Reparacion motor changchai 2.0

DF3.0 T - DF2.0T
4F20TCI -
4F20TCI Diesel Engine
Service Manual
CHANGCHAI CO.LTD., CHINA

4F20TCI 型柴油机维修手册 Service Manual of 4F20TCI Diesel Engine
I
Table of Contents
Foreword.......................................................................................................................................... I
Chapter 1 Engine Trouble and Removal.......................................................................................1
Chapter 2 Main Technical Specifications and Parameters of Engine.........................................7
Chapter 3 Disassembly of Engine ................................................................................................12
Chapter 4 Engine Maintenance ...................................................................................................40
Chapter 5 Assembly of Engine.....................................................................................................46
Chapter 6 Electrically Controlled High-Pressure Common Rail System ................................75
Chapter 7 Supercharger...............................................................................................................78
Chapter 8 Charge Inter-cooling System......................................................................................81
Chapter 9 EGR System.................................................................................................................83
Chapter 10 Starting System..........................................................................................................85
Chapter 11 AC Generator ............................................................................................................89

Foreword
“Changchai” 4F20TCI diesel engine is an electrically controlled high-pressure
common rail diesel engine developed by Changchai Co., Ltd. on its own. It uses the
internationally advanced technology, its performance and reliability reach the
advanced world standard, and its emission also arrives at the EURO-IV emission level.
In addition, it features compact structure and light weight. So it is an ideal auxiliary
power of the diesel engine used for light truck, pickup truck, SUV and other vehicles.
The manual is provided by Changchai Co., Ltd., and it is prepared for the
professional service and technical personnel, containing excellent pictures and texts
and enjoying great practicability. In this manual, it gives a brief introduction to the
technical specifications and parameters, structural features, etc of the diesel engine,
and in detail describes the assembly, disassembly and maintenance of the engine by
both picture and text; besides, it also offers the technical data regarding failure
analysis and the like.
The technical personnel of the authorized service center of the company can,
after getting acquainted with the contents hereof and the related data, provide better
services for the vehicles in which “Changchai” electrically-controlled high-pressure
common rail diesel engine. If a certain part is to be replaced, please use the part of the
same kind as approved by the company at the authorized service center, and do not
use any part not approved yet.
The data and descriptions supplied herein deal with the existing product only. As
the product is subject to improvement and perfection, and changes may be made
hereto to meet the needs of the users, there may exist some conflict between the
manual and the product, so the product will prevail.

1
Chapter 1 Engine Trouble and Removal
I. Engine Start Failure
Cause for Trouble Method of Removal
1. Low start engine speed
（1）insufficient chart in battery or joint
getting loose
（1）Charging voltage should be more than 10V; tighten joint;
repair binding post when necessary.
（2）Poor contact of starting motor
carbon brush with commutator
（2）Repair or replace carbon brush.
（3）Starting motor gear cannot come
into flywheel gear ring.
（3）Remove flywheel disc to another place. Check installation
condition of starting motor when necessary, and remedy
misalignment between starting motor and gear ring axial line.
2. Abnormal fuel oil system
（1）no oil in fuel tank or valve of fuel
tank not opened
（1）Fill oil; open valve.
（2）Air in fuel system; water in oil; oil
at joint.
（2）Expel air; replace diesel oil; tighten joint.
（3）Oil way blocked. （3）clean pipe, replace oil-water separator, clean oil inlet pipe
of oil delivery pump.
3. Insufficient compression pressure
（1）Over small valve lash. （1）Adjust it as specified.
（2）Air leakage in valve. （2）Grind valve.
（3）air leakage at cylinder head spacer （3）Replace cylinder head spacer, and tighten cylinder head
bolt as specified.
（4）Piston ring getting worn or glued,
overlapping at opening
（4）Replace, clean and adjust.
4. over low air temperature, failure in
pre-heating loop
Check preheating loop, and remove trouble.
5. failure in electric control system,
electrically controlled connector being in
poor contact or getting loose
check all connectors, or receive inspection by professional
service unit.
II. Abnormal Engine Oil Pressure
1. no pressure or over low pressure in engine oil
（1）Over low oil level, and engine oil getting
deteriorated or thinned.
（2）Oil pipe cracking; pipe joint not pressed properly or
oil leakage therein; damage in engine oil pressure gauge.
（1）Fill engine oil; replace engine oil.
（2）Weld; tighten; replace.
（3）Pressure spring of engine oil filter getting deformed （3）Replace.

2
or fractured.
（4）Over large clearance between engine oil pumps. （4）Send to factory for repair; replace.
（5）Damage to engine oil pump spacer. （5）Replace.
（6）Over large fitting clearance between bearings. （6）Check; replace.
2. over high engine oil pressure
（1）Pressure limiting valve of engine oil pump or
pressure regulating valve of engine oil filter not working
properly; oil not returning smoothly.
（1）Check and adjust.
（2）over low air temperature; over great engine oil
viscosity.
（2）Use engine oil of specified brand; engine
oil viscosity decreasing after engine is warmed
up.
3. no engine oil at rock arm shaft
（1）Oil duct of upper cylinder head and oil hole at
bottom of rock arm shaft seat.
（1）Clean; unblock.
（2）Camshaft bushing installed improperly. （2）Check and adjust.

3
III. Exhaust Smoke
1. white smoke in exhaust
（1）Fuel injector blocked by carbon deposit; needle
valve seized.
（1）Check, clean, repair or replace.
（2）Over heavy load. （2）Adjust load, to make it fall within the
specified range.
（3）Improper valve clearance; valve not sealed
well.
（3）Check valve clearance, contact condition of
valve sealing face, valve spring elasticity, etc, and
remove trouble.
（4）Air inlet pipe and air filter blocked, causing
poor air intake.
（4）Remove and clean air filter.
（5）failure in electric control system （5）Find out cause for trouble, and remove
trouble, and clear trouble code.
（6）failure in turbocharger （6）Check turbocharger, find out cause for
trouble, and remove trouble.
2. white smoke
（1）Poor oil atomization; oil leakage. （1）Check, adjust or replace fuel injector.
（2）Over low temperature of cooling water. （2）raise temperature of cooling water.
（3）Water entry into cylinder. （3）Check cylinder head spacer.
（4）failure in electric control system. （4）Find out cause for trouble, and remove
trouble, and clear trouble code.
3. blue smoke in exhaust
（1）Over great wear in piston ring, or engine oil
whisking into combustion chamber due to
inadequate elasticity of carbon deposit.
（1）Clean or replace piston ring.
（2）Over high engine oil level. （2）Drain unwanted engine oil.
（3）Gas ring reversely installed on the 2nd
conical
surface.
（3）Put face marked with “UP” up.
IV. Under Power
1.Air entry into fuel system. 1.Expel air from fuel system.
2. Air filter blocked. 2.Clean or replace filter core.
3. failure in electric control system. 3.Find out cause for trouble, and remove trouble, and
clear trouble code.
4.Air leakage in valve. 4.Check valve clearance, valve spring elasticity, wear in
valve guide, valve seizure, condition of valve sealing
face, etc, replace parts when necessary, and grind valve.
5.Inadequate compression pressure. 5.Check whether cylinder head spacer is damaged,
whether cylinder liner is excessively worn, or whether

4
piston ring is glued; if any problem exists, replace them.
6.。Improper timing for air distribution. 6. 。Cam is excessively worn, and camshaft can be
replaced.
7.。Air leakage in fuel injector seat surface. 7.。Replace copper washer, clean seat hole plane,
tighten bolt of pressing plate of oil injector.
8.。Cylinder head bolt getting loose. 8.。Tighten with specified tightening moment.
9.。Accelerator position sensor not extending to
bottom.
9.。Fix accelerator position sensor.
10.。Damage to supercharger. 10.。Find out cause, repair or replace it.
11.poor oil supply or over low pressure in low
pressure oil way
11. check low pressure loop and oil in oil tank, and
remove trouble.
12improper position of or signal defect in
accelerator position sensor
12.。Check accelerator position sensor.
13 intercooler blocked 13。Check intercooler pipe, and unblock pipe that is
blocked.
V. Abnormal Noise
1.。Over great valve clearance, and clear, rhythmed
knock.
1。Adjust valve gap.
2.piston touching valve, heavy, even and rhythmed
knock. (feeling vibration caused by piston knock by
putting hand on cylinder head / cover nut gently)
2。Raise valve clearance properly; correct
clearance between connecting rod bearings, or
replace connecting rod bushing or connecting
rod shell; replace cylinder head spacer.
3.。Piston touching cylinder head bottom, heavy,
strong knock.
3.。Replace cylinder head spacer.
4。Valve spring broken, valve push rod bent, or valve
tappet worn, causing valve mechanism to make slight
knock.
4.。Replace spring, push rod or tappet, etc, and
adjust valve clearance.
5.。Over great clearance between piston and cylinder
liner, causing noise, and noise deadening as diesel
engine is warmed up.
5.。Replace cylinder liner and piston according to
wear condition.
6.。Over great clearance between connecting rod
bearings, causing heavy, strong knock, when rotation
speed is reduced all of a sudden.
6.。Replace connecting rod bearing shell.
7.。Over great clearance between connecting rod
bushing and piston pin, causing slight but sharp noise,
and it can be quite clear at idle speed in particular.
7.。Replace connecting rod bushing or piston pin.
8.。Crankshaft thrust plate worn and over great axial
clearance, causing hitting noise resulting from
crankshaft moves to and fro at idle speed.
8.。Replace crankshaft thrust plate.

