Jac Refine Motor 2.8 PDF

WORKSHOP MANUAL
4DA1-2B SERIES TRUCKS

Mainly for the truck HFC1042K2T (D825)
JAC INTERNATIONAL
2008.04
JAC motors
4DA1-2B SERIES
WORKSHOP MANUAL
Foreword Contents
This workshop manual was prepared as Group
Name Page
reference to properly carry out servicing Code
and maintenance on JAC vehicles.
0000 General
All the maintenance data in this manual is
based on the model HFC1042K2T ( D825). 1000 Engine
And it also can be as reference for the
other models listed in the Chapter 1600 Clutch
“General”. Their main common
1700 Gearbox
configurations are as follows:
HFC4DA1-2B(HFC4DA1-2B1) engine; 2200 Driveshaft
JAC MSB-5M transmission, hydraulic
2400 Rear axle
brake and JAC new model cabin.
All information in this manual is the latest 2901 Front suspension

data and status of the vehicle at the time
2911 Rear suspension
of publishing for your reference. However,
due to technological advance or product 3000 Front axle
updating etc., all contents in this manual
are subject to modification. We reserve 3400 Steering gear
the right of modification of this manual
3500 Brake
without prior notice.
Please inform Customer Service 3700 Electric system
Department of JAC International if there is
any mistake, and you will be highly 5000 Cabin
appreciated.
Tel：0086-0551-2296344
Fax：0086-0551-2296454
Email：hwfw@jac.com.cn
General
General
Specifications
Vehicle Model
VIN
The mechanic performance table of bolts in China
Specifications
Main specifications of the trucks equipped with HFC4DA1-2B engine

The common configurations： HFC4DA1-2B engine, displacement: 2771cc; Max Power (Kw/rpm): 68/3600; Max Torque (N.m/rpm) : 210/2000-2200;
JAC MSB-5M transmission, hydraulic brake, JAC new model cabin, no power assist of clutch.
Series
Wheelbase Overall Size GVW Power Exhaust
Model Number Rear axle Tire A/C Pre-heater
(mm) （mm) （L*W*H) Kg Steering Braking
for produce
D817-5.375
HFC1042K3T D840 2490 4850*1730*2240 3495 7.00R16 option option yes yes
(4.875/5.714/5.571/6.142)
HFC1042K3RT
D842 ↑ ↑ 4918*1868*2154 ↑ ↑ ↑ ↑ ↑ ↑
double cabin
HFC1042K2T 3360 D800-6.142 5995*1900*2250 5740 7.00R16 option option yes yes
HFC1042K2R1T ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑
HFC1042K2RT
↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑
double cabin
Main specifications of the trucks equipped with HFC4DA1-2B1 engine
The common configurations： HFC4DA1-2B1 engine, displacement: 2771cc; Max Power (Kw/rpm):80/3600; Max Torque (N.m/rpm) : 240/2000-2200;
JAC MSB-5M transmission, hydraulic brake, JAC new model cabin, no power assist of clutch.
Series Number Wheelbase Overall Size GVW Power Exhaust
Model Rear axle Tire A/C Pre-heater
for produce (mm) （mm) （L*W*H) Kg Steering Braking
HFC1042K2T D825 3360 D800-6.142 5995*1900*2250 5740 7.00R16 option option yes yes
HFC1042K2R1T D826 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑
HFC1042K2RT
D827 ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑
double cabin
General
Vehicle Model
Company Vehicle Type Main Code from

Product
Code Name Code Specifications company
Serial No.
Code
Company Code Name：HFC-----represents JAC motor

Vehicle Type Code：1---Cargo truck 2---Off-road vehicle 3---Dumper
4---Tractor 5---Special purpose vehicle 6---Passenger car
7---Sedan 9---Semitrailer
Main Specifications Code：25---represents the maximum gross weight is 25 tons.
Product serial No.： 1---Product development serial No.（1st change，2nd development）
Code from company：K---Diesel R1---King cabin
For example：HFC3251KR1 represents JAC vehicle with king cab, 25 tons maximum gross weight,
the first change.
General
VIN----Vehicle Identification Number

VIN comprises of 17 digits. They separately represent:
黑色
中国安徽江淮汽车股份有限公司制造
36.5
VⅠN L J 1 1 K D F A 4 4 0 0 0 2 5 2 1
2- O 3
品牌：江淮型号 R2
73
发动机型号额定功率 kW
总质量 kg 整备质量 kg
出厂编号出厂日期年月
119
125
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
L J 1 1 K D B C X 8 X X X X X X X
Sequence Number
Vehicle Description
Symbol
Assembly Plant
World Manufacturer Identification

Year
Check Code
General
The mechanic performance table of bolts in China
Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9
Tensile strength limit  b max(MPa) 600 800 900 1040 1220
Yield limit  s max(MPa) 480 640 720 940 1100
Corresponding to Hyundai standards 4T 6T 7T 8T 10T

The number before the radix point represents one percent of the nominal tensile strength;
The number after the radix point represents ten times of the ratio of the nominal yield limit and
nominal tensile strength.
SECTION Ⅰ
ENGINE
HFC4DA1-2B(4DA1-2B1)
Introduction
We prepare this manual to help technicians get to know and understand 4DA1
Series engine so that they are able to master quick maintenance and service.
The manual gives you instructions on assembly and disassembly of parts and
systems of 4DA1 Series engine, general maintenance standards, special tools
as well as common fault diagnosis and troubleshooting.
Our products are subject to continuous innovation. If any information in this
manual is not applicable for the innovative products, the discrepancies will be
modified in a second edition.
No part or parts of this manual may be reproduced or illegally used in any form
or by any means without written consent of Jianghuai Automobile.
1
Table of Contents
1. Maintenance.......................................................................................................................................... 5
1.1 Diagnosis and troubleshooting ..................................................................................................... 5
1.1.1 Start problems..................................................................................................................... 5
1.1.2 Unstable idle speed ............................................................................................................ 7
1.1.3 Insufficient power................................................................................................................ 8
1.1.4 High fuel consumption ........................................................................................................ 9
1.1.5 High oil consumption ........................................................................................................ 10
1.1.6 Engine overheating........................................................................................................... 10
1.1.7 White smoke coming out of engine exhaust .................................................................... 10
1.1.8 Black smoke coming out of engine exhaust......................................................................11
1.1.9 Low oil pressure.................................................................................................................11
1.1.10 Abnormal engine noise ....................................................................................................11
1.1.11 Engine cooling problem .................................................................................................. 12
1.2 Data and specifications............................................................................................................... 20
1.2.1 Data and specifications............................................................................................................ 20
1.2.2 Engine cooling .................................................................................................................. 21
1.2.3 Starting system ................................................................................................................. 21
1.2.4 Charging system............................................................................................................... 22
1.3 Maintenance standards............................................................................................................... 22
1.3.1 Engine mechanical system............................................................................................... 22
1.3.2 General terms for diesel performance.............................................................................. 24
1.4 Maintenance work ....................................................................................................................... 26
1.4.1 Air filter .............................................................................................................................. 26
1.4.2 Lubricant system............................................................................................................... 27
1.4.3 Fuel system ...................................................................................................................... 28
1.4.4 Cooling system ................................................................................................................. 30
1.4.5 Drive belt adjustment ........................................................................................................ 32
1.4.6 Engine control (governed speed, valve clearance, injection timing, compression pressure)
................................................................................................................................................... 33
1.5 Tightening torque ........................................................................................................................ 39
1.5.1 Torque for cylinder head, cylinder head cover and rocker shaft support ....................... 39
1.5.2 Torque for crankshaft, bearing cap, connecting rod bearing cap, crankshaft damper pulley,
flywheel and oil pan ................................................................................................................. 41
1.5.3 Torque for timing pulley chamber, timing pulley, timing gear and camshaft race ............ 42
1.5.4 Engine fuel system ........................................................................................................... 42
1.5.5 Torque for cooling system and lubricant system .............................................................. 43
1.5.6 Torque for intake manifold, exhaust manifold and exhaust pipe ...................................... 44
1.5.7 Engine electrical system................................................................................................... 45
1.5.8 Torque for engine mounting bracket................................................................................. 46
1.6 Special tools ................................................................................................................................ 47
2. Engine mechanical system ............................................................................................................... 49
2
2.1 Cylinder head .............................................................................................................................. 49
2.2 Valve spring, valve guide oil seal, valve guide and push rod ..................................................... 56
2.3 Camshaft and tappet................................................................................................................... 64
2.4. Rocker arm assembly ................................................................................................................ 72
2.5 Oil pump...................................................................................................................................... 75
2.6. Crankshaft.................................................................................................................................. 80
2.7. Piston and connecting rod ......................................................................................................... 95
2.8 Cylinder block............................................................................................................................ 106
3.4 DA1 Series Engine ......................................................................................................................... 118
3.1 General.......................................................................................................................................118
3.2 Right support of engine..............................................................................................................119
3.3 Left support of engine .......................................................................................................................... 121
3.4 Air-intake manifold..................................................................................................................... 123
3.5 Exhaust manifold....................................................................................................................... 125
3.6 Oil cooler ................................................................................................................................... 127
3.8 Cylinder head cover .................................................................................................................. 130
3.9 Rocker shaft assembly.............................................................................................................. 131
3.10 Valve stem oil seal and valve spring ...................................................................................... 134
3.11 Timing gear.......................................................................................................................................... 138
3.12 Cylinder head assembly and gasket....................................................................................... 146
3.13 Oil pan ..................................................................................................................................... 157
3.14 Oil pump assembly ................................................................................................................. 160
3.15 Piston, Piston ring and connecting rod ................................................................................... 164
3.16 Camshaft and tappet............................................................................................................... 177
3.17 Crankshaft front oil seal .......................................................................................................... 197
3.18 Crankshaft rear oil seal ........................................................................................................... 200
3.19 Crankshaft and main bearing.................................................................................................. 207
4 Engine cooling system ..................................................................................................................... 229
4.1 General...................................................................................................................................... 229
4.2 Water pump............................................................................................................................... 232
4.2.1 On-vehicle repair ............................................................................................................ 232
4.2.2 Single-piece repair.......................................................................................................... 236
4.3 Thermostat ................................................................................................................................ 239
4.4. Radiator.................................................................................................................................... 241
4.5 Drive belt adjustment ................................................................................................................ 244
5 Fuel system........................................................................................................................................ 246
5.1 General...................................................................................................................................... 246
5.2 Fuel filter assembly ................................................................................................................... 250
5.3 Fuel injector............................................................................................................................... 253
5.4 Injection pump assembly .......................................................................................................... 258
5.5 Fuel system related parameters ............................................................................................... 266
5.6 Fuel tank.................................................................................................................................... 267
5.7 Fuel lever gauge ....................................................................................................................... 269
6 Starting system（To mention in a reference） .............................................................................. 270
6.1 General...................................................................................................................................... 270
3
6.2 Starting circuit............................................................................................................................ 271
6.3 Starter motor ............................................................................................................................. 272
7 Intake/exhaust system ...................................................................................................................... 281
7.1 General...................................................................................................................................... 281
7.1 Air filter ...................................................................................................................................... 282
7.2 Exhaust pipe and charger assembly......................................................................................... 284
4
1. Maintenance
1.1 Diagnosis and troubleshooting
1.1.1 Start problems

1. The starter motor fails to work.
Check Causes Remedies
The battery terminal post is loose. Clean and/or tighten the loose terminal
There is bad connection caused by post(s)
oxidation or corrosion.
Battery
The battery is uncharged or in Charge the battery or replace the old
shortage of charge. battery with a new one
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
Fuse The fuse is short circuited. Replace the fuse with a new one
Starter switch The starter switch or relay has failed. Replace the starter switch or relay
The solenoid switch has failed. Repair or replace the solenoid switch
Starter motor
The starter motor has failed. Repair or replace the starter motor
2. The starter motor works well, but the engine fails to run.
The battery terminal post is loose. Clean and/or tighten the loose battery
There is bad connection caused by terminal post(s)
oxidation or corrosion.
Battery
The battery is uncharged or in Charge the battery or replace the old
shortage of charge. battery with a new one
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
The pinion is broken. Replace the broken pinion
The solenoid switch has failed. Repair or replace the solenoid switch
Starter motor
The brush is worn or the brush spring Replace the brush and/or the brush
is too soft. spring
The piston or crankshaft bearing is Repair or replace the damaged part(s)
Engine
jammed or damaged.
3. The engine rotates but it cannot be ignited to start.

Brake mechanism The fuel cut-off solenoid valve is Replace the fuel cut-off solenoid
of engine broken.
The fuel fails to flow into the injection pump.
Fuel The fuel tank is empty. Fill in the fuel tank
Fuel pipe system The fuel pipe is clogged or broken. Repair or replace the fuel pipe
The fuel tube joint is loose. Retighten the fuel tube joint
Fuel filter The fuel filter overflow valve cannot be Repair or replace the fuel filter
closed. overflow valve
5
A fuel filter component is clogged. Replace the fuel filter component or
the filter element
Fuel system There is air in the fuel system. Release the air from the fuel system
Fuel feed pump The fuel feed pump is broken. Repair or replace the fuel feed pump
The fuel flows into the injection pump.
The fuel in service is incorrect. Use the correct fuel
Fuel
There is water in the fuel system. Replace the fuel
Fuel system There is air in the injection pump. Release the air from the fuel system
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel injector is Adjust or replace the fuel injector
Fuel injector
too low.
Atomizing is bad.
The damage of fuel injector results in Replace the delivery valve
fuel dripping after injection.
Something is wrong with the control Repair or replace the control rack of
rack of injection pump. injection pump
The injection pump plunger is worn or Repair or replace the injection pump
Injection pump
jammed. plunger assembly
The drive shaft of injection pump is Replace the drive shaft
jammed or damaged.
The governor spring of injection pump Replace the governor spring of
is jammed. injection pump
4. Quick start system

Preparation work
1. Disconnect the connector of temperature switch
2. Verify whether the glow plug is power on
a) Confirm the start switch is at OFF position
b) Use voltmeter to connect cylinder wall with any glow plug
c) Switch the start switch to the ON position
If the glow plug is power on, the voltmeter indicates 12 V. If the pointer of voltmeter doesn’
t
move, it means the glow plug is power off.
3. Trouble shooting
The glow plug is power on.
The indicator lamp of glow The indicator lamp is broken. Replace the indicator lamp
plug is off.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow The quick start timer is broken. Replace the quick start timer
plug is on for 0.3 s.
6
The indicator lamp of glow After the engine is started, switch Replace the quick start timer
plug is on for 3.5 s. the start switch from ST (start) to
ON. If the relay of glow plug keeps
closed for less than 14 s, it
indicates something is wrong with
the quick start timer.
Switch the start switch from OFF Replace the quick start timer
to ON. If the relay of glow plug
keeps closed for less than 14 s, it
indicates something is wrong with
the quick start timer.
Temperature switch The temperature switch is broken. Replace the temperature switch
Connectivity of glow plug The connectivity of glow plug is Replace the glow plug
bad.
The glow plug is power off.
The indicator lamp of glow The fuse of indicator lamp blows Replace the broken fuse
plug is off. out.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow The glow plug relay is broken. Replace the glow plug relay
plug is on for 3.5 s. When the start switch is switched
from OFF to ON, the glow plug
relay is not switched on.
The quick start timer is broken. Replace the quick start timer
A line fault occurs in the circuit of Repair or replace corresponding
glow plug relay. line(s)
The fuse blows out or there is a Replace the fuse or
line fault. corresponding line(s)
When the start switch is switched
from OFF to ON, the glow plug
relay is switched on.
1.1.2 Unstable idle speed

Idle speed system The idle speed is not proper. Adjust the idle speed
High idle speed control The high idle speed control device Repair or replace the high idle
device is broken. speed control device.
Throttle control system The adjustment of throttle control Adjust the throttle control system
system is not proper.
Leakage or blockage occurs in the Repair or replace the fuel system
fuel system.
Fuel system There is air in the fuel system. Release the air from the fuel
system
There is water in the fuel system. Replace the fuel
7
A fuel filter component is clogged. Replace the fuel filter component
Fuel filter
or the filter element.
The fuel feed pump is broken. Repair or replace the fuel feed
Fuel feed pump
pump.
The opening pressure of fuel Adjust or replace the fuel injector
Fuel injector
injector is too low.
Atomizing is bad.
The damage of delivery valve
results in fuel dripping after Replace the delivery valve
injection.
Injection timing is not proper. Adjust injection timing
The injection volume is too low. Increase injection volume
The idle speed spring is broken. Replace the idle speed spring
Injection pump
The shifter is broken Repair or replace the shifter
The regulator valve is not at Adjust or replace the regulator
proper position. valve
The plunger spring is broken Replace the plunger spring
The plunger is worn. Replace the plunger assembly
The cam is worn. Replace the worn cam
Valve clearance The valve clearance is not proper. Adjust the valve clearance
The gasket of cylinder head is
worn.
Compression pressure Replace relevant parts
The cylinder liner is worn.
The piston ring is sticky.
1.1.3 Insufficient power

An air filter component is Clean or replace the filter
Air filter
clogged. component
Fuel There is water in the fuel. Replace the fuel
Replace the fuel filter component
Fuel filter A fuel filter component is clogged.
or the filter element
Repair or replace the fuel feed
Fuel feed pump The fuel feed pump is broken.
pump
The opening pressure of fuel
Fuel injector
injector is too low. Adjust or replace the fuel injector
Atomizing is bad.
The high pressure fuel pipe is Replace the high pressure fuel
High pressure fuel pipe
damaged or blocked. pipe
Repair or replace the regulator
Injection pump The regulator valve is damaged.
valve
8
The delivery valve is damaged. Replace the delivery valve
The timer is broken. Repair or replace the timer
The cam is worn. Replace the worn cam
The control lever doesn’
t work
Adjust or replace the control lever
well.
Adjust injection timing
The injection timing is not correct. Repair or replace the injection
pump timer
The governing spring is too soft. Replace the governing spring
The plunger is worn. Replace the plunger assembly
worn.
The valve spring is too soft or
Valve spring Replace the valve spring
broken.
Exhaust system The exhaust pipe is clogged. Clean the exhaust pipe
Seal of full-load adjusting The seal of adjusting screw is Properly adjust the seal of
screw opened or improperly adjusted. adjusting screw and seal again
1.1.4 High fuel consumption

Repair or replace corresponding
Fuel system There is a fuel leak.
parts of fuel system
Clean or replace the air filter
Air filter An air filter component is clogged.
component
The idle speed is not adjusted
Idle speed Adjust the idle speed
properly.
The opening pressure of fuel
Fuel injector injector is too low. Adjust or replace the fuel injector
Atomizing is bad.
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
The damage of delivery valve
Injection pump results in fuel dripping after Replace the delivery valve
injection.
worn.
The valve spring is too soft or
Valve spring Replace the valve spring
broken.
9
1.1.5 High oil consumption
The oil type is not correct. Replace the engine oil
Engine oil
The oil volume is too high. Adjust the oil level
The oil leaks from the oil seal
Oil seal and gasket Replace the oil seal and/or gasket
and/or gasket.
Air vent The air vent is blocked. Clean the air vent
Intake valve and exhaust The valve stem and valve guide Replace intake valve, exhaust
valve are worn. valve and valve guide
1.1.6 Engine overheating

Cooling water The cooling water is insufficient. Supply enough cooling water
Fan clutch The oil leaks from the fan clutch. Replace the fan clutch
Fan belt Loose or damaged fan belt results Replace the fan belt
in slipping.
Radiator The radiator cap is damaged or Replace the radiator cap or clean
the radiator core is blocked. the radiator core
Water pump The water pump is broken. Repair or replace the water pump
Cylinder head and cylinder Damaged cylinder head results in Replace the sealed cap
block leakage of cooling water.
Sealed cap
Thermostat The thermostat is broken. Replace the thermostat
Cooling system The cooling system is clogged by Remove foreign matters from the
foreign matters. cooling system
1.1.7 White smoke coming out of engine exhaust

Cooling water The cooling water is insufficient. Supply enough cooling water
Fuel There is water in the fuel system. Replace the fuel
Fuel injection timing Fuel injection timing is delayed. Adjust the fuel injection timing
worn.
Intake valve and exhaust The valve oil seal is worn.
Replace valve oil seal, valve and
valve The valve stem and valve guide
valve guide
Valve oil seal are worn.
10
1.1.8 Black smoke coming out of engine exhaust
Air filter An air filter component is clogged. Clean or replace the air filter
component
Fuel injector The opening pressure of fuel Adjust or replace the fuel injector
injector is too low.
Atomizing is bad.
Injection pump The damage of delivery valve Replace the delivery valve
results in fuel dripping after
injection.
The injection volume is too high. Reduce injection volume
1.1.9 Low oil pressure

Engine oil The oil viscosity is not correct. Replace the engine oil
The oil volume is too low. Increase the oil volume
Oil pressure gauge or The oil pressure gauge or Repair or replace the oil pressure
assembly assembly is broken. gauge or assembly
Oil pressure indicator light The indicator light is broken. Replace the indicator light
Oil filter An oil filter component is clogged. Replace the oil filter component or
the filter element
Safety valve and bypass The safety valve is jammed and/or Replace the safety valve and/or
valve the bypass valve spring is too soft. bypass valve spring
Oil pump The oil pump strainer is blocked. Clean the oil pump strainer
A component in the oil pump is Replace relevant parts in the oil
worn. pump.
Rocker shaft The rocker shaft bearing is worn. Replace the rocker shaft bearing
Camshaft The camshaft and its bearing are Replace the camshaft and its
worn. bearing
Crankshaft and bearing The crankshaft and its bearing are Replace the crankshaft and/or its
worn. bearing
1.1.10 Abnormal engine noise

1. Engine slap
Verify the engine is completely warmed up before troubleshooting.
Fuel The fuel is not correct. Replace the fuel
Fuel injection timing Fuel injection timing is not proper. Adjust the fuel injection timing
Fuel injector The opening pressure of fuel Adjust or replace the fuel injector
injector or atomizing is not proper.
11
Compression pressure The gasket of cylinder head is Replace the gasket of cylinder
worn. head or piston ring
The piston ring is broken.
2. Air leak noise
Exhaust pipe The connection of exhaust pipe is Tighten the connection of exhaust
loose. pipe
The exhaust pipe is broken. Replace the exhaust pipe
Fuel injector and/or glow The fuel injector and/or glow plug Replace the gasket
plug are loose. Tighten the fuel injector and/or
glow plug
Exhaust manifold The connection to exhaust Tighten the connection to exhaust
manifold is loose. manifold
Cylinder head gasket The cylinder head gasket is worn. Replace the cylinder head gasket
3. Continuous noise
Fan belt The fan belt is loose. Adjust the tightness of fan belt
again.
Cooling fan The cooling fan is loose. Retighten the cooling fan
Water pump bearing The water pump bearing is worn Replace the water pump bearing
or damaged.
Alternator or vacuum pump The alternator or vacuum pump is Repair or replace the alternator or
broken. vacuum pump
4. Clapping noise
Rocker arm The rocker arm is broken. Replace the rocker arm
Flywheel The flywheel bolt is loose. Retighten the flywheel bolt
Crankshaft and thrust The crankshaft and/or thrust Replace the crankshaft and/or
bearing bearing is worn or damaged. thrust bearing
Crankshaft and connecting The crankshaft and/or connecting Replace the crankshaft and/or
rod bearing rod bearing is worn or damaged. connecting rod bearing
Connecting rod bushing and The connecting rod bushing and Replace the connecting rod
piston pin piston pin are worn or damaged. bushing and/or piston pin
Piston and cylinder liner The piston and cylinder liner is Replace the piston and cylinder
worn or damaged. liner
1.1.11 Engine cooling problem

Engine overheating The coolant level is too low. Fill in the coolant
The thermostatic control is Replace the thermostatic control
broken.
The thermostat is broken. Replace the thermostat
12
Something is wrong with the Repair or replace the cooling
cooling element. element
The radiator is blocked. Clean or replace the radiator
The radiator cap is damaged. Replace the radiator cap
The oil level is too low or the oil is Fill in or replace the oil
disqualified.
The cylinder head gasket is worn. Replace the cylinder head gasket
The exhaust system is blocked. Clean the exhaust system or
replace the damaged parts
The fan belt is loose. Adjust the fan belt
The fuel injection volume is too Adjust the fuel injection
high.
The injection timing is not correct. Adjust the injection timing
Engine overcooling The thermostat is broken. Replace the thermostat
Long engine preheating The thermostat is broken. Replace the thermostat
time The thermostatic control is Replace the thermostatic control
broken.
Check the battery and make the following diagnosises.
13
The starter doesn’
t run.
Check the battery
Charging is invalid or the life of

battery is expired. The battery is normal.
Check the battery
Check the terminal post
Connection is interrupted.
The terminal post is OK.
Clean the battery terminal post and reconnect it. Check the starter or the starter switch
Faulty
Repair or replace
Turn on the headlamp and starter switch
The headlamp is off or dim. The headlamp is bright.
a) The starter circuit has open circuit.

a) The battery has insufficient charge.
b) The starter coil has open circuit.
b) The starter coil is short-circuited.
c) The starter switch is faulty.
c) A starter part is faulty.
14
The engagement between the pinion and tooth
flank is not good.
When the starter switch is switched to ST (start)

position, check whether there is voltage at the
terminal post "S" of solenoid switch.
Yes No
Or
In this case, check whether the voltage at 3BW
connector of solenoid switch on the starter relay is
normal
The pinion and gear The sliding resistance
ring are worn badly. of starter is too high.
Normal Abnormal
Repair or replace the Repair or replace the
starter, and replace starter
the gear ring.
There is an open circuit Check there is voltage at
between the starter switch 3BW connector of starter
and the solenoid switch, or switch on the starter relay
the connection between them
is faulty.
Repair
Yes No
The connection of starter There is an open circuit

switch is faulty. between the starter
switch and the battery, or
the connection between
them is faulty.
Replace the starter

switch
Repair
15
The starter switch is switched to ST (start) position, but
the solenoid switch doesn't work.
When the starter switch is switched to ST (start)

position, check whether there is voltage at the terminal
post "S" of solenoid switch.
Yes No
Check the grounding cable Check whether the instrument

indicator light is normal
Good Bad Normal Abnormal
Repair
Verify the circuit between the There is an open circuit
starter switch and the between the battery and
terminal post "S" of solenoid the starter switch, or the
Or connection is faulty.
switch.
The sliding The solenoid switch or

part of pinion coil has an open circuit
doesn’ t move. or is burned out. Repair
Check the starter The starter switch

relay connection is faulty.
Repair or replace the starter. Check the clutch Replace the starter
and starter switch switch
16
The pinion engages with the gear ring well, but
the engine doesn't run.
Check the grounded cable
Good Bad
Repair or replace the

grounding cable
A fault occurs between The solenoid starter The exciting coil has The armature coil The clutch of
the brush and rectifier. switch is burned out. an open circuit or is has an open circuit or pinion slips.
damaged. is damaged.
Repair or replace the starter
17
The starter switch is switched from ST to ON,
but the starter doesn't stop.
Disconnect the wiring of starter switch and verify the operation of starter switch
Connector No.
Terminal Post No.

The position of
starter switch Terminal Post No.
key
OFF
Locked
Accessory
ON
ON
Start
Besides the wiring mentioned above, other circuits should be opening.
Yes No
The solenoid switch contact is Replace the solenoid switch

melted and hard to move.
Otherwise, the return spring is
broken or damaged.
Replace the starter switch
18
4DA1 Series oil filter and oil cooler
with bypass-type filter
Battery
Indicator
light
Oil pressure switch
Vertical cylinder oil gallery
Regulator
Oil filter and cooler
valve
Idler gear
shaft Camshaft Vacuum
bearing pump
Bypass Full-flow Safety Oil
filter oil filter valve nozzle
Crankshaft Rocker
bearing shaft
Oil Safety Oil pipe
cooler valve
Rocker
Piston arm
Connecting
Oil pump Relief Timing rod bearing
valve gear
Oil
strainer
Oil pan
① Opening pressure of relief valve at oil filter: 430-470kPa
② Opening pressure of safety valve at oil filter: 960-100kPa
The lubrication system for 4DA1 Series engine is full-flow type.

The lubricant flows from the oil pump to the vertical cylinder oil gallery through oil cooler
and oil filter pump (the replaceable oil filter is equipped on the oil filter).And then, the
lubricant is delivered from the vertical cylinder oil gallery to the main parts of engine.
19
1.2 Data and specifications
1.2.1 Data and specifications

Engine model
4DA1 4DA1-1
Item
Turbocharged
Natural admission (NA)
Engine type Inter-cooling (TCI)
Four strokes, high mounted valve, water cooling
Combustion chamber type ω type direct injection
Dry type, thin-wall chrome-plated steel cylinder
Cylinder liner type
liner
Cylinder number - cylinder bore  stroke mm 4— 93×102
Number of piston ring 2 gas rings, 1 oil ring
Total piston displacement L 2.771
Compression ratio 18.2 17.5
Design compression pressure kPa 3040
Engine weight (net) kg 230 240
Fuel injection sequence 1— 3— 4— 2
16 to the top dead 12 to the top dead
Fuel injection timing 
center (before) center (before)
Above -5 Above -14 Above -29
Ambient temperature Above 4 ℃
Required fuel type ℃ ℃ ℃
Light diesel fuel type 0# -10 # -20 # -35 #
Idle speed r/min 750±50
Valve clearance Intake valve mm 0.30～0.40
(cold) Exhaust valve mm 0.30～0.40
Valve clearance Intake valve mm 0.30
(hot) Exhaust valve mm 0.30
Open (before top dead center)  24.5
Intake valve Close (after bottom top dead
55.5
center) 
Open (before bottom top dead
54
Exhaust valve center) 
Close (after top dead center)  26
Lubricant system
Lubrication method Pressure feed lubrication and spray lubrication
Required oil (class AP1) CF-4 15W-40
Oil pump type External gearing
Oil filter type Full-flow type, paper element, replaceable
Oil volume (including oil filter) L 6
Oil cooler type Water cooling
20
Engine model
4DA1 4DA1-1
Item
Fuel system
Injection pump type VE dispensing pump
Speed governor type Mechanical, all-speed
Injector type Small pressure cell, cellular type
Injector opening pressure MPa 19.0-20.0 18.6-19.6
Main fuel filter type Paper cartridge and water separator
Air filter type Dry-type paper filter element
Alternator output V-A 14-60
Starter motor output V-kW 12-2.8
1.2.2 Engine cooling

Coolant pump Centrifugal impeller
Pulley drive ratio 1.12
Thermostat type Wax-type thermostat, dual valves
Valve opening temperature ℃ 82
Valve full opening temperature ℃ 95
Coolant total volume L 10
1.2.3 Starting system

Type S14-204A
Rating
Voltage V 12
Output kW 2.8
Time s 30
Number of pinion 9
Rotation direction (view from the pinion end) Clockwise
Weight (approximate) kg 5.4
No load characteristics
Voltage/current V/A 11/160 or less
Revolution speed r/min 4100 or above
Load characteristics
Torque N·m 8.5
Revolution speed r/min 1750 or above
Brake characteristics
Torque N·m 31
21
1.2.4 Charging system
Type JFB161
Rated voltage V 14
Rated output A 60
Regulation voltage V 14.4-15
Rated revolution speed r/min 5000
Rotation direction (view from the pulley end) Clockwise
Polarity Negative earth
Operate mode Continuous rating
Regulator type IC regulator
Pulley effective diameter mm 80
Weight (with pump) kg 6.1
1.3 Maintenance standards
1.3.1 Engine mechanical system

Standard dimension Ex-work
Wear
configuration
No. Designation Fitting way limit
4DA1 4DA1-1 Clearance
(mm)
(mm)
Contact width of valve and
retainer
1.
Intake valve 1.7 2.2
Exhaust valve 2 2.5
Valve sinkage
2. Intake valve 0.65 1.28
Exhaust valve 0.65 1.20
3. Valve retainer bore angle 15°，45°， 75°
4. Flank clearance 0.10-0.17 0.30
5. Axial runout clearance of idler A 0.07 0.20
0.010
Tappet outer diameter Φ13  0.028
6. Gapping 0.01~0.046 0.10
0.018
Tappet bore Φ13 0
7. Push rod radial runout 0.3

8. Rocker shaft deflection 0.3
0
Rocker shaft outer diameter Φ19 0.02
9. Gapping 0.01~0.05 0.20
0.03
Rocker bore Φ19  0.01
22
0.039
Intake valve stem diameter Φ8 0.054
10. Gapping 0.039~0.071 0.20
0.017
Valve guide bore Φ8 0
0.064
Exhaust valve stem diameter Φ8 0.079
11. Gapping 0.064~0.096 0.25
0.017
Valve guide bore Φ8 0
Free height of valve spring 48
12.
Squareness of valve spring Φ1.4
0.025
Idler A bearing outer diameter Φ45 0.055
13. Gapping 0.025~0.080 0.20
0.025
Idler A bearing inner diameter Φ45 0
Cylinder liner bore 0.060
14. Overtopping height of the Φ93  0.021

cylinder liner to the body 0~0.08
Axial runout clearance of 0.05~0.114 0.20
15. camshaft Gapping
Cam height of camshaft 42.02±0.05 0.38
0.025
Inner diameter of camshaft 0
Φ50
16. bearing bush Gapping 0.025~0.080 0.12
0.025
Camshaft journal diameter Φ50 0.055
Camshaft bearing bush
17. 0.02 0.10
deflection
0 0 0.002~0.015
Piston pin Φ31 0.005 Φ34 0.005
18. Gapping 0.03
0.010 0.010
Piston pin hole Φ31  0.002 Φ34  0.002
Connecting rod big end 0
thickness 33 0.04
19. Gapping 0.175~0.290 0.35
Crankshaft connecting rod 0.250
journal bore 33  0.175

Intake/exhaust valve cold
20. Gapping 0.3~0.4
clearance
0.068
Main shaft diameter Φ70 0.086
21. Main bearing halfshell (after Gapping 0.031~0.066 0.11
0.003
assembly) Φ70 0.033
0 0
Piston pin outer diameter Φ31 0.006 Φ34 0.006
22. Connecting rod bushing inner Gapping 0.008~0.026 0.05
0.020 0.020
diameter Φ31  0.008 Φ34  0.008
23
Crankshaft connecting rod 0.070
journal Φ53 0.085

23. Gapping 0.029~0.069 0.10
Connecting rod bearing 0.016
halfshell hole (after assembly) Φ53 0.041

Piston outer diameter
grouping
Group A 92.957~92.970
Group B 92.970~92.983
Group C 92.983~92.996 Grouping
24. 0.051~0.077
Cylinder liner grouping (after Gapping
pressing in)
Group A 93.021~93.034
Group B 93.034~93.047
Group C 93.047~93.060
Piston ring end gap 1.5
First gas ring 0.2~0.4 0.2~0.4
Second gas ring 0.2~0.4 0.6~0.85
Oil ring 0.1~0.3 0.35~0.65
25.
Piston ring end gap
First ring 0.09~0.125 0.078~0.139 0.15
Second ring 0.05~0.075 0.045~0.09 0.15
Oil ring 0.03~0.07 0.03~0.07 0.15
Vertical height of injector to
0.36 0.53
26. cylinder head lower 3.94  0.23 mm 2.41  0.31 mm
undersurface
1.3.2 General terms for diesel performance

Net power
The correction value for effective power outputted by the engine with all on-board parts
Total power
The correction value for effective power outputted by the engine with essential parts for operation
Rated power
The total output power given by the manufacturer at the specified rated speed according to the
specific engine application, as indicated on the nameplates of engine HFC4DA1 and 4DA1-1
Maximum power
The maximum total power outputted by the engine at full-load working condition, which is generally
greater than or equal to the rated power
Load
The ratio between the actual engine output power and the possible maximum power at the same
speed, which is expressed by percentage
Maximum no load governed speed
The speed which the engine reaches when the accelerator reaches its limit and the engine runs
under no load working condition
To avoid diesel overspeed, the speed indicates the maximum speed control given by the injection
24
pump governor. The maximum no load governed speed of HFC4DA1 and 4DA1-1 is 4000～4200
rpm.
Maximum rated speed
The maximum speed that the governor allows at full load.
The maximum rated speed of HFC4DA1 and 4DA1-1 is 3600 rpm.
Minimum rated speed
1. The allowable minimum speed at the following three maximum speed of engine: 45% of
maximum rated speed, 1000rpm and the speed provided by the idling governor, whichever is
greaterThe minimum rated speed of HFC4DA1 and 4DA1-1 is 1620 rpm.
2. The minimum speed specified by the manufacturer
Full load filter paper type smoke
Under full load (i.e. external characteristics) working condition, the blackening of filter paper in a
specific area (working diameter: 32 mm) by the smoke in a specified length of air column taken
from the engine exhaust pipe
To measure the speed range from the minimum to the maximum rated speed, arrange proper
testing points including full load working conditions at the maximum power speed and maximum
torque speed.
Free accelerating working condition
When the engine runs at idle speed, the condition that pedaling the accelerator pedal rapidly but
gently to make the injection pump provide maximum fuel
Keep this condition before the engine reaches the allowable maximum speed given by the
governor. Once it reaches the maximum speed, release the accelerator pedal to make engine
returns to idling.
Free accelerating filter paper type smoke
Under free accelerating working condition, the blackening of filter paper in a specific area (working
diameter: 32 mm) by the smoke in a specified length of air column taken from the engine exhaust
pipe
Speed characteristics
The characteristics of main performance index (torque, power, oil consumption, exhaust
temperature and smoke, etc.) changes depending on the speed when the engine fuel governing
mechanism keeps the same
External characteristic
The speed characteristic when the engine fuel governing mechanism is fully opened
It is also called full load speed characteristic.
Load characteristic
The characteristic of performance index changes depending on load when the engine keeps
running at the same speed
25
1.4 Maintenance work
Only qualified personnel should be allowed to

perform general maintenance work.
Type marking
Engine Serial Number
The engine serial number is stamped at the left
side of the rear end of cylinder block.
1.4.1 Air filter

Dry-type paper filter element
Depending on the type of filter element, the
method for cleaning a filter element is different.
Dust accumulated at the filter element

Turn the filter element by hand and blow the
compressed air into the filter element in order to
blow off the dust.
Pressure of compressed air (392-490 kPa)
Caution:
Protect the filter element from colliding by
other objects in cleaning. Otherwise, the filter
element may be damaged.
Carbon and dust accumulated at the filter

element
1. Prepare the cleaning liquid for air filter
(DonaldmnDl400) originally provided by JAC,
and dilute it with water.
2. Immerse the filter element in the cleaning

liquid for 20 minutes.
26
3. Take the filter element out of the cleaning
liquid and flush it with running water.
The water pressure should be less than 274 kPa.
4. Dry the filter element at a place with good

ventilation.
Use a fan for quick drying.
Note:
Never use the compressed air or open fire for
quick drying.
It may result in damage of filter element.
Generally, it will take two to three days to
completely dry a filter element. In this case, a
standby should be prepared for temporary
use.
1.4.2 Lubricant system

Main oil filter (paper filter element)
Replace procedure
1. Loosen the oil drain plug to drain out the oil.
2. Several minutes later, retighten the oil drain

plug.
3. Unscrew the used filter counter-clockwise

with a filter wrench.
4. Clean the fitting surface of oil cooler to

ensure suitable fitting with the new oil filter.
5. Apply a thin layer of oil to the O-ring.
6. Screw in the new oil filter until the filter O-ring

makes perfect contact with the sealing
surface.
7. Further screw in the filter by 1+1/4 turn with a

filter wrench.
Filter wrench: 1010300FA-9101
27
8. Check the oil level. If necessary, fill in some
oil until the oil level reaches the specified
level. The filling oil volume is approximate
0.7 L.
9. Start the engine and verify there is no oil leak

from the main oil filter.
1.4.3 Fuel system

Fuel filter
Replace procedure
1. Unscrew the used filter counter-clockwise
with a filter wrench.
2. Clean the fitting surface of the filter upper

cover to ensure suitable fitting with the new
fuel filter.
3. Screw in the fuel filter until it makes perfect

contact with the sealing surface.
4. Further screw in the filter by N 2/3 turn with a

filter wrench.
28
5. Loosen the bleeder plug on the overflow
valve of injection pump.
6. Operate the priming pump until the fuel flows
out of the fuel filter.
7. Retighten the bleeder plug.
8. Repeatedly operate the priming pump and
verify there is no fuel leak.
Note:
It is strongly recommended that you should
use a fuel filter provided by JAC or an original
one.
Procedure of water drain from the fuel filter

If water content in the water separator exceeds
the specified value, the indicator light will light up.
Discharge water and other impurities from the
water separator according to the following steps.
1. Park the vehicle at a safe place.
2. Open the engine hood and put a container
(approximate 0.2 L) at the end of ethylene
hose under the water drain plug of water
separator.
3. Unscrew the water drain plug
counter-clockwise (about five turns) and
operate the priming pump about ten times
until approximate 0.1 L water drains out.
4. Once the water drains is finished, screw in
the water drain plug clockwise and manually
operate the priming pump several times.
5. Verify there is no fuel leak from the water
drain plug after the engine starts.
Also, verify the indicator light of fuel filter is
off.
If frequent water drain from a water separator
is required, you may ask for a fuel tank for
water drain from a local JAC distributor.
29
Bleeding
1. Loosen the bleeding screw on the overflow
valve of injection pump.
2. Operate the priming pump until the fuel with
foam flows out of the bleeding screw.
3. Tighten the bleeding screw.
4. Repeatedly operate the priming pump and
verify there is no fuel leak.
1.4.4 Cooling system

Coolant level
Check the coolant level. If necessary, fill in the
radiator reservoir.
If the coolant level falls under “MIN”, carefully
check whether there is a leakage in the cooling
system. And then, fill in the coolant until it reaches
“MAX”.
Reservoir
Note:
Never make a reservoir overflow.
The radiator filler cap should be opened only if it
Long life coolant is very necessary.
Freezing point (C)
Coolant level check can only be performed when

the engine is cold.
For mixing ratio between the cooling water and
anti-freezer, please refer to the left figure.
Mixing ratio (%)
Cooling System Check

Place an American tester for radiator filler on the
radiator.
Apply test pressure on the cooling system and
check the leakage.
The test pressure shall not exceed the specified
pressure.
Test pressure: 196kPa
30
Radiator filler cap check
The radiator filler cap is designed to keep the
pressure at 105 kPa in the coiling system. Use
radiator filler cap tester to check the cap.If the
radiator filler cap doesn’ t keep at the specified
pressure in testing, it shall be replaced by a new
one.
The pressure of radiator filler cap
Pressure valve 88-118 kPa
Negative pressure valve (reference value) 1.0 -3.9 kPa
Thermostat test
1. Completely immerse the thermostat in the
water.
2. Heat up the water.
Continuously stir the water to avoid directly
heating the thermostat.
3. Check the initial opening temperature of
thermostat.
The initial opening temperature of thermostat:
82℃
4. Check the full opening temperature of
thermostat.
The full opening temperature of thermostat:
95℃
The valve lift at full opening: 8mm
31
1.4.5 Drive belt adjustment
Check whether the drive belt is worn or damaged.
If necessary, replace it with a new one. Check the
belt tension. If necessary, make proper
adjustment.
· Check the belt tension.
· Press the central section of belt by a force of
Air conditioning compressor
drive belt and power steering 100N and check deflection of each belt.
pump drive belt
· Standard deflection
mm
Alternator and fan pulley
drive belts
Air conditioning 8-10
compressor drive belt
Alternator and fan
pulley drive belts Power steering pump
drive belt
Alternator drive belt

· Mount the alternator drive belt and adjust the
belt tension.
· Mount fixing bolts and tighten them to the
specified torque.
Alternator
Fixing bolt torque 37.5
Adjusting plate fixing bolt torque 25
Air conditioning compressor pulley

drive belt and power steering pump
drive belt
· Move the oil pump to adjust the oil pump drive
belt tension
Tighten the bolt to the specified torque.
Adjuster locking bolt torque 37 N·m
32
1.4.6 Engine control
(governed speed, valve
clearance, injection timing,
compression pressure)
Idle speed check
1. Handle the parking brake and brake driving
wheels.
2. Place the transmission at neutral position.
3. Start the engine and warm it up.
4. Remove the engine control cable from the
control lever.
5. Mount the tachometer on the engine.
6. Check the engine idle speed.
If the engine idle speed exceeds the
specified range, you must make adjustment.
Engine idle speed:750±50 r／min
Adjust the idle speed

1. Loosen the locking nut (s) of idle adjusting
bolt (s) on the injection pump.
2. Use idle adjusting bolt to adjust idle speed to
the specified range.
3. Use the locking nut (s) to lock the idle
adjusting bolt (s).
4. Check the idle speed control cable is
tightened (no looses).
If necessary, eliminate any loose of the
cable.
Accelerator control cable adjustment

1. Loosen clamp bolts for the accelerator
cables.
2. Check whether the control knob is turned to
the idle speed position.
3. Place the accelerator lever at the fully closed
position, and then tighten the control cable in
the arrow direction to eliminate any loose.
33
Valve clearance adjustment
1. Turn the crankshaft until the to the crankshaft

damper reaches the top dead center. When
the line aligns the timing pointer, either the
first cylinder piston or the fourth cylinder
piston locates at the top dead center of
compression stroke.
2. Check whether there is any loose rocker

shaft seat nut.
Before adjust the valve clearance, tighten
any loose rocker shaft support nut.
Torque of rocker shaft support nut 55 N·m
3. Check the clearance at the intake valve push

rod and exhaust valve push rod in the first
cylinder.
If there is clearance at the intake valve push
rod and exhaust valve push rod in the first
cylinder, the piston in the first cylinder locates
at the top dead center of compression stroke.
If there is compression force applied on the
intake valve push rod or exhaust valve push
rod in the first cylinder, the piston in the
fourth cylinder locates at the top dead center
of compression stroke.
Adjust the valve clearance in the first or fourth

cylinder when corresponding cylinder piston
locates at the top dead center.
34
Valve clearance (cold) :
0.3-0.4 mm(optimum value: 0.35 mm)
4. Loosen each valve clearance adjusting

screw as shown in the figure.
5. Insert a proper clearance gauge between the
rocker arm and valve stem.
6. Turn the valve clearance adjusting screw
until you feel there is slight resistance on the
clearance gauge.
7. Screw down the locking nut.
8. Turn the crankshaft 360°.
9. Realign the timing marking at the crankshaft
damper pulley to the line of top dead center.
10. Adjust clearance for other valves as shown in
the figure.
35
Adjust injection timing
Step 1 Remove the front screw (at the rear end of

Dial indicator Gauge stand
injection pump) on the injection pump distribution
plunger.
Step 2 Mount special tools for injection advance angle
adjustment: dial indicator and gauge stand.
Step 3 Turn the engine crankshaft clockwise to a position
with approximate 45°to the top dead center of the first
Special tools
cylinder.
Step 4 Turn the engine crankshaft about 8°to left or right,
the pointer of dial indicator shall stand still.
Step 5 Turn the dial indicator to zero the pointer. The
position of dial indicator shall not be changed after zero
adjustment.
Step 6 Turn the crankshaft clockwise to the top dead
Use a tool to turn the
center. For assembly, to determine the top dead center,
crankshaft
use a lever indicator to measure the height difference
between top surface of piston in the first cylinder and
upper surface of body. For commissioning and
inspection, alignment timing marking (position marking of
crankshaft pulley top dead center and timing marking on
the gear case) is allowed to use.
Step 7 Unscrew two tight nuts to the injection pump
flange and the connecting bolt to the injection pump
support. Crankshaft position timing marking
marking
Step 8 Pull the injection pump inward or outward to make
the reading of dial indicator show X mm. Dial indicator
zeroing
Step 9 Screw down two tight nuts to the fuel pump flange
and the connecting bolt to the injection pump support.
Fuel pump running shall be avoided in screwing.
Step 10 Repeat Step 3 to verify zero adjustment.If the
zero adjustment is not proper, return to Step 5.
Step 11 Repeat Step 6 to verify the reading of dial
indicator. If the reading is not correct, return to Step 7.
Step 12 Remove the special tools: dial indicator and
gauge stand.
Step 13 Mount the front screw on the injection pump The crankshaft locates at the
top dead center.
distribution plunger. Injection advance angle adjustment
is over.
Type X Value（mm）
HFC4DA1 1.60
HFC4DA1-1 1.50
36
The essential torque is given below.
Tightening torque for the tight nuts to the injection pump flange: 25±5Nm;
Tightening torque for the connecting bolt to the injection pump support: 25±5Nm;
Tightening torque for the bolt to the distributive head of injection pump: 35±5Nm;
Tightening torque for the nut to the high pressure fuel pipe: 30±5 Nm
If the special tools like dial indicator and seat stand are not available, it is allowed to use “Overflow”
method to make injection advance angle adjustment.
Note:
A new cooper gasket must be used when you mount a plug at the top of distributor.
37
Compression pressure measurement
1. Start the engine and keep idling until the
coolant temperature reaches 70-80℃.
2. Remove the following parts:

★ All glow plugs (or injectors)(Measuring
at the injector hole or the glow plug hole
is optional depending on different gauge
outfits.)
★ Fuel cut solenoid connector
★ Fuse for Quick On Start System(QOS) on
a connector
3. Mount the joint and pressure gauge in the

glow plug hole in the first cylinder (or in the
injector hole).
Compression pressure gauge
(with joint): 1002100FA-9101
Joint: 1002100FA-9102
4. Use the starter motor to run the engine and

record the readings on the pressure gauge.
Compression pressure at 200 r/min
Nominal Limit
3040 2158
5. For other cylinders, repeat Step 3 and 4.

If the measured value is less then the limit
value, refers to the section “Diagnosis and
troubleshooting”in this manual.
38
1.5 Tightening torque
1.5.1 Torque for cylinder head, cylinder head cover and rocker
shaft support (N·m)
Step 1 Step 2 Step 3
39
40
1.5.2 Torque for crankshaft, bearing cap, connecting rod
bearing cap, crankshaft damper pulley, flywheel and oil pan
(N·m)
Step 1 Step 2
41
1.5.3 Torque for timing pulley chamber, timing pulley, timing
gear and camshaft race (N·m)
1.5.4 Engine fuel system (N·m)
42
1.5.5 Torque for cooling system and lubricant system (N·m)
43
1.5.6 Torque for intake manifold, exhaust manifold and exhaust
pipe (N·m)
44
1.5.7 Engine electrical system (N·m)
Cold district is
excluded.
45
1.5.8 Torque for engine mounting bracket (N·m)
Independent
suspension
Left-mounted
Right-mounted
46
1.6 Special tools
Illustration Tool No. Tool Name
1010300FA-9101 Oil filter wrench
1003016FA-9101 Valve oil seal erector
1003102FA-9101 Valve guide replacer
Compression pressure
1002100FA-9101
gauge
1002100FA-9102 Pressure gauge joint
1100300FA-9101 Measuring unit
1002420FA-9101 Front oil seal erector
1002430FA-9101 Rear oil seal erector
Valv spring
1003015FA-9101
compressor
1007017FA-9101 Camshaft gear puller
47
Camshaft bearing
1002107FA-9101
replacer
1002430FA-9102 Rear oil seal remover
1002106FA-9101 Cylinder liner erector
1002106FA-9102 Cylinder liner remover
Piston mounting taper

1004001FA-9102
sleeve
1007011FA-9101 Timing gear puller
Crankshaft timing gear

1007011FA-9102
erector
1002420FA-9101 Front oil seal erector
48
2. Engine mechanical system
2.1 Cylinder head
Disassembly sequence
1. Thermostat chamber assembly
2. Injector body
3. Glow plug and glow plug connector
4. Rocker shaft and rocker
5. Push rod
6. Cylinder head
Reassembly sequence
Reassemble all parts in reverse
sequence.
Note:
· In disassembly, you should collect all
parts of valve set and identify each
part so that they will return to their
original positions by assembling.
· Before you remove the cylinder head
from the engine and disassemble the
valve mechanism, you should carry
out a compression test and record
the test result.
49
Disassembly
1. Thermostat casing and water outlet
assembly
2. Injector body
1) Unscrew the injector body support nut.
2) Use an injector remover and a sliding

hammer to disassemble the injector and
its support together.
3. Glow plug and glow plug connection

board
5. Push rod
6. Cylinder head
· Unscrew the cylinder head bolts in
several times according to the sequence
number given in the figure. Unscrew a
bolt in at least two times.
Note:
If you don’t unscrew the cylinder head bolts in
several times according to the sequence
number, bad effect like warping may incur on
the undersurface of cylinder head.
50
Cleaning
· Cylinder head bolt
· Cylinder head
Carefully clean up any oil sludge, smoke and
carbon deposit until the natural color of metal is
exposed. Never use an electrical wire brush on
any gasket or sealing surface.
Inspection and repair

If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.
· Check whether there is leakage, corrosion or
blow-by gas of cylinder head gasket and
contact surface. If a gasket fails, investigate
the causes:
- Improper assembling
- Loose or warping cylinder head
- Insufficient tightening torque for the
cylinder head bolt
- Warping cylinder block surface
1. Check whether the cylinder head bolt thread
is damaged or drawn out. Also, check
whether the cylinder head is damaged
caused by improper tool usage.
Caution
Any questionable bolt must be replaced by a
new one.
2. Check whether there is any crack on the
cylinder head, particularly the valve edge and
exhaust port.
3. Check whether there is any corrosion at the
cylinder head cover plate, any sand or loose
hole inside the cylinder head.
Caution
Never repair the key surface of cylinder head.
If it is broken, replace it with a new one.
4. There are strict requirements for flatness of
cylinder head undersurface and contact
surface of intake and exhaust manifolds.
Use grinding process to repair these
surfaces. If the surface ”flatness” exceeds
the specified value, you should grind the
surface until the flatness meets the
requirement. If the flatness exceeds the
specified value too much, the part shall be
replaced by a new one.
51
mm
Nominal Limit
Warpage of
cylinder head 0.05 or less 0.20
undersurface
Height of
92 91.55
cylinder head
5. Check the contact surface of water jacket
bowel-like plug.
6. Use a ruler or clearance gauge to measure
the warpage of contact surface between the
exhaust manifold and cylinder head.
If the measurement value is greater than the
nominal value but less than then limit value,
you should regrinding the contact surface
between the exhaust manifold and cylinder
head.
If the measurement value exceeds the
specified limit, the manifold has to be
replaced.
Warpage of exhaust manifold mm

Nominal Limit
0.05 or less 0.20
Reassembly
6. Cylinder head
1) Mount the valve seat
1. Carefully place the attachment ①
(its outer diameter is slightly less
than that of valve seat) on the valve
seat ②.
Note
Make sure that the surface contacting
with the valve seat is the smooth side of
attachment.
2. Use a table press ③ to gradually
press the attachment until the valve
seat seats in place.
52
Note
Never apply excess compressive force
on the valve seat when you use a table
press. Otherwise, the valve seat may be
damaged.
Measure upper height of valve guide from the
upper surface of cylinder head.
Upper height of valve guide (H) (reference value)
13 mm
Note
If a valve guide has been disassembled,
you should replace the valve and valve
guide in pairs.
2) Lower spring seat

3) Valve stem oil seal
· Mount a new oil seal to the valve.
· Use a special tool to guide.
Oil seal erector: 1003016FA-9101
4) Valve
· Apply oil to the part above the borehole
diameter of valve stem before you install a
valve.
5) Valve spring
· Mount the valve spring on the upper
spring seat.
Caution
· The section with painting on the
valve spring shall be placed
downwards.
· Supply compressed air from glow
plug hole to cylinder until the valve
seats in place.
· Install the valve cotter with special
tools.
Valve spring compressor: 1003015FA-9101
53
6) Valve cotter
· Use a spring compressor to press the
valve spring to the proper position.
· Mount the spring seat and valve cotter.
· Use a soft-faced hammer to tap the cotter
head until it seats in place.
5. Push rod

· Tighten the rocker shaft fixing bolt.
55±5 N·m
3. Glow plug and glow plug connection

board
· Tighten the glow plug.
25±5 N·m
2. Injector body
1) Install the injector copper gasket ① and
O-ring ② onto the injector body ③.
Make sure tight contact between the
O-ring and injector groove.
2) Apply oil in the cylinder head hole where
the injector body seats.
3) Mount the injector body and injector
pressure plate together to the cylinder
head.
40±5 N·m
4) Tighten the injector body nut and gasket
⑤ to the specified torque.
40±5 N·m
54
2. Fuel injector
· Use a wrench or a special tool to tighten
the nut (s) on the fuel injector to the
specified torque as shown in the figure.
Caution
· When you mount the return pipe, injector
and injection pipe, use air to blow off dust.
Injector tightening torque 34±5N·m
1. Thermostat casing assembly

· Tighten the thermostat casing assembly
fixing bolt.
25 ±5 N·m
55
2.2 Valve spring, valve guide oil seal, valve guide and push rod
1. Rocker assembly
2. Valve cotter
3. Valve spring
4. Valve
5. Valve guide oil seal
6. Valve guide
Reassemble sequence
sequence.
Disassembly
1. Rocker assembly
2. Valve cotter
Use a special tool to compress the valve spring.
3. Valve spring
4. Valve
6. Valve guide
Valve guide replacer: 1003102FA-9101
56
Valve spring
Caution
Visually check the valve spring. If there is
damage or obvious abnormal abrasion, you
should replace it with a new one.
1. Free height
· Measure the free height of valve spring.If the
height is less than the specified limit value,
the spring shall be replaced.
Free height mm
Nominal Limit
48.0 47.10
2. Squareness
· Use a steel square to measure the
squareness of valve spring. The
measurement value shall be less than 1.2
mm.
· If measurement value exceeds prescribed
limit, the valve spring shall be replaced.
Limit 1.5 mm
3. Spring tension
· Use a spring tester to compress the spring to
the installation height. Measure the
compression spring tension.
If the measured tension is lower than the
prescribed limit, the spring shall be replaced.
Tension N
Installation
Nominal Limit
height
38.9mm 296 268
57
Valve guide
Caution
Carefully clean up the carbon deposit at the
valve head to protect the valve seat contact
surface from damaging.
Carefully check whether there is any damage
or abnormal abrasion on the valve stem.
If so, replace the valve and valve guide in
pairs.
1. Valve guide clearance
· Use a micrometer to measure the outer
diameter of valve stem.
If the out diameter of valve stem is lower than
the specified limit, replace the valve and
valve guide in pairs.
Mm
Nominal Limit
Valve Intake valve 7.946-7.961 7.880
stem Exhaust valve 7.921-7.936 7.850
diameter
· Use a micrometer to measure the inner
diameter of valve guide.
· Make a subtraction between the valve guide
inner diameter and the valve stem outer
diameter.
If the subtraction value is lower than the
specified limit, replace the valve and valve
guide in pairs.
Valve guide clearance mm

Nominal Limit
Inlet clearance 0.200 7.880
Exhaust 0.250 7.850
clearance
58
Valve guide replacement
1. Use a special tool to knock the valve guide
out from one side of combustion chamber.
2. Apply oil to the outer surface of valve guide.

