be overhauled. overhaul.
A10 Coolant is hot.
Check if there is water leakage, and replenish the coolant if
1. Coolant level in radiator is low.
needed.
2. Radiator is blocked. Check the radiator, clean or repair it.
3. Water pump belt is slack. Adjust its tension as demanded.
4. Water pump gasket is damaged and
Check and repair or replace it.
its vane is worn.
5. Thermostat fails Replace
6. Water pipe is damaged, so that air Check the water pipe, joint and gasket, and replace any
gets in. damaged part.
A11 Parts are worn very quickly.
1. Air filter element is disqualified or
Check it and replace with the qualified filter element.
damaged.
2. Intake system is short circuited. Check the intake pipe, gasket and connecting pipe bushing,
repair or replace it.
4. Oil passage is blocked. Clean the oil passage.
5. Engine oil grade is disqualified. Change the engine oil as demanded.
87
6. Piston ring is broken or worn. Replace any damaged part.

7. Cylinder lining or piston is worn or Dismount the piston and cylinder liner for inspection, and
scratches the inside of cylinder. repair or replace them if needed.
8. Oil filter is not replaced timely. Replace it as demanded.
9. Some component is so worn as to
Check the mileage to confirm the overhaul.
need to be overhauled.
10. Crankshaft and driven parts are
Check the mounting bracket and repair it.
misaligned.
11. The used engine oil is disqualified. Change with the oil with standard grade.
A12 Loud noise
1. Fuel is inferior. Change the fuel
2. Coolant temperature is excessively
Check the thermostat, and replace it if needed.
low.
Check, repair or adjust it.
timing is wrong.
4. Fuel injection nozzle has poor
Check, repair or adjust it.
atomization.
5. Fuel injection pump injects too much
Check and adjust it (by the professional manufacturer)
fuel.
Check if the shock absorber or connecting bolt is damaged,
6. Shock absorber is worn.
and replace any damaged part.
7. Valve leaks or poorly adjusted. Dismount the valve for inspection and adjustment.
8. Gear has excessively widened
Check and replace the damaged part.
clearance or is broken at some teeth.
9. Cylinder lining or piston is worn or
Check and repair or replace it.
scratches the inside of cylinder.
10. The pushrod is bent or fractured. Replace
11. Piston ring is broken or worn. Check or replace the damaged part.
A 13. Starter motor does not work.
1. Battery needs to be charged up. Check, charge or replace it.
2. Wire is poorly connected. Clean up the wires and tighten the terminals.
3. Fuse is burnt out. Replace it.
4. Brush is in poor contact Clean or replace it.
5. Starter motor is short circuited inside. Check or replace the assembly.
A14. Starter motor is powerless.
1. Battery needs to be charged up. Charge or replace the battery
2. Bearing bushing wears. Replace it.
3. Brush is in poor contact Clean or replace it.
4. Commutator is not clean or its brush Remove the oil stains; polish it with sandpaper or replace the
88
burns. commutator assembly.
5. Welding seam at terminal is opened. Re-weld it.
6. Switch is in poor contact. Check and repair it.
7. Clutch wears or slips. Adjust the clutch operating torque or replace the assembly.
A15. Generator cannot generate any electricity at all.
1. Open circuited; short circuited or joint Check the wires of both generator and ammeter, and repair
is loosened. them if needed.
2. Rotor and stator coils are open
Repair or replace the assembly.
circuited, short circuited or grounded.
3. Rectifier tube is damaged. Replace it.
4. Insulation layer of terminal paper is
damaged and the wires are not Repair them.
connected.
5. Adjusting voltage of regulator is too
Repair them.
low.
6. Regulator contact is burnt. Repair or replace the assembly.
A16 Generator is not sufficiently charged.
1. Open circuited; short circuited or joint
Repair them.
is loosened.
2. Rotor and stator coils are open
Repair or replace the assembly.
circuited, short circuited or grounded.
3. Generator belt is loosened. Check and adjust the belt tension.
4. Rectifier tube of generator is
damaged or the battery is in poor Repair them.
contact.
5. Regulator voltage is adjusted too low. Adjust it
6. For the regulator, the magnetic coil or
resistance wire is disconnected.
7. Battery electrolyte is insufficient or the
Replenish the electrolyte or replace the battery.
battery is old.
A17 Charging current is unsteady.
1. Stator or rotor coil is short circuited or
open circuited.
2. Brush is in poor contact Repair them.
3. Wiring terminal is loosened and thus
Repair them.
in poor contact.
4. Voltage regulator is damaged. Repair them.
5. Voltage is poorly adjusted. Check and adjust it.
A18 Generator is charged excessively.
89
1. Battery is short circuited inside. Repair or replace it
2. Regulator voltage is too high. Repair or adjust it.
3. Regulator is grounded poorly. Repair them.
4. Regulator contact fails or is
contaminated; voltage coil or resistance Repair or replace it
is disconnected.
A19 Generator has abnormal sound
1. Generator is mounted improperly. Repair them.
2. Bearing is damaged. Replace bearing
3. The rotating part touches the fixed
part.
4. Rectifier is short circuited. Replace
5. Stator is short circuited. Repair or replace it
Appendix B Diagnosed fault code table