5
9.。Exhaust pipe getting loose or broken 9。Tighten exhaust pipe bolt or replace exhaust
pipe.
10。Air inlet and outlet pipe of supercharger blocked
or air leakage therein.
10.。Remove block or leakage.
VI. Serious Vibration
1.。Water or air in diesel oil. 1.。Expel air, filter diesel oil, or replace it.
2.。Poor alignment when installing diesel engine;
bearing bolt getting loose.
2.。Correct alignment; tighten.
3. poor contact of sensor or actuator and wiring
harness of electric control system
3.。Check connectors at wiring harness.
VII. Over Heat in Diesel Engine
1.。Fuel oil whisking into crankcase, water in engine
oil, engine oil getting deteriorated or thinned,
inadequate or excessive engine oil; small engine oil
flow, low pressure, over small fitting clearance
between bearings.
1.。Check and replace piston ring; replace engine
oil; check oil level; check cylinder head spacer;
check wear and tear in inner and outer rotor;
check and adjust fitting clearance between
bearings.
2. abnormal oil injection in electric control system 2.。Find out cause for trouble, and remove it.
3.。Water pump impeller damaged or broken; fan
positioned improperly; thermostat failure; pipe of
cooling system blocked; too much sediment in water
jacket; inadequate displacement of water pump;
inadequate water; cylinder head spacer damaged; gas
entry into water duct.
3.。Check and replace water pump impeller;
check fan adhesive tape for tension or replace
adhesive tape; check mounting position of
radiator; check working condition of thermostat;
clean cooling system and water jacket; check
clearance between water pump impellers; fill
water; replace cylinder head spacer.
4、。Trouble in cooling fan and its circuit. 。Check cooling fan and circuit, and remove
trouble.

6
VIII. Excessive Oil Consumption
1.。Engine oil used is over low in viscosity or not right
in brand.
1. 。Use engine oil of specified brand.
2.。Piston and cylinder liner is excessively worn and
torn; oil return hole in piston ring is blocked.
2.。Replace or clean oil return hole.
3.。Piston ring is glued; gas ring is reversely installed
or excessively worn.
3。Clean, adjust or replace.
4。Oil leakage occurs at front/ rear oil seal of
crankshaft, faying surface of oil sump, etc.
4.。Check or replace related parts.
5.。Over high oil temperature or pressure causes steam
to splash.
5.。Reduce temperature; check and adjust
pressure limiting valve of engine oil pump or
pressure regulating valve of engine oil filter.
6. turbocharger is faulty. 6. check turbocharger, and remove trouble.
IX. Soar in Speed
1.。Excessive lubricating oil flees. 1。As above in VIII. Reduce fleeing lubricating
oil.
Auto Stop
1.。Air in oil way; diesel oil filter blocked. 1.。Expel air; clean diesel oil filter.
2.。Piston seized; axle neck and bearing bush
seized.
2.。Fitting clearance is not right, and it needs to be
repaired or replaced. Lubricating oil breaks, or oil
pressure is very low, and lubricating oil way needs
to be checked.
3. trouble in electric control system. 3.。Find out cause, and remove fault.
Rise in Engine Oil Level
1. 。Water leakage in cylinder head spacer. 1.。Replace cylinder head spacer.
2.。Water leakage in cylinder head or engine body. 2.。Repair or replace.

7
Chapter 2 Main Technical Specifications and Parameters of
Engine
I. Main Technical Specifications and Data of Engine
1. Main Technical Parameters of Engine
Item Specification and Parameter
Model 4F20TCI 4F20ATCI 4F20BTCI 4F20CTCI
Type In-line, water-cooling, four-stroke, direct-injection, charge
inter-cooling, electrically controlled high-pressure common rail,
electrically controlled EGR
Mode of Air Intake supercharging type
Type of Cylinder Head dry type
Number of Cylinders 4
(mm) Cylinder Diameter (mm) 84
(mm) Piston Stroke (mm) 95
(L) Total Displacement (L) 1.995
Compression Ratio 17.5:1
Working Sequence of Cylinder 1－3－4－2
Rated Power / Rated Speed
(kW/r/min)
75/3600 60/3200 50/3200 40/3200
(N·m) Max. Torque (N·m) 223 201 170 135
Max. Torque Speed (r/min) 2400 2200
External Characteristic Min. Fuel
Specific Consumption (g/kW.h)
220
Direction of Rotation of Crankshaft anti-clockwise (viewed from flywheel end)
Mode of Lubrication force-feed and splash lubrication
Mode of Cooling forced water cooling
Mode of Start-up electric starting
(kg) Net Mass (kg) 240
Exhaust
Phase
inlet valve ON 21° crank angle before top dead center (TDC)
inlet valve OFF 36.75° crank angle after bottom dead center (BDC)
exhaust valve ON 54° crank angle before bottom dead center (BDC)
exhaust valve OFF 26.5° crank angle after top dead center (TDC)
Cold-State
Valve
Clearance
(mm) 0.20～0.25
(mm) 0.25～0.30
Max. No-Load Speed (r/min) ≤3960 ≤3520
Idle Speed (r/min) 800
Turbine Back Exhaust Temperature ≤600

8
Lubricating Oil Temperature (℃) ≤130
Optimal Effluent Water (℃) 80～90
Lubricating
Oil Pressure
at rated speed (MPa) 0.2~0.4
(MPa) at idle speed
(MPa)
≥0.05
Emission Control Device POC＋DOC
Lubricating Oil Capacity of Oil
Sump (L)
3.8
Overall Dimension: L x W x H 653×596×649
2．Tightening Moment of Main Bolts and Nuts
Part and Name Thread Specification Tightening Moment（N·m）
cylinder head stud M11×1.5 120~140
main bearing cap bolt M12 140~150
connecting rod bolt M10×1.25 60~70
flywheel bolt M10 70~80
crankshaft pulley bolt M14×1.5 120~130
fuel injector pressing plate bolt M6
torque：7~8N.m
turn by 90°～95°
high-pressure oil pipe nut at fuel
injector end
M12×1.5 27±2
high-pressure oil tube nut at rail end M14×1.5 36±2
high-pressure oil tube nut at pump end M12×1.5 20±2
speed sensor and phase sensor bolt M6 8±0.5
oil pump installation bolt M8 30±5
connecting nut of oil pump and gear
wheel
M14×1.5 70±5
3．Specification of Main Accessories of Engine
fuel injector model CRI2.2
high-pressure oil pump type CP1H
supercharger model HP48/ER21/HP50-3
generator
rated current（A） 110
nominal voltage
(V)
14
engine oil filter JX0801
diesel oil filter oil-water separator
thermostat
type 2054A wax type thermostat 2054A
opening
temperature (℃)
72±2

9
full opening
temperature(℃)
84
starter QDJ158Y/SJ13-25101
II. Fitting Clearance and Wear Limit of Main Parts
S.N. Name Standard Size (mm)
Fitting
Nature
Fit-up Gap of
New Engine (mm)
Wear Limit
（mm）
1
crankshaft connecting
rod journal and
connecting rod bush
hole
shaft Φ52h6(
0
019.0 )
hole Φ52
089.0
05.0


clearance 0.05~0.108 0.2
2
crankshaft main
journal and main
bearing bush hole
shaft Φ68h6(
0
019.0 )
hole Φ68 079.0
040.0


clearance 0.040~0.098 0.12
3
connecting rod big
end face clearance
30b11
16.0
29.0