Use a special tool to mount a new valve
guide from one side of cylinder head upper
surface and check the valve guide height.
Height 13 mm
Note
If a valve guide has been disassembled, you
should replace the valve and valve guide in
pairs.
Valve thickness
1. Measure the valve thickness.
2. If the meausred value is lower than the
specified limit, replace the valve and valve
guide in pairs.
Valve thickness mm
Nominal Limit
Exhaust value 1.5
59
Valve seat conical surface angle on the
valve
1. Measure the valve seat conical surface
angle.
2. If the measurement value exceeds the limit,
you should replace the valve, valve guide
and valve seat together.
Nominal: 45°
Valve sinkage
1. Mount the valve (1) to the cylinder head (2).
2. Use a depth gauge or a ruler and steel
square to measure the valve sinkage from
the bottom surface of cylinder head.
If the measurement value exceeds
prescribed limit, the valve seat shall be
replaced.
Valve sinkage mm
Nominal Limit
4DA1
Exhaust
Series 0.65 1.20
value
Valve contact width

1. Check the roughness and flatness of valve
contact surface. Make sure that the contact
surface is smooth.
2. Measure the valve contact width.
If the measurement value exceeds
prescribed limit, the valve seat shall be
replaced.
Contact width mm
Nominal Limit
Exhaust value 2 2.5
60
Valve seat replacement
Disassemble valve seat
1. Perform arc welding at the inside periphery
① of valve seat ②.
2. Cool down the valve seat for several
minutes.
The contraction will facilitate the disassembly
of valve seat.
3. Use a screwdriver ③ to pry off the valve
seat.
Carefully pry off it. Otherwise, the cylinder
head ④ may be damaged.
4. Carefully clean up carbon deposits and other
foreign matters on the valve seat installation
hole of cylinder head.
Assemble valve seat

1. Carefully place the attachment ① (its
borehole diameter is slightly less than that of
valve seat) on the valve seat ②.
Note
Make the smooth side of attachment
contact with the valve seat.
2. Use a table press ③ to gradually press the
attachment until the valve seat seats in
place.
Note
Never apply excess compressive force
on the valve seat when you use a table
press. Otherwise, the valve seat may be
damaged.
Valve seat correction

1. Clean up the carbon deposit on valve seat
surface.
2. Use a milling cutter (blade angle of 15°, 45
°and 75°) to minimize abrasion and rough
areas of valve seat so that the contact width
reaches the nominal value.
You should only eliminate abrasion and
rough areas. Don’ t cut off too much.
Carefully avoid cutting off good areas on
valve seat surface.
61
Valve seat angle: 45°
Note
You may use an adjustable milling cutter
guide lever. It is not allowed to stir the
milling cutter guide lever in the valve
guide hole.
3. Apply grinding paste on valve seat surface.

4. Insert the valve into the valve guide.
5. Turn the valve for perfect fitting with the valve

seat while tapping it from top or bottom.
6. Check the valve contact width is proper.
7. Check whether the valve seat surface has
completely contacted with the whole valve
periphery.
Bending of push rod

1. Put the push rod on a platform.
2. Roll the push rod along the platform and use
a feeler gauge to measure bending of push
rod. If the measurement value exceeds
prescribed limit, the push rod shall be
replaced.
Push rod bending limit:
0.4 mm or less
3. Visually check whether there is any excess
abrasion or damage at both ends of push
rod.
If so, replace the push rod.
Reassembly
6. Valve guide
· Apply oil to the outer surface of valve guide.
Use a special tool to mount a new valve
guide from one side of camshaft.
62

· Press in a new oil seal with a special tool.
4. Valve
· Apply oil to the outer surface of valve stem.
3. Valve spring
· Mount the valve spring on the upper spring
seat. The section with painting on the valve
spring shall be placed downwards (i.e. the
spring with less pitch placed downwards).
2. Valve cotter
· Use a spring compressor to press the valve
spring to a proper position.
· Use a soft-faced hammer to slightly tap the
cotter head until it seats in place.
1. Rocker assembly
Installation torque:55±5 N·m
63
2.3 Camshaft and tappet
Assembly sequence
1. Cylinder head assembly
2. Flywheel
3. Cylinder block liftback
4. Oil pan assembly
5. Oil pump assembly
6. Camshaft timing gear
6a. Camshaft timing pulley
7. Camshaft thrust plate
7a. Camshaft pulley central flange
8. Camshaft
9. Tappet
Reassembly sequence
sequence.
Disassembly
2. Flywheel
3. Flywheel baffle
4. Oil pan assembly
· Remove camshaft timing gear bolt(s)
from the camshaft.
Note
Fasten the camshaft to avoid turning.
· Pull out camshaft timing gear ② with a
universal puller ① .Universal puller:
1007017FA-9101
· Remove the thrust washer ③.
64
7. Camshaft thrust washer
8. Camshaft
9. Tappet

1. Measure the camshaft thrust

clearance
· Measure the camshaft axial clearance with a
dial gauge.
This shall be done before disassembling the
camshaft gear.
If the camshaft axial clearance exceeds
prescribed limit, the thrust washer shall be
replaced.
Camshaft axial clearance mm
Nominal Limit
0.005-0.114 0.2
2. Camshaft journal outer diameter

· Use a micrometer to measure the outer
diameter of each camshaft journal in
direction ① and ② . If the measurement
value exceeds prescribed limit, the camshaft
shall be replaced.
Journal outer diameter mm
Nominal Limit
49.945—49.975 49.60
3. Cam height
· Use a micrometer to measure the cam height
a. If the measurement value is lower than the
prescribed value, the cam shall be replaced.
Cam height mm
Nominal Limit
42.02±0.05 41.65
65
4. Camshaft radial runout
· Put the camshaft on a V block.
· Measure the radial runout with a dial gauge.
If the measurement value exceeds prescribed
limit, the camshaft shall be replaced.
Radial runout mm
Nominal Limit
0.04 or less 0.10
5. Camshaft and camshaft bearing

clearance
· Measure the camshaft bearing inner
diameter with a dial gauge.
Camshaft bearing inner diameter mm
Nominal Limit
50.00—50.03 50.08
Camshaft bearing clearance mm

Nominal Limit
0.025—0.080 0.12
If the camshaft bearing inner diameter or the

journal clearance exceeds the prescribed values,
the camshaft bearing shall be replaced.
Camshaft bearing replacement

Camshaft bearing disassembly
1. Remove cylinder block stopper.
2. Disassemble the camshaft bearing
with a camshaft bearing replacer.
Camshaft bearing replacer:
1002107FA-9101
66
Camshaft bearing assembly
1. Align the oil hole on the bearing to the oil
hole on the cylinder block.
2. Mount the camshaft bearing with a camshaft
bearing replacer.
Camshaft bearing replacer: 1002107FA-9101
Tappet
Visually check whether there is any point
corrosion, crack and other abnormities on contact
surface between the camshaft and tappet. If so,
replace the tappet.
See left figure.
① Normal contact
② Crack
③ point corrosion
④ Abnormal contact
⑤ Abnormal contact
Note
The tappet has spherical surface.Never use an
oilstone or similar tools to grind the spherical
surface when you repair the tappet.If the
tappet is damaged, you must replace it with a
new one.
Tappet outer diameter

1. Measure the tappet outer diameter with a dial
gauge. If the measurement value exceeds
prescribed limit, the tappet shall be replaced.
Tappet outer diameter mm

Nominal Limit
12.72—12.90 12.70
67
2. Measure the upper tappet installation hole
inner diameter on the cylinder block and
calculate the clearance.
If the clearance exceeds the limit value,
replace the tappet and/or cylinder block.
Clearance between the tappet and tappet hole

mm
Nominal Limit
0.010-0.046 0.10
Reassembly
9. Tappet
1) Apply oil to the tappet ① and in the upper
tappet installation hole on the cylinder block.
2) Determine the tappet position according to
the identification made in disassembling (if
the tappet is newly used).
Note
The tappet shall be installed before
assembling the camshaft.
8. Camshaft
1) Apply oil to the camshaft and camshaft
bearing.
2) Install the camshaft to the cylinder block.
Be careful not to damage the camshaft bearing.
7. Camshaft thrust washer

Mount the thrust washer to the cylinder block and
tighten the thrust washer bolt (s) to specified
torque.
Thrust washer bolt torque : 25±5 N·m
68
1) Install camshaft timing gear to the camshaft.
The timing gear mark (“Y-Y”) shall face
outwards.
2) Tighten the timing gear bolt to the specified
torque.
Timing gear bolt torque 110±10 N·m

· Apply some oil on the oil pipe O-ring and
mount it to the cylinder block O-ring groove.
· Install the oil pump assembly and oil outlet
pump to the cylinder block. Tighten the fixing
bolt(s) to specified torque.
25±5 N·m
· Tighten sleeve nut(s) to the following
specified torque:
30±5 N·m
4. Oil pan assembly

As shown in the figure, apply recommended silica
gel (Loctite 598) or equivalent in alignment on the
arc area of the fifth bearing cap, groove, the arc
area of timing gear casing and oil pan gasket.
· Mount the rear lip of seal washer into the

groove of the fifth bearing cap.
· Make sure the lip perfectly contacts with the
groove.
· Install the oil pan to the cylinder block.
· Tighten oil pan bolt(s) to the specified torque.
Oil pan bolt torque 23.5±3.5 N·m
69
3. Flywheel baffle
· Tighten the flywheel baffle fixing bolts to the
specified torque.
Flywheel baffle bolt torque 85±10N·m
2. Flywheel
· Apply some oil to fixing bolts.
· Screw down the flywheel bolts to the
specified torque in two steps by torque
tightening method.
Tighten them as the sequence number shown in
the figure.
Flywheel bolt torque N·m
25 70 120±10

1) Assemble the valve seat
1. Carefully place the attachment ①(its outer
diameter is less than that of valve seat) on
the valve seat ②.
Note
Make the smooth side of attachment contact with
the valve seat.
2. Use a table press ③ to gradually press the
attachment until the valve seat seats in
place.
Note
Never apply excess compressive force on the
valve seat when you use a table press. Otherwise,
the valve seat may be damaged.
Measure the upper height of valve guide from the
upper surface of cylinder head.
Upper height of valve guide (H) (reference value):
13 mm
70
Note
If a valve guide has been disassembled,
you should replace the valve and valve
guide in pairs.
2) Lower spring seat
3) Valve stem oil seal
· Mount a new oil seal to the valve.
· Use a special tool to guide.
4) Valve
5) Valve spring
· Mount the valve spring on the upper spring
seat.
Caution
· The section with painting on the valve spring
shall be placed downwards.
· Supply compressed air from glow plug hole
to cylinder until the valve seats in place.
· Install the valve cotter with a special tool.
6) Valve cotter
· Use a spring compressor to press the spring
in place.
· Use a soft-faced hammer to tap the cotter
head until it seats in place.
71
2.4. Rocker arm assembly
Disassembling sequence:
1.Rocker shaft assembly
2.Rocker shaft elastic retainer
3. Rocker arm
4. Rocker shaft support
5. Rocker arm
6. Rocker shaft spring
7. Rocker shaft
Reassembling sequence:
sequence.
Disassembly
1. Rocker shaft assembly
2. Elastic retainer of rocker shaft
3. Rocker arm
4. Rocker shaft retainer
5. Rocker arm
7. Rocker shaft

If excessive abrasion and damage is found
during checking, adjust, repair and replace
parts in time.
Measure the outer diameter of rocker shaft at
its swinging position with a dial gauge.
Replace the rocker shaft if the diameter
exceeds prescribed limit.
mm.
Nominal Limit
18.98— 19.00 18.9
72
Oil film clearance
1. Measure the inner diameter of rocker shaft
hole with a vernier caliper or dial gauge.
Inner diameter of rocker shaft hole mm
Nominal Limit
19.010— 19.030 19.100
2. Measure the outer diameter of rocker shaft.If
the measured value exceeds prescribed limit,
replace rocker arm or rocker shaft.
Clearance between rocker arm and rocker
shaft mm
Nominal Limit
0.01— 0.05 0.10
3. Check the upper oil hole of rocker arm is

blocked.
Blow clean the oil hole of rocker shaft with
compressed air if necessary.
Rocker arm correction

Check there is abrasion or scratch with the
upper valve stem contact surface.
If there is slight abrasion or scratch of step
shape with the contact surface, polish it with
oil.
The rocker arm has to be replaced if this
abrasion or scratch is serious.
73
Radial runout of rocker shaft
1. Put the rocker shaft on a V block.
2. Measure the radial runout at middle part of
rocker shaft with a dial gauge.
If the radial runout is slight, correct this
runout with a table press.
If the radial runout of rocker shaft exceeds
prescribed limit, the rocker shaft has to be
replaced.
Radial runout of rocker shaft mm
Limit
0.2
Reassembly
7. Rocker shaft
 Apply a thin layer of oil to the rocker
shaft.
 The rocker shaft should be placed in
such a way that the bigger hole (ø4)
faces the engine forepart.
 Install the rocker shaft, rocker shaft
retainer and spring together.
5. Rocker arm
4. Rocker shaft retainer
3. Rocker arm
2. Elastic retainer of rocker shaft
 Install the rocker shaft assembly on the
cylinder head.
 Tighten the flywheel baffle fixing bolts to
the specified torque.
74
2.5 Oil pump
Assembling sequence:
1. Flywheel
2. Rear plate of cylinder block
3. Oil pan assembly
5. Oil pipe
6. Strainer
7. Pump cover
8. Driven gear and bush
9. Drive gear
10. Driven shaft
11. Pinion pin
12. Pinion
13. Drive shaft
14. Oil pump body
sequence.
Disassembly
1． Flywheel
2. Flywheel baffle
3． Oil pan assembly
75
4． Oil pump assembly
5. Oil pipe
6. Strainer
7. Pump cover
9. Drive gear
10. Driven shaft
11. Pinion pin
 File flat the tip of pinion stop pin.
 Knock out the pinion pin with a hammer
and bar.
 Remove the pinion.
12. Pinion
13. Drive shaft
14. Oil pump body

Housing and gear
The oil pump assembly must be replaced if one of
the following conditions is found:
 The driven gear sleeve is worn or
damaged seriously.
 The upper gear teeth is worn or
damaged seriously.
Clearance between upper gear teeth and

inner housing wall
 Measure the clearance between upper gear
teeth and inner housing wall with a clearance
gauge.
 If the clearance between upper gear teeth
and inner housing wall exceeds prescribed
limit, either the gear or housing has to be
replaced.
Clearance between upper gear teeth and inner
housing wall
mm
Nominal Limit
0.14 0.20
76
Clearance between gear and cover
 Measure the clearance between gear
and cover with a clearance gauge.
 If the clearance between gear and cover
exceeds prescribed limit, the housing
must be replaced.
Clearance between gear and cover mm
Nominal Limit
0.06 0.15
Clearance between drive shaft and oil

pump body
 Use a micrometer to measure the
borehole diameter of drive shaft.
 Measure the inner diameter of pump
body with a dial gauge.
 If the Clearance between drive shaft and
oil pump body exceeds prescribed limit,
the oil pump assembly has to be
replaced.
Clearance between drive shaft and oil pump
body mm
Nominal Limit
0．04 0．20
Clearance between driven shaft and

bush
 Use a micrometer to measure the outer
diameter of driven shaft.
 Measure the inner diameter of bush with
a dial gauge.
 If the clearance between driven shaft
and bush exceeds prescribed limit, the
bush must be replaced.
Clearance between driven shaft and bush mm
Nominal Limit
0.05 0.15
Reassembly
14. Oil pump body
13. Drive shaft
12. Pinion
77
11. Pinion pin
 Install new drive shaft on the pump body.
 Install the pinion on the drive shaft.
 Drill a hole withφ5mm (0.20in) bore bit
for the pinion and drive shaft to pass
through.
 Insert the pinion pin into the hole.
Rivet the pin.
10. Driven shaft
9. Drive gear
7. Pump cover
6. Strainer assembly
 Mount the strainer assembly and screw
down its fixing bolts.
20±5 N·m
5. Oil pipe
 Apply oil containing molybdenum to the
oil pump driven gear and camshaft drive
gear.
 Tighten the oil pump fixing bolts to the
specified torque.
20±5 N·m

 Apply recommended liquid sealant or
equivalents to the fifth bearing cap arch
section, groove and timing gear
chamber arch section shown in the
diagram.
78
 Mount the rear lip of seal washer into the
 Make sure that the lip is perfectly in
contact with the groove.
 Install the oil pan on the cylinder block.
 Tighten oil pan bolt(s) to the specified
torque.
Oil pan bolt torque: 23.5±3.5 N·m
2. Flywheel baffle
 Align the flywheel baffle with the anchor
pin of cylinder block, and tighten
flywheel baffle bolt(s) to the specified
torque: 85±10 N·m
1． Flywheel
 Apply some oil to fixing bolt.
 Screw down the flywheel bolts to the
tightening method.
Step Ⅰ Step Ⅱ Step Ⅲ

25 70 120±10
79
2.6. Crankshaft
Assembling sequence:
1. Cylinder head assembly and
gasket
2. Oil pan
3. Timing gear
3a. Timing belt and pulley
4. Front oil seal
5. Timing pulley chamber
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
11. Rear oil seal of crankshaft
12. Main bearing cap
13. Crankshaft
sequence.
Disassembly
1. Cylinder head assembly and gasket
2. Oil pan assembly
3. Timing gear
4. Timing gear chamber
80
8. Flywheel
9. Flywheel baffle
10. Rear oil seal
 Push in the oil seal, install the special
tools according to the sequence shown in
the diagram to facilitate removing the oil
seal.
Rear oil seal remover: 1002430FA-9102
Note: Take care not to damage the flywheel
baffle and crankshaft sealing surface
during oil seal removal.
12. Crankshaft

If excessive abrasion or damage is found
during checking, adjust, repair and replace
parts in time.
1. Crankshaft
Thrust clearance
Install dial gauge according to the sequence
shown in the diagram and measure the thrust
clearance of crankshaft.
If the thrust clearance exceeds prescribed
limit, the thrust bearing shall be replaced in
pair.
Thrust clearance mm
Nominal Limit
0.040-0.201 0.30
2. Main bearing clearance

1) Remove the main bearing cap according to
the sequence shown in the diagram.
Place the removed main bearing cap
according to the sequence number of
cylinder.
2) Remove crankshaft. Dismantle main bearing.
3) Clean the upper and lower bearings and
main journal of crankshaft.
4) Check the bearing is damaged or
excessively worn.
If excessive abrasion or damage is found
during checking, the bearing has to be
replaced in pair.
81
5) Install the upper bearing and thrust washer
on their original positions. Carefully install the
crankshaft.
6) Mount the lower bearing to the bearing cap in
its original position.
7) Install plastic cord clearance gauge on the
main journal of crankshaft.
8) Install main bearing cap. Apply oil to the
threads and mating surfaces of bolts. Tighten
the bolt to the specified torque.
170±10 N·m
Note:
The crankshaft is not allowed to rotate.
9) Remove main bearing cap.
10) Measure the width of plastic cord clearance
gauge and determine the oil film clearance.
If the oil film clearance exceeds prescribed
limit, the main bearing and (or) crankshaft
has to be replaced in pair.
11) Remove the plastic cord clearance gauge off
bearing and crankshaft.
Dismantle crankshaft and bearing.
Oil film clearance mm(in)
Nominal Limit
0．031— 0．066 0．11
3. Radial runout
1) Carefully put the crankshaft on a V block.
Slowly rotate the crankshaft and measure the
radial runout.If the radial runout of crankshaft
exceeds prescribed limit, the crankshaft has
to be replaced.
Radial runout mm
Nominal Limit
0.05 or less 0．08
82
Measure the diameter of main journal and
crankpin and the uneven abrasion.
If the abrasion of crankshaft exceeds prescribed
limit, the crankshaft has to be replaced.
mm
Nominal Limit
Main journal
69.91— 69.932 69.910
diameter
Crankpin
52.91— 52.930 52.900
diameter
Uneven
0.05 or less 0.08
abrasion limit
Crankshaft inspection
Check the main journal of crankshaft and
crankpin surface are damaged or excessively
worn.
Check there is excessive abrasion or
damage on the mating surface of oil seal.
Check the oil hole is blocked.
The tested part has to be kept in Inspection on soft nitrogen treatment of

balance to prevent testing fluid
flowing.
No testing fluid is crankshaft
necessary around
the oil hole. 1. Thoroughly clean the crankshaft with a
Sliding surface of
crankpin or main
kind of organics. There must be no oil
journal stains on the tested surface.
About 10mm 2. Prepare some solution containing 5％
— 10 ％ ammonium cupric chloride
(dissolved in distilled water).
3. Apply the solution on the tested surface
with an injector.
Keep the tested surface in full level state
to prevent solution flowing.
Note:
The solution is not allowed to wash the oil
hole and area around.
Test
1. Wait for 30— 40 seconds.
If the color does not change after 30— 40
seconds, the crankshaft can be used.
If the color changes (the tested surface
becomes copper color), the crankshaft has to
be replaced.
83
2. Clean the crankshaft surface with steam
immediately after test is completed.
Note:
There is high corrosiveness with
ammonium cupric chloride solution.
Therefore, it is absolutely necessary to
clean the crankshaft surface immediately
after test is completed.
Crankshaft bearing selection
When assembling new crankshaft bearing or
replacing old bearing, see the selection table
below.
When selecting and installing new crankshaft
bearing, pay attention to the diameter size
mark of the upper journal hole and crankshaft
main journal 2.
Note:
Although there are oil grooves and holes
(cylinder block side) with all the upper
bearings of main journal and there are not oil
grooves and holes (bearing cap side) with all
the lower bearings, still pay attention to
identify them during assembly.
84
Main bearing hole diameter Crankshaft main journal
Main bearing Oil film
(mm) diameter (mm)
size mark clearance
Size mark Bore diameter Size mark Outer diameter
0.010
1 ＞69.926-69.932 Black（Φ2  0.006 ） 0.036-0.062
1 73.988-74.000
2 ＞69.920-69.926 0.014 0.034-0.060
Blue（Φ2  0.010 ）
3 69.914-69.920 0.040-0.066
1 ＞69.926-69.932 0.006 0.031-0.057
Green（Φ2  0.002 ）
2 ＞69.920-69.926 0.037-0.063
2 73.975-73.987
0.010
3 69.914-69.920 Black（Φ2  0.006 ） 0.035-0.061
Reassembly
13. Crankshaft
 Install the main bearing on the cylinder
block and main bearing cap.
 Make sure that their positions are
correct.
 Apply fresh oil to the upper and lower
main bearing surfaces.
 Carefully install the crankshaft.
 Apply oil to the thrust washer.
 Install the thrust washer on the third
main journal. Its oil groove must face the
crankshaft.
85
other equivalents to the fifth crankshaft
bearing cap ① as shown in the drawing.
 Install arc gasket ② on the fifth bearing
cap. Put the arc gasket into the bearing
cap groove with fingers.

other equivalents to the fifth crankshaft
bearing cap ③ as shown in the drawing.

other equivalents to points ③ and ④ of
the fifth crankshaft bearing cap cylinder
block mating surface as shown in the
drawing.
Note:
Ensure that there in no oil stain on the
mating surface of bearing cap before
coating liquid sealant.
Make sure the liquid sealant do not block
cylinder thread hole and bearing.
 Install the bearing cap, and make sure

the arrow mark on its top points at
engine forepart.
 Apply oil to crankshaft bearing cap bolts.
 Tighten the crankshaft bearing cap bolts
step by step in several times according
to the sequence shown in the drawing
until specified torque is reached.
Nm
Step Ⅰ Step Ⅱ Step Ⅲ (final
(sealing (sealing torque)
torque) torque)
20 110 170
86
Note:
Manually rotate the crankshaft to check
whether it is flexible.

Install the oil seal on the cylinder block with
an oil seal erector.
Rear oil seal erector: 1002430FA-9101
Notes:
Clean the rust and chips off the press-in
portion of the oil seal.
Pay attention to the press-in direction of
the oil seal.
1) Connect the adaptors of special tools to
the rear end of the crankshaft with two
bolts.
2) Install the oil seal to the periphery of the
adaptors.
3) Insert the socket into the adaptor and
screw down the bolt (M12XL75L=70) until
the adaptor tip is in contact with the
socket.
4) Remove the adaptor and socket.
5) Check the oil seal installation depth and
flatness after it is installed.
Depth standard: 12.5±0.3mm
10. Flywheel baffle
Align the baffle with the upper anchor pin of
cylinder block.
Tighten the flywheel baffle bolts to the
specified torque: 85±10N·m
9. Flywheel
1) Thoroughly clean out the oil stains on the
crankshaft thread(s).
2) Install the flywheel on the crankshaft, and
then mount the washer(s).
3) Apply oil to flywheel bolt thread(s).
4) Align the flywheel with the anchor pin of
crankshaft.
5) Screw down the flywheel bolts to the
tightening method. Tightening sequence
is shown in the diagram.
Step Ⅰ Step Ⅱ Step Ⅲ (final
(sealing (sealing torque)
torque) torque)
25 70 120±10
87
8. Piston and connecting rod assembly
 Apply oil to cylinder hole, connecting rod
bearing, crankpin, piston ring and piston.
Check the position of piston ring
opening is correct.
 Encase piston/connecting rod assembly

into each cylinder with a piston ring
compressor.
The front mark must face the engine
forepart.
 The number on cap should be in pair
with the one on connecting rod. Align the
printing mark on connecting rod with the
one on cap.
 Apply oil to the threads and mating
surfaces of nuts.
 Screw down the connecting rod cap nuts
in two steps by torque tightening method
according to the following descriptions.
N·m
First step Second step
(pretightening) (tightening)
20 85±5
Check the crankshaft rotates freely after the
connecting rod nuts are tightened.

 Tighten bolt(s) and injection nozzle
plug(pressure limiting valve) to the
specified torque.
Bolt: 20±5 N·m
Injection nozzle plug
(pressure limiting valve): 30±5 N·m
88
1) Prepare some solution containing 80％
oil and 20％ supramoly.
2) Apply a thin layer of the above solution
to the teeth of oil pump pinion.
3) Install the oil pump and tighten bolt(s) to
25±5 N·m
Note:
Take care not to damage O-ring when
screwing down oil pipe bolt(s).
4) Tighten sleeve nut(s) to the specified
torque:
30±5 N·m

1) Install timing pulley chamber on the
cylinder block.
2) Use bolt(s) to tighten both timing pulley

chamber and timing pulley chamber
gasket(s) to the specified torque.
25±5 N·m
3) Cut off the gasket tip on the mating

surface (as shown in the diagram).
4. Front oil seal of crankshaft

Install the front oil seal of crankshaft on the
gear chamber cover assembly with a front oil
Front oil seal seal erector as shown in the diagram.
of crankshaft Front oil seal erector: 1002420FA-9101
Note:
Take care not the twist the front oil seal.
89
3． Timing gear
11) Crankshaft gear
① Install crankshaft gear
② Install crankshaft gear ② with crankshaft
gear erector ①.Crankshaft gear timing
mark (“K-X”) must face the outside.
10) Camshaft timing gear

① Install camshaft timing gear to the
camshaft with timing gear mark (“Y-Y”)
toward outside.
② Tighten camshaft timing gear bolt(s) to
the specified torque:
110±10 N·m
9) Idler gear
① Apply some oil to the idler gear and its
shaft.
The oil hole in idler gear shaft must face
upward.
② Idler gear setting marks “X” and “Y”
should face the engine forepart during
assembly.
③ Align idler gear setting mark “X” with

setting mark “X-X”of crankshaft timing
gear ①.
④ Align idler gear setting mark “Y” with
setting mark “Y-Y” of camshaft timing
gear ②.
⑤ Install thrust ring and bolt(s) on the
cylinder block.
Thrust ring oil hole must be toward
upward, while its chamfer shall face the
outside.
⑥ Tighten idler gear bolt(s) to the specified
torque.
25±5 N·m
90
8) Idler gear “B”and its shaft
shaft.
② Align idler gear setting marks “B”③ “Z”
with “A”④ “Z-Z”.
③ Tighten idler gear bolt(s) to the specified
torque.
110±10 N·m
7) Injection pump
① Install O-ring ① on injection pump
flange ②.
② Install the injection pump to the timing
gear chamber.
Align idler marks “B”③ “V-V”.
③ Temporarily tighten six injection pump

nuts ⑤.
The final screwing down of injection
pump nuts is conducted after the rear
support bolt(s) of injection pump is
tightened.
④ Install rear support ⑥ and rear support

bolt⑦ of injection pump on the cylinder
block.
⑤ Mount rear support bolt ⑧ to the
injection pump support ⑨.
Finally tighten rear support bolts ⑦ and
⑧ to the specified torque.
25±5 N·m
91
6) Timing gear injection pipe
① Install the oil pipe to the timing gear
chamber and idler gear “A”.
② Tighten oil pipe punching bolt ① and
bolt ② to the specified torque.
20±5 N·m
5) Timing gear chamber cover

① Align the timing gear chamber with
timing gear chamber anchor pin, then
install timing gear chamber cover.
⑥ Tighten gear chamber cover bolt to the
specified torque.
25±5 N·m
4) Crankshaft damper pulley

Screw down the crankshaft damper
pulley bolt(s) to the specified torque.
Note:
While screwing down the damper
pulley bolt(s), fix the flywheel gear to
prevent crankshaft rotating.
210±15 N·m
3) Cooling fan assembly

 Install the fan pulley and cooling fan
assembly to the water pump in turn and
tighten the bolt to the specified torque.
12.5±2.5N·m
2) Drive belts of the alternator and
power steering pump
 Mount drive belts of the alternator and
power steering pump and adjust the belt
tension.
 Press the belt center with 100N force.
Drive belt deflection 8～10 mm
92
1) Fan guard
 Install the fan guard and coolant storage
tank hose.
 Fill in coolant.

section, groove and timing gear
chamber arch section shown in the
diagram.

 Make sure the lip perfectly contacts with
the groove.
 Install the oil pan to the cylinder block.
torque.
1. Cylinder head
Cylinder head assembly

① Mount the anchor pin to the cylinder
block.
② Install cylinder head gasket with top
mark toward upside.
③ Clean the lower cylinder head surface
and upper cylinder block surface.
④ Mount the cylinder head carefully.
⑤ Apply oil to the threads and mating
surfaces of cylinder head bolts.
⑥ Tighten the cylinder head bolts to the
specified torque in three steps according
to the sequence shown in the diagram.
93
Cylinder head bolt torque N·m
65 85 105±5
Push rod
 Apply oil to the push rod and insert it into
the cylinder head.
Rocker shaft assembly

① Loosen all adjusting screws.
② Install the rocker shaft so that the bigger
oil hole (Φ4) faces engine forepart.
③ Tighten the rocker shaft support bolt(s)

to the specified torque according to the
sequence shown in the diagram.
Rocker shaft support bolt torque
55±5 N·m
 Adjust the valve clearance.
94
2.7. Piston and connecting rod
2. Oil pan assembly
5. Connecting rod bearing cup
7. Piston ring
8. Piston ring retainer
9. Piston pin
10. Piston
11. Connecting rod
Reassembly sequence
Reassemble all parts in reverse sequence.
Disassembly
2. Oil pan assembly
5. Connecting rod cap
 Scrape carbon deposits on upper
cylinder wall with a scraper before
disassembling the piston and connecting
rod.
95
7. Piston ring
 Remove the piston ring with a piston ring
expander.
 Place the removed piston ring as the
sequence number in the drawing.

 Dismantle piston pin retainer with pliers.
9. Piston pin
Note:
Place parts removed from each cylinder.All
the parts have to be reassembled to the
original positions.
10. Piston
11. Connecting rod

Piston and piston ring
Piston
Carefully clean up carbon deposits on the
piston top and piston ring groove.
Notes:
Never use metal brush for cleaning the
piston.Otherwise it will damage the
piston.Visually inspect if there are any
cracks, scratches or other signs of
excessive abrasion on each piston.
If so, replace the piston.
Piston outer diameter
1. Measure the outer diameter of the piston
at the position of each piston group.
Position of each piston group:
Distance to the piston top is 73.9 mm
96
Outer diameter groups of 4DA1 series pistons
Mark G mm
Diameter mark Outer diameter
A 92.957～92.970
B 92.970～92.983
C 92.983～92.996
Front mark 4 DA1 series cylinder liner bore diameters

mm
Diameter mark Outer diameter
A 93．021～93．034
B 93．034～93．047
C 93．047～93．060
Measure the cylinder bore diameter (refer to

“Inspection of the cylinder block” in this
section). If the piston clearance does not
comply with the specified values, replace the
piston and/or cylinder liner.
Piston clearance mm
4DA1 Series 0.051～0.077
Piston ring
If during engine overhaul it is found that any part is
worn-out or damaged, you should replace it.
1. Piston ring opening measurement
 Install the piston ring into the cylinder liner.
97
 Push the piston ring with the piston into the
most narrow part of the cylinder liner bore in
such a way that it is vertical to the cylinder
wall.
4DA1 series piston ring opening gap mm
Piston ring 4DA1 4DA1-1 Limits
First gas ring 0.2～0.4 0.2～0.4 1.5
Second gas
Top mark (first ting) 0.2～0.4 0.6～0.85 1.5
(Second ring) ring
Oil ring 0.1～0.3 0.35～0.65 1.5
2. Measure the clearance between the piston

ring groove and piston ring with a clearance
gauge. If the clearance exceeds the specified
limits, you should replace the piston
4DA1 series piston ring end gap mm
Piston ring 4DA1 4DA1-1 Limits
First gas ring 0.09～0.125 0.078～0.139 0.15
Second gas 0.05～0.075 0.045～0.09
0.15
ring
Oil ring 0.03～0.07 0.03～0.07 0.15
Piston pin
Visually inspect if there are any cracks,
scratches or other signs of abrasion on the
piston pin and replace the piston pin if
necessary.
1. Measure the piston pin outer diameter with
a micrometer at three positions in two
directions.If the measurement values
exceed the specified limits, the piston pin
has to be replaced.
Piston pin outer diameter mm
Nominal Limits
4DA1 30.994～31.000 30.970
4DA1-1 33.994～34.000 33.970
98
2. Measure the inner diameter of the
connecting rod small end.If the clearance
between the connecting rod small end and
pin does not comply with the specified
values, you have to change the connecting
rod or bushing and pin.
mm
Nominal Limits
0.008～0.026 0.05
3. Insert the piston pin into the piston and

rotate it.If the pin rotates freely and is
compact with the piston, it means the
clearance is permissible.If there is any
clearance or the surface between them is
rough, measure the clearance.If the
clearance exceeds the specified values,
you have to replace the piston and piston
pin.
mm
Nominal Limits
4DA1 系列 0.002～0.016 0.04
Replacing the bushing

Disassembly: use suitable compression bar
and table press or hammer.
Assembly: use suitable compression bar and
table press
Notes:
The bushing should be aligned with the oil
hole on the connecting rod.
Grind the bushing bore with a pin hole
grinder before mounting new bushing.
99
Connecting rod
1. Check the centerline deviations of two
connecting rod holes with a connecting rod
aligner.
If the amount of inclination or twist exceeds the
specified limits, you have to replace the
connecting rod.
mm
Nominal Limits
Amount of inclination
0.08 or less 0.20
(Per l00m)
Twist
0.05 or less 0.15
(Per l00m)
2. Measure the axial clearance of the connecting
rod
Measure the connecting rod thrust clearance at
its big end with a clearance gauge.
If the clearance exceeds the specified limits,
you have to replace the connecting rod.
Axial clearance mm
Nominal Limit
0.175～0.290 0.350
3. Measure the oil film clearance between the
connecting rod and crankshaft:
1) Remove the connecting rod cap nut and the
cap.
Place the removed connecting rod
according to the cylinder sequence number
2) Clean the connecting rod bearings and
crankpin.
3) Inspect the connecting rod bearings
carefully.
Even if there is only one damaged or
severely worn-out bearing, all the bearings
have to be replaced.Reassemble the
bearings to their original positions.Place a
plastigage on the crankpin.
4) Reinstall the connecting rod cap to its
original position.
5) Screw down the connecting rod cap nut to
the specified torque in two steps via torque
tightening method according to the following
instructions.
N·m
4DA1 20 85
Series
Note:
Never rotate the crankshaft.
100
6) Remove the connecting rod cap
7) Measure the plastigage width and determine
the oil film clearance. If the oil film clearance
exceeds the prescribed limit, the connecting
rod bearings shall be replaced in pair.
8) Remove the plastigage from the bearings
and crankpin.
Clearance between the crankshaft main
journal and bearing mm
Nominal Limit
4DA1 Series 0.029— 0.066 0.100
Reassembly
11. Connecting rod
10. Piston
9. Piston pin
Apply oil to the piston pin and piston pin hole.
Apply a thin layer of oil to the piston pin.
Manually press the piston pin into piston pin
hole.
Weigh each piston and connecting rod
assembly.
Select the piston and connecting rod
assembly in such a way that the assembly
weight difference varies within the specified
limits.
Weight variation 4DA1 Less than 10g
after combined 4DA1-1
Less than 8g
as an assembly
Note:
When replacing the piston/connecting rod
assembly, do not change the piston/piston
pin assembly.
101
 Mount the piston onto the connecting rod
in such a way that the piston front mark
Front mark and connecting rod mark should face the
same direction.
JAC mark
7. Piston ring
 Install the piston ring with a piston ring
expander.
The TOP mark should face upward
during gas ring erection.
 The position of the identification sign is
shown in the drawing.
TOP mark (first ting)
(Second ring)
 Mount the piston ring in following

sequence.
① Oil ring
 Oil ring with a spiral cup ring
② Second gas ring
③ First gas ring
 The TOP mark should face upward
during gas ring erection.
 First gas ring: TOP.

No 1 gas ring  Second gas ring: TOP.
 Apply some oil to all piston rings after
installing the rings.
No 2 gas ring Check whether all piston rings can
rotates freely.
 Install the bearings onto the connecting
Oil ring rod and its cap.
Apply fresh oil to the bearing surfaces.
102
 Apply oil to the cylinder hole, connecting
rod bearings and crankpin.
 Check whether the piston ring opening
position is correct.
 Install the piston/connecting rod
assembly into each cylinder with a piston
ring compressor.
 The front mark must be towards the
engine forepart.
5. Connecting rod bearing cap

 Screw down the connecting rod cap nut
in two steps via torque tightening method
according to the following instructions.
N·m
4DA1 Series 20 85
Check if the crankshaft rotates freely

after tightening the cap nut.

 Mount the piston cooling oil pipe to the
cylinder block.
 Screw down the oil pipe bolt and relief
valve to the specified torque.
Oil pipe bolt torque N·m
(1)M8×1.25 25
N·m
(2)M6×1.00 7.5
Oil-pressure adjusting valve torque N·m
(3)M16×1.5 30
Note:
Turn the crankshaft slowly; make sure the
piston and the oil injection pipe don’
t interfere
with each other.
103
 Apply some oil on the oil pipe O-ring and
mount it to the cylinder block O-ring
groove.
 Install the oil pump assembly and oil
pump to the cylinder block and tighten
the fixing bolt(s) to the specified torque:25±5 N·m
Tighten sleeve nut(s) to the following

specified torque:30±5 N·m

section, groove and timing gear chamber
arch section shown in the diagram.
 Make sure that the lip is perfectly in

contact with the groove.
torque
104
① Mount the anchor pin to the cylinder
block.
② Install cylinder head gasket with its top
mark toward upside.
③ Clean the lower cylinder head surface
and upper cylinder block surface.
④ Mount the cylinder head carefully.
⑤ Apply oil to the threads and mating
surfaces of cylinder head bolts.
⑥ Tighten the cylinder head bolts to the
specified torque in three steps according
to the sequence shown in the diagram.
65 85 105±5
Push rod
 Apply oil to the push rod and insert it into
the cylinder head.
Rocker shaft assembly

① Loosen all adjusting screws.
② Install the rocker shaft so that the bigger
oil hole (Φ4) faces engine forepart.
③ Tighten the rocker shaft support bolt(s) to

the specified torque according to the
Rocker shaft support bolt torque 55±5 N·m
 Adjust the valve clearance
105
2.8 Cylinder block
2. Oil pan
3. Timing gear
4. Front oil seal
9. Flywheel
13. Crankshaft
14. Tappet
15. Camshaft
16. Cylinder block
Reassembly sequence
Reassemble as the opposite order of
disassembly.
Disassembly
106
2. Oil pan assembly
3. Timing gear
4. Front oil seal
9. Flywheel
10. Flywheel baffle
13. Crankshaft
14. Tappet
15. Camshaft
16. Cylinder block

1. Remove the gasket(s) and any other attached

matters on the surface of cylinder block.
Be careful to prevent matters falling into the
cylinder block by accident.
Take care not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal

retainer and the seal on the oil pan assembly
surface.
3. Wipe the cylinder block clean.

Inspection of cylinder liner protrusion size
1. Put ruler ① at the top edge of cylinder liner

to be measured.
2. Measure the protrusion size of each cylinder
liner with clearance gauge ②.
The difference between any two adjacent

cylinders in cylinder liner protrusion height shall
not exceed 0.05mm.
Standard value mm
0～0.08
107
Flatness
1. Remove the dowel from cylinder block.
2. Install cylinder liner detacher on the cylinder
liner.
3. Check the base on the detacher shaft covers
the bottom edge of cylinder liner firmly.
4. Slowly rotate the detacher shaft hand wheel
anticlockwise to pull out the cylinder liner.
Detacher base of cylinder liner:

1002106FA-9102 (4DA1 Series)
Note: be careful not to damage the

upper surface of cylinder during
disassembling the cylinder liner.
5. Measure four edges and two diagonals of

cylinder block upper surface with ruler ①and
clearance gauge ②.
If measurement value exceeds the limit, the cylinder
block has to be replaced.
Measurement of cylinder liner bore

diameter
Measure the bore diameter of cylinder liner along
thrust direction ②-② and the axial direction ③
of crankshaft with inside dial indicator in the depth
of 20mm,90mm,160mm, and take the average
value of 6 sizes as group size.
If measurement value exceeds prescribed limit,
the cylinder liner has to be replaced.
Notes:
The inner surface of dry cylinder liner is
chromalized, so it is not allowed to reface or
perform honing.
If there are nicks or burns with the inner surface
of cylinder liner, the cylinder liner has to be
replaced.
108
Group selection of cylinder liner
Measure the inner diameter of cylinder block and
choose appropriate cylinder liner group.
Standard over-fitting mm
0.001～0.019
Too little over-fitting of cylinder liner will have

adverse effect on cooling efficiency of engine.
If the over-fitting of cylinder liner is too large, it will
be difficult for the cylinder liner to encase gas.
Note:
There are two ways to select cylinder
liner.
Method I
The surface of the cylinder block has been
marked during manufacturing to indicate the
correct size of cylinder liner.Cylinder liner groups
(1, 2, 3, 4, etc.) are written with permanent ink.
When there is doubt with cylinder liner marks,
select the cylinder liner properly with the method
below.
Method Ⅱ
Measurement of cylinder block bore diameter
1) Measure the diameter at measuring point (A)
Ⅰ -○
○ Ⅱ -○
Ⅰ 、○ Ⅲ -○
Ⅱ 、○ Ⅲ。
The measuring point is the position 20mm,

90mm, 160mm away from the cylinder block
surface.
109
2) Calculate the average value of 6 measured
sizes to determine appropriate cylinder liner
group.
3) Refer to the table below according to the
average value, and apply proper cylinder liner.
4DA1 Series mm
Cylinder Average value of

Outer diameter of
liner cylinder bore
cylinder liner
groups diameter
0 94.991～95.000 95.001～95.010
1 95.001～95.010 95.011～95.020
2 95.011～95.020 95.021～95.030
3 95.021～95.030 95.031～95.040
4 95.031～95.040 95.041～95.050
Cylinder liner installation

1. Install the cylinder liner with special tools.
1) Thoroughly clean the cylinder liner and hole
surface with new kerosene or diesel oil.
2) Dry the surface of cylinder liner hole with
compressed air.Cylinder liner erector
1002106FA-9101
Note:
Be sure to carefully remove all the
foreign matters from the cylinder liner
and cylinder hole before installation.
110
3) Insert cylinder liner ① into cylinder block ②
from the top of cylinder block.
4) Install cylinder liner erector ③ at the top of

cylinder liner.
The position of cylinder block shall ensure
that the erector center is directly under
desk-top pressing machine shaft ④.
Erector 1002106FA-9101
Note:
Check the cylinder liner is in vertical with desk-top
pressing machine and without swinging.
5) Apply detent force 500kg (4900N) to the

cylinder liner with desk-top pressing machine.
6) Apply 2500ka (1102.5lb/24500N) force to put
the cylinder liner in place completely.
7) After the cylinder liner is installed, measure
the protrusion size.
See “Inspection of cylinder liner protrusion
size”in this chapter.
Measure the inner diameter of cylinder liner
hole and choose appropriate piston group.
Reassembly
16. Cylinder block
15. Camshaft
· Coat oil on tappet and in the installation hole
of upper cylinder block tappet.
· Fix position according to the position mark
made during removal (if the tappet is reused).
111
· Coat oil on the camshaft and camshaft
bearing.
· Install the camshaft on the cylinder block.
Be careful not to damage the camshaft
bearing.
14. Tappet
13. Crankshaft
· Install the main bearing on the cylinder block
and main bearing cap.
· Ensure that their position is correct.
· Apply fresh oil to the upper and lower main
bearing surfaces.
· Carefully install the crankshaft.
· Apply oil to the thrust plate.

· Install the thrust plate at the third main journal
bearing.Its oil groove must face the
crankshaft.

· Apply recommended liquid sealant or other
equivalents to the fifth crankshaft bearing cap
① as shown in the drawing.
· Install arc gasket ② on the fifth bearing cap.
Put the arc gasket into the bearing cap groove
with fingers.
Note:
Ensure that there in no oil stain on the mating
surface of bearing cap before coating liquid
sealant.Make sure the liquid sealant do not
block cylinder thread hole and bearing.
112
· Apply recommended liquid sealant or other
equivalents to the fifth crankshaft bearing cap
③ as shown in the drawing
· Install the bearing cap, and make sure the

arrow mark on its top points at engine
forepart.
· Apply oil to crankshaft bearing cap bolts.
· Tighten the crankshaft bearing cap bolts step

by step in several times as the sequence
shown in the drawing until specified torque is
reached:
170±10 Nm
Note:
Manually rotate the crankshaft to check it is
flexible.

· Install the oil seal on the cylinder block with
Notes:
Clean the rust and chips off the press-in
portion of the oil seal.
Pay attention to the press-in direction of the
oil seal.
1) Use two bolts to connect the adaptors of
special tools to the rear end of the
crankshaft.
adaptors.
113
3) Insert the socket into the adaptor and screw
down the bolt until the adaptor tip is in contact
with the socket.
5) Check the oil seal size after it is installed.
Standard value mm
12.5±0.3
10. Flywheel baffle
· Tighten the flywheel baffle fixing the bolt(s) to
the specified torque:
85±10N·m
9．Flywheel
· Apply oil to the fixing bolts.
· Screw down the flywheel bolts to the specified
torque in two steps via torque tightening
method.
Tighten them as the sequence number shown
in the drawing.
8．Piston and connecting rod

1) Press the piston pin into piston pin hole with
fingers.
assembly.Select the piston and connecting
rod assembly in such a way that the assembly
weight difference varies within the specified
limits.
Weight 4DA1 4DA1-1
variation
after
Less than
combined Less than 8g
10g
as an
assembly
2) Clamp the connecting rod by a vice.Be careful

not to damage the connecting rod.
3) Encase the piston pin retainer into piston with
pliers.
Note:
When changing the piston/connecting rod
assembly, do not change the piston/piston pin
assembly.
114
4) Install the piston onto the connecting
rod.Mark ① on the piston head and casting
symbol “F908”② on the connecting rod
should be toward the same direction.
5) Apply oil to the piston pin and piston pin hole.

Forcibly push the piston pin into piston with
fingers until it is in contact with piston pin
retainer.
6) Forcibly press the piston pin retainer into

piston retainer groove with fingers.
Check whether the connecting rod swings
freely on the piston pin.
7) Install the piston ring with piston ring

expansion lip.
The TOP mark on gas ring should be toward
upwards.
Identification sign is shown in the drawing.
N mark (top ring)
(the second ring)
115
8) Mount three piston rings with a piston ring
replacer.
Gas ring NO.1
Piston ring replacer:
Install the piston ring as the sequence
number shown in the drawing.
Gas ring NO.2 ① Oil ring
② The second gas ring
③ The first gas ring
Oil ring
Notes:
Make sure that the surface with marks is
toward the upward when gas ring is installed.
Encase the spiral cup ring into the oil ring, and make
sure that there is no clearance at any side of the
Cup ring
NO.2 gas ring
spiral cup ring before the oil ring is installed.
9) Apply some oil to the piston ring surface.

10) Check whether the piston ring turns freely in
Mark
NO.1 gas
the piston ring groove.
Oil ring ring 11) Place the piston ring opening as shown in the
drawing.
12) Carefully remove the oil stains or other foreign
matters from the back of connecting rod
bearing or the installation surface of
connecting rod bearing.
13) Apply some oil to the upper bearing surface.
Apply some oil to the cylinder wall.
116
14) Place the piston in such a way that the front
mark on the bearing cap must be toward the
engine forepart.
Encase the piston into engine block with
piston installation taper sleeve.
Piston installation taper sleeve:
1004001FA-9102
15) Push in the piston with a hammer handle until
the connecting rod touches the crankpin.
In addition, rotate the crankshaft until the
crankpin is at bottom dead center.
16) Place the bearing cap in such a way that its
front mark is toward the engine forepart.
17) Install connecting rod bearing cap.
Align the cylinder sequence mark on
connecting rod bearing cap with the one on
connecting rod.
18) Apply oil to the thread and mating surface of
each connecting rod bearing cap bolt.
19) Screw down the connecting rod bearing cap
bolt to the specified torque in two steps via
Front mark torque tightening method.
Torque of connecting rod bearing cap bolt N·m

(pre-tightening) (tightening)
4DA1
20 85
Series
Note:

4. Front oil seal
3.Timing gear
2. Oil pan assembly
See “Crankshaft”in 2.6 for the reassembly of

“7 - 1”.
117
3.4 DA1 Series Engine
3.1 General
4DA1 Series
ωtype combustion chamber is adopted in 4DA1 Series engine, and this kind of design provides
outstanding economical efficiency of fuel within wide running range.
The cylinder head gasket is piled up with sheet steel.
Tighten the fixing bolts of such parts as cylinder head, connecting rod and flywheel with torque tightening
method.
Dry cylinder liner made of chromized steel has high durability.
The piston with automatic heat compensation is supported with cast steel, which is used to reduce the
noise resulted from heat expansion and cold engine.
The crankshaft by soft nitrogen treatment has long life.Because of its soft nitrogen treatment, the
crankshaft can not be refaced.
Both the crankshaft main bearing and connecting rod bearing are made of aluminum alloy.This kind of
bearing is particularly easy to be damaged when encountering foreign matters such as metal chips.
Therefore, it is very important to keep the oil hole and other associated surfaces clean and remove
foreign matters.
The crankshaft’s soft nitrogen treatment (nitrogen treatment) improves its intensity, and saves the step of
refacing crankpin and main journal.
4DA1-1 engine is equipped with fuel injection device for cooling piston in the fuel line, and the fuel is
injected toward piston from the fuel line of cylinder block via non-turn valve.
Be careful not to damage the oil nozzle when disassembling and assembling piston and connecting rod.
4DA1 Series is direct injection engine, and the fuel injector had five holes, which enables inlet air and
fuel injection to gain optimum mixing ration.
118
3.2 Right support of engine
Locking bolt
Alternator fixing bolt 1. Fan cowl
2. Fan belt
3. Support rubber
Independent suspension Assembling sequence

Dependent suspension As assembling, go on according to the
reverse sequence of disassembly.
Disassembly
Preparation:
· Remove the ground cables of battery.
1. Fan guard
· Remove the storage tank hose and fan
guard.
2. Fan belt
· Remove locking bolts of adjusting plate.
· Loosen the alternator fixing bolt and then
remove the fan pulley drive belt.
3. Support rubber
·Remove the two fixing nuts at the beam side.
119
· Remove the generator from the engine.
· Remove the support rubber nut from engine foot rest side.
· Lift the engine to remove the support rubber.
Assembly
3. Support rubber
· Lift the engine to install the support rubber.
· Tighten the fixing nut(s) to the specified torque.
Engine foot rest side N·m
Beam side N·m
Drive belt of air 40

compressor
Drive belt of 2．Fan pulley drive belt
power steering
oil pump
·Install the fan pulley drive belt.
·Press the middle part of fan pulley drive belt with 100N force to let
the belt go down for 8-10mm.
·Tighten the fixing nut(s) to the specified torque.
Generator fixing bolt N·m
37.5
1．Fan guard
·Install the fan guard and tighten the storage tank hose.
120
3.3 Left support of engine
1. Air-intake duct
2. Fan cowl
3. Support rubber
Assembling sequence
Independent suspension As assembling, go on according to
Dependent suspension the reverse sequence of
disassembly.
Disassembly
Preparation:
1. Air-intake duct
· Remove the air-intake duct.
2. Fan guard
· Remove the storage tank hose and fan guard.
3. Support rubber
· Remove the two fixing bolts at beam side.
121
· Remove the support from engine foot rest side.
· Remove the support rubber nut from engine foot rest side.
· Lift the engine to remove the support rubber.
Assembly
3. Support rubber
· Lift the engine to install the support rubber.
Engine foot rest side N·m
82
Beam side N·m
40
2．Fan guard
· Install the fan guard and tighten the storage tank hose.
1．Air-intake duct
· Install the air-intake duct.
· Connect the ground cables of battery.
122
3.4 Air-intake manifold
1.Vacuum hose
2. Air-intake duct
3. Crankcase vent hose
4. High pressure oil pipe
5. Oil scale guide
6. Air-intake manifold
Assembling sequence
As assembling, go on according to the
Disassembly
Preparation:
· Discharge coolant completely.
1. Vacuum hose
2. Air-intake duct
· Unscrew high pressure oil pipe clip.
· Loosen the taper nut(s) at injection pump side.
· Loosen the taper nut(s) at injector side, remove the pipe and
put it aside.
5. Oil scale guide
· Remove the fixing bolt(s) and disassembly the oil scale guide.
123
· Remove the fixing bolt(s) and nut(s) of manifold.
Assembly
· Tighten the fixing bolt(s) and nut(s) to the specified torque.
Bolt and nut N·m
20
5. Oil scale guide
·Install the guide and tighten it together with the manifold.