FM FM
S/N Fault description SPN S/N Fault description SPN
I I
Inside of cylinder, the exhaust Injector 3 low-end is
001 brake valve is short circuited to 571 3 167 short circuited to the 1415 18
the ground. ground.
Inside of cylinder, the exhaust
Injector 3 is open
002 brake valve is short circuited to 571 4 168 1415 5
circuited.
power supply.
Inside of cylinder, the exhaust 3rd cylinder injector is
003 571 5 169 1415 11
brake valve is open circuited. faulty.
Disconnection between
3rd cylinder and other
Accelerator and brake signals
004 91 7 170 cylinders in the same 1415 6
are not credible.
Bank or short circuit to
weak power supply
3rd cylinder injector is
Air mass and flow sensor
005 132 3 171 short circuited to power 1415 3
voltage is below the lower limit.
supply.
3rd cylinder injector is
Air mass and flow sensor
006 132 4 172 short circuited to the 1415 7
voltage is above the high limit.
ground.
Injector 3 low-end is
007 Intake heater switch is kept on. 2898 7 173 short circuited to its high 1415 4
end.
Twofold signal relation between Injector 4 high-end is
52025
008 accelerator pedal sensors 1 and 2 174 short circuited to power 1416 15
2
2 is unauthentic. supply
Accelerator pedal sensor 1 Injector 4 high-end is
009 voltage is above the upper 91 3 175 short circuited to the 1416 17
threshold. ground.
90
Accelerator pedal sensor 1 Injector 4 low-end is

010 voltage is below the lower 91 4 176 short circuited to power 1416 16
threshold. supply.
1/2 signal relation between Injector 4 low-end is
011 accelerator pedal sensors 1 and 1 0 177 short circuited to the 1416 18
2 is unauthentic. ground.
Accelerator pedal sensor 2
Injector 4 is open
012 voltage is above the upper 29 3 178 1416 5
circuited.
threshold.
Accelerator pedal sensor 2
4th cylinder injector is
013 voltage is below the lower 29 4 179 1416 11
faulty.
threshold.
Atmosphere pressure sensor
signal is incredible.
weak power supply
Atmosphere pressure sensor 4th cylinder injector is
015 voltage is higher than the upper 108 3 181 short circuited to power 1416 3
threshold. supply.
Atmosphere pressure sensor 4th cylinder injector is
016 voltage is below the lower 108 4 182 short circuited to the 1416 7
threshold. ground.
017 Intake heater is open circuited. 2898 5 183 short circuited to its high 1416 4
end.
Injector 5 high-end is
Intake heater is short circuited to
power supply.
supply
Intake heater is short circuited to
the ground.
ground.
The original voltage of battery is
below the lower threshold.
supply.
The original voltage of battery is
higher than the upper threshold.
ground.
Intake pressure sensor signal is Injector 5 is open
022 1 0 188 1417 5
incredible. circuited.
Intake pressure sensor voltage
023 is higher than the upper 102 3 189 1417 11
faulty.
threshold.
Intake pressure sensor voltage
is below the lower threshold.
weak power supply
The identification required by 5th cylinder injector is
025 cruise control is wrong, fault 597 11 191 short circuited to power 1417 3
indicator lighting up. supply.
91
Before the brake pedal is 5th cylinder injector is

