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Great Wall GW4D20, Maintenance Manual

The Great Wall GW4D20 Maintenance Manual is a comprehensive guide for maintaining your vehicle in top condition. Get your free download of this essential manual from our website, ensuring you have all the information you need to keep your GW4D20 running smoothly for years to come.

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Chapter XI Electrical System 

 

 

 

Great Wall Baoding Internal Combustion Engine   
Manufacturing Company Limited 

477 

 

3. On-board Maintenance 

 

Fig. 11-3-10 Removal and reinstallation procedures of the generator assembly 

 

Removal procedure 

①

  Generator terminals and 

harness plug 

②

 Generator belt 

③

 Generator assembly 

Reinstallation procedure 
Reinstalling them in the 
opposite order of removal

 

Summary of Contents for GW4D20

Page 1: ...GW4D20 GW4D20B MAINTENANCE MANUAL OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES Edited by Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited GREAT WALL ENGINES...

Page 2: ...shooting maintenance disassembly and assembly adjustment repair and other related information of the GW4D20 GW4D20B turbocharged diesel engines so as to provide reference for the related maintenance p...

Page 3: ...the diesel engine or the parts supplied by auto and machinery manufacturers please refer to the maintenance manual of the vehicle or machinery carrying the engine For your life and property security...

Page 4: ...ss or damage caused by using this manual Our company has its authorized repair stations in various regions users can get consultation and after sale service from the nearest authorized repair station...

Page 5: ...ical Information of Engine 9 Section I Structure of Engine 9 1 Cylinder head and cylinder body 9 2 Crank and Connecting Rod Mechanism 9 3 Valve Actuating Mechanism and Intake Exhaust System 9 4 Turboc...

Page 6: ...2 Technical Maintenance Contents 37 3 Technical Maintenance for Air cleaner 40 4 Technical Maintenance for Oil Supply System 41 5 Technical Maintenance for Fuel Lubrication System 43 6 Technical Maint...

Page 7: ...Mounting Assembly 75 14 Timing Mechanism Mounting Assembly 1 76 15 Timing Mechanism Mounting Assembly 2 77 16 Fuel Supply System Mounting Assembly 1 78 17 Fuel Supply System Mounting Assembly 2 79 18...

Page 8: ...or Overhigh Charging Current of Generator 108 19 Insufficient Capacity Difficulty in Starting or Overhigh Self Discharge of the Storage Battery109 Section II Malfunction Diagnosis 110 1 Start up syste...

Page 9: ...ction I General 384 1 Components of Fuel Supply System 384 2 Components of High Pressure Common Rail System 386 Section II On Board Maintenance 400 1 Fuel Filter Assembly 400 2 Fuel Injector Assembly...

Page 10: ...earance of the rotor 456 Chapter X Electronic Control EGR System 457 Section I General 457 Section II On board Maintenance 458 Chapter XI Electrical System 462 Section I Storage Battery 462 1 Storage...

Page 11: ...d be prepared before operation and their functions 3 Repair Procedures Most repair processes begin with an overview illustration which identifies all parts and how they are disassembled and assembled...

Page 12: ...g the Clutch Assembly This form provides a shortcut for the experienced technical personnel to obtain the data required The work task title on the top makes the content of repair clear at a glance whi...

Page 13: ...etermination in order to find the engine problems or malfunctions Washing cleaning clean up without dust oil stain etc Tightening fastening make an object rotate to fix or secure it the object is fixe...

Page 14: ...mage detected after the engine is disassembled Records and conclusions of technical appraisal for major parts Registration of replacing with new pieces and repaired pieces Results of quality tests dur...

Page 15: ...ggles Section V Main Contents of Maintenance Process Regulation The contents of the maintenance process regulation for the engine are as follows 1 The procedure sequence and detailed operation content...

Page 16: ...al without twisting or prying it 3 4 Clean the battery terminal and the cable connection terminal with special cleaning cloth do not scrape them with a file or other abrasive objects 3 5 Unscrew the n...

Page 17: ...proper locations 10 1 If the vehicle is to be jacked up only at the front or rear end be sure to block the wheels at the opposite end in order to ensure safety 10 2 Be sure to hold the vehicle with a...

Page 18: ...ed with the mobile communication system such as the two way wireless communication equipment and cellular phone the following precautions should be observed 1 Install the communication antenna away fr...

Page 19: ...is the foundation and framework of the diesel engine 2 Crank and Connecting Rod Mechanism For the crank and connecting rod mechanism of engine see Fig 2 1 2 The crank and connecting rod mechanism can...

Page 20: ...el injected into the cylinder increases and the fuel burns more fully and therefore the power per liter and output power of the diesel engine are improved Fig 2 1 6 Fuel Supply System 5 Fuel Supply Sy...

Page 21: ...e is as shown in Fig 2 1 9 With the action of external force the startup device makes the stationary diesel engine begin to rotate before it can rotate independently The startup device is constituted...

Page 22: ...1 Front View of GW4D20 Turbocharged Diesel Engine Assembly Equipped with Delphi Common Rail System 1 Accessory Tension Pulley Assembly 2 Generator Assembly 3 Generator Belt 4 Power Steering Fuel Pump...

Page 23: ...r View of GW4D20 Turbocharged Diesel Engine Assembly Equipped with Delphi Common Rail System 1 Clutch Assembly 2 Starting Motor Assembly 3 EGR Condenser Assembly 4 EGR Valve Assembly 5 Fuel Inlet of H...

Page 24: ...esel engine assembly see Fig 2 3 3 Fig 2 2 3 Left View of GW4D20 Turbocharged Diesel Engine Assembly Equipped with Delphi Common Rail System 1 Refrigeration Compressor Assembly 2 Water Inlet 3 High Pr...

Page 25: ...ngine assembly see Fig 2 2 4 Fig 2 2 3 Right View of GW4D20 Turbocharged Diesel Engine Assembly Equipped with Delphi Common Rail System 1 Engine Lifting Hook 2 Turbocharger Assembly 3 Air Outlet of Ai...

Page 26: ...quipped with Delphi Common Rail System 1 Fuel Injector Assembly 2 Suppercharger Assembly 3 Water outlet Pipe Component 4 Heater Water Return Pipe Component 5 High Pressure Fuel Rail Pressure Sensor 6...

Page 27: ...ding to the national standards 1 15min power the Max effective power of engine when the engine constantly rotates for 15 minutes under the standard environmental condition 2 1h power the Max effective...

Page 28: ...andards to protect the normal ecological environment for human beings The poisonous gases produced by the engine during working mainly come from the exhaust gas blowby from the crankcase and vaporized...

Page 29: ...que property curves of the GW4D20 turbocharged diesel engine see Fig 2 4 1 Fig 2 4 1 Power Torque Property Curves of GW4D20 Turbocharged Diesel Engine ge Fuel consumption rate g kW h G Fuel consumptio...

Page 30: ...all Baoding Internal Combustion Engine Manufacturing Company Limited Fig 2 4 2 Power Torque Property Curves of GW4D20B Turbocharged Diesel Engine ge Fuel consumption rate g kW h G Fuel consumption vol...

Page 31: ...Rated Power and Corresponding Rotation Speed r min 110 4000 GW4D20 100 4000 GW4D20B Max Torque and Corresponding Rotation Speed N m r min 310 1800 2800 Min Fuel Consumption Rate g kW h 210 Max No loa...

Page 32: ...all cycles and water circulation direction Normal water temperature 80 90 Max water temperature 110 thermostat full opening temperature 80 the thermostat is located at the water inlet Net mass of dies...

Page 33: ...14 5 0 3 Starting Motor Voltage V 12 Output power kW 2 Rotation direction Clockwise viewing from the direction of driving gear Continued Item Unit Technical Parameter Storage Battery Rated voltage V...

Page 34: ...ly System Fuel filter DELPHI Integral type equipped with fuel water separator Cooling system Water pump type Centrifugal type BOSCH Rotary installation type equipped with fuel water separator Pumping...

Page 35: ...eft side of cylinder body DELPHI Max fuel supply pressure 1600 bar BOSCH Max fuel supply pressure 1600 bar Xin Feng Max fuel supply pressure 1600 bar Electronic Control Unit ECU Inside the engine hood...

Page 36: ...y in forming lubricating oil film thus decreases the service life of parts For the diesel engine that is put into service after strict assembly and running in its service life lies on proper maintenan...

Page 37: ...ey Timing tension pulley cylinder head 22 26 14 3701014 ED01 Fastening bolt of accessory idle wheel Oil pump timing hood 22 26 15 3701016 ED01 Fastening bolt of accessory tension pulley Compressor sup...

Page 38: ...Fit Clearance of Parts Fit Clearance Value mm Remarks 1 Camshaft axial clearance 0 060 0 115 See Page 153 210 220 230 293 2 Crankshaft axial clearance 0 10 0 28 See Page 131 165 275 288 3 Side clearan...

Page 39: ...26 0 046 N A Thickness of shell 1 980 1 984 Clearance 0 024 0 044 Blue Thickness of shell 1 984 1 988 Clearance 0 022 0 042 3 64 013 64 018 N A Thickness of shell 1 980 1 984 Clearance 0 024 0 044 Blu...

Page 40: ...ly Parts Remarks 1 Working surface of main bearing shell See Page 133 165 274 288 2 Main journal and oil hole See Page 134 165 274 288 3 Between crankshaft thrust plate and crank arm thrust face See P...

Page 41: ...sealant 6 Threaded section of water drain screw plug Anaerobic thread fixing sealant LOCTITE 243 thread fixative 7 Threaded section of oil pressure alarm assembly Anaerobic thread fixing sealant LOCTI...

Page 42: ...lyte level of the storage battery and refill to the specified level if the electrolyte is not sufficient 1 6 Check if the timing belt is installed properly and if the timing mark is correct 1 7 Check...

Page 43: ...r second level of road surface it should not be driving on road surface in bad condition full speed and overspeed driving are absolutely not permitted 3 3 The max allowed rotation speed of diesel engi...

Page 44: ...ngine regularly and change some of the parts according to the engine s technical status and operating time or driving distance Attention with the purpose of keeping a good technical condition preventi...

Page 45: ...lace the diesel filter normally per 8000 10000 km for GW4D20B turbocharged diesel engine coolant Check the fluid level Air cleaner clean Normally replace the filter core per 30000 km Parts and various...

Page 46: ...the oil filter are per 5000 km or per 100 h If the diesel used contains impurities the cycle for replacing the fuel filter should be shortened If the fuel filter is blocked by impurities the fuel filt...

Page 47: ...l tank when the diesel engine is running If the vehicle is running in the hot climate the fuel tank should not be fully filled or else the fuel will overflow due to fuel extension wipe the fuel as soo...

Page 48: ...od working condition for the air cleaner 2 2 First class technical maintenance On the basis of fulfilling daily maintenance content the following maintenance content should be added after the diesel r...

Page 49: ...conditions of the piston ring cylinder connecting rod small end bushing and connecting rod bearing shell replace them if necessary 4 Check the wear conditions of the main shaft bearing shell and thrus...

Page 50: ...livery it will be equipped by the vehicle manufacturer and the airflow of the selected air cleaner should be no less than 450 m3 h Fig 2 8 11 Seasonal technical maintenance for diesel engine It is ver...

Page 51: ...enter the inner side of filter core clean face The filter core should be replaced with a new one in following cases The filter core is polluted by carbon deposit or grease The filter core is seriousl...

Page 52: ...or quality diesel is used in the diesel engine or fuel is contaminated by impurities it is recommended that the time to replace the filter core should be advanced because the filter will be blocked so...

Page 53: ...tem should be selected upon the ambient temperature Caution different grades of oil should not be mixed 5 2 Measuring of the Oil Level Engine oil is a consumable which ensures the diesel engine to ope...

Page 54: ...e parts therefore after the oil has been used for some time e g after the vehicle traveling distance accumulates to 8000 10000 km the oil should be overall replaced Method to replace the engine oil 1...

Page 55: ...should be replaced after the new vehicle travels for 2500 km afterward the oil and the oil filter assembly should be replaced at the same time per 8000 10000 km of traveling distance Method to replace...

Page 56: ...ed immediately Attention The diesel engine running in the low engine oil pressure condition may cause serious mechanical damage 1 When the low oil pressure indicator lamp flashes or keeps on park the...

Page 57: ...6 3 Generally the service life of the long acting antifreeze and antirust fluid is 1 2 years the fluid should be replaced when expired When replacing the antifreeze and antirust fluid run the diesel...

Page 58: ...nths accumulative working time 100 h Replace the air cleaner filter core E F Per 5000 km or per 6 months accumulative working time 100 h 8 Technical Maintenance During Storage If the storage period is...

Page 59: ...e whether the engine vehicle needs to be repaired When the vehicle is handed over the owner and the staff from the service station work together to check the engine and to define the repair class Info...

Page 60: ...ainly aiming to the components or parts which are easy to wear In order to balance uneven wear between parts of the engine one or two minor repairs between two overhauls can ensure the engine to work...