· Connect the high pressure oil pipe and tighten the taper nut(s)
to the specified torque.
Taper nut torque N·m
30
· Install the clip of high pressure oil pipe at the original position.
2. Air-intake duct
1. Vacuum hose
· Add some coolant.
· Start the engine and check whether the coolant leaks.
124
3.5 Exhaust manifold
1. Front exhaust pipe nut
2. Front exhaust branch pipe bolt
3. Heat insulating plate
4. Exhaust branch pipe
Assembling sequence
Disassembly
Preparation:

· Remove the fixing nut(s) at exhaust manifold side.
2. Front exhaust pipe support bolt.
125
4. Exhaust manifold
· Remove the bolt(s) and nut(s) of manifold, and then
dismount the manifold and gasket(s).
Assembly
4. Exhaust manifold
· Tighten the fixing bolt(s) and nut(s) to the specified
torque.
Manifold bolt torque N.m
30

· Install the heat insulating plate and tighten the bolt(s) to
Heat insulating plate bolt torque N.m
25
2. Front exhaust pipe support bolt

· Tighten the fixing bolt(s) to the specified torque.
Support bolt torque N.m
40

N.m
40
126
3.6 Oil cooler
Type I
1. Water hose
2. Oil cooler fixing bolt
3. Oil cooler
Type II
1.Water hose
2. Oil filter element
3. Oil cooler fixing bolt
4. Oil cooler
Assembling sequence
4D A1 Series reverse sequence of disassembly.
Disassembly
Preparation:
·Remove the ground cables of battery.
·Discharge the coolant completely.
·Place the wiping cloth at oil cooler 9 to prevent oil immersion.
1. Water hose
·Remove water inlet and outlet hoses.
2. Oil filter element
3. Fixing nut of oil cooler
4. Oil cooler
Inspection
Relief valve
1. Install an oil pressure gauge at the position where the oil line is
near oil filter.
2. Start the engine and check the opening pressure of the relief
valve.
Opening pressure of relief valve kg/cm 2
4.7
127
3. Oil cooler
Inspection of water passage leakage
1. Block one end of the oil cooler water passage.
2. Immerse the oil cooler into the water.
3. Add compressed air at the other end of the oil cooler water
passage.
(2kg/cm2(28.5pai/19.60kpa))，bubbles rising on the surface
indicates that there is leakage with the water passage.
Assembly
3. Oil cooler
· Install O ring onto the oil filter and place the oil cooler.
2. Fixing nut of oil cooler

Tighten the fixing nut(s) of oil cooler to the specified torque.
Oil cooler nut torque N.m
30
1. Water hose
· Connect the water hose.
· Start the engine and check whether the oil leaks.
128
Oil filter element
Disassembly
· Place a container under the oil filter to receive oil.
· Remove the oil filter element with a filter wrench.
· Filter wrench: 1010300FA-9101
Assembly
· Coat a thin layer of oil on the oil filer O ring.
· Screw new oil filter element into the filter until the sealing
surface in jointed with O ring.
· Tighten the oil filter with the filter wrench, and screw down
1 1
another 1 circles for I type, while screw down another 1
8 4
circles for II type.
· Start the engine and check whether the oil leaks from the oil
filter.
129
3.8 Cylinder head cover
2. Cylinder head cover
Assembling sequence
As assembling, go on according to
the reverse sequence of
disassembly.
Disassembly
Preparation:
·Dismantle crankcase vent hose from air-intake duct side.

Assembly
·Apply oil to the rocker arm and valve spring.
·Install the gasket(s) of cylinder head cover on the cylinder head
cover.
The gasket(s) must be flat and without damage.
·Tighten the cylinder head cover nut(s) to the specified torque.
N·m
13
1. Connect the crankcase vent hose.
·Connect the crankcase vent hose to the air-intake pipe.
·Connect the ground cables of battery.
130
3.9 Rocker shaft assembly
Assembling sequence
Disassembly
Preparation:
Remove the ground cables of battery.
Loosen the bolt(s) and nut(s) of rocker shaft support in sequence
and remove the rocker shaft assembly.
Assembly
· Install the rocker shaft so that the bigger oil hole (Φ4) locates at
engine forepart.
· Align the fixing bolts with the holes on the rocker shaft, and
tighten them to the specified torque.
N．m
55
131
① Rotate the crankshaft until TDC line of the crankshaft damper
pulley is aligned with timing pointer, and either the first cylinder
piston or the fourth cylinder piston is at the top dead center (TDC)
② Check the nuts of rocker shaft support are loose.
Tighten all the loose nuts of the rocker shaft support before
adjusting valve clearance.
Rocker shaft support nut torque N.m
55
③ Check the clearance between intake valve and exhaust valve
push rod for the first cylinder.If there is clearance between intake
valve and exhaust valve push rod for the first cylinder, the first
cylinder piston locates at the top dead center of compression
stroke.
If there is no clearance between intake valve and exhaust valve
push rod for the first cylinder, the fourth cylinder piston locates at
the top dead center of compression stroke.
Top dead center of the first

cylinder compression stroke
The piston of cylinder must locate at the top dead center of
compression stroke when the valve clearance of the first cylinder
or fourth cylinder is adjusted.
Valve clearance (cold state) mm
0.3-0.4
④ Loosen the adjustment screw(s) for each valve clearance shown

in the drawing.
⑤ Insert a clearance gauge with proper thickness between the
rocker arm and valve stem end.
132
Top dead center of the fourth
⑥ Rotate the adjustment screw(s) for valve clearance until a touch
of resistance is felt on the clearance gauge.
⑦ Tighten the locking nut(s) firmly.
⑧ Rotate the crankshaft for 360o.

⑨ Then align TDC line of crankshaft damper pulley with timing
pointer.
⑩ Adjust the clearance of other valves shown in the drawing.
● Install the cylinder head cover and tighten the bolt(s) to the
specified torque.
N．m
13
133
3.10 Valve stem oil seal and valve spring
3. Valve spring
4. Valve stem oil seal
Assembling sequence
disassembly.
Disassembly
Preparation:

· Loosen the bolt(s) and nut(s) of rocker shaft support in
sequence and remove the rocker shaft assembly.
3. Valve spring
· Compress the valve spring with a special tool and remove
the valve cotter.
Caution:
· Place the removed valve springs as the cylinder number
sequence.
134
· Remove the valve stem oil seals with pliers.
Caution:
The valve stem oil seal that has been removed should not be used
again.
Assembly
· Install new valve stem oil seals on the valve guide with a
special tool.
Special tool: 1003016FA-9101
3. Valve spring
· Place upper valve spring retainer on the valve spring.
Caution:
· The colored part of valve spring should be downward.
· Add compressed air to the cylinder from glow plug and lift the
valve to set it in place.
· Install the valve cotter with special tool.
· Valve spring compressor: 1003015FA-9101

· Install the rocker shaft so that the bigger oil hole (Φ4) locates at
engine forepart.
· Align the fixing bolts with the holes on the rocker shaft, and
tighten them to the specified torque.
N·m
55
· Valve clearance adjustment
135
① Rotate the crankshaft until TDC line of the crankshaft damper
pulley is aligned with timing pointer, and either the first cylinder
piston or the fourth cylinder piston is at the top dead center (TDC)
55

cylinder piston locates at the top dead center of compression
stroke.
If there is no clearance between intake valve and exhaust valve
push rod for the first cylinder, the fourth cylinder piston locates at
the top dead center of compression stroke.
The piston of cylinder must locate at the top dead center of

compression stroke when the valve clearance of the first cylinder
Top dead center of the first cylinder or fourth cylinder is adjusted.
compression stroke
0.3-0．4
④ Loosen the adjustment screw(s) for each valve clearance shown
in the drawing.
136
Top dead center of the fourth

cylinder compression stroke ⑦ Tighten the locking nut(s) firmly.
⑧ Rotate the crankshaft for 360o.
⑨ Then align TDC line of crankshaft damper pulley with timing

pointer.
· Apply oil to the rocker arm and valve spring.
· Install the gasket(s) of cylinder head cover on the cylinder head
cover. The gasket(s) must be flat and without damage.
· Install the cylinder head cover and tighten the bolt(s) to the
specified torque.
Cylinder head cover bolt torque N·m
13
· Connect crankcase vent hose.
137
3.11 Timing gear
1. Fan cowl
2. Drive belt of power steering pump
3. Drive belt of alternator
4. Cooling fan assembly
5. Crankshaft damper pulley
6. Acoustic hood
7. Acoustic hood liner
8. Timing gear chamber cover
9. Oil pipe
10. Idler gear
11. Idler gear
12. Oil injection pipe
13. Timing gear of camshaft
14. Crankshaft gear
Assembling sequence
Disassembly
Preparation:
· Discharge the coolant completely.
1. Fan guard
2. Power steering pump drive belt
· Unscrew the bracket bolt(s) and adjusting bolt(s) for power
steering pump and remove the drive belt.
3. Alternator drive belt
· Unscrew the alternator bracket bolt(s) (lower part) and adjusting
plate locking bolt(s) and remove the drive belt.
· Unfasten tight nut(s), and dismount fan assembly, collar and fan
pulley.
6. Acoustic hood
138
9. Oil pipe
10. Idler gear

1) Measure the timing gear play of camshaft and crankshaft before
disassembling the idler gear.
2) First measure the axial clearance for idler gear before
disassembling the idler gear.
Note:
Refer to the following items for details on gear clearance and
axial clearance measurement methods.
Timing gear clearance measurement
1) Install a dial gauge onto the timing gear to be tested. Fix the gear
to be examined and the gear connected to it.
2) Swing the gear to be checked left and right as much as possible.
Read out the dial gauge readings.
If the measured value exceeds prescribed limit, the timing gear has to
be replaced.
Timing gear clearance mm
Standard Limit
0.10--0.17 0.30
Axial clearance measurement of idler gear ”A”
Insert a clearance gauge between the idler gear and thrust ring to
measure the clearance and determine the axial clearance of idler
gear.
If the measured value exceeds prescribed limit, the thrust ring has to
be replaced.
Axial clearance of idler gear mm
Standard Limit
0.07 0.2
139
11. Idler gear
12. Injection pump

1) Remove six injection pump bracket bolts ① from timing gear
chamber.
2) Remove rear bracket bolt ② from injection pump bracket ③.

3) Remove rear bracket bolt④ and bracket⑤ of injection pump from
the cylinder block.
4) Draw out both the injection pump and injection pump timing gear
toward the engine backside.
Note:
Cover the hole in injection pump delivery valve body with a cover or
equivalents to prevent foreign matters falling into the valve.
1) Measure the axial clearance of camshaft with a dial gauge.

Measure the clearance before disassembling the camshaft gear.
If the axial clearance of camshaft exceeds prescribed limit, the
thrust washer has to be replaced.
Axial clearance of camshaft mm
Standard Limit
0.050--0.114 0.2
2) Remove camshaft timing gear bolt(s) from the camshaft.
Note:
Keep the camshaft fixed to prevent its rotating.
140
3) Pull out camshaft timing gear② with universal puller ①.
Universal puller: 1007011FA-9101
4) Remove thrust washer ③.
14. Crankshaft gear
Assembly
14. Crankshaft gear
1) Install crankshaft gear
2) Install crankshaft gear ② with crankshaft gear erector ①.·
Crankshaft timing gear mark (“X-X”) must face the outside.

Crankshaft gear erector: 1007011FA-9102
1) Install the thrust washer onto the cylinder block.
2) Tighten thrust washer bolt(s) to the specified torque.
N·m
25
3) Install camshaft timing gear to the camshaft.
The timing gear mark (“Y— Y”) has to face the outside.
4) Tighten the timing gear to the specified torque.
N·m
110
12. Injection pump
1) Install O-ring ① to injection pump flange ②.
2) Install injection pump to the timing gear chamber.
Align the mark “V-V”of idler gear “B”③ with the mark “V”of
injection pump timing gear ④.
141
3) Temporarily tighten six nuts ⑤ for injection pump.
The final screwing down of injection pump nuts is conducted after rear
bracket bolt(s) of the injection pump is (are) tightened.
4) Install rear bracket ⑥ of injection pump and rear bracket bolt

⑦ on the cylinder block.
5) Mount rear bracket bolt ⑧ to injection pump bracket ⑨.
Do not screw down those bolts.

Rear bracket bolt ⑦ and ⑦ will be tightened to the specified torque
after the injection pump nuts are tightened.
6) Tighten the injection pump nuts to the specified torque.
N·m
25
7) Screw down injection pump bracket bolt(s) to the specified torque.
N·m
25
11. Idler gear
1) Apply some oil to the idler gear and its shaft.
The oil hole in idler gear shaft must be toward upward.
2) Arrange idler gear marks “X”and “Y”so that they both face the
engine forepart.
142
3) Align idler gear mark “X”with the mark “X— X”of crankshaft
timing gear ①.
4) Align idler gear mark “Y”with the mark “Y— Y”of camshaft timing
gear ②.
5) Install the thrust washer and bolt(s) onto the cylinder block.
Thrust ring oil hole must be toward upward while its chamfer should
face the outside.
6) Tighten idler gear bolt(s) to the specified torque.
N·m
20
10. Idler gear
1) Apply some oil to the idler gear and its shaft.

2) Align mark “Z”of gear “B”③with mark “Z— Z”of idler gear “A”④.
3) Tighten idler gear bolt(s) to the specified torque.
N.m
110
9. Lubrication oil pipe

1) Install the lubrication oil pipe on the timing gear chamber and idler
gear “A”.
2) Tighten lubrication oil pipe punching bolt ① and bolt ② to the
specified torque.
Oil pipe punching bolt torque N·m
20

1) Align timing gear chamber anchor pin with the timing gear
chamber, then install timing gear chamber cover.
2) Tighten gear chamber cover bolt(s) to the specified torque.
143
6. Acoustic hood

Screw down the crankshaft damper pulley bolt(s) to the specified
torque.
Note:
While screwing down the damper pulley, hold the flywheel ring gear to
prevent crankshaft rotating.
Pulley bolt torque N·m
210

· Install fan silicone oil clutch and cooling fan assembly (as this
sequence) on water pump, and tighten them to the specified
torque.
N·m
12.5
Install alternator drive belt and adjust the belt tension.

Press the belt center with 100N force.
Drive belt deflection mm
8-10
· Tighten idler gear locking nut(s) to the specified torque.

N·m
25
144
· Install power steering pump drive belt and adjust the belt
tension.
· Press the belt center with 100N force.
8-10
· Tighten idler gear locking nut(s) to the specified torque.
N·m
25
1. Fan guard
· Install fan guard and storage tank hose.
· Start the engine and check the coolant leaks.
145
3.12 Cylinder head assembly and gasket
1. Upper radiator hose
2. Heater hose
3. Air compressor drive belt
4. Engine wire
5. Air-intake duct
7. Oil return hose
9. Glow plug wire
10. Oil scale guide
11. Oil cooler tube
12. Air compressor assembly
13. Vacuum modulator
14. Front exhaust hose
15. Bypass hose
17. Rocker shaft
18. Push rod
20. Cylinder head gasket
Assembling sequence
As assembling, go on according
to the reverse sequence of
disassembly.
Disassembly
Preparation:
·Discharge the coolant in the radiator and engine completely.
1. Upper radiator hose
·Remove the upper radiator hose at engine side.
146
2. Heater hose
· Remove the heater hose from the heater pipe.
3. Air conditioning compressor drive belt
·Unscrew idler locking nut(s).
·Loosen adjusting bolt(s) and remove the drive belt.
4. Engine wire
Temperature ·Detach wire connector from upper thermostat cover component.

sensor
5. Air-intake duct
·Remove anchorage clip(s) and air-intake duct.
·Unscrew high pressure oil pipe anchorage clip(s).
·Loosen the taper nut(s) at injection pump side.
·Loosen the taper nut(s) at injection pump side and remove the
pipe.
Note:
Plug the holes in injector body and delivery valve body to prevent
foreign matters falling in.
7. Oil return hose
·Remove the oil return hose at oil return pipe side.
·Dismantle crankcase vent hose(s) from air-intake pipe.
9. Glow plug wire
10. Oil scale guide
·Remove oil scale guide out of the cylinder head.
147
11. Oil cooler tube
· Dismantle the fixing bolt(s) at rear side of cylinder head.
12. Air conditioning compressor assembly
· Remove the wire connector of clutch.
· Remove fixing bolt(s) of the air conditioning compressor and
temporarily bind the compressor to the frame side with wires.
13. Front exhaust pipe

· Remove exhaust pipe fixing bolt(s) out of the exhaust
manifolds.
· Remove exhaust pipe support bolt(s).
14. Bypass hose
148
16. Rocker shaft
· Loosen rocker shaft support bolt(s) bit by bit as according to
the sequence shown in the diagram.
Note:
Disobedience will have unfavorable influence on the rocker shaft.
17. Push rod

· Loosen cylinder head bolt(s) bit by bit according to the
Note:
Disobedience will bring unfavorable influence to the lower

surface of cylinder head.
· Remove cylinder head gasket and anchor pin.
Assembly
Before assembling, carefully remove carbon deposits on piston top

and upper cylinder block surface and also clean the place where the
gasket is installed.
149
Note:

1) Install the anchor pin onto the cylinder block.
2) Install cylinder head gasket with top mark toward upside.
3) Clean the lower cylinder head surface and upper cylinder block
surface.
4) Mount cylinder head gently.
5) Apply oil to the threads and mating surfaces of cylinder head

bolts.
6) Tighten the cylinder head bolts to the specified torque in three

steps according to the sequence shown in the diagram.
First step Second step Third step
65 85 105
17. Push rod
· Apply oil to the push rod and put the rod in cylinder head.
150
1) Loosen all adjusting screws.

2) Install the rocker shaft so that the bigger oil hole (Φ4) faces
engine forepart.
3) Tighten the rocker shaft support bolt(s) to the specified torque

according to the sequence shown in the diagram.
Rocker shaft support bolt torque N.m
55
·Valve clearance adjustment

① Rotate the crankshaft until zero scale line of the crankshaft
damper pulley is aligned with timing pointer, and either the first
cylinder piston or the fourth cylinder piston is at the top dead center
(TDC) of compression stroke.
55
151
cylinder piston locates at the top dead center of compression stroke.If
there is no clearance between intake valve and exhaust valve push
rod for the first cylinder, the fourth cylinder piston locates at the top
dead center of compression stroke.
The piston of cylinder must locate at the top dead center of compression
stroke when the valve clearance of the first cylinder or fourth cylinder is
adjusted.

0.3-0.4
Top dead center of the first
cylinder compression stroke ④ Loosen the adjustment screw(s) for each valve clearance shown
in the drawing.


⑦ Tighten the locking nut(s) firmly.
Top dead center of the fourth ⑧ Rotate the crankshaft for 360o.
⑨ Then align zero scale line of crankshaft damper pulley with timing
pointer.

·Apply oil to the rocker arm and valve spring.
·Install cylinder head cover gasket(s) of on the cylinder head cover.
·The gasket(s) must be flat and without damage.
·Tighten cylinder head cover nut(s) to the specified torque.
Cylinder head cover torque N.m
13
14. Bypass hose
152
13. Front exhaust pipe
· Connect the pipe with manifold and tighten bolt(s) and nut(s) to
Manifold nut torque N·m
37
Pipe support bolt torque N·m
40
12. Air conditioning compressor assembly
· Install the fixing bolt(s) of air conditioning compressor and

screw down the bolt(s) to the specified torque.
Compressor bolt torque N.m
20
153
11. Oil cooler tube
· Install tube bolt(s) and tighten the bolt(s) to the specified
torque.
Tube nut torque N·m
25
10. Oil scale guide
9 Glow plug wire connector
7. Oil return hose

· Install oil return hose with new copper washer.

· Install taper nut(s) at injection pump side.
· Install taper nut(s) at injector side.
· Tighten taper nut(s) to the specified torque.
Taper nut torque N·m
30
· Assemble the anchorage clip(s) of pipe within specified torque.
5. Air-intake duct
154
4. Engine wire
Temperature
sensor ·Connect temperature sensor and thermometer component wire.
·Check drive belt is worn or damaged, and replace if necessary.
·Check the belt tension, and adjust if necessary.
·Check the tension of drive belt.
Air conditioning compressor and

power steering pump drive pulley
Alternator and fan pulley drive belt · Apply a force of 100N to the belt center and check the deflection
of each belt.
· Deflection standard value
mm
Alternator and fan
pulley drive belt
Sinkage
Alternator and fan pulley drive belt 8— 10
Air conditioning compressor drive belt
Power steering pump drive belt
Tension adjustment
Air
conditioning Idler pulley Power steering pump and air conditioning compressor drive belts.
compressor
Adjusting Adjusting bolt · Loosen power steering pump locking bolt and adjust belt tension
plate
Power steering pump pulley
with the adjusting bolt.
Fan pulley
Alternator
Cooling fan pulley belt
Alternator bolt Idler pulley
Crankshaft pulley · Loosen alternator bracket and locking bolt(s), and then adjust the
Adjusting bolt
belt tension with the adjusting bolt of regulator.
155
Torque standard value N.m
Alternator fixing bolt 40
Adjusting plate fixing bolt 25
Adjusting plate locking bolt 25
2. Heater hose
· Install the heater hose, and then tighten the anchorage clip(s)
firmly.
1．Upper radiator hose

·Connect the radiator hose, and then tighten the anchorage clip(s)
firmly.
156
3.13 Oil pan
1. Vacuum oil pump
2. Engine support bolt
3. Stiffener plate
4. Oil pan assembly
Assembling sequence
Disassembly
Preparation:
· Lift the automobile.
· Discharge the coolant completely.

oil hose②
Note:
Install oil drain plug with new gasket.
N.m
oil hose①
80
1. Vacuum pump oil hose

· Remove oil hose ① out of the oil pan.
157
·Remove engine support bolts at both left an right sides.
3. Stiffener plate and rubber cushion
·Remove exhaust pipe bracket.
·Remove the stiffener plates out of oil pan (both left and right).
·Take out the rubber cushion.
4. Oil pan
·Lift the engine for about 50mm.
·Remove the oil pan from the cylinder block.
Assembly
4. Oil pan
·Apply recommended liquid sealant or equivalents to the fifth
bearing cap arch section, groove and timing gear chamber arch
section shown in the diagram.
158
·Install back lip portion of the gasket into the fifth groove.
·Make sure that the lip portion is compact with the groove.
·Install the oil pan on the cylinder block.
·Tighten oil pan bolt(s) to the specified torque.
Oil pan bolt torque N·m
23.5
3. Stiffener plate and rubber cushion
·Install rubber cushion.
·Install the stiffener plates at both left side and right side and
tighten bolts to the specified torque.
Engine block side N.m
37.5
Clutch housing side N.m
87
· Install exhaust pipe bracket.

· Install bracket bolts and tighten the bolts to the specified torque.
Bracket bolt torque N.m
40
· Install the oil hose on the oil pan.
·Add some oil.
·Connect the ground cables of battery.
·Start the engine and check whether the coolant leaks.
159
3.14 Oil pump assembly
1.Vacuum oil pump
2. Engine bracket bolt
3. Stiffener plate and rubber
cushion
4. Oil pan assembly
Assembling sequence
As assembling, go on
according to the reverse
sequence of disassembly.
Disassembly
Preparation:
· Lift the automobile.
· Discharge the oil completely.

Oil hose ②
Note:
Oil hose ①
N.m
80
· Remove oil hose ① out of the oil pan.
160
·Remove engine support bolts at both left an right sides.
3. Stiffener plate
· Remove exhaust pipe bracket.
· Remove the stiffener plates out of oil pan (both left and right).
4. Oil pan assembly

· Lift the engine for about 50mm.
· Remove the oil pan from the cylinder block.
5 Oil pump assembly

·Remove oil pump assembly from the cylinder block.
Assembly
·Prepare some solution containing 80％ oil and 20％ supramoly.

· Apply solution to the oil pump pinion teeth.
5．Oil pump assembly

· Apply some oil to the oil pipe O-ring and put it into the cylinder
block O-ring groove.
· Install the oil pump assembly with oil pipe to the cylinder block,
and tighten fixing bolts to the specified torque.
N.m
25
161
Tighten sleeve nut(s) to the specified torque.
N.m
30
4. Oil pan assembly

· Apply recommended liquid sealant or equivalents to the fifth
· Install back lip portion of the gasket into the fifth groove.
· Make sure that the lip portion is compact with the groove.
· Install the oil pan on the cylinder block.
23.5
3. Stiffener plate
· Install the stiffener plate and tighten bolt(s) to the specified
torque.
Engine block side N.m
37.5
Clutch housing side N.m
87
· Install exhaust pipe bracket.
162
· Lay down the engine, and install bracket bolts and tighten the
bolts to the specified torque.
· Install the oil hose on the oil pan.
· Add some oil.
· Start the engine and check whether the oil leaks.
163
3.15 Piston, Piston ring and connecting rod
2. Oil pan assembly
assembly
Assembling sequence
disassembly.
Disassembly
Preparation:
·Discharge the coolant completely.
·Discharge the oil completely.
Note
· Install oil drain plug with new gasket.
N.m
80
1) Upper radiator hose
·Remove the upper heater hose at engine side.
2) Heater hose
164
· Remove the heater hose from the heater pipe.
3) Air conditioning compressor drive belt

· Unscrew idler locking nut(s).
· Loosen adjusting bolt(s) and remove the drive belt.
4) Engine wire
· Detach wire connector from upper thermostat cover
component.
5) Air-intake duct
·Remove anchorage clip(s) and air-intake duct.
6) High pressure oil pipe
·Unscrew high pressure oil pipe anchorage clip(s).
·Loosen the taper nut(s) at injection pump side.
·Unscrew taper nut(s) at fuel injector side and remove high
pressure oil pipe(s).
7) Oil return hose
·Remove the oil return hose at oil return pipe side.．
8) Crankcase vent hose
·Dismantle crankcase vent hose(s) from air-intake pipe.
9) Glow plug wire
10) Oil scale guide
·Remove oil scale guide out of the cylinder head.
11) Oil cooler tube
·Remove pipe bracket bolt(s) at rear side of cylinder head.
·Remove cooler tube from the cylinder head.
165
12) Air conditioning compressor assembly
·Remove the wire connector of clutch.
·Remove the wire connector of electromagnetic clutch.
·Remove fixing bolt(s) of the air conditioning compressor and
temporarily bind the compressor side with wires.
13) Vacuum modulator hose
·Remove vacuum modulator hose from the vacuum modulator.
14) Front exhaust pipe
·Remove exhaust pipe fixing bolt(s) from the exhaust manifold.
·Remove exhaust pipe support bolt(s).
15) Bypass hose
16) Cylinder head cover
17) Rocker shaft
·Loosen rocker shaft support bolt(s) bit by bit according to the
Note:
Disobedience will have unfavorable influence on the rocker
shaft.
18) Push rod
166
19) Cylinder head assembly
Note:
surface of cylinder head.
20) Cylinder head gasket

Oil hose ②
2. Oil pan assembly
1) Vacuum pump oil hose

Oil hose ①
·Remove oil hose ① out of the oil pan.
2) Engine support bolt
·Remove engine support bolt(s).
3) Stiffener plate
·Remove exhaust pipe bracket.
·Remove stiffener plate.
167
4) Oil pan
·Lift the engine for about 50mm.
·Remove the oil pan from the cylinder block.
·Remove the oil pump from the cylinder block.
· If it is intended to reassemble the lower bearing of connecting
rod, please attach a label to each bearing, and mark the
disassembling sequence of cylinder and its installation position.
168
5. Piston and connecting rod with upper bearing
1) Scrape carbon deposits on upper cylinder wall with a scraper
before disassembling the piston and connecting rod.
2) Move the piston to the top of cylinder head, push upward the
lower part of connecting rod with a hammer handle or
equivalents, then take out the piston and connecting rod.
3) If it is intended to reassemble the upper bearing of connecting

rod, please attach a label to each bearing, and mark the
disassembling sequence of cylinder and its installation position.
4) Clamp the connecting rod with a vice.

Take care not to damage the connecting rod.
Remove each piston ring with piston ring replacer.
Do not try to remove the piston ring with other tools other than
piston ring replacer.
Excessive tension of piston ring will reduce the elastic force of
piston ring.
169
5) Dismantle piston pin retainer with pliers.
6) Gently knock out the piston pin with hammer and bar copper.
If it is intended to reassemble piston and piston pin, please attach

a label to each piston and piston pin, and mark the disassembling
sequence of cylinder and its installation position.
Assembly
5. Piston and connecting rod with upper bearing
1) Try to push the piston pin into piston pin hole with your finger
pressure.
Weigh each piston and connecting rod assembly.
Select the piston and connecting rod set in such a way that the
weight difference of various assemblies is within the specified
limits.
Model Assembly mass difference (g)
4DA1 ≤10
4DA1-1 ≤8
2) Clamp the connecting rod with a vice.
Take care not to damage the connecting rod.
3) Encase piston pin retainer to the piston with pliers.
Note:
When replacing the piston/connecting rod assembly, do not
change the piston/piston pin assembly.
170
4) Install the piston onto the connecting rod.
Front mark ① on the piston head and connecting rod “F908”

casting symbol ⑦ should face the same direction.
5) Add oil to the piston and piston pin hole.
Push piston pin into the piston with your finger until it touches the
piston pin retainer.
6) Press the piston pin retainer into piston retainer groove with
fingers.
Check whether the connecting rod can freely swing on the piston
pin.
7) Install piston ring and piston packing ring.
The gas ring mark “JAC”should face upward.
Identification mark is shown in the drawing.
Mark (first ring)

(second ring)
171
8) Assemble three piston rings with a piston ring replacer.
The assembling sequence of piston ring is shown in the diagram.
① Oil ring
② Second gas ring
③ First gas ring
Note:
First gas ring Support
spring
opening Mount the gas rings with chamfer toward upward.
Install the spiral ring into oil ring groove and make sure that
there is no clearance at either side of the packing ring before
Oil ring Second gas ring the oil ring is installed.
10) Check whether the piston ring can turn freely in piston ring
groove.
11) The cutout position for placing piston ring is shown in the
drawing.
12) Carefully wipe off the foreign bodies on connecting rod bearing
back and bearing mating surface.
13) Apply some oil to the upper bearing surface.
172
14) The front mark on piston head must be toward the engine
forepart during installation.
Compress the piston ring with a piston ring compressor.
Piston ring compressor: 1004022FA-9101
15) Push in the piston with a hammer handle until the connecting
rod touches the crankpin.
In the meanwhile, rotate the crankshaft until the crankpin

reaches its bottom dead center.

1) The front mark on the bearing cap must be toward the engine
forepart during installation.
Align the cylinder sequence mark on connecting rod bearing cap

with the one on connecting rod.
3) Apply oil to the thread and mating surface of each connecting rod
Front mark bearing cap bolt.
4) Screw down connecting rod bearing cap bolt to the specified

torque in two steps via torque tightening method.
Connecting rod bearing cap bolt torque N·m
First step (sealing torque) Second step (final torque)
20 85
Note:
Manually rotate the crankshaft to check whether it is flexible.
173
·Prepare some solution containing 80％ oil and 20％ supramoly.
·Apply solution to the oil pump pinion teeth.
·Apply some oil to the oil pipe O-ring and put it into the cylinder
·Install the oil pump assembly with oil pipe on the cylinder block,
Oil pump bolt torque N·m
25
·Tighten sleeve nut(s) to the specified torque.
Sleeve nut torque N·m
30
Note:
Be careful not to damage O-ring when tightening the oil pipe
bolt(s).
2. Oil pan assembly

1) Apply recommended liquid sealant or equivalents to the fifth
bearing cap arch section, groove and timing gear chamber
arch section shown in the diagram.
174
2) Install back lip portion of the gasket into the fifth groove.
Make sure the lip portion is compact with the groove.
3) Install the oil pan to the cylinder block.
Tighten oil pan bolt(s) to the specified torque.
23.5
4) Install the stiffener plate and tighten bolt(s) to the specified

torque.
Engine block side
Stiffener plate bolt torque N.m
30
5) Install exhaust pipe bracket.
6) Install support rubber and tighten nut(s) to the specified torque.
Support rubber nut torque N.m
40
175
Oil hose ②
7) Mount vacuum pump oil hose ① to the oil pan.

Oil hose ①
Refer to “3.12 Cylinder head assembly and gasket”.
176
3.16 Camshaft and tappet
1. Transmission assembly and
clutch assembly
2. Engine assembly
gasket
4. Timing gear
5. Oil pan
6. Oil pump
7. Camshaft and tappet
Assembling sequence
disassembly.
Disassembly
Preparation:
·Discharge coolant completely.
·Discharge the oil completely.
Note:
Oil drain plug torque N·m
80
177
1. Transmission assembly and clutch assembly
· Hoist the automobile and support it with a suitable and safe
bench.
1) Transmission
Setting mark ① Transmission
· Make a setting mark on the flange yoke and parking brake
drum.
· Disassemble the drive shaft on the flange yoke.
· Move aside the drive shaft and bind it on the frame so as to
facilitate maintenance work.
② Parking brake cable
· Move the connecting cover away.
· Dismantle connecting bolts.
· Remove anchorage clips and withdraw bracket cables.
Shift cable Anchorage clip

Pin
Select cable
③ Wire connector
Pin
· Detach the wire connectors of vehicle speed sensor, neutral
switch and backup light switch.
④ Shift and select cables
· Remove the shift and select cables at transmission side.
178
Elastic hose ⑤ Clutch slave cylinder
·Remove the clutch hose clips and clip bracket (only for vehicles
with right steering wheel).
Clutch pipe
·Disassemble the lower slave cylinder assembly together with
hoses, and bind them to the frame so as to facilitate
maintenance work.
⑥ Exhaust brake assembly
⑦ Front exhaust pipe
⑧ Transmission assembly
Note:
Sometimes the exhaust pipe bracket, gear control bracket and
anchorage clips are at mounting positions or directions.In
order to prevent this, please make correct mounting marks on
those parts.
·Use a transmission jack to jack up the transmission.
179
Caution:
In order to prevent transmission overturn, use chains or belts
to secure it to the jack.
Do not let the transmission hover over the clutch, or it will destroy
the clutch.
· Remove nuts securing the transmission bracket at beam side.
· Angles of the engine and transmission have to be adjusted so

that they can be easily disassembled.
· Use a jack or crane to jack up the rear part of engine.
Caution:
After jacking up the engine, place a wooden block under it to
protect the oil pan.

· Remove the transmission binding bolts.
· Draw out the transmission assembly backwards.
⑨ Bracket
2) Clutch
· Hoist the vehicle and support it with a suitable and safe bench.
Caution:
Make sure that no clutch fluid is left on the coating surface, or
wash it away immediately.
① Pressure plate assembly
② Driven plate assembly

· Use a guiding centralizer to prevent the driven plate assembly
falling freely.
· Mark the flywheel and pressure plate flange to ensure

alignment during installation.
· Loosen fixing bolts of the pressure plate assembly.
2. Engine assembly
1) Radiator assembly
· Remove the upper and lower hoses of the radiator.
· Remove storage tank hose.
· Remove the shock-absorbing rubber at both sides.
· Remove radiator support.
2) Air intake duct
180
3) Heater hose
4) Engine control cable
· Unscrew the locking nut(s) at the bracket and remove throttle
wire(s) from the injection pump control lever.
5) Glow plug wire
6) Fuel hose
· Remove fuel inlet hose and return hose.
7) Oil pressure switch wire
· Loosen adjusting nut(s) and remove the drive belt.
· Remove the wire connector of electromagnetic clutch.
· Remove fixing bolt(s) of the air conditioning compressor and
temporarily bind the compressor to the frame with wires.
9) Power steering pump and bracket assembly (power steering
type)
· Loosen adjusting nut(s) and remove the drive belt.
· Remove pipe bracket fixing bolt(s) and anchorage clip (s).
Bracket
· Remove power steering pump fixing bolt(s) and temporarily
Locking nut
bind the pump to the frame with wires.
Anchorage
clip
Anchorage
clip
181
10) Modulator vacuum hose (exhaust brake type)
· Remove the vacuum hose at modulator side.
11) Vacuum pump hose (exhaust brake type)
· Remove the vacuum hose at both vacuum tank and
solenoid valve sides.
· Remove exhaust pipe fixing bolt(s) from the exhaust
manifold.
· Remove exhaust pipe support bolt(s).
· Remove fixing nut(s) from front exhaust pipe.
13) Support rubber
① If mounted at right side
· Remove the two fixing nuts at beam side.
② If mounted at the left side
· Remove the two fixing nuts at beam side.
182
14) Engine assembly
· Slowly hoist the engine with a crane.
· Lift the engine with its front part higher than rear part.
· While taking out the engine assembly, be careful to avoid
breaking any oil pipe, brake pipe, etc.
· Place the engine on an engine support.
· Unscrew high pressure oil pipe anchorage clip(s).
· Loosen the taper nut(s) at injection pump side.
· Unscrew taper nut(s) at fuel injector side and remove high
pressure oil pipe(s).
2) Oil return hose
· Remove the oil return hose at oil return pipe side.
3) Crankcase vent hose
· Dismantle crankcase vent hose(s) from air-intake duct.
4) Glow plug wire
5) Oil scale guide
· Remove oil scale guide out of the cylinder head.
183
6) Oil cooler tube
· Remove pipe bracket fixing bolt(s) at rear side of cylinder
head.
· Remove oil scale guide out of the cylinder head.
7) Bypass hose
· Remove crankcase vent hose and cylinder head cover bolt(s).
9) Rocker shaft
· Loosen rocker shaft support bolt(s) bit by bit according to the
Note:
Disobedience will bring unfavorable influence to the rocker
shaft.
10) Push rod

Note:
surface of cylinder head. 12) Cylinder head gasket
4. Timing gear

· Unfasten tight nut(s), and dismount the fan assembly and fan
pulley.
184
3) Acoustic hood
4) Acoustic hood liner
① Measure the axial clearance of camshaft with a dial gauge.

Measure the clearance before disassemble the camshaft gear.
If the axial clearance of camshaft exceeds prescribed limit, the

thrust washer has to be replaced.
Axial clearance of camshaft mm
Standard Limit
0．050—0．114 0．2
② Remove camshaft timing gear bolt(s) from the camshaft.
Note:
Keep the camshaft fixed to prevent its rotating.
③ Pull out camshaft timing gear ② with a universal puller ①.
④ Remove the thrust washer ③.
5. Oil pan
· Remove vacuum pump oil hose ① out of the oil pan.
Oil hose ②
Oil hose ①
185
· Remove stiffener plate and rubber cushion from both sides of
the oil pan.
· Dismantle oil pan bolt(s) and remove the oil pan from the
cylinder block.
6．Oil pump assembly

· Remove oil pump assembly from the cylinder block.

· Remove the oil pan from the cylinder block.
· Be careful not to damage the camshaft bearing.
· Take out the tappet from the cylinder block.
186
Assembly
· Coat oil on the tappet and in the installation hole of cylinder
block tappet.
· Place the tappet according to the position mark made during

removing (if the tappet is intended to be reused).
Note:
The tappet must be installed before camshaft is assembled.

· Coat oil on the camshaft and camshaft bearing.
· Install the camshaft on the cylinder block.
Be careful not to damage the camshaft bearing.

· Prepare some solution containing 80％ oil and 20％
supramoly.
· Apply enough solution to the oil pump pinion teeth.
· Apply some oil to the oil pipe O-ring and put it into the cylinder
· Install the oil pump assembly with oil pipe on the cylinder block,
25
Tighten sleeve nut(s) to the specified torque.
30
187
5．Oil pan
· Apply recommended liquid sealant or equivalents to the fifth
· Install back lip portion of the gasket into the fifth groove.
· Make sure that the lip portion is compact with the groove.
· Install the oil pan to the cylinder block.
23.5
4. Timing gear

· Install the thrust washer onto the cylinder block and tighten
thrust washer bolt(s) to the specified torque.
N·m
25
· Install camshaft timing gear to the camshaft.
The timing gear mark (“Y— Y”) has to face the outside.
Align idler gear marks “B”“V-V”with injection pump timing gear
mark “V”.
Align idler gear marks “B”“Z”with idler gear marks “A”“Z-Z”.
Arrange idler gear setting marks “X”and “Y”so that they both face
the engine forepart.
Align idler gear mark “X”with crankshaft timing gear mark “X— X”.
188
Align idler gear mark “Y”with camshaft timing gear mark “Y— Y”.
· Tighten the timing gear to the specified torque.
Timing gear bolt torque N·m
110
Align timing gear chamber anchor pin with the timing gear
chamber, then install timing gear chamber cover.
Tighten gear chamber cover bolt to the specified torque.
Gear chamber cover bolt torque N·m
25
6) Lower acoustic hood
7) Upper acoustic hood
Screw down the crankshaft damper pulley bolt(s) to the specified
torque.
Note:
While screwing down the damper pulley, hold the flywheel ring
gear to prevent crankshaft rotating.
Crankshaft pulley bolt torque N·m
210

·Install the fan pulley and cooling fan assembly (in this installation
order) on water pump, and tighten those parts to the specified
torque.
N·m
12.5
189
Refer to “3.12 Cylinder head assembly and gasket”.
2. Engine assembly
14) Engine assembly
· Hoist the engine support with a crane.
13) Support rubber

· Tighten fixing bolts to the specified torque after all of them
(left: 2, right: 2) have been inserted into their corresponding
holes.
Support rubber bolt torque N.m
40

· Connect exhaust pipe and tighten nut(s) to the specified
torque.
Exhaust pipe nut torque N·m
67
· Install exhaust pipe support bolts and tighten bolts and nuts
Support bolt and nut torque N·m
40
11) Vacuum pump hose

· Install the vacuum hose at both vacuum tank and solenoid
valve sides.
190
· Connect the vacuum hose to the modulator.
9) Power steering pump and bracket assembly (power steering
type)
· Install power steering pump and pipe bracket, then tighten

Bracket
Locking nut
Pump bolt torque N·m
Anchorage 20
clip
Anchorage
clip Pipe bracket bolt torque N·m
20
Anchorage clip bolt torque N·m
10
· Install power steering pump drive belt and adjust the belt
tension.
· Check drive belt is worn or damaged, and replace if

Air conditioning compressor necessary.
drive belt and power steering
pump drive belt · Check the belt tension, and adjust if necessary.
· Press the central section of belt with a force of 100N and

check the deflection of each belt.
Alternator and fan · Deflection standard value

pulley drive belt
mm
Initial tension
Power steering pump drive belt 8—10
· Loosen power steering pump locking bolt(s) and adjust belt

tension with adjusting bolt.
10) Modulator vacuum hose
191
Power steering pump locking bolt torque
N·m
37.5
Idler locking nut torque
N·m
25

· Install the fixing bolt(s) of air conditioning compressor and
screw down the bolt(s) to the specified torque.
Compressor fixing bolt torque N·m
20
· Connect the wire connector of electromagnetic clutch.
· Install air compressor drive belt and adjust the belt tension.
· Check drive belt is worn or damaged, and replace if

necessary.
· Check the belt tension, and adjust if necessary.
· Press the central section of belt with a force of 100N and

check the deflection of each belt.
· Deflection standard value
mm
Initial tension
Air conditioning compressor drive belt 8— 10

· Loosen rir conditioning compressor locking bolt(s) and adjust
belt tension with the adjusting bolt of adjuster.
Idler locking nut torque N·m
25

· Connect oil pressure switch wire connector.
6) Fuel hose
· Connect fuel delivery hose and return hose, and then tighten
the anchorage clip(s) firmly.
192
5) Glow plug wire
· Install wire connector and tighten bolt(s) firmly.
① Mount the control cable to engine control lever.
② Place the throttle lever at fully-off position and pull tight the
control cable along the arrow direction to prevent slackness.
③ Tighten the throttle cable bracket bolt(s).
3) Heater hose
· Connect the radiator hose, and then tighten the anchorage
clip(s) firmly.
2) Air intake duct

· Connect the air-intake duct, and then tighten the anchorage
clip(s) firmly.
① Install shock-absorbing rubber at both sides.
② Mount radiator support.
③ Connect the upper and lower hoses of the radiator.
④ Connect storage tank hose.
1. Transmission assembly and clutch assembly
2) Clutch
193
· Apply multifunctional supramoly grease to the splines of
driven plate hub.
· Mount the driven plate assembly with a guiding centralizer.

· Screw down pressure plate fixing bolts in turn.
Pressure plate fixing bolt torque N·m
25
· Remove the guiding centralizer.
Note:
If a new pressure plate is installed, make sure to remove the
protection diaphragm spring cable after tightening the
pressure plate to the specified torque.
1) Transmission
⑨ Mounting bracket
Mounting bracket nut torque N·m
69
· Use a transmission jack to jack up the transmission.
Caution:
In order to prevent transmission overturn, use chains or belts
to secure it to the jack.
· Shift the transmission to high speed gear.
· Tilt the transmission in the same straight line with the engine.
· Rotate parking brake drum outputs to ease the clutch spline

engagement.
194
Clutch cover to flywheel casing bolt torque
N·m
M10：46
M12：91
· Hoist the engine and let the transmission enter the rear
transmission bracket.
Rear engine support nut and bolt torque
N·m
MlO：40
M12：69
⑦ Front exhaust pipe
Front exhaust pipe bolt torque N·m
37
Exhaust brake bolt torque N·m
17
⑤ Clutch slave cylinder
Slave cylinder bolt torque N·m
20
· Adjust the slave cylinder before mounting return spring.
a) Unscrew the push rod locking nut.
b) Turn the adjusting nut until it is against the release fork.

c) Back off the adjusting nut by 1½ turns.(The free gap of
release fork is about 2mm).
d) Screw down the locking nut.
Push rod locking nut torque N·m
16
③ Wire connector
195
① Drive shaft
· Align previously made marks.
Drive shaft nut torque N·m
66
· Add some oil.
196
3.17 Crankshaft front oil seal
1. Fan cowl
6. Front oil seal
Assembly sequence
Disassembly
Preparation:
 Remove battery ground cables.
 Discharge coolant completely.
1. Fan guard
 Unscrew bracket fixing bolt(s) and adjusting bolt(s) of the

power steering pump, then remove the drive belt.
 Unscrew alternator bracket fixing bolt(s) and adjusting

plate locking bolt(s), then remove the drive belt.
 Unfasten tight nut(s), and dismount the fan assembly,

collar and fan pulley.
197
6. Front oil seal
 Tap around the oil seal with a plastic hammer and a

screwdriver, and take out the oil seal out of the gear
chamber cover.
Exercise care to avoid damaging the seal mating surface.
Assembly
6. Front oil seal
 Mount the oil seal ① onto the gear chamber cover ② with
an erector.
Pay attention to the seal mounting level ③ shown in the

diagram.
Mounting depth ③ = l mm
Screw down the crankshaft damper pulley bolt(s) to the

specified torque.
Note:
210
 Install the fan pulley, spacer block and cooling fan

assembly (in this installing order) to a water pump, and
tighten those parts to the specified Tightening torque
N·m
12.5
3． Alternator drive belt
 Mount the alternator drive belt and adjust the belt tension.
 Refer to the “Drive belt adjustment”in this section.
198
2. Front oil seal
 Mount power steering pump drive belt and adjust the belt
tension.
 Refer to the “Drive belt adjustment”in this section.
1. Fan guard
 Install the fan guard and storage tank hose.
 Add in some coolant.
 Start the engine and check whether there is any leakage

of the coolant.
199
3.18 Crankshaft rear oil seal
1. Transmission and clutch assembly
2. Flywheel
3. Rear oil seal
Assembly sequence
Disassembly
Preparation:
 Remove the battery ground cable.
1. Transmission and clutch assemblies
Hoist the car and support it with a suitable and

Setting mark
safe bench.
1) Transmission
① Transmission
Mark the parking brake drum and flange yoke

beforehand.
 Remove the flange yoke drive shaft.
 Put the bundled up drum and flange yoke

aside so as to facilitate maintenance work.
200
 Detach the connecting hood.
 Remove connecting bolts.
 Dismantle anchorage clips and withdraw

bracket cables.
③ Wire connector
 Detach wire connectors of the vehicle

Shift cable Anchorage clips
speed sensor, neutral switch and back-up
Gear pin
light switch.

Select cable  Remove the shift and select cables on
Gear pin transmission side.

Elastic hose
 Remove the clutch hose clips and clip
bracket
Clutch
hose
 Disassemble the slave cylinder assembly

with Elastic hoses, and bind it to the frame
so as to facilitate the maintenance work.
201
⑦ front exhaust pipe
Notes:
Sometimes the exhaust pipe bracket /gear

control bracket and anchorage clips are in the
wrong mounting positions or directions.In order
to prevent this, please mark correct mounting
signs on those parts.
 Use a transmission jack to jack up the

transmission.
Caution:
In order to prevent transmission overturn, use

chains or belts to secure it to the jack.
Do not let the transmission hover over the

clutch, or it will destroy the clutch.
 Remove nuts securing the transmission

mounting bracket on the beam side.
 Angles of the engine and transmission

have to be adjusted so that they can be
easily disassembled.
 Use a jack or crane to jack up the engine

rear part.
Caution:
After jacked up the engine, place a wooden

block under it to protect the oil pan.
 Remove the transmission binding bolts.
 Draw the transmission assembly

backwards.
2) Clutch
 Hoist the car and support it with a suitable

and safe bench.
Caution:
Make sure no clutch fluid is left on the coating

surface, or wash it away immediately.
202
 Use a guiding centralizer to prevent the
driven plate assembly dropping freely.
 Mark the flywheel and pressure plate
flange to ensure alignment during
installation.
 Loosen fixing bolts in the pressure plate
assembly.
2. Flywheel
3. Rear oil seal
 Push in the oil seal and mount special
tools according to the left diagram to
dismantle the oil seal.
 Rear oil seal detacher: 1002430FA-9101
Note:
Take care to avoid damaging the crankshaft and oil
seal pedestal while removing the oil seal.
Assembly
3. Rear oil seal
 Mount the oil seal to the cylinder block with
Notes:
Clean the rust and chips off the press-in portion of
the oil seal.
Pay attention to the press-in direction.
1) Use two bolts to connect the adaptor of special
tools to the crankshaft rear end.
2) Install the oil seal to the periphery of the adaptor.
3) Insert the socket into the adaptor portion and
screw down it with a bolt (M12×1.75L=70) until the
adaptor tip is against the socket.
Standard value mm
12．2— 12．8
203
2. Flywheel
 Apply some oil to fixing bolts.
 By using of the torque tightening method,
screw down the flywheel bolts to the
specified torque in two steps according to
the left diagram.
25 70 120
2) Clutch
 Apply multifunctional supramoly grease to
the splines of driven plate hub.
 Mount the driven plate assembly with a
guiding centralizer.
Guiding centralizer:
1601100FA-9101

Screw down pressure plate fixing bolts in turn.
Pressure plate fixing bolt torque N·m
25
 Remove the guiding centralizer.
Note:
If a new pressure plate is installed, make sure to

remove the protection diaphragm spring cable after
tightening the pressure plate to the specified torque.
1) Transmission
⑨ Bracket
Bracket nut torque N·m
69
204
transmission.
Caution:
 Shift the transmission to high speed gear.
 Make the transmission tilt in the same
straight line with the engine.
 Rotate parking brake drum outputs to ease
the clutch spline engagement.
Clutch cover to
flywheel casing bolt torque N·m
M10：46
M12：91
 Hoist the engine and let the transmission

enter the rear transmission bracket.
Rear engine bracket nut
and bolt torque N·m
M10：40
M12：69

Front exhaust pipe bolt torque N·m
37

Exhaust brake bolt torque N·m
17

Slave cylinder bolt torque N·m
19
205
 Adjust the slave cylinder before mounting
return spring.
a) Unscrew the push rod locking nut
b) Turn the adjusting nut until it is against
the release fork.
c) Back off the adjusting nut by 1½ turns.
(The free gap of release fork is about
2mm/0.lin).
d) Screw down the locking nut.
 Push rod locking nut torque N·m
16

③ Wire connector
① Drive shaft
 Align previously made marks.
Drive shaft nut torque N·m
66
 Connect battery ground cables.
206
3.19 Crankshaft and main bearing
1. Transmission and clutch
assemblies
2. Engine assembly
gasket
4. Timing gear
5. Oil pan
6. Oil pump
7. Piston oil cooling pipe
assembly
10. Water pump assembly
11. Flywheel and flywheel baffle
12. Rear oil seal
13. Crankshaft and main bearing
Assembly sequence
disassembly.
207
Disassembly
Preparation:
 Discharge the coolant in the radiator and
engine completely.
and safe bench.
Setting mark 1) Transmission
① Transmission
 Mark the parking brake drum and flange
yoke beforehand.
 Remove the flange yoke drive shaft.
 Bind the removed drive shaft to the frame

 Detach the connecting hood.
 Remove connecting bolts.
 Dismantle anchorage clips and withdraw
bracket cables.
③ Wire connector
Shift cable Anchorage clips  Detach wire connectors of the vehicle
Gear pin speed sensor, neutral switch and back-up
light switch.
 Remove the shift and select cables on
transmission side.
Select cable
Gear pin
208
Elastic hose
 Remove the clutch hose clips and clip
bracket (only for vehicles with right
steering wheel).
 Disassemble the slave cylinder assembly

with Elastic hoses, and bind it to the frame

Notes:
Sometimes the exhaust pipe bracket, gear
control bracket and anchorage clips are in the
wrong mounting positions or directions. In order
to prevent this, please mark correct mounting
signs on those parts.
transmission.
Caution:
209
Do not let the transmission hover over the
clutch, or it will destroy the clutch.
 Remove nuts securing the transmission
mounting bracket on the beam side.
 Angles of the engine and transmission
have to be adjusted so that they can be
easily disassembled.
 Use a jack or crane to jack up the engine
rear part.
Caution:
After jacked up the engine, place a wooden
block under it to protect the oil pan.
 Remove the transmission binding bolts.
 Draw the transmission assembly
backwards.
2) Clutch
and safe bench.
Caution:
Make sure no clutch fluid is left on the coating
surface, or wash it away immediately.
 Use a guiding centralizer to prevent the
driven plate assembly dropping freely.
 Mark the flywheel and pressure plate

flange to ensure alignment during
installation.
 Loosen fixing bolts in the pressure plate
assembly.
2. Engine assembly
 Remove the upper and lower hoses of the
radiator.
 Remove storage tank hose.
 Remove the shock-absorbing rubber on
both sides.
 Remove radiator support.
2) Air intake duct
210
3) Heater hose
 Unscrew the locking nut(s) at the bracket
and remove throttle wire(s) from the
injection pump control lever.
5) Glow plug wire
6) Fuel hose
 Remove fuel inlet hose and return hose.
 Unscrew idler locking nut(s)
 Loosen the adjusting nut(s) and remove
the drive belt.
 Remove the magnet clutch wire connector.

 Remove fixing bolt(s) of the air
conditioning compressor and bind the
compressor to the frame temporarily with
wires.
9) Power steering pump and bracket

assemblies (power steering type)
Bracket  Unscrew idler locking nut(s)
 Loosen the adjusting nut(s) and remove
Locking nut
the drive belt.
 Remove pipe bracket fixing bolt(s) and
anchorage clip (s).
Anchorage
clip  Remove power steering pump fixing bolt(s)
Anchorage and bind the pump to the frame
clip temporarily with wires.
211
 Remove exhaust pipe fixing bolt(s) of the
exhaust manifolds.
 Remove exhaust pipe support bolt(s).
 Remove front exhaust pipe fixing nut(s).
11) Support rubber

① If mounted on the right side
 Remove the two fixing nuts on beam side.
② If mounted on the left side
 Remove the two fixing nuts on beam side.
12) Engine assembly

 Slowly hoist the engine by a crane.
 Lift the engine with its front part higher
than rear part.
While taking out the engine assembly be
careful to avoid breaking any oil pipe, brake
pipe, etc.

 Unscrew high pressure oil pipe anchorage
clip(s).
 Remove taper nut(s) on the injection pump
side.
 Remove taper nut(s) on the fuel injector
side and high pressure oil pipe.
212
2) Oil return hose
 Remove oil return hose(s) of the injection
pump.
3) Crankcase vent hose(s)
 Dismantle crankcase vent hose(s) from the
air-intake duct.
4) Glow plug wire

5) Oil scale guide
 Remove oil scale guide out of the cylinder
head.
6) Oil cooler tube D

 Remove pipe bracket fixing bolt(s) on the
rear side of cylinder head.
 Remove cooler tube from the cylinder
head.
7 Bypass hose
 Remove crankcase vent hose and cylinder
head cover bolt(s).
213
9) Rocker shaft
 Loosen rocker shaft support bolt(s) bit by
bit according to the sequence shown in the
diagram.
Note:
Disobedience will bring unfavorable influence
to the rocker shaft.
10) Push rod
 Loosen cylinder head bolt(s) bit by bit
according to the sequence shown in the
diagram.
Note:
Disobedience will bring unfavorable influence
to the cylinder head lower surface.
12 Cylinder head gasket
 Remove cylinder head gasket and anchor
pin.
4. Timing gear
 Unfasten tight nut(s), and dismount the fan
assembly and fan pulley.
3) Acoustic hood
 Remove oil seal from the timing gear
chamber cover.
6) Oil pipe
7) Idler gear
 Measure camshaft and crankshaft timing
gear clearances before disassembling the
idler gear.
 Measure axial clearance for idler gear
before disassembling the idler gear.
Note:
Refer to the following items while measuring
gear clearance and axial clearance.
214
Timing gear clearance measurement
1) Install a dial gauge onto the timing gear to
be tested.
Fix the gear to be tested and the gear
connected to it.
2) Swing the gear to be tested left and right.
Read out the dial gauge readings.
If the measured value exceed prescribed limit,
the timing gear has to be replaced.
Timing gear clearance mm
Standard value Limit
0.10— — 0.17 0.30
Axial clearance measurement of idler gear ”A”

Measure the clearance between idler gear A
and thrust ring with a clearance gauge and
determine the idler gear axial clearance.
If the measured value exceeds prescribed limit,
the thrust ring has to be replaced.
Idler gear axial clearance mm
0.07 0.2
9) Idler gear
10) Injection pump
 Remove six injection pump bracket bolts①
from the timing gear chamber.
 Remove rear bracket bolt② from the
injection pump bracket③.
 Remove rear bracket bolt④ and bracket⑤
from the cylinder block.
 Drag both the injection pump and injection
pump timing gear out towards the engine
backside.
Note:
Cover the hole in injection pump delivery valve
body with a cover or equivalents to prevent
foreign bodies falling into the valve.
215
① Measure the camshaft axial clearance with
a dial gauge.
Measure the clearance before disassemble the
camshaft gear.
If the camshaft axial clearance exceeds
prescribed limit, the thrust washer has to be
replaced.
Camshaft axial clearance mm
0.050— — 0.114 0.2
② Remove camshaft timing gear bolt(s) from

the camshaft.
Note:
Protect the camshaft against rotating.
③ Pull out camshaft timing gear② with a
universal puller①.
Universal puller: 1007011FA-9101
④ Remove the thrust washer③.
12) Crankshaft gear

 Detach crankshaft gear② with crankshaft
gear detacher①.
Crankshaft timing gear detacher:
1007011FA-9101
5. Oil pan
 Remove the stiffener plate from both sides
of the oil pan.
 Remove the oil pan from the cylinder
block.
216
6. Oil pump
 Remove the oil pump from the cylinder
block.
7. Piston cooling oil pipe (4DA1-1) / hexagonal

head plug (4DA1)
 Remove the oil cooling pipe from the
cylinder block.

