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‫‪wp12‬‬
 Preparations - Fuel (WP12)

Fuel (WP12)
Preparations
Special Tool

Fuel Filter Wrench Oil-water Separator

Fuel Sensor Wrench Fuel Sensor

Fuel Injector Puller Fuel Injector

Recommended Tool

Air Duster Gun

Inner Hex Spanner

Equipment
Torque Wrench 0-25 kgf.m

Accessory
Diesel Fuel
 Preparations - Exhaust, Turbocharger (WP12)

Exhaust, Turbocharger (WP12)

Preparations
Recommended Tool

Inner Hex Spanner Turbocharger

Equipment
Torque Wrench

Torque Wrench
 Preparations - Cooling(WP12)

Cooling (WP12)
Preparations
Recommended Tool

Ice Point Tester Coolant

Equipment
Torque Wrench 0-50 kgf.m

Torque Wrench 200—1000 kgf.m

 Preparations - Lubrication (WP12)

Lubrication (WP12)
Preparations
Recommended Tool

Inner Hex Spanner Oil Cooler

Oil Cooler Wrench Oil Cooler

Equipment
Torque Wrench 0-50 kgf.m
 Preparations - Engine Mechanical (WP12)

Engine Mechanical (WP12)

Preparation
Recommended Tool

Engine Roll-over Stand Engine Assembly

Valve Clearance, Piston Ring Gap,

Thickness Gauge
Cylinder Head

Plane Meter Cylinder Head

Outside Micrometer Crankshaft, Camshaft

Inside Micrometer Cylinder Liner, Crankshaft, Camshaft

Magnetic Stand Crankshaft

Crankshaft Oil Seal Driver Crankshaft Oil Seal

Connecting Rod Bushing Reamer Connecting Rod

Liner Puller Cylinder

Cylinder Compressor Gauge Cylinder

Puller Timing Gears

 Preparations - Engine Mechanical (WP12)

Valve Dismantling Device Valve

Valve Guide Punch Valve

Valve Seat Reamer Valve

Valve Guide Reamer Valve

Valve Lapping Machine Valve

Inside Hexagon Bolt Dismantling

Air Compressor
Device of Air Compressor

Equipment
Torque Wrench 0-50 kgf.m

Torque Wrench 50 — 200 kgf.m

Accessory
Oil

Trichloroethylene Cleaner

510 Glue

Molybdenum Dioxide Powder

 Preparations - Starting, Preheating System (WP12)

Starting, Preheating System (WP12)

Preparations
Recommended Tool

Inductive Galvanometer Starter

Equipment
Torque Wrench 0-50 kgf.m
 Preparations - Charging System (WP12)

Charging System (WP12)

Preparations
Recommended Tool

Universal Electric Tester Generator

Equipment
Torque Wrench 0-50 kgf.m
 Maintenance Specification – Fuel (WP12)

Fuel (WP12)
Maintenance Data
Common rail pressure 160Mpa
Metering valve resistance 2.6~3.4Ω(1500r/min)
Fuel injector opening pressure 29~30 Mpa

Torque Requirements
Fastener N.m
Fuel tank pulling belt fixing nut (M10) 45±5
Fuel tank pulling belt fixing nut (M12) 81±8
Fuel tank pulling belt fixing nut (M16) 202±20
Fuel tank inlet/outlet fuel pipe 46±6
Oil-water separator seat fixing bolt(M10) 45±5
Oil-water separator seat fixing bolt(M12) 81±8
Inlet and outlet fuel pipes link bolt 46±6
 Maintenance Specification – Air Exhaust, Turbo-charging (WP12)

Air Exhaust, Turbo-charging (WP12)

Torque Requirements
Fastener N.m
Exhaust pipe bolt 60±10
Heat insulation cover fixing bolt 25±5
Bolt of exhaust pipe fixing bracket 45±5
Muffler bracket fixing nut 80±10
Turbine fixing bolt 45±5
 Maintenance Specification – Cooling (WP12)

Cooling (WP12)
Maintenance Data
Item Item
Cooling method Water-cooled forced circulation
Type of radiator Corrugated radiator
Water pump Type Centrifugal
Rated speed 3648 r/min
Thermostat Type Wax-type, core-combination
Opening temperature 80±2 ℃
Full opening temperature 95 ℃
Fan Type O-shaped fan
Intercooler Type Corrugated with flat pipe, air-cooled

Torque Requirements
Fastener N.m
Auxiliary water tank fixing bolt 23±2
Radiator slotted nut 70
Wind-collecting cover fixing bolt 20
Intercooler fixing bracket 23±2
Intercooler fixing bolt 23±2
Cooling fan fixing bolt 20
 Maintenance Specification – Lubricating (WP12)

Lubricating (WP12)
Maintenance Data
Item Item
Lubricating method Pressure lubrication
Lubricating oil capacity (oil pan) 23 L (first filling of 25 L)
Oil pressure 350~550kPa
Oil pressure at idle speed ≥ 100kPa
Oil filter Type Spin-type with paper filter element, double-cylinder parallel
Oil pump Type Gear pump (single-stage pump for general application,
two-stage pump for special application)
Safety valve opening pressure 1550±150kPa
Oil cooler Type Water-cooled
Bypass valve opening pressure 600±36kPa
Pressure withstand testing 1500kPa
pressure
Clearance between driving/driven gear and bump ≤ 0.3mm
chamber wall
Meshing clearance of Standard value 0.05mm
driving/driven gear Limit value 0.20mm

Torque Requirements
Fastener N.m
Oil pan fixing bolt 25
Oil drain bolt 25
Oil pump fixing bolt 62.5±2.5
Oil cooler fixing bolt 25
 Maintenance Specification – Engine Mechanical (WP12)

Engine Mechanical (WP12)

Maintenance Data
Item Standard Value
Main bearing clearance 0.095~0.171mm
Clearance of connecting rod bearing 0.059~0.135mm
Crankshaft axial clearance 0.102~0.305mm
Axial clearance of connecting rod plane 0.15~0.35mm
Connecting rod small-end sleeve x piston pin clearance 0.04~0.061mm
Piston pin seat x piston pin clearance 0.005~0.018mm
Opening clearance of cold First ring 0.35~0.55mm
piston ring Second ring 0.4~0.6mm
Oil ring 0.2~0.4mm
Side clearance of cold piston First ring
ring Second ring 0.08~0.115mm
Oil ring 0.04~0.075mm
Intake valve stem x valve guide clearance 0.02~0.048mm
Exhaust valve stem x valve guide clearance 0.025~0.053mm
Valve sinkage Exhaust 1.08~1.48mm
Intake 0.85~1.05mm
Distance of cylinder liner top above the body upper part 0.05~0.10mm
Camshaft axial clearance 0.1~0.4mm
Camshaft axial clearance 0.04~0.12mm
Tappet x tappet hole clearance 0.025~0.089mm
Cylinder liner outer diameter x interference and clearance of -0.02~0.023mm
body cylinder liner hole
Rocker arm x rocker arm axial clearance 0.012~0.066mm
Timing gear x side clearance of intermediate gear 0.015~0.33mm
Valve clearance Intake 0.3mm
Exhaust 0.4mm
EVB (cold state) 0.25mm

Name Heating Temperature Suggested Heating Time

Crankshaft gear Inductive heating, 180 ℃ -
 Maintenance Specification – Engine Mechanical (WP12)

Piston 60 ℃ 10 minutes
Flywheel ring gear 150 ℃ 10 minutes
Front flange of crankshaft Inductive heating, 290 ℃ -
Note: it is suggested to use the box-type electric furnace (3.6Kw 6A 380V 50Hz )with a maximum heating temperature of
400 ℃ as the heating furnace.

Loctite Sealant Range Main Application Parts to be Sealed

242 Applied to the thread surface for locking and Stud of timing gear chamber
sealing to prevent loosening from vibration, Thrust washer of camshaft
medium strength Timing gear bolt of camshaft
Intermediate idler bolt
Filter seat bolt
Oil cooler seat bolt
Air compressor shaft-end thread
Rear plug of main oil duct
Safety valve plug
Main oil duct’s pressure limiting valve thread
Suction filter bolt
262 Applied to the thread surface for permanent Auxiliary bolt of cylinder head
locking and sealing to prevent loosening from
vibration
271 For loose fastening Bowl plug of auxiliary oil duct
Bowl plug of main oil duct
Air compressor outlet x connecting elbow
according to circumference
277 For sealing between core and hole Bowl plug of cylinder block's water chamber
Bowl plug of camshaft hole
Bowl plug of cylinder head
Cylinder head copper sleeve
Bowl plug of intake pipe
Part of oil-gas separator elbow connected to
cylinder block

Exhaust valve's lower spring seat bottom

Part of pipe joint assembly connected to
water pipe joint
 Maintenance Specification – Engine Mechanical (WP12)

510 Applied to bright metal surface for sealing Joint surface between cylinder block and
crankcase
Body front and rear surface
Joint surface between air compressor and
timing gear chamber
Joint surface between filter seat and
crankcase

Torque Requirements
Fastener N.m
Main bearing bolt First time Tighten in the required order
Second time 80
Third time 275±25
Cylinder head bolt First time Tighten main and auxiliary bolts in the
required order by 40±10
Second time 100 tighten auxiliary bolts
Third time 200 tighten main bolts
Fourth time Tighten auxiliary bolts and nuts by 90°
Fifth time Tighten main bolts by 90°
Connecting rod bolt First time Tighten symmetrically
Second time 120
Third time Further tighten 90°±5°, inspect torque
210±40
Flywheel bolt First time Tighten symmetrically
Second time 70±10
Third time Further tighten two 90°
Flywheel housing bolt First time 50±10 tighten symmetrically
Second time Further tighten 120°±5°, inspect
torque 255±25
Intermediate gear bolt First time 60±5 pre-tighten
Second time Further tighten 90°±5°, inspect torque
112.5±12.5
Oil pump’s intermediate gear shaft fixing bolt 62.5±2.5
Rocker arm seat bolt 105±5 N.m
Camshaft gear fixing bolt Tighten symmetrically with 34±2 N.m
Fuel injector fixing bolt Tighten symmetrically and note the
consistence of lateral clearance, 11±1
Crankshaft damper connecting bolt 65±5 tighten symmetrically with
Air compressor gear fixing bolt 210±10
High-pressure fuel pipe nut Fuel injector end 22.5±2.5
High-pressure pump end 30±5
 Maintenance Specification – Starting, Preheating System (WP12)

Starting, Preheating System (WP12)

Maintenance Data
Item Specification
Starting method Electric start
Starter Model HEF95-L24V
Voltage 24 V
Cold start Without auxiliary starting device -10 ℃
With auxiliary starting device -30 ℃

Torque Requirements
Fastener N.m
Ignition switch fixing bolt 25
Starter fixing nut 60
Heater fixing nut 25
Fuel (WP12)
Fuel System .......................................11B-3
General.............................................11B-3
Precautions ....................................11B-12
Part Drawing...................................11B-13
Testing & Adjustment .....................11B-14
Fuel Tank..........................................11B-16
Part Drawing...................................11B-16
Replacement ..................................11B-17
Cleaning .........................................11B-20
Oil-water Separator .........................11B-21
Part Drawing...................................11B-21
Replacement ..................................11B-22
Fuel Fine Filter .................................11B-24
Replacement ..................................11B-24
 Fuel (WP12) – Fuel System

Fuel System
General
The parameters of the traditional mechanical fuel injection system (injection timing, injection quantity and
injection pressure) are controlled by mechanical means. For example, the fuel injection quantity is
controlled by a fuel supply gear rack in a fuel injection pump, and the injection timing is controlled by a
mechanical timing device, i.e. the fuel injection is controlled by an adjusting device in advance.
Therefore, the control range and accuracy are limited. The injection pressure is generated due to the rise
of an injection pump plunger, the starting time of the fuel injector is also caused by the rise of the
injection pressure, therefore, the control of the fuel injection time is inaccurate, and apparently,
according to the needs of a diesel engine, pre-injection and regular repeated injection are even
impossible to achieve.
The ECU computer-controlled high-pressure common-rail fuel injection system has the following unique
advantages:
1. Generation of injection pressure is independent of engine speed, and the injection process
is relatively independent, which can guarantee the stability of injection pressure.
2. Commencement of injection and fuel injection quantity are controlled completely
separately, so random accurate control of injection timing can be achieved.
3. Multiple injection of pre-injection, main injection and compensation injection can be
achieved, which is entirely determined by the performance and emission requirements of
the diesel engine.
In other words, according to the different requirements of diesel engine performance, the
fuel injection process can be accurately controlled.
4. The fuel injection system has sensitive response and can achieve injection control of a
variety of speed ranges.
5. The accuracy of the fuel injection quantity is higher, and the minimum steady injection
quantity is 1mm³/time.
6. The injection pressure is increased (from currently 160Mpa to 180Mpa), so the atomization
effect is improved, fuel and air are fully mixed, and the emissions and noise are reduced.
7. The driving torque peak value of the fuel pump is smaller, which reduces the driving power
and noise.
8. The high-pressure common-rail system can replace the traditional fuel injection system in
case that the major structural of the diesel engine is unchanged, thereby speeding up the
upgrading and improvement of the diesel engine.
In short, the old mechanical pump is controlled by mechanical means, so the control accuracy, response
speed and sensitivity are relatively rough. The high-pressure common-rail fuel system is controlled by a
computer, so the control accuracy, response speed and sensitivity of controlling changes are very
accurate.
 Fuel (WP12) – Fuel System

Common-rail
Fuel Metering Valve Pipe
Rail Pressure Sensor
Pressure
High-pressure Limiting Valve
Fuel Pump

Fine Filter

Fuel Feed Pump

Fuel Injector

Primary Filter with Hand Fuel Pump

Low-pressure Part

Electronic Control Unit

Fuel Tank with Coarse Crankshaft Camshaft Accelerator Water Boost Oil
filter Position Sensor Phase Sensor Pedal Temperature Pressure Pressure
Sensor Sensor Sensor Sensor

Seen from the drawing, the high-pressure common-rail fuel injection system basically consists of a
low-pressure fuel line, a high-pressure fuel line, an information acquisition part and a control and
actuating member, wherein the low-pressure fuel line consists of a fuel tank, a primary fuel filter with a
hand fuel pump, a low-pressure fuel supply pump and a fuel fine filter; the high-pressure fuel line
consists of a high-pressure fuel pump, a common-rail pipe and a fuel injector; the information acquisition
part consists of a crankshaft position sensor, a camshaft phase sensor, an accelerator pedal sensor, a
water temperature sensor, a boost pressure and temperature sensor, an oil pressure sensor and other
sensors; and the control and actuating member consists of a central processing unit (ECU), a fuel
metering valve, a fuel injector solenoid valve, etc. The system also provides a fuel return line, and
surplus fuel passing through the high-pressure fuel pump and the fuel injector, and the fuel effluent from
a pressure limiting valve after the common-rail pressure exceeds the limited pressure flows back to the
fuel tank from the fuel return pipe.
 Fuel (WP12) – Fuel System

Information Acquisition
Control Unit Control and Actuating Content
Content
Accelerator Pedal Position
Fuel Injection Time
Sensor
Crankshaft Position Sensor Fuel Injection Pressure
Number of Times of Fuel
Camshaft Phase Sensor
Injection
Common-rail Pressure
Fuel Injection Quantity
Sensor
Boost Pressure and
To (ECU) To Common-rail Pressure
Temperature Sensor
Water Temperature Sensor Cold Start
Oil Pressure and
Start Control
Temperature Sensor
Air Conditioning Acceleration
Vehicle Speed Sensor
Control
Air Conditioning Sensor (Air
Conditioning Switch)
Start Signal Sensor (Neutral
Position Switch)

The above is the control process of the Bosch common-rail injection system. The ECU central
processing unit collects all instant parameters influencing the dynamic property, economy and emission
of diesel fuel, and simultaneously according to the driver's operational command - namely the position of
the accelerator pedal, the ECU comprehensively calculates the optimum values of various actuating
parameters such as the injection timing, fuel injection pressure, fuel injection quantity, number of times of
fuel injection, etc., thereby achieving the optimum operation state of the diesel engine.
Primary Fuel Filter with Hand Fuel Pump
The primary fuel filter with a hand fuel pump is simultaneously provided with an oil-water separator.
When the filter filters the fuel, water is gathered in a water collector, and the seperated water shall be
emptied from a drain screw in time in daily maintenance. The coarse filter is screwed on the filter
housing and shall be replaced periodically in maintenance. A hand fuel pump is installed on the filter
cover of the coarse filter, and when the filter is assembled for the first time or maintained and replaced,
or air exists in the system, the air in the low-pressure loop shall be discharged by the hand fuel pump. An
exhaust bolt is arranged on the housing of a filter connecting flange, by unscrewing the exhaust bolt and
repeatedly pressing the hand fuel pump, fuel accompanied with air is exhausted from the exhaust bolt
until the outflow fuel contains no air, and then the exhaust bolt is screwed.
High-pressure Fuel Pump
The high-pressure fuel pump integrates the low-pressure fuel line and the high-pressure fuel line. The
high-pressure pump has two tasks: first, a gear pump connected with the high-pressure fuel pump is the
fuel feed pump of the low-pressure fuel line, and the gear pump pumps fuel through the primary fuel filter
and the ECU and supplies fuel to the high-pressure pump through the fuel fine filter; and second, two
sets of plungers or the high-pressure fuel pump provides high-pressure fuel as high as 160Mpa to the
high-pressure common rail.
 Fuel (WP12) – Fuel System

Fuel Supply Pump

Fuel Outlet t (to

FMU)

Fuel Inlet t (from Fuel Tank)

In a low-pressure oil path, fuel flows through the ECU inner chamber to perform the function of cooling
the ECU.
The fuel feed pump is a straight gear type fuel pump which is driven by driving a straight small gear by
an inner ring gear integrated with a camshaft of a high-pressure pump. The fuel feed pump feeds the fuel
from the fuel tank to the high-pressure fuel pump.
The high-pressure part of the high-pressure fuel pump comprises two cam type camshafts, a roller type
tappet rod, plungers, fuel outlet joints and a fuel metering valve. Two rows of cams are alternately
arranged on the camshafts on three surfaces, and when the camshafts rotate, two pairs of plunger
pistons simultaneously pump the fuel for six times back and forth. Two fuel outlet valves are arranged in
two fuel outlet joints of the high-pressure fuel pump and can supply high-pressure fuel of 160MPa to
common-rail pipes.
 Fuel (WP12) – Fuel System

1 Plug 7 Air Gap Gasket

2 Solenoid Valve Housing 8 Magnetic Core

3 Sleeve 9 O-Ring

4 Tappet 10 Plunger with Control Gap

5 Coil 11 Spring

6 Housing 12 Snap Ring

A fuel metering valve is arranged on the fuel outlet pipeline of the high-pressure fuel pump and is mainly
used for receiving the instruction of the ECU to randomly change the capacity of the fuel entering the
high-pressure pump, thereby changing the high-pressure fuel feed pressure of the high-pressure pump,
i.e. changing the common-rail pressure. When a fuel metering unit has a fault, the engine operates at the
limited rotation speed of 1500r/min, and meantime, the resistance value of the metering valve is 2.6-3.4
ohm. The ECU controls the capacity of the fuel entering the high-pressure pump by the on-off time of
pulse signals. It is noteworthy that when the coil of the fuel metering valve is not electrified, the metering
valve is all-pass and can supply maximal fuel flow. In other words, maximal common-rail pressure can
be formed.
 Fuel (WP12) – Fuel System

