DK5 Engine Manual

DK4 Diesel engine
Service Manual
Mianyang Xinchen Engine Co.,Ltd.

Jan. 2010 First Edition
CATALOGUE
Safety Warnings …………………………………… 003

Applicable types of vehicle………………………….. 004
Engine repair & maintenance ……………………… 005
Engine maintenance & electric control system …… 032
Engine repair & mechanical system………………… 089
Engine repair & troubleshooting …………………… 182
Page 2 14:14
Safety warnings
 Don’t change the usage range of the engine at will.
 Don’t adjust fuel supply pressure at will.
 Don’t convert engine at will.
 Don’t adjust and clean engine while the engine is running.
 People with loose cloth and long hair must keep away from the running engine,
don’t touch the running parts. After engine running, the temperature of the exhaust
system and turbocharger system of engine are so high that don’t contact them to
avoid burning.
 When engine is under high temperature, don’t open the filler cap of the coolant
immediately to avoid the high temperature fluid spurting out to hurt people.
 When engine is under high temperature, don’t stop it immediately, should keep
running of the engine at idle speed at least 5 minutes.
 When assembling and disassembling the injector, the injector and copper gasket
should be one-one correspondence fixed.
 Water in oil-water separator should be drained in time according to the instruction.
 The engine, vehicle lines, oil tubes and rubber parts, etc should be kept away from
the exhaust manifold, turbocharger and rotating parts.
Page 3 14:14
Applicable types of vehicle
Light-duty bus ORV
Light-duty truck
Pickup
Page 4 14:14
DK4 Diesel engine
Service manual
Maintenance
Page 5 14:14
Engine maintenance attentions
1. Issues about prevention of impurities invasion
(a) If impurities of dust, sand and metal particles, etc invade into the interior of engine, engine problems may be
caused.
(1) Completely clean the sand and dirt, etc in the engine.
(2) The removed parts should be covered with plastic film to prevent dust and sand.
2. Issues about preventing the scratch of engine parts
(a) If the matching surface or rotating parts of the engine are scratched, that may cause oil leakage or ablation.
(1) When disassembling the matching surface of the engine parts, should use plastic hammer to hammer parts lightly
in stead of using the screwdriver.
(2) When fixing parts with pliers, should wrap parts with aluminum plate firstly.
3. Issues about cleaning engine parts
(a) Before assembly, all parts should be cleaned clear and dried with air, then coated with specified oil.
(b) Parts forbid to be cleaned with alkaline drugs : aluminum parts and rubber parts( cylinder head cover and
gasket, etc).
(c) Parts forbid to be cleaned with cleaning oil ( kerosene, petrol, etc): rubber parts (cylinder head cover and gasket ,
etc).
4. Issues about assembly location and direction
(a) Assemble the parts in sequence as the original location and direction.
Page 6 14:14
(b) Must strictly mark the parts in sequence.
(c) When collecting the removed parts, pay attention not to change the location and direction
of the parts.
(d) Must strictly assemble the parts in sequence as the marked location and direction .
5. While repairing the engine, must put the assembly parts in the work piece support firstly.
6. The removed parts must be collected in sequence.
7. The sliding parts and rotating parts must be coated with engine oil.
8. The cushions and seals could not be reused, must change them with new one.
9. Basic attentions
(a) Pre-spraying bolts
(1) The pre-spraying bolt is coated with sealant on part of
threads.
(2) If it’s necessary to retighten, loose or rotate the bolts, must
put specified sealant on them firstly.
Notice: While correcting the torque, the tightening torque
could not less than the minimum.
(3) When re-using the pre-spraying parts, must clean the Sealant
sealant of bolt and thread hole firstly, then degrease them with
gasoline, and dry with the compression air, lastly put the specified
sealant on the bolt and tighten it with required torque.
(4) For some kinds of the sealant must be put for a long time to
become hard.
Page 7 14:14
10. Removal of the fuel system parts
(a) Removal workplace of the fuel system parts
(1) The Removal workplace should be ventilated, without sparks, away from the electric welding machine,
grind, drill, electric machines and stove, etc.
(2) Forbid to work at the pit or nearby place where filled with gaseous fuel.
(b) Removal of the fuel system parts
(1) The extinguisher must be prepared before removal.
(2) To prevent static generation. Should sprinkle enough water on the ground at the time that fuel switch,
vehicle and fuel tank connect with the ground wire.
(3) Don’t use electrical equipments such as electric pump and working light, since they may cause sparks
or they are usually under high temperature.
(4)Don’t use iron hammer since it may cause sparks.
(5) The cloth pieces polluted by fuel must be disposed separately.
11. Removal of the air intake system parts
(a) If the metal particles enter into the air gallery, the engine and
turbocharger devices may be damaged.
(b) When disassembling the parts of intake system, must use clean
cloth or plasters to plug the removed parts and the opening side of the engine.
(c) When installing the air intake system, must ensure that no metal
particles and sands entered into the parts.
Page 8 14:14
12. Hose clamps disposal
(a) Must confirm the insertion depth and hose clamp
location before disassembling the hose, in order to recover Stick tightly
the hose as it is.
(b) Must replace the distorted or loose hose clamps.
(c) When reusing the hose, the hose clamps should be fixed at
original location of the hose.
Hose clamps trace
(d) After fixing the leaf spring hose clamps, press it along
the arrow until stuck tightly.
13. Applicable fuel (recommend):
Summer: No.0
Winter: No.-10
-20℃: No.-20
-30℃: No.-35
14. Applicable lubricant (recommend): API Grade CF-4 (or above) 20W-50
GB11122 Grade CF-4 (or above) 20W-50
Page 9 14:14
Notice：
(1) Must use clean engine oil in accordance with required grade. Common engine
oil could not be used to avoid accidents such as cylinder score and bearings
burning, etc.
(2) Engine oil filled in the engine could not contain impurities and water. Should
keep the oil filler inlet of oil tank clean.
(3) Forbid to mix diesel engine oil with different grade and brand oil. When
replacing engine oil in technical maintenance, forbid to mix the new and old oil.
(4) Replace oil filter in time according to the requirement.
Page 10 14:14
15. Coolant selection
(1) Should select antirust & antifreeze coolant to avoid engine faults such as higher
water temperature and cylinder score, etc caused by water scale of waterway
(water jacket).
(2) Antifreeze is harmful to human. So it should be stored in its original container,
and don’t touch it.
(3) Distilled water and clean soft water (boiled water, snow and rain water ) could
be used instead of antifreeze, if use hard water such as river, well, spring and tap
water, the water must be cleaned and softened, add 2g Na3C2P can soften the
water.
Notice：
(1) When operating diesel engine, forbid to add coolant randomly, should meet the
requirement of the manual.
(2) If the coolant is insufficient due to leakage of the cooling system, add the same
kind of coolant in engine after troubleshooting. Should add coolant in the engine
when engine is cool.
(3) Forbid to use poor quality coolant and forbid to mix different types of coolant, or
else, the service time of engine will be affected by corrosion, scale deposit, etc.
(4) Forbid to use kinds of hard water without treatment. Otherwise water scale will
be produced, and that will cause engine troubles such as high water temperature
and cylinder score, etc.
Page 11 14:14
Technical specifications
1. Key technical specifications of generator and starter
Name Items Specifications

Nominal voltage 14V
Generator
Rated current 80A
Voltage 12V
Starter
Output power 2.7kW
Page 12 14:14
Technical characteristics
1. Key technical specifications of generator and starter
Names of bolt Names of bolt

Tightening torque Tightening torque
and nut and nut
Camshaft timing
90 N·m～98N·m
gear bolt 1st time: 85 N·m
Cylinder head
2nd time: tighten 90°
bolt
Main journal 1st time: 50 N·m±5.0N·m 3rd time: tighten 90°
cover bolt 2nd time: tighten 90°
Flywheel bolt 178N·m

Crankshaft
Connecting rod 1st time: 35 N·m±3.5 N·m 365N·m
pulley bolt
nut 2nd time: tighten 90°
Notice : while tightening the main bolts and nuts of diesel engine, must use the special
torque wrench.
Page 13 14:14
Technical characteristics
Specifications of key accessories

System & name of accessories Type Accessory system & name Type
Oil pump type Rotor

Lubricant
Water pump type centrifugal
system
Oil filter type Full flow type
Cooling system
Fuel filter type Full flow type
Pellet type
Thermostat type
thermostat
HP pump type Plunger type
Oil supply
system
HP pump type CP1H HP pump
Preheating Glow plug
12V
system voltage
Injector type 6 ports
EGR electric
Air intake Supercharge Exhaust
control EGR system
system type turbocharger
system
Page 14 14:14
Use of diesel engine
a. Preparation of start
• Inspect whether all the parts of the engine are in normal state, correct connection, well
tightening and flexible rotation.
• Fill engine oil, fuel and cooling water according to requirement, and observe whether there is
the leakage phenomenon.
Notice: When oil level is below the warning level of oil dipstick, fill oil in time to avoid major
accident.
Inspect the tension of water pump belt
• Inspect the liquid level of electrolyte in battery.
• Inspect joints tightening of electrical equipments such as battery, generator and starter.
• If air entered into the fuel system, remove the air out before starting of the engine.
• Exhaust method:
Firstly, exhaust the oil inlet pipe and pump oil with pump until air bubbles completely
drained out. Secondly, release the screw cap at the outlet of the injection pump, and pump
with starter until fuel flows from the outlet of the injection pump.
Page 15 14:14
b. Start of diesel engine

Under any circumstances, the start of diesel engine should be on the no-load (neutral
state) state.
• Turn key to ON to connect power, observe whether all of the electrical
instruments are in good condition.
• Start the diesel engine.
• Turn switch to Start, then the engine could be started in 15 seconds, if it could
not, try again two minutes later. If it can not be started continuously more
than 3 times, restart after troubleshooting. After engine start, should release
the switch immediately to completely separate the starter gear and flywheel
gear in order to avoid damaging the starter.
• After engine start, the diesel engine should run at idle speed for 3-5min. Check
whether the oil pressure gauge is in good condition, and the cycle of cooling
water works well. Forbid to promptly run the engine at high speed after start.
Page 16 14:14
c. Cold start
When the ambient temperature is low, it might be hard to start the diesel engine. The
lower the ambient temperature is, the harder to start the engine. When the temperature is
under -15 ℃, it might be hard to start the engine if without taking some cold start supporting
measures. The cold start difficulty may be caused by the followings.
• When the ambient temperature is low, the temperature of air enter into the cylinder block is
low, the temperature of compression point is too low to reach the compression burning
temperature.
• When the ambient temperature is low, the viscosity of diesel is high, the diesel atomization
quality is poor, so it’s hard to burn.
• When the ambient temperature is low, the engine will have high engine oil viscosity, high
starting resistance torque, low starting speed, great air leakage in compression stroke, great
heat transfer rate of working medium and low of compression end, that may make the engine
difficult to start. When the ambient temperature is low, the interior resistance in battery
increase greatly, the charging and discharging ability decrease greatly, that may lower the
starting torque and make the engine difficult to start. The measures to solve the problem are:
• Select the right diesel
• Select the right engine oil
• Select the right starter and storage battery
• Preheat the diesel engine. Release the coolant firstly and preheat the engine with hot water.
The process is to add adequate hot water into the radiator, and release the water after the
water get cold through water jacket, then refill the hot water to run the engine, after that,
release the hot water after heating the engine, lastly add antirust antifreeze fluid to the engine.
Page 17 14:14
d. Inspection during engine running
• Inspect if there are knock, looseness or other abnormal sounds.

• Inspect whether there are abnormal burning smell caused by electrical
equipments.
• Inspect whether there is water, oil or fuel leakage from the fuel,
cooling or lubricating systems.
• Inspect whether the instruments of engine oil pressure, coolant
temperature, current and diesel level are in normal state.
• If any of the above troubles happened, resolve the trouble promptly.
Page 18 14:14
e. Stop running of the engine
• When diesel engine is running with full load, before stop running of the
engine, should firstly reduce the speed and load of the engine to
minimum no-load speed and keep run for 3～5min. Forbid to stop
engine suddenly when the engine is under high water temperature and
with heavy load.
• When temperature is under 5℃, if no antifreeze is added into the
cooling water, release the cooling water of engine completely after
engine stop to avoid frosting the cylinder block.
Page 19 14:14
5. Running-in of diesel engine
Before using a new or repaired diesel engine, the engine load

should be increased gradually during running-in process. All the
operating parts should work well after running-in process, that will
help to avoid the abnormal wear and damage of the engine. The
performances of service life, reliability and economy of an engine
greatly depend on the early running-in process. Therefore, the
running-in process must be in accordance with the requirement.
Page 20 14:14
a. Engine Running in
• For the vehicle with new engine, running in 2000km is needed in accordance with the requirement
(see table below).
• For vehicle, after repairing engine parts such as piston, piston ring, cylinder liner, main bearing
bush and connecting rod bearing bush, the diesel engine, etc. , the vehicle should be driven to 1/3
mileage of the following mileage in the table during running-in process. In running-in period, the
assembly quality of the engine could be further inspected and adjusted if necessary.
Mileage（km） Load Engine speed（r/min）
0～300 No load Less than the rated speed of 50%
>300～1000 Less than the rated load of 25% Less than the rated speed of 50%
>1000～1500 Less than the rated load of 50% Less than the rated speed of 50%
>1500～2000 Less than the max. rated speed

Less than the rated load of 75%
Page 21 14:14
b. Running-in attentions
• During running-in process, pay attention to observe the working
condition of the engine systems, inspect if there are oil, water or air
leakage, if the temperature of oil pressure and coolant is normal, if the
speed is stable and if the color of air exhaust is normal. In case of any
part goes wrong, troubleshoot firstly and continue to running-in.
• During running-in period of the engine, one should drive the vehicle on
the road of grade 1 or grade 2, forbid to drive on the road with poor
driving conditions, especially on the beach. Forbid to drive with full-
speed and overload.
Page 22 14:14
c. Technical maintenance after running-in