Page 61: ...Requirements for Engine Removal and Reinstallation Fig 2 10 1 Assembling according to technical requirement 1 General Technical Requirements for Assembling Assembling is to connect the engine parts i...

Page 62: ...ould be from center to two ends and from interior to exterior the parts should be tightened diagonally The tightening torque for fasteners of diesel engine are listed in Table 2 6 1 Table 2 6 2 and th...

Page 63: ...ution In order to remove correctly and efficiently it is necessary to make clear the structure of the GW4D20 GW4D20B turbocharged diesel engine first 2 3 For the parts whose technical conditions are n...

Page 64: ...ulley puller 5 8840 2035 0 Crankshaft timing pulley installer 5 8522 0024 0 Valve spring compressor 9 8523 1423 0 J 29760 See Page 106 122 127 218 Valve oil seal remover 5 8840 0373 0 See Page 122 219...

Page 65: ...68 274 287 Rear oil seal installer 5 8840 2539 0 See Page 135 268 275 289 Slide hammer 5 8840 0019 0 See Page 241 Transmission first shaft front bearing remover 5 8840 2000 0 See Page 241 Transmission...

Page 66: ...onditions Filter core blocked by dust Move the filter core with hands and blow the filter core from the inner side to the outer side with compressed air the dust will be removed by doing this See Fig...

Page 67: ...oil filter is disposable and is not allowed to be reused Replacing Sequence 1 Protect the generator with plastic cloth or paper boards Loosen the oil drain plug to drain out the oil Warning Collect t...

Page 68: ...in accordance with technical Maintenance requirements Replacing Sequence 1 Loosen the fuel filter in the anticlockwise direction with a filter spanner Fuel filter spanner 5 8840 0253 0 2 Clean the ma...

Page 69: ...water deposit remove it in time Fig 2 12 12 Checking the coolant level in the fluid reservoir for reference only Fig 2 12 13 Mixing ratio of coolant 5 Cooling System 5 1 Coolant level Check the coolan...

Page 70: ...tor filler cover tester See Fig 2 12 15 During testing the radiator filler cover must be replaced if it cannot keep the specified pressure Design pressure of the radiator filler cover Pressure valve 8...

Page 71: ...is closed when the thermostat is at a low temperature The thermostat should be replaced if the valve cannot be closed 7 Check if the thermostat rubber sealing ring is aged and deformed the sealing rin...

Page 72: ...o throttle pedal 1 Loosen the lock nut 2 Adjust the height between bolt and base plate Adjust the height between bolt and base plate 18 28 mm 3 Check if the throttle pedal is 5 10mm upper the pedal bu...

Page 73: ...mation of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 63 Section XIII Engine Parts and Tightening Torques 1 Engine Bracket Mounting Assembly Cylinder body assemb...

Page 74: ...GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 64 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 2 Cylinder Body Mounting Assembly Cylinder body component Sectional view of th...

Page 75: ...rmation of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 65 3 Cylinder Body Component Upper cylinder body Crankshaft Lower cylinder body Step 1 Step 2 Step 3 Turn...

Page 76: ...OCHARGED DIESEL ENGINES 66 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 4 Cylinder Head Mounting Assembly 1 DELPHI cylinder cover assembly BOSCH or XINFENG cylinder cove...

Page 77: ...formation of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 67 5 Cylinder Head Mounting Assembly 2 DELPHI camshaft bearing cap BOSCH or XINFENG camshaft bearing cap...

Page 78: ...Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 6 Cylinder Head Mounting Assembly 3 Step 1 Step 2 Step 3 Step 1 Step 2 Step 3 Turn for 90 5 Turn for 120 5 Turn for 120 5 Tu...

Page 79: ...Chapter II Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 69 7 Piston Connecting Rod Mounting Assembly Step 1 Step 2 Turn for 90 5...

Page 80: ...MAINTENANCE MANUAL OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 70 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 8 Crankshaft Flywheel and Clutch Mounting Assembly...

Page 81: ...ormation of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 71 9 Air Intake and Exhaust Systems Mounting Assembly 1 DELPHI air intake manifold pipe BOSCH or XINFENG...

Page 82: ...0 GW4D20B TURBOCHARGED DIESEL ENGINES 72 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 10 Air Intake and Exhaust Systems Mounting Assembly 2 Cylinder head mounting assemb...

Page 83: ...Chapter II Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 73 11 Oil Pan and Engine Oil Collector Mounting Assembly...

Page 84: ...OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 74 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 12 Engine Oil Pump Mounting Assembly Cylinder body assembly Engine oil pump...

Page 85: ...ngine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 75 13 Engine Oil Cooler and Cooling Pipelines Mounting Assembly Upper cylinder body Engine oil filter mounting assembl...

Page 86: ...MAINTENANCE MANUAL OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 76 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 14 Timing Mechanism Mounting Assembly 1...

Page 87: ...of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 77 15 Timing Mechanism Mounting Assembly 2 BOSCH or XINFENG crankshaft timing belt pulley component DELPHI cranksh...

Page 88: ...L OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 78 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 16 Fuel Supply System Mounting Assembly 1 Note DELPHI fuel supply system...

Page 89: ...r II Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 79 17 Fuel Supply System Mounting Assembly 2 Note BOSCH fuel supply system mounting ass...

Page 90: ...OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 80 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 18 Fuel Supply System Mounting Assembly 3 Note XINFENG fuel supply system...

Page 91: ...Chapter II Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 81 19 Turbocharger Mounting Assembly 1 Note VGT turbocharger mounting assembly...

Page 92: ...E MANUAL OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 82 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 20 Turbocharger Mounting Assembly 2 Note WGT turbocharger mounting...

Page 93: ...Chapter II Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 83 21 EGR System Mounting Assembly Air intake manifold pipe Cylinder head...

Page 94: ...OF GW4D20 GW4D20B TURBOCHARGED DIESEL ENGINES 84 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 22 Electronic Control System Sensor Cylinder body assembly Crankshaft posit...

Page 95: ...Chapter II Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 85 23 Generator Mounting Assembly Cylinder body assembly Generator belt...

Page 96: ...B TURBOCHARGED DIESEL ENGINES 86 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 24 Throttle Mounting Assembly Exported AT vehicle model Air intake manifold pipe Common veh...

Page 97: ...ical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 87 25 Thermostat and Water Pump Mounting Assembly Cylinder body assembly Thermostat shield Cylind...

Page 98: ...20 GW4D20B TURBOCHARGED DIESEL ENGINES 88 Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 26 Engine and Compressor Mounting Assembly Cylinder body assembly Cylinder body as...

Page 99: ...I Technical Information of Engine Great Wall Baoding Internal Combustion Engine Manufacturing Company Limited 89 27 Vacuum Pump and Steering Pump Mounting Assembly Cylinder head assembly Cylinder body...

Page 100: ...ction do not remove any part blindly 3 The diagnosis and elimination for complex malfunctions should be done by professional persons by means of appropriate apparatus and specialized equipment If the...

Page 101: ...lace the fuel filter 4 Check whether the fuel inlet pipe is leaking and whether the filter screen on the fuel inlet pipe connector is blocked reinstall the screen after eliminating the blockage 5 See...

Page 102: ...the oil supply system see Page 86 88 Malfunction in air intake and exhaust systems exhaust temperature higher than the normal one and poor exhaust gas color 1 Air cleaner blockage 2 Blockage in exhau...

Page 103: ...ector Examine and repair or replace the high pressure oil pump and the fuel injector Malfunction in the pressure sensor of high pressure oil track Damaged pressure sensor of high pressure oil track Re...

Page 104: ...sharper when you suddenly step on the gas 2 Replace the bush of the connecting rod small end and make it within the specified clearance scope 3 Excessive clearance between the piston and the valve kn...

Page 105: ...Fasten the fuel injector and or the glow plug replace the gasket 3 Fasten the exhaust manifold pipe 4 Replace the cylinder gasket Continual noise 1 Wear or damage of the water pump bearing 2 Damage o...

Page 106: ...ne properly and run the engine longer 3 See Chapter 11 for troubleshooting the oil supply system see Page 86 88 Exhaust with blue smoke 1 Stuck or overly worn piston ring insufficient elasticity the c...

Page 107: ...lace the piston ring or the piston 5 Replace the oil seal valve or valve guide pipe 6 Repair the cylinder aperture Too low oil pressure 1 Applied inappropriate oil 2 Blockage of the safety valve 3 Blo...

Page 108: ...troubleshooting the oil supply system see Page 86 88 6 Replace the radiator cap or the wash radiator 7 Replace the coolant temperature sensor 8 Replace the cylinder gasket 9 Replace the thermostat 10...

Page 109: ...the turbocharger oil return hose leading to oil leakage from the turbo and the compressor shaft end 4 Damage and malfunction of the turbocharger sealing ring 5 Turbo shaft rotor out of balance 6 Fric...

Page 110: ...place the turbocharger assembly 3 Check repair or replace it Caution 1 When the diesel engine is disassembled and reinstalled for troubleshooting it is strictly forbidden to let foreign materials ente...

Page 111: ...1 Check the injector electromagnetic valve 12 Check the control unit Diesel engine stalls but it can be restarted 1 Looseness of the fuse connecting cable connector 2 Ignition switch contactor 3 Wrong...

Page 112: ...njector connecting circuit 3 Check or replace the fuel injector Diesel engine wobble during idling 1 Incorrect fuel 2 Air left in fuel system 3 Blockage of overlow pressure of the low pressure oil cir...

Page 113: ...the low pressure oil circuit 4 Overhaul the preheat system 5 Check the lubrication system oil level and drain off the excessive engine oil Diesel engine exhausting black smoke 1 Blockage of the air cl...

Page 114: ...adjusting system Damage of the high pressure fuel rail pressure sensor Replace the high pressure fuel rail pressure sensor High pressure fuel rail pressure adjusting system Check the metering valve an...

Page 115: ...th the two contacts 2 Breakage or bending of the starter armature shaft 3 Sticking or galling of the gear teeth face 1 Disconnect the power supply immediately check fasten the circuit and repair the c...

Page 116: ...ssure fuel rail and pressure sensor replace defective parts if necessary Fuel injector electromagnetic valve Fuel injector electromagnetic valve not working or bad contact Check the working status of...

Page 117: ...olant temperature sensor winter Wrong information for the coolant temperature in winter glow plug not working Replace the coolant temperature sensor 17 Difficulty in Starting Due to Malfunction in the...

Page 118: ...r The glow plug indicator lamp is on for 3 5 s 1 The glow plug relay is damaged The glow plug relay is not connected after the starting switch is set from OFF to ON 2 Damaged glow plug relay wire 3 Th...

Page 119: ...left between the positive and negative poles 5 Short circuit of pole plates due to active substance falling off from the pole plates and excessive sediment short circuit of pole plates due to damage o...

Page 120: ...attery Charging failure or out of service Normal storage battery Check the terminal Normal connection of terminal Check the starter or starting switch Clean the storage battery terminal and then recon...

Page 121: ...tarting relay is normal Yes No Or Serious wear between the pinion and the gear ring High slipping resistance for starter Repair or replace the starter and replace the gear ring Repair or replace the s...

Page 122: ...pair it Open circuit or connection malfunction between the storage battery and the starting switch The slipping part of pinion cannot move Open circuit or burnout of the electromagnetic switch or the...

Page 123: ...nect the connecting wire of the starting switch and check the starting switch All the wires except the wires above should be disconnected Replace the starter switch The contact of electromagnetic swit...

Page 124: ...roubleshooting Dirty air cleaner Replace the filter core of the air cleaner Blockage in the compressor air intake pipe Clear the foreign matters or replace the broken components accordingly Blockage i...

Page 125: ...lace the turbocharger accordingly Improper control of the high pressure fuel pump or fuel injector Replace or adjust the high pressure fuel pump and relevant components accordingly Improper timing of...

Page 126: ...Clean the lubricating oil and avoid long time idling Check whether the idle speed time of engine is too long more than 20 min Check whether the turbocharger air intake pipe is throttled Tighten the pi...

Page 127: ...r blade has interference with its housing Eliminate the factors that largen the turbocharger clearance or replace the turbocharger Check whether the idle speed time of engine is too long more than 20...

Page 128: ...ressure or oil level in the crankcase or blockage of crankcase vent 8 Overhigh engine lower blow by Improper diagnosis method for oil leakage Remove the connecting pipe between the gas compressor hous...

Page 129: ...tor and fuel rail Fuel return hose component Heater water return pipe component Cylinder head cover assembly Fuel injector assembly GER condenser air intake pipe EGR condenser air outlet pipe EGR cond...

Page 130: ...engine accessories 1 Removing the engine belt Rotate the tension pulley with tools to make the belt loose enough and then remove the belt as shown in Fig 4 1 2 2 Removing the wedge idle wheel loosen...

Page 131: ...and then remove fuel return hose component Disassembling the heater water return pipe component 1 Remove the 2 hexagon flange bolts M6 16 connecting the heater water return pipe component to the cylin...

