01 Dk4a Engine

Service Manual of DK4A Diesel Engine
Mianyang Xinchen Power Machine Co., Ltd.
August, 2007
1
Table of Contents
Safety Warning ································································································································· 1
Main matched vehicle types·············································································································· 2
Service Manual of DK4A Diesel Engine Care and Maintenance ··················································· 3
Service Manual of DK4A Diesel Engine Electric Control System·················································· 13
Service Manual of DK4A Diesel Engine Mechanical System························································· 42
Service Manual of DK4A Diesel Engine Function Diagnosis and Fault Remedy ························· 114
Afterword······································································································································ 129
2
Safety Warning
√ The engine, whose operating range must not be changed at will and whose delivery pressure must not be
regulated freely, must not be remodeled at pleasure.
√ The engine in operation must not be adjusted or wiped.
√ Running components of engine must not be approached by loose clothes and long hair or touched by
hand.
√ Upon the operation of engine, its exhaust system and supercharging system are very hot and must not be
touched by body in order to avoid the scald.
√ Do not open the coolant filler cap directly as the engine is very hot, with a view to avoid the scald by hot
fluid stream.
√ The engine at high temperature must not be stopped immediately; instead it should idle for at least 5 min.
√ After being dismounted, both fuel injector and copper washers should be assembled in a one-to-one
manner.
√ The oil-water separator should be drained timely in accordance with instructions.
√ The engine, together with components such as wires across the vehicle, fuel pipes and rubber hoses,
must not get close to exhaust pipe, supercharger and rotational parts.
1
Main matched vehicle types
SUV light-duty bus Cross-country vehicle
Pickup MPV light-duty truck
2
Care and Maintenance
Notes for Engine Repair

1. Issue of prevention against invasion by foreign bodies
(a) The invasion of foreign bodies such as dust, gravel and metal grains into engine may invite the problem.
(1) Thoroughly clear the sand and soil on the exterior of engine.
(2) Disassembled parts should be covered by plastic film to prevent the intrusion of dust.
2. Issue of protection of components from scuffing
(a) The injury of fitting surface or rotating section on a component may lead to the oil leakage or burnout.
(1) Instead of a screwdriver, a plastic hammer should act gently on the fitting surface of a component to be
disassembled.
(2) Fixation of a component on a jaw vice, if required, should be done through an aluminum sheet, rather
than being accomplished directly.
3. Issue of component cleaning
(a) Every component, prior to the assembling, should be cleaned fully and then dried in air while being spread
with appointed grease.
(b) Components, for which the alkaline chemical is forbidden to be used, include aluminum ones and rubber
ones (cylinder cover gasket etc.).
(c) Components, for which the cleaning oil is forbidden to be used, are rubber ones (cylinder cover gasket etc.).
4. Issue of assembling position and direction
(a) Assemble every part as per the pre-assembly position and direction.
(b) If there is a requirement that pre-assembly position and direction be clearly marked out, it must be strictly
followed;
(c) Take care not to change the assembling position and direction of every dismounted part being arranged and
realigned in the disassembling order;
(d) This must be followed for parts marked with assembling position and direction.
5. For an engine in maintenance, its components that have been dismounted must be placed on a work
support prior to the maintenance.
6. Those dismounted components must be arranged and realigned in the disassembling order.
7. A sliding or rotating section must be spread with engine oil.
8. Nonreusable parts, such as washers and gaskets, must be renewed.
9. Basic notes
(a) Pre-coated bolt
(1) A pre-coated bolt is one whose thread has been coated with sealant.
(2) Such a bolt being retightened or loosened or turned must be pre-coated with appointed sealant.
Note: the torque being calibrated must not be below the lower limit of allowable tightening torque.
3
(3) In the reuse of a pre-coated part (bolt etc.), the bolt thread, together with the inside of tap hole, must be
cleared of old sealant at first, later degreased with gasoline, dried with compressed air, and then spread with
appointed sealant, finally tightened under a required torque.
(4) Depending on the applied sealant, sometimes the bolt must be laid up for specified period to allow the
hardening of sealant.
10. Dismounting of components in fuel system

(a) Site of dismounting the components in fuel system
(1) The disassembly should be done on a airy site where there are no spark-generating devices such as
electric welder, grinder, motor and furnace etc.;
(2) Please do not operate in a pit or its neighborhood which might have been full of gaseous fuel.
(b) Dismount the components in fuel system
(1) Extinguishers must be prepared prior to the formal operation;
(2) In order to prevent the generation of static electricity, the site ground must be sprinkled with enough
water when the fuel changeover switch, vehicle and fuel tank are being grounded;
(3) Please do not use the electric apparatuses such as electric pump and working light, as they may spark or
become very hot;
(4) Please do not use those tools which may spark in the operation;
(5) Rags with fuel must be handled separately.
11. Dismounting of components in engine intake system
(a) The intrusion of metal grains into intake channels will endanger the engine and turbocharger etc.;
(b) During this dismounting course, parts in intake system that have been taken down must be plugged with
clean rags or adhesive tapes, so does the opening on engine side;
(c) It must be made sure that no metal or gravel has invaded the intake components being installed.
4
12. Handling of hose clamps
(a) Make sure of the insertion depth of hose and the position of hose clamps before removing the hose so that
these clamps can be totally restored in due course;
(b) Those deformed or loosened clamps must be changed;
(c) As the hose is being reused, its clamps must be placed where the original clamps are located;
(d) A plate-spring clamp, upon its installation, must be tightened by applying force in the arrow direction.
13. Applicable fuel (recommended): in summer： 0#

In winter：-10#
At -20℃：-20#
At -30℃：-35#
14. Applicable grease (recommended): API CF-4(or higher) 20W-50
GB11122 CF-4(or higher) 20W-50
Note：
(1) Make sure to use clean oil with required brand, which must never be replaced by normal oil in order to
avoid the occurrence of accidental faults such as engine scuffing and shell sticking.
(2) The oil into diesel engine must not contain impurities and water. The area near fuel tank filler should
remain clean.
(3) It is strictly forbidden to mix diesel fuel or oil of different brands and manufacturers. Mixture of both new
and old oil is strictly prohibited in the replacement of oil for technical maintenance.
(4) Change the oil filter timely, as regulated.
15. Choosing of coolant
(1) The coolant should be anti-freeze and rust-proof to prevent water channel (jacket) from scaling，as the
scale may result in such faults as high water temperature and engine scuffing.
(2) As the antifreeze is harmful to human body, it should be stored in an original vessel to avoid the contact by
some person.
5
(3) In the absence of antifreeze, distilled water or clean soft water (boiled water, snow water, rainwater) may
be used. But water from river, well or stream or tap water, which is hard and intended to be used, must be
kept clean and softened by adding 2g trisodium phosphate (TSP) into 1L water.
Note：
(1) In the use of a diesel engine, it is disallowed to add freely some coolant against the regulations in this
manual just because of the insufficiency of coolant.
(2) If the leakage of cooling system leads to the insufficiency of coolant, after the remedy of fault, the same
brand of coolant should be added when the engine has become cool.
(3) Do not use inferior coolant or confuse various brands of coolant, otherwise the lifespan of diesel engine
may be seriously affected by corrosion and scaling etc.
(4) It is strictly banned to use various kinds of unprocessed hard water. Otherwise, the consequent scaling may
bring about such faults as high water temperature of engine and engine scuffing.
Technical Characteristics
1. Main technical parameters of generator and starter
Name Item Parameter
Nominal voltage 14V

Generator
Rated current 80A
Voltage 12V
Starter
Delivered power 2.7kW
Name of bolt or
Name of bolt or nut Tightening torque Tightening torque
nut
Camshaft timing gear First：85 N·m

90 N·m～98N·m
bolt Second：another
Cylinder head bolt 90°tightening
Bolt on main bearing First：50 N·m±5.0N·m Third：another
cap Second：another 90°tightening 90°tightening
Flywheel bolt 178N·m

Crankshaft pulley
365N·m
Connecting-rod First：35 N·m±3.5 N·m bolt
nut Second：another 90°tightening
Note: a special torque wrench must be used for tightening main bolts and nuts.
Specifications of main accessories
Accessory systems and their name Type Accessory systems and their name Specifications
Lubrication Oil pump Rotor type

