WP10四气门国二系列车用柴油机维修手册 EN

1006235381
Maintenance Manual of
WP10 Series Four-valve
China II Vehicle Diesel
Engine
.
Weichai Power Co., Ltd.

Maintenance Manual of WP10 Series Four-valve China II Vehicle Diesel Engine
WP10 Series Four-valve China II Vehicle Diesel Engine

Foreword
Independently developed by Weichai Power Co., Ltd., WP10 engine is a high speed engine boasting
many advantages such as And it boasts many advantages such as compact structure, outstanding
performances including reliable running, strong power and good economy, as well as fast start, easy
operation and maintenance.
This Manual mainly covers the precautions for operation, maintenance method, common inspection and
adjustment, as well as troubleshooting process of this series of engine. During preparation of this
manual, efforts have been made to present comprehensive, concise and practical knowledge on the
engine. It shall be noted that the engine troubleshooting is a complicated work requiring attention to
detail and certain knowledge and experience. Thus, do not disassemble the engine especially its key
parts such as the electronic control system and turbocharger at will before identifying the fault cause;
otherwise, the fault will not be eliminated, and what's worse, serious fault may occur due to improper
refitting. The engine shall be maintained and checked with the special apparatus. Therefore, users
having no relevant experience and equipment are not allowed to disassemble or adjust the engine.
With the increasing variants and continuous improvement of this engine, this Manual will be subject to
change without notice. The relevant product information is available on the website: www.weichai.com.
The after-sales service of this product is provided by Weichai Power Co., Ltd.
Your suggestions and opinions on the product are appreciated.
Notice
♦ Always read this Maintenance Manual carefully
before operation, strictly observe the operation and
maintenance procedures, and pay attention to the
warning instructions and signs herein. Please pay
attention to the following issues because the
engine warranty will be affected if the operation is
performed not in accordance with the requirements
of this Manual!
♦ This engine has been tested in strict accordance Please refer to this Manual.
with the test specification before delivery.
Therefore, the fuel injection pump or ECU shall not
be adjusted at will.
♦ For the engine with a turbocharger, as the

turbocharger rotor shaft is a precise high-speed
rotating part, please keep any objects (such as
hands, tools and cotton yarns) away from the
turbocharger inlet when the engine is running to
avoid personal injury or damage to the engine; do
not disassemble the rotor assembly by yourself.
Do not touch the high-speed rotating part by hands
♦ Do not loosen or remove the main bearing bolt

and connecting rod bolt of the engine without
permission as they are subject to strict torque and
rotation angle requirements. For the torque and
times of use of important bolts, please refer to the
annex in this Manual.
Tightening torque requirement

♦ Always fill the engine with the oil or fuel that is of

grade specified in this Manual, and filtered by a
special filter; for the fuel, subject it to a precipitation
more than 72 h. Prior to start, always check that
the coolant and oil levels are satisfactory, and if
not, please fill the engine with fuel or oil of grade
specified in this manual at an authorized gasoline
station.
Please refer to the relevant chapter in this Manual
♦ Before running a new engine, subject it to
running-in for 50 h.
♦ Never run the engine without an air filter.
♦ After starting an engine in cold state, accelerate
it slowly rather than abruptly, and do not idle it for a
long time.
♦ Regularly check the coolant, and never use

water or inferior coolant as the engine coolant.
Please use the coolant of proper grade in
accordance with the requirements of this Manual
for operation at low temperatures.
♦ The engine has been preserved before delivery
for avoiding rust. Generally, its preservation period
is one year, and it shall be checked and necessary Please refer to the relevant chapter in this Manual
measures shall be taken when this valid period
expires.
♦ Always have the components of the electrical
system maintained by Weichai professional
technicians.
♦ Please have the diesel engine overhauled and

serviced at the Weichai Power designated service
station in case of a fault. Do not use the spare
parts not specified by Weichai Power for
maintenance; otherwise, Weichai will not assume
any responsibility for damage to the engine
therefrom.
Weichai special spare parts

Instructions for signs
Wear gloves Risk of electric shock
Wear protective clothing Risk of mechanical injury
Risk of being caught up in the

Wear ear plugs machine
Be aware of suspended heavy

Wear goggles objects
Wear helmet Be aware of steam
Wear safety shoes Risk of explosion
Wear protective mask Risk of corrosion
Keep ventilated Risk of scalding
Torque control Avoid winding

Checks required No open flame
Tool requirement No smoking
Serious warning No touching
Caution
Caution No smoking
Warnin
g
Warning No touching
Most of accidents occurred during engine operation, maintenance and repair are caused by failure to
observe the safety rules and basic precautions. Only the well-trained operators with required skills and
appropriate tools can operate, maintain and repair the engine.
The violation of instructions in this Manual may lead to serious accident. Weichai Power Co., Ltd. cannot
foresee all potential hazards, and meanwhile, the rules and instructions specified in this Manual are not
exhaustive.
Precautions for Engine Disassembling and Maintenance

♦ Prepare necessary common tools, special maintenance tools, measuring instruments, etc. before
maintenance.
♦ Use a crane with sufficient lifting capacity or a rigid jack to lift the engine, and use chains, cables or
lifting belts instead of ropes as lifting tools.
♦ Use special lifting and turnover tools when lifting and turning over the engine.
♦ Use Weichai original spare parts or the parts recommended by Weichai; otherwise the service life of
the engine may be shortened or personal injury may be caused.
♦ Make sure that the maintenance area and the surroundings are suitable for safe operation.
♦ Make sure that the workshop or the surrounding of the engine is clean and tidy.
♦ Before working, please take off your watch and other ornaments and wear well-fitted working clothes.
♦ Before working, check that the corresponding personal protective equipment (goggles, gloves, shoes,
mask, working clothes, helmet, etc.) are within the period of validity.
♦ Ensure that fire extinguishers are available near the maintenance area.
♦ Prevent the battery electrolyte from splashing to clothing, skin or eyes; otherwise, it will burn skin or
clothing. Keep away from sparks and open flames when charging the battery.
♦ When disassembling complicated parts, make matching marks or other marks at the disassembling
position.
♦ Confirm whether the removed parts can be reused. Please refer to this Manual for details.
♦ Regularly calibrate the measuring instruments.
Declaration
Due to the diversified product variants of the company, the illustrations in this Manual are schematic and
may not match the real product you purchased. For the detailed structure, the real product shall prevail.
The symbols in the illustrations indicate the steps or conditions requiring your attention during operation!
Contents
Chapter I Operation Instructions ............................................................................................................. 1
1.1 Outline drawing of engine ..........................................................................................................1
1.2 Designation of engine model .....................................................................................................3
1.3 Main specifications .................................................................................................................... 4
1.4 Hoisting ...................................................................................................................................... 4
1.5 Running ......................................................................................................................................5
Chapter II Maintenance ..............................................................................................................................7
2.1 Fuel, lubricating oil, coolant, and auxiliary materials ................................................................ 7
2.1.1 Fuel ................................................................................................................................. 7

2.1.2 Lubricating oil ..................................................................................................................7
2.1.3 Coolant ............................................................................................................................8
2.1.4 Auxiliary materials ...........................................................................................................9
2.2 Daily maintenance ................................................................................................................... 10
2.2.1 Daily inspection .............................................................................................................10

2.2.2 Daily maintenance ........................................................................................................ 11
2.3 Description of maintenance of all levels ..................................................................................12
2.3.1 Replace oil .................................................................................................................... 12

2.3.2 Replace oil filter and filter element ...............................................................................12
2.3.3 Replace fuel filter and filter element .............................................................................12
2.3.4 Check air seal ............................................................................................................... 14
2.3.5 Check and adjust valve clearance ............................................................................... 14
2.3.6 Check air filter element .................................................................................................15
2.4 Regular maintenance interval and specification ..................................................................... 16
2.4.1 Regular maintenance interval and specification .......................................................... 16
2.5 Cleaning, protection and handling ...........................................................................................17
2.5.1 Cleaning and protection ............................................................................................... 17

2.5.2 Protection during storage ............................................................................................. 18
2.5.3 Preservation ..................................................................................................................18
2.5.4 Handling ........................................................................................................................18
Chapter III Typical Faults and Troubleshooting ................................................................................... 19

3.1 Overview .................................................................................................................................. 19
3.1.1 Overview ....................................................................................................................... 19
3.2 Fault diagnostic methods ........................................................................................................ 19
3.2.1 Traditional fault diagnostic methods ............................................................................ 19
3.3 Typical faults and troubleshooting ...........................................................................................20
3.3.1 Engine startup failure ....................................................................................................20

3.3.2 Stop shortly after start .................................................................................................. 20
3.3.3 Underpower .................................................................................................................. 21
3.3.4 Excessive fuel consumption ......................................................................................... 22
3.3.5 Unstable engine speed .................................................................................................23
3.3.6 Low oil pressure ............................................................................................................24
3.3.7 High coolant temperature ............................................................................................. 25
3.3.8 Accelerated wear of parts .............................................................................................25
3.3.9 Heavy noise .................................................................................................................. 26
3.3.10 Starter motor does not work .......................................................................................... 27
3.3.11 Underpowered starter motor ..........................................................................................27
3.3.12 Inoperative alternator ..................................................................................................... 28
3.3.13 Undercharged alternator .............................................................................................. 28
3.3.14 Unstable charging current of alternator ....................................................................... 29
3.3.15 Overcharged alternator ................................................................................................ 29
3.3.16 Abnormal sound from alternator ...................................................................................29
Chapter IV Introduction to Engine Systems ............................................................................... 31
4.1 Cooling system ........................................................................................................................ 31
4.1.1 Cooling system ............................................................................................................. 31
4.2 Lubrication system ...................................................................................................................31
4.2.1 Overview ....................................................................................................................... 31
4.3 Fuel system ..............................................................................................................................33
4.3.1 Schematic diagram of fuel system ............................................................................... 33
Chapter V Disassembling and Assembling of Engine ........................................................................ 35
5.1 Intake manifold assembly ........................................................................................................35
5.1.1 Exploded view ...............................................................................................................35

5.1.2 Disassembling tools and preparations ......................................................................... 35

5.1.3 Disassembling steps .....................................................................................................36
5.1.4 Inspection and maintenance ........................................................................................ 36
5.1.5 Assembling steps ......................................................................................................... 36
5.2 Fan and hub group .................................................................................................................. 37
5.2.1 Exploded view ...............................................................................................................37

5.3 Oil-gas separator assembly .....................................................................................................38
5.3.1 Exploded view ...............................................................................................................38

5.4 Turbocharger ........................................................................................................................... 40
5.4.1 Exploded view ...............................................................................................................40

5.5 Turbocharger lubricating oil pipe assembly ............................................................................ 42
5.5.1 Exploded view ...............................................................................................................42

5.6 Low-pressure fuel pipe assembly ............................................................................................43
5.6.1 Exploded view ...............................................................................................................43


5.7 High-pressure fuel pipe assembly ...........................................................................................45
5.7.1 Exploded view ...............................................................................................................45

5.8 Fuel filter assembly ..................................................................................................................46
5.9.1 Exploded view ...............................................................................................................46

5.9 Air compressor assembly ........................................................................................................ 48
5.9.1 Exploded view ...............................................................................................................48

5.10 Fuel injection pump assembly ................................................................................................. 49
5.10.1 Exploded view ...............................................................................................................49

5.11 Starter assembly ......................................................................................................................52
5.11.1 Exploded view ...............................................................................................................52

5.12 Oil cooler assembly ................................................................................................................. 53
5.12.1 Exploded view ...............................................................................................................53

5.13 Oil filter assembly .................................................................................................................... 55
5.13.1 Exploded view ...............................................................................................................55

5.14 Exhaust manifold assembly .....................................................................................................57
5.14.1 Exploded view ...............................................................................................................57

5.15 Tensioner & belt assembly ...................................................................................................... 59
5.15.1 Exploded view ...............................................................................................................59

5.16 Thermostat ...............................................................................................................................61
5.16.1 Exploded view ...............................................................................................................61

5.17 Water pump inlet pipe assembly ............................................................................................. 62
5.17.1 Exploded view ...............................................................................................................62


5.18 Water pump assembly .............................................................................................................64
5.18.1 Exploded view ...............................................................................................................64

5.19 Water outlet pipe assembly ..................................................................................................... 65
5.19.1 Exploded view ...............................................................................................................65

5.20 Alternator assembly .................................................................................................................67
5.20.1 Exploded view ...............................................................................................................67

5.21 Lifting ring assembly ................................................................................................................68
5.22.1 Exploded view ...............................................................................................................68

5.22 Cylinder head cover assembly ................................................................................................ 69
5.22.1 Exploded view ...............................................................................................................69


5.23 Valve train assembly ............................................................................................................... 71
5.23.1 Exploded view ...............................................................................................................71

5.24 Fuel injector assembly .............................................................................................................77
5.24.1 Exploded view ...............................................................................................................77

5.25 Cylinder head assembly .......................................................................................................... 79
5.25.1 Exploded view ...............................................................................................................79

5.25.2 Preparations before disassembling ..............................................................................79
5.26 Crankshaft pulley assembly .................................................................................................... 85
5.26.1 Exploded view ...............................................................................................................85

5.27 Flywheel housing assembly .................................................................................................... 86
5.27.1 Exploded view ...............................................................................................................86

5.28 Flywheel assembly .................................................................................................................. 87
5.28.1 Exploded view ...............................................................................................................87

5.29 Oil pan assembly ..................................................................................................................... 89
5.29.1 Exploded view ...............................................................................................................89

5.30 Suction strainer assembly ....................................................................................................... 91
5.30.1 Exploded view ...............................................................................................................91

5.31 Oil pump assembly .................................................................................................................. 92
5.31.1 Exploded view ...............................................................................................................92

5.32 Gear drive assembly ................................................................................................................93
5.32.1 Exploded view ...............................................................................................................93

5.33 Piston nozzle assembly ........................................................................................................... 96
5.33.1 Exploded view ...............................................................................................................96


5.34 Piston & connecting rod assembly .......................................................................................... 97
5.34.1 Exploded view ...............................................................................................................97

5.35 Timing gear chamber assembly ............................................................................................ 101
5.35.1 Exploded view .............................................................................................................101

5.35.2 Disassembling tools and preparations .......................................................................101
5.35.3 Disassembling steps ...................................................................................................101
5.35.4 Inspection and maintenance ...................................................................................... 101
5.35.5 Assembling steps ....................................................................................................... 102
5.36 Oil seal assembly ...................................................................................................................102
5.36.1 Exploded view .............................................................................................................102

5.36.2 Preparations before disassembling ............................................................................103
5.37 Crankshaft assembly ............................................................................................................. 103
5.37.1 Exploded view .............................................................................................................103

5.38 Thrust plate assembly ........................................................................................................... 105
5.38.1 Exploded view .............................................................................................................105


5.39 Main bearing shell assembly ................................................................................................. 107
5.39.1 Exploded view .............................................................................................................107

5.40 Oil dipstick assembly ............................................................................................................. 109
5.40.1 Exploded view .............................................................................................................109

5.41 Engine block assembly ..........................................................................................................110
5.41.1 Exploded view .............................................................................................................110

Annex A List of DTCs ............................................................................................................................ 113
Annex B Fitting Clearances for Main Engine Parts ........................................................................... 114
Annex C Tightening Torque of Other Main Bolts of Engine .............................................................116

Chapter I Operation Instructions

1.1 Outline drawing of engine
Fig. 1-1 Outline drawing 1 (intake side)
No. Name No. Name No. Name No. Name

1 Fuel filter 2 Starter 3 Turbocharger 4 Intake manifold
5 Fuel injection pump
1
Fig. 1-2 Outline drawing 2 (exhaust side)

Air compressor
1 Oil filter 2 Oil cooler cap 3 4 Thermostat cover
assembly
Exhaust manifold
5
heat shield
2
Fig. 1-3 Outline drawing 3 (fan end)
1.2 Designation of engine model
Variant code
Stage code of emission standard
Power code
Application code
Product series code
3
1.3 Main specifications

Table 1-1 Main Specifications
Item Technical Parameters

Type 4-stroke, water-cooled, with mechanical pump
Aspiration method Turbocharged and intercooled
Bore×stroke (mm) 126× 130
Number of cylinders 6
Displacement (L) 9.726
Compression ratio 17:1
Firing order 1-5-3-6-2-4
Fuel system Mechanical pump
Starting method Electric start
Lubrication method Pressure lubrication
Cooling method Forced circulation water-cooling
Rating 350~-580
Oil pressure (kPa)
Idling 130~-280
Oil pan capacity (L) See Chapter II in this Manual for details
Rotation direction of crankshaft (viewed from fan) Clockwise
Number of valves for each cylinder 4
Emission standard China II
Fuel supply advance angle See engine nameplate
Coolant outlet temperature (°C) (T+1)~93T represents thermostat opening temperature
Turbocharger downstream exhaust gas temperature (°C) ≤550
Intercooler downstream intake air temperature (°C) 50~55
1.4 Hoisting
When hoisting the engine, keep the crankshaft centerline horizontal. Never hoist an inclined engine or
hoist the engine by one side. The engine should be hoisted and seated slowly.
4
Correct Wrong
Fig. 1-4 Hoisting of engine
1.5 Running
When the engine is running normally, the temperature and pressure shall meet the requirements
specified in Table 1-2.
Table 1-2 Main Specifications of Engine in Operation
Items Technical Parameters

Intake resistance (kPa) Clean filter element ≤ 3, dirty filter element ≤ 6.5
Exhaust resistance (kPa) ≤7
Oil pressure (kPa) See relevant content in Table 1-1 of this chapter
Oil temperature (°C) 85~115
Coolant temperature (°C) See relevant content in Table 1-1 of this chapter
5
6
Chapter II Maintenance
2.1 Fuel, lubricating oil, coolant, and auxiliary materials
2.1.1Fuel
Summer: 0# diesel (GB252).
Winter: Generally -10# light diesel is used. But when the ambient temperature of the diesel engine is
lower than -15°C, -20# diesel shall be used.
When the ambient temperature is lower than -30°C, -35# diesel shall be used.
2.1.2Lubricating oil
The selection criteria of engine oil is given in Table 2-1.
Table 2-1 Selection Criteria of Special Engine Oil for Weichai Power Engines
Category Grade Packing specification

