YND20 ENGINE SERVICE MANUAL

Service Manual
——D20 Series China VI Diesel Engine
KUNMING YUNNEI POWER CO., LTD.

Contents
Introduction............................................................................................................................................... 1
Foreword ................................................................................................................................................... 2
Notice ......................................................................................................................................................... 3
Chapter I Main Technical Specifications and Data .......................................................................... 4
I. Main technical specifications ........................................................................................................... 4
II. Specifications of main accessories ................................................................................................. 4
III. Main technical data.......................................................................................................................... 6
IV. Size, fit clearance and wear limit of main parts ............................................................................... 8
Chapter II Disassembly ...................................................................................................................... 10
I. Maintenance requirements and precautions of engine ................................................................. 10

II. Disassembly of engine assembly ...................................................................................................11
III. Disassembly of engine assemblies ................................................................................................11

Chapter III Assembly ........................................................................................................................... 31
I. Assembly of piston cooling nozzle, crankshaft, flywheel and clutch assembly ............................ 31
II. Assembly of piston rod unit ........................................................................................................... 32

III. Assembly of oil pump and pressure regulating valve ................................................................... 33
IV. Subassembly and assembly of cylinder head ............................................................................... 33
V. Assembly of water pump, oil pump, gear housing and flywheel housing ..................................... 35
VI. Assembly of timing linkage and chain cover ............................................................................. 36
VII. Assembly of valve cage cover, oil module assembly, oil pan, and flywheel assembly ............. 37
VIII. Installation of intake and exhaust system and fuel system ....................................................... 38
IX. Cooling system .............................................................................................................................. 40
X. EGR system assembly .................................................................................................................. 40
XI. Installation of accessories ............................................................................................................. 41
XII. Installation, use, and maintenance of electronic-control high-pressure common-rail system .. 41

XIII. Installation and adjustment of engine assembly........................................................................ 66
Chapter IV Maintenance and Inspection ........................................................................................... 68
I. Engine body assembly .................................................................................................................. 68
II. Cylinder head ................................................................................................................................ 69
III. Valve timing mechanism ................................................................................................................ 71
IV. Crankshaft, flywheel and clutch..................................................................................................... 73

V. Piston rod assembly ...................................................................................................................... 75
VI. Transmission gear train ................................................................................................................. 76

VII. Lubrication system ..................................................................................................................... 77
VIII. Cooling system .......................................................................................................................... 79
IX. Electronic-control common-rail system ......................................................................................... 81
X. Electric system .............................................................................................................................. 81
XI. Air inlet and supercharged and mid-cooling system ..................................................................... 82

Chapter V Use and Maintenance of Aftertreatment System .......................................................... 89
I. General requirements for aftertreatment system .............................................................................. 89

II. Maintenance of aftertreatment system ............................................................................................. 91
III.Technical parameters of main parts of electronic control system of aftertreatment system ............ 93
IV. Maintenance and installation of aftertreatment system................................................................... 94
V. Common faults and handling methods ........................................................................................... 103

Chapter VI Fault Code of Electric Control System and Aftertreatment System ......................... 107
Chapter VII Use of Diesel Engine .................................................................................................. 129
I. Diesel ............................................................................................................................................... 129
II. Engine oil ........................................................................................................................................ 130
III. Coolant, storage battery, power steering pump, and air compressor ........................................... 131
IV. Starting of diesel engine ................................................................................................................ 134
V Running-in of diesel engine............................................................................................................. 136
VI. Operation of diesel engine ............................................................................................................ 136
VII. Stop of diesel engine .................................................................................................................... 137

VIII. Safety warnings ........................................................................................................................... 138
Chapter VIII Maintenance of Diesel Engine ................................................................................... 139
I. First forced running-in maintenance ................................................................................................ 139
II. Regular forced maintenance .......................................................................................................... 139

III. Routine maintenance ..................................................................................................................... 140
IV. Technical maintenance in winter ................................................................................................... 140
Chapter IX Analysis and Troubleshooting for Common Faults.................................................... 142
I. Difficult starting ................................................................................................................................ 142

II. Unstable low idling speed (idle speed) ........................................................................................... 143
III. Unstable revolving speed .............................................................................................................. 143
IV. Insufficient diesel engine power .................................................................................................... 144
V. Limited revolving speed .................................................................................................................. 144
VI. Shutdown of diesel engine ............................................................................................................ 145

VII. Abnormal smoke exhaust ............................................................................................................. 146
VIII Overheated diesel engine ............................................................................................................ 146
IX. Abnormal noise during operation of diesel engine ........................................................................ 147
X. Excessive engine oil consumption ................................................................................................. 148
XI. Excessive fuel consumption .......................................................................................................... 148
XII. Failure of lubrication system ........................................................................................................ 149

XIII. Failure of cooling system ............................................................................................................ 149
XIV. Aftertreatment system ................................................................................................................. 150

XV. Starter failure ................................................................................................................................ 150
XVI. Failure of charging generator ..................................................................................................... 151
XVII. Air compressor failure ................................................................................................................ 151
XVIII. Fault diagnosis of turbocharger ................................................................................................ 152
XIX. Failure of power steering pump .................................................................................................. 154
XX. Case study on the maintenance of electronic-control high-pressure common-rail diesel engine
............................................................................................................................................................ 155
Chapter X Fault Diagnosis ............................................................................................................... 174
Chapter XI Storage ............................................................................................................................ 174

Introduction
"Yunnei" D20 series electronic-control high-pressure common-rail diesel engine is
developed by Kunming Yunnei Power Co., Ltd. on the basis of D19TCI diesel engine
developed by Yunnei in cooperation with FEV. The product adopts four-valve, double
overhead camshafts, roller rocker, BOSCH electronic-control high-pressure common-rail
system, DOC + DPF + SCR + ASC aftertreatment, etc. It meets the requirements of the
latest national emission regulations (China VI), and is suitable for the new generation of
energy-saving and environmental-protection high-speed diesel engine for light commercial
vehicles. This series of diesel engine has passed the test under high temperature (+ 40 ℃),
plateau (4500m), and high cold (- 25 ℃) conditions, with low fuel consumption, low noise,
good acceleration, high reliability, low emission, convenient use and maintenance, etc. It is
therefore an ideal power for pickup and light truck. It can also meet the performance (power,
economy, operability, comfort) requirements of different matching models through
calibration and demarcation with the full vehicle.
This manual is provided by Kunming Yunnei Power Co., Ltd. and is written for professional
maintenance/technical personnel. With excellent texts and accompanying pictures, it has
strong practicability. This manual introduces in detail the main technical parameters,
structure, principle, use, maintenance and troubleshooting methods, which can be used as
a basis for the use and maintenance of the engine. The pictures, photos and parameters in
this paper are for reference only, and the actual product shall prevail.
1
Foreword
Thank you for choosing the vehicle equipped with Yunnei diesel engine. This manual is
prepared for you to understand the use, maintenance and repair of Yunnei diesel engine.
To ensure your personal and property safety, please read this manual before use.
Please remember the Yunnei service hotline and the service phone of the Yunnei marketing
department in your area. If you need any service or have any questions about the engine
you purchased, please contact us by phone, and we will provide you with warm help.
In this manual, the symbol “ ” indicates the danger that may cause personal injury and
other damages. Please strictly follow the operation procedures.
In this manual, the word "attention" indicates the danger that may cause slight injury to
people or damage to parts. Please carefully follow the operation procedures.
2
Notice
1. To ensure your personal and property safety, please read this manual carefully before
use. And the diesel engine shall be used, maintained and repaired in strict accordance
with the manual.
2. The starting, running in, operation and shutdown shall be carried out correctly
according to the requirements in this manual. The new engine or the overhauled diesel
engine must be run in before use. The running in can make the surface of all moving
parts achieve good coordination, so as to avoid abnormal wear and damage. The
service life, reliability and economy largely depend on the running in, so please run in
strictly according to the specification. Do not run in at idle speed in-situ.
3. The operator shall pay attention to the safety warning signs and shall not be close to
the area with safety warning during the operation of diesel engine.
4. To extend the life of starter and battery, the continuous starting time shall not exceed 15
seconds. When it needs to be started again, turn the ignition key back to the OFF
position and wait for 2 minutes.
5. It is not allowed to remove the air filter during use. The air filter shall be maintained
according to regulations. During reassembly, the upper and lower gasket of filter
element shall be installed to ensure sealing.For connecting the air filter with the hose,
the hose shall be firmly clamped to prevent the hose from being worn out due to the
vibration. Avoid unfiltered air entering the cylinder.
6. Electronic control oil supply system is an important system of diesel engine. Its
components(ECU, high-pressure fuel rail, high-pressure oil pump, fuel injector, harness,
relevant sensors, and actuator) shall not be disassembled or adjusted at will. When
adjustment is needed, it must be carried out at the technical service station authorized
by Yunnei.
7. After the run-in period expires, please go to our company's special service station for
maintenance according to the requirements of the attached Engine Service Manual.
8. Please refer to the Engine Service Manual for details of "three guarantees".
9. Please keep the engine "certificate" and "Engine Service Manual" properly.
3
Chapter I Main Technical Specifications and Data
I. Main technical specifications
Table 1
Model D20TCIF
In-line, water-cooled, four-stroke, supercharged and
Type
mid-cooling, high-pressure common rail
Number of cylinders × diameter ×
4×81×97
stroke
Total displacement of piston L 1.999
Cylinder sleeve type No cylinder sleeve
Combustion chamber type Direct injection
Air-breathing mode Supercharged and mid-cooling
Compression ratio 16.2:1
Low idling speed r/min 800
High idling speed r/min ≤3520
Rated power / speed
93/3200
kW/r/min
Maximum torque / speed
350/1600~2500
N·m/r/min
Minimum fuel consumption rate
≤205
g/kW·h
Engine fuel ratio % ≤0.2
Working sequence of each cylinder 1-3-4-2
Crankshaft rotation direction Clockwise (from the front of diesel engine)
Lubrication mode Pressure-spatter mixing
Cooling mode Forced circulation water cooling type
Engine oil capacity L 5.5
Aftertreatment DOC+DPF+SCR+ASC
Exhaust emission China Ⅵ
Net weight kg 210~250
II. Specifications of main accessories

Table 2
Name of accessories Specification of accessories
High pressure oil Type High-pressure common-rail pump

pump Model CB4
High pressure fuel Type Hot forging rail
rail Model HFR-20
Type Electronically controlled
Fuel injector
Model CRI1-20
Type Paper filter-element rotation type
Diesel filter
Model YN33CRD-11510-1
4
Oil-water Type Paper filter-element rotation type
separator Model YN33CRD-11500-1
Oil filter Type Filter element type
Type Centrifugal
Water pump The flow is 200L / min and the lift is 15m at water temperature
Rated flow
of 80℃ and speed of 6680rpm.
Type Rotor pump
Oil pump
Rated flow ≥70L/min(at 3200r/min)
Type DC deceleration
Starting motor Model and
QDJ2581(24V/3.7kW)
specification
Type Silicon rectifier
Charging
Model and
generator 70A/28.5V
specification
Glow plug Model 24V
Type Waxy thermostat
Thermostat
Temperature Opening temperature :78±2℃; full-opening temperature: 92℃
Type 6PK poly V-belt
Accessory belt
Specification 6PK2660
Technical parameters of main parts of electric control system Table 3

Nominal voltage V 24
Working voltage range V 8～32
Working environment temperature ℃ -40～70
ECU
Maximum internal temperature ℃ 105
Atmospheric pressure measurement
kPa 50～115
range
Working voltage V 5±0.15
Water temperature
20℃ kΩ 2.5±0.15
sensor Thermistor
100℃ kΩ 0.186±0.004
(TF-W)
Working temperature ℃ -40～130
860±86 (at below
Crankshaft position Coil resistance Ω
20℃)
sensor
Working clearance of sensor mm 0.5～1.5
(DG6)
Nominal voltage V 5
Camshaft position sensor Working voltage range V 4.7～18
(PG3.8) Working clearance of sensor mm 0.3～1.0
Rated pressure MPa 200
Fuel rail
Maximum axial force of installation kN 21
Working voltage of rail pressure sensor V 5±0.25
5
Working voltage V 5±0.25
Intake pressure
temperature sensor
Pressure range kPa 20～300
Rated voltage V 24
Glow plug (24V)
Running current(at 20s) A
Working pressure MPa ≤0.2
Rated flow L/h 300
Voltage of water level sensor V 24
Oil-water separator Resistance of water level sensor kΩ 560±5.6
Pressure difference between inlet and
kPa 10(at rated flow)
outlet of filter element
Burst pressure MPa ≥1
Oil-water separation efficiency ≥95％
Working pressure MPa ≤0.2
Rated flow L/h 300
Diesel filter Pressure difference between inlet and
kPa 15(at rated flow)
outlet of filter element
Filtration accuracy and efficiency 3～5μm；≥95.5％
Rated speed r/min 3000
Oil supply per cycle mm 3 657

/rev
Fuel injection pump
Rated rail pressure bar 2000
Clockwise (from the
Rotation direction
front)
Working environment temperature ℃ -30～120
Fuel injector (at 10MPa
Flow cm 3
pressure,30s)
III. Main technical data

1. Valve timing (based on crank angle) Table 4
Opening of intake valve (before TDC) 32.8°
Closing of intake valve (after BDC) 47.2°
Opening of exhaust valve (before BDC) 41.3°
Closing of exhaust valve (after TDC) 30.7°
2. Various temperature and pressure ranges of diesel engine Table 5

Model D20TCIF
Discharge temperature at 15 min power ≤ 750℃
Oil temperature under declared working condition ≤ 120℃
Outlet water temperature of cooling water under declared working condition ≤ 95℃
Oil pressure 200~600kPa
Oil pressure at the lowest idle speed ≥ 100kPa
3. Tightening torque of main bolts Table 6

6
Name Specification Tightening torque N.m
Main bearing bolt M11×1.5-10.9 Rotation angle method 50Nm+120°
Connecting rod bolt M9×1-10.9 Rotation angle method 30Nm+120°
Flywheel bolt M10×1-10.9 Rotation angle method 40Nm+90°
Cylinder head bolt (KAMAX) M12×1.5-10.9 Rotation angle method 50Nm+270°
Mounting bolt for camshaft cover M6 11～15
Mounting screw for fuel pump flange M8 22～29
Gland nut for fuel pump shaft end M18×1.5 85~90
Camshaft sprocket bolt M12×1.5-10.9 Rotation angle method 80Nm+45°
Bolt for moving rail and fixed rail of chain M8 22～28
Tensioner of fuel pump chain M22x1.5 60
Camshaft chain tensioner bolt M6 8～12
Fixing bolt of chain cover M6 10～14
Torsion damper bolt M18x1.5-10.9 400~450
Flywheel housing bolt M12 75～85
Drain plug of oil pan M14×1.5 35~45
Glow plug M8×1 8～10
Fixing bolt of fuel rail M8 22～29
Union nut of fuel rail end M14×1.5 26～30
Union nut of fuel pump end M16×1 33～37
Union nut of fuel injector end M14x1.5 20~24
Compression bolt of pressing plate of fuel injector M8-10.9 34～38
Exhaust pipe nut M8 36～40
Supercharger nut M8 36～40
Bolt of oil inlet of supercharger M10×1.5 20~28
Bolt of oil inlet of supercharger M12 32~40
Connecting nut of generator M8 23～27
Fixing bolt of generator bracket M10 43~47
Bolt of automatic tensioning wheel M10 40～50
Bolt of fan connecting shaft M8 23～27
Water temperature sensor M12x1.5 16-18
EGR exhaust temperature sensor M14x1.5 35~40
4. Main installation data Table 7

Valve deflection of new engine 0.85~1.15 mm
The length of the nozzle head extending out of the bottom plane of the cylinder head 2~2.7mm
Clearance between crankshaft position sensor and signal tooth 0.5~1.5mm
Clearance between camshaft position sensor and signal tooth 0.3~1.0mm
5. Tightening torque of common bolts and nuts (for reference) Table 8

Nominal diameter of bolt mm
Bolt strength grade 6 8 10 12 14 16 18 20
Tightening torque N.m
4.6 4~5 10~12 20~25 35~44 54~69 88~108 118~147 167~206
7
5.6 5~7 12~15 25~31 44~54 69~88 108~137 147~186 206~265
6.6 6~8 14~18 29~39 49~64 83~98 127~157 176~216 245~314
8.8 9~12 22~29 44~58 76~102 121~162 189~252 260~347 369~492
10.9 13~14 29~35 64~76 108~127 176~206 274~323 372~441 529~637
12.9 15~20 37~50 74~88 128~171 204~273 319~425 489~565 622~830
IV. Size, fit clearance and wear limit of main parts

Table 9
Fit dimension Fit tolerance Wear limit
No. Name of parts
mm mm mm
0.01
Inner diameter of cylinder hole φ81( 0 ) 0.0775～
1 0.15
Outer diameter of piston skirt φ80.915±0.0075 0.1025
0.012
Piston pin hole φ30 (  0.006 ) +0.006～
2 0.03
Outer diameter of piston pin φ30
0
( 0.005 ) +0.017
0.033
Bushing hole of connecting rod small end φ30( 0.02 )
3 0.02～0.038 0.08
0
Outer diameter of piston pin φ30( 0.005 )
+0.069
Main bearing bush hole of crankshaft φ60 ( +0.03 )
4 0.03～0.088 0.15
0
Main journal of crankshaft φ60 ( 0.019 )
0.034
Bearing bush hole of connecting rod φ50 ( 0.018 )
5 0.018～0.053 0.15
0
Connecting rod journal of crankshaft φ50 (  0.019 )
6 Opening clearance of the first piston ring 0.2～0.35 0.8

7 Opening clearance of the second piston ring 0.5～0.70 1.0
8 Opening clearance of the third piston ring 0.25～0.50 1.0
9 Compression clearance 0.589～0.946
10 Axial clearance of crankshaft 0.09～0.24 0.50
11 Axial clearance of connecting rod big end +0.35～+0.63 1.0
0.021
Cam bearing seat hole φ24 ( 0 )
12 0.04～0.074 0.15
0.04
Camshaft journal φ24 ( 0.053 )
13 Axial clearance of intake camshaft 0.07～0.202 0.3
14 Axial clearance of exhaust camshaft 0.07～0.202 0.3

0.024
Hydraulic tappet hole φ12 ( 0.006 )
15 0.006～0.035 0.07
0
Outer diameter of hydraulic tappet φ12 ( 0.011 )
16 Intake valve deflection 0.85~1.15 2.0

17 Exhaust valve deflection 0.85~1.15 2.0
0
18 Thickness of inner and outer rotors of oil pump 25 (  0.02 ) 0.03~0.08 0.15
8
0.06
Depth of inner cavity of oil pump cover 25 ( 0.03 )
Meshing clearance between idler gear and
19 0.2~0.3 0.45
crankshaft gear
Meshing clearance between idler gear and
20 0.2~0.3 0.45
blast pump gear
9
Chapter II Disassembly
I. Maintenance requirements and precautions of engine
1. Non professional maintenance personnel shall not dismantle and repair the engine
arbitrarily. The customer should ask the dealer or Yunnei special service station for
repair.
2. The operator shall be familiar with the structure, technical data, parts assembly
relationship and technical dismounting requirements of the diesel engine, and master
the correct disassembly and assembly method and use methods of maintenance tools.
If the user does not have the necessary technical conditions, please contact Yunnei
special service station.
3. The disassembly sequence is generally from the outside to the inside, from the
assembly to the parts. In order to improve the assembly efficiency and ensure the
correctness of the assembly, it is necessary to check marks and mark during
disassembly. The removed parts shall be cleaned and inspected carefully. The parts
that can be reused shall be stored by category according to the assembly. The
precision parts shall be separated from the general parts and stored in clean
containers.
4. The assembly sequence is generally from inside to outside, following the principle of
first assembling parts into assembly units, then assembling assembly units into
assemblies. During assembly, pay attention to the installation dimension, orientation, fit
clearance, tightening torque, etc., and avoid missing of parts, wrong fitting, scratching
the fitting surface of parts and foreign matters falling into the engine. Proper spanner
shall be used for assembling bolts and nuts, and the force shall be even and
appropriate. Use the appropriate cotter pin, spring washer, etc. for locking. In addition,
pay attention to checking the part label and assembly mark to ensure the correct
position and movement relationship between parts.
5. Ensure that the diesel engine is always in a clean and complete state. Before
disassembling and assembling parts, the parts shall be cleaned to ensure the
assembly quality. The complex adjustment and maintenance should be carried out
indoors to prevent the inside of diesel engine being polluted.
6. The engine adopts Bosch electronic-control high-voltage common-rail system. The
negative pole must be used for battery bonding and the positive pole must be controlled
by the main power switch of the whole vehicle. The main power switch must be
disconnected during maintenance to prevent damage to ECU. The components of
electronic control system shall not be immersed in water or drenched by rain, and each
sensor shall not bear impact and gravity.
7. Look out during maintenance or disassembly and assembly to prevent bumping,
crushing, or personal injuries caused by improper use of tools.
10
8. The quality parts shall be used for the replacement.
II. Disassembly of engine assembly

If the engine must be removed and lifted out from the vehicle, the engine shall be
separated from the transmission (it is also allowed to lift the engine and transmission out
from the vehicle together after all the connections of the transmission are disassembled).
The steps are as follows:
 Turn the ignition switch to the LOCK position and disconnect the negative battery cable.
 Unscrew the drain plug on the oil pan, drain the oil, and collect it.
 Dismantle the inlet and outlet hose of the engine and drain the coolant.
 Dismantle the power connection wires of generator, starter, connectors of sensors, and
oil temperature and water temperature sensors.
 Disassemble the fuel pipeline and pull out the fuel inlet pipe and return pipe.
 Dismantle the air intake pipe and the connecting hose of air filter.
 Release the radiator bracket and take out the radiator, intercooler and air shield as a
whole.
 Release the clutch cable.
 For the engine with vacuum booster, steering pump, air conditioner or blast pump,
disconnect the corresponding connecting pipeline.
 Release the connection between the tailpipe and the aftertreatment pipeline.
 Loosen the connecting bolts between the engine and the transmission to separate the
transmission from the engine.
 Loosen the fixing bolts of the front bracket of the engine, and hang the front and rear
lifting eyes of the engine with slings to lift it down smoothly.
III. Disassembly of engine assemblies

1. Disassembly of fan and belt
11
Figure 2.1
Disassembly procedure:
1. Silicone oil clutch fan assembly
2. Poly V-belt
Key points for disassembly:
 For removing the poly V-belt, use a square wrench with side length
of 13mm to insert the groove on the belt wheel of automatic
tensioning wheel, and turn the tensioning wheel anticlockwise to
remove the belt. Do not use water or gasoline to clean the belt after
removal. Also, pay attention to avoiding applying oil on the belt to
prevent slipping.
2. Removal of outer pipeline of front-end generator support
12
Figure 2.3
1. Weldment of water inlet pipe of heater 4. PFM seat-connecting hose of throttle
2. PFM sensor seat support 5. Electronic throttle body
3. PFM sensor seat 6. Throttle body gasket
 When the PFM sensor seat is disassembled, the PFM sensor can be removed together
without disassembly.
3. Removal of front-end gear train component
13
Figure 2.4
1. Generator 6. Fan pulley
2. Generator support 7. Fan support assembly
3. Generator support frame 8. Idler assembly 2
4. Automatic tensioning wheel assembly 9. Starter
5. Idler assembly 1
 The bolts on idler assembly 1 are left-hand bolts, whose direction of turning is opposite
to that of bolts of other components.
14
Figure 2.5
1. Front lifting lug 6. Hinged bolt M14 (30·m) 11. Vacuum rubber tube
7. Return hose of air

2. Steering pump 12. Vacuum pump
compressor (with ball
assembly assembly
joint)
3. Power steering pump 8. Hinged bolt M10 (25

13. Vacuum pump gasket
bracket N·m)
4. Air conditioning 9. Water inlet hose of air

compressor assembly compressor
10. Air compressor

5. Air conditioner bracket
assembly (with gear)

 When the air compressor is disassembled, the oil inlet pipe assembly shall be reserved
temporarily; it shall be removed subsequently along with the cooling water pipe. Only
the hinged bolt shall be removed.
4. Disassembly of EGR system
15
Figure 2.6
1. EGR water outlet hose 9. EGR pipe gasket 2
2. EGR water inlet hose 10. EGR valve
3. EGR exhaust temperature sensor 11. EGR valve gasket
4. Vacuum hose 12. EGR air inlet pipe
5. EGR escape pipe 13. EGR pipe gasket 1
6. EGR gasket 3 14. EGR cooler
7. EGR mixing pipe 15. EGR by-pass control valve
8. EGR pipe gasket 4
 For the removal of EGR air inlet pipe, only loosen the bolts at the rear cover plate of the
cylinder head. It shall be removed later together with the EGR cooler.
 When the EGR is removed, it is unnecessary to remove the EGR valve, water inlet
hose and water outlet hose. They can be removed together with the EGR cooler.
5. Disassembly of cooling system
16
Figure 2.7
Figure 2.8
1. Weldment of large-circulation water outlet pipe 10.Union pipe gasket of water
17
outlet of cylinder head
2. Weldment of water inlet pipe for heater 11. Water return hose
3. Water inlet hose for heater 12. SCR water return pipe weldment
4. Engine cooling – large-circulation hose 13. SCR water return hose
5. Small-circulation steel pipe weldment 14. Small-circulation pipe weldment
6. Oil inlet pipe assembly of air compressor 15. Water return pipe weldment
7. Small-circulation by-pass pipe 16. Water pump assembly
8. Small-circulation water return hose 17. Water pump gasket
9. Water outlet union pipe of cylinder head
 The welding parts of the water inlet pipe of the heater have been removed with the
generator bracket at first.
 The water inlet hose of heater can be removed together with the large-circulation water
outlet pipe.
 The oil inlet pipe assembly of air compressor needs to be removed after the
small-circulation steel pipe weldment.
 If not necessary, the water outlet union pipe of the cylinder head can not be
disassembled and kept on the cylinder head assembly.
 The small-circulation pipe weldment and water return pipe weldment at the water pump
can be removed together with the water pump, if not necessary. If they need to be
disassembled, pay attention to the O-ring close to the water pump to prevent its
damage or loss.
6. Disassembly of fuel injection system
18
Figure 2.9
Disassembly step：
1. Oil return pipe assembly of fuel 9. Lubricating pipe assembly of

injector high-pressure oil pump
2. High pressure oil pipe from cylinder 1 10. Fuel return pipe
to cylinder 4 11. Fuel return hose
3. Pressing plate bolt of fuel injector
12. Fuel return pipe joint
(34-38N.m)
13. Fuel inlet pipe
4. Washer
14. Fuel inlet hose
5. Fuel injector pressing plate
15. Fuel inlet pipe joint
6. Fuel injector
16. Mounting screw of high pressure
7. High pressure oil pipe from pump to pump (22-29N.m)
rail
17. High pressure pump
8. High pressure fuel rail
19
 Push open the spring locking clip of oil return pipe of fuel injector, and then pull out the
oil return pipe of fuel injector.
 For removing the high-pressure oil pipe, use a wrench to clamp the joint on the fuel
injector and high-pressure oil pump to prevent the joint from loosening.
 For disassembling the fuel injector, protect the copper gasket and O-ring of the fuel
injector from damage or loss.
 For removing the fuel return pipe, loosen the engine oil module cover bolts and one
fixing nut of air inlet pipe. The oil return hose and pipe joint can be removed together
with the oil return pipe.
 For removing the fuel inlet pipe, loosen one bolt of the cylinder block. The fuel inlet
hose and pipe joint can be removed together with the fuel inlet pipe.
 Install protective caps on the oil inlet and outlet joints of fuel rail, injector, high-pressure
oil pump and oil return pipe of injection pump to ensure that all oil inlets and outlets are
clean.
 The fuel injection pump shall be disassembled together with the timing linkage. If the
connection is too tight for disassembly, the high-pressure oil pump shaft can be lightly
impacted by copper rod, but do not damage the thread at the end of the shaft. The
high-pressure oil pump is equipped with O-ring, which should be prevented from
damage or loss.
7. Removal of oil pan, chain cover, and valve cage cover
20
Figure 2.10
Disassembly step：
1. Valve cage cover 10. Oil pan gasket

2. Rubber gasket of valve cage cover 11. Torsional shock absorber bolt (425N.
m)
3. Oil-gas separator assembly
12. Pressing plate of torsional shock
4. Oil filler cap
absorber
5. Camshaft position sensor
13. Torsional shock absorber assembly
6. Oil scale
14. Front oil seal
7. Oil scale sleeve
15. Crankshaft speed sensor
8. Oil pan reinforcement plate
16. Chain cover
9. Oil pan
17. Chain cover gasket
 The dipstick and dipstick sleeve are removed together with the water pump.
 The oil pan, valve cage cover and shock absorber assembly must be removed before
removing the chain cover.
 When the bolts of torsional shock absorber are removed, the rear end of crankshaft
shall be fixed. For specific fixing method, one bolt can be screwed into the left and right
sides of the flywheel assembly, and then a tool bar can be used to clamp it.
 Avoid damaging the front oil seal installed on the chain cover.
 Generally, the oil-gas separator assembly, oil filler cover and camshaft position sensor
need not be disassembled separately;they can be removed together with the valve
cage cover.
8. Removal of chain timing system
21
Figure 2.11
1. Oil pump chain 8. Camshaft chain
2. Oil pump sprocket 9. Fuel pump chain
3. Camshaft chain tensioner 10. Fuel pump sprocket
4. Fuel pump chain tensioner 11. Camshaft sprocket
5. Chain guide (4) 12. Crankshaft sprocket
6. Camshaft sprocket bolt 13. Chain guide - camshaft
7. Fuel pump sprocket nut (85Nm)
 Use special tools to clamp the intake and exhaust camshaft before removal of camshaft
sprocket bolts.
 Before removal of camshaft chain tensioner, press the hydraulic tensioner tappet back
to its original position. In order to prevent the plunger from popping out, use the fixed
22
pin to clamp the plunger of the tensioner before disassembly.
9. Disassembly of cylinder head
Figure 2.12
Disassembly step：
1. Glow plug 5. Intake camshaft

2. Cam bearing cover bolt (13N) 6. Rocker arm assembly
3. Cam bearing cover 7. Hydraulic tappet
4. Exhaust camshaft 8. Cylinder head bolt (120~205Nm)
 After the cam bearing cover, rocker arm assembly and hydraulic tappet are removed,
they shall be placed in order.
 The glow plug must be removed to prevent damage such as bumping or breaking
caused by placing the cylinder head.
 Use the torque wrench to remove the cylinder head bolts in the specified sequence.
 The valve, valve spring, etc. do not need to be disassembled; they can be removed
together with the cylinder head assembly.
When the cylinder head assembly is removed, the air inlet pipe, air inlet union pipe,
exhaust pipe, supercharger, tail pipe, etc. do not need to be removed.
If they need to be disassembled, follow the steps below:
23
10. Removal of exhaust pipe
Figure 2.13
1. Weldment of oil return pipe of 9. Supercharger
supercharger 10. Supercharger gasket
2. Flange gasket 2 of supercharger oil 11. Exhaust pipe heat shield
return pipe
12. Protective cover bolt of exhaust pipe
3. Flange gasket of supercharger oil
(10 ± 2N·m)
return pipe
13. Flat gasket of protective cover bolt
4. Supercharger oil inlet pipe bolt of exhaust pipe
(32-40N·m)
14. Exhaust pipe
5. Supercharger oil inlet pipe bolt 2
(20-28N·m) 15. Exhaust pipe gasket 2 (1)
6. Supercharger oil inlet pipe 16. Exhaust pipe gasket 1 (4)
7. Tail pipe 17. Cover plate of supercharger oil

return port
8. Tail pipe gasket
18. Flange gasket of supercharger oil
return pipe
 The specification of hollow bolts at both ends of oil inlet pipe of supercharger is different,
which needs to be distinguished.
24
 The cover plate of oil return pipe of supercharger can not be disassembled temporarily;
it can be removed together with the cylinder block.
11. Removal of air inlet pipe
Figure 2.14
1. Air inlet union pipe 3. Air inlet pipe
2. Gasket of air inlet union pipe 4. Gasket of air inlet pipe
 After the air inlet and exhaust and the glow plug are removed, and confirm that there is
no other connection with the engine body, lift the cylinder head assembly through the
lifting lug (the front lifting lug shall be installed in place together with the steering pump
bracket).
12. Removal of oil cooler and oil suction pan
25
Figure 2.15
1. Engine cooling water outlet union 9. Outer rotor of oil
pipe 10. Plug screw of pressure regulating
2. Gasket of engine cooling water outlet valve of oil pump
union pipe 11. Pressure regulating valve spring
3. Oil module cover 12. Guide post of pressure regulating
4. Oil module cover gasket valve spring
5. Oil module assembly 13. Pressure regulating valve plunger
6. Main shaft nut of oil pump 14. Oil suction pan
7. Oil pump cover 15. Oil suction pan gasket
8. Oil pump inner rotor and main shaft
assembly
 If the cylinder block is not replaced, the oil pump, pressure regulating valve, etc. do not
need to be removed.
13. Removal of clutch and flywheel
26
Figure 2.16
1. Clutch and pressure plate assembly 3. Flywheel bolt (85 ~ 125N·m for
disassembly)
2. Driven plate assembly
4. Flywheel ring gear assembly