026 depressed, the cruise control 597 7 192 short circuited to the 1417 7
suppression is wrong. ground.
027 Brake signal is not credible. 597 2 193 short circuited to its high 1417 4
end.
028 Brake signal is wrong. 597 19 194 short circuited to power 1418 15
supply
Coolant temperature rising Injector 6 high-end is
029 range does not reach the min. 110 18 195 short circuited to the 1418 17
value in a certain period of time. ground.
Coolant temperature does not Injector 6 low-end is
030 reach the min. value in a certain 110 17 196 short circuited to power 1418 16
period of time. supply.
Coolant temperature signal is
unavailable.
ground.
Engine rpm signal is Injector 6 is open
032 190 2 198 1418 5
unauthentic. circuited.
Clutch status signal is not 6th cylinder injector is
033 598 2 199 1418 11
credible. faulty.
52019
034 OBD torque limit activation error 11 200 cylinders in the same 1418 6
8
weak power supply
Cold start indicator is open
circuited.
supply.
Cold start indicator is short
circuited to power supply.
ground.
Cold start indicator is short Injector 6 low-end is
037 circuited to the ground. 626 4 203 short circuited to its high 1418 4
end.
Coolant temperature and oil
Fuel gauge is open
038 temperature signals are 110 2 204 1442 7
circuited.
improper.
The coolant temperature sensor
works normally, but the coolant Power supply of fuel
039 110 15 205 1442 9
temperature exceeds the gauge is short circuited.
threshold.
Coolant temperature sensor
Fuel gauge is short
040 voltage is higher than the upper 110 3 206 1442 10
circuited to ground
threshold.
Coolant temperature sensor Cruise signal unreliable
041 voltage is below the lower 110 4 207 (invalid switch 596 2
threshold. combination)
Off-vehicle start/stop button is 52020 OBD indicator is open 52021
042 5 208 5
stuck. 3 circuited. 9
92
OBD indicator is short

There is only camshaft signal, 52021
043 4203 13 209 circuited to power 3
entering into “Limp Home”. 9
supply.
OBD indicator is short 52021
044 Camshaft signal is lost. 4201 12 210 4
circuited to the ground. 9
045 Camshaft period is wrong. 4201 2 211 Cylinder 1 misfires 1323 3
Camshaft synchronization is
046 4201 11 212 Cylinder 10 misfires 1332 3
wrong.
The synchronization between
047 camshaft and crankshaft is 4201 13 213 Cylinder 11 misfires 1333 3
wrong.
048 Crankshaft signal is lost. 4203 12 214 Cylinder 12 misfires 1334 3
Crankshaft synchronization is
wrong.
Crankshaft has wrong quantity of
teeth.
Crankshaft teeth have wrong
period.
Crankshaft and camshaft have
052 the signal deviation higher than 4201 14 218 Cylinder 5 misfires 1327 3
threshold.
053 Engine rpm exceeds the limit. 1769 11 219 Cylinder 6 misfires 1328 3
Engine rpm signal is open
circuited.
Engine rpm signal is short
Engine rpm signal is short
circuited to the ground.
Total number of misfired
The butterfly valve of exhaust 52020
057 5 223 cylinders exceeds the 1322 3
brake is open circuited. 8
limit.
The butterfly valve of exhaust
52020 Multi-state switch signal
058 brake is short circuited to power 3 224 976 19
8 is incredible.
supply.
The butterfly valve of exhaust
52020 Multi-state switch voltage
059 brake is short circuited to the 4 225 976 3
8 exceeds the upper limit
ground.
Multi-state switch voltage
Fan actuator (PWM wave) is
060 4815 7 226 is lower than the lower 976 4
open circuited.
limit
Fan actuator (PWM wave) is Oil level sensor signal is
061 4815 9 227 98 2
short circuited to power supply. unauthentic.
Fan actuator (PWM wave) is Oil level sensor voltage
062 4815 10 228 98 3
short circuited to the ground. is above the upper limit
Fan actuator (digital signal) is Oil level sensor voltage
063 4815 5 229 98 4
open circuited. is below the lower limit
Fan actuator (digital signal) is
064 4815 3 230 Oil pressure is too low. 100 17
short circuited to power supply.
93
Oil pressure is too high