Diesel engine CF-4 and above 4L, 18L, 170kg
For the temperature and viscosity of engine oil, refer to Table 2-2.
Table 2-2 Correspondence of Oil Viscosity to Applicable Ambient Temperature
Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature range, °C temperature range, °C
0W -35~-15 10W-50 -25~50
0W-20 -35~20 15W-30 -20~30
0W-30 -35~30 15W-40 -20~40
0W-40 -35~40 15W-50 -20~50
5W -30~-10 20W-30 -15~30
5W-20 -30~20 20W-40 -15~40
5W-30 -30~30 20W-50 -15~50
5W-40 -30~40 20 -10~20
5W-50 -30~50 30 -5~30
10W-30 -25~30 40 5~40
7
Table 2-2 Correspondence of Oil Viscosity to Applicable Ambient Temperature (Cont'd)
Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature range, °C temperature range, °C
10W-40 -25~40 50 15~50
Note: For the viscosity grade of the oil in the table, the smaller the number before W, the better the low
temperature performance of the oil; the larger the number after W, the greater the viscosity of the oil; the
requirements for viscosity-temperature property of engine oil are detailed in GB 11122.
Caution
1. Before starting the engine, always check the oil level in the oil pan.
2. Never check the oil level when the engine is running.
3. Never mix the engine oil from any of other manufacturers with the special oil for Weichai
Power engines.
The filling amount of engine oil is shown in Table 2-3.
Table 2-3 Filling Amount of Engine Oil
Qty. of filter(s)
Filling amount of Diesel engine

Model
engine oil (L) Fuel filter
Oil filter
Fuel coarse filter Fuel fine filter
WP10 22~26 2 1 1
Note:
1) The filling amount of engine oil given herein is for reference only. For actual filling amount, the oil dipstick shall prevail.
2) Weichai fuel system protector or water separator, if equipped, shall be replaced together with the fuel filter.
3) The quantity of filters given herein is for reference only. For the actual quantity, the actual model shall prevail.
2.1.3Coolant
The special coolant for Weichai Power engines with freezing points of -25°C, -35°C and -40°C are
available. Please select the coolant with appropriate freezing point according to the local ambient
temperature. Generally, the freezing point of the selected coolant shall be 10°C below the ambient
temperature. The coolant for heavy-duty engine is given in Table 2-4.
Table 2-4 Selection Criteria of Coolant
Category Grade Packing specification

HEC-II-25
Coolant for heavy-duty engine HEC-Ⅱ-35 4 kg, 10 kg
HEC-Ⅱ-40
8
Caution
1. Always check the coolant on a regular basis, and change it in time as appropriate to prevent
corrosion damage.
2. Never change the engine coolant with water or coolant of inferior quality.
2.1.4Auxiliary materials
The auxiliary materials for the engine are shown in Table 2-5.
Table 2-5 Auxiliary Materials for the Engine
No. Name Color Purpose and application

To be applied to smooth metal surfaces to prevent
Molykote Pulver
1 Black blocking, e.g. external surface of cylinder liner
(fine molybdenum powder)
e.g. external surface of cylinder liner
To be applied for lubrication before the pressure of
Molykote G-N-U.plus
2 Dark grey lubricating oil builds up,
(molybdenum disulfide oiling agent)
e.g. intake valve stem
The reference for sealant application of engine is given in Table 2-6.

Table 2-6 Reference for Sealant Application of Engine
Additional
Designation Main purpose Examples of application position
remarks
Timing gear chamber stud
Camshaft thrust plate bolt
Camshaft timing gear bolt As an option,
To be applied to the
Intermediate idler bolt DriLoc204
thread for locking and
Weichai special Filter seat bolt thread-locking
prevention of looseness
type 242 sealant Oil cooler bolt adhesive can be
due to vibration. It has
Main oil passage downstream plug screw used for
medium strength.
Relief valve plug screw pre-application.
Main oil passage pressure-limiting valve threads
Suction strainer bolt
To be applied to the
thread surface for
Weichai special
locking, sealing and Cylinder head auxiliary bolt None
type 262 sealant
prevention of looseness
due to vibration.
9
Table 2-6 Reference for Sealant Application of Engine (Cont'd)
Additional
Designation Main purpose Examples of application position
remarks
Bowl plug for auxiliary oil passage
Bowl plug for main oil passage
Bowl plug for water chamber of cylinder block
Bowl plug for camshaft hole
Bowl plug for cylinder head
Weichai special For sealing between
Copper socket for cylinder head None
type 277 sealant core and hole
Bowl plug for intake manifold
Oil-gas separator ventilation elbow connected to
cylinder block
Exhaust valve spring lower seat bottom surface
Pipe joint assembly connected to water pipe joint
To be applied to smooth Mating surface of cylinder block and crankcase
Weichai special
metal surfaces for Front and rear end faces of engine block None
type 510 sealant
sealing Mating surface of filter seat and crankcase
2.2 Daily maintenance

2.2.1Daily inspection
1. Check the level of coolant, oil and fuel; and check if those positions requiring grease are properly
greased.
2. Check for the leakage of fuel, oil, coolant and air.
3. Check if external parts and attachments are properly connected and tightened.
10
4. Check fans and belts for overtension or

undertension.
5. Check if the exhaust temperature, color,
sound and vibration of the engine are normal,
and if the engine speed is stable.
6. Check if the oil inlet and return pipes of the
turbocharger are free from blockage or
leakage.
7. Check that the exhaust manifold is not
leaking and the intake manifold is unblocked.
Fig. 2-1 Check of belt
Fig. 2-2 Check of fan
2.2.2Daily maintenance
1. Check the coolant level, and if the coolant is

not enough, open the coolant filler cap for
topping up.
Caution
Always press down the bleed button before
opening the coolant filler cap, so as to avoid
scalding by hot coolant when the engine is hot.
Fig. 2-3 Coolant filling
11
2. Never start the engine when the oil level is Oil dipstick
below the L mark or above the H mark of oil
dipstick.
At this time, add oil through the oil filler.
Caution
Always check the oil level at least 5 min after

engine shutdown, enabling the oil to return to
the oil pan.
3. Check the fuel level indicated on the
instrument panel, and add fuel timely. Fig. 2-4 Proper oil level range indicated by oil dipstick
2.3 Description of maintenance of all levels

2.3.1Replace oil
1. Unscrew the drain plug at the bottom of oil Oil filler

pan to drain off the oil, and then screw on the
drain plug again.
2. Open the filler cap, add oil via the oil filler
while observing the oil dipstick until the
required level is reached, and then refit the
filler cap.
Drain plug
Fig. 2-5 Drain plug
2.3.2Replace oil filter and filter element
Replace the oil filter and filter element, as shown in

Fig. 2-6.
Replace the oil filter and filter element as follows:
1. Remove the old oil filter.
2. Fill the new filter with clean oil.
3. Before installing a new oil filter, apply oil to its Oil filter
rubber washer.
4. When the rubber washer contacts the base, Fig. 2-6 Oil filter
tighten the filter by another 3/4~1 turn for a
proper tightness.
5. Start the engine to check for oil leakage.
2.3.3Replace fuel filter and filter element
Replace fuel filter and filter element

Replace the fuel filter and filter element as follows:
12
1. Remove the old fuel filter element, and then the water collector on the fuel coarse filter if it can be
used again.
2. Lubricate the seal.
3. Screw the filter by hand until the seal fits the connection.
4. Continue to screw the filter until it is installed firmly (by about 3/4 turn).
5. Discharge the air until no bubbles appear. Carry out a leakage test.
Fuel filter
Fig. 2-7 Fuel filter

Air discharging of fuel coarse filter
Caution
When the filter is replaced with a spin-on fuel coarse filter or the fuel delivery pipe is refitted, air
discharging needs to be performed for the fuel coarse filter.
The air discharging of the fuel coarse filter is performed as follows:
1. Shut down the engine.
2. Remove the bleeding bolt.
3. Use a hand pump to discharge air until only the fuel flows from the bleeding bolt.
4. Re-tighten the bleeding bolt. Water draining of water collector
Caution
The water draining of the water collector is performed as follows:

When the water collector is full or the spin-on filter is replaced, the collected water needs to be drained.
1. Remove the drain plug at the bottom of the water collector to drain the water, as shown in Fig. 2-8.
13
2. Refit and tighten the drain plug.
Fig. 2-8 Water draining of water collector

Replacement of water collector
Replace the water collector as follows:
1. Shut down the engine.
2. Drain water from the water collector.
3. If possible, remove the water collector by hand as shown in Fig. 2-9. If the old water collector is too
tight to be removed, use the installation tool of the new water collector.
4. Lubricate the sealing ring of the new water collector with a few drops of oil.
5. Install the new water collector by hand and tighten it with the tool.
6. If the water collector is to be reused on a new spin-on filter, check the water collector for damage.
7. Install the water collector by a torque of 20 N·m with a torque wrench.
Fig. 2-9 Replacement of water collector

2.3.4Check air seal
Check if the intake hose is cracked due to aging, and if the hoop gets loosened. When necessary,
tighten or replace related parts to ensure the tightness of intake system.
2.3.5Check and adjustment of valve clearance
Valve clearance adjustment sequence
14
1. Turn the crankshaft to place the piston of

cylinder #1 at the TDC of the compression
stroke, and adjust the intake valve clearance
B of cylinders #1, #2 & #4, the exhaust valve
clearance A of cylinders #1, #3 & #5 and the
clearance C of EVB to 0.38 mm, 0.58 mm
and 0.38 mm respectively.
Loosen the EVB adjusting screw completely,
and adjust the locknut and adjusting screw of
the exhaust valve clearance to adjust the
exhaust valve clearance to 0.58 mm; insert
the feeler gauge under the EVB adjusting
screw, and adjust the EVB clearance to 0.38
mm. In this case, the piston in the EVB valve
Fig. 2-10 Diagram of valve clearance
bridge shall be completely compressed;
2. Turn the crankshaft to place the piston of cylinder #6 at the TDC of the compression stroke
clockwise (viewed from the free end), and adjust the intake valve clearance of cylinders #3, #5 &
#6, the exhaust valve clearance of cylinders #2, #4 & #6 and the clearance of EVB with the method
mentioned above.
2.3.6Check of air filter element
When the intake resistance indicator gives alarm (i.e. turns red), shut down the engine, and maintain the
outer element of air filter (note: never remove or clean the inner element) with the following notices in
mind:
1. Check the inner surface of outer element and the outer surface of inner element, and if any dust is
found, it indicates that the outer element is damaged or improperly installed, and thus shall be
drawn higher attention;
2. Use clean air below 0.5 MPa to blow away dust on the outer element from inside to outside, and
never clean the filter element by oil or water.
Caution
1. Never remove or clean the inner element;
2. Never blow the outer element from outside to inside, and if there is too much dust on the outer
surface of filter element, tap the element by hand to make the dust fall; do not remove or clean the
inner element, but always replace it with the outer element.
High pressure air pipe
Fig. 2-11 Blowback with compressed air
Caution
15
Never run the engine without an air filter; otherwise, dust and foreign matters may enter the
engine to cause premature engine wear!
2.4 Regular maintenance interval and specification
2.4.1Regular maintenance interval and specification
Table 2–7 Three types of use conditions for vehicles
(WGI type) (WGII type) (WGIII type)

Under harsh use conditions (cold or
hot climate, high dust content,
short-distance transportation, use on With annual mileage of less than
With annual mileage of more than
construction sites, and buses, 6x104 km, and for short- and
6x104 km, and for long-distance
municipal engineering vehicles, medium-distance transportation (for
transportation.
snowplows and fire trucks), or with delivery of goods).
annual mileage of less than 2x104 km
or annual operation of less than 600 h.
Table 2–8 Initial inspection, routine inspection and maintenance interval
Use condition (WGI) (WGII) (WGIII)

Mileage of 1000~1500 km
Initial inspection Mileage of 1500 ~2000km Mileage of 1500 ~2000km
Operation of 30~50 h
Every 5000 km
Routine inspection (P) Every 1×104 km Every 1.5×104 km
Every 150 h
Every 1×104 km
Level 1 maintenance (WD1) Every 2×104 km Every 3×104 km
Every 300h
Level 2 maintenance Every 2×104 km
Every 4×104 km Every 6×104 km
( WD2 ) Every 600h
( WD3 ) Every 1200h
( WD4 ) Every 2400h
Table 2-9 Regular maintenance interval and specification
Item Initial Routine Level 1 Level 2 Level 3 Level 4

maintenance inspection maintenance maintenance maintenance maintenance
Change the diesel engine oil
● ● ● ● ● ●
(at least once a year)
Replace the oil filter or filter
● Every time the diesel engine oil is changed
element
Check and adjust the valve
● ● ● ● ●
clearance
16
Table 2-9 Regular maintenance interval and specification (Cont'd)
Initial Routine Level 1 Level 2 Level 3 Level 4

Item
maintenance inspection maintenance maintenance maintenance maintenance
Check and adjust the nozzle
● ●
opening pressure
Replace fuel filter element ● ● ● ●
Clean the fuel coarse filter or
● ● ● ●
replace the filter element
Check the coolant level and
● ● ● ● ● ●
add
Change the coolant Refer to relevant regulations in the manual
Tighten the cooling pipe
●
clamp
Tighten the intake manifold,
● ● ● ● ●
hose and flange connector
Check the service indicator of
● ● ● ●
the air filter
Clean the dust cup of the air
filter (except for automatic ● ● ● ● ●
dust exhaust type air filter)
Clean the main filter element
When the indicating light is on
of air filter
Replace the main filter
Refer to the relevant provisions in instruction manual for details
element of air filter
Replace the safety filter
After the main filter element has been cleaned for 5 times.
element of air filter
Check and tighten the V-belt ● ● ● ● ● ●
Check the clearance of
●
turbocharger bearing
Check and adjust the fuel
● ●
injection pump on test bench
Check and adjust the clutch
travel and the wire rope ● ● ● ● ● ●
condition
Adjust the idle speed ●
2.5 Cleaning, protection and handling

2.5.1Cleaning and protection
1. Warm the engine up, drain the engine oil away, clean the oil filter, and add a proper amount of
anti-rust oil;
2. Empty the fuel tank, and then add a proper amount of anti-rust oil mixture into the tank;
3. Empty the radiator and then add a proper amount of coolant containing anti-rust agent into the
radiator;
4. Start the engine, and run it at an idle speed for 15~25 min;
5. Drain off the oil, fuel and coolant;
6. Preserve other parts of the engine.
17
2.5.2Protection during storage

Block inlets and outlets of fuel, oil, air and coolant with caps or plastic clothes; seal up the whole engine
with the VCI film.
2.5.3Preservation
The preservation period of the engine is 1 year, and the engine outside this period shall be preserved
again as follows:
1. The engine shall be preserved in a clean environment. The engine block and parts shall be
thoroughly cleaned to remove corrosion, oil stain and dust before preservation.
2. The engine can be preserved by immersion, spraying, coating, filling, or other methods as
appropriate.
3. Preserved parts: turbocharger air inlet/air outlet, air compressor inlet, and intake manifold port.
2.5.4 Handling
Pack the engine for handling where appropriate.
18
Chapter III Typical Faults and Troubleshooting

3.1 Overview
3.1.1Overview
Engines of this series are designed and manufactured under a strict quality assurance system, and have
been subject to specified tests before delivery. Moreover, the engine is precise machinery whose lasting
good performance is related closely to a proper maintenance. The premature failure of engine is
generally resulted from:
1. Operation against regulations, improper management and misuse;
2. Failure to inspect and maintain the engine as specified, and more serious, replacement of
maintenance with repair;
3. Use of defective spare parts, or even counterfeit and shoddy parts due to their cheap price, which
will dramatically shorten the service life of engine;
4. Use of fuel and lubricating oil of improper grade or poor quality.
Caution
1. The engine troubleshooting is a complicated work. Thus, do not disassemble or remove the engine
at discretion before determining its basic fault cause; otherwise, the fault will not be eliminated, and
even more serious fault may occur due to improper refitting.
2. Key components of the engine such as the high pressure fuel pump and turbocharger should be
maintained and inspected by special apparatus and based on certain experience. Therefore, users
having no relevant experience and equipment are not allowed to remove or adjust the engine at
random.
3.2 Fault diagnostic methods
3.2.1Traditional fault diagnostic methods
1. Observation: Determine the fault by

observing the symptom of diesel engine, such
as smoke.
Fig. 3-1 Observation
19
2. Listening: Determine the fault location,

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

3.3.1Engine startup failure
Steps Checking points Checking methods
The oil circuit of fuel
supply pump including Check and clean away the dirt, and check
Step 1 ...... ......
suction screen or hose, is the cleanliness of fuel.
obstructed.
Bleed air from the system, and check the

Step 2 ...... Air enters the fuel system ......
tightness of joints and repair damaged parts.
The fuel injection pump is Check the plunger and delivery valve, and
Step 3 ...... ......
faulty repair or replace damaged parts.
Check the fuel atomization quality of fuel

Step 4 ...... The fuel injector is faulty ......
injector.
The valve train or fuel feed

Step 5 ...... ...... Check and adjust it.
pipe is damaged or leaky
The high pressure fuel

Step 6 ...... ...... Repair and replace it.
pipe is damaged or leaky
Check the tightness of valves and cylinder

The compression pressure
Step 7 ...... ...... gasket, and the wear condition of piston
of cylinder is insufficient
rings, and repair or replace damaged parts.
The ambient temperature

Step 8 ...... ...... Use starting aids.
is too low
3.3.2Stop shortly after start

Remove the fuel filter housing, clean away
Step 1 ...... The fuel filter is clogged ...... the internal dirt and moisture, and if
necessary, replace the filter element.
20
Check if the fuel pipes and joints are airtight

Air enters the fuel
Step 2 ...... ...... and if the bleeding screw is tightened
system
properly, and bleed air from the system.
The fuel supply pump