After running-in process, the engine should be inspected, cleaned and adjusted
again, remove the metal powder in lubricant and adjust the unreasonable
clearance. Main content are:
• Release the engine oil in lubricant system and clean it. Replace the oil filter and
engine oil in accordance with the requirement.
• Inspect and adjust the valve clearance, the cold clearance of the intake and
exhaust valves are:
Intake (0.2mm～0.3 mm) Exhaust (0.35 mm～0.45 mm）
• Inspect the tightening condition of all parts bolt. Retighten the bolts of the
cylinder head as requirement (at the time of air, water or oil leakage occurs) .
Notice：The diesel engine can be used normally after running-in maintenance

according to the technical requirement. Otherwise, the service life of the engine
will be shortened.
Page 23 14:14
d. Use attentions for new vehicle

When driving a new vehicle, the driver should abide by the following rules,
that not only can prolong the service life of engine, also can save the diesel.
Maintain the normal coolant temperature and oil pressure .
• Maintain the normal speed of the vehicle and avoid running in high speed.
• While starting the engine, forbid to accelerate suddenly.
• For a new vehicle, at the early time of driving in 300km, try to avoid sudden
brake.
• When the transmission is changed to high speed gear, the vehicle should not be
running in low speed.
• Don’t run the vehicle with high speed gear or low speed gear for a long time.
Should change to proper gear according to different driving conditions.
• For a new vehicle, after running to 2000km, technical maintenance is needed.
Page 24 14:14
6.Technical maintenance of diesel engine

Periodic maintenance could keep the engine in good technical condition for
a long time. Please maintain your engine in accordance with the requirement.
During maintenance, must pay attention to parts cleaning. Clean the removed
parts before reassembling and ensure correct installation. Lastly, start the
diesel engine and inspect the operation.
a. Technical maintenance period
According to different conditions of the parts, the engine technical
maintenance is divided to daily maintenance and periodic maintenance. The
following working hours and mileage are supposed to drive on the road of
grade 1 or grade 2. If the driving condition is much worse, the working hours
and mileage should be cut to half.
• Daily maintenance：In general, after 8～10h working hours.
• Periodic maintenance：After 100h running or 5000km driving, after 200h
running or 10000km driving, after 1600h running or 80000km driving.
Page 25 14:14
b. Content of technical maintenance
To ensure the normal working condition of the diesel engine, technical maintenance
should be done while using.
Daily technical maintenance
(1) Inspect the liquid level of the diesel, coolant and engine oil, fill them if necessary.
Notice: when the engine is power off, all kinds of liquid level could be correctly inspected.
Notice: Don’t fill fuel when engine is running. Don’t fill fuel fully when vehicle have to run
under the high temperature. Otherwise, the fuel will spill out due to expansion. Once it
happened, wipe and clean immediately.
(2) Clean the dirt and spilled electrolyte in battery to ventilate the vent hole. If the battery
is used in general situation, it is no need to maintain it. If it is used under high
temperature, should periodically inspect the liquid level of the battery and keep the
liquid level is over the pole plate 10-15mm, fill distilled water as necessary.
(3) Start the diesel engine, and inspect whether there are oil, water and air leakage. Take
measures immediately when there is leakage.
(4) Inspect the fixing of all accessories.
(5) Start the diesel engine, observe the working conditions of engine running and
instruments. Please repair or replace the damaged instruments in time.
(6) Keep the diesel engine clean, especially for the electronic equipments, what must be
kept away from oil stain, and for the radiator of water tank, it should not be covered
with something else.
Notice: If have to run the engine under the dust condition, remove the air filter every day
and clean the dust.
Page 26 14:14
C. Periodic technical maintenance
Except for the above maintenance, after 100h running or 5000km driving
of the engine, the engine should be maintained as followings:
(1) Clean the oil filter element, air filter element and diesel engine filter element.
(2) Inspect the coolant and clean the radiator.
(3) Inspect the fixing condition of the diesel engine.
(4) Inspect the tension of the water pump belt.
(5) Inspect and adjust the valve clearance if necessary.
Page 27 14:14
Except for the above maintenance, after 200h running or 10000km driving of the
engine, the engine have to be maintained as followings:
(1) Replace the engine oil in oil pan and replace the oil filter element.
(2) Replace the diesel filter element.
(3) Inspect the valve clearance and adjust if necessary.
(4) Inspect the performance and water seals of the water pump.
(5) Inspect the connectors of electric equipments and wires whether they connect well,
replace the damaged connectors.
(6) Clean the scale deposit of water pipe in the cooling system.
(7) Clean the ventilation system of crankshaft case.
(8) If necessary, inspect the rotor of turbocharger. Remove the connecting pipe of
compressor and air filter, and rotate the rotor, if the rotor can rotate stably and freely,
That is ok. Or else, remove and inspect the inner of the rotor.
Notice: While inspecting the working conditions of the rotor, must ensure the cleanness of
the removal spot and external environment. Should keep the extraneous matter out of
the inner of turbocharging system, otherwise serious damage will be caused. In general,
only the turbocharger manufacturer and the special service center have the ability to
reassemble. So don’t self-remove the turbocharger assembly.
(9) Remove the compressor cover as necessary and inspect whether there are oil leakage
from the compressor. Meantime, clean the inner of compressor cover and the impeller
surface of compressor. Please ensure not to damage the vane whiling cleaning. It should
be done by the service man of turbocharger manufacturer.
Page 28 14:14
Except for the above maintenance, after 1600h running or 80000km driving of the engine, the engine
have to be maintained as followings:
(1) Remove and clean the diesel engine, clean the oil stain and scale deposit, clean all the oil lubricant
tubes and oil galleries.
(2) Remove the cylinder head as necessary and grind the valves, clean the carbon deposit of combustion
chamber.
(3) Inspect the wear conditions of piston rings, cylinder liner, top end bushing and bearing bush of
connecting-rod, replace the part if necessary.
(4) Inspect the wear conditions of the main bearing bush and thrust washer.
(5) Inspect the wear conditions of the driving mechanism, mating surface of drive gears, and measure the
meshing clearance, repair or replace them if necessary.
(6) Inspect the oil pump, overhaul, measure and adjust the wearing parts.
(7) Inspect the gaskets of cylinder, intake and exhaust manifold, replace the damaged or ineffective ones.
(8) Inspect the generator and starter, clean all parts and bearings in generator and starter, and add new
lubricant grease on them after dying. Inspect the wear conditions of starter gears and ensure the
driving device rotate flexibly.
(9) Remove and inspect the turbocharger as necessary and replace the wearing parts.
——Clean the air intake connecting pipe, compressor impeller, compressor housing, and clean the carbon
deposit of the impeller and volute casing.
——Inspect the moving parts of turbocharger. Rotate the rotor with fingers, if the rotor can rotate
several circles with inertia force, the rotor is flexible. If the rotor can not rotate flexibly or with the
sound of sticking or collision, should adjust and repair the parts.
——Inspect the axial travel of rotor shaft, if the travel is over 0.3mm, that means the wear of the thrust
bearing of turbocharger is great and should be replaced.
——Inspect the radial clearance of the compressor impeller and compressor housing, press the impeller
along side the radial direction with fingers, meantime the minimum clearance between the impeller
and compressor housing could not less than 0.1mm, or else replace the floating bearing.
Page 29 14:14
Seasonal technical maintenance
(1) Must use the fuel and engine oil designed for using in winter. Attention
to the fuel with moisture in case of fuel freezing.
(2) Better to add anti-freezer into cooling system, otherwise, after engine
stop running, release the cooling water until the water temperature
falls to 40－50℃.
(3) Don’t park vehicle outdoors in cold areas.
(4) Cold start engine could heat the engine oil and cooling water.
Page 30 14:14
Technical maintenance attentions

• The user should abide by the technical maintenance requirement to maintain
the engine. Forbid to cut down the maintenance items and prolong the
maintenance period at will.
• When disassembling the engine to maintain, avoid dust entering into the inner
of the engine.
• For the complicated maintenance or adjustment with higher technical
requirement, should ask for professional technical engineers or maintain the
engine in special service station appointed by Mianyang Xinchen Engine Co.,
Ltd.
Page 31 14:14
DK4 Diesel engine
Service manual
Electric control system
Page 32 14:14
3.1.1 High pressure pump
3.1.2 Injector
1. Basic principle of 3.1 Key parts 3.1.3 Fuel rail
diesel engine 3.1.4 ECU
3.2.1 Crankshaft position sensor

2. Overview of the 3.2.2 Phase sensor
common-rail system 3.2.3 Air flow sensor
3.2.4 Glow plug
3. Parts of the 3.2.5 Glow plug control unit
3.2.6 Return line
common-rail system 3.2 Other parts
3.2.7 Fuel filter
3.2.8 Water temperature sensor
3.2.9 Accelerator pedal sensor

3.2.10 High pressure oil tube
3.2.11 EGR valve
3.2.12 Turbocharger
Page 33 14:14
1. Basic principle of diesel engine
Suction stroke Injector Compression stroke
Intake valve open Exhaust valve closed Intake valve Exhaust valve
closed closed
Air intake
Page 34 14:14
1. Basic principle of diesel engine
Power stroke Exhaust stroke
Intake valve Exhaust valve Intake valve Exhaust valve open

closed closed closed
Exhaust
Page 35 14:14
2. Overview of the common-rail system
1. Air flow sensor

2. ECU
3. High pressure pump
4. Oil- rail （high pressure
accumulator）
5. Injector
6. Crankshaft position sensor
7. Coolant temperature
sensor
8. Fuel filter
9. Accelerator pedal sensor
Page 36 14:14
Page 37 14:14
Driver’s
Acceleration operation
pedal
Control unit
Acceleration or deceleration
EDC16C of vehicles
High pressure control Torque control

Injection pressure control Fuel injection quantity
control
Related parts
Fuel injection time control
High pressure pump
Related parts
Rail and oil tube
Injector
Pressure control unit
Sensors
Page 38 14:14
High pressure circuit Rail pressure sensor Rail
Fuel pump
HP pump Fuel rail Injection
Low pressure circuit Injection
Fuel pump HP pump

Sensor
HP pump Oil tank HP pump
ECU
Injection Oil tank
Page 39 14:14
3. Parts of the common-rail system---key parts
Fuel rail
Fuel pump
Injection
High pressure
pump
ECU
Page 40 14:14
3.1.1 Key parts---High pressure pump
Fuel pump
Page 41 14:14
The common-rail high pressure pump integrates
with the oil delivery pump of three radial plungers. It is
driven by gear and lubricated with diesel. A fuel inlet
metering valve is installed in the pump used to
metering the fuel capacity. The compression capacity
depends on the required fuel rail pressure.
Main parameters：
Pump material: Cast-iron
Max. pressure level: 1450bar
Max. fuel delivery: 843mm3/r
Rotation direction: Clockwise
Drive ratio: 2/3
Page 42 14:14
Oil inlet valve
Plunger
High pressure
valve Driveshaft
Housing
Fuel inlet
Feul return
Triangle ring
Fuel inlet metering valve
Fuel inlet
metering
valve
Page 43 14:14
Wrong way
Wearing parts
Right way
Page 44 14:14
 Drive shaft, all fittings( fuel inlet, fuel return fittings, high pressure
fittings) and fuel inlet metering valve must be protected with the
protective caps well. The protective caps could not be taken down
without connection.
 Catch the high pressure pump improperly or remove the packing
early, that will damage or brake the pump.
Dirt
Page 45 14:14
Packing method of high

pressure pump
1.The high pressure pump should be packed with clean plastic

bags to prevent leakage.
2. All surfaces of the pump should be packed with shockproof
materials in order to avoid removal in transportation.
Page 46 14:14
Assembly method of high pressure pump

 Before installing the oil pump, take down the protective cap of the shaft firstly and clean with petrol,
alcohol, glycol or propane.
 Correctly hold the oil pump by hand, install a flange into the pump, correctly select the installation
location of the oil control unit. When installing the flange, keep the axle’s level, and slightly rotate the
pump body or put some lubricant grease on the O-ring of the flange to install the flange into the pump
successfully.
 Fix the high pressure pump into the flange of the engine with the tightening torque of the mounting
bolts described in this manual.
Gear chamber Fuel pump
齿轮室 Bearing 燃油泵齿 Gearbox High pressure
盖
cover 轮gear pump
Fixing bolt M8 (hex socket
heat bolt is recommended)
Tightening torque:30±5Nm
Tightening nut of drive gear:M14×1.5

Tightening torque:70 ±5Nm
Page 47 14:14
Assembly and Removal of the high pressure oil tube
 Take down the protective caps of high pressure oil pipe and high pressure connector, tighten the
connectors with required tightening torque in accordance with the manual, make the oil tube suffer
the axial force only, and make the sealing face between the oil tube and connector connect well and
won’t leak.
Notice: While removing the high pressure connector, must keep the connector tight with a wrench. If
the connector is released inadvertently, it can be re-tightened only for once. Must replace the
connector and the washer to prevent leakage.
t
Keep the arrow part still while releasing

the oil tube
Tightening torque of oil tube joint

20±2Nm
Page 48 14:14
3.1 Key parts---High pressure pump
Oil-fill of the high pressure pump
到高压泵
To high pressure pump
The high pressure pump is not allowed to run without oil.
If that happened, the inner friction will cause parts breakage
or even damaged. For the first time using the pump or there
is air enter into the oil gallery, must eliminate the air 排气孔螺栓
Bolt of exhaust vent
according to the following methods, and ensure the oil-fill
pressure not more than 4 bar: Manual pump
手动泵
Manual pump
Fuel filter
 Loosen the exhaust port bolts of the
fuel filter.
 Press the manual pump of fuel filter
Filter
until all the air are 排气孔螺栓
Bolt of exhaust
vent
exhausted and fuel flows
out of the air exhaust port.
 Tighten exhaust port bolt. Tank
 Repeat the above procedure if

necessary.
Page 49 14:14
Oil inlet metering

valve
Page 50 14:14
Page 51 14:14
Gear pump
Page 52 14:14
Oil outlet
Pressure
side
Inlet with metering valve

