1000374003WP3.7WP4.1 Service Manual

1000374003
Maintenance Manual of WP3.7/WP4.1 Series China

V Vehicle Diesel Engine
Weichai Power Yangzhou Diesel Engine Co., Ltd.

Maintenance Manual of WP3.7/WP4.1 Series China V Vehicle Diesel Engine
WP3.7/WP4.1 Series China V Vehicle Diesel Engine

Maintenance Manual of WP3.7/WP4.1 Series China Ⅵ Vehicle Diesel Engine
Foreword
The series engine is a high-speed engine independently developed by Weichai Power Co., Ltd. and manufactured
by Weichai Power Yangzhou Diesel Engine Co., Ltd. and it boasts many advantages such as compact structure,
outstanding performances including reliable running, strong power and good economy, as well as fast start, easy
operation and maintenance.
This Manual mainly covers the precautions for operation, maintenance method, inspection and adjustment, as
well as diagnosis and troubleshooting of common faults of this series of engines. During preparation of this
manual, efforts have been made to present comprehensive, concise and practical knowledge on the engine. It
shall be noted that the engine troubleshooting is a complicated work requiring certain knowledge and
experience and attention to details. Thus, do not disassemble the engine especially its key parts such as the
electronic control system and turbocharger at will before confirming the fault cause; otherwise, the fault will not
be eliminated, and what's worse, serious fault may occur due to improper reassembling. The engine shall be
maintained and checked with the special apparatus. Therefore, users having no relevant experience and
equipment are not allowed to disassemble or adjust the engine.
With the increasing variants and continuous improvement of the series engine, this Manual will be subject to
change without notice. And, we hope you can pay attention to the technical information released by us timely.
Weichai Power Co., Ltd. is authorized to carry out the after-sales service of this product, and users can access
relevant product information through the website of www.weichai.com.
Suggestions and opinions on further improvement of the product are appreciated.
Notice
♦ Always read this Maintenance Manual carefully before

operation, strictly observe the operation and maintenance
procedures, and pay attention to the warning instructions
and signs herein. Please take notice of the followings because
the engine warranty will be affected if the operation is
performed not in accordance with this Manual!
♦ This engine has been tested in strict accordance with the
test specification before delivery. Therefore, the fuel injection
Please refer to this Manual
pump or ECU shall not be adjusted at will.
♦ For the engine with a turbocharger, the rotor shaft of the
turbocharger is a precise high speed rotating part, please WARNING
keep any objects (such as hand, tool, cotton yarn) away from
the turbocharger when the engine is running, so as to avoid
personal injury or engine damage. Do not disassemble the
rotor component.
Do not touch the high-speed rotating part with

hands!
♦ Do not loosen or remove the main bearing bolt and
connecting rod bolt of the engine without permission as they
are subject to strict torque and rotation angle requirements.
For the torque and times of use of important bolts, please
refer to the annex in this Manual.
Tightening torque requirement

♦ Always fill the engine with the oil or fuel of grade specified WARNING
in this manual, and filtered by a special filter; for the fuel,
subject it to a precipitation more than 72 h. Prior to start,
always check that the coolant and oil levels are satisfactory,
and if not, please fill the engine with fuel or oil of grade
specified in this manual at an authorized gasoline station.
♦ Before running a new engine, subject it to running-in for 50
h. Please refer to the relevant chapter in this
Manual
♦ Never run the engine without an air filter.
♦ After starting a cold engine, accelerate it slowly rather than
abruptly, and do not run it at an idle speed for a long time.
♦ Regularly check the coolant, and never change the engine WARNING
coolant with water or coolant with poor quality. At a low
temperature, please select the coolant of the correct grade in
accordance with the requirements of this manual.
♦ The engine has been preserved before delivery for
avoiding rust. Generally, its preservation period is one year,
and it shall be checked and necessary measures shall be
taken when this valid period expires. Please refer to the relevant chapter in this
Manual
♦ Please have the diesel engine disassembled and repaired at
the Weichai Power designated service station in case of a
fault. Do not use the spare parts not specified by Weichai
Power for maintenance; otherwise, Weichai will not assume
any responsibility for damage to the engine therefrom.
♦ Always have the components of the electrical system
maintained by Weichai professional technicians.
♦ When replacing key components (Turbocharger, fuel
pump, fuel injector, ECU, exhaust after-treatment system
and EGR system) that affect emissions, it is necessary to
ensure that the replaced components are of the same
manufacturer and model as the original components,
otherwise Weichai will not assume any responsibility for all Weichai special spare parts
consequences caused.
Warning Signs
Wear gloves Risk of electric shock
Wear protective clothing Risk of mechanical injury
Risk of being caught up in

Wear ear plugs
the machine
Be aware of suspended
Wear goggles
heavy objects
Wear helmet Be aware of steam
Wear safety shoes Risk of explosion
Wear protective mask Risk of corrosion
Keep ventilated Risk of scalding
Torque control Avoid winding

Checks required No open flame
Tool requirement No smoking
Serious warning No touching
Caution
Caution No smoking
Caution
Warning No touching
Most of accidents occurred during engine operation, maintenance and repair are caused by failure to observe
the safety rules and basic precautions. Only the well-trained operators with required skills and appropriate tools
can operate, maintain and repair the engine.
The violation of instructions in this Manual may lead to serious accident. Weichai Power Co., Ltd. cannot foresee
all potential hazards, and meanwhile, the rules and instructions specified in this Manual are not exhaustive.
Precautions for Engine Disassembly and Maintenance
♦ Prepare necessary common tools, special tools, measuring instruments, etc. before maintenance.
♦ Use a crane with sufficient hoisting capacity or jack to lift the engine, and use chains, cables or lifting belts
instead of ropes as hoisting tools.
♦ Use special tools to hoist and turn the engine.
♦ Weichai original spare parts or the parts recommended by Weichai should be used; otherwise the service life
of the engine may be shortened or personal injury may be caused.
♦ Make sure that the working site and the surroundings are suitable for safe operation.
♦ Make sure that the workshop or the surrounding of the engine is clean and tidy.
♦ Before working, please take off your watch and other ornaments and wear well-fitted working clothes.
♦ Before working, check that the corresponding personal protective equipment (goggles, gloves, shoes, mask,
working clothes, helmet, etc.) are within the period of validity.
♦ Ensure that fire extinguishers are available near the maintenance area.
♦ Prevent the battery electrolyte from splashing to clothing, skin or eyes; otherwise, the skin or clothing will be
burnt. Keep away from sparks and open flames when charging the battery.
♦ When disassembling complicated components, make matching marks at the proper positions.
♦ Confirm whether the removed parts can be reused. Please refer to this Manual for details.
♦ Regularly calibrate the measuring instruments.
Declaration
Due to the diversified product variants of the company, the illustrations in this Manual are schematic and may
not match the real product you purchased. For the detailed structure, the real product shall prevail.
The symbols in the illustrations indicate the steps or conditions requiring your attention during operation!
Table of Contents
Chapter I Operation Instructions ....................................................................................................................1

1.1 Outline drawing of engine .......................................................................................................................... 1
1.2 Description of engine model ...................................................................................................................... 3
1.3 Main specifications ..................................................................................................................................... 4
1.4 Hoisting ....................................................................................................................................................... 5
1.5 Running ....................................................................................................................................................... 5
Chapter II Maintenance of Diesel Engine ........................................................................................................6
2.1 Fuel, lubricating oil, coolant and auxiliary materials .................................................................................. 6
2.1.1 Fuel ................................................................................................................................................. 6
2.1.2 Lubricating oil ................................................................................................................................. 6
2.1.3 Engine coolant ................................................................................................................................ 7
2.1.4 DEF .................................................................................................................................................. 8
2.1.5 Auxiliary materials ........................................................................................................................ 10
2.2 Daily maintenance .................................................................................................................................... 11
2.2.1 Daily inspection ............................................................................................................................ 11
2.2.2 Daily maintenance ........................................................................................................................ 12
2.3 Description of maintenance of all levels .................................................................................................. 13
2.3.1 Oil change ..................................................................................................................................... 13
2.3.2 Replacement of oil filter or oil filter element ............................................................................... 14
2.3.3 Replace fuel filter and filter element............................................................................................ 14
2.3.4 Check and adjustment of valve clearance .................................................................................... 15
2.3.5 Check air tightness of intake system ............................................................................................ 16
2.3.6 Check air filter element ................................................................................................................ 16
2.3.7 Maintenance of urea solution pump ............................................................................................ 17
2.3.8 Maintenance of compressed air filter .......................................................................................... 17
2.4 Engine cleaning, protection and transportation....................................................................................... 21
2.4.1 Cleaning and protection ............................................................................................................... 21
2.4.2 Protection during storage............................................................................................................. 21
2.4.3 Preservation ................................................................................................................................. 21
2.4.4 Transportation of diesel engine ................................................................................................... 21
Chapter III Typical Faults and Troubleshooting.............................................................................................. 23
3.1 Overview ................................................................................................................................................... 23
3.1.1 Overview....................................................................................................................................... 23
3.2 Fault diagnostic methods ......................................................................................................................... 23
3.2.1 Traditional fault diagnostic methods............................................................................................ 23
3.2.2 OBD method ................................................................................................................................. 24
3.3 Typical faults troubleshooting .................................................................................................................. 30
3.3.1 Engine start failure ....................................................................................................................... 30
3.3.2 Insufficient power......................................................................................................................... 33
3.3.3 High fuel consumption ................................................................................................................. 36
3.3.4 High oil consumption.................................................................................................................... 38
3.3.5 Low NOx conversion efficiency..................................................................................................... 40
3.3.6 The starter does not work ............................................................................................................ 41
3.3.7 Inoperative alternator .................................................................................................................. 42
3.3.8 Air compressor fault ..................................................................................................................... 43
3.3.9 High urea solution consumption .................................................................................................. 44
3.3.10 Low/No urea solution consumption ........................................................................................... 45
3.3.11 Urea solution pressure build-up failure ..................................................................................... 46
3.3.12 Unavailable DEF heating ............................................................................................................. 47
3.3.13 DEF crystallization ...................................................................................................................... 48
Chapter IV Introduction to Engine Systems ................................................................................................... 49
4.1 Cooling system.......................................................................................................................................... 49
4.1.1 Cooling system.............................................................................................................................. 49
4.2 Lubrication system.................................................................................................................................... 49
4.2.1 Overview....................................................................................................................................... 49
4.3 Fuel system ............................................................................................................................................... 51
4.3.1 Schematic diagram ....................................................................................................................... 51
Chapter V Disassembling and Assembling ..................................................................................................... 52
5.1 Intake pipe assembly ................................................................................................................................ 52
5.1.1 Exploded view............................................................................................................................... 52
5.1.2 Tools and preparations ................................................................................................................. 52
5.1.3 Disassembling steps...................................................................................................................... 53
5.1.4 Check and maintenance essentials............................................................................................... 53
5.1.5 Assembling steps .......................................................................................................................... 53
5.2 Fan & hub assembly.................................................................................................................................. 53
5.2.1 Exploded view............................................................................................................................... 53
5.3 Low-pressure fuel pipe assembly ............................................................................................................. 55
5.3.1 Exploded view............................................................................................................................... 55
5.4 High-pressure fuel pipe assembly ............................................................................................................ 57
5.4.1 Exploded view............................................................................................................................... 57
5.5 Common rail assembly ............................................................................................................................. 58
5.5.1 Exploded view............................................................................................................................... 58
5.6 Electronic control unit (ECU) assembly .................................................................................................... 59
5.7 Air compressor assembly.......................................................................................................................... 60
5.7.1 Exploded view............................................................................................................................... 60
5.8 Fuel injection pump assembly .................................................................................................................. 62
5.8.1 Exploded view............................................................................................................................... 62
5.9 Pressure limiting valve assembly .............................................................................................................. 65
5.9.2 Exploded view............................................................................................................................... 65
5.10 Fuel filter assembly ................................................................................................................................. 66
5.10.1 Exploded view............................................................................................................................. 66
5.10.2 Tools and preparations ............................................................................................................... 67
5.10.3 Disassembling steps.................................................................................................................... 67
5.10.4 Check and maintenance essentials............................................................................................. 67
5.10.5 Assembling steps ........................................................................................................................ 67
5.11 Oil filter assembly ................................................................................................................................... 68
5.11.1 Exploded view............................................................................................................................. 68
5.12 Oil cooler assembly................................................................................................................................. 69
5.12.1 Exploded view............................................................................................................................. 69
5.13 Turbocharger .......................................................................................................................................... 71
5.13.1 Exploded view............................................................................................................................. 71
5.14 Exhaust pipe assembly............................................................................................................................ 74
5.14.1 Exploded view............................................................................................................................. 74
5.14.4 Check and maintenance ............................................................................................................. 74
5.15 Tensioner & belt assembly ..................................................................................................................... 76
5.15.1 Exploded view............................................................................................................................. 76
5.16 Thermostat assembly ............................................................................................................................. 77
5.16.1 Exploded view............................................................................................................................. 77
5.17 Water pump assembly............................................................................................................................ 79
5.17.1 Exploded view............................................................................................................................. 79
5.18 Water pump inlet pipe assembly............................................................................................................ 81
5.18.1 Exploded view............................................................................................................................. 81
5.19 Alternator assembly ............................................................................................................................... 83
5.19.1 Exploded view............................................................................................................................. 83
5.20 A/C compressor assembly ...................................................................................................................... 84
5.20.1 Exploded view............................................................................................................................. 84
5.21 Hoisting ring assembly ............................................................................................................................ 86
5.21.1 Exploded view............................................................................................................................. 86
5.21.3 Removal steps of the lifting ring assembly ................................................................................. 86
5.22 Cylinder head cover assembly ................................................................................................................ 87
5.22.1 Exploded view............................................................................................................................. 87
5.23 ECU wire harness & sensor assembly ..................................................................................................... 89
5.23.1 Exploded view............................................................................................................................. 89
5.24 Valve train assembly ............................................................................................................................... 91
5.24.1 Exploded view............................................................................................................................. 91
5.25 Fuel injector assembly ............................................................................................................................ 97
5.25.1 Exploded view............................................................................................................................. 97
5.26 Cylinder head assembly .......................................................................................................................... 99
5.26.1 Exploded view............................................................................................................................. 99
5.26.4 Check and maintenance essentials........................................................................................... 101
5.26.5 Assembling steps ...................................................................................................................... 102
5.27 Crankshaft pulley assembly .................................................................................................................. 104
5.27.1 Exploded view........................................................................................................................... 104
5.27.2 Tools and preparations ............................................................................................................. 104
5.27.3 Disassembling steps.................................................................................................................. 104
5.28 Starter assembly ................................................................................................................................... 105
5.28.1 Exploded view........................................................................................................................... 105
5.29 Flywheel housing assembly .................................................................................................................. 107
5.29.1 Exploded view........................................................................................................................... 107
5.30 Flywheel assembly ................................................................................................................................ 108
5.30.2 Exploded view........................................................................................................................... 108
5.31 Oil pump assembly ............................................................................................................................... 110
5.31.1 Exploded view........................................................................................................................... 110
5.32 Oil pan assembly ................................................................................................................................... 113
5.32.1 Exploded view........................................................................................................................... 113
5.33 Piston nozzle assembly ......................................................................................................................... 114
5.33.1 Exploded view........................................................................................................................... 114
5.34 Piston and connecting rod assembly .................................................................................................... 115
5.34.1 Exploded view........................................................................................................................... 115
5.35 Gear chamber housing cover assembly ................................................................................................ 119
5.35.1 Exploded view of gear chamber housing cover assembly ........................................................ 119
5.36 Gear train assembly .............................................................................................................................. 120
5.36.1 Exploded view........................................................................................................................... 120
5.37 Gear chamber assembly ....................................................................................................................... 123
5.37.1 Exploded view........................................................................................................................... 123
5.38 Drain valve assembly ............................................................................................................................ 124
5.38.1 Exploded view........................................................................................................................... 124
5.38.2 Tools and preparation .............................................................................................................. 125
5.39 Crankshaft assembly ............................................................................................................................. 125
5.39.1 Exploded view........................................................................................................................... 125
5.40 Thrust plate assembly ........................................................................................................................... 128
5.40.1 Exploded view........................................................................................................................... 128
5.41 Main bearing shell assembly ................................................................................................................ 130
5.41.1 Exploded view........................................................................................................................... 130
5.42 Dipstick assembly ................................................................................................................................. 131
5.42.1 Exploded view........................................................................................................................... 131
5.43 Engine block assembly .......................................................................................................................... 133
5.43.1 Exploded view........................................................................................................................... 133
5.44 Engine bracket assembly ...................................................................................................................... 135
5.44.1 Exploded view........................................................................................................................... 135
5.45 Urea solution pump .............................................................................................................................. 136
5.45.1 Refitting of urea solution pump ............................................................................................... 136
5.46 Urea solution nozzle ............................................................................................................................. 138
5.46.1 Refitting of urea solution nozzle............................................................................................... 138
5.47 Urea solution tank ................................................................................................................................ 140
5.47.1 Cleaning and installation of DEF tank and DEF tank filter element .......................................... 140
5.48 Urea solution pipeline .......................................................................................................................... 142
5.48.1 Refitting of urea solution pipeline ............................................................................................ 142
5.49 Sensor ................................................................................................................................................... 144
5.49.1 Installation of sensor and cleaning of suction strainer ............................................................ 144
5.50 Operation and maintenance of air-assisted urea solution injection system........................................ 147
5.50.1 Maintenance instructions of air-assisted injection system ...................................................... 147
Appendix B Fit Clearance of Main Engine Parts ........................................................................................... 149
Appendix C Tightening Torque of Other Main Bolts of Engine...................................................................... 150
Chapter I Operation Instructions
1.1 Outline drawing of engine
Fig. 1-1 Outline drawing 1 of engine (intake side)
No. Name No. Name No. Name No. Name

1 Thermostat 2 Intake pipe joint 3 Cylinder head cover 4 Hoisting ring
Oil-gas separator
5 6 Oil cooler assembly 7 Flywheel housing 8 Oil filter
air-outlet pipe
9 Oil pan 10 Fuel filter 11 Engine bracket 12 Fuel pump
13 Gear chamber 14 Water pump pipe 15 Fan
1
Fig. 1-2 Outline drawing 2 of engine (exhaust side)

1 Turbocharger 2 Exhaust pipe 3 A/C compressor 4 Alternator
5 Air compressor 6 Hydraulic pump 7 Starter
2
Fig. 1-3 Outline drawing 3 of engine (fan end)
1.2 Description of engine model
Product variant code
Emission level code
Power code
Application code
Product series code
3
1.3 Main specifications

Tab. 1-1 Main specifications
Items Technical Parameters

4-stroke, watercooled, with electronically controlled
Type
high-pressure common rail system
Aspiration method Turbocharged and intercooled
102×112(WP3.7)
Bore×stroke (mm)
105×118(WP4.1)
Number of cylinders 4
3.66(WP3.7)
Displacement (L)
4.088 (WP4.1)
17:1(WP3.7)
Compression ratio
17.5:1(WP4.1)
Firing order 1--3--4--2
Fuel system Electronic controlled high-pressure common rail
Starting type Electric start
Lubrication method Pressure lubrication
Cooling method Forced circulation water-cooling
Rating point 300-500)
Oil pressure (kPa)
Idle point ≥100
Oil pan capacity (L) See Chapter 2 of this Manual for details
Rotation direction of crankshaft (viewed from fan) clockwise
Number of valves each cylinder 4
Emission standard China V
Fuel supply advance angle —
Coolant outlet temperature (°C) 80~100
Turbocharger downstream exhaust gas temperature ≤550(WP3.7)
(°C) ≤570(WP4.1)
Intercooler downstream intake air temperature (°C) 50 ±5
300 thousand (WP3.7)
B10 life(km)
500 thousand (WP4.1)
4
1.4 Hoisting
When hoisting the engine, keep the crankshaft centerline horizontal. Never hoist an inclined engine or hoist the
engine by one side. Hoist and lower the engine slowly.
Correct Wrong
Fig. 1-4 Hoisting of engine
1.5 Running
When the engine is running normally, the temperature and pressure shall meet the requirements in Table 1—2.
Tab. 1--2 Main technical parameters of engine in operation
Items Technical Parameters

Intake resistance (kPa) ≤3.5
≤32(WP3.7)
Exhaust resistance (kPa)
≤20(WP4.1)
Oil pressure (kPa) See relevant description in this chapter
85~115(WP3.7)
Oil temperature (°C)
85~115(WP4.1)
Water temperature(°C) See relevant description in this chapter
5
Chapter II Maintenance of Diesel Engine
2.1 Fuel, lubricating oil, coolant and auxiliary materials

2.1.1 Fuel
Fuel should meet requirement of GB 19147 standard. Specific grade shall be determined according to the local
ambient temperature.
- 5# Vehicle Diesel: used in area where risk rate is 10% and min. temperature is above 8°C;
- 0# Vehicle Diesel: used in area where risk rate is 10% and min. temperature is above 4°C;
- -10# Vehicle Diesel: used in area where risk rate is 10% and min. temperature is above -5°C;
- -50# Vehicle Diesel: used in area where risk rate is 10% and min. temperature is above -44°C.
2.1.2 Lubricating oil
The criteria for engine lubricating oil selection is presented in Table 1-1.
Table 2-1 Selection criteria of special engine oil for Weichai Power engines
Category Grade Packing specification

Diesel engine CI-4 4L, 18L, 170kg
For the temperature and viscosity of engine lubricating oil, refer to Table 2--2.
Table 2-2 Correspondence of oil viscosity to applicable ambient temperature
Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature range, °C temperature range, °C
0W -35~-15 10W-50 -25~50
0W-20 -35~20 15W-30 -20~30
0W-30 -35~30 15W-40 -20~40
0W-40 -35~40 15W-50 -20~50
0W -30~-10 20W-30 -15~30
5W-20 -30~20 20W-40 -15~40
5W-30 -30~30 20W-50 -15~50
5W-40 -30~40 20 -10~20
6
Table 2--2 Oil Viscosity and applicable ambient temperature (cont'd)
Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature range, °C temperature range, °C
5W-50 -30~50 30 -5~30
10W-30 -25~30 40 5~40
10W-40 -25~40 50 15~50
Note: For the viscosity grade of the oil in the table, the smaller the number before W, the better the low
temperature performance of the oil; the larger the number after W, the greater the viscosity of the oil; the
viscosity and temperature performance requirements of engine lubricating oil are detailed in GB11122.
Caution
1. Before starting the engine, check the oil level in the oil pan.
2. Do not check the oil level while the diesel engine is running.
3. It is not allowed to mix the Weichai Power special oil with other oils.
The filling amount of engine lubricating oil is shown in Table 2-3.
Tab. 2-3 Oil filling volume of the engine
Quantity of filter(s)
Diesel engine
Engine model Oiling amount (L)
Fuel filter
Oil filter
Primary filter Secondary filter
WP4.1 8.5–12
1 1 1
WP3.7 13
Note:
1) The oiling amount given herein is for reference only. Please check the oil dipstick for actual oiling amount.
2) Weichai fuel system protector or water separator, if installed on the vehicle, should be replaced together with
the diesel fuel filter.
3) The number of filters given herein is for reference only. For the actual number, the actual model shall prevail.
2.1.3 Engine coolant

The Weichai Power special coolants with freezing points of -25°C, -35°C and -40°C are available. Please choose
the coolant based on the local ambient temperatures in such manner that the freezing point of coolant should
be 10°C lower than the local air temperature. Special coolants for heavy-duty engine refers to Table 2-4.
Tab. 2-4 Selection criteria of coolant
Category Grade Packing specification

