V80Service Manual 2 Engine Right VI FDJ Y Y 02

Service Workbook
Engine
2012Year
WARNING
Warning: To reduce the possibility of personal injury and property damage, the following
instructions must be observed:
All six service workbooks provided by SMCV are dedicated for professional technicians. Trying to
do service or repair work without appropriate trainings, tools or equipments may cause injury to you or
others. It can also result in vehicle damage or abnormal operation.
Correct service and repair work is essential to personal safety of service technicians, as well as safe
and reliable operation of vehicles. If any part needs to be replaced, use the same part number or other
part number(s) specified by SMCV only. Never use any replacement part which is not approved by SMCV.
The repair instructions suggested and introduced in this workbook are beneficial for correct service
and repair. And sometimes special tools are required.
In this case, any use of the replacement parts, repair instructions or tools which are not suggested
or approved by SMCV should not be allowed until it is proved that this has no threat to the personal
safety or safe operation.
This workbook provides technical data, illustrations and function descriptions of all components on
MAXUS Datong PV, MPV and VAN models and not to any particular vehicle in model year - 2012.For the
specification of any particular vehicle, purchasers should consult their SMCV Distributor or Dealer.
Throughout this workbook, WARNINGS and CAUTIONS are included which should be strictly
observed for reducing personal injuries at the service and repair work. Any incorrect service or repair
will cause damage to the vehicle, left hidden dangers. However, these WARNINGS and CAUTIONS are not
complete. And it is impossible for SMCV to give warnings for all potential dangers resulting from
violation of these instructions.
In order to avoid accidental airbag deployment and relevant potential injury, it is recommended to
service the airbag first when both the airbag and other systems need to be repaired.
No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any
form, whether electronic or mechanical, or by photocopying, recording or other means without prior
permission in writing of SMCV
Error and Advice Reporting
If any error is found in this service workbook, or any advice, you are encouraged to tell us.
You can send any advice via letter or fax to SMCV After Sales at
After Sales, SAIC Commercial Vehicle Co., Ltd
#2500, Jungong Road,
Shanghai City, China Postcode: 200438
The following information should be provided:
Your name
Authorized repair center
Tel. and fax of the authorized repair center
Model year and model
VIN
Description of your concern(s)
Necessary relevant information (e.g. sample or marked page)
Any applicable electronic information part identification number
SMCV will give relevant response in the following ways:
Submitting your concern to relevant service engineer
Consulting relevant service engineer
Satisfying your concern within 10 working days.
Datong users are encouraged to send your concerns to SMCV Customer Support Center at: 400-081-2011.

General Information ........................................................................................ 1-1
Introduction ........................................................................................................................... 1-1
General Precautions ............................................................................................................. 1-1
Fuel system precautions: ...................................................................................................... 1-2
Engine Mechanics........................................................................................... 2-1

Specification.......................................................................................................................... 2-1
Technical Data ................................................................................................................................................... 2-1
Torque ................................................................................................................................................................ 2-4
Layout ................................................................................................................................... 2-7

Exploded view of cylinder head, air intake & exhaust and fuel system assembly.............................................. 2-7
Exploded view of engine block and cylinder power assembly............................................................................ 2-9
Exploded view of front timing & accessories assembly.................................................................................... 2-11
Fault diagnosis.................................................................................................................... 2-13
SPECIAL TOOLS................................................................................................................ 2-18
Repair instructions .............................................................................................................. 2-21

Front end accessory drive belt replacement .................................................................................................... 2-21
Timing Belt Replacement ................................................................................................................................. 2-22
Timing Pulley Case And Damping Pad ............................................................................................................ 2-31
Renewal .......................................................................................................................................................... 2-31
Gear casing cover renewal............................................................................................................................... 2-35
Renewal Crankshaft Front Oil Seal .................................................................................................................. 2-37
Crankshaft Front Oil Seal Renewal .................................................................................................................. 2-39
Oil Pump Renewal............................................................................................................................................ 2-40
Vacuum Pump Renewal................................................................................................................................... 2-42
Camshaft Oil Seal Renewal ............................................................................................................................. 2-44
Cylinder Upper Head and Gasket Renewal ..................................................................................................... 2-46
Camshaft Renewal ........................................................................................................................................... 2-53
Cylinder Head and Gasket Renewal ................................................................................................................ 2-56
Flywheel Ring Gear Renewal........................................................................................................................... 2-63
Crankshaft Rear Oil Seal Renewal................................................................................................................... 2-65
Crankshaft renewal .......................................................................................................................................... 2-67
Replacing the front main bearing ..................................................................................................................... 2-77
Replacing the cylinder liner and cylinder.......................................................................................................... 2-79
liner spacer...................................................................................................................................................... 2-79
Replacing the piston and connection rod ......................................................................................................... 2-82
Replacing the oil filter ....................................................................................................................................... 2-85
Engine oil drainage........................................................................................................................................... 2-85
Replacing the output shaft bearing bracket of.................................................................................................. 2-86
the transmission .............................................................................................................................................. 2-86

Replacing the engine rear suspension carrier ................................................................................................. 2-87
Replacing engine assembly ............................................................................................................................. 2-87
Disassembly /reassembly of turbocharger....................................................................................................... 2-90
Matters Needing Attention for Installing Flywheel on Maintenance Component of Short Engine .................... 2-92
Determination of timing failure ......................................................................................................................... 2-93
Engine Electrics .............................................................................................. 3-1

Specification......................................................................................................................... 3-1
Technical data.................................................................................................................................................... 3-1
Torque................................................................................................................................................................ 3-1
Layout .................................................................................................................................. 3-2
Fault diagnosis ..................................................................................................................... 3-3
Repair instructions ............................................................................................................... 3-4

Replacing the battery ......................................................................................................................................... 3-4
Replacing the battery carrier.............................................................................................................................. 3-5
Replacing the starter motor................................................................................................................................ 3-6
Replacing the battery harness ........................................................................................................................... 3-7
Replacing the Generator.................................................................................................................................. 3-10
Engine cooling system .................................................................................... 4-1

Specification......................................................................................................................... 4-1
Technical Data ................................................................................................................................................... 4-1
Torque................................................................................................................................................................ 4-1
Layout .................................................................................................................................. 4-2

Layout of condenser / cooling fan ...................................................................................................................... 4-2
Lay out of coolant pipe and metallic hardware................................................................................................... 4-4
Layout of EGR cooler parts................................................................................................................................ 4-6
Fault diagnosis ..................................................................................................................... 4-7
Repair instructions ............................................................................................................... 4-8

Replacing the thermostat ................................................................................................................................... 4-8
Replacing the water pump: ................................................................................................................................ 4-9
Replacing the EGR cooler ............................................................................................................................... 4-10
Replacing the coolant ...................................................................................................................................... 4-14
Replacing the expansion tank cap ................................................................................................................... 4-15
Replacing the cooling module.......................................................................................................................... 4-16
Replacing the radiator...................................................................................................................................... 4-20
Replacing the cooling fan................................................................................................................................. 4-20

Engine Control ................................................................................................ 5-1
Specification.......................................................................................................................... 5-1
Technical Data ................................................................................................................................................... 5-1
Torque ................................................................................................................................................................ 5-4
Layout ................................................................................................................................... 5-5
Repair instructions ................................................................................................................ 5-7

Replacing the engine harness............................................................................................................................ 5-7
Replacing the engine water temperature ........................................................................................................... 5-9
sensor (ECU)..................................................................................................................................................... 5-9
Replacing the oil pressure alarm switch............................................................................................................. 5-9
Replacing the speed sensor............................................................................................................................. 5-10
Replacing the camshaft position sensor........................................................................................................... 5-10
Replacing the fuel rail....................................................................................................................................... 5-10
Replacing the engine control module ............................................................................................................... 5-11
ECU............................................................................................................................................................ 5-11
Fuel system..................................................................................................... 6-1

Specification.......................................................................................................................... 6-1
Torque ................................................................................................................................................................ 6-1
Layout ................................................................................................................................... 6-2

Layout of fuel supply system .............................................................................................................................. 6-2
Layout of fuel system ......................................................................................................................................... 6-4

Fuel system oil pumping..................................................................................................................................... 6-6
Replacing the fuel filter cartridge........................................................................................................................ 6-6
Replacing the fuel injector .................................................................................................................................. 6-8
Replacing the high pressure fuel pump............................................................................................................ 6-11
Replacing the fuel tank..................................................................................................................................... 6-14
Replacing the feed pipe.................................................................................................................................... 6-16
Air intake & exhaust System ........................................................................... 7-1

Specification.......................................................................................................................... 7-1
Torque ................................................................................................................................................................ 7-1
Layout ................................................................................................................................... 7-2

Layout of exhaust system................................................................................................................................... 7-2
Layout of air intake system................................................................................................................................. 7-3

Replacing the air filter......................................................................................................................................... 7-5

Replacing the air filter element .......................................................................................................................... 7-7
Replacing the air flow sensor............................................................................................................................. 7-8
Replacing the exhaust pipe front assembly ....................................................................................................... 7-9
Replacing the exhaust silencer assembly........................................................................................................ 7-10
Replacing the exhaust tail pipe assembly........................................................................................................ 7-11
Replacing the accelerator pedal ...................................................................................................................... 7-12
Catalytic converter ........................................................................................................................................... 7-13

General Information
General Information
Introduction
WARNINGS and CAUTIONS are given throughout this Service Workbook in the following form:
WARNINGS: Procedures which must be followed precisely to avoid the possibility of personal injury.
CAUTION: This calls attention to procedures which must be followed to avoid damage to components or
methods which make a job easier to perform. References to the left or right hand side in this Service
Workbook are made when viewing the vehicle from the rear, unless instructed otherwise. To reduce
repetition, operations covered in this service workbook do not always include reference to testing the
vehicle after repair. It is essential that work is inspected and tested after the assembly. And if necessary,
road test can be performed to test the safety performance of the vehicle.
The drawing number of the illustration inset lies in the left bottom of the figure. The illustration insets in
the repair instructions are laid out parallel to the described contents; Parts pointed at by a bold straight
arrow are those to be removed or installed; parts numbered with 1, 2, . . . corresponds to the descriptions
of the same number; The number , , etc, indicates the relevant part in the text.
General Precautions
When disconnecting the vehicle battery, always start from the earth (negative) connection, then the
positive cable. If twin batteries are installed, disconnect both earth (negative) connections, then the
positive cables. When connecting the battery(s), start from the positive cable(s), then the negative.
Anti-dust protection shall be used when fuel or lubrication system connectors are unplugged. Ensure the
engine rotates clockwise (front view) unless specified otherwise. Avoid running pulleys and belts while
working underneath the bonnet.
Be aware that components will be hot if the engine has been running recently. To prevent burns, do not
remove expansion tank cap, cooling water bleed tube, and bleed screw until the engine has been
sufficiently cooled and free of heat (esp. over heat).
Various fastening bolts on this engine can be locked and fastened with the thread-locking adhesive pre-
applied. Before using these bolts again, please clean the screw threads and then apply the Lotite 271.
Do not work underneath the vehicle with only on jack to support. Do secure with lifters or other reliable
support. Ensure the surface of the special tool hole used to install oil seals is free of burrs that could
damage the seal lip. Always wear safety glasses for eye protection.
Always wear gloves when handling oil or grease.
1-1
General Information
Ensure the ignition switch is 'OFF', unless the procedure requires otherwise. Always apply the
handbrake and place blocks against the front and rear of the tyres to prevent movement when working
on the vehicle.
Only run the engine in a well-ventilated area to avoid the danger of carbon monoxide poisoning. Do not
eat or smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose jewelry, loose clothing etc. before starting work on
a vehicle.
To prevent burns, avoid contact with hot parts such as the cooling and exhaust systems. A number of
security-critical bolts are used on this engine which must be renewed if removed. These bolts are marked
within this work book. Sensors and actuators (e. g. injectors) must NOT be connected to an external
voltage supply.
Timing belt storage & transportation: Timing belts must be stored flat and circular. Do not hang on a peg.
Do not remove timing belt from its package before ready to install. Do not crimp or bend into a diameter
of less than 25 mm.
Do not pry the belt off the timing pulley with a pry bar for that might damage the reinforce fibre within it.
Remove with hand ONLY. If the belt is to be reused, check for its rotation direction to ensure correct
reinstallation. A belt MUST be renewed if contaminated with oil, fuel or other detrimental fluids. Do not
attempt cleaning. In case a belt has been contaminated, clean relevant pulleys and identify the source.
Notes: Do not clean with solvent. The timing pulley must have smooth surface to ensure longer belt
service life. Check if the timing pulley is free of roughness or burrs and rotates freely before installing the
belt.
We must turn the vehicle for alignment clockwise (looking from the fore-end) when adjusting the timing
of the engine, otherwise, the mechanism of the air valve would be damaged. We must use special tool
instead of the crankshaft timing pulley bolt to turn the vehicle. The bolt would be loosened when the
vehicle is being turned because the crankshaft timing pulley bolt is turned anticlockwise. The crankshaft
timing pulley bolt is screwed down by "applying the torque plus turning the angle", but can not be done
twice.
The engine emission is under the National Standard IV. So it must use the diesel above the National
Standard IV.
Users should avoid any operations that may cause the pulley surface to freeze.
Fuel system precautions:
Do not attempt removing the fuel injector. Do not carry out any maintenance or repair work to fuel
system while engine is running.
1-2
General Information
The pressure of the diesel could be as high as 1600 bar (23,200 psi) when running from injection pump to
the injector through high pressure fuel pipe. Do not slacken any high pressure pipe when the engine is
running. .
Take extra care for pressurized fuel could be penetrate into human skin, causing harm or death. Avoid
any direct contact with fuel spray. Use thick card to check for fuel leak. Wear protective goggles and
clothing when working on fuel system.
Do not smoke or allow open flame of any type when working on or near any fuel related components.
Fuel vapour can ignite and cause damage and/or personal injury.
Absolute cleanliness must be ensured when handling or overhauling diesel fuel system components
because the tolerances for the injector as well as fuel pump, pipe, rail, etc. are so tight that dirt
contamination could cause rapid wear or other malfunctioning.
Always wash/clean fuel system components before disassembly and then air dry. Do not wire brush
injector nozzles when cleaning. Wipe clean. Cap or cover any open part after disassembly. Before
assembling, examine the parts for dirt, grease, or other contaminants and clean if necessary.
When fitting new parts, lubricate with clean engine oil or clean diesel fuel as appropriate.
1-3
General Information
1-4
Engine Mechanics
Engine Mechanics
Specification
Technical Data
Type 16 valve direct injection fuel rail with turbocharger & intercooler
Bore 2.5 L: 92 mm 2.5 Lplus: 94 mm
Travel 2.5 L: 94 mm 2.5 Lplus: 100 mm
Displacement 2.5 L: 2499.5 cc 2.5Lplus: 2775.9 cc
Power and Torque 2.5 L: 136 PS/3800 rpm 2.5 Lplus: 143 PS/3600 rpm
2.5 L: 300 Nm/1800 rpm 2.5 Lplus: 350 Nm/1800 rpm
Injection sequence (timing belt end as 1-3-4-2

cylinder 1)
Compression Ratio 17.5 : 1 ( 0.5)

Max compression pressure difference 5 bar
between two cylinders
Idle speed 850 rpm
Maximum speed 4500 rpm
Weight (fitted with accessories and 259.5 X 1+5 kg

filled with specified oil and coolant)
Dimension (with accessories)

- Length 687.4 mm
- Width 726.5 mm
- Height 744.7 mm
Emission requirements China
CYLINDER HEAD
Cylinder head gasket thickness: - 1 hole 1.34 mm
- 2 hole 1.44 mm
- 3 hole 1.54 mm
Valve sinkage incylinder head - inlet -0.15 0.15 mm

- exhaust -0.15 0.15 mm
Hydraulic rappet out diameter 11.988 - 12.00 mm
valve
valve cone angle
- inlet 45 25- 45 35
- exhaust 45 25- 45 35
valve stem diameter
- inlet 5.952 - 5.97 mm
- exhaust 5.942 - 5.96 mm
clearance between valve stem and

guide 0.442 - 0.56 mm
- inlet 0.452 - 0.57 mm
- exhaust
valve guide
2-1
Engine Mechanics
valve guide inradius 6.00 - 6.012 mm
valve guide fitted height