30
10.0
0
 clearance 0.16~0.39 0.46
4
piston pin and
connecting rod small
end bushing hole
shaft Φ28h4(
0
006.0 )
hole Φ28
038.0
025.0


clearance 0.025~0.044 0.10
5
piston pin and piston
pin boss hole
shaft Φ28h4（
0
006.0 ）
hole Φ28H5(
009.0
0

)
clearance 0~0.015 0.03
6
piston skirt and
cylinder liner
shaft Φ83.91±0.010
hole Φ84
0.035
0

clearance
0.09~0.1175
0.24
7
crankshaft axial
clearance
28
065.0
145.0


28
10.0
0

clearance 0.065~0.245
8
1st piston ring
opening clearance
0.20~0.40 1.2
9
2nd
piston ring
opening clearance
0.30~0.50 1.2
10
oil ring opening
clearance
0.20~0.40 1.2
11
2nd
piston ring and
piston ring groove
ring 2
005.0
030.0


groove 2
0.06
0.04


clearance 0.045~0.09 0.12
12
oil ring and piston
ring groove
ring 3
005.0
030.0


groove 3
05.0
03.0


clearance 0.035~0.080 0.12
13
cam journal and
camshaft bushing
shaft Φ44e7(
0.050
0.075

 )
hole Φ44E7
0.075
0.050


clearance 0.1~0.15 0.20
14
camshaft axial
clearance
5c11
070.0
145.0


5
10.0
0

clearance 0.07~0.245

10
15
valve tappet and
tappet hole
shaft Φ13 032.0
043.0


hole Φ13H7（
018.0
0

）
clearance 0.032~0.061 0.10
16
rock arm shaft and
valve rock shaft
bushing
shaft Φ15
026.0
044.0


hole Φ15H7（
018.0
0

）
clearance 0.026~0.062 0.20
17
air intake valve and
valve tube hole
shaft Φ8
025.0
035.0


hole Φ8 H7（
015.0
0

）
clearance 0.025~0.050 0.14
18
exhaust valve and
valve tube hole
shaft Φ8
04.0
05.0


hole Φ8H7（
015.0
0

）
clearance 0.040~0.065 0.14
19
idle gear journal and
bushing hole
shaft Φ50f7(
0.025
0.050

 )
hole Φ50H7
0.025
0

clearance 0.025~0.075 0.20
20
idle gear end face
clearance
21.5（
12.0
07.0

 ）
21.5(
0.1
0.2

 )
clearance 0.17~0.32
21
connecting rod bolt
location section and
rod body location
hole
shaft Φ10.2f7(
016.0
034.0

 )
hole Φ10.2 F7(
034.0
016.0

 )
clearance 0.032~0.068 0.15
22
crankshaft and
crankshaft gear hole,
crankshaft and
crankshaft pulley hole
shaft Φ36
0
016.0
hole Φ36H7(
025.0
0

)
23
flywheel and
flywheel gear ring
hole
flywheel
Φ304v7(
477.0
425.0

 )
gear ring
Φ304H9(
130.0
0

)
interference -0.295~-0.477
24
crankshaft and
flywheel hole
shaft Φ80h6(
0
019.0 )
hole Φ80H7(
03.0
0

)
clearance 0~0.049
25
cylinder liner and
engine body hole
cylinder liner
Φ87
0.016
0.006


hole Φ87H6
0.022
0

transition -0.005~0.017
26
idle gear shaft and
gear chamber hole
shaft Φ16h7(
0
0.018 )
hole Φ16H7(
0.018
0

)
27
camshaft bushing and
engine body camshaft
hole
bush Φ49t9(
116.0
054.0

 )
hole Φ49H7(
025.0
0

)
28
camshaft and
camshaft gear hole
shaft Φ30js6(
006.0
006.0

 )
hole Φ30H7(
021.0
0

)
interference -0.006~0.027
29 valve tube and tube Φ13s7(
046.0
028.0

 ) interference -0.010~-0.046

11
cylinder head tube
hole
hole Φ13H7( 018.0
0

)
30
air intake valve seat
and cylinder head seat
hole
seat Φ37.5
12.0
10.0


hole Φ37.5
H7(
025.0
0

)
31
exhaust valve seat
and cylinder head seat
hole
seat Φ34
12.0
10.0


hole Φ34 H7(
025.0
0

)
32
fuel injector copper
bush and cylinder
head copper bush
hole (lower)
bush Φ12.5u8(
060.0
033.0

 )
hole Φ12.5
H7(
018.0
0

)
33
fuel injector copper
bush and cylinder
head copper head
hole (upper)
bush Φ23.5u8(
074.0
041.0

 )
hole Φ23.5H7(
021.0
0

)

12
Chapter 3 Disassembly of Engine
I. Removal of Wiring Harness Assembly
1、。 Remove connectors from
sensors of diesel engine.
2、。Remove retaining clip of wiring
harness from diesel engine with a
wrench.
3、 remove wiring harness assembly.
II. Removal of Oil Return Tube
1、。Remove oil return tube from fuel
injector.

13
2、。Loosen oil return hose clip on
high pressure oil pump with pliers.
3、remove oil return tube and oil
return tee pipe.
III. Removal of High-pressure Oil Tube Parts
1、。Loosen high pressure oil tube
nut on fuel injector.
2、。Loosen high-pressure oil tube
nut on rail.
3、。Remove high-pressure oil tube.

14
4、。Loosen oil tube clip bolt fixing
pump – rail high-pressure oil tube.
5、。Loosen nuts at ends of pump –
rail high-pressure oil tube.
6、。 Remove pump – rail
high-pressure oil tube and oil tube
clip.
7、。Protect oil inlet and outlet of
high-pressure common rail tube
with protective cap.
IV. Removal of Fuel Injector
1、。Loosen fuel injector pressing plate
bolt with inner hex wrench.

15
2、。Remove fuel injector, fuel injector
pressing plate and cushion block,
protect oil inlet of fuel injector, spout
of fuel injector and wiring harness
connecting hole with protective cover,
make signs at fuel injector, and place
the parts removed in sequence.
Removal of Warm-air Water Return Tube Weld Assembly
1、。Loosen warm-air water return
rubber tube clip.
2、。Remove warm-air water return
tube weld assembly.
Removal of Respirator Part
1、。Loosen clip connecting respirator
connecting tube and hose.

16
2 、。 Loosen connecting bolt of
respirator and mounting bracket with
wrench, undo clip connecting
respirator oil return tube and oil sump,
and then remove respirator.
3。Loosen bolts of respirator mounting
bracket.
4 、。 Remove respirator and its
mounting bracket.
Removal of Cylinder Head
1、。Loosen bolts of cylinder head with
wrench.

17
2、。Remove cylinder cover and its
spacer.
Removal of Rock Arm Shaft Part
1、。Loosen bolts of rock arm shaft
part with wrench.
2、。Remove rock arm shaft part, and
push rod.
Removal of Starter and Supercharger Part
1、。Loose fixing bolts of starter with
wrench.

18
2、。Remove starter.
3、。Unscrew bolts of supercharger
exhaust tube with wrench.
4、。Loosen clip fixing supercharger
air outlet and air outlet hose.
5、。Remove supercharger exhaust
tube and its spacer, supercharger air
outlet tube weld assembly and air
outlet hose.

19
6、。Unscrew bolts of supercharger
lubricating oil inlet tube with wrench,
and remove supercharger oil inlet
tube part.
7 、 loosen connecting bolt of
supercharger oil return tube part and
engine body with socket wrench.
8 、。 Loosen connecting bolt of
supercharger and exhaust tube with
wrench.
9 、。 Remove supercharger part,
supercharger cushion block and
spacer.

20
Removal of EGR System, Air Inlet Tube, High-Pressure Common Rail
Tube and Engine Oil Dipstick Part
1、。Unscrew bolts fixing vacuum
solenoid valve with socket wrench,
and remove vacuum solenoid valve.
2、。Loosen connecting bolt of EGR
cooler connecting tube and air inlet
tube.
3、。Loosen bolts shared by air inlet
tube and rear lug.
4、。Remove rear lug.

21
5、。Loosen air inlet tube bolt.
6、。Remove air inlet tube and its
spacer.
8、。 Loosen bolts fixing
high-pressure common rail tube,
and remove high-pressure
common rail tube.
。Note: high-pressure common rail
tube cushion block.
9、。Loosen bolts connecting EGR
tube and exhaust tube, and remove oil
dipstick and its sleeve.