Fan actuator (digital signal) is
065 4815 4 231 or oil temperature signal 100 15
short circuited to the ground.
is unauthentic.
Oil pressure sensor
Cooling fan speed is higher than
066 1639 3 232 voltage is above the 100 16
the upper threshold.
upper limit
Oil pressure sensor
Cooling fan speed is lower than
067 1639 4 233 voltage is below the 100 18
the lower threshold.
lower limit
Fuel heater relay (digital signal) 52026 Oil temperature sensor
068 5 234 175 15
is open circuited. 1 signal is unauthentic.
Fuel heater relay (digital signal) Oil temperature sensor
52026
069 is short circuited to the power 3 235 voltage is above the 175 3
1
supply. upper threshold.
Oil temperature sensor
Fuel heater relay (digital signal) 52026
070 4 236 voltage is below the 175 4
is short circuited to the ground. 1
lower threshold.
Oil temperature and
Fuel heater actuator (PWM) is 52026
071 10 237 coolant temperature 1 0
short circuited to the ground. 1
signals are unauthentic.
Fuel heater actuator (PWM) is
52026 PCV valve is open
072 short circuited to the power 9 238 1443 7
1 circuited.
supply.
PCV valve is short
Fuel heater actuator (PWM) is 52026
073 7 239 circuited to power 1443 9
open circuited. 1
supply.
Fuel booster actuator is open PCV valve is short
074 95 5 240 1443 10
circuited. circuited to the ground.
Pressure-limiting valve
Fuel booster actuator is short on the common rail is not 52347
075 95 3 241 21
circuited to the power supply. opened in case of 0
pressure fluctuation.
Number of times how
many the
pressure-limiting valve
Fuel booster actuator is short 52024
076 95 4 242 on common rail is 11
opened exceeds the
technically required max.
value.
Pressure-limiting valve
Oil-water sensor detects water in 52026 52024
077 11 243 on the common rail is 14
oil. 4 1
opened.
Opening of
It goes beyond limit that the BUS 52206 52024
078 19 244 pressure-limiting valve is 0
receives the accelerator signal. 4 1
timeout.
Rail pressure sensor
CAN received frame CM1 data 52205
079 14 245 voltage is above the 157 15
volume error 6
max. deviation.
CAN received frame CM1 52205
080 19 246 voltage is below the min. 157 17
timeout error 6
deviation.
94