Screw Plug
Spring

Valve Body

To Fuel Tank To Fuel Tank

Oil Port
Valve

The low-pressure fuel feed side of the high-pressure fuel pump is connected with the fuel inlet of the fuel
metering valve in parallel and is provided with a fuel return valve. The valve enables the low-pressure
fuel path to keep a constant fuel feed pressure, and the fuel return pipeline of the high-pressure fuel
pump is connected out of the fuel return valve.
A camshaft phase sensor is arranged in the position of the shell of the high-pressure fuel pump
corresponding to a camshaft fluted disc and transfers the random position of the camshaft to the ECU,
so that the ECU can recognize the running position of each cylinder of the diesel engine.
High-pressure Common-rail Pipe
The common-rail pipe is a fuel pressure storing device which distributes the high-pressure fuel provided
by the high-pressure fuel pump to each fuel injector and weakens the pulsation of the fuel feed pressure
of the high-pressure fuel pump and the pressure oscillation generated by fuel injection of each fuel
injector, so that the pressure fluctuation of the high-pressure fuel path is controlled in a certain range.
Meanwhile, the fuel pressure in the common-rail pipe is also controlled by the fuel metering valve
controlled by the ECU, thereby determining the fuel delivery of each fuel injector according to the
working condition of the diesel engine. A common-rail pressure sensor is installed at the left end of the
common-rail pipe, and the sensor transfers the fuel pressure in the common-rail pipe to the ECU at any
time, so that the ECU can adjust the fuel flow valve as required to change the common-rail inner fuel
pressure value. A pressure limiting valve is also arranged on the common-rail pipe, and the pressure
limiting valve is opened when the pressure in the common-rail pipe exceeds 160Mpa, so that the
maximum pressure in the common-rail pipe can not exceed the set value of 160Mpa.
 Fuel (WP12) – Fuel System

High-pressure Connector (to Common-rail

1 5 Spring
Pipe)
2 Valve Needle 6 Limiting Sleeve

3 Channel 7 Valve Body

4 Valve Spool 8 Fuel Return Channel

Fuel Injector
An electric control fuel injector is a key position of a fuel injection system, and nearly all of the elements
of an electric control system finally serve for the fuel injector. The injection of the fuel injector is
controlled by the ECU, and the ECU controls the fuel injection quantity, the injection timing, the fuel
injection pressure and the number of times of fuel injection of the fuel injector according to the state
information input by each sensor of the engine and the instruction of the driver, thereby achieving
optimal output of the instant state.
The control of the fuel injection pressure is generated on the common-rail pressure provided by the
high-pressure fuel pump, and the injection timing, the fuel injection duration and the number of times of
fuel injection are controlled by voltage signals output by the ECU through a solenoid valve at the upper
part of the fuel injector. The fuel injection quantity of the fuel injector is obviously determined by the
common-rail pressure and the opening time of the needle valve of the fuel injector, wherein the higher
the fuel injection pressure is, the longer the opening time of the needle valve is, and the larger the fuel
injection quantity is.
At present, a fuel injector with seven holes is used by the national III diesel engine.
 Fuel (WP12) – Fuel System

1 Fuel Return Connector 7 Drain Hole

2 Return Spring 8 Control Chamber

3 Solenoid Valve Coil 9 Fuel Inlet

4 Fuel Inlet Connector 10 Plunger

5 Solenoid Valve Spool 11 Needle Valve

6 Ball Valve 12 Nozzle

The high-pressure fuel from the common-rail pipe enters the fuel injector through the fuel inlet joint and
enters the control chamber through fuel inlet holes, the high-pressure fuel generates downward pressure
on the upper cross section of the plunger piston, and simultaneously, the high-pressure fuel enters the
lower chamber and acts on the lower annular area of the needle valve to generate an acting force for
pushing the plunger piston upward. Because the area of the upper cross section of the plunger piston is
greater than the lower annular area of the needle valve, the downward force acting on the plunger piston
is obviously greater than the upward force acting on the needle valve; meantime, the needle valve is
tightly pressed on the injector nozzle under the action of the downward force of the plunger piston and
the action of the spring of the needle valve; and meantime, the nozzle is closed, and the fuel injector is in
an injection stopping state.
When the ECU switches on the solenoid valve of the fuel injector, the solenoid valve core is attracted
upward, the ball valve pressing on the drain hole opens the drain hole, and the fuel pressure acting in
the control chamber is unloaded through the throttling fuel feed hole; and meantime, the fuel pressure
acting on the lower annular cross section of the needle valve overcomes the spring pressure to quickly
push the needle valve upward, thereby opening the orifice of the nozzle for injecting fuel. When the
voltage signals of the ECU disappear, the solenoid valve core enables the ball valve to close the drain
hole under the action of the return spring, the plunger piston immediately enables the needle valve to
return to the original position under the action of the high-pressure fuel of the control chamber, the fuel
injection hole is closed, and the fuel injector stops injecting. Because lifting and closing of the needle
 Fuel (WP12) – Fuel System
valve are determined by the difference of the hydraulic pressure on the upper cross section of the
plunger piston and the lower annular area of the needle valve, the force of the solenoid valve for lifting
the valve core does not need to be very large, so that the reaction speed of the fuel injector is high and is
0.1-0.3ms generally, thus accurate and sensitive injection can be realized.
ECU (central processing unit)
The ECU is the nerve center of the electric control fuel injection system, is actually a simple computer,
gathers various kinds of state information of running of the diesel engine through the sensor,
simultaneously receives the instruction transferred by the driver through the accelerator pedal sensor,
and determines the fuel injection quantity, the injection timing and the number of times of fuel injection of
the fuel system through simple and quick operation (the ECU can control the fuel injector for injecting
fuel for 5 times in each process of circulation, and only a preliminary injection process and a main
injection process are used at present), so that the diesel engine can run in the optimal state in any
working condition.
Another function of the ECU is to realize reliable self-control operation. For example, in order to ensure
the safety in the process of starting the engine, a neutral switch is arranged on the gearbox, and the
control circuits of the neutral switch and the starter are controlled by the EUC; and when the engine is
started, if the gearbox is shifted in any gear, the starting circuits of the engine are broken, so that the
engine can not be started. When the driver opens the air conditioner, the ECU controls the idle speed of
the engine to be improved, so that the engine at the idle speed can not flame out; and if the PTO power
is output, the ECU controls the engine to adapt to the needs of load change to automatically adjust the
output of the torque, etc.
The ECU has self-diagnostic capability of faults, reflects the running faults of the diesel engine caused
by the electric control fuel injection system in the form of fault flash codes, and can store the faults, so
that the faults can be found visually or by a fault diagnosis instrument, thereby providing the
convenience for quickly and accurately processing the faults.
The ECU also has a function of "limp home", i.e. when the diesel engine has a fault which affects the
working reliability and safety, before the fault is eliminated, the ECU can output a "default" for each
executive component, wherein the "default" means that under the preset condition which can not affect
the fault extension, the engine only can maintain general running instructions; meantime, the rotation
speed of the engine can not exceed 1500r/min, and the engine can not exert full power, thus the driver
only can reluctantly drive the vehicle to the home or the maintenance point; and after the fault is
eliminated, the vehicle can restore.
The ECU is provided with three sockets of the connector assembly, wherein one socket has 36 pins and
is connected with the wiring harness of the sensors, one socket has 16 pins and is connected with the
fuel injector and other executive components, and the maximal socket has 89 pins (only more than 40
pins are used currently) and is connected with the wiring harness of the whole vehicle. The wiring
harness of the whole vehicle is not only connected with each sensor of the whole vehicle (such as the
neutral switch of the gearbox, the master cylinder switch of the clutch, the gas pressure sensor, etc.) and
is also provided with a CAN communication bus (not arranged on the vehicle) and a K line. The CAN bus
is a communication bus connected with other computer devices of the whole vehicle, and the K line is a
fault finding cable connected with the electric control injection diagnosis instrument.
The ECU is generally installed at the intake pipe side of the diesel engine and simultaneously needs to
be cooled by the fuel.
 Fuel (WP12) – Fuel System

Precautions
1. Before checking and maintaining the fuel system, disconnect the battery negative cable.
2. Because the fuel is an inflammable substance, when the fuel system is operated, enable
cigarettes, naked flame, indicating lamps, arc equipment and switches to be far from
the working area, and provide ventilating equipment in the working area to avoid
occurrence of personal injury or even death.
3. In order to avoid personal injury, never loosen any fuel pipe joint when the engine runs.
4. Keep the fuel away from rubber or leather components.
5. Manufacture the diesel fuel injection equipment according to very accurate tolerance and
gaps. Thus, when the fuel system is operated, absolutely clean working environment is
very important. Use special plugs to close all openings.
6. Before disconnecting the fuel system pipeline, check and confirm whether dirt or impurity
exists around the fuel pipe joint or not, and if the dirt or impurity exists around the fuel
pipe joint, clean the dirt or impurity, wherein the dirt or impurity may damage the fuel
system or the engine.
7. Do not forcibly bend or twist the fuel system pipeline.
8. Before connecting each pipeline of the fuel system, ensure that each fuel pipe joint is
not damaged, and if the fuel pipe joint is damaged or has cracks, replace the fuel
pipe assembly and ensure that no dirt exists on the surface of the fuel pipe connecting
surface.
 Fuel (WP12) – Fuel System

Part Drawing

1 Hinged Bolt 9 Fuel Return Pipe

2 Flat Washer 10 Fuel Supply Pipe - Coarse filter to Engine

3 Hex Head Bolt 11 Cable Tie

4 Flat Washer 12 Rubber Cushion Block

5 Spring Washer 13 Air Bleed Pipe

6 Hex Head Nut-Style 1 14 Spiral Sleeve

7 Tightening Strap 15 Rubber Ring - Through Hole

Fuel Supply Pipe - Fuel Tank to Coarse
8
filter
 Fuel (WP12) – Fuel System

Testing & Adjustment

Exhaust of Fuel System
When replacing the coarse filter, reassembling the fuel delivery pipe, or emptying the fuel tank, air will
enter the fuel system. If air enters the fuel system, the flow of fuel to the engine will be hindered and can
not flow smoothly. To prevent this from happening, the fuel system shall be exhausted.
Hint:
Part Drawing, refer to Chapter 11B, Fuel - Oil-water Separator, Part Drawing
1. Stop the engine.
2. Dismantle air bleed screw

3. Inflate with hand pump

(a). Inflate with a hand pump until only fuel flows out
from the air bleed screw.

4. Install air bleed screw

 Fuel (WP12) – Fuel System
Drain water collector
When the water collector is full, drain the collected water.
Warning:
There is danger of freezing. Drain the water before freezing.
1. Stop the engine.
2. Dismantle drain screw
(a). Open the drain screw at the bottom of the water
collector to drain the water.

Open Close

3. Install drain screw

 Fuel (WP12) – Fuel Tank

Fuel Tank
Part Drawing

1 Fuel Tank Assembly, 260L, Aluminum Alloy 9 Base Plate - Fuel Tank

2 Fuel Tank Lock Assembly 10 Spring Washer

3 Bracket Assembly 11 Hex Head Nut, Style 1 - Fine Thread

4 Hex Head Nut - Style 1 12 Pin Shaft

5 Rubber Rim Strip 13 Flat Washer

6 Tightening Pull Strap Assembly 14 Cotter Pin

7 Base Plate - Fuel Tank 15 Fuel Sensor

8 Hex Head Bolt - Fine Thread

 Fuel (WP12) – Fuel Tank

Replacement
Hint:
Part Drawing, refer to Chapter 11A, Fuel - Fuel Tank, Part Drawing
1. Open cargo box
2. Disconnect battery negative cable
3. Dismantle guardrail assembly of cargo box, refer to Chapter 77, Interior & Exterior Trim
Parts - Cargo Box Guardrail, Replacement
4. Release fuel pressure
(a). Insert the key to open the fuel tank lock.
(b). Unscrew the fuel tank lock assembly.
Caution:
Be sure to use clean, soft cloth to plug the fuel filler.

5. Disconnect connector of fuel sensor

(a). Disconnect the connector of the fuel sensor.

6. Disconnect outlet pipe of fuel tank

(a). Disconnect the connector nut of the outlet pipe of
the fuel tank.

7. Disconnect fuel return pipe of fuel tank

(a). Disconnect the connector nut of the fuel return
pipe of the fuel tank.
 Fuel (WP12) – Fuel Tank

8. Dismantle fuel tank assembly

(a). Dismantle the fixing nut of the tightening pull strap.
(b). Take off the tightening pull strap of the fuel tank.
(c). Dismantle the fuel tank assembly.

Caution:
• Before operation, check and make sure there is no lines, wiring harness or other foreign
matters around the fuel tank, and clean up if necessary.
• When lifting the fuel tank, due to large size, use appropriate tools or operate with the help
of others if necessary.
• Because the fuel tank is an aluminum alloy workpiece, avoid collision in the process of
dismantlement, handling and installation.
9. Dismantle fuel sensor
(a). Loosen the sealing cover of the fuel sensor with a
special tool.
(b). Rotate the fuel sensor to a proper angle and take it
out lightly.
Caution:
• Before operation, check and make sure there is
no dirt or other foreign matters around the fuel
sensor, and clean up if necessary.
• There is a rubber seal ring in the sealing cover
of the fuel sensor. Do not damage the seal ring
while dismantling.

10. Install fuel sensor

(a). Rotate the fuel sensor to a proper angle and install
to the right position of the fuel tank.
(b). Screw down the sealing cover of the fuel sensor
with a special tool.
Caution:
When installing the fuel sensor, insert after rotating
to the proper angle, and do not cause warp or
deformation.

11. Install fuel tank assembly

(a). Install the fuel tank assembly on the fuel tank
bracket and fix to the right position.
(b). Install the fixing nut of the tightening pull strap of
the fuel tank.
Torque: 45±5N.m(M10)
Torque: 81±8N.m(M12)
 Fuel (WP12) – Fuel Tank
Caution:
• The tightening pull strap of the fuel tank and the connecting nut of the fuel tank bracket
shall be fastened to the specified torque. Excessive torque will cause deformation of the
fuel tank.
• The fuel tank shall be connected firmly and reliably without abnormal vibration.
• Each rubber rim strip shall be even and level.
12. Install fuel return pipe of fuel tank
(a). Install the connector nut of the fuel return pipe of
the fuel tank.
Torque: 46±5N.m

13. Install outlet pipe of fuel tank

(a). Install the connector nut of the outlet pipe of the
fuel tank.
Torque: 46±5N.m

14. Install connector of the fuel sensor

(a). Install the connector of the fuel sensor.

15. Install fuel tank lock assembly

(a). Check whether the fuel tank lock and gasket are deformed or damaged. Replace the fuel tank
lock assembly if necessary.
(b). Periodically lubricate the rotating part.
16. Exhaust of Fuel System, refer to Chapter 11B, Fuel - Fuel System, Testing & Adjustment
17. Install battery negative cable
18. Inspect
(a). After ensuring that the connector assemblies are connected well, open the ignition switch, check
whether the fuel gauge of the meter shows normal, start the engine, and check whether there is
oil leakage at the fuel pipe joints of the fuel system.
19. Install the guardrail assembly of the cargo box, refer to Chapter 77, Interior & Exterior Trim
Parts - Cargo Box Guardrail, Replacement
20. Put down cargo box
 Fuel (WP12) – Fuel Tank

Cleaning
1. Drain fuel
(a). Open the fuel tank lock assembly, unscrew the
drain plug of the fuel tank, after draining the
trapped fuel, clean up dirt on the drain plug and
then install the drain plug.

2. Fill clean fuel

(a). Fill up the fuel tank with fuel until the distance from
the fuel level to the bottom of the fuel tank is
15-20mm.

Compressed
Air 3. Clean fuel tank assembly
(a). Insert a hose with a spraying nozzle into the
bottom of the fuel tank.
(b). Connect the hose with an air duster gun.
(c). Plug the fuel filler with a clean, soft cloth, and open
the switch of the air duster gun for flushing.
• Change the position of the spraying nozzle
while flushing so that precipitate and adherent
matters are flipped along with fuel.
4. Clean fuel tank assembly for many times
(a). After flushing the whole fuel tank with the spraying nozzle, unscrew the drain plug to drain the
dirty oil, and repeat twice to thrice to clean completely
5. Check fuel tank assembly
(a). After cleaning the fuel tank, check whether the fuel tank is damaged, and the damage shall be
promptly dealt.
6. Install fuel tank lock assembly
(a). Check and clean the filter screen of the filler port of the fuel tank.
 Fuel (WP12) – Oil-water Separator

Oil-water Separator
Part Drawing

1 Fuel Inlet 6 Fuel Outlet

2 Filter Cover 7 Spinning Filter

3 Hand Pump 8 Water Collector

4 Air Bleed Screw 9 Drain Screw

5 Mounting Flange 10 Fuel Outlet

 Fuel (WP12) – Oil-water Separator

Replacement
Hint:
Part Drawing, refer to Chapter 11B, Fuel - Oil-water Separator, Part Drawing
1. Dismantle oil-water separator
(a). Counterclockwise rotate with a fuel filter wrench to
dismantle the oil-water separator.

2. Check oil-water separator seat

(a). Check whether the fuel filter seat has defects such as cracks, scratches, obvious damage, etc.
Replace with new parts if necessary.
3. Dismantle oil-water separator seat
(a). Dismantle the hinged bolts of the inlet and outlet
pipes.

(b). Dismantle the fixing bolt of the oil-water separator

seat.

4. Install oil-water separator seat

(a). Install the fixing bolt of the oil-water separator
seat.
Torque: 45±5N.m(M10)
Torque: 81±8N.m(M12)
 Fuel (WP12) – Oil-water Separator

(b). Install the hinged bolts of the inlet and outlet pipes.
Torque: 45±5N.m
Caution:
Check the washers of the inlet and outlet pipes, and
replace with new parts if necessary.

5. Install oil-water separator

(a). Apply a small amount of lubricating oil on the seal
ring of the oil-water separator.
(b). Screw on the oil-water separator by hand until the
seal ring is combined with the interface.
(c). Clockwise screw down the oil-water separator with
the fuel filter wrench (for about 3/4 round).

6. Exhaust of Fuel System, refer to Chapter 11A Fuel - Fuel System, Testing & Adjustment
7. Inspect
(a). After ensuring that the connector assemblies are connected well, open the ignition switch, check
whether the fuel gauge of the meter shows normal, start the engine, and check whether there is
oil leakage at the fuel pipe joint of the fuel system.
 Fuel (WP12) – Fuel Fine Filter

Fuel Fine Filter

Replacement
1. Dismantle fuel fine filter
(a). Dismantle the inlet and outlet pipes of the fuel fine
filter.

(b). Dismantle the fuel fine filter with a fuel filter

wrench.

(c). Dismantle the fuel fine filter seat.

2. Install fuel fine filter

(a). Install the fuel fine filter seat.
Torque: 45±5N.m (M10)
Torque: 81±8N.m (M12)
Fuel (WP12) – Fuel Fine Filter
(b). Install the fuel fine filter with a fuel filter wrench.