22
10、。Loosen bolts fixing EGR cooler
and staple bolt of EGR tube.
11、。Remove EGR system.
。Note: EGR staple bolt and its
cushion block.
Removal of Belt, Generator, Air Pump and Vacuum Tube
1、。Loosen tension pulley bolt.
2、。Remove belt.

23
3、。Loosen generator oil return tube
bolt with wrench.
4、。Loosen generator oil inlet tube
bolt with wrench.
5、。Remove generator oil inlet tube
and oil outlet tube.
6 、。 Loosen bolts connecting
generator and its stay pole.
7、。Loosen bolts supporting generator
on gear chamber.

24
8、。Remove generator.
9、。Loosen bolts of air pump.
10、。Remove air pump and its spacer.
11 、。 Loosen bolts fixing EGR
vacuum tube, and then remove
vacuum tube.
Removal of Exhaust Tube, Thermostat, Water Pump, Tension Pulley and
Power Steering Pump

25
1、。Loosen bolts of exhaust tube.
2、。Remove front lug, exhaust tube
and exhaust tube spacer.
3 、。 Loosen hose clip connecting
thermostat and water pump with
pliers.
4、。Loosen bolts of thermostat, and
remove stay pole of generator.

26
5、。Remove thermostat and its spacer.
6、。Loosen fixing bolts of water
pump water inlet tube weld assembly.
7、。Loosen connecting bolts of water
pump and engine body.
8、。Remove water pump and its rear
cover spacer.

27
9 、。 Loosen connecting bolts of
tension wheel, and then remove
tension wheel.
crankshaft position sensor on gear
chamber cover, and remove
crankshaft position sensor.
power steering pump.
12、。Remove power steering pump.
Removal of Gear Chamber and High-pressure Oil Pump

28
1、。Fix flywheel, and unscrew bolts
of crankshaft pulley with wrench.
2、remove crankshaft pulley.
3、。Loosen bolts of gear chamber
cover.
4、。Remove gear chamber cover and
its spacer.
5、。Remove oil seal of gear chamber
cover.

29
6、。Loosen high-pressure oil pump oil
inlet tube, and remove high-pressure
oil pump oil inlet tube.
7、。Loosen bolts of oil pump gear
8、。Screw bolt into bolt hole on oil
pump gear, and pull out oil pump
gear.
9 、。 Loosen inner hexagonal bolt
fixing high-pressure oil pump.

30
10、。Remove oil pump gear and
high-pressure oil pump.
Removal of Engine Oil Temperature Alarm, Drain Cock, Engine Oil
Cooling Tube and Engine Oil Filter
1、。Remove engine oil temperature
alarm and drain cock with wrench.
2、。Loosen fixing bolts of engine oil
inlet tube weld assembly, loosen clips
of water inlet hose and engine oil
filter cooler, and remove engine oil
cooling tube weld assembly.

31
3、。Loosen bolts of engine oil filter.
4、。Remove engine oil filter and its
spacer.
Removal of Clutch, Speed Sensor and Flywheel
1、。Loosen clutch bolts.
2 、。 Remove clutch driven disc
assembly, compression disc and
cover.

32
3、。Loosen bolts fixing speed sensor
on flywheel housing, and remove
speed sensor.
4、。Fix flywheel, and loosen flywheel
bolts.
5、。Remove flywheel and its bolt tie
plate.
Removal of Cylinder Head
1、。Remove heater plug with wrench.

33
2、。Loosen bolts of cylinder head.
3、。Remove bolts of cylinder head,
and place them in sequence.
4、。Remove cylinder head assembly,
and cylinder head spacer.
Removal of Oil Sump, Gear and Gear Chamber
1、。Turn engine body by 90º or a
proper position, and loosen and
remove bolts of oil sump.

34
2、。Remove oil sump.
3、。Loosen bolts of idle gear pressing
plate.
4、。Loosen bolts of camshaft gear.
5、。Remove camshaft gear, idle gear,
idle gear shaft and crankshaft timing
gear.

35
6、。Loosen bolts fixing gear chamber.
7、。Remove gear chamber.
Removal of Engine Oil Pump and Camshaft
1、。Loosen bolts of engine oil pump
and connecting bolts of engine oil
pump oil outlet tube and engine body.
2 、。 Remove engine oil pump
assembly.

36
3、。Loosen bolts of thrust plate of
gear shaft, and remove camshaft.
。Note: remove engine oil pump
assembly before removing
camshaft.
Removal of Piston Connecting Rod Assembly
1、。Loosen bolts of connecting rod
cap with wrench, and remove
connecting rod cover.
2、。Remove piston and connecting
rod.
3、。Remove four piston connecting
rod assemblies in sequence.

37
4、。Remove check ring for hole with
special pliers, and remove piston pin.
5、。Push off piston ring by hand, and
remove piston ring.
5、。Take out connecting rod bearing
shell.
Removal of Flywheel Housing, Crankshaft, Cylinder Liner Cooling Nozzle
and Cylinder Liner
flywheel housing.

38
2、。Remove flywheel housing.
3、。Remove oil seal from flywheel
housing.
4、。Loosen bolts of main bearing
cover with wrench.
5、。Take down main bearing cover
and thrust plate, crankshaft, and main
bearing shell.

39
6、。Take out tappet.
7、。Remove cylinder liner cooling
nozzle subassembly with socket
wrench.
8 、。 Pull out cylinder liner with
special tool.

40
Chapter 4 Engine Maintenance
Before checking and measuring the engine parts, their surface should be cleaned.
If any crack, excessive wear or damage is found at check, the parts should be adjusted,
repaired or replaced as required.
Cylinder Block
Install cylinder liners into engine
body in right group order, and use
inside micrometer to measure cylinder
liner diameter. Measuring points
should be at three heights of cylinder
liner and two directions that are
perpendicular with each other. One
direction should be parallel with the
vertical axial line of the engine, while
the other should be vertical with the
one. If measured value goes beyond
the specified limit value, a new
cylinder liner should be used.
Inside diameter of group A cylinder
liners: 84.0000~84.0175;
Inside diameter of group B cylinder
liners: 84.0176~84.0350.
Note: if there is any scoring or
scraping in the cylinder liner, a new
one must be used.
Crankshaft

41
Use micrometer to measure inside
diameter of crankshaft main journal
and main bearing shell. If the
measured value of clearance between
them goes beyond the specific limit
value, a new main bearing shell must
be used.
Standard clearance: 0.04~0.098mm
Limit clearance: 0.12mm.
Camshaft
1. Use micrometer to measure outside
diameter of each camshaft journal in
two directions that are vertical with
each other. If measured value goes
beyond the specified limit value, then
a new camshaft must be used.
Standard outside diameter:
43.950~43.925mm
Limit outside diameter: 43.80
2、。Use micrometer to measure height
of air inlet and outlet cams. If cam
wear goes beyond the specified limit
value, then a new camshaft must be
used.
standard
/mm limit /mm
height of
air inlet
cam
35.35~
35.43
35.10
height of 35.51~ 35.25

42
air outlet
cam
35.59
Piston Connecting Rod Assembly
1. Clean off carbon deposit from
piston top and piston ring groove, and
check by visual inspection whether
there is any crack, scar or excessive
wear in each piston; if any, a new
piston must be used.
Use micrometer to measure dimension
of piston skirt 17mm or so from skirt
bottom, and its standard value is
83.90~83.92mm. After grouping, its
fitting clearance with cylinder liner is
0.09~0.135mm, and wear limit is
0.24mm.
2. Use micrometer to measure outside
diameter of piston pin at three
positions and in two directions. If
measured value goes beyond the
specified limit value, then a new
piston pin must be used.
Standard outside diameter:
27.994~28.000mm
Limit outside diameter: 27.980mm
3. Use inside micrometer to measure
piston pin hole. If its clearance with
piston pin goes beyond the specified
limit value, a new piston pin or piston
must be used.
Standard clearance: 0~0.015mm;

43
4. Place piston ring into cylinder liner,
push ring to be vertical with cylinder
wall with piston, and use feeler gauge
to measure clearance between piston
ring openings. If measured value goes
beyond the specified limit value, a
new piston ring must be used.
standard
/mm limit /mm
1st
ring 0.20~0.40 1.2
2nd
ring 0.30~0.50 1.2
oil ring 0.20~0.40 1.2
5、。
Install piston ring into ring groove,
and use feeler gauge to measure
clearance between piston ring and ring
groove. If measured value goes
beyond the specified limit value, a
new piston ring must be used.
standard
/mm
limit
/mm
2nd
ring 0.045~0.09 0.12
oil ring 0.035~0.08 0.12
6、Use inside micrometer to measure
inside diameter of connecting rod
small end. If clearance between inside
diameter of small end and pin does not
comply with the specified value, then
a new connecting rod bush and / or
pin must be used.