HEC-II-25
Coolant for heavy-duty engine HEC-II-35 4kg, 10kg
HEC-II-40
7
Caution
1. Check the coolant regularly, and change it timely according to the actual situation to prevent corrosion.
2. It is forbidden to use ordinary water or poor-quality coolant in the engine.
Coolant filling steps:

1. Remove the pressure cap of the expansion tank, and slowly add coolant (slowly) until the liquid level in the
expansion tank reaches the upper marking line and drops slowly.
2. Keep the pressure cap of the expansion tank open, start the engine and allow it to run at idle speed until the
liquid level no longer drops, and then add coolant to the upper marking line.
3. Put back the pressure cap of the expansion tank and keep the engine running until the water thermostat
reaches the opening temperature (refer to the reference basis for thermostat opening: the pipeline between the
radiator upper tank and the thermostat becomes very hot) until the liquid level no longer drops. In order to
speed up heating and exhaust, it is recommended to run the engine at high speed intermittently in situ.
4. Add the liquid level to the upper marking line, put back the expansion tank pressure cap, and fill the coolant.
Caution
Note: During the entire filling process, the liquid level should not be lower than the lower marking line of the
liquid level in the expansion tank.
2.1.4 DEF
DEF quality
The quality and performance of urea solution should conform to the provisions of GB 29518. The requirements
for concentration and composition of urea solution are presented in Table 2-5.
Caution
1. Unqualified urea solution has the risk of blocking urea pump and urea nozzle. The metal impurities in
unqualified urea solution can easily lead to permanent poisoning of SCR catalyst, resulting in the decrease of
SCR catalytic converter efficiency (if applicable).
2. Urea solution must be added through proper channels or to designated providers.
3. It is strictly prohibited to use any liquid instead of urea solution during normal use.
8
Tab. 2-5 Urea ingredients
Composition Unit Lower limit Upper limit

Weight percentage of urea % 31.8 33.2
Density at 20°C kg/m3 1087 1093
Refractive index at 20°C - 1.3814 1.3843
Weight percentage of
% - 0.2
ammonia bases
Weight percentage of biuret % - 0.3
Acetaldehyde mg/kg - 5
Insoluble substances mg/kg - 20
Phosphorus (phosphorus
mg/kg - 0.5
tetroxide)
Calcium mg/kg - 0.5
Iron mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
Nickel mg/kg - 0.2
Aluminum mg/kg - 0.5
Magnesium mg/kg - 0.5
Natrium mg/kg - 0.5
Potassium mg/kg - 0.5
Storage of urea solution

The urea solution for vehicle should be stored in an enclosed light-resistant container at the ambient
temperature of 5°C--25°C, with the shelf life shown in Table 2-6.
Table 2-6 Shelf life of urea solution for vehicle
Shelf life of urea solution for vehicle

Ambient temperature for storage °C Minimum shelf life (months)
≤10 36
≤25a 18
≤30 12
≤35 6
≥35 b
9
Table 2-6 Shelf life of urea solution for Vehicle (continued)
Shelf life of urea solution for vehicle

Ambient temperature for storage °C Minimum shelf life (months)
Note: The shelf life in the table is specified by giving major consideration to the ambient storage temperature
and initial alkalinity of DEF besides the difference in evaporation between ventilated and non-ventilated storage
containers.
a. In order to prevent the decomposition of urea solution, it is necessary to avoid prolonging transportation or
storage above 25°C
b Check whether each batch of urea solution is qualified before use.
The materials of the urea solution storage containers should be properly compatible with urea solution for
vehicle, without chemical reactions or impurity migration. Containers made of recommended materials in
accordance with GB 29518 such as austenitic alloys and additive-free teflon, polyethylene and polypropylene
should be used. In case of storage below 5°C, a proper space should be reserved in the storage container as the
volume of DEF in the solidification state will be increased by 7% compared to that in the liquid state.
For the vehicle engine filled with urea solution, the effectiveness of urea solution should be noted. The
relationship between the shelf life of urea solution and the ambient temperature during the inventory period of
engine is shown in Table 2-6. If the inventory period exceeds the shelf life, it is required to drain away urea
solution through the drain valve at the bottom of the urea solution tank and fill the tank with acceptable urea
solution before the delivery of vehicle (gen-set). When the ambient temperature is greater than 35°C, it is
necessary to check if urea solution in the urea solution tank is still up to standard before delivery of the vehicle
(gen-set), and if not, replace it with acceptable urea solution
Caution
1. Urea solution should be stored in the tightly closed container, which should be placed in the cool and dry
storage room, far away from strong oxidizers. If urea solution is poured directly into the urea solution tank, it
may splash and cause environmental pollution. It is recommended to use professional filling equipment to fill
urea.
2. Urea solution is corrosive to the skin, and if it contacts the skin or eyes accidentally when filling, wash it
with water as soon as possible; if the pain continues, please seek medical help. If it is swallowed accidentally,
gargle first. Never induce vomiting but immediately seek medical treatment.
2.1.5 Auxiliary materials

Please refer to Table 2-7 for engine auxiliary materials.
Tab. 2-7 Auxiliary materials for the engine
No. Name Color Purpose and application

To be applied to smooth metal surfaces to
1 Molykote Pulver Black prevent blocking,
e.g. external surface of cylinder liner
To be applied for lubrication before the
2 Molykote G-N-U.plus Dark grey pressure of lubricating oil builds up,
e.g. intake valve stem
10
The reference for sealant application of engine is given in Table 2-8.

Tab. 2-8 Reference for sealant application of engine
Designation Main purpose Examples of application position Comments

Camshaft thrust plate bolt
Camshaft timing gear bolt
Bolt of intermediate idler gear
To be applied to the Front cap bolt As an option,
thread for locking and Oil filter seat bolt DriLoc204
Weichai prevention of thread-locking
Oil cooler bolt
special 242 looseness due to adhesive can be
vibration. It has Screw plug for oil cooler regulating valve used for
medium strength. Bolt for oil pump return pipe fixture pre-application.
Air compressor shaft end thread
Bolt of oil suction strainer
Bolts for sensor and wire harness fixtures
To be applied to the As an option,
thread surface for DriLoc204
Weichai locking, sealing and thread-locking
Cylinder head auxiliary bolt
special 262 prevention of adhesive can be
looseness due to used for
vibration. pre-application.
Weichai
For locking and
special sealant Bowl plug for blocking oil hole
tightening
271
Weichai For sealing between
Other bowl plugs
special 277 core and hole
Weichai For sealing of cylinder
Push rod tube - cylinder head
special 270 head top surface
Mating surface of cylinder block and crankcase
Engine block front face - front cap, rear end face -
flywheel housing connecting plate
Weichai Mating surface of oil filter seat and crankcase
special sealant Applied on shining
Water pump rear cover - engine block front end
518 (next metal surface for
face
generation of sealing
sealant 510) Flywheel connecting plate - flywheel housing
Mating surface of cylinder block and oil cooler
cover
Mating surface of cylinder block and oil filler cap
To be applied to
Mating surface of cylinder block and oil cooler
Silica gel smooth metal
cover
surfaces for sealing
2.2 Daily maintenance

2.2.1 Daily inspection
1. Check the level of coolant, oil and fuel; and check if there is sufficient grease at greasing positions.
2. Check for leakage of fuel/oil, coolant and air.
11
3. Check if external parts and attachments are properly connected and tightened.
4. Check the fan, visually check the fan blades for damage, and check if the connecting bolt is properly tightened.
5. Check belts for overtension or undertension.
6. Check the connection of line, and check the connector for
damage.
7. Check if the exhaust temperature, color, sound and vibration
are normal, and if the engine speed is stable.
8. Check if the turbocharger oil inlet and return pipes are free
from blockage or leakage.
9. Check that the exhaust pipe is not leaking and the intake pipe
is unblocked.
Fig. 2--1 Check of fan
2.2.2 Daily maintenance

1. Check the coolant level, and if the coolant is not enough,
open the filler cap for topping up.
Caution
Always press down the exhaust button before opening the
filler cap, so as to avoid scalding by hot coolant when the
engine is hot.
Fig. 2-2 Coolant filler cap
2. When the liquid level in the oil pan is below the “L” marking Oil dipstick
or above the “H” marking, do not start the engine.
When the liquid level is lower than the lower marking line, add
oil from the engine oil filler. When it is higher than the upper
marking line, it is necessary to take out the oil from the dipstick
tube or drain oil through the oil drain plug until the oil level is
between the upper and lower marking lines of the dipstick. It is
recommended that the engine oil approaches the upper
marking line on the oil dipstick.
Caution
Fig. 2--3 Marks of oil dipstick
12
Always check the oil level at least 15~30min after engine shutdown, enabling the oil to return to the oil pan.
3. Check the fuel level, and add fuel timely.
4. Check the urea solution level,
which should be between 30% and 80% of the total capacity of urea solution tank.
Caution
When the urea level is lower than 10%, the alarm system will activate and the instrument driver alarm light
will flash. In such a case, the urea solution needs to be added in time. If it is not added in time, the power
limiting protection measures of the engine may be triggered.
Attention shall be paid when adding urea solution:

1) The urea tank cover and the top of the urea tank shall be kept clean and protected when necessary. The urea
tank cover and other structures shall be dirt-proof and dust-proof and shall not be lost or damaged.
2) Tools and equipment such as funnel and filling pipeline for auxiliary filling shall be cleaned after use and
sealed with plastic bags.
3) The tin foil at the seal of the urea barrel and the sealing sticker on the urea cover must be removed before
filling. Urea solution should be kept clean, away from light and sealed.
2.3 Description of maintenance of all levels

2.3.1 Oil change
1. Unscrew the drain plug at the bottom of oil pan to
drain out oil, and then screw on the drain plug again.
Drain plug
Fig. 2-4 Drain plug

2. Open the filler cap to add oil through the filler; check Oil filler cap
the oil dipstick, and when the required level is reached,
refit the filler cap.
Fig. 2-5 Filler cap
13
2.3.2 Replacement of oil filter or oil filter element

1. Unscrew the filter cover (1) by about (10~15) mm (it indicates that the filter cover has been unscrewed by
about 10 mm when its small hole is exposed), keep it still for (3~4) min, and after the dirty oil flows into the oil
pan, remove it (together with the filter element in normal conditions).
2. Remove the filter element (3) and O-ring (2) from the filter cover, install a new O-ring, apply oil to the surface
of the O-ring, screw the new filter element into the groove of the filter cover, and apply oil to the small O-ring at
the bottom of the filter element.
3. Install the filter cover together with the filter element onto the filter base(4), and tighten the filter cover
according to the torque requirements identified thereon.
4. Start the engine to check for oil leakage.
Caution
Avoid installing the filter element and filter cover separately, instead, combine them before installing them on
the filter base.
Unacceptable oil or oil filter element can cause premature wear of the bushes of the crankshaft and other
parts and increase the risk of excessive emissions.
2.3.3 Replace fuel filter and filter element
1. Remove the used fuel filter element. If the water collector installed on the coarse filter can be reused, remove
the water collector;
2. Lubricate the seal;
3. Screw the filter by hand until the seal is jointed with the interface.
14
4. Continue to screw the filter by hand until the filter is securely installed (approximately 3/4 turn).
5. Ventilate until no bubbles appear;
6. Carry out a leakage test.
Fuel filter base
Primary fuel filter

element
Water level
Water drain sensor
port
2.3.4 Check and adjustment of valve clearance

It is very important to adjust the valve clearance. If the valve clearance is too small, the valve will not close
tightly due to elongation at heating when the diesel engine is running, causing air leakage, and reducing the
diesel engine power; if the valve clearance is too large, the opening time of the intake and exhaust valves will be
shortened, resulting in insufficient intake or incomplete exhaust, reducing the diesel engine power, and exerting
strong impact on the intake and exhaust valves, rocker arm, camshaft, etc.
The clearances of intake valve and exhaust valve should be (0.35~0.40) mm and (0.40~0.45) mm respectively.
The valve clearance should be adjusted when the engine is cold. During adjustment, remove the cylinder head
cover, rotate the crankshaft to align the 1# cylinder TDC mark on the flywheel ring gear with the mark on the
flywheel housing. When the piston of 1# cylinder is at the TDC of the compression stroke, the intake and exhaust
valves of 1# cylinder will be closed. At this time, check the clearances of intake and exhaust valves of 1# cylinder,
intake valve of 2# cylinder and exhaust valve of 3# cylinder with the filler gauge; rotate the crankshaft by a
complete circle to position the 4# cylinder piston at the TDC of the compression stroke, so as to check the
clearances of the exhaust valve of 2# cylinder, intake valve of 3# cylinder and intake and exhaust valves of 4#
cylinder from front to back.
During valve clearance adjustment, it is necessary to remove the fuel injector, and pay attention to the
followings:
15
1. The fuel injector gasket and oil seal for fuel injector and ballast bolt on the cylinder head cover can only be
used once, and a new one shall be replaced after the fuel injector is disassembled.
2. During maintenance and adjustment of the valve clearance, cover the fuel injector hole in the cylinder head
with a piece of wiping paper or other clean cloth after removing the fuel injector and cylinder head cover, so as
to prevent impurities from entering the cylinder head bottom hole. Before refitting the fuel injector, clean the
fuel injector and its bottom hole:
1. Clean the outer surface of the removed fuel injector, and wipe off carbon deposit, gum deposit, etc. The
ultrasonic cleaning method is recommended.
2. Remove the sludge in the bottom hole with type 755 detergent.
3. Scrape the carbon deposit and impurities in the bottom hole with proper tools.
4. Wipe off the sludge and carbon deposit with a piece of clean cotton cloth to avoid jacking up the fuel injector
gasket.
2.3.5 Check air tightness of intake system
Check if the intake hose is cracked due to aging, and if the hoop gets loosened. When necessary, tighten or
replace related parts to ensure the tightness of intake system.
2.3.6 Check air filter element
The use of high-quality air filters and routine maintenance are important for the durability of the engine.
Blockage of air filter will increase the resistance of air inlet system, resulting in excessive inlet temperature and
combustion temperature and black smoke, and will also cause the filter rupture, causing dust to enter the air
inlet system and power cylinder, causing wear of power cylinder and high crankcase blow-by. A high-quality air
filter shall be always used and replaced regularly according to the instructions for use.
The max. permissible intake resistance of the engine is 6 kPa, and it shall be checked when the engine runs at
rated speed and under full load. When this max. permissible intake resistance is reached, clean or replace the air
filter element as specified by the manufacturer.
Caution
Never run the engine without an air filter; otherwise, dust and foreign matters may enter the engine to cause
premature engine wear!
Remove the air filter element from the air filter, tap the end
face to allow the dust to fall, or use the compressed air for back High pressure air pipe
flushing (from the inside out).
Fig. 2--6 Blowback with compressed air
16
Caution
The unacceptable air filter element may cause abnormal blockage of DPF in the aftertreatment system,
resulting in serious failures such as excessive emissions and DPF damage!
2.3.7 Maintenance of urea solution pump

Check of urea solution pump filter element
The maintenance period of the urea pump filter element is detailed in the regular maintenance period and
maintenance specifications of engine in this manual.
Caution
When replacing or disassembling the urea nozzle, it is required to check the state of the urea nozzle. In case of
any damage or deformation, the urea nozzle must be replaced!
Clean urea tank and its filter element
During maintenance, check the urea solution tank and filter for any dirt, and clean them if necessary.
Caution
After the engine is stopped (only T15 is powered off), the SCR system will automatically enter the suckback
state, sucking back the urea solution in the urea pump and urea pipe back to the urea tank, and the stage will
last for 2min, during which the main power switch of the vehicle is prohibited from being turned off.
Maintenance of urea tank
Regularly clean the DEF tank every 60,000 km or 6 months to avoid the blockage and wear of the DEF pump
caused by particulate impurities in the tank;
The DEF tank sensor is an intelligent type and measures the liquid level and DEF concentration, which
correspond to the data in the ECU. If the DEF tank is replaced with an unmatched one, OBD fault may occur,
resulting in limited engine torque. If required, be sure to replace it by the DEF tank of the same type produced
by the original manufacturer.
Caution
Maintenance of post-processed parts shall be carried out at Weichai Service Station by using the special
maintenance tools. Urea pump and urea nozzle are cleaned using Weichai's special urea injection system
testing and cleaning tools!
2.3.8 Maintenance of compressed air filter

After the compressed air filter is installed on a vehicle, draining shall be performed every 5,000 km (or when
necessary). The compressed air filter shall be maintained every 30,000km (or when necessary), otherwise
adverse impacts on air devices may occur.
! The air in the compressed air filter and its connected pipelines must be completely released to form zero
pressure before the following operations are performed.
17
Draining method:
1. Turn the drain valve handle clockwise to move the valve stem upward and open the drain valve, so dirt is
discharged from the stem’s drain hole.
Drain valve
handle
Fig. 2-7 Open the drain valve

2. After the dirt is completely drained, turn the drain valve handle counterclockwise to 1.8±0.3 N.m until it is
tightened.
Tighten the drain valve

Torque: 1.8N·m ±0.3
Fig. 2-8 Tighten the drain valve

Maintenance method:
1. Remove the air pipe connecting the complete vehicle to the compressed air filter.
Remove the outlet pipe

Remove the intake
pipe
Fig. 2-9 Remove the connecting pipes

2. Loosen the bolts connecting the compressed air filter and the complete vehicle, and remove the compressed
air filter.
18
Loosen the bolts that are

connected to the
complete vehicle
Fig. 2-10 Loosen the connecting bolts

3. Clamp the filter base firmly to a vise, unscrew the filter canister counterclockwise with a wrench, remove the
O-ring from the filter canister and place it in the waste bin.
Remove the O-ring
Fig. 2-11 Remove the filter canister

4. Unscrew the end cap counterclockwise, remove the filter element assembly, and place it in the waste bin.
Fig. 2-12 Remove the filter element

5. Clean the inner wall of filter base, the inner wall and external threads of filter canister, the O-ring groove, the
inner walls of intake joint, outlet joint, filter base air passage, etc., and the outer surface of end cap. Blow off
impurities adhered to parts with compressed air, then clean the parts with detergent (or fresh water) and wipe
them clean to ensure the parts are dry.
19
Wash the inner wall of

air passage
air passage
joint
Wash the inner wall

of joint

filter base
Fig. 2-13 Wash the filter base

Wash the external threads of filter canister and
the O-ring groove
filter canister
Fig. 2-14 Wash the filter canister

6. Fix the clean filter base firmly to a vise, pass the new filter element assembly through the center shaft, place it
in the filter base, and tighten the end cap clockwise to 1.3±0.3 N.m.
Tightening torque
1.3±0.3 N.m
Fig. 2-15 Tighten the filter element

7. Insert the new O-ring into the corresponding groove of the filter canister, screw the filter canister into the
filter base, and tighten it to 20~25N.m with a wrench.
20
Refit the O-ring in the Tightening torque

filter groove 20~25 N.m
Fig. 2-16 Tighten the filter canister

8. Keep the operating environment clean during the replacement of filter element assembly, to prevent foreign
matter from entering the compressed air filter.
9. Fix the maintained compressed air filter to the complete vehicle, and connect the air pipes.
2.4 Engine cleaning, protection and transportation

2.4.1 Cleaning and protection
1. Warm up the engine, drain the engine oil away, clean the oil filter, and fill the engine with anti-rust oil;
2. Empty the fuel tank, and then fill it with anti-rust oil mixture;
3. Empty the radiator and then fill it with coolant containing anti-rust agent;
4. Start the engine, and run it at an idle speed for (15~25) min;
5. Drain off the oil, fuel and coolant;
6. Preserve other parts of the engine.
2.4.2 Protection during storage

When the engine is stored in a dry and clean environment, necessary protective measures should be taken to
prevent rain and dust from entering the engine.
In addition, the fuel, oil, air and water inlets and outlets shall be blocked with caps or plastic clothes; the whole
engine shall be sealed up with the VCI film.
2.4.3 Preservation
The seal period of the engine is 1 year, and the engine outside this period should be sealed again as follows:
1. The engine should be sealed in a clean environment. The engine block and parts should be thoroughly cleaned
and free of corrosion, oil stain and dust before sealing.
2. The engine can be sealed by immersion, spraying, coating or filling method as appropriate.
3. Sealed parts: turbocharger air inlet/air outlet and intake pipe port.
2.4.4 Transportation of diesel engine

Outer packing is needed for transportation.
21
Requirements for engine placement and transfer:

1. When the engine is standing, it must be placed on a plane or transfer frame that can bear its own weight
without deformation;
2. When the engine is moving, the lifting appliance must be used, and it is not allowed to move the engine
directly with a forklift;
3. During engine transfer, the engine must be fixed on the transfer rack, and the transfer rack must be fixed on
the mobile equipment.
22
Chapter III Typical Faults and Troubleshooting
3.1 Overview
3.1.1 Overview
Engines of this series are designed and manufactured under a strict quality assurance system, and have been
subject to specified tests before delivery. Moreover, the engine is precise machinery whose lasting good
performance is related closely to a proper maintenance. The premature failure of engine is generally resulted
from:
1. Operation against regulations, improper management and misuse;
2. Failure to inspect and maintain the engine as specified, and more serious, replacement of maintenance with
repair;
3. Use of defective spare parts, or even counterfeit and shoddy parts due to their cheap price, which will
dramatically shorten the service life of engine;
4. Fuel, oil or coolant of improper or non-standard grades are selected.
Caution
1. The engine troubleshooting is a complicated work. Thus, do not disassemble or remove the engine at
discretion before determining its basic fault cause; otherwise, the fault will not be eliminated, and even more
serious fault may occur due to improper refitting.
2. Key components of the engine, such as high-pressure fuel pump and turbocharger, shall be maintained and
checked by using special apparatus and based on certain experience. Therefore, users having no relevant
experience and equipment are not allowed to disassemble or adjust the engine without permission.
3.2 Fault diagnostic methods

3.2.1 Traditional fault diagnostic methods
1. Observation: Determine the fault by observing the symptom

of diesel engine, such as smoke.
Fig. 3-1 Observation method
23
2. Listening: Determine the fault location, symptom and

severity by listening to the abnormal noise of diesel engine.
3. Comparison: Replace a certain assembly or component to
determine whether it is faulty.
Fig. 3-2 Listening