 The input shaft bearing and crankshaft assembly are assembled by interference fit;
they can be removed together with the crankshaft assembly if they do not need to be
disassembled separately.
 Make assembly marks on the clutch and flywheel to maintain the dynamic balance of
the crankshaft after reassembly.
Note: only when the crankshaft needs to be replaced can the clutch assembly and
flywheel be removed.
14. Removal of flywheel housing
27
Figure 2.17
1. Flywheel housing 5. Idler gear shaft
2. Rear oil seal 6. Rear gear housing
3. Retainer ring weldment of idler gear 7. Flywheel housing gasket
4. Idler gear assembly 8. Gear housing gasket
 The flywheel housing is equipped with a rear oil seal, which shall not be damaged
during disassembly.
 The idler gear shaft and the rear gear housing are assembled by interference fit; they
can be removed together with the gear housing if they do not need to be disassembled
separately.
15. Removal of piston rod unit
28
Figure 2.18
1. Connecting rod bolt (65~100N·m) 8. Composite oil ring
2. Connecting rod cap 9. Retainer ring
3. Lower bearing shell of connecting rod 10. Piston pin
4. Piston rod assembly 11. Piston
5. Upper bearing shell of connecting rod 12. Connecting rod bush
6. First gas ring 13. Connecting rod body
7. Second gas ring
 Use the torque wrench to remove the connecting rod bolts, and disassemble the
connecting rod bearing cap (the crankshaft needs to be turned for removal). Pull the
piston rod unit out of the cylinder in the direction of the cylinder head. Pay attention to
the matching of the connecting rod and the connecting rod cap, and do not pull them
out of order.
 Carefully remove the first and second gas rings and the third composite oil ring, and
use the clip forceps to remove the retainer ring of piston pin. Push out the piston pin
gently and remove the connecting rod assembly. The marks of piston and connecting
rod assembly shall be consistent with the number of cylinder.
29
16. Disassembly of crankshaft
Figure 2.19
1. Main bearing bolt (95 ~ 140N·m) 5. Crankshaft thrust plate
2. Main bearing cap 6. Main shaft bushing (upper)
3. Main shaft bushing (lower) 7. Piston cooling nozzle component
4. Crankshaft assembly
 Use the torque wrench to remove the main bearing bolts according to the specified
sequence; disassemble the main bearing cover and thrust plate; and take off the
crankshaft. Check the axial clearance of crankshaft before removal, and replace it if it
exceeds the specified clearance.
30
Chapter III Assembly
I. Assembly of piston cooling nozzle, crankshaft, flywheel and clutch
assembly
 Check whether there is scratch on the engine body surface, and ensure the body is
clean.
 Install piston cooling nozzle and chain nozzle; tightening torque: 10N.m (note: check
whether the O-ring of cooling nozzle is missing or damaged, and replace it if any).
 Install the upper main bearing bush with oil groove into the main bearing hole of the
engine body; align the oil hole of the bearing bush with the oil passage hole on the main
bearing seat of the engine body. The upper and lower bearing bush cannot be installed
reversely, and there is a slip groove on the main bearing seat and main bearing cover,
which is corresponding to the bearing bush. Then apply a little clean lubricating oil. For
installing the bearing bush, it is forbidden to pad any metal or non-metal gasket.
 Install the crankshaft on the main bearing seat hole of the engine body; clean the
crankshaft carefully before installation, and pay special attention to the cleanliness of oil
hole, journal surface and bearing seat surface. Before the installation of crankshaft, a
small amount of lubricating oil shall be applied to the upper bush of the main shaft, and
a small amount of lubricating oil shall be applied to the main journal after installation.
 Install the crankshaft thrust plate on the fourth main bearing seat; the grooved side of
the thrust plate faces outwards, and it must not be installed reversely.
 According to mark 1, 2, 3, 4 and 5 printed on the main bearing cap, install the main
bearing cap from the front (fan end) to the back (flywheel end). The arrow on the main
bearing cap should face forward, and the upper and lower positioning lips should be on
the same side. After confirming that the main bearing cap is aligned with the rabbet of
the engine body, knock the main bearing cap into place with a copper rod.
 The main bearing bolts shall be tightened in two steps from the middle to both sides,
symmetrically and by rotation angle method. In the first step, they are tightened to 30 ±
1.5Nm; in the second step, they are tightened to 50 ± 2.5Nm first; then the angle is
turned 120° ±50 continuously (final monitoring torque: 95-140Nm). A small amount of
engine oil shall be applied to the main bearing bolts before installation. After fastening,
the crankshaft shall rotate flexibly and have axial clearance (0.09-0.24mm). The bolts of
the main bearing cap can only be tightened three times at most. As they have been
tightened twice before leaving the factory, and they must be replaced after one more
time.
 After installation, the crankshaft shall rotate flexibly without jamming, and the axial
clearance of crankshaft shall be checked.
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II. Assembly of piston rod unit
The top of the piston adopts a reentrant direct-injection ω-type
combustion chamber. For assembling, the arrow on the top face
faces the front end of the engine. Wedge-shaped connecting rod is
used to improve the strength of piston.
 Press the copper bush of the connecting rod into the connecting
rod body by interference fit; align the oil hole of copper bush with the oil hole of
connecting rod body (generally, the newly purchased copper bush of connecting rod
has been installed already).
 Install the snap rings of piston pin on one side of the piston.
 Put the piston inner cavity on the connecting rod at room
temperature, align the piston and the connecting rod pin hole,
and install the piston pin. The direction of slip groove of
connecting rod big end hole is the same as that of the piston
avoiding cooling nozzle.
 Install the snap rings of piston pin on the other side.
There are three piston rings for the piston. After the piston ring
is installed into the cylinder hole at normal temperature, the
appropriate clearance should be left at its opening, which is
called "opening clearance". For measuring the opening
clearance of the piston ring, the piston ring can be placed in the
cylinder hole of the new engine body and measured with a
thickness gauge. The standard opening clearance of each
piston ring is as follows: the first gas ring is in the range of 0.25-0.35mm, the second
gas ring is in the range of 0.50-0.70mm, and the oil ring is in the range of 0.25-0.50mm.
The wear limit is 1mm. If it exceeds the limit, it needs to be replaced.
 Use a special tool to install the piston ring in the piston ring
groove, and do not scratch the piston surface. Install the oil ring
first, and the opening of the oil ring shall be opposite to the joint
direction of the pushing-out ring (install the pushing-out ring
into the piston ring groove first); then install the second gas ring;
and finally install the first gas ring. The top and bottom of the
ring shall not be installed wrongly; the side marked with "TOP"
shall face the piston top. The openings of each ring shall be staggered by 120° with
each other and staggered with the direction of the pin hole. The piston ring installed in
the ring groove shall rotate flexibly.
 Apply a small amount of oil to the piston ring, connecting rod bearing bush, piston pin,
etc.
32
 Use a special tool to install the piston rod unit into the corresponding cylinder hole. For
disassembling the piston rod unit, pay attention to the corresponding relationship with
the cylinder, and do not interchange the piston rod units during installation.
 Install the connecting rod cap and connecting rod bolt. Before the connecting rod bolt is
screwed in, apply a little lubricating oil on the working surface of the bearing bush; and
then tighten the bolts for each cylinder alternately and by two steps. In the first step,
they are tightened to 15 ± 1.5Nm; in the second step, they are tightened to 30 ± 2.5Nm
first; then the angle is turned 120° ± 50 continuously (final monitoring torque is
65-100Nm). The connecting rod bolts can only be tightened three times at most. As
they have been tightened twice before leaving the factory, and they must be replaced
after one more time.
In order to ensure the smooth operation of the engine, the quality
of the piston rod unit shall be ensured. If the connecting rod
needs to be replaced, the quality difference between the new
piston rod assembly and the original piston rod assembly of the
same diesel engine shall not be more than 15g.
The connecting rod body and the cap are processed in combination. Each group has
matching marks. Do not install them in the wrong way. After installation, there shall be a
clearance between the two sides of the connecting rod big end and the crankshaft, and the
crankshaft shall rotate flexibly.
III. Assembly of oil pump and pressure

regulating valve
 After the internal and external surfaces of outer rotor of oil
pump are coated with clean oil, install it on the mounting
hole of the engine body; align inner rotor assembly shaft
with the shaft hole of the engine body; and install the inner
rotor shaft components of the oil pump on the outer rotor. After installation, the inner
rotor of the oil pump shall rotate flexibly.
 Align the two locating pins, install the oil pump cover and four bolts, and tighten the
bolts to the specified torque in diagonal sequence.
 Install the pressure-regulating valve plunger, spring guide post, pressure regulating
spring and plug into the pressure-regulating valve hole of the oil pump at the bottom of
the cylinder block in sequence, and tighten the plug.
IV. Subassembly and assembly of cylinder head

 Use a special tool to gently press the valve oil seal into the valve
guide end (note: the oil seal must be pressed into place).
 Install the valves in place one by one. For installing the valves, oil
33
must be applied to the inner wall of the valve guide (note: for repairing the engine, the
valves and guide pipes are one-to-one, and wrongly installation is not allowed).
 Install the valve spring and the upper seat of the valve spring into the cylinder head
according to the mark, compress the spring with the valve spring compressor, install the
locking clip with a tweezer, and loosen the valve spring compressor gently to prevent
the locking clip from coming out. After installation, use the rubber hammer to gently tap
the valve rod end to check whether the locking clip is in place. Check whether the valve
sinking is within the range of 1.0 ± 0.15mm (new engine).
 Measurement of piston protrusion: find the top dead center of the piston, move the dial
indicator to the top of the piston, measure the protrusion of the two points (front and
back) in the axis direction of the crankshaft on the top of the cylinder block, and take the
maximum reading of the dial indicator as the piston protrusion. Select the cylinder
gasket according to the piston protrusion.
Cylinder gasket group Cylinder head gasket

Piston protrusion(mm)
number thickness(mm)
 Visual inspection: the bottom surface of cylinder head and the top surface of engine
body are clean, the cylinder head gasket is flat, and the interlayer of the cylinder head
gasket is free of foreign matters.
 Put on the selected cylinder head gasket, and install the cylinder head by aligning with
the pin bush (note: the cylinder head cannot be pushed or pulled at will to prevent
damage to its bottom). Apply proper amount of clean oil to the head of cylinder head
bolt thread, and install it. Tighten it to the specified torque in the order of diagonal
crossing, from the middle to both sides, and by two steps. In the first step, tighten it to
50 ± 5Nm; in the second step, screw it to 270°±5°by rotation angle method (final
monitoring torque is 120-205Nm). The cylinder head bolts can only be tightened three
times at most. As they have been tightened twice before leaving the factory, they must
be replaced after one more time.
 Apply appropriate amount of oil to the tappet hole of cylinder head and the top of valve
rod, and install the hydraulic tappet assembly and roller rocker assembly in sequence.
 Apply clean oil to the roller rocker and the lower seat of camshaft, and install the intake
and exhaust camshaft into the cylinder head. Note: the TOP position of intake and
exhaust camshaft is upward.
 Install the camshaft cover. After confirming that the camshaft cover is aligned with the
pin bush, tap the camshaft cover with nylon rod to make it in place. After the cam
bearing cover is pre tightened, tighten the camshaft cover bolts 2 times to the specified
34
torque of 13 ± 1Nm from front to back.
 Screw in the glow plug in the cylinder head and tighten it to the specified torque. The
glow plug and the threaded hole of cylinder head must be kept clean without grease
and oil. The installation tools and working environment shall also be kept clean. During
installation, the heating head of glow plug and supporting pipe shall be free from any
mechanical impact.
 Install the water temperature sensor and tighten it.
V. Assembly of water pump, oil pump, gear

housing and flywheel housing
 Install the small-circulation pipe weldment in place by
aligning it with the water pump; assemble the water
return pipe assembly to the water pump, and install one bolt; screw in the bolt 3-5
threads; and fasten the bolt again after the installation of dipstick sleeve. Before the
installation of small-circulation pipe weldment and water return pipe assembly, check
whether the O-ring is in good condition. A small amount of lubricating oil can be applied
to the O-ring.
 Install and tighten four double-screw bolts on the cylinder block, install the water pump
gasket, install the water pump unit into the double-screw bolts, and fasten it with four
nuts.
 Select the installation angle of the pump body, push the fuel pump into place while
keeping the shaft horizontal, and install the bolts and fasten them to the specified
torque. Before installation, check whether the O-ring of oil pump is in good condition.
Apply a small amount of lubricating oil to the O-ring for assembly.
 Screw in the positioning double-screw bolts in the screw holes on both sides of rear end
of cylinder block. Knock in the positioning pins, and gently put the gear housing gasket
on the positioning pins and positioning double-screw bolts on both sides. Assemble the
gear housing in place by aligning it with the positioning pins. Install the fixing bolts and
tighten them to the specified torque.
 Apply appropriate amount of oil to the positioning shaft of idler gear shaft, and install
the idler gear shaft on the gear housing. Apply oil to the idler gear bushing before the
installation of idler gear. Then install the welding parts of idler gear retainer ring and the
fixing bolts, and tighten them to the specified torque. After assembly, the meshing
between the idler gear and the rear end gear of crankshaft shall be flexible and free of
clamping stagnation, and the meshing clearance at the tooth side shall be within the
required range.
 Use a special tool to press the crankshaft rear oil seal into the flywheel housing, and do
not damage the oil seal lip.
 Assemble the flywheel housing gasket on the positioning double-screw bolts and pin
35
bushes on both sides, assemble the flywheel housing in place by aligning it with the
positioning pin bush, and install the fixing bolts and remove the positioning
double-screw bolts.
VI. Assembly of timing linkage and chain cover

 Adjust the position of intake and exhaust camshaft to
make their TOP face upward (i.e. top dead center position
of cylinder 1), and fix the camshaft firmly with special
tooling.
 Turn the crankshaft anticlockwise 75° from the top dead
center; put the high-pressure pump chain into the inlayer
teeth of the crankshaft sprocket and oil pump sprocket
according to the marks; in alignment with the fuel pump
shaft and the front end of crankshaft, push the chain into
place; check whether the small lug at the back of the
crankshaft sprocket is stuck into the corresponding groove
at the front end of the crankshaft. Install the fuel pump nut
and screw it to the bottom manually, but it is not tightened
temporarily.
 Put the camshaft chain on the outer teeth of the camshaft sprocket and oil pump
sprocket according to the marks, and in alignment with the intake and exhaust
camshaft, push the chain into place. Install the bolts of camshaft sprocket and screw
them to the bottom manually, but they are not tightened temporarily.
 Rotate the crankshaft clockwise to the top dead center, and fix the rear end of the
crankshaft with special tooling. Check whether the mark position of the chain and
sprocket is accurate, and after confirmation, respectively tighten the camshaft sprocket
bolt and the fuel injection pump sprocket nut to the specified torque. Assemble the
guide rail as required, and tighten the guide rail bolt to the specified torque. Assemble
the tensioner, and tighten the tensioner bolt to the specified torque; pull out the screw
fixing the plunger of the tensioner to make the plunger pop out of the tension chain.
 Put the oil pump chain on the crankshaft sprocket and the oil pump sprocket, and push
it into place in alignment with the oil pump shaft. Install the oil pump sprocket nut and
tighten to the specified torque.
 Subassembly of chain cover: press the front oil seal onto the chain cover with tooling,
and do not damage the oil seal lip.
 Installation of the crankshaft woodruff key: use the copper rod to tap the woodruff key
gently to make it in place, and then wipe off the copper scraps on the parts with the
non-woven cloth.
 Gluing: the joint surface between chain cover and cylinder head, between chain cover
36
and engine body should be clean, and glue the four joints with a glue gun.
 After the positioning double-screw bolts are screwed into the screw holes on the intake
and exhaust sides, the chain cover gasket is gently sleeved on the positioning
double-screw bolts and pin bushes on both sides, and then the gasket is installed on
the engine smoothly. Align the locating pin bush to make the chain cover in place.
Install the fixing bolts and remove the locating tooling double-screw bolts. Before
installation, check whether the glue line of the chain cover gasket is in good condition.
After installation, trim the redundant part at the top and bottom of the gasket.
 Align the key slot on the shock absorber with the key on the crankshaft, and push it into
place; screw in the pressing plate and bolt; first fasten the shock absorber bolt to about
15N.m, and then fasten it to 425 ± 25N.m.
 Take down the tooling fixing the camshaft and crankshaft, and check whether all chains
and sprockets operate normally by turning clockwise.
 Install the crankshaft speed sensor onto the chain cover.
Before installation, check whether there is bruise, oil stain, rust and dirt on all parts; if
there is any bruise, do not use it; if there is any oil stain, clean it. Before installation, the
piston of cylinder 1 and cylinder 4 shall be at the top dead center to make the camshaft
cannot rotate; before tightening the bolts of crankshaft belt pulley, fix the crankshaft to the
top dead center so that the crankshaft cannot rotate. The marked surface of sprocket and
guide rail shall face outward, and the mark of sprocket shall correspond to the mark of
chain one by one. After assembly, all chains and sprockets shall operate normally without
jamming.
VII. Assembly of valve cage cover, oil module assembly, oil pan, and
flywheel assembly
 Subassembly of valve cage cover: put the rectangular rubber ring and O-ring into the
plug of the fuel injector fulcrum, and install the fuel injector oil seal, the oil seal of fuel
injector pressing plate bolt, and seal ring of fuel injector fulcrum bolt in place on the
valve cage cover. Install the oil-gas separator assembly, and tighten it to the specified
torque. Install the seal ring of valve cage cover. Install the camshaft sensor and the oil
filler cap (note: check whether the rubber gasket is missing or damaged).
 Apply two pieces of plane sealant with width of 2-3mm and thickness of 1mm on the
joint between cam bearing cover I and cylinder head and on the outer ring (ensure that
the two glue lines are close to each other); the length of the glue strip is the same as
that of the joint surface; install the cylinder head cover which has been installed the
above parts on the machined parts of cylinder head within 5 minutes of applying glue;
and tighten the bolts of valve cage cover and fuel injector fulcrum to the specified
torque from the front end to the back end step by step.
 Install the front and rear lifting lugs, and the front lifting lug needs to be installed
37
together with the steering pump support.
 Install the oil suction pan assembly and gasket. Tighten the bolts at the oil pump to the
specified torque, and then tighten the bolts at the bracket.
 Install the oil pan assembly and gasket, and tighten the bolts to the specified torque.
 Install the drain plug and tighten it to the specified torque.
 Install the oil module assembly on the cylinder block and tighten the bolts to the
specified torque.
 Install the engine oil module cover and engine cooling water outlet pipe, and tighten the
bolts to the specified torque.
 Install the flywheel assembly into the rear end of the crankshaft. Tighten the flywheel
bolts to 40 ± 2Nm first; then rotate it 90°±5 0 (final monitoring torque: 85-125Nm). Before
the flywheel is installed on the crankshaft, wipe off the dirt on the end face of the
crankshaft flange and the flywheel rabbet with a clean towel.
 Install the clutch driven plate, clutch pressure plate and cover assembly.
Crankshaft, flywheel and clutch assembly have been calibrated for dynamic balance
before delivery. They shall be assembled according to the marks made during
disassembly. There shall be no oil stain and foreign matters on the end surface of
flywheel and clutch pressure plate.
The clutch pressure plate and cover assembly have been carefully adjusted before
delivery, and need to be carefully adjusted after dismounting.
VIII. Installation of intake and exhaust system and fuel system

 Check whether the O-ring and sealing copper
gasket on the fuel injector are in good condition.
Replace the sealing copper gasket after
removal to avoid air leakage. Clean the
mounting hole of injector of cylinder head, especially the contact surface with the
sealing copper gasket; there shall be no impurities or foreign matters. Dust and foreign
matters shall be prevented from falling into the oil pipe joints on the fuel injector,
high-pressure fuel rail and fuel injection pump. Before installing the high-pressure oil
pipe, it is forbidden to remove their protective caps.
 Remove the protective sleeve on the nozzle of the fuel injector; install the fuel injector
(including sealing gasket), pressing plate of fuel injector, spherical washer, and bolt
according to the cylinder sequence, and pre tighten the bolts by hand. Do not damage
the injection hole, and prevent the copper washer from falling off and the O-ring from
crushing.
38
 Install the high-pressure fuel rail to the two
left screw holes on the cylinder head, and
tighten the fixing bolts of high-pressure fuel
rail to 25 ± 2Nm. The harness plug of
high-pressure fuel rail should face the
flywheel housing of the engine.
 Remove the high-pressure joint of fuel
injector and the corresponding protective cap
of high-pressure joint on the high-pressure
fuel rail, as well as the protective cap of
high-pressure oil pipe of cylinder 1-4. Install 4
fuel rails onto the high-pressure oil pipe of
fuel injector respectively. Check whether the
numbered end of the high-pressure oil pipe is
on the same side with the fuel rail to prevent reverse installation. After confirmation,
screw the nuts at both ends of the high-pressure oil pipe one by one by hand, and pre
tighten to 3 ± 1Nm.
 Install the air inlet pipe stud to the cylinder head, install the air inlet pipe and gasket,
and tighten the nuts to 10 ± 2Nm.
 Install the intake air temperature sensor onto the air inlet pipe.
 Remove the high-pressure joint of oil pump and the corresponding protective cap of
high-pressure joint on the high-pressure fuel rail, as well as the protective cap of
high-pressure oil pipe of pump / rail. Install the high-pressure oil pipe of pump / rail, and
pre tighten the nuts of fuel rail and fuel injector side to 3 ± 1Nm by hand. Tighten the
fixing bolts of oil pipe bracket to the specified torque of 10 ± 2Nm.
 Tighten the high-pressure oil pipe nuts at the fuel injector side one by one to 22 ± 2Nm.
 Tighten the nuts of high-pressure oil pipe at the fuel rail side one by one to 28 ± 2Nm.
 Tighten the high pressure oil pipe nuts of pump/rail at the oil pump side to 35 ± 2Nm.
 Install the fuel injector return pipe assembly.
 Install the fuel inlet pipe assembly. Tighten M8 bolts connecting the fuel return pipe with
the engine body to 25 ± 2Nm.
 Install the fuel return pipe assembly. Tighten M6 bolts connecting the fuel inlet pipe with
the air inlet pipe to 10 ± 2Nm.
 Install the lubricating oil pipe assembly of high pressure oil pump.
 Install the air inlet union pipe and electronic throttle.
 Install the exhaust pipe, exhaust pipe heat shield, supercharger, and tail pipe. Note:
during installation, foreign matters shall not fall into the air inlet and exhaust pipe to
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avoid damaging the diesel engine.
 Install the oil inlet pipe of supercharger.
 Install the engine wiring harness.
IX. Cooling system

 Install the drain valve assembly to the screw hole at the bottom of water jacket on the
exhaust side of cylinder block.
 Install the water outlet union pipe of cylinder head, and the tightening torque of the bolt
at the connection between the union pipe and the cylinder head is 10 ± 2Nm.
 Install the small-circulation steel pipe weldment and SCR water return pipe weldment,
and the tightening torque of bolt is 25 ± 2Nm.
 Install the large-circulation water outlet pipe weldment and rubber pipe.
 Install the water inlet pipe weldment of the heater. The water inlet pipe of the heater
shall be installed together with the lower bracket of the generator and the bracket of the
PFM sensor base. Two bolts shall be tightened manually first, and then fastened when
the accessories are assembled later.
For the installation of water pipes, the corresponding rubber pipe and water pipe shall
be sub assembled into general assemblies, and clamps shall be put on the rubber
pipes as required. After installation, the rubber pipe shall not be distorted.
X. EGR system assembly

 Pre install the EGR cooler: take out the EGR
air inlet pipe, EGR valve, EGR upstream
temperature sensor, rubber pipe of EGR
water inlet and outlet, and gasket; use the
corresponding bolts to sub assemble them on
the EGR cooler, and tighten the bolts to the
specified torque.
 Install the vacuum pump assembly.
 Install the rear cover plate of cylinder head.
 Install the EGR cooler component, and tighten the bolts to the specified torque.
 Screw the EGR water inlet rubber pipe into the water outlet union pipe of cylinder head,
screw the water outlet rubber pipe into the large-circulation water pipe, and tighten the
clamp after confirming that the rubber pipe is not twisted or deformed.
 EGR mixing tube is inserted into the air inlet union pipe, with the inclined cut outward;
install one end of EGR air outlet pipe to EGR cooler, and fix the other end to the air inlet
union pipe by passing through the mixing tube. The gaskets shall not be forgotten, and
the bulge of each EGR gasket shall face the flange surface when they are installed.
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 Install the EGR bypass control valve and bracket onto the rear lifting lug. Use two
vacuum rubber pipes to connect the EGR bypass control valve with the vacuum pump
and EGR cooler respectively, and fix them with bolts and clamps.
XI. Installation of accessories

 Install fan support assembly and fan pulley.
 Install air conditioning compressor bracket and air
conditioning compressor.
 Install the steering pump assembly.
 Install generator bracket and generator.
 Install PFM sensor and sensor base.
 Install the automatic tensioning wheel. Install the
poly V-belt on each belt wheel; for specific
method, insert the square wrench into the square
hole of belt wheel, turn the automatic tension wheeling to the left, and then install the
poly V-belt. After the poly V-belt is installed in place, loosen the tensioning wheel
wrench. Turn the crankshaft pulley for more than two turns to check whether the poly
V-belt is correctly installed in each belt wheel groove.
 Before the fitting of idler assembly, a proper amount of thread-locking glue shall be
applied at the front end of bolt; and the bolts used for the smooth wheel in the idler
assembly are left-handed bolts.
 Install the fan.
 Install the blast pump, and the sealing ring of blast pump shall not be damaged.
 Install the starter.
XII. Installation, use, and maintenance of electronic-control

high-pressure common-rail system
The electronic control system consists of sensor, ECU control unit, actuator and harness.
The relationship between them and the functions of each part are shown in the figure below.
The actuator mainly includes fuel injector, high pressure oil pump, etc. The sensor mainly
includes crankshaft position sensor, camshaft position sensor, water temperature sensor,
air inlet temperature pressure sensor, PFM air-mass flow meter, accelerator pedal, rail
pressure sensor, etc.
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Schematic diagram of electronic control system
Electronic-control China VI D20 series diesel engine adopts BOSCH electronic-control
high-pressure common-rail fuel injection system. As the manufacturing and processing of
high-pressure oil pump and fuel injector are very accurate and the injection hole is small,
the quality and cleanliness of diesel shall be very high, and the diesel from regular gas
station must be used and effectively filtered. Otherwise, Yunnei will not be responsible for
the damage of electronic control system caused.
The main control functions of electronic control system are as follows:
1. Starting control
The starting of electronic-control engine is directly controlled by the electronic control
system. When the engine is started, the oil quantity control module of starting controls the
oil supply to ensure that the engine can be started normally without black smoke.
The driver does not need to step on the accelerator for starting.
2. Torque output control
The intention of driver is transmitted to the control unit through the electronic throttle
opening and its change which is combined with the change of control output torque to
control the acceleration of whole vehicle. The acceleration control includes the acceleration
smoking limit, the driver's driving feeling control during sudden acceleration and
deceleration, the maximum stable speed control of empty vehicle, and the torque reduction
when the engine cooling water temperature is too high, etc.
3. Idle closed-loop control
Idle speed control means that the ECU control unit can automatically adjust the idle speed
according to temperature, battery voltage and request for air conditioning, and make the
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engine run at the set idle speed through the closed-loop control. For example, the lower the
cooling water temperature, the higher the idle speed; when the air conditioner is turned on
at idle speed, the engine speed will rise.
4. Preheating control of starting
The preheating control module of electronic control system heats the intake air under the
cold starting condition to speed up the starting process. Under the control of electronic
control system, the preheating module heats the whole cold start process to different
degrees to prevent the engine from stalling in the process of starting or running. When the
preheating module is working, the preheating indicator light on the instrument panel will be
on to remind the driver that the preheating module is working.
5. Exhaust brake control (optional)
Under the normal operation of engine, the exhaust brake module provides certain reaction
force to reduce the running speed of vehicle.
If it is necessary to perform the exhaust brake, the driver can turn on the exhaust brake
request switch (or foot exhaust brake switch) on the instrument panel. The electronic
control system will control the exhaust brake valve according to the driver's request and the
running state of engine. Once the exhaust brake acts, the engine will not supply oil.
If the driver needs to stop the exhaust brake, turn off the exhaust brake request switch (or
release the foot exhaust brake switch). The ECU determines whether to resume oil supply
according to the control signal.
6. Electronic accelerator pedal control
Like the conventional mechanical engine, the driver controls the engine through the
accelerator, but the electronic control system uses the electronic accelerator pedal. The
electronic throttle feeds the driver's intention (throttle opening) back to the ECU through the
control harness. The control module of oil quantity calculates the oil quantity according to
the throttle opening and engine speed, so that the driver can control the engine speed and
vehicle running speed.
7. Limp home and fail safe control strategy
When the electronic control system fails or the harness fails seriously, the ECU control unit
will enter the fail safe mode, which is a measure for driving safety to protect the engine and
prevent the vehicle from breaking down halfway. In this mode, the system will limit the
maximum power, torque and speed. In this case, the driver shall drive the vehicle to the
nearest maintenance station for repair as soon as possible.
When the output signal of electronic accelerator pedal or the harness has serious faults, the
ECU control unit will enter the limp home control mode. In this mode, the electronic
accelerator pedal signal will be replaced by the fault default value set in the ECU (at this
time, the electronic accelerator pedal does not work); the engine will reduce the power and
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maintain a constant set speed to continue running. In this case, the driver should drive the
vehicle to the nearest maintenance station for repair as soon as possible.
In case of serious faults affecting safety, ECU will force shutdown.
8. Thermal protection control
When the engine cooling water temperature and fuel temperature exceed the allowable
range, ECU will enter the thermal protection control mode to protect the engine from
damage. At this time, the maximum power, torque and speed will be limited, the vehicle can
still run, but the speed and acceleration are limited. Once the temperature drops, the
engine will return to normal. If this happens frequently, the driver shall drive the vehicle to
the nearest maintenance station for repair as soon as possible.
9. Deceleration oil cut-off control
When the engine is running at a high speed, the engine will enter the deceleration oil cut-off
control mode if the accelerator pedal is suddenly released and the deceleration oil cut-off
condition is met. At this time, the ECU will stop fuel injection, and the vehicle coasts in
inertia or downhill.
The engine speed gradually drops. When the speed drops to a certain set value, the ECU
will resume oil supply to maintain the running of engine. The strategy of decelerating oil
cut-off can not only reduce fuel consumption, but also improve the emission pollution
caused by unstable combustion. In addition, it can also improve the braking effect of
engine.
10. Air conditioning control (optional)
When the air conditioning request switch on the instrument panel is turned on, the ECU will
detect the request signal, so as to control the engine to maintain normal operation.
When the engine is idling, the ECU will increase the target idle speed if the air conditioner is
turned on; once the air conditioner is turned off, the ECU will reduce the target idle speed.
For vehicles whose air conditioning clutch is controlled by ECU (see the full-vehicle
manual), ECU controls the relay to operate the air conditioning clutch after receiving the air
conditioning command. For example, when the vehicle is running in high capacity or the
water temperature is too high, the ECU will automatically turn off the air conditioner for a
short time to ensure sufficient engine output power.
11. Noise control
D20 electronic-control China VI engine adopts multiple injections and injection pressure
closed-loop control to reduce the engine noise effectively.
12. Troubleshooting control
The electronic control system can monitor the running state of engine in real time and
diagnose the faults, so as to protect the engine and improve the driving safety. When the
system detects a fault, the engine detection light on the instrument panel will be lit up to
44
inform the driver to check the engine. At the same time, fault code is generated and stored
in ECU for service personnel to read fault information.
Oil passage of high-pressure common-rail fuel system consists of fuel tank, diesel filter,
high pressure oil pump, fuel rail, fuel injector, high pressure oil pipe, and low pressure oil
inlet and return pipe, etc.
The working process of fuel system is as follows:
The diesel oil is drawn from the fuel tank, passes through the oil-water separator assembly
(primary filter) with high-efficiency water separation function and the diesel filter assembly
(fine filter), and then enters the high-pressure oil pump. It becomes the high-pressure diesel
oil by the high-pressure oil pump. According to the working state of diesel engine, the
high-pressure diesel oil is regularly and quantitatively delivered to each fuel injector through
the high-pressure oil pipe and common rail pipe. The diesel oil is injected into combustion
chamber by the atomization of fuel injector. The remaining diesel oil from the fuel injector
and the relief valve of high-pressure oil pump returns to the fuel tank through the oil return
pipe.
The low-pressure oil inlet and return pipes must be smooth and free from bending and
blocking. All joints must be firmly connected and sealed to prevent air from entering the oil
passage. In order to ensure the oil inlet pressure of oil transfer pump of high-pressure oil
pump, it is required that the inner diameter of connecting pipeline of low-pressure oil
passage is not less than φ 8, and that the vacuum degree of oil pressure at the diesel inlet
joint of high-pressure oil pump is not more than 50kPa.
Diesel
Highfilter
pressure
oil pump
and oil-water
separator
CRS1-20 Schematic diagram of high-pressure common-rail fuel system