CAN received frame DashDspl 52205
data volume error 2
upper threshold.
Voltage of rail pressure
CAN received frame DashDspl 52205 sensor in collection
082 19 248 157 3
timeout error 2 interrupt way exceeds
upper threshold
CAN received frame DEC1 data 52206
volume error 2
lower threshold.
Voltage of rail pressure
DEC1 message receiving 52206 sensor in collection
084 19 250 157 4
timeout 2 interrupt way is lower
than lower threshold
Rail pressure deviation is
CAN received frame EBC1 data 52201 52024
085 14 251 above the upper 16
length error 3 3
threshold.
In the fuel metering unit,
CAN received frame EBC1 52201 52024
086 19 252 the amount of fuel 7
timeout error 3 3
exceeds the threshold.
Rail pressure deviation
exceeds the threshold,
52201 52024
087 Data length error 14 253 so does the amount of 5
5 3
fuel in the fuel metering
unit.
above the upper
52201 threshold, and the 52024
088 Timeout error 19 254 0
5 amount of injection is 3
also above the upper
limit.
below the lower
CAN received frame EGF1 data 52205 threshold, and the 52024
089 14 255 1
volume error 3 amount of injection is 3
also below the lower
limit.
Rail pressure peak is
CAN received frame EGF1 52205 52024
090 19 256 below the lower 20
timeout error 3 3
threshold.
Rail pressure peak is
CAN received frame EngTemp2 52202 52024
091 14 257 above the upper 21
data volume error 0 3
threshold.
CAN received frame EngTemp2 52202 Rail pressure drops too 52024
092 19 258 18
timeout error 0 fast. 3
Setting of fuel metering
CAN received frame ERC1DR 52202 52024
093 14 259 unit at over-speed mode 23
is not credible.
Fuel metering unit
CAN received frame ERC1DR 52202 52024
094 19 260 monitor is error at the 24
timeout error 1 3
low idling.
095 ETC1 message data length error 52202 14 261 Output voltage of remote 52027 3
95
2 accelerator pedal 1 goes 7
beyond upper limit
Output voltage of remote
ETC1 message receiving 52202 52027
096 19 262 accelerator pedal 1 is 4
timeout 2 7
lower than lower limit
CAN received frame ETC2 data 52202 52027
097 14 263 accelerator pedal 2 goes 3
volume error 3 8
beyond upper limit
CAN received frame ETC2 52202 52027
098 19 264 accelerator pedal 2 is 4
timeout error 3 8
lower than lower limit
Voltage of sensor power
CAN received frame ETC7 data 52206
099 14 265 supply 1 goes beyond 3509 3
volume error 3
upper threshold
ETC7 message receiving 52206
100 19 266 supply 1 is lower than 3509 4
timeout 3
lower threshold
CAN received frame HRVD data 52205
101 14 267 supply 2 goes beyond 3510 3
volume error 1
upper threshold
CAN received frame HRVD 52205
timeout error 1
lower threshold
It goes beyond limit that the BUS Voltage of sensor power
52206
103 receives the remote accelerator 19 269 supply 3 goes beyond 3511 3
5
signal. upper threshold
RxCCVS message data length 52203
error 0
lower threshold
RxCCVS message receiving 52203
105 19 271 Air filter replacement 107 7
timeout 0
CAN received frame TRF1 data 52021 52028
106 14 272 Fuel filter replacement 11
volume error 7 9
CAN received frame TRF1 52021 Lock vehicle and 52201
107 19 273 1
timeout error 7 execute lock mode 1 4
CAN received frame TSC1AE 52203 Lock vehicle and 52201
108 14 274 2
data volume error 5 execute lock mode 2 4
CAN received frame TSC1AE 52203
109 19 275 Oil change 99 11
timeout error 5
CAN received frame TSC1AR 52203
110 14 276 Oil filter replacement 99 7
data volume error 6
Low-end of starter motor
CAN received frame TSC1AR 52203
111 19 277 relay is short circuited to 1675 3
timeout error 6
power supply.
Low-end of starter motor
CAN received frame TTSC1DE 52203
112 14 278 relay is short circuited to 1675 4
data volume error 7
ground.
CAN received frame TSC1DE 52203 Starter motor relay is
113 19 279 1675 5
timeout error 7 open circuited.
114 CAN received frame TSC1DR 52203 14 280 T50 power-on times out 52025 11
96
ECU temperature sensor
CAN received frame TSC1DR 52203
timeout error 8
lower threshold.
ECU temperature sensor
CANTOTSC1TE data volume 52203
error 9
upper threshold.
Heater relay of adblue
CAN-TOTSC1PE 52203
117 19 283 return pipe (from pump 4346 5
communication error 9
to tank) is open circuited.
CANTOTSC1TE data volume 52204 return pipe (from pump
118 14 284 4346 3
error 0 to tank) is short circuited
to the power supply.
52204 return pipe (from pump
119 CANTOTSC1TR timeout error 19 285 4346 4
0 to tank) is short circuited
to the ground.
CANTOTSC1TR data volume 52204
120 14 286 pressure pipe (pump to 4344 5
error 1
nozzle) is open circuited.
52204 pressure pipe (pump to
121 CANTOTSC1TR timeout error 19 287 4344 3
1 nozzle) is short circuited
CANTOTSC1VE data volume 52204 pressure pipe (pump to
122 14 288 4344 4
error 2 nozzle) is short circuited
to the ground.
52204 Primary relay of adblue 52300
123 CANTOTSC1VE timeout error 19 289 5
2 heater is open circuited. 3
Primary relay of adblue
CANTOTSC1VR data volume 52204 52300
124 14 290 heater is short circuited 3
error 3 3
Primary relay of adblue
52204 52300
125 CANTOTSC1VR timeout error 19 291 heater is short circuited 4
3 3
to the ground.
Fuel temperature sensor voltage
126 174 3 292 pickup pipe (tank to 4340 5
is above the upper threshold.
pump) is open circuited.
Fuel temperature sensor voltage pickup pipe (tank to
127 174 4 293 4340 3
is below the low threshold. pump) is short circuited
The interval of gear up-shifting is 52022 pickup pipe (tank to
128 2 294 4340 4
too long. 1 pump) is short circuited
to the ground.
Water heater solenoid
Oil-water indicator is open
129 624 12 295 valve of adblue tank is 3363 5
circuited.
open circuited.
97