Page 132: ...erature resistance hexagon flange bolts M8 1 25 connecting the EGR condenser air intake pipe to exhaust manifold pipe See Fig 4 1 8 2 Remove the 2 hexagon flange bolts M8 20 connecting the EGR condens...

Page 133: ...4 1 10 Check the supercharger gasket and replace it if there is any damage or deformation Disassembling the exhaust manifold pipe 11 1 Remove the 4 hexagon flange bolts M6 12 fastening the heat shield...

Page 134: ...the intake exhaust camshaft Disassembling the camshaft bearing cap 14 1 Remove the supporting bolts for the 4 fuel injector ballasts 2 Remove the 22 hexagon flange bolts M6 35 and M6 20 fastening the...

Page 135: ...orderly loosened in gradually specified order the lower surface of the cylinder cap might be damaged 2 Take down the cylinder head and cylinder head gasket from the cylinder body Check the cylinder he...

Page 136: ...e flatness of fitting surface between air intake and exhaust manifold pipes These surfaces can be grinded If the irregularities of these surfaces excesses the specified limits these surfaces should be...

Page 137: ...5 Installing the valve lock clamp Compress the valve spring with special tools to install the valve lock camp into the valve spring seat Valve spring compressor 9 8523 1423 0 The valve lock clamp shou...

Page 138: ...amshaft bearing cap and applying sealant Reinstalling the intake and exhaust camshafts 15 1 Apply an appropriate amount of lubricating oil onto the surface of the camshaft journal and inside the beari...

Page 139: ...tools to install the front oil seal and plug cover into the corresponding holes properly without causing any oil leakage Mobil API CI 4 lubricating oil Reinstalling the vacuum pump assembly 13 1 Insta...

Page 140: ...e cylinder head and tighten the 8 fastening nuts M8 1 25 to the specified torque as shown in Fig 4 1 31 Tightening torque for fastening bolt of exhaust manifold pipe 30N m 3N m 2 Install the heat shie...

Page 141: ...astening bolt and nut of air intake manifold pipe 23 N m 3 N m Reinstalling GER condenser air intake pipe EGR condenser air outlet pipe EGR condenser 1 Use 2 hexagon flange bolts M10 16 to install the...

Page 142: ...of the fuel injector ballast on ballast supporting bolt and the other end in fuel injector ballast groove See Fig 4 1 37 5 Install and tighten the fastening bolt washer component of fuel injector ball...

Page 143: ...tighten the 2 hexagon flange bolts M8 16 connecting the water outlet pipe and cylinder head cover See Fig 4 1 39 Tightening torque for fastening bolt of water outlet pipe connecting pipe component 23...

Page 144: ...tor and fuel rail is sealed without leakage after installation Reinstalling the timing system 1 Install the woodruff key to the exhaust camshaft install the timing pulley to the exhaust camshaft and t...

Page 145: ...lve timing is accurate See Fig 4 1 46 Fig 4 1 46 Installing the timing tension pulley Fig 4 1 46 Installing the timing hood component Attention If any pulley mark is not aligned and it is required to...

Page 146: ...ring Company Limited Fig 4 1 48 Installing the engine accessories After the installation check the generator belt Make sure the belt wedge shaped teeth perfectly match the pulley wedge slot Caution Th...

Page 147: ...or camshaft Dismounting procedure Engine accessories Timing system Fuel inlet pipe component of fuel injector Fuel return hose component Heater water return pipe component Cylinder head cover assembly...

Page 148: ...ng tension pulley assembly Loosen the combined fastening bolt of timing tension pulley and remove the camshaft timing belt pulley 4 Removing the camshaft timing pulley Loosen the bolt component of cam...

Page 149: ...y Fig 4 2 7 Removing the fuel injector assembly Disassembling the cylinder head cover assembly 1 Remove the 2 hexagon flange bolts M8 16 for fixing the water outlet pipe connecting pipe component and...

Page 150: ...shaft bearing cap symmetrically to the center See Fig 4 2 9 2 Remove the camshaft bearing cap from the cylinder head Fig 4 2 10 Removing the intake exhaust camshaft Disassembling the Intake exhaust ca...

Page 151: ...Fig 4 2 12 Replace the camshaft if any measured value is below the limitation Heights of the cam Standard Intake camshaft 35 10 35 20 mm Exhaust camshaft 33 58 33 68 mm 3 Checking the radial runout of...

Page 152: ...camshaft and get it in line with the upper surface Axial clearance of camshaft 0 060 0 115 mm Reassembling the camshaft bearing cap 1 Apply anaerobic plane sealant to the junction surface between the...

Page 153: ...splacement after installation Reassembling the fuel injector assembly 1 Tighten the supporting bolts of the fuel injector ballast by using the required torque onto the cylinder head Tightening torque...

Page 154: ...m 3 N m Reinstalling the heater water return pipe component 1 Install the heater water return pipe component and tighten the 2 hexagon flange bolts M6 16 connecting the heater water return pipe and th...

Page 155: ...l injector and tighten evenly the pipe connectors at both ends of the 4 fuel inlet pipes of the fuel injector according to the specified torque Make sure the fuel inlet pipe of fuel injector is sealed...

Page 156: ...stening bolts After taking off the hexagon socket head spanner camshaft pulley dowel pin and crankshaft locking tooling turn the crankshaft 2 circles clockwise with the spanner to make sure the dampin...

Page 157: ...ightening torque for wedge idle wheel 22 N m 26 N m 2 Reinstall the generator belt use a tool to turn the tension pulley and install it after the belt is loose enough See Fig 4 2 29 3 After the instal...

Page 158: ...lic Clearance Adjuster Table 4 3 1 Dismounting and reinstalling sequences for valve valve spring valve oil seal rocker arm and hydraulic clearance adjuster Intake exhaust valve components Camshaft ins...

Page 159: ...n removing do prevent the valve lock clamp from snapping out and hurting anyone Disassembling the valve spring 1 Take out the 16 valve spring seats and valve springs respectively from the cylinder hea...

Page 160: ...rity of valve spring with a steel square See Fig 4 3 6 2 Replace the valve spring if the measured value is above the limitation The perpendicularity limitation of valve spring 1 2 m 1 3 Checking the t...

Page 161: ...alve 5 945 5 960 mm 3 Measure the inner diameter of valve guide with a micrometer 4 Subtract the measured outer diameter value of valve stem from the measured inner diameter value of valve guide Repla...

Page 162: ...0 10 mm Exhaust valve 2 10 0 10 mm 3 3 Checking the valve seat contact taper face angle 1 Measure the valve seat contact taper face angle See Fig 4 3 12 2 Replace the valve valve guide and valve seat...

Page 163: ...e seat 1 Conduct arc weld inside the valve seat 2 Cool the valve seat for several minutes The valve seat will contract by doing so and its removal will become easier 3 Pry the valve seat with a screw...

Page 164: ...lly the accessory whose outer diameter is a little less than the valve seat s onto the valve seat See Fig 4 3 18 Attention Contact the accessory with its smooth surface to the valve seat 2 Apply press...

Page 165: ...0 3 Conduct pressure leakage test on the valve oil seal and the specification is as below the air leaking amount should be less than 20 mL min under 50 70 kPa Attention Do not reuse the removed valve...

Page 166: ...nical surface of the valve spring seat The two pieces of lock clamps should be aligned 3 After the installation use a hammer to tap on the head of the valve to make sure the valve lock clamps will not...

Page 167: ...edure Engine accessories Damping pulley assembly Timing system Cylinder head assembly Flywheel gear ring assembly Oil pan upper and lower body assemblies and oil collector assembly Oil pump assembly C...

Page 168: ...ange face bolts M8 30 M8 35 fastening the engine bracket to the cylinder body and remove the engine bracket 6 Removing the power steering pump assembly and the steering pump support components Unscrew...

Page 169: ...body assemblies and oil collector assembly Disassembling the flywheel gear ring assembly 1 Install the flywheel retainer 2 Orderly unscrew the 8 flywheel bolts fastening the flywheel gear ring assemb...

Page 170: ...crankshaft and replace them if there is any deformation or damage Disassembling the connecting rod assembly and the piston component 1 Unscrew and remove 8 connecting rod bolts in two separated times...

Page 171: ...middle Disassembling the crankshaft and crankshaft position signal panel 11 1 Remove the 3 hexagon lobular socket countersunk head screws for fastening the signal panel to the crankshaft rear part Se...

Page 172: ...e thrust plate to their original position And install the crankshaft carefully 6 Install the lower shaft bearing shell to its original poison of the lower cylinder body 7 Install the plastic gauge to...

Page 173: ...value Standard 0 05 0 20 mm 2 Measure the diameters of the crankshaft main bearing journal and the crank pin and check them for non uniform wear See Fig 4 4 18 Replace the crankshaft if the non unifo...

Page 174: ...crankshaft Reassembly Reinstalling the crankshaft and crankshaft position signal panel 11 1 Select the main shaft bearing shell as per Table 4 4 1 and Table 4 4 2 Install the upper main shaft bearing...

Page 175: ...4 Clearance 0 024 0 044 2 64 007 64 012 Yellow Shell thickness 1 976 1 980 Clearance 0 026 0 046 None Shell thickness 1 980 1 984 Clearance 0 024 0 044 Blue Shell thickness 1 984 1 988 Clearance 0 022...

Page 176: ...the main bearing journal and into the oil hole of the crankshaft Install the crankshaft to the upper cylinder body Mobil API CI 4 lubricating oil Fig 4 4 24 Installing the lower cylinder body Reinstal...

Page 177: ...e bolt 23 N m 3 N m Prompt Apply a small amount of lubricating oil to the thread while installing the main bearing cap bolts Mobil API CI 4 lubricating oil After installation rotate the crankshaft man...

Page 178: ...n ring groove in a correct direction with the top marks TOP of the first and second compression rings facing upwards The piston ring moves smoothly in ring slot without any stagnation and the clearanc...

Page 179: ...mount of lubricating oil to the inner surface of engine pump external rotor and install the external rotor to the engine pump cavity of the upper cylinder body with the marks of internal and external...

Page 180: ...ace bolts M6 6 See Fig 4 4 35 Attention Install and fix the 2 hexagon flange face bolts M8 12 on the fixing oil collector bracket after installing oil pan Mobil API CI 4 lubricating oil Tightening tor...

Page 181: ...ed to the thread of the flywheel bolt before being fixed LOCTITE 243 thread fixative 4 Check whether the end face runout of the flywheel is within the range of specified values after installation End...

Page 182: ...e sure it would not fall out Lubricate the surfaces of the rocker arm and the hydraulic clearance adjuster with lubricating oil again and then insert the whole part into the corresponding hole with th...

Page 183: ...44 Installing the vacuum pump assembly Fig 4 4 45 Installing the fuel injector Tighten the 3 hexagon flange face bolts M6 20 connecting the vacuum pump to the cylinder head as per specified torque In...

Page 184: ...nd of the fuel injector Install 4 short connectors of the fuel return hose into the 4 holes at the upper end of the fuel injector and fix them tightly with the spring clips Install the other long conn...

Page 185: ...kshaft pulley should be pressed and installed to the right position without deflection See Fig 4 4 49 Tightening torque for fastening bolt of crankshaft timing pulley 185 N m 195 N m Attention Use the...

Page 186: ...timing hood components I and II the timing hood and the rear timing hood components Install the rear timing hood components and screw down the hexagon flange face bolt M6 16 as per the specified torqu...

Page 187: ...k of the damping pulley must face forwards Reinstalling the engine accessories 1 Reinstall the power steering pump assembly and the steering pump support components See Fig 4 4 55 2 Reinstall the gene...

Page 188: ...ismounting and reinstallation procedure for piston and connecting rod assembly Dismounting procedure Engine accessories Timing system Cylinder head assembly Oil pan upper and lower body assemblies and...

Page 189: ...re Disassembling the engine accessories 1 Remove the generator belt turn the tension pulley with tools until the belt is loose enough and then remove the generator belt See Fig 4 5 3 2 Remove the tens...

Page 190: ...ling the connecting rod cover 1 Respectively remove the 8 connecting rod bolts tightening the connecting rod cover under the crankshaft and take down the 4 connecting rod covers and 4 lower connecting...

Page 191: ...See Fig 4 5 9 2 Place the removed piston in groups according to the cylinder sequence number and make the corresponding marks Prevent them from being bumped 3 Use a wood chip to remove the carbon dep...

Page 192: ...bore size 1 83 09 83 10mm 2 83 10 83 11mm 3 83 11 83 12mm 1 3 Checking the piston outer diameter Use a screw micrometer to measure the piston outer diameter at the piston group position See Fig 4 5 12...

Page 193: ...mpression ring 0 055 0 100mm Second compression ring 0 035 0 080mm Oil ring 0 030 0 070mm 3 Piston Visually check the piston pin for crack bruise or other damage and replace it if necessary 3 1 Checki...

Page 194: ...unch or a copper bar to knock the piston pin out from the piston pin hole Alternatively use a bench press for disassembly Installation Use a suitable wood punch or a copper bar to gently knock the pis...