 Connection requirements for installation
(1) The adapter and quick coupling shall be used as less as possible, and avoid sudden
change of inner diameter. It is better to use one pipeline to connect the fuel tank with
the diesel filter, one pipeline to connect the diesel filter with the fuel pump, and one
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pipeline to connect the oil return connector of fuel pump with the fuel tank, so as to
make the fuel delivery more smooth and reduce the pressure loss. The total length of
oil inlet pipe shall not exceed 2500mm, the bending angle of oil inlet and return pipe
shall not be less than 90°, and bends shall be no more than 2.
(2) The connecting pipe must be resistant to temperature and pressure. As the pressure in
the oil inlet pipe is lower than the atmospheric pressure, air leakage shall be prevented
during the connection of oil pipe to ensure the normal oil supply capacity of fuel system.
At the same time, the arrangement of oil pipes must avoid mechanical damage, and will
not accumulate drippy or evaporated fuel, not to mention combustion.
(3) The filter tank shall be installed vertically; the primary filter and fine filter shall not be
200 mm higher than the oil inlet of oil pump.
(4) The fuel tank shall be within 100mm lower than the primary filter or within 50mm higher
than the primary filter.
(5) The oil return tail end must be below the liquid level of fuel tank.
(6) The inner diameter of oil inlet pipeline is ≥ 8mm, the total pressure drop of pipeline is ≤
50kPa (including diesel filter and oil-water separator), and the pressure drop of pipeline
is ≤ 10kPa; the inner diameter of oil return pipeline is ≥ 6mm, and the pressure drop of
pipeline is ≤ 10kPa.
 Material requirements of pipeline
(1) Avoid using copper and copper alloy
Copper is very easy to age in diesel oil. These aging products can cause many problems in
fuel. Therefore, avoid direct contact of copper and copper alloy with diesel oil.
(2) Avoid using zinc, lead, tin, sodium and white wax
These elements will be corroded by acidic diesel oil. Neither these elements nor materials
containing these elements can be used to contact diesel oil directly.
If the above elements are used in oil passage, the products formed after these elements
are corroded by diesel may lead to premature aging and abnormal operation of the fuel
injector, damage to the fuel pump, and shortened service life of the diesel filter.
 Check valve
The check valve is located between the oil return pipe of the fuel injector and the main oil
return pipe. Its function is to keep the oil return pressure of the fuel injector between 0.3 and
0.8 bar relative to the atmospheric pressure, so as to ensure the accuracy of the
fuel-injection quantity.
Requirements for fuel tank
(1) According to the QC/T 644-2000 technical conditions of automotive metal fuel tank, the
impurities per liter in the fuel tank shall not be more than 1.5 mg.
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(2) In order to improve the level of oil quantity when the alarm light of whole vehicle is on
and reduce the air entering the oil delivery pipe, it is recommended that the oil quantity
in the fuel tank is 25% - 30% when the alarm light is on.
(3) In order to prevent the air from entering the oil delivery pipe when the vehicle is in the
up and down slope, it is required to move the oil inlet pipe to the center of the fuel tank,
and install an oil storage mechanism in the center to reduce the entering of air. Due to
the high return oil temperature, it is required that the distance between the oil inlet and
return pipe orifice shall not be less than 200mm.
(4) In order to prevent impurities in the fuel tank from entering the low-pressure system, it
is required that the oil delivery pipe is 10-15mm away from the bottom of the fuel tank.
(5) It is required to install a dust-proof equipment on the ventilation device to prevent the
dust from entering the fuel tank. The device must be kept away from the engine and
exhaust pipe to avoid the risk of fire in case of accident.
(6) The fuel tank material shall be plastic or stainless steel.
Note: electronic-control high-pressure common-rail fuel system must be
adjusted by professional maintenance personnel with special equipment, and
the user is not allowed to dismantle and adjust it by himself. For repairing or
replacing the fuel pipeline, please use the genuine accessories of the whole
vehicle factory. Do not buy parts at will to replace!
1. High pressure oil pump
See part (VI) for assembly of high pressure oil pump.
The adjustment of high-pressure oil pump needs special technology, and the user is not
allowed to adjust it by himself. In case of a failure, it shall be sent to the Yunnei
maintenance center for repair.
The main parameters of CB4 high pressure oil pump are as follows: 2:3 transmission ratio,
clockwise rotation, 2000bar rated rail pressure, 3000r/min rated speed, and 657mm 3/rev
theoretical displacement. The oil pump is equipped with an oil quantity control unit to
control the oil supply. The oil delivery pump is a mechanical vane pump, which is integrated
on the high-pressure pump. The oil pump is a single plunger in-line pump, and the camshaft
has 3 lobes. The mounting flange face of the oil pump is provided with an O-ring. The
high-pressure oil pump can bear axial force, and the allowable force size needs to be
evaluated according to the bearing life.
After the fuel injection pump is installed and before the engine is started, press the manual
fuel delivery pump on the oil-water separator by hand to supply oil to and exhaust for the
fuel injection pump. Before the fuel injection pump is replaced, fill 15ml of clean diesel into
the fuel delivery pump of the fuel injection pump.
The external structure of high-pressure oil pump is shown in the figure below.
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CB4 High-pressure oil pump
The high-pressure oil pump is installed on the cylinder block of the engine through three M8
socket head cap screws and spring washers and flat gaskets. Before the installation of the
fuel injection pump, the sealing contact surface shall be clean and free of oil and impurities,
and check whether the O-ring is in good condition. Thread sealant shall be applied to the
thread of the socket head cap screw installed into the sprocket chamber side. The
tightening torque of the bolt is in the range of 22-29N.m.
The oil pump sprocket is installed on the high-pressure oil High pressure oil
pump
pump shaft, and the tightening torque of nut is required to
Connector: 1 928
be 85N.m. 405 521
Terminals: gold
The wiring between the oil quantity control unit on the plating
high-pressure oil pump and ECU is shown in the figure. The connector has two leads which
are respectively connected to the high side drive (pin 509) and the low side drive (pin 512)
on the ECU. Pin refers to the pin connected to ECU, the same below. According to the
signal from ECU, the injection quantity of injection pump is controlled.
Coil resistance of oil metering unit: 2.6 ~ 3.15 Ω (20°)
When the ECU fault light is lit up, the fault code detected by diagnostic instrument displays
the fuel injection pump fails. The ignition must be turned off and the connector connection
must be checked for looseness. Measure both ends of the wire by a multimeter to check for
open circuit. In case of mechanical failure of high-pressure oil pump, the high-pressure oil
pump shall be replaced.
Warning: high-pressure oil pump is a high-tech precision coupling assembly
component. In case of failure, please do not dismantle it at will. Please send it to the
Yunnei maintenance center for repair.
2. Fuel injector
48
The injector is an electronic-control 8-hole injector. It is mainly composed of injector body,
injector coupling, solenoid valve component, and oil inlet joint (with filter).
The injector is to control the opening and closing of the solenoid valve through the control
signal from ECU, and to inject the fuel in the high-pressure fuel rail into the combustion
chamber of the diesel engine with the best injection timing, injection quantity and injection
rate.
CRI1-20 Fuel injector
Normal fuel rail pressure of fuel injector: 40MPa to 200MPa; maximum injection pressure of
fuel injector: 2000bar. Electric power parameters for normal operation of 20 ℃~70 ℃: peak
current: (18 ± 0.5) A; holding current: (12 ± 0.5)A; resistance: (0.255 ± 0.040) Ω. The oil
return pressure of fuel injector is required to be 0.3 ~ 0.8bar (relative pressure). The driving
voltage of the fuel injector is battery voltage (24V). The fuel injector uses IQA to correct the
fuel injection characteristics of each fuel injector, so that the fuel injection difference
between each fuel injector is kept to the minimum, the fuel injection of each cylinder is
uniform, and the low-speed balance capacity of each cylinder is good. When the fuel
injector is replaced, the IQA code of the fuel injector can be input into the ECU with the
diagnostic instrument to make the fuel quantity more balanced.
See the following figure for the wiring of injector circuit. Pin 802, 814, 817, 805 of injector
plug-in circuit wiring are high level, and pin 801, 813, 816, 804 are low level.
Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4
Cable wiring diagram of fuel injector plug-in

Before installing the fuel injector, check whether the pins of solenoid valve are intact and
49
whether there are nicks on the surface of the injector. First install the O-ring in the groove,
position the copper gasket (2mm thickness) on the sealing surface of injector coupling, and
apply a little lube or grease around the O-ring before installing it in the cylinder head. Push
the injector into mounting hole on the cylinder head by hand, and then install the injector
pressing plate and bolts. Make the injector as centered as possible. Tighten the pressing
plate bolts by hand, and then tighten them to 43 ～ 47N.m by wrench. After the injector is
installed, the height of its head protruding from the bottom plane of the cylinder head shall
be within the range of 2.2 ~ 2.8mm.
The oil return interface of the injector is provided with a locking clip. When the oil return pipe
of the injector is installed, first press the oil return pipe joint into place. When the oil return
pipe of the injector is removed, first push open the spring locking clip, and then pull out the
oil return pipe.
The height of the nozzle protruding from the cylinder head has a great impact on the
performance of the engine. When the fuel injector is disassembled and assembled, the fuel
injector and its gaskets ( the copper gasket whose thickness has been adjusted before
leaving factory) must be put back to their original positions. When the gasket of the fuel
injector is replaced, select the same thickness, otherwise it will affect the nozzle convex
height.
When the ECU can not detect the blocking or dripping of the fuel injector, and this fault
information also can not be read by the fault detector, first check whether the wire socket
and plug on each fuel injector are well connected, and whether they are firmly plugged into
each other. Then start the engine and use the mechanical stethoscope to check the
operation of the fuel injector. If a clear and tight "click" can be heard at this time, it means
that the fuel injector works normally. When the fuel injector is blocked, it shall be sent to the
designated Yunnei maintenance center for ultrasonic cleaning.
3. Fuel rail and high pressure oil pipe
The fuel rail is a hot forging, with 4 oil outlets and 1 oil inlet. One end of the fuel rail is
integrated with rail pressure sensor, and the other end has one plug. It is not allowed to
dismantle the rail pressure sensor and plug. The maximum allowable axial force for
installation is 21kN. The cable wiring of rail pressure sensor on the high-pressure fuel rail is
shown in the figure below. The rail pressure sensor has three leads, which are respectively
connected to the power wire (pin 534), the signal line (pin 523) and the ground wire (pin
522). The nominal rail pressure is 200MPa. The common rail is fixed on the air inlet pipe of
engine with 2 M8 bolts.
50
The high-pressure oil pipe is a passage connecting the high-pressure oil pump and the fuel
rail and connecting the fuel rail and the fuel injector. It must be able to withstand the shock
wave of the high-pressure fuel above 2000 bar for a long time. The material of high
pressure oil pipe adopts imported steel pipe, with outer diameter of φ 6.35mm and inner
diameter of φ 3mm.
Installation sequence and requirements of high pressure oil pipe and fuel rail:
1) First, tighten the fuel injection pump and fuel injector to the required final torque on the
installation parts.
2) Remove the protective cap of the high-pressure joint on the fuel injector and fuel rail,
and tighten the connecting nut of the high-pressure oil pipe on the fuel injector and fuel
rail assembly.
3) Remove the protective cap of the high-pressure joint on the fuel injection pump and fuel
rail, and tighten the connecting nut of the high-pressure oil pipe on the fuel injection
pump and fuel rail assembly.
4) Tighten the connecting nut of high-pressure oil pipe at the injector side to the final
torque of 20 ~ 24N.m.
5) Tighten the connecting nut of high-pressure oil pipe at the fuel pump side to the final
torque of 33-37N.m.
6) Tighten the fixing bolt of the fuel rail to the final torque of 23 ~ 27N.m.
7) Tighten the connecting nut of high pressure oil pipe at the fuel rail side to the final
torque of 26-30N.m.
The tightening torque of each nut of high pressure oil pipe shall not be too large, otherwise,
the common rail parts will be damaged. The connection of each high-pressure oil pipe shall
be sealed and reliable.
For removal, first remove the high-pressure oil pipe nut at the fuel rail side, and then
remove the high-pressure oil pipe nut at the fuel injector and high-pressure oil pump side.
For removing the nut of high-pressure oil pipe at the high-pressure oil pump side and fuel
injector side, the connector on high-pressure oil pump or fuel injector must be fixed with
tools to prevent its loosening.
There is a small hole in the rail pressure sensor; when water enters, it will cause the sensor
to rust and lose its functions. Similarly, if the ventilation hole is blocked by paint or other
foreign matters, it will also cause the sensor to fail. Therefore, it should be ensured that the
rubber sealing ring of the connector is in good condition, and the joint cannot be washed
directly with water. Wrap the harness and sensor with plastic paper or tape to prevent
moisture from entering.
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Warning: oil pressure in the common-rail pipe is as high as 2000bar. Do not loosen
the high-pressure oil pipe joint nuts at the high pressure oil pump, rail side and
nozzle side during operation. It is not allowed to weld and repair the common-rail
pipe for reuse.
4. Oil water separator
See the figure below for the structure of oil-water separator. Main technical parameters of
oil-water separator: rated flow：≥ 300L/h; filter fineness：3 ~ 5 μ m; filtration efficiency：≥
99%; water separation rate：≥ 93%; clogging capacity：≥ 100g; under rated flow, inlet and
outlet pressure drop：≤ 10kPa. The oil-water separator shall be firmly fixed on the vehicle
frame and not allowed to be installed on the engine, otherwise, the water filtering effect will
be greatly reduced.
Principle of oil-water separator: diesel enters oil-water separator by oil inlet, is filtered by
filter element, and then flows out by oil outlet. The filter element is inlet water-blocking filter
element, which has two functions of filtering impurities and oil-water separation. When the
water in diesel oil passes through the filter element, it will adhere to the outer surface of the
filter paper, condense into water drops, and fall into the water collecting cup under the
action of gravity.
A water level sensor is installed at the lower part of the oil-water separator. When the
separated water reaches a certain level, the water level sensor sends a signal to the ECU;
at this time, unscrew the drain plug at the lower part to drain water.
Drainage of oil-water separator
If the water-level alarm indicator light of diesel filter on the instrument panel flashes or is
always on, and the output power of diesel engine drops obviously, it means that the diesel
filter is full of water and shall be discharged in time.
52
Indicator light 1 for oil containing water Indicator light 2 for oil containing water
Drainage steps of oil-water separator
(1). Stop the car in a safe place.
(2). Place a container under the drain plug.
(3). Unscrew the drain plug 4 to 5 turns to drain water.
Do not over unscrew the drain plug to prevent it from
falling.
(4). After the water is drained, tighten the drain plug.
Loosen (do not screw off)
the plug screw to drain the
(5). Exhaust the fuel system. (refer to low pressure fuel line water, and then tighten it
exhaust) after draining the water.
(6). If necessary, use hand oil pump to assist drainage.

(7). Start the engine and check the drain plug for leakage. At the same time, check whether
the indicator light of oil-water separator is off.
Note: (1) the water in diesel fuel is very harmful to the fuel system! When the diesel
filter water-level alarm indicator light is on, please drain the water in time!
(2) If the user needs to drain water frequently, please go to Yunnei service station to
drain the water from the fuel tank.
The oil-water separator adopts the filter element of the spin-on filter tank, which is
convenient to be replaced. The replacement cycle: every 8000km or 6 months. Before
installation, the joint of oil-water separator shall be free from damage. After installation, the
inclination with the vertical direction shall be less than 10°.
Replacement method of filter element of filter tank:
1) Thoroughly clean the outer surface of the filter component, and loosen the filter element
of filter tank with a wrench or a suitable tool and remove it.
2) Make sure that the screwed joint is fastened on the filter base and that the inside of the
filter base is clean.
3) Lubricate the sealing ring on the new filter element of filter tank with a little clean fuel.
Screw the filter element of the filter tank onto the filter base by hand until slight
resistance is felt, and then screw it inward for more than 2 / 3 turn.
4) Tighten the filter element of the filter tank with a wrench. Release the oil passage and
53
check for the leakage.
Please replace the filter element in strict accordance with the instructions!
Filter Filter
Drain screw seat
andWater
with
element
watercollection
hand assembly
oil
levelHeater
pump
cup
sensor Sump oil
Pure oil
Water/ sump oil
Structure and principle of oil-water separator

Low-pressure fuel pipeline exhaust
Air entering into the low-pressure fuel pipeline will cause difficulty in starting the engine and
other engine faults. During maintenance, if the fuel tank is emptied and refilled, exhaust the
fuel system.
Generally, there are three ways to mix air into low-pressure fuel pipeline:
1) Air enters the low-pressure fuel pipeline from the oil-water separator (primary filter),
diesel filter (fine filter), and fuel pipe joint of high-pressure oil pump;
2) Air enters the low-pressure fuel pipeline from the damaged part of the low-pressure fuel
pipe;
3) When the fuel level of the fuel tank is too low, the air enters the low-pressure fuel
pipeline when the vehicle is driving on a bumpy road or uphill and downhill.
If air is mixed in the low-pressure fuel pipeline, the air must be discharged by the hand oil
pump on the oil-water separator (primary filter) so that the low-pressure fuel pipeline and
the high-pressure oil pump are filled with fuel, and then the engine can be started.
Air removal steps for low pressure fuel pipeline and precautions: (see the figure and
instructions)
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1) Loosen the bleed screw on the oil-water
separator (primary filter) for 2-3 turns;
repeatedly press and loosen the hand oil
pump on the oil-water separator (primary
1) Loosen
filter) to pump oil to exhaust the air in the
the bleed
screw on oil-water separator (primary filter)until no
the oil water air is discharged from the bleed screw;
separator. tighten the bleed screw.
2) Loosen the bleed screw on the diesel
filter (fine filter) for 2-3 turns; repeatedly
press and loosen the hand oil pump on the
oil-water separator (primary filter) to pump
oil to exhaust the air in the diesel filter (fine
2) Loosen the filter) until no air is discharged from the
bleed screw
on the filter. bleed screw; tighten the bleed screw.
3) Loosen the oil inlet rubber pipe on the
high-pressure oil pump; repeatedly press
and loosen the hand oil pump on the
oil-water separator (primary filter) to pump
the oil to exhaust the air in the oil inlet
3) Loosen the oil pipeline until no air is discharged from the
inlet rubber pipe oil inlet rubber pipe; install the oil inlet
on the
high-pressure oil rubber pipe (generally, this item is not
pump. required; a handful of air injection pump
can automatically exhaust).
4) Press and release the hand oil pump on
the oil-water separator (primary filter) to
pump oil until the hand oil pump is difficult
to press by hand.
Note:
(1) Loosen the bleed screw slowly to
prevent the fuel from splashing;
(2) During the exhaust of the
high-pressure oil pump, turn on the
main power of the vehicle, but do not
start the engine;
(3) It is necessary to exhaust the air in
the low-pressure fuel pipeline,
otherwise it will cause difficulty or even
failure of starting the engine;
(4) The air in the high-pressure oil pipe
and fuel rail will be automatically
discharged back to the fuel tank when
the high-pressure oil pump is running. It
is forbidden to loosen the nuts of the
high-pressure oil pipe for exhaust.
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5. Diesel filter
The diesel filter is a special filter for high-pressure common-rail, equipped with bleed
screws. Main technical parameters: rated flow: ≥ 300L/h; filtering accuracy: 3 ~ 5 μm;
filtering efficiency: ≥ 95.5%; clogging capacity: ≥ 30g; under rated flow, inlet and outlet
pressure drop: ≤ 25kPa.
As diesel oil requires high filtering accuracy, the filter element can not be replaced by
ordinary diesel filter element; otherwise it will seriously affect the service life of common rail
system components.
The life of the diesel filter is related to the quality of the oil used, generally 10000-15000 km.
Please replace it regularly according to the use and maintenance requirements.
6. ECU control unit
ECU control unit is the "brain" of the whole electronic-control system, composed of
hardware and software. For its installation, keep away from the high temperature area of
the engine and vehicle, keep the ventilation in good condition, prohibit the ECU from being
covered, avoid the dust accumulation of long-term use, and prohibit the collision and falling
during the use and maintenance process.
ECU control unit pin

ECU pin connection: there are 7-hole connectors, of which 1 / 2 / 3 / 4 are connected with
the full-vehicle harness, and 5 / 6 / 8 are connected with the engine harness. There are 288
pins in total. See the figure above for ECU pin.
For removing the ECU control unit connector, first move the
black locking device up to the limit position, and then pull out the
connector; for installing the connector, pull down the black
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locking device in the state of removal until a loud click is heard. During disassembly, if it is
difficult to pull out or plug in, check whether the locking device is pulled in place and
whether there is any foreign matter entering the connector; do not pull or plug by force,
otherwise, the ECU pin or connector will be damaged. Note: when the ECU control unit
connector is removed, turn off the ECU main power first.
When ECU control unit connector is disassembled, check whether the pin is bent and
ensure good contact of all contacts. Slightly shake the pins on the socket to see if they are
loose. Check whether the pins are corroded; if they have corrosion, replace the plug or
sealing element.
ECU can not be disassembled for inspection and maintenance, but basic inspection can be
carried out. The ECU fault diagnosis shall be operated with a special diagnostic instrument
and diagnostic software, otherwise the ECU will be damaged.
Note: the ECU controller must be installed in the cab. The installation position
should be waterproof, oil proof and shockproof. The ECU control unit shell and the
bodywork must be well grounded.
7. Sensor:
 Crankshaft position sensor
The model of crankshaft position sensor of Yunnei China Ⅵ diesel engine electronic-control
system is DG6, which is a magnetoelectric sensor, composed of a permanent magnet and
a coil. The sensor continuously detects the change of the signal teeth and converts it into a
voltage signal to output to the ECU.
Crankshaft position sensor DG6 Mounting clearance of sensor

The crankshaft position sensor is installed on the chain wheel chamber cover of engine
head. After installation, the clearance between the sensor and the tooth top of signal panel
shall be 0.5 ~ 1.5mm. For installing the crankshaft position sensor, it is allowed to apply a
little lubricating oil on the O-ring. First press the sensor to the bottom by hand, and then
install the fixing bolt. Do not tighten the bolt when the sensor is not installed to the bottom.
The crankshaft position sensor is connected with pin 617 and 618 of ECU electronic-control
unit. 618 is the high-level positive pole and 617 is the low-level negative pole. The
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connecting wire is wrapped with a shielding layer and connected with the earth wire to
prevent interference.
By monitoring the number of teeth on the signal plate of crankshaft pulley and the position
of missing teeth, the crankshaft position sensor can obtain the signals of diesel engine
speed and crankshaft position, so as to determine the injection time and injection
sequence.
The connecting wire of sensor is a twisted-pair and wrapped with a shielding layer; it is
connected with the earth wire to prevent interference. If the sensor fails, the diesel engine
will not start and work normally.
If the crankshaft position sensor fails, the diesel engine will not start and work normally.
Fault detection method of crankshaft position sensor:
(1) Check the sensor
1) Method by multimeter: measure the resistance between two pins of the sensor. If the coil
resistance is under 20℃, it is about (860 ± 86)Ω.
2) Method by oscilloscope: use an oscilloscope to observe the pulse waveform, and each
tooth (or groove) generates an electric pulse.
(2) Check the connection line
Turn off the ignition and unplug the A-line plug on the ECU. Use a multimeter to check
whether the speed sensor plug is connected with the ECU plug. If the wire is not working,
replace the harness.
 Camshaft position sensor
The model of camshaft position sensor is PG3.8; it is a Hall sensor. The sensor
continuously detects the change of the signal teeth and converts it into a voltage signal to
output to the ECU.
Camshaft position sensor PG3.8 Mounting clearance of sensor

The camshaft position sensor is mounted on the valve cage cover. After installation, the
clearance between the sensor and the tooth top of the signal panel shall be 0.3 ~ 1.0mm.
When the camshaft position sensor is installed, it is allowed to apply a little lubricating oil on
the O-ring. First press the sensor to the bottom by hand, and then
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Cam phase
install the fixing bolt. It is not allowed to fasten the bolt when the sensor is not installed to
the bottom.
The camshaft position sensor is connected with pin 648, 639 and 638 of ECU electronic
control unit. 648 is for the internal 5V power output of ECU, 638 is for the internal grounding
of ECU, and 639 is for the signal acquisition of ECU. The connecting wire is wrapped with a
shielding layer and connected with the earth wire to prevent interference.
The camshaft position sensor can get the camshaft position signal by monitoring the
position of camshaft signal panel boss, so as to determine the injection time and injection
sequence.
The sensor connecting wire adopts twisted shielded pair to prevent interference. If the
sensor fails, the diesel engine will not start and work normally.
If the camshaft position sensor fails, the diesel engine will not start and work normally.
Fault detection method of camshaft position sensor:
(1) Check the sensor
Method by oscilloscope: use an oscilloscope to observe the pulse waveform, and each
tooth (or groove) generates an electric pulse.
(2) Check the connection line
 Turn off the ignition and unplug the A-line plug on the ECU. Use a multimeter to check
whether the speed sensor plug is connected with the ECU plug. If the wire is not
working, replace the harness.
 Intake pressure temperature sensor
The intake pressure temperature sensor is installed on the air inlet pipe and is an integrated
sensor of temperature and pressure. The ECU calculates the oxygen content of current
intake air of engine according to the signal of intake air temperature and pressure, so as to
determine the correction coefficient of the ECU fuel injection quantity.
The intake pressure temperature sensor is connected to pin 632, 621, 606 and 622 of ECU
electronic control unit, and the cable wiring is shown in the figure above. The intake
pressure temperature sensor has 4 leads, which are respectively connected with
temperature signal wire (pin 632), power wire (pin 621), pressure signal wire (pin 606) and
ground wire (pin 622).
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 Water temperature sensor
The water temperature sensor is installed on the water outlet pipe of cylinder head. Its
working principle is the same as that of the intake air temperature sensor. Its main function
is to convert the change of coolant temperature into the change of resistance value, and
then transmit it to the ECU electronic control unit, so as to dynamically adjust the fuel
injection quantity of the diesel engine.
The resistance characteristics of water temperature sensor are shown in the table below,
and its appearance and cable wiring are shown in the figure below.
The water temperature sensor has two leads; one is a signal wire (pin 532), and the other is
a ground wire (pin 525).
Fault detection method of water temperature sensor:
(1) Method by ohmmeter: use an ohmmeter to detect the resistance, and determine
whether the water temperature sensor works normally according to the diesel engine
coolant temperature and Table 2-2.
Remove the water temperature sensor and put the sensor into the water for heating. The
sensor has a fixed resistance value corresponding to different temperatures, as shown in
Table 2-2.
(2) Method by voltmeter: install the water temperature sensor on the diesel engine, run the
diesel engine, and connect the voltmeter on the signal line of sensor. There is a
corresponding voltage drop on the voltmeter according to different coolant temperatures.
Temperature and resistance characteristics of water temperature sensor
Temperatu Resistance Temperatu Resistance Temperatu Resistance
re(℃) (kΩ) re(℃) (kΩ) re(℃) (kΩ)
-40 45.313 20 2.500 100 0.186
-30 26.114 25 2.057 120 0.113
-20 15.462 40 1.175 140 0.071
-10 9.397 60 0.596
0 5.896 80 0.323
 PFM air-mass flow meter
PFM air-mass flow meter is used to measure the air inflow of engine to realize the best fuel
management. PFM sensor integrates boost pressure sensor and temperature sensor, and
transmits the measured pressure and temperature signals to the electronic control unit
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(ECU). ECU can accurately calculate the quality of air entering the engine, and calculate
the accurate fuel injection quantity according to the air inflow. In this way, the combustion of
engine can be controlled accurately, so as to reduce the emission of pollutants.
Connector of harness
Differential
Circuit board
pressure sensor
PFM sensor
The working temperature of PFM sensor ranges from -40 ℃ to 130 ℃, the working voltage
4.85V to 5.0V, and the working current 20mA to 35mA(when the working voltage is 5V).
PFM sensor wiring is connected with ECU pin 536, 531, 527 and 533. See the figure above
for cable wiring. The PFM sensor has 4 leads, which are respectively connected to the
power wire (pin 536), differential pressure signal wire (pin 531), ground wire (pin 527), and
absolute pressure and temperature signal wire (pin 533).
 Electronic accelerator pedal
The electronic accelerator pedal transmits the driver's intention to the ECU; ECU calculates
and determines the fuel injection quantity and timing.
The electronic accelerator pedal adopts double potentiometer signal output and
proportional type to ensure higher driving safety. The working temperature ranges from -40℃
to 80℃, and the working voltage Vcc is 5 ± 0.3V.
The temperature sensor wiring of electronic accelerator pedal is connected to the ECU
full-vehicle harness. There are 6 leads in total; one is a signal wire for sensor 1 (pin 417),
one is a ground wire for sensor 1 (pin 414), one is a power line for sensor 1 (pin 422), one is
a signal wire for sensor 2(pin 418), one is a ground wire for sensor 2 (pin 415), and one is a
power line for sensor 2 (pin 425).
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Simply put, the electronic accelerator pedal is a double sliding resistor, and the voltage of
signal 1 of electronic accelerator pedal is twice that of signal 2.
Fault detection method of electronic accelerator pedal sensor: install the electronic
accelerator pedal sensor and connector, start the diesel engine, step on the electronic
accelerator pedal, connect the voltmeter on the signal line of the sensor,and corresponding
to different throttle opening, there will be corresponding voltage drop on the voltmeter.
Electrical characteristics of electronic accelerator pedal
Throttle opening % APP1 sensor voltage(V) APP2 sensor voltage(V)
0 (0.15±0.03)Vcc (0.075±0.03)Vcc
100 (0.768±0.05)Vcc (0.384±0.06)Vcc
%
O
C
C
V
u
u
a
g
e
e
v
)
t
t
l
Throttle opening (%)
7. Harness
The harness is very important for the whole common rail system. It is the bridge between
the power supply, ECU, sensor and actuator, and it is also the channel to transmit various
information. The harness must meet the following prerequisites:
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- Minimum external electromagnetic interference of common rail system
- Minimum external electromagnetic interference to common rail system
- Suppression of electromagnetic interference in common rail system
In order to meet the above requirements, it is necessary to pay attention to the joint, wire,
fixation and routing of the harness.
In any case, the interconnecting devices of harness shall be dry, water-free, oil-free and
dust-free to prevent short circuit. Although some protective measures have been taken for
the connectors of various parts of harness, the parts and connectors of electronic control
part of engine cannot be washed directly with water.
Selection for harness
(1) Contact part of plug and socket
The contact part of harness joint is prone to aging due to high temperature and high
vibration load, so it is necessary to select the appropriate joint according to the parameter
table. Commonly used materials are tin and gold. The material requirements of male and
female joints are the same.
(2) Wire model
It is recommended to use copper wire; PVC or PUR that can be insulated and resistant to
diesel corrosion shall be used for copper wire sheath; and attention shall be paid to the wire
diameter requirements listed below and the maximum load of wire connecting actuator:
 Diameter of sensor lead and control wire: 0.35 – 1.0 mm2; 0.75 mm2 is recommended;
 Wire diameter of small current controller: 0.75-1.0 mm2; 1 mm2 is recommended;
 Diameter of all 24V supply wires: ≥ 2.5 mm2;
 The diameter of incoming and outgoing wire of battery: 4.0-6.0 mm2.
In view of the domestic wire material, it is strongly recommended to use the wire as thick
and as short as possible for harness, especially the harness related to the fuel injection
system, to ensure the normal operation of the engine.
The harness shall be wrapped with the detachable PVC bellows specified in DIN 40621 to
protect the harness from the corrosion of oil and diesel.
Making harness
(1) Twisted pair
In order to limit the mutual interference between ECU, PWM wave controller and other
electrical components, the incoming and outgoing wires of device must be twisted pair, with
the maximum twisted distance of 2.5cm, as follows:
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(2) CAN bus harness
It is suggested that the CAN bus harness should be twisted pair and shielded to prevent the
capacitance and inductance coupling interference caused by fuel injector, sensor, actuator
and other wires.
Recommended wire diameter: 0.75 mm2
Maximum twisted pair spacing: 25 twisted joints per meter; the maximum length of CAN
bus is 40m; the maximum load number of external hanging is 30; the minimum distance
between joints is 0.1m, and the maximum distance is 0.3m.
(3) Wiring for harness
The harnesses of sensor and actuator shall be on different paths and shall not be parallel.
The wiring shall avoid sharp turns. The harness must be protected against water.
(4) Supply wire for harness
Common rail system devices do not always have unloading device. A Zener diode should
be paralleled outside the device, such as main relay, air conditioning compressor relay and
fan relay.
For connecting the ECU to the battery, the following principles shall be observed:
- If the ECU shares one supply wire with other loads, the peak current obtained by other
loads from the supply wire shall not exceed 5A.
- ECU, battery and engine are recommended to be connected to one point of chassis
together to ensure common ground. Four options are available:
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(5) Other
The unused empty pin on the harness joint shall be sealed with waterproof materials, as
follows:
Measurement for harness

(1) Measurement of harness resistance
The resistance of harness determines the overall function of common rail system when the
battery is weak. It is required to strictly limit the harness resistance to realize all functions.
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Resistance for new Resistance for old
harness (20℃) harness (70℃)
Battery to ECU 47mΩ 67.5 mΩ
ECU to fuel injector 36.5mΩ 60 mΩ
Total resistance equals the sum of the
83.5mΩ 127.5 mΩ
above resistance values.
If the harness resistance cannot meet the above requirements, the following steps can be
taken to reduce it.
 The contact part of the connector shall be made of the same material;
 Connection points of harness shall be as few as possible;
 The harness of power supply and fuel injector shall be as short as possible;
 The harness of power supply and fuel injector shall be as thick as possible;
 Adopt low-resistivity wire.
(2) Inspection of harness
Check whether the harness is consistent with the TD wiring diagram. The details are as
follows:
 Check the wiring and fixation of harness;
 Check the insulation of the harness to the vehicle body and its external protection layer;
 Ensure that the battery negative pole is connected to the vehicle body / chassis through
a short wire;
 Check the maximum load of fuse;
 Check whether other harnesses and fuel injector harnesses are laid in different paths;
 Ensure that the unused joint hole is sealed;
 Check the number of the installed sensor and actuator;
 Check other necessary devices.
XIII. Installation and adjustment of engine assembly