Water pump Centrifugal type
system
Oil filter Full flow
Cooling system
Fuel filter Full flow
Thermostat Wax type
Fuel supply High-pressure pump Cylinder type
system
High-pressure pump CP1H high-pressure pump Pre-heating Voltage of heater
12V
system plug
Fuel injector 6 orifices
Electric EGR
Intake system Supercharger Exhaust turbocharging EGR system
system
6
Operating of Diesel Engine
a. Pre-start preparation
● Check if various engine components are normal and correctly and securely connected, and if every rotating
part is flexible;
● Supplement enough oil, fuel and cooling water as required, and observe if there is leakage;
Note: when the oil level is below the warning mark on dipstick, enough oil should be added timely lest a
major accident might be caused.
● Check the looseness of water pump belts;
● Check the level of electrolyte inside the battery;
● Check the tightening of various connectors on electric devices such as battery, generator and starter;
● Any gas into fuel system must be got rid of prior to the start of diesel engine.
Air discharging method：
Firstly loosen the fuel supply pipe and pump the fuel with hand pump till no bubble exists. And then
unscrew the screw cap at the outlet of fuel injection pump, drive this pump with starter until fuel is seen out
of pump outlet.
b. Starting of fuel engine
In any case, the engine must be started under zero loads (in neutral position)
● Switch on the power supply with key to observe if every electric instrument can indicate normally.
● Start the engine.
● Place the switch in the starting position, where the engine should have been started within 15s. If not, a
second starting attempt should be made after a 2s interval. If three consecutive starting attempts are in vain,
the root cause should be investigated. No further attempt should be made before the remedy of fault. Upon
the successful start of engine, the button of switch should be released immediately to allow the complete
disengagement between starter gear and flywheel toothed ring lest the starter is damaged due to reverse
driving.
● The engine should idle for 3－5 minutes after being started. Meanwhile, the indication of oil pressure gauge
and the cooling water circulation should be checked. Immediately running the just-started engine at a
high speed is strictly banned.
c. Coldstart of fuel engine
In a cold environment, the engine will be hard to be started. The lower the temperature is, the more difficult the
start becomes. At ＜ -15℃ temperature, the difficulty in starting might be caused by the following aspects
without coldstart assistance:
● As the environment temperature is low, the temperature of gas into cylinders is low, so is the compression
end temperature inside the engine. As a result, the compression ignition temperature can’t be reached to
burst into combustion.
● In a cold environment, the diesel fuel has higher viscosity and inferior atomization quality, which make the
ignition very difficult.
● Low environmental temperature may contribute to higher oil viscosity, greater starting resistance torque,
lower starting speed, more air leakage in compression, higher heat transfer rate of working medium to the
surroundings, as well as lower compression end temperature. Thus the ignition becomes difficult.
● Low environmental temperature may increase the internal resistance of battery and weaken its charging and
7
discharging capabilities, thus reducing the starting torque to cause the difficulty in starting. Solutions to
such a coldstart difficulty include:
● Introduction of proper diesel fuel.
● Introduction of proper engine oil.
● Selection of correct starter and battery.
● Preheating of diesel engine. The coolant may be replaced by boiled water to preheat the engine. Supply the
radiator with a proper amount of boiled water, which shouldn’t be let out until the water jacket has become
cold. Add new hot water to start the engine and drain it when the engine gets warm, and then add the
rustproof antifreeze.
d. In-service inspection
● Check if there is knocking, looseness or other unusual sound.
● Check if there is some abnormal burning odor sent out by an overheated electric device.
● Check if there is leakage in fuel, cooling and lubrication systems.
● Check if the readings (indications) for oil pressure, coolant temperature, electric current, fuel level and
others are normal.
● The above cases, if any, should be settled promptly.
e. Engine cutoff
● A diesel engine under heavy load, if expected to stop working, should at first lower its speed and load to a
min. zero-load speed, at which the engine should run for 3～5 minutes before its cutoff. A sudden cutoff is
disallowed for the engine with overhigh water temperature and overweight load.
● If the cooling water fails to be antifreeze in a ＜5℃ environment, it should, after the engine cutoff, be
totally drained out of engine so as to avoid the frost cracking of cylinder block.
5. Running-in of engine
New or just overhauled engine must at first experience a running-in process featuring gradual increase in load
(originally small) prior to its usage. Through this process, a sound fit can be achieved between surfaces of
moving parts to avoid abnormal wear and damage. To a large extent, the service life, working reliability and
economy of engine depend on the running-in result in the initial operation stage of engine. Hence the user
should follow strictly the running-in specifications.
(a) Running-in
● A new engine should complete a 2000 km running-in period on an automobile as per the running-in
specifications (see the following table).
● An engine, whose pistons, piston rings, cylinder liners, main bearing shells and connection-rod bearing
shells have been changed in an overhaul, should complete its running-in period in 1/3 of various road
hauls by automobile, as listed on Table 4-1. The running-in process also allows the further check on
assembling quality of every engine part for necessary adjustment.
Road haul(km) Load on automobile Engine speed(r/min)
0～300 Zero Not more than 50% rated speed of relevant engine
>300～1000 Not more than 25% rated load Not more than 50% rated speed of relevant engine
>1000～1500 Not more than 50% rated load Not more than 50% rated speed of relevant engine
>1500～2000 Not more than 75% rated load Not more than the rated top speed of engine
8
(b) Notes for running-in
● Make sure that in the running-in process, attention should be paid to observe and listen for the working
conditions of various engine systems, and a check should be given on oil leakage, water leakage, air
leakage, oil pressure, coolant temperature, engine speed and exhaust color. A fault or abnormality, if any,
should be removed at first and then followed by further running-in.
● A running-in vehicle should run on a level-1 or level-2 road, rather than on an inferior road (in particular
on a beach). Full-speed or overloaded running is strictly banned.
(c) Technical maintenance after the running-in
Upon the completion of running-in, the engine should be checked, cleaned and adjusted once for the
removal of metal powder deposited in the lubricant and the adjustment of unreasonable clearances. Main
contents involved in this period include:
● Drain the oil in lubrication system, clean the lubrication system, change the oil filter, and renew oil into
specified brand;
● Check and adjust clearances of intake and exhaust valves, as listed below (in cold state):
Intake-valve clearance:(0.2mm～0.3 mm) / exhaust-valve clearance:(0.35 mm～0.45 mm)
● Check the tightening of bolts on all points, and retighten the cylinder head bolts as required (in the case
of oil/water/air leakage)
Note: only after the completion of running-in and maintenance according to technical requirements can the
engine enter normal operation. Otherwise, the service life of engine will be shortened.
(d) Notes for operating a new vehicle
Abiding by the following rules in driving a new vehicle can not only lengthen the service life of vehicle, but
save the diesel fuel.
● Maintain normal coolant temperature and regular oil pressure
● Keep the vehicle running at normal speed instead of a high speed
● It is disallowed to slam acceleration as the vehicle is being started
● Try to avoid sudden braking in the initial 300 km haul
● The vehicle shouldn’t run at low speed when the shift lever of gearbox is pushed into a high gear
● Do not drive the vehicle at high or low speed for a long time, but shift gears in due time according to the
driving conditions
● Carry out the technical maintenance as required when the running-in haul for a new vehicle amounts to
2000km
6. Technical maintenance of diesel engine
Periodic maintenance can keep the engine in a long-time, satisfactory, technical state, so our customers must
follow the specifications for careful technical maintenance, during which special attention should be paid to
component cleaning. The dismounted parts in the reinstallation should be washed up and correctly installed,
and then the engine should be started for a check on its running state.
(a) Technical maintenance period
All items of scheduled technical maintenance fall into 2 categories – daily maintenance and periodic
maintenance based on the law that the deteriorating degree of technical state varies with component. The
following engine operating time or road haul has been suggested by assuming the automobile runs on a
level-1 or level-2 road. Given a tougher environment, both the period and haul should be cut by a half.
● Daily maintenance: generally at the end of every 8～10h shift.
9
● Periodic maintenance: after every accumulated 100h runtime of engine or every 5,000 km road haul of
automobile; after every accumulated 200h runtime of engine or every 10,000km road haul of automobile;
and after every accumulated 1,600h runtime of engine or every 80,000km road haul of automobile.
(b) Contents of technical maintenance
In order to ensure the normal running of engine, the following process should be abided by for technical
maintenance.
● Daily technical maintenance
(1) Check the level of fuel, coolant and oil, and add as required if necessary.
Note：Only in the engine miss can various fluid levels be correctly checked.
Note：Never fuel the fuel tank when the engine is running. On a vehicle working in a sweltering climate,
the tank must not be topped up; otherwise the fuel will overflow due to expansion. Once
overflowing, the spill must be wiped off immediately.
(2) Clear the dust on battery and the spilled electrolyte to ensure the vent holes are unhindered. The battery
in normal use hardly needs any maintenance, but at high temperature, needing regular check on
electrolyte level. The fluid level should be 10～15 mm above the polar plate and if insufficient, should
be made up by distilled water.
(3) After the start of engine, check if there is fuel, water or air leakage (“three leakages”) and timely remove
it if any.
(4) Check the fixedness of all accessories.
(5) Observe the running state of started engine and check the performance of instruments. Timely repair or
change the damaged instruments.
(6) Keep the engine clean. In particular, the electric devices must not be contaminated by oil and the radiator
must not be covered with foreign bodies.
Note: if the engine works in a dusty environment, its air filter should be disassembled daily and dusted.
(c) Periodic technical maintenance of engine
After every 100h running period of engine or every 5,000 km road haul of vehicle, in addition to the above
maintenance contents, the following should also be included:
(1) Clean the cartridges of oil filter, air filter and fuel filter.
(2) Check the coolant and clean the radiator.
(3) Check the fixedness of engine.
(4) Check the looseness of water pump belt.
(5) Check and adjust the valve clearances if necessary.
(1) Change the sump oil and oil filter cartridge.
(2) Change the fuel filter cartridge.
(3) Check valve clearances and adjust them if necessary.
(4) Check the water pump performance and water seals.
(5) Check if electric devices and wires have been connected securely and replace those burned out.
(6) Clean out the furring in pipes of cooling system.
(7) Clean the crankcase ventilation system.
10
(8) Check as required the performance of supercharger rotor and remove the pipe connecting air compressor
and air filter to rotate the rotor. If the rotor runs smoothly and can rotate freely for more than one
revolution, it should be considered as trouble-free. Otherwise, the supercharger should be disassembled
for internal inspection.
Note: make sure that, in the inspection of rotor performance, the surroundings and external environment
around the disassembly site are absolutely clean. No foreign bodies should fall into the
supercharging system, or a serious consequence will be caused. Normally only a Supercharger
Company or special service center is qualified for this disassembly. So the user must not
disassemble and reassemble the supercharger assembly at his discretion.
(9) Dismount the compressor housing as required to check if oil leaks from the compressor end. Meanwhile,
clean the housing cavity and impeller surface of compressor. But take care never to damage the blades at
the time of cleaning. This task should be carried out by a service man from supercharger manufacturer.
(1) Disassemble and wash the engine to remove the oil stains and furring. Clean all the lubrication pipes and
oil channels.
(2) Dismount the cylinder heads as required to polish the valves and to remove the carbon deposited in the
combustion chamber.
(3) Check the wear of piston ring, cylinder liner, connection-rod small end bushing and connection-rod
bearing shell, which, if necessary, should be changed.
(4) Check the wear of main bearing brass and thrust pieces.
(5) Check the wear of engaging surface of drive mechanism and drive gears and measure their engaging
clearances. If necessary, repair or change the troubled ones.
(6) Check the oil pump. Check upon disassembly or measure the damaged parts for adjustment.
(7) Check the cylinder gaskets and intake/exhaust pipe gaskets, and change those damaged or disabled.
(8) Check the generator and starter. Clean all mechanical parts and bearings, which, if blow-dried, should be
re-greased. Check the wear of starter gears and the flexibility of driveline.
(9) Disassemble and check the supercharger assembly as required, and change the damaged or disabled
parts:
− Clean the intake connection pipe, compressor impeller and compressor housing, and get rid of
deposited carbon in impeller and volute.
− Check the movable parts in supercharger and dial the rotor with finger. The rotor rotating for several
revolutions with the aid of inertia force can be regarded as running flexibly. If there is inflexibility
in rotation or seizure or knocking, the rotor should be considered abnormal so that an adjustment or
repair is needed.
− Check the axial displacement of rotor shaft, which, if longer than 0.3 mm, indicates an oversize
wear of supercharger thrust bearing and the replacement necessity for this bearing.
− Check the radial clearance between compressor impeller and compressor housing by pushing down
the impeller radially with finger. At this moment, this clearance should be at least 0.1 mm. If not, the
floating bearing of supercharger should be changed.
Seasonal technical maintenance

(1) Winter-oriented fuel and oil must be used and the water content in fuel should be paid attention to for the
prevention against fuel freezing.
11
(2) The cooling system had better be filled with antifreeze, or all the cooling water should be drained when
water temperature drops to 40－50℃ upon the parking.
(3) A vehicle in a frigid season or region shouldn’t be parked in the open air.
(4) Both oil and cooling water can be heated to support a coldstart.
Notes for technical maintenance

● The operator should, according to the regulations on technical maintenance, maintain the engine by item
and quality, without cutting any item of maintenance or lengthening the maintenance period at will.
● The disassembly-based maintenance should prevent dust from intruding upon the engine.
● Some maintenance operation or adjustment, demanding and complicated, should be carried out by
professional technician or sent to “Special Service Station of Mianyang Xinchen Power Machine Co.,
Ltd.”.
12
Electric Control System
3.1.1 High-pressure pump

3.1.2 Fuel injector
3.1 Core components
3.1.3 Fuel rail
1. Fundamentals of diesel engine 3.1.4 ECU
3.2.1 Crankshaft position sensor

2. Overview of common-rail system
3.2.2 Phase sensor
3. Common-rail system components
3.2.3 Airflow sensor
3.2.4 Heater plug
3.2.5 Heat-plug Control unit
3.2.6 Fuel return pipe
3.2 Other components
3.2.7 Fuel filter
3.2.8 Water temperature sensor
3.2.9 Accelerator pedal sensor
3.2.10 High-pressure fuel pipe
3.2.11 EGR valve
3.2.12 Turbocharger
1. Fundamentals of Diesel Engine
13
2. Overview of common-rail system
14
1. Airflow sensor
2. ECU
3. High-pressure pump
4. Fuel rail (high-pressure
accumulator)
5. Fuel injector
6. Crankshaft position sensor
7. Coolant temperature sensor
8. Fuel filter
9. Accelerator pedal sensor
15
Driver’s
Accelerator pedal operation
Control unit
Acceleration or deceleration of
EDC16C vehicle
High-pressure control Torque control

Injection pressure control Fuel charge control
Relevant parts Injection time control
High-pressure pump Relevant parts
Fuel rail and pipe Injector
Pressure control unit All sensors
Fuel rail
Rail pressure sensor
Fuel pump
Fuel injector
Sensor
High-pressure
pump ECU
High-pressure loop
High-pressure pump fuel rail fuel injector
Low-pressure loop
16
Fuel pump high-pressure pump
High-pressure pump fuel tank
Fuel injector fuel tank
3. Common-rail system components - core components
Fuel pump Fuel rail
Fuel injector
High-pressure pump
ECU
3.1.1 Core components – high-pressure pump
Fuel pump
The common-rail high-pressure fuel pump CP1H, which has integrated the fuel feed pump, has 3 radial
pistons. It is driven by gears and lubricated with diesel fuel. Its fuel delivery is metered by an inlet
17
metering valve inside and its compressed amount depends on the required rail pressure.
Main parameters：
Material of pump body: cast iron
Max. pressure：1450bar
Max. fuel delivery: 843mm3/rev.
Rotational direction: clockwise
Gear ratio：2/3
Fuel inlet valve Piston
High-pressure valve
Driving shaft
Fuel
return
Pump body
Fuel in To fuel rail
Trian
gular
ring
Inlet metering
valve
进油计量
阀
Inlet metering
valve
18
3.1 Core component – high-pressure pump
3.1.1 Core component – high-pressure pump
Disallowed
Damageable
parts
Correct
● The propeller shaft, together with all the fittings (fuel inlet fitting, fuel return fitting and high-pressure
fitting) and inlet metering valve must be protected by protective caps. Such a cap is disallowed to be
taken down before the installation of corresponding connection;
● Incorrect takedown and earlier unpacking might lead to inadvertent drop and breakage of
high-pressure pump;
19
Dirts
drop-in
Correct packing method of high-pressure fuel pump
1. The high-pressure fuel pump should be packed into a clean plastic bag to prevent oil
from leaking out.
2. All the surface of fuel pump should be enveloped by shockproof material to avoid the
movement during the transportation period.
Correct installation of high-pressure pump