3.2.2 OBD method
3.2.2.1 System overview and description of indicator light
1. System overview
1) Overview of Weichai NOx Control System
The NOx control system has three main components:
♦ Driver alarm system:
A system consisting of indicator lights, symbols, optional audible alarms and output information from the vehicle
monitoring system is designed to remind the driver of emission related maintenance items. When related faults
are detected, the driver alarm system will be started immediately.
The driver alarm system indicator is integrated into the vehicle's instrument panel and may vary from one
vehicle manufacturer to another.
♦ Primary driving performance limit system
The engine output torque is limited. When the engine has a related fault, which triggers the primary driving
performance restriction request (request triggering standard Table 1-11), the primary driving performance
restriction is activated and the engine outputs the limited torque only when the vehicle stops (to ensure that the
vehicle is in a safe running state and avoid triggering the torque limit immediately, which may result in a safety
hazard).
♦ Severe driveability restriction system:
Severe driveability restriction system restricts the vehicle operation by limiting vehicle speed. When the engine
has related engine fault, which triggers the severe driving performance restriction request (see Table 1-11 for
the request triggering standard), when one of the two events occurs, the severe driving performance restriction
will be activated and the vehicle speed limit will be implemented:
– "Limit after restart" (restart after engine shutdown)
– "Limit after shutdown" (at least 1 hour after the vehicle stops (determined based on the hand brake signal)
24
Tab. 3-1 Conditions for triggering driver alarm and performance restriction system request in case of failure
Failure type Driver alarm active Torque limited active Activate speed limit
Non-compliant reagent
Immediately 10 hours after failure 20 hours after failure
quality failure
Abnormal reagent
Immediately 10 hours after failure 20 hours after failure
consumption failure
10 hours after the fault 20 hours after the fault
Injection interruption fault Immediately
occurs occurs
36 hours after the fault 100 hours after the fault
EGR valve fault Immediately
occurs occurs
Monitoring
system/emission 36 hours after the fault 100 hours after the fault
Immediately
post-treatment unit type A occurs occurs
fault
The urea level is less than The urea level is less The urea level is less
Reactive agent inventory
10% than 5% than 2.5%
The primary driving performance restriction system and severe driving performance restriction system are not
applicable to rescue vehicles, military vehicles, civil defense vehicles, fire fighting trucks and armed vehicles used
to maintain public order. The permanent deactivation setting of the driving performance restriction system can
only be carried out by the engine or vehicle manufacturer.
2) Description of activation and deactivation of driver alarm and driving performance restriction system
When all conditions evidencing its activation no longer exist, such as adding proper amount of urea or repairing
related faults, the alarm or restriction system shall be relieved.
2. State description of indicator of engines meeting GB17691-2018 Limits and measurement methods for
emissions from diesel fueled heavy-duty vehicles (China VI)
No. Indicator light Condition Declaration Pattern
Display according to Emission system related
1 MIL lamp
regulations fault
Emission control related
2
fault activation alarm
Always on
Alarm activated due to a
3 Driver warning lamp NCD
low urea level
Low urea level, torque or
4 Flash
speed limited
5 Yellow light always on Regenerating
Parking regeneration
6 DPF regeneration Yellow light flashing
required
indicator
Service regeneration
7 Red light always on
required
DPF regeneration Regeneration is
8 Red lamp always on
suppression lamp temporarily inhibited
9 SVS lamp Always on Engine body fault
Note: It shall be subject to the actual instrument settings of the complete vehicle.
25
3. MIL and SVS lamps checking

1) MIL light is used to indicate the faults related to post-treatment emissions. The MIL light is mainly
composed of three parts: self-inspection, readiness display and fault indication.
After T15 is powered on and before the engine starts, the MIL lights go through the 3 stages successively, i.e.,
self inspection → readiness display → fault indication.
The MIL lamp self-test and readiness detection take approximately 25 seconds, and this part has no impact on
fault diagnosis.
This process will be performed after T15 is powered on.
MIL light self-inspection: MIL is on for 5 seconds → off for 10 seconds.
MIL light readiness: If it is ready, MIL light will be on for 5s. If it is not ready, it will flash for 5 times in 5 seconds,
and then come off for 5 seconds, as shown in the figure below.
Indicator light test Ready
MI On
Ignition
switch ON
Interval Interval
MI Off
Indicator light test Not ready

MI On
Ignition
switch ON
Interval Interval
MI Off
MIL lamp fault indication: Post-treatment faults are divided into three types: type A/B/C faults.
No after-treatment related faults:
After the readiness monitoring is completed, the MIL lamp flashes once every 5 seconds, indicating that there is
no fault. After the engine is started, the MIL lamp will automatically go off.
26
Indicator light test Ready Mode 1 - No DTC
MI On
Ignition
switch ON
Interval Interval
MI Off
Type C failure:
After the completion of readiness monitoring, the MIL light flashes twice every 5 seconds, which indicates a class
C fault and does not affect driving. After the engine is started, the MIL light will go out automatically.
Indicator light test Ready Mode 2 - On-demand MI
MI On
Ignition
switch ON
Interval Interval
MI Off
Type B fault:
After the completion of readiness monitoring, the MIL light flashes 3 times every 5 seconds, which indicates a
class B fault. After the engine is started, the MIL light will be on for 15 seconds, and then turn off automatically,
as shown in the following figure.
Indicator light test Ready Mode 3 - Short MI
MI On
Ignition
switch ON
Interval Interval
MI Off
Type A failure:
After the completion of readiness monitoring, the MIL light remains on, which indicates Class A fault. After the
engine is started, the MIL remains on.
Ready Mode 4 - Continuous MI
Indicator light test
MI On
Ignition
switch ON
Interval Interval
MI Off
27
Fig. 3-3 OBD and SVS Lamp

2) The SVS light is used to indicate the engine system fault. When powered on, it will perform self-check, go
on a while and then go off.
♦ In case it stays on after power-on, check for existence of DTC; if there is no DTC, check for circuit fault.
♦ If the SVS lamp does not come on during the self-diagnosis after power-on, this may be caused by the circuit
fault or bulb damage.
3.2.2.2 DTC list
The name of the engine fault and its related Chinese description, P-Code (a code that can be seen on the
diagnostic device when connected to the entire vehicle), fault related components, error causes, and solutions
can be found according to the fault code, so as to facilitate the quick identification of the engine fault cause by
maintenance technicians. The DTC list is shown in the following table.
Table 3-2 OBD method
Steps Checking points Checking methods

Preliminarily judge the fault orientation (mechanics, electrics, and
Preliminarily identify the fault
1 components) according to the symptom and response of the
orientation and location
vehicle; do not replace any component blindly.
DTCs indicate inactive fault and active fault respectively, and the
inactive fault has no impact on the vehicle performance. The
2 Read DTCs (P code) location of fault that affects the vehicle performance can be
determined by reading-recording-clearing-reading-recording
(analysis).
28
Table 3-2 OBD method (continued)

Check the engine step by step and case by case, and do not
replace any component before identifying the fault location. Most
of DTCs indicate the faulty portion only rather than the faulty
component or sensor. Be sure to comprehensively identify the
fault location by taking the actual working process of engine into
consideration during troubleshooting. Scope of troubleshooting
Do troubleshooting as per engine-related DTCs is classified as follows: DTCs of fuel system:
3
DTCs Fuel tank, filter, pipeline and joint, high-pressure fuel pump and
rail, and fuel injector;
DTCs of air system: Air filter, pipeline, turbocharger, charge air
pressure and temperature sensor, inter-cooler, etc.;
Preliminary check of electrics: Harness, connector, sensor,
actuator, etc.
In case no DTC can be read, check if the communication harness
Do troubleshooting without
4 between scan tool and ECU are normal; if no DTC is accessible, do
DTC
analysis and judgment based on experience and data stream.
29
3.3 Typical faults troubleshooting

3.3.1 Engine start failure
Checking
Steps Checking methods
points
Check the fuel
Step 1 ….. ….. Check whether the fuel quality meets the standard.
quality
Check the fuel

Check the fuel level in the fuel tank and verify that the fuel gauge is
Step 2 ….. level, fuel …..
working properly.
gauge
Check the fuel Check if the fuel tank is clean without foreign matter and if the
Step 3 ….. …..
tank breather is not clogged.
Check the
Check whether the gear is in the neutral position and whether the
Step 4 ….. gear, neutral …..
neutral switch is normal
gear switch
Check the
Step 5 ….. auxiliary stop ….. Check whether the auxiliary stop switch is normal.
switch
Check the
Check whether the battery voltage is normal (minimum starting
Step 6 ….. battery …..
voltage is 13～ 16V).
voltage
Check the
Step 7 ….. vehicle engine ….. Check whether the vehicle engine battery is normal.
battery
Check the Check the starter relay harness for open circuit or misconnection
Step 8 ….. …..
starter relay and starter relay for damage.
30
(1) If the starter fails to work:

① Check whether the key switch circuit of the
Determine vehicle (gen-set) is normal and there is no
whether intermittent connection;
the starter ② Check whether the starter relay harness is
is working open or wrongly connected, and whether the
Check the properly, starter relay is damaged, and eliminate the
Step 9 ….. ….. …..
starter whether starting circuit fault.
the starter (2) If the starter works:
does not ① Further check whether the engine runs
work after flexibly;
startup. ② Check whether the valve timing is correct;
③ The minimum driving speed must not be
lower than 150 r/min.
Check whether there is gas, leakage or blockage in the low-pressure

Check of
fuel circuit, primary filter, and secondary filter; if the fuel supply
Step 10 ….. low-pressure …..
pump is not working, check whether the piston, valve and fuel inlet
fuel circuit
filter of the fuel supply pump are blocked.
Check the oil pump: Loosen the high-pressure fuel pipe, drive the
fuel pump with the starter to exhaust gas, and check whether the
high-pressure fuel output is normal. If there is no fuel output or the
fuel output is abnormal, open the metering unit to see whether the
Check of
fuel is normal. If the fuel output recovers to normal after the
Step 11 ….. high-pressure …..
metering unit is open, ECU fault shall be considered. If the fuel
fuel circuit
output is still abnormal, replace the metering unit. If the fuel output
is still abnormal after replacing the metering unit, replace the
overflow valve of the fuel injection pump. If the fuel output is still
abnormal, check the fuel return quantity of the fuel injector.
Check whether the air inlet pipe is blocked, whether the air filter,
inter-cooler front and rear pipes or inter-cooler are blocked. If there
Check the
Step 12 ….. ….. is no blockage, check whether the intake throttle valve functions
intake pile
well, and whether it is stuck in the fully closed position, which stops
air intake. If no problem is found, proceed to the next step.
Check with the scan tool: Further check if the rail pressure is built up
normally. In case of an abnormal rail pressure, it may be caused by
the fuel injector, common rail pipe, high pressure fuel pump and
ECU. Further check if the four power lines between the battery and
Check of the
Step 13 ….. ….. the ECU are connected, and remove the vehicle engine harness from
scan tool
the ECU to check it for burning, which may be caused by a poor
contact with the ECU connector, water invasion due to seal failure or
an excessively high voltage. Check whether the measurement of rail
pressure sensor is normal.
31
Use a fault
Use a fault diagnosis instrument to check whether the flywheel
diagnosis
signal disc and the fuel pump cam signal disc are synchronized
instrument to
(signal 48).
check
If this is not the case, check the crankshaft sensor or camshaft sensor
whether the
for damage; if no damage is found, check the installation of
Step 14 ….. flywheel …..
crankshaft and camshaft speed sensor, the wire harness and the
signal disc and
machining quality of flywheel ring gear. No or incorrect crankshaft
the fuel pump
and camshaft signal will be sent if the mechanical assembly is
cam signal
improper or the sensor harness is faulty, such that synchronization
disc are
will fail and thereafter fuel injection will become abnormal.
synchronized.
1) Common DTC
Check DTCs with the scan tool. Common sync signal DTCs are as
follows:
P0340: Camshaft signal missing;
P0335: Crankshaft signal missing;
P0341: Camshaft signal error;
P0336: Crankshaft signal error.
2) Check of camshaft and crankshaft signals:
Check the resistance of sensor (860±86Ω at 20°C);
Check whether the sensor mounting position is in place (clearance:
0.3mm～ 1.2mm)；
Check the harness between sensor and ECU for open circuit and
short circuit; check the harness connector.
3) Check of sync signal:
Check of DTCs
Check the sensor for contamination, which may lead to signal
Step 15 ….. with the scan …..
distortion.
tool
Check for twisted pair and shielded cable, and check for
electromagnetic interference caused by other signal lines nearby.
Check if the relative position of crankshaft and camshaft is correct as
per the factory timing drawing of engine; Check if the signal wheel is
accurately machined and check it for inconsistent height and width.
4) Inspection of mechanical mounting position:
Mounting position of flywheel: When the piston is at the TDC of No.
1 cylinder, the angle between the corresponding crankshaft position
of sensor and the position of notch should be as specified in the
factory design drawing.
Timing relationship of crankshaft and camshaft: Check the position
of camshaft when the position of crankshaft is fixed, in which case
the relative position of crankshaft and camshaft must be as specified
in the design drawing.
32
3.3.2 Insufficient power

Checking
Steps Checking methods
points
Confirmation Confirm whether the fuel quality and the fuel grade match the
Step 1 ….. …..
of fuel quality application type or whether the fuel quality is poor.
Check whether there are obstacles under the throttle and other
Check the physical reasons that cause the throttle to decrease below 100%.
Step 2 ….. …..
throttle Check whether the throttle feedback voltage is 100% when the
throttle is floored.
(1) Insufficient intake:

① The air filter is dirty and blocked; the intake
hose is leaky, blocked or sucked flat when the
vehicle is running at high speed;
② The turbocharger is not properly matched.
Check whether the turbine end and compressor
end incur oil shortage or oil leakage, and
whether the blade is deformed or damaged;
The checking order
③ The intercooler is damaged with large
is respectively: air
resistance. Focus on checking whether there is
filter →intake
damage or blockage, and whether the intake
hose→turbocharger
and exhaust hose connections are dislodged,
→ intercooler
etc.;
→combustion
④ The intercooler involves poor cooling, which
chamber→exhaust
Check will cause an extremely high intake temperature
pipeline
Step 3 ….. the air ….. ….. and reduce the charge efficiency. It is necessary
(exhaust butterfly
lines to check and remove the sludges on the radiator
valve)
fin and inside the internal pipes to improve the
→muffler. The fault
radiation effect.
troubleshooting
(2) High exhaust back pressure: If the back
related to air
pressure of the exhaust system is too high due
passage includes
to blockage of the exhaust pipe, the residual
the following two
exhaust gas in the cylinder will be increased,
situations:
thus reducing the combustion rate of the
mixture, effective pressure of the cylinder and
combustion efficiency. Focus on checking if the
exhaust pipe is blocked, if serious carbon
deposit occurs in the front and rear exhaust
pipes, if the exhaust brake butterfly valve
rotates flexibly, if the exhaust pipe and joint are
properly sealed and if the SCR tank is blocked.
33
(1) In the case of improper filling of the fuel

tank, the fuel inlet and return pipes should have
their joints tightened and should not be
Fuel tank→primary excessively slim or long to ensure the
Check of fuel filter smoothness of return pipe without leakage.
low-pres →gear pump (2) There should be no inferior diesel fuel
Step 4 ….. ….. …..
sure fuel →secondary fuel residues and impurity deposits, etc.in the oil
circuit filter→high-pressur pan because too much impurities will block the
e fuel pump suction strainer.
(3) Inlet and return pipeline problem,
insufficient fuel supply from fuel feed pump,
fuel metering unit damage.
(1) The high-pressure fuel pump is worn. As a

component maintaining the fuel supply
pressure and a core component of the engine,
the high pressure fuel pump, if damaged, will
directly cause the diesel engine fault. Poor
diesel fuel quality, filter damage and fuel feed
pump damage will result in wear of the
high-pressure fuel pump plunger and control
Check of valve, reducing the fuel supply pressure.
High pressure fuel
high-pre (2) The common rail pipe plays the role of fuel
pump → Common
Step 5 ….. ssure ….. ….. storage and pressure accumulation in the
rail pipe → Fuel
fuel common rail system, with the rail pressure
injector
circuit sensor as its key part. Distortion of the rail
pressure sensor signal will reduce the fuel
pressure in the pipe and directly decrease the
fuel injection volume.
(3) The needle valve controls the fuel injection
quantity by opening and closing the solenoid
valve. The main types of damage include:
serious carbon deposit of nozzle, needle valve
seizure and solenoid valve damage.
Wrong
Step 6 ….. ….. Fuel injector, turbocharger, etc.
configuration
Check the 1) The cylinder gasket is leaky;

sealing and 2) The valve and valve seat are improperly sealed;
Step 7 ….. …..
valve 3) The valve clearance is improper, resulting in an insufficient
clearance intake.
Check the
engine When insufficient power occurs, whether the engine temperature is
Step 8 ….. …..
over-heat too high, resulting in overtemperature protection.
protection
34
Check of Check whether the working condition is beyond the working range
Step 9 ….. turbocharger ….. of the turbocharger, resulting in the triggering of turbocharger
protections protection to limit fuel injection.
Check the Check whether the smoke intensity limit is caused by being in the
Step 10 ….. …..
smoke limit high altitude area.
1) Nozzle fault;
2) DEF pump fault;
3) DEF pipeline fault;
4) DEF tank fault;
5) NOx sensor fault.
After-treatment
Step 11 ….. ….. The above five types of faults will cause the engine to trigger
system fault
after-treatment system torque limitation, which will limit the upper
threshold of the output torque, giving the user a feeling of
underpower. After finding out the faulty location, check the faulty
part or replace it with a new part. After the fault disappears, the
torque limit will be deactivated automatically.
Check the
Check whether the recommended configuration of powertrain
Step 12 ….. powertrain …..
matching is appropriate.
matching
Check the
Step 13 ….. ….. Check the clutch for serious wear, slip, etc.
clutch
Check the
chassis Check whether the friction of the vehicle chassis transmission
Step 14 ….. …..
transmission system is too large and whether the brake clearance is reasonable.
system
Check the tire

Step 15 ….. ….. Check the tire of the vehicle for burst or insufficient pressure.
pressure
Check of ECU
Step 16 ….. ….. The ECU data are not matched because of market data modification.
data
35
1) Demands for engines: power, economy, and emission; 2) Driving

Step 17 ….. Inquiry of user ….. habits: shifting speed, coasting in neutral; 3) Desire to keep up with
others
3.3.3 High fuel consumption

Steps Checking Checking methods
points
Interview with users to verify whether the fault is caused by
Step 1 ….. Inquiry of user ….. additional factors such as environment, special working conditions,
and special time periods that affect fuel consumption.
Step 2 Verification of Check if the user has developed correct driving habits including
driving habits shifting at a reasonable speed, abrupt acceleration and deceleration
….. through ….. and driving at a high speed.
communication
with the user
Check the fuel Check whether the fuel leaks, whether the fuel grade does not
Step 3 ….. …..
quality match the application type or the fuel quality is too poor.
Check the
Check if the vehicle resistance is too great. For example, large goods
Step 4 ….. vehicle …..
will cause a great air resistance.
resistance
Check of
Step 5 ….. odometer and ….. Whether the odometer and fuel gauge are normal.
fuel gauge
36
(1) Insufficient intake:

① The air filter is dirty and blocked; the
intake hose is leaky, blocked or sucked flat
when the vehicle is running at high speed;
② The turbocharger is not properly
matched. Check whether the turbine end and
compressor end incur oil shortage or oil
leakage, and whether the blade is deformed
or damaged;
The checking order ③ The intercooler is damaged with large
is respectively: air resistance. Focus on checking whether there
filter →intake is damage or blockage, and whether the
hose→turbocharger intake and exhaust hose connections are
→ intercooler dislodged, etc.;
→combustion ④ The intercooler involves poor cooling,
chamber→exhaust which will cause an extremely high intake
Check the air pipeline temperature and reduce the charge
Step 6 ….. ….. …..
lines Exhaust butterfly efficiency. It is necessary to check and
valve→muffler. The remove the sludges on the radiator fin and
fault inside the internal pipes to improve the
troubleshooting radiation effect.
related to air (2) High exhaust back pressure:
passage includes the If the back pressure of the exhaust system is
following two too high due to blockage of the exhaust pipe,
situations: the exhaust gas remaining in the cylinder will
increase, thus reducing the combustion rate
of the mixture, effective pressure of the
cylinder and combustion efficiency. Focus on
checking if the exhaust pipe is blocked, if
serious carbon deposit occurs in the front
and rear exhaust pipes, if the exhaust brake
butterfly valve rotates flexibly, if the exhaust
pipe and joint are properly sealed and if the
SCR tank is blocked.
(1) In the case of improper filling of the fuel

tank, the fuel inlet and return pipes should
have their joints tightened and should not be
Check sequence:
excessively slim or long to ensure the
Fuel tank→primary
smoothness of return pipe without leakage.
Check the fuel filter→gear
(2) There should be no inferior diesel fuel
Step 7 ….. low-pressure ….. pump→Secondary …..
residues and impurity deposits, etc.in the oil
circuit fuel
pan because too much impurities will block
filter→high-pressure
the suction strainer.
fuel pump
(3) Inlet and return pipeline problem,
insufficient fuel supply from fuel feed pump,
fuel metering unit damage.
37
(1) The high-pressure fuel pump is worn. As a

component maintaining the fuel supply
pressure and a core component of the
engine, the high pressure fuel pump, if
damaged, will directly cause the diesel engine
fault. Poor diesel fuel quality, filter damage
and fuel feed pump damage will result in
wear of the high-pressure fuel pump plunger
and control valve, reducing the fuel supply
pressure.
High pressure fuel
Check of (2) The common rail pipe plays the role of
pump → Common
Step 8 ….. high-pressure ….. ….. fuel storage and pressure accumulation in the
rail pipe → Fuel
fuel circuit common rail system, with the rail pressure
injector
sensor as its key part. Distortion of the rail
pressure sensor signal will reduce the fuel
pressure in the pipe and directly decrease the
fuel injection volume.
(3) The needle valve controls the fuel
injection quantity by opening and closing the
solenoid valve. The main types of damage
include: serious carbon deposit of nozzle,
needle valve seizure and solenoid valve
damage.
The ECU data are not matched because of market data

Step 9 ….. Check of ECU data …..
modification.
1) The cylinder gasket is leaky;

Check the sealing
Step 2) The valve and valve seat are improperly sealed;
….. and valve …..
10 3) The valve clearance is improper, resulting in an insufficient
clearance
intake.
Step Check the fault

….. ….. The engine cylinder is faulty inside, and friction loss increases.
11 inside the cylinder
Check of
Step Check if the transmission mechanism is not matched with the
….. transmission …..
12 engine or the transmission mechanism is faulty.
mechanism
3.3.4 High oil consumption

Check the oil Check the oil consumption rate and calculate the ratio of the
Step 1 ….. …..
consumption rate amount of oil added to the mileage.
38
Check the
Check the engine for external oil leakage. Tighten the screw, pipe
Step 2 ….. external oil …..
plug and joint. Replace the gasket if necessary.
leakage
Check the
crankcase Check the crankcase ventilation system for leakage and clean the
Step 3 ….. …..
ventilation crankcase ventilation device.
system
Check the air

Step 4 ….. compressor ….. Check whether there is oil in the air compressor pipeline.
pipeline
Check the oil

Step 5 ….. ….. Check the mark of oil dipstick.
dipstick
Check the oil

Step 6 ….. replacement ….. Verify if the oil change interval is correct.
interval
Check for
compliance with Verify if the oil meets the technical specifications under working
Step 7 ….. …..
technical conditions. If not, change the oil and replace the filter.
specifications
Check the
Check the sealing elements and oil seals of the turbocharger
Step 8 ….. turbocharger for …..
compressor and turbine for leaks.
leakage
Check the oil

Step 9 ….. cooler for ….. Check the oil cooler for leakage. Check if there is oil in the coolant.
leakage
Check the oil The oil is contaminated by coolant and fuel; Perform an oil
Step 10 ….. …..
contamination analysis to identify contaminants in the oil.
In case of excessive blow-by, check if the piston ring is installed

Step 11 ….. Check blow-by …..
properly.
Check the
Check the piston, cylinder liner and piston ring for wear and
Step 12 ….. condition inside …..
damage.
the cylinder
39
3.3.5 Low NOx conversion efficiency