Page 195: ...even if only one bearing shell is damaged or heavily worn 5 Install the connecting rod bearing shells to their original positions 6 Place the plastic precision clearance gauge on the crank pin 7 Inst...

Page 196: ...ndard 0 005 0 012mm Clearance between the connecting rod small end hole and the piston pin 0 010 0 024mm Reinstalling the clamping spring Install the clamping springs to both ends of the piston pin Th...

Page 197: ...aft 1 2 3 50 021 50 026 50 015 50 020 50 008 50 014 Connecting rod big end hole diameter 1 53 000 53 006 Yellow 1 Shell thickness 1 473 1 477 Clearance 0 020 0 040 Yellow 1 Shell thickness 1 473 1 477...

Page 198: ...ine Fig 4 5 27 Installing the piston connecting rod group Fig 4 5 28 Installing the connecting rod cover Reinstalling the connecting rod cover Attention Before the installation check the connecting ro...

Page 199: ...r body is clean before reapplying glue 2 Screw down the 15 hexagon flange face bolts M8 25 M6 20 M6 110 and M8 45 fastening the oil pan upper body and lower cylinder body as per the specified order an...

Page 200: ...f upper and lower bodies of oil pan is clean LOCTITE 587 plane sealant Tightening torque for fastening bolt of oil pan lower body 9N m 3N m Reinstalling the cylinder head assembly 1 Check for foreign...

Page 201: ...oil Fig 4 5 35 Installing the exhaust intake camshaft Fig 4 5 36 Installing the camshaft bearing cap 5 Reinstall the intake and exhaust camshafts Install the intake and exhaust camshafts into the cyli...

Page 202: ...23N m 3N m Install the copper washer and O ring of fuel injector to the fuel injector and make sure only one copper washer is installed to each fuel injector and each copper washer is placed horizonta...

Page 203: ...oth ends of the fuel inlet pipe component of fuel rail as per the specified torque Make sure the fuel pipe is sealed without oil leakage after the installation Tightening torque for fuel inlet pipe co...

Page 204: ...head spanner camshaft pulley dowel pin and crankshaft locking tooling turn the crankshaft for 2 circles clockwise with the spanner to make sure the damping pulley camshaft timing pulley and fuel pump...

Page 205: ...re on the same plane Tightening torque for wedge idle wheel 22N m 26N m 2 Reinstall the generator belt use a tool to turn the tension pulley and install it after the belt is loose enough See Fig 4 5 4...

Page 206: ...Limited Section VI Engine oil pump assembly Fig 4 6 1 Disassembling and reinstallation procedure for engine oil pump assembly Dismounting procedure Engine accessories Damping pulley assembly Timing s...

Page 207: ...he power steering pump loosen the 3 hexagon flange face bolts M8 25 and M8 30 fastening the steering pump bracket and the cylinder body and remove the steering pump bracket 6 Remove the generator asse...

Page 208: ...pan lower body from the oil pan upper body Disassembling the engine oil pump assembly 1 Orderly remove the 10 hexagon bolt and plain washer components M8 40 M8 25 and M8 20 fastening the engine oil pu...

Page 209: ...r body with the marked side facing the bottom of pump cavity of cylinder body See Fig 4 6 8 Mobil API CI 4 lubricating oil 4 Assemble the engine oil pump assembly and cylinder body Tighten the 10 hexa...

Page 210: ...embly 1 Place the elastic cylindrical pin in the timing pulley pin hole of crankshaft 2 Align the damping pulley pin holes install the damping pulley to the front end of crankshaft and screw down the...

Page 211: ...assembly Flywheel gear ring assembly Thermostat assembly and thermostat cap Heater water return connecting hose and heater water return pipe component Oil filter assembly and oil cooler assembly Oil p...

Page 212: ...8 30 fastening the steering pump bracket and the cylinder body and remove the steering pump bracket 6 Remove the generator assembly and generator bracket loosen the 3 hexagon flange face bolts M8 30 a...

Page 213: ...M8x25 M8x30 and M10x25 fastening the water pump assembly and the cylinder body and take off the water pump assembly See Fig 4 7 6 2 Remove the water pump gasket Check the water pump gasket for damage...

Page 214: ...and oil cooler Disassembling the oil filter assembly and oil cooler assembly 1 Use a spanner to unscrew the oil filter and take off the oil filter and its seal ring Spanner for the oil filter 5 8840 0...

Page 215: ...r body 3 Take out the front oil seal of crankshaft through the crankshaft oil seal hole of engine oil pump Front oil seal remover 5 8840 2362 0 Caution Do not damage the mating surface of front oil se...

Page 216: ...s of lower cylinder body from both sides of cylinder body to the center Disassembling the crankshaft and crankshaft position signal panel 15 1 Remove the 3 hexagon lobular socket countersunk head bolt...

Page 217: ...cket head cap head screws M6x12 fastening the cooling nozzle onto the upper cylinder body as per the specified torque See Fig 4 7 18 Tightening torque for fastening bolt of cooling nozzle 9 N m 3 N m...

Page 218: ...il groove facing crank arm Attention There is no positioning lip on the upper thrust plate The lower thrust plate has a positioning lip 3 Evenly coat sealant on the top surface of lower cylinder body...

Page 219: ...Make sure the oil seal end face does not tilt and it is properly installed Reinstalling the connecting rod assembly and piston component 12 1 Install the connecting rod bearing shell on the connectin...

Page 220: ...body with the side with the marks of internal and external rotors on the same side Mobil API CI 4 lubricating oil 4 Assemble the engine oil pump assembly and cylinder body Tighten the 10 hexagon bolt...

Page 221: ...l and fix the 2 hexagon flange face bolts M8 12 fastening the oil collector bracket after installing the oil pan upper body Mobil API CI 4 lubricating oil Tightening torque for fastening bolt of oil c...

Page 222: ...heater water return pipe component 1 Insert the heater water return conencting hose into the pipe connector and fasten it with single ear stepless clips Fix it on the cylidner body with clamps and he...

Page 223: ...ange face bolts M8x25 M8x30 and M10x25 as per the specified torque See Fig 4 7 33 Fig 4 7 34 Installing the cylinder head assembly Tightening torque for fastening bolt of water pump assembly M8 23N m...

Page 224: ...ing the damping pulley assembly 1 Place the elastic cylindrical pin in the timing pulley pin hole of crankshaft 2 Align the damping pulley pin holes install the damping pulley assembly and screw down...

Page 225: ...lectronically controlled exhaust gas recirculation EGR technique The opening height of EGR valve is driven by the motor to achieve more precise control of EGR rate so as to control the density of NOx...

Page 226: ...procedure Transmission assembly and clutch assembly Radiator assembly Air intake pipe and air flow sensor Air cleaner Harness Fuel hose Oil pressure switch wire Refrigerating compressor assembly Powe...

Page 227: ...y Lift the vehicle and support it with appropriate safety rack 1 Transmission assembly Remove the drive shaft on the flange yoke Remove the rotation speed sensor connector Remove the fastening bolts c...

Page 228: ...n the operation of the diesel engine Remove and install with care do not collide and keep it clean Apply special storage after removal Fig 5 2 6 Removing the air cleaner Fig 5 2 7 Removing the engine...

Page 229: ...the refrigeration compressor assembly 1 Turn the tension pulley with tools until the generator belt is loose enough and then remove the generator belt 2 Remove the wire connector of electromagnetic c...

Page 230: ...ng gaskets on both ends 4 Check the sealing gasket and replace those damaged or deformed ones Removing the fastening nuts of engine bracket 11 1 Use a crane to hitch the engine hook but don t lift the...

Page 231: ...talytic converter pipe Connect the catalytic converter pipe to the turbocharger or the front exhaust pipe install the sealing gaskets on both ends and tighten the fastening bolts and nuts of catalytic...

Page 232: ...ling the fuel hose 1 Connect the fuel inlet hose and the fuel return hose see Fig 5 2 18 Then tighten the clamp firmly 2 After installation check connectors of the fuel inlet hose and the fuel return...

Page 233: ...ntion The air flow sensor has a mounting direction with the arrow mark toward the air intake port of the turbocharger Caution Keep the air flow sensor clean and prevent dirt or dust from getting into...

Page 234: ...he wire for protecting the diaphragm spring must be removed after the fixing bolts of the pressure plate are tightened to specified torques 3 Transmission assembly Fit 2 transmission dowel pins into t...

Page 235: ...ission assembly and clutch assembly Radiator assembly Air intake pipe and air flow sensor Air cleaner Harness Fuel hose Oil pressure switch wire Refrigerating compressor assembly Power steering pump a...

Page 236: ...ppropriate safety rack 1 Transmission assembly Remove the drive shaft on the flange yoke Remove the rotation speed sensor connector Remove the fastening bolts connecting the transmission and clutch in...

Page 237: ...ence on the operation of the diesel engine Remove and install with care do not collide and keep it clean Apply special storage after removal Fig 5 3 6 Removing the air cleaner Fig 5 3 7 Removing the e...

Page 238: ...n compressor assembly 1 Turn the accessory tension pulley with tools until the generator belt is loose enough and then remove the generator belt 2 Remove the wire connector of electromagnetic clutch 3...

Page 239: ...gaskets 4 Check the sealing gaskets and replace those damaged or deformed ones Removing the fastening nuts of engine bracket 11 1 Use a crane to hitch the engine hook but don t lift the engine 2 Loos...

Page 240: ...sembly as per specified torque See Fig 5 3 14 2 Install the left bracket to the right side of the cylinder body Fix it with 3 hexagon bolts M10 1 25 25 and the spring washer and plain washer subassemb...

Page 241: ...ch Installing the refrigeration compressor assembly 1 Install the refrigeration compressor assembly to the cylinder body and the oil pan align the mounting holes and tighten 4 hexagon flange bolts M8...

Page 242: ...f fuel injector high pressure fuel pump ECU glow plug turbocharger EGR valve and electromagnetic valve of A C compressor etc 2 Check all connectors of the harness for incorrect insertion 3 Install the...

Page 243: ...the air intake port of the turbocharger Caution Keep the air flow sensor clean and prevent dirt or dust from getting into it Installing the radiator assembly 1 Install the radiator assembly See Fig 5...

Page 244: ...d the wire for protecting the diaphragm spring must be removed after the fixing bolts of the pressure plate are tightened to specified torques 3 Transmission assembly Fit the 2 transmission dowel pins...

Page 245: ...fold Pipe Fig 5 4 1 Installation and removal procedures of air intake manifold pipe Removal procedure Air intake connecting hose Intercooler port EGR valve and air outlet pipe of EGR condenser Fuel in...

Page 246: ...tle gasket and replace it if there is any damage or deformation Removing the EGR valve and air outlet pipe of EGR condenser 1 Remove the 2 hexagon flange bolts and 2 hexagon flange nuts M8 25 M8 30 M8...

Page 247: ...ig 5 4 7 Installing the turbocharger pressure sensor Removing the air intake manifold pipe 1 Remove the 7 hexagon flange bolts M8 105 M8 25 and 2 hexagon flange nuts M8 1 25 connecting air intake mani...

Page 248: ...ing the fuel inlet pipe of high pressure fuel rail 1 Install the fuel inlet pipe of high pressure fuel rail and tighten evenly the pipe connectors at both ends of the fuel inlet pipe of high pressure...

Page 249: ...ooler port throttle gasket and intercooler port to the air intake manifold pipe See Fig 5 4 10 2 Tighten the 4 hexagon flange bolts M6 20 fastening the intercooler port according to the specified torq...

Page 250: ...5 1 Installation and removal procedures of exhaust manifold pipe Filter core Removal procedure Air cleaner and turbocharger air intake hose Catalytic converter pipe Turbocharger fuel inlet bolt Turbo...

Page 251: ...bolts of catalytic converter from the turbocharger or the exhaust elbow 2 Remove the fixing nuts from the front exhaust pipe 3 Take out the catalytic converter pipe and the gaskets at the both ends S...

Page 252: ...intake pipe of EGR condenser and exhaust manifold pipe See Fig 5 5 6 2 Remove the 2 hexagon flange bolts M8 20 connecting the air intake pipe of EGR condenser and EGR condenser components See Fig 5 5...

Page 253: ...ied torque See Fig 5 5 9 Tightening torque for fastening bolt of exhaust manifold pipe 30N m 3N m Fig 5 5 10 Installing the heat shield of exhaust manifold pipe 3 Install the heat shield to the exhaus...

Page 254: ...flange bolts M6 12 according to the specified torque Tightening torque for fastening bolt of turbocharger heat shield 9N m 3N m 3 Install the fuel inlet pipe of turbocharger and fuel inlet bolt connec...

Page 255: ...catalytic converter pipe and turbocharger or front exhaust pipe install the sealing gasket at the both ends and tight the fixing bolt and nut to the specified torque See Fig 5 5 14 Tightening torque...

Page 256: ...linder cover Removal procedure Injector harness connector Fuel return hose component Fuel inlet pipe of fuel injector Crankcase vent hose subassembly Water outlet pipe connecting pipe component Vacuum...