- inlet 14.5 - 15.0 mm
- exhaust 16.5 - 17 mm
Valve spring
Free height 45.26 mm
Fitted height 38.0 mm
camshaft
inlet Open at 15 before top dead centre
Close at 64 after bottom dead center

exhaust Open at 66 before bottom dead center
Close at 32 after
End-float 0.10-0.55 mm
Journal to bearing clearance 0.03-0.08 mm
Connection rod
Connection rod bush inradius32.035 32.035-32.050 mm
Big end inradius53.994 53.994-54.014 mm
Piston
Clearance to cylinder hole 2.5 L: 0.069 - 0.103 mm 2.5Lplus :0.068 - 0.104 mm
Piston protrusion 2.5 L 2.5 Lplus
0.46 - 0.609 mm 0.46 - 0.609 mm

with 1.34 mm cylinder head gasket (1 with 1.34 mm cylinder head gasket (1
hole) hole)
0.61 - 0.709 mm 0.61 - 0.709 mm

hole) hole)
0.71 - 0.81 mm 0.71 - 0.81 mm

hole) hole)
Piston ring groove clearance

Type 2.5 L 2.5 Lplus
gas ring No.1 0.093 - 0.188 mm 0.103 - 0.157 mm
gas ring No.2 0.055 - 0.1 mm 0.055 - 0.1 mm
oil ring 0.035 - 0.08 mm 0.045 - 0.09 mm
Piston ring installation rear opening
gas ring No.1 0.30 - 0.50 mm 0.30 - 0.50 mm
gas ring No.2 0.30 - 0.50 mm 0.50 - 0.75 mm
oil ring 0.25 - 0.50 mm 0.25 - 0.50 mm
Crankshaft
2-2
Engine Mechanics
Type 2.5 L 2.5 Lplus
Crankshaft end-float 0.08 - 0.28 mm 0.08 - 0.28 mm
Front end journal diameter 62.985 - 63.005 mm 62.985 - 63.005 mm
Front end journal to bearing clearance 0.04 - 0.049 mm 0.04 - 0.049 mm
Centre journal diameter 63.00 - 63.02 mm 63.00 - 63.02 mm
Centre journal to bearing clearance 0.008 - 0.055 mm 0.008 - 0.055 mm
Rear end journal diameter 89.98 - 90.00 mm 89.98 - 90.00 mm
Rear end journal to bearing clearance 0.045 - 0.08 mm 0.045 - 0.08 mm
Main bearing dimension out-of- 0.25 mm 0.25 mm

tolerance allowance
Connection rod journal 53.935 - 53.955 mm 53.935 - 53.955 mm
Connection rod journal to bearing 0.020 - 0.079 mm 0.020 - 0.079 mm

clearance
Connection rod journal dimension out- 0.25 mm 0.25 mm

of-tolerance allowance
CYLINDER BLOCK
Cylinder liner protrusion 0.01 - 0.05 mm
Cylinder liner protrusion adjustment 0.15 0.17 0.20 0.23 0.25 mm

shims
Cylinder liner inradius 92.006 0.009 mm
Fuel system
Injection system Direct injection, electronic control fuel rail
High pressure pump Bosch CP1H
ECU Bosch EDC17C53
Fuel injector Bosch CR12.2
Glow plug
Type / Model Heat up in cylinder S00002585
Voltage 11 V
Lubrication System
OIL PUMP Rotary
Outer rotor end-float 0.060 - 0.160 mm
Inner rotor end-float 0.060 - 0.160 mm
Outer rotor to body radial play 0.130 - 0.240 mm
Rotor to drive gear play 0.90 - 1.50 mm
Oil pressure regulating valve open 7 bar

pressure
Oil pressure regulating valve spring free 46.8 mm

height
2-3
Engine Mechanics
Minimum oil pressure (warm up) 3.5 bar (3000 rpm)
1 bar (idle 850 rpm)
Cooling System
Thermostat trigger temperature 82C 2C
Pressure cap pressure configuration 1.1 bar
VACUUM SYSTEM
Minimum vacuum at idle 700 mmHg
Engine oil
Specification CI4-(or A3/B4) -10W/40
Capacity 7.65L
Refrigerant
antifreeze specification Non methanol based: Ethylene Glycol based SAIC Motor Commercial Vehicle
Project Team
solution mix 50% coolant 50%
Capacity 7.65L
Sealants / Thread locking adhesives

Loctite adhesive 680 or Loctite Bowl
adhesive 11264
Loctite 510 Turbocharger fuel return pipe adapter
Molykote 111 'O' rings (crankshaft rear bearing, rear bearing seat)
Polymer 400 Cylinder liner 'O'
Loctite adhesive 567 or Kesai new Water

1567F
Scre
Loctite adhesive 271 or Kesai new 1262 Engine support stud
Teflon grease Vacuum
Oil pressure
Molycote P - 1500 grease Fuel
Loctite 5900 Crankshaft rear
Gear
Torque
application Torque Nm
M6 bolt for inlet pipe 11
accessory bracket M10 mounting bolt 45
Cylinder upper head bolt Tighten to 7Nm for 1-16

Tighten to 25Nm for 1-16
Tighten to 32.4Nm for 1-5
2-4
Engine Mechanics
Camshaft position sensor bolt M6 11
Camshaft timing pulley fasten bolt 108
Camshaft timing hole inner hex screw plug 17
Oil filler cap connector pipe Metal connecting pipe: 80; engineering plastic connecting
pipe: 45-50
Clutch bolt M8 36
Connection rod bolt Torque to 30Nm

Tighten (angle method) by 40
88Nm
Oil baffle plate bolt M8 33
Gear casing cover bolt, 12 x 8 mm 12
Main bearig seat bolt 44
Crankshaft drive gear bolts (oil pump / vacuum pump) 11
Speed sensor bolts 11
Crankshaft timing pulley bolts Corner method: 150 Nm+90 (referential torque 275 Nm)
The bolt is allowed to be used for once, and the corner
cannot be refastened after it's fastened at the first time.
Crankshaft shock absorber / pulley bolts 33
CYLINDER HEAD BOLT See the chapter "cylinder cover" for reference
EGR valve mounting bolt 11
EGR cooler mounting bolt M8 33
EGR cooler mounting bolt M10 45
EGR outlet pipe to EGR valve clamping bolt 33
lifting eye bolts 33
Flywheel dust shield 25
exhaust pipe nuts 36
Exhaust heat shield bolts 25
Accessory idler pulley bolts (LH thread) 45
Accessory tension pulley 45
Flywheel bolts See the chapter "flywheel" for reference
High pressure fuel pipe injector bolts 25
High pressure fuel pipe injector bolts 28
High pressure fuel pump timing pulley bolts 88
High pressure pump retaining nuts 25
Fuel injector pressure plate bolts 32
Fuel rail retaining bolts 25
Engine front support fasten bolt See the chapter "Timing belt idler pulley bolts" for reference
Oil cooler to engine block bolts 50
2-5
Engine Mechanics
Engine oil Filter Tighten with hand
Piston cooling nozzle bolts 11
Oil pump bolts 11
Oil pickup pipe bolts 33
Crankshaft speed signal disc 15
Oil pan bolts 15
Oil pan bleed screw plug 80
Thermostat body bolts 25
Timing belt idler pulley bolts (LH threads) 57
Timing belt tension pulley fasten nut 28
Timing pulley case bolts 5 x M6 11
Timing pulley case bolts 3 x M10 45
(Timing front end) timing protection cover 17 xM5 6
Flywheel dust shield support 45
Turbocharger support bolts 33
Turbocharger oil pickup pipe M10X1 24
Turbocharger oil return pipe bolts 11
Turbocharger oil return connector pipe nuts 33
Turbocharger and exhaust pipe fasten nuts 32
Vacuum pump one-way valve 57
Vacuum pump bolts 11
water pump nuts 25
Water temperature sensor 18
Oil pressure alarm switch 12
Engine rear suspension mounting bolts 60 75

Transmission output shaft bear seat bolts 52.5 2.5
Engine front suspension and transmission suspension nut 100 5
CAUTION:Turn clockwise to slacken LH tread.
2-6
Engine Mechanics
Layout
Exploded view of cylinder head, air intake & exhaust and fuel system assembly
1 2
4
9
3 6 7
8 11 10
12
13
5
36
14
35
33 34 15
32 31
30
29
16
28
27 18
17
26
20
19 21
25
24
22
23
1 Fuel injector return pipe 9 Oil dipstick

2 High pressure fuel return pipe (fuel rail to fuel 10 Oil dipstick tube
injector)
11 Camshaft plug
3 Fuel rail
12 Air intake temperature & pressure sensor
4 Fuel injector
13 Cylinder upper head
5 Fuel rail pressure sensor
14 Cylinder upper head shim
6 Oil filler cap
15 Turbocharger air intake pipe
7 Oil/air separator
16 EGR air outlet pipe (EGR cooler to EGR valve)
8 Camshaft position sensor
17 Water temperature sensor
2-7
Engine Mechanics
18 Cylinder head 27 Valve actuating system
19 Cylinder head shim 28 Engine lifting eye
20 Air intake pipe (EGR valve to cylinder upper 29 Exhaust pipe shim
head)
30 Exhaust pipe
21 Heater plug
31 Exhaust pipe heat shield
22 Vacuum pipe
32 Camshaft oil seal
23 Turbocharger oil return pipe
33 Camshaft retaining ring
24 Turbocharger oil pickup pipe
34 Inlet camshaft
25 Turbocharger
35 Exhaust camshaft
26 Thermostat and housing
36 Fuel rail oil return pipe
2-8
Engine Mechanics
Exploded view of engine block and cylinder power assembly
6
7
5 9
10 8
1 3
11
24
12
2
37
4
36
35
14 13
34
33 15
32 17
18
16
31
19
30 20
22 21
29 23
18 25
28
26
27
1 Cooling water pipe 9 Piston

2 Water pump 10 Connection rod bush
3 Oil filter 11 Connecting rod
4 Oil cooler 12 Flywheel dust shield
5 Fresh water pump inlet pipe and coolant inlet 13 Rear main bearing seat
hose
14 Speed sensor
6 Piston ring
15 Flywheel dust shield support
7 Elastic retaining ring for holes
16 Crankshaft speed signal disc
8 Gudgeon pin
17 Connection rod bearing bush
2-9
Engine Mechanics
18 Main bearing seat 28 Oil strainer/pick-up pipe
19 Flywheel 29 Main bearing bush
20 Starter ring gear 30 Crankshaft
21 Crankshaft rear oil seal 31 Vacuum pump
22 Crankshaft rear ring spacer block 32 Crankshaft pulley/damper
23 O seal ring 33 Oil pump drive gear
24 Cylinder liner 34 Vacuum pump/oil pump drive gear
25 Crankcase oil baffle plate 35 Oil pump
26 Oil pan pad 36 Crankcase
27 Oil pan 37 Oil pressure alarm switch
2-10
Engine Mechanics
Exploded view of front timing & accessories assembly
9
8
5 7
6
4
2
3
12
1 3 11 10
13
14
15
16
23 24
22 19
21
20 17
18
1 Engine front support 10 Timing pulley case shim

2 Front end timing protective cover 11 High pressure fuel pump pulley
3 Timing drive belt idler pulley 12 Timing drive belt tension pulley
4 Timing drive belt 13 Crankshaft timing pulley
5 Exhaust camshaft timing pulley 14 Power steering pump
6 Inlet camshaft timing pulley 15 High pressure fuel pump
7 Timing pulley case 16 AC alternator mounting
8 Timing pulley case bush 17 Alternator
9 Timing pulley case damping pad 18 AC compressor
2-11
Engine Mechanics
19 Front end accessory drive belt 22 Timing pulley case damping pad
20 Front end accessory drive idler pulley 23 Crankshaft front seal
21 Front end accessory drive tension pulley 24 Gear casing cover
2-12
Engine Mechanics
Fault diagnosis
Defect Possible cause Solution
Difficult or impossible to start engine Start circuit slacken or corrosion Clean and tighten start circuit
connections
Starter motor and electrical system Check / replace faulty parts

fault
Pre-heating mis-operation (when Follow correct procedure

applicable)
Air intake system hampered Check air intake system pipes or

blocks
Fuel tank too low Fuel refill
Air breach into fuel system Expel air
Specification of fuel oil or engine oil is Adopt the required fuel oil or engine oil
not correct. in this manual. Use the high-quality
fuel oil which is put in the temporary
tank to verify on traveling.
Unexpected engine ignition off Fuel contaminated Replace for clean fuel
High pressure oil pipe leak Check for source, tighten / replace
parts in necessary
Fuel pipe / filter jammed Check circuit and pilot, clean strainer
and replace fuel filter if necessary
Incorrect fuel injection or air intake Check fault code and timing system,
timing adjust timing if necessary
Fuel supply pump failure Repair/Replace fuel pump
2-13
Engine Mechanics
Less engine power Vehicle overload Remove load until within rated
capacity
Fuel supply blocked Check fuel inlet resistance, clean first

filter & strainer and replace fuel filter if
necessary
Poor fuel grade Verify using temporary fuel tank filled

with diesel of correct grade
High pressure fuel pipe or connection Check for source, tighten / replace
leak connector or high pressure fuel pipe
Air breach into fuel system Expel air and check fuel pick-up pipe
for leak
Air intake or exhaust system blocked Check air intake / exhaust system
resistance, check air filter and replace
if necessary
Incorrect fuel injection or air intake Check fault code

timing
Turbocharger broken Check turbocharger pressure, replace

if too low
Fuel injector nozzle blocked, poor Check, clean, or replace fuel injector
atomization
Ambient temperature or altitude too Engine power will decrease as

high ambient temperature or altitude gets
too high; unload the vehicle
appropriately
Check if engine fault indicator light is Check fault code

on
Engine oil level is too high. Examine the engine oil surface height
and adjust it to required range.
Excessive fuel consumption Fuel leakage Check fuel system pipes for sealing,
tighten if appropriate
Poor fuel grade Use recommended fuel
Auxiliary devices fault creating extra Check auxiliary and vehicle parts (ref.
load manufacturer specification)
Air intake system resistance high Check air filter element, replace if
necessary
Check if fault indicator light is on Check fault code
2-14
Engine Mechanics
Engine overheat Insufficient coolant Check for leakage; refill; expel air
Radiator pressure cap fault Check radiator pressure cap

functioning
Engine overload Unload appropriately
Dusty radiator Check radiator, clean if necessary
Cooling fan air-guide hood broken or Check air-guide hood, repair or

vane fallen replace if necessary
Fan drive tape damaged or loose Check tape and tension pulley
Water pump fault Dismantle the pump for inspection
Air/Fuel gas in cooling system Check water circuit for leakage or

loose
Water temperature sensor or Check water temperature sensor and

thermometer broken thermometer
Thermostat fault Replace thermostat
Oil pressure too high Pressure gauge failure Check gauge functioning
Engine operation temperature too low See "coolant temperature too low"
Oil viscosity too high, type incorrect Check / replace with correct type
By-pass block at critical place Check / replace by-pass valve
Oil pressure too low Oil level too low Adjust oil level
Oil viscosity too low, type incorrect Check / replace with correct type
Oil pipe connection loose or oil Check oil leakage

channel plug fall out
Oil diluted by water Detect the cause and replace oil
Oil pressure adjusting valve fault Check / replace pressure adjusting

valve
Oil pressure gauge fault Check oil pressure gauge
Oil filter plugged Check / replace filter
Worn engine shaft, bearing bush, etc. Replace
Black smoke emission from exhaust Engine overload Shift to lower gear
pipe
Air in system Expel air, check fuel pick-up for
leakage
Air intake system hampered Check air intake for block
Turbocharger fault Replace turbocharger
Fuel injector fault Check fault code / replace parts
Check if engine fault indicator light is Check fault code

on
2-15
Engine Mechanics
Engine coolant temperature too low Radiator blinds jam at max opening Check radiator, replace if necessary
Temperature sensor fault Check / calibrate sensor
Thermometer failure Check thermometer, replace if

necessary
Thermostat broken Replace thermostat
Excessive engine noise Drive tape howling Check tape powertrain
Excessive air valve clearance Check / adjust air valve clearance
Turbocharger noise Check for collision between vane and

shell
Insufficient engine oil Check / refill oil
Drive gear noise Check / replace faulty parts
Excessive engine vibration Engine mount loose or damaged Check / replace engine mount
Broken fan or accessories Check / replace faulty parts
Crankshaft torsional vibration damper Check / replace faulty parts

fault
Worn / unbalanced driving system Check / replace with accordance to

components manufacturer specification
Moving parts loose or damaged Check / replace faulty parts
Generator under charge or no charge Battery connection slacken or Clean / tighten battery connection
corrosion
Engine tape slippery Check / replace tape and tension

pulley
Fascia or indicators failure Check / replace fascia or indicator
Engine wiring loose or damaged Repair wires
Generator failure Replace generator _
Inconsistent engine idle speed Air in system Expel air from fuel system and check
fuel intake for leakage
Coolant contamination Fuel spill valve failure Check / replace spill valve
Fuel supply blocked Clean first filter & strainer and check
fuel pipe resistance
Injector nozzle plugged or failure Check / replace nozzle
Injection pump injecting timing Check fault code, adjust timing if

incorrect necessary
Contaminated Coolant in oil, engine internal parts Check / replace faulty parts
leaking
Excessive deposit in oil Check renewal period of oil and its

filter
Fuel in oil, engine operation Check if engine run extensive period

temperature too low under idle
Fuel system leakage Air in fuel system Expel air from fuel system and check
fuel pick-up pipe for leak
2-16
Engine Mechanics
Engine knock Poor fuel grade Verify by starting engine with

temporary fuel tank
Engine overload Shift to lower gear to check if engine

operating over nominal load
Timing incorrect Check / adjust timing
Fuel injector failure Dismantle fuel injector for inspection &

repair
Fuel / oil leakage at exhaust pipe Air intake blocked Check / replace air filter element
Injector nozzle needle valve blocked Locate and replace faulty injector
Turbocharger fuel return pipe blocked Check / clear fuel line
Turbocharger seal ring leaking oil Check / replace turbocharger
Engine run extensive period under idle Improve operation habits