Determination of
fault location Determine the fault point in accordance with DTC and focus on the
Step 1 ….. …..
according to the fault related to NOx conversion efficiency.
DTC
Check of NOx
Check the NOx sensor and exhaust pipe. If the measurement signal
Step 2 ….. sensor and …..
of NOx sensor is large, a conversion efficiency fault will occur.
exhaust pipe
Check of urea Check the DEF injection volume. If the DEF injection volume is
Step 3 ….. solution injection ….. small, the measurement signal of NOx sensor will be large, and a
volume conversion efficiency fault will occur.
Check the nozzle. If the nozzle involve fault such as mechanical

sticking or partially sticking which cannot be detected by the
Step 4 ….. Check of nozzle ….. system, the urea solution injection volume will be small, the
measurement signal of NOx sensor will be large, and a conversion
efficiency fault will occur.
Check the DEF pressure. If the DEF pipeline is leaky, the control of
Check of urea DEF pressure will reduce, and the actual DEF injection volume will
Step 5 ….. …..
solution pressure be small, the measurement signal of NOx sensor will be large, and
a conversion efficiency fault will occur.
Check urea solution. If the quality of urea solution is not

Check of urea acceptable (low concentration, excessive impurity, etc.), the
Step 6 ….. …..
solution measurement signal of NOx sensor will be large, which will lead to
conversion efficiency related fault.
Check of urea
Check if the urea solution is crystallized. If crystallization happens
Step 7 ….. solution for …..
inside the SCR tank, the RPM efficiency of the tank will decrease.
crystallization
Check whether Take fuel samples. If the fuel contains rich sulfur, it will lead to
Step 8 ….. the fuel is ….. post-treatment poisoning, and the conversion efficiency will
compliant decline.
40
Check the engine and SCR tank. If the engine or SCR tank has aged
Check of engine seriously, the original emission of NOx and the measurement
Step 9 ….. …..
and SCR tank signal of NOx sensor will be large, and a conversion efficiency fault
will occur.
Check the factors related to the environment. If the ambient

Check of factors temperature and pressure sensor is damaged, and the vehicle is
Step 10 ….. related to the ….. running in an environment of high temperature, high pressure and
environment high attitude, a conversion efficiency fault will be reported. This is
especially true in regions of high attitudes.
Check of rating Check the rating data. If specific conditions for engine running are
Step 11 ….. …..
data unreasonable, a fault may be reported incorrectly.
3.3.6 The starter does not work

Check the The battery has a low power; in this case, check, charge or replace
Step 1 ….. …..
battery the battery.
Step 2 ….. Check the fuse ….. The fuse is blown out, replace the fuse.
Check the The connecting wire has poor contact; in this case, arrange the
Step 3 ….. …..
connecting line wire, and tighten the terminal.
Check the starter The starter motor is short-circuited, in this case, check and repair
Step 4 ….. …..
motor the motor, or replace the assembly.
Check of the The brush has poor contact; in this case, clean the brush surface,
Step 5 ….. …..
electric brush and replace the assembly if necessary.
Check the
Step 6 ….. ….. Wear of the bearing bushing, replace the assembly.
bearing bushing
Check the The commutator is dirty or singed, remove oil stains or finish with
Step 7 ….. …..
commutator sandpaper, or replace the assembly if necessary.
41
Check the Welding failure occurs at the end of wire; in this case, reweld the
Step 8 ….. …..
connecting wire wire.
The switch has poor contact; in this case, check and repair the
Step 9 ….. Check the switch …..
switch.
Clutch wear and slip occur. Adjust the torque of clutch, or replace
Step 10 ….. Check the clutch …..
the clutch assembly.
3.3.7 Inoperative alternator

Check the Check the alternator and ammeter wiring for open circuit, short
Step 1 ….. …..
connecting wire circuit, and loose joints.
The alternator belt is loosened; in this case, check and adjust the
Step 2 ….. Check the belt …..
belt tension.
Check the rotor The rotor and stator coils are open, shorted or grounded; in this
Step 3 ….. …..
and stator coil case, repair or replace the assembly.
Check the
Step 4 ….. ….. Rectifier damaged, replace the assembly.
rectifier
Check of The terminal paper insulation is damaged, and the wire is

Step 5 ….. …..
terminal paper disconnected.
Check of
regulating
Step 6 ….. ….. The regulator has an excessively low or high regulating voltage.
voltage of
regulator
Check the The regulator contacts are burnt; in this case, repair or replace the
Step 7 ….. …..
regulator contact assembly.
42
Check the
Step 8 ….. ….. Damage of the alternator rectifier, poor contact of the battery.
rectifier
Check the The regulator field coil or the resistor wire is disconnected; in this
Step 9 ….. …..
regulator case, repair or replace the assembly.
Check the The battery contains insufficient electrolyte or is obsolete; in this

Step 10 ….. …..
electrolyte case, add electrolyte or replace the battery.
Check of the
Step 11 ….. ….. Poor contact of the electric brush.
electric brush
Check the
Step 12 ….. ….. The terminal is loose and has poor contact.
terminal studs
Check the
Step 13 ….. ….. Damage of the voltage regulator.
voltage regulator
Check the
Step 14 ….. voltage ….. Improper voltage adjustment.
adjustment
Check the
Step 15 ….. regulator ….. Poor regulator grounding.
grounding
Check the The regulator contact is inoperative or dirty, and the voltage coil
Step 16 ….. …..
regulator contact or resistor wire is disconnected.
3.3.8 Air compressor fault

Check the
Check the pressure relief valve assembly for seizure, and clean and
Step 1 ….. pressure relief …..
replace the failed parts.
valve
Check the valve Remove the cylinder head, check the valve plate, and replace the
Step 2 ….. …..
plate deformed or broken valve plate.
43
Step 3 Check the valve Remove the cylinder head and clean the valve seat plate.
….. …..
seat plate
3.3.9 High urea solution consumption

Communication Communicate with customers, carry out investigation and inquire
Step 1 ….. …..
with the user about the recent urea consumption.
Check of urea
Check whether the urea injection pipe, urea pump and urea tank
Step 2 ….. tank, urea pump, …..
are leaking.
and urea injector
If no leakage occurs, remove the nozzle from the after-processed

box (only remove the installation bolts, but not remove the
Urea solution
Step 3 ….. ….. electrical connectors), connect the DiagSmart, the network and
injection test
the actuator, and use the urea injection test in the DiagSmart
actuator.
Check the urea solution nozzle injection:

(1) When urea injection quantity is large, and the injection is
columnar or continuous, it will lead to high urea injection quantity.
Replace the urea nozzle.
(2) If DEF is injected intermittently in an atomization way
Urea solution
Step 4 ….. ….. accompanied by a click sound upon closure of the needle valve
nozzle injection
which indicates abnormal DEF injection, wait for the DiagSmart to
display the end of the test. If urea solution continuously leaks from
the improperly closed nozzle after urea solution injection stops,
replace the nozzle; in case no urea solution leaks from the nozzle
after being closed, check the urea solution pipeline for leakage.
If the urea solution nozzle hole is enlarged or serious

Check the urea crystallization occurs in the SCR tank because the user uses urea
Step 5 ….. …..
quality solution of inferior quality or adds water in urea solution, the
warranty will become invalid.
44
Check the intake

air filter and Check whether the air filter is blocked; check whether the MAF
MAF pipeline pipe of air intake is deformed or suffocated; check whether there
Step 6 ….. (for EGR route ….. is any foreign matter in the MAF sensor current stabilizing pipe,
model equipped which may cause measurement problems; whether the MAF
with MAF sensor is seriously contaminated by greasy dirt and dust.
sensor)
3.3.10 Low/No urea solution consumption

Communication Communicate with customers, carry out investigation and inquire
Step 1 ….. …..
with the user about the recent urea consumption.
Communicate with the customer to see if a small amount of urea

Urea filling
Step 2 ….. ….. is added frequently (less than 5L). If so, advise the customer to add
amount
10L or more of urea.
Urea injection test in DiagSmart is used to check the working

condition of urea injection system.
(1) If the urea sprayed of the urea nozzle is in a normal spraying
state, accompanied by the clicking sound of needle valve closing,
Urea solution the urea nozzle is normal.
Step 3 ….. …..
injection test (2) If the urea injection is abnormal, check whether the urea nozzle
is blocked by crystallization, whether the nozzle needle valve is
stuck, and whether the urea pipeline is bent. If the crystallization
causes the sticking, remove the crystallization. If the nozzle is
stuck, replace the urea nozzle.
Remove the liquid level sensor of the urea tank and check whether
Check the urea
Step 4 ….. ….. the liquid level float of the urea tank is stuck. If the float is stuck,
tank
find out the cause.
45
3.3.11 Urea solution pressure build-up failure

Determine where the fault locates according to the DTC, and pay
Determination of
special attention to the function faults and component (e.g.,
fault location
Step 1 ….. ….. nozzle, reversing valve, urea solution pump, heating relay, heating
according to the
resistance wire, exhaust temperature sensor, urea solution tank
DTC
temperature sensor, etc.) faults related to pressure build-up.
In a cold region, check urea solution heating components at first

Check of urea according to the DTC to ensure a normal urea solution heating
Step 2 ….. solution heating ….. function. If the faults related to urea solution heating exist at the
components same time, do troubleshooting by referring to the section of Faults
of Urea Heating not Passed for investigation one by one.
Based on relevant fault information obtained in Step 1, if there are

only component faults instead of function faults related to
pressure build-up, check the nozzle, reversing valve, urea solution
Check of related
pump, heating relay, heating resistance wire, exhaust temperature
Step 3 ….. component …..
sensor, urea solution tank temperature sensor, etc. and their
faults
harnesses; component faults may be a possible reason why the
system did not try to build up pressure, and the upstream exhaust
temperature required for pressurization is 180°C.
Cut off power and restart. If the system still does not try to build
Step 4 ….. Check of harness ….. up pressure, further check the harness as the harness between
components may be reversed.
Based on relevant fault information obtained in Step 1, if there are

Check for urea only function faults instead of component faults related to
Step 5 ….. solution leakage ….. pressure build-up, check the installation of urea solution pipes for
and clogging urea solution leakage and clogging since the system may have
made an attempt to build up pressure.
Power off and restart. If the system still fails to build up pressure,
Step 6 ….. Check of harness ….. make further check if the harness between components is
connected reversely.
Check of level in Lack of urea solution in the urea solution tank may also result in
Step 7 ….. the urea solution ….. pressure build-up failure. For relevant signals, refer to the urea
tank solution level.
46
Check of rating
Step 8 ….. ….. Check the rating data.
data
3.3.12 Unavailable DEF heating

Reading of DTC
with DiagSmart Read the DTC with DiagSmart to determine where the fault exists,
Step 1 ….. for ….. and pay special attention to the faults related to urea solution
determination of heating and ambient temperature sensor.
fault location
Check of
ambient Check the ambient temperature sensor and its harness based on
Step 2 ….. temperature ….. the result obtained in Step 1 to verify that the sensor works
sensor and its normally.
harness
Check of DEF
heater relay,
Check the urea solution heating relay, solenoid valve and their
Step 3 ….. solenoid valve …..
harnesses based on the result obtained in Step 1.
and their
harnesses
Check the urea

heating Check the urea solution heating resistor and its harness, and urea
Step 4 ….. …..
resistance solution tank heating coolant pipeline.
and wire harness
Check of urea If a urea solution pump heater fault is reported, and this fault still
Step 5 ….. solution pump ….. exists after power-off and restart, replace the urea solution pump
heating if necessary.
Check of rating
Step 6 ….. ….. Check the rating data.
data
47
3.3.13 DEF crystallization

Check of Check the exhaust pipe and after-treatment tank for
Step 1 ….. …..
crystallization crystallization.
Check of Check the exhaust pipe clamp for looseness, breakage and air
Step 2 ….. …..
connection leakage.
Check of the
Step 3 ….. ….. Check the nozzle base for untight sealing and air leakage.
sealing
Check the upstream NOx sensor. If the measured signal of the NOx
Check of NOx
Step 4 ….. ….. sensor is too large and the urea injection is too much, there will be
sensor
crystallization.
Check whether the urea nozzle is corroded, whether the nozzle

Check of the hole is enlarged, or whether the nozzle is faulty (e.g., the nozzle is
Step 5 ….. …..
urea nozzle stuck in the open position), which will lead to urea over-spray
crystallization.
Check of urea Check if the urea solution used by the user is up to standard with a
Step 6 ….. …..
solution standard concentration of 32.5%.
48
Chapter IV Introduction to Engine Systems
4.1 Cooling system

4.1.1 Cooling system
The cooling system mainly functions to keep the engine in a proper temperature range under all working
conditions. The function of cooling system is to prevent the engine from overheating and overcooling. After the
engine is started in cold state, the cooling system shall ensure that the engine can be warmed up quickly, so as
to reach the normal working temperature as soon as possible. The engine cooling system is a forced circulation
water cooling system, namely, the coolant pump will be used to increase the coolant pressure and then force it
to flow circularly in the engine. The circulation path of the coolant in the forced circulation water cooling system
is as shown in the figure below:
Gas Cool water Hot water
Expansion tank
Heater
Air
compressor
Fan
Thermostat
Cylinder
head
Reservoir tank
Intercooler
Urea tank
Cylinder
block
Water
pump
Oil cooler
Vehicle travelling direction
Fig. 4--1 Schematic diagram of cooling system of diesel engine
4.2 Lubrication system

4.2.1 Overview
The lubrication system is essential for reliable operation of the engine, and it is also a key point in regular
maintenance of the engine.
49
The lubrication system is aimed at wear relief, washing, cooling and rust protection. Oil should be used as per
specifications provided by the company.
It is not allowed to use lubricating oils of grades CE, CD, CC, CB, or CA for the diesel engine. Remember to replace
the oil filter element while changing lubricating oil.
The oil pump sucks the oil from the oil pan through the strainer, and pumps it to the oil filtering and cooling
module through the dirty oil duct on the engine body. The oil reaches the main oil duct after filtration and
cooling. While the oil entering the main bearing from the main oil duct lubricates the main bearing, part of it
reaches the big end bearing of connecting rod through the oil duct on the crankshaft for lubrication, and the
remaining enters the camshaft bearing through the oil groove on the back of the main bearing bush for
lubrication; The turbocharger takes oil from the main oil duct through the transverse oil duct to lubricate and
cool the floating bearing; The piston cooling nozzle takes oil from the main oil duct, cools the piston and
lubricates the small end bush of connecting rod; The vertical oil ducts of the engine body and cylinder head
introduce the oil into the rocker arm shaft from the front end bearing of the camshaft to lubricate the rocker
arm shaft, rocker arm, valve head and guide rod, push rod and tappet; The branch oil duct on the engine body
leads the oil in the main oil duct to the intermediate gear shaft for lubrication; The air compressor and the
high-pressure oil pump take oil from the main oil duct for lubrication through an external oil pipe; The oil in the
main oil duct lubricates the drive gear and bearings of oil pump through branch circuits.
The oil pressure of the lubrication system is adjusted through the safety valve on the oil pump and the relief
valve of the main oil duct. In addition, the oil cooling and filtering module is equipped with the engine cooling
bypass valve and the oil filter bypass valve.
The following is the schematic diagram of diesel engine oil circuit:
Main oil passage (3-5) bar
Main bearing bush
Cooler Oil cooler Piston cooling nozzle Oil pump drive gear shaft bushing
bypass valve
Camshaft bushing Crankshaft
Engine, cylinder Filter bypass Oil filter Piston

head valve
High pressure fuel pump Intermediate idler shaft Air compressor

Turbocharger
Rocker arm
bracket
Big head bush of connecting
rod
Main oil passage Safety valve Oil pump Connecting rod small end bush Oil pump drive gear
Rocker arm
pressure limiting
shaft
valve
Rocker arm bush
Suction strainer
Two ends of push rod
Gear train
Tappet
Oil pan
Fig. 4-2 Schematic diagram of diesel engine oil circuit
50
4.3 Fuel system

4.3.1 Schematic diagram
high-pressure fuel
Rail pressure
pump sensor
Fuel rail
Fuel injector Fuel injector Fuel injector Fuel injector

filter
High pressure
Low pressure
Sensor
Fig. 4-3 Schematic diagram of fuel system

During the normal operation of the diesel engine, the fuel injection pump camshaft drives the integrated fuel
delivery pump to draw fuel from the fuel tank. After being filtered by the filter, the fuel flows to the transfer
pump. After flowing out of the transfer pump, it passes through the metering unit of the fuel injection pump,
and part of it is sent to the plunger cavity and the remaining flows back to the transfer pump. When the plunger
is moving up, the fuel in plunger chamber is compressed and pumped into the common rail pipe, and then flows
into the fuel injector through the high-pressure fuel pipe. The ECU controls the solenoid valve on the injector to
energize, and the fuel is injected into the combustion chamber above of the engine piston through the injection
nozzle.
51
Chapter V Disassembling and Assembling
5.1 Intake pipe assembly

5.1.1 Exploded view
Fig. 5--1 Exploded view of intake pipe assembly

Inlet pressure
1 2 Hexagon flange bolt 3 Intake pipe gasket 4 Intake pipe
sensor component
5 Nut 6 Intake pipe joint 7 Double-end stud 8 Gasket
9 Heater 10 Hexagon flange bolt
5.1.2 Tools and preparations

1. Disassembling tools
General tools for maintenance.
2. Preparations before disassembly
Remove the intercooler connecting hose in advance.
52
5.1.3 Disassembling steps

1. Unscrew the bolts of intake pipe in turn, and remove the intake pipe and gasket;
2. Loosen the fastening nut of the intake connecting pipe, and remove the intake connecting pipe, intake heater
and intake connecting pipe gasket.
5.1.4 Check and maintenance essentials
1. Check the intake pipe for debris or dust. If any, remove it.
2 Check the intake pipe gasket for deformation, tearing, missing, etc. If any, replace it.
3 Check the intake heater for burnout, short circuit, etc. If any, replace it.
4. Connect the intake pipe and the intercooler pipeline properly to avoid leakage.
5.1.5 Assembling steps
1. Fix the intake pipe on the cylinder head with a gasket with the hexagon flange bolt, and tighten it with a
wrench.
2. Fix the pressure and temperature sensor on the intake pipe with the hexagon flange bolt, and tighten it with a
wrench.
3.Insert the support block into the boss above the intake pipe.
5.2 Fan & hub assembly

5.2.1 Exploded view
Fig. 5-2 Exploded view of fan and hub assembly
53

1 Fan 2 Hexagon nut 3 Plain washer 4 Fan clutch
5 Fan flange 6 Double-end stud

1. Assembling and disassembling tools: socket or wrench;
2. Preparations before disassembly: disconnect the fan clutch wire harness from the vehicle.
1. Remove the fan fastening bolt, and remove the fan.
2. Remove the fastening nut of fan clutch, and remove the fan clutch and fan cushion block.
1. Check the fan for cracks and other damage, and if any, replace it.
2. Check the fan cushion block for cracks and other damage, and if any, replace it.
3. Check the fan clutch for cracks and other damage, and if any, replace it.
1. Install the fan clutch and fan cushion block, and tighten the fastening nut of fan clutch
2. Install the fan and tighten the fastening bolt of fan.
54
5.3 Low-pressure fuel pipe assembly

5.3.1 Exploded view
Fig. 5-3 Exploded view of low-pressure fuel pipe

Fuel return pipe Pipe clamp Fuel inlet pipe
1 2 3 Pipe joint 4
assembly assembly assembly

1. Tools: Open-end wrench;
2. Pre-disassembly preparation: remove the acoustic shield.
1. Disassemble the fixing clamp and fixing bolt of fuel return pipe assembly.
55
2. Disassemble the fuel return pipe assembly.
Fig. 5-4 Disassembly of fuel return pipe assembly
3. Remove the fixing bolts of the fuel inlet pipe

assembly.
4. Disassemble the fuel inlet pipe assembly.
Fig. 5-5 Disassembly of fuel inlet pipe assembly

Check if all gaskets are in good surface condition; if not, replace them with new ones.

Install the fixing clamp and fixing bolt of the fuel return pipe assembly.
56
5.4 High-pressure fuel pipe assembly

5.4.1 Exploded view
Fig. 5-6 Exploded view of the high-pressure fuel pipe assembly

Cross recessed pan Pipe clamp High-pressure fuel
1 2 3
head screw assembly pipe assembly

Open-end wrench
2. Preparations:
Remove the acoustic shield.

1. Screw off the hexagon flange bolt, remove the pipe clamp, and then remove the high-pressure fuel pipe
between the pump and the fuel rail.
2. Remove the high-pressure fuel pipe between the fuel rail and the fuel injector.
57

Check whether the joint of the high-pressure fuel pipe is in good condition. If there is any damage, please
replace it with a new one.
1. Install the fuel pipe between the fuel rail and fuel injector.
2. Install the pump and high-pressure fuel pipe, the pipe clamp and tighten the nut.
Note: Tightening torque of high-pressure fuel pipe nuts: (30~40) N·m for fuel injector end, (30~40) N·m for
high-pressure fuel rail end and high-pressure fuel pump end.
5.5 Common rail assembly

5.5.1 Exploded view
Fig. 5-7 Exploded view of common rail pipe assembly

Common rail tube
1 Hexagon flange bolt 2 Hexagon flange bolt 3 4 Common rail
support

1. Tools:
Socket wrench.
Remove the acoustic shield and high-pressure oil pipe assembly.
58
1. Remove the hexagon flange bolt.

2. Remove the common rail.
Fig. 5-8 Removal of the common rail

1. Check if the joint between the common rail pipe and the high-pressure fuel pipe is in good condition; if not,
2. Check if the pins of rail pressure sensor are intact.
1. Install the bracket of common rail pipe.
2. Install the common rail pipe.
5.6 Electronic control unit (ECU) assembly

2. Socket wrench;
3. Preparations:
4. Remove the surrounding related components according to the arrangement of the ECU.

1. Check the ECU surface for oil stains and bumps.
2. Check the pin in the ECU connector for damage.
59
5.7 Air compressor assembly

5.7.1 Exploded view
Fig. 5-9 Exploded view of air compressor assembly

Air compressor
1 2 Rubber O-ring 3 Air compressor gear 4 Hex flange nut
assembly
Air compressor
5 Hexagon flange bolt 6 Hexagon flange bolt 7 8 Hexagon flange bolt
bracket
Combination Air compressor
9 Hollow bolt 10 11 12 Hose clamp
sealing washer lubricating oil pipe
Air compressor Combination sealing
13 14 Hexagon flange bolt 15 Hollow bolt 16
water inlet pipe washer
Air compressor
17
water outlet pipe

1. Disassembling tools: socket wrench or pneumatic wrench, open-end wrench, etc.
2. Preparations: Remove the air compressor lubricating oil pipe.
60
1. Remove the air compressor water inlet and outlet

pipes.
Fig. 5-10 Removal of the water inlet and outlet pipes
2. Remove the connecting bolt of the air compressor

bracket.
3. Remove the bolt connecting the air compressor and
the engine block.
4. Take out the air compressor from the engine block
horizontally.
Fig. 5-11 Removal of the air compressor

No.
1. Check and clean the mating surface of the air compressor and the engine block.
2. Install the air compressor.
3. Tighten the bolt connecting the air compressor and the engine block.
4. Tighten the air compressor support bolts.
5. Refit the air compressor water inlet and outlet pipes.
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5.8 Fuel injection pump assembly

5.8.1 Exploded view
Fig. 5-12 Exploded view of fuel injection pump assembly

Fuel injection pump Fuel injection pump
1 2 O-ring 3 4 Hexagon flange bolt
gear flange
Fuel injection pump
5
assembly

Socket wrench.
Remove the connected low-pressure and high-pressure fuel pipes.
62
1. Remove the hexagon flange stud between the fuel

injection pump flange, timing gear chamber cover and
timing gear chamber.
Fig. 5--13 Disassembly of fuel injection pump flange

fixing bolts
2. Remove the fuel injection pump and gear assembly

from the engine.
Fig. 5-14 Disassembly of the fuel injection pump &

gear assembly
3. Remove the fuel injection pump lock nut.