Page 257: ...HI fuel injector pull out the 4 fuel return hoses connected with fuel injector and then take off the fuel return hose component See Fig 5 6 3 3 Use the BOSCH or XINFENG fuel injector Use a tool to pus...

Page 258: ...valve VGT turbocharger 1 Remove the 2 hexagon flange bolts M6 16 fastening vacuum control valve and pull out the 2 connecting rubber hoses See Fig 5 6 6 2 Remove the 2 hexagon flange bolts M6 12 faste...

Page 259: ...ver packing 1 Check whether the cylinder cover packing is in good condition 2 Clean the cylinder cover packing groove 3 Install the cylinder cover packing into the cylinder cover packing groove and ma...

Page 260: ...e component and vacuum control valve bracket and tighten the 2 hexagon flange bolts M6 16 at the heater water return pipe and cylinder cover according to the specified torque Tightening torque for fas...

Page 261: ...pipe of fuel injector 1 Remove the dust boot at both ends of the fuel inlet pipe of fuel injector 2 Install the fuel inlet pipe of fuel injector and tighten evenly the pipe connector at both ends of...

Page 262: ...tallation make sure the fuel return hose is sealed so strictly that no fuel will leaks from it Installing the injector harness connector Plug the fuel injector harness connector on engine harness to t...

Page 263: ...al procedures of camshaft Removal procedure Engine accessories Timing system Fuel inlet pipe of fuel injector Fuel return hose component Water outlet pipe connecting pipe component Heater water return...

Page 264: ...l assembly See Fig 5 7 2 Removing the timing system 1 Remove the timing hood component I and timing hood See Fig 5 7 3 2 Remove the tension pulley assembly See Fig 5 7 3 3 Remove the timing belt 4 Rem...

Page 265: ...5 Fig 5 7 6 Removing the heater water return pipe component Fig 5 7 7 Removing the cylinder cover assembly Removing the heater water return pipe component 1 Remove the 2 hexagon flange face bolts M6...

Page 266: ...the both sides of camshaft bearing cap to the center See Fig 5 7 9 3 Remove the camshaft bearing cap from cylinder head Removing the intake exhaust camshaft assembly 1 Remove the intake exhaust camsh...

Page 267: ...lace them when it exceeds two times 2 Tightly screw the 16 hexagon flange face bolts M6 35 of the camshaft bearing cap according to specified torques and sequence and then screw down the 6 hexagon fla...

Page 268: ...required torques No air leakage is allowed at the injector gasket Tightening torque for fastening bolt component of fuel injector ballast 25N m 35N m Installing the cylinder cover assembly 1 Check wh...

Page 269: ...fuel return hose in 4 holes at the upper end of the fuel injector and fix them tight with the spring clips Install the other long connector to the fuel return tee on the high pressure pump and fix it...

Page 270: ...elt During the installation make sure the belts except the timing tension pulley are connected with the pulley firmly without any looseness See Fig 5 7 21 6 Install the timing tension pulley Fix the l...

Page 271: ...ng torque for fastening bolt of timing hood component I 9N m 3N m Reinstalling the engine accessories 1 Reinstall the wedge idle wheel and tighten it according to the required torque Visually checked...

Page 272: ...rnal Combustion Engine Manufacturing Company Limited Fig 5 7 25 Connecting the earthing cable of storage battery Fig 5 7 25 3 Fill the engine cooling system with coolant 4 Start the engine and check t...

Page 273: ...r arm and hydraulic clearance adjuster Removal procedure Engine accessories Timing system Fuel inlet pipe of fuel injector Fuel return hose component Water outlet pipe connecting pipe component Heater...

Page 274: ...e wheel and then remove the wedge idle wheel assembly See Fig 5 8 2 Removing the timing system 1 Remove the timing hood component I and timing hood See Fig 5 8 3 2 Remove the timing tension pulley ass...

Page 275: ...8 6 Removing the cylinder cover assembly Fig 5 8 7 Removing the fuel injector assembly Removing the heater water return pipe component 1 Remove the 2 hexagon flange face bolts M6 16 connecting the hea...

Page 276: ...the intake exhaust camshaft assembly 1 Take the intake exhaust camshaft assembly out of the cylinder head See Fig 5 8 8 2 Remove the blank cover and the camshaft front oil seal from the cylinder head...

Page 277: ...anaerobic plane sealant Prompt If the original cylinder head is still used the junction surface between the camshaft bearing cap and the cylinder head should be cleaned before being spread with sealan...

Page 278: ...d of the fuel injector ballast on ballast supporting bolt and the other end in fuel injector ballast groove 5 Install and tighten the fastening bolt components of fuel injector ballast by the required...

Page 279: ...as per specified torque See Fig 5 8 18 Tightening torque for the fastening bolt of water outlet pipe connecting pipe 23N m 3N m 2 Connect the vacuum connecting pipe Installing the fuel return hose co...

Page 280: ...nnectors at the same time in installation so as to avoid the oil pipe deformation Installing the timing system 1 Install the woodruff key to the exhaust camshaft install the timing pulley to the exhau...

Page 281: ...indicator is 1 2 past the lower verge of the installation arm notch and tighten the fastening bolts After removing the hexagon socket head spanner the mounting dowel pin of camshaft pulley and the cra...

Page 282: ...tighten it according to the required torque Visually checked the pulleys should be on the same plane Tightening torque for wedge idle wheel 22N m 26N m 2 Reinstall the generator belt use a tool to tu...

Page 283: ...essories Timing system Fuel inlet pipes of fuel injector and fuel rail Fuel return hose component Water outlet pipe connecting pipe component Heater water return pipe component Cylinder cover assembly...

Page 284: ...the fastening bolts of the wedge idle wheel and then remove the wedge idle wheel assembly See Fig 5 9 3 Removing the timing system 1 Remove the timing hood component 1 and timing hood unscrew 10 hexa...

Page 285: ...t the clip pull out the fuel return connector from the fuel injection circuit and then remove fuel return hose component Fig 5 9 6 Removing heater water return pipe component Removing the water outlet...

Page 286: ...from greasy dirt or being bumped Removing the camshaft bearing cap 1 Remove the 22 hexagon flange face bolts M6 35 and M6 20 fastening the camshaft bearing cap and cylinder head symmetrically from the...

Page 287: ...cylinder head gasket from the cylinder body Warning If the cylinder head bolts are not orderly unscrewed in separated times the lower surface of the cylinder head might be damaged Check the cylinder...

Page 288: ...eal remover 5 8840 0373 0 3 Make pressure leakage test on the valve oil seal The specifications are as follows under the pressure of 50 70 kPa the amount of leaking gas should be no more than 20 mL mi...

Page 289: ...and clean it with silk 2 Insert the cylinder head dowel pin sleeve into the corresponding pin holes on the cylinder body with a special tool and make sure they are properly assembled fit the fixing ho...

Page 290: ...he bearing holes of the intake and exhaust camshafts in the cylinder head Mobil API CI 4 lubricating oil 2 Install the intake and exhaust camshafts into the cylinder head as shown in Fig 5 9 21 3 Alig...

Page 291: ...uum pump fastening bolt 9N m 3N m Installing the fuel injector assembly 1 Tighten the support bolts of the fuel injector ballast by the required torques onto the cylinder head Tightening torque for su...

Page 292: ...6 Tightening torque for fastening bolt of cylinder cover 9N m 3N m Installing the heater water return pipe component 1 Install the heater water return pipe component Tighten the 2 hexagon flange face...

Page 293: ...fuel injector 1 Install the fuel inlet pipe of injector tighten evenly the pipe connectors at both ends of the fuel pipes as shown in Fig 5 9 30 2 Install the fuel inlet pipe of the fuel rail tighten...

Page 294: ...s After removing the hexagon socket head spanner the mounting dowel pin of camshaft pulley and the crankshaft locking tooling turn the camshaft for two circles clockwise with a spanner to make sure th...

Page 295: ...use a tool to turn the tension pulley and install it after the belt is loose enough See Fig 5 9 37 After the installation check the generator belt Make sure the belt wedge shaped teeth perfectly match...

Page 296: ...gasket Removal procedure Engine accessories Timing system Fuel inlet pipes of fuel injector and fuel rail Fuel return hose component Water outlet pipe connecting pipe component Heater water return pi...

Page 297: ...Fig 5 10 3 Removing the timing system 1 Remove the timing hood component 1 and timing hood unscrew 10 hexagon flange face bolts M6 16 M10 35 and M10 50 fastening the timing hood component 1 and timing...

Page 298: ...eater water return pipe component Fig 5 10 7 Removing the cylinder cover assembly Removing the water outlet pipe connecting pipe component 1 Uninstall the vacuum connecting pipe 2 Remove 2 hexagon fla...

Page 299: ...ed fuel injectors carefully according to the cylinder sequence numbers 1 2 3 and 4 and make the corresponding marks to these fuel injectors Protect them from greasy dirt or being bumped Removing the c...

Page 300: ...he EGR condenser 2 Remove the clamp at the connection of the oil cooler water inlet pipe and outlet pipe component 3 Remove the cylinder head assembly loosen orderly the 10 bolts M11 1 5 162 for faste...

Page 301: ...ter installation Installing the vacuum pump assembly 13 1 Install the vacuum pump at the rear end of the cylinder head 2 Remove the 2 hexagon flange face bolts M6 20 connecting the vacuum pump and cyl...

Page 302: ...ournal and inside the bearing holes of the intake and exhaust camshafts in the cylinder head Mobil API CI 4 lubricating oil 2 Install the intake and exhaust camshafts into the cylinder head as shown i...

Page 303: ...t as per the specified torques onto the cylinder head Tightening torque for supporting bolt of fuel injector ballast 23N m 3N m 2 Install the copper washer and O ring to the fuel injector and make sur...

Page 304: ...16 connecting the heater water return pipe to the cylinder cover 2 Tighten a hexagon flange face bolt M8 16 connecting the heater water pipe as per the specified torque to the cylinder head See Fig 5...

Page 305: ...et pipe of the fuel rail tighten evenly the pipe connectors at both ends of the fuel pipes Make sure the fuel inlet pipes of fuel injector and fuel rail are sealed without leakage after installation T...

Page 306: ...ting dowel pin of camshaft pulley and the crankshaft locking tooling turn the camshaft for two circles clockwise with a spanner to make sure that the damping pulley camshaft timing pulley and fuel pum...

Page 307: ...belt use a tool to turn the tension pulley and install it after the belt is loose enough After the installation check the generator belt Make sure the belt wedge shaped teeth perfectly matches the pu...

Page 308: ...ernal Combustion Engine Manufacturing Company Limited Section XI Timing Pulley Fig 5 11 1 Removal and installation procedures of the timing pulley Removal procedure Engine accessories Damping pulley a...

Page 309: ...ping pulley to the front end of the crankshaft See Fig 5 11 3 2 Remove the damping pulley assembly from the front end of crankshaft Removing the timing system 1 Remove the timing hood and the timing h...

Page 310: ...joint on the exhaust side of the cylinder head and the camshaft bearing cap See Fig 5 11 6 5 Adjust the mark position on the crankshaft timing belt pulley so as to align it with the arrow mark on the...

Page 311: ...flange bolts M6 6 M10 35 M10 50 to the cylinder head and the front end of the cylinder body with required torques Tightening torques for fastening bolts of the timing hood and the timing hoods I and I...

Page 312: ...lley with the mounting hole of the engine bracket tighten the tension pulley with fastening bolts Tightening torque for fastening bolt of tension pulley 53N m 57N m 3 Install the generator belt During...

Page 313: ...ng system of coolant 3 Place a container under the oil filter to connect the overflowed lubricating oil Warning Risk of burn from the hot engine oil handle the used oil properly and protect the enviro...

Page 314: ...cooler with the mounting mark on the cylinder body install the cooler on the seat of the oil filter on the cylinder body See Fig 5 12 4 Installing the pipe connector 1 Install the oil filter pipe conn...

Page 315: ...engine oil filter 5 8840 0020 0 No oil leakage is allowed at the oil filter After the installation please carry out the following operations 1 Connect the earthing cable of storage battery Fill coolan...

Page 316: ...ission Fig 5 13 2 Removing the transmission assembly Removal Preparation Disconnect the earthing cable of storage battery Removing the transmission assembly 1 Lift the vehicle and support it with a pr...

Page 317: ...lywheel and the pressure plate to allow alignment during the installation 5 Loosen the 9 bolts fastening the pressure plate in proper order and remove the clutch assembly See Fig 5 13 3 6 Remove the p...

Page 318: ...o the specified torque See Fig 5 13 5 and Fig 5 13 6 Tightening torque for flywheel bolt 75N m 5N m 4 Installing the primary shaft front bearing of transmission Use the installer to Install the primar...

Page 319: ...after tightening the fixing bolt of pressure plate to specified torque make sure to remove the string for protecting the diaphragm spring Installing the transmission assembly 1 Fit the 2 transmission...