speed
Excessive air leakage at crankcase Crankcase ventilation breather pipe Check if ventilation and breather pipe
blocked is blocked
Leakage at turbocharger air seal Check turbocharger air seal
Cylinder head valve tube excessively Check / replace faulty parts

worn
Piston ring damaged or worn Check piston ring and cylinder liner
Leakage in vacuum connecting line Examine the leakage problem of

vacuum connecting line and eliminate
the source of leakage.
Glow plug fault Warm- up too slow Check / replace faulty parts
Not working Check if cables are electrified, check /

replace faulty parts
Vacuum pump suction head low Vane excessively worn Check / replace vacuum pump
Leakage at pipelines Check / replace faulty pipes
Vacuum regulator fault Noise high Check / replace faulty parts
No pressure Check / replace faulty vacuum pipes
Not working Check if electrified, check / replace

faulty parts
Belt worn diagnosis Squeaks at belt Belt slippery, worn, or stretched, check
/replace belt and tension pulley
Long screaming or piercing noise Check belt surface for alien matters
Continuous hiss or quack noise Check tension pulley and its

accessories for failed bearing
2-17
Engine Mechanics
SPECIAL TOOLS
Name Illustration
Name Illustration
Crankshaft front oil seal

installer
Clutch aligner
C00017002
C00016994
Flywheel timing pin
Rear oil seal installer
C00017003
C00016995
Cylinder liner retainers
Inlet camshaft timing pin
C00017004
C00016996
Injection pump wheel

remover
Exhaust camshaft timing
pin
C00017007
C00016997
Fuel pump wheel remover
Camshaft oil seal installer
C00017008
C00016999
Cylinder liner measuring

tool
C00017009
2-18
Engine Mechanics
Name Illustration Name Illustration
Flange retainer Crankshaft bearing fix pin

remover
C00017010 C00017017
Cylinder liner remover Oil pressure release valve

remover
C00017011 C00017018
High pressure pump Piston cooling nozzle

impeller timing tool replacer
C00017012 C00017019
Camshaft support guide Crankshaft front bearing

pin replacer
C00017013 C00017021
Flywheel mounting Valve oil seal replacer

pins toolset
C00017014 C00017029
Camshaft gear locking Tension pulley adjuster

tool
C00017015 C00017030
2-19
Engine Mechanics
Name Illustration
Engine oil Filter
C00017031
Engine oil pan gasket seal

separator remover tool
C00017032
Oil seal puller
C00017033
2-20
Engine Mechanics
Repair instructions
Front end accessory drive belt replacement
Removal
1 Slacken screw, turn the tension pulley counter-

clockwise as illustrated, and remove front
accessory drive belt
CS113000
Installation
1 Installation is reverse of removal procedure.
CS113000
2-21
Engine Mechanics
Timing Belt Replacement

Tools required: C00016996, C00016997,
C00017003, C00017015, C00017016, C00017030.
Removal
1 Remove front accessory drive belt (see

"Replacing the front accessory drive belt").
2 Support the fore-end of the engine, remove three
M10 screws and the engine's front support and
discard three M10 screws.
CS113001
3 Remove screws and front end accessory timing

drive belt tension pulley.
CS113002
4 Remove the 4 M8 screws and crankshaft

damper.
CAUTION:Before taking apart the crankshaft

absorber (4x10 mm), firstly use the turning gear
to turn the vehicle to its engine timing installation
position in order not to cause the bolts to be
loosened when the crankshaft timing pulley bolt
is used to turn the vehicle in the later adjustment
of vehicle timing.
CS113003
2-22
Engine Mechanics
5 Remove the 17 M5 screws and front end timing

protective cover, and check sealant condition of
pads and protective covers.
CAUTION:Screws are pre-applied with adhesive.
CS113004
6 Turn the engine clockwise until the timing marks

on crankshaft pulley is 90 after top dead
centre.
90
CS113006
7 Remove the anti-dust plug, then install flywheel

timing pin C00017003, align the flywheel
properly.
C00017003
CS113222
2-23
Engine Mechanics
8 Remove the inner hex screw plug (2XM6);Insert

the inlet camshaft timing pin C00016996 and
exhaust camshaft timing pin C00016997.
C00016996
CAUTION:If timing pins will not enter, remove
flywheel timing pin, turn crankshaft clockwise for
360, then refit the pin. Then insert the camshaft
timing pin.
C00016997
CS113007
9 Slacken camshaft timing pulley retaining bolts

(2xM12).
CAUTION:Use tool C00017015 to prevent pulley C00017015

from turning. Do not use only the timing drive
belt.
CS113008
10 Slackening the nuts (M10) of belt tension pulley

fasten bolt and use tool C00017030 to turn the
pulley anti-clockwise to lowest point.
C00017030
11 Remove and discard timing drive belt.
CAUTION:Do not turn the crankshaft when the

timing drive belt is removed unless under
professional guidance. Damage to valves,
pistons etc. may result.
CAUTION: Replace idler and tension pulleys
together with timing drive belt.
CS113009
2-24
Engine Mechanics
Installation
1 Retain camshaft timing pulley with new bolts.

Finger-tight the bolts, then undo for 1/16 turns to
ensure the pulley moves freely. 1/
16
CS113010
2 Turn fuel pump timing pulley to align timing

marks as shown in figure on right.
3 Check that flywheel and camshaft timing pins are

fitted.
CS113011
4 Install new timing drive belt;
a. Start from the crankshaft timing pulley. Use

appropriate temporary support to attach the belt and the
timing pulley. Keeping belt taut, fit around the parts below
progressively:
b Fuel pump timing pulley (avoid interrupting timing).
c. Idler pulley.
d. Inlet camshaft timing pulley
e. Exhaust camshaft timing pulley CS113012

f. Idler pulley.
2-25
Engine Mechanics
g.Water pump pulley.

e d
h.Timing drive belt tension pulley. f c
CAUTION:Do not lever belt onto pulley; use finger

pressure only. b
g
h
a
CS113005
5 5Remove temporary supports from the

crankshaft timing pulley.
CS113012
6 Use tool C00017030 to turn the tension pulley

clockwise until its pointer over laps the spring for
1 mm (as illustrated). Torque tension pulley C00017030
fasten nut to: 28Nm.
1mm
CS113013
2-26
Engine Mechanics
7 To tighten camshaft timing pulley bolts, fit tool

C00017016 as follows:
C00017016
Turn the adjusting handle of tool C00017016
counter-clockwise to fit with the teeth on the timing pulley
(which should be able to move freely).
Place the tool on the top middle of camshaft timing

pulley.
Observe through the elliptical hole while turning the

handle until both sliding teeth fit into completely the
groove (as illustrated).
CS113014
Tighten both securing bolts to 108 Nm.
Remove tool C00017016.

108 Nm
108 Nm
CS113015
8 Remove timing pins C00016996, C00016997,

C00017003.
CS113016
2-27
Engine Mechanics
9 Check valve timing and belt tension as follows
Temporarily apply a mark to timing belt.
Turn crankshaft clockwise until the mark is back at

its original place (turned around).
CAUTION:If the mounted cylinder upper head has

been removed, wait 30 minutes before turning the
crankshaft.
CS113017
Continue to turn clockwise until flywheel timing pin

C00017003 can be fitted.
C00017003
CS113018
Check if camshaft timing pins C00016996 and

C00016997 can be fitted.
CAUTION:Crankshaft may have to be rotated a

further 360.
If the timing pin does not enter, refit the belt.
C00016996
C00016997
CS113019
2-28
Engine Mechanics
Check the timing drive belt tension pulley tensioner

and adjust if necessary.
1mm
Remove all of the three timing pins and install the
sealing plug.
CS113223
10 Check the sealing performance around the outer

skirt of the fronr timing protective cover, and then
repair it when necessary. When repairing
it,please first remove the old sealant and clean
up the surface and then apply new Kesaixin
1590.Put it a side for a period of time to wait for
the sealant solidification, and then reinstall the
cover.
11 Replace the pad and protection cover. Apply

thread-locking adhesive to bolts and torque to: 6
Nm.
CS113020
12 Fit crankshaft damper / pulley and torque 4

M8X16 screws to: 33Nm.
CAUTION:The length of screws M8x16 must be as

specified to avoid damaging the timing system.
CS113021
2-29
Engine Mechanics
13 Install the front end accessory drive tension

pulley and M10 screws. Torque to: 45 Nm.
CS113022
14 Install the engine's fore-end support. Adopting a

new screw and screw down twice:
First time down to 25Nm;
Second time down to 50Nm, and then turn the angle

to 60
CAUTION:Order of screwing down the bolts:

firstly tighten the upper bolt and then the lower
two bolts successively.
15 Install the front end accessory drive belt (see
"Front end accessory drive belt replacement"),
CS113023
make sure it is at the center of all pulleys.
2-30
Engine Mechanics
Timing Pulley Case And Damping Pad

Renewal
Tools required:C00016996, C00016997,
C00017003, C00017015, C00017030, C00017016
and the C00016996 and C00017002 for removing
gear casing house)
Removal
1 Remove the timing drive belt (see "Replacing the

timing drive belt").
2 Remove the timing drive belt tension pulley.
CS113031
3 Remove both camshaft timing pulleys. Discard
the camshaft timing pulley bolts.
CS113052
4 Remove the M12 screws and idle pulley.
CAUTION:Left hand thread.
CS113033
2-31
Engine Mechanics
5 Remove the screws (5 M6, 3 M10) and timing

pulley case. remove the timing pulley case
damping pad.
CAUTION: Check pads and seals for damage and 5 M6

replace as necessary.
3 M10
CS113027
Installation
1 Installing timing pulley case damping pad.
2 Apply a small amount of Kesaixin 1591 silicon

rubber sealant on sealing gasket of gear case
cover(shown on the figure ) for waterproof and
sealing effects. The gluing diameter is
3mm~6mm.
CS113315
3 Apply Kesaixin 1591 silicon rubber sealant on

the upper head of cylinder as the gluing path line
shows in the figure. The gluing diameter is
2mm~5mm.
CS113316
2-32
Engine Mechanics
4 To install timing pulley case, torque the follow

bolts to:
5 x M6 11 Nm
5 8mm
3 x M10 45 Nm
CAUTION:Apply Loctite 222 to the 8 retaining

bolts.
3 13mm
CS113224
5 Fit the idler pulley and tighten the bolts to 57 Nm.
CAUTION:Left hand thread
CS113238
6 To install the timing drive belt tension pulley, start

from finger-tight the bolts.
CS113031
2-33
Engine Mechanics
7 Install both camshaft timing pulleys using new

bolts, ensure the contact face is same as before
removed. Tighten bolts finger-tight then slacken 1/
1/16 turns. 16
8 Install new timing drive belt (see "Timing drive
belt").
CS113010
2-34
Engine Mechanics
Gear casing cover renewal

Tools required: C00017010 and C00017032
Removal
CAUTION:Distortion is not allowed on the gear
casing cover.
1 Remove the timing pulley case and its damper

pad (see "Replacing the timing pulley case and
damping pad).
2 Remove crankshaft drive gears and the M16
mounting screws.
CAUTION:For LH thread: Do not remove the C00017010

crankshaft front oil seal before the gear casing
cover.
CS113035
3 Remove the 12 M6 bolts retaining the gear

casing cover.
CS113036
4 Use sealant remover C00017032 to separate the

silica gel sealed gear casing cover from the body
(the areas of the tool used to separate sealing
must be properly lubricated).
C00017032
CS113037
2-35
Engine Mechanics
5 Remove the gear casing cover.
CAUTION:The position of dowel .

1
CS113038
Installation
1 Remove old sealant and clean the joint surface.

2 Apply continuous belt of Loctite 5900 of 3 mm
wide onto the housing.
CAUTION:Install the gear casing cover within 10

min after applying the sealant.
3 Use tool C00017002 to protect the oil seal lip
while installing the housing and torque the bolts
to 12 Nm.
CS113040
4 When installing the crankshaft timing pulley,

please use new bolt (anticlockwise screw
thread).The standard for screwing: 150Nm+90 C00016994
reference torque 275Nm
CAUTION:Attention: After the bolt has been
screwed down by angle turning, it can't be
screwed again.
275Nm
CS113041
2-36
Engine Mechanics
Renewal Crankshaft Front Oil Seal

Removal
1 Remove FEAD and timing belt.
2 Remove crankshaft gear(21mm).
CAUTION:torque left
LDV118
CS113300
3 Make a sign on the tape,hit a little hole on the

Carnkshaft Front Oil Seal.Fit the right bolt and
prize Crankshaft Front Oil Seal with bolt.
CAUTION:Don't hit the hole too deep and avoid to

destroy rear gear.
CS113301
Installation
1 Clear the front of Crankshaft and seal area.

2 Wrap the industrial tape on the front of
Crankshaft,avoid to destroy seal.
CS113302
2-37
Engine Mechanics
3 Fit new Crankshaft Front Oil Seal on the tapa

carefully.
CAUTION:Don't lubricate the meatus of

Crankshaft Front Oil Seal.Insure the meatus of
Crankshaft Front Oil Seal against destroy during
fifting.Oil Seal must be same as the Crankshaft.
CS113303
2-38
Engine Mechanics
Crankshaft Front Oil Seal Renewal

Removal
1 Remove the gear casing cover (see "gear casing

cover renewal").
2 Support the housing with the sleeve of tool
C00017002 , remove the oil seal and discard.
3 Clean crankshaft at area of oil seal contact and

examine for wear, damage etc.
C00017002
CS113042
Installation
1 To press the new crankshaft front oil seal into the

gear casing cover, support the housing under its
oil seal with the sleeve of tool C00017002, then
use tool C00017002 to properly press the seal C00017002
into the housing.
CAUTION:To prevent oil leak, do NOT lubricate
seal lip or crankshaft journal. Touch the outer
edge of the oil seal while installing it.
C00017002
CS113043
2-39
Engine Mechanics
Oil Pump Renewal

Removal
1 Remove gear casing cover, etc (see "gear

casing cover renewal").
2 Remove the 4 M6 inner hex screws and drive
gear.
CS113044
3 Remove the 3 M6 inner hex screws and oil

pump.
CS113045
Installation
1 To install the oil pump, torque the 3 M6 inner hex

screws to: 11Nm.
CAUTION: Lubricate pump components before
fitting.
11Nm
CS113046
2-40
Engine Mechanics
2 Check the end-float of inner rotor.
0.06-0.16mm
CS113047
3 Lightly lubricate oil pump drive gear teeth with

multipurpose grease. Fit the gear and torque
fasten screws to 11 Nm. 11 Nm
4 Install gear casing cover (see "gear casing
coverrenewal").
CS113048
2-41
Engine Mechanics
Vacuum Pump Renewal

C00016997, C00017002, C00017003, C00017015,
C00017016, C00017030 (Hazet tool) .
Removal
1 Remove gear casing cover etc. (see "gear

casing cover renewal") .
2 Remove the 4 M6 inner hex screws and oil pump
drive gears.
CS113056
3 Remove the 3 M6 inner hex screws and vacuum

pump.
CS113049
Installation
1 Check if the vacuum pump oil inlet (pointed

withthe arrow) is clean.
CS113050
2-42
Engine Mechanics
2 2To install the vacuum pump, torque the screws

to 11 Nm.
11Nm
CS113051
3 Install oil pump drive gear and torque fasten

screws to: 11Nm.
4 Fit a new front oil seal into the gear casing cover. 11 Nm
5 install gear casing cover etc (see "gear casing

cover renewal").
CS113048
2-43
Engine Mechanics
Camshaft Oil Seal Renewal

C00016999, C00017003, C00017015, C00017016,
C00017033, C00017030.
Removal
1 Remove front accessory drive belt (see "front

accessory drive belt renewal").
2 Remove and discard timing drive belt (see
"timing drive belt renewal").
3 Remove and discard both fasten bolts of

camshaft timing pulley. Remove the camshaft
timing pulley.
CS113052
4 Use tool C00017033 to punch two holes on

camshaft oil seal that M4X38 mm self-tapping
screws could fit in.
CAUTION:Do not punch on the cylinder upper

head for damage could occur.
CS113053
2-44
Engine Mechanics
5 Fit screws and pry out the camshaft oil seal.
CS113053
Inspection
Clean area around oil seal and examine for damage.
Clean crankshaft where oil seal is attached and examine
for wear, damage etc.
Installation
1 Lightly lubricate oil seal lip with engine

lubrication oil.
2 Put the oil seal on the plastic sleeve of tool
C00016997 until touching its beading. Fit the oil
seal and its cap squarely into place.
C00016999
CS113054
3 install camshaft timing pulley, fasten with new

bolts, finger-tighten the bolts, then slacken for 1/
16 turns. 1/
16
4 Install new timing drive belt (see "Timing drive
belt").
5 Install the front timing protection cover (see

"timing pulley case renewal").
6 Install front accessory drive belt (see "front

accessory drive belt renewal").
CS113010
2-45
Engine Mechanics
Cylinder Upper Head and Gasket Renewal