Step 3 ...... ...... The fuel supply pump does not work.
does not work
The fuel has poor quality

Step 4 ...... or contains excessive ...... Clean the filter and change fuel.
water
The idle speed achieved

Step 5 ...... ...... Re-adjust the governor.
by governor is too low.
3.3.3Underpower
The intake system (air Check the air filter and intake manifold, and
Step 1 ...... ......
filter) is obstructed clean or replace the filter element.
Check the valve timing, check if the exhaust

The exhaust back
Step 2 ...... ...... manifold is obstructed, and adjust and repair
pressure is too high
relevant parts.
The turbocharger system Check the tightness of pipe connection and

Step 3 ...... ......
is under low pressure eliminate leakage problem.
1) The runner of the turbine of the air

compressor is obstructed by dirt - Clean or
replace.
The turbocharger works 2) The floating bearing is inoperative -
Step 4 ...... ......
abnormally Replace.
3) There are carbon deposits and sludge at
the gap between the turbine and back of air
compressor - Clean.
The intercooler is
Step 5 ...... damaged or has air ...... Replace or repair.
leakage
Check the tightness of fuel pipe and joints and

The fuel pipe is leaky or
Step 6 ...... ...... the cleanliness of filter, and repair or unclog
obstructed
the fuel pipe, and replace the filter element.
Clean the fuel tank, filter parts and pipe, and

Step 7 ...... The fuel has poor quality ......
change fuel.
The fuel injection pump

Step 8 ...... ...... Repair or replace.
is worn out
21
The fuel injection nozzle Check the fuel injection pressure and check
Step 9 ...... injects poorly atomized ...... the fuel injection nozzle for carbon deposits,
fuel then adjust and repair.
The valve or injection

Step 10 ...... ...... Check and adjust.
timing is incorrect
The high speed achieved

Step 11 ...... ...... Check the governor and adjust.
by governor is too low
The oil pan contains Check the oil dipstick and drain out some oil to
Step 12 ...... ......
excessive oil. reach specified oil level.
Check the compression pressure of a hot

The cylinder gasket is
Step 13 ...... ...... engine and replace the damaged cylinder
leaky
gasket.
The piston ring is worn

and broken, and the
Step 14 ...... ...... Replace the worn part or overhaul the engine.
bearing shell clearance
is excessive
The cylinder liner or

piston is worn or the
Step 15 ...... ...... Replace the worn part or overhaul the engine.
cylinder scratching
occurs
3.3.4Excessive fuel consumption

The intake manifold is Check and clean the air filter and intake
Step 1 ...... ......
obstructed. manifold.
The exhaust back Check and clean the exhaust manifold and
Step 2 ...... ......
pressure is too high brake valve.
Step 3 ...... The fuel has poor quality ...... Change fuel as specified.
The fuel pipeline is

Step 4 ...... ...... Check and repair.
obstructed
Step 5 ...... The fuel pipeline is leaky. ...... Check and repair.
The fuel injector injects

Step 6 ...... ...... Check and adjust or repair
poorly atomized fuel
The valve or injection Adjust the valve clearance and fuel supply
Step 7 ...... ......
timing is incorrect advance angle as specified.
22
The cylinder gasket is

Step 8 ...... ...... Check the compression pressure.
leaky
The bearing shell

clearance is excessive
Step 9 ...... ...... Check and overhaul.
and the engine needs to
be overhauled
The piston expanding Replace the cylinder liner, piston and piston
Step 10 ...... ......
cylinder occurs ring.
The turbocharger system Check the tightness of pipe and its connection
Step 11 ...... ......
is under low pressure and eliminate leakage problem.
The turbocharger works

Step 12 ...... ...... Check and replace.
abnormally
The intercooler is
Step 13 ...... ...... Replace or repair.
damaged or leaky
3.3.5Unstable engine speed

The fuel has poor quality
Step 1 ...... ...... Change fuel
or contains water or wax
The fuel suction pipe has Check the tightness of the pipe and joints, and
Step 2 ...... ......
air leakage. bleed air.
The governor
Step 3 ...... counterweight and spring ...... Check and adjust (by fuel pump manufacturer)
work abnormally
The fuel supply is

Step 4 ...... ...... Check and adjust (by fuel pump manufacturer)
uneven.
The fuel injection nozzle

Step 5 ...... injects unstably atomized ...... Check and repair
fuel.
Check and clean the compressor runner, and

The surging occurs in the
Step 6 ...... ...... clean away the blockage and carbon deposits
turbocharger.
in the exhaust manifold.
The turbocharger
Step 7 ...... ...... Replace
bearing is damaged
23
3.3.6Low oil pressure

The oil pan contains Check the oil level and leaky position of the oil
Step 1 ...... ......
insufficient oil pan, and add oil.
The pressure regulating

Step 2 ...... valve of main oil passage ...... Check, clean and repair the valve.
is faulty
The suction strainer, oil Check and clean the compressor runner, and
Step 3 ...... pipeline and joint gasket ...... clean away the blockage and carbon deposits
are obstructed or broken in the exhaust manifold.
The oil is of unspecified Change the oil as specified, and use the oil of
Step 4 ...... ......
grade specified grade.
The oil pump inlet pipe is

Step 5 ...... ...... Check, repair or replace the oil pipe and joint.
leaky
The temperature of both

Check if the cooling system works normally
Step 6 ...... coolant and oil is too ......
and correct it.
high
The oil filter is under

Step 7 ...... ...... Replace the filter element with a new one.
excessive resistance
The oil cooler is

Step 8 ...... ...... Check and clean.
obstructed
The main oil passage is

Step 9 ...... ...... Check and clean.
obstructed
The bearing shell has

Step 10 ...... excessive clearance or is ...... Check and replace.
damaged
The components are

Check the running hours of the engine, and
Step 11 ...... worn out and overhaul is ......
overhaul the engine.
required
24
3.3.7High coolant temperature

The radiator contains Check if the radiator is leaky, and add coolant
Step 1 ...... ......
insufficient coolant if necessary.
The radiator is
Step 2 ...... ...... Check, clean or repair the radiator.
obstructed
The water pump belt is

Step 3 ...... ...... Adjust the belt tension as specified.
slack
The water pump gasket

Step 4 ...... is damaged or the pump ...... Check and repair or replace.
impeller is worn
Step 5 ...... The thermostat is faulty ...... Replace.
The water pipe is

Check the water pipe, joint and gasket, and
Step 6 ...... damaged and has air ......
replace the damaged parts.
leakage
Step 7 ...... ......
insufficient oil pan, repair the damaged part and add oil.
3.3.8Accelerated wear of parts

The air filter element is Check the filter element and replace it with a
Step 1 ...... ......
unacceptable or broken unacceptable one.
The intake system is Check, repair or replace the intake manifold,

Step 2 ...... ......
short-circuited gasket and connecting pipe sleeve.
Step 3 ...... ......
insufficient oil pan, repair the damaged part and add oil.
The oil passage is

Step 4 ...... ...... Clean the oil passage.
obstructed
The oil is of unspecified

Step 5 ...... ...... Change oil as specified.
grade
The piston ring is

Step 6 ...... ...... Replace the damaged part.
broken or worn
25
The cylinder liner or

piston is worn or the Remove, check, repair or replace the piston
Step 7 ...... ......
cylinder scratching and cylinder liner.
occurs
The oil filter element is

Step 8 ...... ...... Replace as required.
not replaced in time
The components are

Check the mileage and determine if overhaul
Step 9 ...... worn out and overhaul is ......
is required.
required
The crankshaft is not

Step 10 ...... concentric with the ...... Check and repair the mounting bracket.
driven shaft
The oil quality is

Step 11 ...... ...... Use the oil of specified grade.
unacceptable
3.3.9Heavy noise
Step 1 ...... The fuel has poor quality ...... Change fuel.
The coolant temperature Check the thermostat, and replace it if

Step 2 ...... ......
is too low necessary.
The valve or injection

Step 3 ...... ...... Check, repair and adjust.
timing is incorrect
The fuel injection nozzle

Step 4 ...... injects poorly atomized ...... Check, repair and adjust.
fuel
The fuel injection pump Check and adjust (by fuel injection pump
Step 5 ...... ......
injects too much fuel manufacturer).
Check if any part is damaged and if the

The shock absorber is
Step 6 ...... ...... connecting bolts are tightened properly, and
worn
replace the damaged parts.
The valve has air

Step 7 ...... leakage or is improperly ...... Remove, check and adjust the valve.
adjusted
The gear backlash is

Step 8 ...... excessive or the teeth ...... Check and replace the damaged parts.
are broken
26
The cylinder liner or piston

Step 9 ...... is worn or the cylinder ...... Check and repair or replace.
scratching occurs
The push rod is bent or

Step 10 ...... ...... Replace.
broken
The piston ring is broken or

Step 11 ...... ...... Check or replace the damaged parts.
worn
3.3.10 Starter motor does not work

Step 1 ...... The battery is under charge ...... Check, charge or replace the battery.
The connecting wire has

Step 2 ...... ...... Arrange the wire and tighten the terminal.
poor contact
Step 3 ...... The fuse is blown ...... Replace the fuse.
Clean the surface of the brush or replace the

Step 4 ...... The brush has poor contact ......
brush.
The starter motor is Check and repair the motor, or replace the
Step 5 ...... ......
short-circuited assembly.
3.3.11 Underpowered starter motor

Step 1 ...... The battery is under charge ...... Charge or replace the battery.
Step 2 ...... The bearing bush is worn ...... Replace the assembly.
Clean the surface of the brush or replace the

Step 3 ...... The brush has poor contact ......
brush.
Clean away the oil stains and grind the

The commutator is dirty or
Step 4 ...... ...... surface with sand paper, or replace the
has singe
assembly.
Welding failure occurs at

Step 5 ...... ...... Reweld.
the end of wire
Step 6 ...... The switch has poor contact ...... Check and repair the switch.
The clutch slips due to Adjust the torque of clutch, or replace the
Step 7 ...... ......
wear. clutch assembly.
27
3.3.12 Inoperative alternator

The connecting wire is open
Check and repair the connecting wire of
Step 1 ...... or short-circuited, or the ......
alternator and ammeter.
connector is loose
The rotor and stator coil are

Step 2 ...... open or short-circuited or ...... Repair or replace the assembly.
grounded
The rectifying tube is

Step 3 ...... ...... Replace the assembly.
damaged
The terminal paper

Step 4 ...... insulation is damaged, and ...... Repair.
the wire is disconnected
The voltage achieved by

Step 5 ...... ...... Repair.
regulator is too low
The voltage regulator

Step 6 ...... ...... Repair or replace the assembly.
contacts are burnt.
3.3.13 Undercharged alternator

The connecting wire is open
Step 1 ...... or short-circuited, or the ...... Repair.
connector is loose
The rotor and stator coil are

Step 2 ...... open or short-circuited or ...... Repair or replace the assembly.
grounded
Step 3 ...... Alternator belt is slack ...... Check and adjust the belt tension.
The rectifying tube of

Step 4 ...... alternator is damaged, and ...... Repair.
the battery has poor contact

Step 5 ...... ...... Adjust.
regulator is too low
The regulator field coil or

Step 6 ...... the resistor wire is ...... Repair or replace.
disconnected
28
The battery contains

Step 7 ...... insufficient electrolyte or is ...... Add electrolyte or replace the battery.
obsolete
3.3.14 Unstable charging current of alternator

The stator or rotor coil is
Step 1 ...... going to be open or ...... Repair or replace.
short-circuited
Step 2 ...... The brush has poor contact ...... Repair.
The terminal is loose and

Step 3 ...... ...... Repair.
has poor contact
The voltage regulator is

Step 4 ...... ...... Repair.
damaged
The voltage regulation is

Step 5 ...... ...... Check and adjust.
improper
3.3.15 Overcharged alternator

The battery internal circuit is
short-circuited

Step 2 ...... ...... Repair and adjust.
regulator is too high
The regulator is improperly

Step 3 ...... ...... Repair.
grounded
The regulator contact is

inoperative or dirty, and the
voltage coil or resistor wire
is disconnected
3.3.16 Abnormal sound from alternator

The alternator is improperly
Step 1 ...... ...... Repair.
installed
Step 2 ...... The bearing is damaged ...... Replace the bearing.
29
The rotating part contacts

the fixed part
Step 4 ...... The rectifier is shorted ...... Replace.
Step 5 ...... The stator coil is shorted ...... Repair or replace.
30
Chapter IV Introduction to Engine Systems

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

4.2.1Overview
The lubrication system is essential for reliable operation of the engine, and it is also a key point in regular
maintenance of the engine.
The lubrication system is aimed at wear relief, washing, cooling and rust protection. Oil should be used
as per specifications provided by the company.
31
Caution
It is not allowed to use lubricating oils CE, CD, CC, CB, or CA for the diesel engine. Remember to
replace the oil filter element while changing the oil.
The oil pump sucks the oil from the oil pan through the suction strainer and delivers it to the oil filter on
the oil cooler & filter module through the dirty oil passage on the engine block. The filtered oil reaches
the oil cooler and is cooled by the coolant, and then the oil enters the main oil passage. The oil reaches
every lubrication position through corresponding oil passage from the main oil passage. Part of the oil
reaches the main bearing from the main oil passage, and reaches the connecting rod bearing through
the oil passage on the crankshaft; the piston cooling nozzle takes oil from the auxiliary oil passage to
lubricate and cool the piston and the connecting rod small end; part of the oil reaches the front and rear
camshaft bearings (the first and seventh camshaft bearings) directly from the front and rear ends of the
main oil passage, and reaches the cylinder head through the oil holes at the front and rear ends of the
engine block and the cylinder head to lubricate the rocker arm shaft and the rocker arm; the oil reaches
the other camshaft bearings through the internal oil passage of the camshaft from the front and rear
camshaft bearings; part of the oil in the main oil passage reaches the gear chamber and rear PTO
through the oil passage at the rear of the engine block. The air compressor and the fuel injection pump
also take oil from the main oil passage through the oil passage at the rear of the engine block for
lubrication, and the turbocharger takes oil directly from the main oil passage (outside of the engine
block) for lubrication.
The oil pressure of the lubrication system is regulated through the pressure limiting valve in the oil pump
body and the main oil passage pressure limiting valve.
The schematic diagram of oil circuit of diesel engine is shown in the figure below:
Suction Oil pump Filter seat Oil filter

strainer
Pressure
relief valve
Oil cooler
Piston
Piston cooling
nozzle
Auxiliary oil
passage
Connecting Main
rod bearing bearing
Oil pan
Main oil passage
Camshaft
bearing
Intermediate
gear bearing
Rocker Push
Tappet
arm rod
Turbochar
ger
Pressure
limiting valve
Fig. 4-2 Schematic diagram of oil circuit
32
4.3 Fuel system

4.3.1Schematic diagram of fuel system
Fuel coarse Fuel supply pump

filter
Fuel fine filter
Fuel return
Fuel tank Fuel pump
Fuel injector
Combustion
chamber
Fig. 4-3 Schematic diagram of fuel system

When the diesel engine works normally, the fuel injection pump camshaft will drive its integrated fuel
supply pump to suck fuel from the fuel tank. After being filtered through the filter, the fuel will flow through
the fuel injection pump and then be branched out into two parts: one part will flow into the plunger
chamber and the other part will flow back to the fuel tank. The plunger will move upwards, such that the
fuel in the plunger chamber will be compressed and flow into the fuel injector through the high-pressure
fuel pipe, and then be injected into the combustion chamber on the top of the engine piston through the
fuel injector nozzle.
33
34
Chapter V Disassembling and Assembling of Engine

5.1 Intake manifold assembly
5.1.1Exploded view
Fig. 5-1 Exploded view of intake manifold assembly

Intake manifold Hexagon socket head pressure and Intake manifold
1 2 3 4
assembly cap screw temperature sensor gasket
5 Hexagon flange bolt 6 Hexagon flange bolt 7 Gasket 8 Heater
Intake connecting
9 Plug cap 10 Stud 11 12 Hexagon flange nut
pipe
13 Plug cap
5.1.2Disassembling tools and preparations

1. Disassembling tools:
35
Pneumatic wrench, sleeve.

2. Preparations before disassembling:
Remove the peripheral components in advance.
5.1.3Disassembling steps
1. Remove the peripheral components of intake manifold.
2. Unscrew the intake manifold bolts, and remove the intake manifold, intake connecting pipe and
gasket in turn.
3. Unscrew the intake connecting pipe fastening nuts, and remove the intake connecting pipe, intake
heater and heater gasket in turn.
5.1.4Inspection and maintenance
1. Check the intake manifold for debris or dust. If any, remove it.
2 Check the intake manifold gasket for deformation, tearing, missing, etc. If any, replace it.
3 Check the intake heater for burnout, short circuit, etc. If any, replace it.
4 Connect the intake manifold and the intercooler pipeline properly to avoid leakage.
5.1.5Assembling steps
The assembling steps are in reverse of disassembling steps.
36
5.2 Fan and hub group

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

All-metal hexagon
1 Hexagon flange bolt 2 Fan 3 Fan flange 4
flange locknut
Hexagon bolt with
5 6 Fan cover assembly 7 Fan cover bracket 8 Fan cover bracket
serrated flange
9 Fan cover bracket 10 Fan cover bracket 11 Hexagon flange bolt

1. Disassembling tools: Socket or wrench.
2. Preparations before disassembling: None.
1. To replace the fan cover assembly, remove the bolt at the connection of fan cover assembly and
fan bracket;
2. To replace the fan, remove the bolt connecting the fan to the fan flange;
37
3. Remove the fan flange if necessary.