Page 320: ...ufacturing Company Limited Section XIV Oil pump assembly Fig 5 14 1 Removal and installation procedures of the oil pump assembly Removal procedure Engine accessories Damping pulley assembly Timing sys...

Page 321: ...ion pulley 3 Remove the flat idle wheel assembly and wedge idle wheel assembly 4 Remove the power steering pump assembly and the steering pump bracket loosen the 3 or 4 hexagon flange bolts M8 30 fast...

Page 322: ...flange bolts M6 12 fastening the lower body of oil pan to the upper body of oil pan in proper order 2 Take off the oil pan lower body from the upper body See Fig 5 14 6 Removing the oil pump assembly...

Page 323: ...bolts M8 40 M8 20 in proper order and with specified torques See Fig 5 14 7 Tightening torque for fastening bolt subassembly of oil pump 23N m 3N m There should be no stagnation when the oil pump pul...

Page 324: ...on make sure the belts except the timing tension pulley are connected with the pulley firmly without any looseness 6 30 1 2 Install the timing tension pulley Fix the limit bracket of the timing tensio...

Page 325: ...m 3N m Installing the damping pulley 1 Install the elastic cylindrical pin into the pin hole of crankshaft timing belt pulley 2 Install the damping pulley to the front end of crankshaft and screw the...

Page 326: ...and wedge idle wheel and tighten the bolts with specified torques Tightening torques for fastening bolts of flat idle wheel and wedge idle wheel 22N m 26N m 4 After aligning the limit boss of tension...

Page 327: ...20 Installing the earthing cable of storage battery After the installation please carry out the following operations 1 Connect the earthing cable of storage battery See Fig 5 14 20 2 Fill the lubricat...

Page 328: ...an assembly Fig 5 15 1 Installation and removal procedures for the oil pan assembly Removal procedure Generator belt Refrigeration compressor assembly Engine oil dipstick guide subassembly and engine...

Page 329: ...rigeration compressor assembly 1 Remove the 4 hexagon flange face bolts M8 28 fastening the refrigeration compressor to the cylinder body and oil pan See Fig 5 15 3 2 Take off the refrigeration compre...

Page 330: ...the upper body assembly of oil pan Fig 5 15 7 Installing the oil collector assembly Installation Installing the upper body assembly of oil pan Check the junction surface between the oil pan upper bod...

Page 331: ...ane sealant to the junction surface between the oil pan lower body and upper body evenly See Fig 5 15 8 LOCTITE587 plane sealant 3 Install the oil pan lower body onto the upper body and tighten the 14...

Page 332: ...ed torque See Fig 5 15 11 Tightening torque for the fastening bolt of refrigeration compressor 23N m 3N m Installing the generator belt 1 Install the generator belt properly and make sure the belt wed...

Page 333: ...val and installation procedures for the piston and connecting rod assembly Removal procedure Engine assembly Engine accessories Timing system Cylinder head assembly Connecting rod cover Piston and con...

Page 334: ...ct the earthing cable of storage battery 2 Drain the cooling system of coolant 3 Drain out the engine oil in the lubrication system of the engine Warning When draining out the engine oil the hot oil m...

Page 335: ...head and cylinder body and remove the cylinder head Caution If the cylinder head bolts are not orderly unscrewed in several times the lower surface of the cylinder head might be damaged Removing the o...

Page 336: ...removing the piston and connecting rod use a scraper to clear the carbon deposits on the upper part of cylinder wall See Fig 5 16 8 2 Move the piston to the top of the cylinder and push the lower part...

Page 337: ...and the installation position Removing the piston 11 1 Remove the piston copper bushes from both ends of the piston as shown in Fig 5 16 13 2 Place the removed pistons by group according to the cylin...

Page 338: ...oil ring component the second compression ring and the first compression ring into the corresponding piston ring grooves in order 2 The piston ring should be installed to the piston ring groove in a c...

Page 339: ...ton ring compressor 5 8840 9018 0 Attention The front mark on the piston top should be toward the engine front Piston cylinder clearance 0 07 0 09mm Fig 5 16 18 Inspection for open end of piston ring...

Page 340: ...y is clean before reapplying sealant 2 Tighten the 15 hexagon flange face bolts M8 25 M6 20 M6 110 and M8 45 connecting the oil pan upper body and the lower cylinder body to the specified torque in or...

Page 341: ...ened Otherwise oil leakage may occur Before applying sealant again make sure the junction surface between the upper and lower bodies of oil pan is clean Installing the cylinder head assembly 1 Install...

Page 342: ...er arm overlapping on the valve as shown in Fig 5 16 25 3 Install the intake and exhaust camshafts Apply an appropriate amount of lubricating oil in the bearing holes of intake and exhaust camshafts o...

Page 343: ...e fuel injector Screw down the supporting bolt of fuel injector ballast to the cylinder head as specified Tightening torque for the supporting bolt of fuel injector ballast 23N m 3N m Install the copp...

Page 344: ...njector Take off the dust covers at both ends of the fuel inlet pipe of the fuel injector Install the fuel inlet pipe of the fuel injector as shown in Fig 4 5 30 and tighten the pipe connectors to the...

Page 345: ...nd tighten the fastening bolts After taking off the hexagon socket spanner camshaft pulley dowel pin and crankshaft locking tooling turn the crankshaft by 2 circles clockwise with the spanner to make...

Page 346: ...e for the fastening nuts of engine bracket 95N m 10N m 3 Install the power steering pump the refrigeration compressor and the generator belt After the installation check the generator belt Make sure t...

Page 347: ...ction XVII Front oil seal of crankshaft Fig 5 17 1 Removal and installation procedures for the front oil seal of crankshaft Removal procedure Engine accessories Damping pulley assembly Timing hood Tim...

Page 348: ...8 20 for fastening the damping pulley at the front end of crankshaft See Fig 5 17 3 2 Remove the damping pulley assembly from the front end of crankshaft Removing the timing hood 1 Remove the 6 hexago...

Page 349: ...Mobil API CI 4 lubricating oil 2 Press the front oil seal of crankshaft into the corresponding hole on the engine oil pump with special tools See Fig 5 17 6 Installer of front oil seal 5 8840 2361 0...

Page 350: ...7 9 Tightening torque for the fastening bolt of timing hood 45N m 3N m Fit the seal strips I and II of the timing hood into the sealing grooves I and II of the timing hood respectively Align the mount...

Page 351: ...and wedge idle wheel assembly and then tighten the bolts to the specified torque as shown in Fig 5 17 11 Tightening toque for the flat idle wheel and wedge idle wheel 22N m 26N m 3 Install the genera...

Page 352: ...oil seal of crankshaft Fig 5 18 2 Removing the earthing cable of storage battery Removal Preparation 1 Disconnect the earthing cable of storage battery See Fig 5 18 2 2 Lift the vehicle to an appropr...

Page 353: ...Fig 5 18 4 Guide centering device 5 5825 3001 0 2 Make a mark on the flanges of flywheel and pressure plate to facilitate the alignment during the installation 3 Loosen 9 bolts that fasten the clutch...

Page 354: ...oil seal 3 Install the connector of the special tool to the rear end of the crankshaft with 2 bolts 4 Install the oil seal to the cylindrical surface of the connector 5 Insert the socket into the con...

Page 355: ...bly 23N m 3N m Attention If a new pressure plate is installed the wire for protecting the diaphragm spring must be removed after the fixing bolts of the pressure plate are tightened to specified torqu...

Page 356: ...them in the opposite order of removal Removal procedure Transmission assembly Engine assembly Engine accessory Damping pulley assembly Timing system Cylinder head assembly Clutch assembly Flywheel ge...

Page 357: ...2 Remove the transmission assembly Remove the rotation speed sensor connector Remove the bolts connecting the transmission and clutch in proper order and remove the transmission assembly See Fig 5 19...

Page 358: ...ig 5 19 6 2 Remove the damping pulley assembly from the front end of crankshaft Removing the timing system 1 Remove the timing hood components I and II and the timing hood from the front end of the en...

Page 359: ...liquid on the clutch surface and clean it immediately 1 Remove the pressure plate assembly Remove the driven disc assembly 3 Use guide centering device to prevent the clutch from falling off the drive...

Page 360: ...bolts and flat ring components M8 40 M8 25 and M8 20 fastening the engine oil pump and cylinder body in proper order and remove the engine oil pump assembly See Fig 5 19 12 2 Take out the outer rotor...

Page 361: ...tening bolts of the lower cylinder body from both sides of the cylinder body to the middle in proper order Removing the crankshaft and the crankshaft position signal panel 14 1 Remove 3 hexagon lobula...

Page 362: ...ly an appropriate amount of lubricating oil between the crankshaft thrust plate and crank arm thrust surface Mobil API CI 4 lubricating oil 2 Install the upper thrust plate in the rabbet of the upper...

Page 363: ...shaft rear oil seal to be installed and make sure it is clean without impurity 2 Apply an appropriate amount of lubricating oil to the lip oil groove and the cylindrical surface of the oil seal assemb...

Page 364: ...ntion Two compression rings are not interchangeable Piston ring should not tilt There should not be any defect or impurity in the piston ring groove The three piston rings should be installed into the...

Page 365: ...engine pump cavity of the upper cylinder body with the marks of internal and external rotors on the same side See Fig 5 19 27 Mobil API CI 4 lubricating oil 4 Install the engine oil pump assembly and...

Page 366: ...olts M8 12 on the fixing oil collector bracket after installing oil pan 4 Check the junction surfaces of the upper and lower bodies of the oil pan and make sure there is no dirt or scratch Apply silic...

Page 367: ...ly 1 Driven disc assembly Grease the spline of the clutch driven disc hub with molybdenum disulfide grease Install the driven disc by guide centering device Guide centering device 5 5825 3001 0 2 Pres...

Page 368: ...e ball head of the hydraulic clearance adjuster with lubricating oil of proper amount Fit the hydraulic clearance adjuster to the clip at the rear end of the rocker arm as shown in Fig 5 19 35 And mak...

Page 369: ...e supporting bolt of fuel injector ballast to the cylinder cap as specified Tightening torque of supporting bolt of fuel injector ballast 23N m 3N m Install the copper washer and O ring of fuel inject...

Page 370: ...Install the camshaft timing pulleys and the crankshaft timing pulleys Fit the woodruff key and the camshaft timing pulley to the exhaust camshaft and tightly tighten the fastening bolt and gasket suba...

Page 371: ...ming tension pulley into the position for mounting the bowl shaped plug onto the cylinder head After the mounting pin of the timing tension pulley is adjusted by a socket head spanner so that it is al...

Page 372: ...ries Fig 5 19 47 Installing the engine assembly Installing the engine accessories 1 Install the steering pump support 2 Install the engine bracket and the engine assembly See Fig 5 19 46 3 Install the...

Page 373: ...l the transmission assembly Screw down the fastening bolts connecting the transmission and clutch in proper order and as per specified torque 3 Install the drive shaft After the installation please ca...

Page 374: ...mbly Engine accessory Damping pulley assembly Timing system Cylinder head assembly Water pump assembly Clutch assembly Flywheel gear ring assembly Oil pan lower part assembly oil collector assembly an...

Page 375: ...t the flange yoke 2 Remove the transmission assembly 3 Remove the bolts connecting the transmission and the clutch in proper order and remove the transmission assembly See Fig 5 20 3 Removing the engi...

Page 376: ...II the timing hood and the timing rear hood loosen respectively the 15 hexagon flange bolts M6 16 M10 35 M10 50 fastening the timing hood components and II and the timing hood and remove them from th...

Page 377: ...t orderly unscrewed in separated times the lower surface of the cylinder cap might be damaged Removing the clutch assembly 1 Remove the 6 hexagon flange bolts M8 25 M8 30 M10 25 connecting the water p...

Page 378: ...emove in order the 14 hexagon flange bolts M6 12 fastening the oil pan lower body and remove the oil pan lower body See Fig 5 20 12 2 Use a spanner to remove 2 hexagon flange bolts M6 16 fastening the...

Page 379: ...crankshaft Removing the crankshaft rear oil seal 13 1 Remove the crankshaft rear oil seal from the rear oil sealing groove behind the cylinder body with special tools See Fig 5 20 15 Detacher for the...

Page 380: ...wearing condition of the wall of the cylinder bore and replace the upper and lower cylinder bodies if the condition is worse than that required Installation Installing the upper cylinder body 17 1 Ins...

Page 381: ...e the main shaft bearing shell as shown in Fig 4 4 1 4 4 2 Install the upper main shaft bearing shell with oil groove and oil hole to the upper cylinder body and the lower main shaft bearing shell wit...

Page 382: ...stall the 10 main bearing cap bolts M11 1 5 X87 and tighten them with required torque in order by three steps See Fig 5 19 20 Install the 11 hexagon flange bolts M8 80 connecting and fastening the upp...

Page 383: ...iston Fig 5 20 27 Installing the piston ring 4 Apply an appropriate amount of lubricating oil to the piston ring before the installation use the piston ring expander to install the oil ring component...