 If it is intended to reassemble the lower
bearing of connecting rod, please attach a
label to each bearing, then mark the
cylinder disassembling sequence and its
installation position.
 Scrape carbon deposits on upper cylinder

wall with a scraper before disassembling
the piston and connecting rod.
Move the piston to cylinder head, push
upwards connecting rod underpart with a
hammer handle or equivalents, and then take
out the piston and connecting rod.
 If it is intended to reassemble the upper

bearing of connecting rod, please attach a
label to each bearing, then mark the
cylinder disassembling sequence and its
installation position.
217
11. Flywheel and flywheel baffle
 Install flywheel stopper.
 Loosen flywheel fixing bolt(s) and remove
the flywheel.
 Disassemble the flywheel baffle from
cylinder block.
12. Rear oil seal
 Push in the oil seal and mount special
tools according to the left diagram to
dismantle the oil seal.
Rear oil seal detacher: 1002430FA-9101
Note:
While disassembling, take care to avoid
damage the flywheel baffle and crankshaft
sealing surface.
1) Remove main bearing cap and thrust
plate.
2) Disassemble the crankshaft carefully.
3) Disassemble the upper crankshaft bearing.
Assembly
 The upper crankshaft bearing has an oil
hole and oil groove while the lower
bearing doesn’ t.
 Apply fresh oil to the upper and lower main
bearings.
 Make sure the main bearings are in the
correct positions.
 Wipe off foreign bodies on the bearings.
 Mount crankshaft main bearings to the
cylinder block and main bearing cap.
Note:
Do not apply oil to bearing backside and
cylinder bearing mating surface.
 Bearings should be installed in correct
positions.
 Apply fresh oil to the upper and lower main
bearings.
218
 Install the crankshaft carefully.
 Apply oil to the thrust plate.
 Mount the thrust plate to the third main
journal.
The oil groove on thrust plate must be facing
the crankshaft.

equivalents to the fifth crankshaft bearing
cap as shown in the drawing.

equivalents to the fifth crankshaft bearing
cap surface mating with cylinder block as
shown in the drawing.
Notes:
Before applying liquid sealant, make sure there
is no oil on the main bearing cap mating
surface.
Make sure the liquid sealant will not block
cylinder thread hole and bearings.
 While mounting bearing caps, arrow signs
on each bearing cap must point to the
engine forepart.
 Apply oil to crankshaft bearing cap bolts.
 Tighten the crankshaft bearing cap bolts to
the specified torque bit by bit as shown in
the drawing.
N·m
170
Note:
219
12. Crankshaft rear oil seal
Mount the oil seal to the cylinder block with an
oil seal erector.
Notes:
Clean the rust and chips off the press-in portion
of the oil seal.
Pay attention to the press-in direction.
1) Use two bolts to connect the adaptor of
special tools to the crankshaft rear end.
adaptor.
3) Insert the socket into the adaptor portion
and screw down it with a bolt
(M12×1.75L-70) until the adaptor tip is
against the socket.
Standard value mm
12.2— — 12.8
11．Flywheel and cylinder block flywheel baffle

 Align the flywheel baffle with cylinder block
anchor pin(s).
 Tighten the flywheel baffle to the specified
torque.
Flywheel baffle bolt torque N·m
85
 Lock the crankshaft with hardwood so as

to prevent the flywheel rotating.
 Apply oil to flywheel bolt thread.
 Align the flywheel with crankshaft anchor
pin(s).
 By using of the torque tightening method,
screw down the flywheel bolts to the
specified torque in two steps according to
the diagram.
25 70 120
220
10. Water pump
 Install a O-ring to water pump body.
 Install water pump and tighten the bolt(s)
Water pump bolt torque N·m
25
 Eliminate the gasket burrs.

9. Timing gear chamber
 Install the timing gear chamber to the
cylinder block. Exercise care to avoid
bending front oil seal.
 Tighten the timing gear chamber and its
gasket to the specified torque.
Timing gear chamber
Bolt torque N·m
25

1) Try to manually push the piston pin into
piston pin hole.
assembly.
Select the piston and connecting rod set in a
way that different assembly weight differences
are in the specified limits.
Weight differences
while assembled
4DA1 10
4DA1-1 8
2) Clamp the connecting rod by a vice

Take care not to damage the connecting
rod.
3) Mount piston pin retainer to the piston with
pliers.
Note:
When replacing the piston / connecting rod
assembly, do not change the piston / piston pin
assembly.
221
4) Install the piston onto the connecting rod.
Mark ① on the piston head and connecting rod
“F908”casting symbol ② should point to the
same direction.
5) Add oil to the piston pin and piston pin

hole.
Manually push piston pin into the piston until it
is against the piston pin retainer.
6) Manually mount the piston pin retainer into

piston retainer groove.
Check whether the connecting rod can freely
swing on the piston pin.
7) Install piston ring and piston packing ring.

The gas ring mark JAC should face upwards.
Identification sign is shown in the drawing.
JAC mark (first ring)

(Second ring)
8) Mount three piston rings with a piston ring
erector.
The piston ring mounting sequence is shown in
the drawing.
① Oil ring
② Second gas ring
③ First gas ring
Note: When mounting gas rings the chamfer is
facing upwards.
Install the helical piston packing ring into oil ring
groove and make sure that the packing ring
and the oil ring are closely meshed.
222
First gas ring Coil-spring-loaded
opening
10) Check whether the piston ring can turn
freely in piston ring groove.
11) The cutout position for placing piston ring
is shown in the drawing.
Oil ring Second gas ring
12) Carefully wipe off the foreign bodies on

connecting rod bearing backside and
bearing seat joint faces.
13) Apply some oil to the upper bearing
surface.
14) While installing, the piston head mark must

be towards the engine forepart.
Compress the piston ring with a piston ring
compressor.
Piston ring compressor: 1004022FA-9101
15) Push in the piston with a hammer handle
until the connecting rod touches the
crankpin. In the meanwhile rotate the
crankshaft until the crankpin reaches its
bottom dead center.
16) While installing, the bearing cap upper

front mark must be towards the engine
forepart.
Align the cylinder sequence mark on
connecting rod bearing cap with the one on
connecting rod.
Front mark
223
18) Apply oil to each connecting rod bearing
cap bolt thread and bearing seat joint
faces.
19) Screw down connecting rod bearing cap
bolt to the specified torque in two steps by
utilizing the torque tightening method.
Connecting rod bearing cap bolt torque N·m
First step (sealing Second step (final
torque) torque)
20 85
Note:
7. Piston cooling oil pipe (4DA1-1) / hexagonal
head plug (4DA1)
 Mount the piston cooling oil pipe to the
cylinder block.
Screw down oil pipe bolt and check valve to the
specified torque.
4AD1-1 oil pipe bolt torque N·m
①M8X1．25 20
N·m
②M6X1．00 7.5
Oil pressure regulating valve torque
③M16X1．5 30
4DA1 hexagonal head plug moment
45
Note:
Turn the crankshaft slowly; make sure the piston
and the oil injection pipe don’ t interfere with each
other.
 Prepare some solution containing 80％ oil
and 20％ supramoly.
 Apply enough solution to the oil pump
pinion teeth.
 Apply some oil to oil pipe O-ring and put it
into the cylinder block O-ring groove.
 Install the oil pump assembly with oil pipe
to the cylinder block, and tighten fixing
224
25
 Tighten sleeve nut(s) to the specified torque.
30
Note:
Be careful not to destroy the O-ring when tightening
the oil pipe bolt(s).
5. Oil pan assembly

section, groove and timing gear chamber
arch section.
 Install back lip portion of the gasket into

the fifth groove.
 Make sure the lip portion is compact with
the groove.
torque.
23.5
225
4. Timing gear
12) Crankshaft gear
 Install crankshaft gear
 Install crankshaft gear② with crankshaft
gear erector①.
 Crankshaft timing gear mark (“X-X”)
should face outwards.
Crankshaft gear erector: 1007011FA-9102

 Install the thrust washer onto the cylinder
block.
 Tighten thrust washer bolt(s) to the
specified torque.
N·m
25
 Install camshaft timing gear to the

camshaft.
The timing gear mark (“Y— Y”) has to face
outwards.
 Tighten the timing gear to the specified
torque.
Timing gear bolt torque N·m
110
10) Injection pump

① Install O-ring ① to the injection pump
flange ②.
② Install the injection pump to the timing gear
chamber.
Align the mark “V-V”of idler gear “B”③ with the
mark “V”of injection pump timing gear ④.
③ Temporarily tighten Six injection pump nuts

⑤.
The final screwing down of injection pump nuts
is conducted after tightening the injection pump
rear bracket bolt(s).
226
④ Install injection pump rear bracket⑥ and
rear bracket bolt⑦ to the cylinder block.
⑤ Mount rear bracket bolt⑧ to the injection
pump bracket⑨.
Do not screw down those bolts.
Rear bracket bolt⑦ and ⑧ will be tightened to
the specified torque after tightening the
injection pump nuts.
⑥ Tighten the injection pump nuts to the
specified torque.
Injection pump nut torque N·m
30
⑦ Screw down injection pump bracket bolts

Pump bracket bolt torque N·m
25
9) Idler gear “B”and its shaft
shaft.
② Align mark “Z” of gear “B” ③with mark
“Z— Z”of idler gear “A”④.
 Tighten idler gear bolt(s) to the specified
torque.
Idler gear bolt torque N·m
110
8) Idler gear
shaft.
The oil hole in idler gear shaft must be facing
upwards.
② Arrange idler gear marks “X”and “Y”so
that they both face the engine forepart.
③ Align idler gear mark “X” with the mark
“X— X”of crankshaft timing gear①.
③ Align idler gear mark “Y” with the mark
“Y— Y”of crankshaft timing gear②.
⑤ Install the thrust ring and bolt to the
cylinder body passing through the idler
gear.
Thrust ring oil hole must be facing upwards
while its chamfer facing outwards.
227
⑥ Tighten idler gear bolt to the specified
torque.
Idler gear bolt torque N·m
25
7) Timing gear oil pipe
Install the oil pipe to timing gear chamber and
idler gear “A”.
Tighten oil pipe eyebolt① and bolt② to the
specified torque.
Oil pipe punching bolt torque N·m
20
Align timing gear chamber anchor pin with the
timing gear chamber, then install timing gear
chamber cover.
Tighten gear chamber cover bolt to the
specified torque.
4) Acoustic hood
3) Upper acoustic hood
Screw down the crankshaft damper pulley
bolt(s) to the specified torque.
Note:
While screwing down the damper pulley, hold
the flywheel ring gear to prevent crankshaft
rotating.
210
 Install the fan pulley, spacer block and
cooling fan assembly (in this installing
order) to a water pump, and tighten those
parts to the specified Tightening torque.
N·m
12.5

2. Engine assembly
“3-1”is referred to the “3.16 shaft and tappet”
section.
228
4 Engine cooling system
4.1 General
The engine cooling system is a pressure type

coolant forced circulation version.It has a
radiator cover and its differential pressure and
boiling point are 98 ～ 196kpa and 120℃
respectively.The system consists of a water
pump, thermostat, fan, radiator and other
components.Circulating coolant is used to cool
down the oil in oil filter and turbocharger.
Oscillating valve
Water pump
It is a vane centrifugal pump driven by V drive
belt.
Thermostat
The thermostat belongs to wax type with an
oscillating valve installed on the original valve. It
is installed on the thermostat body.
Radiator
It is a tube type radiator with corrugated fins. In
order to increase the boiling point, a cap with a
valve is installed on the cylinder head thermostat
body. This valve opens at the pressure
0.90— 1.20kg/cm2.
229
Mixing ratio (%)
Anti-freezer
 The relationship between mixing ratio
Freezing point (℃)
and freezing point

The freezing point temperature of engine
coolant changes with the ratio of anti-freezer
in water.
Correct mixing ratio can be determined
according to the graph. Do not add the
attached anti-rust agent or additive with
enhancing cooling ability to the cooling
system without approval of JAC Automotive
Co., Ltd.
 Mixing ratio calculation
Anti-freezer（L/qt）
Maxing ratio =
Anti-freezer（L/qt）+ water（L/qt）
Note: Anti-freezer + water = 10L

Total volume of the cooling system
E.g., total volume of the cooling system is
10L
Mixing Anti-freezer Water

ratio％
L(qt (En)／qt L(qt (En)／
(Ame)) qt(Ame))
0 0 (0) 10(8.80／10.57)
5 0.5(0.44／0.53) 9.5(8.36／10.04)
10 1.0(0.88／1.06) 9.0(7.92／9.51)
15 1.5(1.32／1.59) 8.5(7.48／8.98)
20 2.0(1.76／2.11) 8.0(7.04／8.45)
25 2.5(2.20／2.64) 7.5(6.60／7.93)
30 3.0(2.64／3.17) 7.0(6.16／7.40)
35 3.5(3.08／3.70) 6.5(5.72／6.87)
40 4.0(3.52／4.23) 6.0(5.28／6.34)
45 4.5(3.96／4.76) 5.5(4.84／5.81)
50 5.0(4.40／5.28) 5.0(4.40／5.28)
230
 Mixing ratio
Mixing ratio
Measure the specific gravity of engine cooling
system coolant in 0℃ to 50℃ temperatures with
a draft hydrometer, and then determine the
coolant mixing ration according to the graph.
Specific gravity
Coolant temperature (℃)
231
4.2 Water pump
1. Fan cowl
2. Fan assembly
4. Air conditioning compressor
drive belt
Assembly sequence
disassembly.
4.2.1 On-vehicle repair
Disassembly
Preparation:
 Discharge the coolant.
1. Fan cowl
 Remove storage tank hose and fan
cowl.
2. Fan assembly
 Unscrew the locking nut(s) and take out
the fan assembly.
 Loosen idler locking nut(s) and
adjusting bolt(s), and then remove the
drive belt.
232
 Loosen ac compressor idler locking
nut(s) and adjusting bolt(s).
Dismount the drive belt.
Locking bolt
 Unscrew alternator fixing bolt(s) and
adjusting plate locking bolt(s), then
remove the drive belt.
Assembly
6．Water pump assembly

 Detach the O-ring.
 Put the O-ring into the water pump
groove.
 Install water pump assembly and
tighten the bolt(s) to the specified
torque.
Water pump fixing bolt torque N·m
25
233
Air conditioning idler Inspection
compressor
Adjusting If during inspection it is found that the water
Adjusting bolt
plate pump is severely worn or damaged, repair the
Power steering pump
pulley water pump and replace the worn-out parts. The
whole water pump assembly has to be replaced
Fan pulley
in case of one of the following problems.
Alternator
 There is a crack on the water pump
Alternator bolt idler body.
 The coolant leaks from the water seal.
Crankshaft pulley
adjusting idler  The ball bearing is loose or produces
unusual noise.
 Water pump impeller cracked or
experienced corrosion.

 Install and adjust those drive belts.
Inspect whether the drive belts are
intact. Replace them if necessary.
Check the belt tension, if necessary
adjust the tension.
 Apply a force of 100N to those belts
and check the deflection of each belt.
Ac conditioning compressor and  Standard deflection

power steering pump drive belts
mm
Initial tension
Alternator drive belt 8— — 10
Air conditioning compressor
drive belt
Alternator and fan Power steering pump drive
drive belts
belt
234
Generator fixing bolt torque N·m
40
Adjusting plate fixing bolt torque N·m
25
Ac compressor idler locking nut torque N·m
27
Power steering pump idler
locking nut torque N·m
27
2． Fan assembly
 Fix the fan pulley and fan assembly
onto the water pump, and tighten them
Fan pulley nut torque N·m
12.5
1． Fan cowl
 Install the fan cowl and storage tank
hose.
 Start the engine and check whether
there is any leakage of the coolant.
235
4.2.2 Single-piece repair
1. Set screw
2. Fan center flange
3. Water pump impeller
4. Water seal assembly
5. Oil striker
6. Bearing assembly
7. Water pump body
Reassembly sequence
As reassembling, go on
Disassembly
1. Set screw
 Push down the fan center flange with a
bench press and compression bar.

4. Water seal assembly
5. Oil striker
6. Bearing assembly
1) Heat up water pump body in hot water
(80-90℃／176-194℉).
236
2) Push down the water pump impeller,
water seal assembly and bearing
assembly with a bench press and
compression bar.
Note:
Do not attempt to disassemble the water
pump impeller with a hammer, or it will
destroy the impeller.
7. Water pump body

 If during inspection it is found that the
water pump is severely worn or
damaged, adjust and repair it and
replace the worn-out parts.
Bearing assembly
 Check if there is any noise, stuck and
other unusual phenomena in the
bearing assembly.
Reassembly
7. Water pump body
6. Bearing assembly
1. Set screw
1) Align bearing set screw(s) with water
pump body set screw(s).
Set screw
2) Press the bearing assembly into the
water pump body.
3) Fix the bearing with set screw(s).
5. Oil striker
4 Water seal assembly

1) Coating a thin layer of liquid sealant on
the water seal assembly outer edge.
2) Install the water seal assembly.
237
1) Install the water pump impeller with a
bench press.
2) Measure the distance between water
pump impeller protrusion and water
pump body end face. The water pump
impeller protrusion size has to be
ensured.
Impeller protrusion size (L) mm
24.6

Measure the distance between fan fitting surface
and rear fan cover.
Fan center distance mm
Standard value
79．2— — 79.8
Notes:
1. Never disassemble and install the fan center
flange and water pump impeller for the
second time while mounting those units onto
the water pump shaft with a bench press.
Otherwise replace the whole water pump
assembly. Disassembling and installing
those units for the second time will lead to
the water pump broken during engine
operation with serious overheating.
2. If the force applied to fan center flange and
water pump impeller is less than 1960N
(200kg ／ 44lb), replace the water pump
assembly.
3. Do not use hammers or similar tools to
knock the bearing into water pump body, or
it will destroy the bearing.
238
4.3 Thermostat
1．Switch wire bundle
2．Water outlet pipe
3．Gasket
4．Thermostat
Assembly sequence
Disassembly
Preparation:
 Drain off the coolant in the radiator and
generator .
1． Switch wire bundle
2． Water outlet pipe
Unscrew the fixing bolt(s). Remove both the
water outlet pipe and radiator hose.
3． Gasket
4． Thermostat
Inspection
Put the thermostat assembly into water.
Place a wooden block under the water container.
Do not heat up the thermostat directly.
Increase water temperature gradually with
continuous stirring so as to keep the water
temperature in the container be equalized.
Confirm the main valve opens at the specified
temperature.
239
Valve opening temperature ℃
82
Confirm the secondary valve fully opens at the
specified temperature.
Valve fully opening temperature ℃
95
If during inspection it is found that the thermostat
is severely worn or damaged, repair it and
replace the worn parts.
Assembly
4． Thermostat
3． Gasket
2． Water outlet pipe
 Connect water outlet pipe and tighten
the bolt(s) to the specified torque.
N·m
19
1． Switch wire bundle

 Install the switch wire bundle.
 Start the engine and check whether
there is any leakage of the coolant.
240
4.4. Radiator
1．Storage tank hose
2．Radiator hose
3．Air-intake duct
4．Radiator support
5．Condenser
6．Rubber cushion
7．Radiator assembly
Assembly sequence
disassembly.
Disassembly
Preparation:
 Loosen drain plug and discharge the
coolant.
1． Storage tank hose
 Remove the lower hose from the
radiator.
2． Radiator hose
 Remove the upper and lower hoses
from the engine.
3． Air-intake duct
4． Radiator support
241
5． Condenser
 Remove the condenser from the
radiator and bind it to the vehicle front
with wires temporarily.
6． Rubber cushion
 Remove the rubber cushions on both
bottom sides.
7． Radiator assembly
 Remove upwards the radiator assembly
with hose(s). Notes
Take care to avoid the fan blades
scratching the radiator core.
Inspection
Radiator cap
 Measure the pressure valve opening
pressure with a radiator cap tester.
If the opening pressure exceeds standard
values, replace the radiator cap.
Check opening pressure of the vacuum
valve installed in the radiator cap valve seat
center.
Valve opening pressure N·m
88．2— 117．6
If the vacuum valve can’ t move smoothly due to
rust or dust, clean or replace the radiator cap.
Radiator core
 Fin distortion will deteriorate the thermolysis
effect and cause the cooling system to be
overheated. Flatten the fin and take care to
avoid damaging the fin bottom part.
 Clean off the dust and other foreign bodies.
Wash the radiator
 Wash radiator inside and coolant passage
with water and neutral detergent. Clean the
scale and incrustant completely.
242
Check whether there is any coolant leakage.
 Feed the compressed air with pressure
of 196．9kPa (28．4psi) through the filler
neck into the radiator by a radiator cap
tester, then check if there is any
leakage in the cooling system.
Assembly
7． Radiator assembly
 Install the radiator.
6． Rubber cushion
 Mount the rubber cushions to the both
bottom sides of the radiator.
 Install the radiator assembly with
hose(s).Take care to avoid the fan
blades scratching the radiator core.
5． Condenser
4． Radiator support
3． Air-intake duct
 Connect the air-intake duct and fix the
clip(s).
2． Radiator hose
 Connect the inlet hose and outlet hose
to the engine.
 Fill in coolant until it goes up to the
radiator filler neck and MAX mark of the
storage tank.
1． Storage tank hose
 Start the engine and warm it up. Inspect
the coolant level.
Storage tank
243
4.5 Drive belt adjustment
Idler
Ac compressor Adjusting locking nut
Adjusting plate Adjusting bolt
Power steering pump
Fan pulley
Alternator
Alternator fixing bolt
Idler
Crankshaft pulley
Locking nut
Belt position Adjusting bolt
Crankshaft; alternator; fan

Crankshaft; ac compressor; power steering pump
Crankshaft; ac compressor; power steering pump
Crankshaft pulley
Inspection
Inspect whether the drive belts are intact.
Replace them if necessary. Check the belt
tension, if necessary adjust the tension.
 Check belt tension.
 Apply a force of 100N to those drive
belts and check the deflection of each
belt.
 Standard deflection
244
mm
Belt tension while
adjusting
Alternator and fan pulley
drive belts
Air conditioning
8— 10
compressor drive belt
Power steering pump drive
belt
ension adjustment
1． Fan pulley drive belt
 Loosen generator bracket locking bolt.
Adjust belt tension with adjusting bolts
on the adjusting plate. Tighten the bolt
37.5
25
2． Power steering pump and ac compressor

pulley belts
 Loosen power steering pump locking
nut and adjust belt tension with the
adjusting bolt.
Tighten locking nut to the specified torque.
Locking nut torque N·m
27
245
5 Fuel system
5.1 General
Remember the following points while working on Clean and inspect the O-ring. Replace them if
fuel supply system: necessary.
 While the fuel supply system is working Before repairing any part of the fuel supply
you should cut off battery ground system, relieve the pressure in pipes.
cables anytime except when carrying Before repairing the fuel supply system, please
out tests that need batteries. read the product manual and consult to repairing
 Always prepare dry chemical fire drawings.
extinguishers (class B) near the work A certain amount of fuel in the fuel tank flows
place. through water separator and fuel filter –filters off
 Replace all removed oil pipes and parts moistures and other foreign bodies in the fuel,
with same ones. and then goes through the injection pump
The fuel supply system consists of a fuel tank, plunger to the fuel injector in the best time, so the
water separator, fuel filter, injection pump and engine can work effectively.
fuel injector.
Fuel flowing schematic diagram
Solenoid valve of
cold-start unit
Fuel injector
Fuel cut-off
solenoid valve
Distributor type injection pump
Fuel filter Water separator
Fuel tank
246
Injection pump
Governor spring
Aneroid barometric compensator
Control lever
Control shaft lever Floating lever
Pull lever
From the oil filter
Fuel cut-off solenoid valve
Drive shaft
Plunger
Fuel feed pump
Gear flows to the fuel injector
Delivery valve
Driven plate Control sleeve
Automatically advanced supply injector Plunger spring
From the oil filter
Flows to the fuel injector
A distributor type injection pump is used.A This injection pump features a compact and
Reciprocating / Rotating plunger will deliver lighter structure, which works efficiently.
equal fuel to each fuel injector and this has no Aneroid barometric compensator can be used in
relationship with the cylinder number. vehicles operating in plateau areas and it can
The governor, automatically advanced supply regulate the mixing ratio of fuel air.
injector and fuel feed pump are all installed in the
injection pump case.
247
Fuel filter and water separator
Priming pump
Filter body assembly
Filter body
assembly
Housing
Water
Filter element discharging
level
Double filters Float
Lever
sensing unit
Water
drain plug
Besides the distributor type injection pump, a There is a float in the water separator.When the
filter and water separator is also used. float rises up to the specified level, a warning
The injection pump inside is lubricated with the light reminds the workers to discharge water in
flowing fuel.The fuel must be clean. Before the the water separator.
fuel flows into the injection pump, the fuel filter There is a membrane priming pump installed on
and water separator will filter off moistures and the top of the water separator.Use this pump
other foreign bodies in the fuel. when discharging water and air.
248
Fuel injector
Fuel injector body
Pressure adjusting shim
Injector pressure-adjusting spring

Pressure-adjusting spring seat
Fuel injector Gland nut
The fuel injector injects high-pressure fuel from The high-pressure fuel coming from the injection
the injection pump via an injector nozzle into the pump injects via into the combustion chamber
combustion chamber. the injector and injector nozzle.
4DA1 Series generators use hole-type fuel
injector.It has five nozzles.The fuel injector
consists of injector body and fuel injection nozzle
pairs assembly.
249
5.2 Fuel filter assembly
1. Fuel filter cap
2. Fuel hose
3. Fuel filter assembly
Assembly sequence
Disassembly
Preparation:
1. Fuel filter cap
2. Fuel hose
 Remove the fuel hose connected to the
fuel filter body.
 Plug hose ends to pervert fuel
overflowing.
 Loosen the fixing bolt(s) on the fuel filter
bracket.
ASSEMBLY
 Assemble the fuel filter bracket and
screw down the fixing bolt(s).
2. Fuel hose
 Connect the fuel hose to the filter body.
250
1. Fuel filter cap
 Deliver fuel to the injection pump with a
priming pump, and then discharge the
air in the fuel supply system.
Fuel filter element
Disassembly
 Remove the filter element with a filter
wrench.
 Filter wrench: 1010300FA-9101
Assembly
 Clean the filter element installing
surface so that the element can be
installed securely.
 Coating a thin layer of fresh engine oil
on the new element O-ring.
 For discharging air, fill some fuel into
the new element.
 Screw on the new element until the filter
O-ring sticks to the seal surface
seamlessly. Exercise care to avoid fuel
flowing out.
 Further screw on the element by ⅓ - ⅔
turn with a filter wrench.
 Filter wrench: 1010300FA-9101
Air bleed
 Squeeze up the air inside fuel supply
system to the injection pump by starting
the priming pump.
 Loosen injection pump bleeder plug
and start the priming pump until the air
bleeds totally.
251
 Tighten the bleeder plug.
 Start the engine. If the engine can’
t start
within 10 seconds, repeat the above air
bleed operation.
 Make sure there is no fuel leakage and
tighten the priming pump cover.
Water drain
 When the water in oil-water separator
reaches the specified amount, the
warning light will give a signal. Here
drain water in the following steps.
 Connect a vinyl hose to the water drain
plug.
 Loosen the water drain plug.
 Start the priming pump for several times
to drain the water.
 Tighten the plug after draining the
water.
 Start the priming pump for several times
to check whether there is any fuel
leakage.
 Check whether the warning light has
gone out.
252
5.3 Fuel injector
2. Return pipe
3. Fuel injector
Assembly sequence
Disassembly
Preparation:
 Loosen high pressure oil pipe clamp.
 Loosen the taper nut(s) on the injection
pump side.
 Loosen the taper nut(s) on the fuel
injector side and put aside the high
pressure oil pipe after disconnecting it.
2. Return pipe
3. Fuel injector
Inspection
 Install the fuel injector on the injector
tester.
When the oil pressure is 185kg ／ cm2,
check if there is any oil leakage from the
head portion of the injector.
Replace them if there is any leakage.
253
Disassembly
1. Gland nut
2. Fuel injection nozzle pairs
1) Remove injector parts from the injector
body.
Attach a label to each injector part and the
injector body to ensure that they are
reassembled to the original positions.
Do not change the assembly of injector parts
and the injector body.
2) In order to prevent dust entering the
injector, put it in a tool pan full of clean
diesel oil.
3. Spacer
4. Pressure-adjusting spring seat
5. Pressure-adjusting spring
6. Pressure-adjusting shim
7. Injector body
254
If during inspection it is found that the injector is
severely worn or damaged, you have to adjust
and repair the injector and replace the worn-out
parts.
Inspection on fuel injection nozzle pairs
1. Remove the needle valve from the
needle valve body of oil nozzle.
2. Carefully wash the needle valve of oil
nozzle and the valve body in clean oil.
3. Check if the needle valve moves
smoothly in the needle valve body. If
this is not the case, repair the needle
valve and needle valve body.
Grinding procedure of fuel injection nozzle pairs
1. Grind the needle valve of oil nozzle ①
and needle valve body ② with chrome and
animal oil grinding paste.
Notes:
Do not apply excessive chrome and animal
oil grinding paste to the needle valve seat
joint faces. Too much paste will lead to the
severe abrasion of the needle valve and
valve cone.
2. Carefully wash the needle valve and the
valve body in clean oil after grinding.
Inspection on the needle valve body of oil nozzle
and the needle valve
Check if the needle valve body of oil nozzle and
needle valve are damaged and distorted.
If during inspection it is found that the needle
valve and valve body are damaged or distorted,
replace them.
Reassembly
7. Injector body
6. Pressure-adjusting shim
5. Pressure-adjusting spring
4. High pressure spring seat
3. Spacer
255
2. Fuel injection nozzle pairs
1. Gland nut
Tighten gland nut to the specified torque.
N·m
69
Injector adjustment
1) Install the fuel injector on the injector
tester.
2) Pressurize the injector tester to check if
the injector opens at the specified
pressure.
MPa
4DA1 19 — 20
4DA1-1 18.6 — 19.6
If the injector doesn’ t inject oil under the

specified pressure, adjust it with suitable
adjusting shim according to different pressure
classes.
Adjusting shim available mm
Thickness range 0.50— — 1.50
Grading thickness 0.025
Total no. of adjusting shims 40
Decrease or increase the thickness of adjusting

shims by one grade will increase or reduce the
injector opening pressure by 369.46kPa.
Warning:
The testing liquid in the injector is injected
under high pressure, so it may burn your
skin easily. During testing, your hands
should keep away from the injector tester.
256
Assembly
3. Fuel injector
1) Install the injector gasket ① and O-ring
② onto the injector body ③.
The O-ring should be placed in the injector
groove.
2) Fill engine oil into the injector body
nozzle on the cylinder head.
3) Install both the injector body and
injector pressure plate onto the cylinder
head and tighten to the specified
torque.
N·m
37
4) Tighten the injector body nut and shim

⑤ to the specified torque.
N·m
35
2. Return pipe
257
5.4 Injection pump assembly
1. Fan assembly
2. Fan cowl
3. Power steering pump drive
belt
drive belt
6. Soundproof cover
7. Soundproof cover gasket
8. Air-intake duct
9. Injection pump control wire
10. Fuel hose
11. Water hose of cold start
device
12. Oil pump wire harness
Assembly sequence
disassembly.
Disassembly
Preparation:
 Discharge the coolant.
1． Fan assembly
 Remove the gland nut(s), fan assembly,
collar and fan pulley.
2． Fan cowl
3． Power steering pump drive belt
 Unscrew power steering pump fixing
bolt(s) and adjusting bolt(s), then
remove the drive belt.
258
 Loosen idler locking nut(s) and
adjusting bolt(s) of the air conditioning
compressor and then remove the drive belt.
 Unscrew alternator fixing bolt(s)
(lower side) and adjusting plate locking
bolt(s), then remove the drive belt.
6. Soundproof cover
8. Air-intake duct
 Remove the control wire bracket bolt(s)
and control wire.
10. Fuel hose
 Disconnect fuel inlet hose and return
hose.
11. Water hose of cold start device (CSD)
 Disconnect the water hose from the
injection pump side.
12. Injection pump wire harness
 Dismount the speed sensor (with a
tachometer), solenoid valve of the cold start
Solenoid valve
device (CSD) and the fuel cut-off solenoid
speed
of the cold start valve.
sensor
device 13. High pressure oil pipe
Injection  Loosen high pressure oil pipe clamp.
pump  Remove the taper nut(s) on the
injection pump side.
 Remove taper nut(s) on the fuel injector
Fuel cut-off
solenoid valve side and high pressure oil pipe.
Caution:
 Plug the holes in injector body and
delivery valve body to prevent foreign
bodies falling in.
14. Injection pump assembly
 Loosen injection pump fixing nut(s).
 Unscrew the adjusting and locking bolts
in the injection pump rear bracket.
 Unscrew the generator side fixing
bolt(s). Take out the injection pump from the
engine backside.
Notes:
 Cove holes in injection pump delivery
valve body with a cap (or equivalents) to
prevent foreign bodies falling into the valve.
259
Assembly
14. Injection pump assembly
1. Mount inspection hole covers on the
camshaft timing gear side of the timing
gear chamber and the timing gear side
of the injection pump.
2. Turn the crankshaft clockwise and
check whether the Ⅱ℃ mark on the
crankshaft pulley is aligned with the
index. Place the piston of the first
cylinder on the top dead center of the
compression stroke.
3. Observe and check if the scale on the
timing gear mark “O”is aligned with the
hole index via the inspection hole on
crankshaft timing gear side.
4. Align the injection pump gear mark “O”
with the inspection hole index and
install the injection pump assembly.
 Screw on the injection pump fixing bolts
Camshaft gear Injection pump gear
and tighten them to the specified
torque.
Injection pump fixing bolt torque N·m
25

 Connect the high pressure oil pipes to
the injection pump side and fuel injector
side and screw down these pipes.
 Install the oil pipe fixing clips in the
original positions.
N·m
30
12. Injection pump wire harness

 Fix the injection pump wire harness and
connect it to the switch.
260
11. Water hose of cold start device
 Connect the water hose of cold start
device and tighten the fixing clip(s).
10. Fuel hose

Connect the fuel inlet hose and return hose.
 Connect the defuelling hose(s).
1) Connect the control wire rope to the
engine control lever.
2) Place the throttle lever in fully cut-off
position and pull tight the control wire
towards the arrow direction to prevent it
being slack.
3) Tighten the throttle wire bracket bolt(s).
8. Air-intake duct
6. Soundproof cover

 Mount the alternator drive belt and
adjust the belt tension.
 Apply a force of 100N to the middle part
of the drive belt.
Ac compressor drive Drive belt deflection mm

belt
8— 10
Power
steering
 Screw on the fixing bolt and tighten it to
pump drive
belt the specified torque.
Alternator fan
pulley drive belt
261
Drive belts of the ac compressor and
power steering pump 37.5

25

Drive belts of the  Mount the ac compressor drive belt and
alternator and fan adjust the belt tension.
of the drive belt.力。
8— 10
 Tighten the idler locking nut to the

specified torque.
N·m
27
3． Power steering pump drive belt

 Mount the power steering pump drive
belt and adjust the belt tension.
of the drive belt.力。
8— 10
 Tighten the idler locking nut to the

specified torque.
N·m
27
262
2． Fan cowl
 Install the fan cowl and storage tank
hose.
1． Fan assembly
 Fix the fan pulley, collar and fan
assembly onto the water pump in
sequence, and tighten them to the
specified torque.
N·m
12.5

263
Fuel supply and timing adjustment
 Place the piston of the first cylinder on
the top dead center.
 Remove the top plug of the injection
pump distributor.
 Dismantle wax type cold start device
with screwdriver hand lever.
 Mount a dial indicator and pre-elevate
to 1 mm.
Measuring instrument: 1100300FA— 9101
 Place the top dead center mark on the
crankshaft damper pulley at a position
30°-45°to the index.
 Place the dial indicator at the “0”
position.
 Turn the crankshaft left and right slightly
and observe if the dial indicator is still at
the “0”position.
 Turn the crankshaft in normal direction
and read out the dial gauge readings in
the following cases.
4DA1 16°to the top dead center (before)
4DA1-1 12°to the top dead center (before)
Dial indicator readings mm
4DA1 1.60
4DA1-1 1.50
If the readings are improper, unscrew the
injection pump fixing nut and the bracket
adjusting bolt. Adjust the readings by changing
the injection pump mounting position. When the
dial gauge readings change to the specified
values, tighten the fixing nut and bolt to the
specified torques.
Injection pump fixing nut torque N·m
25
Adjusting Bolt torque N·m
25
 Tighten the top plug of the injection pump
distributor to the specified torque after
removing the measuring instrument.
N·m
35
264
Caution:
 While mounting the top plug of the
injection pump distributor, you should
use a new copper gasket.
 Connect the high pressure oil pressure.
 Fix the oil pipe clamp.
Carry out idle speed inspection and adjustment
1) Pull the parking brake lever and lock the
drive wheel (s).
2) Set the transmission gear to neutral shift.
3) Start the engine and operate it at idle
speed until the water temperature rises to
70°-80°.
4} Reverse the idle control knob. Remove
the control wire from the injection pump
control lever.
5) Install the engine tachometer.
6) Check the idle speed.
If the idle speed exceeds the specified limit,
correct it.
Specified value (r／min) = 700-800
1) Unscrew the locking nut of the idle speed
adjusting bolt.
2) Turn the idle speed adjusting bolt and
adjust the idle speed to the specified value.
3) Tighten the locking nut and adjusting bolt.
4) Check the control wire tension and pull
tight this wire if necessary.
265
5.5 Fuel system related parameters
Test conditions
Items Conditions
Model 4DA1 4DA1-1
Fuel injector
Injector type KBAL—P001 KBAL—P001
Fuel injection nozzle pairs DSLA153P009 DLLA153P034
Injector opening pressure (Mpa) 19 — 20 18.6 — 19.6
Size of high pressure oil pipe
Inner diameter 1.6
Outer diameter 6.5
Length 430
Feeding pressure (kPa) 19.61
Test fuel SAE standard test diesel oil (SAE967D)
ISO standard test diesel oil (ISO4113)
Test fuel temperature ℃ 48—52
266
5.6 Fuel tank
Frame
1.Fuel evaporation hose
2. Fuel supply hose
3. Fuel return hose
4. Fuel level gauge connector
5. Clamp band
6. Fuel tank
Assembly sequence
Disassembly
Preparation:
 Open the fuel filter cap
 Drain oil via the oil drain plug
 Tighten the oil drain plug to the
specified torque after draining the oil.
N·m
29
1. Fuel evaporation hose
2. Fuel supply hose
3. Fuel return hose
 Plug hose ends to pervert the fuel
flowing out.Fasten the hose to the
frame with plugged end upward.
267
4. Fuel lever gauge connector
 Remove the fuel lever gauge connector.
5. Clamp band
 Loosen the fixing nut of the fuel tank
clamp band. Draw out the clamp band
from one end of the frame.
6. Fuel tank
 Withdraw the fuel tank.
Note:
If it is impossible to withdraw the fuel tank,
remove the bracket and pull out the fuel tank
downwards.。
Assembly
6. Fuel tank
Note:
If the bracket is removed while pulling out
the fuel tank, mount it to the frame and
tighten it to the specified torque.
N·m
55
 While mounting the fuel tank to the

bracket, you have to place a piece of
cushion on the bracket.
5. Clamp band
 Tighten the clamp band nuts to the
specified torque.
N·m
12

 Connect the fuel lever gauge connector.
3. Fuel return hose
2. Fuel supply hose
 Insert the hose into the oil pipe with
insert depth above 25mm.
1. Fuel evaporation hose
 Feed fuel into the fuel tank.
268
5.7 Fuel lever gauge
Fuel evaporation
hose Frame
1. Fuel lever gauge
connector
2. Fuel lever gauge
Assembly sequence
Disassembly
Preparation:
 Remove the connector from the fuel
lever gauge.
2. Fuel lever gauge
 Unscrew the fuel lever gauge fixing bolt
(s) and remove the gauge.
Note:
 After removing the fuel lever gauge,
plug the tank port with cotton waste to
prevent dirt falling into the tank.
Assembly
2. Fuel lever gauge
 Connect the wire connector to the fuel
lever gauge
269
6 Starting system
6.1 General
The starting system consists of battery, starter motor, start switch, starting
relay, etc. These parts are connected according to the diagram.The diagram
shows the details of the starting circuit.
Starting relay
Starter motor
Start switch
Holding coil
Contact
“50”terminal post
“30”
terminal post
Magnetic switch
Pinion clutch Suction coil Battery
The starting system utilizes the gear reduction magnetic starter motor and its
shaft can be used as pinion shaft.When the start switch is switched on, the
magnetic switch contact closes causing the armature to rotate.Meanwhile,
Move the movable core by suction and push the pinion forward to engage with
the ring gear by a deflector rod.Then the ring gear starts to run and the engine
starts.When the engine is started and the start switch is switched off, the
movable core returns to the original position while the pinion runs out of the
ring gear, then the armature stops.When the engine speed is higher than the
pinion’s, the latter stays in idle state, so it can’
t drive the armature.
Note:
The starting circuit diagram is only for information and the overall circuit
diagram is prevail in specific cases.
270
6.2 Starting circuit
Starting system Starter

Battery Ignition Battery Accessories Ignition
Key position Key motor
B1 IG1 B2 ACC IG2
ST
Battery
Pulled
Lockup
out
Switch off
Accessories  
Inserted
Switch on     
Start     
Main switch Key switch
15A
engine
Generator ignition
Starter motor
Starting relay
Quick start element
Suction
Holding
coil
coil
Magnetic switch
Starter motor
271
6.3 Starter motor
1. “50”terminal post
3. Ground cable terminal post
4. Starter motor assembly
5. Separator (4JB1, except cold area)
Assembly sequence
As assembly, go on according to the
Disassembly
Preparation:
 Remove the ground cables of battery.
5. Separator (except cold area)
Assembly
5. Separator (except cold area)
 Tighten the fixing bolt(s) and nut(s) to
Starter motor bolt and nut torque N·m
81
 Connect the ground cable terminal
post.
 Connect the wire connector.
 Connect the battery cable and start
switch wire terminal posts, and tighten
nuts to the specified torque.
Fixing nut torque N·m
9
272
Single-piece repair
1. Lead
2. Through bolt
3. Yoke assembly
4. Yoke cover
5. Brush and brush-holder
6. Armature
7. Transmission case
8. Sprag clutch
9. Return spring
10. Steel ball
11. Idler pinion
12. Holder
13. Roller
14. Magnetic switch
Reassembly sequence
As reassembly, go on according to
disassembly.
Disassembly
1. Lead
Remove the magnetic switch lead.
273
2. Through bolt
Unscrew the yoke through bolt.
3. Yoke assembly
Dismantle the magnetic switch yoke.
4. Yoke cover
5. Brush and brush-holder

Remove (pull out) the brush and
brush-holder from the armature with long
nose pliers.
6. Armature
7. Case
8. Sprag clutch
Remove the sprag clutch from the case
Brush Spring
274
9. Return spring
Remove the return spring from the magnetic
spring.
10. Steel ball

Dismantle the steel ball from the sprag
clutch.
11. Idler pinion

Remove the idler pinion from the case.
12. Holder
Remove the holder from the case.
13. Roller
14. Magnetic switch
275
If during inspection it is found that some
parts are worn-out, damaged or flawy,
remove or replace these parts.
Armature
Check the radial runout of the commutator. If
the runout exceeds the limits, replace the
commutator.
Radial runout mm
kW Standard value Limit
2.2
0.02 0.05
2.0
Check if the mica sheet is worn-out.

Insulator
The depth of mica sheet mm
Segment
2.2
Correct 0.7— 0.9 0.20
2.0
Incorrect Check the outer diameter of the commutator.

Outer diameter of the commutator mm
2.2
35.00 34.00
2.0
Short circuit test for the armature

Place the armature in the coil short circuit tester
to check if there is any short circuit in the
armature. Touch the armature core with a piece
of saw blade when rotating the armature slowly.
It will cause the saw blade to vibrate and stick to
the core if the armature is in short-circuit state. If
the saw blade vibrates and sticks to the core, you
have to replace the armature for it is
short-circuited.
276
Earth test for the armature
Touch the segment and armature core with test
probes of the multimeter to check if the armature
is in open-circuit state. If the armature circuit is
closed, it means the armature has been earthed.
If this is the case, replace the armature.
Closed circuit test for the armature

Touch two segments with both test probes of the
multimeter. All test points should in closed-circuit
state. If there is any open circuit, replace the
armature.
Yoke
Earth test for the field winding
Touch the field winding wire or brush with one
test probe of the multimeter and the yoke outer
surface with another test probe to check if the
winding is in open-circuit state. If the multimeter
shows a closed circuit, it means the field winding
has been earthed and you have to replace the
yoke assembly.
Closed circuit test for the field winding

Touch the “C”terminal post wire with one test
probe and the brush with another test probe to
check if the field winding is in closed-circuit state.
If there is an open circuit, replace the yoke
assembly.
277
Brush and brush-holder
Measure the brush length. If the worn-out
length exceeds the limit, replace the brush.
Brush length mm
2.2 14.5
10
2.0 16
Insulation test for the brush-holder

Check if the brush-holder is insulated with a
multimeter. Touch the brush-holder plate
with one test probe and the positive
brush-holder with another test probe. The
brush-holder should be in open-circuit state.
Sprag clutch
Check whether the pinion teeth are worn-out
or damaged and replace the pinion if so.
It should be smoothly to turn the pinion
clockwise.
But when the pinion is turned anti-clockwise,
it should be locked up.
Bearing
Check if the bearings are worn-out and
damaged. If there is any noise during
bearing operation, you have to replace the
bearings.
278
Reassembly
Steel ball
As reassembly, go on according to the
reverse sequence of disassembly and pay
attention to the following items:
Roller
 magnetic switch
 Idler
Idler  Clutch assembly
 Case
1) Install the clutch assembly to the
M terminal
post magnetic switch.
2) Mount the idler and case.
Note:
Remember to mount the steel ball and
“50”terminal spring between the clutch and magnetic
post switch. Install the roller onto the idler
beforehand.
Magnetic switch
Temporarily mount a magnetic switch
between the clutch and case and carry out
Disconnected the following tests. The duration of each test
should not be longer than 3 to 5 seconds.
1. Test of pullout binding force
The negative terminal post of the battery is
connected to the magnetic body and M
terminal post. While the current is flowing
from the positive terminal post to the “50”
terminal post, the pinion should chatter.
2. Holding test
Remove the M terminal post wire. The
pinion remains chattering.
3. Return test
The negative battery terminal post is
connected to the “50” terminal post and
case. The positive battery terminal post is
connected to the M terminal post. At this
time the pinion should chatter. After the “50”
terminal post wire is removed, the pinion
should return to its original position
immediately.
279
“30”terminal post 4. Current value
Complete the circuit according to the
diagram and measure the current value.
Standard value = 120A or lower
Notes:
You should use fully charged batteries.
Choose heavy gage wire for the
flowing-through high current.
280
7 Intake/exhaust system
7.1 General
Engine intake/exhaust system mainly consists of air filter, intake pipe and
exhaust pipe. If it is a supercharged engine, the system also includes the
charger assembly. The installation and maintenance qualities may affect the
engine performance and this factor has become particularly remarkable in the
4DA1-1 type chargers.
281
7.1 Air filter
1. Filter cap wing nut
2. Filter cap
3. Filter element wing nut
4. Air filter element
Assembly sequence
As assembly, go on according to
disassembly.
Disassembly
2. Filter cap
Cleaning
 Clean the air filter inside.
 Clean the air filter cap.
Inspection
 Check if the air filter element is intact
and clear or with holes by light.
Cleaning method
Dust accumulated at the filter element
Manually turn the filter element and blow the
compressor air into the element in order to
blow off the dust.
Pressure of compressed air kPa
392— 490
282
Caution:
In order to protect the filter element, do not
knock the element with other objects during
cleaning.
Filter element with carbon and dust accumulated
1. Prepare the filter cleaning liquid originally
provided by JAC and dilute it with water.
2. Immerse the filter element in the cleaning

liquid for 20 minutes.
3. Take the element out of the cleaning liquid

and flush it with running water.The water
pressure should not exceed 2.8kg ／ cm2
(274kPa／40psi).
4. Dry the filter element at a place with good

ventilation. Use a fan for quick drying.
Note:
Never use the compressed air or open fire for
quick drying or it will damage the filter element. It
will take two to three days to completely dry a
filter element. In this case, it would be better if a
standby element were available.
Assembly
2. Filter cap
283
7.2 Exhaust pipe and charger assembly
Disassembly
1. Loosen the binding bolt(s) of the charger
lubrication oil pipe with a wrench.
284
2. Unscrew the charger exhaust pipe bolt with
a wrench and remove the charger exhaust
pipe.
3. Remove the exhaust pipe heat insulator.
4. Remove the charger and exhaust manifold

subassembly
5. Disassemble the charger assembly
Inspection
(1) Check the airtightness and tightening of the
connecting pipes between the air filter and
charger and between the charger and
engine intake/exhaust pipes.
(2) Check if the fuel inlet/return hoses of the
turbocharger are damaged or blocked and if
the connecting bolt on the connector is tight.
(3) Check of the oil quality and clean or replace
the oil.
(4) Check the air filter and clean or replace the
element periodically.
Notes
Seal ring (1) Protect the charger return pipe from being
Floating Compressor
Spiral case bearing housing bended or damaged.
(2) Make sure the fuel inlet/return hoses of the
Compressor charger are unblocked.
wheel
Thrust (3) Always check the airtightness of the
bearing
connecting pipes between the charger and
Turbine
Intermediate engine.
(4) The duration of idle state shouldn’ t be too
Bypass valve mechanism
+long
285
(5) Make sure the crankcase oil pipes are
unblocked.
(6) Prevent the lower blow-by gas of the engine
to be too much
Faulty diagnosis:
The purpose of faulty diagnosis is to find out the
diesel fault and its reason, so as to clear the fault.
If the charger has been removed, you can’ t carry
out the faulty diagnosis. Never replace the
charger before finding out the fault and clear it.
Inspect and determine whether the charger is

damaged directly according to the follow
items:
A) If the charger rotor rotates smoothly.
B) Check if the compressor wheels are
damaged via the compressor inlet.
B) Check if the compressor wheels rub
with the case via the compressor inlet.
There are four main causes for charger

failure:
A) Foreign matters entering in
B) Lubrication oil impure or aging
C) Lack of lubrication oil
Compressor impeller damaged Compressor impeller damaged by D) Improper use and failure to maintain
by particles solid objects damaged
A)
①. Compressor side:
a. The seal for intake pipes is poor and the air
directly goes into the compressor impeller
Compressor impeller damaged Turbine impeller damaged by without filtering;
by dust particles
b. Replace the air filter without consulting to
the regulations or use poor quality filter
element;
c. Foreign matters enter the front intake pipes
during maintenance.
②. Turbine side:
a. Some parts in the diesel cylinder are
damaged.
b. Objects like bolts have fell into the exhaust
pipes while connecting the exhaust
manifold.
Any matters going into the manifold will break the
charger rotor balance, which will block the rotor
and break the pivot ultimately.
286
B) Impure lubrication oil:
a. Replace the lubrication oil filter without
consulting to the regulations or use
poor quality filter element
b. The filter element has broken down or
the filter in the man diesel oil gallery
Comparison between the bearing
damaged by foreign matters and has been blocked.
new bearing
c. Replace the lubrication oil without
Foreign matters in the oil cause the
bearing to be damaged consulting to the regulations, and didn’t
clean the main diesel oil gallery before
replacing the oil.
d. Foreign matters have fell into the
lubrication oil pipe during charger
replacing or pre-fabrication.
e. The sealer or gasket fragments have
fell into the lubrication oil gallery.
Stripped
Stripped
C) Lubrication oil insufficient or aging:

a) Replace the lubrication oil without
consulting to the regulations or use
inferior oil;
b) The diesel stops abruptly after
heavy-load operation without idling;
Damage caused by foreign matters c) The engine starts without idling;
d) There is no pre-fabrication before
replacing the charger
Assembly
5. Install the charger assembly and tighten the
charger union nut (remember to replace the
gasket during charger installation)
Nut tighten torque Nm
25
287
4. Install the charger and exhaust manifold
subassembly to the cylinder head
(remember to replace the exhaust pipe
gasket)
Bolt tighten torque Nm
30
3. Remove the exhaust pipe heat insulator.

