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Service Manual for

WP6 Engine
Service Manual for Engine

Outline Drawing of WP6 Non-road Three-stage Engineering Machine


Service Manual for Engine

Special Tips
● Before operating the diesel engine, the operator must carefully read the service manual for
diesel engine and operate the machine in strict line with the product service manual.
● Fuel injection pump and fuel injector are precision parts, which should not be disassembled by
the user.
● The supercharger rotor is high-speed rotating part. When the machine is running, any movable
object (such as hand, tool and cotton yarn) is prohibited to approach the turbocharger to
prevent personal injury or machine damage. The rotor assembly should not be disassembled.
● Several bolts like main bearing bolt and connecting rod bolt of the diesel engine have strict
torque and number of uses, which should not be arbitrarily loosened and disassembled by the
user. The connecting rod bolt is disposable bolt so it can’t be reused.
● Fill oil or fuel with grade meeting this Manual in the diesel engine. Filter the oil or fuel by a
special filter element. The fuel will be precipitated over 72 hours. Before driving, be sure to fill
fuel, coolant and oil as required.
● The diesel engine doesn’t work without air filter to prevent air entering the cylinder without
filtering.
● After cold starting of diesel engine, keep it idle running and gradually speed up. Never
suddenly speed up nor keep the idle speed for a long time (3-5 min); after running at high load,
never immediately stop the vehicle (except special condition), but stop the vehicle after
running at low speed for (5-10) min.
● Regularly check the coolant to prevent corrosive damage. Replace the coolant in time as per
the condition. It’s prohibited to use water and coolant of poor quality as the engine coolant.
● The repairing of electrical system components must be performed by professional technician of
Weichai.
● To prevent corrosion, the diesel engine should be sealed before delivery. The oil seal period of
diesel engine is one year. For over one year, check and take necessary supplementary measures.
● Please go to normal gas station to fill fuel of specified grade. Use three-stage special diesel oil
for three-stage diesel engine. Otherwise, Weichai will assume no responsibility for any
problem like excessive emission of diesel engine due to filling improper fuel.
● In case of fault, the user must contact service state specified by Weichai Power to do
disassembly and repairing. In the repairing process, be sure to use spare parts specified by
Weichai Power; otherwise, Weichai will assume no responsibility for diesel engine damage
caused by using the spare parts other than the ones specified by the Weichai Power.
Service Manual for Engine

Preface
This series of diesel engine are high-speed diesel engine independently developed by Weichai
Power Co., Ltd. and manufactured by Weichai (Weifang) Medium-duty Diesel Engine Co., Ltd.
This series of diesel engine are characterized by compact structure, reliable using, good technical
indicators like performance, economy and emission, quick starting, simple operation and convenient
maintenance and so on. Especially the advanced emission index can reach international advanced
emission standard.
This Manual mainly includes attentions for use, maintenance method, common check and
adjustment, common fault diagnosis and troubleshooting of WP6 diesel engine. This Manual is
systematic and comprehensive, simple and practical. It should be noted that judging the fault of
diesel engine is a very meticulous work and requires certain knowledge and experience. Before
finding out the basic cause, the diesel engine should not be disassembled generally; otherwise, the
fault may not be eliminated, but more serious fault will be caused due to improper assembly after
disassembly. Especially, for key parts like electronic control system, supercharger, etc. special
instruments and equipment should be used for check and maintenance. Therefore, the user without
experience and condition should not arbitrarily disassemble and adjust the diesel engine.
With the continuous increasing of diesel engine varieties, any modification should be done without
further notice. The user can go to http://www.weichai.com to obtain latest product information. The
after-sale service of this product is uniformly granted to Weichai Power Co., Ltd. Suggestions and
opinions for further improvement of product from the user are highly appreciated.
December 2015
Service Manual for Engine

Contents
Chapter I Instructions for Use of Diesel Engine ........................................................... 1
1.1 Outline drawing of diesel engine ................................................................... 1
1.2 Definition of diesel engine models................................................................. 2
1.3 Main technical performance parameters of diesel engine .............................. 3
1.4 Unpacking of diesel engine ............................................................................ 6
1.5 Lifting of diesel engine .................................................................................. 6
1.6 Assembly of diesel engine.............................................................................. 6
1.7 Preparation before starting the diesel engine ................................................. 7
1.8 Starting of diesel engine ................................................................................. 7
1.9 Running of diesel engine ................................................................................ 7
Chapter II Maintenance Guide for Diesel Engine ....................................................... 10
2.1 Fuel, lubricating oil, coolant and auxiliary material .................................... 10
2.1.1 Fuel ...................................................................................................... 10
2.1.2 Diesel engine lubricating oil ............................................................... 10
2.1.3 The antifreezing additive of engine cooling system should be
filled as per latest revision ............................................................................. 10
2.1.4 Auxiliary materials .............................................................................. 12
2.2 Daily maintenance ........................................................................................ 14
2.3 Regular maintenance .................................................................................... 18
2.4 Long-term storage maintenance ................................................................... 22
2.4.1 Cleaning............................................................................................... 22
2.4.2 Protection............................................................................................. 22
Chapter III Typical Faults and Troubleshooting of Diesel Engine ............................. 24
3.1 Diagnosis method ......................................................................................... 24
3.2 General fault causes and solutions of diesel engine ..................................... 26
3.2.1 The diesel engine is unable to start ..................................................... 26
3.2.2 The vehicle stops right after startup .................................................... 26
3.2.3 Underpower ......................................................................................... 26
3.2.4 Large fuel consumption ....................................................................... 28
3.2.5 Black smoke in the exhaust gas .......................................................... 29
3.2.6 White and blue smoke in the exhaust gas ........................................... 29
3.2.7 Too much oil at the air inlet and intake pipe of supercharger ............ 31
3.2.8 Unstable speed ...................................................................................... 31
Service Manual for Engine
3.2.9 Too low oil pressure ............................................................................ 31
3.2.10 Too high temperature of cooling water .............................................. 33
3.2.11 Fast abrasion of parts .......................................................................... 33
3.2.12 Big noise ............................................................................................. 34
3.2.13 The starter motor doesn’t work........................................................... 35
3.2.14 Starting motor is short of power ......................................................... 35
3.2.15 The generator fails to completely generate electricity ....................... 35
3.2.16 Insufficient charging of generator ...................................................... 37
3.2.17 Unstable charging current ................................................................... 37
3.2.18 Excessive charging of generator ......................................................... 37
3.2.19 There is abnormal noise from the engine ........................................... 37
Chapter IV Disassembly and Assembly of Engine ..................................................... 40
4.1 General ......................................................................................................... 40
4.1.1 Danger signs ........................................................................................ 40
4.1.2 Safety signs.......................................................................................... 41
4.1.3 Tools used............................................................................................ 43
4.1.4 Attentions for health protection ............................................................ 43
4.1.5 Environmental protection measures .................................................... 44
4.1.6 Attentions for disassembly and assembly of engine ........................... 44
4.2 Cylinder head assembly ............................................................................... 45
4.2.1 Disassembly and assembly of cylinder head assembly ....................... 45
4.2.2 Disassembly, check, maintenance and assembly of cylinder
head cover assembly ...................................................................................... 46
4.2.3 Disassembly, check, maintenance and assembly of cylinder head
assembly ........................................................................................................ 48
4.3 Body assembly ............................................................................................. 53
4.3.1 Disassembly, check, maintenance and assembly of body assembly... 53
4.3.2 Disassembly, check, maintenance and assembly of body component 56
4.3.3 Disassembly, check, maintenance and assembly of front wall cover . 57
4.3.4 Disassembly, check, maintenance and assembly of flywheel housing60
4.3.5 Disassembly, check, maintenance and assembly of oil pan ................ 62
4.3.6 Disassembly, check, maintenance and assembly of piston nozzle ..... 63
4.3.7 Disassembly, check, maintenance and assembly of thrust plate .......... 64
4.3.8 Disassembly, check, maintenance and assembly of front and
rear oil seal ................................................................................................... 65
Service Manual for Engine
4.4 Crank-connecting rod mechanism.......................................................... 67
4.4.1 Disassembly and assembly of crank-connecting rod mechanism ....... 67
4.4.2 Disassembly, check, maintenance and assembly of
piston-connecting rod assembly .................................................................... 68
4.4.3 Disassembly, check, maintenance and assembly of crankshaft ........... 71
4.4.4 Disassembly, check, maintenance and assembly of flywheel and
gear ring ......................................................................................................... 75
4.4.5 Disassembly, check, maintenance and assembly of torsional damper,
crankshaft pulley and hub .............................................................................. 76
4.4.6 Disassembly, check, maintenance and assembly of
crankshaft bearing bush ................................................................................. 77
4.5 Valve mechanism ......................................................................................... 80
4.5.1 Disassembly and assembly of valve mechanism .................................. 80
4.5.2 Disassembly, check, maintenance and assembly of
camshaft assembly ......................................................................................... 80
4.5.3 Disassembly, check, maintenance and assembly of
rocker arm and rockshaft ............................................................................... 83
4.5.4 Disassembly, check, maintenance and assembly of tappet and
push rod ......................................................................................................... 85
4.5.5 Disassembly, check, maintenance and assembly of valve ................... 86
4.6 Intake and exhaust system ............................................................................ 88
4.6.1 Disassembly and assembly of intake and exhaust system.................... 88
4.6.2 Disassembly, check, maintenance and assembly of intake pipe ......... 89
4.6.3 Disassembly, check, maintenance and assembly of exhaust pipe ...... 90
4.6.4 Disassembly, check, maintenance and assembly of
supercharger system ...................................................................................... 91
4.7 Fuel system ................................................................................................... 95
4.7.1 Disassembly and assembly of fuel system .......................................... 95
4.7.2 Disassembly, check, maintenance and assembly of
fuel injection pump ........................................................................................ 96
4.7.3 Disassembly, check, maintenance and assembly of
high pressure oil pipe ..................................................................................... 98
4.7.4 Disassembly, check, maintenance and assembly of fuel injector ..... 100
4.7.5 Disassembly, Check, Maintenance and Assembly of Fuel Filter ....... 101
4.7.6 Disassembly, check, maintenance and assembly of
Service Manual for Engine
low-pressure oil pipe ................................................................................... 103
4.8 Cooling system ........................................................................................... 103
4.8.1 Disassembly and assembly of cooling system .................................. 103
4.8.2 Disassembly, check, maintenance and assembly of fan.................... 105
4.8.3 Disassembly, check, maintenance and assembly of water pump ...... 106
4.8.4 Disassembly, check, maintenance and assembly of thermostat ......... 107
4.10 Starting system ........................................................................................... 108
4.10.1 Disassembly and assembly of starting system .................................. 108
4.11 Vehicle accessory system ........................................................................ 109
4.11.1 Disassembly and assembly of vehicle accessory system ................. 109
4.11.2 Disassembly, inspection, maintenance and assembly of generator .. 110
Appendix A DTC Table ............................................................................................ 120
Appendix B Fit Clearance of Main Parts of Diesel Engine ...................................... 191
Key components and points in the assembling of WP6 series engine
ASSEMBLING OF CYLINDER LINER
Technical requirements:
The cylinder liner should be higher than the upper surface of the cylinder block by 0.05~ 0.10mm.
ASSEMBLING OF NOZZLE
Technical requirements:
Tighten the hollow bolt of nozzle with a torque of 10~15N.m;
ASSEMBLING OF CYLINDER HEAD AND VALVE MECHANISM
Technical requirements
The clearance between tappet and tappet hole should be 0.025~0.089
ASSEMBLING OF CAMSHAFT
Technical requirements:
Tighten (strength is 10.9) the fastening bolt of camshaft thrust plate with a torque of 29-35N.m.
Check if the rotation of camshaft is blocked. Feel its axial clearance manually. The axial is
0.1-0.4mm.
ASSEMBLING OF CRANKSHAFT AND CRANKCASE
Technical requirements
Pre-tighten main bearing bolts (M18,14 in total) with the sleeve 17, from the middle to the
ends .Tightening torque with a torque wrench to 70N.m ,turn angle 90 °so that the torque to reach
180 ~ 230N.m
Check if the rotation of crankshaft is flexible and non-blocking. Feel the crankshaft radial and
axial clearance manually. The axial clearance is 0.102-0.305mm.
PRE-ASSEMBLING AND FINAL ASSEMBLING OF PISTON
Technical requirements:
Technical requirements of pre-assembling:
The oil ring opening and internal spring opening of the oil ring can not overlap. When assembling
the oil ring, the surface marked ”Top” on the two air rings (Trapezoidal ring is on the upper side,
tapered ring is on the lower side) should be upward;
The angle between the first air ring and the piston pin hole is 30°, the angel among three gas rings
is 120°;
Connecting rod big end opposites to the piston gap, the angel between piston retainer ring and
vertical direction of piston should be 45°)
Technical requirements of final assembling
Matching number of connecting rod body of connecting rod big end and connecting rod cover
should be consistent;
Connecting rod bolt (M14×1.5,only be used once), the first tightening torque is 30N·m,the
second turn angle is 60±5°,the last torque should be within the scope of 85~135N·m;
Piston assembling order is 3-4-1-6-2-5
ASSEMBLING OF THE FLYWHEEL AND FLYWHEEL HOUSING
Technical requirements
Technical requirements of assembling flywheel housing:
USE 19#socket wrench and 510flat glue。
The tightening order of flywheel housing bolts is shown as the number in right figure, tightening
torque is 110~140N·m,this bolts can be reused twice;
Technical requirements of assembling flywheel:
Tighten the flywheel bolts diagonally, the first tightening torque is 60+20N·m,and then turn
90°±5°respectively,the torques reach 230~280N·m at same time.
Specification of flywheel bolt: M14×1.5(9 in total) ,can be repeated twice.
ASSEMBLING OF GEAR CHAMBER
Technical requirements:
1)Smear 510 flat glue on mating face of gear chamber and engine block.
2)Adjust asymmetric clamp of the timing gear chamber ; after justification tighten the bolts,
torque is 55-60N.m
3)Intermediate gear bolts , tighten symmetrically to 65~70N·m.
4)Turn crankshaft to top dead center of No.1 and No.6 cylinder whenassembling,and align OT
line to install;
"0-0" on the camshaft timing gear and the crankshaft timing gear "0" corresponds;
The crankshaft gear 0 point and intermediate gear 0 alignment.
Inspection after assembling:
Check the backlash of the circular tooth after assembling timing gear and intermediate gear,
among which, the backlash between timing gear and intermediate gear is 0.015-0.33mm
ASSEMBLY OF LUBRICATING OIL PUMP
Technical requirements:
The tightening torque of two bolts(one is M10×55 ,one is M10×30)is 44~58N·m。
ASSEMBLING OF OIL PAN
The sealing gasket should be smooth and not distorted. Cross-symmetrically tighten the oil pan
bolts and the torque is 22-29N·m
ASSEMBLING OF CYLINDER HEAD AND VALVE MECHANISM
Clearance between exhaust valve stem and valve guide is 0.3~0.35mm, clearance between intake
valve stem and valve guide is 0.2-0.25mm
ASSEMBLING OF CYLINDER HEAD
The cylinder head gasket should only be used once and must be replaced in case of repair.
Tightening order of main bolts: The first tightening torque is 30+5Nm,the second turn
120°clockwise,and turn 90°clockwise in the third time, the torque should be in the range of
240-340Nm;
ASSEMBLE THE ROCKET ARM SEAT TO ADJUST VALVE CLEARANCE
The clearance between rocket arm and rocket arm shaft is 0.012~0.066mm;
Tightening torque of rocket arm seat is 98+10N·m;
Tightening torque of hexagon head bolt in cylinder head cover is (22~29)N·m
Adjustment of valve clearance: Turn the flywheel to make the No.1 cylinder in outbreak position
according to rotating directing of crankshaft, adjust intake valves of No.1, No.2 and No.4 cylinder
and exhaust valves of No.1, No.3 and No.5 cylinder successively. Intake valve clearance is
0.20-0.25mm. Exhaust valve clearance is 0.30-0.35mm. Adjust nut torque:(30~45)N·m,turn
crankshaft 360°according to rotating direction of crankshaft, and adjust the remaining rocket arm
clearance;
ASSEMBLING OF WATER OUTLET PIPE, INTAKE AND EXHAUST PIPES
Technical requirements:
Smear MoS2 on the sealing ring of exhaust pipe. The tightening torque is 45~50Nm. Bolts not in
this range should be replaced
ASSEMBLING OF SHOCK ABSORBER AND PULLEY
Technical requirements:
The torque of crankshaft connecting bolt and pulley is 60+5N·m;
Service Manual for Engine

Chapter I Instructions for Use of Diesel


Engine
1.1 Outline drawing of diesel engine

Fig. 1.1-1 View I of WP6 Diesel Engine

Fig. 1.1-2 View II of WP6 Diesel Engine

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Service Manual for Engine

Fig. 1.1-3 View III of WP6 Diesel Engine

Fig. 1.1-4 View IV of WP6 Diesel Engine


1.2 Definition of diesel engine models

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Service Manual for Engine

Variant code
Emission stage

Power code

Usage code

Product series code

1.3 Main technical performance parameters of diesel engine


Table 1.3-1 Main Performance Parameters of Three-stage Electronic Control Diesel Engine WP6
for Engineering Machine (Excavator)
Item Unit Model
WP6
Engine model
WP6G175E301 WP6G190E301
Four-stroke, water-cooling, in-line, direct injection, wet cylinder
Engine type —
sleeve, high-speed diesel engine
Air intake
— Supercharged and inter-cooling
way
Displacement L 6.75
Cylinder
m×m 105×130
bore×Stroke
Number of
— 6
cylinder
Number of
valve for each — 2
cylinder
Compression
— 18:1
ratio
Ignition order — 1-5-3-6-2-4
Fuel injection
— Electronic control pump
device
Rated power kW 129 140

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Service Manual for Engine
Rated speed r/min 2000 2000
Maximum
Nm 760 860
torque
Maximum
r/min 1300-1500
torque speed
Emission
— Non-road three-stage
level

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Service Manual for Engine

Fuel
consumption
g/(kW·h) ≤250
rate at rated
power
Minimum
fuel
consumption g/(kW·h) ≤210
rate at full
load
Oil
consumption g/(kW·h) ≤0.5
rate
Noise at 1m dB(A) ≤115 ≤116
B10 service
h 6000
life
Lubricating
oil flow in oil L 16 (subject to the scale line of oil dipstick)
pan

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Service Manual for Engine
1.4 Unpacking of diesel engine
After opening the packing case of diesel engine, the user should firstly count the diesel engine and
its accessories as per the factory packing list, check the diesel engine for damage and connector for
looseness. And then the user should do following operations:
(1) Wipe antirust coating, anticorrosive agent, etc. on the exposed part;
(2) Drain seal oil in the fuel filter and fuel system spare parts (it’s allowed to start the engine with
seal oil in the fuel system not discharged, but the engine operation under load is permitted only
when the seal oil in the fuel system is exhausted, the normal diesel oil is supplied).
Attention: the oil seal period of diesel engine is one year. For over one year, check and take
necessary supplementary measures.
(3) Rotate the flywheel and spray solvent in the air inlet till the seal oil in the cylinder is drained.
(4) Spray solvent in the supercharger intake and exhaust hole till the seal oil is drained.
(5) As per the agreement between the manufacturer and user, fill oil in the oil pan as per regulations;
for delivery of oil pan, fill up oil with running-in promoter. It’s suggested that the user should drain
the old oil and replace the new oil after running for 50h.
(6) As per the agreement between the manufacturer and user, as per the user’s requirement, fill up
coolant and check the coolant performance at unpacking. If the antifreezing ability meets -30 oC or-
35 oC, the PH is 7-8 (neutral) and total hardness is (5-15) d [9~15°f (hardness)], the coolant can be
used. If the requirement is not met, drain the coolant and fill the coolant with antifreezing additive.
1.5 Lifting of diesel engine
When lifting, keep the crankshaft centerline of engine level and it’s prohibited to incline or lift by
one side. The lifting and lowering should be slow (refer to Fig. 1-5).

Correct Wrong

Fig. 1-5 Lifting Drawing of Diesel Engine


1.6 Assembly of diesel engine

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Service Manual for Engine
Adopt flexible coupling and ensure that the crankshaft centerline of diesel engine is on the same
axis with the input axis line of drive device (gearbox, transmission box or generator) and ensure that
the crankshaft will not withstand the additional axial force caused by installation.
1.7 Preparation before starting the diesel engine
(1) Check the coolant level
If the engine is assembled on the machine, but the coolant is insufficient, open the filler cap to fill
the coolant. When opening the filler cap with pressure relief valve and exhaust button, if the engine
is hot, be sure to press the exhaust button to completely exhaust air and then open the cap. It’s
prohibited to fill much coolant when the engine is hot; otherwise, the spare parts may be damaged
due to high temperature change. When the starting engine is running (1,000 r/min), keep filling
coolant till the specified position and till the liquid level is stable, finally cover the filler cap.
(2) Check the fuel level
If the engine is assembled on the machine, turn on the power switch and check the fuel level of fuel
gauge or check the fuel tank.
(3) Check the engine oil level
When the oil level is between the upper and lower scale line of oil gauge, if necessary, fill oil from
the oil filler.
(4) Check whether the diesel engine accessories are reliably connected and eliminate abnormal
phenomenon. Check whether the starting system circuit is properly connected and whether the
battery is fully charged. Open the fuel tank valve, loosen the bleeder screw on the fuel coarse filter
and exhaust air in the fuel system by the hand pump of the fuel pump.
1.8 Starting of diesel engine
When the starting condition is available, rotate the electric key to start the diesel engine. If the
engine fails to start in (5-10)s, wait for 1min and repeat above starting process. If it’s unable to start
the engine for three consecutive times, stop starting the engine, find out the reason, eliminate the
fault and start the engine.
After the diesel engine starts, pay attention to the readings of all instruments; the oil pressure gauge
shall immediately displays the pressure. Never keep the cold engine running at high speed but keep
it idle running for a period of time. However, the idle running time should not be too long.
Auxiliary starting device should be used for starting the diesel engine at low temperature. Operate
the heating device by the relay so as to smoothly start it under -30℃.
1.9 Running of diesel engine

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Service Manual for Engine
(1) After the diesel engine starts, keep it idle running for 3min and then improve the speed to
(1,000-1,200) r/min. Add some load and enter the full-load operation when the water is higher than
60℃ and oil temperature is higher than 50℃. The load and speed should be gradually increased to
avoid sudden loading and unloading.
(2) In the breaking-in period of 50h, the diesel engine is not suitable for working under high load.
(3) Slow down for driving on the slope in time. It’s not suitable for working at big torque for a long
term. The load should not be too small and the speed should not be too low, which may cause oil
carry-over and other faults.
(4) For normal use of diesel engine, it’s permitted to keep continuous running at rated power and
rated speed. However, at 105% of rated speed and 110% of rated power, maximally 20min is
permitted. After unloading, the diesel engine can stop after idle running for (1-2) min.
(5) Pay attention to the following reference and check parts below:
Pressure of main oil way of lubricating oil: (380~580) kPa;
Oil temperature of main oil way (85~105)℃;
Coolant water temperature (72~93)℃;
Rear exhaust temperature of turbine≤550℃.
Check the exhaust color to judge the working quality and load of fuel injector. If the smoke color is
not good, stop the vehicle for inspection.
Attention: When the diesel engine is working, check the diesel engine for water, air and oil leakage;
if any, stop the vehicle and eliminate the fault.
(6) The following feature operator of diesel engine should know:
① The fuel consumption is low when the torque is maximum and the fuel consumption rises with
the speed rising.
② The torque reaches the best value in the medium speed (1,200-1,600) r/min of engine.
③ The engine power increases with the speed rising and reaches the rated power at rated speed.
Attention: To avoid damaging the diesel engine, when the diesel engine is working, the cable
connecting diesel engine voltage regulator and battery positive pole should not be dismantled.
Different from DC generator, the voltage of AC generator should not be tested by temporary
grounding.
(7) Attentions for running in cold weather:
① Fuel: select the diesel oil of different grades as per different outdoor temperature in winter.
② Lubricating oil: select lubricating oil of different viscosities as per the season.
③ Coolant: fill antifreezing additive in the cooling system and select different grades and
proportion as per different outdoor temperature.

