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WORKSHOP MANUAL

维修手册

HFC1041P73K1C3V-LD304

Engine

发动机分册

Version No 版本号：JAC-2017010301N3301

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FOREWORD 前言 CONTENT 目录

This Manual is helpful for technical maintenance

staff for JAC and provides effective and correct

maintenance and service for JAC vehicle. To ensure

the customer satisfaction of the JAC products, it is

extremely essential that the professional maintenance

technicians for JAC have the friendly service and the

capability of proper operation; therefore, the

maintenance technicians must fully understand the

contents in this Manual. This Manual shall be

accessible for reference at any time.

本手册用于帮助 JAC 授权的专业维修技术人员，

对江淮汽车提供有效正确的保养及维修。为确保江淮

汽车产品的用户满意，江淮汽车专业维修技术人员的

热情服务和正确操作是十分必要的，因此，维修技术

人员必须充分理解本手册内容。本手册应放在便于使

用的地方，以便随时用来参考。

All contents in this Manual, including pictures, technical parameters are the latest. But if

product modification affects maintenance, JAC will provide technical bulletin or supplementary

volume. Therefore, please obtain the latest information about this Manual. JAC reserves the right

to make change in design, addition or improvement for the product.

本手册的所有内容包括图片、技术参数都是最新的，但是由于产品改进而影响维修时，江淮

汽车将提供技术通报或补充卷。因此，使用本手册应密切注意获取相关信息的最新动态。江淮汽

车保留产品在设计变化、增添或改进方面的权力。

This manual is a guide for vehicle maintenance, maintenance personnel must be strictly in acc

ordance with the maintenance manual operation. This product is a product that has precise requir

ements, maintenance personnel must be professional with relevant skills, and non-professional per

sonnel are forbidden to disassemble vehicle privately. Due to complexity of actual problem, for ite

ms not contained in the manual, please contact with company's customer service, and operate und

er its guidance.

Engine

发动机分册

Chassis

底盘分册

Body structure& electrical

车身结构与电器分册

Circuit

电路分册

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Engine

发动机分册

本手册为汽车维修的指导文件，维修人员须严格按照维修手册进行操作。本产品是具有相当

精密性要求的产品，维修人员必须是具有相关技能的专业人士，严禁非专业人员私自拆分产品。

因为实际问题的复杂多样性，对于维修手册中未涉及事项请及时联系公司客服，在其指导下进行

操作。

During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or

disqualified oil, the vehicle may be damaged.

在对江淮汽车产品保养及维修过程中，若使用非江淮汽车的纯正配件或不合格油料，有可能

会造成车辆的损坏。

of this manual.

Tel：0086-551-62296644

Fax：0086-551-62296633

JAC 国际公司客户服务部

JAC International Customer Service Depart.

2017.01

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2.7CTI Engine Workshop Manual

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2.7CTI Engine Workshop Manual

I

Foreword

To help JAC engine authorized professional maintenance technical personnel, and supply effective

proper maintenance for JAC 2.7CTI engine, we compile the engine workshop manual.

To ensure customer’s satisfactory of JAC engine product, warm service and proper operation of

JAC engine professional maintenance technical personnel is very necessary. Therefore, maintenance

technical personnel must fully understand contents in the manual. The manual must be placed to

available places so that can be used for reference at any time.

All contents in the manual, including pictures, technical parameter, are latest, if due to product

improvement effecting maintenance, JAC will supply technical bulletin or ancillary volume. Therefore,

using the manual should notice to obtain latest trends of related information. JAC has the rights of

design change, add or improvement.

Without JAC written authorization, the manual can’t be copied or revised in any form, including

but not limited electronic, paper, tapes, mechanism, and so on.

Finnal interpretation of the manual is owned to JAC customer service department.

When maintaining JAC engine, if using non JAC engine parts or unquanlified oil, it may

damage engine.

JAC Engine Company

2015.12

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2.7CTI Engine Workshop Manual

II

Content

Foreword ................................................................................................................................................ I

Content .................................................................................................................................................. II

Abbreviation Definition ...................................................................................................................... VI

Chapter I Engine Introduction ............................................................................................................ 1

I、Engine Identification Code ....................................................................................................... 1

1.1 Engine Data Plate Position .............................................................................................. 1

1.2 Printed Location of Engine Identification Code and Engine No. .................................... 1

1.3 Engine Identification Code Instruction ............................................................................ 2

II、Engine Technical Specification Parameter ............................................................................. 4

2.1 Main Technical Specification .......................................................................................... 4

2.2 Main Component Specification ....................................................................................... 5

2.3 Main Inspection and Adjustment Parameter .................................................................... 5

2.4 Oil Specification .............................................................................................................. 5

2.5 Fuel Specification ............................................................................................................ 6

2.6 Urea .................................................................................................................................. 6

III、Tighten Torque ...................................................................................................................... 7

IV、Maintenance Limit ............................................................................................................... 12

V、Special Tool .......................................................................................................................... 18

Chapter II Engine Mechanical System ................................................................................................ 20

I、 Maintenance Note ................................................................................................................. 20

1.1 General Note .................................................................................................................. 20

1.2 Sealant Note ................................................................................................................... 21

1.3 Engine Sealant Use List ................................................................................................. 22

1.4 Engine Sealant Using Detail .......................................................................................... 23

II、 Front Part Auxiliary Driving System .................................................................................. 24

2.1 System Diagrammatic Sketch ........................................................................................ 24

2.2 Belt Inspection ............................................................................................................... 24

2.3 Removal ......................................................................................................................... 25

2.4 Installation ..................................................................................................................... 25

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III

2.5 Installation Note ............................................................................................................. 27

2.6 Removal and Installation of Vacuum Pump .................................................................. 28

III、Timing System ..................................................................................................................... 30

3.1 System Diagrammatic Sketch ........................................................................................ 30

3.2 Removal ......................................................................................................................... 31

3.3 Inspection ....................................................................................................................... 31

3.4 Installation ..................................................................................................................... 31

IV、Intake System ...................................................................................................................... 37

4.1 System Diagrammatic Sketch ........................................................................................ 37

4.2 Removal of Intake System ............................................................................................. 37

4.3 Installation and Check of Intake System ....................................................................... 37

V、Exhaust System ..................................................................................................................... 39

5.1 System Diagrammatic Sketch ........................................................................................ 39

5.2 Removal of Exhaust System .......................................................................................... 39

5.3 Installation and Check of Exhaust System .................................................................... 40

5.4 Fault Judgment of Turbocharger Impeller and Oil Leakage ......................................... 42

VI、Lubricating System .............................................................................................................. 49

6.1 System Diagrammatic Sketch ........................................................................................ 49

6.2 Replacement Oil and Oil Filter ...................................................................................... 50

6.3 Removal and Check ....................................................................................................... 51

6.4 Installation ..................................................................................................................... 52

VII、Valve Mechanism ............................................................................................................... 55

7.1 System Diagrammatic Sketch ........................................................................................ 55

7.2 Removal ......................................................................................................................... 56

7.3 Check After Removal .................................................................................................... 58

7.4 Installation ..................................................................................................................... 62

7.5 Valve Clearance Measurement and Adjustment ............................................................ 65

VIII、Crankshaft Flywheel Mechanism ..................................................................................... 68

8.1 System Diagrammatic Sketch ........................................................................................ 68

8.2 Removal ......................................................................................................................... 69

8.3 Check and Measurement ................................................................................................ 69

8.4 Installation ..................................................................................................................... 73

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IX、Piston Connecting Rod Assembly ....................................................................................... 79

9.1 System Diagrammatic Sketch ........................................................................................ 79

9.2 Removal ......................................................................................................................... 80

9.3 Check and Measurement ................................................................................................ 80

9.4 Installation ..................................................................................................................... 83

X、Cooling System ..................................................................................................................... 85

10.1

System Diagrammatic Sketch ................................................................................... 85

10.2 System Route Diagram ................................................................................................ 86

10.3 Removal, Installation and Check ................................................................................. 86

XI、SCR System ......................................................................................................................... 92

11.1 System Diagrammatic Sketch ...................................................................................... 92

11.2 Connecting Diagrammatic Sketch ............................................................................... 93

11.3 Maintenance Note of SCR System .............................................................................. 93

11.4 Removal, Installation and Check ................................................................................. 94

Chapter III Engine Electronic Control System .................................................................................. 103

I、Precaution ............................................................................................................................. 103

1.1 Maintenance Precaution ............................................................................................... 103

1.2 Precaution of Engine OBD System ............................................................................. 104

II、Structure Principle and Maintenance of Engine Control System ....................................... 106

2.1 Electrical Control System Instruction .......................................................................... 106

2.2 Electrical Control System Constitution Function ........................................................ 108

2.3 OBD System ................................................................................................................ 110

III、Structure Principle and Maintenance of Engine Electronic Component ........................... 115

3.1 Crankshaft Position Sensor .......................................................................................... 116

3.2 Camshaft Position Sensor ............................................................................................ 118

3.3 Intake Pressure Temperature Sensor ........................................................................... 120

3.4 Rail Pressure Sensor .................................................................................................... 123

3.5 Coolant Temperature Sensor Ⅱ ................................................................................. 125

3.6 Exhausting Temperature Sensor .................................................................................. 127

3.7 Differential Pressure Sensor ........................................................................................ 129

3.8 Environment Temperature Sensor ............................................................................... 132

3.9 NO Sensor .................................................................................................................... 133

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3.10 Urea Level Temperature Sensor ................................................................................ 134

3.11 Intake Heater .............................................................................................................. 137

3.12 ECU ........................................................................................................................... 138

3.13 Engine Control Wiring Harness ................................................................................. 146

IV、Engine Control System Fault Diagnosis Procedure .......................................................... 148

4.1 Electrical Control System Common Fault and Main Reason ...................................... 148

4.2 Fault Code List ............................................................................................................ 150

4.3 Electrical Control System Common Fault Code Analysis .......................................... 154

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VI

Abbreviation Definition

ECU：Engine Control Unit

EGR：Exhaust Gas Re-circulation

WGT：Exhaust Gas Bypass Turbocharger

OBD：On-Vehicle Diagnosis System

PWM：Fuel-air Ratio Signal

IMV：Fuel Metering Valve

DOC：Oxidize Catalyst Converter

PLV：Pressure Limit Valve

IQA：Injector Fuel Quantity Amend

START：Key Start

Key：Key

AC：Air-conditioner compressor

EPC：System Malfunction Light

CAN：Controller Area Network

ROM：Read Only Memorizer

RAM：Read and Write Memorizer

MIL：Engine Malfunction Indicating Light

SCR：Selectivity Catalyst Reduction Technology

Unit：

1MPa=10bar=1000KPa

1bar=100kpa

1V=1000mV

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Engine Introduction

1

Chapter I Engine Introduction

I、Engine Identification Code

1.1 Engine Data Plate Position

Engine data plate is located on cylinder cover hood (intake side) of engine.

1.2 Printed Location of Engine Identification Code and Engine No.

Engine identification code is printed on fuel injector installation flange fixed base of rear part of

cylinder body intake side.

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1.3 Engine Identification Code Instruction

1、Engine Identification Code

Part

Front part

Rear part

Product serial number

Code

HFC 4 D E 1 - 1 D

Item

Enterprise

Cylinder

number

Type

Technolog

y platform

Displac

ement

Delimiter

Technolog

y

Emissio

n

Meaning

JAC

4

cylinders

Diesel

engine

E-type

technolog

y platform

2.7L

Lengthwis

e mounted

Turbocharg

ing

Euro V

2、Engine No.

Engine No. F 4 123456

Meaning

Year

（2015 year）

Engine type

(Diesel)

Manufacturing

number

3、Year Instruction

Year Code Year Code Year Code Year Code

2001 1 2009 9 2017 H 2025 S

2002 2 2010 A 2018 J 2026 T

2003 3 2011 B 2019 K 2027 V

2004 4 2012 C 2020 L 2028 W

HFC4DE1-1D

F4400001

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2005 5 2013 D 2021 M 2029 X

2006 6 2014 E 2022 N 2030 Y

2007 7 2015 F 2023 P 2031 1

2008 8 2016 G 2024 R 2032 2

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II、Engine Technical Specification Parameter

2.1 Main Technical Specification

Engine type No. HFC4DE1-1D

Engine type

Straight type, turbocharging

inter-cooling, high pressure common rail

Vehicle equipped type Lengthwise mounted

Emission standard Euro V

Fuel type

GB19147 specified Euro Ⅴ diesel

Main

function

parameter

Rated power (kW) 110

Rated engine speed (r/min) 3200

Max torque (N·m) 355

Engine speed of Max torque (r/min)

1800～2600

Idling engine speed (r/min) 750±30

Main

structure

parameter

Located type Straight type

Cylinder number 4

Valve number 16

Displacement（ml）

2746

Compression ratio 16.5

Cylinder diameter（mm）

93.5

Stroke（mm）

100

Crankshaft rotating direction (facing

to flywheel side)

Anticlockwise

Ignition sequence 1-3-4-2

Lubrication method Pressure and splash combined type

Cooling method Coolant cooling

Externality size

(Length×Width×Height)（mm）

772×654×728

Net weight (kg) 284

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2.2 Main Component Specification

Component name Technical characteristic

Oil filter Full flow type, paper core ring tube, replaceable type

Oil pump Rotor type

Coolant pump Centrifugal type

Thermostat Wax type

Generator Alternating generator

Starter Decelerating type low speed big torque starter

High pressure fuel

pump

Electrical control pump

Fuel injector Electrical control fuel injector

Fuel-gas separator Impact type, free maintenance (integrated PCV valve)

Turbocharger Exhaust gas bypass turbocharger (WGT)

Catalyst converter

assembly

DOC catalyst converter + SCR catalyst converter

2.3 Main Inspection and Adjustment Parameter

Parameter Specification

Valve clearance (Cool state)

Inlet：（0.25±0.03）mm

Outlet：（0.5±0.03）mm

Oil pressure (Idling) ≥98kPa

Thermostat opening temperature 82℃

Thermostat totally opening

temperature

95℃

Fuel injector extrusive height （2.85±0.35）㎜

Oil filling capacity（L） New engine fill 7.9L, when maintenance, fill 6.8L

Urea capacity (L) One-time max fill 18L, first time 21L

2.4 Oil Specification

Check engine oil level, and fill in time when oil is not enough. Use diesel oil accord with national

standard GB 11122 shown in below list, according to (environment temperature) season and local air

temperature.

Oil type

Environment temperature in

using area

Quality grade

15W/40 -20℃～40℃ Not less than CI-4

5W/30 -30℃～30℃ Not less than CI-4

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2.5 Fuel Specification

HFC4DE1 diesel engine uses national standard GB 19147 specified Euro Ⅴ diesel, for areas with

environment protection requirement must use diesel applicable to environmental regulations, choose

according to the below list according to season and local air temperature.

Environment

temperature

More than

4℃

More than

-5℃

More than

-14℃

More than

-29℃

More than

-44℃

Diesel brand

No.

No.0 light

diesel

No.-10 light

diesel

No.-20 light

diesel

No.-35 light

diesel

No.-50 light

diesel

2.6 Urea

Urea should satisfy the requirement of GB 29518 diesel engine No

x

reductant 32.5% urea solution

(AUS 32).

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III、Tighten Torque

Figure No. Name Quantity Specification Tighten torque Remark

1002

Cylinder body

assembly

1002106FE010

Coolant discharging

plug screw

1 R1 1/4

（20～25）N·m

Q1840610 Hexagon flange bolt 4

（10～15）N·m

Install piston cooling

spraying nozzle

1002104FE010

Main bearing cover

bolt

10

M12×1.5×11

9

（10±1）N•m→

（60±2）N•m→

（140°±2°）

Final tighten torque is

(170±40) N•m

1002108FE010

Crankshaft

connecting bolt

10 M10×1.5×83

（65±5） N·m

Q1840835TF61 Hexagon flange bolt 3

（30±3） N·m

Install high pressure fuel

pump flange

Q1841275TF61 Hexagon flange bolt 7

（110±5） N·m

Install flywheel housing

Q1840830F61 Hexagon flange bolt 7

（23±3） N·m

Install flywheel housing

Q1840865TF61 Hexagon flange bolt 3

（30±3） N·m

Install flywheel housing

Q1840620 Hexagon flange bolt 4

（10～15）N·m

Install gear chamber

Q1840620F61 Hexagon flange bolt 2

（10～15）N·m

Install gear chamber

Q1841035 Hexagon flange bolt 4

（28～46）N·m

Install gear chamber

Q1841035F61 Hexagon flange bolt 1

（28～46）N·m

Install gear chamber

1002041FE010 Cylinder cover bolt 10

M14×1.5×14

0

When tighten

manually, tighten

technology is：

(10±1)N•m→

(60±2)N•m+(120

°±2°+(120°±2°)

→reverse(300°±

2°)→(60±2)N•m

+(120°±2°)+(120

°±2°)

Final tighten torque is

(290±50) N•m

1003

Cylinder cover

assembly

1002103GA

Inner hexagon plug

screw of right

balance shaft sleeve

8 R2 1/16

（10±1） N·m

Oil duct plug screw

Q1200825F61 Stud 2

（23±3） N·m

Install intake manifold

1003012FE010

Fixed stud of

exhaust manifold

2 M8×1.25×55

（23±3） N·m

Q1840820F61 Hexagon flange bolt 6

（23±3） N·m

Install shackle

Q1840816F61 Hexagon flange bolt 1

（23±3） N·m

Install wiring harness

fixed bracket

1004 Piston connecting

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Figure No. Name Quantity Specification Tighten torque Remark

rod assembly

1004013FE010 Connecting rod bolt 8 M10×1×42.5

(5±1) N·m

+(20±2) N·m

+(60±2) N·m

+(90°±2°)

1005

Crankshaft

flywheel assembly

1005014FE010

Crankshaft belt

wheel bolt

3

M12×1.25×4

0

（125±5）N·m

1005040FE010

Flywheel tighten

bolt assembly

8

M12×1.25×3

3

（135±5）N·m

1006 Camshaft assembly

Q1840616 Hexagon flange bolt 2

（10±1）N·m

Install camshaft locating

plate

1006023FE010 Rocker arm bolt 8 M8×1.25×50

（40±5）N·m

Install rocker arm

component

1006025FE010 Regulating nut 8 M6×1

（10±1）N·m

Regulate valve clearance

1008 Intake system

Q1840870F61 Hexagon flange bolt 7

（23±3） N·m

Q1840825F61 Hexagon flange bolt 1

（23±3） N·m

Install intake manifold

Q32008F61 Hexagon flange nut 2

（27±3） N·m

Install intake manifold

Q1840620F61 Hexagon flange bolt 3

（10±1）N·m

Install intake manifold

1009 Oil sump assembly

Q1840825F61-9.

8

Hexagon flange bolt 14

（25±3） N·m

Install oil sump

GB900-8×25-T1

F61

Stud 2

（25±3） N·m

Q32008F61 Hexagon flange nut 2

（25±3） N·m

1009104FE010 Oil discharging bolt 1 M16×1.5

（45±5） N·m

Re-tighten torque

Q1840616 Hexagon flange bolt 6

（10±1）N·m

Install oil filter assembly

Q1840612F61 Hexagon flange bolt 2

（10±1）N·m

Oil level gauge duct, oil

level gauge connector

1010 Lubricating system

Q1840835F61-9.

8

Hexagon flange bolt 13

（25±3） N·m

Install oil pump

component

Q1841030F61-9.

8

Hexagon flange bolt 4

（50±5） N·m

Install oil cooler assembly

1010320FE010 Oil filter component 1 M22×1.5

When sealing

ring contacts,

tighten 3/4-1

circle

1010353FA01 Perforated bolt 2 M12×1.5×30

25～31 N·m

Q1840820F61 Hexagon flange bolt 2

（23±3） N·m

Oil return duct connects

to cylinder body

Q1840616F61 Hexagon flange bolt 2

（10±1） N·m

Oil return duct connects

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Figure No. Name Quantity Specification Tighten torque Remark

to turbocharger

1010055FE010

Fixed stud of

turbocharger oil

return duct

1 M8×1.25

（23±3） N·m

Fix inlet oil return duct to

exhaust manifold

Q32008F61 Hexagon flange nut 2

（27±3） N·m

Fixed one inlet oil duct,

fix one oil return duct

1014

Crankcase

ventilation system

1014109FE010

Cylinder cover hood

assembling bolt

11 M6×1×43

（10±1） N·m

Install cylinder cover

hood

1021 Timing system

GB/T70.1

M6×16-12.9

Inner hexagon

cylindrical head bolt

4

（12±1） N·m

Install driving chain

Q1841275TF2 Hexagon flange bolt 1

（125±5） N·m

Install idle gear

1021060FE010

Chain guide rail

fixed bolt

3 M8×1.25×15

（23±3） N·m

Q218B0625-9.8

Inner hexagon

cylindrical head bolt

2

（10±1） N·m

Install tensioner back

cover

1021122FE010 Camshaft chain bolt 1 M14×1.5×52

(100±5)N·m+(90

°±2°)

Final tighten torque is

(250±70)N•m.

1025

Front part

auxiliary driving

system

Q1840825F61 Hexagon flange bolt 2

（23±3） N·m

Install vacuum pump

Q1840820F61 Hexagon flange bolt 1

（23±3） N·m

Install vacuum pump

Q1841040F61-9.

8

Hexagon flange bolt 4

（50±5） N·m

Install fan belt wheel

bracket component

Q1841050F61-9.

8

Hexagon flange bolt 2

（50±5） N·m

Install compound bracket

Q1841080F61-9.

8

Hexagon flange bolt 2

（50±5） N·m

Install compound bracket

Q1841035F61-9.

8

Hexagon flange bolt 1

（50±5） N·m

Install generator

Q18410120F61-

9.8

Hexagon flange bolt 1

（50±5） N·m

Install generator

Q1841030F61-9.

8

Hexagon flange bolt 2

（50±5） N·m

Install power steering

pump bracket

Q1841023F61-9.

8

Hexagon flange bolt 1

（50±5） N·m

Install power steering

pump bracket

Q1840816F61 Hexagon flange bolt 1

（23±3） N·m

Install wiring harness

fixed bracket

Q1840820F61 Hexagon flange bolt 2

（23±3） N·m

Install power steering

pump

Q1840885F61 Hexagon flange bolt 1

（23±3） N·m

Install power steering

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Figure No. Name Quantity Specification Tighten torque Remark

pump

------------------

Idle wheel Ⅰ

installation bolt

1 M10×1.5

（50±5） N·m

-----------------

Idle wheel Ⅱ

installation bolt

1 M10×1.5

（50±5） N·m

Q1841075TF61 Hexagon flange bolt 1

（50~54） N·m

Tensioner fixed bolt

Q1841030F61 Hexagon flange bolt 4

（45±5） N·m

Install fan assembly

1026

Electrical control

system

Q218B0616

Inner hexagon

cylindrical head bolt

3

（10±1） N·m

Install crankshaft position

sensor, camshaft position

sensor, intake pressure

temperature sensor

1026170FB Oil pressure switch 1

（10±1） N·m

1026041FE010

Intake heating

component bolt

1

（10±1） N·m

GB/T16674.1

M6×16-9.8

Hexagon flange bolt 1

（10±1） N·m

Install intake heating

component

1026310FA040

Coolant temperature

sensor

1

（23±3） N·m

1041 Cooling system

Q1840620F61 Hexagon flange bolt 13

（10±1） N·m

8 install coolant pump, 1

install small circulation

water pipe, 1 install

three-way connector, 3

install intake water bend

pipe

Q1840825F61 Hexagon flange bolt 2

（23±3） N·m

Install thermostat valve

base

Q1840625F61 Hexagon flange bolt 3

（10±1） N·m

Install outlet water port

component

1042 Fuel system

Q1840830TF61 Hexagon flange bolt 3

（30±3） N·m

Install high pressure fuel

pump

1042322FE010

Fuel pump gear

fixed nut

1 M18×1.5

（70±5） N·m

Q1840825F61 Hexagon flange bolt 2

（23±3） N·m

Install high pressure fuel

rail

Q18410130TF2 Hexagon flange bolt 4

（60±5） N·m

Install fuel injector

pressing plate

1042112FE010

Fuel pipe fixed nut

Ⅰ

5 M14×1.5

（30±2） N·m

Connect fuel rail and fuel

injector

1042062FE010

Fuel pipe fixed nut

Ⅱ

1 M16×1.5

（35±2） N·m

Connect with fuel pump

1042501FB Bolt spring 1 M5×1×25

（8±1） N·m

Connect 2 clamping

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Figure No. Name Quantity Specification Tighten torque Remark

subassembly plates of fuel pipe bracket

Q1840612F61 Hexagon flange bolt 1

（10±1） N·m

Install fuel pipe bracket

1043 Starter assembly

Q1841060TF61 Hexagon flange bolt 2

（60±5） N·m

Install starter

1044 Exhaust system

1044203FE010

Exhaust manifold

bolt

9 M8×1.25×45

（27±3） N·m

6 install exhaust

manifold, 3 install

exhaust bend pipe

1044018FB

Exhaust manifold

fixed nut

5 M8×1.25

（27±3） N·m

2 install exhaust

manifold, 3 install

turbocharger

1044104FE010

Turbocharger

connecting bolt

3 M8×1.25×35

（23±3） N·m

Installed in turbocharger,

connect to exhaust

manifold

1044105FE010

Turbocharger

connecting bolt

1 M8×1.25×25

（27±3） N·m

Connect turbocharger and

exhaust manifold

1044304FE010

Exhaust bend pipe

bolt Ⅱ

2 M8×1.25×55

（23±3） N·m

Install exhaust bend pipe

1044209FE010

Heat shield fixed

bolt

9 M6×1×12

（10±1） N·m

Install heat shield

1044012FE010

Turbocharger

bracket fixed bolt

3 M10×1.5×20

（45±5） N·m

Install turbocharger

bracket

1016502GD050

Turbocharger with

exhaust pipe stud

2 M10×1.5

（45±5） N·m

Installed in exhaust bend

pipe, connect to DOC

assembly

1044017FB

Turbocharger fixed

nut

2 M10×1.5

（50±5） N·m

Install DOC assembly

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IV、Maintenance Limit

No. Diagrammatic sketch/ Content

Coordination

(mm)

Abrasion

limit(mm)

1、Cylinder

body cylinder

hole—Piston

skirt part

Cylinder body

cylinder hole inner

diameter

Φ93.5

015.0

0



Piston skirt part

outer diameter

Φ93.5

054.0

070.0



Cylinder fitting

clearance

0.054~0.085 0.15

2、Cylinder

cylindricity

0.01mm

3、Piston pin

hole-piston pin

Piston pin hole

diameter

Φ34.5

013.0

008.0



Piston pin outer

diameter

轴 Φ34.5

0

004.0

Radial clearance 0.008～0.017 0.03

4、Piston pin

outer diameter-

connecting rod

small end

bushing hole

Piston pin outer

diameter

Φ34.5

0

004.0

Connecting rod

small end bushing

hole

Φ34.5

017.0

012.0



Radial clearance 0.012～0.021 0.05

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5、Connecting

rod big end

wide-crankshaft

connecting rod

shaft journal

open gear

Connecting rod big

end wide

28

10.0

0



Crankshaft

connecting rod

shaft journal open

gear

28

15.0

20.0



Connecting rod big

end axial clearance

0.15～0.30

6、Piston ring

groove high-

piston ring high

(piston ring side

clearance)

1

st

piston ring

groove high

2.097

10.0

08.0



1

st

piston ring high

2.097

0

029.0

1

st

piston ring

groove-1

st

piston

ring high fit

clearance

0.08～0.129 0.20

2

nd

piston ring

groove high

2.0

06.0

04.0



2

nd

piston ring high

2.0

01.0

03.0



2

nd

piston ring

groove-2

nd

piston

ring high fit

clearance

0.05～0.09 0.17

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3

rd

piston ring

groove high

3.0

04.0

02.0



3

rd

piston ring high

3.0

01.0

03.0



3

rd

piston ring

groove-3

rd

piston

ring high fit

clearance

0.03～0.07 0.15

7、Piston ring

opening

clearance

In Φ93.5

01.0

0



ring

gauge (or in cylinder

hole)

1

st

gas ring

0.25～0.35

0.8

2

nd

gas ring

0.45～0.65

1.0

3

rd

oil ring

0.30～0.50

1.0

8、Crankshaft

main shaft

journal-cranksh

aft main shaft

bushing hole

Crankshaft main

shaft journal

Φ74 (

0

016.0

)

Crankshaft main

shaft bushing hole

Φ79 (

018.0

0



)

Shaft bushing size

2.5（

027.0

033.0



）

Radial clearance 0.054~0.10 0.15

9、Crankshaft

connecting

shaft journal-

connecting

shaft shoe hole

Crankshaft

connecting shaft

journal

Φ59 (

0

016.0

)

Connecting shaft

Φ62.4(

003.0

023.0



)

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bushing hole

Upper shaft

bushing thickness

1.659

01.0

0



Lower shaft

bushing thickness

1.663

006.0

0



Fit clearance 0.039~0.091 0.15

10、Crankshaft

thrust shaft

journal open

gear-main

bearing thrust

gear

Crankshaft thrust

shaft journal open

gear

32.5

04.0

0



Thrust shoe inner

gear width

27.52

05.0

0



Thrust shoe outer

gear width

32.22

2.0

0



Crankshaft axial

clearance

0.1~0.42

11、Valve guide

pipe inner

diameter-valve

rod diameter

Valve guide pipe

inner diameter

Φ6

015.0

0



Valve rod diameter

Intake: Φ6

030.0

045.0



Exhaust: Φ6

050.0

065.0



Fit clearance

Intake valve:

0.030～0.060

Exhaust valve:

0.050～0.080

0.10

12、Exhaust

valve base outer

diameter-exhau

st valve base

hole

Exhaust valve base

outer diameter

Φ31

095.0

075.0



Exhaust valve base

hole

Φ31H7(

025.0

0



)

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Fit clearance

Magnitude of

interference

-0.095~-0.05

13、Intake valve

base outer

diameter-intake

valve base hole

Intake valve base

outer diameter

Φ33.5

08.0

06.0



Intake valve base

hole

Φ33.5H7(

025.0

0



)

Fit clearance

Magnitude of

interference

-0.08~-0.035

14、1-4

camshaft shaft

journal-camshaf

t hole

Camshaft shaft

journal

Φ43.1(

035.0

051.0



)

Camshaft hole

Φ43.1H7(

025.0

0



)

Fit clearance 0.035～0.076 0.12

15、Camshaft

shaft journal

open gear-

camshaft

bearing thrust

gear width

Camshaft shaft

journal open gear

4.0

18.0

10.0



Location block

thickness

4.0

0

03.0

Camshaft axial

clearance

0.10～0.21 0.4

16、Camshaft

bushing inner

diameter-camsh

aft shaft journal

Camshaft bushing

inner diameter after

press fitting

Φ39.1H7(

025.0

0



)

Camshaft 5

th

gear

shaft journal

Φ39.1f6(

025.0

041.0



)

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Fit clearance 0.025～0.066 0.15

17、Flywheel

outer

diameter-flywh

eel gear ring

inner diameter

Flywheel outer

diameter

Φ374.5v7(

587.0

530.0



)

Flywheel gear ring

inner diameter

Φ374.5JS9(

07.0





)

Fit clearance

Magnitude of

interference

-0.46~-0.657

18、Cylinder

cover camshaft

bushing bore-

camshaft

bushing outer

diameter

Camshaft bushing

installation hole

Φ43.1H7(

025.0

0



)

Camshaft bushing

outer diameter

Φ43.1v7(

106.0

081.0



)

Fit clearance

Magnitude of

interference

-0.106~-0.056

19、Camshaft

chain wheel

installation

hole-correspond

ing shaft journal

on camshaft

Hole Φ21.1(

021.0

0



)

Shaft Φ21.1(

040.0

061.0



)

Fit clearance 0.04～0.082

20、Cylinder

cover

flatness-burnt

surface

0.10mm 0.15

21、Fuel

injector

protrusion

amount

2.5-3.2mm

22、Flatness of

top surface of

cylinder body

0.04mm 0.15

23、Piston

extruding

amount

0.34～0.26

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V、Special Tool

No. Tool name Outside drawing Use

1

Valve spring

compressor

Used to remove engine valve and

related components when don’t

need to remove

2

Crankshaft front oil

sealing installation

device

Install crankshaft front oil sealing

3

Oil sump removal

device

Used to remove oil sump

4

Crankshaft rear oil

sealing installation

device

Install crankshaft rear oil sealing

5

Valve oil sealing

installation device

Install valve oil sealing

6 Flywheel fastener

Fixed flywheel to be convenient to

remove

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7 Camshaft fixed tool

Fix rear part location groove of

camshaft

8 Barring tool

Rotate engine by flywheel housing

plugging hole

9

Urea pump main

strainer assembly and

disassembly tool

Used to assemble and disassemble

urea pump main strainer

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Chapter II Engine Mechanical System

I、Maintenance Note

1.1 General Note

1、Note for Discharging Engine Coolant

Discharge engine coolant after engine cooling down.