(c). Install the inlet and outlet pipes of the fuel fine
filter.
Torque: 45±5N.m
Caution:
Check the washers of the inlet and outlet pipes, and
replace with new parts if necessary.
Exhaust & Turbocharger (WP12)

Exhaust System................................ 13B-3

General ...........................................13B-3
Precautions .....................................13B-4
Part Drawing ...................................13B-5
Testing & Adjustment ......................13B-6
Turbocharger .................................... 13B-8
Overhaul .........................................13B-8
 Exhaust & Turbocharger (WP12) – Exhaust System

Exhaust System
General
Supercharger:
All WP12 Series diesel engines are of a turbocharged intercooled model, and the supercharger marched
for the engine is an exhaust gas turbocharger. The engine generates power as a result of the
combustion of fuel in the cylinder, and the input amount of fuel is limited by the intake amount of air into
the cylinder, so the power generated is also limited. If the running performance of the engine has been in
optimum state, in order to increase the output power, only more air is compressed into the cylinder to
increase the amount of fuel and further improve the capacity to do work through combustion. Under
current technical condition, the turbocharger is the only machine which can increase output power with
the engine’s working efficiency unchanged.
The greatest advantage of the turbocharger lies in significantly boosting the engine’s power and torque
without increasing the engine’s displacement. Generally speaking, the power and torque of the engine
which is equipped with the turbocharger will increase by 20 ％ ~30 ％ . The disadvantage of the
turbocharger lies in lagging; in other words, the engine delays to increase or decrease output power
because the impeller has a slow response to the sudden change of the throttle due to inertia effect. A
vehicle which accelerates suddenly or overtakes another vehicle will have insufficient power at that
moment.
The exhaust gas turbocharger is mainly composed of an impeller and a turbine, and also includes some
other control elements. The impeller and turbine are connected by a shaft, which is known as rotor, the
exhaust gas from the engine drives the impeller, which in turn draws the turbine to rotate, so as to
turbocharge the intake system. As the turbocharger is installed at the engine’s exhaust side, the working
temperature of the turbocharger is high, and the speed of the turbocharger’s rotor is very high, which can
reach several hundred thousand rpm. Such high speed and temperature disable common mechanical
needle or ball bearings to work for the rotor, so non-locating bearings must be used for the turbocharger,
which is lubricated by engine oil and cooled by coolant.
Intercooler:
High temperature not only affects charging efficiency, but also is easy to result in explosion. Accordingly,
a device is needed to lower the intake temperature, which is an intercooler. It is installed between the
turbocharger outlet and intake pipe and used for cooling air into the cylinder. The intercooler, as a
radiator, uses air or water for cooling, and the heat of air escapes to the atmosphere through cooling.
According to the test, the intercooler with good performance can not only keep the engine’s compression
ratio at a certain valve without explosion, but also lower temperature to increase intake pressure and
further boost the effective power of the engine. This vehicle is air-air cooled, and the resistance of the
intercooler shall be lower than 5 kPa (in rated condition).
 Exhaust & Turbocharger (WP12) –Exhaust System

Precautions
As the turbocharger usually operates at high speed and high temperature, the temperature of the
turbocharger’s exhaust gas end is about 600℃, and the turbocharger’s rotor rotates by
7,000~100,000 r/min, the following points shall be noted in order to ensure that the turbocharger
operates normally:
1. DO NOT drive immediately after the engine starts
y After the engine starts, especially in winter, run it at idle speed for a while, which allows
lubricating oil to sufficiently lubricate bearings before the turbocharger’s rotor operates at
high speed. Therefore, never step on the accelerator sharply just after the engine starts, to
avoid damaging the oil seal of the turbocharger. The engine shall be idled appropriately
(about 5min, which can be shortened for a short stop) after starting, and then loaded.
2. DO NOT shut down the engine immediately
y DO NOT shut down immediately the engine which has operated at high speed for a long
time. When the engine is running, some oil is supplied to the bearings of the turbocharger’s
rotor for lubrication and cooling. If the operating engine is shut down suddenly, the oil
pressure goes down to 0 rapidly, the high temperature of the turbocharger’s turbine part is
transferred to the middle, and the heat in the bearing support housing can not be taken
away quickly while the rotor of the turbocharger is still rotating under inertia effect. Thus, if
the engine in hot state is shut down suddenly, the oil remaining in the turbocharger will get
overheated to damage the bearings and shaft. As a result, the engine, which has operated
with large load for a long time, shall be run at idle speed for 3~5min, and then shut down
after the rotor rotates at low speed. It is specially prohibited to shut down the engine
suddenly after stepping on the accelerator strongly.
3. Keep clean
y Keep clean while dismantling the turbocharger. Block each pipe joint with clean cloth to
prevent foreign matters from falling into the turbocharger and damaging the rotor. Be
careful not to hit or damage the impeller during repair. Remove the obstructions after
reassembly.
4. Wash the turbocharger
y As the turbocharger usually operates at high temperature, the partial coking of engine oil in
the lubricating oil pipeline easy occurs due to the effect of high temperature, which will
cause and damage to on bearings as a result of insufficient lubrication. Therefore, the
lubricating oil pipeline shall be washed after the turbocharger has operated for a period of
time.
5. Inspect the operating condition of the turbocharger usually
y Inspect the connection of various air pipes before driving and after stopping, and prevent
the turbocharger from failing due to looseness and falling and air from going into the
cylinder due to short circuit. Make sure the tightness of the turbocharger’s pipeline system
and parts, and the heat dispersion of the intercooler.
 Exhaust & Turbocharger (WP12) – Exhaust System

Part Drawing

1 Single Pipe Clamp Assembly 22 Hex Head Bolt

2 Gasket, Oil Return Pipe Flange 23 Stud Bolt

3 Gasket, Turbocharger Flange 24 Stud Bolt

4 Middle Exhaust Manifold 25 Exhaust Pipe Gasket

5 Exhaust Flange Sleeve 26 Oil Return Pipe Assembly, Turbocharger

6 Connecting Hose 27 Pressure Oil Pipe, Turbocharger

7 Rear Exhaust Pipe, Turbocharger 28 Hex Nut

8 Brake, Exhaust Pipe 29 Hex Head Bolt with Flange

Oil Return Connecting Hose,

9 30 Rubber Ring
Turbocharger

10 Bracket, Turbocharger 31 Clamp

11 Intake Pipe Assembly, Air Compressor 32 Connecting Nut

12 Connecting Pipe, Intercooler 33 Hex Head Bolt

13 Elbow 34 Union Nut

14 Sleeve 35 Double Pipe Joint

15 Turbocharger 36 Double Pipe Joint

 Exhaust & Turbocharger (WP12) –Exhaust System

16 Front and Rear Exhaust Manifold 37 Double Pipe Joint

17 Sealing Ring 38 Clamp Sleeve

18 Hex Nut 39 Oil Return Pipe Bolt

19 Stud Bolt 40 Clamp Sleeve

20 Hex Nut 41 Hex Head Bolt

21 Stud Bolt 42 Hose Clamp

Testing & Adjustment

The turbocharger is a key mechanical part which is used for boosting the engine’s power and decreasing
exhaust gas emission. Improper use, maintenance and care may cause the turbocharger to be defective
and disable the turbocharger to work. This text introduces some common faults and solutions of the
turbocharger as follows:
The turbocharger leaks oil.
Symptom 1: Excessive oil is consumed, but the color of exhaust smoke is normal and the power does
not decrease.
Cause: This condition is generally caused by oil leakage.
Solution:
1. First of all, inspect whether the external oil pipes (including oil inlet and return pipes of the
turbocharger) of the engine lubrication system leak oil.
2. Inspect whether there is oil at the exhaust gas outlet of the turbocharger. If any, you can
decide that the sealing ring at one end of the turbine is damaged, and replace it.
Symptom 2: Excessive oil is consumed, the color of exhaust smoke is blue, but the power does not
decrease.
Cause: It is caused by that the oil leaked from the compressor end of the turbocharger leaks oil goes into
the combustion chamber through the intake pipe of the engine. The possible causes are as follows:
1. The oil return pipe of the turbocharger is obstructed, and excessive oil accumulates at the
middle support of the rotor assembly and flows into the compressor impeller along the
rotor shaft.
2. After the sealing ring or oil slinger at the compressor impeller end is damaged, oil will go
into the impeller chamber through the damaged sealing ring or oil slinger, and then into
the combustion chamber through the intake pipe along with turbocharged air in the
impeller chamber.
Solution:
1. Open the outlet of the air compressor or the straight intake pipe (rubber hose) of the
engine, observe whether oil is attached to the pipe orifice or wall. If any, inspect whether
the oil return pipe of the turbocharger is unobstructed. If obstructed, it may caused by the
accumulation of excessive oil at the middle support. Unblock the oil return pipe and then
reassemble.
2. If unobstructed, it is caused by that the sealing ring or oil slinger at the impeller end is
damaged. Disassemble the turbocharger and repair the damaged part.
Symptom 3: Excessive oil is consumed, the color of exhaust smoke is blue or black, and the power
decreases.
Cause:
1. The wearing of the clearance between the piston and cylinder is too big, and the oil goes
 Exhaust & Turbocharger (WP12) – Exhaust System
into the combustion chamber and is combusted.
2. In process of sucking air into the turbocharger, air flow encounters great resistance (such
as clogging of the air filter element, deformation or flattening of the intake rubber hose due
to suction, etc.). The low pressure at the inlet of the air compressor will cause oil leakage,
and the oil leaked will go into the air compressor, then get into the combustion chamber
along with compressed air and be combusted.
Solution:
1. Inspect whether there is oil on the wall of the straight intake hose, the hose is flattened, air
flow is obstructed, or the air filter element is clogged.
2. If there is oil at the pipe orifice and on the pipe wall, wash or replace the air filter element.
There is metallic grating noise.
Symptom: The color of exhaust smoke is black, the power decreases, and there is abnormal noise from
the turbocharger.
Cause:
1. If there is metallic grating noise, it is caused by the friction between the impeller and
turbocharger housing due to the excessive wearing of the turbocharger’s rotor bearings or
thrust bearings.
2. If it is air flow noise rather than metallic grating noise, it is the rotation noise generated by
the rotation of the turbocharger’s rotor at high speed, or the air leakage noise due to poor
connection of the intake or exhaust joint.
Solution:
1. For the former, replace the damaged part or repair according to the wearing condition.
2. For the latter, distinguish carefully, and solve according to the specific condition.
The turbocharger’s bearing is damaged.
Symptom: The turbocharger’s bearing is damaged, the engine’s power decreases, excessive oil is
consumed, the color of smoke is black, and the turbocharger fails to work when the fault is serious.
Cause:
1. The pressure and flow of lubricating oil is insufficient.
y Lubricating oil supplied for the turbocharger’s journal and thrust bearing is insufficient.
y Lubricating oil which keeps floating between rotor journal and bearing is insufficient.
y The turbocharger has operated at high speed, but lubricating oil is not supplied in time.
2. Foreign matters or silt goes into the lubrication system.
3. Engine oil deteriorates due to oxidization.
y The diesel engine overheats, and gas going between the piston and cylinder wall is
excessive;
y Cooling water is leaked into engine oil;
y Improper engine oil is selected, and engine oil is not replaced periodically according to
specified requirement.
Solution:
1. Inspect whether the pressure of lubricating oil is normal, and the oil amount meets the
requirement.
2. Replace lubricating oil periodically according to the specified requirement, and ensure the
cleanliness of lubricating oil.
3. Use lubricating oil strictly according to the specified requirement. Mixing of lubricating oils
is not allowed.
4. Prevent the engine from operating at high temperature, and keep the engine at normal
operating temperature.
 Exhaust & Turbocharger (WP12) – Turbocharger

Turbocharger
Overhaul
Hint:
Part Drawing, refer to Chapter 13B, Exhaust & Turbocharger – Exhaust System, Part Drawing
1. Dismantle the turbocharger
(a). Dismantle the exhaust pipe.

(b). Dismantle the intercooler intake pipe and

connecting elbow.

(c). Dismantle the oil inlet pipe.

(d). Dismantle the oil return pipe.

 Exhaust & Turbocharger (WP12) – Turbocharger

(e). Dismantle the fixing bolts of the turbine.

2. Inspect the turbocharger. Refer to Chapter 13B, Exhaust & Turbocharger – Exhaust
System, Testing & Adjustment.
(a). Install the fixing bolts of the turbine.
Torque: 45±5N.m

(b). Install the oil return pipe.

(c). Install the oil inlet pipe.

Exhaust & Turbocharger (WP12) – Turbocharger

(d). Install the intercooler intake pipe and connecting

elbow.

(e). Install the exhaust pipe.

Torque: 60±10N.m
Cooling (WP12)

Cooling System ................................ 14B-3

General ..........................................14B-3
Precautions ....................................14B-6
Part Drawing ..................................14B-7
Testing & Adjustment ...................14B-12
Auxiliary Water Tank ...................... 14B-15
Overhaul ......................................14B-15
Coolant ............................................ 14B-17
Replacement ................................14B-17
Radiator ........................................... 14B-20
Overhaul ......................................14B-20
Cooling Fan .................................... 14B-22
Overhaul ......................................14B-22
Intercooler ....................................... 14B-23
Overhaul ......................................14B-23
Water Pump .................................... 14B-26
Overhaul ......................................14B-26
Thermostat ...................................... 14B-28
Overhaul ......................................14B-28
 Cooling (WP12) – Cooling System

Cooling System
General
The function of the diesel engine’s cooling system is to transfer outside the heat absorbed by the heated
parts of the diesel engine through cooling medium – coolant, and ensure that the heated parts operate
normally under allowable temperature condition. The cooling for the diesel engine shall be appropriate,
not excessive. Excessive cooling will bring about the following adverse effects for the diesel engine’s
operation: 1. the temperature of the cylinder is too low, the ignition delay period of fuel extends, the
combustion rate lowers, and heat loss due to radiation rises; 2. the diesel engine runs roughly, and its
fuel consumption increases; 3. the viscosity of lubricating oil increases, which results in increase in
moving parts’ friction power loss, and in decrease in the diesel engine’s power. Therefore, only
appropriate cooling can ensure that the diesel engine operates normally and has good economy.
Do not use common water as coolant, because the thermal conductivity of the scale deposit generated
by heating water is 40 times lower than that of cast iron. The scale deposit on the water jacket will lower
the performance of the engine cooling system. After the scale deposit blocks the orifice on the cylinder
gasket in particular, it will disturb smooth water flow and bring about various faults and damages.
The engine cooling system consists of a water pump, a radiator, a fan, a thermostat, an auxiliary water
tank, cooling pipes, the water channel of the cylinder body, and the cooling water chamber of the
crankcase.

1 Switch 7 Pressure Limiting Valve Cover

2 Heater 8 Auxiliary Water Tank
3 Exhaust Pipe, Water Tank 9 Thermostat
4 Water Inlet Pipe, Auxiliary Water Tank 10 Water Pump
5 Water Inlet Pipe, Heater 11 Water Filler Cap
6 Water Pipe 12 Water Tank
 Cooling (WP12) – Cooling System
Water Pump
The water pump is a power unit in the forced-circulation type water cooling system. Its main function is to
generate a certain pressure for coolant and force the coolant into various cooled parts of the diesel
engine, in order to ensure the continuous circulation of coolant in the process of the engine’s operation.
For the WD615 Series diesel engine, the water pump is installed at its front end. The water coming out
from the water pump goes into the right water chamber of the engine body; cooling water goes across
the oil cooler, flows into the water jacket of the cylinder barrel through the right lower channel hole of the
engine body, goes into the water chamber of the cylinder head through the upper water hole after cooling
the cylinder barrel, and drains into the water outlet pipe from the water outlet of the cylinder head after
cooling the cylinder head; the thermostat is installed at the end of the water outlet pipe. The thermostat
has two outlets, one leading to the radiator and the other leading to the water pump inlet, which is small
circulation. When the temperature of coolant is at 80±2 ℃, the thermostat starts to open and fully opens
at 95 ℃, and at the moment, coolant is pumped into the engine body by water pump after being cooled
by the radiator. When the temperature of coolant is lower than 80±2 ℃, the thermostat cuts off the
above channel, and coolant directly flows into the water pump inlet, which can help the diesel engine’s
temperature rise as soon as possible and help the diesel engine reach hot state required for operation,
avoid cold scuffing, and prolong the service life of the diesel engine.
The oil chamber of the water pump is filled with 120cm³ of general purpose lithium base grease fro
automobile, which needs regular filling or makeup.
Radiator
The function of the radiator is to transfer the heat absorbed by coolant from the heated parts into air and
then emit the heat into the atmosphere so as to lower the temperature of coolant.
Fan
The silicon oil fan clutch, adopting silicon oil as medium, transfers torque by using the high viscosity of
silicon oil. The release and engagement of the fan clutch can be automatically control by the
temperature sensor which detects the temperature of air behind the radiator. When the temperature is
low, silicon oil does not flow, the fan clutch releases, and the fan’s speed descends and basically idles.
When the temperature is high, the viscosity of silicon oil engages the fan clutch, and then the fan rotates
together with the water pump shaft, which plays a role in adjusting the engine’s temperature.
The temperature sensing element of the silicon oil fan clutch is a bimetallic coil spring temperature
sensor. Its working process is as follows:
1. When the temperature or air passing through the radiator rises, the bimetallic temperature sensor
deforms as a result of heating to force the valve disc shaft to rotate and open the oil inlet on the driven
plate. The silicon oil stored between the driven plate and front cover flows into the working chamber
between the driving plate and driven plate, the clutch engages, and the fan’s speed increases.
The higher the air temperature, the larger the oil inlet opens, and the faster the fan rotates.
2. When the temperature of air passing through the radiator falls, the bimetallic temperature sensor
recovers to its original shape, the valve disc closes the oil inlet, the silicon oil returns to the oil storage
chamber from the working chamber through the oil inlet under the action of centrifugal force, the clutch
releases, and the fan’s speed gets very low.
Thermostat
The function of the thermostat is to keep the coolant’s temperature appropriate, which ensures reliable
cooling for the diesel engine, and avoids lowering the power and economy of the diesel engine in use
due to too low water temperature. When the temperature of coolant is low, the big circulation valve of the
thermostat closes, the small circulation valve opens, the coolant in the water return pipe of the diesel
engine is directly supplied to the water pump inlet through the small circulation valve, the water pump
 Cooling (WP12) – Cooling System
pumps coolant into the cooling system of the diesel engine again, and the radiation water tank does not
work. When the water temperature of the diesel engine rises to a certain value, the big circulation valve
of the thermostat opens while the small circulation valve closes, and the coolant flows into the radiation
water tank through the big circulation valve and the water return pipe of the water tank, is sucked into the
water pump from the radiation water tank after being cooled, and then is pumped into the cooling
circulation system of the diesel engine.
This vehicle adopts a wax and core combined thermostat. When the temperature of coolant is lower than
the specified value, the refined wax in the temperature sensing element of the thermostat is solid, the
thermostat valve closes the channel between the engine and radiator under the spring action, and the
coolant returns to the engine through the water pump and flows within the small circulation. When the
temperature of coolant rises to the specified value, the wax starts to melt and gradually changes into
liquid, and it presses the rubber hose with its volume increasing and forces the hose to shrink. The
rubber hose applies an upward thrust to the push rod while shrinking, and the push rod exerts a
downward reverse thrust on the valve to open the valve. At the moment, the coolant passes through the
radiator, thermostat valve and water pump, then returns to the engine, and flows within the big circulation.
This is the principle of operation of the thermostat. Mostly, the thermostat is arranged in the water outlet
pipe of the cylinder head, which has the advantages that the structure is simple and bubbles in the
cooling system is easy to eliminate, but has the disadvantages that vibration is usually generated along
with the frequent opening and closing of the thermostat.
Auxiliary Water Tank
The function of the auxiliary water tank is to eliminate vapor in the low pressure part of the cooling
system, which may cause air resistance, and to make up coolant. The pressure of the auxiliary water
tank shall be kept at 50kPa, and its position must be 400mm higher than the diesel engine and radiator.
Various water tank caps in the cooling system shall be kept good, and it is prohibited to open them.
Keeping an internal pressure in the cooling system will enhance the cooling efficiency of the cooling
system, and boiling can be avoided.
 Cooling (WP12) – Cooling System

Precautions
1. Never open the pressure cap when the engine is in hot state. The pressure cap can be
opened when the temperature of coolant falls below 50°C, or hot coolant or vapor emitted
may cause personal injury.
2. When disconnecting the pipeline of the cooling system, collect the residual coolant with a
special container. If the coolant is disused, follow the waste disposal as specified.
3. When disconnecting the pipeline of the cooling system, never allow debris to go into the
pipeline of the cooling system, which may damage the cooling system and engine.
4. When disconnecting the pipe joint of the cooling system, in order to prevent dirt or
impurities from going into the pipe, make sure to use special plug to seal the pipe orifice.
5. Coolant is toxic. If disused, keep it far away from children and pets, and follow the waste
disposal as specified.
6. Different brands of antifreezes are based on different production formulas. If they are
mixed, various additives are likely to react with each other, which will result in failure of
the additives.
7. The shelf life of the antifreeze is two years. Confirm whether the antifreeze is within the
shelf life when filling.
8. The antifreeze must be replaced regularly, generally once every two years or every
40,000km.
9. Drain the old antifreeze during replacement, clean the cooling system, and then fill new
antifreeze.
10. Avoid mixing antifreeze with water. The traditional inorganic antifreeze can not be mixed
with water, or sediment will be generated, which will seriously affect the normal function of
the antifreeze. The organic antifreeze can be mixed with water, but not too much.
11. When the air temperature is below 0 ℃, inspect the concentration of antifreeze regularly.
12. Vehicles, which usually run in the regions above 0 ℃, can use water after anti -rust and
scale prevention treatment as coolant. They are prohibited to use untreated water as
coolant.
13. When using the silicon oil clutch fan, be careful not to place the fan horizontally after
dismantling it, or silicon oil will be leaked from the fit clearance of the sensor shaft, which
will cause failure of the fan.
 Cooling (WP12) – Cooling System

Part Drawing

1 Hex Bolt with Split Pin Hole on Shank 10 Cotter Pin

2 Big Washer 11 Hex Slotted Nut, Style 1 – Fine Pitch Thread

3 Cushion, Radiator Tie Rod 12 Upper Cushion, Radiator

Right Tie Rod, Radiator (symmetrical with

4 13 Sleeve
the left part)

5 Hex Thin Slotted Nut 14 Cushion, Radiator

6 Cotter Pin 15 Hex Bolt with Split Pin Hole on Shank

7 Hex Head Bolt 16 Left Tie Rod, Radiator

8 Spring Washer 17 Radiator with Cowl Assembly

9 Flat Washer
 Cooling (WP12) – Cooling System

1 Worm Drive Type Hose Hoop, Type A 11 Flat Washer

2 Plastic Strap 12 Spring Washer

3 Water Inlet Hose, Radiator 13 Hex Nut, Style 1

4 Water Outlet Hose, Radiator 14 Bracket, Water Pipe Welding Assembly

5 Worm Drive Type Hose Hoop, Type A 15 Hex Head Bolt

6 Engine Water Inlet Pipe Welding Assembly 16 Spring Washer

7 Clamp 17 Flat Washer

8 Fixing Bracket, Water Pipe 18 Cushion block

9 Hex Head Bolt 19 Water Inlet Hose, Engine

10 Limiting Sleeve, Water Pipe

 Cooling (WP12) – Cooling System

1 Worm Drive Type Hose Hoop, Type A 13 Bracket, Cooling Water Hose

2 Exhaust Hose, Radiator 14 Water Outlet Pipe, Auxiliary Water Tank

3 Exhaust Hose, Engine 15 Plastic Strap

4 Worm Drive Type Hose Hoop, Type A 16 Exhaust Hose

5 Water Outlet Pipe, Auxiliary Water Tank 17 Plastic Auxiliary Water Tank

6 Bracket, Engine Water Make-up Pipe 18 Bracket, Auxiliary Water Tank

7 Single Pipe Clamp 19 Hex Head Bolt

8 Hex Head Bolt 20 Hex Head Bolt

9 Flat Washer 21 Spring Washer

10 Spring Washer 22 Flat Washer

11 Hex Nut, Style 1 23 Hex Nut, Style 1

12 Combined Cooling Water Pipe 24 Support Plate, Auxiliary Water Tank

 Cooling (WP12) – Cooling System

1 Silicon Oil Clutch Fan 10 Water Temperature Sensor

2 Thermostat 11 Sealing Ring

3 Sealing Ring 12 Fan Bracket

4 Water Pump 13 Fan Driving Shaft

5 Tension Pulley 14 Hex Head Bolt

6 Idle Pulley (10-groove) 15 Water Temperature Gauge Sensor

7 Belt (10-groove) 16 Engine Front Support

8 Engine Bracket 17 Thermostat Cap

9 Water Pipe Joint

 Cooling (WP12) – Cooling System

1 Clamp 8 Connecting hose

2 Exhaust Pipe, Intercooler 9 Intake Pipe, Intercooler

Hex Head Bolt, Spring Washer and Flat

3 T-clamp 10
Washer Assembly
Hex Head Bolt, Spring Washer and Flat
4 11 Hex Flange Nut
Washer Assembly

5 Fixing Bracket, Intercooler 12 Bracket, Intercooler Pipe

6 Fixing Bracket, Intercooler 13 Clamp, Intercooler Pipe

7 Intercooler assembly
 Cooling (WP12) – Cooling System

Testing & Adjustment

Fan
Manual test method: Start the engine, run it for several minutes and then shut down; pull the fan by hand.
If the clutch is released and the fan can rotate, it shows that the silicon oil fan is good. There are,
however, exceptions that the fan can not rotate at low temperature because silicon oil can not return at
once, which does not always show that the silicon fan is damaged. Start the engine to continue the test,
run it at middle speed and low temperature for 1~2 minutes and then shut down; pull the fan by hand. If
the fan can rotate and operate flexibly, it shows that the silicon fan is good. When the temperature rises
to 88 ℃, shut the engine down, and pull the fan by hand. If the fan does not move, it shows that the
silicon fan is normal; if not, it shows that the silicon fan is defective.

1 Fan 3 Thermometer

2 Radiator 4 Baffle Plate

Dynamic test: Place the thermometer with a range of -18~105 ℃ ahead of the radiator. Put a fixed plastic
plate ahead of the radiator to prevent air from passing through the radiator, and ensure that it can
prevent air passage. If an air conditioner is equipped, the A/C switch must be turned off. Use a timing
lamp to point to the fan blades, start the engine and run it at a speed of 2400r/min. The air temperature
showed by dial thermometer shall reach 88 ℃ within 10 minutes. The ideal engagement of the fan clutch
shall be before 88 ℃. Observe the increase in the fan’s speed. When the air temperature rises to 88 ℃,
take away the plastic plate, and the air temperature starts to fall. The ideal silicon oil fan clutch can lower
the air temperature by 11 ℃ or more, and at the same time, you can hear that the air flow sound of the
 Cooling (WP12) – Cooling System
fan reduces. If the fan clutch fails to meet the above requirement, replace the silicon oil fan clutch
assembly.
Water Pump
In case that the cooling system leaks, you can smell hot antifreeze. But you have to do inspection, and
find out whether the cooling water is leaked from the shaft seal of the water pump. You can use a small
mirror and a lamp to inspect whether the air bleed hole of the water pump leaks water.
Conduct the regular maintenance, and pay attention to inspecting the consumption of coolant in the
water tank.
Do not underestimate the problem of leakage in the cooling system, which will cause air sucked in to
destroy the preset coolant flow mode and result in generation of hotspots, and greatly aggravate
corrosion to the water pump.
If the amount of coolant is insufficient for a long time, it will cause the engine to overheat, and steam
corrosion may occur, which may damage the radiator and cause other problems of the water pump.
When the color of coolant is rusty, it may be the problem of impeller corrosion. At the moment, it is
necessary to inspect the circulation condition of the water pump coolant. Discharge part of the coolant in
the radiator and keep the lever right above the pipe, and warm up the engine to let the thermostat stay in
full opening position. When the engine’s speed is 3,000r/min, you shall see a good water circulation.
Thermostat
The safe life of the wax thermostat is generally for a range of 50,000km, and the wax thermostat shall be
replaced regularly according to its safe life.
1. Inspect the thermostat
(a). The thermostat and thermometer can be put in
hot water.
(b). Inspect the opening temperature of the main
valve of the thermostat.
(c). Inspect the sealing ring of the thermostat.
(d). Replace the thermostat if either of the items
fails to meet the specified value.

Opening Temperature Full-opening Temperature

80 ± 2 ℃ 95 ℃

Water Pipe
Inspect whether the clogging, bulging, aging or cracking of water pipes occurs, and whether the
connection of water pipe joints is secure.
Auxiliary Water Tank
Inspect whether there are cracks on the auxiliary water tank, whether the bulging, aging or cracking of
the auxiliary water tank occurs, and whether the auxiliary water tank cap is in perfect condition.
Coolant
When the engine idles and warms up to the normal operating temperature, the level of coolant in the
bottle shall be between the lowest graduation line and highest graduation line, as shown on the bottle.
Test the concentration of coolant by a freezing point tester.
Radiator
 Cooling (WP12) – Cooling System
Fill water into the radiator, and observe whether water flow is smooth. If not smooth, it shows that the
radiator inside is clogged. Rinse the radiator outside, and wash the radiator inside with hot water. If the
scale deposit can not be eliminated still after the radiator is washed, use a soft metal cleaning rod to
remove the scale deposit, and then wash with the above method. Remove the radiating fin of the
damaged radiating pipe by needle nose pliers, then cut off the damaged radiating pipe, insert the
cleaning rod from the end of the core, pass it through the upper orifice and lower orifice of the cut part
and straighten, cut the same usable radiating pipe from a waste radiator, and solder the upper and lower
joints. Insert the resistance heater into the radiating pipe to be replaced, and supply 24V power. After
resistance wires are hot, the radiating pipe releases as its soldering tin melts. Cut off the power, take out
the radiating pipe and resistance heater together, and change with the new radiating pipe and solder
securely. Install the radiator tester on the radiator cap opening, and inspect the cooling system for
leakage. Pressurize the radiator to 176kPa, inspect the leakage of coolant at normal operating
temperature, and repair if any.
Intercooler
This vehicle is of a turbocharged intercooled type. The intercooler is installed on the front of the diesel
engine, i.e. the front end of the water tank, and it sucks the air from the fan and the headwind of the
vehicle during driving for cooling. Foreign matters such as oil sludge and colloid, which are usually
attached to the internal pipe of the intercooler, not only narrow the air channel to reduce the heat
exchange capacity, but also lower air intake because dirt clogs the air channel, which cause the
problems that the diesel engine’s power falls, the exhaust gas is white, and even the vehicle can not run
normally.
Fill water into the intercooler, and observe whether water flow is smooth. If not smooth, it shows that the
intercooler is clogged. Wash the intercooler with hot water. If the scale deposit can not be eliminated
after washing, replace the intercooler.
 Cooling (WP12) – Auxiliary Water Tank

Auxiliary Water Tank

Overhaul
Hint:
Part Drawing, refer to Chapter 14B Cooling – Cooling System, Part Drawing
1. Dismantle the auxiliary water tank
(a). Disconnect the wiring harness of the auxiliary
water tank.

(b). Open the auxiliary water tank cap.

Caution:
Never open the pressure cap when the engine is in
hot state. The pressure cap can be opened when the
temperature of coolant falls below 50°C, or hot
coolant or vapor emitted may cause personal injury.
(c). Disconnect the pipe of the auxiliary water tank.
Caution:
When disconnecting the pipe joint of the cooling
system, in order to prevent dirt or impurities from
going into the pipe, make sure to use special plug to
seal the pipe orifice.
(d). Dismantle the fixing bolts of the auxiliary water
tank.

2. Inspect the auxiliary water tank. Refer to Chapter 14B Cooling – Cooling System, Testing &
Adjustment.
Cooling (WP12) – Auxiliary Water Tank

3. Install the auxiliary water tank

(a). Install the fixing bolts of the auxiliary water tank.
Torque: 20N.m
(b). Connect the pipe of the auxiliary water tank.
(c). Fill coolant.
(d). Close the auxiliary water tank cap.

(e). Disconnect the wiring harness of the auxiliary

water tank.
 Cooling (WP12) – Coolant

Coolant
Replacement
1. Drain coolant
(a). Disconnect the water inlet hose and exhaust pipe
of the radiator.
Caution:
Never open the pressure cap when the engine is in
hot state. The pressure cap can be opened when the
temperature of coolant falls below 50°C, or hot
coolant or vapor emitted may cause personal injury.
Caution:
When disconnecting the pipe joint of the cooling
system, in order to prevent dirt or impurities from
going into the pipe, make sure to use special plug to
seal the pipe orifice.

(b). Disconnect the water outlet hose of the radiator.

Caution:
When disconnecting the pipe joint of the cooling
system, in order to prevent dirt or impurities from
going into the pipe, make sure to use special plug to
seal the pipe orifice.
Caution:
Coolant is toxic. If disused, keep it far away from
children and pets, and follow the waste disposal as
specified.

(c). Unscrew the auxiliary water tank cap.

(d). Disconnect the water pipe of the auxiliary water
tank.
Caution:
When disconnecting the pipe joint of the cooling
system, in order to prevent dirt or impurities from
going into the pipe, make sure to use special plug to
seal the pipe orifice.
Caution:
Coolant is toxic. If disused, keep it far away from
children and pets, and follow the waste disposal as
specified.
Cooling (WP12) – Coolant
2. Fill coolant
(a). Connect the water inlet hose and exhaust pipe of
the radiator.

(b). Connect the water outlet hose of the radiator.

(c). Connect the water pipe of the auxiliary water tank.

(d). Fill coolant.
(e). Tighten the auxiliary water tank cap.

(f). Fill coolant from the engine water filler.

Caution:
Different brands of antifreezes are based on different
production formulas. If they are mixed, various
additives are likely to react with each other, which
will result in failure of the additives.
Caution:
The shelf life of the antifreeze is two years. Confirm
whether the antifreeze is within the shelf life when
filling.
 Cooling (WP12) – Coolant
3. Inspect the coolant level
(a). Run the engine, and inspect the engine coolant level.
(b). If the level is too low, continue to fill coolant.
 Cooling (WP12) – Radiator

Radiator
Overhaul
Hint:
Part Drawing, refer to Chapter 14B Cooling – Cooling System, Part Drawing
1. Drain coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.
2. Dismantle the radiator
(a). Loosen the shroud.

(b). Loosen the intercooler.

(c). Dismantle the fixing bracket of the A/C pipe.

(d). Dismantle the radiator.

y Dismantle the cotter pin.
y Dismantle the slotted nuts of the radiator.
y Take out the radiator upward.

3. Inspect the radiator. Refer to Chapter 14B Cooling – Cooling System, Testing &
Adjustment.
 Cooling (WP12) – Radiator

4. Install the radiator

(a). Install the radiator.
y Put radiator downward.
y Install the slotted nuts of the radiator.
Torque: 70N.m
y Install the cotter pin.

(b). Install the fixing bracket of the A/C pipe.

(c). Tighten the intercooler.

Torque: 20N.m

(d). Tighten the shroud.

Torque: 20N.m

5. Fill coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.

 Cooling (WP12) – Cooling Fan

Cooling Fan
Overhaul
Hint:
Part Drawing, refer to Chapter 14B Cooling – Cooling System, Part Drawing
1. Dismantle the cooling fan
(a). Loosen the shroud.

(b). Disconnect the silicon oil temperature sensor of

the cooling fan.
(c). Dismantle the fixing clamp of the cooling fan
silicon oil temperature sensor.

(d). Dismantle the fixing clamp of the cooling fan

silicon oil temperature sensor.
(e). Dismantle the cooling fan.

2. Inspect the cooling fan. Refer to Chapter 14B Cooling – Cooling System, Testing &
Adjustment.
3. Install the cooling fan
(a). Install the cooling fan.
Torque: 20N.m
(b). Install the fixing clamp of the cooling fan silicon oil
temperature sensor.
Cooling (WP12) – Cooling Fan
(c). Install the fixing clamp of the cooling fan silicon oil
temperature sensor.
(d). Connect the silicon oil temperature sensor of the
cooling fan.

(e). Tighten the shroud.

Torque: 20N.m
 Cooling (WP12) – Intercooler

Intercooler
Overhaul
Hint:
Part Drawing, refer to Chapter 14B Cooling – Cooling System, Part Drawing
1. Dismantle the intercooler
(a). Dismantle the intake pipe of the intercooler.
(b). Dismantle the fixing bolts of the intercooler.

(c). Dismantle the exhaust pipe of the intercooler.

(d). Dismantle the fixing bracket of the intercooler.

(e). Dismantle the fixing bolts of the intercooler.

(f). Dismantle the fixing bolts of the intercooler.

2. Inspect the intercooler. Refer to Chapter 14B Cooling – Cooling System, Testing &
Adjustment.
3. Install the intercooler
(a). Install the fixing bolts of the intercooler.
(b). Install the fixing bolts of the intercooler.
Torque: 23±2N.m
Cooling (WP12) – Intercooler

(c). Install the exhaust pipe of the intercooler.

(d). Install the fixing bracket of the intercooler.
Torque: 23±2N.m

(e). Install the intake pipe of the intercooler.

(f). Install the fixing bolts of the intercooler.
 Cooling (WP12) – Water Pump

Water Pump
Overhaul
Hint:
Part Drawing, refer to Chapter 14B Cooling – Cooling System, Part Drawing
1. Drain coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.
2. Dismantle the belt

3. Dismantle the thermostat. Refer to Chapter 14B Cooling – Thermostat, Overhaul.

4. Dismantle the water pump

5. Inspect the water pump. Refer to Chapter 14B Cooling – Cooling System, Testing &
Adjustment.
6. Install the water pump
Torque: 63N.m

7. Install the thermostat. Refer to Chapter 14B Cooling – Thermostat, Overhaul.

 Cooling (WP12) – Water Pump

8. Install the belt

9. Fill coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.

 Cooling (WP12) – Water Pump

Thermostat
Overhaul
Hint:
Part Drawing, refer to Chapter 14B Cooling – Cooling System, Part Drawing
1. Drain coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.
2. Dismantle the thermostat

3. Inspect the thermostat. Refer to Chapter 14B Cooling – Cooling System, Testing &
Adjustment.
4. Install the thermostat

5. Fill coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.

Lubrication (WP12)
Lubrication System ......................... 15B-3
General .......................................... 15B-3
Precautions ....................................... 15B-5
Part Drawing ................................. 15B-6
Testing & Adjustment .................... 15B-8
Oil Pan ............................................ 15B-12
Replacement ............................... 15B-12
Oil Filter .......................................... 15B-13
Replacement ............................... 15B-13
Oil Pump ........................................ 15B-14
Overhaul ..................................... 15B-14
Oil Cooler ....................................... 15B-15
Overhaul ..................................... 15B-15
 Lubrication (WP12) - Lubrication System

Lubrication System
General
Functions of Lubrication System
Lubricating function: it can lubricate the surface of the moving part, decrease the frictional drag, abrasion
and watt consumption of the engine.
Cleaning function: the oil circulates continually in the lubrication system to clean the friction surface and
to take away the abrasive dusts and other foreign matters.
Cooling function: the circulation of the oil in the lubrication system can also take away the heat resulting
from the burning and friction to play the role of cooling.
Sealing function: the oil film is formed between the moving parts in order to improve their tightness,
which can avoid air or oil leakage.
Antirust function: the oil film is formed on the surface of the part to protect the surface and to avoid
corrosion.
Hydraumatic function: the oil can also be used as hydraulic oil, take hydraulic pressure staying up for
example, to play the role of hydraulic.
Shock absorption function: the oil film is formed on the surface of the moving part to absorb the shock
and decrease the vibration, and consequently to play the role of shock absorption.
Oil
The application of the oil should be determined according to the standards of the company. Multistage oil
is preferred because it is better for cold start. Multistage oil for yearly use such as 5W30, 10W40, 15W40
and so on can be only used within the specified temperature range. As for the occasional low
temperature cases, take reasonable measures to preheat the oil, or replace it with another kind of oil
which is fit for the ambient temperature.
The replacing time of the oil should be determined according to the need of maintaining.
Pressure Lubrication
 Lubrication (WP12) - Lubrication System
The oil pump sucks the oil from the bottom of the oil pan via the suction filter and presses it into the oil
filter and oil cooler, and then the oil reaches the lubrication location via the oil system. Most of the oil
reaches the main bearing and gets to the connecting rod bearing through the oil hole on the crankshaft.
The cylinder liner surface and the position pin are lubricated by the injecting fuel from the nozzle. The
pressure lubrication of the valve control system, turbocharger, high-pressure oil
pump, air compressor and the intermediate gear bearing is also realized by the oil pipe and tanks. The
bottom of the piston is cooled by the injecting fuel from the nozzle and the oil is cooled by the coolant
through the oil cooler. The oil pressure of the oil circulation system is adjusted via a relief valve. When
the oil engine starts the oil pressure will be on the high level because of the low temperature and the
large viscosity of the oil. But with the increase of the water temperature of the engine, the oil temperature
increases, the oil pressure decreases, and when the full load water temperature of the oil engine is
between 80~95℃, the normal oil pressure is between 350~550kPa.
Oil Pan
The oil pan is made with the method of punch forming by applying sheet steel, its faying face with the
crankcase has a very deep turnup which leads to its large stiffness. Press the low fraying face via 12 oil
pan support blocks and M8 bolts attaching a concave oil pan gasket. The tightness is so good that there
will not be oil leakage.
Oil Cooler
In order to prevent the blocking of the oil cooler and the low temperature, large viscosity and high
resistance at the beginning of the start in winter from leading oil starvation damage to the engine, an oil
cooler safety valve (bypass valve) is set in the engine oil way and the starting pressure of the valve is
600±36kPa
Main Oil Gallery Relief Valve
The main oil gallery relief valve is at the lower right part of the crankcase, and the starting pressure of the
main oil gallery relief valve which bulges in the inner chamber of the oil pan is 500kPa.
Oil Filter
Two multiple pinning filter element structures are applied, and when carrying out the maintaining and
replacement, one can only unscrew the old filter element and install a new one.
Oil Pump
A gear pump is used for the oil pump. Two stage pumps are applied to full-wheel drive road vehicles and
single pumps are used on other vehicle types.
Suction Pump
A suction filter is a filter with a mental net, it is installed on the inlet pipe of the oil pump and is used for
preventing major mechanical impurities from getting into the pump.
Oil Coarse Filter
he coarse filter is used to filter impurities of major particle size out of the oil, since the flow resistance of
the oil is small, it is often installed in series between the oil pump and the main oil gallery, and it is
fully-flow filter. The coarse filter is a filterable one the working principle of which is that when the oil
passes through fine holes or gaps, the impurities of big holes or gaps are kept out of the filter element.
There are structures with different types according to different filter elements.
 Lubrication (WP12) - Lubrication System

Precautions
1. During the dismounting, prevent impurities from entering and keep clean.
2. Check the oil level regularly, a higher level will increase the running resistance of the
engine which will result in unnecessary power loss and oil leakage; a lower level will lead
damage to the engine owing to the poor lubrication.
3. Use the oil with proper viscosity, if the viscosity is too low, the oil film will be damaged,
and part lock phenomenon will occur; if the viscosity is too high, additional resistance will
be produced from the moving parts, which makes the engine start difficult, and the power
loss will increase.
• Choose the oil according to the climate. When the temperature is low, choose the oil with
low viscosity in order to make it convenient for engine start. When the temperature is high,
choose the oil with high viscosity to keep the oil film during the move.
• Choose the oil according to the vehicle conditions. Vehicles with good condition have small
fit clearance, so choose the oil with low viscosity, and vehicles with poor condition have big
fit clearance, so choose the oil with high viscosity.
• Since the oil engine has high firing pressure, and the oil containing sulfur will produce
sulfurous acid which can dilute the oil after burning, choose the dedicated oil for the engine
which can neutralize the sulfurous acid.
4. Replace the engine oil regularly, it would be best not to add oil, adding oil chronically will
accumulate more and more oil contamination and carbon deposit which will block the oil
suction filter, so the moving parts of the engine can not be lubricated, which will damage
the parts seriously.
 Lubrication (WP12) - Lubrication System

Part Drawing

1 Hex Head Bolt 18 Hex Head Bolt

2 Spring Washer 19 Gear Assembly-Oil pump
3 Radial Ball Bearing 20 Hex Nut, Style I
4 Circlip For Hole with Convex Teeth 21 Hex Head Bolt
5 Intermediate Set Collar 22 Hex Head Bolt
6 Intermediate Gear-Oil Pump 23 Gasket-Oil Pump
7 Sealing Ring 24 Gasket
8 Intermediate Gear Shaft 25 Flat Washer
9 Hex Head Bolt 26 Hex Head Bolt
10 8mm Widened Oil Pump 27 Suction Filter Assembly
11 Front Cover-Oil Pump 28 Hex Head Bolt
12 Gear Assembly-Oil Pump 29 Relief Valve Assembly-Oil Pump
13 Housing-Oil Pump 30 Relief Valve Body
14 Cylindrical Pin 31 Circlip For Hole
15 Rear Cover-Oil Pump 32 Relief Valve
 Lubrication (WP12) - Lubrication System

16 Hex Socket Cap Head Screw 33 Spring

17 Driving Gear-Oil Pump 34 Gasket

1 Oil Cooler Core Assembly 11 Wave Shape Circlip

2 Sealing Ring 12 Hex Socket Cap Head Screw
3 Hex Head Plug 13 Hex Socket Cap Head Screw
4 Composite Gasket 14 Main Oil Gallery Assembly
5 Safety Valve Spring 15 Valve Body
6 Safety Valve 16 Valve
7 Wave Shape Circlip 17 Spring Seat-Main Oil Gallery Pressure Valve
8 Hex Socket Cap Head Screw 18 Spring-Main Oil Gallery Pressure Valve
9 Rotary Oil Filter Element Assembly 19 Circlip For Hole
10 Filter Seat Assembly
 Lubrication (WP12) - Lubrication System

Testing & Adjustment

Detection of Pump Oil
As for the engine under normal technical condition within common speed range, the oil pressure should
be between 350~550kPa. If the oil pressure of medium speed is below 300kPa and of idling is below
100kPa, stop the running of the engine and check the lubrication system.
Effect factors of oil pressure:
1. Property of the oil pump, adjustment of the relief valve, resistance of the oil gallery and oil
filter
2. Quality, temperature and viscosity of the oil
• If the viscosity of the oil is low and the temperature is high, the oil pressure will decrease;
otherwise it will increase.
3. Gaps of the crankshaft main bearing, connecting rod bearing and camshaft bearing
• The gearing gap will become larger after wear, the oil leakage amount at the gearing gap
place will increase, but the oil pressure will decrease. As a result, oil pressure is often used as
an important parameter to determine the related gearing gap.
• If the oil pump is under normal technical condition, the decrease of the oil pressure is mainly
caused by the large wear of the crankshaft main journal and connecting rod journal. When
the crankshaft main bearing gap increases by 0.01mm, the oil pressure will decrease by
0.01MPa.
4. Oil pressure gauge and oil pressure sensor
• The oil pressure value can be showed on the instrument panel, but during the regular
detection a dedicated oil pressure gauge should be used, because the oil pressure gauge
and oil pressure sensor can not guarantee a necessary measurement accuracy.
• When detecting, dismantle the oil pressure sensor first and install the oil pressure gauge.
Then start the engine and make it run within specified speed, and now the indicated value on
the oil pressure gauge is the oil pressure of the lubrication.
Detection of Oil Consumption
Effect factors of oil consumption:
1. Lubrication leakage
2. Abnormal working of air compressor
3. Improper selection of oil standards
4. Cylinder-piston assembly wear
• The oil consumption can both reflect the technical condition of the engine lubrication system
and help determine the wear condition of the cylinder-piston assembly
• The main reasons of the large oil consumption are large wear of cylinder-piston assembly,
gap increase and the burning of the oil into the burning chamber on condition that the mark of
the oil is correct and the technical conditions of other mechanisms is normal.
The oil consumption is about 0.1~0.5L/100km; when the engine wear is serious, it can reach 1L/100km
or more. As for the measurement of oil consumption, all that is needed is to make a conversion of the
real oil consumption (L) of the vehicle after running for some mileages (1000~1500 km) into the average
oil consumption (L/100km) per hundred kilometers of the vehicle.
Testing and Analysis of Oil Quality
During the use of the oil, its quality will go bad gradually because of the impurity contamination, oil
dilution, high-temperature oxidation, additive consumption or its performance loss. Visually, the color will
go black and the viscosity will increase or decrease.
 Lubrication (WP12) - Lubrication System
The impurities leading to the oil contamination are mainly from the wear particles on the friction surface,
the outside dust and carbon deposition; the abnormal working, imperfect burning or misfiring of the
engine will make the oil that does not burn flow into the oil pan to dilute the oil; the high temperature
resulting from the engine working, especially when the cylinder-piston assembly wear is serious, the gap
becomes larger, and there is high temperature and pressure gas in the combustion stroke whisking into
the crankcase, it will aggravate the oil oxidation and produce oxide and oxidative polymer. The detergent
dispersant in the oil is an important kind of additive for the oil, and it has the abilities of scattering and
taking away the particles and carbon deposition on the friction surface. The detergent dispersant
consumption and property decrease will also make it lose the function of cleaning and dispersing.
Filter Paper Oil Patch Testing Method
1. Testing Principle

1 Black Circle 3 Diffusion Region

2 Centre Region 4 Translucence Region
• Drop the engaged oil on specified filter, the oil drop will soak and disperse around gradually,
finally multi-ring ringlike oil patches with different color shades will be formed and there are
deep color nuclear in the centre of the patches. If the concentration and particle size of the
impurities in the oil are different and their abilities of cleaning and dispersing differ from each
other, the color shades of each ring region of the oil patches will also be different.
• If the particle size of the impurities in the oil is small and their cleaning and dispersing abilities
are perfect, the impurity particle will disperse father, the impurity concentrations and the color
shade extents of the centre region and diffusion region have no significant differences; if the
particle size of the impurities in the oil is large and they lose the abilities of cleaning and
dispersing, the impurities in the oil will centralize into the centre region gradually, and the
impurity concentrations and the color shade extents of the centre region and diffusion region
 Lubrication (WP12) - Lubrication System
will have significant differences. As a result, the impurity concentration of the centre region on
the oil patch can reflect the total contamination extent, and the subtraction of the impurity
concentration of per unit centre region and the impurity concentration of per unit diffusion
region can reflect the cleaning and dispersing abilities of the detergent dispersant in the oil.
2. Testing Method
• Make two pieces of the same type by using organic glass (cardboard, plastic plate or board
can also be used) with the length and width 12cm×7cm, scrap out a circular hole with the
diameter 5cm, and bond one side with adhesive plaster to make the rear of the filter not touch
the table-board , which can affect the diffusion of the oil patches.
• Take the oil sample out of the engine under thermal condition and put it into the test tube,
poke into the tube oil level to certain depth by using a drop rod with specified size (a mental
rod with a smooth tip, the diameter is 2mm and the length is 150mm), then take out of the
drop rod and drip the third oil drop onto the filter paper to form the oil patch.
• Lay the filter paper with oil drops together with the frame at a place with no blown dust, let it
stand for 2~4h, observe the diffusion formation of the patch, and make a judgment through
comparative analysis with the standard atlas (National Standard GB/T7607-2002 Filter Paper
Oil Patch Testing Method For Combustion Engine Oil)
3. Evaluation Standards
• 1 level: The core region and the diffusion ring in the filter paper patch picture are bright and
colorless or the color is light, and there are no obvious deposition rings. This indicates that
the oil is new or its service time is very short, there is no contamination, and it can be used
sequentially.
• 2 level: There is a clear bound between the deposition ring and the diffusion ring in the filter
paper patch picture, the diffusion ring is wide and the oil ring is bright. This indicates that the
service time of the oil is not long and the contamination extent is slight, the detergent
dispersant properties are good and it can be used sequentially.
• 3 level: The deposition ring in the filter paper patch picture is dull black, the diffusion ring is
wide and the oil ring is bright. This indicates that the service time of the oil is long and the
contamination extent is great, but the detergent dispersant properties are good and it can be
used sequentially.
• 4 level: The deposition ring in the filter paper patch picture is jet black, the diffusion ring
begins to lessen and the oil ring is light yellow. This indicates that the service time of the oil is
very long and the amount of the depositing sediments increases, the detergent dispersant
properties get worse, but it can be used sequentially.
• 5 level: The deposition ring in the filter paper patch picture is jet black and even presents a
fault state, it is not easy to be dried, the diffusion ring is narrow, and the oil ring is large with a
yellow color. This indicates that the contamination of the oil is already quite serious and
detergent dispersant abilities are poor, the detergent dispersant will be used up and it can't be
used anymore, then new oil should be used as the replacement.
• 6 level: There is only very black deposition ring and brown orange oil ring in the filter paper
patch picture, and the diffusion ring has disappeared completely. This indicates that the
contamination of the oil is already quite serious, the contamination impurities completely
gather in the deposition ring, and the detergent dispersant is used up, the detergent
dispersant abilities are lost, and it has already been long since the oil replacement time.
 Lubrication (WP12) - Lubrication System
Oil Pump
1. Check the inwall gap of the driving/driven
gears and pump cavity
• Measure with a plug guage to insert the
gap between the two, and when it is
beyond 0.3mm, replace with a new one.

2. Check the rear gap of the driving/driven

gears
• Insert the rear gap by using a plug gauge to
measure the 1200 three-point, the standard
is 0.05mm, and the use limit is 0.20mm.

Oil Cooler
Dip the oil cooler into water, block the exit, blow compressed air into the oil cooler entrance and observe
if there are bubbles in the water.
 Lubrication (WP12) - Oil Pan

Oil Pan
Replacement
Hint:
Part Drawing, refer to Chapter 15B, Lubrication–Lubrication System, Part Drawing.

1. Drain the lubricating oil

(a). Dismantle the oil drain bolt.

2. Dismantle the oil pan

(a). Dismantle the 12 oil pan support block fixing
bolts.
(b). Receive the oil from the oil pan with a clean
container.

3. Install the oil pan

(a). Install the 12 oil pan support block fixing bolts.
Torque: 25N•m

(b). Install the oil drain bolt.

Torque: 25N•m
(c). Fill lubricating oil.
 Lubrication (WP12) - Oil Filter

Oil Filter
Replacement
Hint:
Part Drawing, refer to Chapter 15B, Lubrication–Lubrication System, Part Drawing.
1. Dismantle the oil filter
(a). Unscrew the oil filter.
(b). Receive the oil from the oil pan with a clean
container.

2. Install the oil filter

(a). Screw down the oil filter.
• Apply clean oil to the sealing ring before
screwing.
 Lubrication (WP12) - Oil Pump

Oil Pump
Overhaul
Hint:
Part Drawing, refer to Chapter 15B, Lubrication – Lubrication System, Part Drawing.
1. Drain the oil, refer to Chapter 15A, Lubrication – Oil Pan, Replacement
2. Dismantle the oil pump

3. Check the oil pump, refer to Chapter 15B, Lubrication – Lubrication System, Testing &
Adjustment
4. Install the oil pump
Torque: 62.5±2.5N•m
 Lubrication (WP12) - Oil Cooler

Oil Cooler
Overhaul
Hint:
Part Drawing, refer to Chapter 15B, Lubrication–Lubrication System, Part Drawing.
1. Drain the oil, refer to Chapter 15B, Lubrication–Oil Pan, Replacement
2. Drain the coolant, refer to Chapter 14B, Cooling–Coolant, Replacement
3. Dismantle the oil cooler
(a). Dismantle the air pipe support of the crankcase.
(b). Dismantle the water gallery cover of the engine.

(c). Dismantle the oil cooler.

4. Check the oil cooler, refer to Chapter 15B, Lubrication–Lubrication System, Testing &
Adjustment
5. Install the oil cooler
(a). Install the oil cooler
Torque: 25N•m

(b). Install the water gallery cover of the engine.

Torque: 25N•m
Caution:
Check the sealing ring to find if there are damages,
if there are, replace it with a new one.
 Lubrication (WP12) - Oil Cooler
6. Fill the coolant, refer to Chapter 14B, Cooling–Coolant, Replacement
7. Fill the oil, refer to Chapter 15B, Lubrication–Oil Pan, Replacement
Engine Mechanical (WP12)

Engine Mechanical ........................... 16B-3

Part Drawing .................................. 16B-3
Precautions .................................... 16B-7
Testing & Adjustment ..................... 16B-8
Engine Assembly ........................... 16B-16
Replacement ................................ 16B-16
Engine Accessories ....................... 16B-17
Replacement ................................ 16B-17
Cylinder Head ................................. 16B-20
Replacement ................................ 16B-20
Rocker Arm and Valve ................... 16B-22
Replacement ................................ 16B-22
Timing Gear .................................... 16B-25
Replacement ................................ 16B-25
Camshaft ......................................... 16B-26
Replacement ................................ 16B-26
Flywheel and Flywheel Housing ... 16B-27
Replacement ................................ 16B-27
Piston and Connecting Rod .......... 16B-28
Replacement ................................ 16B-28
Crankshaft ...................................... 16B-30
Replacement ................................ 16B-30
Cylinder Body ................................. 16B-33
Replacement ................................ 16B-33
 Engine Mechanical (WP12) – Engine Mechanical

Engine Mechanical
Part Drawing
Engine Mechanical (WP12) – Engine Mechanical
 Engine Mechanical (WP12) – Engine Mechanical

1 Cylinder Body 32 Cylinder Head Bolt

2 Main Bearing Bolt 33 O-ring

3 Rear Camshaft Bushing 34 Hex Head Bolt

4 Camshaft Bushing 35 Core Plug

5 Core Plug 36 Core Plug

6 Core Plug 37 Core Plug

7 Nozzle Assembly 38 Pressure Sensor

 Engine Mechanical (WP12) – Engine Mechanical

8 Gasket 39 Sealing Washer

9 Front End Cover 40 Cylindrical Pin

10 Front Oil Seal, Crankshaft 41 Hex Head Bolt

11 Cylindrical Pin 42 Oil Filter Seat

12 Hex Head Bolt with Flange 43 Oil Filter

13 Hex Head Bolt with Flange 44 Hex Head Bolt

14 O-ring 45 Oil Pump

15 Hex Head Bolt 46 Oil Cooler

16 Oil Cooler Cover Assembly 47 Oil Pipe Assembly

17 O-ring 48 Strainer assembly

18 Hex Head Bolt 49 Gasket

19 Screw Plug 50 Wave Spring Washer

20 Cylinder Liner 51 Hex Head Bolt

21 Oil Dipstick Pipe Assembly 52 Pressure Limiting Valve

22 Oil Dipstick 53 Cylindrical Pin

23 Stud Bolt 54 O-ring

24 Locating Pin 55 Oil Pump Driving Gear

25 Locating Pin 56 Magnetic Screw Plug Assembly

26 Upper Half, Main Bearing 57 Sealing Washer

27 Lower Half, Main Bearing 58 Oil Pan Assembly

28 Upper Thrust Gasket 59 Cover Plate

29 Lower Thrust Gasket 60 Oil Pan Support Block

30 Hex Head Bolt 61 Flat Washer

31 Hex Socket Cap Head Screw 62 Hex Head Bolt

 Engine Mechanical (WP12) – Engine Mechanical

Precautions
1. When lifting or supporting the engine, DO NOT allow the jack to come into contact with the
oil pan. When putting down the engine, support the engine outside the engine mount and
flywheel housing by the engine supporting plate, wood frame or other similar tools.
2. When dismantling the intake system, cover the air inlet to prevent foreign matters from
going into the cylinder. If foreign matters go into the cylinder, the cylinder and other parts
may be damaged seriously when the engine is operating.
3. Make sure to disconnect the grounding cable of the battery when conducting maintenance
on the engine body. When it is necessary to supply power to the engine in the course of
inspection or other similar work, pay special attention because short circuit may occur.
4. In order to protect and lubricate the sliding surface in the course of initial operation, apply
a large amount of engine oil to the sliding surface.
5. When disassembling the valve parts, piston, piston ring, connecting rod, connecting rod
bearing and crankshaft journal bearing, place them in order and store.
6. When re-installing parts, install them in their original positions, as shown before
disassembly.
7. When dismantling gaskets, oil seals and other similar parts, make sure to replace them
with new parts.
8. If liquid gaskets are used on parts, dismantle all old gaskets, clean the parts and remove
any oil, grease, water and contaminants, then apply the specified liquid gasket and install
those parts.
9. After applying sealant on a part, install the part within 7 minutes. If not, remove the sealant
from the part and re-apply sealant.
10. In the process of assembly and installation, fasten the part to the specified fastening
torque, and make sure to install the parts correctly.
 Engine Mechanical (WP12) – Engine Mechanical

Testing & Adjustment

Compression Pressure
Measure the compression pressure using the battery and starter motor under no fault state when
the engine cools (the water temperature is 20℃).
1. Dismantle the fuel injector
(a). Dismantle the oil inlet pipe of the fuel injector.
(b). Dismantle the oil return pipe of the fuel injector.

(c). Disconnect the wiring harness of the fuel injector.

(d). Dismantle the fixing bolts of the fuel injector.

2. Install a pressure gauge

(a). Install the pressure gauge into the fuel injector
hole.

3. Measure the compression pressure

(a). Run the starter motor, and read the compression
pressure when the pressure gauge pointer is
stable.
Caution:
y Remember that air will be suddenly emitted
from the fuel injector hole when the motor is
running.
y Measure the pressure of all cylinders.
y When disconnecting the wiring harness joint,
ECM will identify it as a fault and record the
fault code. After finishing measurement, make
sure to eliminate the ECM memory.
(b). Drop engine oil into the cylinder, and then
measure the compression pressure again.
 Engine Mechanical (WP12) – Engine Mechanical

y If the compression pressure rises, it shows that the

clearance between the piston ring and cylinder
liner is too big.

Pressure Difference between

Item Compression Pressure
Cylinders
Standard Value 2.6~2.8MPa 200kPa
Adjust the valve clearance
Adjust the valve clearance in two steps: set the No.1 cylinder at the top dead center on the compression
stroke, and then set the No.6 cylinder at the top dead center on the compression stroke.
1. Set the No.1 (or No.6) cylinder at the top dead
center on the compression stroke
(a). Rotate the crankshaft forward, and align the OT
rule line of the flywheel with the pointer. Inspect
whether there is a clearance between the cam and
rocker arm of the No.1 (or No.6) cylinder (top dead
center on the compression stroke) at this point.

2. Adjust the valve clearance

(a). Adjust the clearance between the fixing seat and
rocker arm.
y Fully loosen the adjusting screws of the
rocker arm.
y Insert a thickness gauge, adjust with the
adjusting screws of the fixing seat, and then
fix with the lock nuts.
y Loosen the adjusting screws of the fixing
seat gradually and re-adjust to such a
degree that the thickness gauge can be
inserted and dismantled flexibly, and then fix
the lock nuts of the fixing seat.
(b) Adjust the clearance between the valve and rocker
arm.
y Fully loosen the adjusting screws of the
rocker arm.
y Insert a thickness gauge between the rocker
arm and cam, adjust with the adjusting
screws of the rocker arm, and then fix with
the lock nuts.
y When inserting the thickness gauge,
fastening the adjusting screws of the rocker
arm, until the thickness gauge stops moving.
y Loosen the adjusting screws of the rocker
arm gradually and re-adjust to such a
degree that the thickness gauge can be
inserted and dismantled flexibly, and then fix
the lock nuts of the rocker arm.
 Engine Mechanical (WP12) – Engine Mechanical

Item Standard Value

Intake Valve Clearance 0.3mm
Exhaust Valve Clearance 0.4mm
Exhaust Valve Brake Clearance 0.25mm

Cylinder No. 1 2 3 4 5 6
Condition Valve Arrangement EXH IN EXH IN EXH IN EXH IN EXH IN EXH IN
Top Dead Center
Valve to ○ ○ ○ ○ ○ ○
of No.1 Cylinder
be
Top Dead Center
adjusted ○ ○ ○ ○ ○ ○
of No.6 Cylinder

Ream the valve seat

1. Ream the valve seat
(a). Install the locating bar on the reamer.
(b). Insert the locating bar into the valve guide for
location.
(c). Slight press the locating bar, and rotate clockwise.
y Ream the inner and outer cone faces, and
then ream the working cone face.

Item Standard Value

Width of Working Cone Face 1.5~1.8mm
Ream the valve guide
1. Ream the valve guide
(a). Use the tap wrench to rotate the reamer
downwards clockwise.
(b). Insert the locating bar into the valve guide for
location.
(c). Slight press the locating bar, and rotate clockwise.
y Ream the inner and outer cone faces, and
then ream the working cone face.

Grind the valve

1. Grind the valve seat
(a). Grind the valve by a grinding machine.
y The rotating and beating frequency of the
grinding machine can be adjusted.
(b). After grinding and cleaning, inspect the sealing
condition of the valve by kerosene.
 Engine Mechanical (WP12) – Engine Mechanical
Inspect and adjust the radial clearance of the camshaft
1. Measure the inside diameter of the bushing
(a). Inspect whether each shaft hole bushing is
installed securely.
(b). Inspect whether the oil gallery and oil hole are
through.
(c). Measure the inside diameter of each bushing by
an inside micrometer.

(d). Measure the outside diameter of each camshaft

bearing by an outside micrometer.

Item Standard Value

Radial Clearance of Camshaft 0.04~0.12mm

Inspect and adjust the axial clearance of the camshaft

1. Measure the axial clearance of the camshaft
(a). Inspect whether there are damages and burrs on
the camshaft thrust groove, thrust baffle plate and
cylinder body joint face.
(b). Insert the thrust baffle plate into the thrust ring
groove, and fix the baffle plate by two screws.
(c). Inspect the axial clearance of the camshaft by a
dial indicator.

Item Standard Value

Axial Clearance of Camshaft 0.1~0.4mm
 Engine Mechanical (WP12) – Engine Mechanical
Inspect and adjust the axial clearance of the crankshaft
1. Measure the axial clearance of the crankshaft
(a). Fix the dial indicator at the crankshaft end by a
magnetic dial indicator seat.
(b). Prize the crankshaft up and down.
y The crankshaft shall go flexibly when
rotating it, free from various jamming
phenomenon.
(c). If the clearance exceeds the range, replace the
crankshaft gasket.

Item Standard Value

Axial Clearance of Crankshaft 0.052~0.255mm

Inspect and adjust the radial clearance of the crankshaft

1. Measure the radial clearance of the crankshaft
(a). Measure each main journal of the crankshaft by an
outside micrometer.

(b). Measure each connecting rod journal of the

crankshaft by an outside micrometer.

(c). Install the main bearings of the crankshaft in the

cylinder body and crankcase seat holes, and
tighten with a torque of 250N.m. Measure the
inside diameter of each bearing by an inside
micrometer.
Caution:
The main bearing with oil groove is the upper half,
and the bearing without oil groove is the lower half.

Item Standard Value

Radial Clearance of Crankshaft 0.095~0.163mm
 Engine Mechanical (WP12) – Engine Mechanical
Inspect and adjust the piston ring clearance
1. Measure the piston ring gap clearance
(a). Measure the piston ring gap clearance.
(b). If the clearance exceeds the range, replace the
piston ring.

2. Measure the piston ring side clearance

(a). Measure the piston ring side clearance by a
thickness gauge.
(b). If the clearance exceeds the range, replace the
piston ring.

Item Standard Value

Gap Clearance 0.4~0.6mm
Top Compression Ring
Side Clearance -
Gap Clearance 0.25~0.4mm
Second Compression Ring
Side Clearance 0.07~0.102mm
Gap Clearance 0.35~0.55mm
Third Oil Ring
Side Clearance 0.05~0.085mm

Inspect the fit clearance of the connecting rod

1. Measure the connecting rod big end
(a). Install the connecting rod into the connecting rod
big end, and tighten the connecting rod bolts.
(b). Measure the hole diameter of the connecting rod
bearing.
 Engine Mechanical (WP12) – Engine Mechanical

2. Measure the connecting rod small end

(a). Press the connecting rod small end bushing into
the shaft hole.
(b). Measure the inside diameter of the bushing.
(c). Measure the inside diameter of the piston pin hole
and the outside diameter of the piston pin.

Item Standard Value

Fit Clearance between Bearing and Crankshaft Connecting
0.059~0.127mm
Rod Journal
Fit Clearance between Connecting Rod Bushing and Piston
0.025~0.046mm
Pin
Fit Clearance between Piston Pin Hole and Piston Pin 0.003~0.014mm

Inspect the roundness of the cylinder liner

1. Measure the roundness of the cylinder liner
(a). Inspect whether the cylinder bores and spigots are
clean, corroded and damaged.
(b). Clean the cylinder bores and spigots with
trichloroethylene cleaning agent.
(c). Measure the inside diameter of the cylinder liner
by an inside micrometer.

(d). Measure two times respectively at the top, middle

and bottom.

Item Standard Value

Out of Roundness Lower than 0.04mm
 Engine Mechanical (WP12) – Engine Mechanical
Inspect the flatness of the cylinder body
1. Measure the flatness of the cylinder body
(a). Place a level ruler on the upper surface of the
cylinder body.
(b). Measure the clearance between the level ruler and
the upper surface of the cylinder body by a
thickness gauge.
Caution:
Three sections respectively in the front, middle and
rear of the upper surface need to be measured, and
the parts of the diagonal shall also be measured.
 Engine Mechanical (WP12) – Engine Assembly

Engine Assembly
Replacement
1. Turn off the battery switch, and then disconnect the battery negative cable.
2. Dismantle the oil inlet pipe of the engine. Refer to Chapter 11 Fuel – Oil-Water Separator,
Replacement.
3. Dismantle the intake pipe. Refer to Chapter 12 Intake – High-mounted Intake Pipe,
Replacement.
4. Dismantle the exhaust pipe. Refer to Chapter 13B Exhaust & Turbocharger – Exhaust Pipe,
Replacement.
5. Dismantle the transmission assembly. Refer to Chapter 31B Transmission – Transmission
Assembly, Replacement.
6. Drain coolant. Refer to Chapter 14 B Cooling – Coolant, Replacement.
7. Dismantle the intercooler hose. Refer to Chapter 14 B Cooling – Intercooler, Overhaul.
8. Dismantle the radiator hose. Refer to Chapter 14 B Cooling – Radiator, Overhaul.
9. Dismantle the auxiliary water tank hose. Refer to Chapter 14 B Cooling – Auxiliary Water
Tank, Replacement.
10. Dismantle the heater hose. Refer to Chapter 51 Heater & Air Conditioner – Heater Water
Pipe, Overhaul.
11. Dismantle the pipeline of the air conditioner compressor. Refer to Chapter 51 Heater & Air
Conditioner -- Refrigeration Pipe, Overhaul.
12. Dismantle the pipeline of the air compressor. Refer to Chapter 18B Engine Mechanical –
Engine Accessories, Overhaul.
13. Disconnect the wiring harness of the Engine ECU.
14. Dismantle the fixing bolts of the engine.
15. Install the fixing bolts of the engine.
16. Connect the wiring harness of the engine ECU.
17. Install the pipeline of the air compressor. Refer to Chapter 18B Engine Mechanical –
Engine Accessories, Overhaul.
18. Install the pipeline of the air conditioner compressor. Refer to Chapter 51 Heater & Air
Conditioner -- Refrigeration Pipe, Overhaul.
19. Install the heater hose. Refer to Chapter 51 Heater & Air Conditioner – Heater Water Pipe,
Overhaul.
20. Install the auxiliary water tank hose. Refer to Chapter 14B Cooling – Auxiliary Water Tank,
Replacement.
21. Install the radiator hose. Refer to Chapter 14B Cooling – Radiator, Overhaul.
22. Install the intercooler hose. Refer to Chapter 14B Cooling – Intercooler, Overhaul.
23. Fill coolant. Refer to Chapter 14B Cooling – Coolant, Replacement.
24. Install the transmission assembly. Refer to Chapter 31B Transmission – Transmission
Assembly, Replacement.
25. Install the exhaust pipe. Refer to Chapter 13B Exhaust & Turbocharger – Exhaust Pipe,
Replacement.
26. Install the intake pipe. Refer to Chapter 12 Intake – High-mounted Intake Pipe,
Replacement.
27. Install the oil inlet pipe of the engine. Refer to Chapter 11B Fuel – Oil-Water Separator,
Replacement.
 Engine Mechanical (WP12) – Engine Accessories

Engine Accessories
Replacement
1. Turn off the main power
2. Dismantle the generator. Refer to Chapter 19B Charging System – Generator, Overhaul.
3. Dismantle the starter. Refer to Chapter 18B Stating & Preheating System – Starter,
Overhaul.
4. Dismantle the heater. Refer to Chapter 18B Stating & Preheating System – Heater,
Overhaul.
5. Dismantle the steering pump. Refer to Chapter 42 Power Steering Mechanism – Steering
Pump Assembly, Replacement.
6. Dismantle the air compressor. Refer to Chapter 51 Heater & Air Conditioner – Air
Compressor, Overhaul.
7. Dismantle the water pump. Refer to Chapter 14B Cooling – Water Pump, Replacement.
8. Dismantle the cooling fan. Refer to Chapter 14B Cooling – Cooling Fan, Overhaul.
9. Dismantle the high-pressure pump. Refer to Chapter 11B Fuel – High-pressure Pump,
Replacement.
10. Dismantle the common-rail pipe. Refer to Chapter 11B Fuel – Common-rail Pipe,
Replacement.
11. Dismantle the fuel fine filter. Refer to Chapter 11B Fuel – Fuel Fine Filter, Replacement.
12. Dismantle the oil pan. Refer to Chapter 15B Lubrication – Oil Pan, Replacement.
13. Dismantle ECU. Refer to Chapter 17 Engine Control – ECU, Replacement.
14. Dismantle the air compressor.
(a). Disconnect the cooling water pipe of the air
compressor.
(b). Disconnect the intake and exhaust pipes of the air
compressor.
(c). Dismantle the lubricating oil pipe of the air
compressor.

(d). Dismantle the fixing bolts of the air compressor.

 Engine Mechanical (WP12) – Engine Accessories

15. Dismantle the oil-gas separator

(a). Dismantle the pipeline of the oil-gas separator.
(b). Dismantle the fixing bolts of the oil-gas separator.

16. Install the oil-gas separator

(a). Install the fixing bolts of the oil-gas separator.
(b). Install the pipeline of the oil-gas separator.

17. Install the air compressor

(a). Install the fixing bolts of the air compressor.
Torque: 63N.m

(b). Install the lubricating oil pipe of the air compressor.

(c). Connect the intake and exhaust pipes of the air
compressor.
(d). Connect the cooling water pipe of the air
compressor.

18. Install ECU. Refer to Chapter 17 Engine Control – ECU, Replacement.

19. Install the oil pan. Refer to Chapter 15B Lubrication – Oil Pan, Replacement.
20. Install the fuel fine filter. Refer to Chapter 11B Fuel – Fuel Fine Filter, Replacement.
21. Install the common-rail pipe. Refer to Chapter 11B Fuel – Common-rail Pipe, Replacement.
22. Install the high-pressure pump. Refer to Chapter 11B Fuel – High-pressure Pump,
Replacement.
23. Install the cooling fan. Refer to Chapter 14B Cooling – Cooling Fan, Overhaul.
 Engine Mechanical (WP12) – Engine Accessories
24. Install the water pump. Refer to Chapter 14B Cooling – Water Pump, Replacement.
25. Install the air compressor. Refer to Chapter 51 Heater & Air Conditioner – Air Compressor,
Overhaul.
26. Install the steering pump. Refer to Chapter 42 Power Steering Mechanism – Steering Pump
Assembly, Replacement.
27. Install the heater. Refer to Chapter 18B Stating & Preheating System – Heater, Overhaul.
28. Install the starter. Refer to Chapter 18B Stating & Preheating System – Starter, Overhaul.
29. Install the generator. Refer to Chapter 19B Charging System – Generator, Overhaul.
 Engine Mechanical (WP12) – Cylinder Head

Cylinder Head
Replacement
1. Disconnect the wiring harness of the fuel injector. Refer to Chapter 17 Engine Control –
Fuel Injector (WP12), Overhaul.
2. Disconnect the oil inlet pipe of the fuel injector. Refer to Chapter 17 Engine Control – Fuel
Injector (WP12), Overhaul.
3. Disconnect the oil return pipe of the fuel injector. Refer to Chapter 17 Engine Control –
Fuel Injector (WP12), Overhaul.
4. Dismantle the cylinder head
(a). Dismantle the valve chamber cover.
(b). Remove the cylinder gasket.

(c). Remove the valve tappet.

(d). Dismantle the clamping block of the cylinder head.
(e). Dismantle the fixing bolts of the cylinder head.

5. Install the cylinder head

(a). Install the fixing bolts of the cylinder head.
Torque: 200 N.m
(b). Install the clamping block of the cylinder head.
Torque: 100 N.m
(c). Install the valve tappet.

(d). Install the lock block of the cylinder head.

Torque: 25N.m
(e). Install the fixing bolts and nuts of the cylinder head.
Torque: 25N.m
(f). Install the cylinder gasket.
Caution:
Do not install reversely.
 Engine Mechanical (WP12) – Cylinder Head
6. Connect the oil return pipe of the fuel injector. Refer to Chapter 17 Engine Control – Fuel
Injector (WP12), Overhaul.
7. Connect the oil inlet pipe of the fuel injector. Refer to Chapter 17 Engine Control – Fuel
Injector (WP12), Overhaul.
8. Connect the wiring harness of the fuel injector. Refer to Chapter 17 Engine Control – Fuel
Injector (WP12), Overhaul.
 Engine Mechanical (WP12) – Rocker Arm and Valve

Rocker Arm and Valve

Replacement
1. Dismantle the cylinder head. Refer to Chapter 16B Engine Mechanical – Cylinder Head,
Replacement.
2. Dismantle the valve chamber cover
(a). Dismantle the fixing bolts of the valve chamber
cover.

3. Dismantle the rocker arm

(a). Dismantle the intake and exhaust valve rocker
arms.
(b). Dismantle the rocker arm support.

(c). Dismantle the rocker arm fixing seat.

(d). Remove the intake and exhaust valve rocker arms.

Engine Mechanical (WP12) – Rocker Arm and Valve

4. Dismantle the valve

(a). Dismantle the valve lock by a valve
dismantling/installing tool.
(b). Take out the valve spring and valve.
(c). Dismantle the valve guide.

5. Install the valve

(a). Install the valve guide by a valve guide bar.
(b). Install the valve spring.

(c). Install the valve lock by the valve dismantling/

installing tool.

6. Install the rocker arm

(a). Install the intake and exhaust valve rocker arms.

(b). Install the rocker arm fixing seat.

Torque: 105±5N.m
 Engine Mechanical (WP12) – Rocker Arm and Valve

(c). Install the rocker arm support.

(d). Install the intake and exhaust valve rocker arms.

7. Install the valve chamber cover

(a). Install the fixing bolts of the valve chamber cover.

8. Install the cylinder head. Refer to Chapter 16B Engine Mechanical – Cylinder Head,
Replacement.
 Engine Mechanical (WP12) – Timing Gear

Timing Gear
Replacement
1. Dismantle the engine accessories. Refer to Chapter 16B Engine Mechanical – Engine
Accessories, Replacement.
2. Dismantle the flywheel housing. Refer to Chapter 16B Engine Mechanical – Flywheel and
Flywheel Housing, Replacement.
3. Dismantle the timing gear
(a). Dismantle the intermediate idler.

4. Install the timing gear

(a). Install the intermediate idler.
y Align the air compressor driving gear with
the locating hole, and fix.
y Align the locating marks of the intermediate
idler and crankshaft gear.

5. Install the flywheel housing. Refer to Chapter 16B Engine Mechanical – Flywheel and
Flywheel Housing, Replacement.
6. Install the engine accessories. Refer to Chapter 16B Engine Mechanical – Engine
Accessories, Replacement.
 Engine Mechanical (WP12) – Camshaft

Camshaft
Replacement
1. Dismantle the timing gear chamber. Refer to Chapter 16B Engine Mechanical – Timing
Gear Chamber, Replacement.
2. Dismantle the camshaft

3. Install the camshaft

(a). Install the camshaft.
(b). Install the fixing bolts of the camshaft.

4. Install the timing gear chamber. Refer to Chapter 16B Engine Mechanical – Timing Gear
Chamber, Replacement.
 Engine Mechanical (WP12) – Flywheel and Flywheel Housing

Flywheel and Flywheel Housing

Replacement
1. Dismantle the transmission. Refer to Chapter 31 Transmission – Transmission Assembly,
Replacement.
2. Dismantle the flywheel
(a). Dismantle the fixing bolts of the flywheel.

3. Dismantle the flywheel housing

(a). Dismantle the fixing bolts of the flywheel housing.

4. Install the flywheel housing

(a). Install the fixing bolts of the flywheel housing.
Torque: First, tighten with 50±10N.m
symmetrically;
Second, tighten by 120°±5°;
Inspection whether the torque reaches
255N.m.

5. Install the flywheel

(a). Install the fixing bolts of the flywheel.
Torque: First, tighten symmetrically;
Second, tighten with 70±10N.m;
Then tighten by 90° two times.

6. Install the transmission. Refer to Chapter 31 Transmission – Transmission Assembly,

Replacement.
 Engine Mechanical (WP12) – Piston and Connecting Rod

Piston and Connecting Rod

Replacement
1. Dismantle the cylinder head. Refer to Chapter 16B Engine Mechanical – Cylinder Head,
Replacement.
2. Dismantle the oil pan. Refer to Chapter 15B Lubrication – Oil Pan, Replacement.
3. Dismantle the piston and connecting rod
mechanism
(a). Dismantle the fixing bolts of the connecting rod big
end.

(b). Beat the connecting rod by a nylon rod to loosen it.

(c). Take out the connecting rod and piston assembly.

4. Dismantle the piston

(a). Dismantle the piston ring.
(b). Dismantle the piston pin clamping spring.
(c). Beat out the piston pin, and remove the piston.
 Engine Mechanical (WP12) – Piston and Connecting Rod

5. Install the piston

(a). Put the piston components in a thermostat at 80 ℃
for 10 minutes, and the install the piston pin and
connecting rod immediately after taking them out.
Caution:
The 45° cutting face of the connecting rod big end
shall back on to the gap of the piston oil nozzle.

(b). Install the locating clamping springs the locating

grooves at both sides of the piston pin hole.
(c). Install the piston ring.
Caution:
The face of the compression ring with “TOP” or
upward mark must be face up. The oil ring has no
difference in both faces.

6. Install the piston and connecting rod

mechanism
(a). Install the piston into the cylinder liner by piston
pliers.
Caution:
Stagger the piston ring gaps by 120°, and keep the
gaps off at least 30° from the piston pin axis. Apply
oil on the outer surface of the piston and the inner
surface of the cylinder liner.

(b). Install the fixing bolts of the connecting rod big

end.
y Tighten the connecting rod bolts
symmetrically.
Torque: First tighten with 120N.m;
Then tighten in order by 90°±5°;
Inspect whether the torque reaches
210N.m.
Caution:
The connecting rod bolts can be used only once
repeatedly.
7. Install the oil pan. Refer to Chapter 15A Lubrication – Oil Pan, Replacement.
8. Install the cylinder head. Refer to Chapter 16A Engine Mechanical – Cylinder Head,
Replacement.
 Engine Mechanical (WP12) – Crankshaft

Crankshaft
Replacement
1. Dismantle the piston and connecting rod. Refer to Chapter 16B Engine Mechanical –
Piston and Connecting Rod, Replacement.
2. Dismantle the flywheel and flywheel housing. Refer to Chapter 16B Engine Mechanical –
Flywheel and Flywheel Housing, Replacement.
3. Dismantle the oil seal of the crankshaft
(a). Dismantle the crankshaft pulley.

(b). Dismantle the front oil seal of the crankshaft.

(b). Dismantle the rear oil seal of the crankshaft.

4. Dismantle the crankshaft

(a). Dismantle the crankcase.
y Dismantle the oil pressure regulator valve.
y Dismantle the fixing bolts of the crankcase.
Engine Mechanical (WP12) – Crankshaft

y Beat out the locating pin of the crankcase.

y Put down the crankcase.

(b). Put down the crankshaft.

5. Install the crankshaft

(a). Install the bearing.
(b). Adjust the radial clearance of the crankshaft. Refer
to Chapter 16B Engine Mechanical – Engine
Mechanical, Testing & Adjustment.
(c). Install the thrust gasket.
(d). Install the sealing ring.

(e). Install the crankshaft.

(f). Adjust the axial clearance of the crankshaft. Refer
to Chapter 16B Engine Mechanical – Engine
Mechanical, Testing & Adjustment.

(g). Install the crankcase.

y Clean the contact face between the cylinder
and crankcase, and apply 510 flange
sealant.
y Put on the crankcase.
y Beat in the locating pin of the crankcase.
 Engine Mechanical (WP12) – Crankshaft

y Install the fixing bolts of the crankcase.

Torque: First, 30 N.m;
Second, 80 N.m;
Third, 250 ±25 N.m.
y Install the oil pressure regulator valve.

6. Install the timing gear chamber. Refer to Chapter 16B Engine Mechanical – Timing Gear
Chamber, Replacement.
7. Install the oil seal of the crankshaft
(a). Install the rear oil seal of the crankshaft.

(b). Install the front oil seal of the crankshaft.

(b). Install the crankshaft pulley.

8. Install the flywheel and flywheel housing. Refer to Chapter 16B Engine Mechanical –
Flywheel and Flywheel Housing, Replacement.
9. Install the piston and connecting rod. Refer to Chapter 16B Engine Mechanical – Piston
and Connecting Rod, Replacement.
 Engine Mechanical (WP12) – Cylinder Body

Cylinder Body
Replacement
1. Dismantle the engine accessories. Refer to Chapter 16B Engine Mechanical – Engine
Accessories, Replacement.
2. Dismantle the crankshaft. Refer to Chapter 16B Engine Mechanical – Crankshaft,
Replacement.
3. Dismantle the cylinder liner
(a). Pull out the cylinder liner by a cylinder liner puller.

4. Install the cylinder liner

(a). Apply a layer of molybdenum disulfide powder on
the outer surface of the cylinder liner.
Caution:
DO NOT apply oil.
(b). Slightly press into the cylinder liner.
Caution:
The part of the cylinder liner, which is higher than the
top plane of the cylinder body, shall be within the
range of 0.05~0.10mm.
5. Install the crankshaft. Refer to Chapter 16B Engine Mechanical – Crankshaft, Replacement.
6. Install the engine accessories. Refer to Chapter 16B Engine Mechanical – Engine
Accessories, Replacement.
Engine Control
Engine Control .....................................17-3
Part Drawing .....................................17-3
Accelerator Pedal .............................17-4
Replacement ..................................17-4
ECU .......................................................17-5
Replacement ..................................17-5
Fuel Injector (WP10) ............................17-6
Replacement ....................................17-6
Fuel Injector (WP12) ............................17-8
Overhaul ...........................................17-8
High-pressure Pump (WP10) ............17-12
Replacement ...............................17-12
High-pressure Pump (WP12) ............17-15
Part Drawing ...................................17-15
Replacement...................................17-16
Common-rail Pipe ..............................17-18
Replacement...................................17-18
Fuel Pressure Sensor........................17-19
Replacement...................................17-19
Crankshaft Position Sensor..............17-20
Replacement...................................17-20
Camshaft Position Sensor ................17-21
Replacement...................................17-21
Water Temperature Sensor...............17-22
Replacement...................................17-22
Oil Pressure Sensor ..........................17-23
Replacement...................................17-23
Intake Pressure Sensor.....................17-24
Replacement...................................17-24
Intake Pressure Sensor –
Intercooler .....................................17-25
Replacement ...............................17-25
 Engine Control –Engine Control

Engine Control
Part Drawing

1 Water Temperature Sensor 5 Fuel Flowmeter Valve

Intake Pressure and Temperature
2 6 ECU
Sensor
3 Common-rail Pressure Sensor 7 Oil Pressure Sensor

4 Camshaft Position Sensor 8 Crankshaft Position Sensor

 Engine Control – Accelerator Pedal

Accelerator Pedal
Replacement
1. Turn off main power
2. Dismantle accelerator pedal
(a). Disconnect the connector of the wiring harness of
the accelerator pedal.
(b). Dismantle the fixing bolts of the accelerator pedal.

(c). Dismantle the fixing nuts of the accelerator pedal.

3. Install accelerator pedal

(a). Install the fixing nuts of the accelerator pedal.
Torque: 25N.m

(b). Install the fixing bolts of the accelerator pedal.

Torque: 25N.m
(c). Connect the connector of the wiring harness of the
accelerator pedal.
 Engine Control –ECU

ECU
Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle ECU
(a). Disconnect the connector of the wiring harness of
the ECU.

(b). Disconnect the fuel pipe of the ECU.

(c). Dismantle the fixing bolts of the ECU.

3. Install ECU
(a). Install the fixing bolts of the ECU.
Torque: 11±1N.m
(b). Connect the fuel pipe of the ECU.

(c). Connect the connector of the wiring harness of the

ECU.
 Engine Control – Fuel Injector (WP12)

Fuel Injector (WP12)

Overhaul
1. Turn off main power
2. Release fuel pressure
3. Dismantle intake manifold, refer to Chapter 16B, Engine Mechanical - Engine Accessories,
Replacement
4. Dismantle valve-chamber cover, refer to Chapter 16B, Engine Mechanical - Cylinder Head,
Replacement
5. Dismantle fuel injector
(a). Dismantle the fuel inlet pipe of the fuel injector.
(b). Dismantle the fuel return pipe of the fuel injector.
(c). Dismantle the wiring harness of the fuel injector.
Caution:
Cover the protective cap of the joint to prevent
pollution.

(d). Dismantle the pressure cap of the high-pressure

joint.

(e). Dismantle the high-pressure fuel pipe joint of the

fuel injector.

(f). Dismantle the bolts of the pressure plate of the fuel

injector.
 Engine Control – Fuel Injector (WP12)
(g). Pull out the fuel injector.
Caution:
Use special tools for dismantling the fuel injector,
and it is not allowed to apply force on the solenoid
valve to pull the fuel injector.

6. Inspect the fuel injector, refer to Chapter 11B, Fuel - Fuel System, Testing & Adjustment
7. Install fuel injector
(a). Install the pressure plate of the fuel injector.
(b). Insert the fuel injector.
Caution:
Dismantle the internal packing of the fuel injector
only before installation.
Caution:
Keep the fuel injector body, O-ring and seal washer
clean and in good condition in the installation
process of the fuel injector.

Caution:
The high-pressure joint, O-ring and seal washer can be used once only.
(c). Install the bolts of the pressure plate of the fuel
injector.
Torque: 3 N.m

(d). Loosen the bolts of the pressure plate to

completely loosen the fuel injector in the cylinder
head hole.
(e). Install the high-pressure fuel pipe joint of the fuel
injector.
Torque: 22.5±2.5N.m
Engine Control – Fuel Injector (WP12)
(f). Install the wiring harness of the fuel injector.
(g). Install the fuel return pipe of the fuel injector.
(h). Install the pressure cap of the high-pressure joint
of the fuel injector.
Torque: 17.5±2.5 N.m
Caution:
Dismantle the protective cap only before
installing the fuel pipe.

(i). Tighten the bolts of the pressure plate.

Torque: 8 N.m + 90°

(j). Tighten the pressure cap of the high-pressure

joint of the fuel injector.
Torque: 52.5±2.5 N.m
 Engine Control – Fuel Injector (WP12)

8. Install valve-chamber cover, refer to Chapter 16B, Engine Mechanical - Cylinder Head,
Replacement
9. Install intake manifold, refer to Chapter 16B, Engine Mechanical - Engine Accessories,
Replacement
10. Exhaust fuel system, refer to Chapter 11B, Fuel - Fuel System, Testing & Adjustment
 Engine Control – High-pressure Pump (WP12)

High-pressure Pump (WP12)

Part Drawing

1 Flange - Fuel Injection Pump 10 Hex Locking Nut

2 Common-rail Fuel Injection Pump 11 Oil Pipe

3 Gear - fuel injection pump 12 Hollow Bolt

4 Hex Head Bolt 13 Sealing Washer

5 O-ring 14 Oil Filler Pipe Cover Assy.

6 Hex Head Bolt 15 Oil Filler Pipe Assy.

7 Hex Head Bolt 16 Gasket - Oil Filler Pipe

8 Starter 17 Hex Head Bolt

9 Stud Bolt 18 Cover Plate

 Engine Control – High-pressure Pump (WP12)

Replacement
1. Release fuel pressure
2. Adjustment high-pressure pump timing
(a). Turn the engine.
(b). Penetrate the spacer bar through a timing hole and
fix the timing gear of the high-pressure pump.

3. Dismantle high-pressure pump

(a). Dismantle the high-pressure fuel pipe of the
high-pressure pump.
(b). Dismantle the low-pressure fuel pipe of the
high-pressure pump.
(c). Dismantle the oil pipe of the high-pressure pump.
(d). Disconnect the camshaft phase sensor.
(e). Dismantle the fixing nuts of the high-pressure
pump.
Caution:
When loosening the nuts of the high-pressure fuel
pipe, fix the fuel inlet joint of the high-pressure pump
with another wrench; if the fuel inlet joint is loosened
carelessly, tighten again at most once only, and
replace the gasket of the fuel inlet joint box.
Caution:
Cover the protective cap of the joint to prevent
pollution.

4. Install high-pressure pump

(a). Adjust the driving gear of the high-pressure pump
and align the timing mark.
Caution:
When handling and assembling the high-pressure
pump, do not let easily worn parts to bear weight,
comprising the high-pressure joints, low-pressure
joints, the fuel control unit, the gear pump and the
camshaft phase sensor.

(b). Align the assembly mark of the connecting plate of

the high-pressure pump.
 Engine Control – High-pressure Pump (WP12)

(c). Align the assembly notch mark of the flange of the

high-pressure pump.

(d). Tighten the fixing nuts of the high-pressure pump.

Torque: 63N.m
(e). Install the camshaft phase sensor.
(f). Install the oil pipe of the high-pressure pump.
(g). Install the low-pressure fuel pipe of the
high-pressure pump.
(h). Install the high-pressure fuel pipe of the
high-pressure pump.

5. Exhaust low-pressure fuel line, refer to Chapter 11B Fuel - Fuel System, Testing &
Adjustment
6. Exhaust high-pressure fuel line
(a). Unscrew the fuel injector and the high-pressure fuel pipe joint of the first cylinder, drive the diesel
engine to rotate by a starter motor, and tighten the joint nut when continuous diesel fuel free of
bubbles is discharged from the joint.
 Engine Control – Common-rail Pipe

Common-rail Pipe
Replacement
1. Release fuel pressure
2. Dismantle intake manifold, refer to Chapter 16A, Engine Mechanical - Engine Accessories,
Replacement
3. Dismantle common-rail pipe
(a). Dismantle the fuel inlet pipe of the common-rail
pipe.
Caution:
Cover the protective cap of the joint to prevent
pollution.
(b). Dismantle the common-rail pipe
Caution:
After dismantling the common-rail component, cover
the protective caps of the fuel injector, the
high-pressure oil pipe, the high-pressure pump and
the common-rail pipe.

4. Install common-rail pipe

(a). Install the common-rail pipe
Torque: 63N.m
(b). Install the fuel inlet pipe of the common-rail pipe.
Torque: 30±5N.m

5. Exhaust low-pressure fuel line, refer to Chapter 11A Fuel - Fuel System, Testing &
Adjustment
6. Exhaust high-pressure fuel line
(a). Unscrew the fuel injector and the high-pressure fuel pipe joint of the first cylinder, drive the diesel
engine to rotate by an electric starter, and tighten the joint nut when continuous diesel fuel free of
bubbles is discharged from the joint.
 Engine Control – Fuel Pressure Sensor

Fuel Pressure Sensor

Replacement
1. Turn off main power
2. Release fuel pressure
3. Dismantle fuel pressure sensor
(a). Disconnect the connector of the fuel pressure
sensor.
(b). Dismantle the fixing bolts of the fuel pressure
sensor.
Caution:
Cover the protective cap of the joint to prevent
pollution.

4. Dismantle fuel pressure sensor

(a). Install the fixing bolts of the fuel pressure sensor.
(b). Connect the connector of the fuel pressure sensor.

5. Exhaust low-pressure fuel line, refer to Chapter 11A Fuel - Fuel System, Testing &
Adjustment
6. Exhaust high-pressure fuel line
(a). Unscrew the fuel injector and the high-pressure fuel pipe joint of the first cylinder, drive the diesel
engine to rotate by an electric starter, and tighten the joint nut when continuous diesel fuel free of
bubbles is discharged from the joint.
7. Turn on main power
 Engine Control – Crankshaft Position Sensor

Crankshaft Position Sensor

Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle crankshaft position sensor
(a). Disconnect the connector of the crankshaft
position sensor.
(b). Dismantle the crankshaft position sensor.

3. Install crankshaft position sensor

(a). Install the crankshaft position sensor.
(b). Connect the connector of the crankshaft position
sensor.
 Engine Control – Camshaft Position Sensor

Camshaft Position Sensor

Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle camshaft position sensor
(a). Disconnect the connector of the camshaft position
sensor.
(b). Dismantle the camshaft position sensor.

3. Install camshaft position sensor

(a). Install the camshaft position sensor.
(b). Connect the connector of the camshaft position
sensor.
 Engine Control – Water Temperature Sensor

Water Temperature Sensor

Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle water temperature sensor
(a). Disconnect the connector of the water temperature
sensor.
(b). Dismantle the water temperature sensor.

3. Install water temperature sensor

(a). Install the water temperature sensor.
(b). Connect the connector of the water temperature
sensor.
 Engine Control – Oil Pressure Sensor

Oil Pressure Sensor

Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle oil pressure sensor
(a). Disconnect the connector of the oil pressure
sensor.
(b). Dismantle the fixing bolts of the oil pressure
sensor.

3. Install oil pressure sensor

(a). Install the fixing bolts of the oil pressure sensor.
(b). Connect the connector of the oil pressure sensor.
 Engine Control – Intake Pressure Sensor

Intake Pressure Sensor

Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle intake pressure sensor
(a). Disconnect the connector of the intake pressure
sensor.
(b). Dismantle the intake pressure sensor.

3. Install intake pressure sensor

(a). Install the intake pressure sensor.
(b).Connect the connector of the intake pressure sensor.
 Engine Control – Intake Pressure Sensor - Intercooler

Intake Pressure Sensor - Intercooler

Replacement
Hint:
Part Drawing, refer to Chapter 17, Engine Control - Engine Control, Part Drawing.
1. Turn off main power
2. Dismantle intake pressure sensor - intercooler
(a). Disconnect the connector of the intake pressure
sensor of the intercooler.
(b). Dismantle the intake pressure sensor of the
intercooler.

3. Install intake pressure sensor - intercooler

(a). Install the intake pressure sensor of the
intercooler.
(b). Connect the connector of the intake pressure
sensor of the intercooler.
Starting & Preheating System (WP12)

Starting & Preheating System ......... 18B-3

General ............................................18B-3
Precautions ......................................18B-4
Testing & Adjustment.......................18B-5
Ignition Switch .................................. 18B-6
Replacement ...................................18B-6
Auxiliary Starting Switch ................. 18B-7
Replacement ...................................18B-7
Preheating Relay .............................. 18B-8
Replacement ...................................18B-8
Starter ................................................ 18B-9
Replacement ...................................18B-9
Heater .............................................. 18B-10
Replacement .................................18B-10
 Starting & Preheating System (WP12) – Starting & Preheating System

Starting & Preheating System

General
Starter
The starting torque is the moment necessary to overcome the resistance from air compression in the
cylinder and the resistance from friction between the relatively moving parts of the engine itself and its
accessories when the engine is started.
The starting speed is the crankshaft speed necessary to start the engine successfully. For the starting of
the diesel engine for automobile, in order to prevent the cylinder from leaking air and too much heat from
dispersing, ensure that there is enough pressure and temperature in the cylinder at the end of the
compression, and also ensure that the fuel injection pump can establish sufficient fuel injection pressure
to form sufficiently strong air eddy in the cylinder, it requires very high starting speed, which can reach
150~300r/min. Or diesel spray is poor, the quality of gas mixture is bad, the engine is difficult to start. In
addition, the compression ratio of the diesel engine is larger than that of the gasoline engine, so the
starting torque for the diesel engine is greater, and the power of the starter necessary to start the diesel
engine is bigger than that necessary to start the gasoline engine.
The DC starter consists of a DC series motor, a control mechanism and an engaging/disengaging
mechanism. It is special for engine starting and needs powerful torque, so a large amount of current will
pass through it, which is up to several hundred amperes.
The DC motor is suitable for the starter as its torque is big at low speed, and gets smaller gradually with
the speed increasing.
The starter adopts the DC series motor, and its rotor and stator parts are made of thick copper wires with
rectangular cross section by winding; the driving mechanism is of a reduction gear structure; and the
control mechanism is based on a manner of electromagnetic attraction.
The driving gear of the reduction gear mechanism is linked with the engine flywheel to start the engine in
a manner of one-way driving. When the speed of the pinion on the motor is higher than that of the ring
gear of the engine flywheel, the motor drives the engine to rotate; when the engine’s speed is higher
than the motor’s, the power transmission relation between them automatically disappears.
The gear-reduction starter is mainly composed of electromagnetically engaged switch, reduction gear,
motor, starting gear (pinion) and overrunning clutch.
Intake Preheater
In order to improve the engine’s starting performance, an intake preheater is installed on the intake duct
of the engine. It is energized when the intake temperature or the temperature of cooling water is lower
than a certain value, and heats air in the air pipe, which is favorable for starting of the engine and
combustion of gas mixture. Generally, the intake preheater is composed of an electric gas mixture
preheater, an intake preheating temperature control switch, an intake preheating relay, etc.
Middle and low-power diesel engines are usually equipped with intake preheaters for cold start. When
the engine is started, after the preheater switch is turned on, heating wires are energized, get hot and
heat the valve body. The valve body extends when heated and forces the valve core to move down, and
its tapered end goes away from the fuel feed hole. Fuel flows into the inner chamber of the valve body
and is vaporized due to heating, the fuel vapor is injected from the inner chamber of the valve body and
ignited by the hot heating wires, and the flame is injected into the intake pipe to preheat intake air. When
the preheater switch is turned off, the power of heating wires are cut off, the valve body gets cold and
shrinks, the valve core moves up to force the tapered end to block the fuel feed hole, the flame goes out,
and preheating is stopped.
 Starting & Preheating System (WP12) – Starting & Preheating System

Precautions
1. The operating time of the starter shall not exceed 5 seconds. If the vehicle needs starting
many times, there must be an interval of at least 10 seconds between every two
operations.
2. The first maintenance for the motor is between 50,000~80,000km. Remove dirt inside, and
re-fill lubricating oil.
3. The second maintenance is between 40,000~50,000km. Inspect the wearing degree of the
carbon brush; if the carbon brush is worn too much, replace it. If not replaced and cleaned,
the contact face between the motor’s rotor and carbon brush is easy to damage, and the
motor needs to be replaced at that time.
4. The carbon brush is close to its limit between about 100,000~150,000km. If the vehicle
usually runs in a short distance and needs starting frequently, the motor shall be
maintained at a mileage below 80,000km; if the vehicle usually runs in a long distance and
needs starting infrequently, the motor can be maintained at a mileage above 80,000km.
5. Frequent maintenance and lubrication of the motor will not increase load and electric
current, and the motor is not easy to damage.
 Starting & Preheating System (WP12) – Starting & Preheating System

Testing & Adjustment

Ignition Switch
Inspect the continuity of various stages of the ignition switch by a multimeter.
Auxiliary Starting Switch
Inspect the continuity of various stages of the auxiliary starting switch by a multimeter.
Starter
Test the starting current, and measure the resistance of the starter cable.
Heater
Test the conduction between the intake preheater and power supply, and between the intake preheater
and grounding cable. Measure the resistance of the intake preheater.
 Starting & Preheating System (WP12) – Ignition Switch

Ignition Switch
Replacement
1. Turn off the main power
2. Dismantle the ignition switch
(a). Dismantle the trim panel of the steering column.

(b). Dismantle the ignition switch

y Disconnect the wiring harness of the ignition
switch.
y Dismantle the fixing bolts of the ignition
switch.

3. Inspect the ignition switch. Refer to Chapter 18A, Starting & Preheating System – Starting
& Preheating System, Testing & Adjustment.

4. Install the ignition switch

y Install the fixing bolts of the ignition switch.
Torque: 25N.m
y Connect the wiring harness of the ignition
switch.

(a). Install the trim panel of the steering column.

 Starting & Preheating System (WP12) – Auxiliary Starting Switch

Auxiliary Starting Switch

Replacement
1. Turn off the main power
2. Dismantle the auxiliary starting switch
(a). Disconnect the wiring harness of the auxiliary
starting switch.
(b). Dismantle the auxiliary starting switch

3. Inspect the auxiliary starting switch. Refer to Chapter 18A, Starting & Preheating System –
Starting & Preheating System, Testing & Adjustment.
4. Install the auxiliary starting switch
(a). Install the auxiliary starting switch.
(b). Connect the wiring harness of the auxiliary starting
switch.
 Starting & Preheating System (WP12) – Preheating Relay

Preheating Relay
Replacement
1. Turn off the main power
2. Dismantle the preheating relay
(a). Disconnect the wiring harness of the preheating
relay.
(b). Dismantle the fixing bolts of the preheating relay.

3. Install the preheating relay

(a). Install the fixing bolts of the preheating relay.
(b). Connect the wiring harness of the preheating
relay.
 Starting & Preheating System (WP12) – Starter

Starter
Replacement
1. Turn off the main power
2. Dismantle the starter
(a). Disconnect the wiring harness of the starter.
(b). Dismantle the starter.

3. Inspect the starter. Refer to Chapter 18B, Starting & Preheating System – Starting &
Preheating System, Testing & Adjustment.
4. Install the starter
(a). Install the starter.
Torque: 60N.m
(b). Connect the wiring harness of the starter.
 Starting & Preheating System (WP12) – Heater

Heater
Replacement
1. Turn off the main power
2. Dismantle the heater
(a). Disconnect the wiring harness of the heater.
(b). Dismantle the heater.

3. Inspect the heater. Refer to Chapter 18A, Starting & Preheating System – Starting &
Preheating System, Testing & Adjustment.
4. Install the heater
(a). Install the heater.
Torque: 25N.m
(b). Connect the wiring harness of the heater.
Charging System (WP12)

Charging System .............................. 19B-3

General ......................................... 19B-3
Precautions ................................... 19B-5
Principle of Operation ................... 19B-6
Testing & Adjustment .................... 19B-8
Generator .......................................... 19B-9
Overhaul ....................................... 19B-9
 Charging System (WP12) – Charging System

Charging System
General
The generator is the main power supply of a vehicle. Its function lies in that it supplies power to all
electrical equipment (starter not included), and charges the battery at the same time when the engine is
operating normally.
Currently, all the vehicles adopt a three-phase AC generator, and its inside is provided with a diode
rectifier circuit which can rectify alternating current into direct current. Therefore, the direct current can
be output from the AC generator of a vehicle. The AC generator must be equipped with a voltage
regulator, which can control the output voltage of the generator and keep it basically constant to meet the
demands of the vehicle’s electrical equipment.
Rotor
The function of a rotor is to generate magnetic field.
The rotor consists of claw poles, a yoke, a field winding, slip rings, a rotor shaft, etc.
Two claw poles, which are processed into a beak shape, are press-installed on the rotor shaft, and the
field winding and yoke are installed in the cavities of the claw poles.
The slip rings, made of copper rings which are insulated with each other, are press-installed on and
insulated with the rotor shaft, and they are respectively connected with both ends of the field winding.
When the slip rings are supplied with direct current, current passes through the field winding, and axial
flux is generated accordingly to magnetize one claw pole into N pole and the other one into S pole, so
that six pairs (or eight pairs) of staggered magnetic poles are formed.
Stator
The function of a stator is to generate alternating current.
The stator is installed outside the stator, and fixed with the front and rear end covers of the generator.
When the rotor rotates inside, the flux in the stator winding changes, and alternate induced electromotive
force is generated in the stator winding.
The stator consists of a stator core and a stator winding (coil).
The stator core is formed by stacking silicon steel sheets which have grooves in the inner ring and are
insulated with each other.
The stator winding includes three groups of coils, which are symmetrically embedded in the grooves of
the stator core. The three-phase winding can be connected with two methods (star connection and delta
connection), both of which can generate three-phase alternating current.
Rectifier
The function of a rectifier is to convert the three-phase alternating current of the stator winding into direct
current.
The rectifier consists of current plates and rectifier diodes. The rectifier of the six-diode AC generator is
formed by that six diodes are respectively press-installed (or welded) on two mutually insulated plates.
The two plates includes one positive plate (with output end bolts) and one negative plate, the latter is
directly connected (grounded) with the generator housing, and the rear cover of the generator can be
directly used as the negative plate.
The six rectifier diodes fall into positive diodes and negative diodes. The diodes leading out the positive
pole are called positive diodes, and three positive diodes are installed on the same plate which is called
positive plate; the diodes leading out the negative pole are called negative diodes, and three negative
diodes are installed on the negative plate or directly on the rear cover.
 Charging System (WP12) – Charging System
End Cover and Brush Assembly
Generally, the end cover is divided into two parts (front end cover and rear end cover), used for
supporting the rotor, stator, rectifier and brush assembly. The end cover is usually cast by aluminum alloy
which can effectively prevent magnetic leakage and has good heat dispersion. The brush assembly is
installed on the rear end cover.
The brush assembly consists of brushes, brush carriers and brush springs.
The function of the brush is to introduce power into the field winding through slip rings. Two brushes are
respectively installed in the holes of the brush carriers, and they keep in contact with the slip rings
through the pressure from springs.
The contact between the brushes and slip rings shall be in good condition, or the power generated by
the generator will be insufficient due to too small field current.
 Charging System (WP12) – Charging System

Precautions
The AC generator and regulator have a simple structure and are easy to maintain. If they are used
correctly, there will be little faults and their service life will be long; if used incorrectly, they will be
damaged soon. Therefore, the following points shall be noted in use and maintenance:
1. The battery’s pole to be grounded must be negative pole. Do not connect inversely. Or the
electronic components of the generator or regulator will be burnt.
2. The connection between the generator and battery shall be secure. If they are
disconnected suddenly, over-voltage will be generated to damage the electronic
components of the generator or regulator.
3. When the generator is operating, do not use the method of sparking to inspect whether the
generator generates power, or the rectifier diodes will be burnt.
4. Once detecting that there is a fault in the AC generator or regulator, overhaul the defective
part immediately and eliminate the fault in time. Or the fault will result in more serious
faults or the lack of electricity of the battery, and thus the vehicle can not move.
5. When the regulator is matched for the AC generator, the voltage grade of the AC generator
must be the same with that of the regulator, the grounding type of the generator must be
the same with that of the regulator, and the power of the regulator shall not be lower than
that of the generator. Or the system can not operate normally.
6. The line connection must be correct. At present, the installation positions and connection
modes of the regulators for various models are different. Pay special attention during
connection.
7. The regulator must be under the control of the ignition switch. When the generator stops,
turn off the ignition switch. Or the field circuit of the generator will always stay in on-state,
which will not only burn the field coil, but also cause the lack of electricity of the battery.
8. When the generator or regulator needs to be dismantled from the vehicle for overhaul
because it is defective, turn off the ignition switch and all electrical equipment at first, and
dismantle the negative cable of the battery and then the conductor joint on the generator.
 Charging System (WP12) – Charging System

Principle of Operation

Alternating current, which is generated by induction in the three-phase winding of the AC generator’s
stator, rectified into direct current by the three-phase bridge rectifier circuit, as shown in the diagram.
The diode has one-way continuity. When forward voltage is applied to the diode, the diode conducts;
when backward voltage is applied to the diode, the diode picks off.
 Charging System (WP12) – Charging System

When the stator’s three-phase winding and six rectifier diodes are connected according to the circuit
diagram, the output ends B and E of the generator will output a ripple DC voltage, as shown in the
diagram. This is the rectification principle.
 Charging System (WP12) – Charging System

Testing & Adjustment

Maintenance
1. Inspect the driving belt of the generator.
2. Inspect the connection of conductors.
3. Inspect whether there is noise during operation.
4. Inspect whether the generator generates power normally.
5. Inspect whether there is over-charger for the battery.
Overhaul
1. External Cleaning
(a) After external cleaning, rotate the rotor of the generator by hand and inspect whether it rotates
flexibly and there is noise during rotation so as to judge whether the bearing is defective.
2. Measurement of Whole Machine
(a) Measure the forward resistance and back resistance (ground end) between the output terminal B
and housing of the generator, and compare them with the standard values. If the measured
values fail to meet the standard values, it shows that the rectifier is defective.
(b) Measure the resistance between the positive brush terminal and negative brush of the generator,
and compare it with the standard value. If the measured value fails to meet the standard value, it
shows that the brush and field winding are defective.
No-load Test
1. Install the generator on the fixture of the test bed, select the sleeve and rubber drive joint,
adjust the fixture in a position where the test generator is concentric with the spindle of
the adjustable speed motor.
2. Inspect whether the connection is correct, and if there is no problem. The adjustable
speed motor on the test bed can be started only after making sure that there is no problem
in connection.
3. Start the adjustable speed motor on the test bed, and use the battery (or power supply on
the test bed) to supply field current to the generator. Increase the speed of the generator
step by step. When the speed is up to 500 ~ 800 r/min, cut off the external power supply
which supplies field current to the generator. The generator shall be able to start
self-exciting power generation.
4. Increase the speed continuously, and observe the reading of the voltmeter at the same
time.
y When the voltage is up to the rated voltage, record the speed of the generator. Turn off the
adjustable speed motor switch, and the no-load test ends.
5. Analyze the no-load test data.
y Compare it with the standard value. If the speed is higher than the no-load speed, it shows
that the generator is defective, and the generator shall be disassembled and tested. If it is
unsure that the generator is defective, continue to do the load test.
Load Test
1. Adjust the rheostat to the maximum resistance position.
2. Start the adjustable speed motor, and increase the generator’s voltage up to the rated
value.
3. Keep the voltage unchanged, and meanwhile increase the generator’s speed and output
current to increase the speed up to the rated value. Record the output current value at the
moment. Turn off the adjustable speed motor switch, and the no-load test ends.
4. Analyze the load test data.
y Compare it with the standard value. If the output current reaches the rated current, it shows
that the generator is in good condition; if not, it shows that the generator is defective, and
the generator shall be disassembled and tested.
 Charging System (WP12) – Generator

Generator
Overhaul
1. Turn off the main power
2. Dismantle the generator
(a) Dismantle the belt.
(b) Disconnect the wiring harness of the generator.
(c) Dismantle the fixing bolts of the generator.

3. Inspect the generator. Refer to Chapter 19A, Charging System – Charging System, Testing
& Adjustment.
4. Install the generator
(a) Install the fixing bolts of the generator.
Torque: 60 N.m
(b) Install the tension nuts of the generator, and install
the belt.
(c) Connect the wiring harness of the generator.