 Install the engine assembly in the reverse order of removal.
 After the engine assembly is installed and tightened, the cooling water added to the
radiator shall be soft water; otherwise the scaling will be serious, the water hole will be
blocked, and the cooling effect will be reduced.
 Unscrew the oil filler cap, fill the oil to the specified height, and the oil level shall be
between the two grooves of oil scale. CJ-4 or higher diesel engine oil shall be added.
 Connect the fuel pipeline, and remove the air as follows:
First check whether the connecting pipeline is tight without air leakage; loosen the bolts
of the diesel filter; pump the oil with the hand oil pump until the oil is discharged, and
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then tighten the bolts.
 After confirming that the connection of engine is secure, start the engine, and check for
and eliminate the oil leakage, water leakage and air leakage.
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Chapter IV Maintenance and Inspection
I. Engine body assembly
1. Cleaning and inspection of engine body
Clean all oil passages of engine body, blow away impurities
by compressed air, and dry the oil passages.
Clean and inspect all threaded holes that secure the cylinder
head. Trim the threaded holes with a screw tap and remove
foreign matters. Then clean and blow down all threaded holes
on the cylinder block (the threaded holes with impurities may
cause the bolt to be stuck, making people mistakenly think
that the tightening torque exceeds the specified value).
After the engine body is cleaned, carefully check the cylinder
block for cracks. Hydrostatic test can be used for inspection.
Inspection method: install the cylinder head and gasket on the cylinder block, close all
water jacket openings, and then inspect whether the cylinder block leaks by 392kPa water
pressure which lasts for 2 minutes. If the crack is not serious, it can be repaired by bonding
or welding. If it cannot be repaired, replace the engine body.
Check whether there is burr, scratch, groove and corrosion on the assembly surface
between the engine body and cylinder head as well as on other machined surfaces. Slight
damage can be smoothed with a very fine dressing stone.
Check the flatness of assembly surface of engine body. The maximum allowable flatness of
the top of the engine body is 0.1mm. If the flatness exceeds the specified value, it shall be
grinded. The flat grinder can be used for grinding, and the thickness of the ground metal
shall not exceed 0.15mm. When the engine body is grinded, the main line in the main
bearing of the engine body should be selected as the benchmark to ensure the
perpendicularity of the cylinder axis. If the deformation of base plane of engine body is
small and flat, it can also be used as a benchmark. Otherwise, the compression ratio will
change.
When the cylinder hole of the engine is worn to a certain extent, the technical performance
of engine obviously deteriorates, the power decreases, and the consumption of fuel and
lubricating oil obviously increases. Therefore, the wear degree of cylinder hole is generally
taken as the main basis of whether the engine needs to be overhauled, and the size,
cylindricity and roundness of the worn cylinder are taken as the sign of whether the engine
needs to be overhauled.
Inspection method for roundness and cylindricity of cylinder hole:
1) According to the diameter and size of the cylinder hole, select a suitable extension rod
and fix it at the lower end of the cylinder gauge.
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2) Correct the size of cylinder gauge.
3) Use the cylinder gauge to measure the upper section, middle section and lower section
of the cylinder. Measure in two directions (parallel and perpendicular to the crankshaft axis)
for each section.
Note: for measuring with the cylinder gauge, the measuring bar shall be perpendicular to
the cylinder axis, otherwise the measurement is not accurate.
4) The roundness and cylindricity are calculated according to the measurement results.
The roundness error is half of the difference between the maximum diameter and the
minimum diameter measured in the same section.
The cylindricity error is half of the difference between the maximum diameter and the
minimum diameter measured in any direction of the cylinder surface.
When the diameter of cylinder hole exceeds the tolerance by 0.15mm and the cylindricity
exceeds the tolerance by 0.04mm, the engine body shall be replaced, as shown in the
following table.
D20
Diameter of cylinder hole mm ＞Φ81.16
Cylindricity of cylinder hole mm ＞0.052
If the cylinder wall is slightly scratched, and the roundness and cylindricity do not exceed
the limit, it can be polished with fine emery cloth.
If the cylinder wall is severely damaged such as burn and scuffing, the engine body should
be replaced.
For calculating the clearance between cylinder and piston, use micrometer to measure the
maximum diameter of piston skirt; the clearance is the difference between this value and
the maximum diameter of the cylinder measured above. It shall not exceed 0.15mm.
II. Cylinder head

1. Cleaning and inspection of cylinder head
Use a scraper and a wire brush to remove the carbon deposits on the combustion chamber
and the valve; to protect the valve seat, do not remove the valve temporarily; and do not
scratch the assembly surface of the cylinder head. After removing the carbon deposit,
remove the valve and clean the valve guide hole. Then the concave part and oil stain of the
cylinder head shall be cleaned with alkaline water (gasoline or pure alcohol) and dried.
Check the assembly surface of cylinder head for damage. Slight scars can be smoothed
with a very fine dressing stone.
2. Inspection and repair of deformation of joint surface between cylinder head and engine
body
The straightedge can be placed on the plane, and then use a feeler gauge to measure the
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clearance between the straightedge and the plane. The flatness tester can also be used.
The flatness of lower plane of cylinder head shall be not more than 0.15mm. If it is greater
than 0.15mm, the plane shall be polished. There are two ways to repair the deformation:
When the deformation is serious, the plane shall be repaired by local pressurization in
combination with scraping. Pad 0.5-0.7mm(thickness)sizing block at both ends of cylinder
head to fix the middle part on the flat plate; pressurize the middle part and heat it to 150℃;
knock the casting surface of cylinder head with small hammer; after 5min, move the
pressing plate to 1/3 of the total length of the cylinder head, and continue the above steps.
Loosen the hold-down device and take out the cylinder head to check its correction. If it
does not meet the requirements, the plane can be corrected with scraping.
Another method is plane milling. During milling, place the cylinder head plane up on the
bracket, and after correction, fasten it. After milling, the height of the cylinder head shall not
be less than 129.8mm, otherwise, it shall be replaced.
3. Inspection and repair of deformation of joint surface between cylinder head and intake
and exhaust manifold
The inspection method is the same as that of the joint surface between cylinder head and
cylinder block. Flatness shall not be greater than 0.1mm. If it is greater than 0.1mm, it shall
be grinded, but the amount of grinding shall not be greater than 1mm.
4. Inspection and repair of crack of cylinder head
Cracks are usually inspected by hydrostatic test. The following methods can also be used
to inspect the subtle cracks that cannot be detected by the naked eye: apply a mixture
( engine oil of 75% and kerosene of 25%) to the parts that may have cracks, wipe the
mixture off with cotton yarn, and immediately apply a layer of zinc oxide methanol solution.
If there is a crack, the solution at the crack will change color. Cracked cylinder heads must
be replaced.
5. Check the valve seat for excessive wear, cracks, and loose exhaust valve seat ring
The intake and exhaust valve seats are pressed on the
cylinder head by interference fit, and they are all mated with
the valve with a conical sealing belt with a 90 ° cone angle.
The width of the sealing belt of the new machine is controlled
within the range of 1.8-2.0mm, and the valve deflection is
controlled within 0.85-1.15mm. If the sealing belt is burnt, it
can be reamed for repair. The amount of metal abraded shall
be limited to the extent that the scar and deviation can be
eliminated. If the valve seat exceeds the tolerance or when
the valve deflection exceeds the 2.0mm of wear limit, the valve seat and valve shall be
replaced. For replacing, use dry ice to cool the valve seat ring, and then press it into the
seat hole quickly; or use hot water to heat the cylinder head to 80 ~ 90 ℃. After the cylinder
head is taken out of the hot water, immediately carry out the following operations, so as to
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install the valve seat ring when the cylinder head is hot.
Air seal test can be used to check the sealing condition after the valve and valve seat are
mated, or use kerosene to check at the valve pit.
III. Valve timing mechanism

1. Camshaft assembly
The intake camshaft and exhaust camshaft are arranged above the cylinder head. They
control the closing of the intake and exhaust valves of each cylinder.
Inspection and repair of camshaft and bushing:
Clean the camshaft. Check the cam surface for dents, scratches, and abnormal wear. Slight
scratches on the surface of the cam can be smoothed with a very fine dressing stone. The
camshaft must be replaced if the reduction of the cam lift is beyond the limit due to severe
wear.
Inspection of the cam lift: measure the height of the cam in the direction of the top-point of
the cam with a micrometer, and measure the diameter of
the base circle in the direction of the base circle. The
difference between the two is the cam lift.
The lift of the intake cam shall be within - mm and shall not
be less than mm (wear limit). The lift of the exhaust cam
shall be within - mm and shall not be less than mm (wear
limit). If the wear limit is exceeded, replace the cam.
Check the clearance between camshaft journal and bearing seat. Measure the diameter of
camshaft journal with micrometer, and measure the bore diameter of bearing seat with
inside dial indicator. The difference between the two is bearing clearance.
If the clearance between camshaft journal and cylinder head cam bearing seat exceeds the
0.4mm of wear limit, replace the camshaft or cylinder head.
Check the coaxiality of camshaft: use V-gage and dial indicator to check the coaxiality. If it
exceeds 0.05mm, replace the camshaft.
If the camshaft needs to be replaced due to the damage of the cam, but the clearance
between the new camshaft journal and the cylinder head cam bearing hole does not
exceed 0.12mm, the cylinder head does not need to be replaced; if the clearance exceeds
the above specified value, the cylinder head should be replaced.
When the engine is installed on the vehicle, check the cam lift according to the following
steps:
After removing the valve cage cover and camshaft chain, install the dial indicator and make
its contact in the vertical direction and contact with the cam base circle. Align the dial
indicator pointer to zero. Turn the crankshaft to make the cam reach the highest position.
Record the cam lift shown by the dial indicator. Continue to turn the crankshaft to make the
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dial indicator pointer return to zero, and check whether the first reading is accurate.
Measure the lift of other cams in the same way.
Check the axial clearance of the camshaft as follows:
Install the dial indicator and make its contact against on the front face of the camshaft. Push
the camshaft towards the rear of the engine until it holds, and align the dial indicator pointer
to zero. Then pull the camshaft toward the front of the engine until it holds, and record the
reading of the dial indicator, which is the axial clearance of the camshaft.
2. Inspection and repair of roller rocker assembly
Clean all parts before inspection. Check the roller rocker and roller for cracks and other
damages, and replace them if any.
3. Inspection of hydraulic tappet
Check whether the excircle face is strained. Check whether there is resistance by pressing
the tappet manually. Replace it if it is damaged.
4. Inspection and repair of valve train
Before inspection, remove the carbon deposit on the valve with a fine wire brush, and then
rinse it.
Check whether the valve head, sealing cone and other parts are burnt, corroded, scratched,
bent and cracked. Minor scratches can be repaired. If there are irreparable damages,
replace it.
Check the valve stem for scratches and excessive wear. The angle of the valve cone and
the diameter of the valve stem shall be inspected with a multimeter. The maximum
allowable value of the radial runout of the valve head cone is 0.05mm, and the maximum
allowable value of the straightness of the stem is 0.01mm.
5. Inspection and maintenance of valve guide
For checking the clearance between the valve and the valve guide, insert the valve into the
corresponding guide. The specific operations are as follows:
A special measuring device is put on the end of the valve stem and fixed with screws. Push
the valve down to separate the valve head from the valve seat, and the end face of the
valve guide is in contact with the measuring device. Place the dial indicator bracket on the
cylinder head, and make the contact of the dial indicator contact the middle area of the ball
part of the measuring device and form a 90° angle with the valve stem. Measure by shaking
in the direction toward the dial indicator, make the valve stem close to the guide pipe wall,
and record the reading of the dial indicator. Push the measuring device further away from
the dial indicator, and record the reading for the extreme position (note: the measuring
device cannot be lifted from the end face of the valve guide). Dividing the movement
amount of the pointer of the dial indicator by 2 is the effective value of the clearance
between the valve stem and the guide pipe.
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If the clearance between the valve guide and the valve stem exceeds the limit due to wear,
the valve guide should be replaced.
IV. Crankshaft, flywheel and clutch

1. Structure of crankshaft, flywheel and clutch
The crankshaft is a full-support casting crankshaft; and the crankshaft and a balance block
are cast into an integral structure. The rear end of the crankshaft is equipped with a
flywheel, which is positioned by a locating pin and connected with flywheel bolts. The main
bearing bushing is a high-tin aluminum-alloy thin-walled bearing bushing with steel backing.
The crankshaft, flywheel and clutch assembly have been calibrated for dynamic balance
before leaving the factory, and should be adjusted carefully after dismounting.
2. Cleaning and inspection of crankshaft:
Wipe the crankshaft and clean it with detergent, and then dry it with compressed air. Pay
attention to protecting the machining surfaces of crankshaft journals from damage.
Check the main journal and rod journal for pits, scratches and cracks. The cracks often
occur in the knuckle between crank arm and journal, as well as in the oil hole. The former is
a transverse crack, which is very harmful. If there is such a crack, the crankshaft should be
replaced; the latter is an axial crack, and the crankshaft should also be replaced if
necessary. The inspection method includes magnetic flaw detection, fluorescent flaw
detection, etc. The slight damage can be smoothed with a very fine dressing stone; for
serious damage, it must be grinded or replace the crankshaft.
Check the cylindricity of the main journal and rod journal. If it reaches 0.016mm, polish the
crankshaft journal.
3. Inspection for bearing bush surface
① The anti-wear materials shall be free of scratches or embedded impurities;
②The bearing bush shall not be stuck or the anti-wear material shall not fall off due to poor
lubrication;
③There shall be no local light spots on the surface of the bearing bush due to improper
assembly;
④The anti-wear material shall not be squeezed aside due to the taper of the journal;
⑤The surface of the bearing bush shall be free of wrinkles and cracks of anti-wear material
and steel strip caused by fatigue.
4. Inspection of bearing clearance and replacement of bearing bush
When the clearance between the main journal of crankshaft and the bearing bush is
measured, the bearing cover and the bearing bush shall be installed on the bearing seat,
and the bolts shall be tightened to the specified torque. Measure the bore diameter with an
inside dial indicator, and measure the diameter of the corresponding journal with a
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micrometer to calculate whether the bearing clearance exceeds the wear limit. If the
cylindricity of one or more main journals and bearing clearance exceed the wear limit, the
bearing bush shall be replaced.
When the clearance between rod journal and bearing bush is measured, install all bearing
bushes and bearing covers on the corresponding connecting rod, and tighten the fixing
bolts of bearing covers to the specified torque. Measure the inner diameter of the
connecting rod bearing hole with an inside dial indicator, and then measure the diameter of
the corresponding connecting rod journal with a micrometer to calculate whether the
bearing clearance exceeds the wear limit.
If the cylindricity of rod journal and bearing clearance exceed the wear limit, the connecting
rod bearing bush shall be replaced.
5. Inspection for flywheel
Check the contact surface between flywheel and clutch for wear. Replace the flywheel if
there is wear or damage. Use a dial indicator to check the runout of the contact surface
between the flywheel and the clutch. If it exceeds 0.2mm, replace the flywheel. Check the
teeth of flywheel ring gear for pit, craze, and wear. Replace the flywheel ring gear if
necessary.
6. Check the runout of the contact surface between flywheel and clutch:
Place the contact of dial indicator against on the working surface of the flywheel, and keep
the crankshaft at the position where the front and rear axial clearance are eliminated, so as
to avoid mistaking the axial clearance for the flywheel runout. Rotate the flywheel, and use
a dial indicator to measure the end face runout of the flywheel at
the radius of 150 mm. The value should not exceed 0.2 mm. If the
reading exceeds the specified value, replace the flywheel.
7. Check the axial clearance of crankshaft as follows:
Install a dial indicator at the rear of the engine, make the
measuring rod of the dial indicator parallel to the crankshaft axis,
and the contact of the measuring rod is against on the flywheel
crankshaft flange. Push the crankshaft in the direction toward the
rear of the engine to counter with the end face of the bearing bush of the rear main bearing.
Align the dial indicator pointer to zero. Push the crankshaft in the direction toward the front
of the engine to counter with the rear end face of the bearing bush of the rear main bearing.
Record the axial clearance value shown by the dial indicator. The value should be in the
range of 0.09-0.24mm.
If the clearance is large, the thrust plate must be replaced. If the clearance is small, the
bearing bush can be removed and check its end face for damage, edge and dirt. If the end
face is clean and smooth, the reason for the small clearance may be that the thrust plate is
not aligned.
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V. Piston rod assembly
1. Structure of piston rod assembly
The top of the piston is a ω-type combustion chamber. The head of the piston has three
ring grooves, and its skirt is oval. The piston ring has two compression rings and one oil ring.
The first compression ring is a tubbish rectangular ring plated with chromium; the second is
a conical twisted ring. The oil ring is a spiral spring packing ring type. The connecting rod is
forged. The wedge-shaped connecting rod is used to improve the strength of the piston.
There is a small oil hole on the small end of the connecting rod to lubricate the connecting
rod bush and the piston pin.
2. Cleaning and inspection of piston rod assembly
Cleaning and inspection of connecting rod: remove the bearing bush from connecting rod
shank and bearing cover before cleaning. If the bearing bush can be used, the mark shall
be made on it so that it can be installed back in place during reassembly. Clean connecting
rod shank, big end hole and small end hole (do not use corrosive solution). Clean the oil
passage with compressed air.
Check the connecting rod for signs of crack and breakage. Replace it if any.
Check the bending and twisting of connecting rod. The limit value is not more than 0.05mm
for 100mm length. If the limit is exceeded, straighten or replace the connecting rod.
Check the bearing bush of connecting rod big end for wear, scratch, and defect, and check
cylindricity. The wear limit of clearance between bearing bush and crankshaft rod journal is
0.15mm. If the wear limit is exceeded, replace the connecting rod bearing shell.
Check the connecting rod bushing hole for wear, scratches, and defects, and check
cylindricity. The wear limit of the clearance between the connecting rod bushing hole and
the piston pin is 0.10 mm. If the wear limit is exceeded, the bushing should be replaced.
Press the new bushing into the small end hole of the connecting rod, and then ream.
Check the connecting rod bolts carefully and replace them if there is any damage. Note: the
connecting rod bolt is a plastic deformation bolt, which can only be tightened three times at
most, and must be replaced after three times. It has been tightened twice before leaving the
factory; it must be replaced after one more dismounting.
3. Cleaning and inspection of piston
Remove carbon deposits on the inside and outside of the top of the piston. Clean the
carbon deposit on the piston skirt with detergent. Do not use corrosive solution and wire
brush for cleaning. Use a special ring-groove cleaning tool to remove the carbon deposit in
the piston ring groove; rinse the oil passage and oil hole. Check the piston ring groove for
excessive steps. The step will make the piston ring edge gap too large and destroy the
work of piston ring. Therefore, if excessive steps are found, the piston should be replaced.
Check the skirt near piston ring land and piston pin boss for pits. Check the piston skirt for
damage and corrosion. If the piston is excessively worn, the piston ring land is deformed,
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the top edge of the piston is broken or there are pits and corrosion, etc., the piston should
be replaced. Check the clearance between piston and cylinder; its limit value is 0.15mm; if
the limit value is exceeded, replace the piston.
4. Cleaning and inspection of piston pin
Clean the piston pin with detergent. Check the
clearance between the piston pin and the pin boss hole
as well as between the piston pin and the bushing hole
of the connecting rod small end. The wear limit of
clearance between piston pin and pin boss hole is
0.03mm. If the clearance exceeds the limit value,
replace the piston and piston pin. If the piston pin has
pits, cracks and abnormal wear, it should be replaced.
5. Cleaning and inspection of piston ring
Clean the piston ring with detergent. Check the piston ring and replace it if there is
corrosion or pit. Replace the piston ring every time the engine is overhauled.
Check the opening clearance of the piston ring in the ring groove of the standard gauge
with a feeler gauge (it can be put into the cylinder hole of the new engine body for simple
measurement). The first compression ring shall be 0.25-0.35mm, the second compression
ring 0.50-0.70mm, and the oil ring 0.25-0.50mm. The wear limit is 1mm. If it exceeds the
limit, it needs to be replaced.
VI. Transmission gear train

Transmission gear train includes the front-end timing chain system and the rear-end gear
drive system. The front-end chain timing system includes five sprockets(the crankshaft
sprocket, the fuel injection pump sprocket, two camshaft sprockets and the oil pump
sprocket). The crankshaft sprocket and the fuel injection pump sprocket are turriform
double-layer sprocket. The accessory parts include fuel injection pump drive chain,
camshaft drive chain, 5 guide rails and 2 hydraulic chain tensioners, as shown in the left
figure below; the rear-end gear system includes crankshaft rear-end gear, idler gear and
blast pump gear, as shown in the right figure below.
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Inspection of rear-end gear:
Clean the rear-end gear with gasoline. If there is damage and uneven wear on one tooth of
a gear, the pair of gear shall be replaced. Use a dial indicator to check the engagement
clearance of the timing gear. For inspection, fix one gear, and make the other gear swing
back and forth. Record the clearance value measured by the dial indicator. The clearance
shall be within the range of 0.2-0.3mm. The gear can also be installed on the engine and
measured with lead wire; if the wear limit of 0.45mm is exceeded, the corresponding gear
pair needs to be replaced.
Inspection of timing chain system:
Clean the timing chain and all drive sprockets with gasoline. Check whether the chain links
and sprocket teeth are damaged, worn or deformed, and replace them if any.
Check whether the hydraulic chain tensioner is normal, and whether the plunger is stuck.
Replace them if any.
VII. Lubrication system

1. Structure of lubrication system
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Lubrication system
The traditional pressure lubrication and splash lubrication are combined in the lubrication
system of diesel engine. The oil pump adopts the rotor structure, which is driven by the
front-end chain of the crankshaft.
The oil passage of the lubrication system is shown in the figure above. The oil from the oil
pan enters the oil pump through the suction filter. After the oil is pressed out by the oil pump,
it is filtered by the oil cooler and filter, and then enters the main oil passage in the engine
body. After that, it is distributed to the crankshaft bearing, connecting rod bearing, gear,
blast pump, etc. for lubrication through each sub oil passage. In addition, the oil in the main
oil passage is distributed to the oil passage on the cylinder head to lubricate the camshaft.
The oil after lubrication flows back to the oil pan through the oil return passage.
Check whether there are cracks and holes in the oil pan, whether the thread of the drain
plug is intact, and whether there are cracks and bends on the installation surface of the oil
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pan. Repair the damage of the oil pan. If it cannot be repaired, replace the oil pan.
1. Cleaning and inspection of oil pump:
Clean all parts with detergent, and wipe out. Clean the inner and outer rotors of the oil
pump, the plunger of the pressure limiting valve and the oil passage with a brush, and
remove the metal scraps and precipitates. Check the inner and outer rotors of the oil pump
and the outer cavity of the oil pump in the sprocket chamber for damage or excessive wear.
Check the end face distance between the inner and outer rotors of the oil pump and the
inner cavity of the oil pump in the gear housing, i.e. check the end face clearance. The
height difference between the two measured by a dial indicator is the end face clearance.
The clearance shall be 0.04-0.09mm, and the wear limit is 0.16mm. If the clearance is not
appropriate, replace the inner and outer rotors of the oil pump and the oil pump cover.
The pressure regulating valve controls the oil pressure; the oil pressure shall be between
80 and 500kPa when the diesel engine is working. If the oil pressure is not within the range,
check whether the pressure regulating valve fits well, whether the oil passage is blocked,
and whether the sliding surface is damaged. If necessary, replace the plunger. Check
whether the spring of pressure regulating valve is damaged and whether its elasticity is
weakened, and replace it if necessary.
Check the performance of the oil pump. After the oil pump is assembled, the assembly test
shall be carried out to determine its working performance.
2. Cleaning and inspection of oil module
The oil cooler and oil filter are integrated into the oil module assembly. After the assembly is
removed, check for leakage and remove the scale on the cooling core of the oil cooler.
The oil filter is a spin on type, and there is a safety valve on the filter base. When the
viscosity of the oil is too high or the filter element is blocked, the pressure will increase;
when the pressure acting on the safety valve exceeds a certain value, the safety valve
opens, and the oil enters the main oil passage directly without passing through the filter
element, so as to ensure the lowest level of lubrication of diesel engine.
The oil filter is generally required to be replaced every 10000km. The user can make
adjustment according to the use conditions.
VIII. Cooling system

1. Structure of cooling system
The cooling system is closed forced-circulation water-cooling type. It is mainly composed of
radiator (water tank), water pump, fan, wind scooper, thermostat, cooling water jacket, and
pipeline, etc. as shown in the figure. The function of the cooling system is to ensure that the
diesel engine works at a suitable temperature. Too high and too low temperature will hinder
the normal operation of the diesel engine, accelerate wear, and lead to excessive heat loss
and poor economy. During normal operation, the temperature of cooling water is in the
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range of 75-95 ℃, and the maximum water temperature of torque limiter is 105 ℃.
Flow diagram of cooling system

2. Structure and overhaul of water pump
Structure of water pump: the water pump is a
traditional centrifugal water pump, which is composed
of water pump shaft, water pump hub, water pump
body, water seal ring, water pump impeller, gasket,
water pump seat, etc. If the water pump shaft shakes
or is worn, replace the water pump assembly.
Installation of water pump:
Install the stud and water pump gasket on the engine body, check whether the water pump
gasket is in good condition, and then install the water pump.
3. Thermostat
The thermostat is a wax thermostat. For checking
whether the thermostat works normally, put the
thermostat and thermometer into the container with
hot water to be heated gradually; observe the
thermometer; and the thermostat starts to open when
the water temperature is 78 土 2 ℃.
When the water temperature is low, the thermostat is

closed, and the cooling water does not flow through
the radiator and directly returns to the water pump.
When the water temperature reaches above 78 ℃, the thermostat is gradually opened, and
the cooling water flows through the radiator to get cooling.
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IX. Electronic-control common-rail system
Please refer to Chapter 3 for the operation precautions of electronic-control common-rail
system.
X. Electric system
1. Generator
Connected Voltage
with
Circuitregulator
diagram Connected with
battery terminal 24V 3W charge
positive lamp
The generator is a silicon rectifier generator. The negative pole shall be connected to
vehicle body, and do not connect reversely. See the following figure for wiring.
The generator is equipped with a voltage regulator, which should be equipped with a
battery of corresponding voltage and capacity to ensure the use. A ground wire must be
added between the diesel engine and the automotive frame, and the wiring should be
correct and firm.
For removing the charging generator, unscrew three interlocking bolts and the bearing nuts
of the rear end cover; tap the front end cover gently to separate them; and then
disassemble them one by one to remove the dirt. In general, do not dismantle.
For checking the generator fault, open the rear cover plate first, and use a multimeter to
measure the diode or integrated circuit regulator one by one (do not use the megger or the
AC power supply above 110 V for test).
2. Starter
Deceleration-type starter motor is adopted.
See the following figure for starter line connection. The cross-sectional area of copper wire
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connected to battery shall not be less than 25 mm2 and its length shall not be more than 2m.
The cross-sectional area of copper wire connected to the power supply line of
electromagnetic switch shall not be less than 4 mm2 and its length shall not be more than
6m.
For cleaning the vehicle or diesel engine, it is strictly prohibited to wash the generator and
starter with water.
XI. Air inlet and supercharged and mid-cooling system

All pipelines for air inlet system shall be sealed without damage and air leakage.
1. Supercharged and mid-cooling system
The supercharged and mid-cooling system consists of air inlet pipe, exhaust pipe, air inlet
union pipe, supercharger, intercooler, etc. The exhaust turbine of the supercharger and the
gas compressor are installed on the same shaft. The exhaust turbine is driven by the
exhaust gas from the engine, and drives the gas compressor to compress the air inhaled
through the air filter, thus increasing the density of air entering the cylinder, increasing the
air inflow, increasing the fuel supply of the injection pump, and improving the output power
of the engine.
(1) Air inlet and exhaust pipe and air inlet union pipe
The function of the air inlet pipe is to send the air to each cylinder of the diesel engine; the
function of the exhaust pipe is to exhaust the waste gas of each cylinder.
Check the air inlet and exhaust pipes as follows:
① Check whether nuts are loose.
② Check air inlet and exhaust pipe gaskets for signs of erosion and air leakage.
③ Check the pipeline (from the gas compressor to the air intake of the cylinder head) for
air leakage. The pipeline must be sealed to ensure the normal operation of diesel
engine.
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(2) Turbocharger
The supercharger is mainly composed of turbine, gas compressor, intermediate housing
and vent valve (see the figure below).
 Turbine part
The turbine part mainly includes turbine shell and single-stage radial flow turbine, which are
a energy converter. When the exhaust gas from the diesel engine enters the nozzle through
the turbine shell and is injected to the impeller, the thermal energy and pressure energy of
the exhaust gas will be converted into kinetic energy, so that the turbine can rotate at a high
speed.
 Intermediate
The intermediate is an intermediate support for bearing the rotor assembly and fixing the
turbine casing and gas compressor casing, and also a lubricating oil tank for lubricating and
cooling the floating bearing rotor.
 Gas compressor
The gas compressor mainly includes single-stage centrifugal compressor impeller, diffuser,
and compressor casing. The air is drawn in by the compressor impeller rotating at a
high-speed through the air filter, increasing the air flow rate and pressure; then the kinetic
energy of the air flow is converted into pressure energy by the diffuser and the compressor
housing; after the pressure is further increased, the air enters the cylinder through the air
inlet pipe of the diesel engine, so that the air density entering the cylinder increases.
The turbine shaft and turbine are welded together by friction. The compressor impeller is
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installed on the turbine shaft by transition fit and compressed by self-locking nuts. The
whole rotor assembly is dynamically balanced to ensure normal operation at a high speed.
The support of the rotor assembly adopts internal support, that is, two full floating bearings
are arranged on the intermediate between the two impellers, and the axial force of the rotor
is borne by the thrust bearing device on the fixed intermediate.
 Vent valve
The vent valve in turbocharger is to
match the diesel engine and the
turbocharger best at a low or medium
speed, so that the diesel engine can
get enough air. In this way, the diesel
engine can adapt to the increased fuel
supply, increase the low-speed torque,
improve fuel consumption, and avoid
increasing the mechanical load due to
excessive combustion pressure in the
cylinder caused by the supercharger
rotor overspeed or high boost pressure
through air exhaust and escape at a
high speed (that is, some exhaust gas
directly enters the exhaust pipe without
passing through the turbine). That is to
say, the vent valve focuses on
improving the low-speed torque 1-adjusting nut;2-vent valve;3-rocker; 4-pin roll;
characteristics of the diesel engine and 5-exhaust manifold; 6-turbine; 7-compressor impeller;
also takes into account the 8-air inlet pipe; 9-lead pipe; 10-closed pressure
chamber; 11-diaphragm; 12-spring; 13-linkage push
performance index and reliability of the
rod; A-exhaust gas inlet; B-exhaust gas outlet; C-fresh
diesel engine at a high-speed.
air; D-pressurized air
The vent valve is a membrane valve, which is divided into two chambers by the membrane.
One chamber is connected with the gas compressor outlet and the other is connected with
the atmosphere. The opening and closing of the vent valve is automatically controlled by
the boost pressure. When the boost pressure reaches or exceeds the specified value, the
membrane will overcome the spring force on the left and move left together with the linkage
push rod to push the rocker to rotate around the pin roll; then the vent valve is opened, the
exhaust by-pass valve bleeds, and the speed of the supercharger is decreased.
Note:
a) The specified opening pressure of the vent valve is set by the manufacturer, and the
user shall not make any adjustment, otherwise the power, economy and reliability of the
diesel engine will be seriously damaged.
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b) In any case, the push rod of the vent valve shall not be used as a handle.
c) In use, stop the vehicle to eliminate if air leakage is found in the lead pipe or the push
rod is not flexible.
d) The vent valve and the closed pressure chamber cannot be repaired. If any damage is
found, they must be replaced completely.
(3) Maintenance for supercharger
In addition to the correct operation, the supercharger must be maintained regularly to
ensure the effective and reliable operation of the supercharged diesel engine. The
turbocharger is a precision high-speed rotating machine, and its maximum speed is 230000
r/min or higher. Thus, it is prohibited to disassemble the supercharger assembly at will.
When the supercharger's rotor cannot rotate flexibly or the diesel engine's performance
becomes poor due to too much dirt or carbon deposit, simple cleaning and washing can be
carried out without disassembling the supercharger completely. The specific methods are
as follows:
a) Remove the dust and oil on the surface of the supercharger.
b) Remove the supercharger from the diesel engine. Do not lift the supercharger with the
push rod of the vent valve as the handle.
c) The lead pipe shall be removed first, and then the regulator shall be removed.
d) Remove the compressor casing, turbine casing, and connecting parts for oil inlet and
return pipes and coolant pipe.
e) Clean and rinse the compressor casing, turbine casing and two impeller surfaces. At
the same time, check whether the impeller is damaged and rubs against the shell.
f) Inject a proper amount of clean detergent from the oil inlet, and turn the impeller by
hand at the same time until it turns flexibly.
g) Assemble the supercharger and install it on the diesel engine. When the supercharger
is installed, all the sealing elements connected with the supercharger shall be replaced
at the same time, and clean lubricating oil shall be filled into the oil inlet of the
supercharger for prelubrication.
 Caution: do not collide with the impeller during the disassembly and cleaning of the
supercharger. If there is any collision, do not correct the deformed blade for reuse. The
detergent can be kerosene, gasoline or diesel oil of good quality.
(4) Inspection of supercharger
Inspection of radial clearance of rotor: during inspection, press down the compressor
impeller and turbine impeller with both hands along the radial direction at the same time,
and measure the minimum clearance between the compressor impeller and the
compressor housing with a thickness gauge. If this value is less than 0.10 mm, replace the
floating bearing (replace the supercharger if repair is not allowed).
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Inspection of the axial clearance of the rotor: during the inspection, the magnetic base can
be fixed on the flange face at the outlet of the turbine housing, make the dial indicator
contact with the end face of the turbine rotor shaft, and then the turbine rotor is pushed or
pulled along the axial direction. The measured difference is the axial clearance value. The
axial clearance value of the rotor of the new supercharger shall be ≤ 0.111mm, and its
service limit shall be ≤ 0.25mm. When the axial clearance of supercharger rotor exceeds
the service limit, the assembly shall be replaced.
Do not replace the supercharger with a new one without determining and eliminating the
cause of damage.
(5) Air-air intercooler
The air-air intercooler is installed in front of the radiator of the water tank. Generally, it is
installed in the upper part in front of the radiator of the water tank, instead of the lower part.
Leave a proper distance at the bottom of the water tank for the cooling of the radiator.
Engine Intercooler Air inflowCompressed air Turbocharger
Exhaust
There shall be no other cooling radiator (such as air conditioner

radiator) in front of the intercooler, and a certain distance shall be
kept from the vehicle body parts for air circulation. The windward
area of the intercooler should not be too small or too large,
generally 3/5 of the windward area of the radiator of the water
tank. If it is too small, intercooling is not effective, affecting the
performance of the engine; if it is too large, heat dissipation for
cooling water will be affected, resulting in high engine water
temperature. For vehicles with rear engine, the windward area of the intercooler can be
equal to that of the radiator of the water tank.
The heat radiating area of air-air intercooler only needs to meet the requirements of
resistance and outlet temperature. The resistance of air-air intercooler is generally ≤ 10kPa,
and the temperature of air after intercooling is ≤ 75℃. The rubber pipe connecting the
intercooler with the engine must be fabric silicone rubber hose, which is not allowed to fail
under the temperature of -40℃ ~ 200℃ and pressure of 300kPa.
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(6) Matching requirements of supercharged and mid-cooling diesel engine
a) The air filter shall be dry-type instead of oil bath type. Air filter flow ≥ 420 m3/h,
resistance ≤ 3kPa; the inner diameter of the air inlet pipe shall not be less than Φ47mm;
the inner wall of pipe shall be clean and smooth, and no air leakage is allowed at each
connection of the pipeline system; the rubber pipe for connection shall be lined with
steel wire, so as to prevent the rubber pipe from being sucked flat when the air flows at
a high speed( this will result in insufficient air intake, power reduction, serious smoking
and oil leakage at the gas compressor of the supercharger). The intake vacuum of the
air inlet pipe (from the air outlet of the air filter to the air inlet of the gas compressor)
shall be ≤ 4.5kPa, and the air filter element shall be replaced when it reaches 6.5kPa. If
conditions permit, an intake vacuum alarm can be installed behind the air outlet of the
air filter to detect the intake resistance, ensure the air inflow of the diesel engine, and
timely remind the operator to maintain and replace the air filter element.
b) The inner diameter of exhaust pipe shall not be less than Φ 45mm. The allowable
exhaust resistance is 25kPa (including aftertreatment system) when the muffler meets
the required noise reduction.
c) Generally, Φ 450 air-draft cooling fan is used. For vehicles with tight layout, the cooling
fan can be reduced appropriately, but other measures shall be taken for cooling.
d) The windward area of the intercooler should not be too small or too large, generally 3/5
of the windward area of the radiator of the water tank. The resistance of air-air
intercooler is generally ≤ 8kPa, and the temperature of air after intercooling is ≤ 75 ℃.
The rubber pipe connecting the intercooler with the engine must be fabric silicone
rubber hose, which is not allowed to fail under the temperature of -40℃ ~ 200℃ and
pressure of 300kPa.
e) The heat radiating area of radiator of water tank shall be no less than 18 m2; the wind
scooper must be installed. The radial clearance between the wind scooper and the fan
shall be about 20mm, and the distance between the front end face of the fan and the
radiator shall be about 30 ~ 60mm.
(7) Use and maintenance of supercharged and mid-cooling diesel engine
a) Maintain the oil filter and change the oil in strict accordance with the instructions.
b) The sundries attached to the intercooler and water tank shall be removed frequently,
and the dust shall be washed with high-pressure water, otherwise, the performance and
service life of the diesel engine will be affected.
c) After the diesel engine is started, it is not allowed to run with load immediately, and it
should be idled for 3-5 minutes to ensure good lubrication.
d) It is not allowed to shut down the engine immediately after heavy load operation, and it
should be idled for 3-5 minutes; it is strictly prohibited to drive down the slope for
flameout.
87
e) The diesel engine should be prevented from idling for a long time. Too long idle time will
result in oil carry-over of the supercharger.
f) When the diesel engine is not used for a long time or a new supercharger is used, fill a
small amount of oil at the oil inlet of the supercharger.
g) When the diesel engine is hot, it is forbidden to touch the supercharger and its
connecting pipeline to avoid scalding.
88
Chapter V Use and Maintenance of Aftertreatment
System
The Yunnei engine adopts DOC + DPF + SCR + ASC aftertreatment system, meeting the
national stage VI emission regulations. The system is composed of DOC (diesel oxidation
catalyst), DPF (diesel particulate filter), SCR (selective catalytic reduction), ASC (ammonia
escape catalyst), 4 exhaust temperature sensors, 2 NOx sensors, 1 particle sensor, 1
differential pressure sensor, urea nozzle, urea supply unit, urea tank, etc. In addition, under
the urea nozzle is a urea mixer composed of blades, and at the end of SCR is a muffler. At
present, the reducing agent of SCR system is 32.5% urea solution (in accordance with DIN
70070 or ISO 2441), which is decomposed into NH3 and CO2 at high temperature. The
reaction between NH3 and NOx in tail gas produces N2 and H2O.
Figure 5.1 Schematic diagram of aftertreatment system
I. General requirements for aftertreatment system