Page 384: ...ce the front of crankcase Installing the engine oil pump assembly 11 1 Apply a small amount of lubricating oil to the engine oil pump seal ring and insert the seal ring into the bottom of the correspo...

Page 385: ...inder body and install the oil pan upper body to the cylinder body LOCTITE587 flat sealant Attention make sure the joint surface between the upper body of oil pan and the cylinder body is clean before...

Page 386: ...bolts should be tightened Otherwise oil leakage may occur Before applying sealant again make sure the joint faces of the upper and lower bodies of the oil pan are clean Installing the electric wheel...

Page 387: ...the cylinder body and tighten the 6 hexagon flange face bolts M8 25 M8 30 M10 25 with required torque See Fig 5 20 36 Tightening torques for fastening bolt of the water pump M8 23N m 3N m M10 45N m 3N...

Page 388: ...m Lubricate the ball head of the hydraulic clearance adjuster with lubricating oil of proper amount Insert the hydraulic clearance adjuster to the clip at the rear end of the rocker arm as shown in Fi...

Page 389: ...ector 7 Install the fuel injector assembly Screw down the fuel injector ballast supporting bolt to the cylinder head as specified Tightening torque for supporting bolt of fuel injector ballast 23N m 3...

Page 390: ...tor fuel inlet pipe at the same time in installation so as to avoid the oil pipe deformation Installing the timing system 1 Install the camshaft timing pulleys and the crankshaft timing pulleys Fit th...

Page 391: ...s except the tension pulley are connected with the pulley without any looseness as shown in Fig 5 20 46 6 Install the timing tension pulley Embed the limit support of timing tension pulley into the po...

Page 392: ...ig 5 20 51 Installing the engine assembly Tightening torque for fastening bolt of damping pulley 23N m 3N m Attention After the assembly the timing mark of the damping pulley should be set forward Ins...

Page 393: ...ack end face of the cylinder head by a special tool there should be no deflection or improper mounting 2 Install the transmission assembly Screw down the fastening bolts connecting the transmission an...

Page 394: ...re common rail fuel supply system It primarily consists of sensor group ECU actuator group and the harnesses connecting with these parts There are different sensors such as camshaft position sensor cr...

Page 395: ...Arrangement for fuel supply pipeline of XINFENG common rail system Fuel tank Fuel filter High pressure fuel rail assembly Fuel return tee High pressu re fuel pump assembly Electronic control unit Fue...

Page 396: ...ump delivers fuel to the high pressure fuel pump through the low pressure actuator MV The fuel delivery volume is in direct proportion to diesel engine speed The low pressure actuator i e IMV see Fig...

Page 397: ...ped with a fuel filter which has an oil water separator used for draining see Fig 6 1 7 With the engine application time increasing and the water level in the fuel filter reaching a certain height the...

Page 398: ...re fuel pump has a sliding sheet type fuel delivery pump which provides a fuel delivery pressure of 0 8 bar XINFENG M680 high pressure fuel pump is a in line two cylinder plunger pump and can withstan...

Page 399: ...e so as to ensures that the injection pressure maintains a fixed value when fuel injector is opened The high pressure fuel rail meanwhile serves as a fuel distributor One of the fuel pipe connectors i...

Page 400: ...time flows out of the fuel return connector of safety valve The safety valve closes after the pressure is released and the system restore to the normal working status If the safety valve is under the...

Page 401: ...shall not be knocked Magnetic and antimagnetic devices shall be kept away from the fuel injector when it is working 3 The fuel injector is electrically driven and can not be shocked by water 4 Do not...

Page 402: ...tall the harness plugs of fuel injector 2 6 ECU Electronic Control Unit ECU is the abbreviation for the electronic control unit of common rail system Its built in processor chip is responsible for col...

Page 403: ...er the installation make sure that the sensor is sealed so strictly that no water leakage will occur 2 7 2 Camshaft Position Sensor Camshaft position sensor works on the principle of Hall effect The t...

Page 404: ...ated by a small air gap There is a soft iron core in the sensor This core is surrounded by the coils and connected with a permanent magnet Fig 6 1 28 Working principle of Hall Effect phase sensor cams...

Page 405: ...agnetic field will be created so that the electromagnetic coil produces a sinusoidal sensing voltage the amplitude of alternating voltage increases as the rotating speed of trigger wheel increases i e...

Page 406: ...ic knock sensor See Fig 6 1 30 This kind of sensor takes advantage of piezoelectricity of crystal or ceramic polycrystalline crystal to work but some use the piezoresistance with silicon to work The s...

Page 407: ...t any clearance See Fig 6 1 30 Tightening torque for fastening bolt of knock sensor 23 N m 3 N m 2 7 5 Accelerator pedal position sensor The working principle of potentiometer type pedal position sens...

Page 408: ...pe of air flow meter and then tighten the clip See Fig 6 1 33 Attention The arrow on the air flow sensor should be in the direction of air intake 2 7 7 Turbocharger pressure sensor The function of the...

Page 409: ...e sensor Benchmark A Glow plug 1 Glow plug 2 Glow plug 3 Glow plug 4 Nozzle 1 Nozzle 3 Nozzle 2 Nozzle 4 Rail pressure sensor Outgoing direction of harnesses Connected to engine compartment harness 1...

Page 410: ...oving the fuel hose 1 Loosen the fuel hose clip on fuel filter and pull out fuel inlet and outlet hoses See Fig 6 2 2 2 Block off fuel hose ends to avoid the fuel overflow Removing fuel filter 1 Loose...

Page 411: ...Operate the manual fuel delivery pump manual fuel pump for several times to check it for the fuel leakage 8 Install the fuel filter support and tighten its fixing bolts Prompt It is recommended to em...

Page 412: ...w the fuel water separator drain plug 3 Loosen the drain plug The tightening and loosening directions for drain plug are the same with those for common bolts See Fig 6 2 7 4 Operate the manual fuel de...

Page 413: ...403 2 Fuel Injector Assembly Fig 6 2 9 Fuel Injector Assembly Removal order DELPHI Fuel Supply System Removal order Fuel injector harness connector Fuel return pipe components Fuel inlet pipe of fule...

Page 414: ...urn pipe assembly Removing the fuel inlet pipe of fuel injector 1 Use a spanner to uniformly loosen the pipe connectors used to fasten both ends of 4 fuel inlet pipes of fuel injector See Fig 6 2 12 2...

Page 415: ...shall be entered into the new ECU Installation Installing the fuel injector 1 Fit the O ring of fuel injector in its groove 2 Make sure that each fuel injector has only one copper gasket that shall b...

Page 416: ...HI fuel injector insert respectively the fuel return rubber hoses into 4 injector heads and position them in place See Fig 6 2 16 2 2 For the BOSCH or XINFENG fuel injector remove the dust cap from th...

Page 417: ...mbly Fig 6 2 18 Removal and installation orders for High pressure fuel pump assembly Removal procedure Engine accessory Timing belt Fuel pump pulley Fuel inlet and outlet pipes of high pressure fuel p...

Page 418: ...lack the belt and then remove it as shown in Fig 6 2 20 Remove the fuel pump pulley 1 Remove the all metal hexagon flange locknuts M14 1 5 which is used to fasten the fuel pump pulley to the fuel pump...

Page 419: ...ber covers or equivalent articles to avoid the introduction of foreign matters Installation Installing the high pressure fuel pump assembly 1 Install the high pressure fuel pump to the left of the cyl...

Page 420: ...y Install the fuel pump pulley to the fuel pump and tighten the pulley by a all metal hexagon flange locknut M14 1 5 See Fig 6 2 25 Tightening torque for the locknuts of the fuel pump pulley 65 N m 3...

Page 421: ...oolant meanwhile cools the oil in the engine oil filter Fig 7 1 1 Schematic diagram for engine cooling system Fig 7 1 2 Water pump assembly 1 Water pump The water pump is a centrifugal vane type see F...

Page 422: ...valve opens at a pressure of 88 118 kPa 2 The overflow rubber pipe of radiator is connected with overflow tank as shown in Fig 7 1 4 3 A drain plug water drain switch is attached at the bottom of radi...

Page 423: ...9 0 15 1 5 8 5 20 2 0 8 0 25 2 5 7 5 30 3 0 7 0 35 3 5 6 5 40 4 0 6 0 45 4 5 5 5 50 5 0 5 0 3 Mixing ratio Measure the specific gravities of coolant between 0 and 50 in the engine cooling system and...

Page 424: ...ing Company Limited Section II On Board Maintenance 1 Water Pump Assembly Fig 7 2 1 Removal and installation orders of water pump assembly Removal order Engine accessory Damping pulley assembly Timing...

Page 425: ...sory Removing the damping pulley assembly 1 Remove the 4 hexagon flange bolts M8 20 which are used to fasten damping pulley at the front end of crankshaft See Fig 7 2 3 2 Remove the damping pulley ass...

Page 426: ...during the check the necessary repair and parts replacement shall be performed The whole water pump assembly shall be replaced if any of the following symptoms occurs 1 The water pump block has any c...

Page 427: ...nts for fuel inlet pipe and fuel return pipe of high pressure fuel pump 4 Install the fuel inlet pipe components of fuel rail and use the specified torque to uniformly tighten the pipe connectors at b...

Page 428: ...llation holes Mount 15 hexagon flange bolts M6 16 M10 35 and M10 50 to the front end of cylinder head and the cylinder body and then tighten these bolts by the required torques See Fig 7 2 11 Tighteni...

Page 429: ...lts of accessory tension pulley 53 N m 57 N m 3 Install the generator belt to make the belt of all pulleys except flat idle wheel in place and ensure that the belt wedge teeth and the pulley wedge too...

Page 430: ...ig 7 2 17 2 Prepare a standby container for collecting the discarded coolant since the coolant is poisonous Properly dispose of the discarded coolant so as to protect the environment 3 Remove the drai...

Page 431: ...18 Removing the thermostat cap 1 Remove 2 hexagon flange bolts M6 20 used for fastening the thermostat cap to the thermostat chamber in cylinder body 2 Remove the thermostat cap from the cylinder body...

Page 432: ...If any severe wear or damage is found on the thermostat during the check then the necessary repair and parts replacement shall be performed 4 Check the thermostat valve lift as shown in Fig 7 2 22 Th...

Page 433: ...tallation the pipe orifice of thermostat cap shall face the front bottom of diesel engine and there shall be no water leakage at the joints Installing the water inlet pipe 1 Fit water inlet pipe to th...

Page 434: ...oolant since the coolant is poisonous Properly dispose of the discarded coolant so as to protect the environment 3 Loosen the drain plug to drain away the coolant from the engine cooling system Warnin...

Page 435: ...ss terminals 2 Remove the bolts fastening the cooling fan and the radiator and take off the cooling fan from the radiator See Fig 7 2 30 Caution In removal operation take care to prevent the radiator...

Page 436: ...ssage by the water and neutral cleaning solution Remove all incrustation and scale 4 Checking the coolant leakage Send the compressed air with a pressure of 196 9 kPa from the radiator filling hole in...

Page 437: ...at the connection point between the upper water rubber hose of radiator and the radiator and tighten the clip See Fig 7 2 35 Installing the overflow tank rubber hose 1 Fit the overflow tank hose to th...

Page 438: ...ormal operation Lubricating oil circuit of turbocharger the lubricating oil flows into the turbocharger from the main oil duct of diesel engine cylinder through the oil inlet pipe and flows back to th...

Page 439: ...oving the air intake pipe of turbocharger Removal Preparation 1 Disconnect the earthing cable of storage battery 2 Place a container under the oil filter to receive the spilled oil Warning Hot oil may...

Page 440: ...he seal ring of oil filter Installation Installing the oil filter Prompt Oil filter core is a disposable part and should not be reused 1 Coat the O ring of oil filter with a thin layer of oil as shown...

Page 441: ...ir intake pipe connector for leakage after the installation Fig 8 2 6 Installing the air intake pipe of turbocharger After the installation please carry out the following operations 1 Connect the eart...

Page 442: ...imited 2 Engine Oil Pump Fig 8 2 8 Removal and installation procedures of oil pump Removal procedure Engine accessories Damping pulley assembly Timing system Engine oil dipstick guide subassembly and...

Page 443: ...8 2 6 6 Remove the generator and its bracket Removing the damping pulley assembly 1 Remove the 4 hexagon flange bolts M8 20 for fastening damping pulley at the front end of crankshaft See Fig 8 2 10...

Page 444: ...out the front oil seal of crankshaft through the oil seal hole of oil pump crankshaft Front oil seal stripper 5 8840 2362 0 Inspection and repair 1 Replace the oil pump assembly when the rotor is fou...

Page 445: ...er body and screw down 6 hexagon flange bolts M6x12 according to the specified torque and order as shown in Fig 8 2 16 Tightening torque for fastening bolt at lower body of oil pan 9 N m 3 N m Install...

Page 446: ...hout any looseness 6 Install the timing tension pulley Embed the limit support of timing tension pulley into the position for mounting the bowl shaped plug onto the cylinder head After the mounting pi...