25
2. Connect the charger exhaust pipe and

tighten the connecting bolt
25
1. Connect the charger lubrication oil pipe and

tighten the two punching bolts
Punching bolt II (M12) tighten torque Nm

41
Punching bolt I (M14) tighten torque Nm

55
288
Engine Electronic Control Maintenance Manual EMS-1
CONTENTS
CHAPTER I.Overview of the System·····················································································2
SECTION I.Characteristics of Fuel Injection ································································4

SECTION II. Emission Control························································································8
SECTION III. Control of Running Status········································································10
CHAPTER II. System Maintenance························································································14
SECTION I. Notices for Common Rail Fuel Injection System Maintenance··············14

SECTION II. Clean and Maintenance Procedure of Common Rail Engine Fuel
System ······························································································································15
SECTION III. Forecasted Malfunction and Remedial Measures of Common Rail
Engine·······························································································································19
SECTION IV. Fuel System ·······························································································21
SECTION V. Electronic Control ······················································································29
SECTION VI. Common Malfunctions and Troubleshooting ········································75
CHAPTER I. Overview of the System
In accumulator-type common rail fuel injection system, the generation of fuel injection
pressure does not depend on the engine speed and fuel injection quantity because the
mutual influence between pressure generating and fuel injection is eliminated completely.
Fuel is stored in high pressure accumulator (rail) and prepared for injection under the
function of pressure; fuel injection quantity is decided by the driver and the fuel injection
beginning and pressure is calculated by ECU according the stored map by itself. ECU
triggers solenoid valve then the injector (fuel injection unit) in every cylinder injects fuel
accordingly. ECU and sensor device of this kind of common rail fuel injection system are
composed by the following elements:
- ECU (Electronic control unit)
- Crankshaft speed sensor
- Camshaft speed sensor
- Throttle pedal sensor
- Supercharging pressure sensor
- Rail pressure sensor
- Coolant sensor
- Air flow meter
ECU collects the requirements from the driver (position of throttle pedal) and the current
working conditions of engine and vehicle. And it manages the signals generated by sen-
sors and received through data circuit. ECU controls the vehicle especially the engine
through closed loop and open loop controlling in virtue of the information. Crankshaft
speed sensor measures engine speed and camshaft sensor calculates the ignition se-
quence (phase). One potentiometer generates electrical signal as a throttle sensor and
informing ECU how much torque the driver needs. The supercharging pressure sensor
detects the supercharging pressure inside the engine with exhaust gas turbocharger and
supercharging pressure control. ECU will adjust fuel injection beginning, rated value of
pre-injection and its parameters to adapt for specific working conditions according to the
data from coolant and barometric pressure sensor when the environment temperature is
lower and the engine is cold. ECU has other sensors and data line to enhance the safety
and comfort of the vehicle according to different model.
Coolant temperature sensor
Supercharging pressure sensor
Rail pressure sensor
Fuel intake flow valve
Control unit
Crankshaft position sensor Fuel injector
Camshaft position sensor

Signal input
Throttle pedal position sensor
信号赋值
Common rail pressure sensor Voltage input
Signal treatment
Supercharging pressure sensor Fuel metering unit
-Fuel quantity
Intake air temperature sensor -Fuel injection beginning time Exhaust gas recirculation
Air flow meter -Pre-injection Turbocharger

-Rail pressure control
Water temperature sensor -Supercharging pressure Pen like glow plug
Brake switch
control
Clutch switch Power fuel pump
-Exhaust gas recirculation
Cruise control device Malfunction indicator
Power supply
Automatic transmission
Diagnosis instrument
AC compressor Pressure control valve
Vehicle speed
SECTION I. Characteristics of Fuel Injection
Characteristics of traditional fuel injection
The traditional fuel injection system adopts distributor fuel injection pump and in-line fuel
injection pump; and there is only main fuel injection phase during injection without
pre-injection and delayed injection (Figure 1). Despite the distributor pump controlled by
solenoid valve develops to pre-injection level. In traditional fuel injection system, the gen-
eration of pressure and reserved fuel injection quantity are related to cam and plunger
closely, which will have the following influence to fuel injection characteristics: fuel injec-
tion pressure increases with the increase of engine speed and fuel injection quantity. Fuel
injection pressure increases in actual process of fuel injection and decreases after the fuel
injection process finished until the fuel injection is closed. Result of the pressure is as
following:
- Fuel injection quantity is smaller but not bigger as the pressure is lower, see (Figure
1);
- Peak pressure value is more than 2 times of average fuel injection pressure;
- Injection rate curve is triangle synchronizing with the requirement of effective com-
bustion.
Peak pressure value is crucial for the components of fuel injection pump and mechanical
loading of driving system. In traditional fuel injection system, it has determinative function
to the forming quality of air/fuel mixture inside of combustion chamber.
Comparing characteristics of common rail fuel injection with that of traditional fuel injection,
the following requirements are made based on ideal fuel injection characteristics:
- Fuel injection quantity and fuel injection pressure do not influence to each other; fuel
injection quantity is decided by every time working condition of every engine (provide
more freedom to from ideal air/fuel mixture);
- All the fuel injection quantity should be as least as possible at the beginning of fuel
injection process (that is ignition lag phase between fuel injection beginning point and
combustion point).
These requirements are consistent with the characteristics of common rail system with
pre-injection and main injection (see Figure 2 and Figure 4).
Common rail system is designed according to standard model and in fact the following
components are the main reasons to compose the fuel injection characteristics:
- Solenoid fuel injector assembled on cylinder head
- Pressure accumulator (rail)
- High pressure pump
- Camshaft position sensor (phase sensor)

Figure 1 Figure 2
Fuel injection curve of common rail fuel injection system
Fuel
Pm Average injection
fuel curve
injection of normal
pressure injection pressure
Ps Maximum
Pm Average fuel injection pressure Pr Rail pressure
Fuel supply Pre-injection

pressure Main injection
Fuel injection pressure
Fuel injection pressure

Fuel injection
beginning
Time Time
High pressure pump used to produce pressure is a radial plunger pump. The generation of
pressure has no relation to injection. There is a fixed driving ratio between high pressure
pump speed and engine speed. Comparing to traditional fuel injection system, fuel sup-
plying is even; the size of common rail high pressure pump is smaller and its driving de-
vice needs not to bear high pressure loading peak.
Fuel injector, composed of fuel injection nozzle and solenoid valve on every fuel pipe,
connects with common rail through several pieces of short fuel pipes. ECU supplies power
to solenoid, the solenoid valve is switched on (fuel injection beginning point); cutting off
the current, solenoid valve will be disconnected and fuel injection is finished. Under given
pressure, fuel injection quantity is in proportion with connection time of solenoid valve, but
there is no relationship with engine speed or oil pump speed (time controls the fuel injec-
tion).
ECU triggers solenoid valve by higher pressure and current to get ultra short connection
time of solenoid valve. Injection time is adjusted by the system of “angle –time”controlled
by electronic diesel. There is one sensor on crankshaft to record the engine speed, and
the sensor on camshaft to check phase (working circulation).
Pre-injection
Pre-injection is set between 0-90°of crankshaft angle before top dead center. Fuel will
deposit on piston surface and cylinder wall, which will cause unnecessary dilution of lu-
bricant, if the fuel injection beginning point appears first 40°of top dead center. There will
be less diesel oil (1-4mm3) entering into cylinder during pre-injection and it will have “pre-
treatment”function to combustion chamber; the combustion efficiency will be increased
and the following effects will get:
- Compression pressure is increased slightly because of the pre-injection function and

partial combustion;
- Ignition lag of main injection is shortened;
- Both combustion pressure increasing and combustion pressure peak will be de-
creased (gentle combustion).
All of these effects can decrease the combustion noise and fuel consumption, and de-
creased the emission greatly. In the pressure curve (Figure 3) without pre-injection, the
pressure increase within top dead center area is very smooth corresponding to compres-
sion force; but gradient becomes very big when the combustion starts, and there is a
relative abrupt peak when the pressure reaches to biggest. Pressure increasing line is too
tilted or peak is too steep, which are the important reasons to cause diesel engine noise.
In the pressure curve with pre-injection (Figure 4), pressure has reached to a higher value
within the top center area, so the gradient of combustion pressure increasing curve will be
decreased.
For pre-injection, it influences the generation of engine torque indirectly by shorten ignition
lag. Increase/decrease of specific fuel consumption can act as the function of main injec-
tion point and time between pre-injection and main injection.
Figure 3 Figure 4
Needle valve lift of fuel injection nozzle and Needle valve lift of injection nozzle and pres-
pressure curve without pre-injection sure curve with pre-injection
h Needle valve lift of main injection hM Needle valve lift of pre-injection
Cylinder pressure P
Needle valve lift
Needle valve lift

Cylinder pressure
h
Crankshaft angle
Crankshaft angle
Main injection
The power outputted by engine comes from main injection stage; this means the main
injection takes the responsibility to enhance engine torque. In accumulator type common
rail fuel injection system, the fuel injection pressure going through the complete process is
constant.
Post injection
Post injection can decrease NOX with the variant of NOX catalytic converter. Post injec-
tion shall be carried out after main injection, and it should happen in definite time during
the process of expansion stroke when the crankshaft angle is 200°after top dead center.
Post injection injects fuel with accurate quantity into exhaust gas. Comparing to
per-injection and main injection process, the injected fuel will not combust but be gasified
in virtue of the remnant heat in exhaust gas. In the exhaust process, the mixture of fuel
and exhaust gas enters into exhaust gas system through exhaust valve under pressure.
Partial fuel will return to combustion chamber through EGR system reaching to the same
effects as early pre-injection. If there is suitable NOX catalytic converter, catalytic con-
verter will use fuel in exhaust gas as reducer to reduce the content of NOX in exhaust gas.
Post injection must get strict verification because post injection lag may cause engine oil
dilution.
SECTION II. Emission Control
Gas mixture formation and combustion
Comparing to spark ignition engine, diesel engine uses the fuel with low volatility (high
boiling point). Gas mixture of air and fuel is formed between fuel injection beginning point
and combustion beginning point and when it is combusting, so its uniformity is lower. The
work of engine is related to excess air ratio, and the emission of carbon black, emission of
CO and emission of HC will be increased and the fuel consumption will be also increased
if the excess air ration is too small.
Formation of air-fuel mixture is decided by the following parameters:
- Fuel injection pressure
- Fuel injection rate (fuel injection continued time)
- Injection distribution (quantity of injection beam, cross section of injection beam and
direction of injection beam)
- Fuel injection beginning point
- Air movement
- Air quantity
The above factors have influences to engine emission and fuel consumption. Both higher
combustion temperature and higher oxygen content will lead to the higher generation of
NOX. It may make carbon black emission deteriorate because of air lack or bad air-fuel
mixture.
Measures to engine
The shape of combustion chamber and intake pipe has great influence to exhaust gas
emission. If the air movement inside of combustion chamber can cooperate with the fuel
injected from nozzle accurately, it may accelerate the effective mixture of air and fuel and
finish the combustion. In addition, it can reach to active effects through even gas mixture
of air and exhaust gas and the cooled EGR (exhaust gas recirculation). 4 valves and the
turbocharger with variable turbine geometry (VTG) also can help to realize low emission
and high specific power.
Influence of fuel injection time
Fuel injection beginning point, fuel injection curve and fuel atomization shall influence fuel
consumption and the emission of poisonous staff.
Fuel injection beginning point
Fuel injection lag may decrease the emission of NOX because of lower circulation tem-
perature. But too late injection may lead to the increase of HC emission, the increase of
fuel consumption and the increase of black smoke under high loading conditions. If there
is only 1°deviation of crankshaft angle between fuel injection beginning point and rated
value, the emission of NOX will increase 5%. It may cause the injection pressure in cyl-
inder increase 10 bar if the fuel injection beginning point deflect 2°of crankshaft angle
(advance angle); but the temperature of exhaust gas will increase 20℃ if the delayed in-
jection reaches to 2°of crankshaft angle (lag). So the adjustment of fuel injection begin-
ning point should be as accurate as possible because it is very sensitive.
Fuel injection rate curve
Fuel injection rate curve describes the fuel flow changes within certain fuel injection period
(between fuel injection beginning point and the end of fuel injection). Fuel injection curve
limits the fuel quantity supplied of ignition lag (between fuel injection beginning point and
combustion beginning point). In addition, it will influence the distribution of fuel inside of
combustion chamber and the air utilization. Fuel injection rate curve must increase slowly
to keep the fuel injection quantity at minimum value at ignition lag phase. Fuel will com-
bust quickly once it is ignited, and there is no active function to noise and NOX emission.
At the last stage of combustion, the fuel injection rate curve must decrease rapidly to
avoid the bad fuel atomization leading to higher HC and carbon black and higher fuel
consumption.
Fuel atomization
Better fuel atomization can accelerate the effective mixture of air and fuel which can de-
crease the emission of HC and carbon black. Higher fuel injection pressure and optimal
geometric shape of the injection hole are the guarantee of better atomization. In order to
avoid the emission of visible carbon black, the fuel injection quantity must be limited ac-
cording to air intake quantity and this will need at least 10~40% excess air (excess air
coefficient＝1.1～1.4).
Fuel will be injected from injection hole (include pressure chamber cubage in pressure
chamber oil nozzle) and atomized after oil nozzle needle valve closed, and HC emission is
increased. So it is a must to reduce this kind of adverse cubage as possible.
SECTION III. Control of Running Status
System calculates accurate fuel injection quantity under every situation in order to make
engine have optimal combustion process under every working condition. It is a must to
consider different parameters in this process.
Calculation of system fuel injection quantity
Switch position A: Start B: Normal operation
Throttle pedal signal Stable running Other signal system
Select the minimum

Select the maximum Exterior correction of
fuel injection quantity fuel injection quantity fuel injection quantity
Idle speed regulator Activated shock ab- Limit value of fuel
sorber injection quantity
Fuel quantity on Stable running

Switch speed regulator
starting
Check the fuel quan- Rail pressure Rail pressure control

tity
Fuel quantity regulating

Fuel injector control
valve control
Fuel injection quantity on starting
For starting, fuel injection quantity is the function of temperature and crankshaft speed.
Fuel injection quantity on starting is calculated from the moment of fuel injection when
start switch is turned to “start”position (A position in the Figure) to then engine reaches to
its lowest speed. The operation of throttle pedal will not influence the fuel injection quan-
tity.
Driving status
Fuel injection quantity can be calculated according to the position of throttle pedal (throttle
pedal sensor) and engine speed when the vehicle runs normally (see Figure, switch is on
B position). Calculate using driving map to make the cooperation of driver’ s input and en-
gine O/P (output) power reach to optimal.
Idle speed control
Fuel consumption mostly is decided by engine efficiency and idle speed under idle speed
control. Obviously, it should keep the idle speed at minimum value under traffic jam be-
cause the vehicle fuel consumption is decided by its working conditions. But no matter
what kind of working conditions, it is a must to set idle speed, then the speed will not de-
crease too much, which will not stop the engine, when it is loaded, for example, when AC
is turned on with vehicle electrical system is loaded; when the shift is changed or when the
power steering device runs.
In order to get the desired idle speed, the idle speed controller should change the fuel
injection quantity until the actual engine speed is same to the desired idle speed. Here,
desired idle speed and speed regulating characteristics are influenced by specific shift
and engine temperature (coolant temperature sensor). In addition, except for exterior
loading torque, interior friction torque must be considered and it will be compensated
through idle speed control. These changes are minor and they are stable within vehicle
service life; it is related to temperature closely.
Stable running control
Mechanical tolerance and aging will lead to torque deviation among engine cylinders. This
will cause engine unstable running during driving especially during idle speed. Stable
running speed regulator calculates the speed change according to the combustion of
every time and compares them. It adjusts the fuel injection quantity of every cylinder ac-
cording to the speed difference it measured to make every cylinder contribute the same to
engine torque. Stable running speed regulator works only when the speed is lower.
Fuel injection quantity control
There are a series of reasons to explain why fuel can not be injected according to the
driver’
s requirement or the quantity can be realized physically. These reasons are:
- Superfluous pollutant emission.

- Superfluous carbon black emission.
- It will lead to mechanical overloading caused by over big torque or engine speed.
- Heat overloading caused by too high temperature of condensing agent, engine oil or
turbocharger.
The limit of fuel injection quantity is formed by several kinds of input forms, like air intake
quantity, engine speed and coolant temperature.
Vehicle speed controller
Vehicle speed controller (constant speed device) starts working when the vehicle runs at
constant speed. It controls the vehicle speed; driver controls the input by operating the
control device on instrument panel to increase or decrease the fuel injection quantity until
actual speed is same with set speed. The control process will break if driver step down
clutch pedal or brake pedal when constant speed device is running. Vehicle will be accel-
erated if the throttle pedal is stepped down and the set speed will be exceeded. Constant
speed device will return to original set speed once the throttle pedal is released. Similarly,
driver only needs to press reset key to set speed again if constant speed device is closed.
Activated shock absorber control
Fuel injection quantity will be changed rapidly if the throttle pedal is stepped down or re-
leased abruptly, and the engine torque will be changed abruptly accordingly. This kind of
abrupt loading changes will make engine bearer and driving system jump acutely, and this
will make engine speed fluctuate (see Figure). Activated shock absorber changes fuel
injection quantity to reduce periodical speed fluctuation by same kind of periodical speed
fluctuation; fuel injection quantity is less when the speed is increased, and fuel injection
quantity is more when the speed is decreased; this can absorb shock effectively.
Activated shock absorber

1.Abrupt throttle pedal movement (driver’s input
signal
2.Speed curve before shock absorber is acti-
vated
Engine speed
Time
Stop the engine
Diesel engine runs as automatic compression ignition principle. This means diesel engine
can be stopped only by break the fuel supply. Engine can be stopped by ECU specified “0
fuel injection quantity”when there is electronic control device. And there are also a series
of spare approached to stop fuel supplying.
CHAPTER II. System Maintenance
SECTION I. Notices for Common Rail Fuel Injection System Maintenance

Only digital multimeter can be used to check common rail fuel injection system:
 It is a must to use parts with good quality otherwise the proper working of common rail
system can not be guaranteed;
 Please abide by the normative maintenance and diagnosis flow during maintenance;
 It is prohibited to decompose/disassemble the components of common rail fuel injec-
tion system during maintenance;
 Be careful and do not let electronic elements (ECU and sensor etc.) drop down during
maintenance;
 Dispose the waste produced during maintenance effectively to protect the environ-
ment;
 Do not take off any part and component of common rail fuel injection system from
their installed position to avoid damage or water/ oil dirt entering into joint-plug part,
which will influence the proper working of common rail system;
 It is a must to put the engine ignition switch to OFF position when the joint-plug part is
disconnected or connected; otherwise it may damage electrical parts;
 Never make the temperature of ECU exceed 80℃ during malfunction heat state
working conditions simulation and other maintenance work which may cause tem-
perature increase;
 Fuel supplying pressure of common rail injection system is very high. So it is
prohibited strictly to disassemble high pressure fuel pipe when the engine is
running during engine maintenance. Stop the engine before the high pressure
fuel piped is disassembled if he fuel system needs to be maintained;
 Do not connect battery anode and cathode incorrectly to avoid electronic elements
damaged; this system adopts cathode grounding;
 Never disassemble battery cable when the engine is running;
 It is a must to disassemble battery anode cable, cathode cable, and ECU before carry
out weld on vehicle;
 Do not check the component input/output electrical signal by the method of piercing
lead surface.
SECTION II. Clean and Maintenance Procedure of Common
Rail Engine Fuel System
Fuel system of common rail engine is composed of low pressure delivery pipe and high
pressure fuel pipe. Maximum pressure can reach above 1,400bar. Some parts of fuel in-
jection pump and HP pump are manufactured by the accurate of 0.1mm. Pressure regu-
lating and injection are controlled by engine ECU, so if the needle valve is clogged by
foreign bodies, the fuel injector will keep open status all the time; and now the HP pump
still works to provide high pressure fuel continuously; superfluous fuel enters into com-
bustion chamber will cause pressure inside of combustion chamber increase heavily
(above 250bar), which will damage the engine seriously.
See the following Figure (Left side), it is the comparison of fuel injector and hair; right
Figure indicates the cooperation clearance of inside components.
Needle valve lift

Hair
Cooperation
Diameter: clearance
Fuel injector hole

Diameter
The accuracy of core component in fuel system is really very high, so they are easy to be
influenced by dust or very small foreign bodies. It is a must to carry out the following
preparation work and procedure. Otherwise it may cause many system malfunctions.
Working procedure
1. It is a must to keep the maintenance place clean (especially there should be no dust);
2. It is a must to keep the maintenance tools clean (away from oil and impurities);
3. Wear ethane apron to prevent hair, dust or impurities entering into engine fuel system;
do not wear gloves but wash your hands;
4. Carry out the following procedure before the maintenance of fuel system:
Carefully listen to the customer with his description of the symptom mal-
function
Check the appearance and connection conditions of lead cable and connector inside of
engine compartment
Carry out check procedure by special diagnosis instrument (carry out road test as
necessary)
Confirm the malfunction; please carry out step 1 to 3 if it is the problem of fuel
system
5. Prepare clean special use tools and airproof cover if the malfunction comes from HP
pump, fuel delivery pipeline or fuel injector and then carry out engine fuel system
steps. Clean the related area of engine compartment completely before maintenance;
6. Replace it by original factory part if you find the failed part according to the above
mentioned working procedure;
Disassemble battery cathode

lead
Confirm if the system pressure is lower before the disassembly of high pressure system
for safety
Correct it by special use tools and torque

wrench
It is a must to use brand new copper washer when fuel injector is disassembled or it is
replaced, and at the same time fasten fuel injector fixation bolt as per the torque re-
quirements. Otherwise the injection position of fuel injector may deviate from correct po-
sition leading to engine running out of control.
Cover disassembled parts by airproof cover and takes away the cover before part re-
placement
Diesel oil common rail fuel

injection system
Fuel pressure sensor

Cut-off valve
High pressure pump (optional) Distributing
pipe
Pressure
regulator
Fuel temperature Oil feed pump Other sensors

sensor
Throttle pedal
Fuel injector
Oil-water separator
Crankshaft
position sensor
Fuel tank Camshaft position High pressure

sensor Low pressure
7. Cover disassembled part with clean and undamaged cover and keeps them properly;
8. Use special use diagnosis instrument for fuel injector matching when the high pres-
sure pump or fuel injector is replaced;
9. Supply fuel to low pressure pipeline by pressing manual oil feed pump on oil-water
separator until it can not be pressed down any more.
Note:
Do not run the engine before the pump is full
10. Recheck installed parts and connect battery lead; start engine and check its working
situations;
11. Check whether or not there is malfunction by special use diagnosis instruments and
clear historical malfunction.
SECTION III. Forecasted Malfunction and Remedial Measures
of Common Rail Engine
System prevention measures to prevent paraffin separation leading to malfunction
Paraffin is a kind of element of the diesel oil used by engine; in the winter it may separate
from fuel and clog the fuel filter to block fuel flowing leading to starting difficulty finally. Fuel
can be divided into summer using fuel and winter using fuel according to temperature
difference; and if the vehicle is filled with fuel not matching to season temperature, the
above mentioned phenomenon may happen.
For common rail engine, pure fuel is a very important factor to maintain the interior accu-
racy of high pressure pump and fuel injector. Comparing to traditional fuel filter, new fuel
filter adopts screen with higher filtering level. There is heating system on fuel filtering de-
vice to prevent interior clog of fuel filter caused by paraffin separation, and ensure the fuel
flows freely.
System prevention measures when there is water in fuel
As mentioned above, if the water content in fuel exceeds standard, the power will be de-
creased or the engine will shake for traditional engine. But the requirement of fuel system
with precise components of common rail engine to fuel is completely different from tradi-
tional engine fuel system; so the water in fuel may cause high pressure pump malfunction
(as the vehicle is parked for long time, bad coating during anti-mildew period may cause
bad lubrication of pump); there is an oil-water separator assembled inside of fuel filter to
prevent water content in fuel exceeding standard and cause malfunction. Water density is
bigger than fuel density, so when fuel flows through fuel filter, water will deposit at the
bottom of fuel filter.
Manual oil feed pump
Temperature
sensor
Fuel heater
Water level sensor

Warning lamp will be lit when the water inside of oil-water separator of fuel filter
exceeds certain range, and then you should screw off the plug to drain the water.
SECTION IV. Fuel System
Composition of fuel system
The design of fuel system is to produce and distribute high pressure, and they are con-
trolled by ECU. So the common rail fuel system is completely different from the traditional
injection pump fuel system.
Fuel injection system of common rail engine is composed of low pressure part which is
used to deliver fuel with low pressure, high pressure part which is used to deliver fuel with
high pressure and ECU control part.
Components of low pressure fuel pipeline
Low pressure fuel pipeline is used to provide sufficient fuel to high pressure fuel pipeline;
and its components are as following:
1. Fuel tank (including screen)
2. Fuel filter (including manual oil feed pump)
3. Low pressure oil feed pump
4. Other low pressure fuel hoses
Fuel tank
Fuel tank must be made up of anti-abrasion material; it should keep 0.3bar pressure under
any kind of working conditions and it can not leak under double of working pressure.
There should be proper hole or safety valve, or take proper measures to make extra high
pressure released according to requirement. Fuel inside of fuel tank will not leak from fuel
tank cap or pressure balance device when there is slight vibration of the vehicle or the
vehicle turns, or the vehicle is parked or running on slope.
Fuel filter (include manual oil feed pump)
Comparing with traditional diesel engine, it needs clearer fuel supplying. If there is impu-
rity inside of fuel, it will damage the fuel system including high pressure pump, fuel injector
etc.. Fuel filter purifies the fuel before fuel reaching to high pressure pump, which can help
the proper working of high pressure pump. The pollutant, impurities and particle may
cause the damage of pump element, fuel supplying valve and fuel injector; so use fuel
filter which can meet the requirement of fuel injection device is a precondition for engine
normal working and service life guarantee. The water in diesel can exist in un-free form
(emulsified oil) or un-free radical form (condensed water generated because of tempera-
ture changes). It may damage the components because of corrosion if these kinds of
water enter into fuel injection system. Similar to other fuel injection system, common rail
system also needs fuel filter with water collecting cavity; it also needs automatic warning
system to excess water content; it is a must to drain water from water collecting cavity
when the warning lamp is lit.
It will cause that engine can not be started or can not work properly if there is fuel over-
flows during running or there is air entering into fuel pipeline when the fuel filter is replaced;
so the manual oil feed pump is installed to discharge air from low pressure pipeline.
Manual oil feed pump, a device to supply fuel to fuel filter, is assembled on the top of fuel
filter, and also it is a device must to be used for the first start of engine. Press manual oil
feed pump until it can not be pressed down anymore before the engine start when the
engine is at the following situations
Manual oil feed pump

Manual oil feed pump is assembled on the top of fuel filter; it is a device to supply fuel to
fuel filter and a device must to be used for the first start of engine. Press manual oil feed
pump until it can not be pressed down anymore before the engine start when the engine is
at the following situations.
1. After fuel is used up
2. After the oil-water separator is drained
3. After fuel filter is replaced
Replacement of fuel filter
1. Intervals of fuel filter replacement: replace it every 15,000km;
2. Intervals of oil-water separator: every ,5000km (same to the time intervals of engine
oil replacement);
3. It is prohibited to use the disassembled fuel filter anymore.
Low pressure oil feed pump
Low pressure oil feed pump is installed at the rear end inside of high pressure pump
housing; it is a kind of gear pump. Low pressure pump supplies fuel from fuel tank to high
pressure pump continuously.
The job of oil feed pump is to supply adequate fuel to high pressure pump, and further
more:
1. Under any working conditions;
2. Under necessary pressure;
3. Last in its whole service life.
Low pressure oil pump is mechanical gear pump and it is assembled at the rear end of
high pressure pump driving by high pressure pump shaft. The main components are two
gears rotating to reverse direction; two gears engaged when they are rotating; so the fuel
is sucked into cavity formed by gear and pump wall and then it is transported to exit
(pressure end). Connection line of rotating gears makes the space between suck end and
pump pressure end airproof to prevent the fuel flowing back.
Fuel supply quantity of gear pump is almost in direct proportion with engine speed; this is
why throttle from intake end can reduce the fuel supplying quantity of gear pump or limit
fuel supplying quantity by overflow valve on exit.
Gear pump is maintenance free. Fill it with fuel from fuel system for first start, and when
the fuel tank is empty, full low pressure pipeline with fuel by manual oil feed pump.
Gear pump
1. Gear
2. Fuel outtake
3. Fuel intake
Low pressure oil feed

pump
Other low pressure fuel hose
Except for steel pipe, the flexible fuel pipe can be protected by anti-flaming woven pipe for
lower pressure part. The arrangement of fuel pipe must avoid mechanical damage, and
also the dropped or evaporated fuel can not congregate nor burn.
Function of fuel pipeline can not be damaged when there is vehicle distortion, engine shift
or similar situations. All fuel pipes must have heat liberation protection measures.
Components of high pressure fuel pipeline
High pressure part produce and reserve sufficient fuel pressure what is need by injector.
Its components are as following:
1. High pressure pump
2. Fuel rail
3. High pressure fuel pipe
4. Fuel injector
High pressure pump
High pressure pump compress fuel to a maximum 1,450bar system pressure and then
fuel enters into pipe like high pressure fuel accumulator (rail) through high pressure pipe.
High pressure pump is the interface of low pressure and high pressure. It can provide
sufficient of high pressure fuel reliably during the whole vehicle service life under all kinds
of working conditions including the extra fuel needed by fast start and fast pressure
building in common rail. High pressure pump produce system pressure continuously
needs by high pressure accumulator (rail). This means it needs not to compress the fuel
for every independent injection process comparing to traditional system.
Fuel is compressed by three plunger pump which are radial arrayed and form 120°angle
each two of them. It only can produce low peak driving torque because every rotation will
produce three times of press stroke, which will keep the stress of pump driving device
evenly. For torque 16Nm, it is only 1/9 of the torque needed by similar distribution pump.
This is to say, comparing to traditional fuel injection system, common rail system has less
load to fuel pump driving device. Increase power of driving fuel pump and set pressure in
common rail is in direct proportion with fuel pump speed (fuel delivery quantity).
Working manner:
Fuel is pumped out from fuel tank by fuel pump passing an oil-water separator, and then
fuel enters into lubrication and cooling fuel pipeline of the high pressure pump through fuel
inlet. Driving shaft with eccentric pulley drives three plungers moving along the shape of
cam. Plungers move downwards because of the fuel pressure (fuel suction stroke). Fuel
intake valve closes when plunger exceeds lower dead center and fuel in pump cavity will
not vent. Now the fuel is compressed and the pressure will exceed the fuel supplying
pressure of oil feed pump. Once the pressure formed reaches to the pressure of common
rail, the fuel out taking valve will open and fuel enters into high pressure circuit. Plunger
pump will continue the fuel supplying until it reaches to top dead center (fuel delivery
stroke). Then pressure will decrease and fuel out taking valve will close. Residual fuel is
decompressed and plunger moves downwards. Fuel in taking valve reopens when the
pressure in pump cavity is lower than fuel delivery pressure, and the fuel pumping process
will restart.
Sectional view of CPIH

Fuel out taking valve
Fuel in taking valve
Working schematic diagram of HP
1. Driving shaft
2. Eccentric cam
3. Plunger pump
4. Fuel in taking valve
5. Fuel out taking valve
6. Fuel in taking
Fuel rail (common rail)
High pressure accumulator (rail) reserves high pressure fuel; at the same time, pressure
fluctuation produced by fuel supply of high pressure pump and fuel injection can be re-
strained. High pressure accumulator is common for all cylinders so it is called as “common
rail”. Common rail can keep its internal pressure unchanged even if there is a large quan-
tity of fuel discharged, because it keeps the fuel injection pressure constant of the injector.
The rail space is full with high pressure fuel forever. It gets the effect of pressure accu-
mulator from compressed fuel by high pressure. The pressure inside of high pressure
accumulator is constant basically when fuel left rail and injected. Also the changes of
pressure produced by high pressure providing pulse fuel supply get balanced. It provides
pressure information to ECU at the same time.
Working schematic diagram of HP
Rail sensor Injector joint High pressure pump joint Fuel injector joint
High pressure fuel pipe
High pressure fuel pipe is used to transport high pressure fuel; it is made of steel and can
bear interval high frequency pressure changes when the engine is at maximum system
pressure. Normally it exterior diameter is 6mm and interior diameter is 2.4mm. The
lengths of the entire high pressure fuel pipe between fuel rail and injector are same; this
means the distances between fuel rail and every injector are same and every bending
point compensates its length difference.
EMS-28
Connect with fuel injector

Engine Electronic Control Maintenance Manual
Connect with high pressure pump

Connect with fuel injector
SECTION V. Electronic Control
 INPUT PARTS
 ECU
 OUT PUT PARTS
Measure and control device of common rail is composed of three main components:
1. Sensor and generator with set value is used to collect running conditions and ex-
pected value. It can transform different physical parameters into electronic signals;
2. ECU changes information to electronic output signal according to specific math cal-
culation method;
3. Execution mechanism transforms electronic signals output by ECU to mechanical

parameters.
Input part
It can also be called as sensor or signal part, and it mainly includes:
 Crankshaft position sensor
 Camshaft position sensor
 Throttle pedal position sensor
 Supercharging pressure, air intake temperature sensor
 Rail pressure sensor
 Coolant water temperature sensor
 Oil-water separator position sensor
 Vehicle speed sensor
 Clutch switch
 Brake switch
 A/C request
 Exhaust brake switch
Piston position inside of combustion chamber decides the time of fuel injection beginning.
Engine piston connects with crankshaft via connection rod. Sensor on crankshaft can
provide all data about piston position. Speed decides the revolutions of crankshaft per
minute. ECU uses the signal from crankshaft speed sensor to calculate an important
variant.
Generation of signal:
There is a magnetic trigger wheel with 60 teeth which connects with crankshaft. In actual
application, there are two teeth missing. This bigger clearance corresponds to the specific
crankshaft position of cylinder No. 1.
Crankshaft speed sensor records the sequence of triggered gear. It is composed of one
piece of permanent magnet and soft iron core with copper loop winding; flux in sensor
changes with the gears passed and clearance to produce a sine alternating current; its
amplitude increases rapidly along the engine speed (crankshaft). It can get sufficient am-
plitude even the speed is 50 rpm.
Calculation of engine speed:
Angle relationship (deviation) between pistons is: crankshaft rotate two complete round
(720°) before every working circulation of cylinder No. 1. If the mutual deviation is even
among pistons, then:
Ignition interval angle (°)＝720°／cylinder numbers
For an engine with 4 cylinders, ignition interval angle is 180°, which is to say, crankshaft
speed sensor must scan 30 gears between two times of ignition. The time interval needed
is called as segmented time, and the average crankshaft speed is engine speed within
segmented time.
Terminal block: 1- signal -, 2- signal +
Resistance: 860 ohm
Crankshaft speed sensor

1.Permanent magnet 2.Sensor housing
3.Engine exterior cover 4.Soft iron core
5.Coil 6.Sense gear
Signal end of crankshaft speed sensor
Crankshaft position
sensor Signal negative end
Shield end
Camshaft position sensor
Camshaft controls air intake valve and air outlet valve of engine; its speed is a half of
crankshaft speed. Camshaft position decides that it is at compression stage and then in-
ject or it is at exhaust stage when piston moves to top dead center. There will be no such
data produced from crankshaft position if it is at starting stage. On the other hand, data
produced by crankshaft sensor is enough to decide the engine status when engine runs
properly. That is to say, ECU can still receive the data about engine working status from
crankshaft sensor even if the camshaft sensor failed during vehicle running.
Camshaft sensor makes sure its position by Hall Effect. A tooth like object made of iron
magnetic material is fixed on the camshaft and rotate together with camshaft. When this
tooth like object passes the semiconductor wafer of camshaft sensor, its magnetic field will
make the electrons perpendicular to semiconductor wafer deflect to current direction. This
will cause an instant voltage signal (Hall Effect) to tell ECU that cylinder No. 1 has entered
into compression stage.
Terminal block: 1 - +5V, 2 –signal +, 3-signal-

Select one from two

circuit designs
Magnetic field
Voltage under control
Rotate direction
switch Computer
Voltage
Constant cur- Impeller Ignition
rent switch switch
Permanent Computer
magnet Vane
switch
Window Voltage
switch
Collector circuit increases to

Switch of around 12V when transistor
transistor changes from connection to
GaAs wafer
disconnection
Amplified signal Stop Con-
with reverse phase nected
Analog Digital
signal Schmitt signal Collector
Amplifier trigger
Emitter
Switch of transistor
Power supply end
Camshaft position
Signal end
sensor
Grounding end
Throttle pedal position sensor
It is different from traditional diesel engine; acceleration signal from driver is not passed to
fuel injection pump through mechanical device anymore, but through throttle pedal posi-
tion sensor checking & recording and then pass it to ECU. Voltage formed on potenti-
ometer of throttle pedal sensor is the function of set value of throttle pedal. The throttle
pedal position of that voltage can be calculated from procedure characteristic curve.
Terminal block: 1- +5V, 2- +5V, 3 -signal 1 grounding, 4- signal 1+ , 5 -signal 2,

grounding, 6- signal 2+.
Sensor power supply 1
Signal 1
Module of throttle Sensor 1 grounding

pedal
Sensor power supply 2
Signal 2
Sensor 2 grounding
Output voltage
Close completely Open completely
Opening degree of throttle pedal
Boost Pressure and Intake Air Temperature Sensor
The boost pressure sensor is connected to the intake pipe and can be used to measure an
absolute pressure of the intake pipe between 0.5-3bar. The sensor is composed of a
pressure unit with two sensor elements, and a evaluation circuit. The sensor elements and
the evaluation circuit are installed on a common ceramic substrate. Each sensor element
has one flare diaphragm with a reference capacity determining the internal pressure. The
diaphragm will move towards a larger or smaller aperture with the function of the inflation
pressure. Pressure-sensitive resistors are on the surface of the diaphragm. When a
pressure is imposed on it, its resistance will change. Such resistors are connected to-
gether to form a resistor bridge, and movement of the diaphragm will change the balance
of the resistor bridge, viz. the voltage of the resistor bridge is a dimension of the boost
pressure. The evaluation circuit is used to amplify the voltage of the bridge circuit and
compensate temperature effects and a linear change of pressure characteristics. An out-
put signal of the evaluation circuit is sent to the ECU. By utilizing the programming char-
acteristic curve, the value of a boost pressure can be figured out.
There is a negative temperature coefficient (NTC) thermistor in the temperature sensor.

This thermistor is connected to a voltage division circuit with a 5V power supply.
The voltage drop of the thermistor is input to the ECU through an analog and a digital
converter (ADC), and is also a dimension measuring the temperature. A characteristic
curve stored in the ECU microprocessor will set the temperature to be a function of a
given voltage.
Terminal block: 1. Pressure signal ground; 2. Temperature signal; 3. +5V; 4 -Pressure

signal
Power supply
Pressure signal
Boost pressure sensor
round
Temperature signal
Rail Pressure Sensor
According to a voltage signal sent to the ECU by the fuel pressure, the rail pressure
sensor must measure the instantaneous pressure of the rail. It should be provided with
high precision and rapid response.
The rail pressure sensor is composed of the following parts:
Integrated sensor elements weld onto the pressure unit;
- A printed circuit board (PCB) with an electronic evaluation circuit;
- A sensor shell with an electric connector.
Fuel oil flows into the rail pressure sensor through a hole in the common rail. An end of the
hole is sealed by a sensor diaphragm. Fuel oil under a high pressure reaches the sensor
diaphragm through a blind hole. A sensor element (semiconductor module) located on this
diaphragm will transform the pressure to an electric signal. Through conductors, such
signal will be sent to the evaluation circuit where the signal will be amplified and sent to
the ECU.
As the shape of the metal layer installed on the diaphragm changes, its resistance will
change accordingly. Such a shape change (it is about 1mm under a pressure of 1,500bar)
caused by an established system pressure will cause the resistance to change and make
the voltage of the 5V bridge formed by resistors change. The voltage will fluctuate be-
tween 0 and 70mv (depending on the pressure imposed), and be amplified to 0.5-4.5V by
the evaluation circuit.
A precise measurement of the rail pressure is critical for efficient operation of the system.
This is one of the reasons why the tolerance for the rail pressure sensor is quite strict in
the process of pressure measurement. In the major conditions, the measurement preci-
sion is approximately ±2% of the full scale reading. Once the rail pressure sensor is
damaged, the pressure relief valve will be triggered by the emergency (alternate) function
and set value.
Terminal block: 1. Pressure signal ground; 2. Temperature signal; 3. +5V;
Power supply
Common rail pressure

sensor
Signal
Ground
Output charge
Cooling Water Temperature Sensor

The coolant temperature sensor is used to inspect the working temperature of an engine;
the ECU will provide an optimum control scheme for the engine according to the tem-
perature. The sensor is installed at the water outlet.
There is a negative temperature coefficient (NTC) thermistor in the coolant temperature

sensor, and it is connected to a voltage division circuit with a 5V power supply.
The voltage drop of the thermistor is input to the ECU through an analog and a digital
converter (ADC), and is also a dimension measuring the temperature. A characteristic
curve stored in the ECU microprocessor will set the temperature to be a function of a
given voltage.
Terminal block: 1. Signal ground; 2. Temperature signal.
Characteristic curve of temperature sensor

(NTC)
Signal
Cooling wa-
ter tem- Ground
perature
sensor
Position Sensor of Oil Water Separator
The position sensor of the oil water separator is used to measure the water content in the
fuel filter; if the water content reaches a certain point, the ECU will control work of the
engine. The sensor is installed at the bottom of the fuel filter.
Position of oil water separator

Signal end of sensor
Oil water separator

Water level sensor
Speed Sensor
The speed sensor sends to the ECU a speed signal, which the ECU will use to calculate
the speed.
Input signal of speed sensor
Clutch Switch
The clutch switch is installed at the clutch pedal and is used to send operation signals of
the clutch pedal to the engine ECU.
Signal of clutch switch
Brake Switch
The brake switch will inspect operation of the brake pedal, and send signals detected to
the engine ECU. The brake switch is provided with two switch structures that are the main
and the auxiliary switches of the brake switch.
When inputting the two signals, the engine ECU will recognize them as normal brake
signals. Such switch signals are related to the accelerator pedal and are used to control
the fuel quantity in the brake process. This indicates that operating the accelerator pedal
will not cause a fault while pedaling the brake; however, operating the brake pedal will
reduce the fuel quantity while pedaling the brake.
Signal of main brake switch
Signal of auxiliary brake switch
A/C Request
The A/C request is an input signal requesting operation of the air-conditioner to control
work of the A/C relay and accelerate the engine speed.
A/C request signal
A/C relay
Exhaust Brake Switch
The exhaust brake switch is an input signal to actuate the exhaust brake, and meanwhile,
together with the brake switch signal and the clutch switch signal, control actions of the
exhaust brake valve.
Exhaust brake switch
Exhaust brake actuator
ECU
The ECU is provided with a metal shell. Sensors, actuators and the power supply are
connected to the ECU through multi-pole plugs. Power supply components directly con-
trolling the actuator are integrated in the ECU. By this way, they can diffuse heat to the
ECU shell in an efficient manner.
Requirements on the ECU include:
- Ambient Temperature: -40 ℃ - +85℃
- Fuel-resistant and anti-lubricant, etc.
- Moisture-resistant
- The mechanical load presents a strict requirement on radiation of electromagnetic

compatibility signals.
The ECU is used to compute signals received from external sensors and limit them on the
permitted voltage level. According to such inputs and those stored characteristic figures,
the microprocessor can work out the duration and the accurate point of oil injection, and
translate them to a time signal curve. Specific requirements on precision and dynamic
response of the engine require a strong computing ability.
The driver stage is triggered by an output signal and provides a proper power to the ac-
tuating element to control the common rail pressure and the high pressure pump elements.
In addition, the actuating element can control functions of the engine (such as the exhaust
gas circulation actuator, boost pressure actuator and the relay of electric fuel pump) and
other auxiliary functions (such as the blower relay, auxiliary heater relay, electric heater
plug relay and the air conditioner). The driver stage is designed with short protection and
over current protection. Such faults and an open circuit will be reported to the microproc-
essor. The trouble-shooting function of the fuel injector driver stage can recognize a wrong
signal curve. Moreover, there are a series of output signals that may be sent to other
automotive systems through different interfaces. In the specific safety concept frame, the
ECU can monitor the whole injection system.
Triggering of the fuel injector has a special requirement on the driver stage. In the fuel
injector, the current from the driver stage generates a magnetic force in the magnetic coil
imposing on the high pressure hydraulic system. To ensure a precise tolerance and high
repeatability of injection quantity, this coil must be triggered before the gradient current
wave. This requires a high voltage formed by the ECU.
The triggering time (injection time) can be divided into the starting current phase and the
maintaining phase by the current control circuit. It must run in a precise manner to ensure
repeatable oil injection under all working conditions. In addition, it must also reduce en-
ergy losses in the ECU and the fuel injector.
Terminal Terminal
Description Description
No. No.
Terminal A
A01 Fuel injector 3 High A31 Fuel injector 2 Low
A02 Fuel injector 2 High A32
A03 A33 Fuel injector 4 Low
A04 A34
A05 A35
A06 A36
Shield cord of crankshaft position
A07 A37
sensor
Common rail pressure sensor
A08 A38
signal-
A09 A39
Boost pressure sensor
A10 A40
signal+
Cooling water temperature
A11 Came shaft position sensor +5V A41
sensor signal-
Crankshaft position sensor sig-
A12 A42
nal-
A13 Boost pressure sensor +5V A43
sensor signal+
A14 A44
A15 A45
A18 A48
Power supply end of fuel meter-
A19 A49 Signal of fuel metering unit
ing unit
Cam shaft position sensor
A20 Cam shaft position sensor signal- A50
signal+
A21 A51
A22 A52
Boost pressure sensor signal Intake air temperature
A23 A53
GND signal+
A24 A54
A25 A55
A26 A56
Crankshaft position sensor sig-
A27 A57
nal+
Common rail pressure sensor Cooling water temperature
A28 A58
+5V sensor signal+
A29 A59
A30 A60
Terminal K
K01 Positive pole of battery K48
K02 Negative pole of battery K49 Closing wire
K04 Negative pole of battery K51
Feedback of warming-up
time
K06 Negative pole of battery K53
K07 K54 A/C request signal
K08 Accelerator pedal sensor 2 GND K55
K09 Accelerator pedal sensor 1 signal K56
K10 K57
K11 K58 Clutch Switch
K12 K59
K13 K60
K14 K61
K15 K62
K16 K63
K17 Main brake switch signal K64
K18 K65
Exhaust brake switch sig-
K19 K66
nal
K20 K67
K21 K68 A/C relay control
K22 K69
K23 K70
K24 K71
K25 K line communication K72 Main relay control
K26 K73
K27 K74 Closing wire
K28 Ignition switch ON K75 Speed signal
K29 Exhaust brake actuator K76
K30 Accelerator pedal sensor 1 GND K77
K31 Accelerator pedal sensor 2 signal K78
K32 K79
Auxiliary brake switch sig-
K33 K80
nal
K34 K81
K35 K82
K36 K83
K37 K84
K38 K85
K39 K86
K40 Oil water separator signal K87
K41 K88
K42 K89
K43 K90
K44 K91 Malfunction indicator light
Accelerator pedal sensor 1 power
K45 K92 Warming-up indicator light
supply
Accelerator pedal sensor 2 power
K46 K93 Warming-up relay control
supply
K47 K94
Output parts
These parts are also called as actuator parts, mainly including:
 Fuel injector
 Oil metering valve
 Glow plug control unit (GCU)
 Malfunction indicator light (MIL)
 Diagnostic interface
 ECU relay
 Warming-up indicator
 A/C relay
 Exhaust brake valve
Fuel injector
To realize an efficient fuel injection beginning and a precise injection point, the common
rail system adopts a specialized fuel injector with hydraulic servos and electric control
elements (electromagnetic valves). At the beginning of oil injection, the fuel injector will
adopt a high starting current to open the electromagnetic valve quickly. The control current
will not reduce to the smaller steady current until the needle valve of oil nozzle reaches its
maximum travel and the oil nozzle completely opens. Now the injection quantity depends
on the starting time and the pressure in the common rail. After the electromagnetic valve is
closed, the oil supply process ends up.
The fuel injection beginning and the injection quantity are controlled by electric fuel injec-
tors. Such fuel injectors replace an fuel injector assembly (a nozzle and an injector body).
Just like the fuel injector assembly of a direct injection diesel engine now, a holder is used
on the cylinder head when the fuel injector is installed. That is, the common rail injector is
installed on the existing direct injection diesel engine and no major change is needed for
the cylinder head.
Design Structure
An fuel injector (as shown in the figure) can be divided into several function blocks:
- Hole type nozzle;
- Hydraulic servo;
- Electromagnetic valve.
As shown in the figure, fuel oil will flow from the high-pressure connecting pipe (4),
through the oil feed groove (10) to the nozzle: through the oil feed hole (7) to the valve
control chamber (8). The control chamber is connected to the oil return line (1) via the
drain hole (6), and the drain hole is opened and closed by the electromagnetic valve. After
the drain hole is closed, the hydraulic pressure on the valve control plug (9) exceeds the
force on the shoulder of nozzle needle (11). Therefore, the needle is pressed into the
needle seating and seal up the high-pressure channel towards the combustion chamber.
When the electromagnetic valve of the fuel injector is triggered, the drain hole opens. In
this way, the pressure in the control chamber descends and the force acted on the plug
decreases, too. Once the hydraulic pressure is smaller than the force on the shoulder of
needle, the nozzle needle will open and fuel oil will be injected into the combustion
chamber through the nozzle. The reason why the hydraulic gain system is applied to in-
directly control the nozzle needle is that the electromagnetic valve is unable to produce a
force to open the needle quickly. The control quantity needed to open the nozzle needle is
excluded from the actual injection quantity, and such oil quantity is lead back to the oil
return line through the drain hole in the control chamber. Except for the control quantity,
losses of fuel oil and the leak amount at the nozzle needle and the valve plug will return to
the oil tank through the oil return line and an oil duct connected to the overflow valve.
According to operation of the engine and the pressure produced by the high-pressure oil
pump, working of the fuel injector can be divided into four stages:
- The fuel injector is closed (due to a high pressure).
- The fuel injector is opened (to inject oil).
- The fuel injector is in full open.
- The fuel injector is closed (oil injection ends up).
Such working stages are caused by the pressure on the fuel injector components. When
the engine is off and the common rail has no pressure, the nozzle spring will close the fuel
injector.
The fuel injector is closed (static state):

In the static state, the electromagnetic valve has not been triggered, and therefore the fuel
injector is closed (a). While the drain hole is closed, the valve spring will press the ball
valve of the armature onto the return orifice, and a high pressure of the common rail will
form in the valve control chamber. Later on, the same pressure will form in the nozzle
chamber. The pressure on the end face of the control plug formed by the rail pressure and
the nozzle spring force are opposite to the opening force on the conical bearing surface of
the needle by fuel oil, and keep the needle in the closed status.
The fuel injector is opened (to inject fuel):
The nozzle is at the static position, and the electromagnetic valve is triggered by the
starting current to ensure a quick open-up (b). The force produced by the triggering so-
lenoid exceeds the spring force, and the armature opens the drain hole. Almost at the
same time, the high starting current reduces to a low maintaining current required for the
electromagnet. Since the air gap of the magnetic circuit becomes small now, this change
is possible. When the ball valve of the drain hole opens, fuel oil can flow from the valve
control chamber into the empty chamber above it, and then return the oil tank through the
oil return line. The drain hole causes an unbalanced pressure and makes the pressure in
the valve control chamber decrease. By this way, the pressure in the valve control
chamber is smaller than the rail pressure maintained in the nozzle chamber. Since reduc-
tion of the pressure in the valve control chamber reduces the force on the control plug, the
nozzle needle begins to open up and inject oil.
The open-up speed of the nozzle needle depends on the flow difference between the
drain hole and the oil feed hole. The control plug reaches its top dead and is maintained
by a layer of oil film, which is formed by the oil flow between the drain hole and the oil feed
hole. Now, the nozzle is completely opened and fuel oil is injected to the combustion
chamber with a pressure almost equal to the pressure in the common rail. The pressure
distribution in the nozzle is similar with the pressure distribution at the start-up stage.
Oil Injector
a The oil injector is closed. (Static status) b The oil injector is opened. (Oil injection)
1 Oil return line 2 Electric joint 3 Control unit (electromagnetic valve)
4 Oil feed hole on the side of the rail (high pressure) 5 Ball valve 6 Drain hole
7 Oil feed hole 8 Valve control chamber 9 Valve control plug
10 Oil feed groove 11 Nozzle needle
The fuel injector is closed (oil injection ends up):
When the electromagnetic valve is no longer triggered, the valve spring will press down
the armature and the ball valve will close the drain hole. The armature is designed with a
two-piece structure. Although the armature block is lead by the pressure shoulder when
moving down, it can rebound with the return spring, and therefore it will not impose a
downward force to the armature and the ball valve.
Closing of the drain hole makes fuel oil enter the control chamber through the oil feed hole
to form a pressure. This pressure is the same as the rail pressure, and increases the force
on the end face of the control plug. The sum of this force and the spring force is larger
than the pressure in the nozzle chamber and causes the nozzle needle to close up.
The closing speed of the nozzle needle depends on the flow through the oil feed hole.
Once the nozzle needle touches its seating, oil injection stops.
Matching of Oil Distributor
In one of the following conditions, it is necessary to match the fuel injector:
Replace the fuel injector;
Replace the ECU;
After repair, the installation sequence number of the fuel injector is disturbed.
During the process of matching, input the match code on the upper part of the fuel injector
(as shown in the following figure) to the diagnostic system in order. For the detailed oper-
ating procedure, refer to the instruction for the diagnostic system.
Oil Injector 1 “High”
Cylinder 1
Oil Injector 1 “Low”
Cylinder 4

Cylinder 3

Cylinder 2
Inlet Metering Valve
Inlet metering valve, the regulation requirement of which is controlled by ECU, is installed
at the oil inlet at the high-pressure stage of the high-pressure pump to regulate fuel supply
and pressure. The control coil of the metering valve is closed when not energized, thus
cutting off oil supply to the pump plunger.
ECU increase or reduce oil supply by changing the sectional inlet area of the metering
components via pulse signals.
Low pressure pump

Electromagnetic coil
Fuel
Filters Spring
High Voltage Pistons
Oil outlet
0-ring
Fuel
Low pressure pump
Power supply end of fuel metering unit
A high-pressure fuel pump

with a metering unit
Signal of fuel metering unit
CP1H and CP4.X Metering devices
Oil quantity Fuel to high-pressure pump
Full load oil
Oil properties
Idle oil
Amp
Glow plug control Unit (GCU)
The glow plug control unit is used to ensure effective cold start and shorten the warm-
ing-up time, which is closely related to exhaust emission. Warming-up time is a function of
coolant temperature. During the starting or the operation of the engine, the working time of
the glow plug is defined by a series of other parameters; including the fuel volume injected
and engine revolution. The control of glow plug is carried out by the use of a power relay.
The main component of the glow plug is a tubular heating element which is hermetically
sealed inside to resist corrosion and heat. The heating element is a set of spiral wires
embedded in magnesium oxide powder (see picture). The spiral wires consist of two se-
ries-wound resistors, a heating coil and a control coil, located in the tip of the heating tube.
The heating coil maintains a resistance value almost independent of temperature while
the control coil is made of positive temperature coefficient (PTC) material. In the new
generation of glow plug (GSK2), the rate of coil resistance increase, as the temperature
rises, is bigger than that of the usual glow plug. The new glow plug GSK can quickly reach
its ignition temperature (850 degrees in 4 seconds) and its low constant temperature
(which is confined within a critical value) demonstrates a superb performance. Therefore,
the GSKZ glow plug remains energized for three minutes after the engine starts. This
post-ignition property reduces noise and emission during the starting and the warming-up
period.
The glow plug control instrument controls the glow plug via a power relay and an electrical
switch group, which control the heating time of the plug as well as protectors and monitors.
More advanced control instruments can identify the faults of individual glow plug with their
diagnostic capabilities and display them to the driver. The input terminal of the control
instrument adopts multi-level sockets to connect with ECU. In order to avoid voltage drop,
the series circuit connected to glow plug uses threaded taper pin or plug.
The start switch of the glow plug controls the pre-heating process and the start-up. When
the key switch is toggled to the "ON" position, pre-heating process starts. When the
heating control light goes out, the glow plug has reached sufficient temperature, and the
start-up process begins. Immediately, the injected fuel droplets are atomized in the com-
bustion chamber with compressed air, and the released heat makes the combustion
process continue.
After the successful start-up, the post-heating in the warming-up process facilitates a
non-disruptive (thus less smoke is generated) speed boosts and idle run. This will help
reduce combustion noise in cold-start. If the start-up fails, the protection circuit of the glow
plug is disconnected to prevent excessive battery discharge.
Fuse 5
Take off glow plug
Warming-up relay
Warming-up time feedback
Warming-up control unit
Malfunction Indicator Light (MIL)
MIL is located on the instrument panel and directly powered by battery voltage. Engine
control module (ECU) lights the MIL by grounding its control circuit. When the ignition
switch is on before the engine starts, the MIL turns on and goes off after five seconds.
Functions of MIL:
MIL informs the driver of a failure and the vehicle needs maintenance as soon as
possible.
MIL lights up when under test.
If diagnostic procedures requested the MIL be turned on, a fault diagnosis code would
be saved. The MIL lights up.
When the ignition switch is on but the engine is not running, MIL will be switched on
for five seconds.
When the engine is turned on, the MIL goes out.
If the self-diagnostic system detects a fault, MIL will remain lighted.
If no malfunction, MIL will be off.