● The first step towards the pump installation is to take down the protective cap on shaft and clean the
fuel on shaft surface with cleaning agent such as gasoline, alcohol, glycol or propane.
● Hold the pump with both hands in a right way and fit it into the engine flange while choosing a proper
installation angle for fuel-flow control unit. In planting the pump, the shaft must be kept horizontal.
To help the sealing ring into flange smoothly, rotate the pump body a little bit or spread the O-ring on
pump flange with some grease.
● Fix the high-pressure fuel pump onto engine flange with the bolt tightening torque given out on the
20
service manual.
Mounting and dismounting the high-pressure pump

● Take down the protective caps from high-pressure fuel pipe and high-pressure fitting. Tighten the
high-pressure fitting with the torque required by service manual so that the fuel pipe is stressed only
axially and the tight-coupling section between sealing surfaces of pipe and connection leaks.
Note：When dismounting the high-pressure fitting is needed, a wrench must be used to keep the
connection from becoming loose. If this connection has been loosened inadvertently, it is
allowed to be retightened only once at most. Also this connection as well as spacer must be
replaced. Otherwise a leakage might be caused easily.
21
Fuel feeding of high-pressure pump
Dry-running is disallowed for a high-pressure fuel pump; otherwise there will be dry friction in the pump,
leading to wear even damage on parts. Therefore for a pump in initial use or with air in its fuel channel, the
following method must be followed to expel air and the fuel feeding pressure must not be higher than 4bar:
● Loosen the air bleeder bolt on fuel filter;
● Push down the hand pump on fuel filter until all the air has been vented and fuel is seen out of
air-bleed hole;
● Tighten the air bleeder bolt;
● Repeat the above process if necessary.
Hand pump
Air bleeder bolt
22
23
24
Pump body is made of cast aluminum and plated with nickel.
Flow rate = 5.5 cm³ / rev.
PM (powder metallurgy) gears, one-piece formation.
Driving tooth
Coupling piece
Casing
Sealing ring Central bushing Driven tooth
25
Rail pressure Fuel rail
sensor
Fuel pump
Injector
Sensor
High-pressure pump with inlet

metering valve
Electric control unit High-pr Low-pres
EDC16 essure sure loop
loop
3.1.2 Core component – fuel injector
This injector, indirectly driven by solenoid valve,

adopts P-type nozzle, spherical bearing surface,
high-pressure orifice, as well as hydraulic coupling
featuring low-pressure fuel return. It is fixed on
engine through a special pressing plate.
Main parameters：
Pressure range：up to 1,450 bar
Nozzle ： small-orifice type with single pin

valve
26
Low Pressure
High Pressure
27
Movement diagram of armature winding (close)
28
Magnet
Valve spring
Armature plate
Stopper plate
Armature spring
Armature bolt
Ball guidance
Ball
Movement diagram of armature winding(open)
Magnet
Valve spring
Armature plate
Stopper plate
Armature spring
Armature bolt
Ball guidance
Ball
Valve, piston, needle closed position
29
Nozzle needle
Ball
A-throttle
Valve piston
Nozzle
Valve, piston, needle open position
Nozzle needle
Ball
A-throttle
Valve piston
Nozzle
30
3.1.3 Core component – fuel rail
Rail
pressure Fuel rail
sensor
Fuel pump
Injector
Sensor

metering valve
Electric control unit High-pr Low-pres
EDC16 essure sure loop
loop
The high-pressure fuel rail welded with laser has 4 hydraulic fittings feeding fuel to 4 injectors respectively, with
one fitting corresponding to high-pressure fuel pump. The rail pressure sensor is fit on the rail axially.
Fittings to various
injectos
Main parameters：
Measurable pressure range：0~1800
bar
Flow limiting valve Temperature range：-40℃~130 ℃
Fitting from high-pressure Power supply voltage：5V（from
pump ECU）
31
Sealing of fuel rail fitting
Hardness of fuel pipe head: ≤HV250
The rail fitting is sealed through the

cone on rail and the head of Welded surface：
high-pressure pipe. With laser welding
technology
No high pressure should be borne by
welded surface.
• The rail pressure sensor is integrated at

the end of rail for inducing the transient
pressure in rail.
• This sensor works by translating the
pressure signal into electric signal
through its component (semiconductor
module), magnifying this signal and
transmitting it to ECU.
• Position of rail pressure sensor: straight
down with an allowable maximum 30°,
disallowed to be in inverted
suspension.
32
Flow limiting valve
• The flow limiting valve is installed inside every

high-pressure fitting connecting fuel rail to
injector.
• This valve functions by preventing the injector
from opening normally and making it inject fuel
continuously in an unusual case. Once the fuel
amount out of rail is above the regulated level, the
flow limiting valve will cut off the fuel passage to
this injector.
3.1.4 Core component – ECU
Fuel rail
Rail
pressure
Fuel pump sensor
Injector
Sensor

metering valve High-pr
essure Low-pres
loop sure loop
Electric control
unit EDC16
33
The common-rail 32-digit electric control unit (ECU),
whose model is EDC16C39, can meet the Euro Ⅲ
emission standard now and probably Euro Ⅳ in the future
through functional expansion.
Main parameters：
Rated voltage：12V
Power consumption：normally 12.5～18W
Working temperature：-40℃≤T≤T maximum environmental temperature
In the flowing air: T maximum environmental temperature =70℃
In the fixed air： T maximum environmental temperature =85℃
Basic software functions：

● Split injection control (pre-jet, major jet and
post-jet）
● Fuel amount control: low idle controller and balance
among all cylinders
● Fuel injection regulation of injector
● Fuel amount limitation and engine-start fuel control
● Accelerator-pedal signal filtering and drivability
pulse spectrum
● Exhaust gas recirculation
● Supercharging pressure control
● Intake throttle control
● Viable swirl control
● Preheating-time control of heater plug
● Fan and AC (air conditioner) control
● Trouble shooting function
● CAN interface
● Procedure updating
34
Installation of ECU
• The ECU must be installed in a dustproof and dry area,

where a small amount of water is allowed to pass within
a short period;
• Ensure water, oil and other fluid won’t permeate into
ECU seals and pressure compensation element through
wires;
• It is disallowed to dip ECU into water;
• No elasticity is allowed where the ECU is installed;
• Don’t dismount the ECU at discretion in the
maintenance process;
• Dismounting the ECU, if really necessary, should be
done more than 1 min. later after the unplugging of
terminal post;
• Before welding, the ECU must be removed into a
storage under full attention;
• No branching of ECU wire!
3.2.1 Other component – Crankshaft position sensor
Function and principle:

• Engine speed & crankshaft position sensor (CPS) is a
magnetoelectric sensor. Installed near the crankshaft, it works
together with 58x ring gear on crankshaft. As the crankshaft
rotates, crown and gullet of 58x ring gear pass through this
sensor with different distances. Then this sensor senses the
change in magnetic resistance. This alternating magnetic
resistance generates an alternating output signal, with which the
ECM can identify the rotational position and speed of
crankshaft.
• Installation position: near the crankshaft. It must be
press-mounted and must not be hammered.
Product features:
z Working temperature：-40℃～120 ℃
z Working clearance：0. 5～1. 5 mm Signal (high)
z Coil resistance：860Ω ±10%(20 ℃)
z Coil induction：370mH ±60mH @1kHz Signal (low)
35
3.2.2 Other component – phase sensor

• Camshaft position sensor is a Hall Effect sensor,
which, near the camshaft, works together with signal
wheel on camshaft. The signal wheel corresponds to a
special position on engine. With this sensor, the ECU
detects the digital voltage signal, through which the
working cylinders of engine can be identified for
one-to-one control.
• Installation position: near the crankshaft. It must be
press-mounted and must not be hammered.
Product features：
z Working temperature ： -40 ～
Signal output (O)
+150℃ ；
z Working voltage：4.7～18 V；
z Working clearance：0.2 ~ 1.8 mm
3.2.3 Other component – airflow sensor

• Airflow sensor is a hot-diaphragm airflow gauge installed on
intake system. It has also a built-in temperature sensor that can
measure the intake temperature. Through this signal, the ECU
can judge the air flow into engine and the load on engine.
• Installation position: on the intake pipe. It should keep a certain
distance from hot components such as turbocharger and exhaust
manifold.
• This sensor must be installed in the same direction as that of
intake air flow！
Power
supply(+)
Product features： Ground (- )

z Rated flow rate：640kg/h ； Temperature output
signal
z Working voltage：14V；
Reference
z Temperature of sensor：-40℃～ frequency
120℃ Flow output signal
36
3.2.4 Other component – heater plug

• The heat plug is used for assisting the coldstart of
diesel engine and improving the warming-up
performance.
• Installation position: in the cylinder head. Ensure

its glow end is correctly placed in the combustion
chamber.
Product features:
z Rated voltage：11V ；
z Power-on time before 850℃：5s±1s；
z Temperature after 60s：1050℃±50 ℃。
3.2.5 Other component – heat-plug control unit

• The heat-plug control unit is controlled by ECU.
Through customized pin interfaces, it can separately
be applied to engines with 4, 5 or 6 cylinders. It can
also troubleshoot one or more heat plugs.
• Installation position: in a proper area of engine
compartment, with pin interfaces horizontally
downward.
Ground (- )
Product features： Code control signal (4,6)

z Rated voltage：12V ； Main relay To heat plug
z Power consumption: 10 ～ Code control signal (6)
18W(when the heat plug is Diagnosis signal
working) ；
3.2.6 Other component – fuel return pipe

Function and principle：
The fuel return pipe collects the fuel returning from injector and send it back to fuel tank. It consists of L fittings,
T fittings and steel-wire reinforced, rubber-covered hoses. Thereof, every fitting has a check inside to ensure the
stable pressure of returning fuel.
Installation position: on the head of every cylinder injector.
37
T fitting
L fitting
Into fuel
injector
Back to fuel tank via
a hose
Product feature：
● System pressure：not more than 2 bar；

● Bending radius of pipeline:≥30mm ；
3.2.7 Other component – fuel filter
Hand
pump Fuel
out
Fuel in
Heater
switch
fuel-water
separator

● In addition to filtering out the impurities in fuel, the fuel filter also integrates hand pump, fuel-water
separator and fuel heater. The hand pump is used for expelling air out of pipes whenever there is an
initial start or the vehicle has been laid up for a long time without being used. It timely reminds the
driver of draining the separated water through the fuel-water separator indicator on dashboard. While
the fuel heater can help improve the coldstart performance of vehicle.
● Installation position：in a correct area on vehicle body, straight up, 20°at most away from the vertical
direction
Product features：
● Working temperature：-40℃～+120 ℃；
● Working pressure: ≤2.0 bar；
● Replacement period：30,000 km；
3.2.8 Other component – water temperature sensor
38
● Coolant temperature sensor is used for detecting the working temperature of engine. The ECU will,
according to different temperatures, provide the optimal control plan for engine;
● This sensor takes a thermistor with negative temperature coefficient as its sensing element;
● Installation position: this sensor is assembled on small circulation channel of engine coolant.
Product features：
● Working voltage：5±0.15 V;
● Working temperature：-40 ℃~ +130℃
Signal ground
Temperature signal
3.2.9 Other component – accelerator pedal sensor

Accelerator pedal sensor is mainly used for picking up the driver’s requirements for vehicle and through
the analyzing calculation of ECU, enabling the engine to supply the required power.
Product features：
● Working voltage：5±0.3 V;
● Working temperature：-40 ℃~ +80℃；
● Pedal force：500±6N;
● Pedal return force：＞5N;
3.2.10 Other component – high-pressure fuel pipe

Installation of high-pressure fuel pipe
Î Installation of high-pressure pipe between fuel rail and injector
39
● Fix the fuel injector onto engine with a final tightening torque exerted on presser bolts and
tighten the rail on engine by hand（3±1Nm）；
● Separately tighten the nuts on injector end and rail end of high-pressure pipe by hand
（3±1Nm）；
● Tighten the nut on injector end of
high-pressure pipe with a final torque of
30±3Nm；
● Screw the rail onto engine with a final 23±
2Nm torque；
● Tighten the nut on rail end of high-pressure
pipe with a final torque of 30±3Nm.
Î Installation of high-pressure pipe between
high-pressure pump and fuel rail
● Manually tighten the nuts on both ends of
high-pressure fuel pipe（3±1Nm）；
● Tighten the connection nuts on both ends of
fuel pipe, fuel pump and fuel rail with a final
30±3Nm torque.
Dismounting of high-pressure fuel pipe