Page 447: ...he specified torque See Fig 8 2 23 After the installation the belt pulleys must be in the same plane by visual check Tightening torques for the flat idle wheel and wedge idle wheel 22 N m 26 N m 2 Ali...

Page 448: ...Manufacturing Company Limited Fig 8 2 24 Installing the generator belt 1 Connect the earthing cable of storage battery 2 Fill lubricating oil to the lubrication system 3 Start the engine and check its...

Page 449: ...ing Company Limited 439 3 Oil Collector Fig 8 2 25 Removal and installation procedures of oil filter Oil pan upper part assembly Oil pan upper part assembly Removal procedure Lower body assembly of oi...

Page 450: ...f the oil pan lower body from the upper body Removing the oil filter 1 Remove 2 hexagon flange bolts M6x16 fastening oil pipe with spanner See Fig 8 2 27 2 Remove 2 hexagon flange bolts fastening the...

Page 451: ...OCTITE587 flat sealant Install the lower body of oil pan to the upper body and screw down 14 hexagon flange bolts M6x12 according to the specified torque and order as shown in Fig 8 2 30 Tightening to...

Page 452: ...ufacturing Company Limited 4 Oil Pan Fig 8 2 32 Removal and installation procedures of oil pan Removal procedure Engine oil dipstick guide subassembly and the engine oil dipstick Oil pan lower body as...

Page 453: ...olts M6 x 12 fastening the lower and upper bodies of oil pan with spanner orderly as shown in Fig 8 2 34 2 Take off the oil pan lower body from the upper body Removing the oil collector 1 Remove 2 hex...

Page 454: ...ing the oil collector 1 Apply appropriate volume of lubricating oil to the oil collector seal Mobil API CI4 lubricating oil 2 Align the oil collector with the oil suction hole of oil pan and put the o...

Page 455: ...e engine oil dipstick 1 Check if the seal ring of oil dipstick guide connector is in good condition and install it in place 2 Insert one end with the seal ring of oil dipstick guide assembly into the...

Page 456: ...jects to the turbine impeller with a certain angle Thus the heat and pressure energies of the exhaust gas are converted into kinetic energy which rotates the turbine at a high speed as shown in Fig 9...

Page 457: ...WGT turbocharger turbocharger with the bypass valve will release a portion of the exhaust gas from the turbine front via the exhaust valve The air release valve in front of the turbine is automatical...

Page 458: ...imited Fig 9 1 7 Identification of the subassembly chamber can not be maintained If there is any damage the whole turbine housing device should be replaced 2 6 Identification of the subassembly The ma...

Page 459: ...al and installation procedures of the turbocharging system WGT turbocharger VGT turbocharger Removal procedure Turbocharger intake hose Air cleaner Catalytic converter pipe Turbocharger heat shield Tu...

Page 460: ...take pipe of the turbocharger 3 Remove the fastening bolt connecting the air cleaner and the body and take off the air cleaner See Fig 9 2 3 The air cleaner filter core should be replaced in the follo...

Page 461: ...emoving the turbocharger fuel return hose component 1 Remove 2 hexagon flange face bolts M6 16 fastening the turbocharger fuel return hose component and the turbocharger See Fig 9 2 7 2 Remove the sin...

Page 462: ...nect the hose to the fuel return hose component and the cylinder fuel return connector and properly install the single ear stepless clip in place See Fig 9 2 7 Installing the turbocharger fuel inlet b...

Page 463: ...ner housing and the machine body See Fig 9 2 12 2 Install the air intake hose connecting the air cleaner and the turbocharger and fasten it with the clip See Fig 9 2 12 3 Connect the air cleaner harne...

Page 464: ...the gas compressor housing the turbine housing and 2 turbine impeller surfaces 6 Fill an appropriate amount of the cleaning agent via the fuel inlet port and rotate the impeller by hands repeatedly t...

Page 465: ...nce and bearing clearance of the impeller shafts are for reference only 3 Checking the axial clearance of the impeller shaft Measure the axial clearance of the impeller by dial indicator See Fig 9 3 3...

Page 466: ...e bearing by the dial indicator See Fig 9 3 5 Bearing clearance of the impeller shaft Standard value Limit value Limit value 0 215mm 6 Checking the radial clearance of the rotor During the inspection...

Page 467: ...rdingly to always allow the EGR system to work under the condition of good emission control and good engine power If the introduced exhaust gas is too much the engine power will decrease the smoke wil...

Page 468: ...nufacturing Company Limited Section II On board Maintenance Fig 10 2 1 Installation and removal procedures of EGR System Removal procedure EGR valve harness plug EGR condenser component EGR valve asse...

Page 469: ...tlet pipe of the EGR condenser See Fig 1 2 3 2 Remove 2 hexagon flange bolts M8 x20 from the intake pipe of the EGR condenser See Fig 1 2 3 3 Loosen the single ear stepless clip fastening the water in...

Page 470: ...nd the EGR condenser air intake pipe gasket at the exhaust manifold pipe Install the EGDD condenser air intake pipe and tighten 2 hexagon flange face nuts and 2 hexagon flange face bolts M8x20 as per...

Page 471: ...of the EGR valve 1 Connect the EGR valve harness connector to the EGR valve See Fig 10 2 7 2 Check the EGR valve harness plug to ensure it is firmly connected After the installation please carry out t...

Page 472: ...e 90 Height of the electrolyte level over the polar plate mm 10 15 Overall dimension mm length width height 300 x 170 x220 Electrolyte specific gravity See Table 11 1 2 and Table 11 1 3 Table 11 1 2 E...

Page 473: ...electrolyte density at 25 C dt the electrolyte density at temperature of t 0 0007 temperature factor t the electrolyte temperature practically measured The proportion of pure water or distilled water...

Page 474: ...nt to use and can be unattended during charging therefore are widely used 2 Controlled silicon voltage regulation charger The controlled silicon voltage regulation charger applies power supply of 220...

Page 475: ...ion 3 to 4 times Single cell can produce plenty of bubbles The equalizing charge stops when the storage battery voltage and electrolyte density tend to be stable Constant current charge it is the char...

Page 476: ...charging Fig 11 1 2 Checking the electrolyte specific gravity of storage battery 4 Checking the Storage Battery Remaining Capacity 1 Checking the electrolyte specific gravity with a specific gravity...

Page 477: ...voltage that storage battery can maintain under high load discharging By doing this the storage battery discharging rate and starting ability can be judged For high rate discharge gauges produced by d...

Page 478: ...oltage 12 V Output power 2 kW Rotation direction clockwise view from the drive gears 1 2 Starter The magnetic gear reduction starter is adopted in the starting system and the starter shaft is used as...

Page 479: ...arates from the gear ring and the armature stops rotating When the engine speed is higher than that of the pinion the latter will be idling so as not to drive the armature to rotate 1 3 Starting Circu...

Page 480: ...e of the storage battery See Fig 11 2 5 Removing terminal Remove the fastening nut for tightening the starting switch wire terminal and then remove the wire Removing the harness plug Hold the plug and...

Page 481: ...ssembly into the mounting hole at the rear end of the cylinder body The rabbet of the starter should be accurate 2 Install the 2 hexagon flange bolts M10 115 fastening the starter to the cylinder body...

Page 482: ...ustion Engine Manufacturing Company Limited Fig 11 2 9 Installing the storage battery cables After the installation please carry out the following operations 1 Connect the earthling cables for the sto...

Page 483: ...y will discharge through silicon diode and burn out the latter 2 After the generator is started check whether the generator is generating electricity with a bulb or multimeter instead of spark test ot...

Page 484: ...des should be replaced Then rest the negative testbar on the out terminal of the diode and the positive testbar on the rear cover The value shown on the ammeter should be above 10000 If the ohm value...

Page 485: ...or installed on the vehicle dashboard See Fig 11 3 7 The indicator is on when the starting switch is turned to ON position If the indicator is off after the engine is started it means the charging sys...

Page 486: ...Fig 11 3 9 On board checking of the charging system W terminal Storage battery Starting switch Fuse Fuse Fuse Oil seal Generator s terminal W terminal Charging relay L terminal IG terminal Charging al...

Page 487: ...ng Company Limited 477 3 On board Maintenance Fig 11 3 10 Removal and reinstallation procedures of the generator assembly Removal procedure Generator terminals and harness plug Generator belt Generato...

Page 488: ...ut the harness plug connected with the generator Caution Pull the plug connector instead of the harness the wire when separating the connector Removing the generator belt Turn the tension pulley with...

Page 489: ...ge slot See Fig 11 3 15 2 Turn the tension pulley with a tool till the generator belt is loose enough and then fit the accessory flat idle wheel into the belt Make sure there is no excessive tension o...

Page 490: ...the earthing cable of the storage battery After the installation please carry out the following operations 1 Connect the storage battery cable with the negative cable connected last See Fig 11 3 17 At...

Page 491: ...ion eyelet loose connections or other damaged that may result in exhaust leakage into the rear compartment or the passenger compartment If there is dust or water in the rear compartment it means that...

Page 492: ...ed catalyst repair or replace it 4 Check for depression damage or the eyelet or crack due to corrosion Section III Front Exhaust Pipe Fig 12 3 1 Removal procedure for front exhaust pipe Installation p...

Page 493: ...he front exhaust pipe Fig 12 3 4 Removing the muffler Removing the Front Exhaust Pipe 1 Remove the fastening bolt and nut which connect the front exhaust pipe and the muffler See Fig 12 3 3 2 Take off...

Page 494: ...t pipe See Fig 12 3 7 2 Connect the front exhaust pipe with the muffler install the sealing gasket and screw down the bolt and nut as per the specified torque See Fig 12 3 7 Tightening torque for the...

Page 495: ...arger screw down the fastening bolts which connect with the catalytic converter pipe and the exhaust elbow as per the specified torque Tightening torque for the bolt and nut of catalytic converter pip...

Page 496: ...related to the reasonableness of the air flow sensor high Exhaust gas recirculation EGR valve P0400 Excessive control error of EGR valve air flow Lit up in the third driving circle Not lit up Slightl...

Page 497: ...it to ground Fuel Injection System Fuel injector P0201 Broken circuit to 1 fuel injector the high end or the low end Lit up in the first driving circle Lit up Slightly reduce the torque by about 10 In...

Page 498: ...uel injector the correction value of MDP higher than the limit value Not lit up Not lit up P0266 Malfunction of the minimum drive pulse MDP drift for 4 fuel injector the correction value of MDP lower...

Page 499: ...1000 r min P0193 Malfunction of the rail pressure sensor high P1190 Malfunction of the rail pressure sensor malfunction of the supply voltage or the analog to digital converter P1194 Malfunction of t...

Page 500: ...000 r min P0253 Drive malfunction of the inlet metering valve IMV short circuit to ground P0254 Drive malfunction of the inlet metering valve IMV short circuit to the supply Inlet metering valve IMV P...

Page 501: ...Not lit up Lit up Camshaft position sensor P0341 Camshaft position signal not within the normal range thus cannot be received Not lit up Lit up P0340 Camshaft position signal completely lost Not lit...

Page 502: ...s resistance value too low 1 fuel injector Not lit up Lit up P1287 The harness resistance value too high 1 fuel injector P1292 The harness resistance value too low 3 fuel injector Not lit up Lit up P1...

Page 503: ...sor P0182 Malfunction of the oil temperature sensor low Lit up in the third driving circle Lit up Slightly reduce the torque by about 10 P0183 Malfunction of the oil temperature sensor high P1180 Malf...

Page 504: ...lfunction of the accelerator pedal position sensor in the 2nd way high P1220 Malfunction of the accelerator pedal position sensor in the 2nd way malfunction of the supply voltage or the analog to digi...

Page 505: ...tage high P1560 Malfunction of the battery voltage malfunction of the analog to digital converter External supply voltage P0642 Malfunction of 1 supply voltage the supply cut off due to overheating No...

Page 506: ...rcuit P0691 Drive malfunction of 1 electric fan short circuit to ground P0694 Drive malfunction of 2 electric fan short circuit to the supply Not lit up Lit up Moderately reduce the torque by about 20...

Page 507: ...Lit up Stop the engine immediately P1604 Malfunction related to integrity of the ECU internal memory integrity of the rated data Not lit up Lit up P1605 Malfunction related to integrity of the ECU in...

Page 508: ...p P1946 Vehicle collision signal sent by the airbag system control unit through CAN message received Not lit up Not lit up Anti theft chip ATC P0633 The key for the anti theft chip not written Not lit...

Page 509: ...er m2 cm2 mm2 Volume V Cubic meter Cubic centimeter Cubic millimeter Kiloliter liter Milliliter m3 cm3 mm kL kl L l mL ml Cubic meter Cubic centimeter Liter m3 cm3 L l Weight G Ton Kilogram Gram t kg...

Page 510: ...A mA Ampere A Rotation speed n Revolution per minute Revolution per second r min r s Revolution per minute r min 1 r min 1 60 s 1 Speed V Meter per second m s Meter per second m s Specific fuel consum...

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