System malfunction light
Diagnostic Interface
It is a standard OBD interface for communication and data transmission with ECU.
Ground Ground
Data
Diagnosis communication interface K line

ECU Relay
The relay supplies power to the ECU and is controlled by the ECU.
Interface K
Battery cathode+Ra Fuse 2

Fuse 1
Battery cathode+Rb
Main relay 2
Fuse 3
Battery cathode+Rc Length≤1.5m Ignition
Main relay
Fuse 4
Warming-up Indicator
Working indicator for the glow plug control unit by ECU control.
Warming-up time
time
indicator
A/C Relay
ECU receives request signal from A/C relay and issues a control signal to the relay.
Air conditioner request signal
AC relay
Exhaust brake valve
The Exhaust brake valve is the EUC’

S output control for the exhaust brake.
Exhaust brake actuator
Fuel Heating Control
When the oil temperature falls below a certain value, the temperature switch on the fuel
filter closes automatically and at the same time, the heater starts heating the oil which
flows through the filter and stops automatically when a certain temperature is reached.
Fuel heating relay
Temperature switch
Heater
Electronic Control System Malfunction and Error Codes
1. Self-diagnosis of the electronic control system
A self-diagnostic function is integrated into the Electronic control unit (ECU). Once a
malfunction is detected, ECU will produce and record a malfunction code and, according
to the seriousness of the malfunction, automatically adopts one of the different malfunc-
tion protection strategies. In most cases, the fail safe strategy is capable of keeping the
engine working under reduced power. In few extreme cases, fail safe strategy ceases oil
injection, and then the engine stops.
2. Error code reading
A special fault detection instrument is used to read error codes.
3. Error code removal
After maintenance, error codes are removed through the fault detection instrument. When
the fault is of a rare occurrence type and when it is automatically removed, the fault indi-
cator light goes out after certain working condition cycles.
4. Fault indicator
When the ignition switch is turned on, the system will carry out self-inspection of related
parts and components, and, if trouble-free, the fault light will go off automatically after a
period of time, if it does not, the system is in fault.
Table of Malfunction Codes
0 The exhaust brake feedback is inconsistent with control order from ECU
P0016 Deviation in relative positions of phase sensor and crankshaft sensor
P0045 The control of supercharger actuator is open-circuited
P0046 Overheating of ECU internal drive module for supercharger actuator control
wire
P0047 The turbocharger actuator control wire is short-circuited to ground.
P0048 The turbocharger actuator control wire is short-circuited to a high potential.
P0069 Supercharger pressure sensor drift
P0071 Invalid ambient temperature sensor signal from CAN.
P0072 Output voltage of ambient temperature sensor drops beyond the lower limit
(short-circuit to ground)
P0073 Output voltage of ambient temperature sensor exceeds the upper limit (con-
nection open-circuit, or is short-circuited to a high potential)
P0087 Fuel pressure drops beyond the lower limit
P0088 Fuel pressure exceeds the upper limit
P0097 Low inlet temperature sensor voltage low (connection is short-circuited to
ground )
P0098 High inlet temperature sensor voltage (connection open-circuit, or is
short-circuited to a high potential).
P0100 The unmodified air mass flow signal from the air flow meter is too strong or too
weak (connection open-circuit or short-circuit).
P0101 The modified air mass flow signal from the air flow meter is too strong or too
weak.
P0102 Negative drift of air mass flow meter
P0103 Positive drift of air mass flow meter
P0104 Zero drift of air mass flow meter
P0110 The supplementary air temperature sensor on air mass flow meter short-circuit
or open-circuit
P0112 Temperature measured by the supplementary air temperature sensor on air
mass flow meter is too low.
P0113 Temperature measured by the supplementary air temperature sensor on air
mass flow meter is too high.
P0115 Invalid cooling water temperature signal from CAN.
P0116 Dynamic characteristics of water temperature sensor are unauthentic.
P0117 Output voltage of cooling water temperature sensor is lower than the lower limit
(connection short-circuit to ground).
P0118 Output voltage of cooling water temperature sensor is higher than the upper
limit (connection open-circuit, or is short-circuited to a high potential).
P0122 The output voltage of accelerator pedal potentiometer 1 exceeds the lower limit
P0123 The output voltage of accelerator pedal potentiometer 1 exceeds the upper limit
P0128 Static characteristics of water temperature sensor are unauthentic.
P0182 Fuel temperature sensor output voltage is too low (connection is short-circuited
to ground).
P0183 Fuel temperature sensor output voltage is too high (connection open-circuit, or
is short-circuited to a high potential).
P0191 Large rail-pressure sensor positive drift.
P0192 Rail pressure sensor output voltage is higher than the lower limit (connection is
short-circuited to ground)
P0193 Rail pressure sensor output voltage is higher than the upper limit (connection
open-circuit, or is short-circuited to a high potential).
P0194 Large rail pressure sensor negative drift
P0195 Invalid oil temperature signal from CAN.
P0197 Oil temperature sensor output voltage is lower than the lower limit.
P0198 Oil temperature sensor output voltage is higher than the upper limit.
P0201 1# cylinder injector open-circuit
P0222 Accelerator pedal potentiometer 2 output voltage exceeds the lower limit
P0223 Accelerator pedal potentiometer 2 output voltage exceeds the upper limit
P0234 Actual supercharged pressure is too strong relative to control target
P0235 Invalid supercharged pressure signal from CAN
P0237 Supercharged pressure sensor output voltage exceeds the lower limit (connec-
tion is short-circuited to ground)
P0238 Supercharged pressure sensor output voltage exceeds the upper limit (connec-
tion open-circuit, or is short-circuited to a high potential)
P0251 Metering unit control line open circuit
P0252 Overheating of the internal drive circuit of the metering unit’
s ECU
P0253 Metering unit’
s control line is short-circuited to ground
P0254 Metering unit’
s control line is short-circuited to a high potential
P025C Not applicable
P025D Not applicable
P0261 The low-end of 1# cylinder injector is short-circuited to the high-end
P0262 The low-end of 1# cylinder injector is short-circuited to a high potential
P0263 Other errors of 1# cylinder injector
P0265 The low-end of 2# cylinder injector is short-circuited to a high potential
P0266 Other errors of 2# cylinder injector
P02683 The low-end of cylinder injector is short-circuited to a high potential
P02693 Other errors of cylinder injector
P02704 The low-end of cylinder injector is short-circuited to the high-end

P0299 Actual supercharged pressure is too weak relative to control target
P0300 Fire in multi-cylinders
P0301 Fire in 1# cylinder
P0335 No crankshaft sensor signal
P0336 Wrong crankshaft sensor signal
P0340 No phase sensor signal
P0341 Wrong phase sensor signal
P0380 Heating plug operates without ECU request.
P0382 Heating plug doesn’
t operate at ECU request.
P0383 ECU’
s control line for heating plug is short-circuited to ground.
P0384 ECU’
s control line for heating plug is short-circuited to a high potential
P0401 Actual fresh air feed is more than that the EGR system preset.
P0402 Actual fresh air feed is less than that the EGR system preset.
P0403 The internal drive module of the ECU of EGR valve actuator’
s control line is
overheated.
P0404 EGR valve actuator’
s control line is open-circuited.
P0405 Voltage of EGR valve position sensor exceeds the lower limit (connection is
short-circuited to ground).
P0406 Voltage of EGR valve position sensor exceeds the upper limit (connection
open-circuit, or is short-circuited to a high potential)
P0475 The control wire of exhaust brake valve open-circuited.
P0476 ECU internal drive module of exhaust brake valve.
P0477 The control wire of exhaust brake valve is short-circuited to ground.
P0478 The control wire of exhaust brake valve is short-circuited to a high potential.
P0480 ECU’
s control wire for fan No.1 is open-circuited.
P0481 ECU’
s control wire for fan No.2 is open-circuited.
P0483 Internal drive module of ECU’
s control wire for fan No.1 is overheated.
P0484 Internal drive module of ECU’
s control wire for fan No.2 is overheated.
P0487 Control line for throttle valve actuator is open-circuited.

P0488 The internal drive module of throttle valve actuator ECU is overheated.
P0489 The control wire of EGR valve actuator is short-circuited to ground.
P0490 The control wire of EGR valve actuator is short-circuited to a high potential.
P0500 Speed sensor acquisition hardware errors
P0501 Speed sensor signal is unauthentic.
P0503 Speed sensor exceeds the upper limit.
P0504 Signals from the main and the additional brake pedals are unauthentic.
P0513 Inconsistencies between the sent and received anti-theft signals.
P0520 Invalid oil pressure signal from CAN
P0521 Unauthentic high oil pressure
P0522 Oil pressure sensor output voltage is lower than the lower limit (connection is
short-circuited to ground)
P0523 Oil pressure sensor output voltage is higher than the upper limit (connection
open-circuit, or is short-circuited to a high potential)
P0524 Incredibly low oil pressure
P0530 ECU internal receiver circuit fault of the duty cycle type air-conditioner’
s pres-
sure signal
P0531 The cycle of the pressure signal of the duty cycle type air-conditioner exceeds
the upper or lower limit or is in special failure mode.
the lower limit.
the upper limit.
P0562 Low battery voltage
P0563 High battery voltage
P0571 Brake pedal signal from the CAN is unauthentic
P0575 Cruise request is unauthentic
P0607 ECU internal control chip error
P060A ECU internal chip CJ940 communication error
P060B Error of ECU internal analog-digital conversion module
P060C ECU internal watchdog chip detection error
P0611 Times of injection restricted
P0615 ECU open-circuited to starting motor’
s control line or drive module overheating
P0616 ECU control line on starting motor is short-circuited to ground.
P0617 ECU control line on starting motor is short-circuited to a high potential.
P0627 Control line for pre-fuel pump is open-circuited.
P0628 Control line for pre-fuel pump is short-circuited to ground.
P0629 Control line for pre-fuel pump is short-circuited to a high potential.
P062A Internal output modules of ECU of pre-fuel pump control line overheating
P062B Injector driver chip error
P062F ECU internal EEPROM read-write error
P0638 Feedback signal of the throttle valve is inconsistent with ECU request.
P0642 Low sensor supply voltage 1
P0643 High sensor supply voltage 1
P0645 Air conditioner’s ECU control wire is open-circuited or ECU internal drive mod-
ule is overheating.
P0646 Air conditioner’
s ECU control wire is short-circuited to ground.
P0647 Air conditioner’
s ECU control wire is short-circuited to a high potential.
P0650 Connection error (short-circuited, open-circuited) of ECU to OBD malfunction
light
P0660 Control wire for variable swirl ratio actuator is open-circuited.
P0661 Control wire for variable swirl ratio actuator is short-circuited to ground
P0662 Control wire for variable swirl ratio actuator is short-circuited to a high potential
P0670 ECU control wire for glow plug is open-circuited or driver modules are over-
heating.
P0686 Main relay opens too early.
P0687 Main relay opens too late.
P0691 ECU control wire for fan 1 is short-circuited to ground.
P0692 ECU control wire for fan 1 is short-circuited to a high potential.
P0693 ECU control wire for fan 2 is short-circuited to ground.
P0694 ECU control wire for fan 2 is short-circuited to a high potential.
P0704 Clutch signal is unauthentic
P0856 Not applicable
P100D Coolant temperature and oil temperature is fairly unauthentic.
P1011 Positive deviation of rail pressure controller exceeds the upper limit.
P1012 Positive deviation of rail pressure controller severely exceeds the upper limit.
P1013 Negative deviation of rail pressure controller seriously exceeds the lower limit.
P1014 Fuel pressure value is unauthentic when the engine operates in reverse towing
mode
P1100 Air mass flow meter software modified excessively
P1101 The analog output voltage of the supplementary air temperature sensor on air
mass flow meter is too high or too low
P1102 Duty cycle output signal of the supplementary air temperature sensor on air
mass flow meter is too high or too low
P1103 Cooling water temperature and oil temperature sensor signals are unauthentic.
P1106 The cycle of the duty cycle’
s output signal of the supplementary air temperature
sensor on air mass flow meter is too high.
P1107 The cycle of the duty cycle’
s output signal of the supplementary air temperature
sensor on air mass flow meter is too low.

P110A Not applicable
P110B Not applicable
P110C Not applicable
P1112 Water temperature error relative to credibility inspection by temperature sensor
on air flow meter
P1200 Excessive positive correction value of injector 1
P1201 Excessive negative correction value of injector 1
P120A Excessive positive correction value of injector 6
P120B Excessive negative correction value of injector 6
P120C Excessive dynamic positive correction value of injector 1
P120D Excessive dynamic negative correction value of injector 1
P120E Excessive dynamic positive correction value of injector 2
P120F Excessive dynamic negative correction value of injector 2
P1210 Excessive dynamic positive correction value of injector 3
P1211 Excessive dynamic negative correction value of injector 3
P1223 High-end short-circuit of injector
P1224 Injector low-end short-circuit to ground
P1225 Other errors of injector
P1229 Injector open-circuited
P122A Other errors of injector
P122B High-end short-circuit of injector (not applicable temporarily, only for cylinder 6)
P122C Injector low-end short-circuit to ground (not applicable temporarily, only for cyl-
inder 6)
P122D Other errors of injector (not applicable temporarily, only for cylinder 6)
P122E Other errors of injector (not applicable temporarily, only for cylinder 6)
P122F Other errors of injector (not applicable temporarily, only for cylinder 6)
P1230 Other errors of injector (not applicable temporarily, only for cylinder 6)
P1231 Injector open-circuited (not applicable temporarily, only for cylinder 6)
P1232 Other errors of injector (not applicable temporarily, only for cylinder 6)
P1233 Other errors of cylinder injector 1
P123A Other errors of cylinder injector 3
P123B Other errors of cylinder injector 3
P123C Other errors of cylinder injector 4
P123D Other errors of cylinder injector 4
P123E Other errors of cylinder injector 4
P123F Other errors of cylinder injector 5
P12FF Not applicable
P1562 Air flow meter supply voltage is too high or too low.
P1601 ECU connection wire to dashboard cooling water temperature is short-circuited
to a high potential.
P1602 ECU connection wire to dashboard cooling water temperature is short-circuited
to ground.
P1603 ECU connection wire to dashboard cooling water temperature open-circuited.
P1604 Overheating of internal driver module of ECU connection to dashboard cooling
water temperature.
P1605 ECU to dashboard engine speed connection is short-circuited to a high poten-
tial.
P1606 ECU to dashboard engine speed connection is short-circuited to ground.
P1607 ECU to dashboard engine speed connection is open-circuited.
P1608 ECU to dashboard warming-up indicator connection is short-circuited to a high
potential.
P1609 ECU to dashboard warming-up indicator connection is short-circuited to ground.
P160A ECU to dashboard warming-up indicator connection is open-circuited.
P160B Overheating of internal driver module of ECU connection to dashboard warm-

ing-up indicator
P160C Error of ECU internal analog-digital conversion module
P1613 Excessive power-on time detected by overrun monitor
P1614 Overrun monitor detects incredible speed
P1616 Watchdog error, shutdown failure.
P1617 Error of excessive high voltage internal power supply, shutdown failure.
P1618 Error of excessive low voltage internal power supply, shutdown failure.
P1619 ECU connection to system malfunction light is short-circuited to a high potential.
P161A ECU connection to system malfunction light is short-circuited to ground.
P161B ECU connection to system malfunction light is open-circuited.
P161C Drive module of ECU connection to system malfunction light is overheated.
P161D Vehicle data damaged.
P161E Vehicle data not available.
P161F Not applicable
P1620 The drive module of variable swirl ratio actuator overheating
P1621 ECU connection to dashboard fuel consumption rate signal is short-circuited to
a high potential.
P1622 ECU connection to dashboard fuel consumption rate signal is short-circuited to
ground.
P1623 ECU connection to dashboard fuel consumption rate signal is open-circuited.
P1624 Overheating of internal driver module of ECU connection to dashboard fuel
consumption rate signal
P1625 ECU connection to dashboard exhaust brake indicator is short-circuited to a
high potential.
P1626 ECU connection to dashboard exhaust brake indicator is short-circuited to
ground.
P1627 ECU connection to dashboard exhaust brake indicator is open-circuited.
P1628 Overheating of internal driver module of ECU connection to dashboard exhaust
brake indicator
P1629 Throttle valve position sensor error
P1630 Software reset
P1637 Excessive high voltage of ECU internal power supply module
P1638 Excessive low voltage of ECU internal power supply module
P2135 Throttle accelerator pedal potentiometer 1 and 2 are unauthentic in comparison.
P2141 Control wire of throttle actuator is short-circuited to ground.
P2142 Control wire of throttle actuator is short-circuited to a high potential.
P2157 Invalid speed signal from CAN
P2226 Invalid atmospheric pressure sensor signal from CAN
P2228 Atmospheric pressure sensor output voltage is too low1.

P2229 Atmospheric pressure sensor output voltage is too high.
P2264 Error of water level sensor on oil-water separator of the diesel filter
P2267 Water full in oil-water separator of the diesel filter
P2299 Press simultaneously the accelerator and the brake pedal.
P245A EGR cooler bypass valve for the implementation of the Line of Control to pave
the way
P245B Overheating of drive module for control wire of EGR cooler bypass valve ac-
tuator
P245C Control wire of EGR cooler bypass valve actuator is short-circuited to ground.
P245D Control wire of EGR cooler bypass valve actuator is short-circuited to a high
potential.
P2517 Voltage signal of pressure sensor of simulation type air-conditioner exceeds the
lower limit (is short-circuited to a low potential).
P2518 Voltage signal of pressure sensor of simulation type air-conditioner exceeds the
upper limit (is short-circuited to a high potential).
P2519 Invalid air-conditioner switch signal from CAN
P2530 Stop button stuck
P2533 Key switch error T15CD
U0404 Unauthentic TSC request
P0594 Power supply segment circuit fault (open-circuit) of cruise control lamp
P0595 Power supply segment circuit fault (short-circuit to ground) of cruise control
lamp
P0596 Power supply segment circuit fault (short-circuit to battery jar)of cruise control
lamp
P0633 Anti-theft program writing error
U0100 ECM confirms no signal status
U0101 TCM confirms absence status
U0167 When read ImmCtl (maximum fault), EEPROM error / ICM communication
time out Fault
U0426 Response error from ICMF (ICM response fault)
U1001 BCM confirms mute (no signal) status
U1002 BSM confirms absence status
U1003 CAN Bus closed (CAN confirms the closed status)
SECTION VI. Common Malfunctions and Troubleshooting
Fault Cause Information

K49 and K74 cable is
Anti-theft System
open-circuited.
Power supply voltage is lower than
Power supply voltage
10 V.
Main Relay Poor contact of main relay
Fuse ECU fuse burnt out
Engine speed sensor No speed sensor signal
Low voltage oil circuit blocked or
Fuel System
Engine can not start contains air
Camshaft position sensor No camshaft position sensor signal
Warming-up circuit or component

Warming-up circuit
failure
Track pressure sensor No track pressure sensor signal
Fuel control valve No fuel control valve signal
Injector Injector damaged
Control Unit Control unit damaged
Fuse, wiring harness
Loose, poor contact
connector
Ignition Switch Poor contact point
Engine flameout but Fuel Fuel incorrect
could start again Low pressure oil line Blocked or contain air
High pressure oil line Incorrect pressure control
Loose line connections or poor
Injector
contact
Battery voltage Battery voltage is less than 10 V.
Starter Low starter speed
Fuel Low fuel grade
Low pressure oil line
Blocked or contains air
system
High-pressure oil line
Incorrect Pressure Control
Difficult to start system
Injector Working poor or control problem
Warming-up system Do not work at low temperature.
Coolant temperature
No signals or incorrect signals
sensor
Cylinder compression pressure is
Engine mechanical part
too low.
Excessive engine idling Accelerator pedal sensor No accelerator pedal signal or
wrong signal
Coolant temperature
No signals or incorrect signal
sensor
Knocking in Warm- Line connections loose or poor
ing-up and acceleration Injector
contact
Injector drip
Fuel Low fuel grade
Blocked or contains air
system
Line connections loose or poor
Injector
contact
Idle wobbling
Injector drip
High-pressure oil line Hyperbaric excessive pressure
system fluctuations
Individual cylinder compression
pressure is too low.
Intake System Air Filter or intercooler blocked
Insufficient engine Fuel Poor fuel quality
power Low pressure oil line
Poor oil supply or low pressure
system
Turbocharger Supercharged pressure is too low.
Accelerator pedal position Improperly located or incorrect
sensor signals
Exhaust bypass valve Open prematurely
Exhaust brake In a open state
Coolant temperature
Incorrect signals
sensor
Supercharged pressure
Incorrect signals
sensor
Track pressure sensor Incorrect signals
High-pressure oil line Pressure too low in high pressure
system oil line
too low.
Wrong Valve Clearance
Coolant temperature
Incorrect signals
sensor
Engine let out blue or Blocked or contains air
system
white smoke
Warming-up system No operation at low temperature
Lubricant Poor quality or too high oil level
Engine mechanical sys- Burning Oil
tem
engine running black
Intake System Air Filter or intercooler blocked
smoke
Coolant temperature
No signals or incorrect signal
sensor
Turbocharger Supercharged pressure is too low.
too low.
Valve Clearance wrong
Coolant temperature
Engine overheating No signals or incorrect signal
sensor
Insufficient revolution or fan clutch
Cooling fan
damaged
Engine mechanical sys-
Thermostat can not be opened.
tem
SECTION Ⅱ
CHASSIS
Clutch
Clutch equipment
General
Main technical parameters
Clutch assembly
Clutch control equipment
Clutch master cylinder
Clutch cylinder
Troubleshooting
Clutch
General
Clutch assembly
Clutch pressure plate assembly Clutch slave disc assembly

Clutch
Clutch cylinder
Clutch
Main technical parameters
Slave disc
Type Dry single diaphragm type with damping spring
Size Ф 250mm
Quantity of damping springs 4
Friction disc
ID×OD 160×250
Quantity × thickness 2×3.5
Pressure plate
Type Diaphragm spring
Max. pressing force 6276N
Hydraulic cylinder
Clutch master cylinder bore × stroke Ф 19.05×35 (mm)
Clutch cylinder bore × stroke Ф 26.99×19.05 (mm)

Clutch
Clutch assembly
Disassembling drawing
Disassembling sequence
1. Transmission assembly; 2. Clutch pressure plate; 3. Clutch slave disc 4. Release sleeve;
5. Disengaging fork; 6. Guide bearing

Clutch
Steps of disassembling (according to sequence)
Jack up the vehicle and safely support it.
1. Remove transmission (for operations, refer to the transmission part of this manual)
2. Pressure plate assembly;
3. Slave disc assembly.
Use a guide axle to prevent free sipping and fall of slave disc assembly.
Make markings on flywheel and pressure plate, which shall be used for alignment during
reassembling.
4. Remove clutch release fork.
5. Release sleeve assembly.
Remove release sleeve along with return spring.
Caution: Avoid flow of brake fluid onto painted surfaces during disassembling.
Immediately wipe out any such fluid on painted surfaces.
In case of excessive wear, damage or other fault found during inspection, make
necessary adjustment and repair, or replace corresponding parts.
Clutch
Pressure plate assembly

Perform visual inspection of
pressure plate wear, thermal crack,
bending deform. In case of excessive wear
or bending deform, or too deep thermal
crack, replace the pressure plate.
(Pressure plate deformation― ― measure
planeness of pressure plate friction face;
replace pressure plate assembly if the limit
value is exceeded. Limit: 0.3mm)
Clutch cover
Perform visual inspection of wear, crack or

other damage of the whole clutch cover.
Clutch cover with excessive wear, crack or
other damage must be replaced.
Mounting pressing force

Metal block
1) Put clutch pressure plate
Measuring gauge
upside-down;
2) Place an 8mm thick metal block on
pressure plate;
3) Press pressure plate down till distance
“B”is 0mm.
4) Record pressure reading on the gauge.
Standard pressure: 6276N
Height of diaphragm spring

disengaging finger
1) Place an 8mm thick metal block under
pressure plate
2) Press pressure plate down till distance
“B”is 0mm. 2 methods can be used:
a. press top of pressure plate down;
b. tighten pressure plate mounting bolts.
3) Measure from base plane to disengaging
finger end.
Standard height: 40±1mm

Clutch
Slave disc assembly
Visually check torsion spring

for looseness, softening and cracking; in
case of any of these, replace slave disc
assembly.
Visually check friction surface for crack,

grease or excessive charring; in case of
any of these, clean or replace slave disc
assembly. Check if this assembly can
move smoothly on transmission first shaft
spline.
Deform of slave disc
Insert guide axle in spline hub.
Guide axle must be kept very smooth and

straight. Fit a scale gauge on slave disc
outer circle and slowly rotate slave disc
assembly to obtain reading on the gauge.
If measured value exceeds a limit, replace
slave disc assembly.
Limit value: 1.0mm
Wear of slave disc spline

hub
Clean insides of spline hub.
Fit slave disc on transmission 1st shaft

spline.
Fit a surface measuring instrument on

outer circle of slave disc. Slowly rotate
slave disc and measure change of outer
circle.
Replace slave disc assembly if measured
value exceeds a limit.
Wear limit of slave disc spline hub: 1.0mm

Clutch
Slave disc rivet head depth
Use a depth gauge to measure

distance from rivet head to friction surface.
Measure both sides. If measured value is
less than a limit. Replace slave disc
assembly.
Rivet head depth limit: 0.2mm
Release yoke and support
Visually check surface of release

yoke in contact with release sleeve and
support.
Replace part in case of excessive wear or

surface roughness.
Release sleeve assembly
Before disassembling release

sleeve assembly, check wear and roughing
of release sleeve assembly.
A. Surface of release bearing is rough or

noise is heard in rotation when being lightly
pressed.
B. Surface is rough or damaged (surface in

contact with release yoke and release
bearing front cover face).
Warning: The release bearing is loaded with lubricant in advance. Do not place this bearing in
solvent for cleaning, as this will dissolve the lubricant. Note that do not disassemble the release
sleeve if there is no problem. Visually check return spring for cracking and softening. Part
replacement is required in case of such situations.
Clutch
Reassembling
Sequence of reassembling
1. Guide bearing; 2. Clutch release fork; 3. Release sleeve assembly; 4. Slave disc assembly;
5. Pressure plate assembly; 6. Transmission

Clutch
Reassembling steps
1. Release yoke
Apply Supramoly multi-purpose grease

on surface of release yoke in contact
with release sleeve assembly and
support.
2. Release sleeve assembly
it release sleeve with return spring.
3. Slave disc assembly
4. Pressure plate assembly
Apply Supramoly multi-purpose

grease inside slave disc spline hub.
Use guide axle to install slave disc

assembly.
Tighten pressure plate mounting bolts

in the sequence shown by numbers.
Tightening torque for pressure plate

mounting bolts: 18N·m
Warning: After tightening of pressure

plate mounting bolts, remove steel
wire protecting diaphragm spring.
Clutch
Clutch control equipment
Disassembling
1. Clutch pipe and hose; 2. Clutch pedal; 3. Clutch pedal and support assembly; 4. Clutch switch
Clutch
or limit bolt; 5. Axle; 6. Pin; 7. Spring; 8. Clutch cylinder
In case of excessive wear or damage of part found during inspection, make necessary adjustment,
or repair or replace parts.
Reassembling
9
6
10
8
11
4
5
Reassembling sequence
1. Clutch cylinder; 2. Hose; 3. Clutch cylinder; 4. Clutch pedal; 5. Return spring; 6. Pin; 7. Axle; 8.
Clutch switch or limit bolt; 9. Clutch pedal and support assembly; 10. Master cylinder oil inlet hose;
11. Clutch pipe and hose
Clutch
Assembling steps
1. Clutch cylinder
Clutch cylinder mounting bolts mounting

torque: 16 N•m
Before assembling clutch cylinder return

spring, first adjust clutch cylinder jogger.
1) Loosen clutch jogger lock nut;
2) Rotate jogger till pushing against

disengaging fork;
3) Rotate jogger back by 1.5 rounds (free travel of the fork is about 2mm)
4) Tighten lock nut (19 N•m)
2. Clutch hose
3. Clutch master cylinder
Install clutch master cylinder on clutch pedal and support. Tightening torque for mounting nut shall
be 13N·m
4. Clutch pedal
5. Return spring
6. Pin
7. Axle
8. Clutch switch or limit bolt
9. Clutch pedal and support assembly
Tightening torque for bolts of clutch pedal and support assembly is 38N·m.
After above assembling, adjust clutch control equipment.
Clutch pedal height and travel
1) Loosen clutch master cylinder jogger lock nut
2) Rotate jogger to adjust pedal
Clutch pedal height A: 160-180mm
Clutch pedal travel B: 160-170mm
3) Clutch master cylinder jogger lock nut tightening

torque is 13N·m
4) Reinstall instrument and adjust clutch pedal free

travel
1) Loosen clutch switch of pedal limit bolt.
2) Adjust clutch switch or pedal limit bolt so that clutch pedal free travel is 3-5mm.
Clutch
Venting of clutch pipeline
Follow the steps below:
1. Pull parking brake tight;
2. Add brake fluid in oil storage pot to max. level.

During venting, note brake fluid in the pot.
3. Remove rubber cap on venting screw of clutch

cylinder. Connect one end of a plastic pipe to
this screw and the other end to a transparent
vessel filled with brake fluid.
4. Continuously step down clutch pedal for a

number of times and then keep the pedal down.
5. With the pedal stepped down, loosen venting

screw to vent air. Later, tighten the venting
screw.
6. Repeat above operations till air in pipeline is

completely vented.
After venting operation, add brake fluid in the oil

storage pot to the “MAX”marking.
Clutch
Disassembling
1. Jogger and dust sleeve; 2. Piston assembly and return spring; 3. Cylinder body; 4. Clip;
5. Oil inlet hose; 6. Valve seat assembly
In case of excessive wear or damage found during inspection, make necessary adjustment, repair
or replacement of parts.
Clutch master cylinder assembly
Use brake fluid to clean clutch master cylinder body.

Check oil return hole for clogging; clean if necessary.
Measure ID of master cylinder body.
Master cylinder ID: 19.050---19.102mm
Clearance between clutch master cylinder piston and

ID of the cylinder: 0.12mm (limit)
Warning: For disassembled clutch master cylinder,

repair pack must be replaced.
Clutch
Reassembling
1. Cylinder body; 2. Piston assembly and return spring; 3. Jogger and dust sleeve; 4. Clip;
5. Oil inlet hose; 6. Valve seat assembly
Precautions on reassembling:
1. Before reassembling, use clean brake fluid to wet pump body and piston;
2. Apply a thin layer of grease on the rubber cup;
3. Prevent damage of rubber cup lip during assembling.

Clutch
Clutch cylinder
Disassembling
Sequence of disassembling
1. Jogger; 2. Dust cover; 3. Piston assembly; 4. Venting screw; 5. Cylinder body
In case of excessive wear or damage of part found during inspection, make necessary adjustment
or repair/replacement of the part.
Clutch cylinder assembly
Use brake fluid to clean clutch

cylinder body.
Measure master cylinder inner diameter.
Master cylinder ID: 26.99---27.042mm
Clearance between clutch cylinder piston

and cylinder ID: 0.12mm (limit)
Warning: For disassembled clutch cylinder,

repair pack must be replaced.
Clutch
Reassembling
Sequence of reassembling
1. Push rod; 2. Dust cover; 3. Piston assembly; 4. Venting screw; 5. Cylinder body
Precautions on reassembling:
1. Before reassembling, use clean brake fluid to wet pump body and piston;
2. Apply a thin layer of grease on rubber cup;
3. Prevent damage of rubber cup lip during assembling.

Clutch
Troubleshooting
Sluggish clutch (noise of gear grinding during shifting)
Check hydraulic circuit
YES Faulty hydraulic circuit Liquid leakage Air in circuit
Replace Repair or replace
Check clutch master cylinder and cylinder
YES NO
Check free clearance Repair or replace
YES Excessive gap
Check clutch plate Adjust
YES Clutch plate warping
Check diaphragm spring Replace clutch plate
YES Weak diaphragm spring or worn pointer tip Faulty spring clamp
Replace pressure plate assembly Replace pressure plate

assy
Check spline shaft
YES Sliding not free
Clean, repair, apply grease
Check guide bearing
Worn or damaged guide bearing
Replace guide bearing

Clutch
Slipping of clutch
Check master cylinder and slave cylinder
YES NO
Check clutch pedal Repair or replace
YES Clutch switch keeping pedal down
Adjust clutch switch setting
Check clutch pedal free gap & slave cylinder
YES No gap
Check clutch plate Adjust
Hardened friction disc surface Worn clutch plate Engine oil/grease on clutch plate
YES
Repair/replace clutch plate assy Replace clutch plate assy Replace clutch plate assy
Check diaphragm spring
YES Weak spring force
Replace pressure plate assy
Check pressure plate and flywheel
Warping flywheel Warping pressure plate
Repair or replace Repair/replace pressure plate assy

Clutch
Vibration of clutch (clutch vibration during engaging start of clutch)
Check clutch plate
Clutch/friction disc poor contact Clutch plate warping/wear Hardened clutch plat surface
Replace clutch plate assy Replace clutch plate assy Repair or replace
No engine oil/grease on clutch Weak or broken clutch plate Loose clutch plate rivet
plate surface damping spring
YES
Replace clutch plate assy Replace clutch plate assy Replace clutch plate assy
Check pressure plate and flywheel
Warping or wear of pressure plate Warping or wear of flywheel
YES Repair or replace Repair or replace
Check diaphragm spring
YES Weak diaphragm spring force
Replace pressure plate assy
Check engine support or rubber pad
Loose engine support Deteriorated rubber pad
Tighten Replace rubber pad assembly

Clutch
Noise of clutch (check clutch noise during engaging and disengaging of clutch
to determine cause of noise)
Check release fork or link rod
NO
YES Repair or replace
Check clutch pedal
Cracked clutch disc or damping Weak damping spring force Exposed rivet head
spring casing or broken spring
YES
Replace clutch plate assy. Replace clutch plate assy. Replace clutch plate assy
Check release bearing
YES Poor lubrication of release bearing Worn release bearing
Replace release bearing Replace release bearing
Check guide bearing
Worn guide bearing
Replace guide bearing

Gearbox Assembly
General
Technical parameters
Tightening torque
Gearbox disassembling
Gearbox reassembling
Trouble shooting
General
1) Direction for use

1. All forward gears of MSB-5M (reinforced) gearbox have clamping ring synchronizer, in order to
reduce abrasion between the gear and the synchronizer and enable the synchronizer and gear to
declutch smoothly so as to prevent the gear being destroyed, the action of shifting the gear must
be gentle. Only after the vehicle has stopped steadily can forward gear be shifted to reverse gear
or reverse gear to forward gear.
2. Special attention must be paid to: The fifth gear of gearbox is overdrive gear; to avoid the
overdrive gear being damaged, the fifth gear can only be used when the vehicle is not overloaded,
the road surface condition is excellent, and the vehicle is running at the speed above 50 km/h.
When at the fifth gear, in case some kind of situation requires the vehicle to slow its speed to
below 50 km/h, it is necessary to shift to lower gear; if it continues to run at the fifth gear, it is
extremely easy to break up the fifth gear.
3. The gearbox uses 80W/90 GL-4 gear oil in winter and 85W/90 GL-4 gear oil in summer.
Generally, the vehicle has to change its gear oil after running every 6,000 km. After draining dirty
oil, put the gearbox at reversing gear, jack up the rear axle, pour kerosene into it, let the gearbox
gear rotate for 2-3 minutes, then after draining the dirty oil again, fill it with pure gear oil.
4. When the vehicle is running downhill, it does not allowed to turn off the engine; and it is
forbidden to start the engine by using the inertia running downhill under the flameout condition, so
as to avoid the gear being damaged.
2) Assembling diagram
2
3) Diagram of gear shifting mechanism
Rated input torque 254.8N·m
Assembly mass Approx. 78Kg
1st 5.529
2nd 2.782
3rd 1.641
Speed ratio
4th 1
5th 0.785
Rev 5.271
Lube oil amount 2.7L
Use (GL-4) 85W/90 in summer

Lube oil brand
Use (GL-4) 80W/90 in winter
3
II. Tightening torque N·m
4
5
III. Gearbox disassembling drawing
Disassembling of large parts
1 Separation bearing 11 Odometer driven gear 20 Secondary axle bearing
2 Separation shifting yoke 12 Rear cover bolt 21 Secondary axle
assembly 13 Rear cover assembly
3 Clutch housing bolt 14 Breather valve 22 Intermediate axle front
4 Clutch housing 15 Odometer driven gear bearing, retaining ring
5 Gearbox side cover bolt driving gear 23 Intermediate axle rear
6 Gearbox gear side cover 16 Odometer driven gear bearing, retaining ring
and side cover gasket driving gear spacer 24 Intermediate axle
7 Gearbox top head bolt 17 Shifting yoke and shifting assembly
8 Top head assembly yoke shaft 25 Reversing gear
9 Second axle nut 18 Primary axle bearing
10 Flange 19 Primary axle assembly
6
Important operation-- gearbox assembling
When disassembling, do use jack or similar

tool so as to guarantee safety of disassembling
and facilitate disassembling.
Assembling
Gearbox assembly
(1) Align the inclined line of gearbox to the

inclined line of engine.
(2) Adjust the gearbox to the direct gear

position, turn the secondary axle flanged disc
to align it with clutch.
Gearbox cover assembly
Insert a screwdriver to the groove indicated by

the arrow in the picture. Remove the gearbox
cover assembly from the gearbox body. Do not
disassemble it roughly, be careful and put it
down gently.
Clutch housing bolts
Torque (N·M) 68.6-91.3
Intermediate axle front bearing
Use a copper bar and a hammer to strike the

rear end of the axle, move the intermediate
axle for about 3mm.
Use special tool to insert to the stop ring

groove; remove the front bearing.
Primary axle ball bearing

rear end of the axle; move the primary axle
for about 3mm.
Use special tool to insert into the brake ring

groove; remove the ball bearing.
Gearbox rear cover bolts
Torque (N·M) 68.6-91.3
Secondary axle ball bearing

rear end of the axle; move the secondary
axle for about 3mm.
Use special tool to insert into the brake ring

groove; remove the bearing.
Spring pin, shifting yoke, shifting yoke

shaft
Before disassembling, put all the shifting

yoke axles at neutral position.
After pushing out the spring pin, push the

rear end of the shifting yoke shaft forward.
Then, strike the rear end of the shifting yoke

shaft forward and gently, remove the shifting
yoke and the shifting yoke shaft.
Secondary axle assembly
When disassembling, use strong steel cable,

and pay attention to safety.
Disassembling of small parts
Top head assembly
1 Oil filling plug 2 Reversing lamp switch 3 Elastic cylindrical pin 4 External selected
gear rocker arm combined part 5 Plain washer 6 Internal selected gear rocker arm 7 External
shifting gear rocker arm combined part 8 Internal shifting gear rocker arm 9 Oil seal
Important operation
Reversing lamp switch
Torque N·m 30-50

Primary axle assembly, secondary axle assembly, intermediate axle assembly,
reversing gear
1 Primary axle 14 Retaining ring 23 R/5 gear synchronizer gear
ring
2 Primary axle connection gear 15 1/2 gear synchronizer gear
ring ring 24 R/5 gear synchronizer
assembly
3 Needle roller bearing 16 1/2 gear synchronizer
assembly 25 Secondary axle reversing gear
4 Retaining ring
26 Needle roller bearing
17 1/2 gear synchronizer gear
5 3/4 gear synchronizer gear ring
ring 27 Secondary axle
6 3/4 gear synchronizer assembly
18 Secondary axle first gear 28 Intermediate axle fifth gear
7 3/4 gear synchronizer gear ring
19 Needle roller bearing 29 Retaining ring
8 Secondary axle third gear
20 Secondary axle fifth gear 30 Intermediate axle assembly
thrust washer 31 Reversing axle pin
10 Retaining ring
21 Secondary axle fifth gear 32 Reversing axle
11 Secondary axle thrust washer
22 Retaining ring 33 Reversing gear
12 Secondary axle second gear
Essential points for attention
Synchronizer assembly
spring filler block Disassemble the synchronizer assembly altogether;

then disassemble the gear sleeve, slide block, spring
matchin
synchronizer and synchronizer tooth hub.
g sleeve
tooth hub
synchronizer assembly
Ball bearing
When disassembling, use bench press.
Retaining ring
Remove the retaining ring with ring pliers.
Thrust plate
IV. Inspection and repair
Gear inner hole
Gear 1, 2, 5 Standard Limit
0.05-0.09mm 0.2mm
Ball bearing radial runout
Limit 0.2mm
Shifting yoke
Standard Limit
10.0mm 9.0mm
Gap between synchronizer tooth hub
and slide block
Standard 0.09-0.31mm
★ Important operation— Secondary axle

radial runout
Gap between synchronizer gear

ring and connection gear
Gear Standard Limit
Gear 3, 4 1.0mm
Gear 1, 2, 5 1.5mm 0.5mm
Limit spring free length
Standard Limit
39.8mm 38.5mm
V. Gearbox reassembling
Reassembling of small parts

Secondary axle assembly, primary axle assembly, intermediate axle assembly,
reversing axle assembly
1 Secondary axle 2 Needle roller bearing 3 Secondary axle first gear 4 1/2 gear
synchronizer gear ring 5 1/2 gear synchronizer assembly 6 1/2 gear synchronizer gear ring
7 Retaining ring 8 Needle roller bearing 9 Secondary axle second gear 10 Secondary axle
thrust washer 11 Retaining ring 12 Needle roller bearing 13 Secondary axle third gear 14
3/4 gear synchronizer gear ring 15 3/4 gear synchronizer assembly 16 3/4 gear
synchronizer gear ring 17 Retaining ring 18 Needle roller bearing 19 Secondary axle
reversing gear 20 R/5 gear synchronizer assembly 21 R/5 gear synchronizer gear ring 22
Retaining ring 23 Secondary axle fifth gear 24 Secondary axle fifth gear thrust washer 25
Intermediate axle assembly 26 Retaining ring 27 Intermediate axle fifth gear 28 Primary
axle 29 Primary axle connection gear 30 Reversing gear 31 Reversing axle 32
Reversing axle pin 33 Needle roller bearing
Important operation
Synchronizer assembling
When pressing the synchronizer assembly onto the secondary

axle, take care not to fall off the synchronizer gear sleeve, slide
block, and synchronizer spring.
Retaining ring assembling
Select appropriate retaining ring to insert in, and get a minimum

axial gap.
Top head reassembling
1 Oil seal 2 Inner shifting gear rocker arm 3 Outer shifting gear rocker arm combined part 4
Plain washer 5 External selected gear rocker arm combined part 6 Inner selected gear
rocker arm 7 Elastic cylindrical pin 8 Reversing lamp switch 9 Oil filling plug
Important operation
Oil seal assembling
Strike the oil seal into place gently with special

tools.
Reversing lamp switch
Torque N·m 30-50
Internal/external shifting gear rocker arm
Assembling of internal/external shifting gear

rocker arm
Large parts reassembling
1 Housing 2 Intermediate axle assembly 3 Reversing gear 4 Secondary axle assembly 5

Secondary axle bearing 6 Primary axle assembly 7 Primary axle bearing 8 Intermediate axle
rear bearing, retaining ring 9 Intermediate axle front bearing, retaining ring 10 Inner driven
gear and driving gear spacer 11 Inner driven gear driving gear 12 Rear cover and oil seal
13 Rear cover bolt 14 Flange 15 Secondary axle nut 16 Breather valve 17 Inner driven
gear 18 Side cover and side gasket 19 Side cover bolt 20 Shifting yoke, shifting yoke shaft
21 Top head assembly 22 Top head bolt 23 Clutch housing 24 Clutch housing bolt 25
Separation bearing 26 Separation shifting yoke assembly
Important operation
Secondary axle assembling
Use strong steel cable while assembling, and

pay attention to safety.
Interlocking pin, steel ball
Put the steel ball into the housing, insert the

interlocking pin into pin hole of shifting yoke,
make it arrive at the other side of the housing
through the case hole, 3/4 gear shifting yoke,
and 3/4 gear shifting block in sequence.
Spring pin
Do not reuse the disassembled spring pin;

Incorrect Correct replace it with a new one.
Primary axle bearing
Please assemble it with special purpose

sleeve.
Clutch housing
Apply the connection surface of the clutch

housing with liquid sealant.
Primary axle
Assemble primary axle into the gearbox; and

make sure the primary axle turns flexibly.
Gearbox rear cover bolt
Torque (N·m) 68.6-91.3

VI. Trouble shooting
1. Gearbox noises
If there is noise coming from the gearbox area during idling, inspect the clutch first. If the noise
stops when treading down the clutch pedal, it shows the noise is coming from the gearbox.
Check gear oil level
Fill the Check gear oil quality....type,

recommend Too low YES pollution, foreign matters, viscosity
ed gear oil
Fill the
Sufficient recommended gear Insufficient
lube oil
Gearbox overhaul
Gear worn or damaged Bearing/spline worn or damaged Axial clearance too

large
Replace Replace Replace

II. Gear out-of-gear
Clearance too big, loosened or Check control parts for clearance,

maladjusted loosening or mal-adjustment
Check whether each YES

Adjust or replace
connection is loosened
Loosened Loosened
Gear change
Tighten
mechanism overhaul
Connecting Shifting arm worn Gear change Circlip elastic YES (

piece or bent lever groove force
loosened worn weakened
Gearbox
Replace Replace Replace Replace
overhaul
Gear sleeve and connection Spline has excessive

Bearing worn Gear worn
gear worn excessively clearance at rotating
excessively excessively
direction
Replace Replace Replace Replace

III. Gear cannot shift smoothly (having noise when shifting)
Check free clearance of clutch pedal
Adjust to
Check gear oil level YES Incorrect
specified value
Fill the
Check control rod
YES Too low recommended
moving and length
lube oil
Gear change
Adjust to
YES mechanism NO
specified value
overhaul
Check whether the shifting yoke

shaft and shifting arm are bent Bent too much Replace
Gearbox
Not bent Check axial clearance of parts
overhaul
YES Synchronizer parts worn out or Clearance

damaged too big
Replace Replace
Drive shaft
General
Fixed torque
Disassembling and reassembling
Trouble-shooting
General
Bearing fixing mode Outer spring ring
Cross length Mm 71
Cross length outside diameter Mm 18.44
Shaft tube specification Diameter × thickness Mm 69×2.5
Flange bolt specification 10
Flange dimension Reference diameter Mm 85
Max. unbalance g·cm/rpm Not exceeding 35/3200

Fixed torque
N·m
变速箱侧
Gearbox side
46-56
41-51
46-56
Rear axle side

后桥侧
Disassembling
3
4
Disassembling steps
1. Differential end nut
2. Middle suspension
3. Transmission end nut
4. Drive shaft assembly
Important operation
As the drive shaft requires good balance, assembly

mark should be made on the universal joint during the
disassembling.
Disassembling
Universal joint
2
3
4
5
1. Cross grease nipple 4. Cross
2. Universal bearing retaining ring 5. Flange yoke
3. Needle bearing
Importance operation - disassembling
1. Needle bearing
Knock on the flange yoke to remove the

bearing and then tap on the cross to remove the
needle bearing. Remove the other bearings in the
same way.
Center bearing
1
2
6 3
1. Nut 5. Center bearing
2. Washer 6. Dust shield
3. Yoke
4. Middle rubber
If wearing or other faults are found on the

components during the inspection, repair or
replacement should be carried out.
Cross
Needle bearing
Visual inspection
Flange yoke
Check the following components for wearing,
Yoke
damage and other abnormal conditions.
Center bearing
Vibration isolating rubber bearing
Bracket
Cross pin diameter
Cross pin
diameter
(mm)
Dimension Limit
18.44 18.34
Hj Spline side play

Spline
花 housing
键套
(mm)
Standard Limit
花键shaft
Spline 轴
0.1 0.3
Side
侧play
隙
Unbalance inspection (for reference only)
Measure the unbalance value of certain

point in cross.
Speed at measurement Unbalance
(rpm) (g·cm)
3200 35
Reassembling
Center bearing
6
5
3 4
1.. Middle rubber 5. Washer
2. Center bearing 6. Nut
3. Dust shield
4. Yoke
Important operation
Apply grease on oil seal lip and middle

bearing
Grease. Recommended grease type:
Fuchs EPT-2.5 grease
Filling-up quantity 20 - 25g.

Important operation
Staking on the nut after the middle nut is

tightened.
Two symmetrically on circumference.
Universal joint
4
3
2
1
1. Flange yoke 4. Universal bearing retaining ring
2. Cross 5. Cross grease nipple
3. Needle bearing
Important operation - - - reassembling
1. Flange yoke
The flange yoke of the drive shaft must be installed

as shown in the figure. The spline spindle and spline
yoke should be assembled in alignment as shown by
the arrow.
2. Needle bearing
Apply Fuchs EPT - 2.5 grease on the oil

seal and needle bearing. Use cross as
the guide to fit needle bearing in the flange yoke by
knocking with soft face hammer.
3. Cross grease nipple
Install the grease nipple to the specified

angle on the cross. Make sure that the
grease nipples face upward.
4.Universal bearing retaining ring
Do not use worn universal bearing retaining ring.

After the bearing is installed, select and fit the
appropriate universal bearing retaining ring to make
the cross end play not exceed 0.1mm.
Assembly
Gearbox side
变速箱侧
1 3
4
后桥侧
Rear axle side
Assembling steps
1. Drive shaft assembly 3. Middle suspension
2. Transmission end nut 4. Differential end nut

Importance operation - Assembly
1.Transmission side nut
Torque（N·m） 46-56
2. Differential end nut
3. Middle support nut
Trouble-shooting
Noise
Check middle spline shaft
YES Worn
Replac
Check cross bearing
YES Worn or stuck
Replac
Check middle bearing
YES Worn
Replac
Vibration
Check shaft run-out
YES NO
Replace
Check shaft
YES Unbalance
Adjust
Check gearbox rear shell bushing
YES Worn
Replace
Check sliding yoke spline shaft
YES Stuck
Replace
Rear Axle
Rear Axle Assembly
Chapter I Introduction of Rear Axle Structure
Chapter II Disassembling, inspection, and reparation
Chapter III Assembly and adjustment of rear axle assembly
Chapter IV Use and maintenance of rear axle assembly
Chapter V Trouble shooting of rear axle
63
Rear Axle
Chapter I Introduction of Rear Axle Structure
I. General description of the structure

Types of Rear Axle Structure (Table 1)
Item Content
Type of axle case Press-welding integral type
Type of axle shaft support Full floating type
Type of reduction gear Single-stage hypoid spiral bevel gear
Number of planetary gears 4 planetary gears
Rated axle load 4 tons
Maximum output torque 8500N·m
This series of rear axle is the drive axle for two-wheel drive vehicle, and the rear suspension is of
the rigid-axle type suspension structure. It is composed of the final gear, differential and axle case
etc., which is the final reduction and driving mechanism in the automotive power transmission
system. The final gear can both change the power transmission direction, and reduce the rotation
speed and increase the torque. It is composed of the drive gear and the driven gear. The end with
spline of the drive gear is jointed to the propeller shaft universal joint assembly through the drive
gear flange, and the middle of it is supported by two conical bearings which are installed in
opposite direction, so as to bear the axial force and the tangential force. The small face neck of the
drive gear is installed on the conical roller bearing, which only bears the radial force. The driven
gear is fixed on the differential left casing by the bolts.
Differential allows the left wheel and the right wheel to generate different rotation speed, it is
composed of such components as the differential right casing and left casing, cross shaft, four
planetary gears, and two axle shaft gears etc.
One end of the rear-axle shaft is jointed to the axle shaft gear with spline, the flange on other end
is connected to the hub and brake drum assembly by the bolts.
64
Rear Axle
II. Explosion diagram and details of rear axle assembly:

1. Drive gear flange 2. Drive gear 3. Dust fender 4 Oil seal-drive
self-lock nut flange gear
5 Drive gear inner and 6 Bearing seat bolt 7 Spring washer 8 Drive gear
outer bearing bearing seat
9 Adjusting 10 O-ring 11 Compressible 12 Drive gear
washer-bearing seat spacer
13 Guide bearing spring 14 Guide bearing 15 Type 1 Hex nut 16 Spring washer
collar guard assembly
17 Drive gear guide 18 Differential 19 Differential 20 Differential
bearing bearing bearing casing (right)
adjusting nut
21 Axle shaft gear thrust 22 Axle shaft gear 23 Planetary gear 24 Planetary gear
washer shaft
25 Driven gear 26 Differential 27 Bolt-driven gear 28 Bolt-differential
casing (left) casing
29 Nut-differential casing 30 Spring washer 31 Flat washer 32 Bearing cap
33 Bearing cap bolt 34 Spring washer 35 Reduction 36 Spring washer
casing bolt
37 Reduction casing bolt 38 Reduction 39 Spring washer 40 Final drive
casing nut casing
41 Hex bolt 42 Locking 43 Spring washer 44 Rear axle
plate-adjusting casing
nut assembly
45 Normally open vent 46 Filler plug 47 Filler plug 48 Drain plug
plug sealing ring
49 Drain plug sealing ring 50 Find thread hex 51 Type 1 fine 52 Spring washer
bolt thread hex nut
53 Rear brake assembly 54 Axle shaft nut 55 Taper sleeve 56 Spring washer
(left and right)
57 Axle shaft bolt 58 Axle shaft 59 Axle shaft oil 60 Lock washer
seal
61 Bearing nut 62 Rear hub outer 63 Hex bolt 64 Spring washer
bearing
65 Tyre bolt 66 Tyre outer nut 67 Tyre inner nut 68 Rear hub inner
nut
69 Rear hub 70 Rear hub inner 71 Rear brake drum 72 Rear hub inner
bearing oil seal
73 Hex bolt 74 Spring washer 75 Oil catcher
65
Rear Axle
III. Sealant and Adhesive Applied on Rear Axle（Table 2）

Item Specified sealant and adhesive
Installation surfaces of the rear axle casing 515 Anaerobic sealant

assembly and final reduction assembly
Driven gear bolt GY-340 Anaerobic sealant
Differential casing bolt GY-340 Anaerobic sealant
Reduction casing bolt Mechanical sealant 605
Hub inner cavity ZL-2 GB5671-85 Automobile General purpose

Lithium Base Grease.
Installation of the final reduction assembly No. 10 motor oil

components
VI. Detailed List of Rear Axle Wearing Parts（Table 3）

Description Quantity
Drive gear oil seal 1
Rear hub inner oil seal 2
Rear hub inner bearing 2
Rear hub outer bearing 2
Drive gear inner bearing 1
Drive gear outer bearing 1
Axle shaft oil seal 2
Drive gear nut 1
Differential bearing 2
Left and right plate friction lining 2 pieces for each
O-ring 1
Drive gear, bearing seat adjusting washer According to actual need
66
Rear Axle
V. Table of Main Bolts Tightening Torque（Table 4）

Bolt (nut) Name HF15015 (N.m)
Drive gear nut 250~280
Drive gear bearing seat bolt 75~113
Bolt –driven gear 108~161
Differential casing bolt 45~79
Reduction casing bolt 45~79
Guide bearing guard plate bolt 16~26
Bearing cap bolt 122~185
Adjusting nut locking plate bolt 16~26
Rear brake back plate nut 78~115
Axle shaft bolt 45~79
Hub inner nut 287~346
Lock washer small hex bolt 6~12
Filler plug 44.1~53.9
Drain plug 44.1~53.9
67
Rear Axle
Chapter II Disassembling, Inspection and Reparation of Rear Axle
I. Disassembling
Remove the rear axle
1. Put wooden wedges under the wheel in the front and

behind, to hold the wheel in position.
2. Loosen the wheel nuts of the outer side wheel.
3. Jack up the rear axle.
Remove the axle shaft
1. Loosen the axle shaft nuts.
2. Remove the axle shaft. If it is difficult to remove the

axle shaft, use copper hammer to slightly knock on the
axle shaft flange, until the axle shaft is loosen off.
Disassemble the wheel hub
1． Remove the lock washer.
2. Remove the nub bearing lock nut.
Note:
Use the hub bearing adjusting nut spanner to

remove the adjusting nut.
3. Remove the wheel hub assembly.
Note: use rear hub extractor，to remove the hub.
68
Rear Axle
4. Remove the axle shaft oil seal from the end of the
axle sleeve.
Note: when assembling, the outer ring of the axle shaft

oil seal shall be applied with lithium base grease and
then pressed into the rear hub.
5. Remove the oil seal from the hub assembly.
6. Remove the bearing cup of the inner and outer

bearing.
7. Remove the brake drum and oil retainer.
69
Rear Axle
Disassemble the axle case and the final

reduction gear
1）Bleed out the final reduction gear lubricating oil.
2）Disassemble the connection between the propeller
shaft and main reduction gear.
3 ） Use jack to remove the final reduction gear
assembly.
4）Remove the hose, steel pipe, and wire cluster.
5）Remove the brake assembly.
6）Remove the rear axle.
·Jack up the axle casing.
·Remove the U bolt and upper and lower base plates,
lower down the jack, and pull out the axle casing.
Disassemble the main reduction gear assembly
1）Before disassembling, measure and record the

tooth clearance of the drive gear and the driven gear.
Note: After adjustment, check the engagement of the

gears.
2）Remove the locking plate;
3）Make assembly marks on the bearing cap and

casing;
The disassembled bearing cap and reduction casing

shall be placed separately per left and right
according to the matching number, in order to avoid
mismatching during re-assembling.
70
Rear Axle
4）Loosen the fixing bolts of the bearing cap, use

differential spanner to remove the adjusting nut;
5） Remove bearing cap and bolt;
6） Remove the differential assembly;
7） Use stripper to remove the drive gear assembly,

at the same time remove the adjusting washer;
71
Rear Axle
Disassemble the differential assembly
1） Remove the differential right casing;
2） Remove the axle shaft gear and washer;
3） Measure and record the tooth clearance of the

planetary gear;
Note: when measuring the tooth clearance, make

sure to press down the planetary gear cross
shaft.
4）Remove the planetary gear cross shaft assembly,

and then remove the planetary gear and washer
from the cross shaft;
72
Rear Axle
5） Take out the axle shaft gear and the thrust

washer on the axle shaft/
shaft;
6） Remove the driven gear;
7） Remove the differential bearing from the

differential casing;
Disassembling of the drive gear
1） Remove the drive gear flange.
3） Remove the stopper elastic ring for shaft and

take off the drive gear guide bearing;
73
Rear Axle
4） Press out the drive gear from the bearing seat;
5） Remove the adjusting washer and the bearing

spacer;
6） Remove the bearing from the drive gear;
7） Remove the oil seal from the bearing seat;
8） Remove the bearing cone, remove the bearing

cup.
74
Rear Axle
Key points for check-up during disassembling
1. Check the drive gear flange for any wearing or damage.
2. Check the bearing for any wearing or color change。
3. Check the gears for any crack.
4. Check the drive gear and driven gear for any wearing or crack.
5. Check the axle shaft gear, planetary gear, and planetary gear shaft for any wearing or crack.
6. Check the axle shaft spline for any wearing or damage.
II. Table of Rear Axle Maintenance Parameters（Table V）
Item Value
Drive and driven gear clearance 0.18～0.23mm
Planetary, axle shaft gear clearance 0-0.15 mm
Without oil seal

Drive gear rotational torque
Apply gear oil 10-20 Kgf·cm
Hyperbolic gear oil:（GL-5）85W/90