C00017003, C00017015, C00017013, C00017016,
C00017030
Removal
CAUTION:Cap connections to prevent dirt
ingress.
1 Remove timing pulley case, etc. (see "timing

pulleycase renewal").
2 Disconnect the following:
- camshaft position sensor
- Inlet temperature pressure sensor .
- fuel pressure sensor
- Fuel injector connector .
CS113056
3 Disconnect air-intake elbow and tube.
4 Remove the fuel injector (see "fuel injector

renewal").
CS113057
5 Disconnect fuel return pipe and fuel rail. (press

the adapter clamps inward to release).
6 Disconnect the high pressure fuel pump and fuel

rail.
CS113058
2-46
Engine Mechanics
7 Remove the fuel rail and screw (1 M8, 2 M12).
CAUTION:Do NOT remove end connectors from

fuel rail for they have been pre-tighten to specific
torque and passed stress test.
CS113059
8 Disconnect the breather pipe and remove oil/gas

separator. Discard the 'O' ring.
9 Remove the oil re-fill cap connection pipe and

discard the sealing washers.
CAUTION:It is critical to remove the cylinder

upper head. Remove the cylinder upper head as
illustrated below:
CS113060
10 Remove both bolts (M8) on the cylinder upper

head and fit two guide pinsC00017013.
11 Remove valve actuating mechanism on exhaust

side ( right bottom figure). C00017013
CAUTION:The valve actuating mechanism
installation process for installation is identical to C00017013
removal.
12 Remove remaining cylinder upper head bolts.
CS113061
2-47
Engine Mechanics
13 Carefully lift the cylinder upper head and

remove.
CAUTION:Remove and retain the orifice plug if

it is loose.
14 Plug the cylinder head air inlet to shield off 1
foreign objects.
2
3
3
CS113229
15 Remove the cylinder upper head gasket.
C00017013
CS113064
Installation
1 Lubricate valve gear with clean engine oil

beforeinstallation (avoid oil contamination of
timing belt and related gears, pulleys etc. ).
2 Check if the flywheel timing pin C00017003 is in
place (crankshaft is 90 after top dead center).
C00017003
C00016996
C00016997
CS113063
2-48
Engine Mechanics
3 Refit the guide pin C00017013 (if already

removed).
4 Check if top of cylinder head is clean, then install

new cylinder upper head gasket (dry). C00017013
5 refit the valve actuating mechanism back.
CAUTION:Apply Vaseline between valve

actuating mechanism and valve stem ends.
Install the valve actuating mechanism squarely
into place.
6 Clean cylinder upper head joint surface.
CS113064
7 Check alignment of both orifice plugs.
8 Lower the cylinder upper head slowly onto the

guide pin C00017013. Ensure valve actuating
mechanism is not hampered during installation.
9 Remove the guide pin C00017013.
10 Install and finger-tighten remaining fasten bolts.
CAUTION:Any upper head bolt with defect shall

be replaced. New bolts have been pre-lubricated.
Lubricate old bolts before installing. Fit two bolts
diagonally opposite guide pins. Finger-tight
bolts. CS113065
11 cylinder upper head bolts tightening sequence:
Progressively tighten upper head bolts 11 and 16 to

7 Nm.
12
torque all bolts in sequence illustrated25 Nm. 15 14 13
16
CAUTION:Absolute cleanliness must be ensured 5 4 3 2
when installing fuel system components. 1
6
7 8 9 10 11
CS113236
2-49
Engine Mechanics
12 install fuel rail, and smoothly install retain bolts.
13 Inspect high pressure pipe conical ends for

damage/distortion and replace as necessary.
14 Install the fuel injector (see "fuel injector

renewal").
CAUTION:Use new copper washers and 'O' rings

(lubricated) to install injectors
CS113066
15 install high pressure fuel pipe (fuel rail to

injection nozzle) and finger-tighten the nuts.
CS113067
16 install the high pressure fuel pipe between high

pressure fuel pump and fuel rail, finger-tighten
the nuts.
CS113068
2-50
Engine Mechanics
17 Tighten fuel injector pressure plate bolts. Torque

to: 32 Nm.
18 torque the fuel rail bolts to: 25 Nm.
32 Nm
CS113069
19 Tighten the high pressure fuel pipe.
- Torque the high pressure fuel pipe fuel rail end nuts to
28 Nm;
- Torque the high pressure fuel pipe fuel injector end

nuts to 25Nm.
CS113070
20 Fit fuel return pipe onto the fuel injector.
CAUTION:Pull the fuel return pipe when refitted

to fuel rail and fuel injector to check connection
strength. Replace connection clamps if pulled off.
CS113071
2-51
Engine Mechanics
21 Reconnect:
camshaft position sensor

3
inlet temperature pressure sensor ,
fuel pressure sensor

2
fuel injector connector . 4
CS113072
22 Refit oil/gas separator using new 'O' seal ring.

Connect breather pipe.
CS113060
23 Use the new O type ring to reinstall the tank filler

cap connecting tube. Tightening torque: metal
connecting tube is 80Nm; engineering plastic
connecting tube is 45-50Nm.
CS113073
2-52
Engine Mechanics
24 Install air-intake elbow.
25 Install timing pulley case, etc. (see "timing pulley

case/damper pad renewal").
CS113057
Camshaft Renewal
C00016999, C00017003,C00017015, C00017013,
C00017016, C00017033, C00017030.
Removal
CAUTION:Plug camshaft access hole tightly after
installation. However, it is not recommended for
this stage.
1 Remove cylinder upper head etc. (see "cylinder

upper head and gasket renewal").
2 Remove the position sensor together with
exhaust camshaft (M6 inner hex screw) and
discard the 'O' seal ring.
3 Unplug the camshaft. The area around the plug
hole must be cleaned to guard against dusts
before drilling a hole at its middle to pry out the
plug. The area around the plug hole must be
cleaned before a new plug is properly pressed
on using a sleeve of appropriate dimension.
4 Remove the camshaft timing pin (if installed).
CS113075
2-53
Engine Mechanics
5 Remove the camshaft oil seal in the sequence

belo
CAUTION:Do not damage the cylinder upper head
by drilling.
Use the punch C00017033 for the camshaft oil seal.
Drill two holes to fit the M4 x 38 mm.
Self-tapping thread is acceptable.
fit the screws and pull out the oil seal.
CS113076
6 Remove the camshaft retainer ring.
7 Pull out the camshaft with care.
CAUTION:The surface of cylinder upper head

bearing seat must not be damaged.
CS113077
8 Identify the camshaft.
CAUTION:If both camshafts are removed, they 2

can be identified by the timing pin locations as
illustrated. (The air-intake camshaft timing pin
is at the front).
CS113078
2-54
Engine Mechanics
Installation
1 Lubricate the camshaft.
CAUTION: If fitting new camshaft(s), lubricate

journals with engine oil.
2 Carefully fit camshaft(s) ensuring square entry to

avoid damaging the bearing.
3 Install the camshaft retainer ring. Before

installation, please examine to see whether the
retainer ring is damaged or not, and change it
when necessary.
4 Measure camshaft end-float(s). It should be:
0.10 - 0.55mm.
CS113079
5 Install the camshaft oil seal:
Apply light engine lubrication oil to the oil seal lip
Place the oil seal on the tool C00016999 sleeve,

touching the beading. C00016999
Drift oil seal and cap into place using toolC00016999.
6 Fit new camshaft plastic plugs into the cylinder

upper head rear access hole.
CS113054
2-55
Engine Mechanics
7 Turn the camshaft to install timing pin

C00016996 and C00016997.
C00016997
C00016996
CS113080
8 Use new 'O' seal ring if camshaft position sensor

has been removed.
9 Refit the upper head to the cylinder head (see

"cylinder upper head renewal").
Cylinder Head and Gasket Renewal

C00017003, C00017004, C00017009, C00017015,
C00017013, C00017030.
Removal
1 Remove the cylinder upper head and upper head
gasket, etc. (see "cylinder upper head renewal").
2 Disconnect the glow plug connector and
coolant temperature sensor connector .
3 Remove the EGR cooler and fresh water pump
inlet pipe
4 Remove the coolant hose.

1
2
CS113081
2-56
Engine Mechanics
5 Remove the thermostat casing and 3 M8 screws

and discard the gasket.
CS113082
6 Remove the exhaust pipe heat shield.
CS113083
7 Remove the turbocharger oil pick-up pipe and

fuel return pipe. Discard the flange gasket.
8 Disconnect turbocharger inlet and exhaust pipe.
CS113084
2-57
Engine Mechanics
9 Remove exhaust pipe and 9 M10 screws.

Record the correct installation condition before
discarding the exhaust pipe gasket.
CS113085
10 Remove valve actuating mechanism:
hydraulic tappet 2
3
pinchcock
rocker arm
CAUTION:Valve actuating mechanisms shall be

numbered before being removed to provide ID for 1
re-installation. Put the tappet in upright position
to avoid oil drain, and preferably in a bath of
engine oil.
CS113086
11 Remove and discard cylinder head bolts (18 X

M10).
CAUTION:Allow the engine to cool down before

removing cylinder head bolts. Start from outer
sides to the middle.
12 Remove the cylinder head and put it on wood
blocks (avoid projected parts of valves and fuel
injectors).
CS113087
2-58
Engine Mechanics
13 Remove and discard cylinder head gasket, and

record down the number of holes on it for
identifying the thickness before discarding.
CS113088
14 Install cylinder liner retainer C00017004 to

prevent crankshaft from lifting the cylinder liner
during rotation and damage the seal.
C00017004
CS113089
Installation
CAUTION:Apply clean engine lubrication oil to
moving parts (avoid contaminating timing drive
belt and connecting pulleys).
1 Cylinder head gasket identification

If cylinder liner or piston are not replaced, use a cylinder
head gasket as thick as the one used before (according
to the number of holes). If not, choose among the
following after obtaining piston protrusion.
Piston Thickness Holes

protrusion
0.460-0.609 1.34 1
0.610-0.709 1.44 2
0.710-0.810 1.54 3 CS113088
2-59
Engine Mechanics
Take the steps below to obtain the protrusion:
Remove flywheel timing pin C00017003 temporarily.
Position tool C00017009 fitted with suitable dial

indicator vertically over axis of gudgeon pin and
approximately 5 mm from edge of piston 1.
Turn the crankshaft to locate the top dead centre. Set

the dial indicator to zero.
Maintain the position, allow the probe to touch top of

the block (not the cylinder liner), and the reading is the
piston protrusion.
CS113090
Repeat steps above to obtain protrusions of the other
three pistons.
Calculate the average protrusion and select

appropriate gasket according to steps below.
2 Turn the crankshaft 90 clockwise to refit flywheel

timing needle. C00017003.
3 Remove cylinder liner retainer C00017004.

90
4 Clean contact faces and install the new cylinder
head gasket (dry) just selected.
5 refit cylinder upper head (see "cylinder upper C00017003

head renewal").
CS113091
6 Fit cylinder head using new bolts. Tighten bolts
in 4 steps as below:
Step 1: tighten the bolt with a torque of 30 Nm in the order

of 3,2,1,10,9,8,7,6,5,4,11,12,13,14,15,16,17,18, and
tighten again to ensure all bolts are tightened to 30Nm. Exhaust side
11 12 13 14
Step 2: turn the bolts by 75 in the order of
Timming system side
1 9 3 7 5
Fly wheel output side
10,9,8,7,6,5,4,3,2,1, and turn the bolts on both sides by

50 in the order of 11,12,13,14,15,16,17,18.
Step 3: turn the bolts by 75 in the order of

10,9,8,7,6,5,4,3,2,1, and turn the bolts on both sides by 10 2 8 4 6
75 in the order of 11,12,13,14,15,16,17,18.
15 16 17 18
CAUTION:New cylinder head bolts must be used Air intake side
and pre-lubricated.
CS113241
7 Install cylinder upper head (see "cylinder upper

head renewal")
2-60
Engine Mechanics
8 Connect glow plug to water temperature

sensor .
1
2
CS113081
9 install exhaust manifold gasket.
CS113092
10 Install the exhaust pipe and torque nuts in steps

below:
Stage 1 Tighten in sequence illustrated to 36 Nm.
Stage 2 Re-tighten in same sequence to the same

torque 36 Nm.
7 3 2 6
9 5 1 4 8
CS113227
2-61
Engine Mechanics
11 Install turbocharger oil pick-up pipe and fuel

return pipe.
CS113230
12 Refit the thermostat casing using a new gasket.

Tighten bolts to 25Nm.
CS113082
13 Refit heat shield.
14 Refit the coolant pipeline.
15 Refit the EGR pipeline.
16 Fit timing pulley case, etc. (see "timing pulley

case/damper pad renewal").
CS113083
2-62
Engine Mechanics
Flywheel Ring Gear Renewal

Tools required: C00016994, C00017014.
Removal
1 Remove the clutch (see "clutch renewal" ).

2 Remove both diagonal bolts, then install guide
pin C00017014 to support the flywheel.
Warning: The flywheel is heavy object, ensure

sufficient support during its removal.
3 Remove 8 M10 flywheel bolts (discard) and the
flywheel.
C00017014
CS113093
Installation
1 Clean the junction surface between flywheel and

crankshaft. Check whether the locating pin is
installed correctly. Protruding height of locating
pin:7.6 0.5mm.
2 Install the flywheel bolts following the steps
below.
1
Stage 1 Using new bolts, progressively tighten all bolts 50Nm
8 3
in sequence illustrated to 50 Nm.
5
Stage 2 Slacken the bolt .
6
Stage 3 Re-torque the bolt to 25 Nm.
7
4
Stage 4 Continue screwing the bolt (angle turning 2
method) 25Nm 60
75
60(length of bolt 40 mm); 90
CS113094
75(length of bolt 40 mm 50 mm);
90(length of bolt 50 mm 60 mm);
Follow the process in step 1, repeat step 2, 3 and 4 to

torque all other bolts.
CAUTION:torque one bolt ONLY at a time
2-63
Engine Mechanics
3 Install the clutch and use tool C00016994 to

make the alignment. Torque the clutch bolts one
by one to: 36 Nm.
C00016994
CS113095
2-64
Engine Mechanics
Crankshaft Rear Oil Seal Renewal

C00017014, C00017037
Removal
1 Remove the clutch (see "clutch renewal").

2 Remove the flywheel and discard its bolts (see
"flywheel renewal").
3 Remove the crankshaft rear oil seal ring and

crankshaft rear ring shim . Discard crankshaft
3
rear oil seal ring and the 'O' seal ring of the 1
ring shim . Ensure the crankshaft thrust
washer is not affected unless replaced.
CS113096
4 Use tool C00017033to pry the oil seal out of the

bearing seat by steadily moving around
crankshaft rear parts.
CAUTION:Do not cause damage to crankshaft

thrust washer or bearing seat. C00017033
CAUTION:The hook of tool C00017033 has to be

slightly trimmed.
CS113097
Installation
CAUTION:
"New oil seal metal seat has been included in

the new oil seal. Do not remove the oil seal from
the seat.
"Do not remove the 'O' seal ring from the ring
shim.
"The seal lip has been lubricated.
2-65
Engine Mechanics
1 Clean oil seal installation part and the crankshaft

thrust washer, than apply engine lubrication oil to
the washer.
2 Install new 'O' seal ring onto the crankshaft rear
ring shim. To install crankshaft rear ring shim,
align the smaller dowel hole with the crankshaft
dowel (1). 1
CS113098
3 Fit the crankshaft rear oil seal to the guide pin,

ensure the oil seal retaining sleeve is fitted into
the corresponding hole on crankshaft rear ring
shim, and the rear oil seal alignment hole is fitted 1
with the dowel of crankshaft (1).
CS113099
4 Fit tool C00016995 to the guide pin, then use two

old flywheel bolts to press oil seal into the
crankshaft rear main bearing.
5 install flywheel (see "flywheel renewal"). Remove

guide pins. C00016995
6 Install the clutch (see "clutch renewal").
CS113100
2-66
Engine Mechanics
Crankshaft renewal
C00016996, C00016997, C00017002, C00017003,
C00017004,
C00017015, C00017013, C00017014, C00017016,
C00017030.
Optional tools: C00017011, VM1054, VM1059,

VM1060, VM1069, VM1073
Removal
1 Remove cylinder head, etc. (see "cylinder head

renewal").
2 Remove flywheel (see "flywheel casing
renewal").
3 Remove flywheel dust shield and 5 M10 screws.
4 Remove rear oil seal and crankshaft rear ring

shim.
CS113101
5 Pull the rear bearing seat out by the two bolts as

illustrated.
CS113102
2-67
Engine Mechanics
6 Remove oil pump and vacuum pump drive gear

and 4 M6 screws.
CS113056
7 Remove flywheel dust shield support and 4 M10

inner hex screws.
CS113103
8 Remove the oil pan and 21 M6 screws.
9 Discard the oil pan pad and clean joint surface.
CS113104
2-68
Engine Mechanics
10 Remove fuel pick-up pipe and 2 M8 screws.

Discard the 'O' ring.
CS113105
11 Remove the speed sensor and discard 'O' seal
CS113106
12 Remove piston cooling nozzle retain bolts (4 M6

inner hex screws), and pull out the injection
nozzle using tool VM1060. Discard the 'O' ring.
CAUTION:Take care when removing piston

cooling nozzle. Damaged nozzles could cause
severe harm to the engine.
CS113107
2-69
Engine Mechanics
13 Follow the steps below to remove the piston and

connection rod.
CAUTION:The piston cooling nozzle has to be

removed before the piston and connection rod.
-Clear the carbon deposits off piston tops.
- Mark each pair of connection rod and its cap

2 2
CAUTION:Mark with painting or other similar
ways instead of punching. Assign temporary
numbers (1 - 4) to provide identification for
installation.
CS113108
-Remove the connection rod bearing cap and push the

piston/ rod out.
CAUTION:The connection rod and its bearing cap

has "fracture split" joint surface. No object shall
be laid or dropped upon; lay the rod and cap on
their sides. Do not knock open the fracture
splitting joints.
-refit connection rod bearing caps correctly onto the
connection rod, torque the bolts to 10 Nm.
CAUTION:New connection rod bolts has to be

used when refitting the piston /rod. CS113109
-Leave all connection rod bearing bush unmoved

unless replacement is needed.
14 Properly store the oil dipstick tube and its stand.

Discard the 'O' ring.
CS113110
2-70
Engine Mechanics
15 Pull out crankshaft bearing seat lock pin using

tool VM1054.
CS113112
16 Remove the oil pressure regulating valve using

tool C00017017.
C00017017
CS113113
2-71
Engine Mechanics
17 Tool C00017003 could be used to protect

crankshaft front bearing.
C00017003
CS113114
18 Carefully slide the crankshaft backwards until

there is large space between its bearing seat and
crank arm.
CS113115
19 Crankshaft bearing seat:
-Make a mark on every crankshaft bearing seat

temporarily to ensure the location of the bearing seat and
the fitting surface remain unchanged.
CS113116
2-72
Engine Mechanics
-Check if both semi disks of each crankshaft bearing

seat have been marked. If not marked.
- Remove M6 inner hex screws of each crankshaft

bearing seats in turn.
20 Take the crankshaft out.
Warning: The crankshaft is heavy object.
CAUTION:Avoid damage to the crankshaft

journal. Remove the bearing from its seat,
CS113117
for installation:
CAUTION:Apply clean engine lubrication oil to
moving parts before installing (ensuring the oil
does not contaminate timing belt and timing
pulleys etc. near by).
CAUTION:Ensure cleanliness during assembling

to prevent dirt entering oil ways.
1 Lubricate crankshaft bearing seat installation

parts.
2 Assemble the crankshaft components as in the
following steps. Please refer to the appendix:
- Encircle crankshaft front journal with tool VM 1069 (if

provided) and apply engine lubrication oil along the shaf.
- Install the crankshaft into the block.
-Install the bearing bush inside the three intermediate

bearing seats. The upper bush is not same as the lower
bush, as it is with oil groove while the lower bush is CS113118
without oil groove.Please do not install them falsely.
- Install the bearing pedestal according to related marks
and correct orientations (the notches on the bearing
pedestal should direct uniformly toward the front of diesel
engine).
-Torque bearing seat bolts to 44 Nm.
CS113119
2-73
Engine Mechanics
-Align the dowel hole of the three bearing seats with

their corresponding holes on the block.
CAUTION:Push the crankshaft into position with

care to avoid disturbing alignment.
-Remove tool VM1069 (if used).
CS113120
- Install the locating pin correctly to fasten the middle

bearing seat. One end of the screw thread of the locating
pin should face toward the oil pan.
C00017017
CS113121
3 Rear end main bearing (increased requirements)
- Fit a new 'O' seal ring to the rear bearing seat.
CAUTION:In the installation of the rear end main

bearing, the junction surface of the rear end
bearing seat and the machine body must be
provided with the sealing agents such as Loctite
5699 (or other similar objects), as shown in the
figure. 1."O"-shaped ring 2.Silicone sealing
agent 1 2
CS113122
2-74
Engine Mechanics
-Align rear main bearing seats using two alignment

bolts and press into position.
CS113123
4 install flywheel dust shield and torque retaining

bolts to 25 Nm.
5 Install crankshaft rear oil seal (see "crankshaft

rear oil seal renewal").
6 Install flywheel (see "flywheel renewal").

25 Nm
CS113124
7 Install the locating pin for the crankshaft bearing

seat with one end of the screw thread facing
toward the oil pan. Install the oil deflector at its
original place and fix the dipstick tube support
and fuel sucking pipe (use the new O type
sealing ring).Tighten bolts to 32 Nm.
CS113125
2-75
Engine Mechanics
8 If oil pressure regulating valve has been

removed, fit new 'O' seal ring to its seat and
apply engine lubrication oil. Press the oil
pressure regulating valve into position (use tool
C00017018if available).
C00017018
CS113126
9 Fit new gasket in between the block and oil pan

meets to install the pan. Torque bolts to 15 Nm.
15 Nm
CS113127
10 Install the flywheel dust shield bracket under the

oil pan and torque the bolts to 45 Nm.
45 Nm
CS113128
2-76
Engine Mechanics
11 Install speed sensor
CS113129
Replacing the front main bearing

Removal
1 Remove crankshaft etc. (see "Replacing the

crankshaft").
2 Use the tool C00017021 to remove old bearing
C00017021
CS113130
Installation
1 Use tool item C00017021 to install the bearing

bush into the body crankshaft hole.After the
bearing bush is installed. it's height is way up to
the front-end surface of the body or exceeds the
front-end surface by 0.3 mm.
C00017021
CS113131
2-77
Engine Mechanics
2 Select corresponding bearing bush in

accordance block mark.When block is marked
"H","brown"bearing bush shall be selected.
CAUTION: Oil hole in bearing bush must be

aligned with the oil hole in the block.
CS113240
2-78
Engine Mechanics
Replacing the cylinder liner and cylinder

liner spacer
Removal
1 Remove the crankshaft etc. (see "Replacing the

crankshaft").
2 Remove the piston and connection rod (see
"Replacing the piston and connection rod")
3 Use the tool C00017011 to pull out the cylinder

liner etc.
C00017011
4 Remove and discard the green and the black O
type sealing rings. Remove carefully the
adjustable pad of cylinder jacket.
C00017011
CS113132
Installation
1 Confirm the desired thickness of cylinder liner

space
- Put the cylinder liner into the block (without spacer or
O ring). Apply pressure downwards and turn the cylinder

liner clockwise and anti-clockwise by 45 for several
times.
CS113133
2-79
Engine Mechanics
- Position dial gauge on the block as illustrated and

zero gauge.
CAUTION:all readings should be taken on high

pressure fuel pump side.
CS113134
- Move the gauge until the contact head is seated on
the cylinder liner and the readings of dial gauge indicate

the height difference between cylinder and the block.
CS113135
- Choose the spacer (5 choices), and adjust the cylinder
liner protrusion to the specified value range.
Cylinder liner protrusion: 0.01 to 0.05
CAUTION:only one spacer can be used.

-Fit the selected clean spacer on the cylinder liner.
-Fit new O rings as follows:
Install the black O type sealing ring at the two grooves on

top of the cylinder jacket (coolant sealing ring).
Install the green O type sealing ring at the groove in the

bottom of the cylinder jacket (lubricating oil sealing ring).
-Lubricate the lower part of the engine body where

cylinder jacket is installed (use a small amount of
Vaseline to lubricate and replace the O type sealing
ring instead of lubricating oil).
-Carefully fit the cylinder liner, ensuring the spacer is

installed correctly. Use retainer C00017004 to retain the
cylinder liner.
-Measure cylinder liner protrusion: (operate as before).

The protrusion shall be: 0.01 to 0.05.
2-80
Engine Mechanics
CAUTION:the engine can only be started 6 hours

after the cylinder liner has been installed. If the
engine is not refitted after the cylinder has been
fitted, the cylinder liner shall be compressed for
at least 12 hours.
2-81
Engine Mechanics
Replacing the piston and connection rod

Removal
1 Remove the piston and connecting rod

assemblies (see "Replacing the crankshaft").
Clean piston and connecting rod assemblies.
Inspect the piston for any scratch or wear etc.
Inspect if all piston rings can turn freely in their

grooves.
Inspect the piston pins for any wear.
Pay attention to the mark to ensure correct installation.
A The arrow on the piston head directs the front.
B The identification marks on the connection rod and

connection rod bearing cap are on the same side.
C The flange of connecting rod bearing cap is in the

same direction as indicated by the arrow on the top
surface of the piston.
2 Remove the snap springs on both ends of the

piston pin and remove the piston pin so as to
separate piston and connection rod.
A
2 2
C
CS113136
Installation
CAUTION:Four connecting rods are provided

together as per pack. When it comes to change
the connecting rod, we need to use the
replacement parts of the same weight. The weight
grouping marks are seen from the colors on the
rods.
2-82
Engine Mechanics
3 Clean the carbon deposits on the piston head,

piston skirt and ring groove if the old piston is to
be refitted. Ensure the oil hole in the oil ring
groove clean.
4 If the new piston / piston ring is to be installed, it

shall be installed in the middle and about 15 mm
away from the cylinder liner top, and then the
ring gap shall be measured as illustrated. For
correct ring gap, refer to "Technical Data".
5 Piston ring or cylinder liner must be replaced if

the ring gap exceeds the size range given.
CS113137
6 The marks on three rings (TOP) must face

up.These rings must be identified with color
codes,the first one with yellow,the second one
and oilring with green.Color code is located at
the side of ring.
CS113138
7 Refit the piston and connection rod as

illustratedif they have been detached.
CAUTION:If we need to reinstall a used piston, we

A
should clear away the carbon accumulated on the
head and skirt of piston and circular groove. If we
need to install an old piston ring, we must make
2 2
an orientation mark on it when it is removed from
B
the piston. If we reuse it, we should install it into
the circular groove on its original direction. The
opening position of the piston ring should be
staggered every 120 on the circumferential C
direction. CS113136
2-83
Engine Mechanics
Fit each piston and connecting rod assembly as follows:

Opening of second ring
CAUTION:make sure all pistons are refitted to the
original cylinder if not replaced.
120 120
-Position the piston ring gap position as illustrated, and
compress the piston ring with appropriate tool.
-Carefully fit piston with the arrow on piston top pointing

to front of engine.
Opening of first ring Opening of third ring
CAUTION:ensure no damage will be caused to Opening position of the piston ring
connection rod big end or crankshaft journals.
CS113241
- Fit appropriate connection bearing cap with
identification marks aligned.
- Fit new bolts and tighten as the following 3 steps.
CAUTION:new bolts are all pre-lubricated.

First step - 10
Second step - 30
Third step - 40
CAUTION:After finishing the third step, use the

torque wrench (set to 88 Nm) to check the
tightening torques of all bolts.
CAUTION:Piston cooling nozzle can only be fitted

after the piston and connection rod are fitted. Fit
the O rings on the piston cooling nozzle. Fit the
nozzle. (VM 1060 can be used if available) and

tighten to 11 Nm.
CAUTION:Take care when fitting piston cooling

nozzle. Damage to cooling nozzle could cause
serious engine damage.
CS113140
2-84
Engine Mechanics
Replacing the oil filter

Removal
1 Discharge the oil and clean the area surrounding

the filter seat.
2 Use the threads to fix the oil filter to the
modularized oil cooler, and remove the oil filter
by turning anti-clockwise using hand after
slackening it with tool C00017031.
CS113141
Installation
- Clean joint surface.
-Screw down the joint of oil cooler (re-screw) with a

tightening torque of 50Nm.
- Fill clean engine oil into the filter.
- Lubricate the seal ring.
- Install the filter and tighten with hand. Do not
over-tighten.
- Fill the oil.
Engine oil drainage
1 There is a oil pan bleed screw plug (M14x1.5)

under and in the front of the engine Put the oil
drum (capacity is 10 L or above) under the
appropriate position, and unscrew the bleed
screw plug (80 Nm) to drain the oil.
2 Scrap the used seal ring of the bleed screw plug.
3 After the oil is drained completely, fit a new

sealing washer for the bleed screw plug and
tighten to the specified torque (80 Nm).
CS113239
2-85
Engine Mechanics
Replacing the output shaft bearing bracket of

the transmission
Removal
1 Remove 4 retaining bolts and remove output shaft

bearing bracket of the transmission.
CS113142
Installation
1 Install output shaft bearing bracket of the
transmission
CAUTION:setting pin is provided.
2 Tighten 4 M10x30 bolts with a torque of: 52.5 2.5

Nm
2-86
Engine Mechanics
Replacing the engine rear suspension carrier

Removal
1 Slacken 4 bolts fixing engine rear suspension

carrier, and then remove engine rear suspension
carrier.
CS113143
Installation
1 Install engine rear suspension carrier.
2 Tighten 4 M10x35 bolts with a torque of:
60~75Nm.
Replacing engine assembly

Removal
1 Open engine hood and disconnect the battery
(see "Replacing the battery").
2 Remove anti-splash shield and disconnect the
pipe to power steering pump, and then use the
container to collect steering fluid.
3 Empty the coolant in the radiator and collect into the

container (see "Replacing the coolant").
4 Remove the cooling module from the vehicle (see

"Replacing the cooling module")
5 Disconnect the connection part of the transmission

cable.
CS113231
2-87
Engine Mechanics
6 Remove the exhaust pipe front assembly (see

"Replacing the exhaust pipe front assembly").
CS113212
7 Slacken the strap, and disconnect the

turbocharger tube connecting the air filter and
engine assembly.
CS113207
8 Disconnect all pipes and harness connecting

with the engine.
9 Remove the front 2 tires of the vehicle, and

disconnect the connection part from axle and
front brake assembly. (see "Replacing the tire",
"Replacing the axle")
CS113232
2-88
Engine Mechanics
10 Lift the vehicle to a certain height with a lifter and

disconnect the engine rear suspension.
CS113233
11 Lower the lifter to a certain height and use the

bracket to hold the engine assembly.
CS113234
12 Unbolt the nut on the engine front suspension

and transmission suspension carrier, applying
the engine weight completely on the bracket.
13 Lift up the vehicle with the lifter and allow the

engine assembly enough height to be moved out
from the engine compartment.
14 Remove the bolts connecting the engine and the

transmission to separate them.
CS113235
Installation
CAUTION:As a self-locking nut, Engine front

suspension nut shall be used only once at most
so as to provide strong fastening performance.
2-89
Engine Mechanics
Disassembly /reassembly of turbocharger

Removal
Note:1.Exhaust manifold 2. Turbocharger bend
3. Turbocharger branch 4. Turbocharger
1 After the thermal shroud is disassembled, the air

1
inlet piles, air exhaust pipes, oil inlet and outlet
pipes of the turbocharger and others shall be
disconnected, and it's necessary to separate the
turbocharger bend from the turbocharger
according to the following operations. 2
4
3
CS113304
2 Disassemble and scrap four turbocharger bend

fixing nuts.
CS113305
3 Disassemble the fixing nut on the turbocharger

frame (arrow in Figure 3), and disassemble the
nuts under the frame and disassemble the
frames in a rotary mode.
CS113306
2-90
Engine Mechanics
4 Disassemble and scrape four fixing nuts, and

disassemble the turbocharger to separate it from
the exhaust manifold.
CS113307
Scrap the gasket

Note: it's necessary to use correct self-lock nuts
to replace the previous one (Figure 5). The
correct nut is provided with two flat mouths
(arrow), and it's necessary to install it in a correct
mode, that is, the tail ends of the two flat mouths
shall be outwards.
A new gasket shall be installed.
The turbocharger is installed on the exhaust manifold, the

new self-lock nuts are used (see the above "notes" for
reference). CS113308
Tightening torque - 32 Nm.
The frame shall be reinstalled.
Tightening torque:
Upper bolt (to the bend) - 25Nm.
Lower bolt (to the machine body) - 45Nm.
The reinstallation shall be completed according to the

steps converse to the disassembly steps.
2-91
Engine Mechanics
Matters Needing Attention for Installing Flywheel on Maintenance

Component of Short Engine
1. Maintenance component status of short engine
The short engine timing has been well adjusted and
camshaft timing locked by cam timing pin. The flywheel
has not been installed yet. So, the flywheel timing cannot
be locked by flywheel timing pin.
2. Steps of flywheel installation after

unpacking maintenance component of short
engine:
1 Remove the bolt of crankshaft rear seal plate
and take off the plate (only used for
transportation of short engine).
2 Install two guide pins C00017014. Then, install
assembly part of flywheel ring gear.
3 Install flywheel bolts for pre-tightening (8 PCS).
C00017014
CS113093
4 Adjust flywheel timing. Then, install flywheel

timing pin C00017003. If the pin cannot be
inserted, it is necessary to clockwise or
anticlockwise rotate crankshaft slightly (within 5
crank angle).
5 Knock the round pin with tool to make it move
into assembly part of flywheel ring gear. The
protrusion height of pin is 7.25-7.35 mm.
Notethe spherical surface of flywheel round pin

is outward. C00017003
6 Tighten flywheel bolts as required. As for

replacement of flywheel ring gear, please refer to CS113222
Maintenance Manual.
Note the 2 plug screws and 2 washers attached

on engine for installing cam timing pin hole are
hung on cylinder head.
2-92
Engine Mechanics
Determination of timing failure