 The aftertreatment system shall meet the requirements of emission and noise.
 The exhaust resistance caused by the aftertreatment system shall not exceed the limit
value of the engine to avoid affecting the engine performance.
 The urea injection control unit and power harness shall be arranged in the place with no
water, less dust and small vibration.
 The layout of the inlet and outlet pipes of the urea injection pump shall be conducive to
the removal of air and prevent the urea from staying in the pipeline. It is recommended
that there are three arrangements as shown in Fig.5.2, Fig.5.3 and Fig.5.4.
89
Figure 5.2 Layout form 1 (urea injection unit higher than urea supply unit, urea supply unit
higher than urea tank)
Figure 5.3 Layout form 2 (urea injection unit higher than urea tank, urea tank higher than urea supply
unit)
90
Figure 5.4 Layout form 3 (urea supply unit higher than urea tank, urea tank higher than urea injection
unit)
II. Maintenance of aftertreatment system

1. Maintenance of urea tank:
The urea tank is mainly used to store urea water solution. It needs to be maintained every
half a year or 30000 km.
1) Urea solution shall be added to the highest level of urea tank to 100%. When urea
solution is consumed to 20%, urea solution shall be added.
2) Open the drain plug at the bottom for cleaning the tank when the engine is maintained
every year, and discharge the sediment.
3) If white crystal is found at the vent valve or filling port during irregular inspection, it can
be washed with clean water or wiped with wet cloth.
4) If the vent valve is blocked, it can be unscrewed and cleaned with clean water or
replaced.
5) Replace the filter screen in the tank every 2-3 years.
6) Check the plug-ins and pipe joints irregularly.
2. Maintenance of urea nozzle:

The inlet diameter of the nozzle is 7.89, and clean the nozzle with clean water and
compressed air every half a year or 30000km to ensure the nozzle is smooth. Before
disassembling the urea nozzle, make sure that the system has completed purge and cooled
to the safe temperature.
(1) Inspect the quick coupling and the urea nozzle for damage.
91
(2) Before disassembly, the pollutants at the urea nozzle and pipeline connection shall be
removed.
(3) If the nozzle is blocked, the nozzle shall be soaked in clean water for 4-6 hours, and
then the cavity of the nozzle shall be cleaned with compressed air. If the blockage cannot
be cleaned, the nozzle shall be replaced.
3. Maintenance of urea pipe and pump

(1) Visually inspect the urea pipe, mark the position that has crystal, and check for leakage.
(2) Check whether the urea pipe is damaged and whether the urea pipe is connected
reliably.
(3) Clean and dry the urea pipe, and remove all urea crystallization on the urea pipe.
(4) Start the vehicle to check for the leakage of the urea pipe; focus on the position where
the urea crystallization occurred. If the urea pipe or joint leaks, please replace the urea
pipe.
4. Maintenance of aftertreatment sensor

Please regularly check and clean nitrogen-oxygen sensor, exhaust temperature sensor,
differential pressure sensor, PM sensor and ambient temperature sensor; and check
whether their connecting wires and connectors are connected reliably.
5. Maintenance of DPF
Except for DPF, the mechanical parts and catalyst of aftertreatment system do not need
maintenance. DPF maintenance includes disassembly and assembly and cleaning.
 Disassembly and assembly of DPF
The disassembly step of DPF is as follows:
Step 1: mark between DOC and DPF as well as between DPF and SCR for recording their
relative positions in the circumferential direction.
Step 2: loosen the flange thread connection between the front pipe and DOC.
Step 3: loosen the hoop between SCR and DPF.
Step 4: remove the hanger on DPF or DOC, and take DOC and DPF off the vehicle
together.
Step 5: loosen the hoop between DOC and DPF to separate them.
The installation step is the reverse of the above.
 Cleaning of DPF
After DPF runs for a long time, the ash left over from combustion will accumulate on the
DPF, which will increase the exhaust back pressure of the engine and shorten the
regeneration mileage. Thus, it needs to be cleaned regularly. For the specific interval,
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please refer to the engine maintenance manual. It is recommended to use similar
equipment as shown in Figure 5.5 for cleaning.
Figure 5.5 Schematic diagram of DPF cleaning equipment
The cleaning process:

High temperature baking High pressure
in muffle furnace gas cleaning
The main functions of the above equipment:

Back pressure test equipment: test the back pressure change before and after DPF
cleaning by giving a certain amount of air.
Muffle furnace: provide high temperature to burn off the SOF and soot in DPF.
Dust cleaning equipment: use a small bunch of high-pressure gas to blow out the ash and
unburned carbon particles in DPF.
Dust collection equipment: collect the dust blown by high pressure gas. Check the SCR air
pipeline for leakage, and replace it if there is leakage.
III.Technical parameters of main parts of electronic control

system of aftertreatment system
Working voltage V 24
Urea pump Maximum supply
g/h 5400
capacity
Outlet pressure bar 5 (relative pressure)
Urea nozzle Injection flow range g/h 54～5400
Inlet pressure bar 5 (relative pressure)
Working voltage V 9 ～32
Urea tank
Working temperature ℃ -40℃～85
Differential pressure Working voltage V 5
93
sensor Working temperature ℃ -40℃～85
Measurable pressure
kPa 0～100
differential range
Working voltage V 5V±0.1
Exhaust
Measurable
temperature sensor ℃ -40～900℃
temperature range
Measurable
℃ -40℃～120℃
Ambient temperature
temperature sensor Working voltage V 5V±0.25
Output characteristics Ω 40186～40.7
Working voltage V 16～32
Measurement range PPM 0～3000
NOx sensor
-40≤probe≤850, probe
Working temperature ℃
harness≤210, SCU:-40～125
Working voltage V 16～32
Sensitivity of
mg/m3 1.51±0.48
PM sensor measurement
-40≤probe≤850,probe
Working temperature ℃
harness≤210, SCU:-40～105
Working voltage V 9-32
Working temperature ℃ -40℃～85
ECU control unit
Working current A ＜8 (with heater wire)
Quiescent current mA ≤2
Electromagnetic Working voltage V 18～32
water valve Power W 9
Urea inlet/return Working voltage V 24
pipe Power W 25W/m, joint 3 W per one
IV. Maintenance and installation of aftertreatment system
1. Aftertreatment assembly
(1) The aftertreatment system is connected with the whole vehicle frame through three
hoops and hangers.
(2) The front end of DOC is connected to the front pipe through flange and gasket, and the
position of flange determines the installation angle of aftertreatment.
(3) Wrap the front pipe and aftertreatment with materials. The material is to ensure the
performance of the aftertreatment system, and do not damage it during installation.
(4) After the aftertreatment is installed, check whether it interferes with other parts or is too
close to the parts with poor heat resistance (such as plastic parts and rubber parts).
(5) Except for DPF, the mechanical parts and catalyst of aftertreatment system do not need
maintenance. DPF maintenance includes disassembly and assembly and cleaning.
94
Mixer
Figure 5.6 Schematic diagram of aftertreatment assembly
2. NOx sensor
(1) The upstream NOx sensor is installed in front of DOC, on the straight pipe at the front
end of DOC cone, more than 5cm away from the air outlet of supercharger; the downstream
NOx sensor is installed in the rear of SCR, more than 10cm away from the tail end of SCR
taper pipe.
(2) Requirements for installation angle of probe: the angle between the probe and the
horizontal direction is ≥ 10°, as shown in Figure 5.7; the angle between the probe and the
gas flow direction is 90°±3°, as shown in Figure 5.8.
Figure 5.7 Schematic diagram of Figure 5.8 Schematic diagram of

installation angle of horizontal direction installation angle of gas flow direction
(3) The tightening torque of NOx sensor is 60 ± 10Nm. The tightening torque shall not be
too large to avoid damaging the sensor. The removal of NOx sensor shall be minimized
after installation.
(4) SCU is installed on the vehicle frame with the installation torque of 8Nm. It is
recommended that SCU be installed horizontally. When the installation space is limited,
SCU is allowed to rotate along its vertical axis and long axis, and it is not allowed to rotate
along its short axis, as shown in Figure 5.9 below.
95
Figure 5.9 Schematic diagram of SCU installation
3. PM sensor
(1) PM sensor is installed in the downstream of SCR and SCR is installed in the
downstream of DPF, so tail gas can be well mixed and particles can be distributed uniformly;
the sensor is more than 10cm from the tail end of SCR taper pipe.
(2) Requirements for installation angle of probe: the angle between the probe and the
horizontal direction is shown in Figure 5.10; the green area is recommended for installation;
the angle between the probe and the gas flow direction is 85° ± 5°, as shown in Figure 5.11.
Figure 5.10 Schematic diagram of Figure 5.11 Schematic diagram of

installation angle of horizontal direction installation angle of gas flow direction
(3) The tightening torque of PM sensor is 50 ± 10Nm. The tightening torque should not be
too large to avoid damaging the sensor.
(4) SCU is installed on the vehicle frame with a mounting torque of 12N. m. It is
recommended that SCU be installed horizontally. When the installation space is limited,
SCU is allowed to rotate along its vertical axis and horizontal axis, and to rotate finitely
along its longitudinal axis; vertical installation is not allowed, as shown in Figure 5.12.
96
Figure 5.12 Schematic diagram of SCU installation direction
4. Differential pressure sensor

(1)The hose shall be firmly fixed on the mounting hole to ensure no
leakage of tail gas and normal operation of the system. Two 10 mm
hoses (it is recommended to use hoses of different colors for upstream
and downstream to prevent installation errors) shall have an inner
diameter of 7-9 mm, and the mounting holes shall be at least 2 cm into
the hose.
(2) The first fixing point at the sensor side shall be as close as possible
to the sensor (<10cm) and on the same carrier as the sensor; ensure
that the maximum vibration cannot exceed the allowable value.
(3) It is recommended that the total length of hose and metal pipe
should be more than 80cm (30cm of metal pipe), and the pipeline Figure 5.13 Differential
pressure sensor
from DPF to sensor should rise continuously (at least 15 ° upward)
to ensure that condensate can flow out.
(4) Make sure that the hose at the interface can withstand the temperature.
5. Exhaust temperature sensor

(1) The minimum bending radius of the extension wire of the exhaust temperature sensor is
12.5mm, as shown in Figure 5.14.
Figure 5.14 Bending radius of extension wire
(2) It is recommended to fix the harness every 250mm to avoid fatigue. When the harness
is not protected by the additional sheath, the harness cannot be fixed at the position close
97
to the friction and wear. Do not contact the harness with tail gas or hot surface. Avoid
internal or external stress on harness or sensor.
(3) The top of the sensor is preferably placed in the center of the tailpipe and perpendicular
to the gas flow direction; the sensor can be installed at any angle within 360° of the exhaust
pipe.
It can be installed at
any angle within
360°.
Figure 5.15 Installation position of exhaust temperature sensor
Note: four exhaust temperature sensors need to be installed in the

aftertreatment system.
(4) For installing the sensor, align the mounting hole and screw the hex nut. First tighten the
hex nut by hand, and then tighten it to 30-40Nm by open wrench. Do not use impact gun for
installation. Pneumatic torque wrench can be used. No contamination, burrs or welding slag
is allowed on the surface of sealing flange, thread and mounting hole. 302HQ or materials
with considerable thermal stability and expansibility are recommended for welding base.
Bending is strictly prohibited.
6. Urea tank
The urea tank is used to contain urea water solution, and the integral material is plastic. It
includes one urea outlet, one urea return port, one water inlet for heater, one water outlet
for heater, one vent valve, one coarse filter, one filling port, one drain port, and one
electrical interface. The integrate of sensor and heater is installed at its top. The sensor can
sense the liquid level and temperature. The heater can use the heat of engine cooling water
to deice. The vent valve is used to balance the gas pressure inside and outside the tank.
The tank is equipped with a coarse filter to prevent particles larger than 70 μ m from
entering the injection system. The bottom of the tank is provided with a plug hole for
draining residual liquid.
98
portSensor
Filling Solenoid
for urea Φ14 water
valve inletSEA5/16’’
Φ14 water outlet urea
SEA3/8’’ urea inlet
outlet Vent pipe
Figure 5.16 Structure diagram and interface dimension of urea tank
Installation steps:
(1) Carefully position the urea tank on the mounting bracket of the vehicle.
(2) Tie the strap to the installation groove of the tank body and pre lock the strap to the
vehicle frame.
(3) Use a spanner to lock screw to fix the tank (self-locking nut is recommended).
(4) Connect each liquid pipeline joint and harness connector, and then connect to the SCR
system.
(5) Check whether the installation is in place. If necessary, slightly adjust the position of the
urea tank.
7. Urea supply unit

(1) The urea supply unit (SM) pressurizes the diesel exhaust fluids (DEF) in the urea tank
and delivers it to the urea injection unit (DM), and then the urea injection unit sprays DEF
into the exhaust pipe. In addition to these two components, the system includes other non
Bosch components which are controlled by the engine control unit (ECU) of Bosch.
(2) The interface definition of urea supply unit is shown in the figure below: the suction pipe
(SL) sucks urea from urea tank into urea supply unit. Part of urea is returned to the urea
tank through the return pipe (BL). The pressure pipe (PL) connects the urea supply unit with
the urea injection unit to deliver the pressurized urea to the urea injection unit.
99
Figure 5.17 Schematic diagram of interface
(3)The reference point for installing the urea supply unit (SM) on the vehicle is located in
the bottom center of the right mounting hole, and the allowable installation position is
shown in the figure below.
Figure 5.18 Allowable installation position
8. Urea injection unit

(1)In the Denoxtronic 6-5 system, the urea injection unit injects the required amount of urea
into the exhaust pipe for catalytic reduction of NOx. This process is controlled by Bosch
control unit. The injection unit is mounted on the exhaust pipe at a fixed angle.
100
Figure 5.19 Schematic diagram of joint of urea injection unit
(2) In the Denoxtronic 6-5 system, the reference point of the urea injection unit (DM) is
located in the top center of the urea hydraulic joint.
Figure 5.20 Reference point of urea injection unit
(3)The gasket on the urea injection unit (DM) is disposable. New gaskets shall be used for
each installation. The urea injection unit shall be tightened according to the required torque
(8 ± 2Nm) and the installation sequence in the figure.
101
Figure 5.21 Installation sequence for bolts
(4) For installation, install the harness first, then the hydraulic pipe. For disassembly,
remove the hydraulic pipe first, then the harness. The hydraulic pipe and the harness
should be away from the heat source.
(5) If the coolant joint on the urea injection unit is damaged, it can be replaced separately.
The size of the joint nut is M12 × 1.5.
(6) There is no special requirement for the torque of the coolant joint during removal, but
the coolant joint must be kept clean. The final fixing torque for installation is 5.5 ± 0.5Nm.
9. Ambient temperature sensor
The ambient temperature sensor is used to measure the ambient temperature. When the
ambient temperature is too low, the system automatically heats the urea pipe to prevent the
urea from freezing. The installation of the sensor shall be able to accurately reflect the
ambient temperature of the aftertreatment system.
Figure 5.22 Ambient temperature sensor

Resistance table corresponding to temperature
102
10. Urea pipe
Each aftertreatment system has three urea delivery pipes, which are respectively used for
the delivery of urea solution from urea tank to urea pump (inlet pipe), from urea pump to
urea nozzle (outlet pipe), and from urea pump backflow to urea tank (return pipe). The urea
delivery pipe is equipped with an electric heater. When the temperature is too low, the
system will start the electric heater to heat or thaw the urea solution in the pipe to ensure
the normal flow of the urea solution.
Size of quick
Urea pipe Start-stop end Remarks
union
From urea tank to urea metering
Inlet pipe 9.49 (3/8") With heater
pump
Injection pipe 6.3 (1/4") From urea metering pump to nozzle With heater
From urea metering pump to urea
Return pipe 7.89(5/16") Without heater
tank
The longer the pipeline is, the more carefully the pipeline shall be arranged. The pipeline
from the outlet of the liquid storage tank to the urea solution inlet of the metering injection
pump shall go up all the way; local arch is not allowed to prevent the air interception.
V. Common faults and handling methods

1. Failure of urea pump
1) Check whether the "click" can be heard within a few seconds after power-on by key
switch to judge whether the urea is powered on normally. (if the heating water valve of the
urea tank is installed on the vehicle, the heating water valve will make a sound for
self-inspection under normal conditions after power on).
2) If the sound for internal self-inspection and heating water valve self-inspection cannot be
heard after power on, check whether the urea harness connector falls off, whether the
harness and connector are damaged, and whether the SCR system fuse and battery
voltage are normal.
3) If the user can only hear the sound of the heating water valve, it may be an internal fault.
First, check whether the appearance is damaged. If there is no abnormality, use the
103
diagnostic instrument to read the fault code to determine.
4) If the sounds are normal, check whether the pipeline from the urea tank to the urea pump
falls off, bends and is damaged.
5) Check whether the compressed air pipe from urea to filter falls off, bends and is
damaged.
6) Check whether the compressed air pipe from the filter to the air-take falls off, bends and
is damaged.
7) When the compressed air pressure of the vehicle is normal, power on for self-inspection.
When the internal self-inspection sound is heard, check whether there is any sound of
compressed air ejected through the urea nozzle. If there is no sound of ejection, check
whether the injection pipe from the urea pump to the urea nozzle falls off, bends and is
damaged. Remove the urea nozzle from the flange, and check whether the orifice is
blocked. If the orifice is covered by crystallization, immerse the orifice in clean water, and
power on again after cleaning.
8) Check whether the vent hole of urea tank is blocked.
9) Check whether there is urea in the urea tank.
10) Check whether the exhaust temperature sensor is installed in the correct position on
the exhaust pipe.
11) Use the diagnostic instrument to read out the fault code, find out the fault point
according to the fault code, and eliminate the relevant functional faults and build pressure
for related components, such as faults related to urea pump, nozzle, heating component,
and air pressure. Proceed to the next step according to the prompts in the fault code table.
12) If the ambient temperature is lower than -11°C, eliminate the fault of the aftertreatment
heating component according to the fault code to ensure the normal heating function.
13) Check whether the air supply pressure is within the normal range; check whether the
nozzle is blocked.
14) If there is no problem in the above inspection, but the pressure build-up fails, it may be
the urea suction fault. Use the diagnostic instrument to carry out the manual suction test.
15) Use the diagnostic instrument to read the CID (Calibration ID) and check whether the
software and data version are correct.
2. Urea crystallization
1) Use the diagnostic instrument to read out the fault code, and determine the fault
according to the fault code, such as faults related to NOx conversion efficiency and NOx
signal.
2) Too much urea injection can result in crystallization. Check whether there is failure of
urea injection.
104
3) Check the exhaust pipe for air leakage, such as cracking. Remove SCR catalyst and
exhaust tubulation for inspection, and check whether there is obvious urea crystallization
inside. If there is obvious crystallization, it will increase the engine back pressure and fuel
consumption.
4) Check whether there is urea crystallization around the nozzle base.
5) Check whether the exhaust pipe downstream of the urea nozzle has obvious corrosion.
The common cast iron exhaust pipe will be corroded by urea. Stainless steel should be
used.
6) Use the diagnostic instrument to read CID and check whether the software and data
version are correct.
3. Strong ammonia odour

1) Check the catalyst for damage and absence. If there is no catalyst, the ammonia gas can
not react with NOx in the exhaust gas after the injected urea produces ammonia gas by
hydrolysis and pyrolysis; the ammonia gas will be directly discharged into the atmosphere.
2) Check whether the carrier in the catalyst is damaged or missing.
according to the fault code, such as faults related to NOx conversion efficiency and NOx
signal.
5) Check the nozzle. If the nozzle is damaged and the atomization is abnormal, the urea
injection can not completely hydrolyze, reducing the conversion efficiency and resulting in
ammonia leakage.
4. Heating system failure of urea pump

1) Read out the fault code with the diagnostic instrument, and determine the fault according
to the fault code, such as faults related to the heating of aftertreatment system, the ambient
temperature sensor, the urea heating pipe and the urea tank heating.
2) Check the ambient temperature sensor and confirm that the sensor works normally; if the
ambient temperature sensor sends by message, check whether the message is sent
normally.
3) Check the heating of aftertreatment system, urea heating pipe, urea tank water valve
and harnesses.
4) Check whether the water line of heating of urea tank circulates normally and whether the
water inlet and water outlet are connected reversely.
5) If the heating of urea pump fails and the failure still exists after power off and restart,
replace the urea pump.
105
5. Low NOx conversion efficiency

1) Read out the fault code with the diagnostic instrument, and determine the fault according
to the fault code, such as faults related to NOx conversion efficiency.
2) Carry out the following inspections in turn:
Check NOx sensor and exhaust pipe. If the measurement signal of NOx sensor is too large,
conversion efficiency failure will be reported;
Check the urea injection. If the amount of urea injection is too small, the measurement
signal of NOx sensor will be too large, and then the low conversion efficiency will occur;
Check whether there is leakage in the urea injection pipe. If there is leakage, the actual
urea injection quantity is small, which will cause the measurement signal of NOx sensor to
be too large, and then lead to the low conversion efficiency;
Check the urea solution. If the quality of urea solution is unqualified (the concentration is
lower than 32.5%), the measurement signal of NOx sensor will be too large, and then the
low conversion efficiency will occur;
Check whether there is urea crystallization in SCR catalyst; if so, the conversion efficiency
will decrease;
Check the engine and SCR catalyst. If the engine or SCR catalyst is aged seriously, the
original NOx emission will be too large or the measurement signal of NOx sensor will be too
large, which will lead to conversion efficiency failure;
3) If necessary, use the diagnostic instrument to read the CID and check whether the
software and data version are correct.
6. Abnormal urea consumption

1) Check the urea tank for leakage and damage.
according to the fault code, such as faults related to nozzle, urea pump, exhaust
temperature sensor, and urea tank temperature sensor.
3) If the ambient temperature is lower than -11 °C, first check the heating component of the
aftertreatment system according to the fault code.
4) Check whether the urea pump works normally.
5) If the system works normally, check the nozzle for blockage or other faults.
6) If necessary, use the diagnostic instrument to read CID and check whether the software
and data version are normal.
106
Chapter VI Fault Code of Electric Control System and
Aftertreatment System
This manual is about light-up rules, written for common faults of Yunnei Bosch MD1CE108
China VI engine. Fault diagnosis (DSM) is an important part of Bosch electronic-control
ECU. It can provide fault diagnosis information for after-sales service, so as to solve
problems quickly and accurately.
Brief description of the rules for lighting up the OBD (MI) light: refer to 3.12 of HJ
437-2008 Technical Requirements for Engine and Vehicle On-board Diagnosis (OBD)
System for definitions.
Light up OBD (MI) light:
• If the ignition switch of the vehicle is turned on but the engine is not started, the MI light
will be on.
• If the emission exceeds the OBD limit, or the OBD system fails to meet the monitoring
requirements of the OBD system, the MI light will be on.
Light off OBD (MI) light:
• After the engine is started, the MI light goes out if no fault has been previously detected.
• For other faults, the MI light goes off, if the monitoring system for activating MI no
longer detects the fault and no other fault that would activate the MI separately is
detected during three consecutive operating cycles, or 24 hours of engine operation.
Storage and removal of OBD fault codes: refer to Appendix C4 of HJ 437-2008
Technical Requirements for Engine and Vehicle On-board Diagnosis (OBD) System
for definitions.
Brief introduction of the rules for lighting up SVS light:
Light up SVS light:
• When the ignition switch is on, the SVS light will be on.
• When the engine components or accessories fail, the SVS light will be on.
Light off SVS light：
• When the ignition switch is on, the SVS light goes out if no fault is detected previously.
• The SVS light goes out when the fault of engine components or accessories is cured.
Notes：
1. This manual is applicable to vehicles using MD1CE108 system.

2. Faults and system responses described in this manual may not cover all possibilities.
3. The faults involved in this manual will be updated according to the changes in the status
of the used hardware.
107
Remarks: ON means to turn on the light immediately, ON_3DC means to turn on the
light after three driving cycles, and OFF means not to turn on the light.
Fault
Corresponding
Component / Fault class Type of
Fault code information regulatory
system code (class monitoring
requirement
A/B/C)
FC. 1 electrical /
Battery voltage is too Class Component electronic
P056385
high. C fault monitoring component
monitoring
Battery voltage
FC. 1 electrical /
Class Component electronic
P056284 Battery voltage is too low.
C fault monitoring component
monitoring
FC. 1 electrical /
Vehicle speed The speed signal is Class Component electronic
P050164
sensor unreasonable. C fault monitoring component
monitoring
When the high and low
idle speed regulation is FC.14 idle speed
Class Component
P050785 activated, the engine control system
C fault monitoring
speed exceeds the upper detection
Idle speed limit.
control system When the high and low
idle speed regulation is FC.14 idle speed
Class Component
P050684 activated, the engine control system
C fault monitoring
speed exceeds the lower detection
limit.
FC. 1 electrical /
Class
Failure of sensor power Component electronic
P064312 B1
supply module 1 monitoring component
fault
monitoring
FC. 1 electrical /
Class
Sensor power Failure of sensor power Component electronic
P065312 B1
supply module supply module 2 monitoring component
fault
monitoring
FC. 1 electrical /
Class
Failure of sensor power Component electronic
P069912 B1
supply module 3 monitoring component
fault
monitoring
Voltage signal of FC. 1 electrical /
barometric pressure Class Component electronic
P222912
sensor is above upper C fault monitoring component
limit. monitoring
Ambient
barometric pressure Class Component electronic
atmospheric P222811
sensor is below lower C fault monitoring component
pressure sensor
limit. monitoring
FC. 1 electrical /
Failure of ambient Class Component electronic
P222764
pressure sensor reliability C fault monitoring component
monitoring
FC. 1 electrical /
Voltage signal of ambient
Ambient P007312 temperature sensor is
temperature above upper limit.
monitoring
sensor
Voltage signal of ambient Class Component FC. 1 electrical /
P007211
temperature sensor is C fault monitoring electronic
108
Fault
Corresponding
requirement
A/B/C)
below lower limit. component
monitoring
Dynamic value rationality
detection failure of water
temperature sensor Class FC.12 engine
Component
P011626 (water temperature B2 cooling system
monitoring
appreciation does not fault monitoring
reach the threshold value
in a certain period of time)
Dynamic value rationality
detection failure of water
temperature sensor Class Component FC.12 engine
Coolant
P011627 (water temperature B2 monitoring cooling system
temperature
appreciation does not fault monitoring
sensor
reach the threshold value
in a certain period of time)
FC. 1 electrical /
Voltage of water
P011812 temperature sensor is
above upper limit.
monitoring
FC. 1 electrical /
Voltage of water
below lower limit.
monitoring
FC. 1 electrical /
Failure of temperature Class
Component electronic
P100564 sensor reliability during B1
monitoring component
system’s cold start fault
monitoring
Failure of temperature FC. 1 electrical /
Class
sensor reliability during Component electronic
P100064 B2
system’s cold start monitoring component
fault
(combination 0) monitoring
Class
P100164 B2
fault
Class
P100264 B2
Air temperature fault
sensor of system
Class
P100364 B2
fault
Class
P100464 B2
fault
FC. 1 electrical /
Unreasonable boost Class
P023985 pressure sensor signal- B1
too large fault
monitoring
Unreasonable boost Class FC. 1 electrical /
Component
P023984 pressure sensor signal- B1 electronic
monitoring
too small fault component
109
Fault
Corresponding
requirement
A/B/C)
monitoring
Voltage signal of intake FC. 1 electrical /
Class
air temperature sensor of Component electronic
P009812 B2
engine intake manifold is monitoring component
Temperature fault
above upper limit. monitoring
sensor of engine
Voltage signal of intake FC. 1 electrical /
intake manifold Class
air temperature sensor of Component electronic
P009711 B2
engine intake manifold is monitoring component
fault
above upper limit. monitoring
FC. 1 electrical /
Voltage signal of boost Class
P024212 pressure sensor is above B1
upper limit. fault
monitoring
FC. 1 electrical /
Voltage signal of boost Class
P024111 pressure sensor is below B1
Boost pressure lower limit. fault
monitoring
sensor of intake
FC. 1 electrical /
manifold Unreasonable boost Class
too large fault
monitoring
FC. 1 electrical /
Unreasonable boost Class
too small fault
monitoring
Class
downstream temperature Component electronic
P040D12 B2
Downstream sensor of EGR cooler is monitoring component
fault
temperature above upper limit. monitoring
sensor of EGR Voltage signal of FC. 1 electrical /
Class
cooler downstream temperature Component electronic
P040C11 B2
sensor of EGR cooler is monitoring component
fault
below lower limit. monitoring
FC. 6.3 poor
cooling
Severe
Too low EGR (exhaust Class performance of
functional
EGR cooler P245792 gas recirculation) cooler B2 EGR cooler
failure
efficiency fault (severe
monitoring
functional failure
monitoring)
The deviation value of
boost pressure Severe
FC. 8 intake air
adjustment controls (the functional
Class regulation and
set value of boost failure
P226385 B1 turbocharging
pressure minus the actual monitoring
fault pressure control
value) is higher than the or function
Deviation of system a3)
upper limit (the positive monitoring
boost pressure
deviation is too large).
adjustment
The deviation value of
controls Severe
boost pressure FC. 8 intake air
functional
adjustment controls (the Class regulation and
failure
P226384 set value of boost B1 turbocharging
monitoring
pressure minus the actual fault pressure control
or function
value) is lower than the system a3)
monitoring
lower limit (the negative
110
Fault
Corresponding
requirement
A/B/C)
The time where boost