Check the fan and fan cover assembly for cracks and other defects, check if the fan rotates normally,
and if not, replace it with a new one.
5.3 Oil-gas separator assembly
5.3.1Exploded view
Fig. 5-3 Exploded view of oil-gas separator assembly

1 Hexagon flange bolt 2 Clamp 3 Pipe joint 4 Pipe clamp assembly
Oil-gas separator
5 6 Pipe clamp assembly 7 Spring washer 8 Hexagon flange bolt
oil-outlet pipe
Oil-gas separator Oil-gas separator
9 10 Clamp 11 12 Hexagon flange nut
air-outlet pipe assembly
Hexagonal socket
13 14 Spring washer 15 Gasket 16 Joint
screw
38

1. Disassembling tools: Socket wrench or pneumatic wrench.
2. Preparations before disassembling: Fix the engine reliably and remove those components blocking
the oil-gas separator.
1. Remove the clamp and pipe clamp assembly of the oil-gas separator air-outlet pipe, and then take
down the pipe.
2. Remove the clamp and pipe clamp assembly of the oil-gas separator oil-outlet pipe, and then take
down the pipe.
3. Remove the two fixing bolts 14 on the oil-gas separator air-inlet pipe joint.
4. Remove the hexagon flange nut for fixing the oil-gas separator on the cylinder head lift hook clamp.
5. If it is necessary to inspect the oil-outlet pipe reaching into the oil pan, remove the oil-outlet pipe
joint, and then remove the oil-outlet pipe upward.
1. Check these components for damage, cracks, etc. and these pipes for hardening, cracking and
other failures, and replace the corresponding part if any.
2. Check if the oil-gas separator is clogged by blowing air into the pre-separator air-inlet pipe; if the air
flow is obstructed, blow high-pressure air into the pipes of the oil-gas separator so as to remove the
impurities and oil stains inside the oil-gas separator. If the pre-separator is still clogged after above
operations, replace the pre-separator with a new one.
3. Check if the oil-gas separator is clogged by blowing air into the oil-gas separator air-inlet pipe; if the
air flow is obstructed, replace the oil-gas separator with a new one.
1. The assembling steps are in reverse of disassembling steps. Ensure that the positions of pipes and
joints are correct according to the exploded view, pay attention to the rotation angle and fixation
position of the pipe during installation, and ensure that sufficient clearance with adjacent
components is reserved.
39
5.4 Turbocharger
5.4.1Exploded view
Fig. 5-4 Exploded view of turbocharger

Turbocharger heat
1 2 Turbocharger 3 Stud 4 Plug cap
shield
2-type all-metal 2-type all-metal
5 6 7 Turbocharger gasket 8 Stud
hexagon lock nut hexagon lock nut

1. Disassembling tools: Pneumatic wrench, sleeve.
2. Preparations before disassembling: Remove other peripheral components on the turbocharger.
1. Loosen the turbocharger heat shield bolts, and then remove the turbocharger heat shield.
2. Loosen the fixing bolts of the turbocharger.
3. Take off the turbocharger and gasket in turn.
40

1. Check the running conditions of rotor
Turn the air compressor impeller gently with hand. If the impeller rotates by more than 1 turn, it
indicates that it is normal. If the impeller stops soon, it indicates that the bearing has been worn
abnormally or collision or seizure occurs between the rotating parts and the stationary parts. In this
case, do troubleshooting timely.
2. Check of rotor displacement

Press the measuring head of the dial
indicator against the air compressor end,
push and pull the rotating shaft with hand
axially, measure and record the difference
value, as shown in Fig. 5-5 Check of rotor
displacement. The rotor displacement shall
be less than 0.15mm. Otherwise, it indicates
that the thrust bearing plate or thrust plate
and bearing body are worn. In this case, do Fig. 5-5 Check of rotor displacement
troubleshooting timely.
3. Check the radial clearance of the air

compressor impeller
Press down or lift up the air compressor
impeller with hand radially, as shown in Fig.
5-6, and measure the radial clearance of the
rotor, which shall be less than 0.1mm on one
side; use a feeler gauge to measure the
minimum and maximum clearances between
the air compressor impeller and air
compressor casing, which shall be within Fig. 5-6 Check of the radial clearance of the air compressor
impeller
0.4~0.8 mm; if any of the two clearances is
out of this range, check the bearing and do
troubleshooting.
Caution
The measurement described above shall be carried out on a cold turbocharger.
1. The bolts and nuts for connecting the turbocharger and the exhaust manifold are made of special
heat-resistant steel, and shall not be replaced with general bolts and nuts.
2. All gaskets are disposable and shall be replaced with new ones in case of repair.
3. Do not apply silica gel on the oil-inlet and oil-outlet pipe gaskets.
4. Do not adjust the pressure of the turbocharger vent valve at will.
1. Pre-apply the molybdenum disulfide to the studs fixing the turbocharger, install two studs
respectively on the exhaust manifold flange and turbocharger flange, and install the turbocharger
gasket.
2. Install the turbocharger, and tighten the fixing nuts.
41
5.5 Turbocharger lubricating oil pipe assembly

5.5.1Exploded view
Fig. 5-7 Exploded view of turbocharger lubricating oil pipe assembly

1 Hexagon socket head 2 Turbocharger oil-inlet 3 Turbocharger oil-out 4 Self-locking washer
cap screw pipe gasket pipe gasket
5 Oil pipe bolt 6 Turbocharger oil-inlet 7 Turbocharger
pipe assembly oil-outlet pipe
assembly

Disassembling tools: Pneumatic wrench, Allen wrench, sleeve, copper hammer, lubricating oil and
brush.
Preparations before disassembling: Remove peripheral components on the turbocharger.
The disassembling steps are in reverse of assembling steps.
1. Check for oil leakage at each connection of the oil-inlet and -outlet pipes. If any, replace the pipes.
42
2. Check the oil-inlet and -outlet pipes for damage. If any, replace the pipes.
1. Install the turbocharger oil-inlet pipe assembly with the oil-inlet pipe gasket at the oil inlet of the
turbocharger, loosely install the hexagon socket head cap screws with self-locking washers, screw
the lower inlet of the turbocharger oil-inlet pipe assembly into the screw plug of the engine block
main oil passage, tighten it with a wrench, and tighten the screws with an Allen wrench.
2. Install the turbocharger oil-outlet pipe assembly with the oil-outlet pipe flange gasket at the oil outlet
of the turbocharger, loosely install the oil-outlet pipe bolts with self-locking washers, use a copper
hammer to knock the lower end of the turbocharger oil-outlet pipe assembly into the engine block
and tighten the oil-outlet pipe bolts with a pneumatic wrench.
5.6 Low-pressure fuel pipe assembly
5.6.1Exploded view
Fig. 5-8 Exploded view of low-pressure fuel pipe

Fuel return pipe
1 Hexagon flange bolt 2 Gasket 3 Gasket 4
assembly
Fuel inlet pipe Fuel inlet pipe Fuel inlet pipe
5 6 7 Plug cap 8
assembly assembly assembly
9 Gasket 10 Hollow bolt 11 Hollow bolt 12 Hollow bolt
43

1. Disassembling tools: Open-end wrench.
1. Remove the hollow bolt.
2. Remove the low-pressure fuel pipe.
Avoid knotting and bending the low-pressure pipe, especially when rubber or plastic hose is adopted.
The low-pressure pipe, joint and hydraulic components must be connected reliably to avoid leakage.
Avoid using the fuel pipe and connector made of copper, zinc, lead and tin.
The fuel supply and return pipes shall be dipped below the lowest fuel level of the fuel tank, and the fuel
tank shall be designed with the breather with filter screen.
Keep certain spacing between the fuel inlet pipe orifice and the fuel return pipe orifice to prevent the air
bubbles in the return fuel from being sucked into the fuel inlet pipe once again, and to reduce the
temperature of the sucked fuel.
The fuel return pipe shall be dipped below the lowest fuel level of the fuel tank to prevent air from
entering the fuel pump via the fuel return pipe after the vehicle stops, causing difficult engine start.
The ventilation system of the fuel tank shall be designed with an appropriate air filter screen to prevent
dust particles and other pollutants from entering the fuel tank, so as to reduce fuel contamination,
prolong the service life of the filter, and reduce the wear of high-pressure common rail system
components. Check if there is any air in the low-pressure fuel circuit and bleed the air if any.
Air bleeding method: Bleed the air in the coarse filter primarily. Unscrew the bleed screw on the coarse
filter, and then press the hand pump on the coarse filter manually until fuel flows out of the bleed screw
continuously.
44
5.7 High-pressure fuel pipe assembly

5.7.1Exploded view
Fig. 5-9 Exploded view of high-pressure fuel pipe assembly

High-pressure fuel
1 Hexagon flange bolt 2
pipe assembly

1. Disassembling tools: Open-end wrench
2. Preparations before disassembling: Remove the intake manifold
1. Remove the bracket for fixing the high-pressure fuel pipe;
2. Remove the high-pressure fuel pipe;
Check if the high-pressure fuel pipe joint nut is loose, and if so, tighten it.
45
Check if there is any air in the high-pressure fuel line as follows: loosen the high-pressure fuel pipe of a
cylinder, and then drive the diesel engine to run with a starter until fuel flows out of the high-pressure fuel
pipe continuously! (It is not recommended to remove the high-pressure fuel pipe joint frequently!)
1. Loosen the bracket for fixing the high-pressure fuel pipe so as to adjust it;
2. Install the high-pressure fuel pipe, align the joint with the mounting surface, and then install the
fastening nuts loosely;
3. Tighten the fastening nuts in turn according to the specified torque;
4. Install and then tighten the bracket for fixing the high-pressure fuel pipe.
Caution
Tightening torque of high-pressure fuel pipe fastening nuts shall be 25~35 N•m both at the fuel
injector end and the fuel pump end.
5.8 Fuel filter assembly
5.9.1Exploded view
Fig. 5-10 Exploded view of fuel filter assembly
46

1 Fuel filter 2 Hexagon flange bolt 3 Support block

1. Disassembling tools: Socket wrench.
2. Preparations before disassembling: Remove the low-pressure fuel pipe connected to it.
1. Remove the low-pressure fuel pipe connected with the fuel filter.
2 Remove the hexagon flange bolt for fixing the filter seat.
1. Check the water level of the fuel coarse filter water collection cup periodically, drain the water in the
cup if necessary, and replace the fuel filter element about every 20,000 km.
1. Remove the fuel filter element with the appropriate wrench.
2. Clean the filter seat.
3. Apply oil to the new filter element gasket.
4. Tighten the filter element in place by hand until the sealing ring comes into contact with the sealing
surface of the filter seat.
5. Tighten the filter element by 3/4 to 1 lap with a suitable wrench.
47
5.9 Air compressor assembly

5.9.1Exploded view
Fig. 5-11 Exploded view of air compressor assembly

1 Hollow bolt 2 Combination washer 3 Sealing ring 4 Air compressor gear
Air compressor
5 Air compressor 6 Hexagon flange bolt 7 8 Combination washer
water-inlet pipe
Air compressor water
9 Hollow bolt 10 11 Combination washer 12 Pipe joint
outlet pipe
Air compressor
13 Pipe joint 14
oil-inlet pipe

1. Disassembling tools: Socket wrench or pneumatic wrench, open-end wrench, etc.
2. Preparations before disassembling: Remove the air compressor lubricating oil pipe.
1. Remove the air compressor water inlet and outlet pipes.
2. Remove the air compressor oil-inlet pipe.
48
3. Remove the bolt connecting the air compressor and the gear chamber.
4. Take out the air compressor from the gear chamber horizontally.
None.
1. Check and clean the junction surface between the air compressor and the front cap.
2. Refit the air compressor.
3. Tighten the bolt connecting the air compressor and the gear chamber.
4. Refit the air compressor oil-inlet pipe.
5. Refit the air compressor water inlet and outlet pipes.
5.10Fuel injection pump assembly
5.10.1 Exploded view
Fig. 5-12 Exploded view of fuel injection pump assembly
49

Fuel injection pump Fuel injection pump
1 2 Stud 3 Hexagon flange nut 4
assembly flange
Fuel injection pump Hexagon bolt with
5 O-ring 6 Hexagon head bolt 7 8
gear serrated flange
Fuel injection pump Fuel injection pump Hexagon socket head Fuel injection pump
9 10 11 12
bracket bracket cap screw bracket
Hexagon bolt with
13 14 Wire harness bracket 15 Change lever 16 Hexagon flange bolt
serrated flange
Smoking limitator
17 Speed control lever 18 Hexagon flange bolt 19 Hollow bolt 20
pipe assembly
21 Gasket 22 Plain washer 23 Screw 24 Hexagon nut
25 Hexagon head bolt
5.10.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench;
2. Preparations before disassembling: Remove the connected low-pressure fuel pipe and
high-pressure fuel pipe
5.10.3 Disassembling steps
1. Remove the hexagon nut connecting the fuel injection pump flange and the gear chamber;
2. Remove the fuel injection pump and gear assembly from the engine;
3. Remove the fuel injection pump lock nut;
4. Remove the hexagon bolt connecting the fuel injection pump and the flange;
5. Remove the fuel injection pump flange.
5.10.4 Inspection and maintenance
Check the commencement of fuel supply:
1. Turn the engine flywheel to the position 30°~40° before TDC of the compression stroke of cylinder
#1;
2. Remove the high-pressure fuel pipe of 1# cylinder of the fuel injection pump, turn the flywheel
counterclockwise (in the rotation direction of the engine) until the fuel level at the high-pressure fuel
pipe joint of 1# cylinder is agitated, and then read the reading of fuel injection advance angle on the
flywheel.
Adjust the commencement of fuel supply:
Turn the flywheel to the position as the specified fuel supply advance angle before TDC of the
compression stroke of cylinder #1 (in the rotation direction of the engine only). Remove the
high-pressure fuel pipe of 1# cylinder, open the throttle to the max, bleed the air in the fuel line, slowly
turn the flywheel in the rotation direction of the engine, and stop turning the flywheel immediately once
any fuel flows out of the delivery valve of 1# cylinder, and record this fuel delivery position on the
flywheel end. Keep the fuel pump at this position and then tighten its fixing bolts. Then, check if the fuel
supply advance angle meets relevant requirements. If not, unscrew the fuel pump fixing bolts and turn
the fuel pump to adjust the advance angle.
50
5.10.5 Assembling steps
1. Install the fuel injection pump flange and the

fuel injection pump gear to the fuel injection
pump, rotate the fuel injection pump gear to
align the round hole mark on the gear with the
notch on the fuel injection pump flange, as
shown in the figure on the right.
Tighten the fuel injection pump gear locknut
M24×1.5 to 250~300 N·m.
2. Then, install the fuel injection pump and the
gear assembly to the diesel engine when the Fig. 5-13 Round hole in the gear aligned with the notch
piston reaches the TDC of the compression on the flange
stroke of 1# cylinder. When installing the fuel
injection pump assembly, insert a Φ4 pin into
the holes in the intermediate flange and the
gear, pull out the pin after tightening the fuel
injection pump assembly, and then plug up
the holes with a screw (M5) coated with
sealant.
3. Tighten the fuel injection pump bracket mounting bolt.
51
5.11Starter assembly
Fig. 5-14 Exploded view of starter assembly

1 Stud 2 Starter 3 Hexagon flange nut

1. Disassembling tools: Socket wrench, pneumatic wrench, open-end wrench, and other common
tools.
1. Remove the hexagon nut.
2. Hold the starter with both hands and remove it along the starter gear rotation axis.
1. During maintenance, pay attention to protecting wiring terminals and wire harnesses. It is strictly
prohibited to impact on or pull terminals and wire harnesses.
52
2. During installation, check if the insulation coverings, sleeves, pads, etc. are intact, and replace the
damaged ones. The #30 terminal of the starter shall not be shorted to the housing.
1. Apply the automotive lithium base grease to the starter gear.
2. Install the stud.
3. Install the starter.
4. Tighten the nuts.
5.12Oil cooler assembly
Fig. 5-15 Exploded view of oil cooler assembly

Hexagon socket
1 O-ring 2 Washer 3 4 Oil cooler
head cap screw
Oil cooler cap
5 6 Oil cooler cap 7 Support block 8 Hexagon flange bolt
gasket
53

9 Gasket 10 Hexagon plug 11 Hollow bolt 12 Gasket
Water outlet pipe
13 14 Hexagon flange bolt
joint

1. Disassembling tools: Socket wrench or pneumatic wrench, copper hammer, etc.;
(1) Open the drain valve to drain the coolant. (2) Prepare a drip pan before removing the cooler.
1. Before disassembling, drain coolant in the engine, loosen a circle of bolts on the oil cooler cap, and
then remove the oil cooler cap and gasket.
2. Loosen the four bolts on the oil cooler, and remove the oil cooler and the sealing ring.
1. Check the oil cooler cap for damage such as cracks, and if any, replace it.
2. Check the oil cooler cap gasket for water leakage, and if any, check if it is in failure, and replace it.
3. Check the oil cooler for damage such as cracks, and if any, replace it.
1. Before assembling, check the oil cooler, and ensure that there are no defects and damage in
manufacturing and use.
2. Clean the junction surface between oil cooler and engine block.
3. Install the sealing ring and the oil cooler.
4. Install the wash spring washer and bolt, and tighten the bolt.
5. Before installing the oil cooler cap gasket, check the oil cooler cap gasket and oil cooler cap, and
ensure that there are no defects and damage in manufacturing and use.
6. Clean the junction surface between oil cooler cap and engine body and install the oil cooler cap
gasket.
7. Install the oil cooler cap bolts, and then tighten them.
54
5.13Oil filter assembly

Fig. 5-16 Exploded view of oil filter assembly
S/N Name S/N Name S/N Name S/N Name

Hexagon socket Wave spring Oil filter seat
1 2 3 Oil filter seat 4
head cap screw washer gasket
5 Spin-on oil filter

1. Disassembling tools: Socket wrench or pneumatic wrench, copper hammer, etc.
55
1. Remove the four bolts on oil filter.