44
Limit clearance: 0.10mm
7、Install connecting rod big end into
connecting rod bearing shell, and
measure inside diameter of connecting
rod bearing shell. If clearance between
inside diameter of connecting rod
bearing shell and crankshaft
connecting rod journal does not
comply with the specified value, then
a connecting rod bearing shell must be
used.
Cylinder Head
1、。Use micrometer to measure valve
and its guide hole. If their fitting
clearance goes beyond the wear limit
value, then both valve and its guide
must be replaced together.
standard
/mm
limit
/mm
inlet
valve
0.025~0.05 0.14
exhaust
valve
0.04~0.065 0.14
2、。Check valve seat ring. If there is
any slight scratch or burn, ream it with
special reamer; and if air tightness can
still not be improved after reaming,
then use a new valve seat ring.

45
3、Use micrometer to measure swing
area of rock arm on rock arm shaft
and inside diameter of rock arm bush.
If clearance between rock arm shaft
and rock arm bush goes beyond the
specified limit value, then a new rock
arm shaft or rock arm must be used.
Standard clearance: 0.026~0.062mm;
VI. Lubrication System
Check whether the parts of the lubrication system are worn or damaged, and
whether the oil way is blocked. Clean, repair or replace them when necessary.
If the sieve on the engine oil strainer is blocked by filth, then it should be cleaned
or replaced. The filter element of the engine oil strainer should be cleaned or replaced.
VII. Cooling System
Check whether the parts of the cooling system such as water pump, thermostat,
fan and radiator are worn or damaged, and whether the oil way is unblocked or sealed.
Clean, repair or replace them when necessary.
The axial clearance between water pump impeller and water pump housing is
0.4~0.6mm.
Check whether the cooling water holes of the cylinder head and cylinder cover
are blocked; if so, they should be unblocked.
Check the fan belt for tension level; if it is not right, adjust it.

46
Chapter 5 Assembly of Engine
Installation of Cylinder Liner, Cooling Nozzle and Tappet
1、。Use gasoline to carefully clean
the cylinder liner and its hole, and
choose right cylinder liner and
piston in line with the grouped
cylinder liner holes.
cylinder
liner hole
group
cylind
er line
group
piston
group
1
IA A
IB B
2
IIA A
IIB B
。Note: At the back end face of the
engine body the cylinder head group
signs “1”, “2” and the like are printed.
The signs from left to right denote the
first, second, third and fourth
cylinders.
2 、 Push the cylinder liner into
cylinder liner hole, and use a special
tool if it is difficult to push it; besides,
force should be applied evenly and
vertically on the top of the cylinder
liner. The height of the upper plane of
Φ92 dead center projecting above the
upper plane of the engine body is
0.02~0.10mm, and it varies within

47
0.05mm in the same diesel engine.
3 、。 Install piston cooling nozzle
subassembly and tighten it with
socket wrench.
4、。Lubricate tappet with lubricating
oil, and place tappet into its hole.
Installation of Crankshaft, Thrust Plate and Main Bearing Cap
1、clean engine body, crankshaft, main
bearing shell, thrust plate, main
bearing cover
2、。Install upper part of main bearing
shell, and smear lubricating oil onto
oil groove of main bearing shell.

48
3、。Lift crankshaft into upper part of
main bearing shell.
4 、。 Install upper thrust plate of
crankshaft at sides of gear-5 main
bearing seat.
。Note: the side of the thrust plate with
oil groove faces out.
5、。Smear lubricating oil onto thrust
plate.
6、。Install lower part of main bearing
shell into main bearing cap, and smear
lubricating oil onto it.
7 、。 Install lower thrust plate of
crankshaft at sides of gear-5 main
bearing seat.
。Note: the side of the thrust plate with
oil groove faces out.

49
8 、。 Smear lubricating oil onto
crankshaft main journal.
9、。Install main bearing caps from
front end of engine body according to
sequence mark made on main bearing
caps, and allow the direction of upper
arrow of main bearing caps point to
gear chamber end.
10、。Use torque wrench to tighten
bolts of main bearing caps in order
from the 3rd
main bearing cap to the
sides three times, and the tightening
moment is 40 N·m, 90 N·m and
140~150N·m respectively.
。Rotate crankshaft 2~3 turns to check
whether it can rotate freely; if not,
adjust it by loosening main bearing
caps.

50
11、。Turn crankshaft by hand in axial
direction, and check whether some
axial float exists in crankshaft, and
axial clearance should be
0.065~0.245mm, or else a new thrust
plate should be used.
Installation of Flywheel Housing and Flywheel
flywheel housing oil seal.
。Note: A new oil seal should be used
after a old one is removed.
2、。Use special tool to press oil seal
into flywheel housing.
3、。Install flywheel housing spacer,
and smear it with sealant.

51
crankshaft rear end journal
4 、。 Install flywheel housing, and
tighten bolts of flywheel housing in
sequence as shown in the figure.
5 、 Remove the part of flywheel
housing spacer protruding from the
lower plane of the engine body with
shovel blade, or else the sealing
property of contact surface of oil
sump and engine body may be
reduced.
6、N·m。Use torque wrench to tighten
bolts of flywheel three times in
sequence as shown in the figure, with
tightening moment of 70~80 N·m.
Installation of Gear Chamber, Camshaft, High-pressure Oil Pump and

52
Gear System
1、。Turn engine body by 180º, smear
both sides of gear chamber spacer
with sealant, and install it onto engine
body.
2、。Install gear chamber, and tighten
its bolts with wrench.
4、。Install timing idle gear shaft.
idle gear shaft functions to fix gear
chamber）
4、。Remove the part of gear chamber
spacer protruding from the lower
plane of the engine body with shovel
blade, or else the sealing property of
contact surface of oil sump and engine
body may be reduced.
5 、。 Smear camshaft journal with
lubricating oil.

53
6、。Install camshaft into engine body.
7、。Install camshaft thrust plate, and
tighten bolts of thrust plate.
8、。Install camshaft gear, and tighten
bolts of camshaft gear ring with
moment of 85±5 N·m. Turn camshaft
by hand in axial direction, and
measure axial clearance of camshaft,
which should fall within
0.07~0.245mm.
9、。Press high-pressure oil pump into
installation hole of oil pump of gear
chamber by hand.

54
10、。Tighten bolts of high-pressure oil
pump with inner hexagonal wrench,
with moment of 30±5 N·m.
11、。Install camshaft timing gear, idle
gear, fuel injection pump gear, paying
attention to gear pairing signs.
12、Install pressing plate of timing idle
gear, and tighten its bolts, with
moment of 25±2 N·m; and tighten
connecting nuts of oil pump and gear,
Note: after pressing plate of timing
idle gear is properly pressed, check
whether idle gear can be moved in
axial direction, and turn flywheel to
see whether crankshaft can run freely.
End face clearance of idle gear should
be 0.17~0.32mm.
Installation of Piston Connecting Rod Assembly
1、Clean all parts.

55
2、Install piston ring by hand or using
special tool.
。Note: when installing oil ring, make
oil ring spring joint to form 180° with
oil ring opening, and allow the side of
air ring engraved with letters.
3、。Smear piston pin with lubricating
oil, and install it together with
connecting rod.
4、Use clamp spring pliers to install
spring ring for piston pin hole.
5、。Smear piston ring with lubricating
oil, and turn piston ring, so that
lubricating oil is evenly distributed in
piston ring groove. After assembled in
ring groove, piston ring should turn
freely, free of seizure. And smear
lubricating oil where piston ring
connects with connecting rod small
end.
6 、 Adjust position of piston ring
opening, to make direction of oil ring
opening be vertical with piston ring in

56
axial direction. Openings of three
rings should be separated by 120°, and
they should not be in the direction of
piston pin hole.
7、。Install connecting rod bush into
connecting rod and its cover, and
place piston connecting rod assembly
into cylinder.
。Notes: (1) Outer circle of piston skirt
should be in line with cylinder liner
grouping; (2) arrow head on piston top
should point to gear chamber end; if
there is no arrow head thereon, the
eccentric side of combustion chamber
should face the installation side of fuel
injector.
8、。Place piston slide bushing onto
piston connecting rod assembly, and
push piston connecting rod assembly
to the right position.
9、。Smear lubricating oil onto inside
of connecting rod cover of connecting
rod bush.