Oil-water indicator is short valve of adblue tank is
130 624 3 296 3363 3
circuited to power supply short circuited to the
power supply.
Oil-water indicator is short valve of adblue tank is
131 624 4 297 3363 4
circuited to the ground. short circuited to the
ground.
52022 Speed 1 is above the
132 High-pressure test error 20 298 84 0
3 max. threshold.
Speed 1, amount of
133 EEPROM read error 2802 14 299 injection and engine rpm 84 2
are unauthentic.
Speed 3 signal pulse is
134 EEPROM write error 2802 12 300 above the upper 1624 3
threshold.
Intake temperature sensor Speed 3 signal pulse is
135 voltage is above the upper 105 3 301 below the lower 1624 4
threshold. threshold.
Intake temperature sensor Average period of the
136 voltage is below the lower 105 4 302 vehicle speed signal is 1624 8
threshold. below the threshold
Nozzle is worn by more than
52021 Warning lamp is open 52025
137 20%, which is repeated for 20 16 303 5
0 circuited. 0
times.
Nozzle is worn between 5% and 52021 Power supply of warning 52025
138 15 304 3
20% for 500ms. 0 lamp is short circuited. 0
INJdriverIC initial version Warning lamp is short 52025
139 507 9 305 4
number is wrong circuited to the ground. 0
Original voltage of
After INJdriverIC is powered on, 52026
140 507 10 306 oil-water sensor is above 3
the initialization is wrong. 4
the upper threshold.
Original voltage of
Injector nozzle is worn by 20% 52021 52026
141 14 307 oil-water sensor is below 4
or above 0 4
the lower threshold .
Injector nozzle is worn by 52021 CAN communication 52200
142 13 308 12
0~20% 0 error 0
Twofold relation of
INJdriverIC powering-on again is 52025
143 507 11 309 remote accelerator 2 is 2
wrong. 3
unbelievable.
Credibility verification of
Injector 1 high-end is short 52027
144 1413 15 310 remote accelerator and 7
circuited to power supply 7
brake sensors
145 1413 17 311 key message fault 14
Injector 1 low-end is short 52021
146 1413 16 312 Key message timeout 19
circuited to power supply. 8
Receiving of DEC1
Injector 1 low-end is short
147 1413 18 313 message T50 signal is 14161 31
circuited to the ground.
wrong.
98
Under the condition that

T15 is not powered off,
52021
148 Injector 1 is open circuited. 1413 5 314 the zero of engine RPM 0
8
lasts beyond a certain
value.
315 TCO1 message timeout. 52203
149 1st cylinder injector is faulty. 1413 11 14
2
Disconnection between 3rd 316 TCO1 message data
cylinder and other cylinders in length wrong. 52203
150 1413 6 19
the same Bank or short circuit to 2
weak power supply
1st cylinder injector is short 317 Brake signal is not
151 1413 3 597 14
circuited to power supply. credible.
1st cylinder injector is short 318 Signal from CAN clutch
152 1413 7 598 19
circuited to the ground. is wrong
Injector 1 low-end is short 319 N-gear CAN input signal
153 1413 4 59 19
circuited to its high end. is wrong.
320 When ECU is powered
Injector 2 high-end is short on, the idling sleep 52020
154 1414 15 5
circuited to power supply switch does not work 2
normally.
321 CCVS message fault
155 1414 17 when brake signal takes 17
message path.
322 CCVS message fault
156 1414 16 when clutch signal takes 18
message path.
323 ETC1 message fault
157 1414 18 when clutch signal takes 18
message path.
52202
158 Injector 2 is open circuited. 1414 5 when N-gear signal 17
2
takes message path.
52202
159 2nd cylinder injector is faulty. 1414 11 when N-gear signal 18
3
takes message path.
Disconnection between 3rd 326 DEC1 message fault
cylinder and other cylinders in when N-gear signal 52206
160 1414 6 18
the same Bank or short circuit to takes message path. 2
weak power supply
2nd cylinder injector is short 52206
161 1414 3 when T50 signal takes 17
message path.
2nd cylinder injector is short 328 The voltage generated 52347
162 1414 7 25
circuited to the ground. by generator is high. 1
Injector 2 low-end is short 329 The voltage generated 52347
163 1414 4 26
circuited to its high end. by generator is low. 1
Injector 3 high-end is short 330 High battery voltage 52347
164 1415 15 27
circuited to power supply 2
Injector 3 high-end is short 331 Low battery voltage 52347
165 1415 17 28
99
Injector 3 low-end is short