2. Remove the oil filter assembly and oil filter
seat gasket;
Fig. 5-17 Exploded view of oil filter assembly

1. Check oil filter assembly for damage, and replace it if any.
2. Check the oil filter seat gasket for damage, and if any, replace it.
1. Before assembling, check the oil filter seat gasket and the oil filter assembly, and ensure that there
are no defects and damage in manufacturing or use.
2. Clean the junction surface between oil filter assembly and engine block.
3. Install the oil filter seat gasket and the oil filter assembly.
4. Install the wash spring washer and bolt, and tighten the bolt.
56
5.14Exhaust manifold assembly

Fig. 5-18 Exploded view of exhaust manifold assembly

Exhaust manifold Upstream exhaust Exhaust manifold
1 2 3 Plain washer 4
liner manifold sealing ring
Exhaust manifold Downstream Exhaust manifold
5 6 7 Sleeve 8
bolt exhaust manifold bolt
Exhaust manifold
9
heat shield

1. Disassembling tools: Pneumatic wrench, sleeve.
2. Preparations before disassembling: remove components suck as turbocharger.
The disassembling steps are in reverse of the assembling steps.
1. Check the exhaust manifold for cracks and other damage, and check the flange for deformation; if
any, replace the exhaust manifold with a new one.
57
2. Check the exhaust manifold flange for indications of air leakage; if any, replace the exhaust
manifold gasket with a new one.
3. Check the exhaust manifold gasket for deformation, tear, missing, etc., and if any, replace it.
4. Check the exhaust manifold sealing ring for sintering, rust, carbon deposition, etc. If any, replace
the seal ring.
5. During refitting of exhaust manifold, note to avoid scratching the surface of exhaust manifold
connector.
6. The exhaust manifold bolt shall be greased with anti-seize lubricant (molybdenum disulfide), and
the exhaust manifold bolt can only be used for twice at most.
7. Bolts and nuts used in the exhaust system are made of heat-resistant steel. Do not replace them
with general bolts and nuts.
1. See from free end to flywheel end, the openings of 4 sealing rings should be toward left/toward
right/toward up/toward down in order.
2. The exhaust manifold bolts should be coated with molybdenum disulfide. The exhaust manifold
bolts can be reused up to 2 times.
3. Tighten the exhaust manifold bolts from middle to both sides symmetrically. Tighten the exhaust
manifold bolts in three steps. Step 1,screw on the bolts but not tighten; Step 2，tighten the bolts with
the torque of 30N.m; Step 3，tighten the bolts to 65-80 N.m.
58
5.15Tensioner & belt assembly

Fig. 5-19 Exploded view of tensioner & belt assembly
59
No. Name No. Name S/N Name S/N Name

Hexagon head Automatic
1 2 3 Poly V-belt 4 Poly V-belt
bolt tensioner
Automatic Hexagon socket
5 6
tensioner head cap screw

1. Disassembling tools: Socket wrench or pneumatic wrench, open-end wrench, etc.
2. Preparations before disassembling: Remove the fan and hub assembly.
1. Remove the outer belt.
2. Remove the outer automatic tensioner.
3. Remove the inner belt.
4. Remove the inner automatic tensioner.
1. Check these belts for multiple cracks, serious eccentric wear and other failures, and replace the
corresponding part if any.
2. Check the tensioner for collision, abnormal sound, seizure and other failures, and replace the
corresponding part if any.
3. Make sure that the belt is caught in the belt groove when replacing the belt, and avoid the
occurrence of such abnormalities as tooth jumping of belt.
1. Install outer automatic tensioner and inner automatic tensioner.
2. Loosely install the inner belt to make the belt pass through the crankshaft pulley, fan pulley and
automatic tensioner, with the automatic tensioner freely placed without tensioning. Rotate the
automatic tensioner counterclockwise with a square wrench, place the belt properly and confirm it
is completely seated in the groove before tensioning it. Loosely install the outer belt to make it pass
through the fan outer pulley, A/C pulley, automatic tensioner and alternator pulley. Rotate the
automatic tensioner counterclockwise with a square wrench, place the belt properly and confirm it
is completely seated in the groove before tensioning it.
60
5.16Thermostat
Fig. 5-20 Exploded view of thermostat assembly

Hexagon head Wave spring
1 2 3 Thermostat cover 4 Sealing ring
bolt washer
Thermostat Water outlet pipe
5 6
assembly gasket

1. Disassembling tools: Socket wrench or pneumatic wrench, open-end wrench, rubber hammer.
2. Preparations before disassembling: Remove all the fluid line connecting hose from the thermostat
assembly.
Unscrew the fastening bolts of thermostat cover, and take the thermostat cover and the thermostat.
Check the thermostat for fracture, abnormal wear and other damage, and if any, replace it.
61

Caution
Before assembling, check the thermostat, thermostat cover and hexagon flange bolt, and ensure that
there are no defects and damage in manufacturing or use;
5.17Water pump inlet pipe assembly
Fig. 5-21 Exploded view of water pump inlet pipe assembly

Water inlet pipe Water pump inlet Hexagon flange Hexagon flange
1 2 3 4
gasket pipe bolt bolt
Hexagon flange
5 6 Heater joint 7 Gasket 8 Hexagon nut
bolt
Water outlet pipe
9
joint

1. Disassembling tools: Socket wrench or pneumatic wrench, open-end wrench, copper hammer.
62
2. Preparations before disassembling: Remove the fan and gear train belt, and remove the alternator.
1. Remove the 2 hexagon flange bolts 5.

2. Remove the hexagon flange bolt 3, and
remove the water pump inlet pipe and gasket.
3. Remove the heater joint and water outlet pipe
joint.
Fig. 5.-22 Exploded view of water pump inlet pipe

1. Verify that all parts are free of defects and damage in manufacturing and use before assembling.
2. Check the pipe joint and its assembly for blockage, cracks or other damage, and if any, replace
them.
3. Check the water inlet pipe gasket for damage such as fracture, etc., and if any, replace it.
4. Check the studs for thread scratches and other damage, and if any, replace them.
The assembling steps are in reverse of the disassembling steps.
63
5.18Water pump assembly

Fig. 5- 23 Exploded view of water pump assembly

Water pump Water pump
1 2 Stud 3 Hexagon lock nut 4
pulley assembly
Water pump Hexagon flange
5 6 7 Stud 8 Stud
gasket lock nut

1. Disassembling tools: Open-end wrench, socket wrench or pneumatic wrench, copper hammer.
2. Preparations before disassembling: Remove the fan and gear train belt, and remove the inlet pipe
of water pump.
1. Remove the hexagon flange nut 5 from the

water pump, and remove the water pump and
water pump gasket.
2. Remove the studs.
Fig. 5-24 Exploded view of water pump assembly
64

1. Verify that all parts are free of defects and damage in manufacturing and use before assembling.
2. Check the pipe joint and its assembly for blockage, cracks or other damage, and if any, replace
them.
3. Check the water inlet pipe gasket for damage such as fracture, etc., and if any, replace it.
4. Check bolts for thread scratches and other damage, and if any, replace them.
The assembling steps are in reverse of the disassembling steps.
5.19Water outlet pipe assembly
Fig. 5-25 Exploded view of water outlet pipe assembly
65

Water outlet pipe Hexagon flange Hexagon flange
1 2 Water outlet pipe 3 4
gasket bolt bolt
Coolant Temperature
5 6 Clamp 7 Washer 8
connecting hose sensor
Assembled Hexagon head
9 Joint 10 Joint 11 12
sealing washer screw plug
13 Washer

Open-end wrench, socket wrench or pneumatic wrench, copper hammer, slotted screwdriver.
Disconnect all water intake and return hoses and sensor harnesses from the outlet pipe.
1. Remove the sensor wire harness from the water outlet pipe, and then remove the clamp from the
coolant connecting hose;
2. Loosen the fixing bolts of the water outlet pipe in order;
3. Take the water outlet pipe and the gasket;
4. Remove the thermostat if further removal is required.
1. Before removal, check the water outlet pipe for water leakage, cracks, wear, corrosion and other
damage; if there is any crack, replace the water outlet pipe, and in the event of corrosion affecting
the reliability, analyze the causes and replace the pipe.
2. In the event of water leakage at the joints, replace the joints and tighten them, and then check if
water leakage still exists; if the connecting thread is damaged, replace the water outlet pipe.
1. Assemble the gasket and the thermostat body to the water outlet pipe in turn and tighten the bolts;
Caution
It is recommended to use the water outlet pipe gasket once only, and replace it during service.
2. Wipe the water outlet pipe mating face, install the water outlet pipe to the cylinder head, and install
the fastening bolts.
3. Tighten the fastening bolts;
4. Install the sensor wire harness to the water outlet pipe.
66
5.20Alternator assembly
Fig. 5-26 Exploded view of alternator assembly
No. Name S/N Name No. Name No. Name

Hexagon flange
1 Hexagon bolt 2 3 Press block 4 Alternator
bolt

1. Disassembling tools: General disassembling tools.
2. Preparation before disassembling: Disconnect the wires of alternator from the battery and the
vehicle, and remove the fan and belt.
1. Remove the hexagon flange bolt for the short supporting leg.
2. Remove the hexagon flange bolt for the long supporting leg.
3. Take off the alternator.
67

Check if insulation pads and bushes are intact during the installation. The damaged ones must be
replaced. The positive terminal of alternator shall not be short-circuited to the housing. Otherwise, the
alternator shall not be installed on the vehicle in order to prevent it from causing serious accidents.
1. Position the alternator upright.
2. Refit the bolt for the long supporting leg, and tighten the nut.
3. Jack up the alternator, and refit the bolt for the short supporting leg.
4. Tighten the bolt.
5.21Lifting ring assembly
Fig. 5-27 Exploded view of lifting ring assembly
No. Name No. Name No. Name S/N Name

1 Lifting ring

1. Disassembling tools: Torque wrench, open end wrench, socket wrench or pneumatic wrench.
2. Preparations before disassembling: Check that the engine is secured reliably.
68

The lifting ring is fixed onto the lifting ring clamping block with the thread connector, and used for lifting
the engine. During disassembling, loosen the thread connectors to remove the lifting ring.
After disassembling, check the lifting ring for cracks, heavy deformation and other defects. If any of the
above defects exists, replace it with a new one for assembling, so as to avoid safety accidents.
5.22Cylinder head cover assembly
Fig. 5-28 Exploded view of cylinder head cover assembly

Cylinder head Cylinder head Wave spring
1 2 3 4 Support block
cover gasket cover washer
Hexagon flange
5
bolt
69

1. Disassembling tools: Socket wrench or pneumatic wrench.
2. Preparations before disassembling: Check that the engine is fixed reliably, and remove parts above
the cylinder head cover.
Loosen the bolts and support screws of the cylinder head cover in turn to vertically remove the cylinder
head cover, cylinder head cover gasket, etc. upward.
1. Check the cylinder head cover for cracks, serious wear and other damage, and if any crack occurs,
replace it with a new one.
2. If oil leakage occurs at the cylinder head cover gasket, check the cylinder head cover gasket for
failure and the sealing surface between the top surface of the cylinder head and the underside of
cylinder head cover for wear. If oil leakage is found, replace the cylinder head cover gasket with a
new one, and then check it for oil leakage.
1. The cylinder head cover gasket shall only be used once, and shall be replaced with a new one in
case of repair. Before installing the cylinder head cover gasket, check that it has no manufacturing
and usage defects or damage.
2. Clean the sealing surface between the cylinder head and the cylinder head cover, and assemble
the cylinder head gasket, cylinder head cover, locating sleeve, etc. in turn correctly.
3. Install and tighten the bolts of the cylinder head cover.
70
5.23Valve train assembly

Fig. 5-29 Exploded view of valve train assembly

Valve spring
1 Engine block 2 Exhaust valve 3 Cylinder head 4
bottom retainer
Valve spring top EVB valve bridge Rocker arm EVB adjusting
5 6 7 8
retainer assembly assembly screw
Hexagon head EVB bracket Rocker arm shaft
9 Adjusting nut 10 11 12
bolt assembly assembly
Rocker arm
13 14 Valve bridge 15 Valve collet 16 Valve spring
bracket assembly
Camshaft Hexagon head Camshaft timing
17 Intake valve 18 19 20
assembly bolt gear
Hexagon head
21 22 Thrust plate 23 Tappet 24 Tappet
bolt
71

1. Disassembling tools: Dial gauge, torque wrench, lubricating oil reservoir and lubricating oil, towel,
camshaft guide tool.
1) The disassembling work is conducted on the assembling bench.
2) Disassemble the camshaft timing gear and the camshaft after disassembling the intermediate
gear of the flywheel housing.
3) Take out the tappet from the lower part of the engine block after pulling out the camshaft.
4) After removing the cylinder head cover, remove the rocker arm and the rocker arm shaft.
5) Take out the push rod after removing the rocker arm and the rocker arm shaft.
6) Remove the cylinder head from the engine block after disassembling the cylinder head, and
then remove the valve.
1. Remove the rocker arm and the rocker arm shaft. See their disassembling steps for details.
2. Remove the push rod tappet. See the removal steps of the push rod tappet for details.
3. Remove the intake and exhaust valves. See the removal steps of the valve for details.
4. Remove the camshaft and the camshaft timing gear. See the removal steps of the camshaft and
the camshaft timing gear for details.
1. Disassembling steps of rocker arm and

rocker arm shaft
1) Rotate the crankshaft and check the
rocker arm for flexible rotation.
2) Measure the valve clearance and check
its change.
3) If the rocker arm cannot rotate flexibly or
the valve clearance changes
significantly, loosen the hexagon head
screw, then gently remove the EVB
bracket, rocker arm shaft assembly, Fig. 5-30 Exploded view of rocker arm and rocker
intake and exhaust rocker arms and arm shaft
rocker arm bracket, and mark them to
avoid mixture of rocker arms of
cylinders.
2. Removal steps of push rod tappet

1) Upon removal of the rocker arm and
rocker arm shaft, take out the push rods
and place them in order.
2) After removing the cylinder head (as
detailed in the removal steps of cylinder
head), take out the tappets and place
them in order.
Fig. 5-31 Exploded view of push rod and tappet
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3. Disassembling steps of valve

1) Press the valve spring with the valve
spring compressor, valve spring
pressing plier or other tools to remove
the valve collet, valve spring upper seat
and valve internal/external spring.
2) Take the valve out of the valve seat.
Fig. 5-32 Removal of valve and spring
4. Disassembling steps of camshaft

1) Rotate the camshaft, and check if the
camshaft and the timing gear are flexible
without blockage.
2) Use a dial gauge to check the camshaft Fig. 5-33 Exploded view of camshaft
for axial play.
3) Check the backlash of timing gear.
4) Rotate the crankshaft on the removal &
refitting work bench for the engine to
locate the camshaft timing gear in
correspondence with the TDC of the
cylinder #1. Check the camshaft
hexagon bolt for looseness, and remove
the hexagon head bolt of camshaft
timing gear, timing gear and dowel pin.
5) Remove the hexagon head bolt of the
camshaft thrust plate, the thrust plate
and camshaft.

1. Inspection and maintenance of rocker arm and rocker arm shaft
1) Clean the rocker arm and check its appearance for cracks or other defects.
2) Check the rocker arm bore for wear and scratches and measure its diameter.
3) Check the ball pin and rocker arm elephant foot for wear.
4) Check if all oil passages are unblocked.
5) Measure the diameters of the rocker arm bore and shaft, and calculate the fit clearance.
6) Check the wear of EVB adjusting screw, and check the EVB bracket for cracks or wear.
2. Inspection and maintenance of valve
1) Check the valve stem and valve stem end face for wear.
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2) Check the valve cone for wear or damage.

3) Check the valve cone and arc surface for carbon deposit and sintering.
4) Check the valve bridge upper end face and the contact surface of valve for wear.
3. Inspection and maintenance of tappet and push rod
1) Clean the push rod and the tappet.
2) Check if the oil passages of tappet and push rod are unblocked.
3) Check the push rod for bending, and check the wear of the external surface.
4) Check the push rod ball joint and concave end for wear.
5) Check the tappet surface and bottom surface for wear.
6) Check the internal concave end of the tappet for wear.
4. Inspection and maintenance of camshaft
1) Check the contact surface between the cam and the tappet for wear, and check the main
journal for seizure or wear.
2) Check the timing gear hexagon head bolt for deformation, the camshaft timing gear for teeth
collision or the teeth surface for serious wear.
Assemble the camshaft and camshaft timing gear. See their assembling steps for details.
Assemble the push rod and tappet. See the assembling steps of push rod for details.
Assemble the intake and exhaust valves. See their assembling steps for details.
Assemble the rocker arm and the rocker arm shaft. See their assembling steps for details.
Assembling steps of camshaft assembly
1. Clean the camshaft hole with towel, check it

for bump, and apply a proper amount of
lubricating oil to the inner circumference of
camshaft bush with the oil reservoir. If any
bump is found at the camshaft hole, it shall
not be repaired for use. Fig. 5-34 Exploded view of camshaft assembly
2. Place the camshaft guide tool and lubricating sleeve into the camshaft hole, clean the camshaft and
check it for bump, align the cylinder at the tail of guide tool with that at the head of camshaft, and
then insert the camshaft into the camshaft hole. After the camshaft is installed, remove the
camshaft guide tool and lubricating sleeve. When inserting the camshaft, be sure not to scratch the
camshaft bush.
3. Install the camshaft thrust plate, apply clean lubricating oil to both sides of the camshaft thrust
plate, rotate the camshaft to ensure it rotates freely, apply 242 sealant to threads of thrust plate
bolt, and tighten the bolt with the torque of (35±3) N•m.
4. Grind the rear end face of cylinder block, degrease and then wipe it to ensure the junction surface
is flat and clean, tighten the parallel pin at the rear end face of crankshaft, then install the flywheel
housing connecting plate and tighten four fastening bolts.
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5. Apply special sealant to the connecting plate continuously and evenly.