4. Remove the hexagon flange bolt between the fuel
injection pump and its flange.
5. Remove the fuel injection pump flange.
Fig. 5--15 Disassembly of the fuel injection pump

and its gear

1. Check the fuel injection pump flange for fuel leakage.
2. Check if the rubber O-ring and fuel injection pump metering unit are intact. If not, replace them with new
ones.
3. Check the fuel injection pump for cracks and other problems; if any, replace it with a new one.
63
1. Refit the fuel injection pump flange, and apply a small

amount of lubricating oil to the rubber O-ring on the fuel
injection pump.
Fig. 5-16 Refitting of the rubber O-ring of the

fuel injection pump flange
2. Refit the hexagon flange bolt between the fuel injection

pump and its flange.
Fig. 5--17 Refitting of fixing bolts of the fuel

injection pump
3. Install the fuel injection pump gear, and tighten its lock nut
M14×1.5 to 90~95 N·m by one time.
Fig. 5--18 Refitting of the fuel injection pump

gear
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4. Tighten the fuel injection pump flange to the gear chamber

with 5 bolts.
Fig. 5-19 Assembling of the fuel injection pump

to the engine block
5.9 Pressure limiting valve assembly

1. Tools: socket or wrench.
2. Pre-disassembly preparation: The engine has been drained of oil.
5.9.2 Exploded view
Fig. 5-20 Exploded view of main oil passage pressure limiting valve assembly
65

Main oil passage Hexagon socket
1 Gasket 2 pressure-limiting 3 Spring washer 4 head cap screw
valve M8×40

1. Remove the fastening screw of relief valve.
2. Remove the relief valve and gasket.
1. Check the relief valve housing and large nut for oil leakage, and the mounting surface for scratches and other
defects.
2. Check the body mounting surface for scratches and other defects.
1. Check the relief valve and the sealing surface of the engine body to ensure that the sealing surface is intact
without scratches and dents.
2. Replace with a new gasket, assemble the relief valve on the engine body with a gasket, and tighten the
screws.
5.10 Fuel filter assembly

5.10.1 Exploded view
Fig. 5--21 Exploded view of fuel filter assembly
66

Hexagon flange bolt
1 Fuel filter bracket 2 Fuel filter assembly 3
M10*30

2. Pre-disassembly preparation: Remove the fuel inlet and outlet pipes on the fuel filter.
1. Remove the fastening bolt of fuel filter assembly.
2. Remove the fuel filter assembly.
3. Remove the fastening bolt of fuel filter bracket.
4. Remove the fuel filter bracket.
1. Visually check the fuel filter, and check the junction of the fuel filter element and the filter seat for oil leakage.
2. Check the seal ring of fuel filter element for defects and bumps.
3. The sealing ring between the filter element and the filter seat is disposable.
4. After replacing the filter element, bleed the entire pipeline.
1. Install the fuel filter bracket.
2. Install the fastening bolts of fuel filter bracket.
3. Install the fuel filter assembly.
4. Install the fastening bolts of fuel filter assembly.
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5.11 Oil filter assembly

Fig. 5-22 Exploded view of oil filter assembly

Hexagon flange bolt Hexagon flange bolt
1 Oil filter 2 3
M6×50 M6×45

2. Pre-disassembly preparation: Remove the lubricating oil pipe of the oil filter.
1. Remove the fastening bolts of the oil filter assembly.
2. Remove the oil filter assembly.
1. Check the oil filter seat for cracks and the process plug for oil leakage.
2. Check the O-ring groove of the oil filter seat for defects and bumps
3. Check the body mounting surface for defects and bumps.
68

1. Wipe the oil filter and the corresponding mounting surface of engine body with a towel.
2. Check whether the O-ring is correctly clamped into the O-ring groove of the oil filter seat, install the oil filter
seat on the engine body, and tighten the bolt.
5.12 Oil cooler assembly

Fig. 5-23 Exploded view of oil cooler assembly

Oil filter lubricating Hexagon flange bolt
1 Gasket 2 3 4 Gasket
oil pipe. M8×25
Hexagon flange nut Hexagon flange bolt Hexagon flange bolt Combination
5 6 7 8
M8 M8×35 M8×25 sealing washer
Oil cooler cap
9 Oil cooler assembly 10
gasket
69

2. Pre-disassembly preparation: Drain the coolant inside the engine, and remove the high-pressure oil pump and
high-pressure oil pipe.
1. Remove the fastening bolts and nuts of the oil filter

lubricating pipe, and remove the oil filter lubricating oil pipe.
Fig. 5-24 Removal of lubricating oil pipe of oil

filter
2. Remove the fastening bolts of the oil cooler assembly, and

remove the oil cooler assembly and its gasket.
Fig. 5-25 Removal of oil cooler assembly

1. Check the oil cooler assembly for cracks, and the mounting surface of oil cooler cover for scratches and
bumps.
2. Check the lubricating oil pipe of the oil filter for cracks and the connector for oil leakage.
3. Check whether there is oil (oil-water mixture) between the cooler fins.
1. Check the joint surface between the engine body and the oil cooler cover for burrs, and handle and clean it;
Replace the oil cooler gasket and check whether the gasket is defective.
2. Install the oil cooler assembly on the engine body with the oil cooler gasket, and tighten 22 bolts in sequence.
Note that 3 bolts shall be assembled with combined sealing washers (see the disassembly drawing for details).
3. Check the flanges at both ends of the lubricating oil pipe of the oil filter and the corresponding mounting
surface to ensure no defects and burrs; Replace the gasket and check whether the gasket is defective.
70
4. Install the lubricating oil pipe of the oil filter on the oil cooler cover and oil filter seat with gaskets; Loosen the
upper bolt and lower nut, and tighten the lower flange of the oil pipe with a force less than 5N·m; Tighten the
upper bolt with a force of 25 N·m; Tighten the lower nut with a force of 25 N·m.
5.13 Turbocharger
Fig. 5--26 Exploded view of the turbocharger assembly

Oil return pipe
1 Hexagon flange bolt 2 Gasket 3 4 Turbocharger
assembly
Heat resistant stud Turbocharger Combination sealing
5 6 7 Lock nut 8
bolt gasket washer
Oil inlet pipe Oil return pipe
9 Hollow bolt 10 11 12 Hexagon flange bolt
assembly gasket

1. Assembling and disassembling tools
General tools required for maintenance.
2. Preparations
Remove the air filter and hose, intercooler pipe and exhaust tailpipe connected to the vehicle.
71

1. Unscrew the bolts of the turbocharger oil return pipe,
and then take off the turbocharger oil return pipe and
gasket in turn.
2. Loosen the hollow bolt of the turbocharger oil-inlet
pipe, and then take off the hollow bolt, combination
sealing washer and turbocharger oil-inlet pipe in turn.
3. Remove the fixing bolts of the turbocharger.
4. Take off the turbocharger and gasket in turn.
Fig. 5-27 Disassembly of the turbocharger assembly

1. Check the connection parts of the turbocharger and the engine pipe for looseness, if any, eliminate in time.
2. Check the turbocharger for air/oil leakage, if any, solve in time.
3. Check the turbocharger fastening bolts for looseness, if any, eliminate in time.
4. Check the air filter, if too much dust accumulates, clean or replace in time.
5. Check the running of turbocharger rotor.
Turn the air compressor impeller gently with hand. If the impeller rotates by more than one turns, it indicates
that it is normal. If the impeller stops soon, it indicates that the bearing has been worn abnormally, or collision
or seizure occurs between the rotating part and the stationary part. In this case, do troubleshooting timely.
6. Check the displacement of turbocharger rotor.

Press the measuring head of the dial indicator against the air
compressor end, push and pull the rotating shaft with hand
axially, measure and record the difference value, as shown in the
figure below. The rotor displacement shall be less than 0.09mm.
Otherwise, it indicates that the thrust bearing plate or thrust plate
and bearing body are worn. In this case, do troubleshooting
timely.
Note: The measurement described above shall be carried out on a
cold turbocharger. Fig. 5-28 Check of rotor displacement
72
7. Check the radial clearance of the air compressor impeller.

Press down or lift up the air compressor impeller with hand
radially, as shown in Fig. 5-29, and use a feeler gauge to measure
the minimum and maximum clearances between the air
compressor impeller and the air compressor casing, which shall be
within 0.183~0.57 mm; if any of the two clearances is out of this
range, check the bearing and do troubleshooting.
Note: The measurement described above shall be carried out on a Fig. 5-29 Check of the radial clearance of
cold turbocharger. the air compressor impeller
8. In case of failure to clear any faults or satisfy the disassembling

and assembling conditions upon the removal or refitting of the
turbocharger, ask the production or maintenance department for
treatment.
Note: The bolts and nuts for connecting the turbocharger and the exhaust pipe are made of special
heat-resistant steel, and shall not be replaced with general bolts and nuts.
Note: All gaskets are disposable and shall be replaced with new ones in case of repair.
Note: Do not apply sealant to the oil-outlet pipe gasket.
Note: Do not adjust the pressure of the turbocharger vent valve at will.
Note: If the turbocharger has not been in use for a long time (more than 7 days), remove it, and fill it with oil via
the turbocharger oil inlet before use.

1. Pre-apply the molybdenum disulfide to the stud bolt of the turbocharger, screw the end with short thread into
the exhaust pipe flange, and refit the turbocharger gasket.
2. Refit the turbocharger, and tighten the fixing nuts to (35±3) N.m.
3. Install the turbocharger oil return pipe gasket and oil return pipe in turn, apply molybdenum disulfide + clean
lubricating oil to the fixing bolt and then tighten it. The sealing gaskets at both ends of the oil return pipe shall
not fall out.
4. Add a proper amount of clean lubricating oil on the turbocharger oil inlet, wipe off the excessive lubricating
oil, and manually rotate the turbine shaft to lubricate the suspension bearing and thrust bearing.
5. Refit the combination sealing washer, turbocharger oil-inlet pipe and hollow bolt.
6. Refit the exhaust tailpipe gasket and the exhaust tailpipe to the torque of (65±3) N.m.
7. Refit the exhaust tailpipe bracket.
8. Refit the air filter and hose, intercooler pipe and exhaust tailpipe connected to the vehicle.
73
5.14 Exhaust pipe assembly

Fig. 5-30 Exploded view of exhaust pipe assembly

Exhaust pipe heat
1 Hexagon flange bolt 2 3 Socket 4 Exhaust pipe
shield
5 Exhaust pipe bolt 6 Exhaust pipe gasket

1. Tools: Air wrench and socket.
General tools required for maintenance
Remove the exhaust pipe.

1. Loosen the bolts of exhaust pipe heat shield in turn and remove the exhaust pipe heat shield.
2. Unscrew the exhaust pipe bolts in turn, and then remove the bolt, the sleeve, the exhaust pipe and its gasket.
5.14.4 Check and maintenance

1. Check whether there is any debris in the exhaust system.
74
2. Check the exhaust pipe body for crack or other damage, and check if the flange is deformed; replace the
exhaust pipe with a new one when necessary.
3. Check the exhaust pipe flange for leakage; replace the exhaust pipe gasket with a new one.
4. Check the exhaust pipe gasket for deformation, tear, missing, etc., replace when necessary.
5. Bolts and nuts used for the exhaust system are made of heat-resistant steel. It is not allowed to replace them
with common bolts and nuts.
6. Before tightening the bolts or nuts, apply the anti-sintering

agent onto them. Tighten the bolts of the exhaust pipe
according to the following requirements: The tightening
sequence is shown in Fig. 5-31 Tightening sequence of exhaust
pipe bolts, and the bolts 1 and 4 are for positioning. Tighten
the bolts by three times in sequence. Firstly, tighten the bolts
to 25 N·m; secondly, tighten the bolts to 50 N·m; thirdly, Fig. 5-31 Tightening sequence of exhaust pipe
tighten the bolts to (65~80) N·m. The exhaust pipe bolts can be bolts
reused twice at most.

1. Check the exhaust pipe:
1. The mating surface between the exhaust pipe and cylinder head shall be free of burr, oil stain, bump, etc.
2. Inner cavity of exhaust pipe shall be free of burr, flash, iron filings, etc.
2. After separating the exhaust pipe with gaskets, tighten it with exhaust pipe bolts.
75
5.15 Tensioner & belt assembly

Fig. 5-32 Exploded view of tensioner and belt assembly

Automatic
1 V- belt 2 Poly V-belt 3 Idler 4
tensioner
Hexagon socket
5
head cap screw

1. Tools: Socket wrench or pneumatic wrench, open-end wrench.
2. Preparations: Remove the fan & hub assembly.

1. Remove the outer belt.
2. Remove the outer automatic tensioner.
3. Disassemble the outer idler.
4. Remove the inner belt.
76

1. Check the belt for cracking, eccentric wear and other failures, and replace when necessary.
2. Check the tensioner for abnormal noise and clamp stagnation, and replace when necessary.
3. When replacing the belt, make sure that the belt is stayed in the groove to prevent abnormalities such as belt
slippage.
1. Install the outer automatic tensioner and idler.
2. Install the inner belt.
3. Install the outer belt loosely. The belt passes around the crankshaft pulley, fan pulley, idler pulley, A/C
compressor pulley, generator pulley and automatic tensioner and is placed freely without tension. Rotate the
automatic tensioner counterclockwise with a square wrench, place the belt properly and confirm it is completely
seated in the groove before tensioning it.
5.16 Thermostat assembly

Fig. 5-33 Exploded
77

Hexagon head
1 Gasket 2 3 Combined gasket 4 Thermostat body
screw plug
Hexagon flange
Coolant Temperature
5 Clamp 6 7 bolt 8
connecting hose sensor
(M8×25)
9 Gasket 10 Screw plug 11 Thermostat cover 12 Combined gasket
13 Screw plug

1. Tools: Socket or wrench;
2. Pre-disassembly preparation: drain the coolant in the engine, and disassemble the large circulation hose
connecting the thermostat and the radiator; Remove the front drive belt, and remove the left and right AC
compressors and their brackets.

1. Remove 3 hexagon flange bolts and remove thermostat
cover, thermostat and gasket.
Fig. 5--34
2. Remove 2 hexagon flange bolts, loosen the coolant
connecting hose clamp, and remove the thermostat body
and gasket.
Fig. 5--35
78

1. Check the thermostat cover and thermostat body for cracks, and if any, replace them with new ones;
2. Check the thermostat for seizure, crack and other damage, and replace it if any;
3. Check whether the coolant connecting hose is cracked or crushed, and if so, replace it.

1. Fix the thermostat body and gasket with 2 hexagon flange bolts, and connect them to the hose with coolant
clamp
2. Install and fix the thermostat cover, thermostat and gasket with 3 hexagon flange bolts.
5.17 Water pump assembly

Fig. 5-36 Exploded view of the water pump assembly

Hexagon flange bolt Sealing gasket of
1 Water pump pulley 2 3 Water pump 4
M10×55 water pump
79

2. Pre-disassembly preparation: drain the antifreeze in the engine before disassembly; Remove the poly V-belt;
Remove the fan and hub, and loosen the small circulation water return hose clamp.
1. Prepare before removal, and remove the water pump pulley after the fan is removed.
2. Remove the 5 hexagon flange bolts.
3. Remove the water pump assembly and gasket.
1. Check the water pump impeller for marks of abnormal wear and cavitation.
2. Check the water pump pulley for cracks.
3. Check the water pump housing for cracks.
1. Check whether the mounting surface of water pump and the sealing belt on the mounting surface of engine
body are complete and whether there are scratches; Check whether the water pump rotates flexibly.
2. Install the water pump and gasket on the engine body with hexagon flange bolts.
80
5.18 Water pump inlet pipe assembly

Fig. 5-37 Exploded view of water pump inlet pipe assembly

Hexagon flange bolt
1 2 Water pump pipe 3 Gasket
M8×20

1. Tools: socket wrench.
2. Preparations before disassembly: Remove the rubber hose connecting the radiator and the water pump inlet
pipe.
81

1. Remove the 2 hexagon flange bolts.
2. Remove the water pump inlet pipe and gasket.
Fig. 5--38

Check if the parts are complete. Check whether the water inlet pipe is intact, and each joint surface shall be free
of damage.

1. Ensure that the mounting surfaces of the water pump and water inlet pipe are smooth and free of oil stains,
and replace the sealing gaskets.
2. Install the water pump inlet pipe on the water pump and tighten it with 2 hexagon flange bolts.
82
5.19 Alternator assembly

Fig. 5-39 Exploded view of alternator assembly

1 Adjusting nut 2 Alternator 3 Hexagon flange bolt 4 Hexagon flange bolt

1. Tools: General tools;
2. Preparations: Disconnect the wiring between the generator and the battery and vehicle, and remove the fan
and belt.

1. Remove the short bolt;
2. Remove the long bolt;
3. Remove the alternator.
83

Check if insulation pads and bushes are intact during the installation. The damaged ones must be replaced. The
positive terminal of alternator shall not be short-circuited to the housing. Otherwise, the alternator shall not be
installed on the vehicle in order to prevent it from causing serious accidents.
1. Position the alternator properly.
2. Refit the bolt for the long supporting leg, and tighten the nut.
3. Jack up the alternator, and refit the bolt for the short supporting leg.
4. Tighten the bolt.
5.20 A/C compressor assembly

Fig. 5.-40 Exploded view of the A/C compressor assembly

1 A/C compressor 2 Hexagon flange bolt 3 Hexagon flange bolt 4 Hexagon flange nut
A/C compressor
5 6 Hexagon flange bolt 7 Hexagon flange nut 8 Bush
bracket
A/C compressor
9 Hexagon flange bolt 10 11 Hexagon flange bolt 12 Spring washer
bracket
84

A/C compressor
13 Hexagon flange bolt 14 A/C compressor 15 Hexagon flange nut 16
bracket
17 Hexagon flange bolt

1. Disassembling tools: Socket wrench or pneumatic wrench, open-end wrench, etc.
2. Preparations before disassembly: Remove the front end accessory belt.

1. Remove the related accessories in the front end accessory drive system such as belt, tensioner, alternator,
etc. See the disassembling steps of alternator assembly and front end accessory drive system assembly for
details.
2. Remove the fixing bolt of the A/C compressor, and take off the A/C compressor.
3. Remove the fixing bolt of the A/C compressor, and take off the bracket from the engine block.

1. Check the assembling conditions of the dowel pins of the A/C compressor bracket and the A/C compressor
before assembling.
2. Check that the A/C compressor and its bracket are free of dirt and apparent manufacturing defects.

1. Check that the dowel pin of the A/C compressor bracket is knocked into the engine block.
2. Refit the A/C compressor bracket, and tighten the bolts.

3. Check that the dowel pin of the A/C compressor is knocked into the A/C compressor bracket.
4. Refit the A/C compressor, and tighten the bolts.
85
5.21 Hoisting ring assembly

Fig. 5-41 Exploded view of hoisting ring assembly

Rear hanger plate Front hanger plate
1 2 Hexagon flange bolt 3 Hexagon flange bolt 4
of engine of engine

Tools and equipment required: socket wrench or pneumatic wrench, torque wrench, open-end wrench.
5.21.3 Removal steps of the lifting ring assembly

1. Unscrew the four M8 bolts for fastening the front and rear
engine lifting rings, and remove the engine lifting rings.
Fig. 5-42 Disassembling of engine hanger plate

1. Check the engine lifting rings for crack and deformation. If any crack or severe deformation is found, the lifting
rings shall be replaced.
2. Check if the lifting rings bend or deform when lifting the engine.
3. Check if the fastening bolts of the front and rear lifting rings fail, and if so, replace with new bolts.

1. Confirm the front and rear lifting rings of engine and the corresponding hexagon flange bolts of the front and
rear lifting rings.
2. Tighten the hexagon flange bolts M8 on the front and rear engine hanger plates. The tightening torque is
37±3N·m.
86
5.22 Cylinder head cover assembly

Fig. 5-43 Exploded View of cylinder head cover assembly

Oil-gas separator Waste gas bypass
1 2 Hose clamps 3 4 Hexagon cap nut
air-outlet pipe pipe
Combination Cylinder head
5 6 Filler cap assembly 7 8 O-ring
sealing washer assembly
9 Spacer block 10 Nut 11 Double-end stud 12 Double-end stud
Breather outlet
13 Spacer block 14
pipe clamp

1. Tools:
Socket wrench or pneumatic wrench, open-end wrench, etc.
2. Preparations:
Remove the components covering the cylinder head cover.
87

1. Loosen the compression nut, sealing cover and conical washer of the cylinder head cover in turn, and take out
the cylinder head cover and sealing ring upwards.

1. Before the disassembling, check the surrounding of the sealing ring of cylinder head cover for any oil leakage.
If necessary, please carefully check the relevant parts.
2. Before the removal, check the cylinder head cover for oil leakage, crack, damage, etc., and if necessary,
3. Before the removal, it is required to check the oil filler for any oil leakage. If necessary, please carefully check
the relevant parts.
4. If oil leaks from the sealing ring of cylinder head cover, check the sealing ring for failure, the sealing surface of
cylinder head for scratch or heavy deformation after the removal of the cylinder head cover and its sealing ring.
If the sealing ring fails, replace it; if the cylinder head cover itself involves heavy deformation or scratch, replace
it.
5. If oil leakage is found at the oil filler, check the threads and sealing gasket of the oil filler for failure after the
removal of the oil filler cap, and if so, replace the oil filler cap; if the sealing surface between the cylinder head
cover and oil filler cap is so scratched as to cause oil leakage, replace the cylinder head cover.

1 Before installing the sealing ring of cylinder head cover, check the new one to ensure no manufacturing
defects or damage.
2 Clean the upper surface of the cylinder head, and properly install the sealing of cylinder head cover.
3. Clean the cylinder head cover, and properly refit it on the cylinder head.
4. Install the conical washer, sealing cap of cylinder head cover and cap nut, and tighten the cap nut.
5. Clean the corresponding sealing surfaces of the oil filler cap and the cylinder head cover, and tighten the oil
filler cap.
88
5.23 ECU wire harness & sensor assembly

Fig. 5-44 Exploded view of the ECU harness & sensor assembly

Wire harness Wire harness
1 Engine wire harness 2 3
bracket bracket

Socket wrench.
Remove the insulator.
89

1. Remove the mounting bracket of the engine wire
harness.
2. Remove the engine wire harness.
Fig. 5-45 Removal of engine wire harness

None

1. Install the fixing bracket of engine harness.
2. Install the engine harness
3. Refit the speed sensor.
4. Connect the sensor pull port to the corresponding interface of the harness.
90
5.24 Valve train assembly

Fig. 5-46 Exploded view of valve train assembly

1 Hexagon flange bolt 2 Cover plate 3 Signal disc 4 Camshaft gear
5 Hexagon flange bolt 6 Thrust plate 7 Camshaft assembly 8 Exhaust valve
Integral rocker arm Valve spring top
9 10 Valve collet 11 12 Valve spring
shaft assembly retainer
13 Cylinder head 14 Intake valve 15 Push rod 16 Engine block
17 Tappet

1. Tools:
1) Dial indicator, torque wrench, oilcan and lubricating oil, towel, camshaft guiding tool.
2. Preparations before disassembling:
91
1) The disassembling should be performed on assembling bench.