57
10、。When installing connecting rod
bush, pay attention to pairing signs on
connecting rod body and its cover, and
install connecting rod cover correctly.
11 、。 Use bush rocker to tighten
connecting rod bolts, until connecting
rod cover engages with connecting rod
body totally, and then use torque
wrench to tighten connecting rod bolts
twice to torque of 60~70 N·m.
Installation of Engine Oil Pump and Flywheel Housing
1、。Install engine oil pump assembly
in installation position of engine oil
pump, and provide spacer where oil
outlet tube of engine oil pump
connects with engine body.
2、。Tighten installation bolts of engine
oil pump, with moment of 15~20
N·m.
3、。Tighten engine oil pump with
inner hexagonal wrench, with moment
of 15~20 N·m.

58
4、。Place oil sump spacer onto oil
sump, and smear sealant onto sides of
oil sump spacer.
5、。Install oil sump onto engine body,
and tighten bolts of oil sump, with
moment of 25±5N·m.
Installation of Cylinder Head Assembly and Cylinder Head Cover
1、。Clean all parts.
2、。Smear lubricating oil onto valve
stem, and install valve into cylinder
head.
。Note: Do not mix inlet valve and
outlet valve when installing them.
3、。Install valve stem seal ring (valve
protection cap) onto valve guide, and
properly install valve seal ring with
special tool.

59
4、。Place valve spring and its upper
seat onto valve stem, and by pressing
valve spring upper seat with special
tool install valve lock clamp.
5 、。 Place engine straight, install
positioning sleeve, and then put
cylinder head spacer onto engine
body.
。Note: The lubricating oil hole in
cylinder head spacer should be in
alignment with that in engine body,
and wrong placement of spacer should
be avoided.
6、。Lift cylinder head assembly onto
engine body, smear bolts of cylinder
head, and install them into bolt hole of
cylinder head.
。Note: Close attention should be paid
to installation position of short and
long bolts of cylinder head, and

60
installation position of cylindrical pin
bolts.
7、。Use torque wrench to tighten bolts
of cylinder head three times in
sequence as shown in the figure. The
last tightening moment should be
120~140 N·m.
8、。Smear sealant onto heater plug,
install heater plug, and tighten it with
wrench.
9、。Install rocker arm seats and inlet/
outlet valve rocker arm in right
sequence, and assemble rocker arm
shaft parts.
。Note: The front and rear rocker arm
seats should be rightly installed, and
both inlet and outlet valve rocker arms
should be installed in right position.
10、。Smear lubricating oil onto push
rod, place it into its hole, make lower
part of push rod be in good contact
with tappet, and fill lubricating oil into
groove at upper end of push rod.

61
11、。Install rocker arm onto cylinder
head, and place valve clearance
adjusting screw into groove on the top
of push rod.
12、。Tighten fixing bolt of rocker arm
shaft, turn flywheel, loosen valve
clearance adjusting screw, and use
feeler gauge to adjust valve clearance.
Inlet valve clearance should be
0.20~0.25mm, and outlet valve
clearance should be 0.25~0.30mm.
After that, tighten valve clearance
lock nut, with moment of 20±5 N·m.
13 、。 Install cylinder head cover
spacer, and smear sealant onto sides of
cylinder head cover spacer.
14、。Install cylinder head cover, and
tighten its bolts, with moment of 20±2
N·m.
Installation of Exhaust Tube, Gear Chamber Cover, Crankshaft Pulley
and Power Steering Pump

62
1、。Install upper and lower spacers of
exhaust tube rightly.
2、。Install exhaust tube and front lug,
and tighten nuts of exhaust tube, with
moment of 30±2 N·m.
3、。Install vacuum tube.
4、。Install air pump spacer, smear its
sides with sealant, and install air
pump, paying attention to pairing sign
on air pump gear. Tighten fixing bolts
of air pump, with moment of 30±2
N·m.

63
5、。Smear lubricating oil onto gear
chamber cover oil seal, and press oil
seal into gear chamber cover with
special tool.
6、。Install gear chamber cover spacer,
and smear its sides with sealant.
7、。Install gear chamber cover, tighten
bolts of gear chamber cover, and
install wiring harness retailing clip on
one screw. Install camshaft position
sensor, and tighten bolts, with moment
of 8±0.5 N·m.
crankshaft pulley journal.

64
9 、。 Install crankshaft pulley onto
crankshaft, and tighten bolts of
crankshaft pulley with torque wrench
to 120~130 N·m.
10、。Install power steering pump, and
tighten fixing bolts of steering pump,
IX. Installation of Water Pump, Thermostat, Tension Wheel, Generator
and Belt
1、。Install water pump spacer, install
water pump onto engine body, fix
water pump water inlet tube weld
assembly onto gear chamber cover
with bolts, and place cushion block at
fixing bolts.

65
2、。Install thermostat housing spacer
onto cylinder head, install thermostat,
and tighten thermostat bolts. Install
generator stay pole, and clamp small
circulation tube with clip.
3、。Install tension wheel onto gear
chamber cover, and tighten bolts, with
4、。Install generator assembly, and
tighten long bearing bolts, with
moment of 40±2 N·m. Tighten fixing
bolts of generator stay pole, with

66
5、。Install and tension belt.
。Tension check: on generator pulley
and crankshaft pulley bracket, apply
50~60 N onto belt. The belt should be
pressed down within 11~13mm from
its original position.
6、。Install generator oil inlet tube and
oil return tube, and tighten bolts and
nuts of oil inlet and return tubes. Oil
inlet tube connects generator and air
pump.
Installation of High-pressure Common Rail Tube, Air Inlet Tube, Engine
Oil Filter, Drain Cock, Engine Oil Temperature Alarm and Engine Oil
Cooling Tube
1、。Install high pressure common rail
tube, place rail cushion block between
common rail tube and cylinder head,
and fasten it with bolts, with moment
of 20±2 N·m.

67
2、。Install air inlet tube spacer and air
inlet tube, tighten bolts of air inlet
tube (two bolts are shared by warm-air
water return tube), with moment of
20±2 N·m, and also install rear lug.
3、。Install engine oil filter spacer and
engine oil cooling filter assembly, and
tighten fixing bolts of engine oil filter.
4 、。 Install engine oil temperature
alarm and drain cock.
5、。Install engine oil cooling tube
weld assembly, and clamp other hoses
of engine oil filter cooler with clip.
Installation of EGR System

68
1、。Install EGR flange spacer and
EGR system assembly, and tighten
flange bolts.
2、。Install oil dipstick sleeve when
installing bolts between EGR tube and
exhaust tube.
3、。Install high pressure oil pump oil
inlet tube weld assembly when
installing fixing bolts of EGR cooler,
and clamp hose between oil pump and
oil inlet tube weld assembly with clip.
4、。Install EGR tube staple bolt and its
cushion block onto flywheel housing,
and tighten and fix flywheel and EGR
vacuum tube and wiring harness
retaining clip together with bolt.

69
5、。Install vacuum solenoid valve onto
rear lug, and tighten it with bolt. Use
EGR hose to connect EGR valve,
vacuum battery valve and vacuum
tube rightly, with reference to
connection signs on vacuum solenoid
valve.
Installation of Supercharger Assembly, Starter Assembly and Respirator
Assembly
1、。Install supercharger cushion block
at air outlet of exhaust tube, and
install spacers at sides of cushion
block.
2、。Install supercharger, and tighten it
with lock nut, with moment of 30±2
N·m.
3、。Install supercharger oil return tube
and spacer, and tighten fixing nuts of
oil return tube, with moment of 10±2
N·m.

70
4、。Install supercharger oil inlet tube,
and tighten bolts of oil inlet tube, with
5 、。 Install starter assembly, and
tighten fixing bolts of starter, with
6、。Install supercharger exhaust tube
and spacer and supercharger air outlet
tube weld assembly, and tighten bolts
of exhaust tube. Fix supercharger air
outlet tube weld assembly bracket and
exhaust tube together.
7 、。 Install supercharger air outlet
hose, and fix it with clip.