2、Note for Disconnecting Fuel Pipe

1）Release fuel pressure before disconnecting and removing;

2）Plug opening to avoid fuel leaking after disconnecting pipe.

3、Note for Dismantling and Disassembly

1）When illustrating to use special tool, please use special tool. Always pay attention to safety, don’t

force to operate or not follow the instruction.

2）Be careful not to damage fitting surface or sliding surface.

3）If necessary, use tape or equivalent product to plug opening of engine system to avoid inletting

foreign matter.

4）Mark and arrange disassembled components systematically to be convenient for troubleshooting

and assembly.

5）Basic principle of loosening bolt and nut is: first loosen the outermost, and then loosen the

diagonal position, and so on. If specified loosening sequence, please operate according to specified

sequence.

4、Note for Inspection, Maintenance and Replacement

Thoroughly check component before maintaining or replacing; if necessary, please replace.

5、Note for Assembly

1）Use tension wrench to tighten nut and bolt.

2）Basic principle of tightening bolt and nut is in several steps with the same degree of tightness, first

tighten middle, and then tighten the inner and outer diagonal positions. If specify tighten sequence, please

operate according to specified sequence.

3）Replace new gasket, oil seal or “O”-type ring.

4）Thoroughly wash, clean and dry every component. Carefully check whether there is blocking in

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engine oil or engine coolant pipe.

5）Don’t damage slipping surface or fitting surface. Clear cloth scraps or dust etc. foreign matter

thoroughly. Spread engine oil to sliding surface before assembly.

6）First release air in pipe when re-fill engine coolant after draining engine coolant.

7）After maintain, start engine and increase engine speed to check whether there is leaking in engine

coolant, fuel, engine oil and inlet/outlet.

8）Make sure to spread lubricant before installing all “O”-type ring of lubrication system.

6、Component need to be tighten with fixed angle

1）Use angle wrench to final tighten the following engine components:

① Cylinder cover bolt

② Main bearing cover bolt

③ Connecting rod bolt

④ Crankshaft belt wheel fixed bolt

2）Please don’t final tighten according to torque value.

3）Torque values of these components apply to pre-tighten procedure.

4）Ensure screw thread and base surface clean, and spread engine oil.

1.2 Sealant Note

1、Remove Sealant

Use scraper or oil sump separating special tool to separate fitting

surface and clear used sealant after removing fixed nut and bolt.

Note

：

■Be careful not to damage fitting surface.

■Insert scraper, and then knock side to slip as shown in right

picture.

■Please use plastic hammer to knock component slightly to

remove in the place where can’t use scraper.

■Please be careful not to damage fitting surface if it has to use

screw-driver etc. tools.

2、Sealant Applying Procedure

1）Use scraper to clear attached used sealant on applied surface

Knock

Slid

Scraper

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and fitting surface of gasket.

Note

：

■Clear used sealant thoroughly from sealant applied surface groove, fixed bolt and bolt hole.

2）Clean sealant applied surface and fitting surface, and clear attached water, lubricant and foreign

matter.

3）Place sealant of specified size to specified place.

Note

：

■Make sure sealant to be spread to groove.

■Generally place sealant to inside of bolt hole.

■Install combined component according to detailed specified time in this manual after spreading

sealant, generally is 3-10 minutes.

■If there is blot in sealant, please clean immediately.

■Please don’t re-tighten bolt or nut after installing.

■After installing for 30 minutes, fill engine oil and engine coolant.

1.3 Engine Sealant Use List

Sealing part Sealant Sealing strip diameter

Cylinder body-lower cylinder box

Loctite 5182 anaerobic

adhesive

（1.5±0.5）mm

Gear wheel chamber-cylinder body, lower

cylinder box

Loctite 900H silica gel （2.5±0.2）mm

Flywheel housing-gear wheel chamber Loctite 5900H silica gel （2.5±0.2）mm

Engine front part-fitting surface of cylinder

body and lower cylinder box

Loctite 5900H silica gel 2mm

Oil sump-oil pump housing, cylinder body,

gear wheel chamber

Loctite 5900H silica gel 2mm

Bowl-type plug-installation hole

Tonsan 1608 anaerobic

adhesive

Coolant drain plug screw- cylinder body

Oil pressure switch screw thread

Coolant temperature sensor screw thread

Fuel injector installation bolt

Loctite 516 anaerobic

adhesive

Remark: can use other products with similar function to replace, but can’t be less performance than

sealant in the table.

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1.4 Engine Sealant Using Detail

1）Connecting surface of cylinder body and lower cylinder box:

tighten bolt in 3 minutes after cylinder body and lower cylinder box

combined.

2）Connecting surface between gear wheel chamber and

cylinder body, lower cylinder box: install in 10 minutes after

spreading sealant.

3）Connecting surface of flywheel housing and gear wheel

chamber: install in 10 minutes after spreading sealant to flywheel.

4）Engine front part: spread sealant in connecting position of

cylinder body and lower cylinder box, as shown in right figure, and

install in 10 minutes after spreading sealant.

5）Connecting surface of oil sump and oil pump housing,

cylinder body, gear wheel chamber: spread sealant in “T”-shape

structure position formed by oil sump, oil pump housing, cylinder

body and oil sump, cylinder body, gear wheel chamber.

6）Bowl-type plug and installation surface: spread sealant in

bowl-type plug and installation surface.

7）Coolant draining plug screw: spread sealant to coolant

draining plug screw before installing.

8）Screw thread of coolant temperature sensor, fixed bolt of

high pressure fuel pump: spread screw thread sealant before installing.

Oil sump

housing

Lower

cylinder box

Gear wheel

chamber

Fly wheel

housing

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A B C

II、Front Part Auxiliary Driving System

2.1 System Diagrammatic Sketch

1、Engine；2、Idler wheel II；3、Vacuum pump；4、Idler wheel I；5、Power steering pump

bracket；6、Power steering pump；7、Fan belt wheel bracket assembly；8、Automatic tensioner

tension wheel (belong to automatic tensioner)；9、Compressor；10、Automatic tensioner；11、

Belt；12、Compound bracket

2.2 Belt Inspection

① Mechanical automatic tensioner tension belt, make sure

belt is always in reasonable tension range. It doesn’t need to

inspect belt tension in daily use, and judge whether belt needs to be

replaced according to the relevant position indicating in tensioner.

Indicating line should be between installation position A and limit

tension position C when working normally; if exceeds range C,

replace belt.

② Visually check extrinsic feature surface of engine belt to check whether there is crack,

1

2

3

4

8

9

Coolant

pump

Crankshaft belt wheel

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abrasion and spalling in driving belt surface; if any, please replace. Check belt carefully. If there are

faults as shown below, please replace new belt:

a. Belt crack

b. Belt abrade, wire is exposed

c. Belt arris damaged seriously, and even totally drop

d. Belt aging, lack of flexibility

e. Reverse side rubber hardening, smooth and no flexibility, and hardening to the range that there is

no mark when scratching by nail

③ Check whether automatic tensioner and idler wheel are flexible, and check its clearance and

noise; if needed, please replace automatic tensioner and idler wheel.

2.3 Removal

① Pull tension arm hole of automatic tensioner clockwise, and

take down belt;

② Remove automatic tensioner and compound bracket;

③ Remove fan clutch fixed bolt, and take down fan clutch, fan

belt wheel press plate and fan belt wheel;

④ Remove fan belt wheel bracket fixed bolt, and take down

fan belt wheel bracket;

⑤ Remove generator fixed bolt, and take down generator;

⑥ Remove power steering pump and power steering pump

bracket;

⑦ Remove idler wheel I and idler wheel II.

2.4 Installation

① Install compound bracket component. Check whether

location sleeve dropped before installing, and there are 2 location

sleeve in fitting surface of cylinder body, and 2 location sleeve

(compressor location sleeve) in compound bracket;

Fixed bolt

Fan assembly

Fan belt wheel

bracket

Fan belt wheel

press plate

Location sleeve between with A/C

Location sleeve between with

cylinder body

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② Install generator, and tighten generator fixed bolt;

③ Install A/C compressor, and tighten fixed bolt;

④ Check whether location sleeve on power steering pump

bracket dropped before installing, and flat surface in side of location

sleeve should face to anti-rotation convex platform on power steering

pump bracket, and doesn’t connect to anti-rotation convex platform;

⑤ Install power steering pump, and tighten power steering

pump installation bolt. (At this condition, if bolt can’t be tightened,

tighten bolt according to torque requirement after belt tensioning.)

⑥ Install fan belt wheel bracket assembly;

⑦ Install and tighten fan belt wheel stud;

⑧ Install idler wheel Ⅰ, and tighten fixed bolt;

⑨ When installing tensioner components, first insert

location pin on tensioner component to pin hole on compound

bracket, and tighten tensioner fixed bolt;

⑩ Install belt, pull out automatic tensioner belt installation

pin. If not inserting installation pin, pull automatic tensioner

tension arm hole clockwise;

11 Install fan belt wheel, press plate and fan assembly;

Fixed bolt

Fan assembly

Fan belt wheel

bracket

Fan belt wheel

press plate

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2.5 Installation Note

① If there is little lubricant oil on belt, should use dry cloth or paper to clean, and it’s forbidden to

clean belt by cleaning agent.

② Remember position of driving belt installation passing round to avoid misplacing. When

installing, operate according to the contrary sequence of removal.

③ When installing driving belt to belt wheel, check coordination condition of driving belt and belt

wheel. If driving belt and belt wheel not coordinate well, it will affect using life of driving belt. At last,

after installing driving belt and adjusting, check whether driving belt on belt wheel is running at grade.

If not, it will cause driving belt early damage.

Attachment: Front End Driving System Belt Diagnosis

Condition Possible reason Measure

Belt arris becomes too

thick (one or several

strips separate from belt)

1. Foreign matter embedded into belt

wheel groove

2. Damaged when installing

1. Clear foreign matter of belt wheel

groove

2. Replace belt

Arris or belt abraded

1. Belt wheel not aligned

2. Environment causes abrasion

3. Belt wheel gets rusty

4. There is sharp angle or bulge on

top end of belt wheel groove

5. Belt rubber aging

1. Align belt wheel

2. Clean belt wheel, replace if

needed

3. Belt wheel gets rusty

4. Replace belt wheel, check belt

5. Replace belt

Belt trackslip

1. Belt trackslip due to belt tension

not enough

2. Belt or pulley exposed in substance

that reduce friction (belt oil, oil,

ethylene glycol)

3. Bearing of driven component

damage (seizure)

4. Be heated and excessive trackslip

make belt abraded and harden

1. Check if needed/Replace

tensioner

2. Replace belt and clean belt wheel

3. Replace damaged component or

bearing

4. Replace belt

Belt vertical crack

1. Belt not lead in well when getting

into belt groove

2. Top edge of belt wheel groove

abrades rubber, exposed core rope of

rope

1. Replace belt

2. Replace belt

“Groove jumping” (Belt

can’t stay in right

position of belt wheel)

1. Belt tension not right

2. Belt wheel is not in the range of

design common difference

3. There is foreign matter in belt

wheel groove

4. Belt wheel not aligned

5. Belt core rope disconnected

1. Check if needed/Replace

tensioner

2. Replace belt wheel

3. Clear foreign matter from groove

4. Align component

5. Replace belt

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Condition Possible reason Measure

Belt crack (Note: install

new belt, check and

remove existed fault)

1. Belt tension not right

2. Damage core rope of pulling rope

when installing belt

3. Not aligned seriously

4. Bracket, belt or bearing damaged

1. Replace, check if needed/ replace

tensioner

2. Replace belt

3. Align belt wheel

4. Replace damaged component and

belt

Noise (When belt

running, hear or feel

harsh scream, squeak

scream)

1. Belt tension not right

2. Bearing noise

3. Belt not aligned

4. Belt and belt wheel not matching

5. Driven component causes vibration

6. Belt flattening surface separated

1. Check if needed/Replace

tensioner

2. Check and maintain

3. Belt aligned

4. Install right belt

5. Find faulted driven component

and maintain

6. Replace belt

Fault (weaving fiber

outside belt surrounding

is damaged or separated

from belt)

1. Tension sheath contacts to fixed

object, and overheating cause

weaving fiber aging

2. Belt sheath connection position

crack

1. Check friction condition, replace

belt

2. Replace belt

Rope edge fault (belt

edge flexible part

exposed or separated

from belt)

1. Belt tension not right

2. Belt contacts to fixed object

3. Pulley (one or several) is more than

common difference

4. Adhesive force between flexible

part and rubber is not enough

1. Check if needed/Replace

tensioner

2. Replace belt

3. Replace pulley

4. Replace belt

2.6 Removal and Installation of Vacuum Pump

① Install vacuum pump assembly, ensure its square convex

platform to be inserted into groove of camshaft end, and then tighten

vacuum pump installation bolt;

② Remove according to the contrary sequence of installation;

③ Ensure connecting surface of vacuum pump is clean before installing.

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Attachment: Front End Driving System Bolt Tighten Torque

No.

Name

Quantity

Specification

Tighten torque

Remark

Q1840825F61 Hexagon flange bolt 2 （23±3） N·m

Install vacuum

pump

Q1840820F61 Hexagon flange bolt 1 （23±3） N·m

Install vacuum

pump

Q1841040F61-9.8 Hexagon flange bolt 4 （50±5） N·m

Install fan belt

wheel bracket

component

Q1841050F61-9.8 Hexagon flange bolt 2 （50±5） N·m

Install compound

bracket

Q1841080F61-9.8 Hexagon flange bolt 2 （50±5） N·m

Install compound

bracket

Q1841035F61-9.8 Hexagon flange bolt 1 （50±5） N·m Install generator

Q18410120F61-9.8 Hexagon flange bolt 1 （50±5） N·m Install generator

Q1841030F61-9.8 Hexagon flange bolt 2 （50±5） N·m

Install power

steering pump

bracket

Q1841023F61-9.8 Hexagon flange bolt 1 （50±5） N·m

Install power

steering pump

bracket

Q1840816F61 Hexagon flange bolt 1 （23±3） N·m

Install wiring

harness fixed

bracket

Q1840820F61 Hexagon flange bolt 2 （23±3） N·m

Install power

steering pump

Q1840885F61 Hexagon flange bolt 1 （23±3） N·m

Install power

steering pump

------------

Idler Ⅰ installation

bolt

1 M10×1.5 （50±5） N·m

Idler wheel Ⅰ

installation bolt

------------

Idler Ⅱ installation

bolt

1 M10×1.5 （50±5） N·m

Idler wheel Ⅱ

installation bolt

Q1841075TF61 Hexagon flange bolt 1 （50~54） N·m

Tensioner

assembly fixed

bolt

Q1841030F61 Hexagon flange bolt 4 （45±5） N·m

Install fan

assembly

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III、Timing System

3.1 System Diagrammatic Sketch

1、Gear wheel chamber； 2、Idler gear wheel lower gasket； 3、High pressure fuel pump gear wheel；

4、Idler gear wheel assembly I； 5、Tensioner cover fixed bolt； 6、Tensioner rear cover；

7、Tensioner rear cover sealing ring； 8、Tensioner； 9、Camshaft chain wheel；

10、Camshaft chain wheel press plate； 11、Camshaft chain wheel fixed bolt； 12、Chain；

13、Movable rail； 14、Inner hexagon cylinder head bolt； 15、Driving chain wheel fixed bolt；

16、Inner hexagon cylinder head bolt； 17、Idler gear wheel upper gasket； 18、Driving chain wheel；

19、Idler gear wheel shaft； 20、Idler gear wheel location pin；

21、High pressure fuel pump fixed nut； 22、High pressure fuel pump gear wheel gasket；

23、Fuel pump flange sealing ring； 24、Fuel pump flange； 25、High pressure fuel pump；

26、High pressure fuel pump fixed bolt； 27、Movable rail

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3.2 Removal

① Remove all components of front end driving system according to “2.3 Front End Driving

System”;

② Rotate top dead center mark T of outer annulus of

crankshaft belt wheel to align to base mark of fuel pump housing,

which is convenient to confirm piston upper dead center position, and

insert with pin;

③ Separate engine from transmission;

④ Use flywheel clamp to seize flywheel, remove flywheel

fixed bolt, and take down flywheel and flywheel housing;

⑤ Use special tool to fix rear part of camshaft connecting to

vacuum pump key groove;

⑥ Remove camshaft toothed wheel fixed bolt;

⑦ Remove chain tensioner fixed bolt, and take down tensioner;

⑧ Loosen fuel injector fixed nut;

⑨ Loosen camshaft toothed wheel fixed bolt. Remove camshaft bolt bushing and idler gear wheel

shaft;

⑩ Remove gear wheel chamber fixed bolt.

3.3 Inspection

Check whether there is abrasion, crack and damage in camshaft gear wheel, crankshaft gear wheel,

fuel injector gear wheel and idler wheel; if any, please replace in time.

3.4 Installation

1、Gear Wheel Chamber Installation

① Clear remained sealant in gear wheel chamber and

cylinder body before installing; check whether there is clash,

Camshaft phase

position fixed plate

Camshaft phase

position fixed plate

This side clings to top

side of cylinder head

Insert into camshaft

position groove

Locating

sleeve

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scratch and sealant strip in connecting surface of fuel pump housing and chain wheel chamber, and

ensure connecting surface clean;

② Check whether fixed bolt and screw thread hole of gear wheel chamber is damaged or stripped;

③ Check/Install gear wheel chamber locating sleeve on cylinder body. Locating sleeve of gear

wheel chamber and cylinder body are interference fit, extrude height:

4.5±0.3mm; Locating sleeve and gear wheel chamber are clearance

fit;

④ Install gear wheel chamber sealing ring to gear wheel

chamber, and check whether sealing ring is damaged before installing,

and ensure sealing ring to be embedded into sealing groove when

installing;

⑤ Before installing gear wheel chamber, evenly spread

sealant to connecting surface of gear wheel chamber and cylinder

body, complete installation at a time, and ensure it isn’t loosen

after installation. Clear overflowed unnecessary sealant (left/right

side and bottom side) of connecting surface after installing. Sealant

type: Loctite 5900H silica gel; sealant diameter: (2.5±0.2)mm;

ensure to complete installation in 10 minutes after spreading

sealant;

⑥ Tighten gear wheel chamber fixed bolt Ⅰ, Ⅱ, Ⅲ, Ⅳ,

bolt Ⅰ-Q1840620F61/bolt Ⅱ-Q1840620 installation torque:

10±1N•m; bolt Ⅲ-Q1841035F61/bolt Ⅳ-Q1841035 installation

torque: 37±9N•m.

2、Installation of Timing System

① Ensure upper dead center mark T of outer circle of

crankshaft belt wheel aligned to base mark fuel pump housing, and

to be convenient to ensure position of piston upper dead center,

and insert with pins.

② Install idler gear wheel assembly, driving chain wheel.

Before installing idler gear wheel assembly, install driving chain

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wheel to idler wheel;

③ Install lower heel block (thickness 2.5mm) of idler wheel

on cylinder body, and install idler gear wheel locating pin (split pin)

on idler gear wheel shaft, locating pin protruding idler gear wheel

end surface height 5mm;

④ Install idler gear wheel assembly to idler gear wheel shaft,

and should spread proper lubricant oil to surface of idler gear wheel shaft, and then slightly push idler

gear wheel assembly into idler gear wheel shaft; after installing upper heel block (thickness 4mm) of

idler gear wheel, tighten idler gear wheel fixed bolt. Oil groove on two shims both face to gear wheel;

⑤ Install camshaft according to “7.4 Valve System”, you

should spread proper lubricant oil to all shaft journals and cam

before install camshaft to cylinder head, and then push camshaft

into cylinder head cam bearing hole slightly from front part of

cylinder head, and ensure there is no scratch or damage. Axial

positioning groove faces to rear part of cylinder head, and adjust

angle of camshaft to make key groove of rear part straight up;

⑥ Fix camshaft by special tool in front part of cylinder head;

⑦ Camshaft axial locating plate is installed in rear part of

cylinder head, rounded side faces to flywheel end of engine (outward), and pay attention to not install

reversely, and tighten camshaft locating plate bolt;

⑧ Install fixed rail and moveable rail, spread proper lubrication oil to chain side of fixed rail

before installing, and tighten fixing bolt;

⑨ First install chain to driving chain wheel, mesh camshaft chain and chain, and install it to

Idler gear wheel

locating pin

Gap upward

This side clings to top

part of cylinder head

Insert into camshaft

locating groove

Camshaft phase

position locating plate

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camshaft, and at last install camshaft chain wheel pressing plate, and pre-tighten installation bolt;

⑩ Install chain tensioner assembly and tensioner rear cover. Before installing tensioner rear cover,

install sealing ring into sealing groove of tensioner rear cover. Before installing chain tensioner

assembly, first check whether its sliding bushing is sliding flexibly, and there isn’t any clamping

stagnation phenomenon, and then spread proper lubricant oil to shaft journal surface of chain tensioner,

slightly push into installation hole of chain wheel chamber; before chain tensioner assembly is pressing

movable rail, movable rail should move flexibly around chain guide rail fixed bolt, and there is no any

clamping stagnation phenomenon. At the same time, pre-tighten and tighten fixed bolts of two tensioner

rear cover, and avoid rear cover skew when tightening, and causes sealing ring side scrap damaged;

11 Ensure signal gear on camshaft to face to partial upper side of intake side, and tighten camshaft

chain wheel bolt;

12 Tighten camshaft chain wheel bolt, and remove cam

phase position fixed plate for installation;

13 Rotate crankshaft clockwise until top end center mark P

of outer annulus of crankshaft belt wheel aligned to base mark of

fuel pump housing, thus to ensure position of piston top end center,

and insert with pin;

14 Before installing high pressure fuel pump, check high

pressure fuel pump sealing ring, if sealing ring is damaged, it need

to be replaced, and spread lubricant oil to sealing ring; spread

anaerobic type screw thread sealant to installation bolt of high

pressure fuel pump before installing. Install high pressure fuel

pump to high pressure fuel pump flange, and align timing mark on fuel pump to mark on fuel pump

installation flange;

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15 Install high pressure fuel pump gear wheel to fuel pump

shaft, align locating pin groove on gear wheel to locating pin on

fuel pump, pre-tighten fixed nut, and rotate gear wheel until mark

aligned to mark on fuel pump installation flange, namely fuel

pump is in top dead center;

16 Install fuel pump assembly to front idling wheel gear, and

tighten connecting bolt of flange and cylinder body;

17 Use limit rotation shaft in rear part of crankshaft to get

struck crankshaft by flywheel bolt;

18 Tighten high pressure fuel pump gear wheel nut;

Align mark

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Attachment: Bolt Tighten Torque of Timing System

Part Code Name Quantity Specification Tighten torque Remark

GB/T70.1

M6×16-12.9

Inner hexagon

cylindrical head bolt

4 (12±1) N·m

Install driving

chain wheel

Q1841275TF2 Hexagon flange bolt 1 (125±5) N·m

Install idling

gear wheel

1021060FE010

Chain guide rail

fixed bolt

3 M8×1.25×15 (23±3) N·m

Q218B0625-9.

8

Inner hexagon

cylindrical head bolt

2 (10±1) N·m

Install

tensioner rear

cover

1021122FE010

Camshaft chain

wheel bolt

1 M14×1.5×52

(100±5)N·m+(

90°±2°)

Q1840835TF61 Hexagon flange bolt 3 (30±3) N·m

Install high

pressure fuel

pump flange

Q1840620 Hexagon flange bolt 4 (10～15) N·m

Install gear

chamber

Q1840620F61 Hexagon flange bolt 2 (10～15) N·m

Install gear

chamber

Q1841035 Hexagon flange bolt 4 (28～46) N·m

Install gear

chamber

Q1841035F61 Hexagon flange bolt 1 (28～46) N·m

Install gear

chamber

Q1840830TF61 Hexagon flange bolt 3 (30±3) N·m

Install high

pressure fuel

pump

1042322FE010

High pressure fuel

pump gear wheel

fixed nut

1 M18×1.5 (70±5) N·m

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IV、Intake System

4.1 System Diagrammatic Sketch

1、Intake bending pipe 2、Intake bending pipe sealing ring 3、Intake manifold

4、Fixed nut 5、Intake pipe gasket 6、Hexagon flange bolt 7、Hexagon flange bolt

8、Intake bending pipe fixed bolt 9、Intake heating component

4.2 Removal of Intake System

1、Remove fixed bolt of oil level gauge and intake pipe;

2、Crosswise loosen fixed bolt and nut of intake pipe from two sides to middle. Take down intake

manifold and intake bending pipe assembly, and take down intake manifold sealing ring;

3、Remove intake pressure sensor;

4.3 Installation and Check of Intake System

① Before installing, clean all components, and there is no scraps in intake manifold and intake

bending pipe;

② Check all gaskets and ensure there is no damage, scratch or crumple to ensure its sealing function;

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③ Install intake manifold gasket and intake manifold, surface

of intake manifold gasket should be flat, and there is no scratch or

crumple. Bolt tighten sequence should obey to the principle of from

middle to two sides and tightening crosswise, and tighten torque

should be even to avoid air leakage;

④ Intake heating component installation: First remove

insulation gasket, install intake heating component to intake port of

intake manifold, and install insulation gasket and tighten bolt. When

installing, 30° chamfering faces to intake manifold side, 45°

chamfering faces to intake bending pipe side (after installing, fixed

bolt is vertical, and wiring terminal is 30°tilting);

⑤ Install and tighten connecting bolt of heating component and intake pipe;

⑥ Check state of intake pressure temperature sensor sealing ring, install intake pressure temperature

sensor to intake manifold, and tighten fixed bolt;

⑦ Install intake bending pipe to intake manifold, and before installing ensure sealing ring is rightly

installed in groove on intake bending pipe, and tighten fixed bolt;

Attachment: Tighten Torque of Intake System Bolt

Part No. Name Quantity Tighten torque Remark

Q1840870F61 Hexagon flange bolt 7 （23±3） N·m

Q1840825F61 Hexagon flange bolt 1 （23±3） N·m Install intake manifold

Q32008F61 Hexagon flange nut 2 （27±3） N·m Install intake manifold

Q1840620F61 Hexagon flange bolt 3 （10±1）N·m

Install intake bending

pipe

1026041FE010

Intake heating

component bolt

1 （10±1） N·m

GB/T16674.1

M6×16-9.8

Hexagon flange bolt 1 （10±1） N·m

Install intake heating

component

Q218B0616

Inner hexagon stud

bolt

3 （10±1） N·m

Install intake pressure

temperature sensor

Intake manifold direction

Wiring terminal of

heating component

Intake heating

component

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V、Exhaust System

5.1 System Diagrammatic Sketch

1、Turbocharger 2、Exhaust bending pipe gasket 3、Exhaust bending pipe

4、Catalyst converter gasket 5、Turbocharger bracket 6、Exhaust manifold

7、Turbocharger gasket 8、Exhaust pipe gasket 9、Heat insulation plate I

10、Heat insulation plate II

5.2 Removal of Exhaust System

1、Remove connecting nut of turbocharger and catalyst converter;

2、Remove fixed bolt and gasket of turbocharger inlet/return oil steel pipe;

3、Remove fixed bolt of turbocharger bracket and cylinder body;

4、Remove fixed bolt of exhaust manifold, and take down exhaust manifold and turbocharger

assembly;

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5.3 Installation and Check of Exhaust System

① Check whether surface of turbocharger impeller is flat,

whether there is damage or scratch and abrasion due to foreign matter

getting in, and check whether turbocharger is rubbing housing, check

whether axial clearance of turbocharger is too large and rotating

flexibly. If there is any fault above, replace turbocharger, and at the

same time check whether there is leakage in all components of intake

system and pipe, thus to avoid turbocharger being damaged too early

again;

② Check gaskets, and there is no damage, scratch, crumple,

and ensure its sealing function;

③ Install exhaust manifold gasket to stud of cylinder head

exhaust side;

④ Install exhaust manifold, and tighten fixed bolt and nut;

⑤ Before installing turbocharger, tighten stud to turbocharger.