Oil inlet
Page 53 14:14
The housing is made of cast alumium, nickle-plating
Flow rate = 5.5 cm³/ r
Powder metallurgy gear, one-step molded
Coupling plate Drive gear
Housing
Seal Central Driven gear
bushing
Page 54 14:14
3.1.2 Key parts---Injector
Fuel rail
Rail pressure sensor
Fuel pump
Injector
Sensor
High pressure pump with oil

inlet metering valve
High pressure circuit Low pressure circuit
Electric control unit
EDC16
Page 55 14:14
The injector is driven indirectly

by the solenoid valve. It uses the
hydraulic connection with P-type
nozzle, spherical seat surface, high
pressure nozzle orifice and low
pressure oil return, which is fixed in
the engine with special plate.
Main parameters：
Range of pressure: max.1450 bar
Injection nozzle: micro-spray hole
type with single pintle
Page 56 14:14
HighHigh
pressure pipe
pressure fitting
connector
Injector
Body body
Armature groupvalve
Solenoid
Injection
Nozzle
nozzle
Page 57 14:14
Low Pressure
High Pressure
Page 58 14:14
Page 59 14:14
Schematic of armature assembly (closed)
电枢组运动示意图（关闭位置）
Magnet
Valve spring
Armature plate
Stopper plate
Armature spring
Armature bolt
Ball guidance
Ball
Page 60 14:14
Schematic of armature assembly (open)

Magnet
Valve spring
Armature plate
Stopper plate
Armature spring
Armature bolt
Ball guidance
Ball
Page 61 14:14
Valve, piston, needle closed position

Nozzle needle
Ball
A-throttle
Valve piston
Nozzle
Page 62 14:14
Valve, piston, needle open position
Nozzle needle
Ball
A-throttle
Valve piston
Nozzle
Page 63 14:14
3.1.3 Key parts ---Fuel rail
Rail pressure sensor Fuel rail
Fuel pump
Injector
Sensor

inlet metering valve High pressure circuit Low pressure ciucuit
EDC16
Page 64 14:14
3.1.3 Key parts---Fuel rail
The laser welding high pressure fuel rail has four hydraulic connectors,
which will seperately supply fuel for four injectors. There is a hydraulic
connector correspondent to the high pressure fuel pump. The rail pressure
sensor is fixed on fuel rail along the axial direction.
Main parameters：
Measurable pressure range:
0~1800 bar
Flow control valve Temperature: -40℃~130 ℃
Voltage supply: 5V（from ECU）
Rail pressure
sensor
Page 65 14:14
Sealing of the fuel rail connector
Hardness of oil tube

head≤HV250
It is sealed by the conical

surface of fuel rail and
head of the high Welding surface:
with laser welding
pressure pipe.
technology
The welding face will

not suffer high pressure.
Page 66 14:14
Rail pressure sensor
 The rail pressure sensor is integrated at

the end of the fuel rail, which is used to
induct the instantaneous pressure of the
fuel rail.
 The principle of the rail pressure sensor is
to convert the pressure signal to electric
signal through the sensor elements
(semiconductor assembly), then transmit
the signal to ECU.
 Location of the rail pressure sensor:
allowed to be fixed downward vertically
with maximum degree of 30℃, but not
allowed to be hanged inverted.
Page 67 14:14
Flow control valve
 The flow control valve is installed

in the inner of high pressure
connectors from fuel rail to
injectors.
 It‘s role is to stop continous open
and fuel injection in special
circumstances. Once the fuel
output is greater than the rated
level, the valve will cut off the fuel
passage.
Page 68 14:14
3.1.4 Key parts---ECU
Rail pressure sensor Rail
Fuel pump
Injector
Sensor

inlet metering valve High pressure circuit Low pressure circuit
EDC16
Page 69 14:14
The type of the common-rail with 32bit

ECU is EDC16C39, it can reach the
emission level of Euro Ⅲ, Euro Ⅳ emission
level will be reached in future by function
expansion.
Main parameters：
Rated voltage：12V
Power consumption: 12.5~18W in general situation
Working temperature: -40℃≤T≤Tmax. value of ambient temperature
Air flow: Tmax. value of ambient temperature =70℃
Air not flow: Tmax. value of ambient temperature =85℃
Page 70 14:14
Installation of ECU
 ECU must be installed in the anti-rust and dry area.
It is allowable that a small amount of water in ECU
in a short term.
 Make sure no water, oil and other liquids immerse
into the sealing pieces and pressure compensation
components through wire harness.
 Forbid to submerge ECU in water.
 Make sure no flexibility at the installation location
of ECU.
 Don’t remove ECU while repairing the engine.
 If need to remove ECU, firstly pull the battery plug
out more than one minute.
 Before welding operation, must remove the ECU,
and carefully store it.
 Forbid to add any circuit to the connecting wire of
ECU.
Page 71 14:14
3.2.1 Other parts---crankshaft position sensor
Principle and functions：
 The engine speed and crankshaft position sensor is magnetoelectric
sensor, which is installed near the crankshaft, functioning with the
58x ring gears of crankshaft. When crankshaft rotates, the top of
ring gears and gear slot will pass through the sensor with different
distances, the sensor can induce the change of magnetic reluctance.
Then the alternative reluctance causes the alternative output signal,
judged from the signal, ECU can confirm the rotating part and
speed of the crankshaft.
 Installation: the sensor is installed near the crankshaft. When
installation, must press assembly, and forbid to beat it.
Product characteristics：
 Working temperature : -40℃ ~ 120 ℃ Signal (high)
 Working clearance: 0. 5 ~ 1. 5 mm
 Coil assistance: 860 ±10%(20 ℃) Signal (low)
 Coil inductance: 370mH ±60mH @1kHz
Page 72 14:14
3.2.2 Other parts---phase sensor
Principle and function：

 Camshaft position sensor is a kind of hall-effect
sensor, which is installed near the camshaft,
functioning with the signal wheel of camshaft.
The signal pulley corresponds to the specific
location of the engine. ECU can get the digital
voltage signal tested by the sensor, then judge and
control the working cylinder one to one.
 Installation: Installed near the camshaft. When
installation, must press to assembly, forbid to beat
it.
 Working temperature：-40 ~ +150℃ ； Ground(-)
 Working voltage：4.7 ~ 18 V； Signal output (O)
 Working clearance ：0.2 ~ 1.8 mm Power(+)
Page 73 14:14
3.2.3 Other parts---air flow sensor
Principle and functions：
 The air flow sensor is a kind of hot-film air flow meter, which is
installed in the intake system. Meanwhile it has a built-in
temperature sensor, which can measure the temperature of
intake air. Through the signal comes from the temperature
sensor, ECM can judge the entering amount of air and engine
load.
 Installation: air flow sensor is installed in the intake pipe,
should keep distance with the high temperature parts such as
turbocharger and exhaust manifold.
 The installation direction should be the same as
the direction of the inlet airflow. Power(+)
接地(-
Ground (-) )
温度输出信号
Temperature
Airflow  Nominal flow: 640kg/h ； output signal
Reference
Reference
 Working voltage: 14 V；频率
Frequency
流量输出信号
 Sensor temperature: -40℃ ~ Flow output signal
120 ℃
Page 74 14:14
3.2.4 Other parts---glow plug

 The glow plug is used to assist the cold-
start of the diesel engine, and improve the
warm-up performance.
• Installation: the glow plug is installed in
the cylinder head, must ensure the correct
location of the heating-end of flow plug in
combustion chamber.
 Rated voltage: 11V
 Electricity time at the temperature of 850℃: 5s±1s
 Temperature after 60s: 1050℃±50 ℃
Page 75 14:14
3.2.5 Other parts---Flow plug control unit

 The glow plug control unit is controlled by ECU,
which is connected with the specific stitches, and
can be used in engines of 4, 5 and 6 cylinders.
Meantime, the control unit has the function of
analyzing fault of glow plugs.
 Installation: it is installed in the proper location
of engine compartment, the connector parts
should be face down.
 Rated voltage：12V ； Ground (- )
Coding control signal(4,6)
 Power consumption :10~18W
Main relay connect with
( while flow plug is working) ； flow plug
Coding control signal(6)
Diagnostic signal
Page 76 14:14
3.2.6 Other parts---fuel return pipe
T-type connector
The fuel return pipe collects the fuel
L-type return of the injectors and transfers it
connector
to fuel tank. It consists of L-type, T-
type connectors and strength rubber
Insert injector
flexible hose. Among them, there are
through hose to fuel tank check valves installed in connectors in
order to ensure the stability of the fuel
return pressure.
Product characteristics： Installation: it is installed at the top of

 System pressure：Max. 2 bar； injectors.
 Pipeline bending radius:≥30mm；
Page 77 14:14
3.2.7 Other parts---Fuel filter
Manual pump
Oil outlet  Except for filtrating fuel impurities, the fuel
filter integrates with the manual pumping
device, oil-water separator, and fuel heating
Oil inlet device. The manual pumping device is used to
exhaust the air in pipe under the conditions of
first start the engine or for the vehicle unused
for a long time. The oil-water separator light in
the instrument will remind the drivers of
Heating switch releasing the separated water in time. The fuel
heating device can help to improve the cold
start performance of vehicles.
 Installation: it is vertically down installed in
the proper location of vehicle, the maximum
offset of the angle is 20°.
Oil-water separator  Working temperature：-40℃~ +120 ℃ ；
 Working pressure: ≤2.0 bar ；
 Replacement cycle：30,000 km；
Page 78 14:14
3.2.8 Other parts---Water temperature sensor

 The coolant temperature sensor is used to measure the
working temperature of the engine. According to
different temperature, ECU will select and provide the
best control program for the engine.
 The coolant temperature sensor takes the thermistor of
negative temperature coefficient as the induction
components.
 Installation: The coolant temperature sensor is installed
in the minor circulation channel of the coolant.
Ground
 Working voltage：5±0.15 V;
 Working temperature：-40 ℃~ +130℃ Temperature signal
Page 79 14:14
3.2.9 Other parts---Accelerator pedal sensor

The accelerator pedal sensor is used to attain
the driving requirement of vehicle from the
driver, and through the analysis of ECU to make
the engine support the corresponding power.
 Working voltage：5±0.3 V
 Working temperature: -40 ℃~ +80℃
 Pedal force: 500±6N
 Pedal return spring load＞5N
Page 80 14:14
3.2.10 Other parts---High pressure fuel pipe
Installation of high pressure fuel pipe
 Installation of the high pressure fuel pipe between fuel rail and
injectors
 Tighten the pressure plate bolts with final tightening torque, fix the
injectors in engine. Manually tighten the fuel rail.(3±1Nm)
 Manually tighten the nuts of the injection end and fuel rail end of
high pressure fuel pipe (3±1Nm)
 Tighten the nuts of the end of injectors with final tightening

torque. The tightening torque is 30±3Nm
 Finally tighten the rail to engine, The tightening torque is

23±2Nm
 Tighten the nuts of the end of the fuel rail with final tightening
torque. The tightening torque is 30±3Nm.
 Installation of the high pressure fuel pipe between fuel rail and high
pressure pump
 Manually tighten the bolts at both ends of high pressure fuel pipe
（3±1Nm）；
 Finally tighten the connecting nuts of both end of high pressure

fuel pipe, fuel pump and fuel rail. The tightening torque is
30±3Nm.
Page 81 14:14
3.2.10 Other parts---high pressure fuel pipe
Removal of high pressure fuel pipe
 Removal of the high pressure fuel pipe between the fuel rail and
injectors
 Loosen the nuts of high pressure fuel pipe between the injectors and fuel
rail.
 While releasing the nuts of high pressure fuel pipe in both end of the
injectors, must fix the high pressure connector of the injectors.
 Remove the high pressure fuel pipe.
 Release the pressure plate and remove it.
 Use the special disassembling tools of injectors, take the injectors out from
the engine cylinder head.
 Put all the protective caps back to injectors and fuel rail.
 Removal of the high pressure fuel pipe between fuel rail and high
pressure pump
 Loosen the nuts of high pressure fuel pipe between the injectors and high
pressure pump.
 While releasing the nuts in the end of pump of the high pressure fuel pipe,
must fix the pump connector with a wrench.
 Take down the high pressure fuel pipe.
 Put all the protective caps back to the high pressure pump and fuel pipes.
Page 82 14:14
3.2.11 Other parts---EGR valve

 EGR valve locates in the intake manifold, it’s function is to make amount
of exhaust gas enter into the intake system to recycle.
 One side of the EGR valve diaphragm connects with a pivot rod, the other
side connects with the spring. (The spring makes the valve normally close)
When the vacuum pressure (or air pressure) added in diaphragm is
greater than the spring force, the pivot rod is pulled away from it’s
location, the channel is open and make the exhaust gas enter into the
recycling system. The capacity of the recycling exhaust gas and intake air
is related.
 In essence, EGR depends on deterioration combustion to reduce the NOx
emissions. The two conditions of generating NOx are high temperature
and more oxygen. To make certain amount of exhaust gas enter into the
intake pipe through control valve, and make it mix with fresh air, then
enter into cylinder to burn. The inert exhaust gas can reduce the burning
speed, maximum burning speed and NOx.
Page 83 14:14
3.2.12 Other parts---Turbocharger
 The turbine of turbocharger connects with the exhaust pipe, and the
compressor connects with the intake pipe. The impellers of turbine and
compressor rotate with the same shaft. The turbine is driven by exhausted
air so as to drag the compressor, that can improve the intake pressure and
increase the air charging capacity.
 when diesel engine is running with high speed and high load, to prevent the
high speed and high supercharging pressure of the turbocharger, the
exhaust bypass valve will open under conditions of high speed and high load,
and it will release some exhaust gas to reduce the speed and control the
compression ratio of the turbocharger.
Main points：
 Since the full-floating bearing of the turbocharger needs the high quality lubricant,
should select and use the engine oil in accordance with the requirement.
 To ensure the lubrication of bearings, should run the engine at idle speed for several
minutes after start, in order to make the lubricant reach a certain temperature and
pressure. Similarly, don’t stop the engine suddenly, should reduce the load of engine
gradually and run the engine at idle speed for several minutes.
 Should regularly clean the air filter and inspect the leakage of the air intake system in
accordance with the requirement.
Page 84 14:14
DK4 Diesel engine
Maintenance manual
Mechanical system
Page 85 14:14
Cylinder head assembly
Cylinder head
cover
◎ The cylinder head cover is made the resin material with light
weight and good damping performance. The resin material
not only can reduce the engine weight, but can ensure the
strength of the cylinder head cover. After improving the
shape of the cylinder head cover, engine noise is greatly
reduced. And the oil cut capacity is increased by setting the Cylinder
baffle plate in cylinder head cover and extending the vent head cover
pipe out of the top of the cylinder head cover. In addition, gasket
the baffle plate and vent pipe are all made of the resin
material so that engine weight are reduced.
◎ The cylinder head cover gasket is made of the material of

acrylate rubber with good heat-resistance and oil-resistance
performance. That ensures the reliability.
◎ The cylinder head is made of the aluminum alloy material

with light weight and good heat conductivity. In addition,
the use of DOHC, 4-valves and vertical injectors in center of
the cylinder head increases the performance and reliability Cylinder
of the engine, and realizes the goal of low emission and head
miniaturization.
◎ The cylinder head gasket is made of the four over-lapping

steel with good sealing and heat-resistance performance.
Cylinder head
gasket
Page 86 14:14
Injector hole
◎The air inlet port is the independent port, the

two inlet ports in different shapes improve the
vortex of cylinders and promote the mixture of
fuel and air.
◎ The use of the water jacket of upper and lower EGR gas exit
two layers increases the cooling performance

and rigidity of cylinder head. And the
reliability of cylinder head is increased by
improving the casting method (strength
casting method ). Two-step water
A-A Sectional view jacket
◎ Set flow plug in intake valves, ensure the 1# Exhaust port
reliability and start-up ability of the engine. Glow plug
◎ Set the EGR passage in cylinder head, that not Injector central
configuration
only can increase the cooling effect of EGR gas,
but reduce the volume of cylinder head.
EGR passage
1# Air inlet port
Page 87 14:14
◎ The sealing performance of cylinder head could be improved by setting #1-#4 cylinders-in
one independent gasket in cylinder head.
◎ The edge of the cylinder port is double edges structure. This structure will control the
spring characteristics of cylinder head gasket in minimum, and can ensure the sealing
performance of cylinder head while pressure is rising.
Double edges structure
Edges of cylinder port