FC. 1 electrical /
pressure adjustment Class
Function electronic
P259C52 controls does not enter B1
the closed loop is more fault
monitoring
Boost pressure than the threshold value.
adjustment The time where boost
controls pressure adjustment FC. 1 electrical /
Class
controls enters the closed Function electronic
P056E52 B1
loop from the switch is monitoring component
fault
more than the threshold monitoring
value.
FC. 8 intake air
Severe
Cooling efficiency of Class regulation and
functional
Intercooler P026A00 intercooler is lower than B2 turbocharging
failure
the lower limit. fault pressure control
monitoring
system c)
FC. 1 electrical /
Class
P004513 Drive circuit is open. B1
fault
monitoring
FC. 1 electrical /
Overheated drive chip in Class
P00454B electronic control unit B1
(ECU) fault
monitoring
FC. 1 electrical /
Class
Drive circuit shorted to Component electronic
P004812 B1
storage battery monitoring component
fault
monitoring
FC. 1 electrical /
Supercharger Class
Control circuit shorted to Component electronic
P004711 B1
ground monitoring component
fault
monitoring
The deviation of FC. 8 intake air
supercharger controller is Class regulation and
Function
P00469B higher than the upper limit B1 turbocharging
monitoring
(positive deviation is too fault pressure control
large). system b)
The deviation of FC. 8 intake air
supercharger controller is Class regulation and
Function
P00469C lower than the lower limit B1 turbocharging
monitoring
(negative deviation is too fault pressure control
large). system b)
FC. 1 electrical /
The deviation of air flow Class
Function electronic
P0100F3 meter(HFM) is higher B1
than the upper limit. fault
monitoring
FC. 1 electrical /
HFM fresh air The deviation of air flow Class
Function electronic
flowmeter P0100F1 meter (HFM) is lower than B1
the lower limit. fault
monitoring
Class FC. 1 electrical /
HFM sensor shorted to Component
P010312 B1 electronic
ground monitoring
fault component
111
Fault
Corresponding
requirement
A/B/C)
monitoring
FC. 1 electrical /
Class
P010211 HFM hardware failure B1
fault
monitoring
The time where EGR FC. 6 exhaust
Class
controller does not enter Function gas recirculation
P04D8F0 B1
the closed loop exceeds monitoring system (EGR)
fault
the threshold value. monitoring b)
EGR controller
After the engine is started, FC. 6 exhaust
Class
EGR controller l is not Function gas recirculation
P041800 B1
activated within the monitoring system (EGR)
fault
limited time. monitoring b)
The difference between
the set air quantity and FC. 6 exhaust
Class
the actual fresh air inflow Function gas recirculation
P0401FF B1
is higher than the upper monitoring system (EGR)
fault
limit (the fresh air inflow is monitoring a3)
EGR control too small).
deviation The difference between
the set air quantity and FC. 6 exhaust
Class
the actual fresh air inflow Function gas recirculation
P0401FE B1
is lower than the lower monitoring system (EGR)
fault
limit (the fresh air inflow is monitoring a3)
too large).
the set value and the FC. 6 exhaust
Class
actual value of EGR valve Function gas recirculation
P04019C B1
opening is higher than the monitoring system (EGR)
fault
upper limit (the positive monitoring b)
the set value and the FC. 6 exhaust
Class
actual value of EGR valve Function gas recirculation
P04029B B1
opening is lower than the monitoring system (EGR)
fault
lower limit (the negative monitoring b)
FC. 1 electrical /
Class
Drive circuit of EGR valve Component electronic
P213A13 B1
is open. monitoring component
EGR valve fault
monitoring
FC. 1 electrical /
Class
Overheated EGR valve Component electronic
P213A4B B1
driver chip in ECU monitoring component
fault
monitoring
FC. 1 electrical /
Class
EGR valve drive circuit Component electronic
P214212 B1
shorted to battery monitoring component
fault
monitoring
FC. 1 electrical /
Class
EGR valve drive circuit Component electronic
P214111 B1
shorted to ground monitoring component
fault
monitoring
EGR valve is stuck in OFF Class Component FC. 1 electrical /
P042F73
position. B1 monitoring electronic
112
Fault
Corresponding
requirement
A/B/C)
fault component
monitoring
FC. 1 electrical /
Class
EGR valve is stuck in ON Component electronic
P042E72 B1
position. monitoring component
fault
monitoring
FC. 1 electrical /
Voltage of EGR valve Class
P040612 position sensor is above B1
the upper limit. fault
monitoring
FC. 1 electrical /
Voltage of EGR valve Class
P040511 position sensor is below B1
monitoring
Self-learning deviation of
FC. 1 electrical /
fully off position of Class
P2108F0 electronic throttle valve B2
(TVA) exceeds the limit fault
monitoring
value.
FC. 1 electrical /
TVA controller has a Class
P211184 permanent negative B2
deviation. fault
monitoring
FC. 1 electrical /
TVA controller has a Class
P211285 permanent positive B2
deviation. fault
monitoring
FC. 1 electrical /
Class
P210013 H-bridge drive is open. B2
fault
monitoring
FC. 1 electrical /
Class
H-bridge drive current Component electronic
P21001D B2
overload monitoring component
TVA throttle fault
monitoring
valve
FC. 1 electrical /
Class
Overheated H-bridge Component electronic
P21004B B2
driver chip in ECU monitoring component
fault
monitoring
FC. 1 electrical /
High voltage part of Class
P2100F0 H-bridge drive circuit B2
shorted to power supply fault
monitoring
FC. 1 electrical /
Low voltage part of Class
P210012 H-bridge drive circuit B2
shorted to power supply fault
monitoring
FC. 1 electrical /
High voltage part of Class
P2100F1 H-bridge drive circuit B2
shorted to ground fault
monitoring
FC. 1 electrical /
Low voltage part of Class
P210011 H-bridge drive circuit B2
shorted to ground fault
monitoring
113
Fault
Corresponding
requirement
A/B/C)
FC. 1 electrical /
Class
Open and overloaded Component electronic
P2100F2 B2
H-bridge drive circuit monitoring component
fault
monitoring
FC. 1 electrical /
Class
Overheated H-bridge Component electronic
P210092 B2
drive circuit monitoring component
fault
monitoring
FC. 1 electrical /
Class
Low H-bridge drive circuit Component electronic
P2100A2 B2
voltage monitoring component
fault
monitoring
TVA position feedback FC. 1 electrical /
Class
sensor value is above the Component electronic
P262212 B2
upper limit (analog monitoring component
fault
signal). monitoring
FC. 1 electrical /
TVA position feedback Class
P262111 sensor value is below the B2
lower limit (analog signal). fault
monitoring
FC. 1 electrical /
Class
Camshaft signal Component electronic
P034129 B1
interference or loss monitoring component
fault
monitoring
FC. 1 electrical /
Class
No camshaft signal Component electronic
Camshaft sensor P034031 B1
detected monitoring component
fault
monitoring
FC. 1 electrical /
Too much deviation Class
P034001 between camshaft signal B1
and crankshaft signal fault
monitoring
FC. 1 electrical /
Class
Crankshaft signal Component electronic
P033629 B1
interference or loss monitoring component
fault
Crankshaft monitoring
sensor FC. 1 electrical /
Class
No crankshaft signal Component electronic
P033531 B1
detected monitoring component
fault
monitoring
FC. 1 electrical /
Fuel injector Fuel injection control Class
power supply P062DF0 module 1 (harness) is B1
module 1 short circuited. fault
monitoring
FC. 1 electrical /
Fuel injector Fuel injection control Class
power supply P062EF0 module 2 (harness) is B1
module 2 short circuited. fault
monitoring
FC. 1 electrical /
Cylinder 1(in firing order) Class
P020113 injector drive circuit is B1
open. fault
Fuel injector monitoring
Cylinder 2(in firing order) Class FC. 1 electrical /
Component
P020313 injector drive circuit is B1 electronic
monitoring
open. fault component
114
Fault
Corresponding
requirement
A/B/C)
monitoring
FC. 1 electrical /
open. fault
monitoring
FC. 1 electrical /
open. fault
monitoring
Cylinder 1(in firing order)
injector harness is short FC. 1 electrical /
Class
circuited (high-voltage Component electronic
P026212 B1
part or low-voltage part monitoring component
fault
shorted to power supply monitoring
or ground)
Class
P026812 B1
fault
or ground)
Class
P027112 B1
fault
or ground)
Class
P026512 B1
fault
or ground)
Cylinder 1 (in firing order) FC. 1 electrical /
Class
harness low-voltage part Component electronic
P026111 B1
shorted to high voltage monitoring component
fault
part monitoring

Class
P026711 B1
fault
part monitoring

Class
P027011 B1
fault
part monitoring
Class
P026411 B1
fault
part monitoring
Cylinder 1(in firing
Emission FC. 7 fuel
order)fuel quantity Class
P061101 limit system
correction (FBC) exceeds C fault
monitoring monitoring d)
the limit value.
115
Fault
Corresponding
requirement
A/B/C)
Emission FC. 7 fuel
P0611F0 limit system
the limit value.
Emission FC. 7 fuel
the limit value.
Emission FC. 7 fuel
the limit value.
The drive circuit of fuel FC. 1 electrical /
Class
gauging unit (MeUn) of Component electronic
P0251F1 B1
high pressure oil pump is monitoring component
fault
open-circuit. monitoring
The drive circuit chip of
FC. 1 electrical /
fuel gauging unit (MeUn) Class
P02524B of high pressure oil pump B1
is overheated. fault
monitoring
Fuel gauge
The high voltage part of FC. 1 electrical /
Class
drive circuit of fuel Component electronic
P025112 B1
gauging unit(MeUn) is monitoring component
fault
shorted to power supply. monitoring
The high voltage part of FC. 1 electrical /
Class
drive circuit of fuel Component electronic
P025111 B1
gauging unit(MeUn) is monitoring component
fault
shorted to ground. monitoring
Positive deviation of rail
pressure exceeds (actual Class
Function FC.7 fuel system
P0087F2 rail pressure is lower than B1
monitoring monitoring a)
the set value) the limit fault
value (MeUn scheme).
When the fuel supply of
fuel gauging unit(MeUn)
reaches the maximum set
Class
flow, the positive Function FC.7 fuel system
P0087F5 B1
deviation of rail pressure monitoring monitoring a)
fault
exceeds the limit value
(the actual rail pressure is
Rail pressure lower than the set value).
control system When the fuel supply of
fuel gauging unit(MeUn)
reaches the minimum set
Class
flow, the negative Function FC.7 fuel system
P0087F4 B1
deviation of rail pressure monitoring monitoring a)
fault
exceeds the limit value
(the actual rail pressure is
higher than the set value).
The actual rail pressure is FC. 1 electrical /
Class
lower than the minimum Component electronic
P008700 B1
rail pressure (MeUn monitoring component
fault
scheme) monitoring
P0088F0 The actual rail pressure is Class Component FC. 1 electrical /
116
Fault
Corresponding
requirement
A/B/C)
higher than the maximum B1 monitoring electronic
rail pressure (MeUn fault component
scheme) monitoring
FC. 1 electrical /
Rail pressure sensor Class
P019185 signal drift fault (too high B1
voltage) fault
monitoring
FC. 1 electrical /
Rail pressure sensor Class
P019184 signal drift fault (too low B1
voltage) fault
Rail pressure monitoring
sensor FC. 1 electrical /
Voltage signal of rail Class
P019312 pressure sensor is above B1
the upper limit. fault
monitoring
FC. 1 electrical /
Voltage signal of rail Class
P019211 pressure sensor is below B1
monitoring
Upstream temperature
Class
signal of diesel oxidation Function
P042564 B2
catalyst (DOC) is monitoring
fault
unreasonable.
Upstream
Voltage signal of DOC FC. 1 electrical /
temperature Class
upstream temperature Component electronic
sensor of P042812 B2
sensor is above the upper monitoring component
oxidation fault
limit. monitoring
catalyst
Voltage signal of DOC FC. 1 electrical /
Class
P042711 B2
sensor is below the lower monitoring component
fault
limit. monitoring
Upstream temperature
Class
signal of particle Function
P2031FB B2
filter(DPF) is monitoring
fault
unreasonable.
Upstream Voltage signal of DPF FC. 1 electrical /
Class
temperature upstream temperature Component electronic
P203312 B2
sensor of particle sensor is above the upper monitoring component
fault
filter limit. monitoring
Voltage signal of DPF FC. 1 electrical /
Class
P203211 B2
fault
limit. monitoring
FC.5 oxidation
Severe catalyst
Class
DOC oxidation Efficiency of oxidation functional (including diesel
P042200 B1
catalyst catalyst (DOC) is too low. failure oxidation
fault
monitoring catalyst DOC)
monitoring
DPF differential pressure Class
Function
P2452F0 sensor signal is B1
monitoring
Differential unreliable. fault
pressure sensor Voltage signal of DPF Class FC. 1 electrical /
Component
P244B85 differential pressure B1 electronic
monitoring
sensor is above the upper fault component
117
Fault
Corresponding
requirement
A/B/C)
limit. monitoring
Voltage signal of DPF FC. 1 electrical /

Class
differential pressure Component electronic
P244A84 B1
fault
limit. monitoring
Class
DPF adsorbed particle Function FC.2 DPF
P246385 B1
overload monitoring system b)
fault
Class
DPF adsorbed particle Function FC.2 DPF
P244B00 B1
overload monitoring system b)
Particle fault
filter(DPF) Emission
Too low DPF particle Class FC .2 DPF
P2002F0 limit
efficiency A fault system c),a)
monitoring
Class
Too high DPF Function FC.2 DPF
P2459F0 B1
regeneration frequency monitoring system c)
fault
FC.13 exhaust
The particle sensor is not Class
PMS particle Component and oxygen
P24AEFD installed correctly in the B1
sensor removal monitoring sensor detection
tailpipe. fault
a)
The temperature signal of

FC. 1 electrical /
the built-in temperature Class
P24C664 sensor of the particle B1
sensor probe is fault
monitoring
unreasonable.
The initial temperature of FC. 1 electrical /
Class
the temperature sensor Component electronic
P24C6F0 B1
built in the particle sensor monitoring component
fault
probe is unreasonable. monitoring
PMS particle
FC. 1 electrical /
sensor PCB temperature of Class
temperature P24C6F7 particle sensor controller B1
module is unreasonable. fault
monitoring
The voltage signal of the FC. 1 electrical /
Class
temperature sensor built Component electronic
P24C685 B1
in the particle sensor monitoring component
fault
probe is too high. monitoring
The voltage signal of the FC. 1 electrical /
Class
temperature sensor built Component electronic
P24C684 B1
in the particle sensor monitoring component
fault
probe is too low. monitoring
FC. 1 electrical /
Power supply of power Class
P24AE17 supply module of particle B1
sensor is too high. fault
Electrical and monitoring
communication FC. 1 electrical /
Power supply of power Class
module of PMS Component electronic
P24AE16 supply module of particle B1
particle sensor monitoring component
sensor is too low. fault
monitoring
CAN communication Class Component FC. 1 electrical /
P24AE29
module of particle sensor B1 monitoring electronic
118
Fault
Corresponding
requirement
A/B/C)
cannot receive command fault component
message. monitoring
FC. 1 electrical /
Interdigital electrode built Class
P24AEF6 in particle sensor probe is B1
short circuited. fault
monitoring
FC. 1 electrical /
Class
Particle sensor heating Component electronic
P24B309 B1
module failure monitoring component
fault
monitoring
FC. 1 electrical /
Class
P24B313 B1
module is open circuited. monitoring component
fault
monitoring
FC. 1 electrical /
Heating module Class
of PMS particle P24B363 B1
module is open circuited. monitoring component
sensor fault
monitoring
FC. 1 electrical /
Class
Heating module shorted Component electronic
P24B315 B1
to battery monitoring component
fault
monitoring
FC. 1 electrical /
Class
Heating module shorted Component electronic
P24B314 B1
to ground monitoring component
fault
monitoring
FC. 1 electrical /
Negative pole fails when Class
P24AEF1 the interdigital electrode is B1
powered down. fault
monitoring
FC. 1 electrical /
Class
Interdigital electrode Component electronic
P24AEF0 B1
failure monitoring component
fault
monitoring
FC. 1 electrical /
Negative pole fails when Class
P24AEF2 the interdigital electrode is B1
Interdigital powered on. fault
monitoring
electrode of PMS
FC. 1 electrical /
particle sensor Class
Too high interdigital Component electronic
P24AEF3 B1
electrode voltage monitoring component
fault
monitoring
FC. 1 electrical /
Class
P24AEF4 B1
shorted to battery monitoring component
fault
monitoring
FC. 1 electrical /
Class
P24AEF5 B1
shorted to ground monitoring component
fault
monitoring
FC. 1 electrical /
Particle sensor CAN Class
U04A487 message EGSPMData1 B1
CAN bus monitoring component
loss fault
monitoring
U04B287 Particle sensor CAN Class Component FC. 1 electrical /
119
Fault
Corresponding
requirement
A/B/C)
message EGSPMData2 B1 monitoring electronic
loss fault component
monitoring
CAN signal receiving FC. 1 electrical /
Class
timeout of SCR upstream Component electronic
U011387 B1
nitrogen-oxygen sensor monitoring component
fault
(i.e. signal loss) monitoring
CAN signal receiving
FC. 1 electrical /
timeout of SCR Class
U0113F6 downstream B1
nitrogen-oxygen sensor fault
monitoring
(i.e. signal loss)
FC. 1 electrical /
Class
Urea quality sensor Component electronic
U111E87 B1
message timeout monitoring component
fault
monitoring
FC. 1 electrical /
Class
Urea level temperature Component electronic
U112287 B1
sensor message timeout monitoring component
fault
monitoring
FC. 1 electrical /
Class
CAN communication Component electronic
U002888 B1
interruption monitoring component
fault
monitoring
FC.3 selective
SCR catalyst Nitrogen and oxygen Emission
Class catalytic
conversion P20EEF0 emissions of engine limit
A fault reduction (SCR)
efficiency exceed 1.2g/kW.h. monitoring
monitoring d)
FC.3 selective
Urea Class
Urea consumption Function catalytic
consumption of P3000F1 B1
deviation (injection test) monitoring reduction (SCR)
SCR system fault
monitoring b)
FC. 1 electrical /
SCR system does not Class
SCR system P20FF00 complete injection within B1
nominal time. fault
monitoring
FC.3 selective
Class Emission
Absolute deviation catalytic
P206AF4 B1 limit
over-limit of urea quality reduction (SCR)
fault monitoring
monitoring c)
Urea quality
FC.3 selective
Class Emission
Relative deviation catalytic
P207F09 B1 limit
over-limit of urea quality reduction (SCR)
fault monitoring
monitoring c)
FC. 1 electrical /
Voltage of upstream
A fault monitoring component
below the lower limit.
monitoring
Upstream
FC. 1 electrical /
temperature Voltage of upstream
sensor of SCR P043517 temperature sensor is
catalyst above the upper limit.
monitoring
The dynamic detection FC. 1 electrical /
Class Component
P042685 shows that the upstream electronic
A fault monitoring
temperature is too high. component
120
Fault
Corresponding
requirement
A/B/C)
monitoring
FC. 1 electrical /
The dynamic detection
P042684 shows that the upstream
temperature is too low.
monitoring
FC. 1 electrical /
Static detection failure of
P04261C upstream temperature
sensor
monitoring
Large closed-loop control
FC. 1 electrical /
deviation of exhaust Class
P244C85 temperature is higher B1
than the upper limit(low fault
monitoring
exhaust temperature).
Large closed-loop control
FC. 1 electrical /
deviation of exhaust Class
P244D84 temperature is lower than B1
the lower limit(high fault
monitoring
exhaust temperature).
FC. 1 electrical /
Voltage of downstream Class
P043A16 temperature sensor is B1
Downstream monitoring component
below lower limit. fault
temperature monitoring
sensor of SCR FC. 1 electrical /
Voltage of downstream Class
catalyst Component electronic
P043A17 temperature sensor is B1
above upper limit. fault
monitoring
Exhaust temperature FC. 1 electrical /
Class
sensor signal at low Component electronic
P0544FB B1
temperature is unreliable monitoring component
fault
(combination 1). monitoring
Class
P2031FC B1
Exhaust fault
temperature
sensor Class
P242AF0 B1
fault
Class
P246EF0 B1
fault
FC. 1 electrical /
Class
Heater failure of urea Component electronic
P305700 B1
supply unit monitoring component
Heater strip of fault
monitoring
urea supply
Dynamic monitoring of FC. 1 electrical /
pump and Class
temperature sensor of Component electronic
temperature P305700 B1
heater of urea supply unit monitoring component
sensor of heater fault
is unreliable. monitoring
strip
Cold starting of Class FC. 1 electrical /
Component
P05EB00 temperature sensor of B1 electronic
monitoring
heater of urea supply unit fault component
121
Fault
Corresponding
requirement
A/B/C)
is unreliable. monitoring
Dynamic monitoring of FC. 1 electrical /

Class
P306000 B1
urea supply unit is monitoring component
fault
unreliable. monitoring
Cold starting of FC. 1 electrical /
Class
P05EB00 B1
urea supply unit is monitoring component
fault
unreliable. monitoring
FC. 1 electrical /
Class
P263D13 Heater is open circuited. B1
fault
monitoring
FC. 1 electrical /
Class
Heater of urea Component electronic
P263D11 Heater shorted to ground B1
supply module monitoring component
fault
monitoring
FC. 1 electrical /
Class
Heater shorted to power Component electronic
P263D12 B1
supply monitoring component
fault
monitoring
Measured values of
FC. 1 electrical /
pressure sensor of urea Class
P204A9B supply unit are B1
unreasonable (measured fault
monitoring
values are too high).
Measured values of
FC. 1 electrical /
pressure sensor of urea Class
P204A9C supply unit are B1
Urea pressure unreasonable (measured fault
monitoring
sensor values are too low).
FC. 1 electrical /
Signal voltages of Class
P249EFF pressure sensor of urea B1
supply unit are too high. fault
monitoring
FC. 1 electrical /
Signal voltages of Class
P249D16 pressure sensor of urea B1
supply unit are too low. fault
monitoring
FC. 1 electrical /
Permanent fault of motor
P05EEF0 speed deviation of urea
supply unit
monitoring
FC. 1 electrical /
Drive circuit of urea
P05EE13 supply unit is open
circuited.
Urea supply unit monitoring
FC. 1 electrical /
The driver chip of urea
P05EE4B supply unit in ECU is
overheated.
monitoring
Drive circuit of urea FC. 1 electrical /
Class Component
P05EE12 supply unit is shorted to electronic
A fault monitoring
power supply. component
122
Fault
Corresponding
requirement
A/B/C)
monitoring
FC. 1 electrical /
Drive circuit of urea
P05EE11 supply unit is shorted to
ground.
monitoring
FC. 1 electrical /
Control end of relay of Class
P304313 urea heating block is open B1
circuited. fault
monitoring
FC. 1 electrical /
Control end chip of relay Class
P304413 of urea heating block is B1
overheated. fault
Relay of urea monitoring
heater block FC. 1 electrical /
P304512 urea heating block is B1
shorted to power supply. fault
monitoring
FC. 1 electrical /
P304612 urea heating block is B1
shorted to ground. fault
monitoring
FC.3 selective
Class
Urea return pipe of SCR Function catalytic
P20A0F0 B1
system is blocked. monitoring reduction (SCR)
fault
monitoring a)
FC.3 selective
Urea pressure pipe or
Class Function catalytic
P20E8F0 urea injection unit of SCR
A fault monitoring reduction (SCR)
system is blocked.
monitoring a)
FC.3 selective
Class
SCR system pressure Function catalytic
P305400 B1
fluctuates too much. monitoring reduction (SCR)
fault
monitoring a)
FC.3 selective
Class
Urea pressure Too high SCR system Function catalytic
P20FE84 B1
control system injection pressure monitoring reduction (SCR)
fault
monitoring a)
FC.3 selective
Class
Too low SCR system Function catalytic
P20FE85 B1
injection pressure monitoring reduction (SCR)
fault
monitoring a)
FC.3 selective
Class
Too high SCR system Function catalytic
P20E985 B1
pressure monitoring reduction (SCR)
fault
monitoring a)
SCR system pressure FC.3 selective
Class
buildup failure (it is Component catalytic
P304017 B1
reported after the nominal monitoring reduction (SCR)
fault
maximum retries) monitoring a)
FC. 1 electrical /
Failure of injection valve
P204764 of urea injection unit
Urea injection A fault monitoring component
(stuck)
valve monitoring
Driver chip of urea Class Component FC. 1 electrical /
P20474B
injection unit in ECU is A fault monitoring electronic
123
Fault
Corresponding
requirement
A/B/C)
overheated. component
monitoring
FC. 1 electrical /
Low voltage part of urea
P204712 injection unit is shorted to
power supply.
monitoring
FC. 1 electrical /
High voltage part of urea
P2047FF injection unit is shorted to
power supply.
monitoring
FC. 1 electrical /
High voltage part of urea
P2047FE injection unit is shorted to
low voltage part.
monitoring
FC. 1 electrical /
Urea injection unit is Class Component electronic
P204711
shorted to ground. A fault monitoring component
monitoring
FC. 1 electrical /
Urea injection unit is open Class Component electronic
P204713
circuited. A fault monitoring component
monitoring
Drive circuit of reversing FC. 1 electrical /
valve of urea supply unit Class Component electronic
P20A013
is open circuited or A fault monitoring component
Driver chip of low voltage FC. 1 electrical /
part of reversing valve of Class Component electronic
P20A04B
urea supply unit in ECU is A fault monitoring component
Urea return overheated. monitoring
pump Drive circuit of low voltage FC. 1 electrical /
part of reversing valve of Class Component electronic
P20A012
urea supply unit is shorted A fault monitoring component
to power supply. monitoring
Drive circuit of FC. 1 electrical /
low-voltage part control of Class Component electronic
P20A011
urea conversion valve is A fault monitoring component
FC. 1 electrical /
Class
P203F00 Empty urea tank B1
fault
monitoring
Urea level is low to level 1 FC. 1 electrical /
Class
limiting value which Component electronic
P203FF3 B1
activates driver guide monitoring component
fault
system. monitoring
Liquid level of FC. 1 electrical /
urea tank Class
P203FF4 Liquid level alarm B1
fault
monitoring
FC. 1 electrical /
Liquid level sensor failure Class
P20F500 (measured values are B1
slightly high) fault
monitoring
P20F400 Liquid level sensor failure Class Component FC. 1 electrical /
124
Fault
Corresponding
requirement
A/B/C)
( measured values are B1 monitoring electronic
slightly low) fault component
monitoring
FC. 1 electrical /
Class
Temperature of urea tank Component electronic
P20431C B1
is too high. monitoring component
fault
monitoring
FC. 1 electrical /
Class
Temperature sensor of Component electronic
P205A64 B1
urea tank is unreliable. monitoring component
Temperature fault
monitoring
sensor of urea
Signal of temperature FC. 1 electrical /
tank Class
sensor of urea tank is Component electronic
P205B85 B1
unreasonable (measured monitoring component
fault
values are too high). monitoring
Signal of temperature FC. 1 electrical /
Class
sensor of urea tank is Component electronic
P205B84 B1
unreasonable (measured monitoring component
fault
values are too low). monitoring
FC. 1 electrical /
Drive circuit of heater Class
P202A13 valve of urea tank is open B1
circuited. fault
monitoring
FC. 1 electrical /
Driver chip of heater valve Class
P202A4B of urea tank in ECU is B1
overheated. fault
Heater valve of monitoring
urea tank FC. 1 electrical /
P202A11 valve of urea tank is B1
shorted to ground. fault
monitoring
FC. 1 electrical /
P202A12 valve of urea tank is B1
shorted to power supply. fault
monitoring
SCR system shuts down FC. 1 electrical /
Class
due to heating component Component electronic
P05F800 B1
failure during SCR system monitoring component
fault
heating. monitoring
FC. 1 electrical /
Control end of heating Class
P20B913 relay of urea return B1
pipeline is open circuited. fault
monitoring
Driver chip of control end FC. 1 electrical /
Class
SCR heating of heating relay of urea Component electronic
P20B94B B1
system return pipeline in ECU is monitoring component
fault
overheated. monitoring
Control end of heating FC. 1 electrical /
Class
relay of urea return Component electronic
P20B912 B1
pipeline is shorted to monitoring component
fault
power supply. monitoring
Class
relay of urea return Component electronic
P20B911 B1
fault
ground. monitoring
125
Fault
Corresponding
requirement
A/B/C)
FC. 1 electrical /
P20BD13 relay of urea pressure B1
monitoring
Class
of heating relay of urea Component electronic
P20BD4B B1
pressure pipeline in ECU monitoring component
fault
is overheated. monitoring
Class
relay of urea pressure Component electronic
P20BD12 B1
fault
Class
relay of urea pressure Component electronic
P20BD11 B1
fault
ground. monitoring
FC. 1 electrical /
P20C113 relay of urea suction B1
monitoring
Class
P20C14B B1
suction pipeline in ECU is monitoring component
fault
Class
relay of urea suction Component electronic
P20C112 B1
fault
Class
relay of urea suction Component electronic
P20C111 B1
fault
ground. monitoring
Class
P263D4B B1
supply unit in ECU is monitoring component
fault
FC. 1 electrical /
SCR downstream Class
P2205F1 nitrogen-oxygen sensor B1
heating failure fault
monitoring
FC. 1 electrical /
SCR upstream Class
P232CF0 nitrogen-oxygen sensor B1
monitoring
FC. 1 electrical /
Nitrogen-oxygen Component electronic
sensor monitoring component
monitoring
FC. 1 electrical /
SCR upstream Class
P232C00 nitrogen-oxygen sensor B1
monitoring
SCR downstream Class FC. 1 electrical /
Component
P229E64 nitrogen-oxygen sensor B1 electronic
monitoring
installation failure fault component
126
Fault
Corresponding
requirement
A/B/C)
monitoring
FC. 1 electrical /
SCR upstream Class
installation failure fault
monitoring
FC. 1 electrical /
P232B02 nitrogen-oxygen sensor B1
signal deviation fault fault
monitoring
FC. 1 electrical /
SCR upstream Class
P232C02 nitrogen-oxygen sensor B1
signal deviation fault fault
monitoring
Measured values of SCR FC. 1 electrical /
Class
downstream Component electronic
P232B12 B1
fault
are too high. monitoring
FC. 1 electrical /
Measured values of SCR Class
P232D12 upstream nitrogen-oxygen B1
sensor are too high. fault
monitoring
Measured values of SCR FC. 1 electrical /
Class
P232B11 B1
fault
are too low. monitoring
FC. 1 electrical /
Measured values of SCR Class
P232D11 upstream nitrogen-oxygen B1
sensor are too low. fault
monitoring
FC. 1 electrical /
Internal wiring of SCR Class
P24E614 upstream nitrogen-oxygen B1
sensor is short circuited. fault
monitoring
Internal wiring of SCR FC. 1 electrical /
Class
P22A313 B1
nitrogen-oxygen sensor is monitoring component
fault
short circuited. monitoring
FC. 1 electrical /
P24E613 upstream nitrogen-oxygen B1
monitoring
Internal wiring of SCR FC. 1 electrical /
Class
P22A301 B1
nitrogen-oxygen sensor is monitoring component
fault
FC. 1 electrical /
P232B29 nitrogen-oxygen sensor B1
signal ready timeout fault
monitoring
FC. 1 electrical /
SCR upstream Class
P232D29 nitrogen-oxygen sensor B1
signal ready timeout fault
monitoring
Internal wiring of SCR Class Component FC. 1 electrical /
P232BF5
downstream B1 monitoring electronic
127
Fault
Corresponding
requirement
A/B/C)
nitrogen-oxygen sensor is fault component
FC. 1 electrical /
P232EF5 upstream nitrogen-oxygen B1
monitoring
Upstream
FC.13 exhaust
nitrogen-oxygen sensor Class
Component and oxygen
P220185 rationality check failure B1
monitoring sensor detection
(nitrogen-oxygen value is fault
a)
slightly large)
Upstream
FC.13 exhaust
nitrogen-oxygen sensor Class
Component and oxygen
P220184 rationality check failure B1
monitoring sensor detection
(nitrogen-oxygen value is fault
a)
slightly small)
128
Chapter VII Use of Diesel Engine
I. Diesel
Please fill the standard China VI diesel oil, otherwise it will cause failure to the fuel system.
The grade of diesel is related to the ambient temperature; when the temperature decreases,
paraffin in diesel oil will be separated out, blocking the fuel pipeline. For ambient
temperatures in different regions and seasons, please select different grades of diesel
according to the following table. Otherwise, it will be difficult to start the diesel engine.
Ambient
Above 5°C Above -5℃ Above -10℃ Above -25℃
temperature
Light diesel Light diesel Light diesel Light diesel
Diesel grade
No.0 No.-10 No.-20 No.-35
1. Diesel cleanliness
Compared with the traditional mechanical fuel system, the electronic control system
requires more stringent fuel cleanliness. As its fuel pressure is higher, its control is more
accurate, and the matching of its internal moving elements is more precise, the unclean fuel
will reduce the service life of the fuel injection pump and the fuel injector.
1) Oil filter is a key part to ensure the cleanliness. The electronic-control high-pressure
common-rail diesel engine adopts two-stage special and efficient diesel filter, i.e. the
oil-water separator (primary filter) installed on the vehicle and the diesel filter (secondary
filter) installed on the engine.
2) The diesel filter and oil-water separator must be provided by Yunnei appointed
manufacturer. Yunnei will not be responsible for the faults caused by the use of inferior
diesel filter and oil-water separator, such as starting difficulty, insufficient power, and worn
parts of fuel system.
3) Please replace the diesel filter element regularly according to the maintenance
regulations.
Note: please fill up the diesel oil at the regular gas station. If the diesel engine
fails due to the use of poor quality diesel, you will not enjoy the warranty
service.
2. Oil and water separation

The moisture in diesel oil is very harmful to the
common-rail system!
Water will cause corrosion and wear of high pressure oil pump,
fuel rail and fuel injector. If the water level alarm indicator of
diesel filter on the instrument panel is on, it means that the
diesel filter is full of water which should be discharged in time. Loosen (do not unscrew)
the plug to drain the water,
Drainage steps: and then tighten it after
draining the water.
129
1) Loosen the drain plug (but do not unscrew it) and drain the water until diesel oil flows out.
2) After draining, tighten the drain plug.
Note: when the water level alarm indicator is on, please drain the water in
time!
3. Air removal in the fuel pipeline

If air enters the fuel pipeline, the air in the pipeline and high-pressure oil pump must be
discharged with the hand oil pump on the diesel filter. The engine can be started only when
the pipeline and high-pressure oil pump are filled with fuel.
Note: the air in the high-pressure oil pipe and fuel rail will automatically drain back to
the fuel tank when the high-pressure oil pump is running, and it is not allowed to
loosen the nut of the high-pressure oil pipe for its removal.
The steps and precautions for removal are as follows:
1) Loosen the vent screw on the diesel filter, repeatedly press and loosen the hand oil pump
to pump oil until there is no air at the vent screw, and tighten the vent screw.
2) Loosen the vent screw on the oil-water separator, repeatedly press and loosen the hand
oil pump to pump oil until there is no air at the vent screw, and tighten the vent screw.
3) Pump the oil with the hand oil pump until the injection pump is full of fuel.
II. Engine oil