166 1415 16
Appendix C Fitting clearance among main parts of engine

S/N Item Theoretical value (mm)
1 Main bearing clearance 0.095～0.171
2 Connecting rod bearing clearance 0.059～0.135
3 Axial clearance of crankshaft 0.102～0.305
4 Axial clearance at the connecting rod plane. 0.15～0.35
Clearance between the connecting-rod small-end
5 0.04～0.061
lining and piston pin
Clearance between the piston pin base and piston
6 0.005～0.018
pin
Work clearance of piston ring opening at cold state
0.35～0.55
The 1st ring
7 0.4～0.6
The 2nd ring
0.2～0.4
Oil ring
Piston ring end clearance at the cold state
The 1st ring 0.08～0.115
8
The 2nd ring 0.04～0.075
Oil ring
Clearance between the intake valve stem and valve
9 0.02～0.048
guide
Clearance between the exhaust valve stem and
10 0.025～0.053
valve guide
The plane value meaning the valve bottom is
11 concaved into the cylinder head
1.08～1.48/0.85～1.05
Exhaust/intake
The plane value meaning the cylinder jacket top
12 0.05～0.10
exceeds the top surface of engine block
13 Axial clearance of camshaft 0.1～0.4
14 Camshaft bearing clearance 0.04～0.12
15 Clearance between the tappet and its hole 0.025～0.089
Interference clearance between cylinder liner
16 -0.02～0.023
excircle and cylinder liner hole
17 Clearance between the rocker and rocker shaft 0.012～0.066
Clearance between the timing gear and
18 0.015～0.33
intermediate gear
Clearance between the crankshaft rpm sensor and
19 1.0±0.5
flywheel
100

2-Engine System CMT 96

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2-Engine System CMT 96

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Maintenance Manual

Engine cylinder number

Engine Models WP13G530E310

Engine performance parameters

Exploded drawing of engine block assembly

2221 Disassembly procedure of pre-assembled parts of engine body

223 Disassembly and assembly of piston

2. Take down the nozzle assembly; Nozzle inspection ring

Disassembly drawing of cooling nozzle of piston

2232 Inspection and maintenance of piston nozzle

Lower thrust plate

Upper thrust plate

Disassembly drawing of upper and lower thrust collars

Front oil seal Front end cover

Disassembly drawing of oil seal

Tightening sequence of timing gear chamber bolts

Exploded drawing of front end cover

Hexagon head bolt

Rear oil seal

Double end studs

Waveform elastic Access plate

Installation drawing of flywheel housing

Oil pan support

Disassembly drawing of oil sump

Tightening sequence of oil sump bolts

Exploded drawing of cylinder head

Secondary bolts of cylinder head

Cylinder head gasket

Seal cartridge of valve rod

Valve rod sealing sleeve

Installation of seal cartridge of valve rod

Main bolts of cylinder head

Gluing of bottom hole in auxiliary bolt

Tightening sequence of main bolts of cylinder head

Exploded drawing of cylinder head cover

1-Hoisting ring 2-Hoisting ring clamp

Lifting ring Fixing bolt for oil-gas

Metal oil tank

Oil cooler cover bolts

Cover plate bolt

Oil return cover plate

Oil cooler cover

Disassembly drawing of oil-gas separator

Disassembly drawing of shock absorber and crankshaft pulley

Disassembly drawing of flywheel

Piston connecting rod

Crankshaft timing Flywheel housing

Oil pump gear

Disassembly drawing of crankshaft

Tightening sequence of main bearing bolts

Exploded drawing of piston and connecting rod assembly

Twisted conical ring

Piston pin retaining

Connecting rod bushing

Connecting rod lower

Connecting rod bolt

Connecting rod cap

Disassembly drawing of piston and connecting rod mechanism

The opening of the retaining ring is offset

Assembly schematic of piston pin retainer

Schematic of assembly relation between piston and connecting rod

First gas ring Second gas