6. Fasten the camshaft thrust plate and timing gear onto the camshaft with bolts. The counter bore on
the connecting plate must be aligned with the marked tooth on the camshaft timing gear.
Assembling steps of push rod and tappet
1. Check the tappet and the push rod for any defects; if any, replace them with new ones. Before
assembling the tappet, make sure to clean it with compressed air, and then check if the oil hole is
unblocked.
2. Apply clean lubricating oil to the outer circumference and bottom surface of valve tappet evenly.
3. Install the tappet into the tappet hole with a tappet installation tool. The tappet and tappet hole shall
be free of bump during the installation.
4. After assembling the cylinder head (see its assembling steps for details), clean the push rod with
compressed air, and then check if the oil hole is unblocked.
5. Apply clean lubricating oil to the push rod, and ensure that the ball joint and concave end are
sufficiently lubricated.
6. Install the push rod with its spherical surface downward.
Assembling steps of valve and spring
Check the valve retainer end face for carbon deposit and sintering. If the valve involves wear, serious
carbon deposit, sintering or other defects, replace it with a new one.
1. Apply molybdenum disulfide grease onto the

intake and exhaust valve stems evenly, and
then install the intake and exhaust valves into
the cylinder head, ensuring that the intake
and exhaust valves can slide in the guide
smoothly.
2. Tighten three dowel pins at the top surface of
each cylinder head to the limit.
3. Install the intake valve spring bottom retainer,
refit the valve stem protective boots to the
intake and exhaust valve guide rods, and
then assemble the valve stem seal.
Fig. 5-35 Exploded view of valve and spring
Note: Be sure to check if the valve stem seal internal spring is intact prior to assembling.
1. Install the valve spring.
2. Install the valve spring top retainer, press the valve spring and install the valve collet.
3. Use a rubber hammer to tap the intake and exhaust valves to locate the valve collet in position after
installing the collet; if the valve collet or valve spring top retainer is not located in position, find out
the causes and eliminate them.
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Assembling steps of rocker arm and rocker arm shaft

1. Place the rocker arm on the operation platform, drive the adjusting screw in the rocker arm and
loosely fit the nut for inspection.
2. Install the parallel pin into the pin hole on the bottom surface of rocker arm shaft, and tighten the pin
to the limit, ensuring it is free of cracks.
3. Assemble the rocker arm bracket and rocker arm shaft assembly together and ensure they fit
closely, apply a small amount of lubricating oil to the rocker arm shaft assembly, then install the
rocker arm assembly to ensure it rotates flexibly, and insert two hexagon socket head cap bolts into
the rocker arm shaft assembly.
4. Install the parallel pin into the pin hole on the EVB bracket and tighten it to the limit.
5. Install the EVB adjusting screw and adjusting nut on the EVB bracket loosely, then install the fuel
injector harness bracket and insert the hexagon head bolt into it. The fuel injector harness bracket
is positioned with parallel pin.
6. After assembling the valve push rod (see its assembling steps for details), fit the combination
subassembly of valve bridge and EVB valve bridge on the intake and exhaust valves respectively.
7. Install and pre-tighten the rocker arm components, align the pin hole on the underside of rocker
arm bracket with the dowel pin on the top surface of cylinder head and locate the pin hole in
position completely. Install the rocker arm ball pin into the circular hole of valve push rod.
8. Install and pre-tighten the EVB bracket components. Align the pin hole on the underside of EVB
bracket with the dowel pin on the top surface of cylinder head and locate the pin hole in position
completely.
9. Tighten the bolt of rocker arm shaft assembly and the hold-down bolt of EVB bracket.
Adjustment sequence and method of valve clearance
1. Turn the crankshaft to place the piston of cylinder #1 at the TDC, where the scribe line on flywheel
is aligned with that on flywheel housing, to determine the cylinder #1 TDC of compression stroke.
2. Adjust the intake valve clearances of cylinders #1, #2 and #4 and exhaust valve clearances of
cylinders #1, #3 and #5. The intake valve clearance is (0.38±0.03) mm; the exhaust valve
clearance is (0.58±0.03) mm; the EVB clearance is (0.38±0.03) mm. The tightening torque of the
adjusting nut of intake and exhaust valves is (45±5)N·m, and that of the EVB is (50~65)N·m.
3. The adjustment method of clearance of exhaust valve is as follows:
Loosen the EVB adjusting screw completely, adjust the locknut and adjusting screw of the exhaust valve
to adjust the exhaust valve clearance to (0.58±0.03) mm; insert a filler gauge under the EVB adjusting
screw, and adjust the EVB clearance to (0.38±0.03) mm, at this time, the piston in the EVB shall be
completely compressed.
Install the turning gear on the flywheel housing and tighten two outside hexagon nuts, then turn the
crankshaft to place the piston of cylinder #6 at the TDC.
Adjust the intake valve clearances of cylinders #3 #5 and #6 and the exhaust valve clearances of
cylinders #2 #4 and #6. The piston of cylinder #6 is at the burst TDC. The intake valve clearance is
(0.38±0.03) mm; the exhaust valve clearance is (0.58±0.03) mm; the EVB clearance is (0.38±0.03) mm.
Check the valve timing of cylinder #1 in cold state. The intake valves open at (22±5)° before the TDC,
and the exhaust valves close at (22±5)° after the TDC.
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5.24Fuel injector assembly

Fig. 5-36 Exploded view of fuel injector assembly

High-pressure Fuel injector
1 Lock nut 2 3 Fuel injector 4
joint clamp
Hexagon head
5 Spherical washer 6
bolt

2. Preparations before disassembling: Remove the rocker arm cover and high-pressure fuel pipe.
1. Remove the hexagon head bolt fixing the fuel injector clamping block.
2. Remove the clamping block and the fixing block of the fuel injector.
3. Loosen the high-pressure joint gland nut.
4. Take out the fuel injector assembly from the cylinder head.
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1. Check the nozzle head for carbon deposit, and clean it if necessary.
2. The fuel injector nozzle shall be replaced at a special service station authorized by Bosch.
3. Note the engraved nameplate on the fuel injector, and note that fuel injectors of different part
numbers are not exchangeable.
4. Location: at the solenoid valve on the top of the fuel injector.
5. Specification: 1st line: model of fuel injector, e.g., WPCRIN2;
6. 2nd line: Weichai part No., e.g., 611600080035;
7. 3rd line: Bosch part No., e.g., 0445B29850.
1. Before assembling, be sure to apply the lubricating oil onto the O-rings of the fuel injector and
high-pressure joint, the threads of high-pressure joint and the contact surface of gland nuts and
joints.
2. Loosen the fuel injector clamping bolt to ensure its axial force on the fuel injector is 0 kN.
3. Install the fuel injector in the cylinder head, and tighten the fuel injector clamping bolt with the
torque of 3N·m.
4. Loosen the fuel injector clamping bolt to ensure its axial force on the fuel injector is 0 kN.
5. Pre-tighten the high-pressure joint (nut) with the torque of 15~20 N·m.
6. Tighten the clamping bolt of fuel injector by 10N·m+120°.
7. Tighten the high-pressure joint (nut) with the torque of 50~55 N·m.
8. Repeated use of the high-pressure joint, O-ring and gasket is not allowed, and the tightness of
O-ring and gasket shall be checked after assembling.
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5.25Cylinder head assembly

Fig. 5-37 Exploded view of cylinder head assembly

Cylinder head Cylinder head Cylinder head
1 2 3 4 Clamping block
gasket auxiliary bolt subassembly
Valve stem seal - Cylinder head Valve stem seal -
5 Cylinder head nut 6 7 8
intake bolt exhaust
Lifting ring
9 Clamping block 10
clamping block
5.25.2 Preparations before disassembling

1. Tools and equipment required: Socket wrench or pneumatic wrench, torque wrench and open-end
wrench.
2. Preparations before disassembling: Remove the cylinder head cover, intake manifold, exhaust
manifold, water outlet pipe, high-pressure fuel pipe, high-pressure connector, oil-gas separator,
and other parts that might be fixed on the cylinder head or might cause interference to the
disassembling of the cylinder head in advance.
1. Loosen and remove the eyebolts at both ends of engine.
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2. Loosen the cylinder head auxiliary bolt and nut, and remove the clamping block. The clamping
block has three structures, i.e. the cylindrical one installed on an auxiliary bolt between two cylinder
heads, another one installed on two auxiliary bolts on a cylinder head at both ends of engine for
installing the lifting ring plate, and the other one installed on an auxiliary bolt on a cylinder head at
both ends of engine.
3. Loosen the cylinder head main bolt, remove it and put it in place.
4. Remove the fuel injector. Since the nozzle of the fuel injector projects beyond the bottom surface of
the cylinder head, the fuel injector must be removed before disassembling cylinder head;
otherwise, it is liable to scratch the fuel injector head when the cylinder head is placed.
5. Remove the cylinder head, and place it on the cardboard to avoid wearing the top surface of
combustion chamber and other sealing surfaces. To remove multiple cylinder heads, mark the
cylinder number on the cylinder heads for subsequent problem analysis and solving.
6. Remove the cylinder head gasket. To remove multiple cylinder head gaskets, mark the cylinder
number on the cylinder head gaskets for subsequent problem analysis.
7. To replace or check the cylinder head auxiliary bolt, remove it.
8. Remove the rocker arm bracket, intake and exhaust valves and other valve trains.
9. To check or replace the valve stem seal, remove the seal with a special tool or rotarily lift and
remove it by clamping its lateral wall with pliers. The removed valve stem seal shall be scrapped
and can not be reused.
1. Before disassembling the cylinder head, check the connection of the cylinder head and engine
block for any indications of water, oil or air leakage and other abnormalities. If any, replace the
cylinder head gasket with a new one, and then check if the fault is eliminated. See this section for
disassembling and assembling methods of cylinder head gasket.
2. Check the appearance of cylinder head, and carefully check the cylinder head for discoloration and
crack. If any crack is found, perform dye penetrant inspection.
3. Before disassembling, check the lubricating oil inlet pipe for oil leakage, cracks, wear, corrosion
and other damage; if there is any crack, replace the lubricating oil inlet pipe, and in the event of
corrosion affecting the reliability, analyze the causes and replace the pipe. If oil leakage occurs at
the hollow bolt, replace the hollow bolt and assembled sealing washer, tighten the new ones, and
then check for oil leakage.
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4. Before disassembling valve train, check the

valve sinkage. The valve sinkage is the
vertical distance between the bottom
surfaces of the valve and the cylinder head.
The difference between its measured value
and required value indicates the wear of the
valve and valve seat indirectly. A depth
micrometer can be used to measure the valve
sinkage, as shown in the figure.
5. Required valve sinkage is given in the table
below. If the valve sinkage exceeds the
permissible range, verify the wear of the Fig. 5-38 Depth micrometer
valve and valve seat; install an unused valve
and then measure the valve sinkage to check
the wear of valve seat. If the fault remains,
replace the cylinder head to ensure the
reliability of diesel engine. If the valve sinkage
does not exceed the permissible range,
remove the valve to check the sealing
surfaces of the valve and valve seat ring for
obvious wear and abnormal damage.
Table 5-1 Required valve sinkage
Position Required valve sinkage (mm)

Intake -0.2~0.2
Exhaust -0.2~0.2
6. After disassembling valve train, check the internal condition of cylinder head air inlet and outlet, and
check them for water leakage. If any, clean them, then perform dye penetrant inspection to find the
fault position, and replace the cylinder head with a new one.
7. Clean the cylinder head, especially the combustion chamber surface, valve seat, intake and
exhaust valves and air inlet and outlet, to remove carbon deposit and glue from the surface, and
check the condition of surface.
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8. Check the inner diameter of valve guide. The

inner diameter of valve guide is the contact
surface of the valve guide with valve. If it
exceeds the permissible value due to wear,
the valve guiding will be affected, reducing
the reliability of the diesel engine. Use an
inside micrometer to measure the inner
diameter of the valve guide as shown in the
figure below. The permissible inner diameter
of the valve guide is (9.0~9.015) mm. If the
permissible value is exceeded, replace the
cylinder head to ensure the reliability of diesel
engine.
9. Remove the cylinder head gasket, check the
cylinder head gasket for visible damage and
analyze the cause. The cylinder head gasket
shall be replaced with a new one once
removed, no matter it is faulty or not.
10. Before removal, check the rubber lip of the
valve stem seal for damage and the spring for
failure and other abnormalities. The valve
stem seal shall be replaced with a new one Fig. 5-39 Inside micrometer
once removed.

1. Refit the cylinder head auxiliary bolt
1) The cylinder head auxiliary bolt is allowed to
be used for three times, and shall be replaced
after that.
2) Apply anaerobic threadlocker 262 to the
screwing end of the cylinder head auxiliary
bolt (end with short threads).
3) Clean the threaded holes on the cylinder
block.
4) Tighten the bolt with torque of (76~102) N.m.
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2. Refit the cylinder head gasket

1) The cylinder head gasket is disposable,
and shall be replaced with a new one in
the case of repair.
2) Wipe up the inner wall of the cylinder
liner and apply the clean lubricating oil
onto it, wipe the top surface of the
engine block, and place the cylinder
head gasket with corresponding pin
holes aligned.
3) Check if holes on the cylinder head
gasket are aligned with those on the
cylinder block and if the cylinder head
gasket is assembled correctly.
Fig. 5-40 Cylinder head gasket
3. Refit the valve stem seal
1) The valve stem seal is disposable, and
shall be replaced with a new one in the
case of repair.
2) Check if the valve stem seal is faulty,
and if the spring of the valve stem seal is
intact.
3) Install the valve stem seal onto the valve Fig. 5-41 Valve stem seal
guide.
4) Apply lubricating oil onto the lip of the
valve stem seal.
5) Use the valve stem seal assembling tool
and the rubber hammer to install the
valve stem seal.
4. Refit the cylinder head
1) Before assembling the cylinder head,
check that the valve, valve spring, collet
and other valve train parts are installed
in place.
2) Carefully clean the cylinder head to
ensure it is free of dust, debris, sand or
other dirt, and then clean its bottom
Fig. 5-42 Valve stem seal refitting tool
surface.
3) Check that there is no foreign matter in
the air and water passages of cylinder
head. Check if there is foreign matter in
the cylinder, and if the cylinder head
gasket and the bottom surface of the
cylinder head are clean.
4) Before the bolts of the cylinder head are
fastened, position the cylinder head by
way of pin-surface.
5) Refit the cylinder head.
5. Refit the clamp
1) Clean the clamp.
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2) After applying clean lubricating oil to the

bearing surface of clamping blocks,
install them on the cylinder head in turn.
The applied oil shall be of a proper
amount to prevent it from flowing into
the gaps between cylinder heads.
3) The clamp shall be so refitted that the
groove has the same direction with the
gap between cylinder heads.
4) Screw the cylinder head auxiliary nut
onto the cylinder head auxiliary bolt with
hands.
6. Refit the cylinder head bolt and auxiliary bolt
1) Tighten M14 cylinder head auxiliary
bolts (stud bolts) #1~#21 and M16 main
bolts #22~#45. They are allowed to be
used for three times.
2) Align the bolts with the cylinder head in
sequence, apply a proper amount of Fig. 5-43 Tightening of cylinder head bolts
clean lubricating oil to the threads and
shoulder pressure-bearing surfaces of
cylinder head main bolts and the
shouldered nuts, and then install them
on the cylinder head, cylinder head
auxiliary bolt and clamping block
respectively.
3) Tighten the main bolts with the torque of
(30~50) N.m.
4) Tighten the auxiliary bolts and nuts with
the torque of (30~50) N.m.
5) Knock the clamping blocks to locate
them in position.
6) Use a torque wrench to tighten the nuts
of auxiliary bolts with the torque of 100
N·m in order and mark the nuts.
7) Use a torque wrench to tighten the main
bolts with the torque of 200 N·m in order
and mark the bolts.
8) Use the torque wrench to tighten the
nuts of auxiliary bolt by 90° in order and
mark new position of the nuts.
9) Use the torque wrench to tighten the
main bolts by 90° in order and mark new
position of the bolts.
10) Use the torque wrench to re-tighten the
nuts of auxiliary bolts by 90° in order
until the nuts are tightened to (120~160)
N·m simultaneously.
11) Use the torque wrench to re-tighten the
main bolts by 90° in order until the bolts
are tightened to (240~340) N•m
simultaneously.
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5.26Crankshaft pulley assembly

Fig. 5-44 Exploded view of crankshaft pulley assembly

Hexagon flange Torsional Crankshaft
1 2 Crankshaft pulley 3 4
bolt vibration damper assembly

1. Disassembling tools: Torque wrench, automatic tightening machine, etc.
2. Preparations before disassembling: Remove the belt before disassembling the crankshaft pulley
group.
Screw off the hexagon flange bolts to remove the crankshaft pulley and the torsional vibration damper
from the crankshaft.
1. Check the vibration damper for bumps. If so, it is forbidden to use it; check the radiator fin for
falling-off or deformation.
2. Check the pulley for damage and the tightening position of the bolt for crushing.
1. Position the torsional vibration damper and crankshaft pulley to the front end of the crankshaft in
turn.
2. Refit the crankshaft pulley and torsional vibration damper onto the crankshaft with eight M10
hexagon flange bolts, and then tighten them to 60 (0, +10) N•m in a symmetric way. Apply a little
lubricating oil to the threads and flange faces of the bolts before refitting.
85
5.27Flywheel housing assembly

Fig. 5-45 Exploded view of flywheel housing assembly

Flywheel housing Flywheel housing
1 Flywheel housing 2 3 4 Access panel
bolt bolt
Hexagon head
5 6 Speed sensor 7 Parallel pin
bolt

2. Preparations before disassembling: Remove the transmission, clutch and the flywheel.
1. Check that the junction surfaces are free from burrs, oil stains, bumps, etc.
2. Check that sealant is evenly and consistently applied to the junction surface of the engine block
and flywheel housing.
3. Apply lubricating oil on the flywheel housing bolts before refitting and tighten them symmetrically in
the order as shown.
4 After tightening the bolts, check the coplanarity of flywheel housing bottom surface and engine
block bottom surface, which shall not exceed 0.5 mm.
86

1. Tighten 2 cylindrical pins at the
pre-assembled upper rear of engine block.
(Tool: Copper hammer)
2. Note: The parallel pin must be tightened to
the limit.
3. Check if the junction surface of cylinder block
and flywheel housing is clean without burrs,
and remove the oil; afterwards, apply sealant.
(Tools: sealant application tools; auxiliary
materials: 755 cleaning agent and 510
sealant)
4. Note: The applied sealant strip shall be even
and continuous.
5. Hoist the flywheel housing. The rear and
non-rear PTO flywheel housing bolts shall be
the same in specifications, quantity and
refitting method.
1) Apply the clean lubricating oil to the
threads and bearing surface of the
flywheel housing bolts;
2) Tightening sequence: Tighten the bolts
symmetrically to (110~140) Nm in the
order as shown. The flywheel housing
bolts can be reused twice.
3) After screwing down the bolts, check the
coplanarity of flywheel housing bottom
surface and engine block bottom
Fig. 5-47 Exploded view of flywheel assembly
surface, which shall not exceed 0.5 mm.
6. After the bolts are tightened in place,
make paint marks on them in the same
direction with a special paint marker.
(Auxiliary material: marker)
7. Refit the access panel onto the flywheel
housing and tighten the bolts.
5.28Flywheel assembly
Fig. 5-46 Refitting sequence of flywheel housing bolts