Î Dismounting of high-pressure pipe between fuel rail and injector
● Unscrew the nuts on high-pressure pipe between fuel rail and injector；
● When the nut on injector end of this pipe is being unscrewed, the high-pressure fitting on
injector must be fastened；
● Take down the high-pressure pipe；
● Release and pick off the pressing plate；
● Take the injector out of cylinder head with a a special
remover;
● Return all the protective caps onto injector and rail.
Î Dismounting of high-pressure pipe between high-pressure
pump and fuel rail
● Unscrew the nuts on high-pressure pipe between fuel
rail and high-pressure pump；
● In the effort to loosen the nut on pump end of this pipe,
the high-pressure fitting on pump must be fastened
with a wrench to avoid its follow-up；
● Pick off the high-pressure pipe；
● Return all the protective caps onto high-pressure pump
and fuel pipe.
3.2.11 Other component – EGR valve
● The EGR valve, which is on the intake pipe, is used for driving a certain amount of exhaust gas
40
into intake system for recycling.
● The diaphragm of EGR valve is connected to a pivot on one end and to a spring on another end (it
is just this spring that keep the valve normally closed). When the
vacuum pressure (or air pressure) on diaphragm is greater than the
spring force, the pivot will be pulled off its original position to open
up the passage, through which the exhaust gas can enter the recycling
system. The amount of recycled exhaust gas directly hinges on the
intake amount.
● In nature, the EGR relies on worsen combustion to reduce the NOx.
As the NOx can be produced under two conditions – high
temperature and abundant oxygen, so by leading a certain amount
of post-combustion exhaust gas into intake pipe via the control valve
to join fresh air for in-cylinder combustion, such inert gas can slow
down the combustion speed and lower the maximum combustion
temperature and consequently reduce the amount of NOx .
3.2.12 Other component – Turbocharger
● The turbine of turbocharger is connected to exhaust pipe, so do compressor and intake pipe. As
the turbine rotates coaxially with compressor impeller, the compressor can be towed by driving
the turbine with exhaust gas, thus increasing the intake
pressure and air charge.
● When the engine runs at a high speed and under a heavy load,
overhigh turbocharger speed and supercharging pressure can
be reduced by turning on the exhaust byway valve to bleed
some exhaust gas, thus decreasing the turbocharger speed
and controlling the compression ratio.
Essentials in operation：
● As the turbocharger adopts full-floating bearings with very
high lubrication requirement, oil of supercharging diesel
engine should be used as required.
● To ensure the lubrication of bearings, the engine should idle for several minutes upon the start to
bring the lubricant up to a certain temperature and pressure. The same is true in stopping the
engine, which means, instead of stalling suddenly, it should have its load gradually decreased and
finally idle for several minutes before stalling.
● The relevant regulations should be abided by to regularly clean air filter and check the leakage of
intake system.
41
Mechanical System
Cylinder head components

● Light and perfectly shockproof, the resin
material adopted by cylinder head cover
has not only reduced the engine weight,
but ensured the strength of cylinder head
cover. With the improvement in the shape
of this cover, engine noise has been
reduced. By installing a traverse baffle in
the cover and extending the ventilation
duct out of cover roof, the fuel cutout
capability has also been enhanced. In
addition, both traverse baffle and
ventilation duct are made of resin, so the
engine becomes lighter.
● The cylinder head gasket adopts
heatproof and oil-proof ACM (acrylate
rubber) to ensure its reliability.
● The cylinder head is made of light
aluminum alloy with superior thermal
conductivity. Also, adopting the DOHC
and 4-valve structure and vertically
aligning injectors at the center of cylinder
head has endowed the engine with not
only higher performance but better
reliability, achieving the low-emission,
downsizing target.
● The cylinder head gasket is formed by
4-layer steel pieces with superior sealing
performance and heat resistance.
● Cylinder head
− Independent intake holes are adopted. The introduction of two intake holes in different shapes has
improved the eddy current in cylinders and facilitated the mixture between fuel and air.
− The adoption of 2 layers (upper and lower) of water jacket has enhanced the cooling capacity and
rigidity. On top of this, optimized casting method (reinforced casting) has also made the cylinder
head more reliable.
− An electric heater plug between intake valves has ensured the reliability and startability.
− With the EGR channel designed in cylinder head, the EGR gas has been cooled more effectively and
the cylinder head becomes smaller.
42
− The sealing capability has been enhanced by surrounding the cylinder bores on cylinder head gasket
with an integrated independent gasket for #1-#4 cylinders.
− Cylinder bores adopt a double-edge structure, which can hold the elasticity of cylinder head gasket
within a minimum threshold to ensure the sealability against the rising pressure of combusted air.
43
Camshaft timing system
● The camshaft timing system is composed of timing gear system and toothed belt, making the engine
shorter and the change of belt easier.
● High-strength material adopted by timing belt has created more reliability.
● Hydraulic automatic tensioner can keep the belt tension constant.
● Gear chamber and gear covers are made of aluminum alloy. On the timing gear chamber cover is a
crankshaft position sensor.
● Both inner and outer covers of sprocket chamber are made of resin. Sealing gaskets around the outer
cover of sprocket chamber has reduced the engine vibration and noise. The camshaft seal is installed on
the cylinder head.
44
Camshaft timing system
Oil-pressure tensioner
● The piston ring built in the tensioner pushes the idler pulley via a push rod to exert a certain tension
force on belt. But forced by check valve ball, oil will enable the push rod to move towards the looser
side of belt, thus keeping the tension on belt constant.
● Once the belt becomes loose, the push rod will be forced by piston spring to move up, and the oil in
chamber A will burst through the check valve ball into chamber B, vice versa. If the engine speed drops,
the tension on belt will increase so that the tensioner pulley will push the push rod. At this moment, the
check valve ball cuts off the passage from chamber B to chamber A, so the chamber B will be highly
stressed to prevent the invasion (into chamber B) by push rod. In this way, the belt tension can remain
constant through the up-and-down continuous action of push rod.
● Dismounting
1. Dismount the outer cover of timing belt chamber.
(1) Dismount the phase sensor and its support.
(2) Remove the wire tube clamps.
(3) Unscrew 6 bolts to take down the outer cover of sprocket chamber.
2. Dismount the timing belt
(1) Rotate the crankshaft clockwise until the marks on two toothed pulleys (sprockets) are aligned
with each other.
(2) Evenly loosen 2 bolts to take down the tensioner.
(3) Dismount the timing belt and mark arrows according to its moving direction (its original moving
direction should remain unchanged when the belt is being assembled）
45
● Installation
1. Prevent the valves and pistons against damage
To turn the camshaft in the absence of timing belt (dismounted), the crankshaft needs at first to be
turned 90°anticlockwise.
Note：
− Never turn the crankshaft when the timing belt has been removed,（The mutual interference
between pistons and valves will invite the damage）
− In the installation of timing belt, the camshaft must firstly return to the alignment mark. Then
rotate the crankshaft clockwise until it is aligned with alignment mark.
2. Check the timing belt tensioner（idler）
(1) Turn the idler by hand to confirm it can rotate freely.
(2) Confirm the sealing area has been lubricated evenly.
Note：
− Please repair the leaks when there are water beads and oil stains on the timing belt and every
pulley.
− Every pulley to be installed must be wiped clean with rags until no oil stains can be found.
− Please don’t dismount the timing belt idler, unless very necessary,
46
3. Install the timing belt
(1) Align the alignment marks of every pulley, as shown in the picture.
(2) Install the timing belt in the “driveshaft toothed pulley– camshaft toothed pulley –timing belt
idler” sequence.
※ Reference： Install the timing belt and make the line on the back of belt aligned with the
notch on every pulley.
(3) Fix the tensioner on a press and press the push rod downward.
※ Note：
① Please protect the tension rod top of tensioner from damage by using rags.
② Carry out the compression as the tension rod of tensioner faces up.
(4) Slowly press the tensioner push rods and after their alignment with cylinder bore, fix them with
inner hexagon spanners（with a same 1.5 mm width on both sides）.
※ Note：The load on tension rods must not exceed 980N（100 kgf）（in a frigid region, the
tensioner can be heated to a ＜80℃ temperature to increase the press-mounting speed）
※ Reference：after the tension rods have been aligned with cylinder bores, press the pressing
plate while aligning it with bores and inserting inner hexagon spanners.
(5) Install the tensioner with inserted inner hexagon spanners.
47
※ Benchmark：T=13N.m
※ Note：An inclining tensioner can’t function normally. Please tighten every bolt evenly.
(6) Pull inner hexagon spanners out of tensioner.
(7) Turn the crankshaft for 2 rev. clockwise. Confirm all the alignment marks on all the toothed
pulleys are aligned.
4. Install the outer cover of timing toothed-belt chamber
(1) Fix the outer cover of sprocket chamber with 6 bolts.
※ Benchmark：T=6.0N.m
(2) Install the phase sensor support.
(3) Connect the wires.
Cylinder head assembly

● Dismounting
1. Dismount the cylinder head cover.
(1) Loosen the presser bolts and presser- bolt washers of injector, and then dismount the injector
presser plates for 4 cylinders.
(2) Take down the injectors and record the corresponding cylinder numbers of injectors.
(3) Unscrew the bolts on cylinder head cover and take down the cover.
(4) Take down the injector seals and presser- bolt seals from cylinder head cover.
2. Take down the seals at the pivot of presser plates.
3. Dismount the timing toothed belt
(1) Remove the phase sensor.
48
(2) Take down the outer cover of timing belt chamber.
(3) Rotate the crankshaft to the compression TDC (top dead center) of cylinder 1.
(4) Take down the timing toothed belt
4. Dismount the timing toothed pulley (or sprocket)
(1) Fasten the camshaft with a monkey spanner and loosen the bolts on camshaft timing sprocket.
(2) Loosen the bolts on camshaft timing pulley until there are 2～3 threads for bolts to completely exit
the camshaft screws (don’t let bolts completely out lest the sprocket being pulled out will drop).
(3) Draw the timing pulley with a special tool (tension tool) (no hammering! Very great engaging
force exists in the cone fit between sprocket and camshaft, so hammering the sprocket will lead to
its deformation or damage).
49
(4) Dismantle the pulley key from camshaft.
5. Dismount the timing belt tightener (idler)
Unscrew the timing idler bolts with a hexagon spanner.
6. Dismantle the inner cover of timing belt chamber
Unscrew the fastening bolts and nuts, and then take down the inner cover of timing belt chamber.
7. Dismount the camshaft
(1) Evenly loosen the bolts and remove the cover of camshaft bearing shell in the sequence shown in
the picture.
※ Note:
① Pry the camshaft with a right tool but without an oversize force.
② Please don’t damage the thrust surface of camshaft and cylinder head.
(2) Remove the camshaft seal.
(3) Dismantle the intake camshaft and exhaust camshaft.
8. Dismantle the cylinder head
(1) Evenly loosen the cylinder head bolts for several times in the illustrated sequence, and take down
the bolts and washers.
(2) Check the cylinder head bolts
Measure the illustrated position with vernier calipers.
※ Standard value: φ11.67～11.97mm
※ Limit value: φ11.60mm
※ Reference: Make the measurement in multiple positions. Renew the product if the measured
50
values are below the limit.
9. Dismantle the cylinder head gasket
● Installation
1. Install the cyinder gaskets
(1) Measure the piston protrusion.
Measure the piston protrusion (the distance to the upper surface of cylinder block) with dial gauge
and flat-seat probe.
※ Note:
① The probe should be vertical to the upper surface of cylinder block.
② Choose one position respectively in front of and behind every piston. Measure two points
for every cylinder (8 points in total).
(2) Choose cylinder gaskets based on the maximum piston protrusion.
※ Note:
① The thickness of a cylinder gasket should be identified according to the position of notch
at the rear end of cylinder gasket.
51
② Choose cylinder gaskets according to all the protrusions.
(3) Install the chosen gaskets onto cylinder blocks.
※ Note:
① Clean the lower surface of cylinder head and the upper surface of cylinder block.
② No foreign bodies into cylinder gaskets!
2. Install the cylinder head
※ Note:
① Confirm the pulley notch is just 90° ahead of the TDC before installing cylinder
gaskets.
② Tighten the cylinder head bolts in a plastic-range tightening method.
(1) Fit washers onto cylinder head bolts and then insert them into cylinder head.
(2) Pre-tighten the cylinder head bolts for several times in the illustrated sequence, and then tighten
them with the required torque.
※ Standard value: T=85N.m
(3) Mark the top of cylinder head bolts and keep these marks on the front side of engine.
(4) Turn every cylinder head bolt for 90°.
52
※ Note: Tighten the cylinder head bolts in the tightening sequence.
(5) Tighten every cylinder head bolt for another 90°.
(6) Conform all the marks on all cylinder head bolts are on the rear side of engine.
3. Install the camshaft