4 cylinders-in one gasket
Page 88 14:14
Camshaft timing system
◎ The camshaft timing system consists of the
timing gear system and gear belt. That could Gear chamber inner housing
not only shorten the length of the engine, but Camshaft
convenient to change the gear belt. Timing belt Timing gear case
◎ The timing gear belt is made of the high-

strength material, that can improve the
reliability.
◎ The automatic hydraulic tensioner can

maintain the tension of the belt.
◎ The gear case and gear housing are made of

the material of aluminum alloy. A
crankshaft position sensor is installed in the
timing gear case cover.
Timing gear
◎ The inner and outer housings of gear Auto tensioner
case cover
chamber are made of the resin material. The Gear chamber outer
vibration and noise of the engine are housing
reduced by setting sealing washers around
the outer housing of the gear chamber. The
camshaft oil seals are installed in cylinder
head.
Page 89 14:14

Oil pressure tensioner Anti-rust seal
◎ The build-in plunger spring of tensioner pushes the

tensioner through push rod and transfers a certain Return spring
tension to tensioner. while under the action of the
check-valve ball, the engine oil will make the push
rod move to the looser side of the belt, that
maintains the belt a constant tension.
Push rod
◎ Once the belt is loose, the push rod will move Chamber A
upward under the action of the plunger spring,
engine oil in chamber A will push the check-valve Plunger
and flow to chamber B. Or vise versa. When engine
speed decreases, belt tension will increase, the
tensioner of the belt will push the push rod. Check-valve ball
Meantime, the check-valve ball will cut off the
passage from chamber B to A, then chamber B is
Plunger spring
under the state of high pressure to prevent the push Chamber B
rod from pushing in. Through such kind of up and
down movement of the push rod, the tensioner of
belt will maintain stably.
Page 90 14:14
Alignment mark
☆Removal
1. Remove the outer housing of the
timing gear chamber.
(1) Remove the phase sensor and the bracket. Alignment mark
(2) Remove the pipe clamps of wire harness.

(3) Remove the 6 bolts and the outer housing of
the gear chamber.
2. Remove the timing pulley.

(1) Rotate the crankshaft clockwise, align the
alignment mark of the two pulleys.
(2) Loosen the 2 bolts uniformly, and remove
the tensioner.
(3) Remove the timing belt and mark on the belt
according to it’s running direction (when
assembling the belt , don’ change it’s
running direction.)
Page 91 14:14
☆Installation
1. Don’t damage the valves and pistons
If need to rotate the camshaft under the condition of the timing
pulley has been removed, should rotate counterclockwise the
crankshaft of 90°firstly.
Notice：
• Don’t rotate the crankshaft under the condition of the timing pulley
has been removed.( pistons and valves will mutually interfere and
may cause damage.)
• While installing the timing pulley, the camshaft must recover to
align the alignment mark, then rotate the crankshaft clockwise until
it is aligned with the alignment mark.
2. Inspect the tensioner( Idler pulley )
(1) Rotate the tensioner by hand, and make sure that the tensioner
could rotate freely.
(2) To confirm the lubricant in sealing parts distributed uniformly.
Notice：
• When there is water and oil sticking on the timing pulley and other
pulleys, please inspect and repair the leaked part.
• Before installation, all pulleys should be cleaned with cloth, and
ensure there is no oil on it.
• Don’t assemble the timing idler pulley at will.
Page 92 14:14
Camshaft timing system Alignment mark
3. Install the timing pulley
(1) As shown in the illustration, align the alignment mark of all

pulleys.
(2) Install the timing belt in sequence of driveshaft pulley, camshaft

pulley and timing belt idler pulley.
※Re: Install the timing belt, make the back line of the belt aligned
with the gap of the belt.
Alignment mark
(3) Fix the tensioner in press machine, and press the push rod
downwards.
※Notice：
① To prevent damage of the top of the pull rod of the tensioner,

please protect the pull rod with cloth.
② When the pull rod of the tensioner is upward, make compression.
Page 93 14:14
⑷ Slightly compress the push rod of the tensioner, after aligning the
push rod with the cylinder port, fix the push rod with a hexagon
socket (1.5mm width of both sides).
※Notice: The load on pull rod could not exceed 980N（100kgf）（in

cold areas, you can heat the tensioner to 80℃ to improve the
assembling speed）
※Re：After aligning the pull rod with the cylinder port, align the
ports while the press plate port is compressing downward, and
install the hexagon socket.
⑸ Install the tensioner when the hexagon socket was installed.
※Reference value：T=13N.m
※Notice: When the tensioner is inclined, it will not work as usual,
please tighten all bolts uniformly.
⑹ Unplug the hexagon socket from the tensioner.
⑺ Rotate the crankshaft two turns to ensure all the pulleys is
aligned with the alignment marks.
4. Install the outer housing of the timing gear chamber
⑴ Install the outer housing of the gear chamber with 6 bolts.
※Reference value: T=6.0N.m
⑵ Install the bracket of phase sensor.

⑶ Connect wire harness.
Page 94 14:14
Injector
Press plate bolt of
☆Removal injector
1. Remove the cylinder head cover

Press plate of injector
⑴ Loosen the press plate bolts and bolts washer

of injectors. Remove all the press plate of
injectors. Injector seals
⑵ Remove injectors and mark the

corresponding cylinder No. of the injectors.
⑶ Loosen the bolts of the cylinder head cover

and remove the cylinder head cover.
⑷ Remove the injector seals and bolt seals of Seals of press plate bolt
press plate from the cylinder head cover.

Seals of press plate pivot
2. Remove the pivot seals of press plate from the

cylinder head bolts with convex plate.
3. Remove the timing pulley
⑴ Remove the phase sensor.
Page 95 14:14
(2) Remove the outer housing of the timing gear

chamber.
(3) Rotate the crankshaft to the top dead center of
compression of the 1st cylinder.
(4) Remove the timing pulley.
4. Remove the timing pulley

(1) Fix the camshaft with an adjustable wrench, and
loosen the mounting bolts of the cam timing
pulley.
(2) Loosen the mounting bolts of the cam timing
pulley until it remain 2～3 thread out of the bolt
hole (don’t unplug the bolts completely to avoid
dropping it onto the ground).
(3) Pull the timing pulley with special tools( pulling
tool).（Don’t beat the pulley, since there is great
meshing force between the cone face of the pulley
and camshaft, the beating will cause deformation
or damages).
Page 96 14:14
(4) Remove the pulley key from the camshaft.
5. Remove the tensioner (idler pulley) from the

timing pulley.
Using a hexagon wrench, remove the

tensioner bolts.
6. Remove the outer housing of the timing pulley

Nut
Loosen the tightening bolt and nut, then
remove the outer housing.
7. Remove the camshafts
(1) Uniformly loosen the bolts and remove the

camshaft bearing caps uniformly in the
sequence shown in the illustration.
Page 97 14:14
※Notice： Intake camshaft
① Lever the camshafts with tools, don’t exert too much

force on it.
② Don’t scratch camshafts and thrust face of the cylinder
head.
Exhaust camshaft
⑵ Remove the seals of camshaft

⑶ Remove the intake and exhaust camshafts.
8. Remove the cylinder head
⑴ Loosen the cylinder head bolts uniformly in the

sequence shown in the illustration, then remove the
bolts and washers of the cylinder head.
⑵ Inspect bolts of the cylinder head
measure the icon length shown in the illustration with
vernier caliper.
Measure the length
※Reference value：φ11.67～11.97mm
※Limit value：φ11.60mm
※Re：measure the length from different locations, replace
a new product if the value is less than the limit value.
9. Remove the cylinder head gasket
Page 98 14:14
☆Installation
1. Cylinder head installation
⑴ Measure the protuberance of pistons Protuberance
Measure the protuberance of pistons with a

micrometer gauge and plain measuring head.
※Notice：
① The measure head is vertical with the upper
surface of the cylinder block.
② Select the measuring location at the front and
rear of the piston, measure two locations for each
cylinder (8 locations in total) Measuring location
⑵ Select the proper cylinder gasket according to the

maximum protuberance of the pistons.
※Notice： Center
① The thickness of the cylinder gasket is identified

from the location of its rear gap.
Page 99 14:14
② Select the proper cylinder gasket according to the

protuberance of pistons Sign selection Max. protuberance
⑶ Install the selected gasket in cylinder block.
※Notice：
① Clean the surface of cylinder head and the upper
surface of cylinder block.
② Don’t make impurities enter into the cylinder gasket.
2. Install the cylinder head
※Notice：
① Before installing the cylinder gasket, confirm the gap
of crankshaft pulley is at the location of 90°ahead of
the top dead center.
② Tighten the cylinder head bolts with the plastic area
tightening method.
⑴ Install washers on the cylinder head bolts, and insert to
cylinder head.
Page 100 14:14

⑵ Pre-tighten the cylinder head bolts uniformly

in the sequence shown in the illustration, and
tighten them with required torque.
※Reference value: T=85N.m
⑶ Mark on the bolt head of cylinder head and on

front end of the engine.
⑷ Tighten 90°of all the cylinder head bolts.

※Notice: Tighten the cylinder head bolts
uniformly in the sequence shown in the
illustration.
⑸ Repeat to tighten 90°of all the cylinder head 1st time 90° 2nd time 90°
bolts.
⑹ Confirm all the marks on cylinder head bolts

are located in the rear of the engine.
Front end of engine
Paint mark
Page 101 14:14

Key slot of pulley
3. Camshaft installation
※Notice：Since the thrust clearance of camshaft (axial clearance)

is small, so the camshaft should be installed horizontally, that
can prevent the breakage, scratch or burr of the thrust face.
• (1) Inspect whether the crankshaft is located 90°ahead of the

top dead center.
• (2) Make the key slot upward and install the intake camshaft
in the cylinder head.
※Notice：Put engine oil on the cam, thrust face and gear of Alignment marks
camshaft and put oil on the journal of the cylinder head.
• (3) Mesh the gears of intake and exhaust camshaft, and install
the exhaust camshaft.
※Notice： Put sealant
• Put engine oil on the cam, thrust face and gear of camshaft
and put oil on the journal of the cylinder head.
• (4) Put the sealant on the location shown in the illustration,
then install the camshaft into the cylinder head.
Page 102 14:14

⑸ As shown in the illustration, align the bearing

caps of camshaft, and install the caps into the
cylinder head.
⑹ Tighten the bearing caps of camshaft uniformly in
the sequence shown in the illustration
※Reference value：T=19N.m
⑺ Inspect and adjust valve clearance.
(a) Measure valve clearance in sequence shown in

the illustration (cold state).
Exhaust
TDC of 1# cylinder
※Reference value：Intake:0.20～0.30mm
Exhaust:0.35～0.45mm
※Notice：The measurement of valve clearance
should be done under the cold state.
(b) Rotate the camshafts, measure the valve
clearance of other cylinders, and make a record.
Intake
Page 103 14:14

(c) Adjust the valve clearance

① Remove the camshafts and valve tappets.
② Measure the thickness of the tappets with a

micrometer gauge.
③ Calculate the thickness of valve tappets which

is in accordance with the reference value.
※Reference value：IN:A=B+(C-0.25mm)
EX:A=B+(C-0.40mm)
④ Select the proper valve tappets A Selected valve tappet
⑤ Install the selected valve tappets. B Thickness of the valve tappet
⑥ Re-install the camshafts, inspect and adjust the Valve clearance has been
valve clearance until the thickness of the C
measured.
clearance is in accordance with the above
reference value.
Page 104 14:14

4. Install the oil seals of camshaft
⑴ Put a little of MP lubricant on lip of the new oil seals.
※Notice：Note don’t make impurities on the lip of oil

seals.
⑵ Install the oil seals with special tools.
※ Reference value: 0.5mm～-1.5mm（from the end of

cylinder head）
※Notice: oil seals could not be installed slantways.
5. Install the inner housing of timing gear chamber

⑴ Put sealant on the location shown in the illustration.
※Notice：
① Clean and degrease the installing surface.
② Install the inner housing of timing gear chamber

after putting on sealant in 3 minutes, and tighten
the bolts in 15 minutes.
③ Don’t start the engine in 2 hours after installation.