87

Crankshaft Flywheel ring Radial ball
1 2 3 Flywheel 4
assembly gear bearing
Wave spring Hexagon head
5 Circlip for hole 6 7 8 Stud
washer bolt
1-type hexagon
9 10 Flywheel bolt
nut

2. Torque wrench, automatic tightening machine, travelling crane, guide studs, needle-nosed pliers,
etc.
4. Before disassembling the flywheel assembly, it is required to remove the parts connected to the
flywheel output end, such as the clutch etc.
1. Check the flywheel bolts for thread damage and other failures.
2. Check the flywheel surface for crushing.
3. Check the flywheel ring gear for damage.
4. Check the contact surface of flywheel with clutch or other parts for crazing.
1. Fix and refit the flywheel ring gear onto the flywheel by hot mounting.
2. Tighten the parallel pin at the rear end of crankshaft to the limit.
3. Refit the rear oil seal of crankshaft onto the crankshaft, and press the rear oil seal with the rear oil
seal tooling.
4. Lift and refit the flywheel.
1) Insert the flywheel guide rod into the two bolt holes, which have the longest space between
each other, on the crankshaft;
2) Pass the flywheel through the guide rod and into the flywheel housing.
5. Insert the flywheel bolts into the flywheel and refit the flywheel onto the crankshaft.
1) Apply the clean lubricating oil to the threads and bearing surface of the flywheel bolts;
2) Tighten the flywheel bolts;
3) Tighten nine M14×1.5 bolts by diagonally pre-tightening them for the first time; diagonally
tightening them to 60-80N•m for the second time, and then tightening them for 90°±5° twice to
the final torque of (230-280) N·m. Replace the bolt which fails to reach the torque after the
turning. They can be reused twice.
88
5.29Oil pan assembly

Fig. 5-48 Exploded view of oil pan assembly

Magnetic screw Hexagon flange Oil pan holding
1 2 Washer 3 4
plug bolt block
5 oil pan 6 Gasket

1. Disassembling tools: Socket, wrench, copper hammer, etc.;
2. Preparations before disassembling: Remove the flywheel housing group, the oil dipstick group and
the accessories drive belt train system, and then loosen the oil pan drain plug to drain the oil
completely.
89
1. Drain the oil completely before removing the

oil pan. Place the oil container under the oil
pan drain plug and use the plug wrench to
loosen the oil drain plug and drain the oil;
2. Remove the oil dipstick assembly and take
care not to damage the oil dipstick during
removal;
Fig. 5-49 Exploded view of oil pan drain plug
3. Remove the fastening bolts on the junction

surface of the oil pan and engine block with a
wrench to remove the oil pan holding block,
and then separate the engine block from the
oil pan with a crane sling and other
equipment;
4. Separate the oil pan, and check it for flatness
and damage.
Fig. 5-50 Exploded view of oil pan bolts and

holding block

1. Drain the oil completely before removing the oil pan. Place the oil container under the oil pan drain
plug and use the plug wrench to loosen the oil drain plug to drain the oil;
2. Check the sealing ring between the oil pan and the engine block for damage;
3. Check the pressed surfaces of bolts and holding block for crushing and damage;
4. Tighten the oil pan fastening bolts to (22-29) N•m.
The assembling steps are in reverse of disassembling steps for the oil pan.
90
5.30Suction strainer assembly

Fig. 5-51 Exploded view of suction strainer assembly

Oil suction Hexagon head
1 Gasket 2 3 Plain washer 4
strainer bolt

1. Disassembling tools: Socket, wrench, copper hammer, etc.
2. Preparations before disassembling: Remove the oil pan.
1. Loosen two hexagon head bolts on the

suction strainer.
2. Remove the suction strainer and gasket.
Fig. 5-52 Exploded view of suction strainer

assembly
91

Check the suction strainer and its gasket for damages such as cracks, and if any, replace them.
1. Before assembling, ensure that there is no defects and damages due to manufacturing and use.
2. Clean the junction surface between suction strainer and oil pump and the inner cavity.
3. Install the suction strainer and its gasket.
4. Install the hexagon head bolts and tighten them.
5.31Oil pump assembly
Fig. 5-53 Exploded view of oil pump assembly

Hexagon socket Hexagon socket
1 2 3 Oil pump 4 Oil pump gasket
head cap screw head cap screw

1. Disassembling tools: Socket wrench, copper hammer, etc.
92
2. Preparations before disassembling: Remove the oil pan, suction strainer, etc.
Loosen two hexagon flange bolts on the oil pump, and then remove the oil pump and its gasket.
1. Check the oil pump for damages such as cracks and the inner cavity for smoothness, and replace
the oil pump if necessary.
2. In the event of oil leakage at the oil pump gasket, check the oil pump gasket for failure, and if any,
replace it.
1. Before assembling, check the oil pump and its gasket, and ensure that there is no defects and
damages due to manufacturing and use.
2. Clean junction surface of oil pump and crankcase.
3. Install the oil pump gasket.
4. Install the oil pump.
5. Install two hexagon flange bolts and tighten them.
5.32Gear drive assembly
Fig. 5-54 Exploded view of gear drive assembly
93

Timing gear Hexagon head Intermediate gear
1 2 3 4 Gear cover plate
chamber bolt assembly
Intermediate gear Hexagon flange
5 Idler shaft 6 7 Engine block 8
shaft bolt
Camshaft timing Crankshaft timing Intermediate gear Intermediate gear
9 10 11 12
gear gear assembly shaft
Hexagon head
13 Sealing ring 14
bolt

Disassembling tools: Torque wrench, automatic tightening machine, turning tool, dial gauge, etc.
Preparations before disassembling: Remove the air compressor and high-pressure fuel pump.
1. Observe the mark of mounting bolt of

camshaft timing gear to check if the bolt
rotates, and remove the camshaft timing
gear.
2. Observe the mark of intermediate gear
mounting bolt to check if the bolt rotates;
remove four bolts of the intermediate gear to
remove the gear cover plate; tighten a M8
bolt into the idler shaft to pull the shaft out;
during this operation, avoid intermediate gear
assembly 3 falling off. Fig. 5-55 Exploded view of gear drive assembly
3. Screw off hexagon head bolt 14 to remove

intermediate gear assembly 11 and
intermediate gear shaft 12 with the timing
gear chamber; remove the intermediate gear
shaft and remove the intermediate gear
assembly from the opening on the timing gear
chamber, as shown in Figure 5-55.

1. Check whether the mounting bolt threads are in good condition.
2. Check all gears for tooth flank peeling off or tooth breakage, the bolt pressure-bearing surface for
crushing and the threaded hole or through hole on the gear for deformation.
3. Check whether there is abnormal wear between the idler shaft and intermediate gear bushing.
Check if the oil hole is blocked by foreign matters.
94
1. After refitting of the oil pump gear and

crankshaft timing gear, place the oil pump
intermediate gear assembly between the oil
pump gear and the crankshaft timing gear
with the oil pump intermediate gear bearing
holes aligned with the holes on the
crankcase.
2. Place the idler shaft into the intermediate
gear assembly with the V-shaped teeth on
the gear facing outwards (in a way that the Fig. 5-56 Refitting position of intermediate gear
V-shaped teeth will not be blocked by the assembly
intermediate gear shaft), as shown in Fig.
5-56. Refit the timing gear in a way that #1
cylinder piston is positioned at the TDC; refit
the diesel engine upside down.
3. Refit intermediate gear shaft 12 of the
intermediate gear assembly, and tighten
hexagon head bolt 14 to the specified torque.
4. Refit intermediate gear shaft 6 of the
intermediate gear assembly in a way that the Fig. 5-57 Refitting of camshaft timing gear
side with threads and notches faces towards
the operator. Refit the gear cover plate and
tighten 4 fixing bolts of intermediate gear to
the specified torque. Mark the bolt positions
on the bolt heads with a marker.
5. Rotate the camshaft in place to ensure that the scribe line on the camshaft timing gear is aligned
with the OT mark on the timing gear chamber, as shown in Fig. 5-57; tighten 4 fixing bolts of
camshaft gear to the specified torque. Mark the bolt positions on the bolt heads with a marker.
6. Measure the backlashes between gears.
95
5.33Piston nozzle assembly

Fig. 5-58 Exploded view of piston nozzle assembly

Piston nozzle
1 Hollow bolt 2
assembly

Socket wrench.
Remove the components like crankshaft, etc.
1. Remove the hollow bolt.
2. Remove the nozzle assembly.
Check the nozzle for clogging, and replace it with a new one if it is clogged.
96

Check the dowel pin for damage, and replace it if necessary. Align the dowel pin with the pin hole on the
engine block, and knock the nozzle body with a copper hammer to refit the dowel pin completely into the
pin hole.
Refit the hollow bolt by the tightening torque of 20~30N·m.
5.34Piston & connecting rod assembly
Fig. 5-59 Exploded view of piston & connecting rod assembly

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

1. Disassembling tools: Torque wrench, automatic tightening machine, travelling crane, needle-nosed
pliers, etc.
2. Preparations before disassembling: Remove the parts such as the cylinder head, valve train and oil
pan before disassembling the piston and connecting rod assembly.
97
1. Carefully remove the carbon deposit at the

top of cylinder and take care not to damage
the cylinder inside. Place the engine at a slant
angle, turn the crankshaft to place the piston
at the BDC, and remove the connecting rod
bolt and the connecting rod cover.
Afterwards, turn the crankshaft to place the
piston at the TDC and knock out the piston
with a wooden hammer. In this process, take Fig. 5-60 Exploded view of connecting rod big end
care to prevent the cylinder block from being
stuck by the connecting rod big end. Place
the bearing shell and connecting rod cover in
the original order.
2. Use the circlip pliers for hole to carefully

remove the circlip from each side of the
piston, push out the piston pin, and remove
the connecting rod body. Number the
connecting rod bodies respectively, and place
them in order;
3. Use the piston ring pliers to remove the first
compression ring, second compression ring
and oil ring, and mark them separately; Fig. 5-61 Exploded view of piston pin and
connecting rod bearing shell
4. Apply the radial and tangential force to the
connecting rod bearing shell to separate the
bearing shell from its mounting position, and
then remove the bearing shell. Number the
bearing shells in the order of the cylinder
number respectively, and place them in the
order.

1. Check that the piston surface and cavity, piston ring, and piston pin surface are free from burrs, oil
dirt or bumps; check if there are cracks at the filleted corner at the combustion chamber throat and
the piston pin seat, and if any, replace the corresponding parts.
2. Check the outer perimeter and upper & lower end faces of piston ring for abnormal wear.
3. The weight difference between groups of aluminum pistons shall not exceed 10g. The pistons of
the same weight shall be refitted on the same diesel engine, instead of being mixed.
4. After the piston ring is refitted onto the piston, there shall be no collision between pistons.
5. Check that the big end and small end of the connecting rod are free of burr or bump; check that the
oil hole periphery of the small end bearing bush is free of cracks, deformation or discoloration.
6. Check the connecting rod side for abnormal wear and the connecting rod body for bending.
7. Check the connecting rod bush alloy layer for abnormal wear, peeling, etc.
8. The cylinder numbers on the connecting rod body must be consistent with those on the connecting
rod cover; the weight group marks of the same connecting rod shall be the consistent.
9. If the connecting rod body is scratched or damaged, replace the connecting rod.
10. The connecting rod bolt can be used for 3 times at most; the length of bolts shall not exceed
75.3mm.
11. Visually check the bearing shell surface for any scratch or burr.
98
12. Before installing the connecting rod bearing shell, clean the bottom hole and shell; do not apply
lubricating oil to the bottom hole and the back of shell.
13. Replace the connecting rod bearing shell if its surface shows corrosion, cavitation, denudation or
scratch.
14. Check the wear condition of connecting rod bearing shell, and check the alloy layer for
discoloration, peeling, slippage and other defects.
1. Seat the connecting rod bearing shell past

the fracture split by applying radial and
tangential force to avoid scratching the steel
backing. Ensure the lip on the connecting rod
bearing shell is exactly aligned with the
groove of connecting rod big end and
connecting rod cover. Remember to apply
lubricating oil to the inner surface of the
bearing shell after installation.
2. Use the circlip pliers for hole to refit a circlip
for hole into the piston retainer ring groove,
and rotate the circlip to ensure a complete
refitting.
Fig. 5-62 Assembling of connecting rod bearing

shell
3. Insert the connecting rod small end into the

piston cavity, align the connecting rod small
end with the piston pin hole, then refit the
piston pin, and finally refit the piston pin
retainer on the other side. The retainer
opening shall be located at an offset angle of
30° from the piston centerline, and the two
retainers shall be staggered by 60°. Clean
and apply a proper amount of clean
lubricating oil to the connecting rod small end
hole and the piston pin before the refitting.
The make mark on the connecting rod and
the orientation mark of piston shall be on the
same side, and the connecting rod and the
piston of the same engine shall be in the
same mass group. Fig. 5-63 Assembling of piston pin
4. Hang the assembled piston & connecting rod to

the pallet in the order of the cylinder number,
and then use the piston ring pliers to refit the
coil spring loaded oil-control ring, twist taper
faced ring and keystone barrel faced ring in
turn into the piston ring groove. The piston
ring shall be assembled in parallel in the ring
groove without distortion. The "TOP" surface
of the piston ring shall be upward, and the Fig. 5-64 Assembling of piston ring
piston ring shall rotate flexibly in the ring
groove.
99
5. Adjust the opening directions of the piston rings: the opening of the first compression ring shall be
located at an offset angle of 30° from the piston pin centerline; the openings of the second
compression ring and the first compression ring shall be staggered by 120°; the opening of the oil
ring shall be located at an angle of 120° from the first and the second compression rings
respectively, and at the vertical bisector of the piston pin centerline.
6. Wipe the cylinder inner wall, crank web and piston & connecting rod assembly, and apply the clean
lubricating oil onto the kinematic pairs.
7. Turn the crankshaft to locate the pistons of

cylinders #1 and #6 near the BDC, and gently
place the piston & connecting rod assembly
in the cylinder liner when the orientation mark
of the piston faces to the engine front end.
Hold the piston ring compressor to press it
against the cylinder liner. Push the piston into
the cylinder liner via the compressor. Then
pull the connecting rod downward to install it
onto the crankshaft journal. Connecting rod
bolt: Pre-tighten it to 35N·m and then rotate it
by 120°.
Note:
The piston number shall be consistent with the
cylinder number, the connecting rod cover
shall match with the connecting rod body, and
the connecting rod bolt shall be coated with
clean lubricating oil before refitting. Refit the
remaining cylinders in the same way.
Fig. 5-65 Assembling of connecting rod assembly
100
5.35Timing gear chamber assembly

Fig. 5-66 Exploded view of timing gear chamber assembly

Timing gear Hexagon flange Hexagon flange
1 2 3 4 Washer
chamber bolt bolt
Hexagon screw
5 6 O-ring 7 Parallel pin 8 O-ring
plug

2. Preparations before disassembling: Remove the front end accessories.
1. Remove the fastening bolts of the gear chamber;
2. Remove the screw plug and combined washer;
3. Remove the intermediate gear shaft;
4. Remove the oil pump intermediate gear shaft and the oil pump intermediate gear bolts;
5. Remove the timing gear chamber;
6. Remove the sealing ring;
Check if the parts are complete as per the parts list. Check the state of the gear chamber assembly, and
ensure that the junction surfaces are free from burrs, oil stains and bumps, etc.
101
1. Installation requirements of gear chamber:

Tighten the gear chamber bolts symmetrically
and diagonally in the order shown in the
figure.
2. Before assembling, observe if the sealing ring
has scratches and other defects. If any,
replace the sealing ring in time. While
replacing, apply oil to the sealing ring, press it
into the groove completely and prevent the
groove from scratching the sealing ring.
3. To remove the gear chamber, first remove the
fastening bolts from the gear chamber, and
then remove the intermediate gear shaft and
the oil pump intermediate gear shaft. Place Fig. 5-67 Tightening sequence of gear chamber
the removed gear chamber in a clean bolts
environment.
4. First insert the intermediate gear shaft into
the intermediate gear and place them into the
gear chamber; then apply sealant to the back
of the gear chamber, and press and fit the
sealing ring.