Note: CJ-4 or above diesel engine oil specified by Yunnei must be used,
otherwise, you will not enjoy the warranty service.
The viscosity of the engine oil is related to the ambient temperature. When the ambient
temperature decreases, the viscosity and starting resistance increase, making it difficult for
the diesel engine to reach the starting speed. Thus, for ambient temperatures in different
regions and seasons, different viscosity grades of oil should be selected according to the
following table.
Ambient temperature Oil number Corresponding SAE oil number
Above -10℃～0℃ 15W/40 CJ-4 15W/40 CJ-4
-20℃～-5℃ 10W/30 CJ-4 10W/30 CJ-4
Above -30℃ 5W/30 CJ-4 5W/30 CJ-4
Extremely cold area 0W/30 CJ-4 0W/30 CJ-4
Check oil level:
1) Shut down the engine at normal temperature of the engine, and wait for 5 minutes.
2) Take out the oil scale, wipe it with a cloth, and then insert it to the bottom again.
3) Pull out the oil scale again to check whether the oil level is between the upper and lower
scribed lines; add oil if it is insufficient.
Replace the engine oil
130
Please replace the oil and filter element regularly according to the maintenance regulations.
The oil change period should be shortened when the engine is started frequently or
operated under high speed and heavy load.
Note: please check the engine oil level and change the oil regularly. When the oil
level suddenly rises or falls, check the cause immediately.
III. Coolant, storage battery, power steering pump, and air

compressor
1. Coolant
Make sure to use automobile antifreeze with anti-boil, anti-corrosion, anti-rust and
anti-scaling function as engine coolant.
Note:
1) In addition to anti-freezing function, antifreeze also has anti-corrosion, anti-boil, and

anti-scaling function.
2) Choose the coolant with different freezing points according to the temperature of the
service environment. The freezing point of the coolant should be at least 10 ℃ lower than
the lowest temperature in the area so as not to lose the anti freezing effect.
3) Please purchase the antifreeze produced by regular well-known enterprises and passing
the inspection by the state-designated check station. Do not buy inferior products to avoid
damaging the engine and causing economic loss.
4) Different grades of antifreeze should not be mixed to avoid chemical reaction and
131
damage to the overall performance of antifreeze.
5) When suspended matter, sediment or odor is found in the antifreeze, the antifreeze has
deteriorated and failed; the cooling system shall be cleaned in time and all antifreeze shall
be replaced.
6) Avoid direct contact with or inhalation of antifreeze. After skin contact, clean it with water
immediately. The waste liquid shall be treated centrally to avoid environmental pollution.
7) When the coolant level suddenly drops, check the cause immediately.
8) Do not open the coolant compensation tank or radiator cap when the engine is hot.
Otherwise, there is a risk of scalding!
2. Storage battery
1) Keep the battery surface clean and dry. If there is corrosive liquid, it should be washed
off with alkaline water.
2) Ensure that the battery connector is clean and secure.
3) If the vehicle will not be used for 7 days or more, it is necessary to cut off the positive
pole of the battery (or cut off the main power switch) to avoid electric leakage.
Note:
1) As the hydrogen released during the reaction of the battery will explode, do not place the
battery near fireworks or sparks.
2) Do not let the battery liquid touch the skin, eyes, fabric or painted surface. Do not rub
eyes with hands after touching the battery; wash hands thoroughly; once the acid liquor
comes into contact with eyes, skin or clothes, wash with water for at least 15 minutes and
see a doctor in time.
3) As the temperature drops in winter, the discharge rate of the battery drops sharply;
therefore, it is recommended to check the battery at the special service station before the
arrival of winter, and replace it if necessary.
①In cold season, fully charge the battery.
②A cold start requires a greater current draw, so it will take a longer time to recharge the
battery.
③The electrolyte of undercharged battery has low specific gravity, which is easy to freeze
and damage the battery.
④In winter, the storage battery should be kept warm.
⑤The battery should be refilled with distilled water shortly after the engine is started.
⑥If the distilled water is added after engine operation, the added distilled water cannot be
mixed with the original electrolyte, which may cause the unmixed distilled water to stay on
the upper layer and freeze.
132
3. Power steering pump
The cleaning, oil change and protection of the power steering system shall be carried out in
the vehicle maintenance center with the power steering oil change equipment. The old oil of
the system shall be replaced by a special equipment; then the system shall be cleaned with
the cleaning agent; and finally the power steering cleaning agent shall be replaced with the
new oil (added with the power steering protection agent) until the oil change ends. This can
ensure that the system works safely and reliably to avoid early damage and extend its
service life.
Detection of liquid level in power steering
oil pot Method A
B
Method A
Check the level in the liquid storage tank.
When the oil temperature is in the range of
50-80 ℃, use the "hot" area of the dipstick to
check the liquid level; when the oil
temperature is in the range of 0-32 ℃, use the
"cold" area to check the liquid level.
Method B
Check the level in the liquid storage tank.
When the engine is cold, add the power steering fluid to the "Max" line if the liquid level is
lower than the "Min" line.
Note:
1) Pay attention to choosing the correct type of power steering oil. Do not confuse the
power steering oil with the brake fluid, otherwise the working efficiency and service life of
the power steering pump will be affected.
2) Check the use of the power oil pump frequently. The cleanliness of the power steering oil
is very important, which directly affects the reliability of the power steering pump. Thus, the
oil should be replaced regularly. When the cleanliness of the oil is reduced, it should be
replaced. When the user fills the oil by himself / herself, he/she must have a filtering device
(the filtering accuracy is 25 μ m).
3) If the vehicle stops for a long time, do not work at full load immediately when it is
restarted. Run it at no load for 5 minutes, and then drive it after the power steering oil and
other oil reach normal working condition.
4) When the vehicle steers, observe whether the power steering system operates normally,
whether there is impact or noise, and whether there is leakage in the power steering oil
circuit, so as to find and eliminate faults in time.
5) It is forbidden to use the steering pump without oil, otherwise its service life will be
133
shortened.
6) The continuous time of turning the steering wheel to the dead angle position shall not
exceed half a minute, otherwise the service life of the pump will be shortened.
7) After a new steering pump runs for 5000km or every 10000km after that, the oil shall be
replaced, and the filter element in the oil tank shall be cleaned or replaced at the same time.
Note: power steering fluid is toxic and should be placed in a marked container. Keep
it out of reach of children.
4. Air compressor
1) Do not increase the pressure setting of the pressure regulating valve at will.
2) The dryer, check valve, pressure regulating valve, pipeline unloading valve and safety
valve on the gas exhaust piping shall be inspected regularly.
3) Disassemble the cylinder head to clean the valve block of air compressor every
10000km. Remove the cylinder head; disassemble the valve seat plate, limiting plate and
discharge valve plate; use wood chip and copper wire brush to remove the carbon deposits
on the valve block and in the valve seat plate and cylinder head cavity; and clean them in
solvent. Install to restore it. Note that the valve block shall not be installed reversely; the
common gasket shall not be used instead of the cylinder head gasket and cylinder block
gasket; the set screw (M5/M6) of the limiting plate of the discharge valve plate shall be
tightened to the specified torque. Do not omit the small washer in the groove of discharge
valve plate. If the air intake environment is poor, the cleaning frequency shall be increased.
Note:
When the air compressor is working, there will be a small amount of oil vapor in the
compressed air. After a period of use, the oil vapor will deposit in the air storage tank
together with the water. When you discharge the water in the air storage tank, there
is oil-water mixture discharged. As long as the engine oil consumption is normal, it
is a normal phenomenon.
IV. Starting of diesel engine

Note: please do not step on the accelerator for starting, and do not run the diesel
engine at high speed immediately after starting!
134
Ignition switch Trouble light
 Starting steps at normal temperature and precautions:

1) Turn on the main switch of vehicle power supply.
2) Turn on the power supply with the key, and observe whether the indication of each
electric instrument is normal.
3) After the power supply is turned on, the system will light the trouble light to carry out
self-inspection on the circuit of the trouble light. If there is no fault in the system, the
trouble light goes out after 3 seconds. If there is a minor fault in the electronic control
system, the trouble light is lit but not flashes; if a serious fault is detected, the trouble
light is lit and flashes.
Note: when the fault indicator on the instrument panel is on, please go to the
special service station in time for maintenance.
4) Start the diesel engine: turn the key to the "start" position, the diesel engine shall be
able to start smoothly, and the starting time shall not exceed 5 seconds. If it cannot be
started, it shall be started after 10-15 seconds.
Cold start in winter: when the ambient temperature is lower than
the set preheating temperature for starting, the preheating indicator
light on the instrument panel will automatically light up when the key
switch is turned to the "ON" position. After the preheating is Preheating
completed, the preheating indicator light will flash, and the engine indicator light
can be started during the flashing of preheating indicator light. If the start is not
successful or the preheating indicator is off but the engine does not start, turn
the key switch to the "ACC" position to reset. After power off for 2 minutes,
conduct the second preheating and starting according to the above operations.
5) After starting the diesel engine, immediately release the key switch to completely
disconnect the starter gear from flywheel gear ring, so as to prevent the starter being
driven by engine.
135
6) Do not run the diesel engine at high speed immediately after starting. Check whether
the pressure indication of engine oil is normal. When the ambient temperature is low,
warm up the engine after starting.
V Running-in of diesel engine

The new or overhauled diesel engine must be run in before use. Running-in can make the
surfaces of all moving parts fit well, so as to avoid abnormal wear and damage. The service
life, reliability and economy of the diesel engine largely depend on the running-in, so please
run in strictly according to specification.
Running-in specification
Vehicle speed of running-in
Load of Engine speed Mileage of of
Phase (percentage of maximum
running-in of running-in running-in
speed)
It is forbidden for
No load 0% 0
1 no-load running-in.
25% load 50% ≤2600rpm 500 (500 km in total)
1000 (1500 km in
2 50% load 70% ≤2600rpm
total)
1500 (3000 km in
3 75% load 75% ≤3000rpm
total)
2000 (5000 km in
4 90% load 100% ≤3000rpm
total)
Note: it is forbidden for no-load running-in！
The running-in can be carried out together with the whole vehicle. Running-in mileage is
5000km or 3 months (whichever occurs first).
During the running-in, do not drive with the maximum throttle, the speed shall not be greater
than 60km/h, and do not run the diesel engine at a high speed. Do not drive the vehicle at a
too high or too low speed for a long time. Change the speed frequently no matter how fast
or how slow the driving speed is to prevent the diesel engine from dragging at a low speed.
It is strictly forbidden to step on the accelerator violently after starting, and it should be idled
for 3-5 minutes.
After running-in, please go to special service station for "forced running-in maintenance".
VI. Operation of diesel engine

There are some signs before the fault occurs. During the operation, please pay attention to
whether the indication of each instrument is normal. In case of any abnormality, stop for
inspection immediately.
1) Engine oil pressure: if the oil pressure alarm light flashes repeatedly, it indicates that the
oil pressure is low; stop for inspection.
136
2) When the fault indicator light on the instrument panel is on during operation, please go
to the special service station for maintenance in time.
3) Precautions for wading: the height of control unit and harness from the water shall be
more than 200 mm in principle when the vehicle passes water accumulated pavement,
so as to avoid damage to and failure of electric control system due to water inflow.
4) Coolant temperature: when the water temperature is too high (over 102 ℃), the engine
will enter the thermal protection state, the ECU will automatically reduce the output
power of the engine, and in serious cases (the water temperature is over 105 ℃), the
engine will automatically shut down. At this point, the user should find out the causes to
eliminate them.
5) If the water temperature is less than 70 ℃, it means that the engine is too cold, which
may lead to early wear. Thus, insulation measures should be taken, such as a protective
cover for the radiator.
6) Engine noise: if the engine and its related components make abnormal noise, it
indicates that the engine is not working normally or the moving parts are in friction; stop
for inspection.
7) Exhaust color:
If there is a lot of white smoke or black smoke from the engine exhaust, it indicates that
the engine combustion is abnormal; stop for inspection.
8) Limp home: in case of some non fatal faults, the engine fault indicator will be lit. To
ensure driving safety and make it convenient for maintenance, the control unit allows
the engine to perform the limp home function, that is, allowing the engine to run at a
lower speed and load, so that the vehicle can slowly drive to the nearby maintenance
station for troubleshooting.
Note:
(1) Do not stop the overheated engine immediately.

(2) The diesel engine is not allowed to work for a long time under overload.
(3) Do not allow the diesel engine to work when the coolant is "boiling" or work for a
long time when the water temperature is too low.
(4) Do not allow the diesel engine to idle for more than 10 minutes.
(5) It is strictly prohibited to add cold water to the engine immediately in case of high
temperature and water shortage.
VII. Stop of diesel engine

1. Before stopping the diesel engine, make sure that the gear is in neutral position.
137
2. Before flameout, the diesel engine should be idled for 3-5 minutes to make it fully cooled.
During this period, check whether the engine has water, oil and gas leaks and abnormal
noise, and whether the oil pressure is normal. And do not stop suddenly when the
temperature is too high and the load is too large, otherwise the turbocharger and the engine
will be damaged.
3. After flameout, turn the key switch to the "OFF" position immediately. Turn off the main
power supply of the vehicle 25 seconds after turning off the key switch. The electronic
control unit (ECU) needs to store the running state parameters of the engine for a period of
time after the key switch is turned off. Otherwise, the trouble light will always be on
when the engine is started again.
4. When the ambient temperature is lower than 0 ℃, open the drain switch of the engine
body and water tank after shutdown to drain the cooling water to avoid damaging the
engine body, water pump and radiator by freezing. If a suitable antifreeze is used, it is not
necessary to drain water.
VIII. Safety warnings

1. When the diesel engine is running, do not touch the fan, belt pulley, belt and other
exposed rotating parts to avoid injury.
2. The operator shall not immediately open the radiator filler cap when the diesel
engine is hot to avoid being scalded by high temperature water vapor.
3. When the diesel engine is in hot state, do not touch the exhaust pipe and other
high-temperature parts to avoid scalding.
4. It is forbidden to fill the engine with cold water when the temperature of the diesel
engine is too high and there is water shortage.
5. The diesel engine will exhaust harmful gases such as CO2 and soot during
operation, so effective ventilation must be ensured.
6. The influence of exhaust gas, discharge smoke and noise on the surrounding
environment, people and goods must also be considered.
7. The diesel engine is equipped with a post processor. Its surface temperature is
high when the vehicle is running and before the vehicle is stopped, so it is necessary
to avoid parking directly above the flammable materials.
138
Chapter VIII Maintenance of Diesel Engine
I. First forced running-in maintenance
Note: you will not enjoy the quality warranty service if you do not carry out the
first forced running-in maintenance.
From the date of purchase (subject to the issuing date of invoice), please make sure to go
to the special service station for running-in maintenance after 5000 km or 3 months
(whichever occurs first). The maintenance contents are as follows:
1) Replace the engine oil and oil filter drum.
2) Replace the filter drums for the diesel filter and oil-water separator.
3) Replace the filter element of air filter or clean it with compressed air.
4) Check the air inlet pipe for air leakage and damage.
5) Check the water tank and keep the coolant within the specified range.
6) Check for the leakage of fuel, engine oil, coolant and sealing surface, and eliminate
them.
7) Check and adjust the belt tension, and visually check the belt for abnormal wear.
8) Check whether all parts of external components of diesel engine are connected reliably.
9) Check whether the engine ECU and harness are fixed firmly and reliably.
10) Check the idle state of the engine; slowly throttle up the engine and listen to the engine
for abnormal noise.
11) Query the fault memory of the electronic-control diagnosis system, and clear the stored
fault code.
Note: before unplugging and inserting the harness connector, first turn off the
ignition switch and then disconnect the main battery switch 30 seconds later! For
electrowelding, be sure to turn off the main power supply and unplug all plug-ins on
ECU and sensor!
II. Regular forced maintenance

Note: if you do not carry out regular forced maintenance, you will not enjoy the
quality warranty service.
After the first running-in maintenance, in addition to routine maintenance, please go to the
special service station for regular forced maintenance every 10000 km or 6 months
(whichever occurs first). The contents of regular forced maintenance are as follows:
1) Change engine oil and its filter drum.
2) Replace the diesel filter drum and oil-water separator drum.
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3) Replace the filter element of air filter or clean it with compressed air.
4) Clean the fuel tank.
6) Check the water tank and expansion tank and keep the coolant within the specified
range.
7) Check and eliminate the leakage of fuel oil, engine oil, coolant and sealing surface.
8) Check and adjust the belt tension, and visually check the belt for abnormal wear.
9) Check whether all parts of external components of diesel engine are connected reliably.
10) Check whether the engine ECU and harness are fixed firmly and reliably.
11) Check the idle state of the engine; slowly throttle up the engine and listen to the engine
for abnormal noise.
12) Query the fault memory of the electronic-control diagnosis system, and clear the stored
fault code.
III. Routine maintenance

In addition to the first forced running-in maintenance and regular forced maintenance, the
user should pay attention to the following contents in the routine maintenance:
1) Check whether the engine oil is between the upper and lower scale lines of the oil scale.
If it is insufficient, add it.
2) Check whether the engine oil is deteriorated, and replace it in time in case of
deterioration.
3) Drain the water in the water collecting cup of the oil-water separator regularly (such as
within one week).
4) Clean the filter element of air filter with compressed air. The maintenance and
replacement cycle should be flexibly adjusted according to the actual situation.
6) Check whether ECU harness and connectors of each sensor are reliably connected.
Keep the electronic control harness and connectors dry and clean. It is forbidden to
wash the parts and connectors of the electronic control part of the engine directly with
water.
7) Check whether the ventilation filter screen of fuel tank is damaged or blocked.
IV. Technical maintenance in winter

Precautions for use in winter:
When the ambient temperature is lower than 0 ℃, paraffin will be separated from diesel oil,
which will make the oil become viscous and reduce the fluidity of diesel oil. If diesel oil for
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summer is used in winter, it is likely to cause failure.
Use the fuel oil and engine oil suitable for winter, and pay attention to the water content in
the fuel oil to avoid freezing.
1) The cooling system must be filled with antifreeze suitable for the ambient temperature.
2) In severe cold seasons and areas, vehicles shall not be parked in the open air as much
as possible.
3) For cold start, the engine can only be started when the preheating indicator light
changes from lighting to flash.
The operation and maintenance requirements of diesel engine are roughly as above.
Please read them carefully. Through reasonable and effective maintenance, the engine will
always be in the best condition to reduce unnecessary maintenance, loss, and ultimately
save use costs and increase benefits.
Note:
1) The operation and maintenance requirements of diesel engine are roughly as

above. Please read them carefully.
2) Through reasonable and effective maintenance, the engine will always be in the
best condition to reduce unnecessary maintenance, loss, and ultimately save use
costs and increase benefits.
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Chapter IX Analysis and Troubleshooting for Common Faults
Note: troubleshooting is recommended to be carried out in the authorized
Yunnei service station, otherwise you may lose the warranty service.
I. Difficult starting
Fault characteristics and causes Troubleshooting
1. Check the fuel oil system a) Choose the right grade of fuel oil according to the
regional temperature;
a) Improper selection of fuel oil grade;
b) Add fuel oil to the fuel tank and turn on the fuel tank
b) There is no oil in the fuel tank or
switch;
the fuel tank switch is not opened;
c) Loosen the vent screw, press the hand oil pump on the
c) Air is mixed into the low-pressure
oil-water separator (primary filter) repeatedly to
fuel pipeline;
remove air, and tighten the vent screw. Go to the
d) Water is mixed in fuel oil; Yunnei service station for maintenance if necessary;
e) The oil circuit or filter is blocked by d) Loosen the drain plug of the oil-water separator to drain
impurities for a long time. the accumulated water;
e) Remove the filter regularly to clean or replace the filter

element.
2. Insufficient cylinder pressure a) The elasticity of the valve spring decreases, and
replace the valve spring; the valve cone is not tightly
a) Air leakage of valve;
sealed, and grind the valve;
b) Air leakage at the joint between
b) Replace the cylinder head gasket;
cylinder head and engine body;
c) Remove the close-burning, replace the piston ring, and
c) Wear, close-burning and opening
adjust the opening position of the piston ring;
overlapping of piston ring;
d) Replace the engine body or piston.
d) Wear of cylinder hole or piston
exceeds specified limit.
3. The temperature is too low. a) Heat the cooling water and use diesel oil of appropriate
grade;
a) The viscosity of diesel oil is high, so
it is not easy to atomize and it even b) Check the corresponding harness and relay; when the
blocks the fuel pipeline; preheating light flashes, start the engine immediately.
b) The preheating device fails or in the

preheating state, the timing of
starting is not appropriate.
4. Check the electric system. a) Charge the battery, or configurate the storage battery
that meets requirements;
a) Electric quantity of storage battery
is insufficient or storage battery b) Fasten the wiring of electric system;
configuration is too small;
c) Repair the electromagnetic switch of starter or replace
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b) Poor wiring of electric system; the starter;
c) Electromagnetic switch of starter d) Find out the cause and deal with it;
has a fault;
e) Repair or replace the brush, clean the communtator
d) The starter gear cannot be surface with fine sandpaper, and blow out the dust;
embedded in the flywheel gear
f) Check the corresponding harness and relay, and
ring;
replace the preheating device.
e) The starter brush is in poor contact
with communtator.
f) Preheating device fails.
II. Unstable low idling speed (idle speed)
1. The low idling speed (idle speed) is 1. Check the common rail system at Yunnei service
less than 780rpm. station.
2. Air is mixed into the low-pressure 2. Loosen the vent screw, repeatedly press the hand oil
fuel pipeline. pump on the oil-water separator (primary filter) to
remove air, and then tighten the vent screw. If
necessary, go to the Yunnei service station for
maintenance.
3. Compression pressure of cylinder is a) The elasticity of valve spring decreases; replace the
insufficient. valve spring.
a) Air leakage of valve; The valve cone is not tightly sealed; grind the valve.
b) Air leakage at the joint between b) Replace the cylinder head gasket;
cylinder head and its gasket;
c) Remove the close-burning, replace the piston ring,
c) Wear, close-burning and opening and adjust the opening position of the piston ring;
overlapping of the piston ring;
d) Replace the engine body or piston.
d) Wear of cylinder hole or piston
exceeds specified limit.
4. The accelerator pedal and its related 5. Check relevant parts and replace if necessary. Go to
harness are in fault, the alarm light the Yunnei service station for maintenance.
is on, and the idle speed rises to
1100rpm.
III. Unstable revolving speed
1. Check the fuel pipeline. a) Loosen the vent screw, press the hand oil
pump on the oil-water separator (primary
a) Air is mixed into the low-pressure fuel
filter) repeatedly to remove air, and then
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pipeline; tighten the vent screw. Go to the Yunnei
service station for maintenance if necessary;
b) Too much water in the fuel;
b) Change fuel oil;
c) There is oil leakage in the fuel pipeline.
c) Tighten the joint of oil pipe or replace the oil
pipe.
2. The cylinder head gasket is not tightly 2. Check the condition of cylinder head bolt
sealed. and cylinder head gasket; tighten the bolt or
replace the cylinder head gasket.
3. The electronic control system does not work 3. Check the common rail system at Yunnei
properly. service station.
IV. Insufficient diesel engine power
1. Clean the filter element and replace it if

1. The filter element of air filter is blocked.
necessary.
2. Remove the sundries and dust on the surface

2. Intercooler is too dirty.
of intercooler.
3. Exhaust manifold and exhaust main are

3. Remove the sundries in the exhaust pipe.
blocked.
4. Air is mixed into low-pressure fuel pipeline. 4. Loosen the vent screw, repeatedly press the
hand oil pump on the oil-water separator
(primary filter) to remove air, and then tighten
the vent screw. If necessary, go to the Yunnei
service station for maintenance.
5. The reserve fuel quantity of the fuel tank is 5. Add enough fuel to the fuel tank and select the
insufficient and the fuel quality is poor. fuel that meets requirements.
6. Insufficient supercharge pressure. 6. Adjust or replace the supercharger.
7. Vehicle runs at a high-speed for 20-30

7. The postprocessor is slightly blocked.
minutes with no load.
8. The postprocessor is seriously blocked 8. Replace the postprocessor at the Yunnei

(torque limit). service station.
V. Limited revolving speed
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1. Failure of fuel pipeline, diesel filter or oil a) Loosen the vent screw, press the hand oil pump
pump on the oil-water separator (primary filter)
repeatedly to exhaust air, and then tighten the
a) There is air in them. The alarm light is on,
vent screw. Go to the Yunnei service station for
and the engine speed is limited.
maintenance if necessary;
b) There is water in them. The alarm light is
b) Loosen the drain plug of the oil-water separator to
on, and the engine speed is limited.
drain the accumulated water.
2. Check brake switch, relay and accelerator 2. Check the parts and replace them if necessary.
pedal sensor of corresponding harness, and
corresponding harness. The engine speed
drops to 1100rpm, and the alarm light is on.
3. The air inlet pressure sensor or relevant 3. Check the parts and replace them if necessary.
harness fails. The alarm light is on, and the
engine speed is limited to about 2400rpm.
4. The water temperature sensor or relevant 4. Check the parts for open circuit, loose connection
harness fails. The alarm light is on, and the or short circuit.
engine speed is limited to about
2500-2600rpm.
5. The camshaft sensor or relevant harness 5. Check the parts for open circuit, loose connection
and relevant engine components are in fault. or short circuit.
The alarm light is on, and the engine speed is
limited to about 2500-2600rpm.
6. Vehicle speed sensor and its related 6. Check the parts for open circuit, loose connection
harness are in fault. The alarm light is on, air or short circuit.
conditioning is turned off, and the engine
speed is limited.
VI. Shutdown of diesel engine
1. Fuel pipeline, diesel filter, oil a) Loosen the vent screw, press the hand oil pump on the
pump or fuel injector is in oil-water separator (primary filter) repeatedly to remove air,
fault. and then tighten the vent screw. Go to the Yunnei service
station for maintenance if necessary.
a) There is air in them. The
alarm light is on. b) Check whether the overflow valve of the oil pump is stuck,
and replace it if necessary; check whether the injection
b) There are particles and
quantity and fuel return quantity of the fuel injector are normal,
impurities in the oil pump or
and replace it if necessary.
fuel injector. The alarm light is
on.
2. The air inlet pressure sensor 2. Check the parts for open circuit, loose connection or short
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or relevant harness fails. circuit.
The alarm light is on.
3. The rail pressure sensor and 3. Check the parts for open circuit, loose connection or short
its related harness are in circuit.
fault. The alarm light is on.
4. The valve seat of fuel 4. Check at the Yunnei service station, and replace the fuel
injector is worn. injector.
5. Rail pressure sensor is 5. Check at the Yunnei service station, and replace the
damaged. high-pressure fuel rail.
6. The flow control unit of fuel 6. Check at the Yunnei service station, and replace the
injection pump is damaged. high-pressure oil pump.
VII. Abnormal smoke exhaust
1. White smoke a) Check for faults and remove them;
a) There is water in the cylinder. b) Replace the fuel.

b) There is water in the fuel.
2. Blue smoke a) Adjust or replace the piston ring;
a) Engine oil pumping; reverse installation, b) Replace the valve;

jamming or excessive wear of piston ring.
c) Replace the oil seal.
b) Too large clearance between valve stem
and guide pipe.
c) The oil seal of valve stem is damaged.
3. Black smoke a) Clean the dust in the air filter and exhaust pipe
or replace the filter element of the air filter;
a) Air filter and exhaust pipe are blocked;
b) The valve cone is not tightly sealed. Grind
b) Poor valve sealing;
the valve;
c) Intercooler is too dirty;
c) Remove the sundries and dust on the surface
d) The electric control system does not work of intercooler;
properly.
d) Check the common rail system at Yunnei
service station.
VIII Overheated diesel engine
1. The cooling water in the 1. Top up or replace the cooling water in the water tank.
water tank is insufficient or
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polluted.
2. The cooling system is not 2. Remove the scale and dirt to make the pipeline
smooth. unobstructed; check whether the front end face of radiator is
covered with plastic cloth, paper, etc.
3. The water pump belt is loose. 3. Adjust the tension of water pump belt.
4. The water pump does not work

4. Repair or replace the water pump.
properly.
5. Thermostat fails. 5. Repair or replace the thermostat.
6. The quality of lubricating oil is

6. Replace the lubricating oil.
poor.
7. Water temperature gauge fails. 7. Replace the water temperature gauge.
8. The diesel engine is

8. Reduce its load.
overloaded.
IX. Abnormal noise during operation of diesel engine
1. When the clearance between the piston and the cylinder 1. Replace the piston or cylinder
is too large, the cylinder will make an impact sound after liner.
the diesel engine is started. The sound is reduced as the
diesel engine heats up.
2. When the clearance between piston pin and pin hole is 2. Replace the parts to ensure the
too large, there will be a light and sharp sound. The specified clearance.
sound is clearer at idle.
3. When the clearance between the main bearing and the 3. Replace the parts to ensure the
connecting rod bearing is too large, you can hear an specified clearance.
impact sound if the engine speed suddenly decreases.
At low speed, the sound is heavy and powerful.
4. When the axial clearance of crankshaft is too large, the 4. Replace the crankshaft thrust
impact sound of crankshaft moving forward and plate to ensure the specified
backward can be heard during idling. clearance.
5. When the valve spring is broken, the disordered sound 5. Replace the parts.
or light rhythmic knocking sound can be heard at the
cylinder head cover.
6. When the piston top touches the cylinder head or valve, 6. Adjust the valve timing or replace
metal impact sound can be heard near the cylinder head the cylinder head gasket.
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at low speed.
7. When the gear wear clearance is too large, the impact 7. Replace the gear as the
sound can be heard at the gear housing if the engine circumstances may require.
speed is suddenly reduced.
8. Replace the generator as the

8. When the main shaft of the generator is worn, abnormal
circumstances may require, and
sound can be heard, and the battery voltage may be
measure the battery voltage with
abnormal.
a multimeter.
X. Excessive engine oil consumption
1. Too much lubricating oil causes oil splashing. 1. Drain some oil.
2. Check and replace the sealing

2. There is oil leakage at each seal.
gasket.
3. The oil return hole of oilring of the piston ring is 3. Remove the carbon deposit from the
blocked by carbon deposit. oil return hole.
4. Poor oil quality. 4. Change the oil.
5. The piston ring is worn and stuck. 5. Replace the piston ring.
6. The clearance between cylinder hole and piston is

6. Replace the engine body or piston.
too large.
7. The oil seal of valve stem is worn. 7. Replace the oil seal of valve stem.
8. Air filter is seriously blocked, and oil-gas separator 8. Replace the filter element or oil-gas
ejects engine oil. separator.
XI. Excessive fuel consumption
1. The air filter is blocked. 1. Clean the filter element or replace it.
2. Remove the sundries and dust on the surface of

2. The intercooler is too dirty.
intercooler.
3. Tighten the oil circuit joint, and replace the oil pipe;
3. Fuel system leaks oil.
check whether the oil pump is broken.
4. The exhaust pipe is blocked. 4. Remove the dirt from the exhaust pipe.
5. The fuel quality is poor. 5. Select specified fuel oil.
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6. The valve leaks air. 6. Grind valve seat ring or replace it.
7. Compression pressure of cylinder

7. See item 2 of "I. difficult starting".
is insufficient.
8. Supercharge pressure is
8. Adjust or replace the supercharger.
insufficient.
XII. Failure of lubrication system
1. The oil pressure is too low. a) Add oil to the scribed line of oil scale;
a) Insufficient oil in the oil pan; b) Clean the oil circuit and blow it with
compressed air;
b) The oil passage is blocked;
c) Clean the oil filter or replace the filter
c) The oil filter is blocked;
element;
d) The diesel engine is overheated. The oil
d) Reduce the load, change the oil or
temperature is high and the oil becomes thin.
reduce the oil temperature.
2. Use the oil that meets the

2. Poor oil quality.
requirements.
3. The pressure regulating valve of gear housing is 3. Repair or replace the pressure
stuck and too much oil is returned. regulating valve.
4. The filter screen of oil pump is blocked. 4. Clean the filter screen of oil pump.
5. The inner and outer rotors of the oil pump are worn 5. Adjust or replace the inner and outer
or the end clearance is too large. rotors of the oil pump.
6. Replace the oil pipe or tighten the

6. The oil pipe is broken or the connection is loose.
connection.
7. Repair or replace oil pump assembly

7. The oil pump assembly fails.
parts.
8. The connecting rod bearing bush and main bearing 8. Replace connecting rod bearing bush
bush are worn. and main bearing bush.
9. The oil pressure gauge is damaged. 9. Replace the oil pressure gauge.
XIII. Failure of cooling system
1. The water temperature is too high. a) Add enough cooling water to the water tank;
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a) Insufficient cooling water; b) Replace the radiator cap spring;
b) Soft radiator cap spring; c) Tighten the water pump belt tension or replace the
water pump belt;
c) Loose or damaged water pump belt;
d) Replace the thermostat;
d) Thermostat failure;
e) Repair or replace the water pump;
e) The water pump does not work
normally; f) Clean the coolant gallery and remove the scale;
f) Too much crud in coolant gallery; g) Clean the radiator pipeline and unblock it;
g) Radiator is blocked; h) Repair or replace the radiator;

h) Radiator leaks water; i) Replace gasket or sealing gasket;
i) Water pump leaks; j) Tighten the connection or replace the hose.
j) The connecting hose of radiator is

loose or broken.
2. The water temperature is too low. a) Replace the thermostat;

a) Thermostat failure; b) Select according to regulations;
b) Improper selection of thermostat; c) Set up wind protection.
c) The ambient temperature is too low.
XIV. Aftertreatment system
1. Level I alarm of OBD lamp (the OBD lamp a) Check and repair or replace the differential
flashes intermittently) pressure sensor.
a) There is no obvious decrease in engine b) Check the DOC + SCR postprocessor or drive
power. The differential pressure sensor is at 80 km/h for 0.5 hours to clean and clear the
loose and damaged. fault code.
b) There is no obvious decrease in engine

power. The postprocessor is slightly blocked.
2. Level 2 alarm of OBD lamp (the OBD lamp is a) Check and replace the DOC + SCR
always on) postprocessor, and clear the fault code.
a) The engine power is obviously reduced. The
postprocessor is seriously blocked or burnt.
XV. Starter failure
1. The starter does not rotate. a) Clean and tighten contacts;

a) Poor contact of connecting wire; b) Fully charge the battery;
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b) The battery is under charged; c) Clean the commutator surface;
c) Poor brush contact; d) Repair or replace the starter.