Put sealant on
Page 105 14:14

⑵ Install the inner housing of gear chamber with 4

bolts and nuts.
※ Reference value：T=10N.m
6. Install the tensioner ( idler pulley) of timing pulley After

assembly,
Install the idler pulley with a hexagon socket. must ensure
the tensioner
※ Reference value：T=35N.m rotate freely
around it’s
installing
7. Install the timing pulley of camshaft.
shaft.
⑴ Install the pulley key on camshaft.
⑵ Install the timing pulley of camshaft.
When
⑶ Fix the camshafts with an adjustable wrench, then
install the mounting bolts of the timing pulley of assembly, the
camshaft. ( before tightening the bolts, must washer
ensure the installing surface of the pulley is 2mm chamfer
higher than the camshaft.) should face to
the side of
※ Reference value：T＝90～98N.m tensioner.
Page 106 14:14

Installing surface of
8. Install the timing belt pulley
Notice：Must replace the timing belt after driving to
50000km. When installing the timing belt, must align the
Mounting bolt of
belt timing mark with the pulley timing mark.
pulley
9. Install the outer housing of timing gear chamber Camshaft end

10. Install the cylinder head cover
⑴ Install the pivot seal of press plate in the convex cylinder head bolt.
⑵ Install the seals of injector and press plate bolt. Thrust groove of
⑶ Put sealant on the location shown in the illustration. camshaft
※Notice：
① Clean and degrease the installing surface.
② Install the cylinder head after coated with
sealant in 3 minutes, and tighten the bolts in 15
minutes.
③ Don’t start the engine in 2 hours after
the installation.
⑷ Install the cylinder head cover with 10 bolts and 2
nuts.
※Reference value：T=9.0N.m
11. Install the injectors Put sealant on
Inspect the completeness of the copper washer of injectors, and insert the numbered
injectors into the corresponding cylinders.
Page 107 14:14

12. Install the press plate of injector
13. Put the bolt washer through the press

plate bolt of the injector, then install and
Bolt washer of press plate
tighten the press plate bolt.
※Reference value: T＝30±3N.m
Page 108 14:14

Intake air and exhaust system
1. Related items of valve
Exhaust camshaft
◎ The structure of the camshaft is DOHC4 Driven gear
Main gear
valve structure. The exhaust camshaft is
driven by intake camshaft with gears. Valve
tappet
Valve (without
spring washer)
◎ The camshaft is used alloy iron cast Intake camshaft
material. The weight of the engine has Camshaft
Valve
been reduced through reducing the
Timing pulley of camshaft
thickness of cam and diameter of camshaft.
◎ The valve is made of heat-resistant steel

material. Four valves are oppositely
aligned. In addition, the goals of high
speed and low oil consumption has been
realized by reducing the valve stem
diameter, valve weight and inertance.
◎ The valve tappets not contain the washers,
that can reduce the components and
engine weight.
Page 109 14:14

Crankcase ventilation device
◎Guide the blow-by gas which contains plenty of

hydrocarbon into the intake air system to re-burn, that can
improve the emission performance of the engine.
◎ The goal of low emission can be realized by designing the

blow-by gas passage to annular shape, making the vent
pipe out of the top of the cylinder head cover and reducing
the content and consumption of the engine oil of the blow-
by gas.
Page 110 14:14

Sectional view of cylinder head

cover (blow-by gas passage) Blow-by gas
◎ The blow-by gas is reverted to
the air intake side of
turbocharger from crankcase
to vent pipe of top cylinder
head cover.
Fresh air
Blow-by gas
Air-flow view
Page 111 14:14

Compressor housing
Turbocharger
◎ The type of the turbocharger is the exhaust

pressure reduction turbocharger. When Turbine housing
turbocharging pressure is greater than the
supposed value, the actuator of exhaust reducing
valve starts to work to release the exhaust
pressure by bypass passages, so that to reduce
the speed of turbocharger and control the
increase of pressure. The maximum
turbocharging pressure depends on the elasticity
of the exhaust reducing valve.
◎ By reducing the weight of rotor and improving

the shape of intake port and vane, the
accelerator response and supercharging ability
are increased greatly. Meantime, the reliability
of the engine is fully ensured. Exhaust reducing
valve
◎ Cool the compressor housing with air cooling
method, reduce the exhaust temperature with
intercooler. Actuator
Exhaust pressure reduction

turbocharger
Page 112 14:14

EGR valve
EGR valve position sensor
◎ The engine adopts the electronic control Vacuum pressure

EGR system to reduce the emission. port Spring centering device
◎ Install the EGR valve in the intake air

passage. By cooling the EGR valve with
air and EGR cooler of large capacity Intake air passage
and multi-tube type, Much more
exhaust gas could be circulated.
◎ Set the EGR passage in cylinder head to

make the exhaust gas circulate at the
intake side, that will increase the cooling EGR valve
effect and shorten the engine volume.
EGR gas
◎ The EGR valve position sensor will

closely monitor and control the actual
location of EGR valve.
Page 113 14:14

Intake manifold
Intake air and exhaust system EGR radiator (EGR waste pipe)
EGR valve
☆ Removal
Vacuum
1. Remove the intake regulator
pipe of throttle valve.
Throttle valve body

Bracket of intake pipe
2. Remove the EGR vacuum

regulator and the bracket.
Bracket EGR vacuum regulator
Page 114 14:14

3. Loosen the 2 bolts and 2 nuts to

remove the EGR waste pipe.
4. Remove the EGR valve and 2

gaskets from the intake
manifold.
5. Loosen the 4 bolts and 2 nuts to

remove the intake manifold and
Gaskets
intake manifold gasket.
Page 115 14:14

6. Remove the 4 bolts and remove the heat Heat insulator
insulator of exhaust manifold.
7. Remove the oil intake pipe and return

pipe of supercharger.
⑴ Loosen the bolts of oil intake pipe (from

A, B shown in the illustration), and
remove the oil intake pipe of Exhaust manifold
supercharger.
Turbocharger
⑵ Loosen the 4 nuts (from A, C shown in
the illustration) and remove the oil
Oil intake pipe of
return pipe of supercharger.
supercharger
8. Loosen the 3 nuts and remove the
bracket of turbocharger. Bracket of
turbocharger Oil return pipe
turbocharger.

exhaust manifold and the gasket.
Page 116 14:14
☆Installation
1. Install the intake manifold gasket
※Notice: Clean the installing surface

between cylinder head and intake
manifold.
2. Install the intake manifold and

tighten the 4 bolts and 2 nuts.
3. Install the vacuum regulator and it’s

bracket.
Bracket Vacuum regulator
Page 117 14:14

4. Install the EGR valve and throttle body
⑴ Provisionally fix the EGR, install the 2 Gaskets

gaskets.
（see the illustration）
Intake manifold
EGR radiator
⑵ Install the throttle body with 3 bolts. (waste pipe) EGR valve
5. Install the EGR waste pipe

Vacuum
regulator
⑴ Firstly install the cylinder head with
gasket and nuts, but don’t tighten the
nuts.
⑵ Put gasket on EGR and install it with

bolts.
Throttle valve body
⑶ Tighten the bolts and nuts. Bracket
Page 118 14:14

6. Install the exhaust manifold with

gasket
Exhaust manifold
7. Install the turbocharger
Turbocharger
8. Install the oil inlet pipe and the
return pipe
⑴ Tighten the 2 nuts of oil inlet pipe Oil inlet pipe
and the turbocharger,
and install the oil inlet pipe. Bracket of
turbocharger Oil return pipe of
⑵ Respectively install the gaskets of turbocharger
the oil return pipe and the
turbocharger, and install the oil
return pipe of the turbocharger.
9. Install the bracket of the

turbocharger
Page 119 14:14

Cylinder block assembly
◎ The cylinder block is made of the high
rigidity alloy cast iron material without
cylinder liner.
Cylinder
◎ The oil pan is made of the anti-rust steel block
plate material, vehicles’ carrying
capability is increased by changing the
part of oil deposit to rear of the engine.
Meantime, to prevent air entering into oil
pan while vehicle is running up and
down hills or turning corners from
suction port due to the change of oil level,
the location of the suction port of the oil
filter is changed.
Oil pan
◎ Good sealing liquid gasket is installed insulator
between the peripheral edge of oil pan
Oil filter
and cylinder block.
◎ Oil pan insulator between oil pan and
transmission is used as the damping
material to reduce the standing wave
noise.
Oil pan
Page 120 14:14

Gear driving system

☆ Removal
Removal steps of the gear driving system: Nut

☆ Removal
• 1. Remove the front-end gears and timing
pulley system.
• 2. Remove the water pump. Loosen the bolts
and nuts and remove the water pump and
gasket.
• 3. Remove the pulley chamber cover.
• 4. Install the locking bolt (M6) to idler pulley
and press the bolts.
Page 121 14:14

Hold
Gear driving system
• 5. Remove the gears of fuel pump and remove the
fuel pump (fuel feed pump) assembly.
• 6. Remove the timing gear of crankshaft
(1) Provisionally install the pulley bolts to crankshaft. Drive
(2) Remove the timing gear with tools.
(3) Remove the pulley bolt from crankshaft.
• 7. Remove the thrust washer of idler pulley.
• 8. Remove the idler pulley pair
※Notice: ensure the main gear and idler pulley pair are
not offset. (pressed by bolt of M6)
• 9. Remove the idler pulley shaft
• 10. Remove the oil seal of pulley chamber
Tap the oil seal out with a slot-head screwdriver and
hammer, and the screwdriver must be wrapped in
tape. Wrapped in tape
Page 122 14:14

Gear driving system

• 11. Remove the oil pan
(1) Remove the bolts and nuts Nuts
(2) Remove the oil pan with the special

knife.
• ※Notice：
① Don’t make the oil pan deformed.

② Don’t slant the oil pan if there are oil
remains.
• 12. Remove the oil filter
Remove the bolts and nuts, remove the

oil filter and filter seat.
Nuts
Page 123 14:14

Gear driving system
• 13. Remove the timing gear box
(1) Loosen the bolts and union stud, and Union studs
remove the timing gear box.
(2) Pry the gear box from the location shown

in the illustration with a slot-head
screwdriver, and remove the timing gear box.
Gasket
Fuel pump rotor
※Notice: Don’t fall the oil pump rotor of timing
gear box to the earth.
(3) Remove the oil pump rotor and the gasket.
Page 124 14:14

Gear driving system
• (4) Remove the bolt stud
• (5) Remove the 2 O-rings from

cylinder block
O-ring
Page 125 14:14

Gear driving system
☆ Installation
• 1.Install the timing gear box
(1) Install 2 new O-rings in the timing gear box.
(2) Install a stud bolt in the location shown in the
illustration.( while replacing the stud bolt)
※Standard value：T=8.0N.m{82kgf.cm}
(3) Clean and degrease
① Clean and degrease the installing surface. Gasket
② Clean and degrease the bolts and bolt holes.

(4) Install the oil pump rotor in the timing gear box.
(5) Install new pump gasket in the timing gear box.
Oil pump rotor
(6) Put sealant on the location shown in the
illustration (The diameter is about 4mm).
Page 126 14:14

Gear driving system
⑺ Install the timing gear box with 8

bolts and union bolts.
※Reference value:
T=13N.m{133kgf.cm}（bolt）
T=16N.m{163kgf.cm}（union
bolt）
Union bolts
⑻ Remove the bolts and fill oil of 50cc.
Page 127 14:14

Gear driving system

• 2. Install the oil filter
Replace the bracket and install the oil filter with bolts and
nuts.
※ Standard value: T=8.0N.m{82kgf.cm}

Bolts
• 3. Install the oil pan

(1) Cleanness and degreasing Nuts
① Clean and degrease the installing surface
② Clean and degrease the bolts and bolt holes
(2) Put sealant on the location shown in the illustration
and install the oil pan.
(3) Tighten the bolts and nuts
※ Standard valve: T=16N.m{163kgf.cm}
Page 128 14:14

Gear driving system
• 4. Install the gear of fuel pump
(1) Install the fuel pump (fuel feed pump)

assembly.
※Standard value: T=30N.m{305kgf.cm}
(2) Install the gear of fuel pump.
(3) Replace the O-ring and install nuts.
(4) Tighten the nuts with tools.
Page 129 14:14

Gear driving system
• 5. Install the camshaft timing gear

Alignment marks
As shown in the illustration, align the

camshaft timing gear with the oil pump
gear, install the camshaft timing gear
with tools and hammer.
• 6. Install the idler pulley shaft
(1) Put engine oil on the idler pulley shaft
(2) Install the idler pulley shaft
Page 130 14:14

Gear driving system

Alignment marks
• 7. Install the idler pulley pair
Align the fuel pump gear with

the crankshaft timing gear, and
install the idler pulley pair with
tools. Alignment marks
Page 131 14:14

Gear driving system

Drive gear of oil feed pump
• (2) Running principle of idler gear pair
Drive gear of oil pump Drive gear of
• Structure: gapless gear driving vacuum pump
This structure is made of main and driven gears,

there is a torsion spring between the two gears, two
ends of the torsion spring are fixed top of the pins
of main and driven gears, the spring makes the
tooth face of the gears keep an angle, the shape of
the angle looks like a scissors.
Crankshaft timing gear Idle gear
Feature:
Gear pair
When temperature decreases, the gap between the
main gear and driven gear of the double overhead Crankshaft timing
camshaft is big. At this time, because of the bounce gear
of the torsion spring, a small angle is formed
between the tooth faces of main gear and driven Idle gear
gear of gapless gears, that will fill the gap. And vise
versa.
• Feature: can reduce the noise of the engine. Scissors gear structure
Page 132 14:14

Gear driving system
• 8. Install the thrust washer of idler pulley

(1) Fix the installing hole with locking bolt of
thrust washer of idler pulley.
※ Reference: make the cross recess of thrust washer
toward to back.
(2) Install the thrust washer of idler pulley with
bolts.
※Standard value：T=75N.m{765kgf.cm}
• 9. Install the oil seals
• 11. Install the timing gear box.