※ Note: As the camshaft has a small thrust clearance (axial clearance), it should be installed
horizontally lest the thrust surface will have such defect as damage, scratch or burr.
(1) Check if the crankshaft is 90°ahead of TDC.
(2) Let the keyway face up and fit the intake camshaft onto cylinder head.
※ Note: Apply the engine oil on the cam, thrust surface and gears of camshaft and the axle
journal of cylinder head.
(3) Let the gears on intake camshaft and exhaust camshaft engage, and then install the exhaust
camshaft.
※ Note:
Apply the engine oil on the cam, thrust surface and gears of camshaft and the axle journal of
cylinder head.
(4) Spread the illustrated position with sealant and then install the camshaft onto cylinder head.
53
(5) Align the camshaft bearing shell covers and fit them onto cylinder head, as shown in the picture.
(6) Tighten the camshaft bearing shell covers in the illustrated sequence.
⑺ Check and adjust the valve clearances.
(a) Measure the valve clearances in the illustrated positions (in cold state).
※ Reference: intake: 0.20～0.30mm
Exhaust: 0.35～0.45mm
※ Note: Valve clearances need to be measured when the valves are in cold state.
(b) Rotate the camshaft to measure and record the valve clearances of other cylinders.
54
(c) Adjust the valve clearances
① Dismantle the camshaft and take down the valve tappets.
② Measure with dial gauge the thickness of valve tappets that have been just taken down.
③ Calculate the tappet thicknes when valve clearances meet the Standard values.
※ Standard values: IN:A=B+(C-0.25mm)
EX:A=B+(C-0.40mm)
④ Choose the valve tappets.
⑤ Install the chosen valve tappets.
⑥ Reinstall the camshaft and check the valve clearances, which, if beyond the Standard value
range, should be readjusted as per the above steps until the Standard values are met.
A Valve tappet to be chosen
B Thickness of just removed valve tappet
C Valve clearance that has been measured
4. Install the camshaft seal

(1) Apply a thin layer of MP grease on new seal lip.
※ Note: Pay attention not to let foreign bodies stay on the lip.
55
(2) Beat the seal in with special tooling
※ Standard value: 0.5mm～-1.5mm（to the end face of cylinder head end）
※ Note: The fuel seal can’t be installed obliquely.
5. Install the inner cover of timing belt chamber
(1) Spread the illustrated position with sealant.
※ Note:
① Clean and degrease the mounting surface.
② Install this cover within 3 minutes after applying the sealant, and tighten it within 15 min.
③ Don’t start the engine within 2h after this installation.
(2) Fix the inner cover of sprocket chamber with 4 sets of bolt and nut.
6. Install the timing belt tightener (idler)
Mount the timing belt idler with hexagonal socket wrench.
56
7. Install the camshaft timing pulley
(1) Fit the pulley key onto camshaft.
(2) Mount the camshaft timing pulley.
(3) Fasten the camshaft with monkey wrench, and then screw the mounting bolts of camshaft timing
pulley. (Before tightening the bolts, the sprocket mounting surface must be checked to be 2mm
above the camshaft end face).
※ Standard value: T＝90～98N.m
Upon the assembling,

the tensioner must be
ensured capable of
freely revolving around
its mounting axis.
In the assembling
course, the chamfer of
gasket should face the
tensioner side.
8. Install the timing belt

Note: after every 50,000km use, the timing belt must be renewed. The timing belt in installation must
ensure its timing mark is aligned with that on sprocket.
9. Install the outer cover of timing belt chamber
10. Install the cylinder head cover
(1) Mount the presser pivot seals on cylinder head bolts with a projection.
57
(2) Install the injector seals and presser bolt seals.
(3) Spread the illustrated position with sealant.
※ Note:
② Install this cover within 3 minutes after applying the sealant, and tighten it within 15 min.
③ Don’t start the engine within 2h after this installation.
(4) Fix the cylinder head cover with 10 bolts and 2 nuts.
※ Standard value: T=9.0N.m
11. Install the fuel injector
Check if the copper gasket of injectors is intact, and insert the numbered injectors into the
corresponding cylinders.
Sprocket mounting surface
Sprocket mounting bolt
Camshaft end face
12. Install the injector presser plate

13. Thread the presser bolt washers onto injector presser bolts, install these bolts and tighten them.
※ Standard value: ＝30±3N.m
58
Intake and exhaust systems
I Valve-related items
● Adopt the DOHC4 valve structure, in which the intake camshaft drives the exhaust camshaft through
gears.
● Camshafts are made of alloy cast iron. By reducing the thickness of cam nose and shortening the camshaft
diameter has the engine become lighter.
● 4 Valves are made of heatproof steel and oppositely aligned. In addition, a high-speed, low-consumption
target has been achieved with smaller diameter of valve stems, lighter valves and lower inertia.
● Valve tappets have no spacers, thus decreasing the quantity of components and reducing the engine
weight.
Crankcase ventilator
● Lead the gas blowby containing a large amount of hydrocarbon into take system, where it can
combust once again to improve the exhausting preformance.
● By designing the blowby passage into a loop and extending the ventilation duct out of the top of
cylinder head cover have both the oil content in blowby and the oil consumption been reduced , thus
achieving the low-emission target.
● The gas blowby in crankcase, via the ventilation duct at the top of cylinder head cover, is restored to
the intake side of turbocharger.
59
Turbocharger
● The turbocharger is an exhaust depressurization type. Once the supercharging pressure goes beyond
the set value, the actuator on exhaust pressure-reducing valve begins to take action. It releases the
exhaust pressure through the byway and lowers the supercharger speed in order to keep the
supercharging pressure rising continuously. The maximum supercharging pressure depends on the
spring force of exhaust pressure-reducing valve.
● Lighter rotor, together with improved air inlet shape and blade shape has not only contributed to
quicker response and stronger supercharging performance, but fully ensured the engine reliability.
● The compressor casing is cooled by air, while the exhaust temperature is brought down through
intercooler.
60
EGR valve
● An electric EGR system has been adopted to reduce the emission.
● Install the EGR vale on intake channel, cool it with air, and with the aid of a large-capacity
multi-pipe EGR cooler, achieve a large amount of EGR gas.
● Through the EGR channel designed inside the cylinder head, the end gas can be recycled directly on
the intake side, so the EGR gas can be cooled more effectively and the engine becomes smaller.
● EGR-valve uplift sensor has been used. It can closely monitor the actual uplift of EGR valve so as to
accurately control the EGR.
● The use of spring centering device has reduced the lag on both “on” and “off” sides of EGR valve,
thus improving the EGR regulating accuracy .
61
● Dismounting
1. Dismantle the throttle intake pipe.
2. Take down the throttle body.

3. Remove the EGR vacuum regulator and vacuum regulator support.
4. Unscrew two bolts and two nuts to remove the EGR exhaust pipe.
62
5. Remove the EGR valve and two washers from intake manifold.
6. Unscrew 4 bolts and 2 nuts to take down the intake manifold and intake manifold gaskets.
7. Remove the fuel inlet pipe and return pipe from turbocharger.
(1) Take down the screw plugs on fuel inlet pipe (see A and B in the picture), and remove the fuel
inlet pipe from turbocharger.
(2) Take down 4 nuts (see A and C in the picture), and remove the fuel return pipe from
turbocharger.
8. Take down 3 nuts and then the turbocharger.
9. Take down 8 nuts and then the exhaust pipe as well as exhaust pipe gaskets.
63
● Installation
1. Install the intake manifold gaskets.
※ Note: Clean the mounting surface between cylinder head and intake manifold.
2. Install the intake manifold, and tighten 4 bolts and 2 nuts.

3. Install the vacuum regulator and vacuum regulator support.
64
4. Install the EGR valve and throttle body.
(1) Temporarily fix the EGR, with 2 washers installed (as shown in the picture).
(2) Fasten the throttle body with 3 bolts.
5. Install the EGR exhaust pipe.

⑴ At first install the cylinder-head end with gaskets and nuts - without tightening them for the
time being.
(2) Put on the gaskets to mount the EGR end with bolts.
(3) Tighten the nuts and bolts on both ends.
6. Put on the exhaust manifold gaskets and install the exhaust manifold.
7. Fit the turbocharger return pipe onto turbocharger.
8. Put on the turbocharger gaskets to install the turbocharger.
9. Install the fuel inlet pipe and return pipe of turbocharger.
65
(1) Tighten 2 nuts as shown in C.
(2) Put on the nuts at both ends of fuel inlet pipe (see A and B) and mount the turbocharger inlet
pipe.
10. Install the throttle intake pipe.
● The cylinder block is made of alloy cast iron with high rigidity and has no sleeve.
● The oil sump formed by rustproof steel sheets has increased the loading capacity of vehicle
66
through its oil storage newly set at the rear end of engine. Meanwhile, it has changed the
position of filter suction port lest air will be sucked in due to the change in oil level as the
vehicle is uphill or downhill or takes a turn.
● There is a oil level sensor on one side of sump, which can notify the driver of oil level drop.
● Liquid spacer with superior leak-tightness has been used between sump outer edge and
cylinder block.
● Sump isolator has been adopted between sump and transmission as shock absorber to reduce
the noise of standing waves.
Pinion unit
● Dismounting
This system is dismounted as follows:
● Dismounting
1. Dismount the front-end pinion unit and timing belt system.
2. Dismount the water pump, unscrew bolts and nuts, and take down the pump and washers.
3. Remove the sprocket chamber cover.
4. Install the locking bolts（M6） onto idler and compress them.
67
5. Dismount the fuel pump pinions and fuel pump (feed pump) assembly.
6. Dismount the crankshaft timing gears.
(1) Temporarily install the pulley bolts on crankshaft.
(2) Remove the crankshaft timing gears with right tools.
(3) Unscrew the pulley bolts from crankshaft.
7. Take down the idler thrust pieces.
8. Take down the idler set.
※ Note: Confirm no deviation has been found on primary and secondary idler gear pairs
(compressed by M6 bolts).
9. Take down the idler shaft.
10. Take down the sprocket chamber seal.
Hammer out the seal with a taped, slotted screwdriver and a hammer.
68
11. Dismantle the oil sump.
(1) Dismount bolts and nuts.
(2) Remove the sump with a prying knife.
※ Note:
① Don’t deform the sump.
② Don’t tip the sump where oil has not been drained totally.
12. Dismount the oil strainer.

Screw out bolts and nuts, and take down the filter and filter base.
69
13. Dismount the timing gear chamber.
(1) Screw out bolts and union studs to dismount the timing gear chamber.
(2) Pry the illustrated position with a slotted screwdriver to take down the timing gear chamber.
※ Note: Don’t let the oil pump rotor inside the timing gear chamber slip.
(3) Take down the oil pump rotor and washers.
(4) Dismount the bolts.
(5) Remove two O rings from cylinder block.
70
● Installation
1. Install the timing gear chamber.
(1) Fit two new O rings on timing gear chamber.
(2) Install the studs in the illustrated positions (in the replacement of studs).
※ Standard value: T=8.0N.m{82kgf.cm}

(3) Cleaning and degreasing.
② Clean and degrease the bolts and bolt holes.
(4) Install the oil pump rotor on timing gear chamber.
(5) Put new pump washers on timing gear chamber.
(6) Spread the illustrated position with sealant (in a 4 mm or so diameter).
71
(7) Install the timing gear chamber with 8 bolts and union studs.
※ Standard value: T=13N.m{133kgf.cm}（bolt）
T=16N.m{163kgf.cm}（union stud）
(8) Remove the screw plug to inject 50cc oil.
2. Install the oil strainer.

Renew the washers and mount the oil filter with bolts and nuts.
※ Standard value: T=8.0N.m{82kgf.cm}
72
3. Install the oil sump.
(2) Spread the illustrated position with sealant (in a 4 mm or so diameter) and mount the sump.
(3) Tighten the bolts and nuts.
※ Standard value: T=16N.m{163kgf.cm}
4. Install the fuel pump gears.

(1) Mount the fuel pump (feed pump) assembly.
73
(2) Mount the fuel pump gears.
(3) Renew O rings, and put on the nuts.
(4) Tighten the nuts with a right tool.
5. Install the camshaft timing gear.

As illustrated, align the camshaft timing gear with oil pump gear and then mount the crankshaft timing
gear with some tool and hammer.
6. Install the idler shaft.