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Service Manual for Engine
④ Starting: in winter, if necessary, adopt the auxiliary starter. After the diesel engine starts, keep
it running at high speed after the oil pressure and water temperature are normal.
⑤ Battery: before cold season, be sure to check the electrolyte level, viscosity and unit voltage, if
the diesel engine is not used for a long time and under low temperature, take down the battery
and keep it in a warm room.
⑥ Parking: for parking in cold weather, firstly disassemble the load and keep it running at idle
speed for (1-2) min. Stop the vehicle after water temperature and oil temperature are lowered.
pay attention that it’s not allowed to drain the coolant with antifreezing additive after stopping.
If there is no antifreezing additive in the coolant, be sure to open the water drain valve or water
block at the body, oil cooler cover, radiator, water inlet, etc. to empty the coolant and prevent
frost crack of engine.

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Service Manual for Engine

Chapter II Maintenance Guide for Diesel


Engine
2.1 Fuel, lubricating oil, coolant and auxiliary material
2.1.1 Fuel
Summer: 0# diesel oil (GB252)
Winter: Generally -10 diesel oil is used; -20 diesel oil is used when the using ambient temperature
of diesel engine is lower than -15℃; and -35 diesel oil is selected when the ambient temperature is
lower than -30℃.
The fuel must comply with C.6 in Annex C of national standard GB 17691-2005 (revised after June
2008).
2.1.2 Diesel engine lubricating oil
Lubricating oil capacity of diesel engine: 16L; the lubricating oil capacity is based on the mark of
oil dipstick (the oil capacity for different models may be slightly different).
Selection of lubricating oil: to ensure safe and reliable running of the diesel engine, please select the
lubricating oil of CH-4 or high quality grade.
(It’s recommended using Weichai special oil. For the first time, be sure to use special oil of Weichai
Power). It’s revised as the latest form.
Ambient Multigrade oil Ambient
temperature temperature

Fig. 2.1.2-1 Drawing for Lubricating Oil Grade Selection


Attention: It’s allowed to replace the low-grade oil with the high-grade oil. When changing
the oil each time, replace the oil filter element!
2.1.3 The antifreezing additive of engine cooling system should be filled as
per latest revision
The antifreezing additive is ethylene glycol. It’s allowed to use home-made long-term antifreezing
additive that has reliable quality. For specific using method, refer to relevant instructions. It’s
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Service Manual for Engine
recommended using following two types of long-term antifreezing additive:
JFL-336# Long-term antifreezing additive
FD-30# Long-term antifreezing additive

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Service Manual for Engine
It should be noted that the long-term antifreezing additive should be replaced regularly as per
relevant requirements.
Calculation of antifreezing additive (for reference)
Total volume of coolant: 40L (assembled in the engine with radiator)
Check temperature of current antifreezing solution: -20ºC
Minimum antifreezing temperature to be met: -30ºC
Calculation method: Find the total volume of coolant “40L” on the horizontal axis, draw a line
across the line and find the intersection 1 and 2 of oblique of above -20ºC and -30ºC (refer to Fig.
2.1.4-1).
Check: at -20ºC, the volume of antifreezing additive is 13.5L.
The difference between the volume of antifreezing additive at -30ºC and at - 20ºC is 4L.
For above difference of 4L, add 50% volume to make calculation, and the additional 50% is
necessary. Before filling the antifreezing additive, be sure to drain part of coolant, so that the
antifreezing additive in the coolant may be discharged.
The volume of antifreezing additive added is 4L+50%x4L=6L.

Lowest freezing temperature


Volume of anti-freezing additive

Volume of coolant (L)

Fig. 2.1.4-1 Calculation Charge of Anti-freezing Additive


2.1.4 Auxiliary materials
Table 2 -1 Auxiliary material
S/N Name Color Usage and Application

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Service Manual for Engine
Molykote Pulver Apply it on the smooth metal surface (such as
1 (Fine molybdenum Black cylinder sleeve external surface) to prevent
powder) occlusion.
Molykote Play the lubrication function before the
2 G_N_plus Dark grey lubricating oil pressure is built up
(oil mos 2) e.g.: apply it on the intake valve stem, etc.
Table 2.1.5-2 Reference Table of Gluing of Diesel Engine
Supplementary
Grade Main Usage List of Gluing Parts
Instruction
Flywheel housing bolt
Camshaft thrust plate bolt
Camshaft timing gear bolt
Intermediate idle pulley bolt
Front end cover bolt
Apply it on the Oil filter seat bolt
thread surface to Oil cooler bolt
Weichai
prevent looseness Oil cooler adjusting valve plug
special 242
and apply medium Bolt of oil pump oil return pipe As an option, use the
force. fixing device DriLoc204 thread glue
Air compressor shaft end for pre-gluing.
thread
Suction filter bolt
Bolt of sensor and harness
fixing device
Apply it on the
Weichai thread surface to
Cylinder head bolt
special 262 lock, seal and
prevent looseness.
Weichai Fasten it to prevent Bowl-shaped plug of oil filler
special 271 looseness. plug
Weichai Sealing between
Other bowl-shaped plug
special 277 core and hole
Weichai Seal the cylinder
Push rod pipe-cylinder head
special 270 head top surface

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Service Manual for Engine

Matching surface between


cylinder block and crankcase
Connecting plate between body
front and front end cover, rear
end and flywheel housing
Matching surface between oil
filter seat and crankcase
Weichai
Apply it on the Water pump rear cover-body
special 518
bright metal surface front end surface
(510 update
for sealing Flywheel housing connecting
product)
plate-flywheel housing
Matching surface between
cylinder block and oil cooler
cover
Matching surface between
cylinder block and oil filler
cover plate
2.2 Daily maintenance
 Check the coolant level and water temperature
Observe the coolant level through the glass sight hole. If the coolant is insufficient, open the water
filler cap to fill in coolant.
Attention: Open the filler cap, be sure to press the exhaust button to prevent personal injury
due to hot coolant when the engine is hot.

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Service Manual for Engine

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Service Manual for Engine
Fig. 2- 1 Exhaust Button

Expansion
tank

Fig. 2-4 Expansion Tank


Attention: Before the diesel engine starts, be sure to check the coolant level.
 Check the oil level
Check whether the oil level is in the scale scope of oil dipstick. When the oil level is lower than the
scale line of oil dipstick or higher than the upper scale of oil dipstick, it’s not allowed to start the
diesel engine.
After the diesel engine stops, check the oil level and wait for at least 5min, till the oil flows back to
the oil pan. Oil dipstick

Fig. 2-5 Schematic Diagram of Oil Dipstick


Attention: Before the diesel engine starts, check the oil level.
 Check the fuel level

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Service Manual for Engine
Check the fuel level indication in the instrument panel and fill fuel in time. The diesel oil shall meet
the regulation. Pay attention to the cleanliness of diesel oil. Before filling, it should be kept for
above 72 hours. The diesel oil should be filled in the oil through the built-in filter.

Fig. 2-6 Check the Fuel Page Indication on the Instrument Panel
Attention: Before the diesel engine starts, check the diesel oil level.
 Check three leakages
Check the diesel engine external surface for water, air and oil leakage.
 Check the fan
Check the fan blade for damage, the plastic fan for deformation, the iron fan rivet for looseness, the
blade for bending and connecting bolt for fastening and ensure that the fan is working reliably.
 Check the belt
The belt is automatically tensioned by the belt pulley. The user can check the belt tension by
pressing the belt by hands. Visually check the triangle belt for crack or bruise; if necessary, replace
it.
 Check whether the exhaust color is normal
The normal exhaust color is light grey. Find out the reason for color change and eliminate the fault.
 Check whether the sound is normal
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Service Manual for Engine
 Check whether the speed and vibration are normal
2.3 Regular maintenance
 Replace the oil
Put the diesel engine on the horizontal position. Put a container below the engine to collect oil.
Unscrew the drain plug at the bottom of oil pan, empty the oil and screw down the drain plug. Open
the filler cap and fill oil through the oil filler. The oil should be filtered by the filter. Observe the
scale of oil dipstick till the requirement is met and then assemble the filler cap.

Fig. 2-7 Oil Filler Fig. 2-8 Oil Drain Valve


 Replace the oil filter or filter element
Replace the oil filter as per following steps:
A. Disassemble the bolt connecting old oil cooler module and the body and take down the oil cooler
module;
B. Before assembling the new oil cooler module, apply the oil on the rubber mat;
C. Assemble the new oil cooler module on the body and fasten the bolt;
D. Start the diesel engine and check it for oil leakage.

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Service Manual for Engine

Fig. 2- 9 Oil Filter


 Check and adjust the intake and exhaust valve clearance
Check and adjust the intake and exhaust valve clearance as per following steps:
A. When the diesel engine is in cold state, turn (as per running direction of diesel engine) it to 1,6
cylinder top dead center. At this time, the cutting on the flywheel is aligned with the OT scale
on the flywheel housing. Refer to Fig. 2-10.

Flywheel
OT scale line
is aligned scale line
with
flywheel
scale line

Fig. 2-10 Flywheel Scale Line


B. Disassemble the valve rocker arm hood on the cylinder cover and judge the compression
stroke of 1# or 6# cylinder (clearance between cylinder intake and exhaust valve of
compression stroke and rocker arm).

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Service Manual for Engine

Fig. 2-11 Adjusting the Valve Clearance


C. Use the feeler gauge 1 to check the clearance between rocker arm and valve stem end as per
Table 3. The intake valve clearance of WP6 diesel engine is 0.2mm; the exhaust valve
clearance is 0.3mm. If the clearance is too big or small, loosen the adjusting nut 2 and adjust
the clearance through the adjusting screw 3. Maintain the position of adjusting screw 3. Refer
to Fig. 2-11 tightening lock nut 2. Use the feeler gauge to check other clearance again.

Adjusting
bolt

Fig. 2-12 Adjusting Screw


D. After checking 1# cylinder or 6# cylinder, rotate it for 360°and keep the 6# or 1# cylinder at
working stroke, check and adjust the remaining valve.
Table 2.3.3-2 Valve Adjustment Table
2# 3# 4# 5#
1# cylinder 6# cylinder
cylinder cylinder cylinder cylinder
Compression It’s unable
Intake and Intake Exhaust Intake Exhaust
stroke of 1# to make
exhaust valve valve valve valve valve
cylinder adjustment
Compression It’s unable to Intake and
Exhaust Intake Exhaust Intake
stroke of 6# make exhaust
valve valve valve valve
cylinder adjustment valve
 Replace the fuel filter element
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Service Manual for Engine
Replace the fuel filter element as per following steps:
A. Disassemble old fuel filter element; If the water vessel on the coarse filter can be reused, take
down the water vessel.
B. Lubricate the seal.
C. Screw down the filter by hands till the sealing is combined with the interface.

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Service Manual for Engine
D. Keep twisting the filter (for about 3/4 circles) till the filter is firmly assembled by hands.
E. Exhaust air till no bubble appears.
F. Perform leakage test.

Fuel filter

Fig. 2-13 Fuel Filter


 Check the air intake system
Check the intake hose for aging and crack and check whether the hoop is loosened. If necessary,
fasten or replace the part and ensure the airtightness of intake system.
2.4 Long-term storage maintenance
2.4.1 Cleaning
Before sealing, all rusty parts should be removed by proper method. All parts (lubricating oil way,
lubrication system, supercharger, etc.) processed by protective agent should be thoroughly cleaned.
2.4.2 Protection
(1) After warm-up, empty the oil, clean the oil filter and add antirust oil to the diesel engine oil tank
or oil pan.
(2) Empty the diesel oil in the fuel system, fill antirust mixed oil to protect the fuel way.
(3) If no cooling emulsion is filled in the diesel engine, drain the cooling water, add cooling water
emulsion and antirust oil to protect the cooling water chamber. Before sealing, use above emulsion
and start it for idle running for (15-25)min as per the starting procedure.

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Service Manual for Engine
(4) Disassemble the cover plate of intake pipe short surface, use the pressure nozzle to spray
antirust oil in the intake pipe, rotate the crankshaft by hands while injecting oil so as to open the air
valve to make the antirust oil flow to the combustion chamber. Once sealing is completed, never
rotate the crankshaft to prevent scratching the oil film on the cylinder wall.
(5) Drain oil liquid in the diesel engine, drain the antirust liquid from the base or by a pump, empty
the emulsion from the cooling system and open all liquid discharge switches.
(6) Disassemble the rocker arm hood and spray antirust oil to the valve spring and rocker arm.
(7) Apply the protective oil to all processed parts and easily rusting parts of diesel engine.
After above procedures, it can be stored.
To prevent moisture and impurity entering the diesel engine, in the transportation process
and storage period, cover the open parts like intake, exhaust, cooling pipe of diesel engine by a
cover and hood the engine by a plastic hood.

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Service Manual for Engine

Chapter III Typical Faults and


Troubleshooting of Diesel Engine
The WP6 series diesel engine is designed and manufactured under strict quality assurance system.
Each diesel engine has received specified test. Meanwhile, the diesel engine is a type of precision
machine and its function should be guaranteed permanently, which is closely related to normal
maintenance. Early failure of diesel engine is generally caused by following reasons:
◆ Operation against rules, improper management and use;
◆ Never perform maintenance as per regulations even replace the maintenance with repairing;
◆ The accessories are manufactured improperly, especially counterfeit and shoddy products
purchased will greatly shorten the service life of diesel engine;
◆ The fuel and lubricating oil grade are proper or disqualified.
3.1 Diagnosis method
Common diagnosis methods for diesel engine:
◆ Observation method: observe the fault characteristics like smoke exhausting of diesel engine
and judge the fault condition (Fig. 9-1);
◆ Auscultation method: judge the fault part and degree as per the abnormal noise of diesel engine
(Fig. 9-2).

Fig. 3-1 Observation Method Fig. 3-2 Auscultation Method


◆ Cylinder deactivation method: Stop one cylinder and judge whether the cylinder is faulty. The
method is generally to stop supply oil to the cylinder that is suspected of fault, compare the
engine state change before and after cylinder deactivation and further find out the faulty part or
shrink the scope.
◆ Comparison method: replace some assemblies or spare parts to confirm the fault.
Attention:
1. Judging the fault of diesel engine is a very meticulous work. Before finding out the basic
cause, the diesel engine should not be disassembled generally; otherwise, the fault may
not be eliminated, but more serious fault will be caused due to improper assembly after
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Service Manual for Engine
disassembly.
2. For key parts like high-pressure oil pump, supercharger, etc., check and maintenance
should be done by the personnel with certain experience by special instruments and
equipment. Therefore, the user without experience and condition should not arbitrarily
disassemble and adjust the diesel engine.

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Service Manual for Engine
3.2 General fault causes and solutions of diesel engine
3.2.1 The diesel engine is unable to start
Fault Cause Solution
1. Oil way blockage of fuel delivery
Check and discharge dirt and check the fuel cleanliness
pump oil filter screen or hose
2 Air in the fuel system Exhaust air, check the joint airtightness and repair it
Check the plunger and oil drain valve, repair or replace
3. Fuel injector fault
damaged parts
4. Fuel injector fault Check the atomization of fuel injector
5. air distribution or oil supply pipe
Check and adjust
damage or oil leakage
6. High-pressure oil pipe damage
Repair and replace
and oil leakage
7. Insufficient compression pressure Check the valve airtightness, cylinder gasket airtightness,
of cylinder piston ring abrasion, repair or replace it
8. Too low temperature Add auxiliary starting device
3.2.2 The vehicle stops right after startup
Disassemble the filter body, clear internal pollutant and water,
1. Fuel filter blockage
if necessary, replace the filter element
Check the oil pipe and joint air tightness, check whether the
2. Air in the fuel system
bleeder screw is tightened and exhaust remaining air
3. Fuel delivery pump doesn’t Check the fuel delivery pump piston and valve, clean and
work repair it
4. Poor fuel quality and too much
Clean the filter and replace the fuel
water content
5. Too low idle speed Adjust it again
3.2.3 Underpower
1. Air intake blockage (air filter Check the air filter, intake pipe, clean or replace the filter
blockage) element
Check the valve timing, check the exhaust pipe for blockage,
2. Too high exhaust back pressure
adjust and repair it
3. Insufficient pressure of
Check and eliminate the leakage at the pipe connection part
supercharging system

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Service Manual for Engine

4. Abnormal working of
Replace the assembly
supercharger
4.1 Fouling of compressor and
Clean or replace
turbine flow pass
4.2 Floating bearing failure Replace
4.3 Carbon deposit and oil sludge
at the back clearance of turbine Clean
and compressor
5. Inter-cooler damage and air
Replace or repair
leakage
Check the oil pipe and joint airtightness, the filter pollution
6. Fuel pipe oil leakage or
degree and fuel pipe, repair or clear the fouling and replace
blockage
the filter element
7. Poor fuel quality Clean the oil tank, filter parts and oil pipe and replace the fuel
8. Excessive abrasion of fuel
Repair or replace
injection pump or governor
9. Fuel injection pump smoke
Replace and repair
limiter diaphragm damage
10. Smoke limiter air pipe damage
Replace
and leakage
11. Poor atomization of injection Check the fuel injection pressure, carbon deposit in the
nozzle injection nozzle, adjust and repair it
12. Incorrect air distribution or oil
Check and adjust 之 Check and adjust it
supply timing
13. Too low of high speed of speed
Check the governor control characteristics and adjust it
governor
14. Too high oil level of oil pan Check the oil dipstick and drain excessive oil
For warm-up, check the compression pressure and replace the
15. Air leakage of cylinder gasket
damaged cylinder gasket
16. Piston ring abrasion and
fracture, too big clearance of Replace the worn parts or overhaul the engine
bearing bush
17. Cylinder sleeve or piston Replace the worn parts or overhaul the engine

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Service Manual for Engine
abrasion or scuffing
3.2.4 Large fuel consumption
1. Intake pipe blockage Check the air filter and intake pipe and clean it
2. Too high exhaust back pressure Check the exhaust pipe and brake valve and clean it
3. Poor fuel quality Replace the fuel as per regulations
4. Fuel pipe blockage Check and repair
5. Oil leakage of fuel pipe Check and repair
6. Poor atomization of fuel injector Check and adjust or Repair
7. Incorrect air distribution or oil Adjust the valve clearance and advance angle of fuel supply
supply timing as per regulations

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Service Manual for Engine

8. Air leakage of cylinder gasket Check the compression pressure


9. Too big clearance of bearing
bush and the engine needs Check and overhaul
repairing
10. Piston cylinder expansion Replace the cylinder sleeve, piston and piston ring
11. Insufficient pressure of Check and eliminate the leakage at the pipe and connection
supercharging system part
12. Abnormal working of
Check and replace
supercharger
13. Damage or air leakage of inter-
Replace or repair
cooler
3.2.5 Black smoke in the exhaust gas
1. Intake pipe blockage or high
Clean
exhaust back pressure
2. Poor fuel quality Wash and replace
3. Incorrect air distribution or oil
Make adjustment as per regulations
supply timing
4. Poor atomization of injection
Check, repair or replace
nozzle
5. Too much fuel in the fuel
Check and adjust (to be done professional factory)
injection pump
6. Insufficient pressure of Check and eliminate the leakage at the pipe and connection
supercharging system part
7. Abnormal working of
Check and replace the assembly
supercharger
8. Inter-cooler damage and air
Replace or repair
leakage
9. Wrong action point of smoke
Make adjustment again (to be done professional factory)
limiter
3.2.6 White and blue smoke in the exhaust gas
1. Poor fuel quality and fuel with
Replace the fuel
much water
2. Too low temperature of cooling Check the working temperature of thermometer, if necessary,

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Service Manual for Engine
water replace it
3. Incorrect air distribution or oil
Check and adjust
supply timing
4. Poor atomization of injection
Check and repair
nozzle
5. Low compression pressure,
Check the piston ring, cylinder sleeve, cylinder gasket, and
incomplete combustion or piston
repair it
cylinder expansion
6. Improper matching of piston
Keep matching
ring and cylinder sleeve
7. Piston ring opening not
Adjust and assemble A
staggered
8. Piston oil ring failure Replace
9. Too big fit clearance of piston
Repair and replace
and cylinder sleeve
10. Supercharger seal ring abrasion Check and replace

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Service Manual for Engine

11. Abrasion of supercharger


Check and replace
thrust bearing
12. Supercharger oil return pipe
Clean or repair
blockage
3.2.7 Too much oil at the air inlet and intake pipe of supercharger
1. Supercharger seal failure Repair or replace the supercharger
2. Oil-gas separator failure Replace
3. Too high level of oil pan and
Check and discharge appropriate oil as per regulations
excessive oil in it
3.2.8 Unstable speed
1. Poor fuel quality or fuel with
Replace the fuel
water or wax
2. Air in the fuel suction pipe Check the oil pipe and joint airtightness and exhaust air
3. Abnormal working of speed
governor hammer and governing Check and adjust (to be done by professional factory)
spring
4. Uneven oil supply Check and adjust (to be done by professional factory)
5. Unstable atomization of
Check and repair
injection nozzle
6. Spraying vibration of Check and clean the compressor passage, discharge the
supercharger fouling and carbon deposit in the exhaust passage.
7. Supercharger bearing damage Replace
3.2.9 Too low oil pressure
1. Too low oil level or oil shortage
Check the oil level and check it for oil leakage, and fill oil
of oil pan
2. Main oil way pressure adjusting
Check the valve, clean and repair it
valve fault
3. Blockage or fracture of filter, oil Check and clean the compressor passage, discharge the
pip, joint gasket, etc. fouling and carbon deposit in the exhaust passage.
4. The oil grade fails to meet the Replace the oil as per regulations and select the oil of proper
regulations grade
5. Oil pump oil inlet leakage Check the oil pipe and joint, repair or replace it
6. The cooling system temperature Check the cooling system work and correct it

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Service Manual for Engine
is too high and the oil temperature
is too high
7. The oil filter resistance is too
Replace a new filter element
big
8. Oil cooler blockage Check and clean

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Service Manual for Engine

9. Main oil way blockage Check and clean


10. Too big clearance of bearing bush or
Check and repair
bearing bush damage
11. Excessive abrasion of parts and Check the working hour of engine and perform
overhaul needed overhaul
3.2.10 Too high temperature of cooling water
1. Too low level of water tank Check it for water leakage, and fill water
2. Water tank blockage Check the water tank, clean or repair it
3. Water pump belt loosened Adjust the tension force as per regulations
4. Water pump gasket damage and water
Check, repair or replace
pump impeller abrasion
5. Thermostat fault Replace
Check the water pipe, joint, gasket, etc. and replace the
6. Water pipe damage and air in the pipe
damaged parts
7. Too low oil level or oil shortage of oil
Check the oil level and leakage, repair and fill oil
pan
3.2.11 Fast abrasion of parts
1. The air filter element is disqualified or
Check and replace qualified filter element
broken
Check the intake tube, gasket and connecting pipe
2. Short circuit of air intake system
sleeve, repair or replace it
3. Too low oil level or oil shortage of oil
Check the oil level and leakage, repair and fill oil
pan
4. Oil way blockage Clean the oil way
5. The oil grade fails to meet the
Replace the oil as per regulations
regulation
6. Fracture or abrasion of piston ring Replace the damaged parts
7. Abrasion or scuffing of cylinder sleeve Disassemble and check the piston and cylinder sleeve,
or piston repair or replace it
8. The oil filter element is not replaced in
Replace it as per requirements
time
9. Excessive abrasion of parts and
Check the mileage and confirm overhaul
overhaul needed