• (1) Remove the locking bolt from idler pulley.
Page 133 14:14

Gear driving system
• (2) Install a new O-ring in the location

shown in the illustration.
• (3) Cleanness and degreasing

• ① Clean and degrease the installing face.
• ② Clean and degrease of bolts and bolt
holes.
• (4) Put sealant on the location shown in the

illustration (the diameter is about 4mm),
and install the timing gear box.
• (5) Tighten the bolts and nuts
Standard value：T=13N.m{133kgf.cm}
Page 134 14:14

Gear driving system
• 12. Install the pump assembly

⑴ Install a new pump gasket in the
cylinder block.
⑵ Install the pump assembly with bolts
and nuts. Nuts
• 13. Install the inner housing of belt

pulley chamber and other parts
Page 135 14:14

Ⅱ Cylinder block assembly

☆ Removal
• 1. Inspect the connecting rod
Main point: inspect the axial clearance
Means: measure the axial clearance with metering
gauge
Standard value: 0.10～0.30mm
Limit value: 0.40mm
Reference: must replace the connecting rod and
crankshaft while the value of axial clearance is
greater than the limit value.
• 2. Inspect the connecting rod bearing
Main points: inspect the clearance of oil diaphragm
Inspection steps:
(1) Remove the connecting rod bolts with a socket
wrench.
(2) While sliding the connecting rod cover back and
forth with 2 main bearing bolts, remove the
connecting rod cover and connecting rod bearing.
Page 136 14:14

Check piece
⑶ Clean the inner and outer surfaces of the
connecting rod bearing, and clean the crank
pin.
※Notice: ensure no scratches and breakage.
⑷ Set check piece along the rotating direction

of crankshaft, and install the connecting rod
cover.
⑸ Put some engine oil on the thread and
bottom end of the connecting rod bolt.
⑹ Tighten the connecting rod bolts with a
socket wrench.
※Standard value：T=35N.m{355kgf.cm} Match mark
Page 137 14:14

(7) Mark with color on the head of connecting rod bolt

and front end of engine.
(8) Based on the colored mark, tighten the bolts of Tighten 90° Colored mark
90°.
(9) Ensure all the colored marks toward to the same
direction.
(10) After removing the connecting rod cover, measure Front of the
the widest part of the check piece. engine
※Standard value: 0.036～0.054mm
※Limit value: 0.1mm
※Notice: must remove the check piece after inspection.
Reference: must replace the connecting rod bearing if

it’s value is greater than the limit value.
Page 138 14:14

Selection method of connecting rod bearing
select bearing（symbol C）= connecting rod cover Grouping

（symbol A）＋crankshaft（symbol B） symbol C
e.g. symbol of connecting rod is 1, when crankshaft

symbol is 2, the symbol of bearing should be 3 (1＋2=3).
Group selection
Grouping symbol A
Front
Connecting rod cover 1 2 3

（symbol A）
Crankshaft（symbol B） 1 2 3 1 2 3 1 2 3
Bearing selection 2 3 4 3 4 5 4 5 6
（symbol C） Grouping symbol B
Page 139 14:14

• 3. Remove the connecting rod
① Remove the 2 connecting rod bolts with a

socket wrench.
Reference: confirm the match marks of connecting

rod and connecting rod cover.
② Install the connecting rod cover and bearings

with 2 connecting rod bolts while the cover is
sliding back and forth.
③ Remove the connecting rod of pistons from
cylinder block.
Match mark
※Notice: connecting rod matching
④ Remove the bearings from connecting rod.
• 4. Remove the piston rings

① Remove the 1st and 2nd rings with special
tools of piston ring.
② Remove the oil ring by hand.
Page 140 14:14

● 5. Inspect piston and piston pins

① Remove the locking ring of piston pin hole
with a slot-head screwdriver.
② Use piston heater to heat the connecting rod

which connects with the piston.
③ Remove piston pins and pistons from the

connecting rod which connects with piston.
※Reference: the removed parts must be kept

separately in sequence of assembly.
Page 141 14:14

• 6. Inspect the crankshaft

Main point：inspect the axial clearance
Testing tool：metering gauge
Standard value：0.040～0.240mm

Reference：must replace the crankshaft thrust washer and
crankshaft if its value is greater than the limit value
• 7. Remove the crankshaft
① Loosen and remove the 10 bolts of main bearing cap for 2 to

3 times uniformly in the sequence shown in the illustration.
② Remove the main bearing cap, main bearing bush and
crankshaft thrust washer, then remove the crankshaft.
Reference：the removed parts must be kept separately in

sequence of assembly.
Page 142 14:14

• 8. Remove the injection nozzles

① Remove the oil check valve
② Remove the injection nozzles
• 9. Remove the bolts

① Remove the bolts
② Remove the plug screw
• 10. Remove the hose connector of

wheeled pump
• 11. Remove the stud bolt
• 12. Remove the dowel pin jacket of
cylinder head
• 13. Remove the dowel pin of timing gear
housing O-ring
• 14. Remove the dowel pin of engine rear

seal seat.
• 15. Remove the dowel pin of rear cover
• 16. Remove the plug screw
Page 143 14:14

• 17. Inspect the cylinder block

(1) Inspect the shape of cylinder block
Testing tools: ruler and feeler gauge
Inspecting method: measure the upper surface
deformation of cylinder block with ruler and feeler
gauge shown in the illustration.
(2) Inspect the diameter of cylinder hole

Grouping symbol of cylinder diameter
Testing tool: metering gauge of cylinder bore
※Standard value: 92.00～92.03mm

Page 144 14:14

Reference：
Must replace the cylinder block or bore Front
The axis of
the cylinder if its value is greater than the crankshaft
limit value.
The grouping symbol of cylinder bore is

carved on the upper surface of the
cylinder block.
Symbol selection of
Cylinder bore [mm]
cylinder bore
1 92.00-92.01
2 92.01-92.02
3 92.02-92.03
Page 145 14:14

• 18. Inspect the piston with piston pin
Main points：
(1) Inspect the exterior diameter of pistons
Testing tool: metering gauge
Testing location: away from the piston upper surface of
63.63mm
※Standard value：91.92～91.95mm
※Notice：if the piston was replaced, replace the piston rings.
※Reference：the exterior diameter symbol of pistons is

carved on the upper surface of pistons.
(2) Inspect the piston clearance

① Inspecting method
The piston clearance can be calculated according to the Symbol selection
minimum bore and exterior diameter of cylinder. Cylinder bore of
of piston exterior
piston [mm]
diameter
※Limit value：0.14mm 1 91.92～91.93
※Notice：the minimum cylinder diameter is equal to value 2 91.93～91.94
on the cylinder push surface
3 91.94～91.95
Page 146 14:14

Reference：If the value is greater than the limit value, must replace the cylinder
block or take use of the O/S piston after boring the cylinder.
• fine boring size=（O/S piston size）＋（piston clearance）－（grinding
0.02mm）
Exterior diameter of Interior diameter of

O/S Type
piston [mm] piston [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 Ovality and taper calculation

After boring cylinder block, must measure the cylinder bore with metering gauge to
calculate the ovality and taper.
Limit value：ovality, taper 0.02mm
Reference：ovality…………A-B or a-b
taper……………A-B or a-b
Re-inspect the piston clearance
Page 147 14:14

⑶ Inspect the piston pins
① Inspect the exterior diameter of piston pins
Inspecting tools: metering gauge

※ Standard value：34.000～34.008mm
※Notice：Since no symbol marked on piston pins, don’t confuse

these piston pins.
Reference：Pin hole diameter symbol is carved on the upper

surface of the pistons.
Grouping symbol
② Heat pistons to the temperature about 80℃ with piston heater.
of pin hole
※Notice：Select the piston which has the same symbol with the
grouping symbol of pin hole diameter.
③ Put some engine oil on piston pins, insert the pins into pistons,
and confirm all the pins are inserted correctly.
※Notice：Don’t change the matched piston and piston pin at

will.
Page 148 14:14

• 19. Inspect the piston rings
(1) Inspect the clearance of piston slot, that is the side 2nd ring, oil ring
clearance.
Inspecting method:
① Before testing, install rings in piston firstly, and ensure the
side face of the piston and ring side face are at the same
surface.
② Measure the clearance of piston and piston slot with feeler
gauge. 1st ring
Standard value:
Piston ring 1st ring 2nd ring Oil ring

Side clearance 0.065～0.105 0.050～0.090 0.030～0.075
(2) Inspect the opening clearance of piston rings

Inspecting method:
① Press piston rings in piston and keep 120mm away from the
upper surface of cylinder block
② Measure the opening clearance with feeler gauge
Standard value:
Piston ring 1st ring 2nd ring Oil ring
Opening clearance 0.25～0.45 0.40～0.60 0.20～0.40
Limit value 0.85 1.07 0.77
Page 149 14:14

• 20. Inspect the connecting rod
Main point: inspect the vertical clearance of the top

end of connecting rod
(1) Measure the bushing bore of the top end of

connecting rod with gauge
Standard value：
Little head-end symbol 1 34.016～34.020mm
Little head-end symbol 2 34.020～34.024mm
(2) Calculate the vertical clearance
Calculate the vertical clearance according to the Grouping symbol of little head-
bushing bore of the top end of the connecting rod end of connecting rod
and the exterior diameter of the piston pin.
Standard value: 0.012～0.020mm

Limit value: 0.08mm
Reference: must replace the connecting rod bush

and piston pins if the value is greater than the limit
value.
Page 150 14:14

• 21. Inspect the vertical clearance of crankshaft
(1) Align the stuck key with the oil port, install the
main bearing bush with oil slot in cylinder block.
※Notice: don’t put engine oil on the installing face

and back of the crankshaft main bearing bush. Oil slot
(2) Put crankshaft on cylinder block
(3) Put engine oil on thrust washer of crankshaft and

make the oil slot crankshaft outward. Then install
the thrust washer in front and rear of 5# main
journal.
Oil slot
※Reference: push the crankshaft back and forth,
install it after the clearance of the installing part of
crankshaft thrust washer increased. Front edge
(4) Align the stuck key with the oil port, install the
main bearing bush in main bearing cap.
※Notice: don’t put engine oil on the installing face

and back of the crankshaft main bearing bush.
Page 151 14:14

(5) Put engine oil on thrust washer of crankshaft and make

the oil slot outward. Then install the thrust washer in
front and rear of 5# main journal.
(6) Set the check piece along the direction of crankshaft
journal.
Oil ring slot
※Notice: Don’t rotate the crankshaft before getting the

testing result of radical clearance. Check piece
(7) As shown in the illustration, install the main bearing

bush covers in cylinder block after confirming the
marks and symbols.
(8) Put a little of engine oil on the threads and bottom of
the main bearing cap bolts, then uniformly tighten the
bolts for 2-3 times uniformly in the sequence shown in
the illustration.
(9) Make colored marks on the top of main bearing bush

cover and front side of the engine.
(10) Re-tighten all the bolts 90°based on the colored
marks as standard value.
(11) Confirm all the colored marks are at the same
direction.
Page 152 14:14
(12) Remove the main bearing bush cover and measure the
widest part of the check piece.
※Limit value：0.10mm
※Notice：Must remove the check piece after inspection.
Reference：Must replace the main bearing bush if the value

is greater than the limit value.
Selection method of main bearing bush Grouping symbol A
Symbol selection
Cylinder block 1 2 3
（Symbol A）
Crankshaft 1 2 3 1 2 3 1 2 3
（Symbol B） Grouping symbol B
Select bearing 2 3 4 3 4 5 4 5 6 Grouping symbol C
（Symbol C）
Page 153 14:14

1. Install the injection nozzles
Align the side dowel pin hole of injection nozzles

with the cylinder block, and install the nozzles.
• 2. Install the crankshaft
① Align the stuck key with the oil port, install the
main bearing bush with oil slot in cylinder block.
※Notice：don’t put engine oil on the installing face

Front edge
and back of main bearing bush.
② Put crankshaft in cylinder block
Oil slot
Page 154 14:14

③ Put some engine oil on crankshaft thrust washer and

turn the oil slot outward. Then install the crankshaft
thrust washer in front and rear of the No.5 journal.
Reference: Push crankshaft back and forth, install it
after the clearance of installing part of crankshaft
thrust washer is increased. Oil slot
Front edge
④ Align the stuck key with the oil port, and install the
main bearing bush in main bearing bush cover.
※Notice: don’t put engine oil on the installing face and

back of the main bearings.
⑤ Put engine oil on thrust washer of crankshaft and

make the oil slot crankshaft outward. Then install the
thrust washer in front and rear of 5# main bearing
bush cover.
Oil slot
Page 155 14:14

⑥ As shown in the illustration, install crankshaft in

cylinder block after confirming it’s front side
mark.
⑦ Put a little of engine oil on the bolts threads and
bottom of the main bearing cap, and uniformly
tighten the bolts in the sequence shown in the
illustration.
※Notice: tighten the mounting bolts of main
bearing bush cover with plastic area tightening
method.
Tighten 90°. Colored mark
⑧ Make colored mark on the bolts top of the
connecting rod and front side of engine.
⑨ Based on the colored mark, retighten all the
bolts of 90°.
Front of engine
⑩ Confirm all the colored marks are at the same
direction.
Page 156 14:14

• 3. Install the pistons with piston pins

① Install the locking rings in pistons
※Notice: While installing, must make the gap of

end A of locking ring is in line with the gap of
end B of the locking ring.
② Heat piston to 80℃ with piston heater.
③ Align the front side mark of the piston with the

mark of connecting rod.
④ Press piston pins in pistons with thumb, and
install the connecting rod in plug screw. Mark directs front
⑤ Install the new locking ring of piston pin hole.
Mark directs front
Page 157 14:14

4. Install the piston rings

① Install the expansion rings in pistons
② Install the oil ring with special tools
③ Place the expansion ring and oil ring
shown in the illustration.
④ Install the 1st and 2nd piston rings with
special tools. Must keep the marked face
upward.
2nd compression ring Coil spring
⑤ Place the 1st ring,2nd ring, oil ring and
coil spring shown in the illustration.
Reference：
Piston rings Assembly mark
1st ring A1or1N