Install turbocharger and turbocharger gasket to exhaust manifold, and

tighten fixed bolt and nut;

⑥ When installing turbocharger inlet oil pipe assembly, check

whether two ends of banana-shape connector not installed grommet.

Copper gasket is disposable component, replace new after removing;

⑦ Install turbocharger return oil steel pipe assembly, and

check the condition of sealing gasket when installing;

⑧ Fix turbocharger return oil pipe fixed stud to joint under

exhaust manifold, and after respectively fixing inlet/return oil pipe to

stud by respective clamp, tighten with fixed nut;

⑨ Install exhaust bending pipe and gasket;

⑩ Connect catalyst converter and exhaust bending pipe, and

tighten fixed nut;

11 Install exhaust pipe heating insulation cover and exhaust

bending pipe heating insulation cover;

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Attachment: Tighten Torque of Fixed Bolt of Exhaust System

Part No. Name Quantity Specification Tighten torque Remark

1044203FE010

Exhaust manifold

bolt

9 M8×1.25×45 （27±3）N·m

6 install exhaust

manifold, 3 install

exhaust bending

pipe

1044018FB

Exhaust manifold

fixed nut

5 M8×1.25 （27±3）N·m

2 install exhaust

manifold, 3 install

turbocharger

1044104FE010

Turbocharger

connecting

double-screw bolt

3 M8×1.25×35 （23±3）N·m

Installed on

turbocharger,

connecting to

exhaust manifold

1044105FE010

Turbocharger

connecting bolt

1 M8×1.25×25 （27±3）N·m

Connect

turbocharger and

exhaust manifold

1044304FE010

Exhausting bending

pipe bolt Ⅱ

2 M8×1.25×55 （23±3）N·m

Install exhaust

bending pipe

1044209FE010

Heat insulation

plate fixed bolt

9 M6×1×12 （10±1）N·m

Install heat

insulation plate

1044012FE010

Turbocharger

bracket fixed bolt

3 M10×1.5×20 （45±5）N·m

Install

turbocharger

bracket

1016502GD050

Turbocharger

connecting to

exhaust pipe

double-screw bolt

2 M10×1.5 （45±5）N·m

Installed on

exhaust bending

pipe, connecting

DOC assembly

1044017FB

Turbocharger fixed

nut

2 M10×1.5 （50±5）N·m

Install DOC

assembly

1010353FA01 Crossing hole bolt 2 M12×1.5×30 25～31 N·m

Q1840820F61

Hexagon flange

bolt

2 （23±3）N·m

Connecting return

oil pipe and

cylinder body

Q1840616F61

Hexagon flange

bolt

2 （10±1）N·m

Connecting return

oil pipe and

turbocharger

1010055FE010

Turbocharger return

oil pipe fixed

double-screw bolt

1 M8×1.25 （23±3）N·m

Fix inlet/return oil

pipe to exhaust

pipe

Q32008F61 Hexagon flange nut 2 （27±3）N·m

1 fixes inlet oil

pipe, 1 fixes return

oil pipe

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5.4 Fault Judgment of Turbocharger Impeller and Oil Leakage

When there is fault in turbocharger, no matter oil leakage or abnormal noise, first check state of

turbocharger impeller, and ensure whether state of turbocharger impeller is normal. If impeller is

normal, troubleshoot relevant oil leakage of booster end of turbocharger, oil leakage of turbine end

of turbocharger, abnormal noise fault of turbocharger according to different fault mode.

1、Check Method of Turbocharger Two Wheels Damaged by Foreign Matter

Remove malfunction turbocharger from engine, and check damage condition of turbine and impeller,

and whether there is knock mark of foreign matter, whether there is foreign matter in turbocharger inlet/

outlet pipe.

Normal impeller Impeller damaged by hard object

Impeller damaged by particulate matter Impeller damaged by particulate matter

Responsibility Judgment:

All turbocharger impeller damage faults are not damaged by turbocharger quality problems, are all

caused by users or improper maintenance and usage of intake system.

Possible reasons:

(1) Turbocharger is not maintained for a long time

(2) Use inferior filter

(3) Pull out pipe between fuel-gas separator and intake pipe, air without filtering gets into

turbocharger through connector, and dust will abrade impeller.

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2、Check Method of Oil Leakage Fault of Booster side of Turbocharger

① Turbocharger itself causes booster side oil leakage

A：Booster impeller damaged;

B：Booster impeller clamped or turbocharger abraded;

② Other reasons cause booster side oil leakage

Oil leakage of turbocharger booster side is related to many factors, sometimes oil leakage of

turbocharger booster side is not because of turbocharger, but due to other factor causing oil leakage of

turbocharger booster side, and affect factors are shown below:

A：There is oil getting into turbocharger intake pipe in crankcase respiratory system;

B：There is blockage in turbocharger intake system;

C：There is air leakage between pipe of turbocharger booster to engine intake pipe;

D：Turbocharger returns oil not smoothly;

E：Engine is in idling working condition for a long time;

③ Check method of oil leakage of booster side of turbocharger

A：Check Condition of Turbocharger Impeller

Judge the condition of impeller by visually check appearance of booster impeller (methods of

impeller damage and judging whether impeller is damaged are the same), and at the same time can judge

intake condition: normal impeller angel is about 90°right angle, there is no any round angle. If impeller

angle becomes round, it indicates turbocharger intake is fairly dirty, and there is a little tiny particle, as

shown in below picture. Due to turbocharger impeller is high speed rotating component, when there is

tiny particle in intake system, it will cause high speed friction with impeller, and impeller angle will

become round because of abrasion. And some tiny particle may get into interior component of

turbocharger, accelerate abrasion of turbocharger and leading to oil leakage of turbocharger.

Responsibility Judgment:

When impeller leaking oil due to round angle phenomenon, it can judge that turbocharger damage

due to worse intake quality, it’s user’s responsibility, not turbocharger quality problem.

Possible reasons:

(1) Air filter element isn’t maintained for a long time or filter element damaged causing air get into

turbocharger directly;

(2) Use inferior filter element;

(3) Pull out pipe between fuel-gas separator and intake pipe, air without filtering gets into

turbocharger through connector, and dust will abrade impeller.

Note: If turbocharger impeller angle is slight round and slightly leaking oil, it doesn’t need to

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replace turbocharger, but should check intake system before engine turbocharging to ensure whether air

filter and intake pipe are clean; if not, replace air filter and clean intake pipe. As such, if turbocharge

impeller angle is round, check intake system before engine turbocharging to ensure whether air filter and

intake pipe are clean; if not, replace air filter and clean intake pipe.

B：Check Whether Turbocharger Impeller is Clamped (Scrub Housing)

After ensuring turbocharge impeller is normal, please check whether there is interfere phenomenon

between turbocharger impeller and turbocharger housing, namely scrubbing housing, as shown in below

pictures. When there is scrubbing housing phenomenon of turbocharger, impeller speed will drop

rapidly and even stop running, turbocharger booster will not compress air, namely turbocharging; and at

this time, due to engine continuous intake air, it will become from normal positive pressure (more than

atmosphere pressure) to negative pressure (less than atmosphere pressure) in booster, and it will cause

oil in turbocharger be absorbed from opening sealing ring of rotor shaft.

Impeller scrubbing housing Impeller scrubbing housing leading to serious abrasion

Rotate impeller to observe whether there is phenomenon of clamping or scrubbing housing; if there

is, hold two sides of impeller to shake up and down, if impeller shaking very strongly, it indicates

abrasion has already exceeded standard value, namely, turbocharger is damaged already. Or hold two

sides of impeller to shake up and down, if impeller could touch turbocharger housing, it indicates

abrasion has already exceeded standard value, namely, turbocharger is damaged already.

When turbocharger impeller shaft abraded, axial and radial clearance of impeller shaft will become

large, at the same time turbocharger leaking oil amount will be very large; certainly leaking oil amount

depends on its abrasion amount (except for abrasion causing impeller shaft locked). Due to more

abrasion amount, axial and radial clearance of impeller shaft will be more larger, leaking oil amount will

be more larger.

If turbocharger impeller gets stuck and not interfere to housing, it indicates impeller shaft is locked

already.

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Responsibility Judgment:

Impeller scrubbing housing but impeller shaft clearance is normal, it’s turbocharger’s quality

problem.

If impeller scrubbing housing but impeller shaft clearance is larger than standard value, it indicates

impeller shaft abraded too much, thus shaft clearance too large causes impeller scrubbing housing when

rotating, but oil quality and turbocharger maintenance are important factors, they are user’s

responsibility and have nothing to do with turbocharger quality.

Impeller shaft locked is also closely related to oil quality and turbocharger maintenance, which is

user’s responsibility and has nothing to do with turbocharger quality.

Turbocharger shaft rotation speed is very fast; if oil quality is bad or there is impurity, shaft

abrasion speed will be also very fast. Therefore during the procedure, shaft clearance will become big or

shaft will be locked.

C、Check Whether There is Oil Getting into Turbocharger Intake Pipe From Crankcase

Breath System

Remove intake pipe of turbocharger booster intake port, and check whether there is oil in intake pipe

and turbocharger booster intake port; if there is oil both in intake pipe and booster intake port, it indicates

there is remained oil in crankcase breath system getting into turbocharger, thus causes that there is oil in

turbocharging inter-cooling system, and causes the false phenomenon of turbocharger leaking oil. Due to

one side of crankcase ventilation hose connects to engine cylinder hood, crank exhaust gas will be

discharged from the pipe when engine running, and as the same it will take out some oil; but the other

side of crankcase ventilation hose is connected to intake pipe of turbocharger, oil gets into turbocharger,

causing the false phenomenon of leaking oil.

If also can’t conform problem by above check, remove connected part of breath hose of engine

cylinder hood and cylinder hood, block hose with cork, and clean turbocharger and all pipes, connect

well to test run; if there is no oil leaking in inter-cooling system any more, it indicates oil in breath

system getting into turbocharger; if there is more oil leaking again, it indicates it’s not related to breath

system, and it needs further check.

Responsibility Judgment:

Oil in crankcase ventilation hose getting into turbocharger causes turbocharger false phenomenon of

leaking oil, in this condition, turbocharger is normal, and there is no need to replace turbocharger, and

only need to remove the related problem of crankcase pressure too large.

D、Check Whether There is Blockage Phenomenon in Turbocharger Intake System

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When turbocharging system is blocked seriously, it may affect engine power performance, but

slight blockage may not affect engine power performance. When find engine bad power performance

and turbocharger leaking oil at the same time, intake system may be blocked. Slight blockage doesn’t

affect engine power, but either serious blockage or slight blockage will cause turbocharger leak oil.

Because when turbocharger intake is blocked, intake vacuum degree increases, booster outtake pressure

decreases, and oil will be sucked out by too low intake pressure from turbocharger impeller shaft

opening ring.

Responsibility Judgment:

When intake system blockage causes turbocharger leak oil, turbocharger is normal and not

damaged, there is no need to replace turbocharger, and should check intake blockage position prior.

Check whether air filter is too dirty or there is blockage.

Check pipe between air filter and turbocharger intake port, and can remove the pipe length by

length to check; if there is blockage, please clear.

Note: Intake system blockage generally is air filter too dirty.

E、There is Leaking Air Phenomenon between Pipes of Turbocharger Booster and Engine

Intake Pipe

When there is leaking air phenomenon in engine boosting inter-cooling pipe, pressure in

turbocharger booster will decrease, pressure in turbine and booster will lose balance, causing booster

leak oil; at the same time, there is compressed air leaking in position of pipe leaking air, and there is oil

in leaked compressed air, which will be attached to leakage point, and appearance will be ugly.

There are some engines due to not installing gasket in combining intake pipe and outtake pipe leads

to the position leak oil seriously, and intake pressure decreasing greatly leads to turbocharger leaking oil

more seriously.

Observe all connecting points of turbocharging inter-cooling pipe, if connecting point attached oil,

it indicates there is leakage in the connecting point, and should deal with it.

If there is no obvious leaking point, check whether there is damage in pipe and inter-cooler

concealment position; handle pipe to check in order to feel leaking position. Installation position of

inter-cooler may affect inspection of leaking position, and remove inter-cooler from vehicle to check if

necessary. Use water to check leakage, namely, stuff up one port of inter-cooler, fill water, and observe

its change condition of water level; if water level decreases, it indicates there is leakage. And also can

observe whether there is water leaking to judge whether there is leakage.

Responsibility Judgment:

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When due to leakage air of engine turbocharging inter-cooling pipe causing turbocharger leak oil,

it’s not related to turbocharger itself quality, turbocharger is normal and there is no need to replace. Deal

with leakage air position to ensure all turbocharging inter-cooling pipe not leak, therefore remove the

leakage oil fault.

F、Turbocharger Return Oil not Smoothly

When turbocharger return oil not smoothly, oil pressure in turbocharger will rise up, thus oil will

leak from opening ring of turbine and booster; if oil leakage too much when the fault happens, oil in oil

sump will decrease obviously.

1、Ensure whether pressure in engine crankcase is too large. Because turbocharger is gravity return

oil, when crankcase pressure is too large, return oil will get stuck. After engine running for a long time,

you can pull out oil level gauge to check whether there is gas injecting fuel; if there is the phenomenon, it

indicates crankcase pressure is too large.

2、Check whether there is blockage in turbocharger return oil pipe. Observe whether return oil hose

is bending; if bending, it will affect oil return; if normal, remove return oil pipe to check.

Responsibility Judgment:

When turbocharger return oil not smoothly causing turbocharger leak oil, turbocharger is normal and

there is no fault, as long as deal with return oil pipe blockage problem, and then is OK. Of course, return

oil pipe blockage will cause turbocharger leak oil seriously, therefore clean oil in turbocharger and

inter-cooler pipe.

G：Engine is In Idling Working Condition For A Long Time

When engine idling running for a long time, gas pressure in turbocharger booster is lower, but oil

pressure in middle of turbocharger is higher, thus oil in middle of turbocharger will leak from opening

ring of impeller side. As the same, if engine idling running for a long time, turbine side may leak oil.

When check items above and there is no problem, pay attention to user’s using habit, user possibly

idling running for a long time causes the fault. Inquiry user’s using condition carefully, and inform user

that can’t idle running for a long time.

Responsibility Judgment:

When engine idling running for a long time causing turbocharger leak oil, it doesn’t need to replace

turbocharger, because turbocharger is normal and there is no fault.

3、Check Method of Turbocharger Turbine Side Leaking Oil Fault

① Turbocharger itself reason causes turbine side leaking oil

A：Turbine impeller damaged;

B：Turbine impeller clamped;

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C：Turbocharger shaft abraded;

② Other reasons cause turbine side leaking oil

Oil leakage of turbocharger turbine side is related to many factors, sometimes oil leakage of

turbocharger turbine side is not because of turbocharger, but due to other factor causing oil leakage of

turbocharger turbine side, and affect factors are shown below:

A：Engine is in idling working condition for a long time;

B：Turbocharger returns oil not smoothly;

C：Engine leaking oil seriously leads to oil get into turbocharger turbine from exhaust pipe;

③ Check method of oil leakage of turbocharger turbine side

A：Turbine impeller damaged;

B：Turbine impeller clamped;

C：Turbocharger shaft abraded;

D：Engine is in idling working condition for a long time;

E：Turbocharger returns oil not smoothly;

Fault modes shown above are similar to fault modes of turbocharger booster leaking oil, and please

refer to troubleshooting method of related fault of turbocharger booster leaking oil to remove these

faults.

Fault leaking oil seriously leads to oil get into turbocharger turbine from exhaust pipe.

When engine leaking oil seriously, maybe there is redundant oil getting into turbocharger turbine

from exhaust pipe, causing the false phenomenon of turbine leaking oil. At this time, exactly judge

whether oil is leaking from turbocharger turbine side or other places; when removing turbocharger,

carefully observe turbocharger turbine condition, and observe whether there is oil in inlet port of

turbocharger turbine at the same time; if there is oil, it indicates oil gets into turbine from engine exhaust

pipe; or else, it indicates there is no oil in engine exhaust pipe or don’t affect turbocharger.

Note: When checking the fault, pay attention to that whether there is oil leaking in turbocharger

booster side. When booster side is leaking oil seriously, more oil gets into cylinder from engine exhaust

pipe, but redundant oil can’t be totally burnt and discharging from exhaust pipe. There is amount of oil

in engine exhaust pipe, which indicating engine leaking oil and oil discharged from exhaust pipe. Inlet

port of turbocharger turbine is clean and there is no oil, which indicating there is no oil in engine exhaust

pipe.

Responsibility Judgment:

There is oil leaking in exhaust pipe, which is not directly linked to turbocharger, therefore there is

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no need to replace turbocharger.

VI、Lubricating System

6.1 System Diagrammatic Sketch

1、Oil sump； 2、Oil discharging plug screw & gasket； 3、Oil sump sealing ring；

4、Oil level gauge； 5、Turbocharger oil return pipe； 6、Turbocharger oil inlet pipe；

7、Oil pump； 8、Oil cooler； 9、Oil filter； 10、Oil strainer

Oil pump is crankshaft direct-drive pump, its housing is front part cover plate.

Oil pump atmospheric valve opening pressure: 400-500Kpa

Oil filter by-pass valve opening pressure: 80-120Kpa

Oil cooler by-pass valve opening pressure: 100-140Kpa

Below figure is 2.7CTI lubricating system related diagrammatic sketch and route diagram.

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6.2 Replacement Oil and Oil Filter

After long time usage, there will be impurity, dust and dirt in oil. And due to some unburned

fuel mixed in oil, which makes oil thin, and some exhaust gas along with acid anhydride gets into

oil, which makes oil go bad and corrode engine components. Therefore, after using oil for a period

of time (such as vehicle running 15000km), discharge all oil and replace new oil. And should use

oil not less than CI-4 and accord with the regulation of GB 11122.

① Clean oil filling port cover on cylinder head hood with cloth, and pay attention to not mix

external sundries. Remove oil filling port cover;

② Remove oil discharging plug screw on oil sump to discharge oil, and pay attention to oil

temperature may be very high;

③ Use special tool to remove engine oil filter;

④ Clean installation surface of oil filter0;

⑤ Before connecting oil filter and oil cooler central screw arbor, tighten central screw arbor,

tighten torque is 50-60N.m;

⑥ Spread a little oil to O-type ring of new oil filter;

⑦ Once O-type ring of oil filter connects installation surface of oil filter, please use special

tool to tighten according to specified tightening process;

⑧ Replace new oil discharging plug screw gasket, and install oil discharging plug screw

gasket on oil sump;

⑨ Fill oil from oil filling port on cylinder head hood;

Cylinder head

Cylinder body

Vacuum

pump

Camshaft bearing

Rocker arm

Tensioner

Cylinder cover main

oil duct

Timing gear

wheel bearing

Cylinder head oil

return hole

Splash

Chain wheel

chamber idler

wheel

Oil strainer

Oil pump

Oil cooler

Oil filter

One-way safety valve

Limit pressure valve

Crankshaft

journal

Connecting

rod journal

Piston cooling

spraying nozzle

Piston

Cylinder body main oil duct

Auxiliary

oil duct

Turbocharger

Oil sump

Turbocharger oil

return pipe

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⑩ Wait for 10min to make oil flow back to oil sump;

11 Pull out oil level gauge from engine, and check whether oil level is between upper and

lower graduation;

12 Install oil filling port cover;

13 Run engine 2

～

3min, and check installation surface of oil filter, and it should not seep oil;

14 Check oil level again;

Note:

■ Be careful to avoid oil scald, and deal with used oil appropriately to protect environment. After

filling oil, tighten oil discharging plug screw according to specified tighten torque, fill new oil, and oil

level.

Note:

■ When filling oil in oil filling port on cylinder head cover, should clean oil filling port to avoid

impurity and dust mixed in. Cover oil filling cover well after filling.

6.3 Removal and Check

① Discharge all oil in engine according to “6.2 Replace Oil and Oil Filter”;

② Remove fixed bolts of oil level gauge, and take down oil level gauge assembly;

③ Loosen fixed bolts and nuts of engine oil sump according to the principle of “from two sides to

middle, cross tighten”. Use drawknife or oil sump separating special tool to separate fitting surface and

clear used sealant. Remove oil sump;

④ Use flywheel clamp to fix flywheel, remove crankshaft belt wheel fixed bolt, and take down

crankshaft belt wheel;

⑤ Refer to “10.3 Removal and Installation of Cooling System” to remove coolant pump;

⑥ Refer to “Exhaust System” to remove turbocharger oil intake pipe;

⑦ Remove oil pump fixed bolt, and take down oil pump. Clear oil pump gasket;

⑧ Remove oil cooler fixed bolt, and remove oil cooler;

Check after Removal:

① Check whether all oil holes of oil pump housing are blocked, and clean oil hole if necessary;

② Check whether there is crack or other damage in oil pump housing, and replace if necessary;

③ Check whether there is scratch, damage or aging in crankshaft front sealing, and replace if any;

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6.4 Installation

① Clean up sealant on cylinder body and oil pump assembly;

Note:

■ Ensure there is no oil contamination, scratch and foreign matter in fitting surface of cylinder

body and oil pump assembly.

② Install or check oil pump positioning sleeve on lower part of

cylinder body. Positioning sleeve hole of front part surface of lower

part of cylinder body and positioning sleeve is interference fit, height

of positioning sleeve protruding front part surface of lower part of

cylinder body is 6mm; positioning sleeve and oil pump housing is

clearance fit;

③ Before installing oil pump component and its gasket, spread sealant to fitting surface of front

part surface cylinder body and lower part of cylinder body. Sealant

type: Loctite 5900H silica gel; sealant diameter: 2mm; ensure to

complete installation in 10 minutes after spreading sealant;

④ Install oil pump positioning hole to align to positioning

sleeve, install oil pump to cylinder body, and tighten oil pump fixed

bolts according to the principle of cross tightening, tighten torque:

25±3N.m;

Note:

■ After installation, inner and outer rotor can rotate smoothly, and there is no clamping

stagnation phenomenon.

⑤ After installing oil pump housing, spread proper engine oil to installation hole, and use special

tool to install crankshaft front oil sealing to oil pump housing, press

front oil sealing to dead port position of installation hole of oil pump

housing, in which flat side outward when installing, and spread

proper oil to labial part. Front oil sealing press to dead port position

of installation hole of oil pump housing;

⑥ After spread sealant to fitting surface of oil pump component and cylinder body, install oil

pump component to oil sump. Before spreading sealant, check that oil pump housing gasket should not

be higher than bottom of lower part of cylinder body; if gasket protrudes bottom of lower part of

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cylinder body, replace gasket. After installation, clean up redundant sealant;

⑦ Install gear wheel chamber and front part timing system according to “3.3 Installation of

Timing System”;

⑧ Install flywheel housing and flywheel according to “8.4 Cylinder Body Crankshaft Flywheel

Mechanism”;

⑨ After spread sealant to fitting surface of oil pump component and cylinder body, install oil

pump component to oil sump. Before spreading sealant, check that oil pump housing gasket should not

be higher than bottom of lower part of cylinder body; if gasket protrudes bottom of lower part of

cylinder body, replace gasket. After installation, clean up redundant sealant. And pre-spread sealant

according to figure as shown below. Sealant should be even and continuous to avoid to affecting sealant

function. Sealant type: Loctite 5900H silica gel; sealant diameter: 2mm; ensure to complete installation

in 10 minutes after spreading sealant;

⑩ Before installing oil sump, install 2 studs on bottom of

middle part of cylinder body, and after installing oil sump, fix

correspondent position with 2 nuts, and fix others with bolt;

11 Before installing oil sump, install filter assembly to oil

sump. Check whether sealing ring on filter is good before installing, insert filter to installation hole of

oil sump, and fasten with filter pipe clamp, tighten bracket bolt at the same time;

12 Put oil sump sealing gasket to sealing groove of oil sump, when installing, press sealing gasket

tightly to make sealing gasket deformation and stick closely to cylinder body and oil pump housing, and

ensure sealing of oil sump with cylinder body and oil pump;

Oil pump

housing

Oil sump

sealing ring

Lower part of

cylinder body

Gear wheel chamber

Fly wheel housing

Spreading sealant position with oil sump fitting surface (4 positions)

Stud

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13 Tighten oil sump bolt according to the principle of first pre-tighten, and then tighten from

middle to two sides, and cross tighten. Re-tighten oil discharging plug screw after installing oil sump;

14 Install oil level gauge assembly, and tighten oil level gauge guide pipe fixed bolt and oil level

gauge guide pipe connector installation bolt. It should be smooth when installing oil level gauge to oil

level gauge guide pipe, and there is no clamping stagnation phenomenon. Check whether sealing ring on

oil level gauge handle and oil level gauge guide pipe is good;

15 Install turbocharger inlet oil pipe refer to “5.3 Check and Installation of Exhaust System”;

16 Before installing oil cooler component, check whether sealing ring of oil cooler seat is good.

Tighten oil cooler fixed bolt;

17 Spread anaerobic type screw thread sealant to screw thread of oil pressure switch, and then

install oil pressure switch to oil cooler seat;

18 Before installing oil filter, tighten oil cooler with oil filter central screw arbor, tighten torque is

50-60N.m;

19 Before installing oil filter assembly, spread proper oil to fitting surface of gasket in oil filter

and oil filter O-type sealing ring. Install oil filter component to oil cooler seat, when sealing ring

connects, tighten 3/4-1 cycle;

Attachment: Tighten Torque of Lubricating System Fixed Bolt

Part No. Name Quantity Specification Tighten torque Remark

Q1840835F61-9.8 Hexagon flange bolt 13 （25±3） N·m

Install oil pump

component

Q1841030F61-9.8 Hexagon flange bolt 4 （50±5） N·m

Install oil cooler

assembly

--------------- Central screw arbor 1 （50±5） N·m

1010320FE010 Oil filter component 1 M22×1.5

When sealing ring

connects, tighten

3/4 -1

cycle

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VII、Valve Mechanism

7.1 System Diagrammatic Sketch

1、Cylinder head； 2、Bowl-shape plug； 3、Valve lock clamp； 4、Valve spring upper seat；

5、Valve spring； 6、Valve spring lower seat； 7、Fixed bolt of wiring harness fixed bracket；

8、Wiring harness fixed bracket； 9、Oil duct screw plug； 10、Lifting lug (front and rear are the same)；

11、Fixed bolt of lifting lug； 12、Stud； 13、Intake valve； 14、Exhaust valve；

15、Rocker arm of intake valve； 16、Rocker arm of exhaust valve； 17、Camshaft；

18、Fixed bolt of camshaft axial positioning plate； 19、Camshaft axial positioning plate；

20、Valve press plate； 21、Rocker arm bracket

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7.2 Removal

① Remove vacuum pump assembly refer to “Removal and Installation of Front Part Driving

System”;

② Remove all high pressure oil pipes and all connector installation protection sleeves;

③ Pull out fuel injector oil return pipe connector, and remove fuel injector oil return pipe and oil

pressure guide rail fuel pump oil return pipe assembly;

④ Remove fixed bolt of oil pressure guide rail, and take down oil pressure guide rail and all

connector installation protection sleeves;

⑤ Remove fixed bolt of fuel injector press plate, and take down fuel injector and fuel injector

press plate;

⑥ Remove fixed bolts of cylinder head hood from two sides to middle, and take down cylinder

head hood;

⑦ Remove crankshaft chain wheel and gear wheel chamber refer to “Removal and Installation of

Timing System”;

⑧ Remove fixed bolts of all rocker arms, and take down rocker arm and rocker arm shaft

assembly, and mark sequence of all rocker arms in detail;

⑨ Take down all valve press plates, and mark sequence of rocker arms and valve press plates;

⑩ Remove fixed bolt of camshaft positioning plate, and take down positioning plate;

11 Rotate and push out camshaft assembly from camshaft bearing hole;

12 Remove fixed bolt of rocker arm shaft bracket, and take down rocker arm shaft bracket;

13 Loosen cylinder head bolt from middle to two sides, take

out cylinder head bolt, and remove cylinder head and cylinder head

gasket;

14 Remove fixed bolts of front and rear lifting lug, and take

down front and rear lifting lug;

15 Use valve spring compressor to compress valve spring, and

remove valve locking plate, valve spring and valve spring seat;

Note:

■Position of piston upper dead point. Mark on removed valve,

valve spring and other components, and record cylinder number

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and position. Place components reliably.

16 Remove valve oil sealing by pliers;

Note:

■ Please don’t reuse valve oil sealing.

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7.3 Check After Removal

1、Cylinder Head Check

① Carefully check whether there is crack, damage or leakage in cylinder head; if any, please

replace new cylinder head;

② After totally clearing dust, sealant residue, carbon deposition and clearing oil duct, use

compressed air to ensure oil duct is not blocked;

③ Check the flatness of bottom surface of cylinder head:

place flatness measuring instrument to burnt surface to observe

displayed reading; and also can place ruler to flat surface, and then

measure clearance of ruler and flat surface by clearance gauge;

Cylinder Head Flatness:

■ Standard common difference——less than 0.05mm

■ Maintenance limit—— 0.15mm

If exceed technical specification, ensure whether can maintain cylinder head surface, or

replace cylinder head.

If valve deepness and protruding quantity of fuel injector can’t keep in the range of technical

specification, please replace cylinder head.

2、Check of Protruding Quantity of Fuel Injection:

Install deepness gauge assembly on cylinder head burnt surface

and reset it. Rotate deepness gauge, measure fuel injector protruding

quantity at the highest point of fuel injector. Record protruding

quantity of each fuel injector.

Standard Value: 2.5-3.2mm

Note:

■ Don’t use thickening or double-layer-type fuel injector gasket to adjust protruding quantity of

fuel injector. This will cause outer connector of fuel injector can’t be aligned and can’t be installed.

If protruding quantity of fuel injector exceeds technical specification, check whether fuel injector

gasket is installed well; check and ensure fuel injector hole is clean and there is no scrap. And also

should ensure fuel injector gaskets are not “piled up” in fuel injector hole. Use clean oil to lubricate fuel

injector O-type ring. Install fuel injector press plate to fuel injector, and then install fuel injector into

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hole. Check again, if also can’t ensure fuel injector is installed rightly, check and replace cylinder head.

3、Valve Check

Valve external diameter check (at least measure at front /

middle /rear part of valve rod)

Standard Value: Intake: Φ6

030.0

045.0



, Exhaust: Φ6

050.0

065.0



If valve is damaged or valve rod is abraded less than min

specification value, must replace valve.

4、Valve Guide Pipe

Inner Diameter Standard Value of Valve Guide Pipe Hole: 6.000-6.015mm.

If exceed limit, replace cylinder head.

5、Clearance of Valve and Valve Guide Pipe

Check clearance between valve rod and valve guide pipe; if exceed limit, replace cylinder.

Clearance of valve rod and valve guide pipe:

Standard Valve:

■ Intake valve: 0.030~0.060mm

■ Exhaust valve: 0.050~0.080mm

Maintenance Limit:

■ Intake valve: 0.1mm

■ Exhaust valve: 0.1mm

If not within range, replace cylinder head.

6、Valve Seat Ring Maintenance:

① Use valve seat guide rod and reamer to revise valve seat.

Intake valve seat is 60°, Exhaust valve seat is 45°;

② After revising, valve and valve seat should be ground

carefully by grinding paste;

7、Replacement of Valve Seat Ring:

① Use punching machine or special tool to install intake valve and exhaust valve seat ring to

counterbore;

② After installing new valve seat ring, make sure to check valve deepness and test whether valve

is leaking;

③ If there is abnormality that can’t grind seat ring, spread a thin layer of fine grinding agent or

Valve

guide pipe

Inner diameter of valve guide pipe

Outer diameter of valve rod

Guide rod

Hobbing

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equivalent evenly to valve, electrical power or manually pump grinding tool to press valve center; and

rotate valve back and forth and grind continuously until valve seat ring and grinding agent on valve both

displaying even contact vein;

④ If need to grind valve, measure head edge thickness to check whether edge material is enough;

Min Limit Value of Valve Edge Thickness:

1.9mm (Exhaust); 1.1mm(Intake). If valve thickness is not

within limit value, make sure to use new valve

.

Make sure to test valve leakage after grinding to ensure normal sealing.

9、Cylinder Cover Bolt Check

Check whether there is damage or corrosion on screw thread of cylinder head bolt. Cylinder head

bolt only can be used twice, replace new bolt after using twice.

10、Camshaft Check

Measure Diameter of Camshaft Journal：

Use micrometer to measure diameter of camshaft 1-5 gear

shaft journal.

Diameter of 1-4 Gear Shaft Journal: 43.049-43.065mm

5 Gear Shaft Journal: 39.059-39.075mm

Measure Camshaft Lift:

Checkout of camshaft lift: Use micrometer to measure cam

height at the direction of cam peach tip, measure cam base circle

diameter at the direction of cam base circle, and the difference

value of two values is cam lift.

Intake Cam Lift: 35.07-35.09mm

Exhaust Cam Lift: 34.05-34.07mm

11、Check Whether Cylinder Head Gasket is Burnt, Slugging Cylinder or Damaged; If Any,

Please Replace.

Note:

■ Cylinder head gasket must be replaced with manufacturer original cylinder head gasket, or

else may cause air-fuel ratio not actual fault.

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12、Rocker Arm Removal Check:

① Check whether rocker arm trolley wheel and ball-head seat

are abraded or damaged; if any, replace rocker arm.

② Remove rocker arm shaft from rocker arm.

③ Don’t remove sleeve in pointed part of rocker arm. The

component can’t be repaired. If find sleeve damaged, must replace

rocker arm.

④ Remove lock tighten nut and regulating bolt.

⑤ Check whether there is crack or over abrasion in hole.

Sleeve can move flexibly on rocker arm, and plastic sleeve limiting

stopper should locate accurately. Check whether sleeve end part is

abraded.

⑥ Use clean engine oil to lubricate rocker arm shaft. Install rocker arm shaft into rocker arm,

rotate rocker arm 180°around rocker arm shaft. Rocker arm can rotate flexibly and there is no retardarce.

If rocker arm can’t rotate flexibly, replace rocker arm shaft and rocker arm.

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7.4 Installation

① Spread lubricant oil to each inner installation paring component;

② Clean component before installing, there is no rag, burr, oxide coating, corrosion, cuttings, oil

contamination, colorant and dust, and there is no knock, touch or scratch when installing;

③ Check/Install cylinder head each bowl-shape plug and oil duct screw plug. Install 11 bowl-type

plug ①, 3 bowl-type plug ⑥, 8 oil duct blocking plug ⑦. Spread bowl-type plug sealant before

pressing all bowl-type plugs, and end surface distance from hole end 1mm after bowl-type plug pressing

in. Spread sealant to seal when installing oil duct screw plug and cylinder head. When tightening 4

rocker arm oil supplying hole blocking plugs, sink cylinder head intake side 2mm;

Note:

■ New cylinder head each bowl-type plug is already installed.

④ Use special tool to press and install valve oil sealing to specified position, and spread a little oil

to lip part;

⑤ Spread oil to each valve, insert guide pipe to valve, and check whether valve can move

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smoothly after installation. Install valve spring;

⑥ Use special tool or proper tool to compress spring and install lock clamp. After installing valve,

slight knock end part of valve rod by wooden hammer or plastic hammer to ensure valve lock clamp is

installed in place;

⑦ Check valve sealing of ground valve seat and valve by

special device: use leakage detector or coal oil leakage detection

method to detect leakage amount of valve. If sealing is no good, grind

and repair valve seat ring refer to “Valve System-Cylinder Head

Check”;

⑧ Check/Install cylinder head positioning sleeve of upper

surface of cylinder body. Positioning sleeve protruding height:

4.5±0.3mm;

⑨ Install cylinder head gasket, and part NO. side upward. Pay attention to intake side oil return

hole position when installing cylinder gasket, and don’t install reversely. After installing cylinder gasket,

check whether each water duct and oil duct hole is unblocked between cylinder body and cylinder head;

⑩ Install cylinder head to cylinder body steadily;

11 Spread proper clean lubrication oil to head of cylinder head

bolt, pre-tighten cylinder head bolt. Tighten for several steps+angle

tighten method: 10N.m→60N.m+240°→Reverse 300°→60N.m+

240°. Monitor final tighten torque, and control to the range of (290±

50)N.m. Tighten according to the method of “from middle to two

sides, cross tighten” when tighten manually;

12 Install camshaft, spread proper lubrication oil to each

shaft journal and cam before installing camshaft to cylinder head,

and slightly push camshaft from front part of cylinder head to

camshaft bearing hole of cylinder head, and there is no knock,

touch or scratch. Axial positioning sleeve faces to rear part of cylinder head;

13 Face round angel side to flywheel side of engine (outward)

when installing camshaft axial positioning plate, and pay attention

to not install reversely;

14 Check axial clearance, and there is no clamping or

Valve lock clamp

Valve spring upper seat

Valve spring

Valve oil sealing

Valve

guide pipe

Valve seat ring

Valve

Round

angle

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stagnation phenomenon when camshaft rotating. Use dialgauge to measure axial clearance when

moving camshaft axially at the same time.

Note:

■ Camshaft axial clearance standard value: 0.10~0.21mm

■ If axial clearance is too large, replace cylinder head. If camshaft thrust surface is damaged,

replace camshaft.

15 Check/Install rocker arm shaft bracket positioning sleeve. Ensure its protruding to installation

surface 3mm after installing rocker arm shaft bracket positioning sleeve. Positioning sleeve and cylinder

head is interference fit, positioning sleeve protruding to cylinder head height is 3mm; positioning sleeve

and rocker arm shaft bracket is clearance fit;

16 Install rocker arm shaft bracket, and tighten bracket fixed

bolt;

17 Install valve pressing plate, and should pay attention to

valve pressing plate long hole facing to exhaust side;

18 Before installing intake/exhaust rocker arm, check rocker

arm components. After installing ball-head seat of intake/exhaust

rocker arm and ball-head seat connecting sleeve, ball-head seat can’t

drop, ball-head seat and ball-head seat connecting sleeve can rotate

flexibly as valve clearance adjusting bolt ball-head;

19 Install adjusting bolt until can’t move, and install lock

tighten nut;

20 When installing intake/exhaust rocker arm, first spread

proper lubrication oil to rocker arm trolley wheel, trolley wheel shaft,

rocker arm shaft journal surface and valve clearance adjusting bolt

ball-head. Tighten rocker arm bolt according to required torque. After installing, rocker arm can rotate

flexibly, and there is no clamping stagnation phenomenon.

21 Install front and rear lifting lug, and tighten fixed bolt;

22 Install intake/exhaust pipe cylinder head stud;

23 Adjust valve clearance refer to “7.5 Measurement and Adjustment of Valve Clearance”;

24 Check state of camshaft position sensor sealing ring, install sensor to cylinder head, and tighten

fixed bolt. Ensure sensor and signal gear installation clearance is 0.35-1.65mm;

25 Install PCV exhaust hose to cylinder head hood, and fasten with clamp, and don’t drop;

Lock tighten nut

Valve clearance

adjusting bolt

Ball-head seat

connecting

sleeve

Ball-head seat

Rocker arm shaft

Rocker arm bolt

Rocker arm

cylinder

Trolley

wheel shaft

Trolley

wheel

Rocker arm shaft bracket positioning pin

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26 Install oil filling port sealing ring to oil filling port cover, and then spread proper lubrication oil

to oil filling port sealing ring surface, install oil filling port to cylinder cover hood, and it can open and

close flexibly, and there is no clamping stagnation phenomenon;

27 Check whether sealing ring in cylinder head hood sealing groove is installed smoothly,

whether there is tensioning or blockage, and after installing turn cylinder head hood, cylinder head hood

sealing ring can’t drop partly. Check whether fuel injector sealing ring on cylinder head hood and

sealing ring of pressing plate bolt is damaged;

28 Check whether gasket on fuel injector component drops,

whether sealing ring is damaged;

29 Install cylinder head hood, before pre-tightening fixed bolt

of cylinder head hood, insert all cylinder fuel injector to installation

hole (don’t install fuel injector pressing plate and pressing plate bolt), and initially position cylinder

head cover;

30 Tighten fixed bolt of cylinder head hood according to sequence;

31 Install high pressure oil rail to cylinder head, and tighten fixed bolt;

32 Press two pressing finger of fuel injector pressing plate to fuel injector, and pre-tighten fixed

bolt of fuel injector pressing plate;

33 Install all high pressure oil pipes, first pre-tighten all nuts, and then tighten;

34 Tighten fixed bolt of fuel injector pressing plate;

35 Install high pressure oil pipe clamps and oil pump outlet oil pipe fixed bracket;

36 Install all fuel system inlet/return oil pipe;

Note:

■ Ensure clean when installing each fuel system component, and ensure un-installed connector

to install protection sleeve.

7.5 Valve Clearance Measurement and Adjustment

① Rotate crankshaft belt wheel T point to correspond with mark point of oil pump, place to 1

st

-4

th

cylinder upper dead point position. Pre-tighten crankshaft belt wheel according to need;

② Measure cooling state valve clearance between rocker arm

ball-head seat and valve pressing plate by clearance gauge. Measure

1&2&3&6 set valve clearance or 4&5&7& set valve clearance

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according to compressing stroke upper dead point corresponding condition;

③ Adjust if needed: loosen adjusting bolt lock tighten nut,

ensure valve clearance by clearance gauge is: intake valve

(0.25±0.03)mm, exhaust valve: (0.50±0.03)mm, and then tighten

valve clearance adjusting bolt lock tighten nut according to required

torque;

④ Rotate crankshaft a round, and measure or adjust remained

valve set clearance;

⑤ After adjusting valve clearance, rotate crankshaft two

rounds, and check whether valve clearance accord with requirement.

If exceed requirement, adjust valve clearance again.;

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Attachment: Tighten Torque of Cylinder Head Assembly Bolt

Part No. Name Quantity Specification Tighten Torque Remark

1002103GA

Right balance

shaft sleeve inner

hexagon screw

plug

8 R2 1/16 （10±1） N·m

Oil duct is

blocked

Q1200825F61 Stud 2 （23±3） N·m

Install intake

manifold

1003012FE010

Exhaust pipe

fixed stud

2 M8×1.25×55 （23±3） N·m

Q1840820F61

Hexagon flange

bolt

6 （23±3） N·m Install lifting lug

Q1840816F61

Hexagon flange

bolt

1 （23±3） N·m

Install wiring

harness fixed

bracket

1002041FE010

Cylinder head

bolt

10

M14×1.5×14

0

(10±1)N•m→(60±

2)N•m+(120°±2°)+

(120°±2°)→Revers

e (300°±2°)→(60±

2)N•m+(120°±2°)+

(120°±2°)

Final tighten

torque is

(290±50) N•m.

Q1840616

Hexagon flange

bolt

2 （10±1）N·m

Install camshaft

positioning plate

1006023FE010 Rocker arm bolt 8 M8×1.25×50 （40±5）N·m

Install rocker

arm component

1006025FE010 Adjusting nut 8 M6×1 （10±1）N·m

Adjust valve

clearance

Q1840825F61

Hexagon flange

bolt

2 （23±3） N·m

Install high

pressure oil rail

Q18410130TF2

Hexagon flange

bolt

4 （60±5） N·m

Install fuel

injector pressing

plate

1042112FE010

Oil pipe fixed nut

Ⅰ

5 M14×1.5 （30±2） N·m

Connect with

fuel rail and fuel

injector

1042062FE010

Oil pipe fixed nut

Ⅱ

1 M16×1.5 （35±2） N·m

Connect with oil

pump

1042501FB

Bolt spring

assembly

1 M5×1×25 （8±1） N·m

Connect two

clamping plate of

oil pipe bracket

Q1840612F61

Hexagon flange

bolt

1 （10±1） N·m

Install oil pipe

bracket

1014109FE010

Cylinder head

hood combined

bolt

11 M6×1×43 （10±1） N·m

Install cylinder

head hood

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VIII、Crankshaft Flywheel Mechanism

8.1 System Diagrammatic Sketch

1、Cylinder head bolt； 2、Cylinder head gasket； 3、Φ18 positioning sleeve； 4、Cylinder body；

5、Thrust gear main bearing bushing assembly； 6、Upper bushing of main bearing bushing；

7、Crankshaft belt wheel； 8、Bolt of crankshaft belt wheel； 9、Lower bushing of main bearing bushing；

10、Φ13 positioning sleeve； 11、Connecting bolt of upper and lower cylinder body；

12、Bolt of main bearing head； 13、Crankshaft； 14、Fixed bolt of flywheel；

15、Flywheel positioning pin； 16、Flywheel assembly； 17、Flywheel housing；

18、Crankshaft rear oil sealing； 19、Sealing ring of flywheel housing cover；

20、Flywheel housing cover； 21、Positioning pin of gear wheel chamber

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8.2 Removal

① Clamp flywheel by flywheel clamp, loosen fixed bolt of flywheel and crankshaft belt wheel,

and remove flywheel assembly;

② Remove crankshaft rear oil sealing and crankshaft rear oil sealing bracket;

③ Remove cylinder head system, refer to “Valve Mechanism”;

④ Remove fixed bolt of crankshaft belt wheel, and take down crankshaft belt wheel;

⑤ Remove oil pump refer to “6.2 Lubricating System”;

⑥ Remove fixed bolt of flywheel housing;

⑦ Remove fixed bolt of gear wheel chamber, and take down gear wheel chamber;

⑧ Remove connecting rod bolt, take down piston connecting rod, and place piston connecting rod

well in order;

Note:

■ The same cylinder piston connecting rod assembly should be installed to original cylinder hole

when installing, thus mark or place well in order; there is mark on connecting rod body and

connecting rod cover to avoid to be mistaken installed.

⑨ Remove bolt of crankshaft main bearing cover according to “from two sides to middle and

cross loosen”;

⑩ Remove crankcase connecting bolt according to “from two sides to middle and cross loosen”;

11 Take down crankshaft, and push out main bearing bushing;

12 Loosen fixed bolt of piston cooling fuel injector; remove piston cooling fuel injector;

8.3 Check and Measurement

1．Crankshaft

Carefully sash crankshaft and clean, and then use compressed air

to dry oil hole.

Measure main bearing journal and connecting bearing journal.

Standard Value:

■ Diameter of main bearing journal: 73.984-74mm

■ Diameter of Connecting rod bearing journal: 58.984-59mm

Calculate clearance of crankshaft main bearing journal-crankshaft main bearing bushing hole:

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difference of diameter of main bearing journal and diameter of crankshaft main bearing bushing hole

measured above, is its fit clearance.

2、Standard Value of Main Bearing Hole Size

■ Diameter of main bearing hole: 79-79.018mm

If main bearing hole size is not in standard range, first check whether

not remove bearing bushing; and then check whether main bearing bolt or

upper/lower cylinder body is installed in place, bolt torque is normal. If

above-mentioned is normal, directly replace cylinder body (including

upper/lower cylinder body).

3、Standard Value of Main Bearing Fit Clearance

Standard fit clearance is 0.054~0.1mm, abrasion limit is not over 0.15mm.

Note:

■ When measuring diameter of crankshaft main bearing bushing hole, should install bearing

cover and bearing bushing to bearing seat, and tighten bolt by specified torque. Use internal

micrometer to measure hole diameter. Diameter value of using internal diameter-outer diameter

value of crankshaft main bearing journal is fit clearance.

4、Bearing Bushing

There is no scratch or impurity in antifriction material of bearing bushing surface; there is no

phenomenon of bearing bushing blocked or antifriction material drop due to bad lubrication; pay more

attention to keep clean when installing.

Measure clearance of oil membrane:

Clearance of oil membrane is difference of outer diameter of measured crankshaft main bearing

journal and inner diameter of bearing bushing.

Standard Value:

■ Crankshaft main bearing bushing: 0.054～0.1mm

■ Connecting rod bearing bushing: 0.039~0.091mm

■ Limit value: 0.15mm

Usage of Plastic Measure Gauge

Generally, use plastic measure gauge to measure clearance of oil

membrane. First clean oil, lubrication oil and other impurity on bearing

bushing and main bearing journal, put plastic measure gauge, which has

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the same width of main bearing bushing, and make it parallel to bearing journal, and keep away from oil

hole. Install crankshaft, main bearing bushing and main bearing cover, and tighten to specified torque.

Don’t turn crankshaft during this procedure. Remove main bearing cover, measure its width at the

widest position according to mark remained on plastic measure gauge. If measured oil membrane

exceeds limit value, replace bearing bushing or choose small size bearing bushing.

5、Check Cylinder Hole:

When engine cylinder hole abraded to a certain extent, technical function of engine becomes bad,

power decreases, fuel and oil consumption increases obviously. Judge abrasion degree of cylinder hole

by detecting cylindricity and roundness after cylinder abraded.

Detect method of roundness and cylindricity of cylinder:

① According to diameter size of cylinder hole, choose proper

connecting rod, fix to lower part of cylinder gauge;

② Revise cylinder gauge size, measure at

3 cross sections and 2 directions of distance from cylinder top 10mm,

80mm, 150mm by cylinder gauge, and get average value;

Note:

■ When measuring by cylinder gauge, it should be vertical between

measured rod and cylinder axial line, or else measurement is not

accurate.

 Calculate deviation of roundness and cylindricity according

measured result. Roundness deviation is half of difference value of

measured max diameter value and min diameter value of the same cross

section; cylindricity deviation is half of difference value of measured max

diameter value and min diameter value of any direction of measured

cylinder surface.

Cylinder hole

diameter

Piston outer

diameter

Standard value of matching

cylinder clearance

φ93.5

015.0

0



φ93.5

054.0

070.0



0.054~0.085

■ Clearance between piston and cylinder hole: 0.054～0.085mm. Limit value is 0.15mm.

6、Check Flatness of Top Surface of Cylinder Body:

■ Standard value: Cylinder body max flatness is 0.04mm

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If exceeds limit value, machining to min limit or replace.

If flatness of nearby area of burnt chamber is abnormal and can’t be processed, replace cylinder

body. To repair of burnt surface, special sealing gasket without thickness adding is available. If

can’t repair burnt surface to get right piston protruding amount, must replace cylinder body.

Note:

■ Measure cylinder body after upper and lower cylinder body being installed, tightening main

bearing cover bolt and connecting bolt, and being replaced in flat. If install cylinder body in engine

platform or without installed main bearing cover, measured value will be not right due to warping.

7、Cylinder Hole Check

Check whether cylinder hole is pulled damaged.

Check whether cylinder hole is burnished. There is reticulate pattern appearance in not burnished

surface, and lines and top part of cylinder hole shapes a 40～

50°angle.

8、Crankshaft Belt Wheel Check

Clean crankshaft belt wheel and signal wheel, and dry belt

wheel by compressed air.

If there is damage or crack in crankshaft belt wheel and

signal tooth, replace belt wheel.

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8.4 Installation

1、Cylinder Body Blocked Confirmation

Check or install 6 bowl-type plugs①, 2 bowl-type plugs ②, 2

bowl-type plugs ⑤, 1 oil duct diameter changed valve ③, and

install 1 coolant discharging bolt ④. Before pressing and installing

bowl-type plug, firstly spread sealant evenly to inwall circle of

installation hole or flange outer round on bowl-type plug, and after

bowl-type plug being pressed into cylinder body, end surface is

(1±0.5)mm height from hole end. Coolant discharging bolt has screw thread sealant, directly tighten

according to required tighten torque. Before installing, check whether screw thread sealant is well, to

avoid affect sealing function. After pressing and installing oil duct diameter changing valve, end surface

is (1±0.5)mm height from hole end.

Note:

■ Overhaul engine cylinder body and before installing, check whether all blockage sealing is

normal.

■ Other blocking plugs of new cylinder body are installed except 2 bowl-type plugs

②

and 1 oil

duct diameter changed valve

③

.

2、Installation of Cylinder Body Assembly

① Install piston cooling fuel injector assembly: install piston

cooling fuel injector assembly to cylinder body;

② Install upper main bearing bushing: align seam allowance

on upper main bearing bushing to clamping bushing groove of

cylinder body main bearing seat hole, and push and install 5 upper

main bearing bushings in place;

Note:

■ When installing upper and lower bushing of main bearing

bushing and anti-thrust main bearing bushing assembly, ensure

there is no dust in bearing bushing and main bearing hole, and bearing bushing locating lip must in

locating groove of main bearing hole. When installing main bearing bushing, check all oil grooves

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and oil holes of upper bushing of main bearing bushing, and must align to cylinder body.

■ Install main bearing bushing assembly with anti-thrust plate on 4

th

main bearing seat which

bears crankshaft axial load.

③ Install lower main bearing bushing: align seam allowance on lower main bearing bushing to

clamping bushing groove on main bearing cover, and push and install 5 lower main bearing bushings in

place;

④ Spread proper clean engine oil to upper bearing bushing; lift and place crankshaft to cylinder

body main bearing hole;

⑤ Spread sealant to fitting surface of cylinder body and lower

cylinder body, the sealant line must be even, and there is no broken

sealant line. Sealant type: Loctite 5182; sealant diameter of anaerobic

adhesive: 1.5±0.5mm; and must complete installation in 3 minutes after spreading sealant;

⑥ Fill oil: Fill clean engine oil to crankshaft main bearing journal, main bearing bushing,

anti-thrust plate. Rotate crankshaft to check whether crankshaft can rotate flexibly; install 5 main

bearing cover to cylinder body in order and direction; slightly knock main bearing cover to install in

place;

⑦ Spread proper clean engine oil to main bearing journal, install lower cylinder body to cylinder

body steadily, and ensure complete installation in one time, and don’t be loosened after installation;

⑧ Install fixed bolt of lower cylinder body, and spread proper engine oil to main bearing bolt

screw thread before installing;

⑨ Main bearing bolt tighten torque is 10N•m→60N.m→140°. Final tighten torque is in the range

of (170±40)N.m;

⑩ Tighten connecting bolt of crankcase in order, and tighten torque of crankcase connecting bolt

is (65±5)N.m;

Note:

■ Make sure that tighten crankcase connecting bolt after tightening all main bearing bolts.

11 Check crankshaft axial float;

■ Axial clearance is 0.10~0.42mm

When crankshaft moving forward and backward to the end

along with graduation indicator, measure clearance between

middle main bearing bushing and crankshaft arm. If measured

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value exceed limit value, please replace anti-thrust bearing bushing assembly, and measure again. If still

exceed limit value, please replace crankshaft until axial float amount is qualified.

12 Check and install crankshaft position sensor, crankshaft position sensor sealing ring must be

good, and tighten fixed bolt. Ensure clearance of crankshaft position sensor and crankshaft belt wheel

signal teeth is 0.5-1.2mm;

13 Install piston connecting rod assembly refer to “9.4 Piston Connecting Rod Mechanism”;

14 Rotate cylinder body to horizontal state, rotate crankshaft to make 1

st

and 4

th

cylinder

connecting rod bearing journal be in lower dead center; overlap installed piston connecting rod using

piston slipping sleeve; push and install piston connecting rod assembly in place;

Note:

■ When assembling piston connecting rod assembly on

cylinder body, use special tool to guide to avoid knock piston

cooling fuel injector.

■ Piston top arrow points to front part of cylinder body, and

piston connecting rod assembly should move flexibly before and

after installing cylinder body: forward mark of connecting rod

big-head (round bulge) and forward mark of piston are in the same side, and pay attention that

connecting rod round bulge side faces to front part of engine when assembling engine.

15 Before installing connecting rod bolt, spread proper engine oil to bolt head flange and screw

thread, and install connecting rod big-head cover. Before installing connecting rod big-head cover, dry

and clean connecting rod broken surface by high pressure air, ensure there is no oil, metal cutting in

connecting surface, and ensure broken surface fitting is good, and there is no clearance. It’s forbidden to

mix install or install connecting rod big-head cover reversely;

Note:

■ Ensure broken surface clean, fitting is good, and avoid damage.

16 Cross tighten by six steps according to the method of “5N.m→10N.m→20N.m→60N.m→

Rotate 45°→Rotate 45° again”. Connecting rod bolt only can be used once;

17 Check connecting rod side clearance;

Check: shake to check connecting rod big-head clearance along axial direction (There is no

clamping stagnation phenomenon when rotating crankshaft).

■ Standard value: 0.15～0.30mm

If connecting rod side clearance exceeds limit value, must replace connecting rod. If still not within

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limit value after replacing connecting rod, must replace crankshaft.

18 Measure piston protruding amount:

■ Standard value: 0.34～0.26mm

If exceed range, check whether piston is right, cylinder body

is processed properly.

19 Rotate engine for on circle, and install 2

nd

and 3

rd

cylinder

piston connecting rod assembly according to the method above;

20 Detect crankshaft rotation torque: rotate crankshaft at least 360°, detected rotation torque

should be not more than 20N.m;

21 Install timing system and gear wheel chamber refer to “3.3

Timing System”;

22 Check and install flywheel housing locating sleeve.

Locating sleeve of flywheel housing and flywheel housing is

interference fit, protruding height is 4mm; locating sleeve and gear

wheel chamber is clearance fit;

23 Before installing flywheel housing, spread even sealant to

connecting surface of flywheel housing and cylinder body, complete

installation in one time, and ensure that it’s not loosened after

installation. After installing, clear unnecessary sealant overflowed by

connecting surface (left and right side surface and lower side surface).

Sealant type: Loctite 5900H gal sealant; sealant diameter: (2.5±0.2) mm; make sure to complete

installation in 10 minutes;

24 Tighten fixed bolt of flywheel housing;

25 After installing flywheel housing, spread proper engine

oil to rear oil sealing installation hole, and use special tool to press

and install crankshaft rear oil sealing to flywheel housing, and the

height of rear oil sealing flat surface end distant from dead center

of installation hole on flywheel housing is 2mm; when installing,

pay attention that flat surface end faces outward, and spread proper engine oil to lip;

Locating

sleeve

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26 Check/Install flywheel housing blocking plug, pay attention to spread oil to sealing ring;

27 Install flywheel. Install fixed bolt of flywheel. First pre-tighten across angle and then tighten

across angle;

28 Check/Install locating pin of flywheel;

29 Check/Install flywheel bearing, make sure to press and

install in place;

30 Use flywheel clamp to fix flywheel, and install oil pump

refer to “6.4 Lubricating System”;

31 Align locating pin on belt wheel to locating pin on

crankshaft, and before installing, spread proper engine oil to belt wheel bolt screw thread. Install

crankshaft belt wheel, and tighten fixed bolt of belt wheel;

Attachment: Tighten Torque of Cylinder Body Assembly Bolt

Part No. Name Quantity Specification Tighten torque Remark

1002106FE010

Coolant

discharging screw

plug

1 R1 1/4

（20～25）

N·m

Q1840610

Hexagon flange

bolt

4

（10～15）

N·m

Install piston

cooling spraying

nozzle

1002104FE010

Main bearing

cover bolt

10

M12×1.5×11

9

(10±1)N•m(Tig

htener 100r/

min)→(60±2)

N•m

(Tightener)

20r/min）→

(140°±2°)(Tigh

tener 20r/min)

When tightening

manually, don’t

need to control

tighten speed, only

need to tighten in

constant speed,

final tighten torque

is (170±40)N•m。

1002108FE010

Connecting bolt

of crankcase

10 M10×1.5×83 （65±5） N·m

Q1840835TF6

1

Hexagon flange

bolt

3 （30±3） N·m

Install high

pressure oil pump

flange

Q1841275TF6

1

Hexagon flange

bolt

7

（110±5）

N·m

Install flywheel

housing

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Part No. Name Quantity Specification Tighten torque Remark

Q1840830F61

Hexagon flange

bolt

7 （23±3） N·m

Install flywheel

housing

Q1840865TF6

1

Hexagon flange

bolt

3 （30±3） N·m

Install flywheel

housing

Q1840620

Hexagon flange

bolt

4

（10～15）

N·m

Install gear

chamber

Q1840620F61

Hexagon flange

bolt

2

（10～15）

N·m

Install gear

chamber

Q1841035

Hexagon flange

bolt

4

（28～46）

N·m

Install gear

chamber

Q1841035F61

Hexagon flange

bolt

1

（28～46）

N·m

Install gear

chamber

1004013FE010

Connecting rod

bolt

8 M10×1×42.5

(5±1) N·m

+(20±2) N·m

+(60±2) N·m

+(90°±2°)

(5±1) N·m+(10±1)

N·m + (20±2)N·m

+ (60±2) N·m+

(45°±2°)+(45°±2°)

1005014FE010

Crankshaft belt

wheel bolt

3

M12×1.25×4

0

（125±5）N·m

1005040FE010

Flywheel tighten

bolt assembly

8

M12×1.25×3

3

（135±5）N·m

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IX、Piston Connecting Rod Assembly

9.1 System Diagrammatic Sketch

1、Connecting rod assembly piston；2、Piston pin clamp ring；3、Combination oil ring；4、2

nd

air ring；

5、1

st

air ring；6、Piston pin；7、Piston pin；8、Upper bushing of connecting rod bearing bushing；

9、Lower bushing of connecting rod

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9.2 Removal

① Pry piston pin lock ring by screwdriver;

Note:

■ When prying out by screwdriver, press piston pin lock ring

by hands to avoid popup and damage person.

② Take out piston ring by special tool or hands;

③ Take out piston pin and connecting rod;

9.3 Check and Measurement

1、Measure piston diameter:

Standard value is:

Outer diameter of piston skirt part: 93.43-93.446mm

2、Check scratch, abrasion and other fault of each piston, if any, please replace piston, piston

ring and piston are replaced together. Check installation of piston pin in pin hole, in room

temperature, piston pin can move smoothly in pin hole by hands.

3、Measure piston ring

① Measure piston ring side clearance

Check end surface clearance between piston ring and all grooves on piston by thickness gauge. If

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measured value exceeds limit value, replace new piston ring, and then measure its side clearance. If side

clearance still exceeds limit value, replace piston and piston ring at the same time. If side clearance is

less than limit value, only replace piston ring.

Piston ring side clearance standard value:

■ First piston ring end surface clearance: 0.08~0.129, abrasion limit: 0.20mm

■ Second piston ring end surface clearance: 0.05~0.09, abrasion limit: 0.17mm

■ Oil ring end surface clearance: 0.03~0.07, abrasion limit: 0.15mm

② Piston ring opening clearance

Place piston ring to cylinder body hole, slightly push piston downward

to right position (distance from upper surface of cylinder hole is more than

50mm). Measure opening clearance by gauge.

If piston ring clearance is not in the range of technical specification:

a) Ensure used piston ring type and component No. are right;

b) Ensure cylinder hole is in the range of technical specification;

c) Ensure piston ring clearance is measured below 50mm of upper

surface of cylinder body;

d) Replace piston ring;

■ First piston ring opening clearance: 0.25~0.35, abrasion limit: 0.80mm

■ Second piston ring opening clearance: 0.45~0.65, abrasion limit: 1.0mm

■ Oil ring opening clearance: 0.30~0.50, abrasion limit: 1.0mm

4、Measure piston pin diameter:

■ Standard value of piston pin outer diameter: 34.496-34.5mm

5、Check piston pin hole size

■ Standard value of piston pin hole inner diameter:

34.508-34.513mm

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6、Measure connecting rod small-head:

■ Connecting rod small-head bushing hole: φ34.5

017.0

012.0



■ Clearance fitting of piston pin outer diameter and connecting rod small-head sleeve is

0.012~0.021mm.

7、Measure connecting rod big-head:

■ Connecting rod big-head bearing bushing hole:

62.377-62.403mm

Note:

■ When measuring connecting rod big-head bearing bushing hole,

install bearing bushing and bearing cover to corresponding connecting

rod, and tighten fixed bolt of bearing cover according to specified torque.

Measure inner diameter of connecting rod bearing hole by inner diameter micrometer.

8、Check connecting rod bearing bushing:

There should not be scratch or imbedded impurity in antifriction material of bearing bushing

surface; and there should not be any phenomenon of bearing bushing struck or antifriction material

dropped due to bad lubrication; and should pay attention to keep clean when installing again.

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9.4 Installation

① Before installing piston pin, spread proper oil to piston pin outer

round and pin hole. Install piston pin lock ring by pressing and installing

piston pin lock ring device (Generally, when removing, only remove one

piston pin lock ring; if there is still one lock ring at the same time, then

there is no this step).

Note:

■ Install piston pin lock ring opening position in place, and avoid

main thrust surface.

② Put connecting rod assembly to piston, pay attention to

connecting rod position, when piston top part mark faces forward,

clamping bushing groove is in intake side, and press piston pin into piston

pin and connecting rod small-head hole.

Note:

■ When installing connecting rod component and piston, forward

mark of connecting rod big-head (round bulge) and forward mark of

piston are in the same side, and pay attention that connecting rod round

bulge side faces to front part of engine when assembling engine.

③ Install second piston pin lock ring by pressing and installing

piston pin lock ring device, if there is no special tool, carefully use

screwdriver to install second piston pin lock ring into piston retaining

ring groove; pay attention to avoid piston pin lock ring popup to hurt

person when installing.

④ Use piston ring caliper to install oil ring and 2 air rings in

piston ring groove, and air ring with letter side should be upward.

⑤ Fill proper oil to all fitting surfaces, and rotate piston ring to

make oil spread to piston ring groove fully.

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⑥ When installing piston ring, make ring surface mark to be

upward, and make openings of 3 rings mutually staggered, and don’t

face to the direction of piston pin hole. When installing oil ring, make

cushion spring joining port of combination oil ring be in opposite

position of oil ring steel belt opening. After installing 3 piston ring,

there is no clamping stagnation phenomenon in ring groove.

⑦ Install connecting rod bushing to connecting rod body. Upper bushing of connecting rod is

rufous, lower bushing is metallic color.

⑧ Install lower bushing of connecting rod bushing to connecting rod big-head cover.

⑨ Install piston connecting rod assembly refer to “8.3 Crankshaft Flywheel Assembly”.

Attachment: Tighten Torque of Piston Connecting Rod Assembly Bolt

Part No. Name Quantity Specification Tighten torque Remark

1004013FE010

Connecting

rod bolt

8 M10×1×42.5

(5±1) N·m+(20±2)

N·m +(60±2) N·m

+(90°±2°)

Fix connecting

rod head cover

Opening direction

of coil loaded spring

Opening direction

of first air ring

Opening direction

of second air ring

Opening direction

of oil ring body

Front part

of engine

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X、Cooling System

10.1 System Diagrammatic Sketch

1、Water outlet port；2、Warm air intake hose； 3、Three-way connector (warm air device, SCR system

intake)；4、Small circulation water pipe；5、Water pump assembly；6、Water intake port；7、Oil cooler

intake pipe；8、Oil cooler return water hose.

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10.2 System Route Diagram

10.3 Removal, Installation and Check

1、Removal

① Remove fixed bolt of fan clutch, and take down fan clutch;

② Remove water outlet port connecting hose;

③ Remove fixed bolt of water outlet port;

④ Take down thermostat;

⑤ Remove three-way connector (connecting SCR and warm

air device);

⑥ Remove warm air water inlet hose;

⑦ Remove vacuum pump refer to “2.4 Removal and Installation of Vacuum Pump ”;

⑧ Remove fixed bolt of small circulation water pipe, and take down small circulation water pipe;

⑨ Remove fixed bolt of thermostat valve seat, and take down thermostat valve seat. Remove

coolant temperature sensor;

⑩ Remove SCR return water hose, warm air device return water hose and oil cooler intake and

outlet hose;

2、Check thermostat:

① Hang closed thermostat to container with water, and don’t let thermostat contact to bottom of

Radiator

Thermostat

Coolant pot

Coolan

t pump

Oil cooler

Cylinder body

Cylinder cover

Warm

air

blower

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container. Heat thermostat, and check water temperature in container

at the same time.

② Check whether valve works normally according to

temperature. Check thermostat opening degree in corresponding

temperature.

Standard:

■ Open valve temperature: 80～84°C, totally open

temperature: 93～97°C. (Totally open stroke is more than 8mm). Thermostat closed temperature

is more than 77°C.

3、Check:

① Check whether there is crack, aging or damage phenomenon in belt;

② Check whether water pump impeller rotates normally, whether there is clamping stagnation and

bearing dropping out phenomenon;

③ Check whether water pump bearing is damaged, sends out abnormal noise or rotates slowly,

and replace water pump assembly if necessary;

④ Check whether sealing component is leaking, and replace water pump component if necessary;

⑤ Check whether engine coolant is leaking, if leaking, replace water pump sealing component;

4、Installation

① Install coolant temperature sensor: spread anaerobic type screw thread sealant to coolant

temperature sensor screw thread, and install it to thermostat valve seat;

② Install water pump. Before installing water pump, check

whether water pump housing sealing ring in sealing groove is good.

After installing water pump, there is no axial endplay in bearing

and belt wheel, and there is no clamping stagnation, rub touch or

noise when rotating by hands; there is no abnormal noise when

running;

③ Check sealing ring of small circulation water pipe, and

pre-install thermostat valve seat and small circulation water pipe;

Thermostat

Thermometer

Water

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④ Pre-tighten thermostat valve seat sealing ring. Install thermostat valve seat and small

circulation water pipe;

⑤ Install thermostat component and water outlet port, when

installing, pay attention that whether sealing ring of thermostat

component is good. Water outlet port should face to exhaust side

of engine;

⑥ Install warm air water inlet hose and three-way connector,

and tighten fixed bolt;

⑦ Install water intake port, and tighten fixed bolt;

⑧ Connect related pipe of warm air, SCR heating, oil cooler,

and water pump;

⑨ Install other components according to the contrary sequence

of removal, and fill coolant according to requirement finally. After

exhausting, fill coolant again to standard range;

Note:

■ After installing, tighten all fixed bolts, and don’t be loosened; water pump should rotate

flexibly, and there is no touching scrubbing and clamping stagnation phenomenon; coolant pipe all

connecting positions should not be leaking.

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Attachment: Tighten Torque of Cooling System Tighten Bolt

Part No. Name Quantity Specification Tighten torque Remark

Q1840620F61 Hexagon flange bolt 13 （10±1） N·m

8 install water pump, 1

installs small circulation

water pipe, 1 installs

three-way connector, 3

install intake bending

water pipe

Q1840825F61 Hexagon flange bolt 2 （23±3） N·m

Install thermostat valve

seat

Q1840625F61 Hexagon flange bolt 3 （10±1） N·m

Install outlet water port

component

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Attachment: Cooling System Diagnosis List

Condition Possible reason

Coolant temperature gauge

reading is low

1. Whether coolant temperature sensor is connected;

2. Whether coolant temperature gauge works normally;

3. In cool environment temperature, coolant level is low, and warm effect is

bad at the same time;

4. Inside air door or controller of warm air heater works abnormally;

Coolant temperature gauge

reading is high or coolant

warning light is on. There

may be or not coolant

reducing or leaking in

cooling system.

1. Tow trailer normally, vehicle crawls in abrupt rampway, runs in slow

moving traffic or open A/C when engine in high temperature environment

(outside). Higher height will exacerbate these conditions.

2. Whether coolant temperature gauge reading is right?

3. Whether coolant temperature warning is unnecessary on?

4. Whether liquid level is low in coolant recycle/overflow tank and radiator?

5. Radiator pressure cover is not installed well. If pressure cover is loosened,

boiling point of coolant will reduce. Please refer to step 6 below at the same

time.

6. Radiator cover sealing is not good.

7. Radiator liquid level is low, but liquid level of coolant recycling overflow

tank is not low. It indicates radiator doesn’t pump coolant in

recycling/overflow tank when engine cooling.

8. Incorrect coolant thickness.

9. Coolant doesn’t flow through system.

10. Cooling plate of radiator or A/C condenser is too dirty or blocked.

11. Radiator core is already corroded or blocked.

12. Brake is dragging.

13. Use shielding plate or paper plate, thus reduce air flow.

14. Thermostat is partly or totally closed.

15. Cooling fan works abnormally.

16. Cylinder gasket leaks.

17. Warm air heater core leaks.

Coolant temperature gauge

reading is not steady

(wave, circulate or no rule)

1. When working in cold weather, warm air blower is in high hot state,

coolant temperature gauge may drop a little.

2. Coolant temperature gauge or coolant temperature sensor installed in

engine loses efficacy or is short circuit. Or wires in the circuit are corroded or

loosen.

3. When vehicle stops after heavy loaded (engine still running), coolant

temperature gauge reading will rise up.

4. Heated engine starts again, coolant temperature gauge reading is high.

5. Liquid level is low in radiator (It will gather air in cooling system, causing

thermostat delayed open).

6. Cylinder gasket leaking causes fuel-air get into cooling system, causing

thermostat delayed open.

7. It’s loosened between coolant pump impeller and shaft.

8. Attachment driving belt is loosened. (Coolant pump is slipped)

9. Intake part of coolant pump leaks air, causing air gather in cooling system,

and leading to thermostat delayed open.

Radiator pressure cover Pressure releasing valve on radiator cover loses efficacy

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Condition Possible reason

sprays vapour and/or

coolant gets into overflow

tank.

Coolant temperature gauge

may exceed normal value,

but not very high, coolant

recycling/liquid level of

overflow tank may be high

There is coolant leaking in

ground, and there is no

steam spraying out in

radiator pressure cover.

Coolant temperature gauge

is high (HIGH) or hot

(HOT).

Explode liquid or early

burnt (not caused by

ignition system). Coolant

temperature gauge may be

high or not.

1. There is coolant leaking in radiator, coolant system hose, coolant pump or

engine.

2. Engine too hot

3. Coolant freezing point is not right. Mixed liquid may be too dense or too

thin.

When engine running,

oneor several hoses are

shrunken

When engine cooling, vacuum produced by cooling system doesn’t get

compensation through coolant recycling/overflow system.

Coolant fan noise

1. Fan impeller is loosen

2. Impeller knock surrounding objects

3. Air blockage of radiator or A/C condenser

Warm air effect not

enough, lose efficacy when

thermostat in open position

1. Whether there is DTC

2. Coolant level is low

3. Warm air hose/connecting gets blocked

4. Warm air hose is twisted

5. Coolant pump does/doesn’t pump coolant through warm air heating core.

After engine fully warming, 2 warm air hose of heater will be hot. If only one

hose is hot, coolant pump may work abnormally or heater core may get

blocked. Attachment driving belt may be trackslipped, causing coolant pump

work not well.

In damp weather, engine

already gets warm and

keeps running. Coolant

temperature gauge is in

normal value range.

In damp weather, (snow, ice or mis-condensed rain) when thermostat opens,

moisture around radiator will be evaporated. Thermostat opening makes hot

water get into radiator. After moisture contacting hot radiator, it will be

evaporated to vapour. This generally happens in cold day, when there is no

fan or airflow blows vapour.

Coolant color

Coolant color is not the necessary indicating of its corrosion state and

antifreezing function. Don’t ensure its state according to coolant color.

Coolant recycle/Liquid

level of overflow tank

changes. Coolant

temperature is normal

Coolant volume changes along with engine temperature, so liquid level of

overflow tank changes. If tank liquid level is between FULL and ADD in

normal temperature, after high temperature working, liquid level will return

to the range.

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XI、SCR System

11.1 System Diagrammatic Sketch

1、SCR catalytic converter；2、Urea injector；3、Differential pressure sensor gas sampling steel pipe I；

4、Differential pressure sensor；5、Differential pressure sensor gas sampling steel pipe II；6、Differential

pressure sensor connecting hose assembly；7、DOC catalytic converter assembly；8、Urea tank assembly；

9、Urea pump；10、Electrical heating urea pipe I；11、Electrical heating urea pipe II；12、Electrical

heating urea pipe III.

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11.2 Connecting Diagrammatic Sketch

11.3 Maintenance Note of SCR System

There may be explosibility gas escaping out from battery. To avoid personal damage as far as

possible, before maintaining battery, must keep engine compartment ventilation well. To avoid

producing electric arc, should first remove battery negative electrode wiring harness, and connect

battery negative electrode wiring harness at last.

There is diesel engine exhausting treatment liquid in SCR injection system. Don’t make the matter

get into eyes. If getting into eyes, use a large number water to wash at least 15 minutes immediately.

Avoid long time contact with skin. If contacting, please use soap and water to clean skin immediately.

Don’t drink it. If absorbing diesel engine exhausting treatment liquid by accident, please go to see a

doctor immediately.

During maintaining, make sure to check whether there is leaking or white deposition in diesel

engine exhausting treatment liquid injection valve and input/output pipe of quick-connector-pipe, around

urea pump filter cover.

NOX

sensor installation seat

Temperature sensor

installation seat

Urea pump

Injector

SCR catalytic

converter assembly

DOC catalytic

converter assembly

Urea tank assembly

Urea level temperature sensor

Differential pressure sensor

connecting steel pipe hose

Air flow

direction

Electrical heating

urea pipe

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11.4 Removal, Installation and Check

① Install urea injector to welding connector of SCR catalytic

converter. Don’t be install reversely, and make sure to keep heat

insulation plate side of SCR injector next to catalytic converter pipe;

② Pre-tighten injector bolt until sealing gasket is pressed flat.

Tighten fixed bolt;

Note:

■ Sealing gasket is disposable sealing component, don’t permit

to install and use again.

③ Install DOC catalytic converter assembly and sealing gasket

according to the marked direction on catalytic converter. Tighten

fixed bolt and nut;

④ Install gas sampling steel pipe and connecting hose. Tighten

fixed bracket bolt of gas sampling steel pipe. Pipe connected

differential pressure sensor must be upward, to avoid water gathered

in pipe and affect pressure measurement;

⑤ Install DOC differential pressure sensor, H mark direction

pipe of differential pressure sensor must be connected to front part high pressure gas sampling pipe of

DOC catalytic converter, and don’t be installed reversely;

⑥ Install upper gas flow arrow direction of SCR catalytic

converter to connect SCR catalytic converter assembly and DOC

catalytic converter assembly, install gasket, and tighten fixed bolt

and nut;

⑦ Install exhausting temperature sensor to temperature

sensor installation seat of SCR catalytic converter assembly, and

1. Injection valve seat

2. Coolant connector

3. Heat insulation

plate

4. Heat insulation

plate

5. Injection valve

6. Coolant housing

7. Sealing gasket

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tighten fixed bolt;

⑧ Install NOx sensor to temperature sensor installation seat of SCR catalytic converter assembly.

Sensor controller is fixed in vehicle beam, controller must be installed horizontally, and tighten fixed bolt;

⑨ Install urea pump, and tighten fixed bolt;

⑩ Install urea tank assembly: slightly push urea tank to

required state along direction in left below firgure (urea tank next

to urea bracket beam), after being pushed to preseted postion, urea

tank ventilation pipe must be in outside of urea tank crossbeam.

Before installing, check and ensure ventilation hole and ventilation

pipe is not damaged or blocked;

11 Install urea tank clamping belt, tighten fixed bolt, and pay attention that whether clamping belt

is installed in clamping groove on urea tank;

12 Install electrical heating urea pipe (liquid absorbing pipe, return liquid pipe, pressure pipe): connect

Urea pump

installation bolt

Urea tank

ventilation pipe

Urea tank bracket

crossbeam

Clamping belt

installation bolt

Urea tank bracket

clamping belt

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electrical heating urea pipe to urea tank and urea pump, urea pump and urea injector. Pressure pipe

respectively is fixed in two sides of urea tank bracket by single pipe clamp.

Connect related pipe according to urea pump connector mark:

INLET: Inlet liquid port——Urea pipe outlet (Electrical heating urea pipe I)

OUTLET: Outlet liquid port——Urea injector (Electrical heating urea pipe III)

BACKFLOW: Backflow port——Urea inlet port (Electrical heating urea pipe II)

a. Connect electrical heating urea pipe III and urea injector;

b. Install urea pipe I and urea pipe II according to the inlet/outlet urea pipe arrow direction of urea

pipe;

13 Install urea tank heating water pipe according to electromagnetic valve direction;

14 Connect urea injector coolant pipe;

Note:

■ Don’t remove protection cover when installing all pipe connectors.

■ After installing, tightly seal all sealing surface, and there should not be any urea or exhausting

gas leaking; all connectors are connected well, and there should not be loosened or dropped.

■ All urea solution mechanism must be clean, to avoid pollution causing component damage.

Liquid absorbing pipe

Backflow pipe

Pressure pipe

Pipe clamp

fixed bolt

Single pipe

clamp

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Removal: operate according to the contrary sequence of installation.

Check whether there is leaking in inlet and outlet pipe of urea pump. Diesel engine exhausting

treatment liquid will remain white deposition around leaking connector. If find deposition, should check

whether diesel engine exhausting treatment liquid pipe connector is damaged.

11.4 Maintenance Operation of SCR System

Generally, every time fill three times fuel, fill once urea solution, disposable maximum filling

volume is 18L, first filling volume is 21L; there is indicating light displaying urea level in vehicle

dashboard, when level is lower than warning level, it needs to add urea solution. Urea solution must be

satisfied with GB 29518 or the same class vehicle urea solution, don’t add agricultural urea or water, or

else will cause OBD warning or limit torque, even damage rear treatment device. If mistake filling fuel

or other solution to urea tank by accident, should stop engine immediately, emptying urea tank and wash

with water immediately; after washing, fill urea solution, if don’t handle it, it may damage rear treatment

device. When filling urea solution by hands, should loosen urea tank cover, guide urea solution getting

into urea tank; when urea solution level already reaching to filling port, it indicates it’s full. During

filling, should avoid urea solution spattering or being remained in tank surface; if there is urea solution

remained in tank surface, please clean with wet cloth; if don’t deal with it, it will appear white mark,

which is normal phenomenon. When filling with filling device, it will automatically stop when level

reaching to full level.

1、Maintenance Requirement and Note:

① When in daily engine maintenance, there should not be oil or fuel getting into catalytic

converter assembly;

② Urea pump main strainer replaces every year or 100000km, which comes first;

③ Urea tank assembly should empty and clean at least every year;

④ Urea filling port strainer should remove and clean at least every year;

⑤ Urea tank ventilation valve assembly should replace every year;

2、Maintenance Operation Method of Urea Pump Main Strainer and Urea Tank:

① Replace urea pump main strainer

1) Open bottom cover of main strainer;

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2) Take out adjustment component;

3) Insert special tool into bottom of main strainer along guiding groove;

4) After inserting in place, rotate special tool along the direction shown in the figure above, and

rotate to the state in below figure;

5) Pull out special tool directly, and take out urea pump main strainer;

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6) Replace new strainer, keep the direction of original main strainer, and push main strainer to

bottom part of urea pump main strainer installation hole;

7) Install adjustment component;

8) Tighten main strainer seat, tighten torque is 15~25N.m;

Note:

■ Keep strainer and urea pump strainer installation hole clean during the whole procedure.

② Clean urea tank assembly

1) Remove urea pipe, water pipe and electrical connector on urea tank;

2) Fix urea tank body, and rotate sensor until to relax state;

3) Slightly raise up sensor;

4) Place a pot to bottom part of urea tank, remove liquid discharging port bolt in bottom part of

urea tank;

5) Discharge remained urea solution in urea tank into pot;

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6) Loosen clamping belt bolt of urea tank bracket;

7) Take out urea tank, and clean the inside of tank;

③ Clean urea filling port strainer;

1) Open urea tank cover;

2) Pry 2 buckles of filling port by screwdriver, and popup buckles out of safety position;

3) Take out filling port assembly;

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4) Take out filling port strainer;

5) Clean filling port strainer;

④ Replace urea tank ventilation valve assembly

1) Remove ventilation valve assembly, take out ventilation valve guide pipe from fixed

clamping groove, and anticlockwise rotate ventilation valve assembly until removable state;

2) Take out ventilation valve assembly;

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3) Replace new ventilation valve assembly;

Attachment: Tighten Torque of SCR System Tighten Bolt

Part No. Name Quantity Specification Tighten torque Remark

1

Urea tank clamping belt fixed

bolt

2 19±3.8N·m

2 Urea pump fixed bolt 4 19±3.8N·m

3 NOX sensor 1 50±10 N·m

Install water outlet

port component

4 Fuel injector fixed bolt 3 ` 8±2 N·m

5 Exhausting temperature sensor 1 45±7 N·m。

6

Turbocharger connecting to

exhaust pipe stud

2 M10×1.5 （45±5） N·m

Installed on

exhausting bending

pipe, connect to

DOC assembly

7 Turbocharger tighten nut 2 M10×1.5 （50±5） N·m

Install DOC

assembly

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Chapter III Engine Electronic Control System

I、Precaution

1.1 Maintenance Precaution

Fault of sensor, actuator, control circuit, ECU or any component in electrical control system will

cause a certain effect to engine running. Due to fault self-diagnosis function of ECU, when maintaining,

connect computer detector to ECU to read fault code and data scream and find fault reason of electrical

control system. But in most conditions, the method only can judge approximate fault range, to ensure

specific fault position, you should troubleshoot further according to relevant technical data of circuit

diagram, detection method, detection step and standard value in “Workshop Manual”.

To improve reliability of engine electrical control system, most components of the system are

designed to be sealed and nondecomposable, and can’t be repaired after damaged. Maintenance of

electrical control system is to find out fault component in system, and replace.

When maintaining electrical control system, must pay attention to the following items to avoid

damage of ECU or controlled component.

1、Only allow to use vehicle special diagnosis tool to detect electrical control system (such as

digital multimeter, vehicle oscilloscope, vehicle diagnosis device and so on);

2、Please use JAC genuine parts when maintaining, or else can’t ensure system work normally.