2) Disassemble the camshaft timing gear and the camshaft after disassembling the intermediate gear of the
flywheel housing.
3) Pull out the camshaft from the engine body.
4) After removing the cylinder head cover, remove the rocker arm and the rocker arm shaft.
5) Take out the push rod after the removal of the integral rocker arm shaft assembly and tappet.
6) With the cylinder head removed, remove the valves.

1. Remove the rocker arm and the rocker arm shaft. See the removal steps of the rocker arm and the rocker arm
shaft for details.
2. Remove the intake and exhaust valves. See the removal steps of the valve for details.
Remove the tappet and the push rod. See the removal steps of the tappet and the push rod for details.
4. Remove the camshaft and the camshaft timing gear. See the removal steps of the camshaft and the camshaft
timing gear for details.
1. Disassembling steps of rocker arm and rocker arm shaft

1) Turn the crankshaft, check if the rocker arm rotates
smoothly;
2) Check the valve clearance;
3) If the rocker arm can not rotate flexibly or the valve
clearance changes significantly, unscrew the hexagon head
screw, then remove the rocker arm shaft assembly slightly. Fig. 5-47 Exploded view of rocker arm and
Unscrew the fixed hexagon bolts of rocker arm seat to remove rocker arm shaft
the rocker arm seat, the intake and exhaust rocker arm
assemblies and the rocker arm spring.
2. Disassembling of the valve

1) Remove the valve bridge, use the valve spring compressor
or valve overhead clamp or other tools to press the valve
spring to remove the valve collet, the valve spring upper seat
and the valve spring.
2) Remove the valves.
Fig. 5-48 Exploded view of valve and valve

spring
92
3. Disassembling of Tappet and Push Rod

1) With the rocker arm and rocker arm shaft removed, take out
the push rods and place them in order.
2) After the removal, modification and disassembly are
completed, take out the tappet from the top of the engine
body with a tool clamp and place it in turn.
Fig. 5--49 Removal of the tappet and the push

rod
4. Disassembling of camshaft
1) Rotate the camshaft, and check if the camshaft and the
timing gear are flexible without blockage.
2) Use a dial gage to check the camshaft for axial play.
3) Check the backlash of camshaft timing gear.
4). Rotate the crankshaft on the removal & refitting work
bench for the engine to locate the camshaft timing gear at the
TDC of cylinder #1. Check the camshaft hexagon bolt for
looseness, and remove the camshaft hexagon bolt and
camshaft timing gear in turn; Fig. 5--50 Removal of the camshaft
5) Remove the hexagon head bolt of the camshaft thrust plate
to remove the thrust plate, and take the camshaft out gently to
avoid scratching the camshaft bearing shell.

1. Check and maintenance essentials of the rocker arm and the rocker arm shaft
1) Clean the rocker arm and check for cracks and other defects.
2) Check the rocker arm bore for wear and scratches and measure its diameter.
3) Check the rocker arm adjusting screw and arc surface at the other side of the rocker arm for wear.
4) Check the oil passages of rocker arm shaft and rocker arm for blockage.
5) Measure the diameters of rocker arm hole and rocker arm shaft, calculate the fit clearance.
6) Check if the rock arm gasket, the rocker arm shaft and the rocker arm seat bore are worn, and if the rocker
arm spring is deformed.
93
2. Valve
1) Check the valve stem and valve stem end face for wear.
2) Check the valve cone for wear and damage.
3) Check the valve cone and arc surface for carbon deposit and sinter.
4) Check the upper end face of valve bridge for wear and check the part that is in contact with valve for wear.
3. Tappet and push rod
1) Clean the push rod and tappet.
2) Check the oil passages of tappet and push rod for blockage.
3) Check the push rod for bending, and check the external surface for wear.
4) Check the push rod ball end and concave end for wear.
5) Check the tappet surface and bottom face for wear.
6) Check the internal concave of tappet for wear.
4. Camshaft
1) Check the contact surface of cam and tappet for wear, and check if the main journal is stuck or worn.
2) Check whether the timing gear fastening bolt is bent or deformed, check whether the camshaft timing gear is
broken or the surface is seriously worn.

1. Refit the camshaft and camshaft timing gear. Refer to their assembling steps for details.
2. Refit the tappet and push rod. Refer to their assembling steps for details.
3. Refit the intake and exhaust valves. See the refitting steps of the intake and exhaust valves for details.
4) Refit the rocker arm and the rocker arm shaft. See the refitting steps of the rocker arm and the rocker arm
shaft for details.
1. Assembling steps of the camshaft assembly

1) Check the removed camshaft and timing gear for wear or
large deviation of other parameters, and if necessary, repair
them, or replace them with new ones. Clean the camshaft hole,
and check the camshaft bush for scratch.
2) Clean the camshaft, and check it for scratch; repair it if Fig. 5-51 Assembling of camshaft
necessary. Then insert the camshaft through the camshaft hole
by using a special tooling (camshaft guide tool) which is clean
and coated with lubricating oil. Avoid bumping the camshaft
surface and bush during refitting;
94
3) Install the camshaft thrust plate, apply clean lubricating oil

to the thrust plate and Loctite 242 thread locker to threads of
hexagon bolts, and tighten the hexagon bolts to the extent
that the camshaft rotates freely.
4) Apply Loctite 277 thread locker on external ring of bowl
plug, and drive it into the camshaft hole by using a special
tool. After that, wipe off excessive thread locker with towel,
and ensure the perimeter of bowl plug has no turnup;
5) Measure the camshaft axial clearance.
6) Assemble the camshaft timing gear: Turn the crankshaft to
place the piston of cylinder #1 at the TDC to align the pin hole
on the camshaft gear with the dowel pin on the camshaft,
rotate the camshaft to align the mark on the camshaft gear
with that on the crankshaft gear (at this time, the mark on the
crankshaft gear is right at the center of the camshaft gear
mark), then apply sealant 242 to threads of hexagon head
bolt, and tighten the bolt. Mark them for sealing with a special
paint marker after they are tightened in place.
2. Assembling steps of tappet and push rod

1) Check the tappet and the push rod for any defects; if any,
replace them with new ones. Before refitting the tappet, make
sure to clean it with compressed air, and then check if the oil
hole is unblocked.
2) Apply clean lubricating oil on the engine block tappet hole
and valve tappet outer circumference evenly.
3) Gently place the tappet into the tappet hole from the
bottom of the engine block to the extent that the tappet
freely rotates in the tappet hole with even resistance. Refit
the camshaft. See the refitting steps of the camshaft.
4) Install the rocker arm bracket to the cylinder head loosely, Fig. 5-52 Assembling of tappet and push rod
and check if the push rod is clean and if it is welded properly.
5) Apply clean lubricating oil to the push rod, and ensure that
the ball joint is sufficiently lubricated.
6) To refit the push rod, pass it through the cylinder head to
place it into the tappet.
95
3. Refitting steps of the valve and spring

1) If the valve is worn or sintered seriously due to carbon
deposit, replace it with a new one. Apply molybdenum
disulfide grease onto the intake/exhaust valve stem evenly,
and then refit the intake/exhaust valve to the cylinder head,
ensuring that the intake/exhaust valve can slide in the guide
smoothly;
2) Turn over the cylinder head, install the lower seat of the
Fig. 5-53 Assembling of valve and valve spring
intake and exhaust valve springs in position in turn, install the
valve stem seals to the intake and exhaust valve guides, and
then install the valve stem seals.
Note: Be sure to check if the valve stem seal internal spring is
intact prior to fitting.
3) Install the valve spring and the valve spring upper seat.
4) Install the valve collet by pressing.
5) Refit the valve bridge, with the opening facing to the
exhaust side.
4. Refitting steps of the rocker arm and the rocker arm shaft
1) Check that all installed parts are clean without bump,
scratch or rust.
2) With the valve push rod and valve bridge (refer to
assembling steps of push rod, tappet and valve for details),
pass the bolts through harnesses to fix the bracket and rocker Fig. 5-54 Refitting of the rocker arm and the
arm bracket components, so as to install the rocker arm rocker arm shaft
bracket components loosely to the cylinder head.
3) Tighten the rocker bracket fixing bolts in place, and then
mark them with a paint marker.
5. Check and adjust the intake/exhaust valve clearance as

follows.
1). Turn the flywheel in the crankshaft rotation direction to
locate 1# cylinder at the burst TDC.
2) Adjust the valve clearance from the front end to the rocker
arm 1-2-3-6 in turn. The cold clearance of intake valve is
0.35~0.4 mm and of exhaust valve is 0.4~0.45 mm.
3） Turn the crankshaft by 360° in the crankshaft rotation
direction, and adjust the clearances of other valves.
4) Check the opening angle of the intake valve and closing
angle of the exhaust valve on 1# cylinder, and record them in
the attached card. The intake valve opens at (18±3)° before
the TDC, and the exhaust valve closes at (17±3)° after the
TDC.
96
5.25 Fuel injector assembly

Fig. 5-55 Exploded view of fuel injector assembly

Fuel injector
1 Fuel injector 2 Spherical washer 3 pressure plate 4 Fuel injector clamp
washer

Socket wrench.
Remove the acoustic shield and high-pressure fuel pipe, and disconnect the engine harness connected to the
fuel injector.
97

1. Remove the bolts fixing the fuel injector pressure plate
2. Remove the spherical washer and fuel injector clamp.
3. Take out the fuel injector from the cylinder head.
Fig. 5-56 Disassembly of fuel injector assembly

1. Check and clean the fuel injector nozzle.
2. Replacement of the injector nozzle must be carried out in Bosch special service station
3. The fuel injector gasket is disposable, and shall be replaced with a new one after the fuel injector is
disassembled.
4. During maintenance and adjustment of the valve clearance, cover the fuel injector hole in the cylinder head
with a piece of wiping paper or other clean cloth after removing the fuel injector and cylinder head cover, so as
to prevent impurities from entering the cylinder head bottom hole. Before refitting the fuel injector, clean the
fuel injector and its bottom hole:
1) Clean the outer surface of the removed fuel injector, and wipe off carbon deposit, gum deposit, etc. The
ultrasonic cleaning method is recommended.
2) Remove the sludge in the bottom hole with type 755 detergent.
3) Scrape the carbon deposit and impurities in the bottom hole with proper tools.
4) Wipe off the sludge and carbon deposit with a piece of clean cotton cloth to avoid jacking up the fuel injector
gasket.

1. Place the fuel injector into the bottom hole of the cylinder head.
2. Refit the fuel injector clamp and spherical washer in turn.
3. Install the fuel injector pressure plate bolt and tighten it with a torque of (29±1) N.m.
98
5.26 Cylinder head assembly

Fig. 5--57 Exploded view of cylinder head assembly

Cylinder head
1 Valve stem seal 2 Cylinder head bolt 3 4 Gasket
subassembly
1. Cylinder cover
5 Cover plate 6 Hexagon flange bolt 7
gasket

1. Tools:
Socket wrench or pneumatic wrench, torque wrench, open-end wrench.
2. Preparations:
2. Remove the fuel injector, cylinder head cover, intake pipe, exhaust pipe, water-outlet pipe, high-pressure fuel
pipe and other parts that might be fixed on the cylinder head or might cause interference to the disassembly of
cylinder head.
99
1 Before removal, make sure to check that the coolant inside

the engine has been drained off through the drain valve;
2. Before disassembling the cylinder head, it must be
ensured that the components of the valve train (such as the
rocker arm shaft assembly, push rod, etc.) installed on the
cylinder head have been disassembled.
3. Before removing the cylinder head, make sure that the
fuel injector pressure plate bolts have been removed,
otherwise the short bolts of cylinder head under the fuel
injector pressure plates cannot be removed.
4. Before disassembling the cylinder head, it must be
ensured that the fuel injector installed on the cylinder head
is removed to prevent the fuel injector nozzle from being
damaged when the cylinder head is placed.
5. Loosen the bolts of the cylinder head in turn. WP4.1 has
18 cylinder head bolts. Make sure that all the cylinder head
bolts are loosened before lifting the cylinder head.
6. Remove the cylinder head, and place it on an object with
low hardness such as cardboard, template and plastic plate,
so as to prevent the bottom surface of the cylinder head
from being bumped or scratched.
7. After the cylinder head is disassembled, it is necessary to
clean up the coolant and other foreign matters on the top
surface of the engine block as appropriate, so as to prevent
them from entering the combustion chamber and causing
other faults.
8. Remove the cylinder head gasket.
9. Remove the intake and exhaust valves by referring to the
removal steps of the valve train.
Fig. 5-58 Disassembly of the cylinder head
10. Remove the valve stem seal. assembly
100

1. Cylinder head
1) Before removing the cylinder head, check it for any
water, oil or air leakage and other abnormalities, so as to
locate and analyze the fault accurately.
2) Clean the cylinder head, especially the combustion
chamber surface, valve seat, intake/exhaust valves,
intake/exhaust ports, remove the carbon deposit and
coke tar, and check the surface condition.
3) Carefully check the cylinder head for discoloration and
Fig. 5-59 Depth micrometer
cracks, and if any crack is found, conduct dye penetration
inspection.
4) The valve sinkage is the vertical distance between the
bottom surface of valve and the bottom surface of
cylinder head. The difference between the measured
value and the required value indicates the wear of valve
and valve seat. A depth micrometer can be used to
measure the valve sinkage, and the measuring tool is
shown in the figure:
5) Refer to the table for the required value of valve
sinkage. If the valve sinkage exceeds the allowable range,
the cylinder head needs to be replaced to ensure the
reliability of the diesel engine. If the valve sinkage is not
exceeding the allowable value, remove the valve and
check the sealing surface of valve and valve seat, and
check the sealing surfaces of valve and valve seat for
obvious wear and abnormal damage. Fig. 5--60 Inside micrometer
Required valve sinkage, mm

Intake valve 0.442~0.75 (positive value indicates that the valve projects beyond the
cylinder head, and negative value indicates that the valve is concave in
the cylinder head)
Exhaust valve 0.434～0.771 (positive value means that the valve protrudes from the
cylinder head, and negative value means that it is depressed)
6) The inner diameter of valve guide is the contact surface

of the valve guide with valve. If it exceeds the permissible
value due to wear, the guide of valve will be affected, thus
reducing the reliability of diesel engine. The inner
diameter of valve guide can be measured with an inside
micrometer. The inside micrometer is shown in the figure.
The permissible inner diameter of the valve guide is
(9~9.015) mm. If the inner diameter is out of this
permissible range, replace the cylinder head to ensure the
reliability of diesel engine.
101
2. Gasket
1) If air, water or oil leaks from the cylinder head gasket,
check and replace the cylinder head gasket.
2) The removal method of the cylinder head gasket is as
described in the context. Check the cylinder head gasket for
visible damage and analyze the cause, and then replace it
with a new one, no matter it is faulty or not. Fig. 5-61 Cylinder head gasket
3. Valve stem seal
1) The valve stem seal is to ensure the sealing of the
lubricating oil at the valve stem, and at the same time, it also
distributes a certain amount of lubricating oil on the valve
stem to prevent the valve stem and the valve guide from
sticking due to dry friction. It is necessary to check all valve
stem seals for detachment before removing the valves. After
removing the valves, carefully check whether the valve stem
seal is intact, cracked or aged; check whether the spring on
the valve stem seal is deformed. If the corresponding valve
and valve guide are worn severely, replace the valve stem
seal.
5.26.5 Assembling steps Valve stem seal mounting tool
1. Valve stem seal

2. The valve stem seal and its refitting instructions are
shown in the figure. Spring
Valve stem seal
Valve guide
1) The valve stem seal can be used only once, and shall be Cylinder head
replaced with a new one when repairing.

2) Check if the valve stem seal is failed, and if the spring of
Fig. 5-62 Valve stem seal
valve stem seal is intact.
3) Install the valve stem seal onto the valve guide.
4) Apply lubricating oil onto the lip of valve stem seal.
5) Use the valve stem seal assembling tool and rubber
hammer to install valve stem seal.
102
3. Assemble the cylinder head gasket

1) The cylinder head gasket is disposable, and shall be
replaced with a new one in the case of repair.
2) Clean the inner wall of the cylinder liner and apply clean
lubricating oil to it. Then clean the top surface of the
engine block, and place the cylinder head gasket after
alignment with corresponding pin bushes.
3) Check if the cylinder head gasket is installed correctly. Fig. 5-63 Cylinder head gasket
4. Refit the cylinder head

1) Clean the cylinder head to ensure no dust, debris, sand
or other dirt.
2) Check if the cylinder head gasket and the bottom
surface of cylinder head are clean.
3) Before tightening the cylinder head bolts, position the
cylinder head with the help of the two pin bushes and the
contact surface of cylinder head and engine block.
4) Assemble the cylinder head
5. Install the cylinder head bolts.

1) The bolts of the cylinder head are as shown in the
figure.
2) The cylinder head bolts are allowed to be reused 3
times, and their tightening sequence is as shown in the
figure.
3) Align the bolts with the cylinder head in the sequence,
apply the lubricating oil onto the threads and
pressure-bearing surfaces of the cylinder head bolts, and
then tighten them by four times. Fig. 5-64 Schematic diagram of cylinder head bolts
4) Pre-tighten with a torque of 40 N·m for the first time
and retighten 40 N·m again.
5) Secondly, rotate for 90° in turn.
6) Rotate for 90° in turn at the third step.
7) Turn 90° in sequence for the fourth time, and tighten it Fig. 5-65 Tightening sequence of cylinder head
to a torque of about 210 N·m~340 N·m. bolts
103
5.27 Crankshaft pulley assembly

Fig. 5-66 Exploded view of crankshaft pulley assembly

Crankshaft pulley Crankshaft Hexagon flange
1 Flange 2 3 4
bolt pulley bolt
5 Parallel pin

1. Tools:
Torque wrench, automatic tightening machine, etc.
Remove the belt before disassembling the crankshaft pulley group.

First unscrew the hexagon flange bolt, remove the crankshaft pulley from the flange. Second unscrew the
crankshaft pulley bolt to remove the flange from the front end of the crankshaft.
104

1. Check the torsional vibration damper for bump, material falling-off, deformation and other defects.
2. Check the pulley for damage and the tightening position of the bolt for crushing.
3. Check the vibration damper bolts and Hexagon flange bolts for damage.
4. Check the appearance of the rubber torsional vibration damper, and check the inner and outer races for slip,
and the rubber strip for cracks.
1. Install the flange to the front end of the crankshaft through the positioning rabbet, and tighten the bolts M12
(6 pcs) connecting the flange and crankshaft at the torque:（50～70）N·m+（140～150）N·m,Note to apply some
oil . For separate pully the M8 bolt torque is (40±3)Nm
2. Install the crankshaft pulley to the front end of the flange through the locating rabbet and locating pin, and
connect the crankshaft belt pulley and the flange with 6 M8 bolts.
5.28 Starter assembly

Fig. 5-67 Exploded view of starter assembly
105

1 Hexagon flange bolt 2 Starter

1. Tools: Socket wrench, pneumatic wrench or open-end wrench;
2. Preparations: None.

1. Remove the Hexagon flange bolt.
2. Hold the starter motor with both hands and remove it along the rotation axis of starter gear.

1. Pay attention to the protection of wiring terminal and wiring harness during maintenance. It is forbidden to
collide and pull the terminals and harnesses.
2. Check the insulating covering, sleeve and pad for damage during installation. Damaged and broken ones must
be replaced. The terminal 30 of starter motor should not shorted to the housing.

1. Apply the lithium grease for vehicles to the starter gear;
The specific steps are as follows:
♦ Put the starter to be assembled on the workbench;
♦ Take out the vehicle extreme-pressure lithium grease with a clean steel ruler and coat it in the two slots of the
starter. The two slots coated with extreme-pressure lithium grease shall be separated by at least four teeth.
♦ Coat the vehicle extreme-pressure lithium grease on the gear meshing surface (i.e., in the tooth space) evenly
rather than the top surface of tooth, and if the top surface is coated, the operator shall wipe it off with a clean
fiber towel.
2. Install the starter.
3. Tighten the hexagon flange bolts. The torque of starter fastening bolts is 50±5 N·m.
106
5.29 Flywheel housing assembly

Fig. 5-68 Exploded view of flywheel housing assembly

1 Speed sensor 2 Plug 3 Flywheel housing 4 Hexagon flange bolt
Hexagon socket
5 Parallel pin 6 Wave spring washer 7
head cap screw

1. Tools: Socket wrench, copper hammer.
2. Preparations before disassembling: Remove the transmission, clutch, and flywheel.

1) Unscrew the fastening bolts of flywheel housing sight glass and remove the sight glass cover.
2) Unscrew the fastening bolts of flywheel housing diagonally.
3) Remove the flywheel housing.
107

1. Check if the parts are complete as per the parts list.
2. Check the state of flywheel housing and engine block.
3. No burrs, oil stain and damage are allowed on the joint surfaces.
4. Pay attention to applying the lubricating oil when refitting the flywheel housing bolts. The flywheel housing
bolts can be reused twice.

1. Use clean rag to wipe the mating surface of flywheel housing and engine block.
2. Check the casting mark of the flywheel housing manufacturer and record it in corresponding part column on
the assembly process card correctly;
3) Install the flywheel housing aligning with the screw hole, and screw in the bolt by 2-3 threads manually;
4. Use the wrench to tighten in the bolts by 2--3 threads symmetrically and evenly starting from the dowel pin.
5.30 Flywheel assembly

1. Tools:
Torque wrench, automatic tightening machine, guide studs, etc.
2. Preparations:
Before disassembling the flywheel assembly, it is required to remove the parts connected to the flywheel output
end, such as the clutch etc.
Fig. 5-69 Exploded view of flywheel assembly
108

1 Crankshaft 2 Parallel pin 3 Flywheel assembly 4 Bearing seat
Deep groove ball
5 6 Flywheel bolt
bearing

Disassemble the flywheel bolt, and take out the flywheel assembly, deep groove ball bearing and bearing seat.
1. Check the flywheel bolts for thread damage or other defects.
2. Check the flywheel surface for crushing.
3. Check the flywheel ring gear for damage.
4. Check the contact surface of flywheel with clutch or other parts for crazing.

1. Tighten the parallel pin at the rear end of crankshaft to the
limit.
2. Refit the rear oil seal of crankshaft onto the crankshaft
flange, and press the rear oil seal with the rear oil seal tooling.
3. Install the bearing seat into the rear end of the crankshaft,
and install the bearing onto the bearing seat. Fig. 5-70 Assembly of the flywheel assembly
4. Install the flywheel.
1) Insert the flywheel guide rod into the two symmetrical bolt
holes on the crankshaft;
2) Pass the flywheel through the guide rod and into the flywheel
housing.
5. Insert the flywheel bolts into the flywheel and refit the
flywheel onto the crankshaft.
1) Apply clean lubricating oil to the thread and pressure-bearing
surface of flywheel bolts.
2) Tighten the flywheel bolts as per the sequence shown in the
figure;
3) Screw them down diagonally; tighten them diagonally to
60N.m for the first time; turn them by 60° in order for the Fig. 5-71 Tightening sequence of the flywheel
second time. bolts
109
5.31 Oil pump assembly

Fig. 5-72 Exploded view of the oil pump assembly

Hexagon flange
1 2 Oil pump 3 O-ring 4 Oil pump pipe
bolt M10×30
5 Hexagon head bolt 6 Spring washer 7 Spline sleeve 8 Oil pump drive gear
Hexagon flange
9 O-ring 10 Bearing cap 11
bolt (M8×20)

2. Pre-disassembly preparation: Drain the oil from the diesel engine and remove the oil pan.
110

1. Remove the fastening bolt of oil pump pipe with a socket
or wrench, and remove the oil pump pipe and seal ring.
Fig. 5-73 Disassembly of oil pump pipe

2. Remove the fastening bolt of oil pump with a socket or
wrench, and remove the oil pump and spline sleeve.
Fig. 5-74 Disassembly of oil pump
111
3. Remove the fastening bolt of bearing cap with a socket

or wrench, and remove the bearing cap and oil pump
drive gear.
Fig. 5-75 Disassembly of oil pump drive gear and its

bearing cover

1. Check if the oil pump rotates flexibly.
2. Check whether the oil pump drive spline has abnormal wear, whether the housing has cracks, and whether
the strainer screen is unobstructed.
3. Check the oil pump drive gear and spline sleeve for abnormal wear.
4. Check the oil pump bearing cap for abnormal wear and cracks.
5. Check the oil pump pipe for cracks, and the flange sealing surface for scratches.