2nd ring A2orCYPR
Oil ring 1st compression ring
Page 158 14:14

5. Install the connecting rod Front edge
Front edge
① Align the stuck key of connecting rod bearings with the oil port, then
install the connecting rod and connecting rod cover.
※Notice: Don’t put engine oil on the installing face and the back of the
connecting rod bearing.
② Put engine oil on cylinder bore, piston exterior and surface of
connecting rod bearing.
③ Confirm the opening direction of the piston ring is right.
④ After confirming the front side mark of piston and connecting rod, use
the piston ring compressor to install the piston connected with the
connecting rod.
※Notice: while installing the pistons, don’t damage the cylinder bore and
crank pin.
⑤ Put a little of engine oil on the thread and bottom end of the connecting
rod.
⑻ Tighten the connecting bolt with a socket wrench.
※Notice: tighten the connecting rod bolts with plastic area tightening
Colored mark
method. Tighten 90°
⑥ Make colored marks on top of the connecting rod bolt and front side of
the engine
⑦ Based on the colored mark, re-tighten all the bolts of 90°
⑧ Confirm all the colored marks are at the same direction Front of engine
⑨ Confirm the normal rotation of crankshaft
⑩ Confirm the thrust clearance of connecting rod
Page 159 14:14

Ⅲ Related parts of piston and crankshaft
Piston
Connecting rod
Main bearing (with refined stripes)
Drive gear of oil pump
Crankshaft
Drive gear of oil feed pump
Crankshaft timing gear Idler gear
Page 160 14:14

Cylinder head cover
◎ The cylinder head cover is made of the material of resin with
light weight and good damping performance. The material
can not only reduce the engine weight, but can ensure the
strength of the cylinder head cover. After improving the
shape of the cylinder head cover, engine noise is greatly Cylinder head
reduced. And the oil cut capacity is increased by setting the
baffle plate in cylinder head cover and extending the vent cover gasket
pipe out of the top of the cylinder head cover. In addition,
the baffle plate and vent pipe are all made of the resin
material. Such kind of material can reduce the engine
weight.
◎ The cylinder head cover gasket is made of the acrylate

rubber material with good heat-resistance and oil-resistance
performance. That can ensure the reliability.
◎ The cylinder head is made of the aluminum alloy material

with light weight and good heat conductivity. In addition, Cylinder
the use of DOHC, 4-valves and vertical injectors in center of head
the cylinder head increased the performance and reliability
of the engine, and realized the goals of low emission and
miniaturization.
◎ The cylinder head gasket is made of the four over-lapping Cylinder head gasket
steel with good sealing and heat-resistance performance.
Page 161 14:14

1. Piston and piston rings
☆ Piston
• Material: the piston is casted with the high temperature
resistance and light quality silicon eutectic alloy, the
outer surface is covered with tin so as to improve the
running-in performance.
• Structure: as shown in the illustration
• Main features:
① Cooling oil gallery is set in the interior side of piston
ring slot. Oil is injected by injection nozzles to cool the
gallery, that solved the problem of the high temperature
of the piston top caused by the increase of the output 1.Grouping mark of piston weight 2.Grouping mark of piston skirt diameter
3.Grouping mark of piston pin hole 4.Mark of print direction 5.Annular ring 6.
power. And improved the wear resistance ability of the contracted lip square toroidal combustion chamber7.Colling oil gallery
pistons.
Piston structure
② The piston adopts the contracted lip square toroidal
combustion chamber which is suitable for the direct
injection system, that improves the combustion Mark upward 1st compression ring
efficiency and achieves the goal of high output, low fuel
consumption and low emission.
☆ Piston rings
2nd compression ring
● The 1st ring is wear-resistance alloy steel ring, which
can ensure the wear-resistance ability of pistons.
• The 2nd ring can reduce the friction by reducing the Oil ring
tension of the ring so as to achieve low fuel consumption.
• The oil ring adopts the spiral expander to ensure the
good oil scraping ability.
Page 162 14:14

2. Crankshaft
The crankshaft is forged, which includes 5
journals and 8 heavy crankshaft. Except of
increasing strength and reducing weight of the
crankshaft, high quality alloy steel material is
used after considering the environmental factor.
In addition, weight balance of the crankshaft
in running is improved, that reduces the
vibration and noise.
Figure structure of crankshaft is as shown in the
illustration.
3. Flywheel
The flywheel is a cast-iron disc mounted in the
rear end of the crankshaft. There are three slots
outward at the friction face, they will release the
chips and heat generated from the friction of
clutch friction plate and flywheel, that will
prolong the service life of the flywheel and
clutch friction. Flywheel ring gear are mounted
in the exterior edge of the flywheel to make the
starter start the engine.
Page 163 14:14

Removal
① Fix the crankshaft with tools

② Loosen the 8 bolts and remove the flywheel
③ Remove the rear partition
Hold Dowel pin hole of
Install the flywheel Dowel pin hole flywheel
of crankshaft
① Install the rear partition with bolts
※Standard value: T=8.0N.m（82kgf.cm）
② Fix the crankshaft with tools
Put sealant on the 2-3 threads of the top of the locking bolt.
※Notice：
a. Clean and degrease the bolts and bolt holes
b. Don’t start engine after installation of the engine in an
hour.
③Align the dowel pin holes or pins on flywheel with the dowel
pin holes or pins on the installing surface of crankshaft
flywheel.
④ Install the flywheel with 8 bolts.
※Notice: tighten the bolts uniformly according to the subtense

and diagonal.
※Standard value: T=178±18N.m{1815kgf.cm）
Page 164 14:14

Lubricating system
◎ The lubricating mode of the engine is full pressure and full filter mode.
◎ Set high efficiency oil coolant at the front side of the oil filter to enhance the cooling
performance.
◎ It adopts the injection nozzles. And the durability and reliability of the engine are
improved by strengthening the cooling and lubricating performance of pistons.
1. Lubricating system structure
Lubricating mode: pressure and splash compound lubrication
lubricating system: includes oil pan, suction filter, oil pump, oil filter, oil intercooler, oil
gallery of cylinder block, piston cooling injector, oil pressure sensor and oil pressure gauge,
etc. (see lubricating system)
Pressure lubrication: parts are lubricated with pressure mode are: turbocharger, main
bearings, connecting rod bearing, and camshafts bearing, etc. (see lubricating system oil
circuit diagram)
E.g.: The turbocharger adopts the pressure lubrication mode. It’s function is to ensure the
rotors and bearings are lubricated and cooled well when engine is running. The circulation
route of turbocharger is: lubricant flows into the turbocharger through oil inlet pipe from
the main gallery of cylinder block, and flows back to oil pan through oil-return pipe.
Splash lubrication: parts are lubricated with splash mode are: piston, piston rings, piston
pins, cylinder liner, camshaft and oil pump gear, etc.
Page 165 14:14

Lubricating system
Main oil orifice

Oil filter
Check valve
2nd-5th crankshaft
Element of oil
journals Throttle orifice
filter
Supercharger
1st crankshaft
journal Top Oil
Exhaust Intake
injection
End of camshaft camshaft
Oil cooler port
connecting
rod
Oil pump
Piston cooling
Gear oil Cam gear Valve lifter Valve lifter
Idle gear shaft Vacuum pump passage
injection
Oil filter
Oil pan
Lubricating system diagram
Page 166 14:14

Lubricating system
Lubricating system oil circuit diagram
Page 167 14:14

Lubricating system
2. Oil filter Oil cooler
Structure： Oil filter
The oil filter consists of filter seat

assembly, rotating element and seals.
The safe valve is installed in the inner
of the filter, the relief valve in it can
make the surplus oil flow back to oil
Oil drip pan
pan.
Type: full-flow type filter
Oil cooler housing Oil drain pipe
※Suggestion: for new vehicle, after driving to 2000km, LLC exhaust pipe
should replace the oil filter. Hereafter, after driving to
Oil filter specifications
8000km, the engine oil and oil filter should be replaced.
※Notice: unclean oil will aggravate the breakage of parts Type Full-flow type
and may plug the oil circuit, therefore must periodically
Filter type Filter paper
maintain the oil filter according to the technical
requirement. Filter volume[cm3] 90
※Notice: ensure no oil leak from the mating surface of Exterior diameter
φ76.3*84.4
oil filter housing and filter seat, and parts should be in *height [mm]
good condition.
Page 168 14:14
Lubricating system
3. Oil pump
• Oil pump is a kind of gear pump (see right illustration),

it is fixed on gear chamber and rotate with the spiral
gear of camshaft.
• Features： 6
① Small volume
The size of the oil pump is small, it consists of 5 vanes
5
and 6 cycloid teeth. The driving force from crankshaft
timing gear drives the oil pump through the drive gear. 4
In addition, the drive gear of oil pump and timing gear
box combined into one so as to reduce the volume of 3
engine and achieve the miniaturization of the engine.
② Low friction
2
The interior pressure reduction method can control
the oil inlet resistance and reduce the friction.
• Technical requirement of installation: 1

① After assembly, ensure the oil pump could rotate
freely and stably, and no clamping phenomenon. Oil pump
② Ensure no oil leak from the mating surface.
1. Gear chamber 2. Sealing face of oil pump 3. Inner rotor
③ The open pressure of relief valve is 480±49kPa．
4. Outer rotor 5. Relief valve bolts washer 6. Relief valve bolts
Page 169 14:14

Lubricating system
4. Oil pan
• The oil pan is used to seal the crankshaft case,
and collect and store the lubricant.
• After assembling the oil pan, should inspect
whether there are oil leakage whiling the
engine is running. If oil leaks out, tighten the
bolts and nuts of the leaked part, remove and
check the oil pan if the oil leakage could not Oil pan
be stopped. 1. Oil pan 2. Oil exhaust bolt 3. Bolt washer
5. Oil dipstick
• The dipstick is the special tool for testing the
1st air hole

oil level of lubricating system.
• There are up (7.5L) and down (5.5L) marks
on dipstick for checking the oil level.
2nd air hole

Oil dipstick
Page 170 14:14

Cooling system
◎ The cooling method is water-cooled

pressure forced circulation method.
There is a thermostat with bypass Cylinder head
valve at the water intake location. Water
Open
exhaust pipe Close
Cylinder block
Radiator
◎ The structure of water jacket in Water Close
Oil cooler
pump
cylinder head has upper and lower Thermostat
two layers, that enhances the Open
cooling ability of water jacket to the Water intake pipe
bottom of cylinder head.
◎ The kind of the radiator is new

developed aluminum radiator.
Page 171 14:14

Cooling system
From thermostat
To oil cooler
Water pump
◎ The water pump cover is made of the
aluminum alloy material in light weight.
◎ Improve the shape of turbine shell, and

shorten the volume of water pump.
Cylinder
Water pump specifications block
Diameter of rotor [mm] 75
Diameter of bearing [mm] 30
With air-conditioner
Number of vanes 6
Exhaust [L/min] (5000r/min) 180
Compressor of cooler
☆ Removal Tensioner pulley
1. Open the bolt to drain the coolant.
Without air-conditioner
2. Remove the belt.
Tensioner pulley
Page 172 14:14

Cooling system
3. Remove the fixing bolts of oil dipstick

Generator bracket
4. Remove the generator and generator
bracket
5. Remove the air-conditioner compressor

and it’s bracket
6. Loosen the 4 nuts and remove the fan and

fan pulley
7. Remove the phase sensor

Pipe of oil
dipstick
8. Remove the outer housing of timing belt Generator
chamber and timing belt.
9. Remove the camshaft timing pulley
10. Remove the idler pulley of timing pulley
11. Remove the inner housing of timing belt

chamber
Page 173 14:14

Cooling system
12. Remove the water pump assembly
⑴ Inspect whether there are coolant

flows out from the water exhaust plug
screw.
⑵ Rotate the pulley to ensure there are

no abnormal sound and clamping.
13. Remove the water inlet pipe
Page 174 14:14

Cooling system
13. Remove the thermostat
⑴ Immerse the thermostat in water and heat it gradually.
⑵ Inspect the temperature when valve is fully open.
Fully closed size

※Standard value：80～84℃
⑶ Inspect the valve lift

Above 10mm
※Standard value：
Lift: above 10mm
Temperature under the condition of fully open: 95℃
⑷ Inspect whether the valve of thermostat is fully closed

while the thermostat is under the condition of low
temperature (under 40℃)
※Reference：must replace the thermostat if the valve is not
fully closed.
Page 175 14:14

Cooling system
☆Installation
1. Install the thermostat

⑴ Fix the gasket in thermostat
Rocker valve
⑵ Install the thermostat shown in the
illustration and make the rocker
valve upward.
※Reference：the thermostat should be

controlled 15°up of the swing valve.
2. Install the water inlet pipe

Install the water inlet pipe with 3 bolts.
※Standard value：T＝13N.m
Page 176 14:14

Cooling system
3. Install the water pump assembly

Replace the gasket and install the water pump with 5 bolts
and 2 nuts.
※Standard value：T=13N.m
4. Install the inner housing of timing pulley chamber.
5. Install the timing pulley.
6. Install the camshaft timing pulley.
7. Install the timing belt, timing pulley chamber, outer Generator bracket
housing of timing pulley chamber and phase sensor.
8. Install the water pump pulley, fan clutch and fan.
9. Install the bracket of air-conditioner compressor and air-

conditioner compressor.
10. Install the generator bracket and generator
11. Fix the pipe of oil dipstick
12. Install the belt Generator
Page 177 14:14

DK4 Diesel Engine
Maintenance Manual
Functions and troubleshooting
Page 178 14:14

General introduction of fundamental control of
electronic control system
Running control
In order to achieve the best combustion, no matter what
working conditions the engine is running in, ECU will
calculate the proper quantity of fuel injection. Since during
this process, different parameters under different conditions
have to be considered.
The calculation of fuel injection quantity in

ECU is as following:
Page 179 14:14

Calculation of fuel injection quantity in ECU
Switch at A: start Switch at B: running operation
Signal inputted by Signal from other systems
driver (accelerator Constant speed in constant speed (such as
pedal) ABS,ASR,MSR)
Exterior
Max. fuel Min. fuel injection
interference of fuel
injection volume selection
injection volume
volume
Idle speed Activated Limit value of fuel

regulator damper injection volume
Stable running
Start fuel
Switch Starting speed regulator
volume
process
Fuel volume for Pressure of

Rail pressure control
testing common rail
Control of pressure
Injector control
control valve
Page 180 14:14