71
8、。Install air-oil clutch (respirator)
bracket, and fix it onto cylinder head
with bolt.
9、。Install respirator, connect it to its
tube with hose, and clamp its tube
with hoop. Install respirator oil return
hose, and clamp it with loop.
10,、。Connect respirator oil return
tube to oil sump, and clamp it with
loop.
Installation of Fuel Injector, High Pressure Oil Tube, Warm-air Water
Return Tube and Fuel Injector Oil Return Tube
1、。Install fuel injector, fuel injector
pressing plate connecting plate and
fuel injector pressing plate. The big
inclined plane of connecting plate
should face out.

72
2 、。 Install spherical washer onto
pressing plate, use torque wrench to
tighten inner hexagonal screws of
pressing plate with moment of 7~8
N·m, and turn wrench further by
90°~95°.
3、。Use special wrench to tighten nuts
of high-pressure oil tube at fuel
injector end, with moment of
27±2N·m.
4、。Use special wrench to tighten nuts
of high-pressure oil tube at rail end,
with moment of 36±2N·m.
5、。Install warm-air water return tube
weld assembly, tighten bolts, onto one
bolt install wiring harness retaining
clip, connect water return tube nipple
to water pump, thermostat, EGR
cooler and engine oil cooler through
hose, and clamp them with hoop.
6、。Clamp pump-rail high-pressure oil
tube with rubber ring and oil tube clip,
and fix it onto air inlet tube with bolt.

73
7 、。 Use wrench to tighten
high-pressure oil tube nuts at rail end,
8。Use special wrench to tighten nuts
of high-pressure oil tube at pump end,
9、。 Press fuel injector oil return tube
onto fuel injector oil return port by
hand.
10、。Connect fuel injector oil return
tube to high-pressure oil pump oil
return hose through T tube, and clamp
them with clip.
Installation of Speed Sensor, Wiring Harness and Clutch Assembly
1、。Install speed sensor, and tighten
speed sensor for the ECU with bolt,
with moment of 8±0.5N·m; speed
sensor should be installed 0.5~1mm
from flywheel gear ring.

74
2、。Install wiring harness, tighten and
fix wiring harness onto warm-air
water return tube weld assembly and
cylinder head cover with bolt, connect
wiring harness connector to relevant
sensor, and fix wiring harness with
retaining clip.
3、。Fix clutch driven disc assembly
onto flywheel with fixing mandrel.
4、。Fix clutch compression disc and
its cover onto flywheel with bolt, and
tighten bolts on the cross to 25±2N·m.

75
Chapter 6 Electrically Controlled High-Pressure Common
Rail System
The electrically controlled high-pressure common rail technology refers to an oil
supply method in which the generation of the injection pressure and the injection are
totally independent from each other, in the closed-loop system comprising the
high-pressure oil pump, pressure sensor and ECU. The high pressure fuel oil is
pumped into the common oil supply tube by the high-pressure oil pump, and in this
way precise control can be exercised over the oil pressure inside the common oil
supply tube. The oil injection system of this kind can ensure that the injection pressure
does not vary with engine speed, and so the defects in the traditional diesel engine can
be greatly reduced. It follows the pressure-time metering principle rather than the
general pulsation theory. The high-pressure common oil duct is coupled with the
cylinder injection solenoid valve control, and the last pulse of the controller is used to
introduce the injection signal into the solenoid valve to activate an injection, and the
oil level control is realized through the nozzle storage pressure and opening duration;
and the injection pressure can reach 145MPa.
The electrically controlled common rail fuel injection technology of the diesel
engine integrates the computer control technology, modern sensing and detection
technology and advanced fuel injection mechanism. Its main features are embodied as
follows: the modern sensing and detection technology is used to measure the main
parameters of the diesel engine in actual operating conditions, such as diesel engine
speed, torque, power, oil temperature, oil pressure, water temperature, supercharging
pressure, etc, and transfer them to the ECU; the ECU compares these measured
parameters with the optimized operating MAPs of the diesel engine that have been
input in advance; and the optimum value is got by calculation, based on which the
pressure of the fuel oil rail (common oil supply tube), opening time and duration of
the high-speed solenoid of the fuel injector and injection frequency of the fuel
injection, to make the diesel engine work in the best working condition. The electrical
pulses generated by the ECU triggers the fuel injector solenoid valve in sequence, in

76
which way the starting and ending time of each fuel injection of the engine can be
decided, and the fuel injection rate and frequency can be flexibly controlled. The
common rail injection structure causes unvaried high-pressure fuel oil, directly or
indirectly, through the common oil supply tube, and distributes it to each fuel injector.
The high-speed solenoid on-off valve features high frequency, flexible control, easy
transplantation of system structure and wide scope of application. And the technology
can make sure that the diesel engine can realize best air/ fuel ratio and good
atomization.
The high-pressure common rail system comprises the fuel tank, diesel oil filter,
high-pressure oil pump, rail, electrically controlled fuel injector, high-pressure oil
tube, low-pressure oil return pipe, etc.
The high-pressure fuel oil supplied by the high-pressure oil pump is stored in the
common rail tube, and the ECU sends signal to the fuel injector to control injection
timing and fuel charge; and the high-pressure oil pump contains the gear oil delivery
pump in it; and the diesel oil filter has the oil-water separation function; and the fuel
injector can provide electrically controlled injection based on the engine status signal
made by the ECU.
ECU (EDC17)
Fuel oil filter
High-pressure oil pump
Rail
Oil tank
Fuel injector
Engine speed, camshaft position, air flow,
accelerator position, temperature sensor
Rail pressure sensor
High-pressure Common Rail System

77
Initial Air Exhaust and Oil Filling of Fuel Oil System before
Start-up of Diesel Engine
Dry running is not allowed for the high-pressure pump, lest the inside dry
friction might cause wear and tear and even damage in the parts. Before a new engine
is installed, air should be expelled from the low-pressure loop of the fuel oil system,
and then 60ml is filled to lubricate the oil pump.
Steps:
1. Loosen air exhaust nut;
2. Press hand pump, until diesel and air are expelled from air exhaust nut.
3. Tighten air exhaust nut;
4. Diesel oil entering the pump can be used to lubricate the oil pump.
Notes:
The hand pump of the fuel oil filter is only allowed to move up and down to
pump oil, and no tightening or loosening is allowed.
After expelling air from the low-pressure oil way of the fuel oil system, make
sure that all joint clips are properly fastened, to avoid leakage.
Do not allow diesel oil to pollute engine, use drip pan to collect dripping diesel
oil at exhaust, and properly dispose of waste diesel oil.

78
Chapter 7 Supercharger
Supercharger Structure
Use
1、Start
（1）。After the engine is started, the pressure at the oil inlet of the supercharger
should be closely observed, and there must be pressure within 3 sec; if not, the
supercharger may be burned out due to absence of lubricating oil.
（2）。After started the engine should be allowed to run under no load for over 5min,
until the pressure and temperature of the lubricating oil become normal basically, and
then it is permitted to run under load. At low air temperature, the dead time can be
properly extended.
（3）。After the lubricating oil is replaced, and the filter is cleaned, the filter should be
filled with clean lubricating oil. Then make the oil inlet joint loose, and fill the
lubricating oil into the oil inlet of the supercharger. Before starting an engine that is
out of service for over one week, please loosen the oil inlet of the supercharger and
then fill the lubricating oil.
2、Run

79
（1）。The pressure at the oil inlet of the supercharger should be kept at 200 ~ 400kPa
during running.
（2）。Check the supercharger for abnormal noise or vibration from time to time; if
any, remove them.
（3）。Closely observe the pressure and temperature of the lubricating oil of the
supercharger; neither the turbine inlet temperature nor the supercharger speed can go
beyond the specified value; if not, find out the cause, and remove the trouble.
3、Stop
。When running at high speed under full load, the engine is not allowed to stop at
once, except in emergency cases. Gradually reduce the speed and load, and then run it
under no load for 5min, before stopping it, to avoid damage to the supercharger due to
over heat or oil starvation.
。The mode of operation of “acceleration – shut-down – coasting in neutral” is
not allowed for the vehicle engine. The lubricating oil pump does not work, when the
engine stops. At high temperature, the supercharger may be damaged, if no circulating
lubricating oil takes away heat.
Routine Check and Service
。To make the supercharger work normally, frequent service must be given to the
supercharger and supercharging system.
1、。Check whether the inlet and outlet pipes of the air compressor are in good
condition; if any crack or air leak is detected, they should be promptly removed. If the
inlet pipe breaks, the air may enter the air compressor through the crack, and the
foreign substances going with it can cause damage to the air compressor impeller; and
if the outlet pipe breaks, and in it air leaks occurs, the air entering the engine cylinder
may be not enough, as a result of which poor combustion can take place.
2、。Check whether the oil inlet and outlet pipes of the supercharger are in good
condition; if leakage occurs, remove it promptly.
3、Check all bolts and nuts of the supercharger; if they become loose, tighten
them promptly. In particular, check whether the bolts of the inlet flange of the vortex
housing of the supercharger get loose; if so, the supercharger may be damaged due to

80
vibration. Besides, gas may also leak, leading to reduced speed and then inadequate
air supply.
4、。If any abnormal noise is detected in the supercharger, it should be stopped to
find out the cause and remove the trouble. Before the cause is ascertained, it is not
allowed to run any more, lest the engine and supercharge might be damaged.
5、。Check and replace the lubricating oil on a periodical basis, as required by the
engine manual.