1. Install the oil pump spline sleeve on the oil pump drive shaft, assemble them together to the mounting hole of
engine body, and tighten the two fastening bolts.
2. Install the oil pump drive gear to the body mounting hole, assemble the bearing cap to the body mounting
hole and pay attention to the matching with the drive gear. Replace the O-ring at the bearing cap with a new
one.
3. Install the oil pump pipe to the engine body and the corresponding flange of the oil pump, tighten the bolt,
and pay attention to replacing the O-ring at the flange with a new one.
112
5.32 Oil pan assembly

Fig. 5-76 Exploded view of oil pan assembly
No. Name No. Name No. Name 3 No. Name

Combination Hexagon flange bolt
1 Oil pan assembly 2 3 Drain plug 4
sealing washer M8×14

1. Tools: Socket or wrench;
2. Preparations before disassembly: Remove the drain plug of oil pan to drain the oil completely.

1. Remove the fastening bolts of the oil pan.
2. Take care not to damage the sealing surface between the oil pan and the engine block when disassembling
the oil pan, and clean away the sealant on this sealing surface.

1. Check the sealing surface between the oil pan and the engine block for damage.
2. Check the weld of oil pan for scratch and oil leakage.
113

1. Wipe the sealing surface between the engine block and the oil pan with towel, and apply silicone sealant to
the sealing surface of engine block or oil pan without discontinuity.
2. Refit the oil pan assembly after aligning the threaded holes at the bottom of the engine block.
3. Tighten the fastening bolts of oil pan from the middle to the sides.
4. Screw up the drain plug with the combination sealing washer, and replace the used combination sealing
washer with a new one.
5.33 Piston nozzle assembly

Fig. 5-77 Exploded view of piston cooling nozzle assembly

1 Parallel pin 2 Valve body 3 Piston nozzle 4 Bolt
114

1. Tools:
Socket wrench.
Remove the crankshaft and related parts.
1. Remove the hexagon socket set screw.
2. Remove the nozzle assembly.
Check the nozzle for clogging, and replace it with a new one when necessary.
1. Locate the nozzle assembly with the parallel pin to loosely install it to the cylinder block, and then tighten the
bolts.
2. Check whether the nozzle is unblocked, check the mating surface of the nozzle and engine block for bumps or
burrs, and repair or replace the nozzle if necessary.
5.34 Piston and connecting rod assembly

115

Trapezoidal barrel Coil spring loaded
1 2 Twist cone ring 3 4 Piston
ring oil-control ring
Connecting rod Connecting rod
5 Piston pin 6 Piston pin retainer 7 8
body cover
Connecting rod Connecting rod Connecting rod
9 Connecting rod bolt 10 11 12
lower shell upper shell bush

1. Tools:
Torque wrench, automatic tightening machine, travelling crane, needle-nosed pliers, etc.
2. Preparations:
Before removing and checking the piston and connecting rod assembly, remove the cylinder head, valve
mechanism and oil pan.

1. Carefully remove the carbon deposits on the top of the
cylinder and do not damage the inside of the cylinder. Place the
engine at an angle, turn the engine so that the piston is at the
BDC, and remove the connecting rod bolts and connecting rod
caps. Then turn the engine to the TDC and knock out the piston
with a wooden hammer. Be careful to prevent the cylinder block
from being caught by the connecting rod big end. Place the
bearing bushes and connecting rod caps in the original order.
Fig. 5--78 Exploded view of connecting rod
2. Use the circlip pliers to remove the circlip at both sides of big end
piston carefully, push out piston pin, and remove the connecting
rod body. Number the connecting rod bodies respectively, and
place them in order;
3. Use the piston ring pliers to remove the first compression
ring, second compression ring and oil ring, and mark them
separately; Fig. 5--79 Exploded view of piston pin and
4. Apply the radial and tangential force to the connecting rod connecting rod bushing
bearing shell to separate the bearing shell from its mounting
position, and then remove the bearing shell. Number the
bearing shells in the order of the cylinder number respectively,
and place them in the order.

1. Check the filleted corner at the combustion chamber throat and the piston pin seat for cracks, and if any,
replace the corresponding parts; check the piston skirt and head for scuffing of cylinder bore; check whether the
piston pin hole is worn normally;
2. Check if the piston ring is blocked in the piston ring groove;
3. Check the outer perimeter and upper & lower end faces of piston ring for abnormal wear;
4. Check the outer perimeter of the piston pin for abnormal wear;
5. Check the big end bottom hole, rod body and small end oil hole of the connecting rod for crack;
116
6. Check the sides of connecting rod for abnormal wear and the connecting rod body for bending;
7. Check the connecting rod bushing alloy layer for abnormal wear, peeling;
8. The cylinder number on the connecting rod body shall be the same with that on connecting rod cap; the
weight grouping marks of connecting rods of one engine shall be the same;
9. If the connecting rod body is scratched or damaged, replace the connecting rod;
10. The bolt of connecting rod can be used for 3 times at most;
11. Visually check the bearing shell surface for any scratch or burr;
12. Before installing the connecting rod bearing bush, clean the bottom hole and bearing bush; do not apply
lubricating oil to the bushing hole in connecting rod and the back of bearing bush;
13. If the surface of connecting rod bearing bush appears corrosion, erosion and abrasion, it is necessary to
replace the connecting rod bearing bush with new one;
14. Check the wear of connecting rod bearing bush, and check the alloy layer for discoloration, peeling,
deformation and other defects.

1. Seat the connecting rod bearing shell past the fracture split
by applying radial and tangential force to avoid scratching the
steel backing. Ensure the lip on the connecting rod bearing shell
is exactly aligned with the groove of connecting rod big end and
connecting rod cover. Remember to apply lubricating oil to the
inner surface of the bearing shell after refitting. Fig. 5-80 Assembling of connecting rod
bearing shell
2. Use the circlip pliers to install a circlip into the piston pin
circlip groove, and rotate the circlip to ensure proper fitting.
3. Insert the connecting rod small end into piston cavity, and
align the connecting rod small end with piston pin hole, then fit
the piston pin and piston pin circlip at the other side. The circlip
opening should be offset from the centerline of piston by 30°,
and the two circlips shall be staggered by 60°. Clean and apply
lubricating oil to connecting rod small end hole and the piston
Fig. 5-81 Assembling of piston pin
pin before assembling. The factory marking on connecting rod
and the orientation mark of piston shall be on the same side,
and the connecting rods and pistons of one engine shall be in
the same mass group respectively.
4. Hang the assembled piston & connecting rod to the pallet in
the order of the cylinder number, and then use the piston ring
pliers to refit the coil spring loaded oil-control ring, twist taper
faced ring and keystone barrel faced ring in turn into the piston
ring groove. Ensure that the piston rings are assembled in the
ring groove in parallel without distortion. The "TOP" face of the
piston ring shall be upward, and the ring shall rotate flexibly in
the ring groove.
117
5. Adjust the opening direction of piston rings: the opening of

the first ring should be offset from the centerline of piston pin
by 30°; the openings of the second ring and the first ring shall
be staggered by 120°; the opening of the oil control ring shall
be staggered by 120° from the opening s of the first ring and
the second ring respectively, and locate on the vertical bisector
of the piston pin centerline.
6. Wipe the cylinder inner wall, crank arm and piston
connecting rod component, and apply clean lubricating oil onto
the kinematic pair.
7. Turn the crankshaft to locate the pistons of cylinders #1 and
#4 near the BDC, and gently place the piston & connecting rod
assembly in the cylinder liner when the orientation mark of the
piston faces to the engine front end. Hold the piston ring
compressor to press it against the cylinder liner. Push the
piston into the cylinder liner via the compressor. Then pull the
connecting rod downward to install it onto the crankshaft
journal. Connecting rod bolt: Pre-tighten it to 30N·m and then
rotate it by 90° to (100-160)N·m and bolts can only be used
once.
8. Note: The piston number shall be consistent with the
cylinder number, the connecting rod cover shall match with the
connecting rod body, and the connecting rod bolt shall be
coated with clean lubricating oil before refitting. Install the
piston and connecting rod assemblies of remaining cylinders in
the same way.
118
5.35 Gear chamber housing cover assembly

5.35.1 Exploded view of gear chamber housing cover assembly
Fig. 5--82 Exploded view of gear chamber housing cover assembly

Gear chamber
Timing gear
1 housing cover 2 Hexagon flange bolt 3 Phase sensor 4
chamber cover
gasket
5 Timing pointer 6 Hexagon flange bolt 7 Hexagon flange bolt 8 Hexagon flange bolt
9 Parallel pin

2. Preparations: Remove the oil pan, etc.

1. Remove the timing pointer.
2. Loosen the adjusting plug screw and remove the combined washer.
3. Remove the bolts of gear chamber cover, and remove the gear chamber cover and its gasket.
119

2. Avoid secondary use of combined washer, and replace it after disassembly.
3. No burrs, oil stain and damage are allowed on the joint surfaces.
1. Drive in the dowel pin on the gear chamber cover;
2 Refit the gear chamber cover gasket and the gear housing cover, and screw on and tighten the gear housing
cover bolts in diagonal order.
3. Install the combination washer and tighten the adjusting screw plug.
4. Install the timing pointer.
5.36 Gear train assembly

Fig. 5-83 Exploded view of gear train assembly
120

Camshaft timing Camshaft timing Intermediate gear
1 Hexagon flange bolt 2 3 4
gear pressure plate gear shaft
Intermediate gear Intermediate gear
5 6 7 Hexagon flange bolt
assembly cover plate

1. Folding tool:
Torque wrench, automatic tightening machine, turning tool, dial gage, etc.
2. Preparations: Remove the fuel injection pump assembly etc. before removing the gear drive assembly.
1. Rotate the crankshaft, and check if the camshaft assembly and

camshaft timing gear rotate flexibly and smoothly;
2. Use a dial gauge to check the camshaft for axial play;
3. Check the backlash of each gear pair;
4. Check the bolts of camshaft timing gear for looseness, remove
the bolts of camshaft timing gear, and then remove the camshaft
Fig. 5--84 Exploded view of camshaft timing
timing gear and its pressure plate.
gear
5. Check whether the intermediate gear shaft bolts are loose,
remove the intermediate gear shaft bolts, intermediate gear
cover plate, intermediate gear assembly and intermediate gear
shaft.
Fig. 5-85 Exploded view of intermediate gear

assembly

1. Check whether the mounting bolt threads are in good condition;
2. Check all gears for tooth flank peeling off or tooth breakage, the bolt pressure-bearing surface for crushing
and the threaded hole or through hole on the gear for deformation;
3. Check whether there are abnormal wear between the intermediate gear shaft and the intermediate gear
bushing. Check whether any oil hole is blocked by foreign matters.
121
1. Install the camshaft timing gear: align the keyway of the Timing mark
camshaft timing gear with the keys on the camshaft assembly,

mount the camshaft timing gear to the camshaft, then screw
the camshaft timing gear bolt onto the camshaft through the
pressure plate and signal disc, and then tighten the bolts of
camshaft timing gear according to the tightening process.
Timing mark
2. Insert the locating pin of the intermediate gear shaft into the
locating hole of the engine block, grease the inner hole of the
intermediate gear assembly and install it on the intermediate Fig. 5--86 Gear pairing mark
gear shaft. During the assembly, turn the crankshaft to TDC of
the first cylinder, and the middle gear with dot mark teeth are
required to be located in the crankshaft gear with dot mark
two teeth; The dot marked teeth of the camshaft timing gear
are located in the two dot marked teeth of the middle gear.
The fuel injection pump gear and the hydraulic pump
transmission gear do not need to be marked.For WP3.7 Euro Ⅳ
/ Euro Ⅴ, WP4.1 Euro Ⅳ diesel engines, when installing the air
compressor gear, let the camshaft timing gear with line
marking teeth located between the two teeth of the air
compressor gear with dot marks. For the WP4.1 Euro
V/non-road three-stage diesel engine, the air compressor gear
does not need to be fitted with the mark.
3. Measure the backlash between the gears.
4. Before assembly, check whether the tooth surfaces of each gear collide, whether there are flanging burrs in
the oil holes of the intermediate gear shaft, and whether the intermediate gear bush collides.
122
5.37 Gear chamber assembly

Fig. 5-87 Exploded view of gear chamber assembly

Timing gear
1 2 Hexagon flange bolt 3 Parallel pin 4 Hexagon flange bolt
chamber gasket
Timing gear
5 6 Cup plug
chamber

2. Pre-disassembly preparation: remove the gearbox, clutch and oil pan.
1. Remove the front cap.
2. Remove the hexagon flange bolt.
2. Check the condition of the gear chamber and the engine block.
3. No burrs, oil stains and damage are allowed on the joint surfaces.
123

1. Drive in the dowel pin at the front end of the cylinder block (making the dowel pin free of edge failure).
2. Install the gear chamber gasket and the gear chamber, and tighten the gear chamber bolts in diagonal order.
3. Install and clean the transition gear shaft, and check it for scratch. Then assemble a pair of bearings and coat it
with appropriate amount of clean lubricating oil; afterwards, assemble the transition gear and transition gear
shaft pressure plate in turn.
4. Install and tighten the bolts.
5.38 Drain valve assembly


1 Drain valve joint 2 Drain valve 3 Clamp 4 Rubber pipe
124
5.38.2 Tools and preparation

2. Preparations: Drain the antifreeze in the engine.
1. Remove the clamp and take down the hose.
2. Remove the drain valve and its connector.
Check whether the drain valve can be opened and closed smoothly; Check whether the hose is crushed and
cracked.
1. Install the drain valve and drain valve joint, and apply thread sealant to the taper thread during installation.
2. Install the hose and clamp.
5.39 Crankshaft assembly

Fig. 5-89 Exploded view of crankshaft assembly
125

Main bearing upper
1 Engine block 2 3 Crankshaft 4 Parallel pin
shell
Crankshaft timing Thrust main bearing
5 6 Main bearing cap 7 Main bearing bolt 8
gear cap
Main bearing lower
9 10 Lower thrust plate 11 Upper thrust plate
shell

1. Tools:
1). Torque wrench, automatic tightening machine, overhead crane, guide studs, etc.
1). Preparations: Remove the belt before disassembling crankshaft pulley.
2) Before disassembling the crankshaft assembly, remove the flywheel, flywheel housing, front end cap,
crankshaft pulley, main bearing cap and piston & connecting rod.
1. Remove the crankshaft pulley assembly, front end cap assembly, piston & connecting rod assembly, flywheel
assembly, flywheel housing assembly, etc. before disassembling the crankshaft assembly. Place the engine block
upside down, remove the main bearing bolts, and remove the main bearing cap and the main bearing lower
shells and place them in sequence.
2. Remove the front and rear thrust plates, and then remove the oil seal. Hoist the crankshaft and place it on the
bracket (if the crankshaft is to be placed for a long time, it shall be placed vertically), and remove the upper main
bearing bushes and put them in order.
3. Place all the disassembled parts as required.
1. Check the crankshaft main journal, connecting rod journal and filleted corner for cracks; clean the oil passages
and check for cracks and other damages.
2. Check the main journal, connecting rod journal and thrust gear for wear, and check whether there are linear
wear lines, metal peeling and cracks.
3. Check the wear of oil seal.
4. Check the main bearing bolt for thread damage.
5. Check the bolt hole on the front and rear end faces of crankshaft for cracks or thread damage.
6. Check the amount of crankshaft journal for wear, crankshaft bending and twisting.
7. Check the front and rear end faces of crankshaft for wear.
1. Lift the crankshaft to the carriage, and be careful to avoid bumps.
2. Check the matching surfaces of crankshaft and the oil passage cavity.
126
1) Check all the matching surfaces of crankshaft for bumps, and replace the crankshaft if necessary;
2) Use compressed air to blow the oil passage cavity to ensure that the inner cavity of the oil channel is clean
and smooth.
3. Clean the main bearing upper bush and the bottom hole of engine block. Install the main bearing upper bush
into the bottom hole.
1) Before pressing the bush, check it for bumps. Do not use any repaired bush.
2) After pressing the shell, align the oil hole with the engine block oil hole, and check that the upper shell fits
closely the main bearing bottom hole of the cylinder block;
3) Wipe up the foreign matters scraped from the bush.
4. Apply clean lubricating oil onto the inner surface of the upper bearing shell.
5. Lift up the crankshaft, purge the oil passage hole with compressed air and wipe the main journal and
connecting rod journal. Then gently lower the crankshaft into the cylinder block, taking care not to scratch the
crankshaft.
6. Refit the upper thrust plate into the thrust plate groove between the engine block and the crankshaft.
1) The oil groove of upper thrust plate should be outward (toward the crankshaft).
7. Clean the lower half of main bearing bush and bearing cap, fit the lower bearing bush into bearing cap, then
install the lower thrust plate.
1) The oil groove of lower thrust plate should be outward (toward the crankshaft).
2) Check bearing bush and the lower thrust plate for damage.
3) Apply automotive lithium grease onto the inner surface of the lower thrust plate;
4) Wipe up the foreign matters scraped from the bush;
8. Refit the main bearing cap onto the engine block.
9. Install the main bearing bolt
1) Before installing the main bearing bolt, carefully check the mating surface of main bearing bolt and main
bearing cap for foreign matters to avoid scratching the main bearing cap, and manually check the chamfer of
bolt pressure-bearing surface for burrs, and replace the bolt when necessary.
2) Apply clean lubricating oil to the pressure surface and threads of main bearing bolt.
127
10. Tighten the main bearing bolts.

1) Tighten the main bearing bolts M16 (10 pcs) in the
sequence shown in the figure in two steps: first pre-tighten it
at (60±5) N•m; second, twist (90±5)° it in sequence;
2) Check that the crankshaft rotates smoothly.
11. Check the axial clearance of crankshaft.
Fig. 5-90 Tightening sequence of main bearing
1) The axial clearance of crankshaft is (0.12 ~ -0.3) mm.
bolts
5.40 Thrust plate assembly

Fig. 5-91 Exploded view of thrust plate assembly
128

Main bearing
1 Engine block 2 3 Crankshaft 4 Parallel pin
upper shell
Crankshaft timing Thrust main
5 6 Main bearing cap 7 Main bearing bolt 8
gear bearing cap
Main bearing lower
9 10 Lower thrust plate 11 Upper thrust plate
shell

1. Tools:
Torque wrench, automatic tightening machine, traveling crane and guide stud.
2. Preparations:
Remove the crankshaft pulley, front cap, clutch, flywheel, flywheel housing, gear assembly and piston &
connecting rod before disassembling the thrust plate assembly.
1. Take out the lower thrust plate from the side of the fifth bearing cap.
2. Remove all the main bearing caps and the lower bearing shells, and lift the crankshaft assembly to the
bracket.
3. Take out the upper thrust plate from the side of the fifth gear of the engine block.
1. Check the thrust plate for integrity and bump.
2. Check the thrust plate for damage, dislodgement, deformation, crushing, etc.
1. Clean the main bearing upper shell and the bottom hole of engine block, press the main bearing upper shell
into the bottom hole, apply clean lubricating oil to the inner surface of the upper bearing shell, lift up the
crankshaft components, and then gently lower the crankshaft into the engine block.
2. Refit the upper thrust plate into the thrust plate groove between the engine block and the crankshaft.
1) The oil groove of upper thrust plate should be outward (toward the crankshaft).
3. Wipe the main bearing lower shell and the main bearing cap, and then press the main bearing lower shell into
the main bearing cap and refit the lower thrust plate.
1) The oil groove of lower thrust plate should be outward (toward the crankshaft).
2) Check the lower thrust plate for damage.
3) Apply Lithium-based grease for automobile to the inner side of lower thrust plate.
4. Refit the main bearing cap onto the engine block, refit the main bearing bolt, and check that the crankshaft
axial clearance is (0.12~-0.3) mm.
129
5.41 Main bearing shell assembly

Fig. 5-92 Exploded view of main bearing bush assembly

Main bearing lower Main bearing upper
1 2 3 Crankshaft
shell shell

1. Tools: Torque wrench, automatic tightening machine and traveling crane.
2. Preparations: Remove the flywheel housing, flywheel, front end cover, crankshaft pulley, main bearing cap,
piston and connecting rod.
1. Push out the bearing shell from the side by hand, and then mark it in relation to the seat holes of the engine
block and main bearing cap.
1. Clean the bearing shell, and check its wear condition.
2. Check the bearing shell for metal peeling, locating lip damage and transverse cracks.
1. Clean the main bearing shell and its mounting bottom hole firstly;
2. If the bearing bushes are not replaced with new ones, fit the upper half (with groove) into engine body and
the lower half into the main bearing cap in sequence; if the bearing bushes are replaced with new ones, install
them directly. Align the bearing bush lips and apply lubricating oil when assembling.
130
5.42 Dipstick assembly

Fig. 5-93 Exploded view of oil dipstick assembly

Oil dipstick Hexagon flange bolt Oil dipstick fixing Oil dipstick tube
1 2 3 4
assembly （M8*16） bracket upper assembly
Oil dipstick tube
5
lower assembly

2. Preparations before disassembly: remove the oil pan.
131

1. Pull out the oil dipstick assembly.
2. Remove the fastening bolt of the oil dipstick tube, and take
off the tube clamp.
3. Unscrew the upper assembly of the dipstick tube with a
wrench.
4. Knock the oil dipstick tube assembly backward at the lower
end of the oil dipstick tube to drive it out from the engine
block mounting hole.
5.-94 Disassembling steps

1. Check if the oil dipstick tube is damaged or loose;
2. Check if the oil dipstick assembly is damaged;
3. Check the oil dipstick sealing ring for crack and bump.