Starting fuel injection volume
For starting, fuel injection volume is the function of
the temperature and speed of crankshaft. The starting
fuel injection volume means the instantaneously fuel
injection while starting switch turns from ON to
START (see above illustration, location A )until the
engine speed achieve the minimum. The driver will not
control the injection volume.
In order to normally start the engine in any conditions,

calibration tests in highland, high temperature area and
extremely cold area will be done to vehicles, the purpose is to
keep the engine could start normally in any conditions.
Page 181 14:14

Start preheating
Turn on the ignition switch, when water temperature
is lower than 75 ℃, glow plug will pre-heat to ensure
normal start , the lower the water temperature is, the
longer the preheating time is needed, the glow plug light
will light for 0-12 seconds. During or after engine start,
when water temperature is lower than 40 ℃, glow plug
will operate for 0-180 seconds in accordance with the
water temperature. Similarly, to ensure normal start and
stable running of the engine, the lower the water
temperature is, the longer the preheating time is needed.
Page 182 14:14

Running state
While vehicle is running normally( the start
switch is at the location of
(上图B, see above
diagram), the injection volume could be
calculated according to the accelerator pedal
device (accelerator pedal sensor) and engine
speed. If calculated according to the
transmission diagram, the input power of
driver and output power of engine will achieve
the best state.
Page 183 14:14

Idle speed control
Under the condition of idle speed control, the
fuel consumption for a vehicle depends on engine
efficiency and idle speed. Under the condition of
heavy traffic, fuel consumption of a vehicle is
decided by it’s working condition, the idle speed
should be kept on the minimum. However, no
matter under what working conditions, idle speed
must be set, so that the speed will not reduce too
fast to make the vehicle almost stop or stop while
loading.
Page 184 14:14

For example, when vehicle electrical system is
loading, the air-conditioner is open, the gear location is
busy automatic shifting, or the power steering devices is
running:
In order to achieve the required idle speed, the idle
speed controller will change the injection volume until
the actual engine speed is the same as the idle speed.
Here, the required idle speed and speed governing
characteristics are effected by specified gear location and
engine temperature (coolant temperature sensor). In
addition, besides the exterior loading torque, the interior
friction torque must be considered although it will be
compensated by idle speed control. The changes are so
small and stable during vehicle service life, and they
have close relationship with temperature.
Page 185 14:14
Stable running control
Since mechanical tolerance and aging will cause

torque offset of cylinders, and that will cause instable
running of the engine, especially when engine is
running at idle speed. The stable speed regulator could
test the changes of speed according to the burning, and
could make comparison. Then adjust the injection
volume of cylinders according to the tested difference of
speed, and make every cylinder provide the same
torque to engine. The stable speed regulator will
function when engine is running at the lower speed.
Page 186 14:14

Control the limit of fuel injection
There are many reasons can explain why the fuel
injection could not be provided according to the drivers’
need or why the maximum fuel injection could not be
realized in physics, following reasons are included:
- Excessive pollutant emissions
- Excessive carbon smoke emissions
- Mechanical overload caused by great torque or engine
speed.
- Heat overload caused by the higher temperature of
condenser, oil or turbocharger.
The limit of fuel injection is caused by different inputs
such as air intake, engine speed and coolant temperature.
Page 187 14:14

Activated damping control
Press or release the accelerator pedal suddenly will
cause the sharply change of fuel injection volume, as
well as the engine torque. Such kind of load changes
may cause great shake of the engine seat and
drivetrains, so as to fluctuate engine speed (see the
following diagram).
Through the same periodical speed fluctuation
frequency, the activated damper will change the fuel
injection volume in order to reduce the periodical
speed fluctuation. When speed increases, the fuel
injection volume is small, vise versa. That can
effectively cushion the vibration.
Page 188 14:14

Activated damper
1. Sudden movement of accelerator pedal ( input signal
from driver )
2. Speed curve when damper is not activated
3. Speed curve when damper is activated
Engine speed
Time
Page 189 14:14

Engine stop
The running of diesel engine is in accordance with the
principle of automatic ignition. That means diesel engine
will stop running through cutting off the fuel supply.
When using electric control device, the engine will
stop running due to no fuel injection controlled by ECU.
Engine system also has been set a series of additional
ways to stop fuel supply.
Page 190 14:14

Integrated fault diagnosis
Sensors monitoring
Through integrated test system, people can
monitor the power supply of sensors and
authenticity of O/P signal (when temperature
is between -40 and 150℃ ). Set a spare signal
for important signal if possible. That is to say,
if important signal is fail, the spare signal will
instead of it and continue to work.
Page 191 14:14

Module monitoring
Besides the microprocessor, a monitoring module

is included in ECU. ECU and the monitoring module
can mutually monitor. If any of them is in trouble,
other one will close fuel injection independently.
Page 192 14:14

Fault identification
Fault identification will function during the
monitoring range of sensors. If the time a fault
happened is over the redesigned time, the signal path
will be identified fault. In this situation, the fault and
fault conditions (such as coolant temperature, engine
speed, etc) will be stored in the fault memory of ECU.
If more faults happened, must re-set to recover
normal state. From this point and in this period, must
confirm the signal path is complete.
Page 193 14:14

Troubleshooting
If the output signal is beyond the permitted range, it can be
changed to the setting value. This process is fit for the following
output signals:
-Battery voltage
-Coolant, air and lubricant oil temperature
-Air charging pressure
-Atmospheric pressure and air volume intake
Furthermore, if the accelerator pedal sensor signal and
brake signal are incorrect, could take reference of the backed-up
value of the accelerator pedal sensor.
Page 194 14:14

System lights
Fault light：
Don’t start engine. After turning on the ignition switch,
the fault light will light in a second to self-inspect. If there are
faults, the light will light again to warn the driver to repair the
engine. If the light lights during engine running, the driver
should stop immediately and inspect the engine.
OBD light：
Don’t start engine. After turning on the ignition switch,
the OBD light will light normally. The light will extinguish
after starting the engine. During running of the engine, if
failures of overproof emissions happened that is caused by
ignition, the OBD light will light to warn the driver to inspect
the engine.
Page 195 14:14

2.5L-TDI engine with common-rail injection
system of BOSCH
Fault diagnosis
1. Main features of diagnostic tester

2. Failure codes
3. Common failures mode
Page 196 14:14

system of BOSCH
Main features of fault diagnostic tester

Diagnostic functions
Read failure codes
Clear failure codes
Read dataflow
Actions test
Read freeze frame
Read version information
Nozzle matching
Engine test
Page up Page down
Home page Back Print Help
Start
Page 197 14:14

system of BOSCH

Failure codes clear
Failure codes
Reference signal of cycle time, checking fault
for signal range
Working abnormal of water level sensor
Accelerator pedal 2 & APP1 not match

Accelerator pedal 1 & APP2 not match
No programming fault for anti-theft device
Completed
Fuel rail pressure voltage is greater than the maximum
Metering unit PWM-power class: metering

unit output opens load
Coolant temperature sensor voltage is greater

than the maximum
Page up Page down
Enter Print
Start
Start
Page 198 14:14

system of BOSCH

Data flow selection Data flow
Engine speed Engine speed 0 rpm

Fuel rail pressure 0 bpa
Fuel rail pressure
Control state of air-conditioner compressor
Control state of air-conditioner compressor
close
Current fuel injection
Volume airflow offset
EGR valve ratio

State of ignition switch
State of pre-heating indication light
Page up Page down Enter Page up Page down Figure-1

Record
Home page Back Print Help Home page Back Print Help
Start Start
Page 199 14:14

system of BOSCH

Motion tests Motion tests
Air-conditioner compressor signal test
Exhaust recirculation executor test

Collection time trim test
Collection time test in revolving feed
table
Signal test of preheat light Motion tests completed
Preheat control test

Signal test of OBD light
Test of metering unit executor
Page up Page down
Back Print Help Enter Print

Home page
Start Start
Page 200 14:14

system of BOSCH
Failure codes Data flow

P0110 Reference signal of cycle time, checking fault for Current torque & max. torque ratio 0.00%
signal range
Linear ambient temperature
P2264 Working abnormal of water level sensor
Engine speed
P 2135 Accelerator pedal 2 & APP1 not match
Accelerator pedal 1 & APP2 not match Speed Primitive value
Primitive value of volume airflow

per unit time
Oil rail pressure
Primitive value of ADC atmosphere 1000.00
Page up Page down Record Figure-1

Page up Page down

Start Start
Page 201 14:14

system of BOSCH

Matching system of diesel engine Matching system of diesel engine
Please input IQA code of 7 numbers
Matching completed
Start Start
Page 202 14:14

system of BOSCH
Motion tests Compression tests

Compression test 1
Outtrim of fuel injection volume

Cylinder speed without FBC
Rail high pressure test
Cylinder 1:0r/min
Speed up test
Cylinder 2::0r/min
compression test 2
Cylinder 3:0r/min
Cylinder 4:0r/min
Page up Page down
Enter Print
Start Start
Page 203 14:14

system of BOSCH
Failure codes
Page 204 14:14

system of BOSCH
Failure codes
Page 205 14:14

system of BOSCH
Failure codes
Page 206 14:14

system of BOSCH
Failure codes
Page 207 14:14

system of BOSCH
Failure codes
Page 208 14:14

system of BOSCH
Failure codes
Page 209 14:14

2.5L-TDI engine with common-rail
injection system of BOSCH
Failure codes
Page 210 14:14

system of BOSCH
Failure codes
Page 211 14:14

system of BOSCH
Failure codes
Page 212 14:14

system of BOSCH
Failure codes
Page 213 14:14

system of BOSCH
Failure codes
Page 214 14:14

system of BOSCH
Failure codes
Page 215 14:14

system of BOSCH
Failure codes
Page 216 14:14

system of BOSCH
Failure codes
Page 217 14:14

system of BOSCH
Common failures
Failures Parts need to be inspected
1.Battery
Crankshaft is not rotating 2.Starter
3.Starter relay
1.Replace fuel filter
2.Injector
3.Engine control unit
4.Fuel feed pump assembly
High idle speed is poor
5.Fuel pressure sensor
6.Fuel quality
7.Water sensor
8.Fuel pipe（blocking between fuel tank and fuel feed pump）
Page 218 14:14

system of BOSCH
Common failures
1.A/C signal return
2.Injector
3.Engine control computer
High idle speed 4.Fuel feed pump
6.Water temperature of diesel engine
7.Accelerator pedal assembly
1.A/C signal return
2.Injector
3.EGR system
4.Compressor
5.Valve clearance
Low idle speed
6.Fuel pipe
8.Fuel feed pump
10.Throttle body of diesel engine
Page 219 14:14

system of BOSCH
Common failures
1.Injection
2.Fuel pipe
3.EGR system
4.Compressor
5.Valve clearance
Idle speed instability 7.Fuel pump
10.Fuel properties
11.Air-conditioner system
12.Power steering system
13.DC generator
Page 220 14:14

system of BOSCH
Common failures
1.EGR system
2.Injector
3.Replace fuel filter
5.Fuel pump
Smoking white smoke
8.Fuel properties
9.Compressor
10.Turbocharger device
Smoking black smoke 1.Black smoke analysis
Abnormal start, running stop 1. Analysis of abnormal start and running stop
Power insufficiency 1. Analysis of power insufficiency and speed fluctuation
Idle speed instability, excess
1. Analysis of idle speed instability and excess vibration
vibration
1. Analysis of knock and abnormal sound
Knock, abnormal sound
Page 221 14:14

system of BOSCH
Common failures
1.Injection
2.ECU power circuit
3.compressor
4.Fuel pipe
5.Valve clearance
Engine speed 6.Eninge control computer
fluctuation 7.Fuel feed pump
10.Air-conditioner system
11.Power steering system
Page 222 14:14

Postscript
◇This manual describes the main points of maintenance for DK4 diesel
engine.
◇ If you can take good use of the information described in this manual,
the maintenance could be done correctly and safely.
Mianyang Xinchen Engine Co., Ltd

Jan. 2010
Page 223 14:14

DK5 Engine Manual

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

DK5 Engine Manual

Hochgeladen von

Copyright:

Verfügbare Formate

DK4 Diesel engine

Mianyang Xinchen Engine Co.,Ltd.

Safety Warnings …………………………………… 003

Light-duty bus ORV

1. Key technical specifications of generator and starter

Name Items Specifications

1. Key technical specifications of generator and starter

Names of bolt Names of bolt

Flywheel bolt 178N·m

Specifications of key accessories

Oil pump type Rotor

b. Start of diesel engine

d. Inspection during engine running

• Inspect if there are knock, looseness or other abnormal sounds.

e. Stop running of the engine

5. Running-in of diesel engine

Before using a new or repaired diesel engine, the engine load

Mileage（km） Load Engine speed（r/min）

0～300 No load Less than the rated speed of 50%

>1500～2000 Less than the max. rated speed

c. Technical maintenance after running-in

Notice：The diesel engine can be used normally after running-in maintenance

d. Use attentions for new vehicle

6.Technical maintenance of diesel engine

C. Periodic technical maintenance

Seasonal technical maintenance

Technical maintenance attentions

3.2.1 Crankshaft position sensor

3.2.9 Accelerator pedal sensor

Intake valve Exhaust valve Intake valve Exhaust valve open

1. Air flow sensor

High pressure control Torque control

High pressure circuit Rail pressure sensor Rail

HP pump Fuel rail Injection

Low pressure circuit Injection

Fuel pump HP pump

Fuel inlet metering valve

Packing method of high

1.The high pressure pump should be packed with clean plastic

Assembly method of high pressure pump

Tightening nut of drive gear:M14×1.5

Keep the arrow part still while releasing

Tightening torque of oil tube joint

 Repeat the above procedure if

Oil inlet metering

Inlet with metering valve

Coupling plate Drive gear

High pressure pump with oil

The injector is driven indirectly

Schematic of armature assembly (open)

Valve, piston, needle closed position

Rail pressure sensor Fuel rail

High pressure pump with oil

Sealing of the fuel rail connector

Hardness of oil tube

It is sealed by the conical

The welding face will

Rail pressure sensor

 The rail pressure sensor is integrated at

Flow control valve

 The flow control valve is installed

Rail pressure sensor Rail

High pressure pump with oil