C00017003, C00017015.
1 Remove the flywheel, as well as the choke plug
and screw of the air intake/exhaust camshaft
locating pin.
2 Rotate the crankshaft absorber clockwise with
the tool C00017015.
C00017015
CS113317
C00017015
CS113318
2-93
Engine Mechanics
3 During rotating, position with the flywheel timing

pin C00017003, air intake camshaft timing pin
C00016996, air exhaust camshaft timing pin
C00016997 in sequense.
C00017003
CS113222
C00016996
C00016997
CS113007
4 If it is impossible to position correctly after two
cyclse of roating clockwise, timing failure is
detemined.
2-94
Engine Electrics
Engine Electrics
Specification
Technical data
Torque
Application Torque value N.m

Battery tray bolt 20 1
Auxiliary battery carrier M5 nut 41
Auxiliary battery carrier M6 nut 51
Starter motor fitting screw 23 2
Starter motor heat shield to engine rear suspension carrier 18 2
bolts
Battery harness to generator positive terminal nut 12.5 2.5

Battery harness to right front longitudinal beam inner plate 12 2.5
M8 cap nut
Battery harness to engine bolt 25 4

Battery harness to engine coil nut 5.5 0.5
Battery harness to engine positive terminal nut 12.5 2.5
Battery harness to battery positive terminal nut 6 1.5
Battery harness to battery negative terminal nut 6 1.5
3-1
Engine Electrics
Layout
Layout of starting & charging devices
1
2
1 Alternator 2 Starter motor
3-2
Engine Electrics
Fault diagnosis
Fault Possible cause Solution
Difficult or impossible to start engine Start circuit slacken or corrosion Clean and tighten start circuit
connections
Pre-heating mis-operation (when Follow correct procedure

applicable)
Air intake system hampered Check air intake system pipes or

blocks
Fuel tank too low Fuel refill
Starter motor and electrical system Consult the authorized maintenance

fault service station to check fault code
Starter motor mal-function Battery under charge

Charge or replace battery
Generator under charge or no charge Battery connection slacken or Clean / tighten battery connection
corrosion
Engine tape slippery Check / replace tape and tension

pulley
Fascia or indicators failure Check / replace fascia or indicator
Engine wiring loose or damaged Repair wires
Generator failure Replace generator
3-3
Engine Electrics
Repair instructions
Replacing the battery
Removal
1 Disconnect two battery terminals, negative
terminal first.
2 Unbolt the bolt fixing the battery cover.
3 Remove battery securing cover and also remove

2 screws fixing the battery cover.
4 Remove the battery.
CS843002
Installation
1 Put in and position the battery.
2 Position battery tray screw and battery cover.
3 Tighten auxiliary battery carrier M5 nut to: 4

1Nm, M6 nut to: 5 1Nm.
4 Connect the two battery pile wires, positive
terminal first.
CS843002
3-4
Engine Electrics
Replacing the battery carrier

Removal
1 Remove the battery (see "Replacing the
battery").
2 Remove 5 bolts fixing battery tray.
3 Remove battery tray assembly.
4 Remove nuts fixing the inlet pre-heating relay to

the battery tray carrier and then remove the inlet
pre-heating relay.
CS843003
5 Remove 2 bolts fixing battery tray carrier.
6 Remove battery tray carrier.
CS843004
Installation
1 Position battery tray carrier. Fit and tighten 2

bolts. Tighten to: 20 1Nm.
2 Fit inlet pre-heating relay. Fit and tighten nuts.
3 Position battery tray assembly. Fit and tighten

nuts fixing battery tray. Tighten to: 20 1Nm.
4 Fit the battery.
3-5
Engine Electrics
Replacing the starter motor

Removal
1 Disconnect earth terminal of the battery.
2 Remove 2 bolts from starter motor heat shield to
engine rear suspension carrier.
3 Remove starter motor heat shield.
4 Remove nuts and disconnect engine control

terminals and battery harness.
2 2
CS843005
5 Remove nuts and disconnect battery harness

from starter motor solenoid.
3
6 Remove 3 bolts fixing starter motor and then
remove the starter motor.
5
3 4
CS843006
Installation
1 Position starter motor, and fit and tighten bolts.

Tighten to: 23 2 Nm.
2 Fix the battery harness onto the positive terminal
of the starter motor, and then tighten the nut.
Tighten to: 12.5 2.5 Nm.
3 Fix the battery harness onto the control terminal
of the starter motor, and then tighten the nut.
Tighten to: 5.5 0.5 Nm.
4 Install starter motor heat shield and fix and
tighten the 2 bolts. Tighten to: 18 2Nm
5 Connect earth terminal of the battery.
3-6
Engine Electrics
Replacing the battery harness

Removal
1 Slacken the nuts and disconnect battery
negative wire and battery negative terminal.
CS863047
2 Open the fuse box cover and slacken the nuts,

and then disconnect battery positive wire and
battery positive terminal.
CS863048
3 Slacken the nuts fixing front harness with 10#

socket, and then remove the front harness from
Pre-fuse box.
CS863049
3-7
Engine Electrics
4 Disconnect the connector and slacken the nut

and clip, and then remove the battery harness
from the engine.
5 Slacken the clip fixing the harness to power

steering pump.
6 Disconnect the oil pressure switch connector.
7 Use a 10# socket to slacken the nuts from

battery harness to starter positive terminal, and
use a 13# socket to slacken the nuts from battery
harness to starter coil, and then remove the
harness from the starter.
CS863050
8 Slacken the nut of earth point bolt of the engine

and then remove the battery harness from the
engine.
9 Slacken the clip fixing the battery harness to the

harness carrier.
CS863051
10 Use a 13# socket to slacken the nut of earth

point bolt of the front longitudinal beam inner
plate, and then remove the battery harness from
earth point.
11 Slacken all clips fixing the battery harness onto

battery carrier and body.
CS863052
3-8
Engine Electrics
12 Disconnect: the connector from battery harness

to front harness.
13 Remove battery harness assembly.
CS863053
Installation
1 Installation is reverse of removal procedure, but

the following must be noted:
- Tighten the nut from battery harness to earth point bolt
of the front longitudinal beam inner plate to: 12 2.5 Nm;
- Tighten the nut from battery harness to earth point bolt

of the engine to: 25 4 Nm;
- Tighten the nut from battery harness to starter positive

terminal to: 12.5 2.5 Nm;
- Tighten the nut from battery harness to starter coil to:

5.5 0.5 Nm;
- Tighten the nut from battery positive wire to battery

positive terminal to: 6 1.5 Nm;
- Tighten the nut from battery negative wire to battery

negative terminal to: 6 1.5 Nm.
3-9
Engine Electrics
Replacing the Generator

Removal
1 Disconnect the battery ground strap.
2 Remove the drive belt(6PK).
3 Remove the wire harness and Connecting plug

From the generator.
CS113243
4 Unscrew air-conditioning compressor fixed to the

engine of the 4 bolts,Unscrew and remove the
compressor.
CS863053
CS113249
5 Unscrew the two installing generator

bolts(M8X110)and nuts(M8).
6 Removal the generator.
CS863053
CS113245
3-10
Engine Electrics
Mount
1 The generator on the air conditioning generator
bracket on the corresponding position,And use
two bolts(M8X110) and two(M8) nut respectively
passes through the mounting hole to
fix,Tightening torque 33Nm.
Notethe bolt is threaded side toward the front of
the engine installation.
CS863053
CS113246
2 Remove the rear wiring harness plug sheath of

generator,The vehicle electrical wiring harness
connection and confirm the connection fasten.
3 Localization of air conditioner compressor,Install

fixed bolt,(see air conditioning compressor
replacement).
CS863053
CS113247
4 Accessory drive belt(6PK) restoration and

tensioned correctly.
CS863053
CS113248
3-11
Engine Electrics
3-12
Engine cooling system
Specification
Technical Data
Antifreeze specification 50/50 solution of Ethylene Glycol and water
Radiator component Heat-sinking capability 1: 51 kw

Intercooler component Heat-sinking capability 2: 13.3 kw
Pressure relief valve of expansion tank cap When the air flow is 10cm3/min:
Opening pressure of dropping valve is 120 -150 KPa;
Opening pressure of vacuum valve is: 7 -10 KPa
Opening temperature of thermostat 88C 2C

Pressure setting of pressure cap 1.1 Pa
NOTE: Heat-sinking capability 1: When the air flow is = 4615 kg/h, water flow = 4895 kg/h, T = below 60
Heat-sinking capability 2: When cold air side flow is =0.85kg/s, pressurized air side flow =0.126kg/s, T = below 125
Torque
Application Torque value (Newton metres)
Radiator to carriage bolt 20 3

Strap - radiator bottom hose 5 0.5
Water pump body bolt 25
Thermostat body bolt 25
4-1
Layout
Layout of condenser / cooling fan
1
2
17 3
15
16
8
9 7
7
18
4
10
5
6
11
12
13
14
CS110007
1 Engine cooling module assembly 11 Auxiliary fan (30A)
2 Air conditioning condenser assembly 12 Nut - engine cooling module installation
3 Intercooler assembly 13 Big washer A level
4 Radiator 14 Bolt - engine cooling module installation
5 Radiator bottom rubber strip 15 Radiator upper cross-member assembly
6 Radiator bottom seal 16 Screw - radiator upper cross-member assembly
7 Radiator top seal 17 Bolt -radiator to body
8 Radiator upper mounting bracket 18 Radiator upper cross-member mounting bracket

assembly
9 Radiator upper rubber strip
10 Main fan (30A)
4-2
4-3
Lay out of coolant pipe and metallic hardware
16 17
15
13 18
6
4
14 2 5
19 3 1
20
7
21 8
13
4
10
13
9
11
12
22
10
13
CS110008
1 Expansion tank 10 Strap

2 Expansion tank cap 11 Radiator to expansion tank hose bracket
3 Bolt 12 Bolt
4 Strap 13 Strap
5 Water tank to water pump hose 14 Radiator top hose
6 Pipe clip 15 Strap
7 Expansion tank water pump hose bracket 16 Engine to water tank hose
8 Bolt 17 Strap
9 Radiator to expansion tank hose 18 Pipe clip
4-4
19 Bolt 21 Pipe clip
20 Hose bracket 22 Radiator bottom hose
4-5
Layout of EGR cooler parts
9
10 7
8
11
9 14
8
9
7
13
12
2
6
1
9
4 5
CS110009
1 EGR valve 8 EGR flange gasket

2 EGR valve gasket 9 Hose clamp
3 Bolt 10 EGR cooler inlet pipe
4 EGR pipe V type clamp gasket 11 EGR cooler block
5 EGR pipe V type clamp 12 EGR cooler outlet pipe
6 EGR outlet pipe 13 Bolt
7 Bolt 14 EGR cooler
4-6
Fault diagnosis
Fault Possible cause Trouble shooting
Overheating engine Insufficient coolant Add coolant
Radiator pressure cap is faulty Replace
Overloaded engine Lower engine load and run
Radiator is too dusty Clean
Coolant air director is damaged or fall Repair or replace

out with the fan
Fan driving adhesive tape is damaged Repair or replace

or loose
Faulty water pump Replace
Air or gas entering into the cooling Sealant or seal component can be
system added to block partial leakage, replace
the cylinder block if the leakage is
serious
Water temperature sensor or Replace

temperature is damaged
Faulty thermostat Replace
Engine coolant temperature is too low Too much cold wind flowing through Replace fan clutch
radiator
Shutter of radiator is jammed at the Replace

biggest opening
Faulty temperature sensor Replace
Temperature gauge failure Replace
Damaged thermostat Replace
4-7
Repair instructions
Replacing the thermostat
Removal
1 Remove thermostat component by-pass hose.
CS113144
2 Remove 3 M8 bolts and thermostat component

and scrap the gasket.
CS113145
Installation

CAUTION: Do not forget the gasket; tightening
torque of the bolt is 25Nm.
4-8
Replacing the water pump:

C00017003, C00017015, C00017016, C00017030.
Removal
1 Remove front accessory drive belt (see

"Replacing the front accessory drive belt").
2 Remove and scrap timing drive belt (see
"Replacing the timing drive belt").
3 Remove timing pulley case (see "Replacing the

timing pulley case and damping pad)
4 Inspect gaskets, seals etc. for damage and

replace as necessary.
5 Remove accessory parts/pipes/hoses etc. as

necessary to install water pump.
This includes:
- Remove heat shield of exhaust pipe.
- Remove the EGR pipe on the back of exhaust pipe.
- Remove the top hose and by-pass hose from the

thermostat housing.
- Remove thermostat housing.
- Remove the air intake pipe from the turbocharger.
- Detach the oil pick-up pipe and oil return pipe on the
turbocharger.
- Remove the exhaust pipe.
- Detach the hose etc. to detach the coolant pipe and the
water pump.
6Remove the nut and then remove the water pump.
CS113146
4-9
Installation
1 Installation is reverse of removal procedure, but
the following must be noted:
- When installing new water pump, use the pipes and
hoses etc. of old water pump on the new one.
- Use new 'O' rings when installing.
- Tighten the nut to 25 Nm.
Replacing the EGR cooler

Removal
1 Remove EGR cooler inlet pipe.
CS113147
2 Remove EGR cooler outlet pipe.
CS113148
4-10
3 Remove EGR outlet pipe, slacken bolts (2 x M8),

and scrap gasket.
CS113149
4 Slacken the bolt connecting EGR cooler and

cylinder head (M10).
CS113150
5 Remove exhaust heat shield bolt (3 x M8),

remove EGR cooler from exhaust manifold,
remove the bolt (2 x M8), and scrap gasket.
CAUTION: After separating with the exhaust

manifold, remove the bolt connecting the cylinder
head, and then remove the EGR cooler.
CS113151
4-11
Installation
a torque of 11Nm and then the carrier bolts (2x M10)
1 Install inlet pipe, and tighten the bolt (4x M6)

witha torque of 11Nm and then the carrier bolts
(2x M10) with a torque of 33Nm.
CS113152
2 Pre-install EGR cooler.
CAUTION: For future installation, do not tighten

the bolt (M10) now.
CS113153
3 Install EGR coolant to exhaust manifold without

forgetting the flange gasket. The tightening
torque of the bolt (M8) is 33Nm.
CS113151
4-12
4 Install EGR outlet pipe to EGR valve. The torque

is 45Nm.
CS113154
5 Connect EGR outlet pipe to EGR cooler, without

forgetting the gasket. The torque is 33Nm.
CAUTION: Tighten the bolt (M10) connecting the

EGR cooler and the cylinder head with a torque of
45Nm after completing the procedures above.
Exhaust heat shield (3x M8), the torque is 25Nm.
CS113149
4-13
Replacing the coolant

Discharge
Warning: When releasing pressure in the cooling
system, cover the expansion tank with a thick
cloth.
1 Open engine hood.