5.36Oil seal assembly
Fig. 5-68 Exploded view of oil seal assembly

1 Rear oil seal 2 Front oil seal
102
5.36.2 Preparations before disassembling

1. Disassembling tools: Special disassembling tools.
2. Preparations before disassembling: Remove the gear chamber, front oil seal and crankcase.
None
1. Before refitting the oil seal, clean the mounting hole and oil seal, and make sure they are free of
dirt. For refitting of oil seal, use a special tool to press the oil seal in steadily. Before refitting, apply
the lubricating oil to the oil seal and press-fitting tool.
2. Do not use the removed oil seal.
None
5.37Crankshaft assembly
Fig. 5-69 Exploded view of crankshaft assembly

Hexagon flange Torsional
1 2 Crankshaft pulley 3 4 Flange
bolt vibration damper
5 Crankshaft gear 6 Flat key 7 Upper thrust plate 8 Crankshaft
Flywheel ring Radial ball
9 Parallel pin 10 11 Flywheel 12
gear bearing
Wave spring Hexagon head
13 Circlip for hole 14 15 16 Stud
washer bolt
1-type hexagon
17 18 Flywheel bolt 19 Lower thrust plate
nut

1. Disassembling tools: Turnover rack, torque wrench, automatic tightening machine, traveling crane,
guide studs, needle-nosed pliers, manual or single-end pneumatic wrench, etc.
103

1) Remove the belt before disassembling the crankshaft pulley.
2) Before disassembling the crankshaft assembly, remove the flywheel, flywheel housing, front
end cap, crankshaft pulley, main bearing cap and piston & connecting rod.
1. Place the engine block upside down, remove the main bearing bolts, remove the main bearing cap
and the main bearing lower shells and place them in sequence.
2. Remove the front and rear thrust plates, and then remove the oil seal. Hoist the crankshaft
assembly with the traveling crane, place the crankshaft on the bracket (if the crankshaft is to be
stored for a long time, it shall be placed vertically), remove the main bearing upper shells and place
them in sequence.
3. Place and sort out all the removed parts as required.
1. Check the crankshaft main journal, connecting rod journal and filleted corner for cracks; check the
unblocked oil passage for cracks and other abnormalities.
2. Check the wear condition of main journal and connecting rod journal, and check them for wear
stretch marks, metal peeling and cracks.
3. Check the wear condition of oil seal.
4. Check the main bearing bolt for thread damage and other defects.
5. Check the bolt holes on the front and rear end faces of the crankshaft for cracks or thread damage.
6. Check the crankshaft journal for wear extent.
7. Check the front and rear end faces of the crankshaft and the boss of thrust block of the crankshaft
for wear.
1. Lift the crankshaft to the carriage, and be careful to avoid bumps.
2. Check the matching surfaces of crankshaft and the oil passage cavity.
1) Check all the mating surfaces of crankshaft for bumps.
2) After pressing the shell, align the oil hole with the engine block oil hole.
3) Wipe off the foreign matters scraped from the shell.
3. Refit the crankcase onto the engine block. The engine block has 3 parallel pins with internal
threads.
4. Refit the main bearing bolt.

1) Before refitting the main bearing bolt,
carefully check the junction surface of
main bearing bolt and crankcase for
foreign matters to avoid scratching the
crankshaft, and manually check the Fig. 5-70 Tightening sequence of main bearing
chamfer of bolt pressure-bearing bolts
surface for burrs; if any, replace the bolt.
104
2) Apply clean lubricating oil to the

pressure-bearing surface and threads of
the main bearing bolt.
5. Tighten the main bearing bolts.
1) Tighten the bolts in the sequence as
shown in Fig. 5-70: When tightening the
main bearing bolts M18 (14 pcs) using
the manual or single-end pneumatic
wrench, apply lubricating oil to threads
and pressure-bearing surfaces of the
main bearing bolts before assembling.
Tighten the main bearing bolts by three
steps in sequence and these bolts can
be reused for 6 times (including
machining). The length of the extended
bolts shall be less than 172 mm. Use a
low-torque pneumatic wrench to tighten
the bolts in the first step; tighten them to
80 N•m in the second step, and to 250
N•m~280 N•m in the third step.
2) Check that the crankshaft rotates
flexibly without any seizure.
6. Measure the axial clearance of the crankshaft. The axial clearance of the crankshaft is (0.102 ~
0.305) mm.
5.38Thrust plate assembly
Fig. 5-71 Exploded view of thrust plate assembly

Crankshaft
1 Upper thrust plate 2 3 Lower thrust plate
assembly
105

1. Disassembling tools: Torque wrench, automatic tightening machine, traveling crane, guide studs,
needle-nosed pliers, etc.
2. Preparations before disassembling: Remove the crankshaft pulley, front end cap, flywheel, flywheel
housing, gear assembly, piston & connecting rod, etc. before disassembling the thrust plate
assembly.
1. Check the thrust plate for integrity and bumps.
2. Check the thrust plate for damage, dislodgement, deformation, crushing, etc.
1. Clean the main bearing upper shell and the bottom hole of engine block, press the main bearing
upper shell into the bottom hole, apply lubricating oil to the inner surface of the upper bearing shell,
lift up the crankshaft, and then gently lower the crankshaft into the engine block.
2. Refit the upper thrust plate into the thrust plate groove between the engine block and the
crankshaft. The oil groove of the upper thrust plate shall be oriented outward (toward the
crankshaft). 3. Wipe the main bearing lower shell and the main bearing cap, then press the main
bearing lower shell into the main bearing cap and refit the lower thrust plate.
1) The oil groove of the lower thrust plate shall be oriented outward (toward the crankshaft).
2) Carefully check the lower thrust plate for bumps before refitting.
3) Apply automotive lithium grease onto the inner surface of the lower thrust plate.
4. Refit the main bearing cap onto the engine block, refit the main bearing bolts, and measure
the axial clearance of the crankshaft. The axial clearance of the crankshaft is (0.102 ~ 0.305)
mm.
106
5.39Main bearing shell assembly

Fig. 5-72 Exploded view of main bearing shell assembly

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

Tools and equipment required: Torque wrench, automatic tightening machine, traveling crane, etc.
Before disassembling the crankshaft assembly, remove the flywheel, flywheel housing, front end cap,
crankshaft pulley, main bearing cap, piston & connecting rod, etc.
107
1. Push out the bearing shell from the side by

hand, and then mark it in relation to the seat
holes of engine block and main bearing cap.
Fig. 5-73 Removal of the main bearing lower shell

1. Clean the bearing shell, and check its wear condition.
2. Check the bearing shell for metal peeling, locating lip damage and transverse cracks.
1. Clean the main bearing shell and its mounting

bottom hole firstly.
2. If the bearing shells are not replaced with new
ones, distinguish the upper and lower shells
properly (the upper shell has an oil groove),
and then refit the upper shell into the engine
block and the lower shell into the main
bearing cap according to the same sequence
of removal; if the shells are replaced with new
ones, refit the new shells directly. During
refitting, align the lips and apply a little oil to
them.
Fig. 5-74 Main bearing upper shell
Fig. 5-75 Main bearing lower shell
108
5.40Oil dipstick assembly

Fig. 5-76 Exploded view of oil dipstick assembly

Oil dipstick upper
1 Oil dipstick 2 Joint 3 Rubber hoop 4
assembly
Hexagon flange Hexagon flange
5 Pipe clamp 6 7 8 Rubber hoop
bolt nut
Oil dipstick lower
9 Joint 10 Screw plug 11 12 Pipe clamp
assembly

1. Disassembling tools: Socket or wrench.
2. Preparations before disassembling: Take care to prevent the oil dipstick from interfering with other
components.
The disassembling steps are in reverse of assembling steps.
1. Check the fixing clip of the oil dipstick for looseness.
2. Check the oil dipstick tube lower assembly and the screw plug for damage.
3. Check the oil dipstick tube upper assembly for damage.
109
1. Refit the oil dipstick tube lower assembly in

the selected mounting hole of the oil dipstick
tube:
2. Before pressing it in, apply sealant 277 in
even and continuous strips to the mating
surface.
3. Refit the oil dipstick tube and the oil dipstick
assembly: Fig. 5-77 Assembling of oil dipstick tube upper and
1) Refit the oil dipstick tube, and insert the lower assemblies
quick connector of the oil dipstick tube
upper assembly into the oil dipstick tube
lower assembly.
2) After fixing the oil dipstick tube as
required, check if the oil dipstick is
inserted or pulled out easily.
5.41Engine block assembly

Fig. 5-78 Exploded view 1 of engine block assembly
110
Fig. 5-79 Exploded view 2 of engine block assembly

1 Parallel pin 2 Cylinder liner 3 Cylinder block 4 Bowl plug
Oil pressure
5 Bowl plug 6 7 Crankcase 8 Washer
sensor
Hexagon socket Hexagon head
9 10 11 Bowl plug 12 Blind rivet
head cap screw bolt
Spring-type
13 14 Bowl plug 15 Camshaft bush 16 Bowl plug
straight pin
Parallel pin with Hexagon head
17 18 Gasket 19 20 Main bearing bolt
internal thread screw plug
Main oil passage
21 Main bearing bolt 22 Bowl plug 23 Camshaft bush 24 downstream plug
screw
Combination
25 26 Sealing ring
washer

2. Preparations before disassembling: Remove the transmission and clutch, flywheel, flywheel
housing, gear chamber and oil pan.
1. Remove the oil pressure sensor.
2. Remove the main oil passage downstream plug screw.
3. Remove the cylinder liner.
4. Remove the camshaft bush.
5. Remove the bowl plug.
6. Remove the crankcase fastening bolts and the main bearing bolts.
111
7. Remove the crankcase and the parallel pin with internal thread.
8. Remove the sealing ring.
Check if the parts are complete as per the parts list. Check the state of the engine block assembly, and
ensure that the junction surfaces are free from burrs, oil stains, bumps, etc.
1. Installation requirements of main bearing

bolts: Before assembling, apply lubricating oil
to supporting surface of the crankcase and
threads of the main bearing bolts. Tighten the Rear
end
Front
end
main bearing bolts by 3 steps in sequence

and these bolts can be reused for 6 times.
The length of the extended bolts shall be less
than 172 mm.
Fig. 5-80 Tightening sequence of main bearing
1) Use a low-torque pneumatic wrench to bolts
tighten the bolts in the first step;
2) Tighten them to 80 N•m in the
second·step;
3) Finally tighten them to (265±25) N•m.
2. Installation requirements of cylinder liner: Check the cylinder liner carefully for cracks before
assembling, and if any, eliminate them. Press and fit the cylinder liner into the cylinder bore using a
special tool, before which apply molybdenum powder to the outer surface of the cylinder liner.
3. Installation requirements of camshaft bush: Disassemble and assemble the camshaft bush using
special tools. Before assembling, check its inner surface carefully for scratches, and if necessary,
replace the camshaft bush. Align the oil hole of camshaft bush with the bottom oil hole of engine
block camshaft.
4. Installation requirements of bowl plug: Before assembling, clean the bottom hole and surface of the
bowl plug, and apply sealant to the bowl plug and its bottom hole evenly. Press and fit the bowl plug
with a special tool, the pressed depth shall be within a chamfer of (0~1) mm, and the height
difference of the bowl plug ends shall be no more than 0.5 mm.
5. Installation requirements of crankcase: Before assembling, clean the upper surface of the
crankcase, and apply sealant to it evenly.
112
Annex A List of DTCs
None
113
Annex B Fitting Clearances for Main Engine Parts

No. Items Theoretical Value/mm
1 Main bearing clearance 0.095~0.171
Connecting rod bearing
2 0.059~0.135
clearance
3 Crankshaft axial clearance 0.102~0.305
Axial clearance of connecting
4 0.15~0.35
rod surface
Clearance between connecting
5 rod small end bushing and piston 0.04~0.061
pin
Clearance between piston pin
6 0.005~0.018
seat and piston pin
Working clearance of piston ring
opening in cold state 0.35~0.55
7 First compression ring 0.4~0.6
Second compression ring 0.2~0.4
Oil ring
Piston ring end face clearance in
cold state
0.08~0.115
8 First compression ring
0.04~0.075
Second compression ring
Oil ring
Clearance between intake valve
9 0.023~0.052
stem and valve guide
Clearance between exhaust
10 0.045~0.072
valve stem and valve guide
Recess of valve bottom surface
below cylinder head surface, ±0.2/±0.2
11 exhaust/intake valve
Projection of cylinder liner top
12 above engine block upper 0.05~0.10
surface
13 Camshaft axial clearance 0.1~0.4
14 Camshaft bearing clearance 0.04~0.12
Clearance between tappet and
15 0.025~0.089
tappet hole
Clearance between piston top
16 and cylinder head bottom 0.6~1.55
surface (compression clearance)
Interference and clearance
between outer diameter of
17 -0.02~0.023
cylinder liner and cylinder liner
hole on engine block
Clearance between rocker arm
18 0.012~0.066
and rocker arm shaft
114
No. Items Theoretical Value/mm

Backlash between timing gear
19 0.015~0.33
and intermediate gear
Clearance between crankshaft
20 1.0±0.5
speed sensor and flywheel
115
Annex C Tightening Torque of Other Main Bolts of Engine

Bolt Name Bolt Specification Torque (N•m) Remark
Oil pump idler bolt M10 60~65
High-pressure fuel pipe
lock nut (fuel injector M14×1.5 30~40
end)
High-pressure fuel pipe
lock nut (common rail M14×1.5 30~40
pipe end)
Fuel injector terminal M4 1.5±0.25
Low-pressure connector
M16 25~35
of fuel injection pump
Rocker arm bracket M10 × 95 - 10.9 51~57
fastening bolt M12 100~110
M16 195~215
Automatic tensioner
M12 10~120
mounting bolt
M10 45~55
Pump gear fastening M24×1.5 250~300
bolt M18×1.5 160~165
Pump bracket fastening
M10 45~50
bolt
Camshaft gear bolt M8 40~45
Valve clearance
M10×1 40~50
adjusting nut
The tightening torque
shall be (30±3) N•m in
Water pump inlet pipe the first step and (70±5)
M10
fastening bolt N•m in the second step.
The re-tightening torque

Oil cooler cap bolt M8 26~32 shall be (29±3) N•m.
M4 1.4~1.6
Grid heater relay nut
M6 2.9~4.4
Front end cap fastening M8 27~33
bolt M10 55~65
Cylinder head cover
M8 25~31
fastening bolt
116

Fuel injector fastening Tighten the bolt to 8 N•m
M8 8
bolt and rotate it by 90°.
ECU fastening bolt M6 10~14
A/C compressor bracket
M12 147~161
fastening bolt
Main oil passage screw
plug, relief valve screw
plug, oil pan screw plug,
M30×1.5 70~90
and left auxiliary hole
screw plug of oil filter
seat
Flywheel housing (cast Double-end stud M10 10~15
aluminum) bolt Bolt M14 ×1.5 140~160
Pre-tighten the bolt and
then tighten it
symmetrically to a torque
of (100±5) N•m first, and
then rotate it by 60°±5° to
Flywheel housing bolt M12 110~190 reach a torque of
(110~190) N•m. The
rotated bolt that fails to
reach this torque shall be
replaced. The bolt can be
reused for 2 times.
Engine hanger plate
M12 100~125
upper bolt
Apply protection to
Exhaust manifold bolt M10 65~80
threads.
Air compressor fixing
M10 55~65
bolt
Water pump fixing bolt M8 25~31
Fan flange bolt M8 25~35
Water outlet pipe bolt M8 25~31
Intake manifold bolt M10 50~60
Oil filter seat fixing bolt M8 35~41
Hydraulic pump fixing
M10 50~60
bolt
83~93
Alternator fixing bolt M10 M12
135~145
Oil pump fixing bolt M10 50~60
Suction strainer and
M10 46~56
suction pipe bolt
Oil pan bolt M8 27~33
117

Heat shield fixing bolt M10 46~56
Camshaft thrust plate
M8 23~29
fixing bolt
118
Weichai Power Co., Ltd. 2019.04.01
Address: Building A, No. 197 Fushou East Street, Hi-Tech Industry Development Zone, Weifang,
Shandong, China
Postcode: 261061
Tel: 0536-8197777
Fax: 0536-8231074
Email: [email protected]
Website: http://www.weichai.com
Service Hotline: 400 618 3066
This document is for reference only. Product parameters or pictures are subject to change without prior notice. The actual
product shall prevail.

WP10四气门国二系列车用柴油机维修手册 EN

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1006235381

Weichai Power Co., Ltd.

WP10 Series Four-valve China II Vehicle Diesel Engine

♦ For the engine with a turbocharger, as the

Do not touch the high-speed rotating part by hands

♦ Do not loosen or remove the main bearing bolt

Tightening torque requirement

♦ Always fill the engine with the oil or fuel that is of

♦ Regularly check the coolant, and never use

♦ Please have the diesel engine overhauled and

Weichai special spare parts

Instructions for signs

Wear gloves Risk of electric shock

Wear protective clothing Risk of mechanical injury

Risk of being caught up in the

Be aware of suspended heavy

Wear helmet Be aware of steam

Wear safety shoes Risk of explosion

Wear protective mask Risk of corrosion

Keep ventilated Risk of scalding

Torque control Avoid winding

Checks required No open flame

Tool requirement No smoking

Serious warning No touching

Precautions for Engine Disassembling and Maintenance

1.1 Outline drawing of engine ..........................................................................................................1

1.2 Designation of engine model .....................................................................................................3

1.3 Main specifications .................................................................................................................... 4

1.4 Hoisting ...................................................................................................................................... 4

1.5 Running ......................................................................................................................................5

Chapter II Maintenance ..............................................................................................................................7

2.1 Fuel, lubricating oil, coolant, and auxiliary materials ................................................................ 7

2.1.1 Fuel ................................................................................................................................. 7

2.2 Daily maintenance ................................................................................................................... 10

2.2.1 Daily inspection .............................................................................................................10

2.3 Description of maintenance of all levels ..................................................................................12

2.3.1 Replace oil .................................................................................................................... 12

2.4 Regular maintenance interval and specification ..................................................................... 16

2.4.1 Regular maintenance interval and specification .......................................................... 16

2.5 Cleaning, protection and handling ...........................................................................................17

2.5.1 Cleaning and protection ............................................................................................... 17

Chapter III Typical Faults and Troubleshooting ................................................................................... 19

3.1 Overview .................................................................................................................................. 19

3.1.1 Overview ....................................................................................................................... 19

3.2 Fault diagnostic methods ........................................................................................................ 19

3.2.1 Traditional fault diagnostic methods ............................................................................ 19

3.3 Typical faults and troubleshooting ...........................................................................................20

3.3.1 Engine startup failure ....................................................................................................20

Chapter IV Introduction to Engine Systems ............................................................................... 31

4.1 Cooling system ........................................................................................................................ 31

4.1.1 Cooling system ............................................................................................................. 31

4.2 Lubrication system ...................................................................................................................31

4.2.1 Overview ....................................................................................................................... 31

4.3 Fuel system ..............................................................................................................................33

4.3.1 Schematic diagram of fuel system ............................................................................... 33

Chapter V Disassembling and Assembling of Engine ........................................................................ 35

5.1 Intake manifold assembly ........................................................................................................35

5.1.1 Exploded view ...............................................................................................................35

5.1.2 Disassembling tools and preparations ......................................................................... 35