1. Knock the lower assembly of the dipstick tube from the upper end of the dipstick tube to make it enter the
mounting hole of engine body. Apply sealant to the interference fit surface between the lower assembly of the
dipstick tube and the engine body during assembly.
2. Screw the upper assembly of dipstick tube into the lower assembly with a wrench.
3. Thread the dipstick tube fastening bolt through the pipe clamp to fix the dipstick tube.
4.Insert the dipstick assembly into the dipstick tube.
132
5.43 Engine block assembly

Fig. 5-95 Exploded view of engine block assembly

Drive gear shaft
1 2 Positioning sleeve 3 Cylinder liner 4 Engine block
bushing
Hexagon head
5 Camshaft bush 6 Cup plug 7 Screw plug 8
screw plug
Combination
9 10 Main bearing cap 11 Main bearing bolt 12 Dowel pin
sealing washer
13 Cup plug 14 Plug cap 15 Oil pressure sensor 16 Joint
pressure and
Hexagon flange Combination
17 18 Cup plug 19 temperature 20
bolt sealing washer
sensor
Hexagon socket
Hexagon head
21 tapered screw 22
screw plug
plug

2. Preparations before disassembly: Remove the transmission and clutch, flywheel, flywheel housing, gear
chamber and oil pan.
133

1. Remove the cylinder liner: Tap the bottom of the cylinder liner
with a copper hammer, knock it evenly on the circumference, and
slowly push out the cylinder liner.
Fig. 5-96 Removal of cylinder liner

2. Remove the main bearing bolts: Remove the main bearing bolts
and main bearing cap with the socket, manual or pneumatic
wrench.
Fig. 5-97 Disassembling of main bearing cap

and main bearing bolt

1. Check if the parts are complete as per the parts list. Check the state of the engine block assembly, ensuring
that the mating surfaces are free from burrs, oil stains, bump, etc.
2. plug screw of the engine block is assembled with sealant, so be careful not to damage the thread in
disassembling.
134

Disassembly and assembly of cylinder liner
[Refitting steps]
1. Take out the cylinder liner and wipe it clean with a towel.
2. Press the cylinder liner into the cylinder hole of the engine body in sequence by hand, place the special
press-fitting tool in the cylinder liner hole, pull the press block to a certain height and put it down, and press the
cylinder liner in place for two consecutive times. Repeat the above actions, and press-fit the cylinder liners of
cylinders 2-4 in place in sequence.
Note: After the cylinder liner is pressed into the engine body, it should be 0.04~0.12mm higher than the upper
plane of the engine body, and the difference between the dimensions of the four cylinder liner on the same
engine body above the upper plane of the machine block should be less than 0.05mm. When installing the
cylinder liner, make sure that the pressure acts evenly and vertically on the end face of the cylinder liner.
Disassembly and assembly of engine body plug
[Refitting steps]
Align the engine block plug screw (the surface is coated with thread sealant evenly) with the mounting hole on
the engine block, manually screw in 2-3 threads, and tighten the plug screw with a pneumatic wrench.
5.44 Engine bracket assembly

Fig. 5-98 Exploded view of the engine bracket assembly

1 Hexagon head bolt 2 Spring washer 3 Engine bracket 4 Hexagon flange bolt
135

1. Tools: Socket or wrench.
2. Preparations before disassembly: Place the engine on the turnover stand or hoist it.
1. Remove the bolt of engine bracket
2. Hold the engine bracket with both hands and take it off.
Check the engine bracket and its bolts for damage, and replace the damaged part in time if any. Check the bolt
for looseness, and tighten it in time if any.
1. Install the engine bracket based on the locating pin.
2. Tighten the hexagon flange bolts.
5.45 Urea solution pump

5.45.1 Refitting of urea solution pump
Cleaning of urea pump:
Pre-cleaning preparation:
1. Turn on the switch on the left side of the device.
2. The device prompts to add purified water.
3. Add 5L purified water each time, and observe that there is overflow at the overflow port.
Observe overflow at the

overflow port when adding 5L
purified water each time
Fig. 5-99 Adding of cleaning fluid

Cleaning of urea pump:
136
1. Connect the urea pump connector of the cleaning equipment, unplug the connector plug and connect the
adapter to the urea pump INLET connector.
2. The hydraulic connector of the adapter box is connected to the OUTLET connector of the urea pump, and the
other end is connected to the overflow port of the mainframe.
Then, connect the other

end to the mainframe
overflow port.
Fig. 5-100 Connection of hydraulic joint of adapter box

3. Connect the blowdown reverse pipe to the urea pump BACKFLOW connector.
4. Connect the electrical connector between the urea pump and the adapter box.
Connect urea pump and

electrical connector of
adapter box
Connect urea pump and

electrical connector of
adapter box
Fig. 5-101 Connection of DEF pump and electrical connector of adapter box
5. Press the start-stop button of the cleaning equipment to start working: start to build pressure, and the urea
pump pressure is stabilized at 9bar. Pulse wash it for two minutes to keep clean.
6. After the normal cleaning and maintenance of the urea pump is completed, it shows that the urea pump has
been tested and the pressure building function is normal.
7. If the pressure is not stable, the program enters the repair stage and starts the enhanced pulse cleaning. If it
shows that the pressure buildup fails after the urea pump is cleaned, please replace the urea pump.
137
Installation of urea pump:

The metering jet pump shall be installed according to the strict directional requirements and the upward arrow
on the pump body, as shown in the figure below.
This direction is upward

Fig. 5-102 Directionality of installation of metering jet pump
The vibration acceleration at the installation position of the metering jet pump shall be less than 8G. If it fails to
meet the requirements, a damping pad shall be used. When installing the metering jet pump, keep its Z axis
vertical and fix it with four M8 bolts. The flatness of the mounting surface shall be within 0.5 mm. When
installed on the vehicle, the special protection is not required for the metering jet pump. It is recommended to
install it in a position with less rain splash and dirt to prevent accidental damage to the connector. If there is a
possibility of accidental collision with other parts or stones, a protective cover is required. Protection class IP69K.
The connection between the metering jet pump and the nozzle shall use a hose to allow for relative vibration
between it and the exhaust pipe.
The metering jet pump shall be installed close to the liquid storage tank. In order to reduce the possibility of air
interception inside the liquid supply pipe, the liquid supply pipe shall as short as possible, and the longest shall
not exceed 6 meters.
When the metering injection pump harness is connected, the power shall be taken from the main switch of the
vehicle battery, and a 10A safety device must be provided to the positive line of the power supply.
5.46 Urea solution nozzle

5.46.1 Refitting of urea solution nozzle
Cleaning of urea nozzle:
Pre-cleaning preparation:
138
1. Turn on the switch on the left side of the device.

2. The device prompts to add purified water.
3. Add 5L purified water each time, and observe that there is overflow at the overflow port.
Observe overflow at the

overflow port when adding 5L
purified water each time
Fig. 5-103 Adding of Cleaning Fluid

Urea nozzle cleaning steps:
1. Connect the cleaning equipment with the urea nozzle hydraulic connector and electrical connector;
Fig. 5-104 Connecting the cleaning equipment to the urea nozzle joint
2. Press the start/stop button of the cleaning equipment to start working, and the urea nozzle starts to spray;
3. After the normal cleaning and maintenance of the urea nozzle is completed, the injection volume of the
orifice is normal. If the nozzle is cracked and leaks, replace the nozzle. If there is no abnormality, the
maintenance is completed;
4. If the injection is abnormal, the program enters the repair. If it shows that the orifice is blocked or constantly
spraying and cannot be repaired, please replace the urea nozzle.
139
Installation of urea nozzle:
The urea injection unit (urea nozzle) is a stainless steel nozzle, with an injection volume of 50~5000ml/h. It is
composed of urea pipe joint, sealing gasket and fixing nut (M6), as shown in the figure below.
urea nozzle
Urea pipe connector
Fixing bolt hole
Figure 5-105 Reference drawing of nozzle

Installation requirements of urea nozzle:
The air-assisted nozzle is installed on the mounting seat with 3 M6*25 nozzles and the tightening torque is
8±2Nm. The nozzle has only one urea pipe interface, and the size is 1/4' (6.3mm), which does not require
electrical control and cooling water cooling.
The orientation of the urea nozzle shall be consistent with the exhaust flow. The urea nozzle is installed on a
bell-shaped device at the inlet of the integrated SCR catalytic muffler. The installation of the urea nozzle
depends on the installation position and angle of the nozzle seat, as shown in the figure below.
Fig. 5-106 Installation position of nozzle seat
5.47 Urea solution tank

5.47.1 Cleaning and installation of DEF tank and DEF tank filter element
Clean the urea tank and urea tank filter element:
140
1. Empty the urea in the tank, use a #10 Allen wrench to

rotate counterclockwise to remove the drain bolt at the
bottom of the urea tank, and drain the urea from the vehicle.
Fig. 5-107 Removal of drain bolt
2. Remove the liquid level and temperature sensor, unplug

the sensor pipeline, and rotate the liquid level and
temperature sensor 90° counterclockwise as shown in the
figure to remove it;
3. For the cleaning method of Weichai urea tank, flush the
inner wall and bottom of the urea tank with a water pipe with
a certain pressure from the sensor mounting hole until the silt
and impurities on the side wall and bottom are removed, or
use a tool to clean the inside of the urea box with full water,
and drain the cleaning water from the drain bolt;
4. Cleaning methods for urea tanks not provided by Weichai
OEM; The cleaning method is the same. Because the boss of
the drain bolt at the bottom of some urea tanks not provided
by Weichai is too high, the sludge and impurities contained in Figure 5-108 Rotate the liquid level and
the cleaning water are easy to accumulate, and the urea tank temperature sensor by 90°C.
cannot be completely cleaned. Remove the urea tank during
cleaning. After cleaning, shake the urea tank, and pour the
cleaning water out of the sensor mounting hole;
5. Install the drain bolt clockwise.
Installation of urea tank and urea tank filter element:
141
1. Before refitting the urea solution tank, make sure that the
interfaces of the temperature & level sensors are well
protected as shown in the figure on the right, for fear of debris
entering the system pipeline, causing the system failure in
work.
2. When refitting the urea solution tank onto the vehicle, keep
away from heat sources, and avoid the risk of the deterioration
of urea solution due to the radiation from heat sources such as
engine, transmission, SCR catalytic converter and exhaust pipe.
Fig. 5-109 Well-protected joints of level &

temperature sensor
The water outlet is Water flows as per

located at the the arrow direction
3. The freezing point of urea solution is -11.5°C. When the downstream side of the
water pump and the
upstream side of the
thermostat.
on the solenoid
valve
system is working at low temperature, the urea solution will Water outlet Solenoid
valve
freeze and the system will not work. Therefore, the urea Return port Heating water inlet
Heating water outlet
solution tank shall be thawed. The urea solution tank is thawed The return position
is in the negative
pressure zone of the
and heated by the engine coolant. The flow path of heating water inlet of the
pump
water is shown in the figure on the right.

Fig. 5-110 Flow path of system heating water
5.48 Urea solution pipeline

5.48.1 Refitting of urea solution pipeline
1. The urea solution pipeline is the passage of urea solution.
Ensure that both ends are well protected before refitting. As
shown in the figure on the right, dirt and impurities shall be
prevented from entering the pipeline and further entering the
system, which may result in system failure.
2. The urea solution pipeline shall be refitted correctly.
Otherwise, the system will not work. Confirm the sizes of the
urea solution pipe fittings before refitting. The type of each
quick connector shall match the type mark on the tank, pump
and urea solution nozzle. The table below shows the matching
relationship between urea solution pipes and water pump, urea Fig. 5-111 Checking for proper protection
solution tank. before installation
142
Interface name Description of interface Dimensions - pump End Dimensions - box End
Connect urea tank outlet and
Suction line SAE J20443/8'' SAE J20443/8''
urea pump inlet
Connect the urea pump outlet
Liquid return pipeline SAE J20445/16'' SAE J20445/16''
and urea tank return port
Connect urea pump injection
Pressure pipeline SAE J20441/4'' SAE J20441/4''
port and urea nozzle
QS series type F Quick QS series type F Quick
Connect compressed air
Air pipeline connector outer connector outer
pipeline and urea pump filter
diameter: 6mm diameter: 6mm
QS series type F Quick QS series type F Quick
Connect urea pump filter and
Filter pipeline connector outer connector outer
urea pump air inlet
diameter: 6mm diameter: 8mm
Note: The inner diameter of the matching pressure pipeline of the OEM is required to be 3 mm.
143
3. The urea solution pipes shall not be bent during refitting. If

the pipes are bent severely as shown in the figure on the right,
the system will not work.
Fig. 5-112 Serious bending of the urea

solution pipeline
5.49 Sensor
5.49.1 Installation of sensor and cleaning of suction strainer
In addition to the liquid level temperature sensor integrated in the DEF tank, the DeNOx2.2 system sensors
involved in the after-treatment also include the exhaust temperature sensor, NOx sensor and ambient
temperature sensor.
1. The NOx sensor and exhaust temperature sensor shall be installed perpendicular to the air flow direction.
Before the integration of the sensors, enough clearance shall be reserved for disassembly; When installing the
NOx sensor probe, the tightening torque shall be 50N·m, and the harness shall be prevented from contacting
high-temperature objects; The exhaust temperature sensor shall be tightened 45N·m ± 5N·m.
2. The ambient temperature sensor shall be installed at a position that can objectively reflect the ambient
temperature, so as to avoid the influence of the vehicle heat source on the sensor measurement.
144
3. The NOx sensor shall be installed perpendicular to the

exhaust pipe and positioned at the outlet of the exhaust
tailpipe and the after-treatment box at an angle of -80°~80°.
The right figure shows the installation angle of NOx sensor.
Exhaust gas
pipe
Fig. 5-113 Mounting angle of the NOX sensor
4. The remaining harness shall be fixed with clamps, to avoid

loosening and damage of harness connectors caused by
vibration during vehicle operation, resulting in interruption
and failure of signal transmission and abnormal system
Fixed point of
operation. When fixing, the bending angle of the harness shall wire harness
not be too large, otherwise the wire will be easily damaged
after long-time operation. Fixing requirements of wire harness: Wire harness
L1>10mm; the length of arc segment L2>50mm; α shall be
within 45~135°. The definitions of parameters are shown in the
figure on the right.
Fig. 5-114 Fixing requirements for sensor and
actuator harness
5. Pay attention to the following cautions when fixing wire

harnesses:
1) For the connection of wire harnesses to connectors, there
shall be no visible wires openly exposed, and the insulation
sheath be intact. When the harness is laid on the vehicle,
adequate protective measures shall be taken to avoid contact
with sharp edges of the vehicle, so as to prevent the harness
against wear and short circuit during the long-term operation
of the vehicle. It is required that the connectors shall be
connected in place to avoid false connection. Otherwise,
unnecessary trouble will be brought to vehicle off-line and Fig. 5-115 Protective wrapping of harness
diagnosis. Moreover, in order to ensure the reliability of signal
communication, the harness shall be bound and fixed orderly.
145
2) At the harness connector, it shall be ensured that the

harness will not be bent too much, and the wire connector
will not be affected by impurities such as oil, water, debris,
mud, etc. If any metal wire head is exposed, it shall be
wrapped with tape to avoid short circuit. The figure on the
right shows the fixation method of wire harnesses of exhaust
temperature sensor and NOx sensor.
Fig. 5-116 Correct fixing method of harness
Cleaning of filter screen at suction port of DEF tank sensor

1. Separate the plastic clip and pull out the filter screen.
2. Clean the filter screen with purified water until the surface
is free of impurities.
Plastic
buckle
Fig. 5-117 Schematic diagram of plastic clip
3. Install the cleaned filter screen, and be careful not to omit 1. Shaft sleeve
the shaft sleeve and sealing ring.
2. O-RING
4. Press and rotate the DEF tank sensor clockwise to
assemble it on the DEF tank. Be careful not to omit the
rubber sealing ring. 3. Filter
screen
5. Reinstall the DEF inlet and return pipes and two cooling
water pipes onto the DEF tank sensor.
Fig. 5-118 Schematic diagram of filter screen
146
5.50 Operation and maintenance of air-assisted urea solution injection system

5.50.1 Maintenance instructions of air-assisted injection system
ECU: DCU BAM timeout (P0060): ignore the historical fault; as for active fault, check the circuits; if the circuits
are normal, check the connectors for water ingress. If all mentioned above are normal, replace the urea solution
pump;
Excessive emission: actual conversion efficiency of SCR below ... (P01FA, P01FB): prove that the hardware is in
good condition, and communicate with the customer about changing fuel.
DCU: message related fault; no treatment is required; clear the fault if you can, otherwise, let it be; Pressure
sensor voltage signal implausible: replace the urea solution pump if the fault is active; Inlet pipe fault, return
pipe fault, air pipe fault, nozzle or injection pipe clogging: check the related pipes; the inlet pipe fault is normally
related to urea solution tank, the air pipe fault is mostly due to insufficient pressure of air reservoir, injection
pipe fault is mostly due to bending, and return pipe fault is mostly due to internal fault of urea solution pump,
requiring replacement of the urea solution pump.
Principle:
For the exhaust aftertreatment system, do troubleshooting only when a fault comes up. The related indicator
lamp will not come on if no DTC is activated, which means that the power of the engine will not be affected.
If the urea solution level does not change, handle the fault according to the DTC if any; if there is no DTC active,
it indicates that the ambient temperature and urea solution level sensor is abnormal, or the running condition
fails to meet the injection requirements.
Inlet pipe fault
Fault effect: ECU reports 005C, the indicator lamp comes on immediately, and the engine torque limit is
activated immediately;
1. Check the inlet pipe for clogging, crystallization, bending, etc.
2. Check the strainer of the urea solution pump inlet.
3. Where the urea solution in the urea solution tank is insufficient, check if the level of the urea solution tank is
consistent with the indication on the instrument; it may be the case that the urea solution in the tank is
insufficient but the urea solution level sensor fails to detect that.
Return pipe clogging
Fault effect: ECU reports 005B, the indicator lamp comes on but the engine torque limit is not activated;
1. Check the return pipe for clogging, and clean the pipe.
2. If the fault is caused by damaged urea solution pump internal pressure sensor, please switch on the power
supply again to check if the fault of pressure sensor occurs again. And if so, it indicates that the pressure sensor
is abnormal. In that case, please replace the urea solution pump. If not, check the return pipe.
Air pipe fault
1. The pressure of air reservoir is low. In such a case, check if the reading of the air pressure gauge is over 6 bar;
2. The air pipe is separated or leaking. In such a case, check the air pipe for leakage;
3. The compressed air filter is clogged. In such a case, connect the air pipe directly to the urea solution pump for
testing;
4. The compressed air pipe is bending or squashed. In such a case, check the pipe.
147
Injection pipe or nozzle clogging
1. Nozzle clogging. When testing the exhaust aftertreatment system, check the urea solution nozzle for clogging,
and clean and repair it. As for the air-assisted injection system, the urea solution nozzle will not be clogged by
crystallization. The clogging problem is because of the impurities in the urea solution. In that case, purge the
urea solution nozzle in reverse direction.
2. Injection pipe bending. Check if the injection pipe is bent, for the pipes are often bundled for arrangement in
vehicle; if so, please restore the injection pipe back to natural state.
High/low power supply voltage
Fault activating condition: when urea solution pump voltage goes above 32V or below 16V, the fault is reported;
In such a case, check the vehicle harness voltage of the connectors of urea solution pump; if the voltage satisfies
the fault activating condition, please repair the vehicle battery.
Message related fault
Faults of this type are further divided into the following two situations: “timeout (or failure to receive signal)”
and “abnormality”.
Message timeout indicates that DCU can not find ECU in working mode;
Message abnormality indicates that DCU receives wrong signal from ECU.
148
Appendix B Fit Clearance of Main Engine Parts
No. Item Theoretical value/mm

1 Main bearing clearance 0.059～0.117
2 Crankshaft axial clearance 0.075 ~ 0.235
3 Connecting rod bearing clearance 0.050～0.109
4 Axial clearance of connecting rod plane 0.1 ~ 0.3
Clearance between connecting rod small
5 0.025～0.043
end bush and piston pin
Clearance between piston pin seat and
6 0.005～0.019
piston pin
Working clearance of piston ring opening
in cold state 0.20～0.45
7 First compression ring 0.40～0.60
Second compression ring 0.20～0.45
Oil ring
Piston ring end face clearance at cold
state 0.08～0.13
8 First compression ring 0.06～0.10
The second ring 0.04～0.08
Oil ring
Clearance between intake valve stem
9 0.025～0.062
and guide
Clearance between exhaust valve stem
10 0.04～0.077
and guide
11 Valve depression 0.4±0.1
Clearance between front journal of
12 0.089 ~ 0.139
camshaft and inner diameter of bush
Clearance between tappet and tappet
13 0.016~0.052
hole
Clearance between rocker arm and
14 0.016~0.045
rocker arm shaft
Intake valve: 0.35 ~ 0.4
15 Valve clearance in cold state
Exhaust valve: 0.4 ~ 0.45
149
Appendix C Tightening Torque of Other Main Bolts of Engine
Allowed Times of Use

Item Bolt Specification Torque (N·m) (Including the First
Installation)
Crankshaft nut
(260～300)N·m+(560～600)N.m
M30×1.5
Crankshaft pulley bolt Crankshaft pulley

and crankshaft
(50～70)N·m+(140～150)N·m
connecting bolt
M12×1.5
Exhaust pipe bolt M10×1.5 (65-80) N•m 2
Locking nut of
M8×1.25 (28±3) N•m 1
supercharger
Valve clearance
M8×1 (27±3) N•m
adjusting nut
Tensioner and idler
M10×1.5 (50±5) N•m
bolt
Locking bolt of air
M18×1.5 (130～150) N·m
compressor gear
Fuel injector pressure
M8×1.25 (29±1) N•m
plate bolt
Intermediate gear
M10×1.5 54N•m 1
shaft bolt
Camshaft gear bolt M12×1.75 (65～75) N·m 1
Fuel injection pump
M14×1.5 (90～95) N.m
gear compression nut
Camshaft press plate
M12 (115±5)N·m
bolt
150
Quality Standard
XK06-002-00352
Weichai Power Yangzhou Diesel Engine Co., Ltd.
Address: No. 218, Chunjiang Road, Yangzhou City, Jiangsu Province
Postcode: 225131
Service hotline: 4006183066
This document is for reference only. Product parameters or pictures are subject to change
without prior notice. The actual product shall prevail.

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1000374003

Maintenance Manual of WP3.7/WP4.1 Series China

Weichai Power Yangzhou Diesel Engine Co., Ltd.

WP3.7/WP4.1 Series China V Vehicle Diesel Engine

♦ Always read this Maintenance Manual carefully before

Do not touch the high-speed rotating part with

Tightening torque requirement

Wear gloves Risk of electric shock

Wear protective clothing Risk of mechanical injury

Risk of being caught up in

Wear helmet Be aware of steam

Wear safety shoes Risk of explosion

Wear protective mask Risk of corrosion

Keep ventilated Risk of scalding

Torque control Avoid winding

Checks required No open flame

Tool requirement No smoking

Serious warning No touching

Precautions for Engine Disassembly and Maintenance

Chapter I Operation Instructions ....................................................................................................................1

Chapter I Operation Instructions

1.1 Outline drawing of engine

Fig. 1-1 Outline drawing 1 of engine (intake side)

No. Name No. Name No. Name No. Name

Fig. 1-2 Outline drawing 2 of engine (exhaust side)

No. Name No. Name No. Name No. Name

Fig. 1-3 Outline drawing 3 of engine (fan end)

1.2 Description of engine model

Product variant code

Emission level code

Product series code

1.3 Main specifications

Items Technical Parameters

Fig. 1-4 Hoisting of engine

Items Technical Parameters

Chapter II Maintenance of Diesel Engine

2.1 Fuel, lubricating oil, coolant and auxiliary materials

Category Grade Packing specification

Applicable ambient Applicable ambient

Table 2--2 Oil Viscosity and applicable ambient temperature (cont'd)

Applicable ambient Applicable ambient

2.1.3 Engine coolant

Category Grade Packing specification

Coolant filling steps:

Tab. 2-5 Urea ingredients

Composition Unit Lower limit Upper limit

Storage of urea solution

Shelf life of urea solution for vehicle

Table 2-6 Shelf life of urea solution for Vehicle (continued)

Shelf life of urea solution for vehicle

2.1.5 Auxiliary materials

No. Name Color Purpose and application

The reference for sealant application of engine is given in Table 2-8.

Designation Main purpose Examples of application position Comments

2.2 Daily maintenance

Fig. 2--1 Check of fan

2.2.2 Daily maintenance

Fig. 2-2 Coolant filler cap