2 Slowly turn the coolant expansion cap 2-3 turns
to release the pressure in the cooling system.
3 Use the lift to lift up the vehicle.
CS113155
4 Loosen radiator bottom hose from the bottom of

the vehicle to discharge the coolant into proper
container.
CS113228
Charge
1 Refit radiator bottom hose and lower the vehicle

after confirming there is no leakage.
2 Unbolt expansion tank cap and charge coolant to
the required level.
3 Tighten expansion tank cap.
CS113155
4-14
Replacing the expansion tank cap

High pressure is open: 120 -150 KPa;Low
pressure is open: 7 -10 KPa
Inspection
1 Visual inspect for any coolant leakage in the

engine and cooling system.
2 Inspect for any sign of splits and distortion, and
the safety of pipe connection.
CS113156
3 Unbolt expansion tank cap.
Warning: Do not open

the expansion tank cap when the cooling system
is overheating, otherwise you may be burned by
the vapor emitted.
4 Choose the correct pressure cap joint and
connect the expansion tank cap to the joint.
5 Connect the pressure hose to the joint.
6 Fix the pressure tester and connect the pressure

hose to the tester. CS113155
7 Pressurize the expansion tank cap slowly to the
specified pressure and inspect for any leaks.
Installation
4-15
Replacing the cooling module

Removal
1 Open engine hood and empty cooling system

(see "Replacing the coolant")
2 Remove bolts, and then remove the air
conditioning grille from the cross-beam mounting
bracket
CS113157
3 Remove the headlamp from the cross-beam

mounting bracket.
CS113158
4 Unbolt the bolt connecting vacuum regulator and

radiator upper cross-beam assembly to separate
them.
CS113159
4-16
5 Remove harness etc. installed at the radiator

cross-beam, and slacken the bolt connecting
cooling module and upper cross-beam
assembly, and remove radiator upper cross-
beam assembly and radiator upper cross-beam
mounting bracket assembly.
CS113160
6 Slacken the pipe and harness connecting engine

cooling module assembly.
CS113161
7 Clear the bottom rubber strip of lower part of

engine cooling module assembly off the front
crash cross-beam seat
CS113162
4-17
8 Remove the engine cooling module assembly

from the vehicle.
CS113163
Installation
1 Install the bottom rubber strip of lower part of

engine cooling module assembly on the front
crash cross-beam seat.
2 Pre-tighten 2 hex flanged bolts, and fix the
engine cooling module assembly onto the body
cross-beam assembly; Tighten 2 hex flanged bolts

with the torque of 20 3 N. m.
3 Install two A type worm drive hose strap

respectively on both ends of radiator top hose,
and connect both ends of radiator top hose
respectively to radiator top and engine as
illustrated, make sure they are connected into
place and then tightened with a 8# socket with
the torque of 5 0.5 N. m;
4 Install two A type worm drive hose strap
respectively on both ends of radiator bottom
hose, and connect both ends of radiator bottom
hose respectively to radiator bottom and engine
as illustrated, make sure they are connected into
place and move two A type worm drive hose strip CS113164
respectively to both ends of radiator top hose
and then tighten with the torque of 5 0.5 N. m;
5 Use the nipper pliers to install 2 steel band type
flexible straps respectively onto both ends of the
hose from radiator to water tank, and connect
both ends of the hose from radiator to water tank
respectively to radiator top and expansion tank
as illustrated, make sure they are connected into
place and then use the nipper pliers to fix the
6 2 steel band type flexible straps respectively to

both connection ends;
4-18
7 Use the nipper pliers to install 2 steel band type

flexible strips respectively onto both ends of the
hose from water tank to water pump, and
connect both ends of the hose from water tank to
water pump respectively to expansion tank and
engine as illustrated, make sure they are
connected into place and then use the nipper
pliers to fix the 2 steel band type flexible strips
respectively to both connection ends;
8 Use the nipper pliers to install the steel band

type flexible strips onto the expansion tank
connection end of the hose from engine to water
tank, and install the steel band type flexible strip CS113165
onto
9 the engine connection end of hose from engine

to water tank, and then connect both ends of
hose from engine to water tank respectively to
expansion tank and engine as illustrated, make
sure they are connected into place, and then use
the nipper pliers to fix steel band type flexible
strips respectively to both connection ends;
10 Install radiator upper cross-beam assembly and

radiator upper cross-beam mounting bracket
CS113166
4-19
Replacing the radiator

Removal
1 Open engine hood and empty coolant in the

cooling system (see "Replacing the coolant").
2 Remove radiator upper cross-beam assembly.
3 Remove engine cooling module (see "Replacing

the cooling module").
4 Slacken radiator connecting bolts.
5 Remove air conditioning condenser and

intercooler.
CS113167
Installation
Replacing the cooling fan

Removal
Warning: Disconnect negative terminal of the

battery first before removing to avoid personal
injury due to the start of fan motor.
1 Open engine hood and remove negative terminal

of the battery.
2 Remove radiator upper cross-beam assembly.
3 Remove engine cooling module (see "Replacing

the cooling module").
CS113168
4-20
4 Remove the bolts fixing the fan to the radiator,

and remove the main/auxiliary fan from the
radiator.
CAUTION: Do not remove the fan from fan motor,

this assembly has passed through dynamic
balance test and adjustment during manufacture.
Such balances cannot be achieved when refitting.
CS113169
Installation
1 Install main/auxiliary fan onto radiator with a

torque of 7 1 N. m.
2 Install radiator upper cross-beam assembly.
3 Connect negative terminal of the battery.
4-21
4-22
Engine Control
Engine Control
Specification
Technical Data
Part Connector Technical Data (static)
Air flow sensor 1#-12V;

2#-0V earth wire;
3#-5V inlet temperature signal;
4#-5V flow sensor signal
1 2 3 4
Inlet temperature pressure 1#-OV earth wire;

sensor 2#-1.0~4.8V pressure sensor signal;
3#-5V pressure sensor power;
4#-5V pressure sensor signal
1 2 3 4
Crankshaft position sensor 0.9K
1 2
Camshaft position sensor 1#-0V earth;

2#-0~4.5V position sensor signal;
3#-5V position sensor power;
1 2 3
5-1
Engine Control
Coolant temperature 1#- signal wire;2#- earth

sensor -40 /45.313K ;
-30 /26.114K ;
-20 /15.462K ;
1 2 -10 /9.397K ;
0 /5.896K ;
10 /3.792K ;
20 /2.500K ;
30 /1.707K ;
40 /1.175K ;
50 /0.834K ;
60 /0.596K ;
70 /0.435K ;
80 /0.323K ;
90 /0.243K ;
100 /0.186K
Accelerator pedal position 1#-5V power;
sensor 2#-5V power;
3#-0V earth;
4#-0.25~3.85 V; signal output;
1 2 3 4 5 6
5#-0V earth;
6#-0.377~1.92 V signal output
Fuel rail pressure sensor 1#- earth;

2#- sensor signal;
3#- power, resistance value: 24.32 K
1 2 3
High pressure fuel pump 3.5
1 2
Brake light switch 1#-12V;

2#-12V;
3#-0V;
4#-12V
2 1
4 3
5-2
Engine Control
Clutch pedal switch 1#- signal wire;

2#-0V
1 2
Fuel injector 0.5
1 2
FUEL HEATER 1
B A
Glow plug 1.2~1.5
Cooling fan 1.0~1.5 ;2#- not in use
C B A
Electronic throttle vacuum 15~20

regulator
1 2
5-3
Engine Control
EGR vacuum regulating 15~20

valve
1 2
Torque
Application Torque value

(N. m)
ECU and fuse box carrier assembly to carriage nut 81

ECU and fuse box bracket assembly to battery carrier bolt 22 3
Engine controller to ECU and fuse box carrier assembly bolt 10 1
5-4
Engine Control
Layout
Layout of engine fuel control system
13
12 5
4 2
3
6
11
7
1
8 9 10
1 Speed sensor connector 8 High pressure pump

2 Camshaft position sensor connector 9 Water temperature sensor connector
3 Fuel injector 10 Air intake temperature & pressure sensor
connector
4 Wiring harness carrier
11 Fuel rail pressure sensor connector
5 Wiring harness assembly
12 Starter motor, EGR and TVA signal circuit
6 ECU connector
interfaces
7 Glow plug connector
13 Preheating power
5-5
Engine Control
Layout of engine control system
1 1 1 1 2 3 4
11
5
10
12
9
8 7 6
1 3 5
2 4 R
1 Fuel injector 7 Water temperature sensor

2 Glow plug 8 Fuel rail parts
3 Speed sensor 9 Fascia
4 Camshaft position sensor 10 Fuel pump parts
5 Vacuum regulator 11 Pre-heating relay
6 EGR valve parts
5-6
Engine Control
Repair instructions
Replacing the engine harness
Removal
1 Remove the clip on the engine harness carrier
tie.
2 Remove M8 bolt on the flywheel side fixing
engine harness carrier.
CS113170
3 Remove M8 bolt on the timing pulley case side
fixing engine harness carrier.
CS113171
4 Disconnect connectors between engine harness
and sensor.
CAUTION: Pay attention to the bayonet and avoid

breaking off the joints when removing
connectors of speed sensor, fuel rail pressure
sensor, water temperature sensor, inlet
temperature pressure sensor and glow plug,
injection pump.
5 Remove engine harness.
CS113172
Installation
5-7
Engine Control
CAUTION: Harness shall be fixed if loosened

during installation, and wiring at the interface
shall be taped if exposed.
5-8
Engine Control
Replacing the engine water temperature

sensor (ECU)
Removal
1 Remove water temperature sensor connector
(see "Replace - remove harness").
2 Water temperature sensor is located on the
cylinder head side near the inlet. Use deep
socket (19 mm) wrench to remove the water
temperature sensor.
CS113173
Installation
1 Tighten with the torque of 18 Nm after applying
LOCTITE 222 sealant on the threads of new
water temperature sensor.
2 Connect connectors to harness.
Replacing the oil pressure alarm switch

Removal
1 Disconnect connectors of oil pressure alarm
switch.
2 Use a 24 mm wrench to remove oil pressure
alarm switch.
CS113174
Installation
1 Tighten with the torque of 12 Nm after applying
LOCTITE 222 sealant on the threads of oil
pressure alarm switch.
5-9
Engine Control
Replacing the speed sensor

See "Replacing the crankshaft".
CS113175
Replacing the camshaft position sensor

See "Replacing the camshaft position sensor" in
"Replacing the cylinder upper head/gasket".
CS113176
Replacing the fuel rail

See "Replacing the cylinder upper head/gasket".
CS113177
5-10
Engine Control
Replacing the engine control module

ECU
Removal
1 Open engine hood and disconnect positive and
negative terminals of the battery.
CS113178
2 Slacken related batteries and two nuts of battery

carrier, and then remove the battery.
3 Slacken interfaces of related connectors.
CS113179
4 Slacken 2 bolts and 2 nuts fixing ECU and fuse

box carrier assembly.
5 Slacken 4 bolts fixing engine ECU assembly to

ECU and fuse box carrier assembly.
CS113180
5-11
Engine Control
6 Remove engine ECU assembly.
CS113181
Installation
1 Tighten 4 hex flanged bolts installing engine
ECU assembly to appropriate positions of ECU
and fuse box carrier assembly with the torque of
10 1 N. m
CS113182
2 Install ECU and fuse box carrier assembly onto

bracket A- appropriate position of battery and
white body assembly.
3 Tighten 2 hex flanged bolts fixing ECU and fuse

box carrier assembly with the torque of 22 3
N.m.
4 Tighten 2 hex flanged nuts fixing ECU and fuse

box carrier assembly with the torque of 8
1N.m.
5 Tighten 2 hex flanged nuts fixing ECU and fuse

box carrier assembly with the torque of 8
1N.m. CS113180
5-12
Fuel system
Fuel system
Specification
Torque
Application Torque value

(Nm)
Fuel filter mount to body dash board nut 81

Fuel filter and fuel filter carrier bolt / nut 21.5 1
Pipe clip to fuel rail carrier seat nut 81
Fuel tank assembly to carriage stud bolt 75 5
Fuel tank assembly to carriage nut 75 5
Fuel tank clamp to carriage bolt / nut 20 1.5
Feed pipe cover to carriage screw 61
High pressure fuel pipe joint 28
High pressure fuel pump timing pulley bolts 88
High pressure pump retaining nuts 25
Fuel injector pressure plate bolts 33
High pressure fuel pump joint 25
Fuel rail retaining bolts 25
6-1
Fuel system
Layout
Layout of fuel supply system
24
21 25
4 8
3
6 20
5 10
22
3
11 32
2 14
12 26
13
1
23
9
7
28
8 31
32
27
30
29
15 31
16 19
17
18
CS110003
1 Fuel rail pipe 9 Bolt - fuel rail oil pick-up pipe
2 High pressure fuel pipe (first cylinder) 10 Fuel injector
3 High pressure fuel pipe (second and third 11 Fuel injector pressure plate bolts
cylinder)
12 Fuel injector pressure plate
4 High pressure fuel pipe (fourth cylinder)
13 Fuel injector pressure plate block
5 Bolt - fuel rail pipe
14 'O' ring - fuel injector
6 Stud bolt - fuel rail pipe
15 High pressure fuel pump
7 Fuel rail oil pick-up pipe
16 High pressure fuel pump timing pulley
8 Clamp
6-2
Fuel system
17 Nut - high pressure fuel pump timing pulley 25 Bolt - main fuel return pipe
18 Stud bolt - high pressure fuel pump 26 Block - main fuel return
19 Nut -high pressure fuel pump 27 Engine pick-up pipe
20 Main fuel return pipe assembly 28 Engine pick-up pipe joint
21 Fuel injector fuel return pipe 29 Engine pick-up pipe
22 Fuel return pipe adapter 30 Bolt - Engine pick-up pipe
23 Oil pump return pipe 31 Strap
24 Bolt - main fuel return pipe 32 Hose clamp
6-3
Fuel system
Layout of fuel system
2
20
21 3
19
22
6
7
8
9
4
5 10
13
18
4 11
17 14
13
16 12
15
7
8
9
CS110004
1 Fuel tank assembly 10 Feed pipe assembly

2 Level sensor solenoid 11 O ring on top of oil filler
3 Level sensor seal ring 12 Feed pipe gaiter
4 Oil filler connecting hose clamp 13 Self-tapping screws
5 Oil filler connecting hose 14 Feed pipe cover
6 Front fuel tank clamp 15 Rear fuel tank clamp
7 Nut - tank clamp to body cross-beam 16 Nut -- Fuel tank assembly to body
8 Gasket - fuel tank clamp to body 17 Gasket - fuel tank lower cone to body cross-
member
9 Paint-free bolt - fuel tank clamp to body
6-4
Fuel system
18 18 Fuel tank lower cone 21 Plastic clamps
19 Fuel tank upper cone 22 Fuel level sensor
20 Stud bolt - fuel tank assembly to body
6-5
Fuel system
Repair instructions
Fuel system oil pumping
Warning: Use suitable gloves to protect the
hands against contact with diesel fuel.
1 Attach a suitable tube (1) to the bleed valve (2),

and place the other end in a suitable container.
2 Open the bleed valve by one turn.
3 Press the stirrup pump on the filter (3)

approximately 50 times until a solid stream of 1
3
fuel appears for a few strokes.
4 Close bleed valve to remove pipe. 2
5 Press the stirrup pump 10 times again.
6 Check that engine will start, and there are no

fuelleaks.
CS113184
Replacing the fuel filter cartridge
1 Clean external surface of fuel filter.

CAUTION: Observe absolute cleanliness to
ensure dirt cannot enter fuel system. Take
precautions to avoid fuel dripping onto electrical
equipment below.
2 Disconnect the electrical connectors on filter
seat.
3 Place a suitable drain tray under fuel filter

cartridge. Unscrew filter by turning it anti-
clockwise.
CS113185
6-6
Fuel system
Installation
1 Unscrew oil and water separation sensor from
the filter seat and refit onto the replacement part.
2 Lubricate 'O' rings on filter with clean diesel fuel,
then screw fuel filter cartridge onto fuel heater
manually, and tighten to a torque of 20-25 Nm.
CAUTION:If the middle threaded joint used for

tightening fuel heater is slackened during the
removal of fuel filter cartridge, check the
tightening torque of middle threaded joint before
installing new filter.
3 Connect the electrical connector onto oil and CS113185
water separation sensor.
4 Pump oil for fuel filter (see "Fuel system oil

pumping").
5 Start engine and check for fuel leaks.
6-7
Fuel system
Replacing the fuel injector
Tools required: C00017007
Removal
1 Remove electrical connectors on the fuel
injector.
CS113186
2 Disconnect fuel return pipe
3 High pressure fuel pipe must be removed first if

No.2, 3 or 4 fuel injector needs to be removed.
Clean the high pressure fuel pipe (17 mm)
before removing it. Cap all connections to
prevent dirt ingress.
CS113187
4 Fuel injector pressure plate must be removed

first if No.1, 2 or 3 fuel injectors shall be
removed. Remove the pressure plate bolt (10
mm) first before removing the pressure plate.
CS113188
6-8
Fuel system
5 Remove the fuel injector.
- Use strut of centre screw fit tool C00017007, to

make sure it is engaged correctly onto the top of fuel C00017007
injector.
- Install tool bridge pieces, washers and nuts (30 mm).
- Screw the nut and pull out the fuel injector.
CS113189
6 Scrap the 'O' ring and copper washer.
2
3
CS113190
Inspection
Do not use wire brush to clean nozzle area. Use clean
cloth to wipe. Prior to refitting, injector bores in cylinder
head must be cleaned to ensure correct sealing of 'O'
ring and copper washer.
CAUTION: Prevent debris falling into combustion

chamber
Installation
Note:Each oil atomizer shall be provided with a
modification code, which shall be read in the ECU
after the oil atomizer is replaced to achieve the
modification of the oil quantity.
1 Install new 'O' ring and copper washer onto the

fuel injector.
2 Apply grease on the fuel injector and 'O' ring.
6-9
Fuel system
3 Install the fuel injector as illustrated on the right.
-Put the fuel injector into the fuel injector bore in cylinder
head and install the pressure plate, and then install the
bolt without resistance.
-Install new high pressure fuel pipe and tighten the nuts
of fuel pipe on both ends manually.
-Put the fuel injector into the fuel injector bore in cylinder
head and install the pressure plate, and then install the
bolt without resistance.
-Install new high pressure fuel pipe and tighten the nuts CS113191
of fuel pipe on both ends manually.
-Tighten the fuel injector pressure plate bolt to 33 Nm.
-Tighten high pressure fuel pipe joint to 25 Nm.
32 Nm
CS113192
4 Connect fuel return pipe. And then check its

tightness by pulling lightly. Replace the clamp if
the joint is pulled out.
5 Connect the electrical connector.
CS113193
6-10
Fuel system
Replacing the high pressure fuel pump

Tools required: VM 192, C00016997, C00017003,
C00017008, C00017012, C00017016, C00017030
Removal
1 Operate as per 1-2 in "Replacing the timing
pulley case / damping pad"
2 Disconnect with the fuel pump:
-Electrical harness connector
-Fuel return pipe

4
1
2
-Pick-up pipe
-Fuel rail oil pick-up pipe Cap all fuel connections to

prevent ingress of dirt etc.
3
3 Use the tool C00017012 to tighten high pressure
fuel pump timing pulley nut (21 mm), and then
slacken the nut 2 to 3 turns.
CS113201
4 Put the tool C00017008 into high pressure fuel

pump timing pulley, and then turn clockwise to fix
it into place. Tighten centre screw until the pulley
is separated with the shaft. C00017008
CS113195
5 Remove the tool C00017008.
CS113196
6-11
Fuel system
6 Slacken timing drive belt tension pulley fasten

nut; Remove and scrap the belt.
CAUTION:Crankshaft shall not be turned when

removing timing drive belt unless instructed H 2587
otherwise. Otherwise parts such as valve and

piston may be damaged.
7 When removing high pressure fuel pump timing
pulley, carefully withdraw the semi-circle key.
8 Remove 3 high pressure fuel pump retaining

nuts (13mm), and then remove the high pressure
fuel pump.
CS113197
Installation
1 If high pressure fuel pump are to be fitted, refit
the parts onto new pump (including semi-circle
key if not fitted yet).
2 Be careful of the semi-circle key when installing
high pressure fuel pump and tighten the nut to
25Nm.
CS113198
3 Do not forget the semi-circle key. Install high

pressure fuel pump timing pulley and tighten the
nut to 88 Nm.
VM 1055
88 Nm
CS113199
6-12
Fuel system
4 Do not forget the semi-circle key. Install high

pressure fuel pump timing pulley and tighten the
nut to 88 Nm.
CS113200
5 Install the following components onto high
pressure fuel pump:
33
-High pressure fuel pump ,
-Fuel pike-up pipe ,

11
-Fuel return pipe ,
22
-Electrical harness connector .
44
6 Install new parts such as timing drive belt etc. as
per 6-14 in the "Replacing the timing pulley case
/ damping pad"
CS113194
6-13
Fuel system
Replacing the fuel tank

Removal
Warning: Fuel evaporates is highly flammable
and if in a specified space it is also explosive and
poisonous. Prepare any of the fire extinguishers
such as bubble, carbon dioxide, gas or powder in
hand so as to handle the fuel.