81
Chapter 8 Charge Inter-cooling System
The charge inter-cooling system comprises the exhaust tube, supercharger,
intercooler, inlet tube, pipeline, etc.
The supercharger uses the exhaust energy from the engine to drive the turbo
wheel to run at high speed, which in turn drives the compressor impeller located at the
same shaft as the turbine to run. The supercharger is installed on the exhaust tube of
the diesel engine. The exhaust expelled from the diesel engine comes into the turbine
housing of the supercharger to drive the turbo impeller to run, and the turbo impeller
drives the compressor impeller to run. The air filtered by the filter is sucked into the
air compressor, which compresses the air in it and then sends it to the intercooler to be
cooled (both density and temperature of the air that is compressed are raised at the
outlet of the air compressor), and the cooled air enters the cylinder to be burned.
Use the exhaust gas turbocharger with bleed valve.
The intercooler should be placed before the radiator or in a windward place
where easy placement can be realized, to reduce the temperature of the air entering the
cylinder, improve the combustion in the diesel engine, and enhance the performance
of emission of the diesel engine.
The intercooler is a gilled tube radiator, and it uses the air-to-air cooling method.
Its inside cavity is for the compressed air to flow through, and its outside is involved
in heat exchange with the ambient air. The intercooler is installed before the water
tank, and the gas temperature at the outlet of the supercharger compressor is reduced
by using the fan to cool down the inter-cooling radiator while the car is running, so as
to increase the gas filling efficiency of the diesel engine, improve the combustion of
the diesel engine, raise the output power, and reduce the emission.

82

83
Chapter 9 EGR System
The exhaust gas recirculation system (“EGR”) means that a small portion of
burned gas is guided from the exhaust tube into the inlet tube and mixed with fresh
gas, to raise the exhaust gas content in fresh gas, and so reduce the combustion
temperature of the engine and the emission of nitrogen oxide (NO). The task of the
system is always keeping the best waste gas recirculation volume, so as to realize the
most ideal combustion.
The accurate EGR rate is controlled by the ECU, and in the ECU the best
working condition of the EGR in all kinds of operating conditions of the engine is
stored, usually called the EGR MAP. The ECU can, based on the accelerator position,
engine speed, clutch pedal and water temperature signals, supply the best EGR rate
(namely waste gas quantity) for the engine in different operating conditions, to meet
the engine emission and performance requirements.
The system uses the inter-cooling method to cool down the re-circulating waste
gas, reduce the waste gas temperature, and increase the recirculation rate.
The system uses the closed-loop control, and control ON and OFF of the EGR
valve by means of vacuum.

84

85
Chapter 10 Starting System
Starting Circuit
。The starting system comprises the battery, starting motor, starting switch,
starting relay, etc, all of which are connected as shown in the figure below. The figure
is a detailed illustration of the starting circuit.

86

87
Starting Motor
The starting system uses the magnetic deceleration starting motor, whose shaft
can be used as a pinion shaft. When the starting switch is turned on, the magnetic
switch contact is closed, and so the armature is driven. At the same time, the movable
mandrel is drawn, and the shift lever pushes the pinion forward to engage with the
gear ring. And then the gear ring runs to start the engine. When the engine is started,
and the starting switch is turned off, the movable mandrel returns to its position. The
pinion disengages from the gear ring, and the armature stops rotating. When the
engine speed is higher than that of the pinion, the latter runs idle, and so the armature
is not driven.
see the figure below for the structure of starting motor.
disassembly sequence
1. lead wire 2. through bolt 3. yoke iron assembly 4. yoke iron cover 5.
carbon brush and carbon brush bracket 6. armature 7. drive end box body 8.
overrunning clutch 9. return spring 10. steel ball 11. small idler gear 12.
retainer 13. roller 14. magnetic switch
assembly sequence
。Assembly sequence is contrary to disassembly sequence.

88
Trouble Judgment of Starting Motor
1、starter does not run
Causes: lack of power of battery;
Wire joint getting loose;
Electric capital being too dirty;
Switch contact is burned or can not be closed;
Open circuit, short circuit or grounding circuit in field winding or armature
winding;
Judgment: If the battery contains sufficient charge, and the wiring is good, then
the trouble lies in the starter itself or switch. Use the starter to connect the
two binding posts of the starter switch. If the starter can run well, then the
trouble lies in the switch; if the starter can still not run, then the trouble
lies in its inside. If no spark is made when starter is used for connection,
it indicates that open circuit exists inside the starter; if great spark is made,
and the starter does not run, it shows that either open circuit or grounding
circuit exists inside.
2、starter runs weakly
Causes: wear and tear in brush or insufficient pressure of brush spring causes poor
contact of brush;
Local short circuit happens in field winding or armature winding;
Starter switch contact is burned out.
3、drive gear cannot engage with flywheel, and impact sound is made
Causes: starter drive gear or flywheel gear is worn or damaged;
Switch closes so early that starter starts to run before drive gear engages.
4、starter idles
Cause: one-way clutch skids.

89
Chapter 11 AC Generator
Generator Structure Chart
I. Structure
180-2400 generator is a W pile head 11-tube AC generator. Its rated voltage is 14V,
and its rated current is 80A. It mainly consists of rotor assembly, front cover assembly,
excitation winding assembly, stator assembly, rear cover assembly, etc.
Schematic Diagram of Electric Output of Generator

90
II. Use and Service
While the generator is in service, close attention must be paid to the aspects as
below:
1. The battery poles must not be wrongly connected, lest the silicon diode might be
quickly burned out.
2. The wires in the charging system should be firmly and reliably connected, lest the
circuit might break abruptly and cause transient over voltage, and so the transistor
element can be burned out.
3. The generator and the regulator should match in terms of type and model.
4. While the generator is in service, the “test fire” method (one end of the wire is
connected to “+” terminal of the generator, and the other is grounded) is not allowed
to check whether the generator works normally.
5. When the semiconductor device is replaced, the power of the electric iron should be
less than 40W, and the operation shall happen quickly, to avoid damage the elements.
6. While the generator is working normally, no connecting wire of the electric
equipment can be removed without permission.
III. Inspection and Maintenance of Common Troubles
Trouble Location Cause Method
total charging
failure (charging
indicator lamp ON)
wire wire is broken or shorted repair
ammeter wrong wiring alter connection
generator
does not
produce
power
1、diode is damaged replace
2、open circuit or short circuit in stator
or excitation winding, or poor insulation
of ground wire or binding post
replace or repair
3、regulator is damaged replace
over small charging
current (starting
performance gets
poor, and light
dark)
wire loosened joint repair
generator
does not
produce
adequate
power
1、over loose generator belt adjust
2、diode damaged (some) replace
3 、 local short circuit in excitation
winding, local short circuit in stator
winding, or joint opening
replace or repair
instable charging
current (charging
indicator lamp
flashes)
wire wire gets loose, or in poor contact repair
generator
1、over loose generator belt adjust
2、trouble in excitation winding or stator
winding
repair or replace
3、binding post gets loose or is in poor
contact
repair
over big charging
current (filament is
easily broken, and
electrolyte is over
quickly consumed)
regulator
over
adjusted
value
1、improper adjustment re-adjust
2 、 dirty, poor contact
(high-speed contact)
repair
3、poor contact
repair
abnormal noise in
generator
generator
1、improper installation of generator repair
2、generator bearing is damaged or gets
loose
replace
3、rotor assembly collides with stator repair or replace

91
assembly
4、short circuit or open circuit in diode replace
5、open circuit in stator winding replace or repair
speed pointer of
instrument does not
move or is not
stable
wire wiring harness and connector get loose repair
tachometer instrument damaged
replace
tachometer
generator seized generator
1、foreign substance falls into electric
motor
remove foreign
substance
2、others
replace
generator

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