Rear axle gear oil
Volume: 3.5 L
Oil applied on the outer rim and lip of the ZL-2 GB5671-85
axle shaft oil seal, and drive gear oil seal
Automobile General Purpose Lithium Base Grease.
Clearance between friction lining and 0.4-0.7 mm（Hydraulic brake）

brake drum
III. Rear axle inspection and reparation
1. Special measuring instrument or tools shall be used for the inspection of components.
Judgment on whether a component can continue in service shall be made according to the
specified maintenance standard table. The broken parts shall be repaired and replaced according
to the requirements. In case one of a pair of matching parts is worn out, which causes the
clearance go beyond the specified value, this part and the other matching part shall all be replaced
as per the corresponding requirements.
2. From the view of preventive maintenance, some of the parts which are still within the reparation
limit or wearing limit shall also be replaced before they exceed the limit.
3. Carefully check the appearance of all the components, through the assigned methods as visual
inspection or red pigment penetration etc. If the outside appearance of the component has the
following abnormal signs, the said component shall be repaired or replaced as per the
75
Rear Axle
requirements.
Abnormal signs:
Uneven wear Eccentric wear  Scrape
Crack Distortion dead or weaken（refer to spring）
Bending deflection Abnormal noise（refer to bearing）
Loosen Color change or seize up Rust
Deterioration（refer the brake friction lining）
4. All the rubber pieces, such as O-ring, oil seal, and gasket etc. shall be discarded after removal,
and they are not allowed to be re-used.
5. In case the transmission system generates abnormal sound or vibrates, first check the total free
play of the rear axle, and then determine whether it is necessary to disassemble the final reduction
gear assembly.
Place the vehicle on the level ground, put the transmission gear and transfer gearbox on neutral
position, pull up the parking brake lever and jack up the vehicle. Turn the flange clockwise to the
end, and make matching marks on the flange dust fender and the reduction casing, and then turn
the flange counter clockwise to the end, measure the moving distance of the two matching marks,
the ultimate free play is 6mm, if the free play exceed that limit, it indicates excessive gear
clearance of the rear axle, and the rear axle shall be disassembled to make adjustment.
Abnormal sound is also one type of noise, it mainly appears as the abnormal sounds generated
under different service conditions (such as vehicle speed, road conditions), like knocking sound or
screeching sound，some of the sounds will gradually disappear through breaking-in, while some of
the sounds will get louder and louder. This is mainly because of the improper assembly and
adjustment. Under the precondition of good quality components, most of such problems can be
solved through adjusting the assembling clearance.
6. Failure of brake return mainly is the problem that the brake seized up after being stepped down
and cannot continue the brake operation. This problem mainly can be solved by adjusting the
brake assembly clearance.
Item Reparation Standard Wearing Limit Remarks
Wear of rear axle leaf spring 1mm
location hole
Radial jumping of left, right — 0.1mm
axle shaft sleeve outer bearing
journal
Radial jumping of axle shaft — 1.5mm
middle un-machined surface
End surface jumping of the hub — 0.15mm
and axle shaft flange coupling
surface
76
Rear Axle
Chapter III Assembling and Adjustment of Rear Axle Assembly
I. Assembling and adjustment of rear axle assembly
（I） The assembling of the final reduction gear assembly is following the reverse procedure of the
above disassembling procedure, before assembling all the components shall be kept clean, free of
such foreign substances as oil dirt, iron dust etc. Apply NO.10 motor oil for lubrication during
assembling, and make adjustment as per the following requirements:
1. Drive gear inner and outer bearing preloading
1.1 When assembling the final reduction gear, the conical roller bearing shall have certain
assembly preload, that is, to give certain preloading force on the basis of eliminating the bearing
clearance. The purpose of it is to reduce the axial replacement caused by the axial force
generated during the transmission process of conical gear, so as to increase the supporting rigidity
of the shaft, and ensure the normal engagement of the conical gear pair. But it also shall not be too
tight, if it is too tight, it will cause low transmission efficiency, and speed up the wearing of the
bearing.
1.2 Adjustment of the drive gear bearing preloading force: under the condition of drive gear flange
nut tightening torque, install the drive gear oil seal, the drive gear is not engaged with the driven
gear, and ensure the drive gear bearing preloading torque (see Table 5). The adjustment of
preload is made by increasing and reducing the drive gear bearing adjusting washers in between
the drive gear inner and outer bearings (for specifications, see Table 6). Reduce the number of
adjusting washers; the preloading torque is increased; while increase the number of adjusting
washers, the preloading torque is decreased.
2. Differential bearing preload adjustment
2.1 Adjustment of differential bearing: the differential bearing shall be adjusted to have certain
preloading force, so as to obtain 0.01-0.02 interference on both sides of it, apply gear oil to the
bearing rotating part under the condition of no engagement between drive gear and driven gear,
the start up friction torque is 0.686-1.586N.m. The differential bearing preload adjustment is
realized through the tightening of the differential bearing nut. When adjusting, first put on the
bearing cap freely, when the adjusting ring can be turned smoothly, then tighten the bearing cap
bolt, and after that adjust the preloading force. The locking slot on the adjusting nut after the
adjustment shall be aligned with the locking plate. After adjustment, the driven gear shall not have
end float misalignment.
2.2 Differential gear clearance adjustment
Use dial gage to measure the differential gear meshing backlash on the planetary gear. Note: take
measurement from more than three points, the standard value is: 0～0.15mm; limit value: 0.3mm。
77
Rear Axle
3. Adjustment of drive and driven gear backlash, and meshing mark

3.1 Adjustment of gear backlash
The normal meshing backlash and the gear backlash variables of the drive and driven gear is
shown in table 5. When adjusting the gear backlash, the measurement shall be taken on four
positions which are evenly distributed along the circumference of the driven gear, the measuring
head of the micrometer shall be perpendicular to the surface of the measured point.
3.2 Adjustment of drive and driven gear meshing mark
First apply red lead to the teeth of drive gear, and then turn the drive and driven gear repeatedly by
hand, there will be red marks on the two working sides of the driven gear, if the marks on the
standard rotation and reverse rotation working sides of the driven gear are on the middle of the
tooth depth and closer to the small end, and occupies 60% of the tooth face, then it is a correct
meshing. See attached Figure (I). The position of correct meshing marks is adjusted through the
adjustment of the drive gear bearing adjusting washer (for specifications, see Table 6) and the
differential bearing adjusting nut.
In order to keep the adjusted differential bearing preload from being changed, the number of
circles of the adjusting nut being turned in on one side shall be equal to the number of circles of
the adjusting nut being turned out on the other side. Check and confirm the clearance again, and
then lock up the locking plate.
（II） The assembling of the rear hub with brake drum assembly is as per the reverse procedure of
disassembling, and the adjustment to be made during assembling is as follows:
1. Adjustment of rear hub bearing backlash
Tighten the bearing nut until the brake drum is no possible or difficult to move, and then slightly
loosen the bearing nut by 1/6-1/8 circle, turn the brake drum, under the condition of no contact
between brake friction disc and the brake drum, the tangent tensile force measured at the tyre bolt
shall be（3-5kg）, or the brake drum can be turned freely by hand.
（III） Rear brake braking clearance adjustment:
1. Liquid brake: for the two-way balanced type brake, first move the two brake chamber adjusting
gears respectively as per the arrow direction indicated at the back plate adjusting hole, so that the
brake drum is tightly against the brake lining, and then turn the brake chamber adjusting gear back
by 5-9 teeth, to allow the brake drum to move freely.
In the actual maintenance process, adjustment shall be made strictly according to the above
procedures and requirements.
Table 6 Washer Specifications（mm）

Drive gear bearing
Drive gear bearing seat adjusting washer
adjusting washer
0.10 0.18 0.05 0.20

0.12 0.20 0.08 0.25
0.14 0.35 0.12 0.35
0.16 0.50 0.15 1.00
78
Rear Axle
Tooth depth
Tooth length
Contact status of driven Causes Adjusting method A-Adjust tooth face contact
gear working tooth face area
1. Driven gear away from

the drive gear
Drive gear to too far
2. Drive gear closer to
from the driven gear
driven gear to achieve
Deviate correct backlash (add
to crest washer)
1. Driven gear closer to the

drive gear
Drive gear is too 2. Drive gear away from the
close to the driven driven gear to achieve
gear correct backlash (reduce
Deviate
to root washer)
1. Driven gear away from

the drive gear
Driven gear is too 2. Drive gear away from the
close to the drive driven gear to achieve
Deviate gear correct backlash(reduce
to small washer)
1. Driven gear closer to the

drive gear
Driven gear is too far 2. Drive gear closer to
from the drive gear driven gear to achieve
Deviate correct backlash (add
to big end washer)
（Figure I）
Adjustment Method of Gear Meshing Backlash
79
Rear Axle
Chapter IV Use and Maintenance
I. Hyperbolic gear has strict requirement on the lubricating oil, the axle casing is only allowed to be
filled with specified hyperbolic gear oil. It is not allowed to use normal gear oil as substitution or to
be mixed with normal gear oil, otherwise it will cause tooth face early wearing, and even the gear
is “shaved bald”.
II. The conical gear of the rear axle final reduction gear has been selected and adjusted before
ex-work, therefore, under normal condition, it is necessary to be disassembled and adjusted. It can
be disassembled and adjusted only when the gear is worn out, the gear clearance exceeds the
specified value or the bearing axial clearance is too big, and the component is damaged and need
to be replaced.
III. The dirt and dust layer on the vent plug of rear axle casing shall be frequently cleaned off. In
primary maintenance, it shall be removed and washed clean, to ensure that the vent pipe is
unblocked. Blocked vent pipe will cause the pressure in the rear axle casing rising up, and lead to
oil leakage at oil seal and joint place of the drive gear, at the same time, and the lubricating oil
level inside of the casing shall also be checked.
1. In the first time of secondary maintenance for a new car, the lubricating oil shall be replaced.
After a new car has been driven for 40000Km or 24 month, the real axle lubricating oil shall be
replaced. First bleed out the gear oil in the rear axle casing, fill in kerosene, and drain it out after
cleaning, and then fill in GL-5（85W/90）lubricating oil. It is not allowed to substitute with normal
gear oil. After the lubricating oil has been replaced when the car has been driven for 80000Km or
48 month, it will be replaced once every 50000Km of driving.
After that, check the lubricating oil quality every four times of the secondary maintenance, if there
are deteriorations such as color change or getting thinner, it shall be replaced with new oil.
2. Check the wearing conditions of the brake shoe lining and the brake drum. After a new car is
driven for 40000Km or 24 month, check the wearing status of the brake shoe lining and the brake
drum, measure the thickness of the place on the brake lining with the severest wearing, the
standard value is 4.6mm, and the limit value is 1.0mm. When the thickness of the brake lining is
smaller than the limit value, the brake lining shall be replaced.
IV. In the third maintenance, the rear axle can be disassembled, and inner cavity and final
reduction gear assembly can be cleaned. After that, tighten the bolts and nuts for each part as per
V. Points of attention:
1. The vehicle shall not be loaded with the weight that exceeding its maximum loading capacity.
2. During the driving process of the vehicle, in order to avoid impact damage to the gears, it is not
allowed to improve the obstacle crossing capacity of the vehicle by releasing the clutch abruptly.
80
Rear Axle
Chapter V Trouble Shooting
I. Hub bearing dragging
Hub bearing
dragging
Excessive hub Bearing lack of Bearing is

preloading force lubrication or use wrong contaminated with
type of lubricating dust
grease
Adjust preload Add or replace Clean and add

lubricating grease lubricating grease
II. Unsmooth wheel
Unsmooth
wheel
Bad lubrication of camshaft or Brake shoe or air chamber return

adjusting arm does not return spring broken or fatigue
back
Add grease or rectify the faulty Replace the faulty

parts parts
81
Rear Axle
III. Abnormal transmission sound
Abnormal transmission
sound
Improper Excessive Drive gear Wear or damage of Too low oil

differential clearance bearing axle shaft gear, surface
gear between drive preload too planetary gear,
clearance and driven small cross shaft thrust
gears washer etc.
Replace the Replace the Adjust the Rectify or replace Add

washer or washer or gear preloading the faulty parts enough
gear force lubricating
oil
IV. Lubricating oil leakage
Lubricating oil
leakage
Oil seal Final reduction Bearing Drain screw Axle Vent plug
worn, fixing bolt seat fixing loosen or casing blocked or
loosen or loosen or bolt the lining deformed damaged
damaged sealant loosen damaged due to
damaged. overload
Replace Tighten the bolt Tighten Tighten the Rectify or Clean or

the oil or re-apply the the bolt as screw or replace the replace
seal sealant per replace the axle the vent
specified lining casing plug
torque
82
Rear Axle
V. Insufficient brake force
Insufficient brake force
Unsmooth Improper Brake Improper Water in Oil on the

camshaft adjustment of the lining contact of brake contact
rotation brake air overheat brake surface of
chamber push or lining brake lining or
rod stroke degrade brake drum
Check Adjust the stroke Replace Rectify Step the Clean off the
the the the lining pedal oil or replace
working friction contact slightly in the brake
status of lining position driving, lining
the drain out
camshaft the water
83
VI. Abnormal brake sound
Abnormal brake sound
Brake Brake lining Uneven Loose Brake Hub Brake Improper Brake lining Damage
lining surface wearing or contact shoe bearing drum installation with oil or on
worn out hardened loose between fixing worn deformed of brake degraded. brake
and or installation brake pin shoe or plate
cause the deteriorated of the brake shoe and loosen return
rivet drum brake spring
projecting lining damaged
out
Replac Replace Rectify the Replace Tighte Replace Replac Tighten Clean or Replac
e the the brake brake the rivet n the the hub e the the locking replace e the
brake lining drum or lockin bearing brake screw of the brake brake
lining tighten the g drum the fixing lining back
bolt screw pin or plate
of the replace
fixing the return
pin spring
Front Suspension
Front suspension
General
Front Suspension
Specifications
Front suspension
Spring type Semi-elliptic blade type leaf spring
Length mm 1140
Width mm 60
Front fixing part Rubber bushing with flange pin
Pin type
Rear fixing bushing type Metal rubber bushing with flange
Pin type
Shock absorber type Double-acting hydraulic cylinder type

Front Suspension
Tightening torque
(Unit:N·m)
34-46
15-25
27-46
157-216
157-196
51-71
126-154
21-34
Front Suspension
Disassembling
5
1
1. Front shock absorber 2.U-bolt 3.Lifting lug pin 4. Fixed pin 5. Leaf spring
Preparations
First, block well the rear wheels, then jack up

the vehicle, and then jack up the front axle with
a screw jack.
Front Suspension
Important operation-Disassembling
1. Front shock absorber
Disassemble the shock absorber assembly, nut, washer

and bearing bush by following the sequence indicated in
the diagram.
2. U-bolts
(1) Loosen U-bolts and nuts (not remove them)
(2) Lift up the vehicle and rest it on the chassis bracket
(3) Remove U-bolts and nuts
3. Lifting
lug pin
Take care not to damage the thread and leaf spring

pin cylindrical surface.
4. Retainer pin
Take care not to damage the thread and leaf spring pin cylindrical
surface.
Front Suspension
Inspection and repair:
If excessive wearing or damage is found during

Leaf spring assembly Buffer block
inspection, it is necessary to repair or replace the
Leaf spring clamp Shock absorber parts.
Center bolt Rubber bushing
U-bolt
Visual inspection
Retainer pin
Inspect the parts listed on the left side visually; if they
Lifting lug pin are damaged or out of use, replace them.
Shock absorber
1. Inspect leakage of shock absorber; little
leakage is allowed.
2. After the vehicle has been running for certain
amount of distance, inspect whether the
temperature of shock absorber has risen; if the
temperature has not risen, it means it does not
work; so it must be replaced.
3. Stretch the shock absorber; if no resistance is
felt, it means the shock absorber does not work;
so it must be replaced.
4.Inspect the bushing at both ends of the shock
absorber; if they are excessively worn, replace
them.
Replacing of leaf spring

Mark
1. Before disassembling the leaf spring, make an

assembling mark on the side surface.
2. Apply grease on both sides of the leaf spring.
3. When disassembling and reassembling, use
bench press.
4. Do not reuse the disassembled center bolt;
replace it with a new one.
When replacing leaf spring, use the leaf spring
marked with “A,B,C”that means the same
camber.
Front Suspension
Center bolt
Tightening torque of center bolt: 34-44N.m
Measure the gap between leaf spring bushing and

leaf spring pin.
If the gap is more than 1mm, replace the leaf

spring bushing or the leaf spring pin.
Replacing of leaf spring bushing
Screw out leaf spring bushing with hand and

screw in a new one.
Front Suspension
Reassembling
2
1
5
1. Leaf spring2. Retainer pin 3. Lifting lug pin 4. U-bolt 5. Front shock absorber
Front Suspension
Front Rear
Important operation - assembling
Leaf spring assembly
The assembling direction of leaf spring must be the

same as that of the original state.
Nut
U- bolt
(1) Park the vehicle on a level surface, install the U-bolt

at the corresponding position of the leaf spring
(2) Lift up the vehicle.
(3) Align the front axle holes and the U-bolt.
(4) Apply machine oil to the nuts before tightening them

so as to avoid damaging the thread.
(5) Tighten the nuts.
Install the leaf spring pin; tighten it to the

specified torque.
Front shock absorber assembly
Nut, washer and rubber bearing bush
Disassemble the shock absorber assembly, nut,

washer and bearing bush by following the sequence
indicated in the diagram.
Tighten the nut until the washer contacts the end fitting
surface.
Front Suspension
Front shock absorber assembly
Main data and specification

Types Two-way hydraulic cylindrical shock
absorber
Max. outer diameter of liquid storage cylinder (mm) ￠45
Max. outer diameter of boot (mm) ￠53
Main stroke (mm) 220
Compression length (mm) 335
Extension length (mm) 555
Rear Suspension
Rear suspension
General
Rear Suspension
Specifications
Rear suspension
Spring type Semi-elliptic blade type leaf spring
Length mm 1250
Width mm 70
Front fixing bushing type Metal bushing with flange pin
Pin type
Rear fixing bushing type Metal rubber bushing with flange
Pin type
Shock absorber type Two-way hydraulic cylindrical shock absorber

Rear Suspension
Tightening torque
(Unit:N·m)
157-196
157-216
157-196
Disassembling
2
4
5
1
1. Rear shock absorber 2. U-bolt 3. Lifting lug 4. Leaf spring pin 5. Leaf spring
Rear Suspension
Preparations
First, block well the front wheels, then jack up the
vehicle, and then jack up the rear axle with screw jack.
1. Rear shock absorber
Remove the shock absorber by loosening the shock

absorber mounting nut.
Important operation
2. U-bolt
After loosening U-bolt and nut, lift up the vehicle;

remove the U-bolt by resting the vehicle on the chassis
bracket; then remove the rear axle assembly.
Important operation
3. Lifting lug
Loosen lifting lug nut; remove the lifting lug plate and
pin.
Rear Suspension
4. Leaf spring pin

Jack up leaf spring assembly with a screw jack,
remove the nut, and then pull out the bolt.
Take care not to damage the thread and leaf

spring pin cylindrical surface.
Inspection and repair:

Visual inspection: If wearing, damage or any other abnormality is found
during inspection, repair or replace the parts according to the actual condition.
Visual inspection
Leaf spring assembly Shock absorber
Leaf spring clamp Buffer block
Center bolt Rubber bushing Inspect the parts listed on the left side visually
U-bolt Auxiliary spring rubber cushion for any wearing, damage or abnormality.
Leaf spring pin
Lifting lug pin
Other inspection and repair steps are the
same as that of the front suspension.
Mark Replacing of leaf spring assembly

1. Before disassembling the leaf spring, make
an assembling mark on the side surface of the
leaf spring.
2. Apply grease on both sides of the leaf
spring.
3. When disassembling and reassembling, use
the bench press.
4. Do not reuse the disassembled center bolt; replace it with a new one.
When replacing leaf spring, use the leaf spring marked with “A,B,C”that means the
same camber.
Rear Suspension
Center bolt
Torque (N.m) 90-110
Clamping bolt
Torque (N.m) 20
Measure the gap between leaf spring bushing

and leaf spring pin.
If the gap is more than 0.4mm, replace the leaf
spring bushing or the leaf spring pin.
Replacing of leaf spring bushing
Disassemble and reassemble the leaf spring
bushing with special equipment.
Rear Suspension
Reassembling
5
1
1. Leaf spring 2. Leaf spring pin 3. Lifting lug 4. U-bolt and nut 5. Rear shock
absorber
Rear Suspension
Important operation-Assembling
The assembling direction of leaf spring must be the

same as that of the original state.
U- bolt
(1) Park the vehicle on a level surface, install the
U-bolt in the corresponding position of the leaf
spring.
(2) Lift up the vehicle.
(3) Align the front axle holes and the U-bolt.
(4) Apply machine oil on nuts before tightening them
so as to avoid damaging the thread.
(5) Tighten the nuts.
Install the leaf spring pin; tighten it to the specified

torque.
Torque (N.m) 157-196
Fill in grease after assembling.
Rear shock absorber assembly
Nut, washer and rubber bearing bush
Disassemble the shock absorber assembly, nut,

washer and bearing bush by following the sequence
indicated in the diagram.
Tighten the nut until the washer contacts the end

fitting surface.
Rear Suspension
Rear shock absorber assembly
Main data and specification

Types Two-way hydraulic cylindrical shock
absorber
Max. outer diameter of liquid storage cylinder (mm) ￠45
Max. outer diameter of boot (mm) ￠53
Main stroke (mm) 220
Compression length (mm) 336
Extension length (mm) 556
Rear Suspension
Trouble shooting of front suspension
Strident tyre noise
Check wheel
YES NO
Adjust
Check steering knuckle spindle
and steering linkage
YES Deformed
Replace
Check suspension fixing bolt
YES Loosened
Tighten
Check tyre pressure
YES NO
Adjust
Rear Suspension
Body bounding
Road test vehicle
Noise is regular Noise is not regular
Replace tyre
Check tyre for balance
YES NO
Adjust
YES NO
Adjust or replace
Check suspension system
YES Damage
Replace
Check bolts and nuts of suspension system
YES Loosened or
Tighten or replace
Rear Suspension
Excessive wearing of tyre or local wearing
Check tyre pressure
YES NO
Adjust
Check wheel alignment
YES NO
Adjust
Check wheel bearing
YES Fault
Replace
Check brake adjustment
YES NO
Adjust
Check wheel rotating condition
YES Not rotate
Rotate wheel with recommended
Check drive method
YES Unstable or incorrect
Drive more evenly

Rear Suspension
Spring broken
Load condition
Check lifting lug pin and pilot
YES Whether bolt, nut loosened Worn or damaged
YES Replace
Check U-bolt
YES Check bolts and nuts Damaged
YES Replace
Check shock absorber
YES Oil Bushing Bracket Damaged
Replace Worn out Broken Replace
Replace Replace
Check spring bushing
YES Worn out or
Replace
Check center bolt
YES Loosened Damage
YES Replace
Rear Suspension
Body inclined
Check spring
YES Rusted Springiness of spring weakened or
Clean Replace
Check lifting lug pin and bushing
YES Insufficie Worn out or broken
Apply grease
Check steel plate bracket and U-bolt
YES Bolt loosened Broken
Tighten
Check
Bushing worn out or broken
YES Replace Check fixing support
YES Damaged
Replace
Rear Suspension
Trouble shooting of rear suspension
Body inclined
Check spring
YES Rusted Springiness of spring weakened or
Clean Springine
Check lifting lug pin and bushing
YES Insufficie Worn out or broken
Apply grease
Check steel plate bracket and U-bolt
YES Bolt loosened Broken
Tighten
Check
Bushing worn out or broken
YES Springine Check fixing support
YES Damaged
Replace
Rear Suspension
Space to ground reduced
Check load condition
Leaf spring
Check leaf spring
YES Broken
Replace
Check clip strip
YES Loosened Worn out or broken
Tighten Replace
Check bushing
YES Deteriorated or
Replace
Lubrication
YES Over lubricated

Insufficient
Fill grease Remove surplus grease
Check parts for loosening
YES Loosened Broken or damaged
Tighten Replace
Rear Suspension
Spring broken
Load condition
Check lifting lug pin and pilot
YES Check whether bolt, nut Worn out or
YES Replace
Check U-bolt
YES Check bolts and nuts Damaged
YES Replace
Check shock absorber
YES Oil Bushing Bracket Damaged
Replace Worn out Broken Replace
Replace Replace
Check spring bushing
YES Worn out or
Replace
Check center bolt
YES Loosened Damaged
YES Replace
Rear Suspension
Body bounding
Road test vehicle
Noise is regular Noise is not regular
Replace tyre
Check wheel for balance
YES NO
Adjust
YES NO
Adjust or replace
Check suspension system
YES Damaged
Replace
Check bolts and nuts of suspension system
YES Loosened or
Tighten or replace
Front axle assembly
General
Technical parameter
Tightening torque of main bolts and nuts on front axle

General
single tyre
The front axle of this model is integrally supported by I beam.

Main data and specifications of front axle
Transmission system form 4X2
Tread (mm) 1440
Front wheel alignment
Diagonal tyre 3— 7（mm）

Front wheel toe-in
Radialply tyre 1— 3（mm）
Front wheel camber 1° （degree）
Positive caster 2°40′ (degree)
Kingpin inclination 7.5° (degree)
Inner turn 37°（degree）

Steering angle
Outer turn 30°（degree）
Amount of grease used for bearing on

320（g）
the side of wheel hub
Tightening torque of main bolts and nuts of the front axle
Unit N·m
50— 75
186± 19.6
441± 49
32.4± 4.9 49± 9.8

441± 49
186± 19.6
113± 14.7
Adjustment of front wheel alignment
1. Measurement and adjustment of toe-in
（1）Place front wheel on a flat place.
（2）Mark the centre of tyre wheel track with

chalk.
（3）Place toe-in measuring device on the

central position of wheel.
(4) Measure the distance (A) between tyre

centrelines in front of vehicle.
(5) Push the vehicle back and forth to turn

every wheel of 180°.
(6) Measure the distance (B) of tyre centreline

on the backside of front wheel according to the
original mark.
Toe-in equals to B less A
In case of misalignment of the toe-in
(7) Unscrew the clamping screw on the end of

connection rod.
(8) Turn the connection rod with a pipe wrench

to adjust toe-in.
2. Turning radius
．Put a wood block beneath back wheel,

（1）
the thickness of which is the same as that of
measuring device.
．Put front wheel on the device and ensure

（2）
it is located at the centre of the device
．Turn front wheel to maximum position in

（3）
clockwise and counter clock-wise direction
respectively.
Note: step on brake pedal when turning the front

wheel.
Inner turning angle
Outer turning angle
If turning angle is incorrect, make adjustment.
Adjustment steps:
（1）．Unscrew the lock nut of adjusting bolt on

steering knuckle
（2）．Adjust the height of bolt until steering

angle meets requirement.
．Tighten the lock nut.

（3）
3. Other parameters of front wheel alignment.
Front wheel camber
Positive caster
Kingpin inclination ． Remove front wheel hub cover.
（1）
（2）． Mount a measuring device of front

Front
wheel alignment parameter on the end of
steering knuckle. Calibrate front wheel
turning angle to zero.
（3）． Measure the front wheel alignment

parameters in the fig.
·If the front steel spring is fatigue 4. In case of incorrectness of parameter

measurement
·If the front I beam is deformed
Repair relevant parts in the left column.
· If king pin, king pin bushing and
bearing are worn excessively
Measurement of side slip
Measurement of side slip should be done after measurement

and adjustment of toe-in and positive caster.
(1) Slow the rolling wheel as possible to pass over the side slip
measuring instrument. Read the side slip measuring
instrument.
(2) If side slip value exceeds 5 mm/m，readjust front wheel

alignment.
Front wheel hub and brake drum
Disassembling
1.wheel 2. wheel hub cover 3. split pin slotted nut 4. washer 5.wheel hub and brake drum
assembly 6. wheel hub oil seal seat 7. wheel hub outer bearing 8. wheel hub inner bearing oil
seal 9. wheel hub inner bearing nut 10.wheel hub inner bearing outer race 11. wheel hub outer
bearing outer race 12. brake drum 13. wheel hub 14. tyre bolt 15. inner nut
Installation sequence is just opposite to the disassembling sequence.
Main operating steps for disassembling
Pull the parking brake and jack up front axle.
1. Remove wheel.
2. Remove wheel hub cover.
Take care not to damage the contacting

surface of wheel hub cover.
3. Remover split pin slotted nut.
4. Remove wheel hub and brake drum

assembly with an extractor.
5. Remove bearing bushing outer race.
1． Wheel hub Inspection and repair
2． Wheel hub bearing, oil seal

3． Knuckle groove Visual inspection of the parts listed in the left
4． Brake drum for damage or failure.
5． Brake shoe, gasket, etc.

Main operating steps of installation.
Add grease according to the fig.
Inside wheel hub 280 g
Inside wheel hub cover 40g

Grease
Adjustment of preload of wheel hub

bearing.
Adjust the clearance of brake gasket in the first

place.
Adjust bearing preload with wheel hub nut.
It proves to be ok if the pulling force at the wheel

bolt is measured as follows:
11.7— 26.4N
Front axis and steering knuckle
Disassembling
1. String rod assembly 2. Steering bend arm 3. Steering straight arm 4. Main pin upper
cover 5. Lock bolt 6. Main pin lower cover 7. Main pin
8. Steering knuckle assembly 9. Adjusting washer 10. Thrust bearing 11. I beam
Main operating steps of disassembling
Pull parking brake and jack up front axle.
Remove string rod assembly with an expeller.

Put a brass stick on the steering straight arm
and punch with a hammer when removing
the steering straight arm.
Remove lock bolt.
I beam
Steering knuckle Inspection and repair
Steering straight arm Visual inspection of the parts listed in the left
String rod Main pin for damage or failure.
Thrust bearing
Adjusting gasket and bushing
String rod ball
Repair I beam
Main pin or testing stick Insert main pin or testing stick into I beam
hole.
Thread
Steel spring positioning bolt Pull straight a thread between the centres of
the sticks
Observe if the thread aligns with two steel

spring positioning bolt holes.
Observe if the two main pins or testing
sticks align with each other from side view.
Inspect the king pin hole surface for any

deformation and wear.
Observe the damage situation of the

steering knuckle surface, especially of the
parts pointed by arrows in the fig.
Inspect with magnetic inspection

equipment.
The contacting area is

bigger than 3/4 of the total
Check contacting situation of steering
area
straight arm, Steering bend arm and ball
cone by colouring the contacting area.
The contacting area should be bigger than

3/4 of the total area.
Otherwise, change relevant parts.

Measure the clearance between
main pin and kingpin bush.
The clearance should be less

than 0.15mm.
Otherwise, change bush.
If the new bush is too tight after put in,

carefully machine the inside surface of the
bush with a reamer.
Concentricity of connection rod is 1mm.
Main operating steps of installation
Housing Add proper amount of grease before

Top installation Thrust bearing
Take care not to make wrong direction.

Bottom
Measure the clearance between steering
knuckle and I beam fist so as to choose
gasket with appropriate thickness.
Standard clearance after installation of

gasket is 0 to 0.1mm.
Ensure notch on the main pin align with lock

bolt hole when installing main pin.
Steering knuckle should turn freely after

filling grease.
Install lock bolt
Tighten it to specified torque.
Install main pin cover with an appropriate

round bar.
Tighten steering straight arm and steering
bend arm to specified torque.
Screw string rod ball to specified torque.

Steering
Steering
General
Specifications
Torque
Steering column and steering shaft
Steering gear disassembling
Power steering fluid filling and attention points
Trouble shooting
1
Steering
General
Steering gear
This model is provided with rotary valve type power steering gear
2
Steering
Steering linkage
Specifications
Steering column and shaft
Tiltable steering gear
Steering wheel  mm 430
Back play ℃ 10～15
Steering shaft type dual connector
Adjustable range Back and forth ℃ 11
Major specifications of the power steering gear

Max. applicable front shaft load 2500kg
Max. theoretical output torque 1580N.m
Steering round 4.2
Output angle ±46°
Output spline (OD×gear) Φ17.5×36
Output spline（big end OD×gear） Φ35×36
Operating pressure 10.3Mpa
Applicable operating temp. -40℃～135℃
Rated pump flow (8-11)L/min
Net weight 18kg
3
Steering
Torque（N·m）
Steering column
50－65
4
Steering
Device and tie rod
90－110
250－280
5
Steering
Steering column and steering shaft

Disassembling and assembling
Disassembling sequence （just contrary to assembly sequence）

1. Steering wheel assembly 12. Hex flanged face luck nut
2. Grouped switch assembly 13. Nylon limit bushing
3. Steering column handle cover 14. Bushing
4. Hex head bolt 15. Shaft sleeve
5. Flat gasket 16. Hex head bolt
6. Steering column handle 17. Steering column shaft sleeve assembly
7. Steering column adjusting lever nut 18. Adjustable steering support assembly
8. Spring 19. Steering column pipe dust cover
9. Limit support 20. Steering column pipe welding assembly
10. Adjusting piece 21. Steering drive shaft assembly
11. Adjusting nut 22. Steering column enclosure assembly
6
Steering
Important operation--Disassembling
Horn button
Pull out the horn button.
Steering wheel
Turn the steering wheel and steering shaft aside, make the mark, to
ensure that parts will be in the original positions during assembly.
positioning mark
Bolt: fix the worm shaft and steering knuckle

fork
(1) Tilt the cabin up, and support the cabin with the
strut.
fixing bolt
(2) Make positioning marks on the steering knuckle
and worm.
(3) Remove the fixing bolts with pneumatic spanner or

positioning fixed wrench, and then pull out the flange fork.
mark
(4) Lower down the cabin slowly.
Necessary correction or parts replacement shall be made if any abrasion, damage or other
abnormalities are found during inspection.
7
Steering
Reassembling
The reassembling sequence is contrary to that of the disassembling.
Important operation--Assembling
positioning
mark
Bolt: fix the worm shaft and the steering knuckle fork.
In fixing, alignment shall be made with the positioning

marks made
Steering wheel
Turn the steering wheel and steering shaft aside, make

the mark, to ensure that parts will be in the original
positions during assembly.
positioning mark
Important operation--Disassembling
Note: Before removing the steering gear assembly, take down the inlet/outlet hoses of the power
steering pipes first. At this time, pay special attention to the connector and screw plug, or seal the
oil injection port with ribbon after the oil pipe is taken down, to prevent dust or other foreign matters
getting in.
Important operation--Assembling
Steering vertical arm

positioning
mark (slot)
Align with the positioning mark.
Tightening torque range: torque (N.m) 250--270
8
Steering
Steering gear disassembling
1、big nut elastic washer + rocker 2、side cover +rocker-arm shaft assembly
3、locknut + adjusting nut assembly 4、thrust needle bearing
5、upper casing assembly 6、thrust ball bearing
7、rotary valve worm nut assembly 8、valve bush seal ring + valve bush seal washer
9、small O ring 10、Upper casing O ring
11、elastic retainer ring 12、input cup
13、steering nut seal washer + seal ring 14、lower casing assembly
15、output end cup + gasket 16、output end seal washer + seal ring
17、locknut 18、side cover assembly
19、rocker-arm shaft assembly 20、side cover O ring
21、side cover cup
9
Steering
Important disassembling steps：
1、Big nut +elastic washer +rocker

Turn the big nut counterclockwise by a torque
wrench, remove the elastic washer, and take
down the rocker arm.
Note: Do not hammer the rocker arm when taking
down it, otherwise the side cover and rocker-arm
shaft assembly will be damaged; and do not
damage the small cone hole in the rocker arm.
2. Side cover assembly + rocker shaft assembly

Turn the input shaft to have the assembly in the
middle position (the drawing shows that marked
line on small end face of the rocker arm is
downward). Remove the fixing screws of the side
cover.
Hit the small end face of the rocker arm with a
rubber hammer, and take down the side cover
assembly and the rocker-arm shaft assembly.
18. Side cover assembly

19. Rocker-arm shaft assembly
Turn the adjusting screw clockwise, and
takedown the rocker arm shaft assembly from the
side cover assembly.
Warning: Further disassembling of
rocker arm assembly is not allowed, or it
will be damaged; the side cover
assembly cannot be further
disassembled except the O ring, or it
will get damaged.
3. Locknut + adjusting nut assembly

Use the tool shown in the drawing to remove the
locknut, take care not to damage the O ring.
10
Steering
3. Adjusting nut
Use the tool shown in the drawing to remove
the locknut, take care not to damage the O
ring on it.
5. Upper case assembly

7. Rotary valve worm nut assembly
When taking down the above 2 assemblies,
take care not to lose the thrust ball bearing
(4) and its different parts(6).
5. Upper case assembly

Disassembly sequence：
1、elastic retainer ring for holes
2、cup on input side
4、upper case
6、upper case O ring
7、small O ring
Note: The needle bearing (3) and the
connector(5) shall not be taken down, or
they will be damaged.
14.Lower case assembly

Disassembly sequence：
1、 Cup on output side
2、 Lower case
3、 Seal ring on output side
4、 Seal washer on output side
5、 Dust ring assembly
Note: The needle bearing (7) shall not be
taken down, or it will be damaged.
11
Steering
Necessary repair or replacement shall be made if any parts abrasion; damage or other problems
are found during inspection.
Visual inspection：
 lower case
Check for any abrasion, damage or other
 rocker arm assembly
problems of the following parts.
 rotary worm nut assembly
 oil seal cup
 bearing
 O ring and seal ring
Turning of the worm nut

Turn the worm to see if it’
s smooth. Check the
spiral chute, the valve bush seals and the nut
seal for any damage.
Note: Do not disassemble the assembly and
do not damage the outer round surface of the
nut. If the valve bush seal or nut seal is
damaged, change them with new ones.
Rocker arm assembly

Check the rocker tooth section and the bearing
support for any abnormal wear. If any, have
them changed at the authorized service station
or manufacturer.
Clearance between rocker shaft and needle

bearing on output side
Limit（mm）：0.2
Clearance between nut and lower case piston

hole
Limit （mm）:0.15
12
Steering
Reassembling of steering gear
Reassembling sequence：
1、output side cup+ gasket 2、output side seal washer + seal ring
3、lower case assembly 4、side cover O ring
5、side cover cup 6、side cover assembly 6、side cover assembly
7、rocker shaft assembly 8、locknut
9、 side cover assembly + rocker shaft assembly 10、input cup
11、 steering nut seal washer+ seal ring 12、rotary valve worm nut assembly
13、 elastic retainer ring for holes 14、upper case O ring
15、valve bush seal ring + valve bush seal washer 16、upper case assembly
17、 small O ring 18、thrust ball bearing
19、thrust needle bearing 20、locknut+ adjusting nut assembly
21、big nut +elastic washer +rocker arm
13
Steering
Warning: The worm, nut, steel ball and valve components in the rotary valve worm
nut assembly are sophisticated parts that do not allow further disassembling;
otherwise, all the assembly will be damaged. And the screwed out length should
be controlled between the worm and nut, or the steel balls will fall out of the chute. All the
seals must be changed with new ones after disassembling.
9、upper case assembly
screw tightening torque：45N·m～55N·m
14、locknut
locking torque：180N·m～210N·m
15、rocker shaft assembly

18、side cover assembly
Turn the adjusting screw of the rocker shaft
assembly counterclockwise, until the rocker
shaft end gets contact with the side cover
bottom, and then turn 3-4 rounds backward.
Side cover assembly +rocker shaft assembly

Screw tightening torque：45N·m～55N·m
Warning: If the teeth are not installed
correctly, the steering gear will have
insufficient travel in one direction,
causing a steering accident. In fixing
the gear rack, check the spline for
any damage, to avoid scratches in
the oil seal of the cup.
14
Steering
11、locknut（side cover）
Adjust the clearance between the rocker shaft
gear rack and nut rack
（1） Fix the steering rocker arm
（2） Have the steering gear in straight
forward position (middle)
（3） Adjust the clearance to the specified
value
Gear clearance (mm)： ≤0.33
（4） Tighten the locknut
Tightening torque（N·m）
：65～80
（5） Check the start torque of the input shaft

Start torque（N·m）：0.4～1.2
21、Tighten the rocker arm

In fixing the rocker arm, ensure that the
tightening torque of the small end face of the
rocker arm is:
250 N·m～280N·m
Warning: ① If non specified power steering fluid is used or two kinds of fluids are
mixed, the sealing will fail, which causes no boosting for steering.② If the steering
gear stays too long at a limit position during operation, the steering oil pump will get
damaged.
15
Steering
Power steering fluid filling and attention points
Oil filling: Fill the oil tank with oil first, start the engine, operate the drive pump at low speed to fill
the hydraulic system with oil. During the engine running, the oil level in the tank will go down
continuously, so, oil filling is needed all the time to avoid air suction into the pump. At the same
time, turn the steering wheel right and left to its limit positions repeatedly for several times, until the
oil in the tank stops going down.
Oil change: jack up the front axle and open the oil reservoir cover. Open the return oil port of the
steering gear, and start the engine in short time less than 15 seconds. Turn the steering wheel
right and left continuously to its limit positions to drain off all the oil inside, and then fill in oil as per
the filling procedure.
Exhaust: jack up the front axle, it will also do to remove the connecting rod, have the engine at
idling, and turn the steering wheel right and left to its limit positions for several times drain off the
air and vaporized oil. When bubbles are removed, the oil level in the tank will go down, and now oil
shall be added from time to time until the oil level gets stable. By now the exhaust process is
finished.
Attention:
1. It is forbidden to mix oils of different types for use.
2. The oil to be filled must pass the filter strainer in the oil reservoir of the steering system.
3.Oil must be added up to between the two specified scale marks on the measuring scale in the oil
reservoir (After the engine is started for 3-5 minutes, check the oil filling if it is between the
specified scale marks. If over-filled, oil will overflows after the engine is started; if under-filled, the
rotary blade pump will get burnt down).
4. In regular oil change, the oil reservoir and filter element inside shall be cleaned and washed,
without any foreign matters allowed in. Take special care that no cotton fabric textiles are used
(such as cotton yarn and emery cloth, etc) to wipe the parts in order not to have any of them taken
into the system and cause failures.
16
Steering
Trouble shooting
Not fully working
Correctio
YES Oil pressure not enough
Check hose & connector for leakage
Loose hose coupling Parts failure
Repair linkage per Change
Check oil pump control
Clogge Damaged YES
Repair or Change
Check oil pump valve
Elasticity Broken YES

Check the
oil
Change
Check the piston ring
Damage YES
Change
Change steering gear box
17
Steering
Wandering
Check the body or chassis for any
Body or chassis deformed YES
Repair
Check wheel bearings
Bearing gap too YES Bearing
Adjust Change
Check linkage
Connector gap too YES Linkage

big or fixed parts
Change
Tighten or
Check front spring
Elasticity YES
Change
Check the control
Valve plunger gap too big Valve plunger clog YES
Tighten Change steering gear box assembly
18
Steering
Pump noises
Correctio
YES Pump noise

after
Check oil
YES Not enough
Refill
Check the hydraulic

loop for any air
Air trapped in the loop
YES
Vent
Check the outlet &

filter for blockage
YES Outlet pipe or filter clogged
Check oil pump Clean or
YES Failure
Overhaul Change
Check steering gear
19
Brake
Brake and Control System
General
Tightening torque
Front brake assembly
Rear brake assembly
Parking brake assembly
Trouble shooting
1
Brake
General
Front brake assembly Rear brake assembly
Parking brake Vacuum booster
2
Brake
Brake master cylinder
Brake pipe drawing

steel pipe connector
hose connector
vacuum hose
flexible hose
vacuum steel pipe
brake oil pipe
rubber hose
A、oil pot；B、vacuum booster, with serial master brake cylinder assembly；C、5-way connector；
D、front wheel cylinder；E、oil pipe tee；F、rear wheel cylinder；G. vacuum pump；H、vacuum
pipe tee；I、venting aux. brake；J. venting aux. brake solenoid valve；K、vacuum barrel；L、vacuum
pipe connecting plate.
3
Brake
Brake Specifications
Service brake
Front Rear
Type Dual leading shoe Duo duplex shoe
Brake drum ID (mm) 320 320
Length (mm) 307 307
Friction plate size Width (mm) 75 75
Thickness (mm) 8.1 8.1
Free length (mm) 208.0 208.0
Brake shoe return
Design length (mm) 224.0 224.0
spring
Design load (N) 225~275 225~275
Clearance between friction plate and brake Below 0.05 at rivet, below 0.2 at side, below 0.3
shoe (mm) at end face
Brake master cylinder
ID (mm) 31.75
Piston stroke（front + rear）(mm) 18+15.5
Wheel cylinder
Front Rear
ID (mm) 30.16 30.16
Parking brake
Brake drum ID (mm) 178
Length (mm) 193
Friction plate size Width (mm) 35
Thickness (mm) 5.0
Spring serial No. First Second
Brake shoe return Free length (mm) 62 49

spring Design length (mm) 70 57
Design load (N) 108～132 90～110
Vacuum booster
Diaphragm diameter (mm) 228+203
Stroke (mm) 35
Pedal
Free stroke (mm) 5～8
4
Brake
Fixed torque (N·m)
Front brake assembly (two leading shoe)
Rear brake assembly (two leading shoe)
5
Brake
Front brake assembly (two leading shoe)
Disassembling
Parts repair: wheel cylinder
1. brake shoe spring rod, hold down spring and spring holder 9.oil cover
2. brake shoe return spring 10.locking claw
3. brake shoe assembly 11.shield
4. brake hose 12.piston
5. brake connecting pipe 13.adjusting screw
6. brake connecting pipe 14.piston cup
7. tee connector assembly 15.venting screw and its cover
8. wheel cylinder assembly 16.wheel cylinder body
6
Brake
Important operation
2、Remove the return spring of the

brake shoe.
4、Hose
Loosen the connecting nut ①, and take down

the clip ② and the hose.

brake drum
Repair or replace the parts if they are
brake friction plate
found worn out, damaged or with other problems
wheel cylinder body after inspection.
piston
Visual inspection
piston cup
Check the following parts for any abrasion,
return spring
corrosion, scratches or other problems.
Thickness of brake friction plates
Max. thickness: 1.0mm
7
Brake
Return spring
Free length: 208.0mm
Design length: 224.0mm
Design load: 225～275N
Washing wheel cylinder parts

The wheel cylinder parts must be
washed and with clean brake fluid.
Do not use any mineral based cleaning
solution like gasoline, kerosene, and
acetone, paint thinner, CO4, etc.
Piston cup
Check the piston cup for any abrasion,
deformation, damage or other problems.
Clearance between wheel cylinder and
piston
Max: 0.15mm.
Brake drum
mm
Standard Maximum
ID 320 321.5
Out-of-roundness ≤0.13
8
Brake
Reassembling
Parts repair: wheel cylinder
1. wheel cylinder body 9.whell cylinder assembly
2. piston brake shoe 10.tee connector assembly
3. piston cup 11.brake connecting pipe
4. shield 12.brake connecting pipe
5. adjusting screw 13.brake hose
6. venting screw and its cover 14.brake shoe assembly
7. locking claw 15.return spring
8. oil cover 16.brake shoe spring rod, hold down spring and its holder
9
Brake
shield Important operation

piston piston cup
3. Piston cup
When fixing the piston cup, have its

grease butterfly side facing the cylinder. First, apply
clean brake fluid to the piston cup, take care not
to damage the cup lip. Apply rubber grease to
the piston shoulder.
4. Shield
To prevent water entry, apply clean

brake fluid to the shield inner surface.
6. Venting screw
Tightening torque：7～12N·m
9. Wheel cylinder assembly
10. Tee connector assembly
10
Brake
11,12. Tee connector assembly
13. Hose
Fix the hose clip ① on the bracket, and tighten

the connecting nut②.
14. Brake shoe
Apply a thin layer of heat resistance grease to

the brake shoe, wheel cylinder and the inner
surface of the back plate.
When fixing the brake shoes, have

their tip sides facing the wheel
cylinder and the adjuster.
11
Brake
Rear brake assembly (two leading show)
Disassembling
 parts repair, wheel cylinder body
1. brake shoe spring rod, hold down spring and spring holder 8.shield
2. brake shoe return spring 9.piston
3. brake shoe assembly 10.adjusting screw
4. brake connecting pipe 11.piston cup
5. brake connecting pipe 12.venting screw and its cover
6. wheel cylinder assembly 13.wheel cylinder body
7. locking claw
12
Brake
Repair or replace the parts if they are

found worn out, damaged or with other
problems after check.
Visual inspection
brake drum Check the following parts for any abrasion,
brake friction plate corrosion, scratches or other problems.
wheel cylinder body ,
piston
piston cup
return spring
Thickness of brake shoe friction plate
Max. thickness: 1.0mm
Return spring
Free length：208.0mm
Design length：224.0mm
Design load：225～275N
13
Brake
Washing wheel cylinder parts
The wheel cylinder parts must be

washed and with clean brake fluid.
Do not use any mineral based cleaning

solution like gasoline, kerosene, and
acetone, paint thinner, CO4, etc.
Piston cup
Check the piston cup for any abrasion,

deformation, damage or other problems.
Clearance between wheel cylinder and

piston
Max: 0.15mm.
Brake drum
mm
Standard Limits
ID 320 321.5
14
Brake
Reassembling
 parts repair, wheel cylinder body
1. wheel cylinder body 8. wheel cylinder assembly
2. piston 9. piston brake connecting pipe
3. .piston cup 10. brake connecting pipe
4. shield 11 brake shoe assembly
5. adjusting screw brake connecting pipe 12. brake shoe spring rod, hold down
6. venting screw and its cover spring and spring holder
7.locking claw 13. brake shoe return spring
15
Brake
Important operation
piston cup piston shield
3. Piston cup
When fixing the piston cup, have its butterfly

grease
side facing the cylinder. First, apply clean brake
fluid to the piston cup, then insert the cup. Take
care not to damage the cup lip. Apply rubber
grease to the piston shoulder.
4. Shield
To prevent water entry, apply clean

brake fluid to the shield inner surface.
Adjusting screw 5.Adjusting screw
When fixing the wheel cylinder adjuster, have

the shallow slot side face the outside.
6 Venting screw
Tightening torque 7～12N·m
9. Wheel cylinder assembly
16
Brake
9, 10. Brake connecting pipe
11. Brake shoe
Apply a thin layer of heat resistant

Adjuster grease to the back plate A between the brake
Side shoe and wheel cylinder as well as the inner
part B.
Narrow When fixing the brake shoes, have
Slot Side the tips face the wheel cylinder and
adjuster.
17
Brake
Parking brake
Disassembling
4 3
1. Parking brake handle 2. Parking brake control cable 3. Parking brake drum
4. Flange 5. Parking brake
18
Brake
Parking brake
Disassembling
1. pull-rod spring 2. return spring 3. adjuster 4 adjusting spring 5. 2nd brake shoe and lever
assembly 6. 1st brake shoe assembly 7. hold down rod 8. control cable assembly
Disassembling steps
Loosen the adjusting nut①, and remove

the control cable from the handle.
Loosen the nut② before removing the handle.
19
Brake
Repair or replace the parts if they are found

worn out, damaged or with other problems after
check.
● brake drum
● brake friction plate
● return spring
● strut
● control cable
● control handle
Brake drum
mm
Standard Limit
ID 178 179
Thickness of brake friction plates
Measure the thickness of brake lining by

a vernier caliper. If it is less than 1mm
thick, the brake shoe assembly should be
changed.
Return spring
Free length：62.1mm
Design length：66.9mm
Design load：54～66N
free length
20
Brake
Reassembling
1. control cable assembly 2. push rod 3. 1st brake shoe assembly 4.2nd brake shoe and lever
assembly 5. adjusting spring 6. adjuster 7. return spring 8. pull-rod spring
Adjustment of parking brake
Brake friction plate adjustment

Move the adjuster upward with a screw driver,
until the brake drum is locked. And then move the
adjuster back for about 25 notches. The
clearance between the brake drum and friction
plates is about 0.5mm by now.
Adjustment of the parking brake handle travel
Pull up the parking brake handle to the end，
count the number of the gears in the brake lever. If the parking brake handle is pulled with a force
of 300N, its travel covers 9 to 14 notches. Adjust the parking brake if necessary.
Before adjustment of the parking brake, make sure that the clearance of the rear brake shoe is
already adjusted.
1. Loosen the locknut, rotate the adjuster to adjust the travel distance.
2. Tighten the locknut.
21
Brake
Trouble shooting
Brake not working
Check the margin of brake pedal

NO YES
Check brake fluid Check operation of vacuum booster
NO YES YES NO
Check the hose on the booster

Change brake Check brake drum & friction disc
YES NO
NO YES
Check wheel cylinders Repair & change booster Change damaged

Change
parts,
NO YES
Change necessary parts Adjustment
22
Brake
Brake
Check the free travel &

margin of the brake
NO YES
Necessary Check driving brake friction

disc gap and brake pedal
YES NO
Necessary
All wheels dragging One wheel
Check for blockage in return

Check driving brake disc
hole of brake master cylinder
NO
Check wheel Adjust the clearance,

cylinders, piston or change the return
Noise from brake
Parts cleaning
Check friction disc
23
Brake
Brake not working
Check free travel of the pedal
NO YES
Check brake
Check brake fluid

NO YES
NO YES
Clean or
Check if the
change the
Add brake fluid and Check for
vent air from the pipes leakage of brake
Change parts
NO YES
Change necessary Check brake drum & friction
NO
Change necessary Adjust brake
24
Brake
Brake
Check side abrasion of tires
NO YES
Change the parts Check wheel positioning
NO YES
Adjust & repair Check for any leakage of brake
NO YES
Change necessary Check the wheel

cylinder operation
NO
YES
Check friction disc of brake drum
NO
YES
Check the brake return spring
NO
Change or repair the parts
25
Electrical System
Electrical System
General
I . Operation table
II. Electric diagram identification
1. Wire code identification:
2 . Electrical component identification:
III .Electrical designations and usages of the complete vehicle
1. Battery
2. Starter
3. Generator
4. Speed sensor
5. Electric preheating
6. Fuel cutoff solenoid valve
7. Wiper
8 .Washer
9. Headlamp
10 .Front small lamp
11. License lamp
12. Direction signal lamp and hazard warning lamp
13. Rear combination lamp
14 .Reversing lamp and switch
15. Interior lamp and switch 150
16. Brake lamp and switch
17. Parking brake lamp and switch
18 Fog lamp and switch
19. Electric horn
20. Vacuum alarm
21 .Various relays
22 .Combined switches
23. Combined instrument
24 .CD player
25. Idle speed boost device
26. Exhaust brake controller
27. Electrical device
1
Electrical System
General
I . Operation table
12 V
4DA1-2B1 4DA1-2B
Battery 6-QA-100D B B
Speedometer B B
Thermometer B B
Instrument Fuel meter B B
Two abnormal shape crystal
B B
Headlamp headlamps
Fog lamp B B
Speedometer B B
Thermometer B B
Fuel meter B B
Illuminator Meter board B B
Direction indicator and hazard
B B
lamp
Far beam indicator B B
Parking brake indicator B B
Brake liquid level indicator B B
Heating plug indicator B B
Oil pressure indicator B B
Indicator and caution Exhaust brake indicator B B
lamp Water separator indicator B B
Brake lamp and reversing lamp B B
Interior lamp Three level lamp changes B B
Intermittent wiper B B
Cigarette lighter B B
Horn B B
CD player and stereo
B O
radio cassette player
Buzzer Vacuum warning buzzer B B
Warm air and air conditioner B O
Manually-operated door and window B B
Motor-driven door and window O O
Note: B: Standard equipment O: Optional
2
Electrical System
II. Electric diagram identification

1. Wire code identification:
Specifications and colors of wires on the wiring diagram are distinguished by different
codes. As different countries use different color codes for the wires, JAC product
users and maintenance personnel should identify the wires according to Wire Color
Code in Electric Maintenance Manual of JAC automobile.
E.g.: 1.5GR
1.5----------Section of wire conductor is 1.5 mm2
G-----------Color of insulating layer is green
R-----------Color strip is red
Wire conductor section -Insulating layer ground color Color strip
1.5 G R
Color strip
Ground color
Cross-section area
Color codes of cables
Vinylon insulated wire

Application circuit
Black - white Black- yellow Black- red
Black (B)
Starter motor (BW) (BY) (BR)
White- red White- black White- blue White-
White (W)
Charging circuit (WR) (WB) (WL) Green (WG)
Red- white Red- black Red- yellow Red- green Red- blue
Red (R)
Lamp circuit (RW) (RB) (RY) (RG) (RL)
Green-
Green- white Green- red Green- Green-
Green (G) orange
(GW) (GR) yellow (GY) black (GB)
Signal circuit (GO)
Yellow- red Yellow- black Yellow- Blue -
Yellow (Y)
Metering circuit (YR) (YB) black (YB) yellow (LY)
Blue- white Blue- black Blue-
Blue (L) Blue- red (LR)
Wiper circuit (LW) (LB) orange (LO)
Lamp green Lamp green - Lamp green -
(Lg) black (LgB) red (LgR)
Brown- white Brown- red Brown-
Brown (Br)
Miscellaneous (BrW) (BrR) yellow (BrY)
3
Electrical System
2 . Electrical component identification:

Electrical components in the JAC automobile electrical diagrams are indicated in
common general signs. Refer to Common Automobile Electrical Signs for details.
Battery unit Fuse Relay Flasher Button

switch
Solenoid Electric Illuminator, Speaker Fuel gauge

valve horn indicator
tº
Combination Buzzer General Radio Thermometer

lamp hand cassette
switch sign player
M
U A
Motor Voltage Semiconductor Twin-filament Amperemeter

regulator diode lamp
Fig. 2 Common automobile electrical signs
III .Electrical designations and usages of the complete vehicle

1. Battery
(1) Battery is a kind of reversible low voltage direct current power supply that can
convert chemical energy into electric energy and vice versa. Lead acid battery is
supplied by JAC, which is dry-charged battery.
(2) Electrolyte in the battery is prepared by pure sulfuric acid and pure distilled water
in a certain proportion. Electrolyte purity is an important factor affecting the electrical
performance and service life of the battery. As the industrial sulphuric acid and
4
Electrical System
ordinary water contains foreign materials as copper and iron that accelerate the self
discharge, it cannot be used in battery. The sulfuric acid and distilled water used must
meet specialized standard.
(3) The battery is composed of six separate single cells that are connected in series
with led rod. The voltage of a single cell is 2V, so the nominal voltage of one battery of
six cells of series connection is 12V.
(4) The battery has charging hole that is sealed by plug screw. Charging hole plug
screw has vent hole to release hydrogen and oxygen generated from chemical
reaction. The vent hole must be kept clear in service. The shell may crack or explode
if it is clogged.
(5) Battery inspection: a If the electrolyte level is too low, please add distilled water to
the max. liquid level; b If the measured specific weight is under 1.23 (at 20℃), add or
replace the electrolyte.; c Keep the terminals reliably connect, remove any corrosive
marks and keep the battery terminal, power line and earth wire connection clean.
Battery inspection:
1. Check the terminal post for
looseness and corrosion
Keep the connection reliable. Remove
Max. level Max. level any corrosive mark and keep the
connection clean.
2. Check the electrolyte level of the
battery
If the electrolyte level is too low ，
Min. level please add distilled water to the max.
liquid level
2. Starter
The function of starter is to convert the electric energy of battery into mechanical
energy to drive the engine.
The starter used in this vehicle is 12V DC series excitation motor. It is composed of
three parts: (1) DC series excitation motor: to convert the electric energy of battery
into mechanical energy to generate torque; (2) Drive mechanism, also called
engaging mechanism: To engage the driving gear of the starter into the engine
flywheel toothed ring when the engine is started, so that the torque of starter is
transmitted to the engine crankshaft, and to disengage the driving gear of starter and
the engine flywheel toothed ring after the engine is started; (3) Control device: To
connect and disconnect the starter and battery.
5
Electrical System
Starter structure:
Adjusting shim
Moving core Reset spring Electromagnetic switch
Screw
Shift yoke
Conducting strip
Clutch
Brush
Driving gear Middle support Armature Reverser Magnetic

plate pole
Starter operating circuit:

Main power switch coil Combined switch (key) Earth
Power supply Main power switch contact Ampere meter Combined switch (start) Starting relay coil Earth
Fuse Starting relay contact Electromagnetic switch Starter

Earth
The maintenance personnel should carry out inspection and repair for the lines
indicated by the starter operating circuit diagram.
3. Generator
AC generator is the main power for the automobile. It is actually a self-exciting
three-phase synchronous generator. There are three windings at an interval of 120º
on the stator core of the generator. The ends of the three windings are connected,
which are usually called star connection. The rotor has field winding on it. Magnetic
field is generated when direct current passes the rotor winding. When the rotor is
turned by the engine, relative cutting movement is generated between magnetic line
of the rotor and three-phase winding of the fixed stator. Three phase alternating
electromotive force, i.e., AC power, is generated in the three-phase winding. DC
power is used in automobile circuit. So the AC power generated by the AC generator
must be rectified before using. The rectifying is made mainly by the silicon rectifier in
the generator. The three phase bridge full wave circuit composed of several silicon
diodes commutates alternating current into direct current.
Silicon rectifying shunt excitation AC generator is adopted in this vehicle, which is
6
Electrical System
composed of three phase AC motor and silicon diode rectifier. Minus earth is adopted.
Do not connect otherwise, or the generator may be damaged.
A
winding
Rotor
Winding
用电设备
蓄电池
Rotor
D D
consumers
Electricity
Battery
D
C
Stator D D D
AC generator Rectifier
Fig. 1 AC generator wiring diagram
4. Speed sensor
Speed sensor is fit on the generator end. The signal is taken from generator speed
signal terminal P. The number of pole pairs is 6. The generator and engine
transmitting ratio is 82: 145. The sensor output waveform is regular square wave.
5. Electric preheating
Electric preheating for the engine is adopted in cold season for this vehicle. The
heating wires should not be electrified for more than 30 sec., or they may be
damaged.
If the preheating effect is not good, check if the circuit is switched on first. If the circuit
is OK, use universal meter to check the heating wire and replace the burned-out
electric heater.
6. Fuel cutoff solenoid valve

There is one electronic component on the rear end of the engine injection pump. Its
function and wiring is as follows:
The electrical component is fuel cutoff solenoid valve. Its function is the same with that
7
Electrical System
of electric engine shut down device. The fuel cutoff solenoid valve is powered on
when the engine is started. The electric magnet lifts up the seal iron, so the injection
pump of the engine starts to supply oil and the engine starts normal operation. When
the engine needs to be shut down, turn the key to shutdown position, so the fuel cutoff
solenoid valve is power off and the seal iron cut the fuel path by the spring operation.
Power supply  Fuse Ignition lock LOCK (shutdown)
7. Wiper
The electric wiper of this vehicle is automatic reset type. For installation, the motor
should be in reset state. Then connect the link rod and wiper blade (wiper blade
position should be in reset state).
The variable speed switch controls the motor circuit to implement variable speed
wiping. The variable speed control circuit is as shown in the figure. The control
process is as follows:
a) Low speed wiping。 When the power switch is ON and the variable speed switch is
in I position, the current flow is as follows: battery positive pole→ power switch→ fusing
element→ brush B3→ armature→ brush B1→ variable speed switch I position
earth→ battery negative terminal. As the brush B2 has an offset angle, the wiper blade
swings fast when the motor is running at high speed.
b) When the power switch is ON and the variable speed switch is in II position, the
current flow is as follows: battery positive pole→ power switch→ fusing
element→ brush B3→ armature→ brush B2→ variable speed switch II position
earth→ battery negative terminal. As the brush B2 has an offset angle, the wiper blade
swings fast when the motor is running at high speed.
c) Shutdown and reset. The automatic reset mechanism of motor wiper is as shown in
Fig. 1－21 (b). The nylon impeller is embedded with copper ring 7 and 9. The copper
ring has two parts. The larger copper ring 9 is connected to the casing to earth.
Contact piece 3 and 5 is made of phosphorus copper or other elastic material.
Wiper variable speed control wiring diagram
8
Electrical System
1-Power switch; 2-Fusing element; 3、5-Auto reset contactor; 4, 6-Contact;

7, 9-Auto reset slide ring (copper ring); 8-Worm wheel; 10-Armature; 11 - Permanent
magnet
Contact 4 and 6 is riveted on one end. As contact 3 and 5 is elastic, when impeller 8
turns, contact 4 and 6 maintains contact with the end surface of impeller 8 (including
copper ring 7 and 9).
When wiper variable speed switch is in "0" position, if the rubber brush does not stop
at bottom edge of the windshield glass, the impeller turning will make contact 6 and
copper ring 9 connect, so the current keeps flowing into the armature. Here the
current forms a circuit from battery positive pole→ power switch→ fusing
element→ brush B1→ variable speed switch→ contact piece 5→ contact 6→ copper ring
9→ earth→ battery negative terminal. The motor runs at low speed until the impeller
turns to the position shown in Fig. 1－21 (a) and contact 4 and 6 connects with copper
ring 7.
When contact 4 and 6 is connected with copper ring 7, the motor cannot stop
immediately owing to the inertia force of armature turning. Instead, electricity is
generated with engine operation. As the direction of electromotive force generated by
armature winding is opposite to that of external supply voltage, the current flows in the
circuit of brush B3→ contact piece 3→ contact 4→ copper ring 7→ contact 6→ contact
piece 5→ variable speed switch→ brush B1. Torque is also generated (called brake
torque) to make the motor stop immediately. Here the rubber brush is just reset to the
bottom edge of the windshield.
The maintenance personnel can look for the fault of wiper circuit according to the
wiper working principle and variable speed control wiring diagram.
a. Main components
Designation Quantity Mounting position
Connecting rod assembly 1 Bottom edge of front windshield
Wipe rod and brush assembly (left) 1 Front windshield
Wipe rod and brush assembly (right) 1 Front windshield
Rain wiper motor assembly 1 Inside the cab
Washer jug assembly 1 Inside the cab
Water pipe assembly 1 Inside the cab
Nozzle assembly 2 Cab front panel
Control switch (combined switch) 1 On steering column
Wiper relay 2 Inside the cab fuse box
9
Electrical System
b. Functional requirements
I. Three operation modes of high speed, low speed and intermittent
II. Automatic reset function of wiper rod
III. Interval of intermittent operation can be adjusted
IV. Linked control of washer and wiper
c. Circuit design
Slow speed relay

High speed relay
High
speed Slow Wiper motor
speed
Motor
Washer
motor
Diode
Combined
switch
Earth
8 .Washer
Dust or dirt may get onto the windshield glass during the driving. To ensure good sight
of the driver, most vehicles have windshield glass washer.
When the washing engine armature is powered on, it turns in the permanent magnetic
field. When the armature shaft turns, it drives the pump shaft via coupling, so the
10
Electrical System
pump rotor also rotates. The pump rotor pumps the washing liquid from the pot to the
wind shield via the outlet hose and the nozzle. In the meantime, the wiper blade
swings to remove the dirt on the wind shield glass.
To use the washer, switch on the washing pump before the wiper. The continuous
work time of washing pump should not exceed 5s, interval not be less than 10s. When
there is no washing liquid in the pot, do not switch on the washing pump. Otherwise,
the motor may be damaged.
9. Headlamp
The headlamp of this vehicle is anti-glare combination lamp. The bulb is twin filament
type (long-distance beam/short-distance beam). When long-distance beam is
switched on, the long-distance beam indicator on the dashboard illuminates at the
same time. Lamp switch and change is operated from the group switch.
If the lamp is not ON, please check in the following sequence.
Step Inspection content Method
Check if the fuse is If the fuse is blown, replace it after the cause is
1
blown found. If not, check the next item.
Turn on the lamp switch to see if the headlamp relay
Check if the lamp relay
2 operates. Or use a universal meter to check if the
operates normally
relay terminal is OK.
If the result of the above checks is acceptable,
Check the headlamp
3 please check if the bulb is damaged. If not, check
bulb
the next step.
Check if the wiring Check if all the terminals are reliably connected
4
connectors are reliable according to the wiring diagram.
Check the combined Check if the lamp switch on the group switch can be
5
switch (lamp switch) normally turned on
11
Electrical System
Main power supply
Headlamp
circuit
Short-distance Long-distance
beam relay beam relay
Left Headlamp Right

Short-
distance Long-
headlamp long-dista Short-
distance Long- headlamp
beam distance
beam nce beam beam distance
beam
indicator
Small Short- Combined

distance
switch
lamp Headl
amp Lamplight beam Lamplight
switch Flicker switch
10 .Front small lamp

The front small lamp of this vehicle (width lamp) is combined lamp, i.e., front small
lamp on the lower part and direction lamp on the upper part. Check for fault according
to the small lamp operating circuit:
Power supply Fuse  Relay coilCombined switchEarth
Relay contact Front small lampEarth
The trouble shooting method is the same with that of front lamp. The difference is that
you need to check the small lamp relay when you check the relay.
11. License lamp

The license lamp is on the plate support on the rear of the vehicle. The license lamp is
ON when the lamplight switch is in any position.
The trouble shooting method is the same with that of small lamp.
12
Electrical System
License lamp
To replace the bulb, remove
one screw fixing the lens.
Check for fault according to the license lamp operating circuit:

Power supply Fuse  Relay coilCombined switchEarth
Relay contactLicense lampEarth
12. Direction signal lamp and hazard warning lamp

The direction lamp and front small lamp is combined. It is on the top of the combined
lamp. The light color is yellow. The operating circuit of the direction lamp is shown
below:
Power supply  Fuse  Flasher ---Combined switch ----Left and right direction lampEarth
---Left and right direction lampEarth
---Warning switch
The direction lamp circuit should be checked according to the circuit diagram. When
the vehicle is at fault or there is other danger, turn on the warning switch. The bulbs of
the direction lamp flicker at the same time to give a warning. The trouble shooting
method is the same as above.
13. Rear combination lamp
Rear lamp is a combined lamp with brake lamp, reversing lamp and direction lamp at
the bottom of the rear of the vehicle on both left and right. The color is red. The rear
lamp control switch is on the lamp switch of the combined switch. Its circuit is:
Power supply  Fuse  Relay coilCombined switchEarth
 Relay contactRear lampEarth
Note: The rear lamp use the same relay with front small lamp. It also share the same
fuse with front small lamp, license lamp, fog lamp and instrument lamp. The
maintenance personnel should pay attention to this in maintenance. The trouble
shooting method of rear lamp is the same with that of front small lamp.
Rear combination lamp

To replace the bulb,
unscrew the four bolts
fixing the lens.
13
Electrical System
14 .Reversing lamp and switch

Reversing lamp position is the same with that of rear lamp. The reversing lamp light is
white in color. The reversing lamp works together with the reverse gear switch
mounted on the gearbox. Its operating circuit is:
Power supplyFuseReverse gear switchReversing lampEarth
Note: the reversing lamp shares the same fuse with brake lamp and roof lamp. Please
pay attention to this in maintenance and repair.
15. Interior lamp and switch 150

The interior lamp is at the middle of the upper edge of the front windshield of the cab.
It has two switches, one is the roof lamp composite switch and the other is the door
post switch installed on the left door post of the cab. Its operating circuit is:
Power supply  Fuse  Interior lamp  Interior lamp switch  Earth

 Door post switch  Earth
Interior lamp switch

circuit diagram
OFF ON
Interior lamp
Door switch
Interior lamp switch position
14
Electrical System
ON OFF Door
16. Brake lamp and switch

Brake lamp position is the same with that of rear lamp. The brake lamp light is red and
the brightness is higher than that of rear lamp. The brake lamp works together with the
brake lamp switch mounted on the brake pedal. Its operating circuit is:
Power supply FuseBrake switchBrake lampEarth
Note: the brake lamp shares the same fuse with reversing lamp and roof lamp. Please
pay attention to this in maintenance and repair.
17. Parking brake lamp and switch

Parking brake switch is integrated with parking brake control lever. When the manual
control lever is lifted, the parking brake switch is ON. Here the parking brake indicator
on the dashboard turns ON. Let down the manual control lever, and the parking brake
switch is OFF and the parking brake indicator is OFF. Its operating circuit is:
Power supplyFuse Parking brake indicatorParking brake switch Earth
Parking brake indicator sign on the dashboard:
P
18 Fog lamp and switch

The fog lamp is combined with the headlamp and its light color is yellow. The working
principle of fog lamp is: when you drive on a foggy day, first switch on any lamp on the
combined switch and then press the fog lamp switch to turn it on. Turn off the lamp
switch on the combined switch or the fog lamp switch to turn off the fog lamp.
Fog lamp operating circuit:
Power supply  Fuse  Relay coil Combined switchEarth
 Relay contact Fog lamp switch Fog lamp Earth
Note: The fog lamp shares the same fuse with the front small lamp, rear lamp, license
lamp and instrument lamp. The maintenance personnel should pay attention to it in
repair.
15
Electrical System
19. Electric horn

The electric horn of this vehicle is dual tone (high and low tone) electric horn. It is
fitted on No. 1 girder on the chassis in the middle of the front bumper. Its operating
circuit is:
Power supply  Fuse  Horn relay coil Horn buttonEarth
 Relay contact Horn Earth
Note: The contact of horn button is an elastic joint on the combined switch that keeps
effective connection with the button contact iron ring on the steering wheel. Pay
attention to the connection state of the contact in maintenance.
Electric horn:
Relay：Horn Wiring diagram
Switch
：Horn
Horn
Horn specifications:
Structural Diaphragm Sound level Base frequency Volume range
shape diameter mm dB (A) range Hz fitting (dual tone)
Disc type >115 105~125 250~650 4: 5
If the horn does not sound or sounds
abnormally when you press the horn
button, check the line and battery voltage
before the following items:
1. Check if the fuse is blown. At the same
time, check if the wire connection is tight.
2. If both the fuse and connector can
operate in normal sequence, remove the
horn from the steering wheel and
short-circuit the horn switch guide line
terminal and the steering shaft thread.
a. No sound --- Poor contact between horn
contact of the combined switch and the
steering wheel bottom.
b. Sound --- The horn switch is at fault.
3. If the horn sounds without stop, the
16 source of trouble may be the horn switch
or bad reset contact ring.
Electrical System
20. Vacuum alarm

When the vacuum pressure in the vacuum cylinder exceeds certain value, the
pressure contact on the vacuum horn closes to complete the circuit. The vacuum
alarm buzzer and alarm lamp on the dashboard is switched on to warn the driver to
find out the cause.
The vacuum abstraction is carried out by the vacuum pump on the generator. The
maintenance personnel should pay attention to this in repair.
Alarm lamp identification:
！
21 .Various relays
The relays for this vehicle include lamp relay, horn relay, warm air relay, starting relay
and preheating relay. As the lamp, horn and warm air does not consume high current,
relay of the same specification is used for these current consumers. The solenoid
switch of the starter and heating plug consumes high current, so they use special
purpose relays that are installed in the chassis electric box. From left to right, starting,
preheating, horn, air conditioner and braking relay.
22 .Combined switches
The combined switch is a switch integrating power, start, lamp, wiper, washer and
direction lamp. There are many lines together, so faults are likely to occur here. It will
help the maintenance personnel a lot to know about the structure of the combined
switch in electric trouble shooting.
Combined switch structural diagram
1. Ignition switch working position conduction diagram
Contact code
ACC ON R ST P1 P2 R1 Remark
and power B B1 R2
220W 240W 60W 220W 40W 40W 60W s
Working gear
Wire color B L BY BR BW LY LW L R Y
Specification mm² 5.0 3.0 3.0 3.0 3.0 1.0 1.0 1.0 0.75 0.75
LOCK 〇〇
ACC 〇〇〇〇
17
Electrical System
ON 〇〇〇〇〇
START 〇〇〇〇〇〇 Automa
tic reset
Power Key in 〇〇
switch
Key out 〇
2 Lamp switch beam selection and overtaking signal conduction diagram

Contact code BT E J B BH HU
Rated power 80W 120W 10W 150W 150W
OFF
〇〇〇 Overtaking
〇〇
Small lamp
〇〇〇 Overtaking
Gear
Short-distance 〇〇〇〇
Headlamp
beam 〇〇〇〇〇〇 Overtaking
Long-distance 〇〇
〇〇
beam
18
Electrical System
3 Direction switch, warning switch, exhaust brake switch and horn conduction
diagram
Contact code TL TB TR B1 F B2 EX ER HO
Rated power 72W 144W 72W 120W 120W 120W
Warning Direction
switch switch
L 〇〇〇〇
OFF OFF 〇〇
R 〇〇〇〇
ON OFF 〇〇〇〇〇
Exhaust OFF
brake
ON 〇
switch
Horn 〇
4 Wiper switch and water spraying switch
Water
Wiping 11 E1 12 AS L H E2 W E3
spraying
OFF 〇〇
INT 〇〇〇〇
OFF
LO 〇〇
HI 〇〇
OFF INT 〇〇
ON
LO HI
EZ
19
Electrical System
23. Combined instrument
Instrument
1. Transparent top cover 6.Pointer component
2. Instrument decorative ring A 7.Gauge plate
3. Instrument decorative ring B 8.Middle cover
4. Black frame 9.Circuit board parts
5. Reset rod 10.Bottom cover
Follow the reverse order of disassembling to reassemble.
20
Electrical System
1 Instrument indicator:
No. Designation Function Color
1 Engine oil pressure alarm ON when the engine oil pressure is too Red
lamp low
2 Charging indicator ON when the battery discharges Red
3 Parking brake alarm lamp ON when the parking brake is switched Red
on
4 Preheat indicator ON during the preheating Yellow
5 Exhaust brake indicator ON when the exhaust brake is switched Yellow
on
6 Left/right direction indicator ON when the direction lamp is switched Green
on
7 Beam indicator lamp ON when the headlamp is switched on Blue
8 Fog lamp indicator ON when the fog lamp is switched on Yellow
9 Hazard alarm lamp indicator ON when the hazard alarm is switched Red
on
10 Fuel oil level alarm lamp ON when the fuel oil level is low Yellow
11 Small lamp indicator ON when the small lamp is switched on Yellow
12 Door open alarm lamp ON when the door is open Red
13 ABS alarm lamp ON when the ABS system is at fault Yellow
14 Brake fault alarm lamp ON when the brake is at fault or the Red
brake fluid is low
1) Main component installation

Main component Model Mounting position
Combined Stepping motor type Under dashboard
instrument
Speed Middle of combined instrument
meter/odometer Electronic
Odometer sensor On gearbox output shaft
Engine oil pressure Varistor type On engine oil pipe
sensor
Water temperature Thermister On engine water inlet pipe
sensor
21
Electrical System
Fuel oil sensor Varistor type Inside oil tank
22
Electrical System
2) Indicator and warning switch:

Engine oil pressure indicator switch
Wiring diagram
Indicator switch position
Switch specification
Working pressure: 0.3- 0.5 KSC.
When the oil pressure is as low as the
switch action pressure, the indicator
is ON.
23
Electrical System
Vacuum alarm switch

Alarm buzzer Wiring diagram
Its position is the inner side of the left
pedal in the cab.
Switch：Vacuum
Switch specification
Stamping sign: 350
Negative pressure (mm hg): 320- 380
Note: The switch has working negative

pressure mark. Make sure that you
replace it with switch of the same
negative pressure when necessary.
ON Parking brake switch

Wiring diagram
OFF
Switch
24
Electrical System
2 Technical requirements:
Technical requirements of combined instrument
3801910D800 Combined instrument assembly
The basic deviation requirements are as follows:
Basic deviation
Indicated speed 20 40 60 80 100 120 140 160
Km/h
Speedometer
Allowable +5 +5 +5 +5 +6 +7
(stepping motor ±3
deviation Km/h 0 0 0 0 0 0
type)
Transmitting 1:637 Interface mode Sensor type
ratio
Indicated mark E 1/2 F
Basic resistance 97 32.5 6
Fuel gauge (Ω)
(stepping motor Allowable ±16 ±6.5 ±3
type) deviation (Ω)
Sensor Designation Fuel oil Model RG1164B1
sensor
Indicated mark C (50) 100 H (115)
(℃)
Water Basic resistance 230 40.4 26.4
temperature (Ω)
gauge Allowable ±30 ±5 ±1.5
(stepping motor deviation (Ω)
type) Sensor Designation Water Model WG1371
temperature
sensor
All alarm indication systems of 3801910D800 instruments conform to GB4094 - 1999

Signs of automobile controls, indicators and signal devices.
DJY7121-1.6-20;DJY7141-1.6-20;DJY7121A-1.6-20 combined socket is adopted for
the instruments.
24 .CD player
A single disk dual track CD player is mounted on this vehicle. The L channel speaker
is mounted in the left door and the R channel speaker is mounted in the right door.
If you find that some functions do not work, please read carefully the operation
instructions in the manual first before you send it for repair. You can check the player
according to the following table. It will help you fix the trouble.
25
Electrical System
Please send the player to the maintenance service station if the fault cannot be fixed.
Do not disassemble the player to repair it by yourself.
General situation
The player does not work and there is no display.
·Check the fuse connection of the player and vehicle
·Check the voltage.
The player works but there is no sound or the sound is very low
·Raise the volume.
·Check the front and rear, left and right balance setting of the horn.
·Check the antenna and connection.
Horn volume lowers by itself
·The internal safety circuit can prevent the internal temperature from exceeding
certain value.
·Raise the volume after the temperature is lowered.
Reception
Cannot get the channel:
·Check if the antenna is fully drawn and if the connection is right.
·Check if the negative terminal (brown line) is grounded (chassis).
·Please use manual tuning if the signal is too weak.
Poor reception:
·Some vehicle (such as Volkswagon and SEAT) needs a 12 V antenna on the top.
Please consult your dealer if there is 12 V power supply to this antenna.
CD
CD ERROR is displayed:
·Check if the CD is correctly inserted, and make sure that the CD is not broken or dirty.
Distortion of sound
·CD cannot be read, damaged or dirty.
CD player out of operation:
·Moisture may condensate on the laser magnetic head when it is very cold. Turn it to
radio reception for about 5 minutes to let the moisture evaporate.
NO CD or NO DISC is displayed.
·Check if there is CD in the CD player.
26
Electrical System
25. Idle speed boost device

A solenoid valve called idle speed boost device is fitted on the rear end (left side of the
chassis) of the vacuum pump on the engine. When the engine is at idle speed and the
air conditioner is switched on, it boosts the idle speed of 700r/min to 850±50r /min, so
that the power generation meets the requirements of the air-conditioner. Its functional
diagram is as follows:
Connecting rubber tube2 Vacuum membrane box Engine throttle lever
Wire1
Drawbar
Wire2
Connecting rubber tube1

Vacuum
pump pipe
Solenoid valve DF156(Suction voltage<9V, Release voltage>1V)
When the air conditioner is switched on, the solenoid valve of the idle speed boost
device operates so that rubber tube 1 and rubber tube 2 is connected. With the
vacuum membrane, the fuel up lever is pushed by the push rod to the fuel up direction,
so that the engine idle is raised to 850±50r /min. The wiring diagram is as follows:
Compressor
Fuse Air conditioner switch electromagnetic clutch
Idle speed boost valve
27
Electrical System
26. Exhaust brake controller

1. Wiring diagram
Acceleration Clutch
switch switch
Alarm
buzzer
Magnetic
valve
Vacuum
switch
2. Switching diagram
ON OFF
3. Accelerator and clutch switch:

Maximum stroke: 4mm;
Working stroke: 2.0-2.8mm.
OFF
Max. travel
4.Position of exhaust brake solenoid valve

(left arrow)
28
Electrical System
27. Electrical device

Disassembly of line bundle connector:
Please always both hands to cut the
connector. Drawing the connector with
single hand will result in rupture of the
wire terminal.
Note: press the lock plates on both sides
before drawing out the connector to cut.
Connection of line bundle connector:

Wrong
Clench both sides (male and female) of the
connector and make sure that the connector
terminal pins match and align with the
holes. Press both sides of the connector
carefully until you hear a clear click.
Correct
Wrong Inspection of line bundle connector:

Use circuit tester to check the connector
Probe continuity. Insert test probe from side of
the connector wire
Do not insert the test probe in connector

open end
Correct
Probe
29
Electrical System
Inspection of fuse line:

Fuse line
The fuse line is fitted on battery positive
Starter
switch
terminal and starter switch B terminal
If there is over current, the fuse is blown to
protect the main power supply from being
overloaded. Please use universal meter to
check the continuity of the circuit.
Starter motor
Pin Disassembly of wire terminal

Barb 1. Insert a pin into the open end of the
Wire
connector shell
2. Press the barb (facing the connector wire
side) and pull the wire on the connector
wire side.
Terminal
Open end
Insertion of wire terminal:

Barb Wire
1. Check if the barb is completely open.
2. Insert the terminal from connector wire
side and press it until the barb fixes it
firmly.
3. Pull the wire gently to reset the terminal.
Terminal
Wrong Precautions of line bundle arrangement:

Use jacket or sleeve to protect the line
bundle and avoid direct contact with sharp
edge or surface.
Correct
30
Electrical System
Wrong There should be sufficient clearance between

the line bundle and bracket. Use ethylene
sleeve and clip to protect the line bundle and
avoid direct contact.
Correct
Sleeve
Clamp
The line bundle between the engine and chassis

should be long enough to avoid abrasion or
damage owing to vibration.
Wrong
Correct
Normal Damaged Fuse:

Fuse is the most used circuit protection of
vehicle circuit. When there is over current in
the circuit，the fuse is blown to prevent the high
current from damaging other parts in the circuit.
Find out the cause of overload current and solve
the problem before you replace the fuse.
Use new fuse of the same ampere to replace the
original one. Otherwise, there will be line
burning or other serious damage to the circuit.
Circuit breaker:
Breaker is a protective device to open the
circuit when the load current exceeds the rated
breaker capacity.
If there is short circuit or other form of
overload, the over current will open the circuit
on both sides of the breaker. When the circuit
is open, the breaker button pops up.
Push
31
Electrical System
Chassis electrical device diagram:

Front side:
Generator
Engine earth
To cab line bundle wire
To compressor
To water
temperature To heater plug
line
Electric horn
Engine oil
pressure alarm Engine line
bundle
Starter
To fluid tank Idle speed boost device
Chassis electrical
devices box
32
Electrical System
Middle and rear side:
Oil water separator
Clamp
Reverse gear switch Exhaust brake solenoid valve

To rear lamp
license lamp
To condenser fan
Band
Battery negative
Battery positive terminal line
Battery
terminal line assembly
33
Electrical System
Air heating & air conditioning equipment
Generator
Troubleshooting
34
Electrical System
General
1. Air conditioner refrigeration cycle

1.1 main parts of refrigeration system
Refrigeration cycle system of integrated air conditioner (warming and cooling) of JAC
vehicle mainly consists of compressor, compressor exhaust hose, condenser
assembly, reservoir, HP hose, F type expansion valve, evaporator assembly, and LP
hose. The reservoir assembly includes internal drier and filter etc., as well as HP/LP
pressure switches, sight mirror and fusible plug installed on casing.
1.2 Refrigerating principle
The compressor sucks in and compresses low temperature, low pressure refrigerant
gas to generate high temperature, high pressure refrigerant gas, which will be sent to
condenser via HP hose for condensing, releasing heat to air passing condenser and
being condensed to high pressure medium temperature liquid. This liquid flows to the
reservoir where impurities in refrigerant are filtered and water content is removed, and
then flows to expansion valve via HP hose, where it is changed to low pressure, low
temperature liquid-gas mixture by throttling and depressurizing effect of the valve, and
then enters the evaporator. This mixed refrigerant will evaporate in the evaporator and
absorb heat from air inside vehicle and flowing pass the evaporator to become
superheated gas, which will enter compressor for next refrigeration cycle. Air inside
vehicle passing the evaporator will discharge heat to the evaporator and become cold
air. In addition, since temperature of evaporator surface is lower than air dew point,
water vapor in air will condense to become dew that will be drained outside the vehicle,
hence reducing temperature and humidity of air inside vehicle. Fig.1 shows air
conditioning refrigeration schematic diagram.
Expansion Reservoir
valve
Evaporator Condenser
Compressor
Fig.1 Air conditioning refrigeration schematic diagram
35
Electrical System
2. Air conditioning warming cycle

2.1 Main parts of warming system
Warming cycle system of integrated air conditioner (warming and cooling) of JAC
vehicle mainly consists of warm air blower, engine, water pump, water valve, water
tank and pipelines etc.
2.2 Warming principle
By means of a water pump, hot coolant of engine is pumped into warm air blower core,
where heat exchange occurs to release heat to air inside vehicle. Later, this coolant
returns to the water tank and enters next warming cycle.
Water pump Warm air

(water tank) blower core
Engine Water valve
Fig.2 Air conditioning warming schematic diagram
3. Electric control
3.1 Main parts of electric control
The electric control mainly consists of power supply switch, electromagnetic clutch,
controller, defrosting thermistor, defrosting temperature controller, HP/LP pressure
switches, electric control box, governing resistor, and connection harness etc.
3.2 Electric control principle
The controller is the control center of air conditioning (refrigerating and warming parts).
Electronic elements in the electric control box are used to control On/Off of
refrigerating and warming, and adjustment of AC fan rotation speed and temperature.
The power supply switch is used to control driving power of the air conditioning. This
switch is a mina part of the controller and functions to turn AC on or off (also referred
to as A/C switch). At gears 1, 2, 3 and 4, refrigeration will be executed.
3.2.1 Temperature control
The defrosting thermistor is a control element that senses temperature of discharged
air from evaporator. It directly converts temperature to electric signal and transmits
36
Electrical System
this signal to the defrosting temperature controller inside electric control box. The
defrosting temperature controller receives electric signal from defrosting thermistor
and control On/Off of compressor EM clutch according to set parameters (i.e. On/Off
of air conditioning refrigeration cycle), so as to control temperature inside the vehicle.
The electric control box is the execution center of air conditioning control. It receives
commands from controller and feedback electric information from defrosting
thermistor, and uses internal relays to control On/Off of compressor clutch.
3.2.2 Pressure protection control
The HP/LP pressure switch is a safety part used to ensure safe operation of
refrigeration system. When the high pressure is ≥3.14MPa or low pressure is
≤0.2MPa, this switch will be turned off, disengaging compressor clutch and stopping
the refrigeration system. When system high pressure falls to 2.5MPa or system low
pressure rises to 0.23MPa, this switch will be turned on, engaging compressor clutch
and starting the refrigeration system.
1. Technical parameters
S/N General item Sub-item Parameter
Code R134a
1 Cooling medium
Amount of filling 0.85kg
Code PAG56
2 Refrigerating oil
Amount of filling 150g
Model 5H14
3 Compressor Voltage 12V
Displacement 138cm3/r
Condenser heat sinking
9000W
capacity
Condenser with
4 Voltage 12V
reservoir assembly
Maximum current 15A
Air flow 1800m3/h
Refrigerating capacity 3900W
Heating capacity 4000W
Front evaporator/
5 Voltage 12V
heater assembly
Maximum current 18A
Air flow 350m3/h
Disconnected at
High pressure protection
2-state pressure ≥3.14Mpa
7 characteristics
switch Connected at ≤2.5Mpa
Low pressure protection Disconnected at
37
Electrical System
characteristics ≤0.2Mpa
Connected at ≥0.23Mpa
2. Structure of main parts of air conditioning
2.1 Heating equipment, blower equipment and evaporator
1
7
3
5
1. Lower cover; 2. Fuse and relay box; 3. Ventilating air duct; 4. Evaporator; 5. Blower;
6. Heating equipment; 7. Instrument stand
For removal of heating equipment, blower and evaporator from instrument stand,
follow this sequence: 1. lower cover 2. fuse and relay box 3. ventilating air duct 4.
evaporator 5. blower  6. heating equipment.
38
Electrical System
Sequence of assembling is the reverse of this sequence. For tightening torques, refer
to the table below:
Tightening torque (N·m)

Diameter of thread (mm) Pitch (mm) Standard
Maximum Minimum
value
6 1 9 12 6
8 1.25 23 26 16
8 1 25 28 17
10 1.5 59 75 37
10 1.25 63 79 45
10 1 64 80 46
12 1.75 95 111 73
12 1.5 97 113 75
12 1.25 99 115 78
Important operation-assembling
● To assembly blower, prevent water leakage.
Sealant Butyl rubber (none-dry type)
Air conditioning panel

● Turn mode handle to left most (FACE direction);
● Turn temperature lever to left most (COLD
direction);
● Turn inner/outer air control lever to left most
Control cable “A”
(INSIDE direction)
Control cable “B”
● Hang control cable “C” on blower clip, press

butterfly nut to bottom and fix cable on clip;
Air heater ● Hang control cable “B” on heater clip, press
butterfly nut to bottom and fix cable on clip.
Control cable “C”

Hang control cable “C”on blower clip, press
butterfly nut to bottom and fix cable on clip
39
Blower
Electrical System
2.2 Structure of condenser assembly
1. Condenser damping pad sleeve; 2. Hex flanged face nut;

3. Pad; 4. Condenser core;
5. Condenser damping pad; 6. Condensing fan assembly;
7. Bolt combination
Important operations
1. When removing pipe from each device, avoid damaging connecting nut or the pipe.
2. Cover pipe port with plastic cloth to avoid ingress of dust in pipe.
40
Electrical System
2.3 Disassembling and assembling of compressor
Disassembling sequence: Assembling sequence:

1. Pipe 4. Compressor
2. Belt 3. Idler
3. Idler 2. Belt
4. Compressor 1. Pipe
Important operations
1. To remove pipe from each device, avoid damaging connecting nut or the pipe.
2. Cover pipe port with plastic cloth to avoid ingress of dust in pipe.
Operation prompts
1.1 To avoid accidents and ensure safety of relevant personnel, non-discipline
personnel must not perform disassembling or repair.
1.2 Use of open flame or smoking is prohibited.
1.3 Always wear working clothes during working. Ensure intact protective devices.
1.4 Perform operation in a weld ventilated environment.
1.5 Before starting the engine, confirm that there is no tool, measuring instrument or
other part on moving and rotating parts, and parts through which electric current flows.
1.6 Before start of engine, blow horns to warn operating workers and confirm safety.
1.7 To check electric lines, take care not to touch terminals or other parts through
which electric current flows; otherwise short circuit may occur due to human body or
41
Electrical System
other part.
1.8 Use fuses of rated capacity. Avoid burning of electric devices such as relay and
fire.
1.9 When using hose and hard pipeline, take care to avoid leakage of gas.
1.10 Thoroughly clean dust at hose or hard pipeline connecting part and inside
pipelines; prevent gas leakage and abnormal operation.
1.11 Avoid water or oil etc. on fan, fan motor or V belt, so as to prevent damage and
fire.
1.12 Before shutdown of air conditioner is confirmed, do not touch belt or fan to avoid
injury.
1.13 Do not place refrigerant cans on engine or radiator, so as to prevent serious
accident.
1.14 Do not subject refrigerant cans to direct sunshine, moisture, or temperatures
exceeding 40℃, so as to prevent serious accident. Store these cans at a cool and dry
place.
1.15 Store refrigerant cans where no fierce collision with other hard matter or iron
ware etc. will occur, so as to avoid serious accident.
1.16 When handling refrigerant gas, wear protective goggles to avoid injury of eyes. In
case such gas enters the eye, timely wash with large amount of clear water to prevent
frostbite; if serious, go to hospital at once.
Items that must be inspected before AC system maintenance or diagnosis
2.1 Visually check hoses for damage and friction.
2.2 Ensure that condenser fins are not blocked by insects, impurities and dirt etc.,
2.3 And that fins have no apparent falling.
2.4 Correct operating direction of condenser fan.
2.5 No overheating of engine water tank.
2.6 Check tension of driving belt and for damage.
2.7 Operation of compressor.
2.8 Check for clogging of evaporator drain hose.
2.9 Check free action of switch at each air outlet.
2.10 Check if blower and evaporator fan can operate at specified fan speed.
2.11 Check that there is no apparent refrigerant leakage or oily dirt on device or
pipeline connector.
42
Electrical System
Troubleshooting
Blower motor rotates but no

hot air comes out from
outlet
Check water
hose
YES Hose sharp

twisting, bending or
clogging
Replace
No air comes out from defroster

outlet
Check connecting pipe

between defroster &
heater
YES Wear
Replace
Check defroster door & control
cable
YES Replace &

adjust
43
Electrical System
Blower speed cannot be

adjusted
Check electric connector
YES Disconnect
Replace
Check control switch
YES Faulty
Replace
Blower motor not rotating
Check fuse
YES Faulty
Replace
Check circuit & connector
YES Open or
disassemble
Replace
Check switch circuit
YES Incorrect
Replace
Check engine motor
YES Faulty
Replace
44
Electrical System
High blower motor noise
Check blower motor bearing
YES Broken
Replace
Cold air blown out intermittently
Check magnetic clutch
YES Slipping or not operating
Replace
Check expansion valve
YES Faulty
Replace
Check wiring
YES Faulty
Repair
45
Electrical System
Insufficient cooling
Check condenser
Check driving belt Clean or

replace
YES Slipping
Check compressor Replace
YES Faulty
Replace
Check expansion
valve
YES Faulty
Replace
Check thermostat
YES Faulty
Replace
Check coolant
YES Insufficient or
excessive
Adjust
46
Cabin
Cabin
Front wall
Front windshield glass
Rear windshield glass
Instrument desk
Ceiling inner trim
Ceiling ventilation
Door
Seat
Seat safety belt
Disassembling and assembling of tilting mechanism
Disassembling and assembling of lock mechanism

Cabin
Front wall parts
Disassembling sequence Assembling sequence
1. Front bumper assembly ▲ 5. Front wall side board assembly
2. Veil 6. Front wall trim board
3. Clip on veil 4. External rear view mirror assembly
4. External rear view mirror assembly 3. Clip on veil
5. Front wall side board assembly 1. Bumper assembly
6. Front wall trim board 2. Veil

Cabin
Front wall side board

Upper rubber Important operation--assembling
Front wall side 5. Front side board
● Use 507 glue to stick upper/lower
Front wall rubber pads on front wall side
side board board
Crossed recessed ● Use 507 glue to stick front wall
pan head tapping side board rubber strip on front
Front wall side
wall side board side
board expansion
● Install front wall side board clip on
5. Install front wall side board assembly

Front wall side on door column.
Install front wall side board sleeve on

front wall side board clip (use cross
recessed pan head screw for fixing)
Cross recessed
pan head tapping screw
Cabin
Front windshield glass
▲ 3. Front windshield glass 1. Front windshield inner rubber strip
2. Front windshield front rubber strip 2. Front windshield front rubber strip
1. Front windshield inner rubber strip ▲ 3. Front windshield glass

Cabin
Important operation---disassembling
1. Front windshield glass
 Tear out sealing strips from upper
flange and each corner of vehicle body
flange, and then slowly push out and
remove the glass. Do not touch glass
surface.
 Use gasoline to wash sealant on
vehicle body.
Important operation---assembling
3. Front windshield glass
Range of application of sealant  As shown in left figure, apply enough
sealant on flange (about 10mm dia.). If not
enough, water leakage may occur.
Sealant Single component

polyurethane glass glue
3. Windshield assembly
 Stick windshield glass on cab
proper front windshield flange.
 Lightly tap glass with rubber

Rubber hammer Windshield hammer so that vehicle body
flange is in full contact with
Sealing strip sealing strips.
Vehicle body
flange
Cabin
Rear windshield glass
▲ 3. Rear windshield assembly 1. Rear windshield glass
2. Rear windshield rubber strip ▲ 2. Rear windshield rubber strip
1. Rear windshield glass ▲ 3. Rear windshield assembly

Cabin
Important operation --disassembling

1. Rear windshield assembly
 Remove sealing strips from upper
flange and each corner of flange,
then slowly push out and remove
the glass. Do not touch coated
surface or glass.
Important operation ---assembling

Seal strip
2. Sealing strip
 Place glass brand position at left
lower corner. Adjust glass center to
Center align with seal strip lower
connector.
Left Right
Connection
Seal strip
 Thread Ф 5-6mm rope in the flange.
Wind rope for one round for
coinciding at lower center of glass.
Rope
1. Rear windshield assembly

Push
 Adjust glass so that it is at center of
windshield. Press glass from outside, then
pull rope toward glass center from inside.
Stick rear windshield rubber strip on vehicle
body flange.
Pull
Avoid twisting of strip and mismatching with
rear windshield; otherwise water leakage
may occur.
Rubber Windshield glass

hammer  Lightly tap glass with rubber hammer so
that vehicle body flange is in full contact with
Sealing strip sealing strips.
Vehicle body
flange
Cabin
Instrument desk
Disassembling Reassembling

1. Instrument desk front cover plate 16. Fuse box and relay box
2. Instrument desk side end cover 15. Cigarette lighter
3. Brake oil pot cover 14. Instrument desk frame
4. Glove box 13. Air conditioning panel
5. Central control panel 12. Radio cassette (or CD) player
6. Instrument hood 11. Left ash tray
7. Relay box cover 10. Combination instrument
8. Idling button 9. Instrument desk cover
9. Instrument desk cover 8. Idling button
10. Combination instrument 7. Relay box cover
11. Left ash tray 6. Instrument hood
12. Radio cassette (or CD) player 5. Central control panel
13. Air conditioning panel 4. Glove box
14. Instrument desk frame 3. Brake oil pot cover
15. Cigarette lighter 2. Instrument desk side end cover
16. Fuse box and relay box 1. Instrument desk front cover plate
Cabin
Important operation-- disassembling

AC panel Radio cassette player
5. Central control panel
 Remove central control panel (do not
touch the panel)
 Remove connector between cigarette
lighter and vehicle body harness.
Central control
Steel clamp Cigarette lighter panel
12 & 13. AC panel and radio cassette (or CD)

player
 Disconnect each connector of radio
cassette (or CD) player and AC control
wire
Screw  Remove radio cassette (or CD) player
and AC panel
AC panel
Radio cassette
14. Instrument desk frame

Brake oil pot and hose
 Remove brake oil pot mountings from
instrument desk frame. You must first
loosen hose and drain oil in the pot;
otherwise brake oil may leak.
 Disconnect all plugs connected to

vehicle body harness
 Remove bolts; do not touch and damage
surfaces of other parts
Cabin
16. Fuse and relay box

Fuse and relay box
 After removal of instrument desk frame,
remove the fuse and relay box installed
on this frame, then the vehicle body
harness.

Fuse and relay box 16. Fuse and relay box
 Fit vehicle body harness on instrument
desk frame, fix fuse and relay box at its
position, and use wire clip to fix harness.
Check harness or wire clip, and then
connect vehicle body harness with
chassis harness.
14. Instrument desk frame

 Fit and tighten bolts in holes 1-4 (as
shown)
 Fit frame on steering column support, fit
and tighten bolts
Torque: N·m 8－10

Cabin
Brake oil pot and hose  Fit brake oil pot on instrument desk
frame
 Tighten nuts at A and B
 Connect the pot to hose and tighten
Torque: N·m 5－11
13. Air conditioning panel

 Thread control wire into instrument
panel, and then firmly fit AC panel.
 Turn mode switchover knob to left most
position (toward FACE direction)
 Turn temperature control knob to left
most position (toward COLD direction)
 Turn inner/outer circulation lever to left
Control cable “A”
Control cable “B”  Hang control cable “A”on blower pawl

hook, push butterfly valve to the end, fix
electric cable on clip.
 Hang control cable “B” on air heater
pawl hook, move butterfly valve to
Air heater lowest position, fix electric cable on clip.
Control cable “C”

Control cable “C”;
 Hang control cable “C”on blower pawl
hook, push butterfly valve to the end,
and then fix electric cable on clip.
Blower
Cabin
12. Radio cassette (or CD) player

 Fit this player inside instrument panel,
and then connected harness connector
and antenna to rear of the radio
Make sure to fit firmly to prevent
vibration
Scre
Air conditioning Radio

panel
Connect harness at each point

below:
A. Antenna cable
B. Radio
C. Blower switch
D. Cigarette lighter
E. Instrument
F. Clutch switch, brake switch, throttle switch
G. Fog light switch, warning switch, warming
up switch
H. Combination switch
I. Washer pot
Cabin
Ceiling inner trim
2. Ceiling inner trim buckle 1. Ceiling inner trim
1. Ceiling inner trim 2. Ceiling inner trim buckle

Cabin
Ceiling ventilation
1. Inner cover assembly ▲ 3. Outer cover & control assembly
▲ 2. Hex nut ▲ 2. Hex nut
▲ 3. Outer cover & control assembly 1. Inner cover assembly

Cabin
Important operation --disassembling

2. Nut
● After removal of nut, place outer
cover and control assembly at air
inlet
Turn by 90° 3. Outer cover & control assembly

● Move outer cover assembly upward
and turn it by 90°, then pull the control
assembly out.

Turn by 90° 3. Outer cover & control assembly
● Place this assembly at air inlet
position
● Move outer cover assembly upward
and turn it by 90°; install control
assembly
2. Hex nut
● At fully open position, tighten the hex
nut
Cabin
1. Inner cover assembly
Top cover
Control Clip
Inner cover
Cabin
Door Disassembling
Right door assembly
16. Door outer upper decorating strip 10. Door hand catch bracket
17. Door lower embedded strip, lower rubber strip 3, 4. Door window lift assembly, front
bracket assembly
2. Door rubber pad 5. Door window assembly
15. Door glass inner/outer water seal 15. Door glass seal strip
13. Door large arm rest 6. Door lock core assembly
12. Door hand catch 1. Door harness assembly
14. Lifting handle Additional note:
18. Door seal strip (15. Door glass seal strip, water seal)
11. Door inner trim board
7. Door seal cover plate assembly
9. Door seal membrane
8. Door inner handle
Cabin
Reassembling
Right door assembly
▲ 1. Door harness assembly ▲ 14. Lifting handle

2. Door rubber pad 15. Door glass water seal
▲ 3. Door window lift assembly 16. Door outer upper decorating strip
4. Door glass front bracket 17. Door lower embedded strip/rubber strip
▲ 5. Door glass assembly 18. Door seal strip
15. Door glass seal strip Additional note:
▲ 6. Door lock core assembly (15. Door glass seal strip, door glass water seal)
7. Door hand catch bracket
▲ 8. Door inner handle assembly
▲ 9. Door seal membrane
10. Door cover plate assembly
▲ 11. Door inner trim board assembly
12. Door hand catch
13. Door large arm reset
Cabin

1. Door harness assembly
● Thread harness assembly
through the hole on door inner
panel and fit a suitable rubber
washer according to shape of the
hole.
● Fit door harness clip on support
bracket and door inner panel
reinforcing part.
3. Door window lift assembly

● First fit the window lift assembly on
the door, then fit glass on lift front
bracket and glass front/rear bracket
● Next, install door window groove
and adjust the glass so that lifting is
smooth.
5. Door window glass assembly

● Fit window lift front bracket and
front/rear glass brackets on door
glass.
● Use a plastic or wood hammer to
tap the groove lightly; when
doing so, cover the glass with
cloth or similar
Cabin
6. Door lock core assembly

● When door lock outer handle is
connected to the connector, rotate
this connector so that handle end
gap is about 5mm.
Torque: N·m 4－8
8. Inner handle assembly

● Firmly insert inner handle
Door lock assembly “a”in door lock “b”position
and rotate the sheath tight.
● Allow certain free gap of inner
handle assembly at door inner trim
board
Right door assembly 9. Door sealing membrane

● Stick butyl rubber tape (Ф 5mm) along
door inside protecting plate
Positioning ● Adjust door sealing membrane
positioning holes to corresponding
positions on door inside protecting
plate, and stick well. Avoid crimple of
tape; otherwise water leakage may
occur.
Cabin
Door inside Door assembly 11. Door inner trim board assembly
protecting plate  Insert 7 inner trim board clips into
Clip
holes on door inside protecting plate.
backin When firmly inserted, a sound of
Clip section
“kata” will be heard; if not, water
Door assembly leakage may occur.
14. Lifting handle

 Adjust this handle to the position
shown in left figure and at 45°with
horizontal line Lift all door window
glasses.
Cabin
Seat

3. Cross recessed pan head tapping screw 1. Floor batten expansion buckle
2. Map batten 2. Map batten
1. Floor batten expansion buckle 3. Cross recessed pan head tapping screw
4. Integral carpet 4. Integral carpet
12. Seat for 2 persons 5. 3-point safety belt
11. Driver seat 6. Hex head bolt, flat washer, spring washer
10. Passenger safety belt buckle assembly 7. Driver safety belt buckle assembly
9. Middle (additional) seat safety belt assembly 8. Middle (additional) seat safety belt buckle ASSY
8. Middle (additional) seat safety belt buckle ASSY 9. Middle (additional) seat safety belt assembly
7. Driver safety belt buckle assembly 10. Passenger safety belt buckle assembly
6. Hex head bolt 11. Driver seat
5. 3-point safety belt assembly 12. Seat for 2 persons
Cabin
Seat safety belt
Seats
6. Passenger safety belt buckle assembly
5. Middle (additional) seat safety belt assembly
4. Middle (additional) seat safety belt buckle assembly
3. Driver safety belt buckle assembly
2. Hex head bolt, flat washer, spring washer
1. 3-point safety belt assembly
Assembling sequence
▲ 1. 3-point safety belt assembly
2. Hex head bolt, flat washer, spring washer
3. Driver safety belt buckles assembly
4. Middle (additional) seat safety belt buckles ASSY
5. Middle (additional) seat safety belt assembly
6. Passenger safety belt with buckle assembly

Cabin
Important operation--- assembling

1. 3-point safety belt assembly
Install seat safety belt mountings on floor.
Note installation direction of seat safety belt
mountings.
Seat safety
belt
Torque: N·m 30－50
Part Part
Rolled edge
Forward
Part
Seat safety
Rolled belt
Forward
Part Part
Cabin
Cab tilting and locking mechanism
Tilting mechanism
Disassembling and assembling sequences

1. Cab rear support and bracket assembly 4. Can rear bracket
2. Can 3. Can front support tilting mechanism
3. Can front support tilting mechanism 2. Cab
4. Can rear bracket 1. Cab rear support and bracket assembly
4. Cab left rear bracket

(Right rear support is symmetric to left rear
support except absence of structure A)
Torque (N·m): 78
Cabin
3. Cab front support tilting mechanism
For installation, align marking I on axle tube

assembly to marking I on torsion bar.
Torque (N·m): 116— — 153
Torque (N·m): (1) 105— — 133
(2) 76— — 92
Cabin
2. Cab
Fit guide pin into support arm guide hole and

then fit cab.
Torque (N·m): 76— — 92
Tilt cab and tighten bolts so that bolts lean

against groove rear end.
Torque (N·m): 105— — 133
1. Cab middle rear support and bracket

assembly
Torque (N·m): 29— — 41

Cabin
Disassembling and assembling of cab locking mechanism
1. Short slide rod assembly
2. Long slide rod assembly
3. Lock mechanism right assembly
4. Lock mechanism left assembly
5. Tilting lock mechanism assembly
Assembling sequence
4. Lock mechanism left assembly
3. Lock mechanism right assembly
1. Short slide rod assembly
Cabin
Important operation--- assembling
Fit tilting lock mechanism assembly on cab rear bracket.

Torque: (N·m): 14— — 24
Tilting lock
mechanism
assembly
4. Locking mechanism left assembly
Torque (N·m): 14— — 24
Tilting lock
mechanism
Locking
mechanism left
3. Locking mechanism right assembly
Torque (N·m): 14— — 24
Locking
mechanism right

1. Long slide rod
Short Long slide rod Apply grease at position A on rod contact face, and then fit
slide
rod long slide rod assembly.
Apply grease at position B on rod contact face, and then fit
short slide rod assembly.
Fit the part with stamp at handle side.
Move handle of cab lock mechanism from position a to

position b (locked position).
Adjust pins e and f of left and right locking mechanism

assemblies, use lock nuts to fit them on bracket, and then fix
them with clips
Bracket

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WORKSHOP MANUAL

4DA1-2B SERIES TRUCKS

All information in this manual is the latest 2901 Front suspension

Main specifications of the trucks equipped with HFC4DA1-2B engine

Main specifications of the trucks equipped with HFC4DA1-2B1 engine

Company Vehicle Type Main Code from

Company Code Name：HFC-----represents JAC motor

VIN----Vehicle Identification Number

World Manufacturer Identification

The mechanic performance table of bolts in China

Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9

Tensile strength limit  b max(MPa) 600 800 900 1040 1220

Yield limit  s max(MPa) 480 640 720 940 1100

Corresponding to Hyundai standards 4T 6T 7T 8T 10T

systems of 4DA1 Series engine, general maintenance standards, special tools

as well as common fault diagnosis and troubleshooting.

Our products are subject to continuous innovation. If any information in this

modified in a second edition.

or by any means without written consent of Jianghuai Automobile.

1.1.1 Start problems

3. The engine rotates but it cannot be ignited to start.

4. Quick start system

1.1.2 Unstable idle speed

1.1.3 Insufficient power

1.1.4 High fuel consumption

1.1.6 Engine overheating

1.1.7 White smoke coming out of engine exhaust

1.1.9 Low oil pressure

1.1.10 Abnormal engine noise

1.1.11 Engine cooling problem

Check the battery and make the following diagnosises.

Check the battery

Charging is invalid or the life of

Check the battery

Check the terminal post

Turn on the headlamp and starter switch

The headlamp is off or dim. The headlamp is bright.

a) The starter circuit has open circuit.

When the starter switch is switched to ST (start)

The connection of starter There is an open circuit

Replace the starter

When the starter switch is switched to ST (start)

Check the grounding cable Check whether the instrument

Good Bad Normal Abnormal

The sliding The solenoid switch or

Check the starter The starter switch

Check the grounded cable

Repair or replace the

Repair or replace the starter

Terminal Post No.

Besides the wiring mentioned above, other circuits should be opening.

The solenoid switch contact is Replace the solenoid switch

Replace the starter switch

Oil pressure switch

Vertical cylinder oil gallery

① Opening pressure of relief valve at oil filter: 430-470kPa

② Opening pressure of safety valve at oil filter: 960-100kPa

The lubrication system for 4DA1 Series engine is full-flow type.

1.2.1 Data and specifications

1.2.2 Engine cooling

1.2.3 Starting system

1.3 Maintenance standards

1.3.1 Engine mechanical system