2 Empty fuel system.
3 Lift the vehicle.
4 Remove feed pipe cover and feed pipe

assembly.
5 Use the bracket to support the fuel tank.
CS113202
6 Remove the front / rear clamp of the fuel tank.
7 Remove nuts fixing the fuel tank onto the body

and the lower cone, and lower the fuel tank by
using the bracket to reach the fuel tank top.
CS113203
6-14
Fuel system
8 Disconnect the connector of level sensor from

the fuel tank.
9 Remove the connection between harness and

pick-up pipe.
10 Remove stud bolts fixing the fuel tank to body

and the upper cone.
11 Remove the fuel tank by using the bracket.
CS113237
Installation
1 Install the upper cone onto upper part of the fuel
tank.
2 Install the stud bolts onto the body cross-beam
with the torque of 70 80 Nm.
3 Use the bracket to lift the fuel tank close to the
installation position, and connect the
corresponding connectors of level sensor on the
harness to the fuel tank.
4 Tighten the harness and pick-up pipe with plastic

clamps.
5 Align the upper cone hole to the stud bolt and

install to the lower part of the body.
6 Install the lower cone, big washer and nuts to the

lower part of the fuel tank and tighten nuts to the
specified torque (70-80Nm).
7 Tighten the feed pipe assembly and fuel tank

filler port with pipe clip and connect the breather
pipe of fuel tank and feed pipe assembly.
8 Connect earth terminal of the battery.
9 Top up the fuel tank.
CAUTION:Take care not to distort any pipe or

cable when filling fuel tank.
6-15
Fuel system
Replacing the feed pipe

Removal
Warning: Fuel evaporates is highly flammable
and if in a specified space it is also explosive and
poisonous. Prepare any of the fire extinguishers
such as bubble, carbon dioxide, gas or powder in
hand so as to handle the fuel.

2 Empty the fuel tank.
CAUTION:All dust, dirt and debris etc. around

parts must be cleaned before disconnecting any
parts of fuel system to prevent foreign material
entering into the fuel system.
3 Remove fuel tank lock barrel assembly.
4 Slacken nuts of feed pipe cover to body and

remove the feed pipe cover. DIESEL
CS113204
5 Slacken the link nut of feed pipe head to body.
CS113205
6-16
Fuel system
6 Slacken the connection between feed pipe

assembly and fuel tank filler port and breather
pipe.
7 Remove the feed pipe assembly from lower part

of right B pillar under the body.
CAUTION:Remove and scrap 'O' ring.
CS113202
Installation
6-17
Fuel system
6-18
Air intake & exhaust System
Specification
Torque
Application Torque value (Newton metres)
Nut - front exhaust pipe flange and engine exhaust outlet 24.7 2.5
elbow
Bolt - front exhaust pipe carrier and carrier seat installation 19 2

Exhaust tail pipe front end pipe clip 60 5
Strap - turbine to intercooler hose 51
Strap - intercooler to engine hose 51
A type worm drive hose strap - crankcase ventilation rubber 2-3
pipe
Bolt - breather pipe to body 51

Self-tapping screws / washers assembly - air flow sensor to 1-1.4
air filter assembly
Piston cooling nozzle bolts 11
Oil pump bolts 11
Oil pickup pipe bolts 32
Air intake pipe 11
Exhaust pipe nuts 36
Exhaust heat shield bolts 25
Turbocharger carrier bolts 32
Turbocharger oil pick-up joints 24
Turbocharger oil return pipe bolts 11
Turbocharger oil return pipe connecting nuts 33
Turbocharger to exhaust pipe nuts 45
7-1
Layout
Layout of exhaust system
3
4 5 6
7
8
8 9
10
1
10
2 10
10
CS110005
1 Exhaust silencer assembly 6 Nut
2 Exhaust tail pipe assembly 7 Front exhaust pipe carrier seat
3 Exhaust pipe shim 8 Bolt
4 Front exhaust pipe carrier assembly 9 Front exhaust pipe installation hook carrier
assembly
5 Exhaust pipe front assembly
10 Rubber hook
7-2
Layout of air intake system
6
2
1
3
4 3
7 5
7
8
23
24 9
7
25 26 27
10
11
12
22 13
23
14 18
21
15
19
20
16 17
CS110006
1 Turbine to intercooler hose 10 Air filter element

2 Rubber pipe 11 Clip
3 Clamp 12 Lower part of air filter
4 Connecting pipe 13 Air filter drain valve
5 Rubber pipe 14 Air filter damping pad
6 Bolt 15 Hose from air filter to breather pipe
7 Strap 16 Side inlet gaiters
8 Air filter assembly 17 Securing clip
9 Upper part of air filter 18 Bolt
7-3
19 Breather pipe. 24 Air filter to turbocharger tube
20 Bottom inlet gaiters 25 Self-tapping screws / washers assembly
21 Intercooler to engine hose 26 Air flow sensor
22 Strap 27 'O' ring
23 Strap
7-4
Repair instructions
Replacing the air filter

Removal
1 Open engine hood, and disconnect air flow

sensor on air filter assembly and front harness.
CS113206
2 Slacken the strap and remove the tube from air

filter to turbocharger.
3 Slacken hose from air filter assembly to air filter

to breather pipe.
CS113207
Installation
1 Install bottom inlet gaiters from lower part of

body wing to the dedicated position.
2 Install the side inlet gaiters to the inside of body
wing and fix with securing clip.
3 Install air filter damping pad to the appropriate

position of the body engine compartment firmly.
7-5
4 Fit the O ring on the connections between air

flow sensor and air filter assembly and use cross
screwdriver, cross groove pan head self-tapping
screw and plain washers assembly to fix the air
flow sensor to the air filter assembly, and tighten
to the specified torque (1-1.4 N. m).
CS113208
5 Install the breather pipe to the appropriate

position of body front engine compartment and
fix the breather pipe with hex flanged bolt, and
tighten to the specified torque (5 1N. m).
6 Install hose from air filter to breather pipe to the
breather pipe.
7 Connect air filter assembly with hose from air

filter to breather pipe, and install the air filter
assembly to the appropriate position of body
front engine compartment firmly.
8 Connect air flow sensor on air filter assembly

CS113206
with front harness corresponding interfaces of
pipes and remove the air filter assembly.
9 Slacken straps and install them to both ends of

the tube from air filter to turbocharger
respectively.
10 Connect the tube from air filter to turbocharger

respectively to air filter assembly and
turbocharger assembly.
11 Use strap to tighten the fit end of tube from air

filter to turbocharger and tighten to specified
torque of 2-3 N. m.
7-6
Replacing the air filter element

Removal
1 Remove 6 clips fixing the air filter cover.

2 Slacken the cover and put it on the side.
CS113209
3 Remove air filter element.
CS113210
Check
To prevent air filter from deformation, foreign materials in the air filter housing as well as those
observed in air flow meter shall be removed immediately in case of air filter element replacement
during after-sale maintenance.
Installation
1 Clean the inside of the air filter.

2 Fit the air filter element.
3 Fit the cover and fix 6 clips.
CS113209
7-7
Replacing the air flow sensor

Removal
1 Open engine hood and slacken the strap

connecting the flow sensor to the tube from air
filter to turbocharger.
CS113206
2 Open engine hood, and disconnect air flow
sensor on air filter assembly and front harness.
CS113211
3 Unscrew 2 self-tapping screws and plain
washers assembly fixing the flow sensor.
4 Remove flow sensor.
CAUTION:Replace used O rings which are

unrecyclable.
CS113208
Installation
1 Replace with new O rings and install flow sensor

and tighten the nuts to 1-1.4 Nm.
2 Use strap to connect the flow sensor with the
tube from air filter to turbocharger.
7-8
Replacing the exhaust pipe front assembly

Removal
1 Remove the bolt connecting the exhaust pipe

front and engine exhaust elbow so as to
separate them
2 Remove front exhaust pipe carrier assembly bolt
so as to separate the exhaust pipe front and
carrier assembly from the vehicle.
CS113212
3 Unbolt the bolt connecting silencer and exhaust

pipe front so as to disconnect them.
4 Slacken lock nut to remove exhaust pipe shim.
5 Clear the rear of exhaust pipe front assembly off

the rubber hook and remove the exhaust pipe
front assembly.
CS113213
Installation
1 Install the rear of exhaust pipe front assembly to

the rubber hook as illustrated firmly.
2 Install the exhaust shim, exhaust pipe front
assembly to the bolt at the appropriate position
on the engine assembly.
3 Use lock nut to fix exhaust pipe front assembly

and tighten to the specified torque.
CS113214
7-9
4 Use hex flanged bolt to install front exhaust

pipecarrier seat to fix exhaust pipe front
assembly and tighten to specified torque (19
2N. m).
CS113212
Replacing the exhaust silencer assembly

Removal
1 Separate the exhaust pipe tail end with the

silencer and clear the exhaust pipe off the rubber
hook, and then remove the exhaust tail pipe
CS113215
2 Slacken strap nut.
3 Clear the rear of the exhaust silencer assembly

respectively off the two rubber hooks and also
separate with the exhaust pipe front assembly.
CS113214
7-10
Installation
1 Install the rubber hooks to the corresponding

hooks of the second and third row passenger
seats cross-beam assembly firmly.
2 Insert the front end of the exhaust silencer
assembly into the exhaust pipe front assembly
about 50mm firmly.
3 Connect the back of the exhaust silencer

assembly respectively with two rubber hooks
firmly.
4 Tighten the strap nut to the specified torque (60

5Nm).
CS113216
Replacing the exhaust tail pipe assembly

Removal
1 Slacken strap nut and disconnect exhaust tail

pipe with silencer.
2 Clear the back of exhaust tail pipe respectively
off the rubber hook and also separate with the
exhaust silencer assembly.
CS113217
Installation
1 Install the rubber hooks to the corresponding

hooks of the five row passenger seats front
cross-beam assembly firmly.
2 Insert the front end of exhaust tail pipe into the
rear of exhaust silencer assembly about 50mm
firmly.
7-11
3 Install the hook of the rear of exhaust tail pipe to

the rubber hook firmly.
4 Tighten the strap nut on the exhaust tail pipe to

specified torque (60 5Nm).
CS113218
Replacing the accelerator pedal

Removal
1 Disconnect the connector from engine harness

to accelerator pedal.
2 Unscrew 4 nuts fixing accelerator pedal to body
front dash board.
CS113219
Installation
1 Tighten 4 nuts for installing accelerator pedal.

(8 1Nm)
2 Connect the connector from engine harness to
accelerator pedal.
7-12
Catalytic converter
The catalytic converter is provided with a "panel brick"

which plays a catalytic role and can obviously reduce the
pollutant exhausted from the diesel engine. N2 CO2
H 2O
The installation of a catalytic converter is of great
importance. The toxicity of the toxic gas exhausted from
the exhaust system of diesel engine must be converted
and reduced firstly, and then the gas can be exhausted to
the air. As shown in the above figure, the catalyst
converts the oxynitride (NOX), carbon monoxide (CO)
and hydrocarbon (HC) into the nitrogen (N2), carbon
dioxide (CO2) and water (H2O) which have smaller NO x
damage extents. If the catalytic converter breaks down, CO
the vehicle cannot pass any emission test, including the HC
MOT (annual inspection).
The catalytic converter is expensive and is unknown to most people, and the basic structure of the "panel brick" is
honeycomb ceramics, which is provided with the catalytic materials such as platinum, palladium and other valuable
metals on the surface. Compared with the silencer (provided with a baffle, it can reduce the exhaust noise), and easier to
be damaged due to abuse. Reasons for the catalytic converter to break down are numerous, ranging from improper
operation to incorrect air-fuel ratio.
Due to the special design and materials, the catalytic converter is easy to be damaged in improper transportation
and it's necessary to place it lightly to prevent it from colliding with other objects. The "panel brick" might be damaged or
be displaced if it drops out or hits with other objects.
The following problems might happen on the catalytic converter in the use process:
Problem Possible reason
A click sound appears in the use Improper transportation

process The "panel brick" cracks
The "panel brick" melts
Foreign bodies entry / turbocharger breaks down
Power consumption The "panel brick" is blocked
Noise The "panel brick" cracks
High emission Not converted
Various factors might cause the catalytic agent to break Note: the catalytic agent can only play an efficient
down in use, for example: role under high temperature, and a high
temperature can be obtained from the heat
Engine misfiring for long time
dissipation of the engine after the catalytic agent
Incorrect fuel-air ratio is installed near the engine.
Fuel additives
Improper fuel, such as biological diesel, gasoline etc.
Carbon deposition
Too high machine oil consumption
Inlet airflow is blocked
Excessive fuel supply
7-13

V80Service Manual 2 Engine Right VI FDJ Y Y 02

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Service Workbook

After Sales, SAIC Commercial Vehicle Co., Ltd

#2500, Jungong Road,

Shanghai City, China Postcode: 200438

The following information should be provided:

Authorized repair center

Tel. and fax of the authorized repair center

Model year and model

Description of your concern(s)

Necessary relevant information (e.g. sample or marked page)

Any applicable electronic information part identification number

SMCV will give relevant response in the following ways:

Submitting your concern to relevant service engineer

Consulting relevant service engineer

Satisfying your concern within 10 working days.

General Precautions ............................................................................................................. 1-1

Fuel system precautions: ...................................................................................................... 1-2

Engine Mechanics........................................................................................... 2-1

Layout ................................................................................................................................... 2-7

Fault diagnosis.................................................................................................................... 2-13

SPECIAL TOOLS................................................................................................................ 2-18

Repair instructions .............................................................................................................. 2-21

Engine Electrics .............................................................................................. 3-1

Layout .................................................................................................................................. 3-2

Fault diagnosis ..................................................................................................................... 3-3

Repair instructions ............................................................................................................... 3-4

Engine cooling system .................................................................................... 4-1

Layout .................................................................................................................................. 4-2

Fault diagnosis ..................................................................................................................... 4-7

Repair instructions ............................................................................................................... 4-8

Layout ................................................................................................................................... 5-5

Repair instructions ................................................................................................................ 5-7

Fuel system..................................................................................................... 6-1

Layout ................................................................................................................................... 6-2

Repair instructions ................................................................................................................ 6-6

Air intake & exhaust System ........................................................................... 7-1

Layout ................................................................................................................................... 7-2

Repair instructions ................................................................................................................ 7-5

Always wear gloves when handling oil or grease.

Fuel system precautions:

Bore 2.5 L: 92 mm 2.5 Lplus: 94 mm

Travel 2.5 L: 94 mm 2.5 Lplus: 100 mm

Displacement 2.5 L: 2499.5 cc 2.5Lplus: 2775.9 cc

Injection sequence (timing belt end as 1-3-4-2

Compression Ratio 17.5 : 1 ( 0.5)

Idle speed 850 rpm

Maximum speed 4500 rpm

Weight (fitted with accessories and 259.5 X 1+5 kg

Dimension (with accessories)

Emission requirements China

Valve sinkage incylinder head - inlet -0.15 0.15 mm

clearance between valve stem and

valve guide inradius 6.00 - 6.012 mm

valve guide fitted height

Fitted height 38.0 mm

Close at 64 after bottom dead center

Journal to bearing clearance 0.03-0.08 mm

Big end inradius53.994 53.994-54.014 mm

Piston protrusion 2.5 L 2.5 Lplus

0.46 - 0.609 mm 0.46 - 0.609 mm

0.61 - 0.709 mm 0.61 - 0.709 mm

0.71 - 0.81 mm 0.71 - 0.81 mm

Piston ring groove clearance