(1) Spread this shaft with oil.
(2) Install it.
74
7. Install the idler set.
(1) After the alignment between fuel pump gear and crankshaft timing gear, mount the idler set with
tools.
(2) Operating principle of idler gear pairs

Structure: backlash-free gear driving
This structure consists of primary and secondary gears, between which there is a torsion spring
with two ends against two pins respectively fastened on primary and secondary gears. Because of
torsions spring, the tooth flanks of primary and secondary gears are staggered from each other by a
small angle into scissors shape.
Features:
At a lower temperature, there is a bigger backlash between the driving and driven gears of twin
overhead camshaft (DOHC). At this moment, under the force of torsion spring, flanks of
backlash-free primary and secondary gears are staggered from each other by a small angle to offset
the backlash between the driving and driven gears, vice versa.
Merits: reducing the engine noise.
75
8. Install the idler thrust piece.
(1) Position the locking bolts of idler thrust piece into the mounting holes.
※ Reference: Let the cross recess of thrust piece face the read end.
(2) Mount the idler thrust piece with bolts.
76
9. Install the fuel seal.
11. Install the timing gear chamber.
(1) Unscrew the locking bolts from idler.
(2) Install new O ring in the illustrated position.

(4) Spread the illustrated position with sealant (in an about 4 mm diameter) and mount the timing gear
chamber.
77
(5) Tighten the bolts and nuts.
Standard value: T=13N.m{133kgf.cm}
12. Install the water pump assembly.

(1) Mount new pump washers on cylinder block.
(2) Mount the water pump assembly with bolts and nuts.
13. Install the sprocket chamber inner cover and other components.
II Cylinder block assembly

● Dismounting
1. Check the connection rod.
Key: Check its axial clearance.
78
Inspection means: measure the axial clearance with dial gauge.
Standard value: 0.10～0.30mm
Limit value: 40mm
Reference: The connection rod as well as crankshaft must be changed if the above clearance is beyond
the limit.
2. Check the connection-rod bearing shell.

Key: Check the oil film clearance.
Inspection steps:
(1) Unscrew the connection-rod bolts with socket wrench.
(2) Slide the connection-rod cover back and forth while removing it and connection-rod bearing shell
with 2 main bearing bolts.
(3) Clean both inside and outside of connection-rod bearing shell and crankshaft pin.
※ Note: Confirm if there is any damage and scuffing or not.
(4) Set the test piece in the crankshaft rotating direction and mount the connection-rod cover.
79
(5) Apply a small amount of engine oil on the threads and root of connection-rod bolts.
(6) Tighten the connection-rod bolts with socket wrench.
(7) Make a colored mark on the top of connection-rod bolts and keep it facing the engine front.
(8) Tighten every bolt by another 90° based on the colored mark.
(9) Confirm every mark faces the same direction.
(10) Measure the widest area of test piece after removing the connection-rod cover.
※ Standard value: 0.036～0.054mm
※ Limit value: 0.1mm
※ Note: The test piece must be removed upon the inspection.
80
Reference: The connection-rod bearing shell must be changed if the above measured value is beyond
the limit.
Method of choosing the connection-rod bearing shell
Chosen shell（symbol “C”）= connection-rod cover （symbol “A”）＋crankshaft（symbol “B”）
E.g.: if the symbol of connection-rod cover is 1 and that of crankshaft is 2, the chosen shell should
have a symbol of 3（1＋2=3）.
81
Chosen group
connection-rod cover （“A”） 1 2 3
crankshaft（“B”） 1 2 3 1 2 3 1 2 3
Chosen shell（“C”） 2 3 4 3 4 5 4 5 6
3. Dismount the connection rod.

① Screw out 2 connection-rod bolts with socket wrench.
Reference: Confirm the matching marks on connection rod and its cover.
② Slide a connection-rod cover back and forth while mounting it and connection-rod bearing shell
with 2 connection-rod bolts.
③ Remove the connection rod with piston from cylinder block.
※ Note: Connection-rod matching.
④ Remove the connection-rod bearing shell from connection rod.
82
4. Dismount the piston ring.
① Remove the 1st and 2nd gas rings with special tools.
② Take down the oil ring by hand.
5. Check the piston and piston pin.

① Remove the locking ring of piston pin hole with a thin, slotted screwdriver.
② Use a piston heater to heat the connection rod with piston to about 80℃.
③ Remove the piston pin and piston from connection rod (with piston).
※ Reference: Those dismounted components must be separately placed according to their

mounting position.
6. Check the crankshaft.
Key: Check its axial clearance.
Inspection tool: dial gauge
83
Reference: The crankshaft thrust washer or crankshaft must be replaced if this clearance goes beyond
the limit.
7. Dismount the crankshaft.

① Evenly loosen 10 main bearing cap bolts in 2～3 steps in the illustrated sequence and remove them.
② Remove the main bearing cap, main bearing shell and crankshaft thrust washer and then crankshaft.
Reference: Those dismounted components must be separately placed according to their mounting
position.
8. Dismount the injection nozzle.

① Dismount the oil check valve. ② Remove the injection nozzle.
9. Dismount the screw plug.
① Unscrew the bolts.
② Remove the screw plug.
84
10. Dismount the hose fitting of geared water pump.
11. Dismount the studs.
12. Dismount the cover of cylinder head pin.
13. Dismount the location pin of timing gear cover.
14. Dismount the location pin of rear oil seal seat of engine.
15. Dismount the location pin of rear cover.
16. Dismount the screw plug.
17. Check the cylinder block.

(1) Check the deformation of cylinder block.
Inspection tools: Ruler and feeler gauge.
Inspection method: Measure the surface deformation with ruler and feeler gauge, as shown in the
right-hand picture.
85
(2) Check the diameter of cylinder bore.
Inspection tool: bore dial indicator.
Reference:
The cylinder block must be replaced or bored when the diameter of cylinder bore is beyond the limit；
Bore grouping number is engraved on the upper surface of cylinder block.
Symbol of chosen bore Cylinder bore [mm]
1 92.00-92.01
2 92.01-92.02
3 92.02-92.03
86
18. Check the piston with piston pin.
Key:
(1) Check the outer diameter (OD) of piston.
Inspection tool: micrometer
Inspected position: 63.63mm to the upper surface of piston
※ Note: The replacement of piston, if necessary, should concur with that of piston ring.
※ Reference: On the upper surface of piston is the engraved symbol of piston OD.
(2) Check the piston clearance.
① Checking method
Calculate the piston clearance based on the min. cylinder bore and piston OD.
87

※ Note: The minimum cylinder bore should be measured in the anti-thrust direction of
cylinder.
Symbol of chosen piston OD Piston ID [mm]
1 91.92～91.93
2 91.93～91.94
3 91.94～91.95
Reference: If the piston clearance is beyond the limit, an O/S piston must not be used until the
cylinder block has been changed or bored.
Precision-bored size =（O/S piston size）＋（piston clearance）－（honed size 0.02mm）
O/S type Piston OD [mm] Cylinder ID [mm]
O/S（0.50） 92.42-92.45 92.50-92.53
O/S（0.75） 92.67-92.70 92.75-92.78
O/S（1.00） 92.92-92.95 93.00-93.03
② Calculate the ellipticity and conicity.

After the cylinder block has been bored, the cylinder bore must be measured with a bore dial
indicator so as to work out the ellipticity and conicity.
Limit: 0.02mm for both ellipticity and conicity
Reference: • Ellipticity…………..A-B or a-b
• Conicity……………A-B or a-b
Recheck the piston clearance.
(3) Check the piston pin.
① Check the OD of piston pin.
88
Inspection tool: micrometer.
※ Note: As there is no symbol on a piston pin, much care should be taken not to confuse it with
other piston pins.
Reference: On the upper surface of a piston is the diameter symbol of piston pin hole engraved.
② Heat the piston with a piston heater to about 80℃.

※ Note: Choose the piston pin of same number according to the grouping number of piston-pin
hole diameter.
③ Apply a small amount of engine oil on piston pin and insert it into piston, confirming with
thumb it has been in place.
※ Note: Don’t make bold to change the matching combinations among pistons and piston pins.
19. Check the piston rings.

(1) Check the clearance between piston rings and grooves, namely lateral clearance.
Checking method:
① At first install the rings on pistons making sure the piston side shares the same plane with
89
piston ring side.
② Measure the clearance between piston ring and groove around the piston with a feeler gauge.
Standard values:
1st gas ring 2nd gas ring Oil ring
Lateral 0.065～0.105 0.050～0.090 0.030～0.075
(2) Check the piston ring gap.

Checking method:
① Press the piston ring with piston until it is 120mm away from the upper surface of cylinder
block.
② Measure the piston ring gap with a feeler gauge.
Standard values:
1st gas ring 2nd gas ring Oil ring
Gap 0.065～0.105 0.050～0.090 0.030～0.075
Limit 0.85 1.07 0.77
90
20. Check the connection rod.
Key: Check the radial clearance of connection-rod small end.
(1) Measure the inner diameter (ID) of connection-rod small end bushing with a gauge.
Standard values:
Symbol “1” of connection-rod small end: 34.016～34.020mm
Symbol “2” of connection-rod small end: 34.020～34.024mm
(2) Calculate the radial clearance.

Calculate the radial clearance based on the ID of connection-rod small end bushing and OD of piston pin.
Limit value: 0.08mm

Reference: The connection-rod bushing, or piston and piston ring must be changed when the radial
clearance is beyond the limit.
91
21. Check the radial clearance of crankshaft
(1) Align the oil hole and block tongue, and mount the main bearing shell with oil groove onto
cylinder block.
※ Note: Don’t apply engine oil on the mounting surface and back of crankshaft bearing shell.
(2) Place the crankshaft on cylinder block.

(3) Crankshaft thrust pieces, after being spread with engine oil, should have their oil groove
positioned outward, and then be mounted in front of and behind the 5# main journal.
※ Reference: Push the crankshaft back and forth. Only when the mounting clearance of
crankshaft thrust pieces has increased can the crankshaft be mounted.
(4) With block tongue aligned, mount the main bearing shell on main bearing cap.
※ Note: Don’t apply engine oil on the mounting surface and back of crankshaft bearing shell.
92
(5) Crankshaft thrust pieces, after being spread with engine oil, should have their oil groove
positioned outward, and then be mounted in front of and behind the 5# main bearing cap.
(6) Set the test piece in the crankshaft journal direction.
※ Note: Don’t turn the crankshaft until the measurement of radial clearance has been
completed.
(7) Mount the main shell cap on cylinder block after determining its front-side mark and number, as
shown in this picture.
(8) Apply a small amount of engine oil on the threads and root of main bearing cap bolts, and then
evenly tighten them in for 2~3 times in the illustrated order.
93
(9) Make a colored mark on the top of main shell cap bolts and keep it facing the engine front.
(10) Tighten every bolt by another 90° based on the colored mark.
(11) Confirm every mark faces the same direction.
(12) Remove the main shell cap and then measure the widest area of test piece.
※ Note: The test piece must be dismantled upon the completion of this inspection.
Reference: The main bearing shell must be changed when the above measured value is beyond
the limit.
Method of choosing main bearing shell
Chosen number
Cylinder block（“A”） 1 2 3
Crankshaft（“B”） 1 2 3 1 2 3 1 2 3
Chosen shell（“C”） 2 3 4 3 4 5 4 5 6
94
● Installation：
1. Install the fuel injection nozzle
Align the location pin on the nozzle side with pin hole on the cylinder block side, and then install the
nozzle.
2. Install the crankshaft

① Align the oil hole and block tongue, and mount the main bearing shell with oil groove onto cylinder
block.
※ Note: Don’t apply engine oil on the mounting surface and back of main bearing shell.
② Place the crankshaft on cylinder block.
95
③ Crankshaft thrust washers, after being spread with engine oil, should have their oil groove
positioned outward, and then be mounted in front of and behind the 5# bearing journal.
※ Reference: Push the crankshaft back and forth. Only when the mounting clearance of crankshaft
thrust washers has increased can the crankshaft be mounted.
④ With block tongue aligned, mount the main bearing shell on main shell cap.
※ Note: Don’t apply engine oil on the mounting surface and back of main bearing shell.
96
⑤ Crankshaft thrust washers, after being spread with engine oil, should have their oil groove
positioned outward, and then be mounted in front of and behind the 5# main shell cap.
⑥ Mount the main shell cap on cylinder block after having determined its front-side mark and number,
as shown in this picture.
⑦ Apply a small amount of engine oil on the threads and root of main bearing cap bolts, and then
evenly tighten them for 2~3 times in the illustrated order.
※ Note: Tighten the mounting bolts of main shell cap in a plastic-range tightening method.
97
⑧ Make a colored mark on the top of connection rod bolts and keep it facing the engine front.
⑨ Tighten every bolt by another 90° based on the colored mark.
⑩ Confirm every mark are in the same direction.
3. Install the piston with piston pin

① Mount new locking ring into piston pin hole on one side of piston.
※ Note: A locking ring in installation must have its end A or B aligned with the notch on the related
piston.
② Heat the piston to about 80℃ with a piston-specific heater.
③ Align the mark on the front side of piston with that on the front side of connection rod.
④ After pressing the piston pin in with thumb, mount the connection rod on screw plug.
98
⑤ Put on new pin hole ring.
4. Install piston rings.