d) Deenergizing of starter itself.
2. The starter is weak in idle starting. a) Replace the bearing sleeve;
a) The bearing sleeve is worn; b) Clean the commutator surface;
b) Poor brush contact; c) Clean oil stain and polish with fine emery
cloth;
c) Commutator is unclean or has burrs;
d) Weld the wire end firmly;
d) End terminal desoldering;
e) Clean and tighten contact points;
e) Poor contact;
f) Repair the switch;
f) Poor contact of switch;
g) The battery shall be fully charged or the
g) The battery is under charged or its capacity
battery with sufficient capacity shall be used.
is too small.
3. The gear is difficult to return; the contact chip

3. Replace the electromagnetic switch.
of electromagnetic switch is burnt.
XVI. Failure of charging generator
1. It does not charge at all or charges insufficiently or has an unstable a) Replace it in case of
charging current. damage.
a) Open the back cover of the generator, and measure the diodes or
integrated circuit regulators one by one with a multimeter;
XVII. Air compressor failure
1. Air compressor does not pump. a) Check the components of pressure

release valve, and clean and replace the
a) Pressure release valve is stuck;
defective parts;
b) Deformation or fracture of valve block;
b) Reassemble and replace parts;
c) Too much carbon is deposited in the air inlet, air
c) Overhaul the cylinder head, and clean
outlet and cavity;
the valve seat plate and valve block;
d) Small washer of exhaust valve plate is not
d) Check whether there are missing parts
installed;
and whether they are installed correctly;
e) The transmission gear slips.
e) Check the compression nut and key.
2. Insufficient air pressure 1) Check the compression nut and key;

a) The transmission gear of air compressor slips; 2) Check in the air filter and pipeline for dirt;
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b) The air filter is blocked; 3) Replace or repair cylinder block, piston
and piston ring;
c) Air leakage due to wear of cylinder block, piston
and piston ring; 4) Replace the valve block and spring;
d) The valve block is not tightly sealed, and the 5) Re tighten the cylinder head bolts or
spring is too soft or broken; replace the cylinder head gasket;
e) Air leakage due to loose cylinder head bolt and 6) Replace the pipeline and joint.
damaged cylinder head gasket;
f) The pipeline between the air compressor and the

air storage tank is broken or the joint leaks air.
3. Oil pumping of air compressor a) Check and replace the air compressor
filter; check for the kinks and deformation
a) Air intake is blocked or air intake filtration is poor;
of the air inlet pipe and remove it;
b) Wear between cylinder block, piston, and piston
b) Check and replace the piston and piston
ring is serious or the lubricating oil moves
ring;
upward due to reversely installed or stuck oil
ring; c) Remove the accumulated oil, soot or
unclean matters on the cooling fin. Check
c) Incomplete cooling of air compressor;
the flow of cooling pipe;
d) Dirt is not discharged from the air storage tank
d) Check the air valve of the air storage tank
regularly;
and remove the dirt;
e) The running time of air compressor is too long;
e) Check and repair the unloading system;
f) The crankcase pressure of the engine is too
f) Replace or repair the ventilation
high;
equipment of crankcase;
g) Oil pressure of engine is too high;
g) Check the lubrication pressure (at the oil
h) Deterioration of lubricating oil. inlet of the air compressor);
h) Replace with qualified lubricating oil.
XVIII. Fault diagnosis of turbocharger

When the diesel engine breaks down, it is also necessary to check and evaluate the
working condition of the turbocharger in addition to handling the diesel engine according to
the fault analysis and troubleshooting methods recommended in this manual.
Common faults of supercharged diesel engine:
1. The power is insufficient; 2. The consumption of lubricating oil is large; 3. The diesel
engine emits black smoke; 4. The working noise is loud.
These faults may be the result of the internal fault of diesel engine and the fault of air
supercharging system formed by turbocharger and diesel engine. When it is suspected that
the turbocharger is faulty, do not remove it from the diesel engine immediately, let alone
dismantle it. If the supercharger is simply replaced for treatment, not only the problem can
not be solved, but also new problems may occur. Carry out fault diagnosis first, and then
find out the causes and eliminate them.
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A turbocharger that has been operating normally is unlikely to fail in the future use. If its
impeller can rotate freely without scratching the inner shell, it may not be a problem of the
turbocharger. Experience shows that most turbocharger failures are related to the abnormal
use of diesel engine. Thus, the following recommended fault diagnosis table is mainly for
the whole air supercharging system. After fault diagnosis and detailed record, remove the
turbocharger for further analysis and inspection if necessary. The analysis and inspection
should be carried out in a professional repair shop or a diesel engine manufacturer.
Problems
Oil seal at turbine side leaks.
leaks.
Oil seal at air compressor side
noise.
Supercharger makes periodic
loud.
Work noise of supercharger is too
Blue smoke from diesel engine.
Excessive engine oil consumption.
Insufficient power of diesel engine.
Black smoke from diesel engine.

Fault diagnosis table
Possible causes Troubleshooting
Clean or replace the filter

√ √ √ √ √ Air filter is too dirty.
element.
Air leakage of the pipeline from Tighten fasteners or
√
air filter to air compressor. replace seals.
Air leakage of the pipeline from
Replace seals or tighten
√ √ √ √ √ air compressor to air inlet pipe
fasteners.
of the diesel engine.
√ √ √ √ Intercooler is too dirty. Clean intercooler.
Air leakage of the joint surface
between intake manifold of the Replace the gasket or
√ √ √ √ √
diesel engine and cylinder tighten fasteners.
head.
Air inlet pipe of air compressor Remove sundries or
√ √ √ √ √ √ √
is not smooth. replace damaged parts.
The outlet pipeline of air Remove sundries or
√ √ √
compressor is not smooth. replace damaged parts.
Air inlet pipe of diesel engine is
√ √ √ Remove sundries.
not smooth.
Gas leakage at the joint Replace seals or tighten
√ √ √ √
surface of turbine gas inlet. fasteners.
Air leakage of the joint surface
between exhaust manifold of Replace seals or tighten
√ √ √ √
diesel engine and cylinder fasteners.
head.
The exhaust pipe of diesel
√ √ √ √ √ √ Remove sundries.
engine is not smooth.
Gas leakage at the joint Replace seals or tighten
√
surface of turbine gas outlet. fasteners.
Muffler or tailpipe is not Remove sundries or
√ √ √
smooth. replace.
Oil return pipe of supercharger Remove sundries or
√ √ √ √
is not smooth. replace oil return pipe.
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Breathing apparatus of
Remove sundries or
√ √ √ √ crankcase of diesel engine is
replace.
not smooth.
Replace engine oil and
Dirt or coking in the middle filter element or
√ √ √ √
shell of supercharger. supercharger as
appropriate.
Clean air compressor or
Fouling of turbine blades or air
√ √ √ √ √ √ √ √ change engine oil and
compressor impellers.
filter element.
Clean the air intake system
Air compressor impeller worn
√ or replace the
or damaged.
supercharger.
Bearing, bearing hole or shaft
√ √ diameter of supercharger is Replace the supercharger.
worn.
Select lubricating oil
√ Wrong grade of lubricating oil.
according to regulations.
XIX. Failure of power steering pump

Common faults of power steering pump: abnormal noise; hard steering.
These faults may be the result of vehicle and steering system faults. When it is suspected
that the power steering pump is faulty, do not immediately remove it from the diesel engine,
let alone dismantle it. If the power steering pump is simply replaced for treatment, not only
can not solve the problem, but also may lead to new problems. Carry out the fault diagnosis
first, and then find out the causes and eliminate them.
A power steering pump that has been operating normally is unlikely to fail in the future use.
If it can rotate freely without abnormal sound, it may not be a problem of the power steering
pump. Experience shows that most failures of power steering pump are related to the
abnormal vehicle use. Thus, it is recommended to check whether the tire pressure,
hydraulic pipeline, transmission system, fluid level of fluid reservoir, filter screen of fluid
reservoir, pipeline joint, and power steering fluid are normal. After the fault diagnosis,
remove the power steering pump for further analysis and inspection if necessary. The
analysis and inspection should be carried out in a professional repair shop or a diesel
engine manufacturer.
Refer to the following table for troubleshooting.
1. The pump does not absorb oil or a) Remove and wash the filter and pipeline, or change the
has no pressure (the actuator oil;
does not move).
b) Check and fasten relevant threaded connections or
a) Filter or oil suction pipe is replace seals to prevent air intrusion;
blocked;
c) Check relevant wearing parts and grind them;
b) There is leakage at the
d) Use the oil with low viscosity;
connection part, and air invades
e) Add oil to the specified level.
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the pump;
c) The parts are worn, the gap is too

large, and the leakage is serious;
d) The viscosity of the oil is higher,

and the sliding resistance of the
blade is large;
e) The oil level is too low.
2. Oil leakage at the joint of oil port. a) Tighten thread connections or replace seals.
a) Loose joints or damaged seals.
3. Loud noise a) Check whether there is leakage of relevant parts. Add

grease to the joint; if noise is reduced, it indicates that
a) Air enters the pump;
there is leakage. Tighten the joint or replace the sealing
b) The pressure impact is too large, ring.
and the unloading groove on the
b) Check for and remove the blockage in the unloading
oil distribution disc is blocked;
groove.
c) The resistance of oil suction pipe
c) Check for and remove the blockage.
is too large, or it is even blocked;
d) Check for and replace the wearing parts of the inner
d) Wear of pump increases.
cavity.
XX. Case study on the maintenance of electronic-control high-pressure

common-rail diesel engine
1. Precautions
(1) Safety tips
 The maximum pressure in the common rail system can reach 2000bar (2000Kg/cm2).
Do not overhaul the fuel injection system when the engine is running.
 Maintenance shall be carried out 30 seconds after the engine is shut down.
The following components are under high pressure:
1. High pressure oil pump; 2. Fuel injector; 3. High pressure oil pipe; 4. High pressure fuel
rail;
Attention: beware of accidents!
 If maintenance measures are taken while the engine is running, make sure that no one
is within the range of high-pressure beam;
 When the vehicle and its components are overhauled (even when they are
disassembled), some combustible substances may flow out, which may cause serious
fire and explosion;
 Before inspection, it is necessary to avoid a source of ignition by appropriate measures,
155
such as disconnecting the battery / using tools that do not produce sparks.
(2) Cleanliness
 Compared with the traditional mechanical fuel system, the fuel system of the
high-pressure common-rail electronic-control diesel engine has more stringent
requirements on fuel cleanliness. The fuel pressure of the electronic control system is
higher, the control is more accurate, and the fit of the internal moving elements is more
precise. The unclean fuel will reduce the service life of the fuel injection pump and the
fuel injector. Thus, the cleanliness of the maintenance shop is very important. There
should be no equipment that pollutes the fuel injection system, such as electric welding
machine and milling machine; the dust and particles caused by these equipment will
damage the fuel system. For outside maintenance, please also pay attention to
ensuring that the low-pressure fuel pipe and high-pressure fuel pipe are clean!
 For disassembling the oil supply system, it is recommended to clean the dust and oil
around the common rail parts first to ensure cleanliness;
 The maintenance personnel should wash their hands when repairing the fuel system,
and the tools should also be clean.
(3) Maintenance technology
 Please assemble the nuts and barrels of all connecting parts of the fuel system in strict
accordance with the torque requirements, otherwise the fuel pump, fuel rail or fuel
injector may be damaged;
 For disassembling the fuel injector, the cylinder number shall be marked. When the fuel
supply system is disassembled, the clean protective cap shall be used, even for a short
time, and the protective cap shall not be removed until the system is assembled. The
common rail parts shall not be unpacked until they need to be used.
2. Faults and its handling

(1) Lack of power and black smoke
Failure
Lack of power; black smoke.
phenomenon
The main causes are as follows:
1. Fuel quality;
Analysis of 2. The air inlet system is blocked or leaks, and the exhausting is not
causes smooth;
3. Air leakage of intercooler;
4. Loose supercharger shaft, damaged turbine, and stuck turbine.
1. Read the fault code with the diagnostic instrument; no fault codes;
2. Check whether the fuel is qualified;
3. Check the air inlet system and exhaust system;
Handling Check whether the air filter is too dirty, whether the clamp of air inlet pipe
is not tight, whether the air inlet pipe falls off or the rubber pipe is broken,
whether the intercooler leaks, and whether the exhausting is not smooth.
4. Check the supercharger shaft for large clearance or jamming. Check
156
the pipeline from supercharger to intercooler.
157
Flow chart for troubleshooting
Check the fuel quality.
Check the fault code and

repair according to the fault
code.
Check whether the air filter of

the air inlet system is too dirty,
whether the clamp of the air
inlet pipe is loose, and
whether the air inlet pipe falls
off.
Check whether the intercooler

leaks air, and whether the
supercharger shaft is loose or
even stuck.
(2) Frequent flameout
When the engine is running, the trouble light is on and the speed is limited. When the
Failure
engine accelerates, the engine stalls. When the engine restarts after flameout, the
phenomenon
hand oil pump must be pressed tightly.
The main cause is that the actual oil pressure of the common rail is higher or lower
than the required oil pressure. The main causes are as follows:
Analysis of
causes 1. The poor quality of diesel oil (including impurities or water) leads to the blockage of
low-pressure oil circuit and diesel filter, which makes the oil supply of oil pump
insufficient at high speed;
158
2. The diesel filter and oil circuit are blocked, the air enters the oil circuit, and oil inlet
and return are not smooth;
3. The measured value of the fuel rail pressure sensor is incorrect. The overflow valve
of the oil pump is stuck, and the oil supply of the oil pump is insufficient.
1. Read the fault code with the diagnostic instrument. Check the fuel gauging control
(MeUn): the positive deviation of rail pressure exceeds the upper limit; check the oil
quantity control mode: the positive deviation of maximum rail pressure exceeds the
upper limit, and affects the set fuel flow; check fuel gauging control mode: rail
pressure is below minimum limit.
2. According to the fault code, it indicates that there is a problem in the oil circuit,
which causes the insufficient fuel pressure. First, start from the low-pressure oil circuit;
3. Check whether the diesel filter is dirty;

Handling
4. Check whether oil inlet and return pipe from the oil return pipe of fuel injector to the
oil pump and from the oil pump to the fuel tank have any bending;
5. Check whether the oil inlet pipe in the fuel tank is blocked or has air;
6. Check the pipeline from fuel tank to filter and from filter to oil pump for blockage or
air.
In this case, the oil return pipe of filter is tightened too tightly by the strapping belt,
which causes the oil return to be blocked and the ECU to report an error.
(3) Fail to start
Failure
Fail to start
phenomenon
1. Voltage is too low.
Analysis of 2. ECU is not powered on or is damaged.

causes 3. Oil pump and fuel rail fail.
4. Fuel injector is worn.
1. If the battery voltage is lower than 24V, the starter speed will be too low, and the
ECU supply voltage will be too low.
2. ECU is not powered on or damaged.

Check whether the main relay has a sound for pull-in or unplug the connector of water
temperature sensor to check whether the plug has a 5V voltage.
Handling 3. Oil pump, fuel rail sensor, and fuel injector fail (read fault codes by diagnostic
instrument).
①Error at low level end of fuel gauging unit (MeUn): short circuit to storage battery;
short circuit to ground.
Measure whether the resistance value of oil inlet metering proportional solenoid valve
is about 2.5 Ω, and whether its connecting circuit with ECU is normal.
159
②Fault of rail pressure sensor: the voltage exceeds the upper limit; the voltage is
lower than the lower limit. Check whether the connecting circuit between common rail
pressure sensor and ECU is normal. When the ignition switch is in the ON position,
read the data flow with the diagnostic instrument, and the output signal voltage of the
common rail pressure sensor is 0.49V.
Note: it is forbidden to use multimeter to measure the resistance of rail pressure
sensor!
③If there is no fault code, check whether the oil pump supplies oil (note: such a case
is rare). Remove the high-pressure oil outlet pipe of the oil pump, and use the starter
to drive the engine to check whether the oil of the oil pump flows out in line. If there is
little oil flowing out (relative to normal vehicles), or even no oil flowing out, it is very
likely that the oil pump fails.
The maintenance personnel should not only read the fault code, but also make full use
of the data flow of the diagnostic instrument. For example, read the data flow of rail
pressure to check fuel system; when the engine is started, check whether the fuel rail
pressure can be established within 10-15 seconds and whether it is greater than
25MPa.
4. Fuel injector is worn.
Pull out the oil return pipe on the fuel injector, and start the engine. If the engine has
not been started successfully, and the oil has started to return, it means that the rail
pressure cannot be established due to the wear of the fuel injector.
160
Check whether the

battery voltage is
greater than 24V,
and whether the
starter speed is too
low (the engine can
be started only
when the engine
speed is higher
than 200r/min).
Check whether the

main relay has a
sound for pull-in or
whether the plug
has a 5V voltage
when the connector
of water
temperature sensor
is unplugged.
Repair according to
the fault code and
check whether the
oil pump has oil
flowing out.
Pull out the oil

return pipe on the
fuel injector, and
start the engine to
check whether the
oil is returned. If the
engine has not
been started
successfully, and
the oil has started
to return, it is an
abnormal
phenomenon.
161
(4) Difficult start
Failure
The engine is difficult to start.
phenomenon
The main causes:

1. The diesel engine does not run for a long time.
2. There is a small amount of air or blockage in the low pressure pipeline.
3. The crankshaft speed signal and camshaft signal are too weak, and the time for
synchronous judgment is long.
Analysis of
causes 4. The ambient temperature is too low and the preheating device fails.
5. The quality of diesel oil and engine oil is too poor.

6. Tooth collision of starter or flywheel ring gear.
7. Piston ring and cylinder hole are worn or the valve is not sealed tightly.
8. Storage battery lacks electricity.
1. Read out the fault code to check whether there is camshaft and crankshaft sensor
signal error.
2. Check whether the low-pressure oil circuit is blocked and whether there is air in the
low-pressure oil circuit.
3. There is no crankshaft signal:

Crankshaft signal failure: there is no crankshaft signal.
Check whether the connector of crankshaft position sensor is loose or in poor contact,
and whether it has short circuit or open circuit.
Measure whether the resistance of crankshaft position sensor is 900Ω (the actual
resistance value is related to the ambient temperature). Measure whether the clearance
between crankshaft position sensor and signal wheel is between 0.5-1.5mm. Check
whether the flywheel signal teeth are damaged. Check whether there is poor contact
Handling
between the connector and the sensor.
Check whether the connector of camshaft position sensor is loose or in poor contact,
whether the timing is installed wrongly after replacing the oil pump, and whether the
connector has short circuit or open circuit.
Measure whether the clearance between camshaft position sensor and signal wheel is
between 0.5-1.5mm.
② If there is no fault code, use an oscilloscope to check the waveforms of both (it is
possible that the signal is not correct but the ECU does not report an error).
162
Crankshaft signal and camshaft signal
4. Check whether the preheating device and related fuse and relay have faults.
5. Check whether the quality of engine oil and diesel oil meets the requirements.
6. Check the starter or flywheel ring gear for tooth collision.
7. Use the diagnostic instrument to carry out compression test to check whether the
piston ring and cylinder hole are worn or the valve is not sealed tightly.
8. When the engine is started, check whether the battery voltage can meet
requirements.
163
Check whether the

battery voltage is
greater than 24V, and
whether the starter
speed is too low (the
engine can be started
only when the engine
speed is higher than
200r/min).
Check whether the

grades of engine oil and
diesel oil meet the
weather requirements.
Check the low-pressure

pipeline for air, blockage
and bending.
Check the crankshaft

speed signal and
camshaft signal for
damage or too much
metal scraps.
Check whether the glow

plug works properly.
Check the starter or

flywheel ring gear for
tooth collision.
Carry out compression

test with the diagnostic
instrument to check
whether the piston ring
and cylinder hole are
worn or the valve is not
sealed tightly.
164
(5) Insufficient engine power and limited speed and torque
Failure Power of engine is insufficient; speed and torque are limited; there is no black
phenomenon smoke; trouble light is on.
The main causes:

1. The fuel injector fails.
2. The water temperature and intake air temperature are too high.
Analysis of
causes 3. Flow metering unit fails.
4. Fault of sensors (water-in-oil sensor, water temperature sensor, intake air

temperature pressure sensor, accelerator pedal unit, camshaft sensor).
5. The signal panel falls off.
1. According to the fault code shown by the diagnostic instrument, the sensors
causing the speed limit are as follows:
2. Check whether the water-in-oil light is on and whether the sensor is damaged
(the speed limit is in the range of 2500-2600r/min).
3. Check the water temperature sensor (the speed limit is in the range of 2500-2600
r/min).
Handling
4. Check the intake air temperature pressure sensor (the speed limit is in the range
of 2000-2400 r/min and the torque is limited).
5. Check the accelerator pedal unit (the idle speed is raised to 1100 r/min
automatically).
6. Check whether the camshaft signal plate falls off and whether the camshaft
sensor is damaged (the speed is limited below 2600 r/min).
165
Insufficient engine
power, and limited
speed and torque Check the fault code and
maintain according to the
fault code.
Troubleshooting
according to the
fault code
Check the height of engine
oil and coolant, and check
whether the connection of
corresponding sensor is
reliable.
Check whether the air filter

of the air intake system is
too dirty, and whether the
Maintain or
Check whether clamp of air inlet pipe is
Yes replace
the supercharger loose or even falls off.
fails or intercooler
Check whether the
leaks air
intercooler leaks air, and
whether the supercharger
No shaft is loose or even
stuck.
Check the Yes
accelerator pedal Maintain or
control unit replace
Check whether the travel
control circuit and
connection of accelerator
No
pedal are secure.
Check camshaft signal, Yes Check whether the

crankshaft signal and Maintain or
camshaft and crankshaft
intake air temperature replace
pressure sensor sensor fail and whether the
signal tooth is damaged.
Check whether the

connecting wire of intake
air temperature pressure
sensor is broken or falls
off.
166
(6) Pressing the accelerator pedal twice for acceleration
Failure
The accelerator pedal needs to be pressed twice to accelerate.
phenomenon
The main causes:
Analysis of 1. The connector of accelerator pedal is loose or in poor contact.

causes 2. The brake pedal can not return to the highest position.
3. The harness of accelerator pedal is in poor contact.
1. Read fault codes.

2. Check whether the connector of accelerator pedal is connected reliably.
3. Check whether the brake pedal rebounds to the highest position.
Handling 4. Check whether the harness between accelerator pedal and ECU is connected
reliably.
5. Check the circuits of brake switch and brake relay.
6. Read the data stream with the diagnostic instrument, and the information of the
main and auxiliary brake switch must be opposite.
167
Check the fault code and

maintain according to the
fault code.
Check whether the

connector of accelerator
pedal is inserted tightly,
and check the on-off of
control harness of each
accelerator pedal.
Check whether the brake

pedal returns to the highest
position, and check the
on/off of circuit.
168
(7) Long starting time, speed limit or flameout
Failure
The starting time is long; speed limit or flameout occurs during operation.
phenomenon
Analysis of 1. There is air in the low-pressure oil circuit;

causes 2. The low-pressure oil circuit is blocked.
Fault codes:
Fuel gauging control Meun: positive deviation of rail pressure exceeds the upper limit;
oil quantity control mode: positive deviation of maximum rail pressure exceeds the
upper limit and affects the set fuel flow.
1. After exhausting the air with the hand oil pump, there may be air in the low-pressure
oil circuit if the starting time is shorter;
2.As shown in the figure below, a new oil circuit is used for test run. If the test run is
Handling normal, it can be judged that there may be air or blockage in the low-pressure oil circuit
from the fuel tank to the diesel filter.
3. Carefully check the low-pressure oil circuit from the fuel tank to the diesel filter.
The reason for the long starting time is that there is air in the low-pressure oil circuit. If
there is air in the low-pressure oil circuit, there will be a buzzing at the solenoid valve of
fuel gauging of oil pump when the key is turned to the "ON" position. Although the
Fault
high-pressure pump has a certain capacity of exhausting, air always enters the
analysis
low-pressure oil circuit. When the engine speed increases, the air entering the common
rail is compressed, and the pressure fluctuation increases, resulting in the deviation of
rail pressure exceeding the upper limit.
169
(8) When the vehicle is uphill or under heavy load, the engine shuts down when
accelerating.
When the vehicle is on the uphill or under heavy load, the trouble light is lit and the
Failure
engine shuts down when the vehicle is accelerating. After flameout, turn the key back
phenomenon
to the LOOK position, and restart the engine; and the engine is normal.
1. The low-pressure oil circuit is blocked;

Analysis of
2. The fuel injector is worn;
causes
3. The oil supply of high-pressure oil pump is insufficient.
1. Fault codes:
Fuel gauging control Meun: the positive deviation of rail pressure exceeds the upper
limit; fuel quantity control mode: the positive deviation of maximum rail pressure
exceeds the upper limit, and affects the set fuel flow.
Handling 2. Remove the oil return pipe of fuel injector, and compare the oil return quantity of
four fuel injectors within one minute at idle speed. It is found that the oil return quantity
of one fuel injector is larger than that of the other three (when the water temperature is
80 ℃, idle for one minute to measure the oil return quantity of each fuel injector).
3. After replacing with the fuel injector with a small amount of fuel return, the test run is
normal.
Due to the poor filtering effect of the diesel filter or the impurities entering into the
high-pressure oil circuit, the ball valve of the fuel injector is worn (as shown in the
figure below), and can not be closed tightly. Thus, the fuel return quantity increases,
and the fuel quantity supplied by the fuel injection pump to the fuel injector also
increases. The large fuel return quantity leads to the increase of the rail pressure
fluctuation, and the ECU limits the torque. After the maximum limit value of torque is
exceeded, the engine shuts down.
Fault analysis
170
(9) Self-inspection trouble light is always on.
Failure
The trouble light is always on.
phenomenon
1. K65 is shorted to ground;

Analysis of causes
2. K55 is shorted to the positive pole of power supply.
1. Read out the fault code with the diagnostic instrument and clear the fault
code;
Handling 2. Conduct an action test on the trouble light;

3. Check whether K65 is shorted to ground;
4. Check whether K55 is shorted to the positive pole of power supply.
Read out the fault code

with the diagnostic
instrument and clear the
fault code. If the trouble
light goes out at this
time, but comes on again
later, it indicates that
there is a fault, and
further search is needed.
Check whether K65 is

shorted to the ground.
Find out the position of
short circuit and remove
the fault.
Check whether K55 is

shorted to the positive
pole of power supply.
Find out the position of
open circuit and remove
the fault.
171
(10) Self-inspection trouble light does not work normally.
Failure The trouble lamp does not light up during ECU self-inspection; the lamp flashes
phenomenon when the ignition switch is turned on or off quickly.
Analysis of 1. The circuit is in poor contact and has open circuit;

causes 2. The ground wire of trouble light is shorted to the positive pole of power supply.
1. Read out the fault code with the diagnostic instrument and carry out action
tests;
2. Check whether the circuit from K55 to trouble light is open;

Handling 3. Check whether the ground wire of trouble light is open;
4. Check whether the ground wire of trouble light is shorted to the positive pole of
the power supply;
5. Check the trouble light.
172
Check the relevant

connecting lines
through the fault
codes read out by the
diagnostic
instrument.
Check the ground

wire for open circuit;
find out the open
circuit position and
remove the fault.
Check whether the

ground wire is
shorted to the
positive pole of the
power supply;
remove the fault.
Use the action test of

the diagnostic
instrument to check
the trouble light.
173
Chapter X Fault Diagnosis
For details of D20TCIF China Ⅵ engine, please refer to Manual Instruction for
Diagnosis—Type XXXXXXXX provided by BOSCH company.
Chapter XI Storage
If the diesel engine or diesel vehicle that has never been used needs to be stored for a long
time, please handle it according to the following requirements.
1. Drain the engine oil.
2. Open the drain valve to drain the coolant in the diesel engine.
3. Drain the diesel oil in the fuel tank and fuel pipeline.
4. The exterior of the diesel engine shall be cleaned of oil, water and dust; the unpainted
parts shall be coated with antirust oil (mixture of dehydrated engine oil and butter);
parts made of rubber products and plastic products shall not be coated with antirust oil.
5. Seal the air filter (or air inlet) and exhaust pipe orifice with oil paper to prevent dust and
dirt from entering.
6. The diesel engine or vehicle shall be placed in a well ventilated, dry, clean room without
strong magnetic field (temperature: -30-60℃, humidity: 0-80%). It is strictly prohibited to
stack them in the place of corrosive chemicals. Protect them from moisture (especially
the electric system).
If the used diesel engine or vehicle needs to be stored for a long time, please handle it
according to the following requirements.
1. After shutdown, drain the engine oil while it is hot; disassemble the oil pan; and clean
the oil pan and sump strainer.
2. Open the drain valve to drain the coolant in the diesel engine.
3. Drain the diesel oil in the fuel tank and fuel pipeline.
4. Remove the dust on the filter element of air filter (paper air filter); clean the filter
element of oil-bath air filter with diesel or kerosene.
5. Remove air inlet pipe and add 300 grams of filtered HC-8 dehydrated engine oil(heating
oil to 110~120℃ until the foam completely disappears) to each cylinder from air
passages; rotate the crankshaft to make the oil evenly adhere to the surfaces of valve,
cylinder sleeve and piston; then install the air inlet pipe.
6. The exterior of the diesel engine shall be cleaned of oil, water and dust; the unpainted
parts shall be coated with antirust oil (mixture of dehydrated engine oil and butter);
parts made of rubber products and plastic products shall not be coated with antirust oil.
7. Seal the air filter (or air inlet) and exhaust pipe orifice with oil paper to prevent dust and
dirt from entering.
174
8. The diesel engine or vehicle shall be placed in a well ventilated, dry, clean room without
strong magnetic field. It is strictly prohibited to stack them in the place of corrosive
chemicals. Protect them from moisture (especially the electric system).
Note: the storage time of the above method is 18 months. If the time is
exceeded, re store according to the above method.
Service manual of D20 series high-pressure common-rail electronic-control diesel engine
Act with honesty / Manufacture by high-quality standard
KUNMING YUNNEI POWER CO., LTD.
Address: No.66 Jingjing Road, Economic and Technological Development Zone, Kunming,
China
Tel: 0871-65633185
Fax: 0871-65633176
Post code: 650200
Website: WWW.Yunneidongli.com.cn
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Service Manual

——D20 Series China VI Diesel Engine

KUNMING YUNNEI POWER CO., LTD.

Chapter I Main Technical Specifications and Data .......................................................................... 4

I. Main technical specifications ........................................................................................................... 4

II. Specifications of main accessories ................................................................................................. 4

III. Main technical data.......................................................................................................................... 6

I. Maintenance requirements and precautions of engine ................................................................. 10

III. Disassembly of engine assemblies ................................................................................................11

II. Assembly of piston rod unit ........................................................................................................... 32

VI. Assembly of timing linkage and chain cover ............................................................................. 36

IX. Cooling system .............................................................................................................................. 40

X. EGR system assembly .................................................................................................................. 40

XI. Installation of accessories ............................................................................................................. 41

XII. Installation, use, and maintenance of electronic-control high-pressure common-rail system .. 41

I. Engine body assembly .................................................................................................................. 68

II. Cylinder head ................................................................................................................................ 69

III. Valve timing mechanism ................................................................................................................ 71

IV. Crankshaft, flywheel and clutch..................................................................................................... 73

VI. Transmission gear train ................................................................................................................. 76

IX. Electronic-control common-rail system ......................................................................................... 81

X. Electric system .............................................................................................................................. 81

XI. Air inlet and supercharged and mid-cooling system ..................................................................... 82

I. General requirements for aftertreatment system .............................................................................. 89

IV. Maintenance and installation of aftertreatment system................................................................... 94

V. Common faults and handling methods ........................................................................................... 103

Chapter VII Use of Diesel Engine .................................................................................................. 129

I. Diesel ............................................................................................................................................... 129

II. Engine oil ........................................................................................................................................ 130

V Running-in of diesel engine............................................................................................................. 136

VI. Operation of diesel engine ............................................................................................................ 136

VII. Stop of diesel engine .................................................................................................................... 137

I. First forced running-in maintenance ................................................................................................ 139

II. Regular forced maintenance .......................................................................................................... 139

I. Difficult starting ................................................................................................................................ 142

III. Unstable revolving speed .............................................................................................................. 143

IV. Insufficient diesel engine power .................................................................................................... 144

V. Limited revolving speed .................................................................................................................. 144

VI. Shutdown of diesel engine ............................................................................................................ 145

X. Excessive engine oil consumption ................................................................................................. 148

XI. Excessive fuel consumption .......................................................................................................... 148

XII. Failure of lubrication system ........................................................................................................ 149

XIV. Aftertreatment system ................................................................................................................. 150

XVI. Failure of charging generator ..................................................................................................... 151

XVII. Air compressor failure ................................................................................................................ 151

XVIII. Fault diagnosis of turbocharger ................................................................................................ 152

XIX. Failure of power steering pump .................................................................................................. 154

Chapter XI Storage ............................................................................................................................ 174

II. Specifications of main accessories

Name of accessories Specification of accessories

High pressure oil Type High-pressure common-rail pump

Technical parameters of main parts of electric control system Table 3

Oil supply per cycle mm 3 657

III. Main technical data

2. Various temperature and pressure ranges of diesel engine Table 5

3. Tightening torque of main bolts Table 6

4. Main installation data Table 7

5. Tightening torque of common bolts and nuts (for reference) Table 8

IV. Size, fit clearance and wear limit of main parts