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Service Manual for Engine
10. The crankshaft is not concentric with
Check the mounting support and repair it
the building axis
11. The oil quality fails to meet the
Adopt the oil grade meeting the standard
requirement
3.2.12 Big noise
1. Poor fuel quality Replace the fuel
2. Too low cooling water temperature Check the thermometer, if necessary, replace it
3. Incorrect distribution or oil supply
Check, repair and adjust
timing

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Service Manual for Engine

4. Poor atomization of injection nozzle Check, repair and adjust it


5. Too high volume of fuel injection
Check and adjust (to be done by professional factory)
pump
Check it for damage, check the connecting bolt
6. Shock absorber abrasion
condition and replace the damaged parts
7. Valve air leakage or improper
Disassemble, check and adjust the valve
adjustment
8. Too big gear clearance or tooth
Check and replace the damaged parts
fracture
9. Cylinder sleeve or piston abrasion or
Check and repair or replace
scuffing
10. Push rod bending or fracture Replace
11. Piston ring fracture or abrasion Check or replace the damaged parts
3.2.13 The starter motor doesn’t work
1. Insufficient charging of battery Check, charge or replace the battery
2. Poor contact of connecting wire Clean the wire and screw down the binding post
3. Fuse blown Replace the fuse
Clean the surface of electric brush or replace the electric
4. Poor contact of electric brush
brush
5. Short circuit of starter motor Repair the motor or replace the assembly
3.2.14 Starting motor is short of power
1. Insufficient charging of battery Charge or replace the battery
2. Abrasion of bearing sleeve Replace the assembly
Clean the surface of electric brush or replace the electric
3. Poor contact of electric brush
brush
Clear the oil stain and use abrasive paper to polish or
4. The commutator is not clean or burnt
replace the assembly
5. Terminal desoldering Weld it again
6. Poor contact of switch Check the switch and repair it
Adjust the working torque of clutch or replace the
7. Slipping of clutch due to abrasion
assembly
3.2.15 The generator fails to completely generate electricity
1. Wire open circuit and short circuit and Check the generator and ammeter wiring and repair it

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Service Manual for Engine
joint loosened
2. Rotor and stator coil open circuit,
Repair or replace the assembly
short circuit or grounding
3. Rectifier tube damage Replace the assembly
4. Pole paper insulation damage and wire
Repair
disconnected

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Service Manual for Engine

5. Too low voltage of adjuster Repair


6. Adjustor contact burnt Repair or replace the assembly
3.2.16 Insufficient charging of generator
1. Wire open-circuit, short-circuit and
Repair
joint looseness
2. Rotor and stator coil open circuit,
Repair or replace the assembly
short circuit or grounding
3. Looseness of generator belt Check and adjust the belt tension
4. Generator rectifier tube damage and
Repair
battery in poor contact
5. Too low voltage of adjuster Adjust
6. The magnetic field coil or resistance
Repair or replace
wire of adjuster is disconnected
7. The battery electrolyte is too little or
Fill electrolyte or replace the battery
the battery is old
3.2.17 Unstable charging current
1. Stator or rotor coil to be subject to
Repair or replace
open circuit and short circuit
2. Poor contact of electric brush Repair
3. Looseness and poor contact of wiring
Repair
post
4. Damage of voltage adjuster Repair
5. Improper adjustment of voltage Check and adjust
3.2.18 Excessive charging of generator
1. Internal short circuit of battery Repair or replace
2. Too high voltage of adjuster Repair and adjust
3. Poor grounding of adjuster Repair
4. Adjuster contact malfunction,
pollution, voltage coil or resistance wire Repair or replace
disconnected
3.2.19 There is abnormal noise from the engine
1. The generator is improperly assembled Repair
2. Bearing damage Replace the bearing

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Service Manual for Engine
3. Rotary part touches the fixed part Repair or replace
4. Rectifier short circuit Replace

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Service Manual for Engine

5. Stator coil short circuit Repair or replace

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Service Manual for Engine

Chapter IV Disassembly and Assembly of


Engine
4.1 General
Disassembly and assembly of engine should be done in strict line with this Manual. Pay attention to
operation of danger signs and safety signs in this Manual to ensure personal safety and avoid
accident.
The disassembly steps of diesel engine are contrary to the assembly steps. For no special
instructions, the Service Manual only selects one for description.
4.1.1 Danger signs
The sign is worldly recognized warning sign. In this Manual,
the sign is used to emphasize the importance of following
information. Confirm that you know the consequence of
danger and the prevention method. Behavior violating the
warning information may cause property loss, personal injury
even personal casualty.
The common danger signs are usually used for general
warning. In this Manual, the warning information can be
classified into different types as per the dangerous
consequence levels (minor wound, serious injury and death).
The warning sign represents a potential hazard. If it’s not
Warning
avoided, it may cause serious injury and death or great
property loss.
The warning sign represents a potential hazard. If it’s not
Attention avoided, it may cause light injury or property loss. The
warning sign is also used for warning of dangerous operation.
Various attentions provided in the Manual describe how to correctly operate and safely use the
engine of our company.

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Service Manual for Engine
However, just reading this Manual can’t eliminate various potential hazards. Correctly
understanding the information in the attentions can help the correct use.
Warning information in this Manual doesn't cover usage in all possible conditions! If the using
procedure and method exceeds the recommended scope of the Manual, please confirm that the
operation may not bring any hazard to you, others and the equipment.
4.1.2 Safety signs
Symbol Definition

Wear hand protective device

Wear ear protective device

Wear eye protective device

Wear head protective device

Wear foot protective device

Wear protective mask

Wear protective clothing

No open fire

No smoking

Mobile phone prohibited

Danger: battery acid fluid

Danger: live cable, electric shock danger

Inflammables

41
Service Manual for Engine

Keep away from hanging heavy objects

Fire extinguisher nearby

In the using process of engine, there are many potential hazards without warning. Therefore, the
Manual is unable to give warning for potential hazards. If the using procedure is not in the
recommended scope, ensure that the procedure may not cause any material loss.

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Service Manual for Engine
4.1.3 Tools used
Symbol Definition

2.5mm hexagon wrench

5mm hexagon wrench

8mm sleeve

Slotted screwdriver

Special tool

10mm flat hexagon wrench

If the methods or tools used are not in the recommended scope of this Manual, the user must ensure
the personal safety and avoid causing life risk to the user or others. The user should also ensure that
the using and maintenance method may not cause damage risk or safety hazard.
4.1.4 Attentions for health protection
The following “attentions for health protection” aims to lower the pollution risk to engine
maintenance personnel, which should be abided by relevant personnel during disassembly and
check of engine.
a) Avoid contacting the used oil for a long time.
b) If possible, please wear the protective clothing and waterproof gloves.
c) Never put the oily stained rag in the pocket.
d) Avoid polluting the clothes (especially underwear) by oil.
e) Frequently clean working clothes, throw away clothes and shoes with oil that is unable to be
cleaned.
f) In case of cutting and injury, please immediately take emergency measures.
g) Before working, be sure to apply protective cream. When the skin contacts mineral oil, the oil
may be easily removed.
h) Wash hands by soap and hot water or sanitizer and fingernail brush to remove all dirt. If the
grease secreted by the skin is washed, the product with lanum can replace the grease secreted
by the skin naturally, which is good for moistening the skin.
i) Never clean the skin by gasoline, kerosene, fuel, thinner or solvent.
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Service Manual for Engine
j) If you feel uncomfortable, immediately go to the doctor.
k) If possible, before handling the part, wipe off oil on the part.
l) When there is risk to eyes, please wear safety goggles or protective mask. Be sure to provide
eye flushing liquid at the reachable place.
m) When repairing the engine, oil or other liquid should not be splashed on the ground. If the
hydrocarbon or other liquid is accidentally leaked, take necessary measures to hinder the area
so as to keep the environment clean and protect the personnel from injury.
n) For handling, storage and recovery of hydrocarbon, ethylene, ethylene glycol or petroleum
must comply with the safety and environment standard executed by the country.
4.1.5 Environmental protection measures
For disposal of exhaust oil and hydrocarbon, please comply with relevant environmental protection
laws and regulations. Please consult local officials for details.
4.1.6 Attentions for disassembly and assembly of engine
Most accidents relating to use, maintenance and repairing of engine may be caused by the safety
rules and basic attentions are not abided by. Therefore, you should know the dangers and take
corresponding preventive measures to avoid the accident. To operate, maintain and repair the
engine, the operator should receive corresponding training and possess applicable skills and apply
proper tools.
Violating relevant instructions of this Manual may cause serious accident, even endanger the life.
Weichai Power Co., Ltd. is unable to foresee all potential hazards. Meanwhile, rules and
descriptions specified in this Manual are not exhaustive.
Before maintenance or repairing, please put the signboard of “Do not use” or similar sign on the
starter switch.
Before using the barring rod, take necessary preventive measures:
a) Ensure that the repairing site and surrounding environment is suitable for safe operation.
b) Keep the surrounding area of repairing workshop or engine clean.
c) Before working, please pick off the ring, necklace and watch. Please wear proper working
clothes.
d) Before working, please verify the validity period of corresponding protective devices (glasses,
gloves, shoes, mask, working clothes, helmet, etc.).
e) Never use faulty or improper tools.
Attention: In the maintenance or repairing process, please shut down the engine.

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4.2 Cylinder head assembly
4.2.1 Disassembly and assembly of cylinder head assembly
4.2.1.1 Exploded drawing for cylinder head assembly

Cylinder head over


combination assembly

Cylinder head
combination
assembly

Fig. 4-1 Exploded Drawing of Cylinder Head Assembly

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Service Manual for Engine
4.2.1.2 Disassembly steps for cylinder head assembly
1) Disassemble the hindering objects like fan, drive belt, etc.;
2) Disassemble the crankshaft ventilation device assembly;
3) Disassemble the hanger plate and support bracket;
4) Disassemble the high-pressure oil pipe and fuel return pipe. Refer to disassembly instructions for
fuel system;
5) Disassemble the cylinder head cover assembly;
6) Disassemble the rock arm seat assembly;
7) Disassemble the cylinder head bolt;
8) Disassemble the fuel injector;
9) Disassemble the cylinder head assembly;
4.2.1.3 Assembly steps for cylinder head assembly
The assembly steps are contrary to the disassembly steps.
4.2.2 Disassembly, check, maintenance and assembly of cylinder head
cover assembly
4.2.2.1 Exploded drawing for cylinder head cover assembly

Hexagon bolt

Sealing washer

Cylinder head
cover

Cylinder head cover


gasket

Fig. 4-2 Exploded Drawing for Cylinder Head Cover Assembly


4.2.2.2 Disassembly steps for cylinder head cover assembly
1) Orderly loosen the cylinder head cover bolts;
2) Take out the cylinder head cover and cylinder head cover gasket upward.

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4.2.2.3 Check and maintenance of cylinder head cover assembly
1) Check the cylinder head cover for crack and other damages, if any, replace new cylinder head
cover;
2) If the cylinder head cover gasket is leaked, check the failure condition of cylinder head gasket
and replace new cylinder head cover gasket;
3) The cylinder head cover gasket can only be used once. Replace a new part in the repairing
process.
4.2.2.4 Assembly steps for cylinder head cover assembly
1) Before assembly, check the cylinder head cover gasket and cylinder head surface for
manufacturing or using defects and damages;
2) Use the oil can to spray clean oil at the connection of rocker arm and valve, rocker arm and
tappet and two points;
3) Put the cylinder head cover gasket;
4) Put the cylinder head cover;
5) Adjust the cylinder head cover gasket at the middle position of cylinder head cover, align two U-
grooves, keep the gasket exposed out from surrounding of cylinder head cover and keep the U-
groove, bolt and center of gasket bottom on a straight line;
6) Fasten the cylinder head cover bolt, when the torque is 10-15 N·m, pay attention to preventing
cylinder head cover gasket deviating from original position in the fastening process.

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4.2.3 Disassembly, check, maintenance and assembly of cylinder head
assembly
4.2.3.1 Exploded drawing for cylinder head assembly

Valve lock clamp


Hexagon bolt

Guide valve spring


Inner hexagon tapered plug
Rocker arm seat
component Outer valve spring

Inner valve spring

Lower valve spring seat

Bowl-shaped Valve stem seal sleeve


piston Valve guide

Double-
end stud
Intake valve seat Exhaust valve seat
Spring Intake
washer valve Exhaust valve
Hexagon nut Cylinder head
gasket

Fig. 4-3 Exploded Drawing for Cylinder Head Assembly


4.2.3.2 Disassembly steps for cylinder head assembly
1) Disassemble the rocker arm seat assembly;
2) Disassemble the cylinder head bolt;
3) Disassemble the cylinder head upward (before disassembly, ensure that the fuel injector is
disassembled and the fuel injector head should be protected from damage). During assembly, never
shake it to prevent residual coolant and lubricating oil flowing out. If the cylinder head gasket is
pasted on the cylinder head, take it down and put the cylinder block back;
4) After disassembling the cylinder head, put it on the paper board or rubber board to avoid
abrading the flame face and valve seal surface of cylinder head. To disassemble several cylinder
heads, mark the serial number on the cylinder head for convenient analysis and assembly;
5) Take down the cylinder head gasket. To disassemble several cylinder head gaskets, mark the
serial number on it.
4.2.3.3 Check and maintenance of cylinder head assembly
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1) Cylinder head

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Service Manual for Engine
Before disassembly the cylinder head, check the cylinder head for water, oil and air leakage and
other abnormal conditions, so as to confirm the faulty part and correctly analyze the problem.
Clean the cylinder head, mainly clean the combustion chamber surface, valve seat, intake and
exhaust valve, intake and exhaust pipe and get rid of surface carbon deposit and mucilage glue, and
check the surface condition.
① Appearance check
Carefully check the change changing and crack of cylinder, if any crack, perform dye penetration
inspection.
② Valve sinkage
The valve sinkage is the vertical distance from the valve bottom to the bottom plane of cylinder
head. The difference between valve sinkage measured value and valve sinkage required value can
reflects the abrasion degree of valve and valve seat. Measure the valve sinkage by a depth
micrometer as shown in the figure:

Fig. 4-4 Figure Name


For required value of valve sinkage, refer to Table 1. If the valve sinkage exceeds permissible scope
and it’s required to replace the cylinder head to ensure the reliability of diesel engine. If the valve
sinkage doesn’t exceed the permissible value, disassemble the valve to check the valve and valve
seat sealing surface. Check the valve and valve seat sealing surface for obvious abrasion and
abnormal damage.
Required value of valve sinkage (mm)
Intake valve 1.0-1.45
Exhaust valve 1.0-1.45

3 Clearance between valve stem and valve guide

The internal surface of valve guide is the contact surface of valve guide and valve. If the clearance
between valve guide and valve stem exceeds the permissible value due to abrasion, it may influence
the guide effect of valve guide, and lower the working reliability of diesel engine. Measure the inner
diameter of valve guide by an ID micrometer as shown in the figure. The OD of guide valve can be
measured by the OD micrometer. The permissible clearance between intake and exhaust valve stem
and corresponding valve guide should be (0.03~0.06) mm. If the permissible scope is exceeded,
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replace the cylinder head to ensure the working reliability of diesel engine.

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Fig. 4-5 Figure Name


④ Cylinder head gasket
If the cylinder head gasket has air, water and oil leakage, replace new parts. Check the cylinder
head gasket for visible damage and analyze the reason. No matter whether the cylinder head has
problem, replace new cylinder head gasket when disassembling the cylinder head.
4.2.3.4 Assembly steps for cylinder head assembly
1) Pre-assemble the rocker arm seat assembly;
2) Put the cylinder head gasket and select 1.4mm thick cylinder head gasket. The cylinder head
gasket is not reused;
3) Assemble the cylinder head assembly on the body;
4) Loosely assemble the cylinder head bolt;
5) Fasten the cylinder head bolt, tighten it at torque of 30N·m, rotate it for 120°±4°and then rotate
it for 120°±4°;
6) The tightening sequence (from 1# cylinder to 6# cylinder) of cylinder head is shown in the
figure below.

Fig. 4-6 Tightening Bolt Sequence

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4.3 Body assembly
4.3.1 Disassembly, check, maintenance and assembly of body assembly
4.3.1.1 Exploded drawing for body assembly

Fig. 4-7 Exploded Drawing for Body Assembly


1-Body; 2, 20-bowl-shaped plug; 3, 4, 5-camshaft liner; 6, 7, 8, 9-plug; 11-cylinder sleeve;
12, 13, 14- O-ring; 15-fixing plate; 16-welding pipe; 17, 31-spring washer;
18-hexagon socket cap screw; 19, 22, 23-round pin; 21-elastic cylindrical pin; 24-shaft;
25, 26-double-end stud; 27, 28, 29-cylinder head bolt; 30-lifting bolt; 32-2 type hexagon nut;
34-hexagon plug
4.3.1.2 Disassembly steps for body assembly
1) Disassemble the cylinder head bolt (Key point 1);

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2) Disassemble the welding bend (Key point 2);
3) Disassemble the vertical oil plug and thread sleeve;
4) Disassemble the cylinder sleeve (Key point 3);
5) Disassemble the camshaft sleeve (Key point 4).
4.3.1.3 Check and maintenance of body assembly
Key point 1: Assembly
Apply lubricating oil to the supporting surface and thread surface of cylinder head bolt and tighten
it as per following specifications:
(1) On the assembly line, use the four-axis tightener to tighten it and the tightening procedure is as
follows:
a. Pre-tighten it to 15N.m b. Tighten it to 60 N.m c. Turn it for 230°±4°.
(2) If it’s unable to use four-axis tightener to screw it down, use the torque wrench to tighten it:
a. Pre-tighten it by the torque of 30N·m; b. Twist the angle of 120°±4°; c. Twist the angle of
120°±4°again.
The tightening sequence of cylinder head bolt is shown in the figure below:

Fig. 4-8 Bolt Tightening Sequence


(3) The tightening sequence of cylinder head bolt is:
3# cylinder-4# cylinder-5# cylinder-2# cylinder-1# cylinder-6# cylinder;
(4) Control scope of tightening torque of cylinder head bolt:
M14-12.9: (230-300)N.m
M14-10.9: (190-285)N.m
Key point 2: Assembly
Assemble greased seal ring on the welding bend, insert it in corresponding hole of body, fix it on
the body by the fixing bolt, inner hexagon bolt and spring washer.
Key point 3:
Check: 1) Measure the protrusion of cylinder sleeve (0.05mm-0.10mm is qualified)

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Service Manual for Engine
Note: the protrusion of cylinder sleeve is the average value in X and Y direction; make
measurement when no seal ring is assembled on the body and cylinder sleeve; cylinder sleeve for
the same body should be grouped and marked consistently.
2) The matching surface and friction surface should be free of rust, scratch and bump. Before
assembly, clean it and apply clean lubricating oil or grease.
Assembly: Put the cylinder sleeve on the body, assemble the seal ring at body and cylinder sleeve,
put the cylinder sleeve vertically in the hole and use the nylon rod to evenly knock it to place.
Key point 4:
Disassembly: Disassemble the camshaft liner by a special tool. Pay attention to protecting other
liner in the disassembly process.
Check: Before liner assembly, be sure to remove and clean grease on the back of liner, back of
bushing and matching bottom hole. The liner, bushing and bottom hole should be free of burr,
overlapping, scrap iron, etc.
Assembly: Apply oil to the body hole, put the camshaft liner on the special tool and assemble it in
the body. At this time, align the oil way hole of camshaft liner with the body oil way hole.
4.3.1.4 Assembly steps for body assembly
The assembly steps are contrary to the disassembly steps for body assembly.

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4.3.2 Disassembly, check, maintenance and assembly of body component
4.3.2.1 Exploded drawing for body component

Body

Thrust bearing
cover

Main bearing
cover

Main bearing
bolt
Main bearing
bolt
Fig. 4-9 Exploded Drawing for Body Component Assembly
4.3.2.2 Disassembly steps for body component
① Disassemble the main bearing bolt (Key point 1)
② Disassemble the main bearing cover (Key point 2)
4.3.2.3 Check and maintenance of body assembly
Key point 1:
Check:
Check and clean the body. Including but not limited to: the assembly environment must be clean;
check the body processing surface transferred from the body line for bump damage, scratch and rust;
in the assembly process, the parts should be free of collision and scratch. Except for special
requirement, the part sharp corner and sharp edge must be blunt.
Assembly:
The 6# cylinder adopts 14 M14-10.9 main bearing bolts. As per the sequence shown in the figure
below, from the middle main bearing, it evenly stretches for two ends. Tighten it for two times:
apply the torque of 70 N·m for the first time and then twist the bolt for 90°±4°for the second time.

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Fig. 4-10 Sequence Drawing for Cylinder Head Bolt


Key point 2: Assembly
Assemble the thrust bearing cover at the back of body and assemble the non-thrust bearing cover at
other positions. During assembly, align two ends, if it’s reversely placed, the main bearing bolt is
unable to be screwed in.
4.3.2.4 Assembly steps for body assembly
The assembly steps are contrary to the disassembly steps of the body assembly.
4.3.3 Disassembly, check, maintenance and assembly of front wall cover
4.3.3.1 Exploded drawing for front wall cover assembly
Front wall
cover

Gasket

Cover
plate

Bolt

Respirator

Intermediate
gear pump Intermediate gear
Radial seal ring component
Baffle

Fig. 4-11 Exploded Drawing for Front Wall Cover Assembly


4.3.3.2 Disassembly steps for front wall cover
① Disassemble the respirator;

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Service Manual for Engine
② Disassemble the cover plate;
③ Disassemble the intermediate gear parts (Key point 1);
④ Disassemble the plug screw;
⑤ Disassemble the front wall cover (Key point 2);
⑥ Disassemble the radial seal ring (Key point 3).
4.3.3.3 Check and maintenance of front wall cover
Key point 1:
Check:
1) After fixing the gear, stir the gear by hands. The clearance is obvious and no blockage is felt in
the rotating process.
2) Check the clearance between intermediate gear and timing gear, which is generally
0.015~0.30mm.
Assembly:
1) Assemble the intermediate gear shaft and intermediate gear assembly, and drop proper oil on the
intermediate gear shaft;
2) Assemble the intermediate gear assembly and keep the intermediate hole and pin shaft concentric;
3) Assemble the baffle, fastening bolt and triangle flange cover plate. The tightening torque of
fastening bolt is 65-70N.m.
Key point 2:
Check: Check whether the front wall cover is clean, whether the matching surface has bump and
burr and whether the seal ring is damaged.
Assembly:
1) Knock the locating pin to corresponding position;
2) Glue the matching surface of front wall cover, the gluing should be even without breakage;
3) Align the pin hole, put the front wall cover and slightly knock the edge of front wall cover by a
nylon rod to keep the front wall cover and body matched;
4) Insert corresponding screw hole in the bolt, assemble corresponding washer and tighten it by a
pneumatic wrench and open end wrench.

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Key point 3:

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Assembly:
Before assembling the oil seal and seal ring, check it and ensure that there is no damage and dirt on
the assembly surface. When assembling tight oil seal and seal ring, apply clean oil on the shaft and
slowly press it by a special tool, and evenly apply force to the surrounding part of oil seal and seal
ring.
Disassembly:
After the oil seal is disassembled, replace a new oil seal.
4.3.3.4 Assembly steps for front wall cover
The assembly steps are contrary to the disassembly steps of front wall cover.
4.3.4 Disassembly, check, maintenance and assembly of flywheel housing
4.3.4.1 Exploded drawing for flywheel housing assembly

Flywheel
housing

Flywheel
housing bolt

Fig. 4-12 Exploded Drawing for Flywheel Housing Assembly


4.3.4.2 Disassembly steps for flywheel housing
① Disassemble the flywheel housing fastening bolt (Key point 1);
② Disassemble the flywheel housing observation window fastening bolt and observation hole
cover;
③ Disassemble the speed sensor;
④ Disassemble the flywheel housing (Key point 2).
4.3.4.3 Check and maintenance of flywheel housing
Key point 1: Assembly

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Service Manual for Engine
Check whether the flywheel is clean. Use the 240# fine oil stone to remove the burr of
corresponding matching surface of body. Clean it by alcohol and glue the matching surface of
flywheel and body. Use 12 M10-10.9 hexagon bolts, 6 M12-10.9 hexagon bolts, 17mm and 19mm
socket wrench.
Step 1: pre-assemble the bolt;
Step 2: respectively tighten the M10 bolt in the arrow direction shown in the figure. The tightening
torque is 80-85Nm. Tighten M12 bolt as per the order 1-2-3-4-5-6 and the tightening torque is 140-
145Nm.

Attention: before screwing above strengthening bolts, apply lubricating oil to the thread and
supporting surface.
4.3.4.4 Assembly steps for flywheel housing
The assembly steps are contrary to the disassembly steps of flywheel housing.

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4.3.5 Disassembly, check, maintenance and assembly of oil pan
4.3.5.1 Exploded drawing for oil pan assembly

Oil pan

Drain plug

Fig. 4-13 Exploded Drawing for Oil Pan Assembly


4.3.5.2 Disassembly steps for oil pan
① Turn over the diesel engine and keep the oil pan upward (Key point 1);
② Disassemble the fastening bolt of oil pan (Key point 2);
③ Disassemble the oil pan and sealing gasket.
④ Disassemble the magnetic plug and composite gasket.
4.3.5.3 Check and maintenance of oil pan
Key point 1:Disassembly
Before disassembling the oil pan, empty the oil. Put the oil container below the drain plug of oil pan
and use the plug wrench to loosen the drain plug and drain the oil.
Key point 2:Assembly
1) Glue the body matching surface along the inside of thread hole;
2) Move the oil pan toward the body matching surface. When the oil pan contacts with the body,
slightly put it to avoid damaging the contact surface;

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3) Insert the bolt and gasket and use the pneumatic wrench to tighten the bolt. The tightening bolt is
20-355Nm.
4.3.5.4 Assembly steps for oil pan
The assembly steps are contrary to the disassembly steps of oil pan.
4.3.6 Disassembly, check, maintenance and assembly of piston nozzle
4.3.6.1 Exploded drawing for piston nozzle assembly

Gasket
Spring
washer

Hexagon bolt

Seal ring Nozzle


component

Fig. 4-14 Exploded Drawing for Piston Nozzle Assembly


4.3.6.2 Disassembly steps for piston nozzle
① Disassemble the hexagon bolt (Key point 1);
② Disassemble the nozzle assembly (Key point 2);
4.3.6.3 Check and maintenance of piston nozzle
Key point 1: Assembly
①_ Tighten the fuel injection nozzle assembly by the bolt with spring washer and pressing plate;
② Press the concave surface of fuel injection nozzle end by the pressing plate;
③ Tighten the bolt: set the TOKU pneumatic wrench at 2 position.
Key point 2: Check
Check the O-ring for damage and check the body nozzle hole for cleanliness without burr.

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Service Manual for Engine
4.3.6.4 Assembly steps for piston nozzle
The assembly steps are contrary to the disassembly steps of piston nozzle.
4.3.7 Disassembly, check, maintenance and assembly of thrust plate
4.3.7.1 Exploded drawing for thrust plate assembly

Thrust plate

Fig. 4-15 Exploded Drawing for Thrust Plate Assembly


4.3.7.2 Disassembly steps for thrust plate
① Disassemble the main bearing cover (refer to 3.3.2);
② Disassemble the crankshaft (refer to 3.4.3);
③ Disassemble the thrust plate (Key point 1).
4.3.7.3 Check and maintenance of thrust plate
Key point 1: Assembly
If the thrust plate is be used in pair, during assembly, keep the thrust plate oil groove outward and
put the “small ear” for preventing mis-assembly at the corresponding position of thrust bearing
cover.
4.3.7.4 Assembly steps for thrust plate
The assembly steps are contrary to the disassembly steps of thrust plate.

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4.3.8 Disassembly, check, maintenance and assembly of front and rear oil
seal
4.3.8.1 Exploded drawing for front and rear oil seal assembly

Front oil seal

Machine
Rear oil seal body

Fig. 4-16 Exploded Drawing for Front and Rear Oil Seal Assembly
4.3.8.2 Disassembly steps for front and rear oil seal
1) Disassemble the front wall cover (refer to 3.3.3);
2) Disassemble the front oil seal (refer to 3.3.3);
3) Disassemble the rear oil seal cover (Key point 1);
4) Disassemble the rear oil seal (Key point 2).
4.3.8.3 Check and maintenance of front and rear oil seal
Key point 1:
Check
Check the matching surface of rear oil seal cover and body for cleaning and bump damage.
Assembly
1) Wipe the matching surface and knock it into two locating pins by a hammer;
2) Glue the joint of rear oil seal cover;

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Key point 2:
Check
Check the seal ring sticky ring sealing surface for damage and oil seal rubber for damage. Check the
rear oil seal cover is clean and whether the processing surface has obvious scratch.
Assembly
Glue the outer ring of front oil seal (radial seal ring) and press it in the rear oil seal cover by a
special tool. Attention: after assembly, the seal ring couldn’t be damaged and the seal ring outer end
should be level with the oil seal cover.
4.3.8.4 Assembly steps for front and rear oil seal
The assembly steps are contrary to the disassembly steps of front and rear oil seal.

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4.4 Crank-connecting rod mechanism
4.4.1 Disassembly and assembly of crank-connecting rod mechanism
4.4.1.1 Exploded drawing for crank-connecting rod mechanism

Piston-connecting rod assembly

Torsional Crankshaft Flywheel


Crankshaft
damper Hub timing gear
Crankshaft pulley Bearing
Hub fastening
bolt

Flywheel bolt
Torsional damper Flywheel
fastening bolt gear ring
Main shaft bushing

Fig. 4-17 Exploded Drawing for Crank-connecting Rod Mechanism


4.4.1.2 Disassembly steps for crank-connecting rod mechanism
① Make inspection before disassembly. Check the axial clearance of connecting rod, and the
tightening torque of connecting rod bolt; Lower the engine inclined side, turn the piston to be
dismantled to the lower dead center, disassemble the connecting rod bolt and connecting cover;
turn it to the upper dead center and knock it out by a hammer. Be careful to avoid clamping the
cylinder block by the big end of connecting rod. Disassemble other pistons by the same
method and put it orderly as per the number.
② Unscrew the front end torsional absorber fastening bolt and hub fastening bolt and take down
the crankshaft pulley, torsional absorber and hub.
③ Unscrew the flywheel bolt and take down the flywheel assembly, bearing and other parts.
4.4.1.3 Assembly steps for crank-connecting rod mechanism
The assembly steps are contrary to the disassembly steps.

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4.4.2 Disassembly, check, maintenance and assembly of piston-
connecting rod assembly
4.4.2.1 Exploded drawing for piston-connecting rod assembly

Piston rod part

Machine body
assembly

Piston rod part

Crankshaft

Fig. 4-18 Schematic Diagram for Piston-connecting Rod Assembly


Top compression
ring

Second compression
Piston pin ring

Piston pin retainer Oil ring


ring

Piston

Connecting
rod body
Elastic locating pin
Connecting rod bushing

Connecting
rod cover Connecting rod
upper bushing

Connecting rod
lower bushing
Connecting rod
bolt

Fig. 4-19 Exploded Drawing for Piston-connecting Rod Assembly

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4.4.2.2 Disassembly steps for piston-connecting rod assembly
① Make inspection before disassembly. Check the axial clearance of connecting rod, and the
tightening torque of connecting rod bolt.
② Lower the engine inclined side, turn the piston to be dismantled to the lower dead center,
disassemble the connecting rod bolt and connecting cover;
③ Turn it to the upper dead center and knock it out by a hammer. Be careful to avoid clamping
the cylinder block by the big end of connecting rod.
④ Disassemble other pistons by the same method and put it orderly as per the number.
⑤ Use the internal circlip plier to carefully disassemble the elastic washer at both sides of piston
and push the piston out and take down the connecting rod body. Number the piston pin and
connecting rod body and put it orderly.
⑥ Use the piston ring assembly pliers to respectively disassemble the top ring, second ring and
oil ring and mark it respectively.
4.4.2.3 Check and maintenance of piston-connecting rod assembly
① Check the circular bead and piston pin seat at the piston combustion chamber throat for crack.
Check the skirt section and head of piston for scuffing; and check whether the piston pin hole
is normally abraded.
② Check whether the external circle of piston ring is abnormally abraded and check whether the
upper and lower end of piston ring is abnormally abraded.
③ Check whether the external circle of piston pin is abnormally abraded.
④ Check the bottom hole of big end, stem body and small head oil hole of connecting rod for
crack; check whether the connecting rod busing alloy is abnormally abraded or peeling off;
check whether the side of connecting rod is abnormally abraded and check the bending
condition of connecting rod.
⑤ Check the abrasion condition of connecting rod bearing bush and check the alloy layer for
color fading, peeling, slipping, etc.
4.4.2.4 Assembly steps for piston-connecting rod assembly
① Use the internal circlip pliers to assemble the elastic washer in the piston retainer ring groove,
rotate the stopper ring and completely assemble it. The retainer ring angle surface should be
inward. The piston pin retainer ring opening should be upward.
② Insert the small end of connecting rod in the inner cavity of piston, align the small end of
connecting rod with the piston pin hole and assemble the piston pin finally assemble the piston
pin retainer ring of the other side. Pay attention that the oblique incision direction should be
the same with the oil inlet of piston cooling oil way. Apply proper clean lubricating oil before
assembling the small end hole of connecting rod and piston pin.
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③ Properly arrange the piston connecting rod components as per the cylinder number and use the
piston ring assembly pliers to assemble the oil ring, second compression ring and top
compression ring in the piston ring groove. The “TOP” of piston ring is upward and the piston
ring and freely rotate in the ring groove.
④_ Wipe the inner wall of cylinder, crankshaft connecting lever, and piston connecting rod
component and apply clean lubricating oil to the kinematic pair parts.
⑤_ Adjust the ring opening direction: assemble the top ring opening at the position 30°deviating
from the centerline of piston pin; the second ring opening and top ring opening should be
staggered for 120°. The oil ring opening and top and second compression ring should be
staggered for 120°, which should be at the perpendicular bisector of piston ring centerline, as
shown in the figure below.

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Top compression ring Second compression ring

Horizontal direction of piston pin

Oil ring

Fig. 4-20 Schematic Diagram for Opening Angle of Piston Ring Assembly
⑥ Turn the vehicle to make 1# and 6# cylinder near the lower dead center. Assemble the 1# and
6# cylinder piston part and loosely assemble the connecting rod bolt. The separation surface of
connecting rod should face the left of cylinder block (i.e. oil cooler). The piston cylinder
number is the same as the cylinder number. The connecting rod cap and connecting rod body
should be used jointly. Apply clean lubricating oil before assembling the connecting rod bolt.
⑦ Tighten the connecting rod bolt: firstly twist it and then apply the torque of 30Nm to
symmetrically tighten it finally rotate it for 58°~65°. Meanwhile, reach the torque of (85-135)
Nm. Assemble other cylinders by the same methods.
4.4.3 Disassembly, check, maintenance and assembly of crankshaft
4.4.3.1 Exploded drawing for crankshaft system assembly

Crankshaft Flywheel
Torsional Wheel Crankshaft
Crankshaft pulley damper hub timing gear
Bearing
Hub fastening
bolt

Torsional damper Flywheel


Flywheel ring gear
fastening bolt bolt
Main shaft
bushing

Fig. 4-21 Exploded Drawing for Crankshaft System Assembly


4.4.3.2 Disassembly steps for crankshaft
① Keep the engine crankcase upward, disassemble the main bearing bolts and put them orderly.
② Take down the crankshaft and flywheel and take out the front and back thrust plate and
flywheel end bearing. Take out the oil seal: put the crankshaft on the bracket (for long-term
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placing, the crankshaft should be vertically placed).

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Service Manual for Engine
③ Put all parts disassembled by category.
4.4.3.3 Check and maintenance of crankshaft
① Check the round part of main journal and connecting rod neck for crack. For the connection of
crankshaft and bearing bush, check and dredge the oil duct and check it for crack and other
abnormalities.
② Check the abrasion condition of main journal and connecting rod journal; and check it for line
shape, metal peeling and crack.
③ Check the abrasion condition of front and rear oil seal.
④ Check the main bearing bolt for thread damage and other failure modes.
⑤ Check the flange bolt hole for crack.
⑥ Check the abrasion degree of crankshaft journal, bending and torsion condition of crankshaft.
4.4.3.4 Assembly steps for crankshaft
① Wipe the bottom hole of cylinder block.
② Clean the bottom hole of upper bearing bush cylinder block and clear the impurity at the
bushing opening.
2.1. Before pressing the upper bearing bush, strictly check it for damage, if any; abandon it rather
than do repairing for reuse.
2.2. After assembling the upper bearing bush, align it with the oil hole and groove with the cylinder
block. The one with deviation exceeds 1/5-1/4 of the oil hole should not be assembled. The upper
bearing bush should be completely fitted with the bottom hole of cylinder block.
③ Apply proper clean lubricating oil to the inner surface of upper bearing bush.
④ Apply oil to the lower plane of cylinder block and wipe it. The lower surface of cylinder block
should be free of grease.
⑤ Apply the gluing line on the lower plane of cylinder block, evenly and continuously apply the
sealant by the rubber roll
⑥ Lift the crankshaft and blow the oil hole by the compressed air and wipe the main journal and
connecting rod journal by a towel, and slightly lower it down to the cylinder block. In this
process, the crankshaft should not be damaged.
⑦ Wipe the upper thrust plate and press it in the cylinder block. The oil groove of upper thrust
plate should be outward (toward the crankshaft).
⑧ On the basis of ensuring flat oil seal without torsion and deformation, use a special tool to put
the oil seal flatly in the seal ring groove at the lower level of the cylinder block.
⑨ Press the lower main journal and lower thrust place in the crankcase (keep the oil groove face
the crankshaft) and assemble the crankcase.
⑩ Apply clean lubricating oil at the bolt supporting surface of crankcase and thread of main
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bearing bolt; loosen the main bearing bolt and then tighten all main bearing bolts as per the
sequence shown in Fig. 4.

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Fig. 4-22 Tightening Sequence of Main Bearing Bolts


⑪ Tighten it by two times, firstly apply torque of 70Nm and then twist the bolt for 90°±4° to
complete the crankshaft assembly.
4.4.4 Disassembly, check, maintenance and assembly of flywheel and
gear ring
4.4.4.1 Exploded drawing for flywheel assembly

Flywheel

Crankshaft

Locating pin
Bearing

Flywheel bolt

Flywheel ring gear

Fig. 4-23 Exploded Drawing of Flywheel Assembly


4.4.4.2 Disassembly steps for flywheel and gear ring
The disassembly steps are contrary to the assembly steps.

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4.4.4.3 Check and maintenance of flywheel and gear ring
① Check the flywheel bolt for thread damage and other failure modes.
② Check the flywheel surface for crushing.
③ Check the flywheel gear ring for damage.
4.4.4.4 Assembly steps for flywheel and gear ring
① Tighten the flywheel gear ring and the flywheel by the bolt.
② Insert the cylindrical pin to the crankshaft rear end and be sure to insert it to the bottom.
③ Insert the flywheel guide rod in the crankshaft thread hole, assemble the flywheel components
and tighten the flywheel bolt diagonally.
Apply lubricating oil to the flywheel bolt thread and pressure bearing surface.
Flywheel bolt: bolt specification of M16-12.9 grade, (6 pieces)
Tightening torque: (285~295) Nm, test value: (285~340)Nm.
4.4.5 Disassembly, check, maintenance and assembly of torsional damper,
crankshaft pulley and hub
4.4.5.1 Exploded drawing for torsional damper, crankshaft pulley and hub assembly

Crankshaft
Torsional damper Crankshaft timing
Hub
gear
Crankshaft pulley

Hub fastening bolt

Torsional damper fastening bolt

Fig. 4-24 Exploded Drawing for Torsional Damper and Crankshaft Pulley, and Hub Assembly
4.4.5.2 Disassembly steps for torsional damper and crankshaft pulley
Unscrew the pulley bolt and take down the pulley and absorber orderly.
4.4.5.3 Check and maintenance of torsional absorber, crankshaft pulley and hub
① Check the absorber for collision and deformation.

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② Check the crankshaft pulley and hub for damage and the bolt tightening part for crushing.
③ Check the hub and torsional absorber fastening bolt for damage.
4.4.5.4 Assembly steps for torsional absorber and crankshaft pulley
After assembling the timing gear, assemble the hub, torsional absorber and crankshaft pulley
orderly:
①_ Tighten the hub on the crankshaft by the hub fastening bolt. Crankshaft hub fastening bolt:
specification of M16-12.9 grade (4 pieces); tightening torque: (300~310) Nm, test value: (300-
360) Nm.
② Tighten the crankshaft pulley and torsional absorber on the hub by the torsional absorber
fastening bolt: torsional absorber fastening bolt: specification of M10-10.9 grade (6 pieces);
tightening torque: (65-70) Nm, test value: (65-80) Nm.
4.4.6 Disassembly, check, maintenance and assembly of crankshaft bearing
bush
4.4.6.1 Exploded drawing for crankshaft bearing bush assembly
Spindle lower
bushing

Crankshaft

Spindle upper
bushing

Fig. 4-25 Exploded Drawing for Crankshaft Bearing Bush Assembly


4.4.6.2 Disassembly steps for crankshaft bearing bush
Push the bearing bush out from the side and mark the bearing bush disassembled and align it with
the base hole of body and crankcase.
4.4.6.3 Check and maintenance of crankshaft bearing bush
① Clean the bearing bush and check the abrasion condition of bearing bush.
② Check the bearing bush for metal peeling off, locating pin damage and horizontal crack.
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4.4.6.4 Assembly steps for crankshaft bearing bush
① Firstly clean and wipe the main bearing bush and assembly bottom hole.

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② If no new bearing bush is replaced, assemble the original bearing bush in the body (upper bush)
and crankcase (lower bush) orderly. Pay attention to distinguishing the upper and lower bush.
The one with oil groove is upper bush. If the new bush is replaced, directly assemble it. During
assembly, pay attention to align the lip and apply little oil.

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4.5 Valve mechanism
4.5.1 Disassembly and assembly of valve mechanism
4.5.1.1 Exploded drawing for valve mechanism assembly

Rocker arm seat Hexagon Valve lock Butterfly elastic washer


Hexagon nut screw clamp Circlip for shaft
Rocker arm Inner valve spring
Adjusting Outer valve spring
Guide valve
screwspring Lower valve
spring Air compressor drive
Valve stem seal sleeve
Camshaft gear
Cylinder head
Valve Crankshaft timing gear
Intake and exhaust valve
Hexagon socket cap screw
tappet

Flange
Hexagon flange bearing
surface toothed bolt
Body Hexagon flange bearing surface toothed
bolt

Sector plate

Fig. 4-26 Exploded Drawing for Valve Mechanism Assembly


4.5.1.2 Disassembly steps for valve mechanism
① Disassemble the rocker arm and rocker shaft; refer to the disassembly steps for rocker arm and
rocker shaft for details;
② Disassemble the intake and exhaust valve; refer to the disassembly steps for intake and exhaust
valve for details;
③ Disassemble the tappet and push rod; refer to the disassembly steps for tappet and push rod for
details;
④ Disassemble camshaft and camshaft timing gear; refer to the disassembly steps for camshaft
and camshaft timing gear for details;
⑤ Disassemble the intermediate gear; refer to the disassembly steps for intermediate gear for
details.
4.5.1.3 Assembly steps for valve mechanism
The assembly steps are contrary to the disassembly steps in 3.5.1.2.
4.5.2 Disassembly, check, maintenance and assembly of camshaft
assembly

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4.5.2.1 Exploded drawing for camshaft assembly
Compressor drive gear

Camshaft
Camshaft timing gear

Hexagon socket cap screw

Flange

Hexagon flange bearing surface toothed bolt

Hexagon flange bearing surface toothed bolt

Body Sector plate

Fig. 4-27 Exploded Drawing for Camshaft Assembly

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4.5.2.3 Check and maintenance of camshaft


① Check the cam surface contacting the tappet for abrasion. Check the main journal for blockage
and abrasion;
② Check the timing gear fastening hexagon bolt for bending and deformation. Check the
camshaft timing gear and compressor drive gear for clamping or serious abrasion of teeth.
4.5.2.4 Assembly steps for camshaft
After assembly, check the camshaft, timing gear and compressor drive gear, in case of abrasion or
other big deviation of parameter, do repairing or replace a new camshaft, timing gear and
compressor drive gear.
①_ Check it for burr and collision damage and ensure no rust, scratch and impurity like scrap iron;
② Apply proper clean oil to the camshaft hole and tappet hole and assemble the tappet. Refer to
assembly steps for tappet, assemble the camshaft and apply even force in the pushing process
of camshaft. Never damage the camshaft surface and body hole. The camshaft end with thread
should be at the front wall cover side.
③ Assemble the sector plate and the tightening torque of bolt is (35±10) N·m. Do painting for
sealing after tightening.
④ Assemble the camshaft at the front of body, assemble the gasket, flange, washer and hexagon
bolt, measure the camshaft axial clearance of 0.1-0.29mm. If the camshaft axial clearance is
too small, check whether there is burr between the camshaft and sector plate. After the burr is
removed, the axial clearance of rear camshaft is not in the above scope, replace the camshaft.
⑤ Rotate the crankshaft, keep the timing gear 0 point close to the camshaft. Put the compressor
drive gear on the camshaft and assemble the camshaft timing gear on the camshaft gear, keep
the camshaft gear 0 point and crankshaft timing gear 0 connected;
⑥ Assemble the gear meshing point, align it and make self-inspection, mark the camshaft timing
gear, crankshaft timing gear 0 position by the marker pen.
⑦ After aligning the asymmetrical hole, apply sealant KB277 on the clean and oil-free camshaft
gear bolt and insert it through the flange hole and then screw it down to the camshaft. Tighten
the timing gear fastening bolt by the pneumatic wrench and then pre-tighten the connecting
bolt between camshaft timing gear and air compressor drive gear. Use the torque wrench to
tighten the gear connecting bolt. The tightening torque of M10 bolt is 85N·m-90N·m;
tightening torque of M8 bolt is 55N·m-60.5 N·m. after reaching the tightening torque, do
painting and sealing; rotate the crankshaft and check whether the gear 0 point is properly
meshed.

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4.5.3 Disassembly, check, maintenance and assembly of rocker arm and
rockshaft
4.5.3.1 Exploded drawing for rocker arm and rockshaft assembly
Hexagonal head bolt

Rocker arm
Hexagon nut Butterfly elastic washer
support

Rocker arm

External retaining ring

Adjusting screw

Cylinder head

Fig. 4-28 Exploded Drawing for Rocker Arm and Rockshaft Assembly
4.5.3.2 Disassembly steps for rocker arm and rockshaft
① Rotate crankshaft and observe whether the rocker arm can rotate freely.
② Measure the valve clearance and check the valve clearance for change.
③ If the rocker arm rotation is not flexible or the valve clearance is great, loosen the hexagon bolt
and slightly take down the rocker arm seat, circlip for shaft, butterfly elastic washer, rocker
arm and butterfly elastic washer, mark it to avoid mixing the rocker arms of different cylinders.
4.5.3.4 Assembly steps for rocker arm and rockshaft
① Check the part assembled for cleaning, damage, scratch and rusting;
② Assemble the rocker arm adjusting screw and bolt, screw down the screw to the bottom and
screw the lock nut to 2-3 screw pitches;
③ Apply proper lubricating oil to the rocker arm seat and rocker arm inner hole, and orderly
assemble the butterfly elastic washer, rocker arm assembly, butterfly elastic washer, and circlip
for shaft on the rocker arm seat;

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④_ After that, assemble the rocker arm seat on the cylinder head by the hexagon bolt;
⑤_ Assemble the valve push rod. Refer to the assembly process of valve push rod for details;
⑥_ Assemble the rocker arm seat component and tighten it, align the concave head of rocker arm
adjusting screw with the valve push road ball head, tighten the hexagon bolt with the
tightening torque of 40~45N·m;
 Check and adjust the intake and exhaust valve clearance.
①_ Rotate the crankshaft till the phase indicator points at the phase disc 0 point; observe the
crankshaft timing gear 0 point and meshing camshaft gear 0 point. At this time, adjust the
valve clearance from the front end number 1-2-3-6-7-10 rocker arms and adjust the intake
valve; firstly plug 0.2mm feeler gauge and use the torque wrench to screw down the nut.
Tightening torque: 20±5 N·m. After adjustment, the plug gauge can be naturally extracted. Use
the 0.25mm feeler gauge to check the clearance, but it’s unable to pass smoothly. Adjust the
exhaust valve: firstly use the 0.3mm feeler gauge, and then use the torque wrench to screw
down the nut. Tightening torque: 20±5 N·m. After adjustment, the plug gauge can be naturally
extracted. And then use the 0.35mm feeler gauge to check the clearance, but it’s unable to pass
smoothly.
②_ Rotate the crankshaft till the phase indicator points at the phase disc 0 point; observe 180°of
crankshaft timing gear 0 point and meshing camshaft gear 0 point. At this time, adjust the
valve clearance from the front end number 4-5-8-9-11-12 rocker arms, and adopt the same
method as ①.
Valve clearance adjustment is added in routine maintenance for the first 100h,and the cycle is
1000h

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4.5.4 Disassembly, check, maintenance and assembly of tappet and push
rod
4.5.4.1 Exploded drawing for tappet and push rod assembly

Cylinder head

Push rod

Machine
body

Tappet

Fig. 4-29 Exploded Drawing for Tappet and Push Rod Assembly
4.5.4.2 Disassembly steps for tappet and push rod
① After unloading the rocker arm and rocker shaft, directly take out the push rod and put it
orderly;
② After disassembling the camshaft, take out the tappet from the lower part of body and put it
orderly.

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4.5.4.3 Check and maintenance of tappet and push rod
① Clean the push rod and tappet;
② Check whether the oil channel of tappet and push rod for smoothness;
③ Check the push rod for bending and check the abrasion degree of external surface;
④ Check the push rod ball head and concave head for abrasion;
⑥_ Check the tappet surface and bottom for abrasion;
⑥ Check the concave head in the tappet for abrasion.
4.5.4.4 Assembly steps for tappet and push rod
① Check whether the tappet and push rod are faulty, if any, replace them. Before assembling the
tappet, be sure to blow off by the compressed air and check the oil hole for smoothness;
② Evenly apply clean lubricating oil to the body tappet hole and valve tappet external circle;
③ Slightly put the tappet in the tappet hole from the lower part of body, the tappet can freely
rotate in the tappet hole and the hand resistance is even. Assemble the camshaft. Refer to the
assembly steps for camshaft for details;
④_ Assemble the rocker arm seat on the cylinder head, and check whether the push rod is clean
and the welding is proper;
⑤_ Apply clean lubricating oil to the push rod and be sure to maintain sufficient lubricating oil at
the ball head;
⑥ Assemble the push rod and slightly insert it through the cylinder head and to the tappet.
4.5.5 Disassembly, check, maintenance and assembly of valve
4.5.5.1 Exploded drawing for valve assembly

Valve lock clamp Valve spring


upper seat
Valve
internal Valve external spring
spring

Valve steam seal


Valve spring
sleeve
lower seat

Cylinder head

Intake Exhaust valve


valve

Fig. 4-30 Exploded Drawing for Valve Assembly

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4.5.5.2 Disassembly steps for valve
① Use the valve spring compressor or valve overhead pliers or other tools to press the valve
spring, take out the valve lock clamp and take out the guide valve spring, internal and external
valve spring;
② Take out the valve from the valve seat.
4.5.5.3 Check and maintenance of valve
① Check the valve stem and valve stem end for abrasion;
② Check the valve cone for abrasion or damage;
③ Check the valve cone for carbon deposit;
④ Check the valve disc surface for carbon deposit and sintering.
4.5.6 Disassembly, check, maintenance and assembly of intermediate
gear
4.5.6.1 Exploded drawing for intermediate gear assembly

Intermediate gear shaft


Baffle

Intermediate gear Hexagon bolt


Shaft
component

Fig. 4-31 Exploded Drawing for Intermediate Gear Assembly


4.5.6.2 Disassembly steps for intermediate gear
① Mark the bolt and confirm whether the bolt is rotating.
② Disassemble 4 M10 hexagon bolts of intermediate gear and take down the gasket.
③ Screw a M8 bolt in the intermediate gear shift, pull it out and pay attention to preventing
intermediate gear falling off. Disassemble the intermediate gear with the idler shaft.

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4.5.6.3 Check and maintenance of intermediate gear
① Whether the bolt thread is good;
② Check all gears for teeth falling and breakage, check whether the bolt bearing surface for
crushing and thread hole or through-hole of gear for deformation;
③ Check the intermediate gear shaft and intermediate gear liner or shaft and intermediate gear
shaft for abnormal abrasion. Check whether all oil holes are blocked by dirt.
4.5.6.4 Assembly steps for intermediate gear
① Assemble the front wall cover assembly on the body as required.
② Assemble the intermediate gear assembly: Assemble the intermediate gear shaft and
intermediate gear assembly and drop proper oil on the intermediate gear shaft.
③ Put the intermediate gear assembly in the front wall cover, align it and insert the oil shaft.
④ Properly put the baffle and fasten it by bolt. The tightening torque is 65-70 N.m.
⑤ After fixing the gear, stir the gear by a hand and check it for clearance or gear blockage.
4.6 Intake and exhaust system
4.6.1 Disassembly and assembly of intake and exhaust system
4.6.1.1 Exploded drawing for intake and exhaust system assembly

Turbocharger
Supercharger fuel
return pipe
Engine exhaust
pipe

Engine intake pipe

Fig. 4-32 Exploded Drawing for Intake and Exhaust System Assembly

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4.6.1.2 Disassembly steps for intake and exhaust system
1) Disassemble the supercharge intake pipe and exhaust pipe and loosen the oil inlet and return pipe
bolt;
2) Disassemble the turbocharger;
3) Disassemble the EGR water and air channel connecting pipe;
4) Disassemble the EGR cooler, EGR valve component and disassemble the EGR coolant bracket.
5) Take down the supercharger oil inlet and outlet pipe and disassemble the exhaust pipe;
6) Orderly loosen the exhaust pipe fastening bolt and take down the exhaust pipe and gasket;
7) Orderly loosen the intake pipe fastening bolt and take down the intake pipe assembly.
4.6.1.3 Assembly steps for intake and exhaust system
The assembly steps are contrary to the disassembly steps.
4.6.2 Disassembly, check, maintenance and assembly of intake pipe
4.6.2.1 Exploded drawing for intake pipe assembly

Intake pipe

Air inlet
pipe Heater

Air inlet
pipe

Blanking
cap

Gasket

Joint

Fig. 4-33 Exploded Drawing for Intake Pipe Assembly


4.6.2.2 Disassembly steps for intake pipe
1) Loosen the hexagon bolt and take down the intake pipe and gasket;
2) Loosen the hexagon bolt and take down the heater and gasket;
3) Loosen the intake pipe fastening bolt and taken down the intake pipe and gasket;

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4) Orderly loosen the intake pipe bolt and take down the intake pipe and gasket.
4.6.2.3 Check and maintenance of intake pipe
1) Check the intake pipe for casting defects, if any, replace the new intake pipe.
2) Check the intake pipe gasket for deformation, fracture, loss, etc. if any, replace it.
4.6.2.4 Assembly steps for intake pipe
The assembly steps are contrary to the disassembly steps. The recommended tightening torque for
intake pipe bolt is 23N·m.
4.6.3 Disassembly, check, maintenance and assembly of exhaust pipe
4.6.3.1 Exploded drawing for exhaust pipe assembly

Exhaust pipe
connecting pipe

Double-end
stud

Lock nut

Exhaust
pipe

Fig. 4-34 Exploded Drawing for Exhaust Pipe Assembly


4.6.3.2 Disassembly steps for exhaust pipe
1) Loosen the hexagon bolt and take down the exhaust pipe, supercharger gasket and EGR exhaust
flange gasket.
2) Orderly loosen the exhaust pipe fastening bolt and take down the exhaust pipe and gasket.
4.6.3.3 Check and maintenance of exhaust pipe
1) Check the exhaust pipe body for crack and other damages and check the flange for deformation,
if any, replace a new exhaust pipe.
2) Check the exhaust pipe flange for leakage, if any, replace a new exhaust pipe gasket.
3) Check the exhaust pipe gasket for deformation, fracture, loss, etc. if any, replace it.
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4) Check the supercharger gasket for deformation, fracture, loss, etc. if any, replace it.
4.6.3.4 Assembly steps for exhaust pipe
The assembly steps are contrary to the disassembly steps.
Attentions for assembly:
1) Apply the bite-preventing agent (molybdic sulfide) to the exhaust pipe bolt. The tightening
torque is 65-80N·m. The exhaust pipe bolt can be maximally reused for two times.
4.6.4 Disassembly, check, maintenance and assembly of supercharger
system
4.6.4.1 Exploded drawing for supercharger system assembly

Turbocharger
Supercharger gasket

Nut

Double-end stud

Fig. 4-35 Exploded Drawing for Supercharger System Assembly


4.6.4.2 Disassembly steps for supercharger system
The disassembly steps are contrary to the assembly steps.
4.6.4.3 Check and maintenance of supercharger system
1. Check the running condition of rotor
Slightly move the air compressor impeller by a hand, it’s normal if it rotates above one round. If it
quickly stops, it means abnormal abrasion of bearing or the rotary part collides with the fixed part
or it’s blocked. Analyze the reason and eliminate the fault.
2. Check the rotor displacement
Put the mutlimeter measuring head at the compressor end, push and pull the rotary shaft along the
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shaft, measure and record the difference in the meter, as shown in Fig. 4.6.4.3-1.

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The rotor displacement should be within 0.088~0.118mm, if the value is exceeded, it means that the
thrust bearing or thrust plate and bearing body are abraded. Analyze the reason and eliminate the
fault.

Fig. 4-36 Diagram for Axial Clearance Measurement

3. Radial clearance check of compressor impeller


Press or spit the compressor impeller by a hand in the radial direction. Measure the minimum and
maximum clearance between compressor impellor and compressor volute casing by the feeler gauge,
as shown in Fig. 4.6.4.3-2. The value is within 0.4-0.8mm. If the scope is exceeded, check the
bearing and eliminate the fault.
Note: make the measurement when the supercharger is cold.

Fig. 4-37 Diagram for Axial Clearance Measurement


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Daily maintenance:
1. Check the connection of supercharger and engine pipe for looseness and eliminate the fault in
time.

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2. Check the supercharger for air and oil leakage and eliminate the fault in time.
3. Check the fastening screw of supercharger for looseness and eliminate the fault in time.
4. Check the air filter, if there is much dust, clean it in time.
4.6.4.4 Assembly steps for supercharger system
1. Assemble the supercharger gasket on the exhaust pipe flange.
2. Put the supercharger gasket on the exhaust pipe flange surface and assemble the supercharger
assembly, loosely assemble 2 types full-metal hexagon locking nut and screw it down.
3. Pour proper clean lubricating oil to the supercharger oil inlet and wipe the overflowing
lubricating oil.
4. Assemble the gasket, double-end stud and connect the silencer.
5. All gaskets can only be used once. Replace a new part in the repairing process.
4.7 Fuel system
4.7.1 Disassembly and assembly of fuel system
4.7.1.1 Exploded drawing for fuel system assembly

Fuel
injector

High-pressure oil
pipe

Fuel filter

Fuel injection
pump

Fig. 4-38 Exploded Drawing for Fuel System Assembly


4.7.1.2 Disassembly steps for fuel system
① Disassemble the pipe and bracing wire connecting the fuel system and vehicle.
② Disassemble the low-pressure oil pipe component. Refer to disassembly instructions of low-
pressure oil pipe for details.

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③ Disassemble the smoke limiter air pipe.
④ Disassemble the high-pressure oil pipe component.
⑤ Disassemble the filter component; refer to disassembly instructions of filter for details.
⑥ Disassemble the fuel injector component; refer to disassembly instructions of fuel injector.
⑦ Disassemble the front wall cover upper cover plate; refer to disassembly instructions of front
wall cover.
⑧ Disassemble the fuel injection pump component; refer to disassembly instructions of fuel
injection pump.
4.7.1.3 Assembly steps for fuel system
The assembly steps are contrary to the disassembly steps.
4.7.2 Disassembly, check, maintenance and assembly of fuel injection
pump
4.7.2.1 Exploded drawing for fuel injection pump assembly

Fuel injection
pump

Fuel injection
pump gear

Fuel injection pump fuel


return pipe

Fig. 4-39 Exploded Drawing for Fuel Injection Pump Assembly


4.7.2.2 Disassembly steps for fuel injection pump
① Disassemble the pipe and bracing wire connecting the fuel injection pump and vehicle.
② Disassemble the hollow bolt connecting the fuel injection pump and low-pressure oil pipe.
③ Disassemble the hollow bolt connecting the fuel injection pump and smoke limiter air pipe.
④ Disassemble the hollow bolt connecting the fuel injection pump and fuel injector fuel return
pipe.
⑤ Disassemble the connecting nut between the fuel injection pump and high-pressure oil pipe in
order.
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⑥ Disassemble the hollow bolt connecting the fuel injection pump and lubricating oil pipe.

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⑦ Disassemble the front wall upper cover plate. Refer to disassembly instructions for front wall
cover.
⑧ Disassemble the fuel pump bolt to disassemble the fuel injection pump gear and pressing plate.
⑨ Disassemble the fixing nut between fuel injection pump and front wall cover to disassemble the
fuel injection pump.
4.7.2.3 Check and maintenance of fuel injection pump
① Check the fuel injection pump for crack and oil leakage, if so, replace it and feed it back to the
manufacturer as per corresponding flow.
② Check the lead seal on the fuel injection pump for damage; if so, replace the fuel pump or adjust
the fuel volume on the fuel pump seat stand.
③ Check the smoke limiter air pipe for crack and joints at two ends for air leakage. If there is crack,
replace the smoke limiter air pipe. If there is air leakage at two ends, replace the hollow bolt gasket
at two ends.
④ Check the lubricating oil pipe for leakage; if so, replace the lubricating oil pipe or hollow bolt
gasket at two ends as per the leakage position.
4.7.2.4 Assembly steps for fuel injection pump
The assembly steps are contrary to the disassembly steps. When assembling the fuel pump gear,
turn the engine disc to correct advance angle of fuel supply and rotate the fuel pump camshaft to
ensure that the fuel is supplied to the first cylinder (from the driving end), and finally screw down
the fixing bolt of fuel injection pump gear.
4.7.3 Disassembly, check, maintenance and assembly of high pressure oil
pipe
4.7.3.1 Exploded drawing for high-pressure oil pipe assembly

Fig. 4-40 Exploded Drawing for Fuel Pump Assembly


4.7.3.2 Disassembly steps for high-pressure oil pipe
① Disassemble the connecting nut of high-pressure oil pipe and fuel injector of each cylinder in
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order.
② Disassemble the connecting nut of high-pressure oil pipe and fuel injector of each cylinder in
order.
4.7.3.3 Check and maintenance of high-pressure oil pipe
① Check the high-pressure oil for crack and oil leakage and so on, if so, replace the high-pressure
oil pipe and feed back as per corresponding flow.
② Check the joint cone surface of two ends of high-pressure oil pipe and ensure good cone surface.

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4.7.3.4 Assembly steps for high-pressure oil pipe
The assembly steps are contrary to the disassembly steps. Keep the high-pressure oil pipe clean and
intact.
4.7.4 Disassembly, check, maintenance and assembly of fuel injector
4.7.4.1 Exploded drawing for fuel injector assembly
Compression bolt
Spherical washer

Hollow bolt

Fuel injector block


Fuel injector

Fig. 4-41 Exploded Drawing for Fuel Injector Assembly


4.7.4.2 Disassembly steps for fuel injector
① Disassemble the hollow bolt connecting the fuel injector of each cylinder and fuel injector oil
return pipe.
② Disassemble the fuel injector compression bolt and take down the fuel injector pressing plate.
③ Disassemble the fuel injector by a special tool.
4.7.4.3 Check and maintenance of fuel injector
① Check the copper seal washer. In case of excessive deformation or other damage, replace it and
clean the fuel injector seat hole surface, clean the carbon deposit and other impurities on it so as to
ensure sealing. Properly assemble the fuel injector, seal washer and adjusting gasket on it to ensure
that the lower cone surface and tip protrusion of nozzle body meets the requirement.
② Check the fuel injector oil return pipe for damage and oil leakage; if any, replace it.
4.7.4.4 Disassembly steps for fuel injector
The assembly steps are contrary to the disassembly steps.

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4.7.5 Disassembly, Check, Maintenance and Assembly of Fuel Filter
4.7.5.1 Exploded Drawing for Fuel Filter Assembly

Fuel filter

Fig. 4-42 Exploded Drawing for Fuel Injection Pump Assembly


4.7.5.2 Disassembly steps for fuel filter
① Disassemble the hollow bolt connecting the fuel fine filter or coarse filter and the low-pressure
oil pipe.
② Disassemble the bolt connecting fuel filter or coarse filter and fixing bracket.
③ Further disconnect the fuel filter element and filter base.
4.7.5.3 Check and maintenance of fuel filter
① Check whether the fuel filter is good.
② Check the connection of fuel filter and filter base for oil leakage, if so, replace the affected parts.
③ Check the fuel filter for blockage, if so, replace the filter element. When replacing the filter
element, fill clean diesel oil in the new filter element, keep the filter base clean and apply
lubricating oil to the rubber gasket. After the rubber gasket contacts the base, screw it down for 3/4-
1 circle to seal it; finally disassemble the bleeder screw on the filter base and press the hand pump
on the fuel injection pump to exhaust air in the filter.
4.7.5.4 Assembly steps for fuel filter
The assembly steps are contrary to the disassembly steps. When replacing the filter element, fill
clean diesel oil in the new filter element, keep the filter base clean and apply lubricating oil to the
rubber gasket. After the rubber gasket contacts the base, screw it down for 3/4-1 circle to seal it;
finally disassemble the bleeder screw on the filter base and press the hand pump on the fuel
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injection pump to exhaust air in the filter.

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4.7.6 Disassembly, check, maintenance and assembly of low-pressure oil
pipe
4.7.6.1 Exploded drawing for low-pressure oil pipe assembly
Refer to Fig. 4.7.5-1 Exploded drawing for fuel system assembly.
4.7.6.2 Disassembly steps for low-pressure oil pipe
①Disassemble the low-pressure oil pipe fixing cylinder head and the fixing bracket on the body.
②Disassemble the hollow bolt connecting low-pressure oil pipe and fuel injection pump.
③Disassemble the hollow bolt connecting the low-pressure oil pipe and fuel fine filter or coarse
filter.
4.7.6.3 Check and maintenance of low-pressure oil pipe
①Check the low-pressure oil pipe appearance for oil leakage; if so, replace it and feed it back to the
manufacturer as per corresponding procedure.
②Check the connector at two ends of low-pressure oil pipe for oil leakage; if so, replace the hollow
bolt seal washer.
4.7.6.4 Assembly steps for low-pressure oil pipe
The assembly steps are contrary to the disassembly steps.
4.8 Cooling system
4.8.1 Disassembly and assembly of cooling system
4.8.1.1 Exploded drawing for cooling system assembly
The function of cooling system is to ensure the continuous working of diesel engine at proper
temperature. Forced circulating cooling is to provide the best guarantee for quickly reaching the
operating temperature. The cooling system consists of water pump, fan, expansion tank, water tank,
thermostat, etc.

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Water
pump

Fan Belt Intermediate


cushion

Air heater Air heater

Pressure limiting valve cover

Expansion
tank

Therm
ostat Water outlet
Fan
Air compressor
Radiator

Cylinder head
Oil cooler

Water
pump Diesel engine body

Fig. 4-43 Drawing for WP6 Series Diesel Engine Cooling Line
4.8.1.2 Disassembly steps for cooling system
①Disassemble the fan and connecting disc. Refer to the disassembly instructions of fan.
②Disassemble the tensioning wheel.
③Disassemble the belt.
④Disassemble the generator, generator bracket, crankshaft belt pulley, and shock absorber.

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⑤Disassemble the thermostat. Refer to the disassembly instructions of thermostat. Disassemble the
water inlet.
⑥Disassemble the air compressor and hydraulic pump.
⑦Disassemble the water pump pipe joint and water pump. Refer to disassembly instructions of
water pump for details.
⑧Disassemble the intermediate cushion of water pump.
4.8.1.3 Assembly steps for cooling system
The assembly steps are contrary to the disassembly steps.
4.8.2 Disassembly, check, maintenance and assembly of fan
4.8.2.1 Exploded drawing for fan assembly

Fan

Fig. 4-44 Exploded Drawing for Fan Assembly


4.8.2.2 Disassembly steps for fan
①Disassemble the screw and washer connecting the fan and connecting disc to disassemble the fan.
②Disassemble the connecting screw washer of connecting disc and belt pulley.
③Disassemble the connecting disc.
④Disassemble the belt pulley.
4.8.2.3 Check and maintenance of fan
Check the fan, connecting disc and belt pulley for crack and other damages.
4.8.2.4 Assembly steps for fan
The assembly steps are contrary to the disassembly steps.
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4.8.3 Disassembly, check, maintenance and assembly of water pump
4.8.3.1 Exploded drawing for water pump assembly

Double click
Double click Double click it to edit the
text
Water pump it to edit the it to edit the
bolt text text

Fig. 4-45 Exploded Drawing for Water Pump Assembly


4.8.3.2 Disassembly steps for water pump
①Disassemble the water pump belt pulley.
②Disassemble the hose and hoop connecting the water inlet and thermostat;
③Disassemble the hexagon bolt and spring washer on the water pump to disassemble the water
pump.
④Disassemble the water pump gasket and water pump intermediate cushion.
4.8.3.3 Check and maintenance of water pump
①Check the water pump gasket for fracture and other damages; if so, replace it.
②Check the bolt and stud for thread scratch and other damages; if so, replace it.
③Check the water pump and intermediate cushion for crack and other damages; if so, replace it.
4.8.3.4 Assembly steps for water pump
The specific assembly steps are contrary to the disassembly steps.

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4.8.4 Disassembly, check, maintenance and assembly of thermostat
4.8.4.1 Exploded drawing for thermostat assembly

Thermosta
t cover

Hoop

Fig. 4-46 Exploded Drawing for Thermostat Assembly


4.8.4.2 Disassembly steps for thermostat
①Disassemble the hoop connecting the upper hose and cooling pipe and thermostat.
②Disassemble the hoop connecting lower hose and water pump and thermostat.
③Disassemble the thermostat.
④Disassemble two coolant connecting hose.
4.8.4.3 Check and maintenance of thermostat
①Check the hoop for failure and damage, if so, replace it.
②Check the coolant connecting hose for crack and other damages; if so, replace it.
③Check the thermostat for crack and other damages; if so, replace it.
4.8.4.4 Assembly steps for thermostat
The specific assembly steps are contrary to the disassembly steps.

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4.10 Starting system
4.10.1 Disassembly and assembly of starting system
4.10.1.1 Exploded drawing for starting system

1-Starter 2-Hexagon bolt 3-Spring washer 4-Flywheel ring gear


Fig. 4-47 Exploded Drawing for Starting System
4.10.1.2 Disassembly steps for starting system
①Disassemble the hexagon bolt 2 and spring washer 3;
② Grasp the starter 1 by two hands and take it down along the rotation axis of starter gear.
4.10.1.3 Check and maintenance of starter
Check whether the starter gear is damaged, if so, replace it.
4.10.1.4 Assembly steps for starting system
The assembly steps are contrary to the disassembly steps.

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4.11 Vehicle accessory system
4.11.1 Disassembly and assembly of vehicle accessory system
4.11.1.1 Exploded drawing for vehicle accessory system

Generator

Generator
bracket

Generator
gasket

Generator bolt

Fig. 4-48 Exploded Drawing for Vehicle Accessory System


4.11.1.2 Disassembly steps of vehicle accessory system
1. Disassemble the generator components
①Loosen the generator tension nut and bolt and nut hinged with the tensioning block, take down
the nut, and tighten the bolt and tensioning block.
② Disassemble another fixing bolt of generator, rotate the generator body and take down the poly
V-belt, fixing bolt and generator.
4.11.1.3 Assembly steps for vehicle accessory system
1. Assemble the generator components
①Put the generator on the generator bracket and loosely assemble it on the bracket and tie rod with
the fixing bolt.
②Assemble the generator poly V-belt.
③Adjust the generator position and tighten the generator poly V-belt by the generator tightening
bolt, and lock the fixing bolt and nut of generator.

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4.11.2 Disassembly, inspection, maintenance and assembly of generator
4.11.2.1 Exploded drawing for generator assembly

Generator

Generator
bracket
Generator
gasket

Generator bolt

1-Generator mounting support 2-Poly V-belt 3-Generator 4- Generator tightening component


Fig. 4-49 Exploded Drawing for Generator Assembly
4.11.2.2 Disassembly steps of generator
①Disassemble the tightening nut of generator, tighten the bolt and nut connected with the bolt
cushion, take down the nut, and tighten the bolt and bolt cushion;
②Disassemble another fixing bolt of the generator, rotate the generator body and take down the
front belt of the generator.
③Disassemble the fixing bolt and generator and the generator bracket.
★Attention: The disassembly and repairing of generator must be done by professionals. For
assembly, check the insulation pad and insulation sleeve for integrity, if damaged, be sure to replace
it! the positive terminal of generator and housing should not be shorted; otherwise, it’s prohibited to
loading to cause serious vehicle accident.
4.11.2.3 Fault diagnosis and maintenance of generator
1. Fault judgment flow of generator
For guaranteed repairing, the user should firstly test and judge whether it’s generator fault. Tool:
test light and flow chart shown in Fig. 3.11.2-2.

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Turn on the power switch of vehicle and connect the test light at terminal B+ and E (negative pole) of
generator

No It means that there is no voltage at terminal B+ of


Whether the test light generator and the wire connecting the positive pole of
illuminates battery is faulty

Yes

Connect terminal E with terminal D+


of generator

No

It means that the internal electrical wiring at terminal


Whether the test light
illuminates D+ of generator is faulty

Yes

Start the engine

Yes
The test light Generator fault
illuminates
No

No fault of generator

Fig. 4-50 Flowchart for Judgment of Generator Fault


2. Fault diagnosis and troubleshooting of the charging system
a) Charging fault
Fault 1: Charging fault
Vehicle
Fault Detection Solution
Phenomenon
①_ Check whether the generator indicator has
(1) The key is at ON a Check the charging voltage to ground, if no, replace the indicator or
and the charging indicator check the circuit.
indicator doesn’t b Check the excitation ② If yes, it means that the generator speed
illuminate circuit for open circuit governor or rotor is faulty, repair or replace the
motor
(2) When the engine a The indicator power
is at idle speed, the is low or the parallel
①_ It’s suggested using 2-6W bulb or repairing
charging indicator excitation resistance is
the circuit
doesn’t go out but loosened
②Adjust the idle speed of engine
goes out at high b The engine idle speed
speed is too low

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①If the voltage at the generator indicator end is very


low, it means that the excitation circuit indicator power is
too low or the circuit is virtually connected. Adjust the
indicator power or check the circuit connector or joint.
a Check whether the ②If the terminal voltage of generator indicator is zero, it
voltage to ground of means that there is short circuit to ground at the
generator excitation excitation wire generator terminal, check the circuit.
end is within 1-3V; ③If the terminal voltage of generator indicator is battery
voltage, it means that the excitation circuit is faulty, and
the generator governor and excitation pipe may be
damaged. Be sure to modify the excitation circuit and
connect the repaired generator.
①_ If the voltage to ground of terminal B+ is zero,
check whether the positive and negative leads from
(3) When the generator to battery are connected.
generator is ② If the voltage to ground of terminal B+ is lower than
working, the the battery voltage, check all joints of positive and
charging negative lead from the generator to the battery for
indicator looseness or the battery for damage. Recommended
doesn’t go out detection method: connect a 2W indicator between
b Check whether the generator output terminal B+ and excitation terminal
voltage to ground of D+/L to observe the working condition of indicator and
generator output eliminate fault:
terminal B+ is the ①_ If the indicator brightness is normal, and the
battery voltage of indicator goes out after the engine is started. The
about 24V generator output voltage is 27-28.5V; the vehicle
excitation line is faulty and needs repairing.
②If the indicator brightness is normal and the indicator
doesn’t go out after the engine is started, the generator
output voltage is 27-28.5V; the generator adjuster is
faulty and needs repairing.
③ If the indicator brightness is normal and the indicator
doesn’t go out after the engine is started, the generator
output voltage is battery voltage; the generator adjuster,
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Service Manual for Engine
rectifier bridge, stator or internal wiring may be faulty
and need repairing or replacing.
b) Too low charging voltage
Fault 2: Too low charging voltage
Vehicle
Fault Detection Solution
Phenomenon

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Learn whether the


Measure the B+ terminal voltage of generator, which is
generator output
generally between 27.8 and 28.4. if the voltage is normal,
power and vehicle
it means that the voltmeter or voltmeter sampling point is
appliance are
faulty and needs repairing or replacing.
properly matched.
a Check the ①_ The idle speed of motor should be higher than
voltmeter for 1,600RPM.
damage. ②The speed of generator driving the air conditioner
b Check the working at high power should be ≥2000rpm or the
generator speed. voltage should be about 27V.
c Check the quality ①_ Check the generator and relevant wheel system belt
and tensioning quality, and be sure to replace the belt with coking, tooth
condition of loss, fracture, deformation, sinking, etc.
The battery
generator and ②Tighten the generator and relevant wheel system belt
charging is
relevant wheel ★Attention: if the belt that needs to replace the belt is
always
system drive belt. dual belt driving, be sure to replace the two belts!
insufficient.
d Check the
The charging If it’s loosened, tighten it.
generator belt pulley.
voltage is low
①_ For working at high load, if the voltage difference is
and the voltage
e Check whether the higher than 1V (if the wire is thin, the voltage drop is
drop at open
wire is properly used great), replace the wire
load is obvious.
and measure the Within 35A, S ≥6mm2 Within 70A, S ≥12mm2
generator and battery Within 100A, S ≥20mm2 Within 150A, S ≥25mm2
terminal voltage ② For working at high load, the wire or connector is hot,
replace the wire or connector.
f Check whether the
①_ The lead with oxidized surface should be assembled
wire and bolt
after the grounding bolt housing surface is polished.
connection of
②Tighten the loose nut and wiring piece and tighten the
charging system is
connector again.
loosened, oxidized,
★Attention: For the reassembled or tightened part, after
virtually connected
the engine is running for 3-5 minutes under high load,
and generates high
check whether it’s very hot.
heat
g Test the phase If the phase terminal (W/R/AC) output voltage is quite
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Service Manual for Engine
output voltage of different from the normal output value, the generator
generator (about a rectifier bridge or stator is faulty, repair or replace it.
half of output
voltage of terminal
B+)

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After charging of 10 minutes, if the charging current


h Check whether the
drops to about 10A, and the charging current is always
battery charging is
30-90A, it means that the battery is damaged and needs
normal
repairing or replacing.
c) Too high charging voltage
Fault 3: Too high charging voltage
Vehicle
Fault Detection Solution
Phenomenon
Measure the B+ terminal voltage of generator, which
a Check the voltmeter for is generally between 27 and 28.4V. if the voltage is
damage normal, it means that the voltmeter calibration value
error is big and needs repairing or replacing.
b Check the wire and
connecting part of
charging system and
check the wiring bolt for ○
1 For poor contact and loose wire, tighten it and
looseness, virtual tighten the connector again.
connection and overheat, ②For short circuit, connect the wire again.
and check whether the
The voltmeter wire and generator
shows high housing is short circuit.
voltage ①_ Observe whether the charging current of battery
changes (from 50A to within 10A) greatly in short
time in the charging process, if not, replace the
c Check the battery for battery as quickly as possible;
normal working. ②Observe whether the battery surface is clean and
dry, the wiring pole and clamp are properly matched;
if damaged, be sure to replace it as quickly as
possible.
d Test the phase output If the phase terminal (W/R/AC) output voltage is
voltage of generator quite different from the normal output value, the
(about half of B+ voltage drop is great when the generator has load.
terminal output voltage) The generator rectifier bridge or stator is faulty and

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Service Manual for Engine
needs repairing or replacing.
e Complete above checks Replace the generator adjuster, rotor or machine.

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The fault isn’t eliminated


d) Unstable charging voltage
Fault 4: Unstable charging voltage
Vehicle
Fault Detection Solution
Phenomenon
When the a Generator or relevant wheel system Tighten the generator and relevant
engine is belt is too loose and bouncing wheel system belt
working b The connection of charging wire is Check the connectors fastening the
properly, the loose and in poor contact charging wire
voltmeter c The collector ring has dirt or the
indicates electric brush is excessively abraded or Clear the dirt or replace the electric
charging but the electric brush spring is too soft and brush and electric brush spring
the pointer broken
swings left and
right so it’s
unable to see
the reading
clearly (or the
d Adjuster damage Replace the adjuster
charging
indicator
illuminates and
goes out
intermittently)
e) Abnormal noise of generator
Fault 5: Abnormal noise of generator
Vehicle
Fault Detection Solution
Phenomenon
a The generator fixing support is
Improve the mounting bracket strength
Abnormal noise deformed or the external machines are
and adjust the mounting state
in the running too close
process of b The generator belt is loose and
Replace the engine belt
generator slipping
c The generator belt pulley is loose Fasten the belt pulley

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d The generator shaft is lacking of oil or
Replace the generator bearing
damaged
The stator coil is short circuit, so
e Deep abnormal noise in the generator
replace it
If the noise is generated by stator iron
f Howling in the generator varies with
core vibration, replace the stator
the speed.
component.

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Appendix A DTC Table


Flash Related
Description P code Problem Fault cause Solution
code parts
The reference
voltage of
analog-digital
converter is P060B
higher than
the upper
threshold
The reference The
voltage of flashing
analog-digital lamp is
converter is P060B illumina
lower than the ting and
ECU internal chip
lower 1-1-1 ECU the Replace the ECU
fault
threshold engine
The test pulse executes
voltage of the limp
analog-digital home
converter is P060B mode
higher than
the upper
threshold
In certain
time, only
P060B
some dataflow
is converted
The voltage of The 1. The accelerator 1. Power on
accelerator accelera pedal signal 1 in and measure the
Accelerat
pedal 1 is tor the vehicle harness voltage to ground
2-2-1 P0123 or pedal
higher than malfunc is short to power of pedal
sensor 1
the upper tions supply. connector 4 pin,
threshold and the 2. Accelerator it’s normal if the
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Service Manual for Engine
engine pedal fault voltage is 5V; 2.
is 3. The pedal signal Power on to
running 1 pin 1.79 is check the voltage
at 1,000 subject to open of accelerator
rounds circuit pedal, the APP1
The voltage of 1. The accelerator voltage is 0.5-
accelerator pedal signal 1 in 0.8V when the
pedal 1 is the vehicle harness pedal is not
P0122
lower than the is short to ground. pressed, and the
lower 2. Accelerator APP1 voltage is
threshold pedal fault 3.2-4.0V when
the pedal is
pressed, it’s
normal;
otherwise,
replace the
accelerator pedal;
The two-time 3. Power off and
signal relation 1. The accelerator check the voltage
between pedal signal line in to ground of
accelerator the vehicle harness pedal connector 6
P2135
pedal 1 and is faulty pin, it’s normal if
accelerator 2. Accelerator the voltage is 0V;
pedal 2 is pedal fault 4. Power off and
unbelievable measure the
resistance to
ground of
connector 6 pin,
it’s normal if the
resistance is>
1MΩ.

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1. The accelerator 1. Power on and


pedal signal 2 in measure the
The voltage of the vehicle harness voltage to ground
accelerator is short to power of pedal
pedal 2 is supply. connector 3 pin,
P0223
higher than 2. Accelerator it’s normal if the
the upper pedal fault voltage is 5V; 2.
threshold 3. Pedal signal 1 Power on and
pin 1.80 is subject measure the
to open circuit voltage of
The voltage of 1. The accelerator accelerator pedal,
accelerator pedal signal 2 in the APP2 voltage
pedal 2 is the vehicle harness is 0.3- 0.4V when
P0222
lower than the is short to ground. the pedal is not
lower 2. Accelerator pressed, and the
threshold pedal fault APP2 voltage is
Accelerat
1.6-2.0V when
2-2-1 or pedal
the pedal is
sensor 2
pressed, it’s
normal;
otherwise,
The 1/2 signal replace the
relation 1. The accelerator accelerator pedal;
between pedal signal line in 3. Power off and
accelerator the vehicle harness measure the
P2135
pedal 2 and is faulty voltage to ground
accelerator 2. Accelerator of pedal
pedal 1 is pedal fault connector 1 pin,
unbelievable it’s normal if the
voltage is 0V; 4.
Power off and
measure the
resistance to
ground of
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Service Manual for Engine
connector 1 pin,
it’s normal if the
resistance is-
0MΩ.
The voltage of
atmospheric 1. Check whether
pressure the voltage of
sensor is P2229 ECU power line
Check whether the
higher than is normal;
Abnorm voltage of ECU
the upper Atmosphe 2. Check the
al power line is
threshold ric atmospheric
atmosph normal or the
The voltage of 2-3-2 pressure pressure display
eric internal
atmospheric sensor (in in plain and the
pressure atmospheric
pressure the ECU) normal value is
test pressure sensor of
sensor is P2228 1,000hPa. If the
ECU is damaged
lower than the deviation is too
lower big, replace the
threshold ECU.
P0000

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Signal of
atmospheric
pressure
sensor from
CAN is
unbelievable
The signal of
atmospheric
pressure
sensor and
P2227
intake
pressure
sensor is
unbelievable
1. Check the
accelerator pedal
sensor, the APP1
voltage is 0.5-
0.8V and the
APP2 voltage is
0.3-0.4V when
Brake the pedal is not
Brake switch,
The signal of switch, Acceler pressed, the
accelerator pedal
accelerator accelerato ator APP1 voltage is
2-2-5 P2299 position sensor or
and brake is r pedal malfunc 3.2-4.0V and the
relevant circuit are
unbelievable position tions APP2 voltage is
faulty
sensor 1.6-2.0V when
the pedal is
pressed, it’s
normal.
2. The resistance
of brake switch is
>1MΩ when the
pedal is
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Service Manual for Engine
completely
loosened and the
resistance is -0Ω
when the pedal is
pressed, it’s
normal; 3. Power
on to check the
1.41 voltage to
ground when the
brake switch is
released, it’s
normal if it’s 0V;
the voltage to
ground of 1.41
when the brake
switch is pressed
is 23-28V, it
means that the
brake circuit is
normal.
1. Power off and
Intake
The intake heater measure the
heater The
griller is damaged resistance
The intake grille or intake
or the intake heater between the
heater is 3-2-2 P0540 intake heater
relay circuit is vehicle harness
normally ON heater doesn’t
subject to open 1.55 and 1.59 and
relay work.
circuit. the heater relay
circuit
joint 1 and 2,

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The voltage is
higher than
the threshold
P1020
when the
1. The
intake heater It’s normal if the
intake
is ON. 3-2-3 resistance is - 0Ω;
heater
The voltage of 2. Measure the
grille
intake heater 1. Intake resistance of
works
(ON) is lower P1021 heater intake heater
abnorma
than the lower grille grille, it’s normal
lly.
threshold 2. Intake if the resistance is
2.
The voltage of heater - 0.4Ω;
The
intake heater grille 3. Measure the
intake
(OFF) is circuit voltage to ground
P1022 heater
higher than and its of heater relay
driving
the upper harness joint, it’s normal
circuit
threshold if the voltage is -
3-2-3 works
The voltage of 0V;
abnorma
intake heater
lly.
(OFF) is
P1023
lower than the
lower
threshold
Power off and
measure the
Intake heater The Intake heater is voltage to ground
is short to P0542 Intake intake short to power of intake heater
power supply 3-2-1 heater heater supply. relay, it’s normal
circuit doesn’t if the voltage is
work. 0V.
Intake heater Intake heater is Power off,
P0541
is short to short to ground. unplug the

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Service Manual for Engine
ground vehicle connector
and relay joint,
and measure the
resistance to
ground of joint 2;
it’s normal if the
resistance is -0Ω.
1. Power off and
unplug ECU
sensor connector
and intake
pressure sensor
The voltage of connector.
The
intake Intake The intake pressure Measure the
intake
pressure pressure connector internal resistance of 2.34
pressure
sensor is 2-3-1 P0238 sensor circuit or harness is docking
is
higher than and its short to power connector 4
abnorma
the upper harness supply. terminal, it’s
l.
threshold normal if the
resistance is -0Ω;
2. Measure the
resistance of
connector
terminal 3 and 4,

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Service Manual for Engine

it’s normal if the


resistance is >
1MΩ; 3. Power
off and unplug
the intake
pressure
connector and
measure the
voltage to ground
of connector 4,
it’s normal if the
voltage is -0V;
1. Power off and
unplug the ECU
sensor connector
and oil pressure
sensor connector;
check the
connection of
The voltage of 2.34 connector 4
intake The intake pressure terminal; it's
pressure connector internal normal if the
sensor is P0237 circuit or harness is resistance is -0Ω;
lower than the short to power 2. Measure the
lower supply. resistance
threshold between sensor
connector 1 and
4, it’s normal if
the resistance is
>1MΩ;
3. Power off and
unplug the intake
temperature

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Service Manual for Engine
sensor connector;
measure the
voltage to ground
of connector 4
terminal; it’s
normal if the
voltage is -0V;
Intake
Check whether
pressure
The intake pressure the intake
sensor signal P0235
sensor is damaged pressure sensor
from CAN is
signal is normal.
unbelievable.
Check whether
The intake
the intake
pressure
The intake pressure pressure and
sensor and
sensor and atmospheric
atmospheric
P0236 atmospheric pressure is
pressure
pressure sensor is normal;
sensor signal
aging. otherwise,
is
replace the
unbelievable.
sensor.

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Service Manual for Engine

ECU is 1. Power off to


The original
damage check the battery
battery
d or voltage; it’s
voltage is
P0563 unable normal if the
higher than
to work battery voltage is
the upper
properly 23-28V; 2. Power
threshold.
. off and unplug
ECU the ECU vehicle
ECU power
power connector and
harness and joint is
harness, battery power
faulty and the
1-2-4 connector line, check the
battery is aging or
The original , battery circuit
the generator is
battery or connection; it’s
ECU damaged.
voltage is generator normal if the
P0562 malfunc
lower than the resistance is 0Ω;
tions
lower 3. Power on to
threshold. check the voltage
to ground of ECU
positive pole, it’s
normal if the
voltage is -24V.
1. It’s 1. Power off to
unable check the
to enter connection
the between brake
cruise 1. The brake signal signal joint and
The brake Brake
mode. relay is faulty; 2. vehicle line 1.41
signal from signal
2-2-3 P0571 2. It’s The brake signal and 1.04; 2.
CAN is relay and
unable relay circuit is Check the
unbelievable its circuit
to judge faulty. resistance to
the ground of brake
reasona signal joint 1 and
bility of 2; it’s normal if
accelera the resistance is
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Service Manual for Engine
tor and >1MΩ; 3. Check
brake. the resistance of
3. The brake signal
brake switch pin, the
lamp resistance is>
priority 1MΩ when the
function clutch is not
is pressed, it’s
invalid. normal if the
resistance is -0Ω
when the clutch
is not pressed.
Brake main
and auxiliary
1. Check the Check the clutch
switch signal P0504 CAN bus
brake signal switch signal
is
unbelievable.
The cold Power on the
The cold The cold The cold start
start ECU, unplug the
starting start indicator 1.38 is
indicato cold start
indicator is 3-3-2 P1635 indicator short to positive
r works indicator
short to power harness pole of power
properly connector,
supply. and supply.
. measure the

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Service Manual for Engine

voltage to ground
of low end 1.38,
it’s normal if the
voltage is -0V.
Power off the
vehicle, unplug
the cold start
The cold indicator
starting The cold start connector, and
indicator is P1636 indicator 1.38 pin measure the
short to is short to ground. resistance to
ground. ground of low
end 1.38, it’s
normal if the
joint or resistance is -0Ω;
cold start 1. Power on the
indicator ECU, unplug the
is cold start
damaged indicator
connector and
The cold start
measure the
indicator harness is
There is no voltage between
subject to open
cold starting 1.04 and 1.38;
P1637 circuit and the
indicator it’s normal if the
flash code
signal. voltage is -21V;
indicator is
2. Measure the
damaged.
resistance of flash
code indicator;
it's normal if the
resistance is<
2KΩ.
The cold The resistance of Measure the
P1638
starting cold start indicator resistance of cold

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Service Manual for Engine
indicator is improper. start indicator;
exceeds the it’s normal if the
temperature. resistance of
common lamp is
40-50Ω and the
resistance of LED
is -1.6KΩ.
Power off the
ECU, unplug the
The voltage of
water
cooling water
Sensor signal line temperature
temperature
The 2.15 is short to sensor joint and
sensor is P0118 Water
water positive pole of measure the
higher than temperatu
temperat power supply. voltage to ground
the upper 2-4-1 re sensor
ure is of terminal 1; it’s
threshold. and its
abnorma normal if the
harness
l. voltage is -0V;
The voltage of
Sensor signal line Turn off the
cooling water
P0117 2.15 is short to vehicle, unplug
temperature
ground. the water
sensor

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Service Manual for Engine

temperature
sensor joint and
measure the
is lower than
resistance to
the lower
ground of signal
threshold.
terminal 2.15; it’s
normal if the
resistance is -0Ω;
The cooling Check the
water connection of
CAN bus
temperature CAN bus and
P0115 communication
sensor signal whether the joint
fault
from CAN is is short to
unbelievable. ground.
1. Check the
connection
between clutch
joint and vehicle
It’s line 1.66 and
unable 1.04; 2. Check
to the resistance to
activate ground of clutch
Clutch
The clutch the The clutch circuit joint; it’s normal
signal and
signal from cruise is subject to open if the resistance is
2-2-2 P0704 its
CAN is function circuit or short >1MΩ; 3. Check
relevant
unbelievable. and the circuit. the resistance of
harness
driving clutch switch pin;
perform it’s normal if the
ance is resistance is -0Ω
affected. when the clutch
is not pressed and
the resistance is
>1MΩ when the
clutch is pressed.
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Service Manual for Engine
The clutch The clutch signal
Check the clutch
state signal is P0704 from CAN bus is
switch signal.
unbelievable. unbelievable.
1. Power off and
unplug the
connector, check
the connection of
1.32, 1.47 and
The 1.29 at vehicle
Vehicle
The vehicle vehicle ON/OFF joint 1
ON/OFF Vehicle ON/OFF
ON/OFF ON/OF and 2; it’s normal
3-4-3 P2530 switch switch and its
button is F switch if the resistance is
and its harness are faulty.
stuck. malfunc -0Ω;
harness
tions. 2. Measure the
resistance to
ground of two
terminals of
vehicle ON/OFF
joint;

135
Service Manual for Engine

it’s normal if the


resistance is>
1MΩ;
3. Measure
whether the
switch is good
and use the
multimeter to
separately test it.
It’s normal if the
two contacts are
connected when
the switch is
pressed and the
two contacts are
disconnected
when the switch
is released.
There is no 1. Check the
camshaft P0340 camshaft sensor
signal. for looseness;
1-1-3 2. Power off and
The camshaft measure the
P0341
signal is Looseness of resistance from
unreliable. Crankshaf The crankshaft sensor connector 2.09
t sensor engine or crankshaft and 2.10 to joint
and its power is sensor harness 1 and 2; it’s
harness limited. short circuit or normal when the
open circuit resistance is - 0Ω;
3. Measure the
resistance to
ground from
sensor joint 1 and
2 to the vehicle;
136
Service Manual for Engine
it’s normal if the
resistance is>
1MΩ;
4. Use an
oscilloscope to
measure whether
the crankshaft
and camshaft
synchronization
is normal; if not,
it may be caused
by gear ring or oil
pump gear
installation or
processing fault.

137
Service Manual for Engine

There is only 1. Check the


camshaft crankshaft sensor
signal and it P0008 for looseness;
enters limp 2. Power off and
home state. measure the
resistance from
There is no the sensor
crankshaft P0335 connector 2.23
signal. and 2.19 to the
joint 1 and 2; it’s
normal if the
The crankshaft resistance is -0Ω;
sensor is loosened 3. Measure the
or the crankshaft resistance to
Crankshaf
The sensor harness is ground from
t sensor
1-1-4 engine subject to short sensor joint 1 and
and its
1-1-2 power is circuit or open 2 to the vehicle;
harness
limited. circuit or the gear it’s normal if the
gear ring.
ring is improperly resistance is>
The installed or 1MΩ;
crankshaft processed 4. Use an
P0336
signal is oscilloscope to
unbelievable. measure whether
the crankshaft
and camshaft
synchronization
is normal; if not,
it may be caused
by gear ring or oil
pump gear
installation or
processing fault.
The Crankshaf The Crankshaft and 1. Check the
5-4-1 P0016
crankshaft and t and engine camshaft sensor crankshaft and
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Service Manual for Engine
camshaft camshaft power is and its harness, camshaft for
signal sensor limited. gear ring or oil looseness;
deviation and its pump gear is 2. Check the
exceeds the harness, improperly crankshaft and
threshold. gear ring installed or camshaft harness
or oil processed. for normality;
pump 3. Check
gear is whether the gear
improperl ring and oil pump
y installed gear is properly
or installed;
processed 4. Use the
. oscilloscope to
observe the
synchronization
signal is normal.
The
Check whether
engine
the pulse number
returns The engine down
The engine of speed sensor is
Speed to idle slope speed is too
speed exceeds 2-2-6 P0219 normal and
sensor speed, high or the speed
the limit. whether the speed
even sensor is faulty.
is normal at the
shuts
idle speed.
down.
The exhaust Power off and
brake unplug V4 joint
butterfly valve to measure the
The
is short to P0478 Exhaust voltage to ground
exhaust Exhaust brake
power supply brake of terminal 4; it’s
3-1-1 brake drive circuit and its
or exceeds the solenoid normal if the
doesn’t harness
temperature valve voltage is 0V.
work
The exhaust Power off and
brake P0477 unplug V4 joint
butterfly valve to measure the

139
Service Manual for Engine
is short to resistance to
ground. ground of
terminal 4; it’s
normal if the
resistance is 0Ω.

140
Service Manual for Engine

1. The exhaust
brake drive circuit
The exhaust
is subject to open 1. Check the
brake
circuit connection of
butterfly valve
2. The exhaust exhaust brake
is subject to
brake drive circuit;
open circuit
P0476 electromagnetic 2. Check whether
valve is damaged the exhaust brake
The exhaust electromagnetic
brake The exhaust brake valve works
butterfly valve drive circuit is properly.
exceeds the overloaded
temperature.
The oil The
The data scaling
volume torque engine
1-2-5 P1007 ECU data FMTC MAP is Modify the data
conversion is power is
non-monotonous.
unbelievable. limited.
Power off the
ECU, unplug the
fan actuator
Fan actuator Fan actuator
The fan connector and
(PWM wave) (PWM wave) is
P0692 is measure the
is short to short to power
Fan unable voltage to ground
power supply. supply.
electroma to work of low end 2.01;
gnetic properly it’s normal if the
3-1-2
harness, and the voltage is -0V;
joint or engine Turn off the
clutch temperat vehicle, unplug
Fan actuator
ure is Fan actuator the fan actuator
(PWM wave)
P0691 high. (PWM wave) is connector and
is short to
short to ground. measure the
ground.
resistance to
ground of low

141
Service Manual for Engine
end 2.01; it’s
normal if the
resistance is 0Ω;
1. Turn off the
EC and measure
the connection of
Fan actuator Fan actuator sensor connector
(PWM wave) (PWM wave) is and joint; it’s
P0480
is subject to subject to open normal if the
open circuit. circuit. resistance is 0Ω;
2. Check whether
the fan clutch is
damaged.
1. Check the fan
Fan actuator Fan actuator
actuator harness;
(PWM wave) (PWM wave)
P0483 2. Check the fan
exceeds the exceeds the
clutch for
temperature. temperature.
damage.

142
Service Manual for Engine

1. Power on and
check the voltage
to ground of fan
speed sensor joint
3; it’s normal if
the voltage is 5V;
2. Power off and
The cooling
unplug the joint
fan speed is
and measure the
higher than
voltage to ground
the upper
1. The fan speed of speed sensor
threshold.
The fan sensor is faulty join 2; it’s normal
P0526
Fan speed speed is 2. The fan sensor if the voltage is
3-1-2
sensor unbeliev harness is faulty 0V;
P0527
able. 3. The fan clutch is 3. Power off and
The cooling
faulty unplug the sensor
fan speed is
connector and
lower than the
joint; and
lower
measure the
threshold.
resistance to
ground of joint 2;
it’s normal if the
resistance is 0Ω;
4. Check the fan
clutch for
damage.
The Power off,
electrom unplug the sensor
The The
agnetic joint and measure
electromagnet Electroma electromagnetic
clutch the voltage to
ic clutch relay 2-1-6 P1008 gnetic clutch fan relay
fan is ground of joint 1
is short to clutch fan harness is short to
unable and 2; it’s normal
power supply. power supply.
to work if the voltage is
properly 0V;
143
Service Manual for Engine
. Power off,
unplug the sensor
connector and
The The
joint; and
electromagnet electromagnetic
measure the
ic clutch P1009 clutch fan relay
resistance to
replay is short harness is short to
ground of joint 1
to ground. ground.
and 2; it’s normal
if the resistance is
>1MΩ;
The oil
with
water
indicato
r
The oil with
Oil with illumina The diesel coarse Maintain the
water sensor
2-1-1 P2269 water tes and filter ponding is diesel coarse
detects water
sensor gives full. filter.
in the oil.
out
water
temperat
ure
alarm.
Power on the
The oil
The oil ECU, unplug the
with
with oil with water
Indicator 1 water Water in oil
water indicator
(oil with water indicato indicator 1.56 pin
indicator connector, and
indicator) is 3-3-4 P1623 r is is short to positive
harness, measure the
short to power unable pole of power
joint or voltage to ground
supply. to work supply.
lamp is of low-end 1.56;
properly
damaged it’s normal if the
.
voltage is -0V.

144
Service Manual for Engine

Turn off the


vehicle, unplug
the oil with water
Indicator 1 indicator
(oil with water Water in oil connector and
indicator) is P1624 indicator 1.56 pin measure the
short to is short to ground. resistance to
ground. ground of low
end 1.56; it’s
normal if the
resistance is -0Ω;
1. Power on the
ECU, unplug the
flash code
indicator
connector and
measure the
voltage of
Indicator 1 The oil with water
connector 1.04
(oil with water indicator harness is
and 1.56; it’s
indicator) line P1625 broken or the flash
normal if the
is subject to code indicator is
voltage is -24V;
open circuit. damaged.
2. Measure the
resistance of the
flash code
indicator; it’s
normal if the
resistance is<
2KΩ.
Indicator 1 The resistance of Measure the
(oil with water oil with water resistance of oil
P1626
indicator) indicator is with water
exceeds the improper. indicator; it’s

145
Service Manual for Engine
temperature. normal if the
resistance of
common lamp is
40-50Ω and the
resistance of LED
is -1.6KΩ.
Check whether
CJ940 ECU power
ECU Engine
communicatio ECU internal chip connection is
2-6-3 P060A internal flameou
n is interfered fault normal, if
chip t
with normal, replace
the ECU.
EEPROM Accumu
P062F
reading error lation
EEPROM informat
P062F
writing error ion like
EEPROM
Fuel
(Electroni Refresh the ECU
consum
2-6-5 c erasable ———— and maintain 20
EEPROM ption/mi
read only safterrun time.
uses leage,
P062F memory)
alternative etc.
value. cannot
be
recorded
System Power off and
repairing fault ECU Engine restart the ECU,
ECU internal chip
2-6-1 P0607 internal limp replace the ECU
System fault
chip fault home if the problem
repairing fault
still exists.

146
Service Manual for Engine

System
ECU
repairing fault
CJ940 voltage During welding, as
P1607
is too high. the vehicle harness
ECU
ECU is not
2-6-3 internal Replace the ECU
CJ940 voltage damage disconnected, the
P1608 chip fault
is too low. ECU internal chip
is broken down.
1. Power off,
unplug the ECU
sensor connector
and intake
temperature
sensor connector;
and check the
connection of
2.36 connector 2
terminal; it’s
The voltage of The intake
The normal if the
intake temperature
intake resistance is -0Ω;
temperature Intake connector is
temperat 2. Measure the
sensor is 2-3-3 P0098 temperatu subject to internal
ure is resistance of
higher than re sensor short circuit or the
abnorma sensor connector
the upper harness is short to
l. terminal 2 and 3;
threshold. power supply.
it’s normal if the
resistance is>
1MΩ;
3. Power off,
unplug the intake
temperature
connector and
measure the
voltage to ground
of connector 2;
147
Service Manual for Engine
it’s normal if the
voltage is -0V;
1. Power off,
unplug the ECU
sensor connector
and oil pressure
sensor connector
The voltage of The intake and check the
intake temperature connection of
temperature connector is 2.36 connector 2
sensor is P0097 subject to internal terminal; it’s
lower than the short circuit or the normal if the
lower harness is short to resistance is -0Ω;
threshold. the battery. 2. Measure the
resistance of
sensor connector 1
and 2; it’s normal
if the resistance
is>1MΩ;

148
Service Manual for Engine

3. Power off,
unplug the intake
temperature
sensor connector
and measure the
voltage to ground
of connector
terminal 2; it’s
normal if the
voltage is -0V;
The intake
Check whether
temperature
The intake the intake
sensor voltage
P0099 temperature sensor temperature
signal from
is damaged. sensor signal is
CAN is
normal.
unbelievable.
The ideal fuel
The supercharger
injection time Superchar Check the
P1300 is damaged or
is limited by ger supercharger.
unmatched.
the current.
The ideal fuel
The
injection time High- Check the high-
engine High-pressure oil
is limited by 1-5-5 P1301 pressure pressure oil
power is pump is damaged.
the fuel oil pump pump.
limited.
volume.
The ideal fuel
injection time ECU
P1302 ECU damage Replace the ECU
is limited by software
the software.
Among 1, 2 1, 2 and 3 1. The Among 1, 2 and 3 1. Power off,
and 3 cylinder fuel cylinder, the fuel unplug 1, 2 and 3
1-5-1 P1203
cylinder, the fuel injector injector high end is cylinder joint,
fuel injector injector of a short to power and measure the

149
Service Manual for Engine
high end is harness cylinder supply or ground. voltage to ground
short to power doesn’t of joint 1; it’s
supply or work. normal if the
ground. 2. The voltage is 0V;
engine 2. Measure the
perform resistance to
ance is ground of joint 1;
affected. it’s normal if the
3. In resistance is>
series 1MΩ.
conditio 1. Power off,
n, the unplug 1, 2 and 3
engine cylinder joint,
is shut and measure the
Among 1, 2
down. voltage to ground
and 3
Among 1, 2 and 3 of joint 2; it’s
cylinder, the
cylinder, the fuel normal if the
fuel injector P1204
injector low end is voltage is 0V;
low end is
short to ground. 2. Measure the
short to
resistance to
ground.
ground of joint 2;
it’s normal if the
resistance is>
1MΩ.

150
Service Manual for Engine

1. Power off and


check the circuit
connection from
fuel injector
connector to
Among 1, 2
joint.
and 3 Among 1, 2 and 3
2. Unplug the
cylinder, the cylinder, the fuel
P1209 fuel injector joint
fuel injector is injector is subject
and measure the
subject to to open circuit.
resistance of two
open circuit.
terminals of fuel
injector; it’s
normal if the
resistance is 0.2-
1Ω.
1. The 1. Power off,
fuel unplug the 4, 5
injector and 6 cylinder
of a joints and
Among 4, 5 cylinder measure the
and 6 doesn’t voltage to ground
Among 4, 5 and 6
cylinder, the work. of joint 1
4, 5 and 6 cylinder, the fuel
fuel injector 2. The terminal; it’s
P120B cylinder injector high end is
high end is engine normal if the
1-5-2 fuel short to power
short to power perform voltage is 0V; 2.
injector supply or ground.
supply or ance is Measure the
harness
ground. affected. resistance to
3. In ground of joint 1;
series it’s normal if the
conditio resistance is >
n, the 1MΩ.
Among 4, 5 engine Among 4, 5 and 6 1. Power off,
P120C
and 6 is shut cylinder, the fuel unplug the 4, 5

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Service Manual for Engine
cylinder, the down injector low end is and 6 cylinder
fuel injector short to ground. joint and measure
low end is the voltage to
short to ground of joint 2;
ground. it’s normal if the
voltage is 0V; 2.
Measure the
resistance to
ground of joint 2;
it’s normal if the
resistance is>
1MΩ.
1. Power off and
Among 4, 5 check the circuit
and 6 Among 4, 5 and 6 connection from
cylinder, the cylinder, the fuel fuel injector
P1211
fuel injector is injector is subject connector to
subject to to open circuit. joint; 2. Unplug
open circuit. the fuel injector
joint and

152
Service Manual for Engine

measure the
resistance
between two
terminals of fuel
injector; it’s
normal if the
resistance is 0.2-
1Ω.
Power off,
unplug the ECU
fuel injector
connector and use
The fuel
the multimeter to
injector 1 low
P0262 measure the
end is short to
voltage to ground
power supply.
of fuel injector 1
The
low end 3.13 pin;
engine
it’s normal if the
power is Fuel injector 1
voltage is -0V;
insuffici harness or joint
Power off,
Fuel ent, the contact is poor;
unplug the ECU
1-4-1 injector 1 speed is harness abrasion
fuel injector
harness unstable causes open circuit
connector 1 joint
Fuel injector 1 or it’s in or/and cylinder
1 and 2 and use
high end and limp head short circuit.
the multimeter to
low end are P0261 home
measure the
subject to state.
resistance to
short circuit.
ground of joint 1
and 2; it’s normal
if the resistance is
>1MΩ.
Fuel injector 1 Power off,
is subject to P0201 unplug the ECU
open circuit fuel injector
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Service Manual for Engine
connector, fuel
injector 1 joint 1
and 2, and use the
multimeter to
measure the
resistance of
ECU fuel injector
connector 3.04
and 3.13 pin to
fuel injector
joints 1 and 2; it’s
normal if the
resistance is - 0Ω.
Power off,
The unplug the ECU
engine fuel injector
power is Fuel injector 2 connector and use
Fuel injector 2
insuffici harness or joint the multimeter to
low end is
P0265 Fuel ent, the contact is poor; measure the
short to power
1-4-2 injector 2 speed is harness abrasion voltage to ground
supply.
harness unstable causes open circuit of fuel injector 2
or it’s in or/and cylinder low end 3.06 pin;
limp head short circuit. it’s normal if the
home voltage is 0V.
Fuel injector 2 state.
P0264
high end

154
Service Manual for Engine

Power off,
unplug the ECU
fuel injector
connector, and
fuel injector 2
joint 1 and 2, and
And low end
use the
are subject to
multimeter to
short circuit.
measure the
resistance of fuel
injector joint 1
and 2; it’s normal
if the resistance is
>1MΩ.
Power off,
unplug the ECU
fuel injector
connector and
fuel injector 2
joint 1 and 2, and
use the
multimeter to
Fuel injector 2
P0202 measure the
open circuit
resistance of
ECU fuel injector
connector 3.11
and 3.06 pin to
the fuel injector
joint 1 and 2; it’s
normal if the
resistance is - 0Ω.
Fuel injector 3 Fuel The Fuel injector 3 Power off,
1-4-3 P0268
low end is injector 3 engine harness or joint unplug the ECU

155
Service Manual for Engine
short to the harness power is contact is poor; fuel injector
power supply. insuffici harness abrasion connector and use
ent, the causes open circuit the multimeter to
speed is or/and cylinder measure the
unstable head short circuit. voltage to ground
or it’s in of fuel injector 3
limp low end 3.12 pin;
home it’s normal if the
state. voltage is -0V.
Power off,
unplug the ECU
fuel injector
connector, and
fuel injector 3
Fuel injector 3
joint 1 and 2, and
high end and
use the
low end are P0267
mutlimeter to
subject to
measure the
short circuit.
resistance of fuel
injector joint 1
and 2; it’s normal
if the resistance is
>1MΩ;
Power off,
Fuel injector 3
unplug the ECU
is subject to P0203
fuel injector
open circuit
connector

156
Service Manual for Engine

and fuel injector


3 joint 1 and 2,
and use the
multimeter to
measure the
resistance of
ECU fuel injector
connector 3.05
and 3.12 pin to
fuel injector joint
1 and 2; it’s
normal if the
resistance is -0Ω.
Power off,
unplug the ECU
fuel injector
connector and use
Fuel injector 4
the multimeter to
low end is
P0271 The measure voltage
short to the
engine to ground of fuel
power supply.
power is Fuel injector 4 injector 4 low
insuffici harness or joint end 3.14 pin; it’s
Fuel ent, the contact is poor; normal if the
1-4-4 injector 4 speed is harness abrasion voltage is -0V.
harness unstable causes open circuit Power off,
or it’s in or/and cylinder unplug the ECU
limp head short circuit. fuel injector
Fuel injector 4
home connector and
high end and
state. fuel injector 4
low end are P0270
joint 1 and 2; and
subject to
use the
short circuit.
multimeter to
measure the
resistance of fuel
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Service Manual for Engine
injector joint 1
and 2; it’s normal
if the resistance is
>1MΩ.
Power off,
unplug the ECU
fuel injector
connector and
fuel injector 4
joint 1 and 2, and
use the
multimeter to
Fuel injector 4
measure the
is subject to P0204
resistance of
open circuit
ECU fuel
injector
connector 3.03
and 3.14 pin to
fuel injector joint
1 and 2; it’s
normal if the
resistance is - 0Ω.
Fuel injector 5
harness or joint
Fuel injector 5 Power off,
Fuel contact is poor;
low end is unplug the ECU
1-4-5 P0274 injector 5 harness abrasion
short to the fuel injector
harness causes open circuit
power supply. connector
or/and cylinder
head short circuit.

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Service Manual for Engine

And use the


multimeter to
measure the
voltage to ground
of fuel injector 5
low end 3.16 pin;
it’s normal if the
voltage is -0V.
Power off,
unplug the ECU
fuel injector
The connector and
engine fuel injector 5
Fuel injector 5
power is joint 1 and 2, and
high end and
insuffici use the
low end are P0273
ent, the multimeter to
subject to
speed is measure the
short circuit.
unstable resistance of fuel
or it’s in injector joint 1
limp and 2; it’s normal
home if the resistance is
state. >1MΩ.
Power off,
unplug the ECU
fuel injector
connector and
fuel injector 5
Fuel injector 5
P0205 joint 1 and 2, and
open circuit
use the
multimeter to
measure the
resistance of
ECU fuel injector

159
Service Manual for Engine
connector 3.01
and 3.16 pin to
fuel injector joint
1 and 2; it’s
normal if the
resistance is - 0Ω.
Power off,
unplug the ECU
fuel injector
The connector and use
Fuel injector 6
engine the multimeter to
low end is
P0277 power is Fuel injector 6 measure the
short to the
insuffici harness or joint voltage to ground
power supply.
Fuel ent, the contact is poor; of fuel injector 6
1-4-6 injector 6 speed is harness abrasion low end 3.16 pin;
harness unstable causes open circuit it’s normal if the
or it’s in or/and cylinder voltage is -0V.
limp head short circuit. Power off,
Fuel injector 6
home unplug the ECU
high end and
state. fuel injector
low end are P0276
connector and
subject to
fuel injector 6
short circuit.
joint 1 and 2,

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Service Manual for Engine

and use the


multimeter to
measure
resistance of fuel
injector joint 1
and 2; it’s normal
if the resistance is
>1MΩ.
Power off,
unplug the ECU
fuel injector
connector and
fuel injector 6
joint 1 and 2, and
use the
multimeter to
Fuel injector 6
P0206 measure the
open circuit
resistance of
ECU fuel injector
connector 3.02
and 3.15 pin to
fuel injector joint
1 and 2; it’s
normal if the
resistance is - 0Ω.
The number
of cylinder Check the fuel
under normal injector harness
The fuel injector
operation is Fuel The of each cylinder
harness of over 3
less than the 1-5-4 P1225 injector engine as per above
cylinders is subject
minimum harness stops check method of
to short circuit or
number of fuel injector
open circuit.
cylinder for harness.
the system
161
Service Manual for Engine
running.
Check the cruise
button switch and
its harness; 1. As
per the pin
drawing, check
the harness
connection; it’s
normal if the
1. Press several
resistance is -0Ω;
cruise switches in
2. As per the pin
The the same time;
drawing, check
The cruising cruising 2. The button
Cruise the switch
signal is 3-4-1 P0564 function triggering time is
switch voltage under
unreliable. can’t be too long;
normal state; it’s
realized. 3. The button
normal if only
switch circuit is
OFF switch has
faulty.
high level; 3. In
the same time,
check the state of
4 switches; and
check whether 2
switches or above
are pressed in the
same time.
ECU1.04 pin
Main relay 2
Neutral connects to
is short to 1-3-2 P0687 ECU1.04
switch, external power
power supply
supply

162
Service Manual for Engine

Power off and


measure the
Pin is
brake, voltage of 1.04
short to or is short to power
clutch, pin and frame
power supply.
etc. grounding wire;
supply.
malfunc it’s normal if the
tion and voltage is 0V.
the oil Power off and
Components like
with oil measure the
neutral switch, AC
ECU1.04 indicato resistance of 1.04
Main relay 2 switch and brake
pin is r is pin and frame
is short to P0686 switch and so on
short to illumina grounding wire;
ground. connecting the
ground. ting. it’s normal when
ECU 1.04 pin are
the resistance is
short to ground.
>1MΩ.
Power off,
unplug the ECU
ECU1.62
Multi-power vehicle connector
and 1.65 Multi-power fuel-
fuel-saving and measure the
pin are saving switch or
switch is short P154A voltage to ground
short to harness is short to
to power of 1.62 or 1.65
the power Multi- power supply.
supply. pin; it’s normal if
supply power
the voltage is -
fuel-
0V.
3-2-7 saving
Power off,
switch
unplug the ECU
malfunc
ECU1.62 vehicle
Multi-power tions Multi-power fuel-
and 1.65 connector; and
fuel-saving saving switch or
P154B pin are measure the
switch is short harness is short to
short to resistance to
to ground. the battery.
ground. ground of 1.62 or
1.65 pin; it’s
normal if the

163
Service Manual for Engine
resistance is >
1MΩ.
Multi-power Multi- Multi-power fuel-
fuel-saving power saving switch is Replace a new
switch signal P154C fuel- aging or the multi-power fuel-
is saving resistance is saving switch.
unbelievable. switch unmatched.
Check the voltage
of ECU positive
ECU is pole (1.02, 1.03,
unable 1.08 and 1.09) to
Main relay 1
to ECU negative
is short to P160E
supply pole (1.05, 1.06,
power supply. ECU Vehicle connector
power 1.10 and 1.11);
1-3-2 power or ECU power line
and the it’s normal if the
line is faulty
engine voltage is about
is 24V.
unable Check the voltage
Main relay 1
to start. to ground of ECU
is short to P160F
positive pole
ground.
(1.02, 1.03,

1.08 and 1.09);


it’s normal if the
voltage is about
24V.
The
engine
flames
System ECU Other causes like
out
communicatio 2-6-4 P060C internal abnormal voltage Replace the ECU
(restart
n fault chip of ECU
it after
powerin
g off)

164
Service Manual for Engine
1. Power off,
unplug the ECU
sensor connector
and fuel pressure
sensor connector
and measure the
connection of
2.27 connector 4
terminal; it’s
normal if the
resistance is -0Ω;
The voltage of The oil pressure 2. Measure the
oil pressure connector is resistance of
sensor is subject to internal sensor connector
P0523
higher than short circuit or the terminal 3 and 4;
the upper The oil harness is short to it’s normal if
limit. Sensor pressure power supply. resistance is>
2-4-3 connector is 1MΩ;
or harness unbeliev 3. Power off,
able. unplug the oil
pressure sensor
connector and
measure the
voltage to ground
of connector 4
terminal; it’s
normal if the
voltage is -0V;
1. Power off,
The oil pressure
The voltage of unplug the ECU
connector is
oil pressure sensor connector
subject to internal
sensor is P0522 and oil pressure
short circuit or the
lower than the sensor connector;
harness is short to
lower limit. and measure the
power supply.
connection of
165
Service Manual for Engine
2.27 connector 4
terminal; it’s
normal if the
resistance is -0Ω;

166
Service Manual for Engine

2. Measure the
resistance of
sensor connector
1 and 4; it’s
normal if the
resistance is>
1MΩ;
3. Power off,
unplug the oil
pressure sensor
connector and
measure the
voltage to ground
of connector 4
terminal; it’s
normal if the
voltage is -0V;
As per the above
The oil pressure
Sensor method, check
The oil connector is
connector the oil pressure
pressure subject to internal
P0520 or harness sensor connector
sensor signal short circuit or the
or CAN and harness; and
is unreliable. harness is short to
bus signal check the CAN
ground.
bus and message.
1. Power off,
The internal pin 4 unplug the ECU
The oil
Oil and 3 of oil sensor connector
pressure is too
pressure pressure connector and oil pressure
high or the oil
P0521 sensor is subject to short sensor connector;
temperature
connector circuit or the signal and measure the
signal is
or harness line is short to connection of
unreliable.
power supply. 2.27 connector 4
terminal; it’s

167
Service Manual for Engine
normal if the
resistance is-0Ω;
2. Power off,
unplug the oil
pressure sensor
connector and
measure the
voltage to ground
of connector 4
terminal; it’s
normal if the
voltage is-0V;
The oil 1. Check the oil
level is level;
low or oil 2. Power off,
pressure The oil level is too unplug the ECU
sensor low or the oil sensor connector
Engine
The oil connector temperature sensor and oil pressure
limp
pressure is too P0524 and connector and sensor connector;
home
low. harness is harness are subject and measure the
state
subject to to open circuit or communication
open short to ground. of 2.27 connector
circuit or 4 terminal; it’s
short to normal if the
ground. resistance is -0Ω;

168
Service Manual for Engine

3. Power off,
unplug the oil
pressure sensor
connector and
measure the
voltage to ground
of connector 4
terminal; it’s
normal if the
voltage is -0V;
1. Power off,
unplug the ECU
sensor connector
and oil
temperature
sensor connector;
and measure the
connection of
2.28 connector 2
The voltage of The oil
terminal; it’s
oil The oil temperature
normal if the
temperature Sensor temperat connector is
resistance is -0Ω;
sensor is 2-4-4 P0198 connector e is subject to internal
2. Power off,
higher than or harness unbeliev short circuit or the
unplug the oil
the upper able. harness is short to
temperature
threshold. the battery.
sensor connector;
and measure the
voltage to ground
of connector 2
terminal; it's
normal if the
voltage is -0V; 3.
Measure the
resistance of oil
169
Service Manual for Engine
temperature
connector 2 and
3, it’s normal if
the resistance is
>1MΩ.
1. Power off,
unplug the ECU
sensor connector
The voltage of
The oil and oil
oil
temperature temperature
temperature
connector is sensor connector;
sensor is P0197
subject to internal and measure the
lower than the
short circuit or the connection of
lower
harness is short to 2.28 connector 2
threshold.
the battery. terminal; it’s
normal if the
resistance is -0Ω;

170
Service Manual for Engine

2. Measure the
resistance of
sensor connector
1 and 2; it’s
normal if the
resistance is>
1MΩ;
3. Measure the
voltage to ground
of connector 2
terminal; it’s
normal if the
voltage is -0V;
1. Check whether
the water
temperature
sensor is normal;
2. Power off,
unplug the ECU
sensor connector
Water
Oil and oil
temperatu
temperature temperature
re, oil Water temperature
and cooling sensor connector
P100D temperatu and oil temperature
water and measure the
re sensor and its harness
temperature connection of
and its
signal 2.28 connector 2
harness
terminal; it’s
normal if the
resistance is 0Ω;
3. Power off,
unplug the oil
temperature
sensor connector

171
Service Manual for Engine
and measure the
voltage to ground
of connector 2
terminal; it’s
normal if the
voltage is-0V;
4. Measure the
resistance of oil
temperature
connector 2 and
3; it’s normal if
the resistance is
> 1MΩ.
1. Check the oil
level; 2. Power
The oil off, unplug the
The oil level is too
level is ECU sensor
low or the oil
too low or The oil connector and oil
The oil temperature sensor
the oil temperat temperature
temperature connector and
P0196 temperatu ure is sensor connector
exceeds the harness are subject
re sensor too and measure the
limit. to open circuit or
connector high. connection of
short to power
and 2.28 connector 2
supply.
harness terminal; it’s
normal if the
resistance is -0Ω;

172
Service Manual for Engine

3. Power off,
unplug the oil
temperature
sensor connector
and measure the
voltage to ground
of connector 2
terminal; it’s
normal if the
voltage is -0V;
4. Measure the
resistance of
sensor connector
2 and 3; it’s
normal if the
resistance is>
1MΩ.
The fuel
Under reversed
injector ECU
towing, the
powering time restarts
charging time of Stop the vehicle,
exceeds the P1613 ECU or
fuel injector is too and restart the
over-speed engine
2-6-2 long and the ECU engine one
monitor stops
is internally faulty. minute after
setting value.
powering off.
The engine Reversed towing
Speed ECU
speed is P1614 cause high speed or
sensor restarts
unbelievable. speed sensor fault
The voltage of Oil 1. Power on the EC,
sensor power pressure Engine unplug the oil
supply 1 is temperatu perform pressure
P0643 Sensor harness
higher than 1-3-1 re and ance is temperature
fault
the upper intake limited; sensor, and intake
threshold. pressure 2. Oil pressure
The voltage of P0642 temperatu pressure temperature
173
Service Manual for Engine
sensor power re sensor temperat sensor connector
supply 1 is ure 3 pin 2.32 and
lower than the and 2.33, measure the
lower intake voltage to
threshold. pressure ground; it’s
temperat normal if the
ure voltage is 5V.
sensor
malfunc
tion
The voltage of
sensor power Acceler
Power on the
supply 2 is ator
P0653 ECU, unplug the
higher than Accelerat pedal
accelerator pedal
the upper or pedal malfunc
Accelerator pedal connector and
threshold. APP2 tions
1-3-1 line or connector is measure the
The voltage of power and the
faulty. voltage to ground
sensor power supply engine
of 3 pin 1.84; it’s
supply 2 is module speed is
P0652 normal if the
lower than the 1,000
voltage is 5V.
lower rpm.
threshold.
Accelerat
or pedal
The voltage of Power on the
APP1 and The Accelerator pedal
sensor power ECU, unplug the
rail accelera or rail pressure
supply 3 is accelerator pedal
1-3-1 P0699 pressure tor pedal sensor pressure
higher than and measure the
sensor malfunc harness or
the upper voltage to ground
power tions. connector is faulty.
threshold. of 4 pin 1.77;
supply
module

174
Service Manual for Engine

The
engine
speed is
1,000, unplug the rail
the rail pressure sensor
The voltage of pressure connector and
sensor power display measure the
supply 3 is is voltage to ground
P0698
lower than the abnorma of terminal 3 pin
lower l and the 2.33; it’s normal
threshold. engine if the voltage is
is in 5V.
limp
home
state.
Power off the
ECU, unplug the
flash code
The flash code
The flash code indicator
indicator drive
indicator is The flash connector and
P1619 The circuit 1.30 is short
short to power code measure the
flash to positive pole of
supply. indicator voltage to ground
code power supply.
harness, of low end 1.30;
indicato
joint or it’s normal if the
3-3-1 r is
the flash voltage is -0V;
unable
code Turn off the
to work
indicator vehicle, unplug
properly
The flash code is The flash code the flash code
.
indicator is damaged indicator drive indicator
P161A
short to circuit 1.30 is short connector and
ground. to ground. measure the
resistance to
ground of low

175
Service Manual for Engine
end 1.30; it’s
normal if the
resistance is-0Ω;
1. Power on the
ECU, unplug the
flash code
indicator
connector and
measure the
The flash code
The flash code voltage of 1.22
indicator harness is
indicator is and 1.30; it’s
P161B open or the flash
subject to normal if the
code indicator is
open circuit. voltage is -24V;
damaged.
2. Measure the
resistance of flash
code indicator;
it’s normal if the
resistance is<
2KΩ.
Measure the
resistance of the
flash code
The flash code The resistance of indicator, it’s
indicator flash code normal if the
P161C
exceeds the indicator is resistance of
temperature. improper. common lamp is
40-50Ω and the
resistance of LED
is -1.6KΩ.

176
Service Manual for Engine

Turn on the key


to check the
Fuse
The voltage of pin
blown,
engine Fuse blown, T15 1.40; it’s normal
T15 signal T15 line
1-2-3 P2533 is line or key switch if the voltage is -
error or key
unable fault 24V; otherwise,
switch
to start. check the circuit
fault
from the pin 1.40
to battery.
1. Turn off the
key and check
whether the 1.61
pin is live; the
normal voltage is
0V; if it’s live, it
T50 turn-on T50 line
T50 means that the
switch or key T50 line or key
1-2-2 P2530 switch circuit is open to
exceeds the switch is switch
fault ground; 2. Turn
limit. stuck
on the key and
return it, if the
1.61 pin is still
live, it means that
the key switch is
faulty.
The time
deviation ECU It’s Power off and
between time internal stopped restart the ECU;
processor and 1-1-5 P0607 processin and ECU body fault replace the ECU
system meter g unit unable if the fault still
is higher than error to start. exists.
the threshold.
Speed 1 is Speed The 1. Power off to
Speed sensor and
higher than 3-2-4 P0501 sensor speed is check the
its harness fault
the maximum and its too high connection
177
Service Manual for Engine
threshold. harness and it’s between sensor
unable 1.70 and 1.71 and
to shut connector;
down. 2. Replace the
speed sensor.
1. Check the
The 1. CAN bus fault CAN bus
VSS or SPS Speed
speed is 2. Speed sensor 2. Check the
sensor signal P1510 sensor,
unbeliev and its harness harness
is invalid. CAN bus
able. fault 3. Replace the
speed sensor
1. Check the
The voltage of
Speed The connection
speed sensor 2
sensor speed is Speed sensor and between sensor
is higher than 3-2-4 P2158
and its unbeliev its harness fault 1.70 and 1.71 and
the upper
harness able. connector;
threshold.

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Service Manual for Engine

The voltage of
speed 2 sensor 2. Replace the
is lower than P2160 speed sensor.
the lower
threshold
1. Check the
1. CAN bus fault CAN bus
The speed Speed
2. Speed sensor 2. Check the
signal from P2157 sensor,
and its harness harness
Can is invalid. CAN bus
fault 3. Replace the
speed sensor
The voltage
signal of Speed
Speed sensor and Check the speed
speed 2 sensor P2159 sensor
its harness fault sensor line
is harness
unbelievable.
The speed 3
signal pulse
width is
P1511
higher than
the upper
threshold.
The speed 3 The Speed sensor pulse
Replace the
signal pulse Speed speed is is too wide or
3-2-4 matched speed
width is lower P1512 sensor unbeliev narrow or the cycle
sensor
than the lower able. is unmatched.
threshold.
The speed
signal average
cycle is lower P1513
than the
threshold.

179
Service Manual for Engine
SPI ECU
communicatio 4-1-4 P0607 internal —— ———— Replace the ECU
n error chip
Power off and
The air
measure the
conditioner
voltage to ground
compressor is P0647
of relay pin 2.11;
short to power The air
The air it’s normal if the
supply. conditio
condition voltage is -0V;
ner The air conditioner
er Power off and
3-1-3 compres compressor line is
compress measure the
The air sor faulty.
or line is resistance to
conditioner doesn’t
faulty. ground of relay
compressor is P0646 work.
pin 2.11; it’s
short to
normal if the
ground.
resistance is>
1MΩ;

180
Service Manual for Engine

Check whether
the air
conditioner
The air compressor
conditioner Air conditioner appliance is
compressor compressor line is connected; if it’s
P0645
relay is subject to open connected,
subject to circuit. measure the
open circuit. resistance of
relay; it’s normal
if the resistance
is-0Ω.
The air
conditioner Power off and
Air conditioner
compressor check whether
P0645 compressor line is
relay exceeds the relay is
faulty.
the damage.
temperature.
Power off and
measure the
resistance
between sensor
The fuel meter The fuel metering
connector
is subject to P0251 unit is subject to
terminal 2.13,
open circuit. open circuit
Fuel Engine 2.12, 2.14 and
1-3-5 metering limp joint 3, 1 and 2;
unit home it’s normal if the
resistance is - 0Ω;
Power off and
The high end of
The fuel meter measure the
fuel metering unit
is short to P0254 voltage to ground
line is short to
power supply. of fuel metering
power supply.
unit joint 1

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Service Manual for Engine
terminal 3.09; it’s
normal if the
voltage is – 0V;
Power off and
measure the
resistance to
The low end of
The fuel meter ground of fuel
fuel metering unit
is short to P0253 metering unit
line is short to
ground. joint 1 terminal
power supply.
3.09; it’s normal
if the resistance is
- 0Ω;
Power off and
measure the
The voltage of
voltage to ground
fuel meter is
Fuel Engine of fuel metering
higher than P025D The fuel metering
1-3-5 metering limp unit joint 1
the upper unit line is faulty.
unit home terminal 3.09; it’s
threshold.
normal if the
voltage is – 0V;
P025C

182
Service Manual for Engine

Power off and


measure the
The voltage of
resistance of fuel
fuel meter is
metering unit
lower than the
joint 1 terminal
lower
3.09 ; it’s normal
threshold.
if the resistance is
-0Ω;
The common
rail pressure
P100E
relief valve is
1. Check the high
opened.
High and and low pressure
The rail 1. High and low
low oil way;
pressure pressure oil way is
pressure 2. Confirm
required time P100F Engine faulty;
oil way; whether the rail
exceeds the perform 2. The rail pressure
1-3-4 fuel pressure sensor is
limit. ance is sensor is faulty;
metering normal;
When the limited 3. The fuel
unit; rail 3. Confirm
pressure metering unit is
pressure whether the fuel
fluctuates, the faulty.
sensor metering unit is
common rail P1010
normal.
pressure relief
valve isn’t
opened.
Power off to
The voltage of check the voltage
rail pressure The rail pressure to ground of rail
Rail Engine
sensor is sensor harness is pressure sensor
P0193 pressure perform
higher than 1-3-3 short to power joint 2 terminal
sensor ance is
the upper supply. 2.14; it’s normal
harness limited
threshold. if the voltage is -
0V;
The voltage of P0192 The rail pressure Power off to

183
Service Manual for Engine
rail pressure sensor harness is check the
sensor is short to ground. resistance to
lower than the ground of rail
lower pressure sensor
threshold. joint 2 terminal
2.14; it’s normal
if the resistance is
>1MΩ;
The rail
pressure
deviation is
2-5-1 P1011
higher than
the upper
threshold.
The rail
pressure
deviation is
1. Check the high
higher than
High and and low pressure
the upper
low oil way
threshold and 2-5-2 P1012 Engine
pressure High and low 2. Check the rail
the fuel perform
oil way pressure oil way pressure sensor
injection ance is
and and relevant part 3. Check the
volume limited
relevant fuel metering unit
exceeds the
part fault 4. Check the fuel
limit.
injector
The rail
pressure
deviation is
lower than the
lower 2-5-4 P1013
threshold and
the fuel
injection
volume is

184
Service Manual for Engine
lower than the
threshold.
The rail
pressure peak
is lower than 2-5-3 P0087
the lower
threshold.

185
Service Manual for Engine

The rail
pressure peak
is higher than 2-5-3 P0088
the upper
threshold.
The oil dosage
unit setting
under super 2-5-5 P1014
speed is
unbelievable
At idle
running, the
variable
modification
2-5-8 P4123
of the oil
volume
metering unit
is wrong.
The fuel
volume of fuel
meter is 2-5-6 P1018
higher than
the threshold.
Power off to
check the voltage
The high end
The The starting relay to ground of
of starter
Starting starter in high-end circuit is starting relay
motor is short P0617
relay and unable short to power joint 1 terminal
to power 1-2-1
its to work supply. 1.37; it’s normal
supply.
harness properly if the voltage is –
. 0V;
The high end The starting relay Power off to
P0616
of starter high-end circuit is check the

186
Service Manual for Engine
motor is short short to ground. resistance to
to ground. ground of starting
relay joint 1
terminal 1.37; it’s
normal if the
resistance is - 0Ω;
Power off to
check the voltage
The low end
The starting relay to ground of
of starter
low-end circuit is starting relay
motor is short P1638
short to power joint 2 terminal
to power
supply. 1.51; it’s normal
supply.
if the voltage is –
0V;
Power off to
check the
The low end resistance to
The starting relay
of starter ground of starting
1-2-1 P1639 low-end circuit is
motor is short relay joint 2
short to ground.
to ground. terminal 1.51; it’s
normal if the
resistance is - 0Ω;
1. Power off
and check the
The starter resistance of
motor is Starting relay and connector
P163A
subject to its harness terminal 1.37 and
open circuit. 1.51 to the
starting relay
joint 1 and 2;

187
Service Manual for Engine

it’s normal if the


resistance is -0Ω;
2. Measure the
resistance of two
terminals of
relay; it’s normal
if the resistance is
-0Ω.
The
Check relevant
Water water
components of
The cooling temperatu temperat
cooling system
water re sensor, ure is Cooling system
2-4-2 P0217 like fan, inter-
temperature is engine too high problem
cooler, water
too high. cooling and the
tank, thermostat,
system power is
etc.
limited
1. Cut off the
1. In the vehicle power supply,
harness, the check the voltage
The output
accelerator pedal to ground of
voltage of
signal line 1 is pedal signal line
remote
short to power 1 pin, if the
accelerator
P1C20 supply. 2. The voltage is-0V, it’s
pedal 1 is Remote Remote
accelerator pedal is normal;
higher than accelerato accelera
2-2-9 faulty. 3. The pedal 2. Check the
the upper r and its tor
signal line 1 pin accelerator; if
threshold. harness failure
2.21 is subject to necessary,
open circuit replace the
accelerator pedal.
The output 1. In the vehicle 1. Cut off the
voltage of harness, the power supply,
P1C21
remote accelerator pedal check the
accelerator signal line 1 is resistance to

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Service Manual for Engine
pedal 1 is short to ground. 2. ground of pedal
lower than the The accelerator signal line 1 pin,
lower pedal is faulty if the resistance is
threshold. >1MΩ, it’s
normal; 2. Check
the accelerator; if
necessary,
replace the
accelerator pedal.
The two-time
1. Check the pin
signal relation
1. In the vehicle harness
between
harness, the connection; 2.
remote
accelerator pedal Check the
accelerator
P1C22 signal line is accelerator; if
pedal 1 and
faulty. 2. The necessary,
remote
accelerator pedal is replace the
accelerator
faulty accelerator
pedal 2 is
pedal。
unbelievable.
1. In the vehicle 1. Cut off the
harness, the power supply,
accelerator pedal check the voltage
2-2-9 P1C23
signal line 4 is to ground of
short to power pedal signal line
supply. 1 pin,

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Service Manual for Engine

The output If the voltage is-


2. The
voltage of 0V, it’s normal;
accelerator pedal is
remote 2. Check the
faulty. 3. The pedal
accelerator accelerator; if
signal line 1 pin
pedal 2 is necessary,
2.22 is subject to
higher than replace the
open circuit.
the upper accelerator pedal.
threshold.
1. Cut off the
power supply,
check the
The output
1. In the vehicle resistance to
voltage of
harness, the ground of pedal
remote
accelerator pedal signal line 1 pin,
accelerator
P1C24 signal line 1 is if the resistance is
pedal 2 is
short to ground. >1MΩ, it’s
lower than the
2. The accelerator normal; 2. Check
lower
pedal is faulty. the accelerator; if
threshold.
necessary,
replace the
accelerator pedal.
The 1/2 signal
relation 1. Check the pin
1. In the vehicle
between harness
harness, the
remote connection; 2.
accelerator pedal
accelerator Check the
P1C25 signal line is
pedal 2 and accelerator; if
faulty.
remote necessary,
2. The accelerator
accelerator replace the
pedal is faulty.
pedal 1 is accelerator pedal.
unbelievable.

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Service Manual for Engine

Appendix B Fit Clearance of Main Parts of


Diesel Engine
(Reference value)
S/N Item Theoretical value
1 Main bearing clearance 0.08-0.11
2 Connecting rod bearing clearance 0.07-0.10
3 Axial clearance of crankshaft 0.04-0.25
4 Plane axial clearance of connecting rod 0.30-0.50
Clearance between connecting rod small
5 0.03-0.08
end bushing and piston pin
Clearance between piston pin seat and
6 0.003-0.015
piston pin
Clearance between valve steam and valve
7 0.03-0.06
guide
Top ring 0.35-0.55
Working clearance of
8 Second ring 0.75-1.05
cold piston ring opening
Oil ring 0.3-0.6
Top ring
End clearance of cold
9 Second ring 0.06-0.095
piston ring
Oil ring 0.05-0.085
The value of valve bottom below the
10 1.0-1.45
cylinder end plane
The value of cylinder sleeve top higher than
11 0.05-0.10
the plane
12 Camshaft bearing clearance 0.10-0.29
13 Camshaft bearing clearance 0.04-0.08
Clearance between valve tappet and tappet
14 0.006-0.035
hole
Clearance between piston top and bottom
15 plane of cylinder head (compression 0.88-1.11
clearance)
The value of piston top higher than the
16 0.25-0.57
upper plane of body
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Service Manual for Engine
Valve clearance (cold Intake 0.2~0.3
17
state) Exhaust 0.3~0.4

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Service Manual for Engine

Clearance between rocker arm and rocker


18 0.016-0.052
shaft
Clearance of secondary Radial 0.03-0.07
19
balance mechanism Axial 0.20-0.40
Side clearance between timing gear and
20 0.07-0.24
intermediate gear

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