① Mount the expansion ring on piston.
② Mount the oil ring with a specific tool.
③ Place the expansion ring and oil ring as shown in the picture.
④ Mount the 1st and 2nd piston rings with a specific tool, with their marked face up.
⑤ Place the 1st and 2nd piston rings, oil ring and support spring.
Reference:
Number of piston ring Assembling mark
1st piston ring A1or1N
2nd piston ring A2orCYPR
99
5. Install the connection rod
① Mount the connection-rod bearing shell, whose block tongue and oil hole have been aligned, on
connection rod and connection-rod cap.
※ Note: Don’t apply engine oil on the mounting surface and back of connection-rod bearing shell.
② Apply engine oil on cylinder inner wall, piston exterior and connection-rod shell surface.
③ Confirm the gap position of piston rings.
④ Upon the identification of marks on front side of piston and connection-rod, mount the piston and
connection rod with a piston-ring compressor.
※ Note: The cylinder inner wall and crank pin must not be damaged in the installation.
⑤ Apply a small amount of engine oil on the threads and root of connection-rod bolts. ⑻ Tighten
connection-rod bolts with socket spanner.
※ Note: Tighten connection-rod bolts in a plastic-range tightening method.
100
⑥ Make a colored mark on the top of connection rod bolts and keep it facing the engine front.
⑦ Tighten every bolt by another 90° based on the colored mark
⑧ Confirm every mark are in the same direction.
⑨ Confirm the crankshaft rotates normally.
⑩ Identify the thrust clearance of connection rod.
Ⅲ Items related to piston and crankshaft
● Light and perfectly shockproof, the resin material adopted by cylinder head cover has not only reduced
the engine weight, but ensured the strength of cylinder head cover. With the improvement in the shape of
this cover, engine noise has been reduced. By installing a traverse baffle in the cover and extending the
ventilation duct out of cover roof, the fuel cutout capability has also been enhanced. In addition, both
traverse baffle and ventilation duct are made of resin, so the engine becomes lighter.
101
● Improvement has been made in the diameter of PVC tubes to prevent water inside the tubes from
freezing at a low temperature.
● The cylinder head gasket adopts heatproof and oil-proof ACM (acrylate rubber) to ensure its reliability.
● The cylinder head is made of light aluminum alloy with superior thermal conductivity. Also, adopting
the DOHC and 4-valve structure and vertically aligning injectors at the center of cylinder head has
endowed the engine with not only higher performance but better reliability, achieving the low-emission,
downsizing target.
● The cylinder head gasket is formed by 4-layer steel pieces with superior sealing performance and heat
resistance.
1. Piston and piston rings

¾ Piston
● Material: light, heat-resistant, eutectic Al-Si alloy casting, whose exterior is tin-plated to improve
the running-in performance.
● Structure: as shown in right-hand picture.
102
● Main characteristics:
① The inside of piston ring groove is designed with cooling oil channel, through which oil out of
injection nozzle cools the piston, solving the problem that the temperature of piston top increases
with power output. As a result, the abrasion resistance of piston is enhanced.
② An reentrant round ω shape suiting the direct injection system has been adopted for combustion
chamber to improve the combustion efficiency, thus achieving the target of high output, low fuel
consumption and low emission.
¾ Piston rings
● The 1st gas ring adopts alloy steel to ensure the wear resistance of piston.
● The 2nd gas ring reduces the piston ring tension and friction to achieve low fuel consumption.
● Oil ring adopts coil spring scraping oil effectively.
1.Piston weight grouping mark 2.Piston skirt diameter grouping mark 3.Piston pin hole grouping mark
4. Print direction mark 5.Insert ring 6.Reentrant quadrangle combustion chamber;7.Cooling oil channel Piston structure
2. Crankshaft
The crankshaft is cast, consisting of 5 journals and 8 balance weights. The Considering the environmental
factor in addition to more strength and less weight, superior alloy steel is therefore chosen. On top of this,
improvement has been made in the weight balance of running crankshaft, and vibration and noise has
been reduced.
For the structure of crankshaft, see this picture.
3. Flywheel
The flywheel is a cast round disc at the rear of crankshaft. It has 3 outward grooves on the friction surface
for taking away a large amount of grindings and heat produced by the friction between clutch disc and
103
flywheel, whose lifespan can therefore be lengthened. On the rim of flywheel is a toothed ring assisting
the starter in starting the engine.
Dismounting
① Fasten the crankshaft with tools.
② Take down 8 bolts and then remove the flywheel.
③ Dismount the rear partition.
Install the flywheel

① Mount the rear partition with bolts.
※ Standard value: T=8.0N.m（82kgf.cm）
② Fasten the crankshaft with tools.
Apply sealant on the thread 2～3 pitch away from the top of locking bolt.
※ Note:
a. Clean and degrease the bolts and bolt holes.
b. The engine must not be started within 1h after this installation.
③ Align the pin hole on flywheel with pin hole or pin on crankshaft flywheel mounting surface.
104
④ Fix the flywheel with 8 bolts.
※ Note: Evenly tighten the bolts on opposite sides and in the diagonal lines.
※ Standard value: T=178±18N.m{1815kgf.cm）
Lubrication system
● This lubrication is characterized by full pressure feed and full filtering.
● On the front end of oil filter is an efficient oil cooler targeting the cooling performance gain.
● The use of oil jet, by cooling and lubricating the pistons more effectively, has made the engine more
durable and reliable.
1. Structure of lubrication system
Lubrication mode: combination of pressure lubrication and splash lubrication.
Lubrication system: including oil sump, oil strainer, oil pump, oil filter, oil intercooler, cylinder-block
main oil channel, piston cooling injector, and oil pressure sensor and oil pressure gauge. (See the
“Lubrication system diagram”).
Pressure lubrication: targeting supercharger, main bearing, connection-rod bearing and camshaft bearing
etc. (See the “Oil-way diagram of lubrication system”)
E.g.：The supercharger adopts pressure lubrication, which is to ensure enough lubrication and cooling of
rotor and bearings in their normal operation. Lubricant for supercharger recirculates from main oil
channel of cylinder block, via oil inlet pipe into supercharger, then through oil return pipe back to oil pan.
Splash lubrication: targeting piston, piston ring, piston pin, cylinder sleeve, camshaft and oil pump gear
etc.
105
Lubrication system
Oil-way diagram of lubrication system
2. Oil filter
Structure:
An oil filter consists of filter bracket assembly, spin-on cartridge and sealing ring. Inside the filter is a
safety valve, along with a pressure limiting valve forcing excessive oil back to sump.
Type: full-flow type.
106
※ Suggestion: For a new vehicle, the 2,000 km running-in haul should end up with the replacement of
oil filter, and thereafter, every 8,000 km should be ended with the replacement of both oil and oil
filter.
※ Note: Unclean oil will exacerbate the wear of parts and might even block the oil way, so oil filter
should be maintained periodically according to technical requirements.
※ Note: No leakage is allowed on the faying surface between oil filter housing and base. Nor should
damage on parts is allowed.
Specifications of oil filter
Type Full flow
Filtering mode With filter paper

3
Filtering capacity [cm ] 90
OD*height [mm] φ76.3*84.4
3. Oil pump
● It is a gear pump (see the right-hand picture) fixed on gear chamber and driven by helical gear on
camshaft.
● Merits:
① Small volume
This small pump adopts 5 blades and 6 cycloidal teeth. It is driven by crankshaft timing gear
through pump driving gear. In addition, the integration of pump driving gear and timing gear
chamber has cut the engine size to achieve the engine downsizing.
② Low friction
Internal depressurization has been introduced to regulate the oil feeding resistance and reduce the
friction.
● Technial requirements of installation
① The assembled pump should rotate flexibly and stably, without any seizure.
107
② No oil leakage is allowed on the frying surface.
③ The opening pressure of pressure regulating valve is 480±49kPa.
Oil pump
1. Gear chamber 2. Oil pump sealing surface 3. Pump inner rotor 4. Pump outer rotor
5. Pressure regulating valve screw-plug washer 6. Screw plug for pressure regulating valve
4. Oil sump
● It functions as a closed crankcase to collect and store the lubricant.
● Upon the installation, oil sump should be checked for leakage in the operation of hot engine. If there
is leakage, the relevant nuts and bolts should be tightened. If the leakage still exists, oil sump should
be dismounted for a check.
5. Dipstick
● Dipstick is a tool checking the oil level in lubrication system.
● On the dipstick are upper (7.5L) and lower (5.5L) marks machined for oil level check.
Oil sump
1. Oil sump 2. Oil drain bolt 3. Oil drain bolt washer
108
Dipstick
Cooling system
● Water-cooled forced recirculation has been adopted for cooling purpose here. A thermostat with
bypass valve has been arranged where the water inlet is located.
● As a double-layer (upper and lower) structure, the water jacket in cylinder head has higher cooling
power towards lower part of cylinder head.
● Newly developed downflow all-aluminum radiator has been adopted.
Water pump
● Water pump casing is made of light aluminum alloy.
● The volute shape is optimized and the pump volume is reduced.
Pump specifications
Rotor diameter [mm] 75
Bearing diamter [mm] 30
Number of blades 6
Displacement [L/min]（at 5000r/min） 180
109
¾ Dismounting
1. Turn on the drain plug to let out the coolant.
2. Remove the integrated belt.
3. Unscrew the dipstick holding bolts.

4. Dismantle the generator and its support.
5. Dismantle the air conditioner compressor and its support.
6. Unscrew 4 nuts and take down the fan and fan pulley.
7. Remove the phase sensor.
8. Dismount the outer cover of timing belt chamber and the timing belt.
9. Dismount the camshaft timing pulley.
110
10. Dismount the timing belt idler.
11. Dismount the inner cover of timing belt chamber.
12. Dismount the water pump assembly.

(1) Check if there is coolant out of drain plug.
(2) Turn the pulley to confirm it is free from abnormal noise and seizure.
13. Dismount the water inlet pipe.
111
13. Take out the thermostat.
(1) Soak the thermostat into water and heat it slowly.
(2) Check the temperature as the valve begins to open.
※ Standard value: 80～84℃
(3) Check the uplift of valve.
※ Standard value: Uplift: over 10mm
Full-open temperature: 95℃
(4) Check if the value is fully closed when the thermostat is at low temperature (below 40℃).
※ Reference: If the value isn’t fully closed, the thermostat must be changed.
¾ Installation
1. Install the thermostat.
(1) Mount the washers on thermostat.
(2) Mount the thermostat as shown in the picture by keeping its rocker valve up.
※ Reference: Keep it within ±15° right above the rocker valve.
2. Install the water inlet pipe.

Fix this pipe with 3 bolts.
※ Standard value: T＝13N.m
112
3. Install the water pump assembly.
Renew the washers and fix the water pump assembly with 5 bolts and 2 nuts.
4. Install the inner cover of timing belt chamber.