3、Please obey to regulatory maintenance diagnosis procedure to maintain;

4、It’s forbidden to disassemble system components when maintaining;

5、When maintaining, be careful to take and place electronic component (electronic control module,

sensor, and so on), and please don’t drop them;

6、Set up environmental protection consciousness, and effectively deal with rejected material

produced in maintenance procedure;

7、When turning ignition switch to “ON”, it’s forbidden to connect or disconnect ECU wiring

harness connector to avoid inductive components of electrical control system producing induce voltage

and cause ECU damage;

8、Connect ECU wiring harness connector reliably, or else it may damage ECU;

9、When removing battery or using external battery connected to start, must first turn ignition

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switch to “OFF”, and then remove or crossover connecting battery. Must especially pay attention that

battery positive and negative electrode can’t be connected reversed;

10、Don’t start engine when not tightening battery electrode. And don’t remove battery electrode

when engine running, or else it will cause engine charging voltage too big, and damage components in

electrical control system;

11、When rotating engine to check cylinder compressing pressure, cut off power supply of fuel

injector or disconnect all wiring harness connectors of fuel injector to avoid injected fuel getting into

exhaust pipe without burnt, and cause three-way catalytic converter damaged.

12、When imitating thermal state working condition of fault and other maintenance that may cause

temperature rising, don’t make ECU temperature over 80℃;

13、Fuel supplying pressure of electrical control injection system is high to 1800bar, thus all fuel

pipes should use high pressure fuel pipes. Even though engine is not running, there is very high fuel

pressure in fuel line, therefore don’t remove fuel pipe when maintaining, and when maintaining fuel

system, release pressure of fuel system before removing fuel pipe;

14、It’s forbidden to detect component input/output signal by the method of piercing wire epiderm;

1.2 Precaution of Engine OBD System

There is a OBD system in ECU, when exhausting system failure due to ageing, fault indicating light

will be on.

■ Before any maintenance or check, turn ignition switch to “OFF”, and disconnect battery negative

electrode wire. Open circuit or short circuit of related switch, sensor and electromagnetic valve will cause

fault indicating light on.

■ After maintaining, must connect and lock connector reliably. Loosen (unlocked) connector may

cause open circuit, thus causing fault indicating light on. (Ensure there is no water, lubrication on

connector, there is no bending or broken in connector pins.)

■ After maintaining, rightly arrange wiring harness and fix. If bracket and wiring harness are

interfered, it may cause short circuit or open circuit, thus causing fault indicating light on.

■ Before handing vehicle to customer, clear history fault information in ECU (after maintaining).

■ Make sure to use 12V battery as power supply.

■ Please don’t disconnect battery wire when engine running.

■ Before connecting or disconnecting ECU wiring harness connector, turn ignition switch to “OFF”,

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and disconnect battery negative electrode wire. Or else, it may damage ECU. Because even though turn

ignition switch to “OFF”, battery still supplies power to ECU.

■ Before removing component, turn ignition switch to “OFF”, and disconnect battery negative

electrode wire.

■ Please don’t disassemble ECU.

■ When connecting ECU wiring harness connector, push button pole to the end to be convenient to

lock ECU reliably.

■ When inserting contact pin connector into ECU or pulling out from ECU, be careful not to damage

contact pin port (bended or broken). Before connecting contact pin connector, first ensure ECU connector

is not bended or broken.

■ Connect ECU wiring harness connector firmly. Bad connect will cause coil and condenser to

produce very high (fluctuant) voltage, thus cause ECU damaged.

■ Keep engine electronic control system component and wiring harness dry.

■ In intake system, even little leakage may cause serious fault, therefore don’t replace intake pressure

sensor easily.

■ It’s forbidden to shake or knock camshaft position sensor and crankshaft position sensor.

■ Read fault code, and ensure there is no fault code after maintaining.

■ When measuring ECU by circuit tester, it’s forbidden to contact two tester probes (Contact of

probes will cause short circuit and damage ECU power transistor).

■ Ensure fuel pipe is installed in place according to the standard.

■ It’s forbidden to step accelerator pedal when starting.

■ It’s forbidden to increase engine speed immediately after starting.

■ Please don’t accelerate before closing engine (Avoid turbocharger damaged due to can’t continue

to lubricate).

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II、Structure Principle and Maintenance of Engine Control System

2.1 Electrical Control System Instruction

1 Intake heater 10 ECU

2 Intake pressure temperature sensor 11 Differential pressure sensor

3 Camshaft position sensor 12 Urea injector

4 Oil pressure switch 13 Exhausting temperature sensor

5 High pressure fuel rail 14 Nox sensor

6 Fuel injector 15 Electromagnetic valve

7 Crankshaft position sensor 16 Environment temperature sensor

8 Coolant temperature sensor 17 Urea pump

9 WGT turbocharger 18 Urea tank (intergrated level temperature

sensor)

Note:

■ The figure is control system diagrammatic sketch, if sensor position is not accord with the

vehicle sensor position, please refer to the vehicle.

Intake

heater

Camshaft

position sensor

High pressure

fuel rail

Fuel injector

Intake pressure

temperature sensor

Oil pressure switch

WGT

turbocharger

Crankshaft

position sensor

Coolant

temperature sensor

Urea pump

Differential

pressure

sensor

Urea injector

Exhausting

temperature

sensor

Nox sensor

Electromagnetic valve

Environment

temperature

sensor

Engine CAN

Diagnosis CAN

Urea tank

(intergrated level

temperature sensor)

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2.2 Electrical Control System Constitution Function

Engine electrical control system is generic terms of all electronic control device installed in engine

(or connected to engine), its function is to control running of all engine systems, to make engine have

good power performance, fuel economical efficiency and emission efficiency.

Engine electrical control system can be divided into 3 parts according to its component, namely

sensor, ECU and actuator. ECU is the control center of engine electrical control system, all sensors in

engine electrical control system measure parameter of engine speed, coolant temperature, intake

pressure temperature, and so on; analyze, judge and calculate according to setting program in ECU, and

transmit instruction signal to actuator of high pressure fuel pump, fuel injector, and so on, according to

calculated result, and control all engine system working.

Control range of control system has already expanded to engine fuel injection system, exhausting

system, and so on.

Sensor Input signal to ECU ECU function Actuator

Crankshaft position sensor

(position)

Engine speed

Piston position

Fuel injection

and mixing

ratio control

High pressure

fuel pump flow

control valve

Fuel injector

Fault indicating

light

A/C relay

Camshaft position sensor (phase

position)

Intake pressure temperature sensor

Intake pipe pressure and

temperature

Battery voltage Battery voltage

Rail pressure sensor Fuel system rail pressure

A/C switch A/C pressure

Wheel speed sensor Vehicle speed

Engine coolant temperature sensor Engine coolant temperature

1、Fuel Injection Control System

Common rail fuel injection system is a fuel direct injection system applied to internal combustion

engine. In common rail fuel injection system, producing of system pressure is divided from fuel

injection function, producing of system pressure is affected by engine speed and fuel injection amount.

Electronic diesel control system (ECU) controls every component of common rail system.

2.7CTI applies BOSCH high pressure common rail system, fuel gets into high pressure fuel pump

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through two-stage filtration, produce high pressure fuel (200~1800bar) and cause high pressure fuel-way,

injected through high pressure fuel injector. ECU controls fuel injection amount according to

requirement, revise fuel quantity according to air-fuel ratio, to accurately control fuel injection pressure,

fuel injection pressure and fuel injection phase position. Single cylinder can complete 4-6 times fuel

injection according to requirement in each working circulation.

2、Exhausting Control System

To reduce exhausting pollution of engine, use DOC+SCR rear treatment system. DOC oxidation

catalytic converter effectively deals with HC and CO, and transforms HC and CO into CO

2

and H

2

O.

SCR rear treatment system deoxidizes NO

x

to N

2

and H

2

O through urea solution in specified condition,

thus effectively reduce NO

x

in exhausting gas.

ECU calculates urea injection amount, controls system deicing and realizes OBD function

according to sampling and treatment of engine related data and all sensors data of rear treatment system.

System control procedure is: obtain engine running state data by CAN bus, sample front and rear

temperature signal of catalytic converter at the same time, calculate urea injection amount of SCR

system in engine actual working condition according to all pulse spectrum calibrated in advance, thus

make NO

x

in engine exhausting gas be accurately deoxidized. It needs vehicle or engine supplies

environment temperature signal through CAN line in system icing function, and system will judge

whether to open urea pipe heating through environment temperature feedback from the signal. Therefore,

when it needs to heat pipe in SCR system, vehicle or engine should install environment temperature

sensor.

Fuel Filter

High pressure

fuel pump

Fuel capacity

metering unit

Electronic fuel

input pump

Fuel tank

Primary filter

Other

actuator

Accelerator

pedal

Crankshaft

sensor

Camshaft

sensor

Other sensor

Fuel injector

Common rail pipe

Rail pressure

control valve

Rail pressure

sensor

Low pressure

High pressure

Fuel backflow

Electrical circuit

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2.3 OBD System

1、Instruction

OBD system is a diagnosis system, which is integrated in engine control system, and it can monitor

fault component that affects exhausting gas discharging and monitor main function state of engine.

The system applies CAN communication, which is equipped with 16 pins fault diagnosis connector

(shown as figure below), and read related data according to related standard design by decompiler.

Standard diagnosis connector

There are four pins in fault diagnosis connector connecting to engine ECU, in which 5

th

pin is

grounding;

16

th

pin connects to battery positive electrode, 6

th

and 14

th

pin are data transmitting pin, which

partly is CAN High and CAN Low of high speed CAN bus.

2、Function Introduction

Functions of diagnosis system mainly are monitoring, fault code storage and warning, lose efficacy

protection and data output.

1）Monitoring Function

Objects diagnosis system monitored mainly are all sensors, actuators in engine electrical control

SCR catalytic

converter assembly

Urea pump

Temperature sensor

installation seat

Nox sensor

installation seat

Electrical heating urea pipe

Urea tank assembly

Urea level temperature sensor

Differential pressure sensor

connecting steel pipe hose

DOC catalytic converter assembly

Airflow direction

Fuel injector

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system and control procedure of electrical control system. Fault self-diagnosis system monitors related

signal of electrical control system continuously when vehicle running, when some signal exceed

presetting range value and the phenomenon doesn’t disappear in some time, fault self-diagnosis system

will judge there is fault in the signal corresponding circuit or component.

■ Used to diagnose component which has input or output relationship with controller (sensor and

driver), mainly test component circuit, and including reasonable judgment of sensor input value at the

same time.

■ System detection is used to diagnose system fault, such as misfire, catalytic converter degradation,

cooling system fault and so on.

■ Detection of control component is used to diagnose hardware fault, communication fault and

internal storage memorizing state, which is related to data of control component.

2）Fault Code Storage and Warning Function

Once fault self-diagnosis system finds there is fault in electrical control system, fault warning light

on dashboard will be on immediately, which warns driver to maintain vehicle to avoid more damage.

Fault self-diagnosis system will also detect fault content and stored in ECU memorizer as fault

code. As long as not remove vehicle battery, detected fault code will always be stored in ECU. When

maintaining, testing personal can apply some method to read fault code stored in ECU, and supply actual

foundation for finding fault component.

No. Name Graphic Remark

1 Engine fault light

Yellow

2 EPC fault light

Yellow

3 Fuel-water separator

Red

4 Pre-heating

Yellow

5 Urea level warning light

Yellow

6 Low pressure oil indicating light

Red

7 Brake fault indicating light

Red

8 Coolant temperature high

Red

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3）Lose Efficacy Protection Function

According to different monitoring objects, fault self-diagnosis system will take different lose

efficacy protection measures.

4）Data Storage Output Function

Data storage unit in ECU is divided into ROM and RAM. Memorizer ROM stores program that is

based on accurate calculation and data from a large number of experiment; when engine running, the

intrinsic program compares and calculates with all sensors signals, to control engine.

There is a special diagnosis connector in vehicle electrical control system circuit, as long as connect

vehicle ECU decompiler to the diagnosis connector, it can visit vehicle ECU storage unit, and read

stored fault code.

Besides, fault self-diagnosis system also can output data flow that reflect working condition of

vehicle electrical control system through diagnosis connector.

3、Fault Light Instruction and Its Control Strategy

1）Engine fault indicating light (MIL): indicating for emission related component or system lose

efficacy, generally, MIL is a indicating light that can be displayed in dashboard.

2）Activation of MIL indicating light obey to the following principle:

① Ignition switch is “ON” (not start), MIL will be always on;

② After engine starting 3s, if there is not fault request that needs to lit MIL, MIL will be off;

③ There is fault request that needs to lit MIL, or there is lightening MIL request outside ECU,

MIL will be on;

④ When there is twinkling MIL request outside ECU, or there is twinkling MIL request due to

misfire, or there is twinkling MIL request in fault internal storage, MIL will twinkle in the frequency of

1HZ;

3）EPC fault indicating light: used to indicating vehicle related fault.

4）In different mode, EPC light working condition has:

① In normal mode, and fault internal storage is vain. Turn ignition switch to “ON”, ECU will be

initialized immediately, from initialization, EPC light will be on for 4s and then off. If start in the 4s,

after finding engine speed, EPC light will be off;

② In normal mode, and there is fault in internal storage. Turn ignition switch to “ON”, EPC light

will be on continuously. After starting, if in fault internal storage fault request EPC light on in fault

mode, EPC light will be on in the following driving circulation; if in fault internal storage fault don’t

request EPC light on in fault mode, EPC light will be off after finding engine speed;

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③ In twinkling mode, and fault internal storage is vain. If ECU monitoring EPC light is in

twinkling mode, EPC light will twinkle and display fault corresponding fault code in fault internal

storage. From turning ignition switch to “ON”, EPC light will be on for 4s continuously, and then after

1s, EPC light will twinkle in the frequency of 2HZ, which indicates there is no fault until engine starting

and finding engine speed. (Mainly used to related fault indicating of ECU anti-theft).

4、Fault Maintenance Step

1）To vehicle with OBD function, fault maintenance generally obey to the following steps:

OBD Troubleshooting Step

1. Connect diagnosis test device to diagnosis connector, and turn on

diagnosis test device;

2. Turn on “ignition switch”;

3. Read fault related information (fault code, freeze frame data and

so on); inquiry workshop manual to ensure fault component and

type; formulate maintenance scheme according to fault related

information and experience;

4. Remove fault;

5. Clear fault memorizer; run vehicle properly, running mode should

satisfy corresponding fault diagnosis condition; read fault

information, and ensure fault is removed.

2）Common use diagnosis device for fault diagnosis

Compare vehicle electrical control system to mechanism system, their maintenance method is basic

different, depending on electronic device and using information of self-diagnosis system to diagnose is a

necessary method of vehicle electrical control system. Common use device of electrical control system

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includes vehicle computer testing device, multimeter, and so on.

Connect data connecting wire of computer testing device to diagnosis connector on vehicle, which

can build connection with vehicle ECU, visit related fault diagnosis data stored in ECU, including fault

code, data flow, and so on, thus learn monitoring result of vehicle fault self-diagnosis system and

working condition of electrical control system, and supply foundation for removing fault rapidly.

Besides, it can also test move, and so on.

① Read and clear fault code

Connect vehicle computer testing device to electrical control system, which can be convenient to

read fault code stored in ECU. By reading fault code, maintenance personal can find short circuit and

open circuit of most sensors and their control circuit in vehicle electrical control system. After removing

fault, also can send instruction to vehicle electrical control system through computer testing device, and

clear fault code stored in ECU to make fault warning light off.

② Read data flow

Connect vehicle computer testing device to electrical control system, and read ECU working

condition and instant data of all input/output signals (such as all sensors signals, ECU calculated result,

control mode, control signal sent to all actuators, and so on). Computer testing device can display these

values on testing device screen as data list, which can make working condition of control system

absolutely clear. Maintenance personal can judge whether system works normally according to change

condition of all data, or compare all signal values in special working condition to standard value, thus to

judge fault type and fault component accurately.

③ Move test

Move test sends working instruction to ECU of vehicle electrical control system through computer

testing device, drive or stop some actuators working to detect the working condition of the actuator, and

find faulted actuator or control circuit.

Besides the basic function mentioned above, vehicle computer testing device also can read vehicle

computer, carry out basic settings, and so on.

④ IQA code written in

Write all fuel injectors IQA code to ECU through computer testing device.

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III、Structure Principle and Maintenance of Engine Electronic

Component

The electronic components involved in this chapter mainly include sensor, actuator and ECU.

Below mainly introduce working principle, structure, circuit and related maintenance of all electronic

components.

Generally, there are 3 wires in basic circuit of sensor, namely power supply, signal and grounding.

Some sensors don’t need power supply, or build-in power supply in ECU, therefore there are only signal

and grounding two wires; if uses housing grounding, there may be one signal wire connecting ECU, thus

make circuit very simple; but circuit of some sensors are very complicated. Complicated degree of

sensor circuit depends on sensor’s type and structure principle, sensors in engine electrical control

system mainly have switch type, resistance type, pulse type, voltage type, and so on.

Switch type sensor is the most simple structure, generally has 2 connecting terminals, its circuit has

grounding type and power supply type, in which grounding type is one terminal of switch is grounding

pin, one terminal of power supply type circuit is connected to power supply.

Resistance type sensor is mostly applied in electrical control system. Its structure has resistance

variable type, potentiometer type, and so on; generally produces signal by the principle of direct circuit

distributing voltage, and to ensure signal precision, ECU supplies a constant basic voltage as working

voltage (generally is 5V).

Resistance variable type sensor has 2 connecting terminals, generally applies grounding type circuit,

one terminal is signal, the other is grounding; potentiometer type sensor has 3 connecting terminals,

namely power supply, signal and grounding.

Pulse type sensor has different principle and structure type, such as electromagnetic type using

electromagnetic induction principle, photoelectricity type using photoelectricity principle, hall type

using hall effect, magnetic resistance type using magnetic resistance principle, and so on; and its circuit

is fairly complicated.

Voltage type sensor generally uses electrochemistry principle and piezoelectric effect to transform

change of detected data into change of voltage. Most voltage type sensors don’t need working power

supply.

Actuators of electrical control system mainly have electromagnetic valve, electrical power motor,

relay, triode switch circuit, indicating light, and so on. Actuator circuit generally is very simple,

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generally only has power supply and grounding two wires. ECU uses grounding control method to most

actuators, power supply of these actuators comes from battery, and grounding wire is connected to ECU.

3.1 Crankshaft Position Sensor

1、Summary

Crankshaft position sensor is magnetoelectricity type sensor; piston position in burnt chamber

decides starting time of fuel injection, engine piston connects to crankshaft by connecting rod,

crankshaft position sensor can supply all data of piston position, and engine speed ensure crankshaft

round per minute.

2、Working Principle

Crankshaft is connected to a ferromagnetic trigger wheel with 60 gears. There are 2 gears missing

in actual used trigger wheel, which corresponding to some specified crankshaft position of 1

st

cylinder.

Crankshaft position sensor records gear sequence of trigger gear, and it consists of permanent magnet

and soft iron core with copper coil. Magnetic flux in sensor changes along with passed gear and

clearance, produce sine AC voltage, and its amplitude increases rapidly along with engine (crankshaft)

engine, and it also can achieve adequate amplitude even though engine speed is 50 r/min.

3、Installation Position

Crankshaft position sensor is installed in exhausting side of engine, and in front part of crankshaft.

4、Technical Parameter and Terminal Definition

Wiring terminal:

Crankshaft position sensor

Sensor signal +

Sensor signal -

Crankshaft position

sensor shielding

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1—Crankshaft position sensor signal terminal

2—Crankshaft position sensor grounding terminal

Resistance: 860Ω;

Clearance between sensor and signal gear top : 0.5~1.5mm.

Temperature range:

Storage temperature: -20~50℃;

Working temperature: -40~120℃.

5、Installation Note

Sensor can only be opened before assembly;

Installing sensor must be pressed to install (It’s forbidden to knock);

Installation bolt tighten torque: 8±2 N.m;

6、Fault Phenomenon and Judging Method

 General Fault Reason:

① Sensor inner component is damaged or inner circuit open circuit, short circuit, can’t produce

signal;

② External circuit of sensor open circuit or short circuit;

③ Installation position of sensor is not right, clearance between rotor is too large, causing output

signal abnormal;

 Fault Phenomenon: power not enough, can’t start;

 Detect Method:

1）Appearance Check

Check whether sensor installation is well, wiring harness connector is connected well and firmly;

check whether distance of hall component and signal wheel accord with standard requirement, and there

is no dirt or iron scurf between them; if any, please clear.

2）Resistance Measurement

Check sensor resistance, if resistance is too large or too small, sensor is damaged.

3）Circuit Detect

① Turn off ignition switch, and measure connecting condition of all wiring harness connectors;

② Measure resistance between ECU control wiring harness and connector, resistance is less than

3Ω;

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3.2 Camshaft Position Sensor

1、Summary

Camshaft position sensor can timely and truely induces relative rotating angle position of engine

camshaft during engine running, supplies electrical signal to engine electronic control module (ECU), so

that ECU rightly judges working phase position of engine each cylinder at the moment according to

camshaft position signal inputed by camshaft position sensor, and make system control fuel injection

and ignition sequence according to specified engine working sequence, thus to more accurately control

engine combustion procedure and reduce harmful combustion emissions. Applicance of camshaft

position sensor is useful to realize optimum control of engine each cylinder ignition and fuel injection

timing.

2、Working Principle

Camshaft position sensor is hall-type sensor, which uses Hall effect

to ensure position of camshaft, trigger wheel of one ferromagnet rotates

along with camshaft, integrated circuit of Hall effect is installed between

trigger wheel and permanent magnet, and permanent magnet produces

magnetic field which perpendicular to Hall-component. If one of the

trigger wheels getting through streamlined sensor component

(semiconductor chip), it changes intensity of magnetic field of

perpendicular Hall-component, which will cause driving electron in long

axis direction voltage deviate to direction that perpendicular to current,

and produces instant signal voltage (Hall-voltage), and calculating circuit integrated with sensor Hall

1 2 3

Camshaft position sensor

+5Vpower supply

Signal

GND

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integrated circuit handle the signal and output with square wave signal.

3、Installation Position

Camshaft position sensor is installed in intake side of cylinder cover and below high pressure fuel

rail.

4、Technical Parameter and Terminal Definition

Working voltage: 5V

Signal gear addendum sensor output voltage: +0.5V

Signal gear dedendum sensor output voltage: -0.5V

Wiring terminal:

1— +5V power supply

2—Signal output

3—Grounding

Clearance between sensor induction terminal and camshaft signal wheel is: 0.35~1.65mm.

5、Installation Note

Sensor surface is clean, and there is no crack;

Tighten torque of sensor installation bolt: 10±2 N.m.

6、Fault Phenomenon and Judging Method

 General Fault Reason:

① Sensor inner component is damaged, or inner circuit is open circuit, short circuit, can’t produce

signal;

② Sensor outer circuit is open circuit or short circuit;

③ Installation position of sensor is not right, clearance with rotor is too large, causing output

signal abnormal.

 Fault Phenomenon:

If camshaft position sensor input signal is wrong, it can’t inject fuel in order, which is easy to cause

engine misfire, idling unsteadily, accelerating weakly, and so on.

Detect Method:

 Appearance Check

Check whether installation of sensor is firmly, wiring harness connector is connected well and

firmly, distance between Hall-component and signal wheel is accord with requirement, there is dust or

iron scurf; if any, please clear.

 Circuit Check

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Hall sensor can produce signal only in the condition of power supply grounding is normal, thus first

check its power supply circuit and grounding circuit.

① Close ignition switch, and disconnect wiring harness connector of sensor.

② Open ignition switch, use multimeter to respectively measure all terminals of sensor wiring

harness connector.

Measure sensor power supply terminal, it should be 4.5～5V reference voltage. If voltage value is

not accord with, it indicates there is fault in control circuit or ECU, and should detect further.

Measure sensor grounding terminal, and resistance between it and battery negative electrode should

be less than 3Ω; if abnormal, should maintain grounding circuit.

③ If check above is abnormal, close ignition switch, disconnect ECU wiring harness connector,

and check whether there is open circuit or short circuit between sensor connecting terminal and ECU

connecting terminal.

3.3 Intake Pressure Temperature Sensor

1、Summary

Intake pressure temperature sensor characterizes engine actual intake state when engine running,

thus it is one of the main components of characterizing engine running working condition and load state.

2、Working Principle

Intake pressure temperature sensor integrates the function of pressure sensor and temperature

sensor.

Pressure sensor part (MAP) is designed by principle of piezoelectricity technical, when induced

Intake pressure

temperature sensor

Power supply

Grounding

Pressure signal

Temperature signal

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pressure, it produces output signal which is proportional to input pressure. Pressure level directly

indicates engine current load and working state. It has conclusive effect to engine management system

output control state.

Core temperature sensor component of temperature sensor consists of semiconductor thermal

resistor of negative temperature coefficient. Its temperature characteristic is negative temperature

coefficient (NTC) thermal resistor, when temperature increases, output resistance value of thermal

resistor decreases; when temperature decreases, resistance value of thermal resistor increases.

ECU supplies 5V direct current signal for engine intake temperature sensor and measure its voltage

drop according to itself circuit, and engine management system will judge engine actual working state

according to the voltage signal.

3、Installation Position

Intake pressure temperature sensor is installed intake manifold, and pressure measurement function

is prior.

4、Technical Parameter and Pin Definition

Working voltage: +5V

Working temperature: -40~130℃

Pressure measuring range: 50~400Kpa, highest is 600Kpa

Pressure measuring response time: ＜1.8ms

Temperature measuring response time: ≤10s

Temperature/℃ Maximum resistance value/Ω Minimum resistance value/Ω

-20 14055 16970

0 5420 6403

20 2323 2690

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40 1100 1254

60 561 631

80 306 339

85 265 297

90 231 255

95 202 223

100 178 195

105 156 171

110 137 151

115 121 133

120 107 118

Pin definition:

1—Grounding

2—Temperature signal

3—Power supply +5V

4—Pressure signal

5、Installation Note

When installing, ensure pressure port faces downward, and angle between it and vertical direction

is less than 60°;

Installation bolt tighten torque: 6±2 N.m;

6、Fault Phenomenon and Judging Method

 General fault reason: sensor inner circuit open circuit, or dirt piled up, intake pipe leaking

causes signal incorrect.

 Fault phenomenon: when fault appears, it will cause fuel injection function of engine ECU

abnormal, and appears the phenomenon of mixed gas too dense or too thin, engine abnormal idling

running or bad accelerating, exhausting pipe giving off black smoke, and so on.

 Maintenance Note: it’s forbidden to disassemble sensor.

 Detect Method:

1）Appearance Check

Check whether sensor wiring harness connector is connected well and firmly. Check whether

sensor installation is loosen or dropped. Check whether extrinsic feature is good, and ensure there is no

knock mark. Check whether sensor check hole is blocked.

2）Circuit Check

① Turn off ignition switch, disconnect sensor wiring harness connector;

② Turn on ignition switch, use multimeter to respectively measure all terminals of sensor wiring

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harness connector;

a、Measure power supply terminal of sensor, and it should be 5V reference voltage. If voltage value

is not accord with, it indicates there is fault in control circuit or ECU, and check further.

b、Measure sensor grounding terminal, and resistance between it and battery negative electrode

should be less than 3Ω; if abnormal, should maintain grounding circuit.

If check above is abnormal, turn off ignition switch, disconnect wiring harness ECU connector, and

check whether there is phenomenon of open circuit or short circuit in wiring harness between sensor

connector and ECU connector.

3.4 Rail Pressure Sensor

1、Summary

Rail pressure sensor is to measure actual pressure in high pressure fuel rail in high pressure

common rail system. Rail pressure sensor transforms pressure signal into voltage signal and transmits to

ECU, thus to realize closed loop control of fuel pressure.

Rail pressure sensor must measure instant pressure in rail, and has adequate precision and fast

response ability.

2、Working Principle

High pressure fuel flows into rail pressure sensor through a hole in common rail, and there is a

sensor membrane sealing in end part of the hole. Fuel in high pressure reaches to sensor membrane

through a blind hole. There is sensor component (semiconductor assembly) on the membrane, and the

pressure is transformed into electrical signal by the component. The produced signal is transmitted to

Rail pressure sensor

Grounding

Signal

Power supply

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calculated circuit by wire, and it will amplify signal and be transmitted to ECU.

Resistance of sensor will change accordingly along with the shape changing of sensor metal layer

installed in membrane. Shape change produced by established system pressure will make resistance

change and cause voltage of 5V conducting bridge consisted by resistance component change. The

voltage change range is 0~70mV (depends on applied pressure), and is amplified to 0.5~4.5V by

calculated circuit.

Accurate measurement of rail pressure is crucial to effective running of system. This is one of the

reasons that common difference of rail pressure sensor is very strict during pressure measurement.

Within main working condition, measurement precision is about ±2％ of full scale reading.

3、Installation Position

Rail pressure sensor is installed in end part of high pressure fuel rail.

4、Technical Parameter and Pin Definition

Fuel pressure signal range: 0.5V~4.5V

Working temperature: -40~120℃

Maximum working rail pressure: 2000bar

Pin definition:

1—Grounding

2—Signal

3— +5V power supply

5、Installation Note

Rail pressure sensor is forbidden to disassemble.

6、Fault Phenomenon and Diagnosis Method

 General fault reason: rail pressure sensor connector fault or sensor damaged.

 Fault phenomenon: engine fault light is on, power not engough, hard to start.

 Detect Method:

① Wiring harness connector check: after disconnected, signal terminal voltage is about 5V, power

supply voltage is 5V, grounding wire is normal;

② When working, signal wire output voltage check: in not starting state, voltage output is about

5V; in idling state, voltage output is about 1V; in normal working state, voltage is 0.5-4V.

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3.5 Coolant Temperature Sensor Ⅱ

1、Summary

Engine coolant temperature sensor detects engine coolant temperature, and transmits signal to ECU

to control starting, idling, fuel injection timing when running normally, fuel injection pulse width, and

supply coolant temperature signal to combination meter to display coolant temperature in combination

meter.

2、Working Principle

Coolant temperature sensor is used to detect engine working temperature, and ECU supplies

optimal control program for engine according to different temperature. There is a negative temperature

coefficient (NTC) thermal resistor in coolant temperature sensor, and the thermal resistor is connected in

voltage division circuit of 5V power supply. Voltage drop on resistor inputs to ECU by analog-to-digital

converter (ADC), and it’s a standard to measure temperature. There is a characteristic curve in ECU

microprocessor, and it sets temperature as function of given voltage value.

3、Installation Position

Coolant temperature sensor Ⅱ is installed on thermostat valve seat of front part of cylinder cover.

4、Technical Parameter and Pin Definition

Working temperature: -40~140℃

Heat response time: ≤10S

Coolant temperature sensor Ⅱ

Grounding

Signal

1 2

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Pin definition:

1—Signal terminal

2—Grounding terminal

5、Installation Note

When installing coolant temperature, must spread screw thread sealant;

Installation tighten torque: 25 N.m.

6、Fault Phenomenon and Diagnosis Method

 General fault reason: short circuit and open circuit, input signal voltage is not accord with

standard value.

 Fault phenomenon: when there is fault in coolant temperature sensor, it will affect dense of

mixed gas. When coolant temperature signal that coolant temperature sensor sends to ECU is lower than

actual coolant temperature, it will cause mixed gas too dense, and appear fault of exhausting pipe giving

out black smoke, idling not steadily when heating vehicle, and so on. When there is short circuit or open

circuit in coolant temperature sensor, fault self-diagnosis circuit of ECU will detect the fault, make

engine fault warning light on, and ECU will start lose efficacy protection function. Coolant temperature

fault causes coolant temperature deviated, which will affect pre-heating plug not working, and cause

engine start difficultly.

 Maintenance Note: after installation, idling run to check whether there is leakage.

Temper

ature/℃

Resistance/kΩ

Standard

value

Minimu

m value

Maximu

m value

Temper

ature/℃

Resistance/kΩ

Standard

value

Minimu

m value

Maximu

m value

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 Check Method:

1）Appearance check

Check whether sensor wiring harness connector is connected well and firmly; whether sensor

installation is loosen or dropped; whether extrinsic feature is good, and ensure there is no knock mark.

2）Circuit check

① Turn off ignition switch, disconnect sensor wiring harness connector;

② Turn on ignition switch, use multimeter to respectively measure all terminals of coolant

temperature sensor wiring harness connector.

a、Measure sensor power supply terminal, it should be 5V reference voltage. If voltage value is not

accord with, it indicates there is fault in control circuit or ECU, check further.

b、Measure sensor grounding terminal, resistance between it and battery negative electrode should

be less than 3Ω; if abnormal, should maintain grounding circuit.

3）Function detect

Disconnect coolant temperature sensor wiring harness connector, remove coolant temperature

sensor, and place coolant temperature sensor to water, heat and measure resistance of coolant

temperature sensor terminals in different temperatures at the same time, corresponding to standard value;

if not accord with, should replace sensor.

3.6 Exhausting Temperature Sensor

1、Summary

There is a temperature sensor installed in front of SCR catalytic converter, and it is used to detect

starting combustion temperature of SCR, SCR controller judges urea injection amount according to the

2

Grounding

Signal

Exhausting temperature sensor

1

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temperature.

2、Working Principle

Exhausting temperature sensor applies PT200 membrane platinum thermal electronic technology,

and sensor resistance increases along with exhausting temperature increasing. ECU calculates

exhausting temperature by voltage resistance change affected on resistance circuit, and can ensure fast

response time and high precision.

3、Installation Position

Exhausting temperature sensor is installed on exhausting pipe in front of SCR catalytic converter.

4、Technical Parameter and Pin Definition

Working voltage: +5V

Working temperature: -40~750℃

Response time:

When gas speed is 11m/s, temperature is 300℃, less than 11s

When gas speed is 70m/s, temperature is 300℃, less than 5s

Pin definition:

1—Signal terminal

2—Grounding terminal

Temperature/℃ Resistance/Ω Voltage/V Resistance error/Ω

-20 185.6 0.783 ±1.9

0 201.0 0.837 ±1.9

50 239.0 0.964 ±1.9

200 349.5 1.295 ±1.9

300 420.2 1.479 ±3.1

400 488.6 1.641 ±4.0

500 554.6 1.784 ±4.9

600 618.3 1.910 ±5.6

700 679.7 2.023 ±6.3

5、Installation Note

Ensure to be in middle and be installed with head-part of inducing face downward;

Installation tighten torque: 40~50 N.m;

It’s forbidden to let engine exhausted deposition carbon, silicon oil, lead, paint or other organics

pollute sensor.

It’s forbidden to pull and drag wire when installing.

It’s forbidden to knot, break or do other operations that damage sensor wiring harness wire.

It’s forbidden to use oil lubricant, cleaner or other impurity on connectors.

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6、Fault Phenomenon and Diagnosis Method

 Appearance Check

Check whether sensor wiring harness connector is connected well and firmly; whether sensor

installation is loosen or dropped. Check whether extrinsic feature is good, and ensure there is no knock

mark.

 Circuit Check

① Turn off ignition switch, and disconnect sensor wiring harness connector;

② Turn on ignition switch, use multimeter to respectively measure all terminals of coolant

temperature sensor wiring harness connector;

a、Measure power supply terminal of sensor, it should be 5V reference voltage. If voltage value is

not accord with, detect further.

b、Measure grounding terminal of sensor, resistance between it and battery negative electrode

should be less than 3Ω; if abnormal, should maintain grounding circuit.

 Function detect

Disconnect sensor wiring harness connector, measure resistance between two terminals; if

resistance too large or too small, it indicates sensor is damaged.

3.7 Differential Pressure Sensor

1、Summary

The function of differential pressure sensor is monitoring differential pressure between DOC in real

time to ensure whether rear treatment system works normally, draw forth pressure between DOC by two

1 2 3

Differential pressure sensor

2 Signal

1 Power supply

3 Grounding

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pressure port on sensor, and sensor transforms the measured result into voltage value to feed back to

control unit, thus it can ensure full oxidation of particle and avoid blocking of catalytic converter.

2、Working Principle

Connect differential pressure sensor to DOC by stainless steel pipe (gas sampling steel pipe) and

high temperature rubber pipe, draw forth pressure from DOC by stainless steel pipe, and then connect

differential pressure sensor by high temperature rubber pipe, rubber pipe can bear temperature more than

150℃. Once differential pressure between DOC two ends is too large or too small, fault light will be on

after ECU receiving feedback voltage, which judges catalytic converter blocked or short circuit.

3、Installation Position

It’s installed on gas sampling steel pipe of DOC two sides.

4、Technical Parameter and Pin Definition

Sensor characteristic parameter

Measureable differential

pressure range kPa

Working temperature ℃

Power supply voltage V

Storage temperature ℃

Highest bearable pressure of

sensor single input end kPa

Bearable pressure range of

sensor kPa

Minimum

value

Normal

value

Maximu

m value

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Pin definition:

1—Power supply terminal

2—Signal terminal

3—Grounding terminal

5、Installation Note

Pipe connected to differential pressure sensor only can be upward, and avoids gathering water in

pipe and influence pressure measurement.

6、Fault Phenomenon and Diagnosis Method

 Fault phenomenon: Fault light/System light is always on

 General fault reason: differential pressure sensor is damaged or not connected well, DOC is

blocked or brokenover

 Detect method

1）Whether sensor extrinsic feature is damaged, check whether connector is loosen, wiring harness

is broken, whethere there is liquid in connector;

2）Check whether pipe is normal, there is the phenomenon of leaking gas;

3）Fault code diagnosis: use diagnosis device to diagnose fault, judge fault possible reason by fault

code, including whether power supply or grounding is normal;

4）Function test: disconnect two connecting pipe, detect output voltage when working, it should be

about 1V, or else sensor is damaged.

Output voltage

Differential pressure value (kPa)

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3.8 Environment Temperature Sensor

1、Summary

Urea of SCR system will be frozen in low temperature environment, and it needs to heat to

unfreeze urea when working, and environment temperature sensor is used to measure temperature of

surrounding environment. ECU controls urea heating according to the temperature signal.

2、Working Principle

There is a temperature sensitive resistance in environment temperature sensor, which changes along

with the change of surrounding environment temperature, causing division voltage change of

temperature sensitive resistance. ECU calculates surrounding environment temperature according to the

voltage signal.

3、Installation Position

It’s installed below engine front bumper.

4、Technical Parameter and Pin Definition

Resistance between 1

st

and 2

nd

pin/kΩ

Environment temperature/℃

3.0~3.6 0

1.1~1.4 20

0.5~0.6 40

Pin definition:

1—Signal

2—Grounding

5、Installation Note

Prevent bending wiring harness when installing.

6、Fault Phenomenon and Diagnosis Method

Environment

temperature sensor

2 GND

1 Signal

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 Fault phenomenon: system light/fault light is always on.

 General fault reason: wiring harness connecting fault, sensor inner fault.

 Detect Method:

1）Whether there is damage in sensor extrinsic feature, check whether connector is loosen,

wiringharness is broken, and whether there is liquid in connector;

2）Fault code diagnosis: use diagnosis device to diagnose fault, judge fault possible reason by fault

code, including whether power supply or grounding is normal;

3）Measure resistance between 1

st

pin and 2

nd

pin of sensor, compare to standard value, and judge

whether there is fault in environment temperature sensor.

3.9 NO Sensor

1、Summary

NO sensor can detect NOx thickness in exhausting gas (after through SCR catalytic converter), thus

to realize closed loop control of SCR system, and also can act on OBD diagnosis.

2、Installation Position

It’s installed on exhausting pipe behind SCR catalytic converter.

3、Technical Parameter and Pin Definition

Working voltage: 12V

Working temperature: -40~130℃

NOx measuring range: 0~1650ppm

Response time: ＜2000ms（10~90℃）

Pin definition:

1—Empty

NO sensor

CAN-H

CAN-L

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2—CAN-H (K86)

3—CAN-L (K64)

4—Grounding

5—Power supply (Main relay)

4、Installation Note

Installation tighten torque: 50±10 N.m;

It’s forbidden to let engine discharged deposition carbon, silic oil, lead, paint or other organics

pollute sensor.

It’s forbidden to pull wire when installing.

It’s forbidden to do operation of knoting, bending or other operations that damage sensor wiring

harness wire.

It’s forbidden to use oil lubricant, cleaner or other impurity on connector.

5、Fault Phenomenon and Diagnosis Method

 Fault phenomenon: engine limit torque, system light/fault light is always on.

 General fault reason: sensor connecting wiring harness fault, sensor inner circuit damage

 Check method:

1）Whether sensor extrinsic feature is damaged, check whether connector is loosen, whether wiring

harness is broken, whether there is liquid in connector;

2）Fault code diagnosis: use diagnosis device to diagnose fault, judge fault possible reason by fault

code, including whether power supply or grounding is normal;

3.10 Urea Level Temperature Sensor

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1、Summary

Urea level temperature sensor can detect urea temperature and level height in urea tank, and urea

temperature supplies foundation for urea heating. When urea level is low, meter indicating light will be

on to remind user to fill in time.

2、Working Principle

Urea temperature sensor and urea level sensor are integrated together and are installed in urea tank.

Both of them are based on division voltage change of variable resistance to measure.

3、Installation Position

It’s installed in urea tank.

4、Technical Parameter and Pin Definition

Working temperature: -40~85℃

Electrical device function parameter:

Rated voltage: U=48VDC

Rated current: I=300mA

Rated power: P=125mW

Urea level temperature sensor

2 Grounding

1 Signal

4 Grounding

3 Signal

Urea temperature sensor

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Pin definition:

1—Urea level signal

2—Urea level grounding

3—Urea temperature signal

4—Urea temperature grounding

5、Installation Note

When installing, avoid bending sensor wiring harness.

6、Fault Phenomenon and Detec Method

 Fault phenomenon: engine limit torque, system light/fault light is always on

 General fault reason: sensor fault, wiring harness fault

 Detect method:

1）Whether sensor extrinsic feature is damaged, check whether connector is loosen, whether wiring

harness is broken, whether there is liquid in connector;

2）Fault code diagnosis: use diagnosis device to diagnose fault, judge fault possible reason by fault

code, including whether power supply or grounding is normal;

Temperature resistance

corresponding list

Level resistance

corresponding list

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3.11 Intake Heater

1、Summary

When engine starts in cold, due to low intake temperature, it’s not easily to be burnt when injecting

fuel at the end of compression stroke, causing cold starting is difficult. Intake heater heats intake gas

when engine starting in cold to ensure engine starting smoothly.

2、Working Principle

Intake heater consists of 3 parts, namely, heating slice, ceramic body and outer housing. Its

working principle is using ohm’s law, connect heating component to power supply to achieve needed

power, and supply enough heat for engine to safisfy cooling starting requirement. Intake heater takes

power from vehicle wiring harness, and is controlled by intake heating relay. ECU K07 pin outputs low

voltage to control intake heating relay working, thus controls heater working.

3、Installation Position

It’s installed in intake manifold.

4、Technical Parameter

Working voltage: 12V

Power: 1.5±0.15kw

Control terminal

Intake heating relay

Main relay output

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5、Note

There should be crack in metal component and insulation shim of intake heater; there is no gear

missing, deformation or other fault that influences product function in screw thread.

Continuous heating time can’t be more than 1min, if first starting fails, second starting time should

be 2 min interval.

3.12 ECU

1、Summary

Electronic control system of diesel engine can accurately adjust fuel injection parameter in different

working condition, which is the only reason that current diesel engine can be applied to all occasions.

ECU collects engine current working information through all sensors and switches, analyzes and

calculates to control fuel injection amount, fuel injection time and fuel injection pressure according to

pre-calibrated optimum parameter, thus adjust engine working state to reach the purpose of saving fuel,

high efficiency, low emission, safety, comfortable and so on.

ECU can be divided into 3 modules:

① The function of sensor is transforming physical signal to electrical signal to make ECU learn

current engine working condition (such as engine speed) and setting value (such as switch position).

Component temperature, current characteristic curve graph

Temperature

Current

s s s s s s s

s

s s s s s s

s

s s s s s s s s s s s s s s s s

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② ECU handles signal achieved from sensor basing on given open loop or closed loop control

arithmetic, and outputs electronic control signal to actuator. Besides, ECU is also connector of vehicle

other system and OBD system.

③ Actuator transforms electrical signal to mechanical move (such as, open electromagnetic valve

in fuel injection system).

ECU will always monitor whether all sensors and actuators are in normal range. At the same time,

it will detect connector void connecting, short circuit, open circuit and rationality with other signal.

When there is fault, ECU will store corresponding fault code of the fault and start safe mode.

There are 2 wiring harness connectors in ECU, including 94 pins vehicle wiring harness connector

and 60 pins engine wiring harness connector.

Working environment temperature: -40~105℃

Working voltage: 12V

2、ECU Pin Definition

A connector

A01 3

rd

fuel injector high voltage terminal A31 2

nd

fuel injector low voltage terminal

A02 2

nd

fuel injector high voltage terminal A32

A03 A33 4

th

fuel injector low voltage terminal

A04 A34

A05 Starter relay control terminal A35 Camshaft position sensor grounding

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terminal

A06 Rail pressure sensor +5V A36

A07

Intake pressure temperature sensor

+5V

A37

Coolant temperature sensor Ⅱ signal

terminal

A08 Camshaft position sensor +5V A38

Differential pressure sensor signal

terminal

A09 A39

A10 A40

Rail pressure sensor grounding

terminal

A11 A41

A12 A42

A13

Crankshaft position sensor signal

terminal

A43

A14

Crankshaft position sensor grounding

terminal

A44 Electromagnetic valve control terminal

A15 A45 Pressure control valve control terminal

A16 1

st

fuel injector high voltage terminal A46 3

rd

fuel injector low voltage terminal

A17 4

th

fuel injector high voltage terminal A47 1

st

fuel injector low voltage terminal

A18

Electronic fuel pump relay control

terminal

A48

A19 A49

A20 Urea injector low voltage terminal A50

Coolant temperature sensorⅡ

grounding terminal

A21

Fuel temperature sensor grounding

terminal

A51

A22 A/C relay control terminal A52 Rail pressure sensor signal terminal

A23 SCR main relay control terminal A53

Intake pressure temperature sensor

temperature signal terminal

A24 Urea injector high voltage terminal A54

Pressure temperature sensor pressure

signal terminal

A25 Heater high terminal relay control A55

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terminal

A26

Differential pressure sensor grounding

terminal

A56 Crankshaft position sensor shielding

A27 A57

Camshaft position sensor signal

terminal

A28

Intake pressure temperature sensor

grounding terminal

A58

Fuel temperature sensor signal

terminal

A29 A59

Exhausting brake relay control

terminal

A30 A60 Fuel quantity gauge control terminal

K connector

K01 Battery positive electrode K48 Starter request grounding

K02 Battery negative electrode K49

K03 Battery positive electrode K50 Engine brake switch signal terminal

K04 Battery negative electrode K51

K05 Battery positive electrode K52 Cruise off

K06 Battery negative electrode K53 Cruise decelerating

K07 Intake pre-heating (heating grid) K54 Starting request signal

K08

Environment temperature sensor

grounding terminal

K55 Clutch switch signal terminal

K09

Urea temperature sensor signal

terminal

K56

K10 Intake pipe heating relay feedback K57

K11

Exhausting temperature sensor 2 signal

terminal

K58

Accelerator position sensor 2

grounding terminal

K12 K59

K13 K60

2

nd

accelerator position sensor signal

terminal

K14 K61

K15 Urea level sensor signal terminal K62

K16 K63

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K17 K64

CAN commnunication 2 low voltage

signal

K18 Urea level sensor grounding terminal K65 Urea pump heating relay feedback

K19 K66

CAN communication 1 high voltage

signal

K20 K67

Accelerator position sensor 1

grounding terminal

K21 K68 Backflow pipe heating relay

K22

Accelerator position sensor 2 power

supply terminal

K69 Urea pump heating

K23 K70

K24 Urea pressure sensor K71

K25 K72 Urea pump

K26 K73 Urea pump motor grounding

K27 K74 Cruise reset

K28

Accelerator position sensor 1 power

supply

K75 Fan switch signal

K29 Intake pipe heating relay K76

K30

Environment temperature sensor signal

terminal

K77 Fuel-water separator signal

K31

Urea pump relay 3 (pressure pipe

heating)

K78 Auxiliary brake switch signal

K32 K79

K33

Intake temperature sensor 1 grounding

terminal

K80

K34 K81

Accelerator position sensor 1 signal

terminal

K35 K82 Urea pressure sensor signal terminal

K36

Exhausting temperature sensor 1 signal

terminal

K83

K37 A/C request signal K84

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K38 Main brake switch signal K85

Urea tank temperature sensor

grounding terminal

K39

Urea pressure sensor grounding

terminal

K86

CAN communication 2 high voltage

signal

K40 Cruise accelerating K87

CAN communication 1 low voltage

signal

K41 K88 Backflow pipe heating relay feedback

K42 K89 Neutral position switch

K43 Engine speed signal output K90 Urea pump motor

K44 K line communication K91

K45 Pressure pipe heating relay K92 Fan relay 1 control

K46 Ignition switch ON K93 Fan relay 2 control

K47 Main relay control K94

3、Circuit Diagram and Vehicle Related Circuit Component

1）Power supply and grounding

Turn ignition switch to “ON”, ECU K46 pin receives Key_on signal, K47 pin outputs low voltage

control signal, main relay starts to supply power to ECU (K01, K03, K05); at the same time, main relay

87

th

pin is output power supply of other electrical control components, including main/auxiliary brake

switch, clutch switch, A/C switch, urea injector, urea level temperature sensor, urea pressure sensor,

electrical heating urea pipe, intake heating, fuel-water separator and so on.

Grounding 1、2、3

ECU power supply

Ignition switch

Start signal

Key_on signal

Main relay

ECU power supply

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Turn ignition switch to “START”, ECU K54 pin receives “Start” signal, A05 pin outputs low

voltage control signal, starting relay starts working, and starter works.

2）A/C related control

After A/C switch being connected, ECU K75 pin receives signal, ECU outputs low voltage control

signal (A22) according to engine working condition to control A/C compressor relay working.

3）Accelerator pedal, brake pedal, clutch pedal

Main brake switch is normally open type, auxiliary brake switch is normally closed type. Brake

switch detect brake pedal move, and transmits detected signal to engine ECU; when ECU detecting the

Start signal

Starting relay

A/C compressor relay

A/C request signal

Auxiliary brake switch

Main brake switch

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two signals, it judges whether brake switch is normal. When stepping brake pedal and accelerator pedal

at the same time, power will get limited.

Clutch switch is normally closed type switch, and ECU related pin is grounding actual time. When

stepping clutch, clutch switch is disconnected, ECU ensure driver steps clutch; further optimize engine

working state and idling speed to promote vehicle driving function. At the same time, clutch switch

indicating switch indicates clutch is stepped, at this time, only turn ignition switch to “START”, starter

can work, which is the necessary condition of starting.

Accelerator pedal position sensor is installed on accelerator pedal, accelerator pedal position sensor

supplies a signal voltage changing along with accelerator pedal position, and ECU supplies independent

5V reference voltage circuit and low voltage reference voltage circuit for each accelerator pedal position

sensor. After stepping pedal, signal voltage of accelerator pedal position sensor 1 increases, namely,

increases from about 0.75V when pedal in free position to more than 4V when pedal is totally stepped.

After stepping pedal, signal voltage of accelerator pedal position sensor 2 increases, namely, increases

from about 0.375V when pedal in free position to about 2V when pedal is totally stepped. 2 data mutual

monitor by control system.

4）Water in fuel level sensor

1 Sensor 1 signal

2 Sensor 1 grounding

3 Sensor 1 power supply

4 Sensor 2 power supply

5 Sensor 2 grounding

6 Sensor 2 signal

Sensor 1 signal

Sensor 1 grounding

Sensor 1 power supply

Sensor 2 grounding

Sensor 2 signal

Sensor 2 power supply

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Water in fuel level position sensor is used to detect water content in fuel filter, and it is installed in

bottom of fuel filter. When water content reaches to some degree, ECU will control engine working.

Once water level exceeds limit, water level sensor sends high voltage signal (11.3-12V) to ECU K77 pin,

and ECU will warn to indicate discharging water.

Note: Make sure to discharge water in water in fuel level sensor in time; and make sure to replace

fuel filter element in regular time according to requirement.

5）Pre-heating relay

Pre-heating relay is connected on vehicle chassis wiring harness, controls its working by ECU K07

pin. When ECU K07 pin outputs low voltage control signal, pre-heating relay starts working, and controls

heater intake and heating.

Note: Continuous heating time can’t be more than 1 minute, if first starting fails, second starting

time needs 2 minutes interval.

3.13 Engine Control Wiring Harness

1、Summary

Engine control wiring harness is on engine, and connects all sensors and actuators of engine to ECU

and vehicle wiring harness (chassis wiring harness). Control wiring harness mainly includes all sensors

installed on engine, actuator connectors, ECU connector and chassis wiring harness connector.

2、Connector Pin Definition

A connector wiring harness pin definition

Main relay output 12V

Signal

Main relay output 12V

Control terminal

Pre-heating relay

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Chassis wiring harness

E is power supply terminal, and the others refer to ECU A connector pin definition.

Note: Crankshaft position sensor, camshaft position sensor, rail pressure sensor, flow control valve,

coolant temperature sensor, fuel injector, pressure control valve, intake pressure temperature sensor are

directly connected to engine control wiring harness; starting relay, differential pressure sensor,

electronic fuel pump relay, urea sensor, fuel temperature sensor, A/C relay, SCR main relay, urea

injector, exhausting temperature sensor are connected to engine control wiring harness through vehicle

chassis wiring harness.

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IV、Engine Control System Fault Diagnosis Procedure

4.1 Electrical Control System Common Fault and Main Reason

1、ECU Fault

In common condition, ECU reliability is fairly well and it doesn’t appear fault in normal usage,

most of ECU faults are due to abnormal use or improper. Main reasons causing ECU fault are the

followings:

1）There is fault in ECU power supply circuit, causing ECU not work;

2）Remove and install ECU wiring harness connector when power is on, because instant high

voltage will cause ECU damaged;

3）Due to water inlet or damp when using, cause ECU inner circuit short circuit or electronic

component damaged, or wire connecting terminal in connector oxidized, and lead to bad contact;

4）If there is partly damage or some input/output circuit damage in ECU control program, it will

cause partial function of electrical control sytem abnormal, such as some cylinder doesn’t inject fuel,

idling automatic control losing efficacy, and so on.

2、Sensor Fault

There are the following types to sensor fault.

1）Sensor inner fault, such as inner circuit open circuit, short circuit or inner component aging,

damage, and so on;

2）Sensor outer control circuit fault, such as short circuit or open circuit of sensor power supply

circuit, grounding circuit, signal circuit, and so on;

3）Accidental fault of sensor inner or outer, such as inner component or connector bad contact,

occasionally appear fault when working;

When there is open circuit or short circuit fault in inner or outer circuit of sensor, signal value of

sensor will exceed normal range, which is easy to be detected by ECU self-diagnosis system. ECU will

lit engine fault warning light on dashboard immediately, and record the fault code in memorizer, and

start losing efficacy protection control to keep engine running.

When sensor inner component aging or other damage, though its signal value doesn’t exceed

normal range, the signal value is not accord with detected actual parameter. The fault sometimes can’t

be detected by ECU self-diagnosis system, therefore it can’t start losing efficacy protection control, thus

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it may cause engine running abnormally.

3、Actuator Fault

There are electronic component and mechanical component in actuator, which are the easiest

faulted components. When some actuator is faulted, it can’t carry out ECU control instruction accurately,

causing engine running abnormally. Common fault reason are the followings:

1）Hardware fault that electronic component in actuator damage or inner circuit short circuit or

open circuit, and so on;

2）Mechanical component in actuator can’t work normally due to aborasion, clamping stagnation

and blockage;

3）Electronic component or mechanical component in actuator due to aging cause actuator work

slowly, function reduced; though work basicly normally, it’s about to damage limit;

4）There is void connecting in electronic component of actuator or there is abnormal fit clearance in

mechanical component, when working due to temperature or other external factors cause actuator fault

occasionally;

4、Control Circuit Fault

Control circuit between Engine ECU and sensor, actuator, power supply, grounding is abnormal,

which will cause sensor, actuator, ECU of electrical control system can’t work normally, and cause

engine fault. Common fault reasons for control circuit mainly are the followings:

1）Power supply fuse due to bad contact and overload fused cause system power supply circuit

fault;

2）Bad grounding of sensor, actuator or ECU grounding wire causes sensor, actuator or ECU work

abnormally;

3）Due to several removal and installation of connector in control circuit, causes connector or

terminal loosen or due to terminal oxidized causes connector bad contact;

4）Connected wire aging, inner broken or outer leather broken, causes short circuit or open circuit

fault.

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4.2 Fault Code List

Fault code

Fault code definition

OBD light

EPC light

P0122

Accelerator pedal position sensor 1 voltage signal lower than lower

limit value

OFF

ON

P0123

Accelerator pedal position sensor 1 voltage signal higher than upper

limit value

OFF

ON

P0219

Engine overspeed indicating

OFF

P0222

Accelerator pedal position sensor 2 voltage signal lower than lower

limit value

OFF

ON

P0223

Accelerator pedal position sensor 2 voltage signal higher than upper

limit value

OFF

ON

P0426

SCR catalytic converter upper temperature sensor dynamic reliability

detection upper temperature too high fault

ON_3DC

ON

P0426

SCR catalytic converter upper temperature sensor dynamic reliability

detection upper temperature too low fault

ON_3DC

ON

P0426

SCR catalytic converter upper temperature sensor statics reliability

detection fault

ON_3DC

ON

P042C

SCR catalytic converter upper temperature sensor signal voltage too

low

ON

P042D

SCR catalytic converter upper temperature sensor signal voltage too

high

ON

P04D4

Exhausting brake control relay driving circuit open circuit OFF

OFF

P04D4

Exhausting brake control relay driving chip in ECU overheating

OFF

P04D4

Exhasusting brake control relay driving circuit short circuit to power

supply

OFF

P04D4

Exhasusting brake control relay driving circuit short circuit to

grounding

OFF

P0504

Brake signal unlikelihood, main brake signal and auxiliary brake signal

change when different

OFF

P0562

Battery voltage too low causes related component stop working

OFF

P0563

Battery voltage too high causes related component stop working

OFF

P0575

Cruise control button signal unreasonable

OFF

P05EE

Urea suppling unit motor speed deviation permanent fault

ON_3DC

ON

P05EE

Urea suppling unit driving circuit open circuit fault

ON

P05EE

Urea suppling unit driving chip in ECU overheating fault

ON

P05EE

Urea suppling unit driving circuit short circuit to power supply fault

ON

P05EE

Urea suppling unit driving circuit short circuit to grounding fault

ON

P05F8

When SCR system heating, heating component faulted causes SCR ON

ON

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Fault code

Fault code definition

OBD light

EPC light

system stop working

P0607

ECU inner chip Cy327 communication fault

OFF

P060B

ECU inner software/hardware bottom monitoring error (MoC)

OFF

P060B

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060B

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P060C

ECU inner software/hardware bottom monitoring error (MoC) OFF

OFF

P0615

Starter relay control terminal open circuit

OFF

P062C

Vehicle speed from CAN bus inaccurate

OFF

ON_3DC

P062F

ECU software fault indicating when reading/writing

OFF

P0645

A/C compressor circuit open circuit

OFF

P0645

ECU inner A/C compressor driving chip overheating

OFF

P0646

A/C compressor driving circuit short circuit to grounding

OFF

P0647

A/C compressor driving circuit short circuit to power supply

OFF

P0668

ECU inner temperature sensor voltage signal value lower than lower

limit

OFF

ON

P0669

ECU inner temperature sensor voltage signal value higher than upper

limit

OFF

ON

P068A

Main relay cut-off too early fault

OFF

P068B

Main relay clamping stagnation fault

OFF

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Fault code

Fault code definition

OBD light

EPC light

P0697

Sensor power supply module 3 voltage exceeds upper limit

ON

P0697

Sensor power supply module 3 short circuit to grounding

ON

P0697

Sensor power supply module 3 voltage exceeds lower limit

ON

P0699

Sensor power supply module 3 fault

ON

P0704

(0704)

Clutch signal unlikelihood

OFF

P1012

ECU inner software/hardware bottom monitoring error (MoF)

OFF

P1013

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1014

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1015

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1016

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1017

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1018

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1019

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P101A

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P101B

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P101C

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P101D

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P101E

ECU inner software/hardware bottom monitoring error (Mon)

OFF

P101F

ECU inner software/hardware bottom monitoring error (Mon) OFF

OFF

P1020

ECU inner software/hardware bottom monitoring error (Mon) OFF

OFF

P1090

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P1091

ECU inner software/hardware bottom monitoring error (MoF) OFF

OFF

P110A

Vehicle function limit 0 activated

OFF

ON

P110B

Vehicle function limit 1 activated

OFF

ON

P110C

Vehicle function limit 2 activated

OFF

ON

P110D

Vehicle function limit 3 activated

OFF

ON

P1608

ECU software reset_0

OFF

P16E6

ICM communication interrupted

OFF

P203B

Urea tank temperature sensor unlikelihood fault

ON_3DC

ON

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Fault code

Fault code definition

OBD light

EPC light

P203F

Urea tank level too low fault

ON_1DC

ON

P2043

Urea tank temperature too high fault

ON_3DC

ON

P2047

Injection valve of urea injection unit fault (clamping stagnation)

ON_3DC

ON

P2047

When in low voltage, Dosing valve fault

ON_3DC

ON

P2047

Injection valve of urea injection unit fault

ON

P2047

Urea injection unit short circuit to battery fault

ON

P2047

High terminal of urea injection unit short circuit to battery fault

ON

P2047

Urea injection unit short circuit to grounding fault

ON

P2047

High terminal of urea injection unit short circuit to grounding fault

ON

P2047

ECU inner urea injection unit driving chip overheating fault

OFF

P204A

Measured value exceeds upper limit value

ON_3DC

ON

P204A

Measured value lower than lower limit value

ON_3DC

ON

P205B

Urea tank temperature sensor signal rationality fault (detected

measured value too low)

ON_3DC

ON

P208A

Urea pump control fuel-air ratio higher than effective range

ON

P208A

Urea pump control fuel-air ratio lower than effective range

ON

P208A

Urea pump motor speed fuel-air ratio higher than upper limit value

ON

P208A

Urea pump motor speed fuel-air ratio lower than lower limit value

ON

P20A0

SCR system urea backflow pipe blocked fault

ON_3DC

ON

P20A0

Urea backflow pump PWM output module open circuit fault

ON

P20A0

Urea backflow pump PWM output module temperature too high fault

ON

P20A0

Urea backflow pump PWM output module short circuit to power

supply fault

ON

P20A0

Urea backflow pump PWM output module short circuit to grounding

fault

ON

P20A6

Pressure reducing fault

ON_3DC

ON

P20E9

SCR system pressure too high fault

ON_3DC

ON

P20FE

When SCR system injecting, pressure too high fault

ON_3DC

ON

P20FE

When SCR system injecting, pressure too low fault

ON_3DC

ON

P2135

Accelerator pedal 1 and accelerator 2 signal rationality fault

OFF

ON

P215A

Vehicle speed signal fault from CAN bus

OFF

ON

P21C7

DNOX relay gets struck in closed position

ON_3DC

ON

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Fault code

Fault code definition

OBD light

EPC light

P21C7

DNOX relay gets struck in open position

ON_3DC

ON

P21C7

Outer relay open circuit fault

ON

P21C7

Outer relay overheating fault

ON

P21C7

Outer relay short circuit to battery fault

ON

P21C7

Outer relay short circuit to grounding fault

ON

P2214

Lower Nox sensor rationality check fault (peak value check)

ON_3DC

ON

P2214

Lower Nox sensor rationality check fault (increment check)

ON_3DC

ON

P2264

Water in fuel level sensor self-check fault (sensor damage)

OFF

ON

P2299

Accelerator pedal and brake pedal signal irrationality fault

OFF

P249D

Urea injection too low fault diagnosis check

ON_3DC

ON

P249E

Urea injection too high fault diagnosis check

ON_3DC

ON

P249E

Urea tank level sensor voltage signal higher than upper limit

ON_3DC

ON

P249E

Urea tank level sensor voltage signal lower than lower limit

ON_3DC

ON

P26E4

Starter relay control terminal lower terminal driving chip in ECU

overheating

OFF

P26E4

Starter relay control terminal lower terminal short circuit to power

supply

OFF

P26E4

Starter relay control terminal lower terminal short circuit to grounding

OFF

P2BAE

Engine Nox discharging more than 5.0g/kW.h fault

ON_3DC

ON

P2BAE

Engine Nox discharging more than 7.0g/kW.h fault

ON_3DC

ON

P3040

SCR system pressure build-up failure fault

ON_3DC

ON

P3053

SCR system urea pressure pipe or urea injection unit blocked fault

ON_3DC

ON

P3054

SCR system pressure wave too much fault

ON_3DC

ON

U0073

Can A communication interrupted

OFF

U0080

CAN C communication interrupted

ON

U0100

CAN communication between ECU and Nox sensor interrupted

ON

U010E

Urea suppling unit CAN communication fault

ON

U0113

Lower Nox sensor CAN signal receiving overtime (namely signal

missing)

ON

4.3 Electrical Control System Common Fault Code Analysis

1、Instruction

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1）Only when in current steady state fault can you maintain, or else it will cause wrong diagnosis;

2）”Multimeter” mentioned below is digital multimeter, and it’s forbidden to check electrical

control system by indicator-type multimeter;

3）If fault code indicates that some circuit voltage is too low, it indicates there is short circuit or

open circuit to grounding in the circuit; if fault code indicates that some circuit fault, it indicates there is

open circuit or several circuits fault in the circuit.

2、Diagnosis Help

1）If fault code can’t be erased, the fault is steady state fault; if it’s occasional fault, firstly check

whether there is loosen phenomenon in wiring harness connector;

2）When maintaining, don’t ignore influence of vehicle maintenance condition, cylinder pressure,

battery power to system.

3、Losing Efficacy Strategy

According to fault state of electrical control system, running strategy is divided into 4 classes:

① First class: default value ② Second class: reduce torque (limit torque) ③ Third class: go

home laming (electronic accelerator lose efficacy, engine speed gets limited) ④ Fourth class: stop

engine

4、Fault Code Diagnosis

1）Fault code-Main relay

Fault code Fault description

Whether is not erased

fault code?

P068A Main relay interrupted too early fault No

P068B Main relay clamping stagnation fault No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine can’t

start; 3. Missfire when engine running.

General fault reason: 1. Main relay damage; 2. ECU damage; 3. Related connecting

wiring harness, connector fault.

2）Fault code—Battery

Fault code Fault description

Whether is not erased

fault code?

Battery+

Main relay

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Battery-

Grounding1

Grounding2

Grounding3

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P0562 ECU inner battery voltage signal too low No

P0562

Battery voltage too low causing related

component stop working

No

P0563

Battery voltage too high causing related

component stop working

No

P0563 ECU inner battery voltage signal too high No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine start

difficultly; 3. Engine can’t start.

General fault reason: 1. Battery power not enough; 2. Engine fault; 3. Relay or fuse

damaged; 4. Related wiring harness, connector damaged.

3）Fault code—Brake switch

Fault code Fault description

Whether is not erased

fault code?

P0504

Brake signal unlikelihood, change when main

brake signal andauxiliary brake signal are

difference

No

Possible fault phenomenon: 1. System light/Fault light is always on.

General fault reason: 1. Brake switch fault; 2. Related wiring harness, connector open

circuit or short circuit.

4）Fault code—Water in fuel level sensor

Fault code Fault description

Whether is not erased

fault code?

P2264

Water in fuel level sensor self-check fault (sensor

damaged)

No

P2269 Water in fuel fault No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough.

General fault reason: 1. Water in fuel level sensor damaged; 2. Related circuit, connector

open circuit or short circuit.

Battery+

Main relay

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Main brake switch

Auxiliary brake switch

Main brake

signal

Auxiliary

brake signal

Battery+

Main relay

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Ignition switch

Power on signal

Battery -

Grounding 1

Grounding 2

Grounding 3

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A

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5）Fault code—Starter relay

Fault code Fault description

Whether is not erased

fault code?

P0615 Starter relay control terminal open circuit No

P26E4

Starter relay control terminal low terminal driving

chip in ECU overheating

No

P26E4

Starter relay control terminal low terminal short

circuit to power supply

No

P26E4

Starter relay control terminal short circuit to

grounding

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine can’t

start.

General fault reason: 1. Relay damaged; 2. ECU damaged; 3. Related connecting wiring

harness, connector damaged, open circuit or short circuit.

6）Fault code—Compressor relay

Fault code Fault description

Whether is not erased

fault code?

P0645 A/C compressor circuit open circuit No

P0645 A/C compressor driving chip in ECU overheating No

P0647

A/C compressor driving circuit short circuit to

power supply

No

P0646

A/C compressor driving circuit short circuit to

grounding

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Idling shaking; 3.

Engine power not enough.

Battery+

Main relay

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Water in fuel

level sensor

Water in

fuel signal

Starting relay

control signal

Ignition switch Ignition switch

Starting relay

Starter

To battery positive

electrode

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General fault reason: 1. Compressor relay damaged; 2. Related connecting wiring

harness, connector damaged, open circuit or short circuit.

Note: The fault code only is compressor relay fault, not involved compressor.

7）Fault code—Exhausting brake relay

Fault code Fault description

Whether is not erased

fault code?

P04D4

Exhausting brake control relay driving circuit

open circuit

No

P04D4

Exhausting brake control relay driving chip in

ECU overheating

No

P04D4

Exhausting brake control relay driving circuit

short circuit to power supply

No

P04D4

Exhausting brake control relay driving circuit

short circuit to grounding

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2、Engine can’t

start.

General fault reason: 1. Exhausting brake relay damaged; 2. ECU damaged; 3. Related

connecting wiring harness, connector damaged, open circuit or short circuit.

Note: The fault code only is exhausting brake relay fault, not involved exhausting brake valve.

8）Fault code—Rail pressure control valve

Fault code Fault description

Whether is not erased

fault code?

P009B

(Rail pressure) pressure control valve (PCV)

driving circuit open circuit

No

P009B

(Rail pressure) pressure control valve (PCV)

driving chip in ECU overheating

No

Main relay

Battery+

Compressor relay

power supply

Compressor relay

control signal 2

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Main relay

Exhausting brake relay

Exhausting brake

relay

power supply

Exhausting brake

relay control signal 1

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P009B

(Rail pressure) pressure control valve (PCV)

driving circuit short circuit to power supply

No

P009B

(Rail pressure) pressure control valve (PCV)

driving circuit short circuit to grounding

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine idling

shaking; 3. Engine hard to start; 4. Engine power not enough; 5.Engine can’t start.

General fault reason: 1. Pressure control valve damage; 2. ECU damage; 3. Related

connecting wiring harness, connector damaged, open circuit or short circuit.

9）Fault code—Fuel quantity metering unit

Fault code Fault description

Whether is not erased

fault code?

P0251

High pressure pump fuel quantity metering unit

(MeUn) connector loosen

No

P0251

High pressure pump fuel quantity metering unit

(MeUn) driving circuit open circuit

No

P0251

Fuel quantity metering unit (MeUn) driving

circuit short circuit to power supply

No

P0251

Fuel quantity metering unit (MeUn) driving

circuit short circuit to grounding

No

P0252

Fuel quantity metering unit (MeUn) driving chip

in ECU overheating

No

Possible fault phenomenon: 1.System light/Fault light is always on or twinkling; 2.

Engine idling shaking; 3. Engine sends out black smoke; 4. Engine power not enough; 5.

Engine can’t start.

General fault reason: 1. Fuel quantity metering unit damaged; 2. ECU damaged; 3.

Related connecting wiring harness, connector damaged, open circuit or short circuit.

Rail pressure

control valve

Rail pressure control

valve control signal 1

Main relay control signal

Power supply input 3

Power supply input 2

Power supply input 1

Main relay

Battery

+

Main relay

Battery+

Fuel quantity metering

unit (MeUn)

Control

signal

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10）Fault code—Fuel injector

Fault code Fault description

Whether is not erased

fault code?

P0201

Ignition sequence 1

st

cylinder fuel injector driving

circuit open circuit

No

P0203

Ignition sequence 2

nd

cylinder fuel injector

driving circuit open circuit

No

P0204

Ignition sequence 3

rd

cylinder fuel injector driving

circuit open circuit

No

P0202

Ignition sequence 4

th

cylinder fuel injector driving

circuit open circuit

No

P062D

Fuel injection control module 0 (wiring harness)

short circuit fault

No

P062E

Fuel injection control module 1 (wiring harness)

short circuit fault

No

P0262

Ignition sequence 1

st

cylinder fuel injector wiring

harness short circuit (high terminal or low

terminal short circuit to power supply or

grounding)

No

P0268

Ignition sequence 2

nd

cylinder fuel injector wiring

harness short circuit (high terminal or low

terminal short circuit to power supply or

grounding)

No

P0271

Ignition sequence 3

rd

cylinder fuel injector wiring

harness short circuit (high terminal or low

terminal short circuit to power supply or

grounding)

No

P0265

Ignition sequence 4

th

cylinder fuel injector wiring

harness short circuit (high terminal or low

terminal short circuit to power supply or

grounding)

No

P0261

Ignition sequence 1

st

cylinder wiring harness

lower terminal short circuit to high terminal

No

P0267

Ignition sequence 2

nd

cylinder wiring harness

lower terminal short circuit to high terminal

No

P0270

Ignition sequence 3

rd

cylinder wiring harness

lower terminal short circuit to high terminal

No

P0264

Ignition sequence 4

th

cylinder wiring harness

lower terminal short circuit to high terminal

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine idling

shaking; 3. Engine sends out black smoke; 4. Engine power not enough; 5. Engine can’t

start; 6. Engine hard to start.

General fault reason: 1. Fuel injector damaged; 2. Related connecting wiring harness,

connector damaged, open circuit or short circuit.

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11）Fault code—Coolant temperature sensor

Fault code Fault description

Whether is not erased

fault code?

P0116

Coolant temperature sensor absolute value

rationality check fault (coolant temperature

doesn’t reach to threshold value in some time)

No

P0116

Coolant temperature sensor dynamic value

rationality check fault (coolant temperature

doesn’t rise to threshold value in some time)

No

P0117

Coolant temperature sensor voltage higher than

upper limit value

No

P0118

Coolant temperature sensor voltage lower than

lower limit value

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough; 3. Engine sends out black smoke.

General fault reason: 1. Coolant temperature sensor damaged; 2. Related connecting

wiring harness, connector damaged, open circuit or short circuit.

12）Fault code—Rail pressure sensor

Fault code Fault description

Whether is not erased

fault code?

Coolant

temperature sensor

Coolant

temperature signal

Coolant temperature

signal grounding

2

nd

cylinder

fuel injector

3

rd

cylinder

fuel injector

4

th

cylinder

fuel injector

1

st

cylinder

fuel injector

1

st

cylinder fuel

injector high terminal

1

st

cylinder fuel

injector

low terminal

4

th

cylinder fuel

injector high

terminal

4

th

cylinder fuel

injector

low terminal

3

rd

cylinder fuel

injector

low terminal

3

rd

cylinder fuel

injector high

terminal

2

nd

cylinder fuel

injector

low terminal

2

nd

cylinder fuel

injector high

terminal

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P0191

Rail pressure sensor signal drifting fault (voltage

too high)

No

P0191

Rail pressure sensor signal drifting fault (voltage

too low)

No

P0193

Rail pressure sensor voltage signal higher than

upper limit

No

P0192

Rail pressure sensor voltage signal lower than

lower limit

No

P018F Switch to CPC working mode times exceed limit No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough; 3. Engine can’t start; 4. Engine misfire when running.

General fault reason: 1. Rail pressure sensor damaged; 2. Related connecting wiring

harness, connector damaged, open circuit or short circuit.

13）Fault code—Intake pressure temperature sensor

Fault code Fault description

Whether is not erased

fault code?

P0235

Turbocharging pressure ssensor signal higher than

upper limit

No

P0235

Turbocharging pressure sensor voltage signal

lower than lower limit

No

P0097

Intake temperature sensor voltage signal lower

than lower limit after turbocharging inter-cooling

P0098

Intake temperature sensor voltage signal higher

than upper limit

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power

not enough; 3. Engine sends out smoke.

General fault reason: 1. Intake pressure temperature sensor damaged; 2. Related

connecting wiring harness, connector damaged, open circuit or short circuit.

Rail pressure

sensor

Rail pressure

sensor power

suply

Rail pressure signal

Rail pressure

signal grounding

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14）Fault code—Camshaft position sensor

Fault code Fault description

Whether is not erased

fault code?

P0340 Not detect camshaft signal No

P0341

There is disturbing or signal missing fault in

camshaft signal

No

P0340 Camshaft signal and crankshaft deviates too much No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough; 3. Engine hard to start; 4. Engine can’t start; 5. Engine misfire when running.

General fault reason: 1. Camshaft position sensor damaged; 2. Related connecting wiring

harness, connector damaged, open circuit or short circuit; 3. Camshaft position sensor

installation fault; 4. Signal panel fault; 5. Clearance between camshaft and signal panel is

not reasonable.

15）Fault code—Crankshaft position sensor

Fault code Fault description

Whether is not erased

fault code?

P0335 Not detect crankshaft signal No

P0336

There is disturbing or signal missing fault in

crankshaft signal

No

P0340

Clearance between camshaft signal and crankshaft

signal deviates too much

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough; 3. Engine hard to start; 4. Engine can’t start; 5. Engine misfire when running.

General fault reason: 1. Crankshaft position sensor damaged; 2. Related connecting

Turbocharging

pressure sensor

Camshaft

sensor

Sensor power

supply

Camshaft signal

grounding

Sensor

power supply

Turbocharging

pressure signal

Signal grounding

Intake temperature

signal

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wiring harness damaged, open circuit or short circuit; 3. Crankshaft position sensor

installation fault; 4. Signal panel fault; 5. Clearance between crankshaft and signal panel

is not reasonable.

16）Fault code—Fuel pump relay

Fault code Fault description

Whether is not erased

fault code?

P0627

Fuel pre-supplying pump (PSP) driving circuit

open circuit

No

P0627

Fuel pre-supplying pump (PSP) driving chip in

ECU overheating

No

P0627

Fuel pre-supplying pump (PSP) driving circuit

short circuit to power supply

No

P0627

Fuel pre-supplying pump (PSP) driving circuit

short circuit to grounding

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power

notenough; 3. Engine can’t start; 4. Engine idling shaking.

General fault reason: 1. Fuel pump relay damaged; 2. Related connecting wiring harness,

connector damaged, open circuit or short circuit.

Note: The fault code is only fuel pump relay fault, not involved electronic fuel pump.

17）Fault code—Environment temperature sensor

Fault code Fault description

Whether is not erased

fault code?

Crankshaft

sensor

Grounding

Fuel pump relay

control signal

Crankshaft

signal +

Crankshaft

signal

-

Shielding wire

grounding

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P0072

Enviroment temperature sensor voltage signal

lower than lower limit

No

P0073

Environment temperature sensor voltage signal

higher than upper limit

No

Possible fault phenomenon: 1. System light/Fault light is always on.

General fault reason: 1. Environment temperature sensor damaged; 2. Related

connecting wiring harness, connector damaged, open circuit or short circuit.

18）Fault code—DOC differential pressure sensor

Fault code Fault description

Whether is not erased

fault code?

P2002

Forbid probability monitoring of differential

pressure sensor

No

P2002 DOC removal No

P2453

When DOC differential pressure voltage signal

AfterRun, higher than upper limit

No

P2455

DOC differential pressure voltage signal higher

than upper limit

No

P2454

DOC differential pressure voltage signal lower

than lower limit

No

Possible fault phenomenon: 1. System light/Fault light is always on.

General fault reason: 1. DOC differential pressure sensor damaged; 2. Related

connecting wiring harness, connector damaged, open circuit or short circuit; 3. DOC

damaged or removed; 5. Gas sampling steel pipe connecting fault; 6. Gas sampling pipe

leaking or blocked.

19）Fault code—Accelerator pedal sensor

DOC differential

pressure sensor

Differential pressure

sensor power supply

Differential pressure sensor signal

Differential pressure

sensor grounding

Environment

temperature

sensor

Environment temperature

sensor signal

Environment temperature

sensor grounding

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2

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Fault code Fault description

Whether is not erased

fault code?

P0122

Accelerator pedal sensor 1 voltage signal lower

than lower limit value

No

P0123

Accelerator pedal sensor 1 voltage signal higher

than upper limit value

No

P0222

Accelerator pedal sensor 2 voltage signal lower

than lower limit value

No

P0223

Accelerator pedal sensor 2 voltage signal higher

than upper limit value

No

P2135

Accelerator pedal sensor 1 and accelerator pedal

sensor 2 signal rationality fault

No

P2299

Accelerator pedal and brake pedal signal

irrationality fault

No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine idling

increases; 3. Engine power not enough; 4. There is no response when engine running to

accelerate.

General fault reason: 1. Accelerator pedal sensor damaged; 2. Related connecting wiring

harness, connector damaged, open circuit or short circuit; 3. Pin connecting fault.

Note: Inquiry and check driver’s driving habbit. Accelerator pedal and brake pedal can’t be stepped at

the same time.

20）Fault code—Clutch switch

Fault code Fault description

Whether is not erased

fault code?

P0704 Clutch switch unlikelihood No

Possible fault phenomenon: 1. System light/Fault light is always on.

General fault reason: 1. Clutch switch damaged; 2. Related connecting wiring harness,

connector damaged, open circuit or short circuit.

Accelerator

pedal sensor

Accelerator pedal

1 power supply

Accelerator pedal

1 signal

Accelerator pedal

1 signal grounding

Accelerator pedal

2 power supply

Accelerator pedal

2 signal

Accelerator pedal

2 signal grounding

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A

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0

1

4

2

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2

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21）Fault code—CAN bus communication module fault

Fault code Fault description

Whether is not erased

fault code?

U0073 CAN A communication interrupted No

U0046 CAN C unactive fault No

U0046 CAN C communication interrupted No

U1402

CAN signal from EMS1 receiving overtime

(namely signal missing)

No

U1403

CAN signal from EMS2 receiving overtime

(namely signal missing)

No

U1404

CAN signal from EMS3 receiving overtime

(namely signal missing)

No

U1405 CAN signal from ICM2 frame length fault No

U1406

CAN signal from ICM2 receiving overtime

(namely signal missing)

No

U1103

Communication between ECU and CAN meter

interrupted

No

P16E6 ICM communication interrupted No

P062C Vehicle speed from CAN bus not accurate

P215A Vehicle signal from CAN bus fault No

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough.

General fault reason: 1. Related connecting wiring harness, connector damaged, open

circuit or short circuit; 2. ECU damaged; 3. ABS/ESP fault; 4. SAS fault; 5. GW fault; 6.

TCU fault; 7. Nox sensor fault.

Battery negative

electrode

Grounding

Clutch switch

Clutch signal

J

A

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-

2

0

1

4

2

5

2

7

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21）Fault code—Nox sensor

Fault code Fault description

Whether is not erased

fault code?

U0113 Lower Nox sensor CAN signal frame length fault No

U0113

Lower Nox sensor CAN signal receiving overtime

(namely signal missing)

Yes

U0100

CAN communication between ECU and Nox

interrupted

Yes

U0113

NOxNoCat2Ds CAN information content exceeds

SAE set reasonable range

No

U0113

SensNOxStabNoCat2Ds CAN information

content exceeds SAE set reasonable range

No

P22A3

Getting into heating mode when NOx sensor 2

diagnosis released, but in given heating time, fault

appears

No

P229E No Yes

P229E No No

P22A6 Nox sensor 2 signal in ready state No

P2201 No Yes

P2214

Lower Nox sensor rationality check fault (peak

value check)

Yes

P2214

Lower Nox sensor rationality check fault

(increment check)

Yes

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough.

General fault reason: 1. Nox sensor installation fault (position fault); 2. Nox sensor

CAN bus

communication

module 1

CAN bus

communication

module 1

CAN_L

CAN_H

CAN_L

CAN_H

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damaged; 3. Related connecting wiring harness, connector damaged, open circuit or

short circuit.

22）Fault code—Catalytic converter upper temperature sensor (Exhausting temperature sensor)

Fault code Fault description

Whether is not erased

fault code?

P0426

SCR catalytic converter upper temperature sensor

dynamic reliability check upper temperature too

high fault

Yes

P0426

SCR catalytic converter upper temperature sensor

dynamic reliability check upper temperature too

low fault

Yes

P0426

SCR catalytic converter upper temperature sensor

statics reliability check fault

Yes

P0435

SCR catalytic converter upper temperature sensor

signal voltage too high

Yes

P2435

SCR catalytic converter upper temperature sensor

signal voltage too low

Yes

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough; 3. Urea consumption too high.

General fault reason: 1. Catalytic converter upper temperature sensor damaged; 2.

Related connecting wiring harness, connector damaged, open circuit or short circuit.

23）Fault code—Urea injection unit

Fault code Fault description

Whether is not erased

fault code?

P2047

Injection valve fault of urea injection unit

(clamping stagnation)

Yes

P2047 When low voltage, Dosing valve fault Yes

P2047 Injection valve fault of urea injection unit Yes

P2047

Urea injection unit driving chip in ECU

overheating fault

Yes

P2047 Urea injection unit short circuit to battery fault Yes

P2047

High terminal of urea injection unit short circuit

to battery fault

Yes

P2047 Urea injection unit short circuit to grounding fault Yes

P2047 High terminal of urea injection unit short circuit Yes

Catalytic converter

upper temperature

sensor

Catalytic converter upper

temperature sensor signal

Catalytic converter upper

temperature sensor

grounding

J

A

C

-

2

0

1

4

2

5

2

7

江淮汽车部门：客户服务部

Engine Electrical Control System

170

to grounding fault

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough; 3. Urea consumption too high.

General fault reason: 1. Urea injection unit fault (blocking, clamping stagnation, abrasion,

leaking); 2. Related connecting wiring harness, connector damaged, open circuit or short

circuit; 3. ECU fault; 4. There ia impurity in urea solution.

24）Fault code—Urea level temperature sensor

Fault code Fault description

Whether is not erased

fault code?

P203D

Urea tank level sensor voltage signal higher than

upper limit

Yes

P203C

Urea tank level sensor voltage signal lower than

lower limit

Yes

P203B Urea tank temperature sensor unlikelihood fault Yes

P2043 Urea tank temperature too high fault Yes

P205D

Urea tank temperature sensor signal voltage too

high

No

P205C

Urea tank temperature sensor signal voltage too

low

No

P205B

Urea tank temperature sensor signal rationality

fault (measured value too high)

No

P205B

Urea tank temperature sensor signal rationality

fault (measured value too low)

Yes

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough.

General fault reason: 1. Urea level temperature sensor damaged; 2. Related connecting

wiring harness, connector damaged, open circuit or short circuit; 3. Urea leaking.

Note: Urea temperature sensor and urea level sensor are integrated together and are installed in urea tank.

Urea

injection unit

Urea injection unit control

signal high terminal

Urea injection unit control

signal low terminal

J

A

C

-

2

0

1

4

2

5

2

7

江淮汽车部门：客户服务部

Engine Electrical Control System

171

25）Fault code—Urea tank

Fault code Fault description

Whether is not erased

fault code?

P203F Urea tank level too low fault Yes

Possible fault phenomenon: 1. System light/Fault light is always on; 2. Engine power not

enough.

General fault reason: 1. Urea level temperature sensor damaged; 2. Urea solution too

little (fill urea solution); 3. Urea tank damaged to leak.

Urea tank level

sensor

Urea level signal

Signal grounding

Urea tank

temperature sensor

Urea temperature

signal

Signal grounding

J

A

C

-

2

0

1

4

2

5

2

7

江淮汽车部门：客户服务部

Compiling 编制 Champion.Wong 汪庆平

Audit 审核 Youwang.Zhang 张有旺

Approve 批准

ANHUI JIANGHUAI AUTOMOBILE CO., LTD