5. Install the timing belt idler.
6. Install the camshaft timing pulley.
7. Install the timing belt, outer cover of timing belt chamber, as well as phase sensor.
8. Install the water pump pulley, silicon oil clutch and fan.
9. Install the AC (air conditioner) compressor support and AC.
10. Install the generator support and generator.
11. Fix the dipstick duct.
12. Install the integrated belt.
113
Function Diagnosis and Fault Remedy
Brief Introduction of Basic Control by Electric Control System
Control of operating state

To enable an optimal combustion process for engine under every working condition, the ECU is required to work
out reasonable fuel delivery in every case. In this process, various parameters must be taken into consideration.
For the calculation of fuel delivery in ECU, refer to the following chart:
Control of operating state
To enable an optimal combustion process for engine under every working condition, the ECU is required to work
out reasonable fuel delivery in every case. In this process, various parameters must be taken into consideration.
For the calculation of fuel delivery in ECU, refer to the following chart:
Starting fuel charge

In terms of starting, the fuel charge is function of temperature and crankshaft speed. It is the accumulated fuel
charge from the moment when the starting switch is turned to “start” position (position A in the previous picture
where fuel is transiently injected) to the moment when engine reaches the required minimum speed. It is immune
to driver.
The vehicle will undergo such standardization tests as plateau test, high-temperature test and high cold test to
ensure the engine can be normally started in various environments so that the vehicle can be driven even in a
formidable environment.
Starting pre-heat
114
In case of starting the engine at <75 ℃ water temperature, the heater plug should pre-work for a period to
ensure a smooth start as the ignition switch is switched on. This pre-working state is demonstrated by 0～12s
illumination of heater plug. The lower the water temperature is, the longer the pre-heating period becomes. If
water temperature is lower than 40℃ during and after the start, the heater plug will also work for 0～180s based
on water temperature, and the increase in its pre-working time will be in proportion to the decrease in water
temperature as well to ensure normal start and stable operation of engine.
Transport condition
When the vehicle is running normally (see the previous picture in which the start switch is in the position B), the
fuel charge can be calculated based on accelerator pedal device (accelerator pedal sensor) and engine speed. The
transmission diagram should be utilized for this calculation concern so as to match the driver’s input to engine
O/P (output) power optimally.
Idle speed control
With the idle speed controlled, fuel consumption will mostly depend on engine efficiency and idle speed. As the
fuel consumption of vehicle hinges on its working condition in a heavy traffic, it is obvious that the idle speed
should at best be minimized. But the idle speed must be set under whatever condition so that engine speed won’t
drop too much under a load to make the engine almost stall or stall.
E.g. when electrical system is being loaded, when AC is on, when automatic gear shift is busy, or when power
steering device is operating – there is a load on engine.
To achieve the required idle speed, the idle speed controller will change the fuel charge until actual engine speed
is just the required idle speed. Here, this speed, together with speed governing characteristics is subject to the
influence from specific gear and engine temperature (coolant temperature sensor). In addition to external load
torque, internal friction torque must also be considered and offset through idle speed control. Minor and quite
stable in the service life of vehicle, these changes are closely related to temperature.
Take the PALADIN as an example: after starting the engine at <5℃ water temperature, this system will govern
the engine speed for 2s preheating period, in which engine speed will exceed the 800rpm target idle speed. The
lower the water temperature is, the higher the speed of started engine will be – but lower than 1000rpm. As the
vehicle runs, the idle speed at every gear is unexceptionally 200rpm.
If the AC is switched on during as engine idles, the AC compressor will start working within 2s, meanwhile the
target idle speed will rise to 810rpm to weaken the influence from compressor operation.
The idle speed controller can unexceptionally stabilize the idle speed at the target point whenever the steering
wheel is turned, the headlamps are turned on or other loading function is activated.
Note: for different vehicle types, both target idle speed and AC idle speed may vary slightly due to the influence
from factors such as load, driveline and noise, and are subject to adjustment and calibration as the case may be.
Smoothrunning control
Mechanical tolerances and aging will lead to the torque deviation among engine cylinders, which will further
cause rough running of engine during its running particularly idling period. Smoothrunning governor can calculate
the speed change based on every combustion process for mutual comparison and regulate the fuel delivery of
every cylinder as per the measured speed difference, enabling every cylinder to make the same contribution to
engine torque. But it functions only when engine runs at a much lower speed.
Control on fuel charge limit
There is a series of reason to demonstrate why the fuel amount required by driver or physically realizable to the
utmost extent can’t be injected, including:
− Excessive pollutant emission
− Excessive carbon black emission
115
− Mechanical overload caused by oversize torque or engine speed
− Thermal overload due to overhigh temperature of condensing agent, oil or turbocharger
This fuel charge limit is the result of various inputs, such as air intake, engine speed and coolant temperature.
Take the PALADIN as an example: for s standard electric fan, its opening temperature is 90℃ and closing
temperature is 88℃; While for a high-speed fan, its opening temperature is 95℃ and closing temperature is 90℃.
If air temperature or load is so high that electric fan can’t control water temperature （≥105℃）, engine will be
overheated. At this moment, the system will automatically regulate the fuel charge to limit the engine output so as
to hold the temperature within a safe range. Thus there will be a little drop in power – from the perspective of
engine protection, this is necessary. If water temperature is higher than 95 ℃ in engine stalling, the fan will also
go on working for 10～120s to bring down water temperature.
The same is true with AC, which will activate its protective function by shutting off when water temperature is
above 105℃, to reduce the load on engine. However, when water temperature drops to 102℃, the AC will
automatically start to work.
Standardizing the protective function of supercharger and oxidation catalytic converter through high-temperature
and plateau tests is also based on such a principle – the system will automatic regulate the fuel charge to limit the
supercharger speed within 180,000 rev./min under various working conditions and keep the exhaust temperature
within 700℃ (sometimes over 700℃ temporarily but below 750℃) .
Also, the temperature threshold for various protective functions will vary with vehicle type, radiation system and
engine compartment structure, but for a common purpose – to ensure safe, steady running of both vehicle and
engine.
Activated shockproof control
Suddenly stepping or releasing the accelerator pedal will result in rapid change in fuel charge and later engine
torque. With such a sudden change in load, elastic engine base and driveline will jerk so violently that engine
speed fluctuates (see the following picture).
This periodic fluctuation in engine speed can be weakened by activating the shock absorber, which will contribute
to the same speed fluctuation frequency to change the fuel charge. The higher the engine speed, the less the fuel
charge; vice versa – this has effectively cushioned the oscillation.
Activated shock absorber

1. Sudden movement of accelerator pedal (signal input by driver)
2. Speed curve with shock absorber deactivated
3. Speed curve with shock absorber activated
116
Engine stalling
A diesel engine will run in the principle of automatic ignition, which means it can only rely on fuel cutoff to stop
running.
An engine with electric control unit can be stopped by meeting the “zero fuel charge” requirement specified by
ECU. Also, the system has been supplied with a series of additional fuel cutoff approaches ready for motion.
Integrated troubleshooting function

Sensor monitoring
An integrated troubleshooting system can monitor if sensors have been fully powered and if their signal is real
(e.g. the temperature is -40℃ ～150℃). If applicable, an important signal should be provided with a redundant
signal, that is to say, in the case of a fault, the redundant signal can be turned to for continuous operation.
Monitoring module
In addition to microprocessor, there is a Monitoring module in ECU. This module and ECU can monitor each
other. If something is wrong, either of them can independently cut off the fuel injection.
Fault identification
Only within the sensor monitoring range can the fault identification function be utilized. If the presence time of a
fault is longer than the preset identification time, this signal channel will be judged as in a trouble. In this case,
this fault, along with its environmental conditions (such as coolant temperature and engine speed etc.) will be
stored in the fault memory of ECU.
In case of a lot of faults, it is necessary to reset the “normalizing” state. In this regard, the signal channel must be
confirmed integral within a specified period.
Fault handling
The output signal of a signal beyond the allowable range can be converted into a set value. This procedure is also
applied to the following input signals:
− Battery voltage
− Temperature of coolant, air and lubricant
− Supercharging air pressure
− Atmospheric pressure and air intake
In addition, if something is wrong with the signal of accelerator pedal sensor or braking signal, the redundant
value of accelerator pedal sensor can be applied.
Take the PALADIN as an example: if water temperature sensor gets into trouble, the system will adopt the
redundant water temperature value, which is －25 ℃ prior to engine start to ensure the success in starting and is
90 ℃ after the start to ensure the smooth running. Meanwhile, electric fan controller will also take 105 ℃ as
the default water temperature. The fan will go on working to ensure water temperature in engine won’t become
overhigh without being monitored. Except the engine speed sensor, most of sensors are provided with their
redundant value to ensure the vehicle, once in trouble, can be driven to a service station for repair.
System lamps
Trouble lamp：
After switching on the ignition switch without starting the engine, the trouble lamp will light up for 1s self-check
and then go out. If there is a trouble in the system, this lamp will light up again to remind the driver of repair. If
the lamp is lightened in engine running, the driver should stop the vehicle immediately for a check.
117
OBD lamp：
After switching on the ignition switch without starting the engine, the trouble lamp will shine constantly. But after
the engine is started, it will go out. If emission from a running engine goes beyond the standard just because of a
fire, the OBD lamp will light up to remind the driver of checking the engine.
2.5L-TDI engine with BOSCH common-rail injection system
Troubleshooting
1. Introduction of Main Functions of Troubleshooter
2. Failure Code List
3. Common Failure Modes
Main Functions of Troubleshooter
118
119
120
Failure Code List
121
122
123
124
125
Common Failure Modes
Failure symptom Checked position
1. Battery
Absence of crankshaft rotation 2. Starter
3. Starter relay
1. Replacement of fuel filter
2. Fuel injector
3. Engine control unit
4. Components of fuel feed pump

Unsatisfactory high-speed idling
5. Fuel pressure sensor
6. Fuel quality
7. Engine water temperature sensor
8. Fuel piping（the pipe between fuel tank and feed pump is jammed）
1. A/C signal loop
2. Fuel injector
3. Engine control computer
Overhigh idle speed 4. Fuel feed pump
6. Engine water temperature
7. Accelerator pedal components
126
1. A/C signal circuit
2. Fuel injector
3. EGR system
4. Compressor
5. Valve clearance
Too low idle speed
6. Fuel piping
8. Fuel feed pump
10. Engine throttle body
1. Fuel injector
2. Fuel piping
3. EGR system
4. Compressor
5. Valve clearance
Unstable idle speed 7. Fuel feed pump
10. Fuel properties
11. Air conditioner system
12. Power steering system
13. AC (alternating current) generator
White smoke emission 1.EGR system
2. Fuel injector
127
3. Replacement of fuel filter
5. Fuel feed pump
8. Fuel properties
9. Compressor
10.Turbocharger
Black smoke emission 1. Analysis on the cause of black smoke
Abnormal starting and engine stalling 1. Analysis on the cause of abnormal starting and engine stalling
1. Analysis on the cause of power deficiency, engine trembling and engine speed
Power deficiency
fluctuation
Unstable idle speed and violent vibration 1. Analysis on the cause of unstable idle speed and violent vibration
Knocking and abnormal sound 1. Analysis on the cause of knocking and abnormal sound
1. Fuel injector
2. ECU power circuit
3. Compressor
4. Fuel piping
5. Valve clearance
Engine speed fluctuation 6. Engine control computer
7. Fuel feed pump
10. Air conditioner system
11. Power steering system
128
Afterword
● This book has described the essentials in repairing a DK4A diesel engine.
● If you apply this material in a flexible way, you are expected to achieve correct and safe engine
maintenance.
● This manual is aimed at engines produced before August 2007.
● Engines produced thereafter are subject to change without notice.
Mianyang Xinchen Power Machine Co., Ltd.

August 2007
129

01 Dk4a Engine

Uploaded by

Copyright:

Available Formats

01 Dk4a Engine

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

01 Dk4a Engine

Uploaded by

Copyright:

Available Formats

Service Manual of DK4A Diesel Engine

Mianyang Xinchen Power Machine Co., Ltd.

Safety Warning ································································································································· 1

Main matched vehicle types·············································································································· 2

Service Manual of DK4A Diesel Engine Care and Maintenance ··················································· 3

Service Manual of DK4A Diesel Engine Electric Control System·················································· 13

Service Manual of DK4A Diesel Engine Mechanical System························································· 42

SUV light-duty bus Cross-country vehicle

Pickup MPV light-duty truck

Notes for Engine Repair

10. Dismounting of components in fuel system

13. Applicable fuel (recommended): in summer： 0#

Name Item Parameter

Nominal voltage 14V

Camshaft timing gear First：85 N·m

Flywheel bolt 178N·m

Lubrication Oil pump Rotor type

Road haul(km) Load on automobile Engine speed(r/min)

Seasonal technical maintenance

Notes for technical maintenance

3.1.1 High-pressure pump

1. Fundamentals of diesel engine 3.1.4 ECU

3.2.1 Crankshaft position sensor

1. Fundamentals of Diesel Engine

High-pressure control Torque control

High-pressure pump fuel rail fuel injector

High-pressure pump fuel tank

Fuel injector fuel tank

3. Common-rail system components - core components

Fuel pump Fuel rail

3.1.1 Core components – high-pressure pump

Fuel inlet valve Piston

3.1.1 Core component – high-pressure pump

Correct packing method of high-pressure fuel pump

Correct installation of high-pressure pump

Mounting and dismounting the high-pressure pump

Air bleeder bolt

Sealing ring Central bushing Driven tooth

High-pressure pump with inlet

3.1.2 Core component – fuel injector

This injector, indirectly driven by solenoid valve,

Pressure range：up to 1,450 bar

Nozzle ： small-orifice type with single pin

Movement diagram of armature winding(open)

Valve, piston, needle closed position

Valve, piston, needle open position

High-pressure pump with inlet

Rail pressure sensor

Hardness of fuel pipe head: ≤HV250

The rail fitting is sealed through the

Rail pressure sensor

• The rail pressure sensor is integrated at

• The flow limiting valve is installed inside every

3.1.4 Core component – ECU

High-pressure pump with inlet

Basic software functions：

• The ECU must be installed in a dustproof and dry area,

3.2.1 Other component – Crankshaft position sensor

Function and principle: