Maintenance Manual of WP2.

3 China V Diesel Engine

Maintenance Manual for WP2.3 China V Diesel

Engine for Vehicles

Weichai Power Yangzhou Diesel Engine Co., Ltd.

Maintenance Manual of WP2.3 China V Diesel Engine

WP2.3 China V diesel engine for vehicles

Maintenance Manual of WP2.3 China V Diesel Engine

Special tips
 Before operation, the diesel engine operator must read this Maintenance Manual carefully and abide
by the operation and maintenance procedures specified herein strictly.
 As the diesel engine has been tested in strict accordance with the test specifications upon delivery, it
is not allowed to adjust ECU data or increase the diesel engine power without permission; otherwise, the
Company will refuse to provide warranty service for the product. Users should be aware of that:
 The rotor shaft of the turbocharger is a high speed rotating part. Please keep any movable objects
(such as hand, tool, cotton yarn) away from the turbocharger inlet when the engine is running, so as to avoid
personal injury or engine damage. For rotor group, disassembling is not allowed unless by professional
turbocharger maintenance personnel or professional service stations authorized by Weichai;
 Various bolts such as main bearing bolts and connecting rod bolts of the diesel engine are subject to
strict torque requirements and service limits, and should not be loosened or removed by users without
permission. Connecting rod bolts are disposable and should not be reused;
 Always fill the diesel engine with the oil or fuel of grade specified in this Manual, and filtered by a
special filter. For the fuel, subject it to a precipitation for more than 72h. Prior to start, always check that the
coolant and oil levels are satisfactory.
 Never run the diesel engine without an air filter; otherwise unfiltered air may enter the cylinders;
 A trial run of 50h should be performed by the user for a new engine.
 After starting a cold engine, accelerate it slowly rather than abruptly, and do not run it at an idle
speed for a long time (3 min). Do not shut down the engine in a sudden after operation with heavy load (except
for special circumstances). Stop the engine after low-speed running for 5 min ~ 10 min;
 After engine shutdown, if the ambient temperature may be lower than 0°C and antifreeze additives
are not added to the coolant, the water in the water tank and diesel engine should be drained;
 Always have the components of the electrical system maintained by professional electrical
technicians.
 Always have the components of the electronic control system maintained by professionals of Weichai
service stations.
 The diesel engine has been preserved before delivery for avoiding rust. The diesel engine
preservation period is one year, and the engine should be checked and necessary measures should be taken
when this valid period expires.
 Replace emission-related key parts (such as turbocharger, fuel injection pump, injector, ECU, exhaust
gas after-treatment system and EGR system) with parts of the same model and type as original ones; otherwise,
Weichai will not be responsible for any consequences.
Maintenance Manual of WP2.3 China V Diesel Engine

Foreword
This series of marine diesel engine is a high-speed diesel engine independently developed by Weichai Power
Co., Ltd. and manufactured by Weichai Power Yangzhou Diesel Engine Co., Ltd. It boasts many advantages such as
compact structure, outstanding performances including reliable running, strong power, good economy and
excellent emission, as well as fast start, easy operation and maintenance.
The contents of this Manual mainly include the precautions for use, maintenance methods, common
inspections and adjustments of WP2.3 China V diesel engine for vehicles, and the diagnosis and troubleshooting
of common faults, etc. Systematic and comprehensive information expressed in a simple and practical way is the
purpose of the manual compilation. It should be noted that the diesel engine troubleshooting is a complicated
work requiring certain knowledge and experience. Thus, do not disassemble or remove the engine at discretion
before determining its fault cause; otherwise, the fault will not be eliminated, and even more serious fault may
occur due to improper refitting. Key components of the engine such as the electronic control system and
turbocharger should be maintained and inspected with special apparatus. Therefore, users having no relevant
experience and equipment are not allowed to remove or adjust the engine at will.
This Manual introduces WP2.3 China V diesel engine for vehicles. With the incessant development and
improvement of products and the continuous production of new products, the contents in this Manual may be
updated. Users (or dealers) should visit Weichai http://www.weichai.com website to obtain the latest product
information.
All suggestions and comments on the product for further improvement will be appreciated.
November 2015
Maintenance Manual of WP2.3 China V Diesel Engine

Contents
Chapter I Operation Instruction ..................................................................................................................................1
1.1 Outline drawing of diesel engine ..................................................................................................................1
1.2 Designation of diesel engine model..............................................................................................................4
1.3 Main technical parameters of diesel engine .................................................................................................4
1.4 Instructions for using new diesel engines .....................................................................................................4
1.5 Hoisting........................................................................................................................................................4
1.6 Unpacking ....................................................................................................................................................5
1.7 Preparations before start .............................................................................................................................5
1.8 Start .............................................................................................................................................................6
1.9 Running .......................................................................................................................................................6
1.10 Stop.........................................................................................................................................................7
Chapter II Maintenance Guidance ...............................................................................................................................8
2.1 Fuel, lubricating oil, coolant, and auxiliary materials ....................................................................................8
2.1.1 Fuel ....................................................................................................................................................8
2.1.2 Lubricating oil .....................................................................................................................................8
2.1.3 Coolant ...............................................................................................................................................8
2.1.4 Auxiliary materials ..............................................................................................................................9
2.1.5 Urea solution ....................................................................................................................................10
2.2 Daily maintenance .....................................................................................................................................11
2.2.1 Daily maintenance ............................................................................................................................11
2.2.2 Daily maintenance ............................................................................................................................11
2.3 Description of maintenance of all levels .....................................................................................................14
2.4 Maintenance of diesel engine in long-term storage ....................................................................................17
Chapter III Typical Faults and Troubleshooting ...........................................................................................................19
3.1 Fault diagnostic methods ...........................................................................................................................19
3.2 General fault causes and troubleshooting methods ...................................................................................19
3.2.1 Diesel engine start failure .................................................................................................................19
3.2.2 Engine flameout soon after start .......................................................................................................20
3.2.3 Underpower .....................................................................................................................................20
3.2.4 Excessive fuel consumption ..............................................................................................................20
3.2.5 Unstable rotating speed ....................................................................................................................20
3.2.6 Low oil pressure ................................................................................................................................21
3.2.7 High cooling water temperature .......................................................................................................21
3.2.8 Fast wearing of parts ........................................................................................................................21
3.2.9 Excessive noise .................................................................................................................................21
3.2.10 Starter motor failure ....................................................................................................................22
3.2.11 Starter underpower......................................................................................................................22
3.2.12 Thorough alternator failure ..........................................................................................................23
Maintenance Manual of WP2.3 China V Diesel Engine

3.2.13 Insufficient charging of alternator ................................................................................................23

3.2.14 Unstable charging current ............................................................................................................23
3.2.15 Excessive charging of alternator ...................................................................................................23
3.2.16 Abnormal noise of alternator .......................................................................................................23
3.3 Fault diagnosis and troubleshooting of after-treatment .............................................................................24
3.3.1 Fault analysis of after-treatment components...................................................................................24
3.3.2 Fault diagnosis and troubleshooting of after-treatment ....................................................................35
Chapter IV Disassembling and Assembling .................................................................................................................40
4.1 Overview....................................................................................................................................................40
4.1.1 Danger sign .......................................................................................................................................40
4.1.2 Safety signs .......................................................................................................................................40
4.1.3 Tools .................................................................................................................................................41
4.1.4 Precautions for health protection .....................................................................................................42
4.1.5 Environmental protection measures .................................................................................................42
4.1.6 Precautions for disassembling and assembling diesel engine ............................................................42
4.2 Engine block group .....................................................................................................................................43
4.2.1 Disassembling and assembling ..........................................................................................................43
4.2.2 Cylinder liner ....................................................................................................................................44
4.2.3 Engine block screw plug ....................................................................................................................44
4.2.4 Nozzle ...............................................................................................................................................45
4.2.5 Oil pan ..............................................................................................................................................46
4.2.6 Front and rear oil seals......................................................................................................................47
4.2.7 Flywheel housing ..............................................................................................................................48
4.2.8 Gear chamber cover .........................................................................................................................49
4.2.9 Gear chamber ...................................................................................................................................50
4.3 Crankshaft and connecting rod mechanism ................................................................................................51
4.3.1 Disassembling and assembling ..........................................................................................................51
4.3.2 Piston connecting rod assembly ........................................................................................................52
4.3.3 Crankshaft ........................................................................................................................................54
4.3.4 Flywheel ...........................................................................................................................................55
4.3.5 Crankshaft pulley ..............................................................................................................................56
4.3.6 Crankshaft bearing bush ...................................................................................................................57
4.4 Cylinder head assembly .............................................................................................................................58
4.4.1 Cylinder head group..........................................................................................................................58
4.4.2 Lifting ring ........................................................................................................................................62
4.4.3 Cylinder head cover ..........................................................................................................................63
4.5 Valve train ..................................................................................................................................................64
4.5.1 Disassembling and assembling ..........................................................................................................64
4.5.2 Camshaft ..........................................................................................................................................65
Maintenance Manual of WP2.3 China V Diesel Engine

4.5.3 Rocker arm and rocker arm shaft ......................................................................................................66

4.5.4 Tappet and push ...............................................................................................................................67
4.5.5 Valve .................................................................................................................................................68
4.5.6 Gear train .........................................................................................................................................69
4.6 Intake and exhaust system .........................................................................................................................70
4.6.1 Intake manifold .................................................................................................................................70
4.6.2 Exhaust manifold ..............................................................................................................................70
4.6.3 Turbocharger system.........................................................................................................................72
4.7 Fuel system ................................................................................................................................................75
4.7.1 Fuel injection pump ..........................................................................................................................75
4.7.2 Fuel injector ......................................................................................................................................75
4.7.3 Low-pressure fuel pipe .....................................................................................................................76
4.7.4 Fuel filter ..........................................................................................................................................78
4.7.5 High-pressure fuel pipe .....................................................................................................................79
4.7.6 Common rail pipe .............................................................................................................................80
4.7.7 Wire harness.....................................................................................................................................81
4.8 Cooling system ...........................................................................................................................................82
4.8.1 Front cover .......................................................................................................................................82
4.8.2 Water pump .....................................................................................................................................83
4.8.3 Drain valve ........................................................................................................................................84
4.8.4 Thermostat .......................................................................................................................................85
4.8.5 Fan....................................................................................................................................................86
4.8.6 Water inlet pipe of water pump ........................................................................................................87
4.9 After-treatment system..............................................................................................................................88
4.9.1 Overview ..........................................................................................................................................88
4.9.2 Requirements for installation matching of after-treatment assembly ...............................................88
4.9.3 Urea solution supply unit ..................................................................................................................88
4.9.4 Urea solution injection unit...............................................................................................................90
4.9.5 Matching requirements of urea solution tank ...................................................................................91
4.9.6 Matching requirements of urea solution heating system...................................................................95
4.10 Lubricating system .................................................................................................................................98
4.10.1 Oil cooler and filter ......................................................................................................................98
4.10.2 Oil suction filter ............................................................................................................................99
4.10.3 Oil dipstick .................................................................................................................................100
4.11 Starting system .................................................................................................................................... 101
4.11.1 Starting system...........................................................................................................................101
4.12 Vehicle accessory system .....................................................................................................................101
4.12.1 Disassembling and assembling of engine bracket .......................................................................101
Maintenance Manual of WP2.3 China V Diesel Engine

4.12.2 Alternator .................................................................................................................................. 102

4.12.3 Hydraulic pump ..........................................................................................................................106
4.12.4 A/C compressor..........................................................................................................................106
Annex A OBD Torque Limit and Unclearable Code List ..........................................................................................107
Annex B Diagnostic Fault Code Table .....................................................................................................................109
Annex C Tightening Torque for General Bolts of Diesel Engine..............................................................................138
Annex D Fit Clearance for Main Parts of Diesel Engine ..........................................................................................139
Maintenance Manual of WP2.3 China V Diesel Engine

Chapter I Operation Instruction

1.1 Outline drawing of diesel engine

1—Intake manifold; 2—Fuel filter; 3—Flywheel housing; 4—Oil pan; 5— Oil filter
Fig. 1-1 Intake side of WP2.3 China V diesel engine for vehicles

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Maintenance Manual of WP2.3 China V Diesel Engine

1—Alternator; 2—Fan; 3—Belt; 4—Hydraulic pump

Fig. 1-2 Free end of WP2.3 China V diesel engine for vehicles

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Maintenance Manual of WP2.3 China V Diesel Engine

1—Exhaust manifold; 2—Turbocharger; 3—Starter

Fig. 1-3 Exhaust side of WP2.3 China V diesel engine for vehicles

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Maintenance Manual of WP2.3 China V Diesel Engine

1.2 Designation of diesel engine model

1.3 Main technical parameters of diesel engine

Tab. 1-1 Main performance parameters of WP2.3 China V diesel engine for vehicles

Item Unit Model

Engine model — WP2.3 Q95E50 WP2.3Q110E50

Intake mode — Turbocharged and intercooled
Cylinder bore × stroke mm×mm 89×92
Total displacement L 2.289
Calibrated power/rated
kW/(r/min) 70/3200 81/3200
speed
Minimum fuel consumption g/kW∙h ≤205
Maximum torque/speed N∙m/(r/min) 245/(1600~2400) 280/(1600~2400)
Maximum idle speed r/min ≤3520
Idle speed r/min 750±20
Noise dB(A) ≤95
Weight kg 225

1.4 Instructions for using new diesel engines

Running-in must be performed prior to use of a new or overhauled diesel engine. Through running-in, the
contact surface of the kinematic pair can reach the ideal matching state, thus avoiding abnormal wear and
damage. Experience has proved that the service life, reliability and economic efficiency of diesel engine depend
greatly on the sufficiency of diesel engine running-in prior to its official operation. Users should pay special
attention to strictly implementing the running-in specifications.

1.5 Hoisting
When hoisting the engine, keep the crankshaft centerline horizontal. Never hoist an inclined engine or hoist
the engine by one side. Hoist and lower the engine slowly, as shown in Fig. 1-1.

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Maintenance Manual of WP2.3 China V Diesel Engine

Fig. 1-4 Hoisting of diesel engine

1.6 Unpacking
After unpacking the diesel engine, the user should first check it and its accessories against the Packing List,
check the appearance of the diesel engine and the fastening condition of connectors, and carry out the following
work afterwards:
◆Wipe the anti-rust coating, corrosion inhibitor, etc. off the exposed parts.
◆ Drain the preservation oil inside the fuel filter and parts of the fuel system (it is also allowed to start the
engine without draining the preservation oil in the fuel system, but only when the preservation oil of the fuel
system is completely consumed and normal diesel oil has been supplied can the engine be allowed to run under
load). Users should be noted that the preservation period of diesel engine is one year and the engine should be
checked and necessary measures should be taken when this valid period expires.
◆ Crank the flywheel and spray solvent into the intake manifold until the preservation oil in the cylinder is
completely bled.
◆ Spray solvent to the intake and exhaust holes of the turbocharger until the sealing oil is completely
drained.
◆ According to the agreement between the manufacturer and the user, fill the oil pan as required if it is
empty. If the oil pan is filled with oil upon delivery, it is recommended that the user drain the old oil and fill the
pan with new oil after the vehicle runs for 2,000 km (or 50 hours).
◆Depending on the agreement between the manufacturer and the user, if the engine has been filled with
coolant before delivery, check the behavior of coolant after unpacking. Acceptable coolant has the freezing
resistance such that it will not freeze at the temperature of -30 °C or -35 °C, the pH value of 7~8 (neutral), and
the total hardness of 5°d~15°d [9°f~15°f (hardness)). If the coolant cannot meet the above requirements, drain it
off, and fill the engine with coolant containing antifreeze additive.

1.7 Preparations before start

◆Check the coolant level
If the engine is installed on the vehicle or on the bench, it is possible to check the coolant level through the
glass sight hole on the expansion tank, and if the coolant is not enough, open the filler cap for topping up. To
open the filler cap with pressure relief valve and exhaust button, if the engine is in a hot state, the exhaust
button must be pressed first. Never add a large amount of coolant to the engine when it is hot; otherwise the
parts may be damaged due to the violent temperature change. If no coolant is available under unusual
conditions, it is allowed to slowly add cold water at certain temperature from the filler until the coolant
overflows. Start and run the engine (1000 r/min), and continue to add coolant till the level is stable. At the end,
close the filler cap.
◆ Check the fuel level
If the engine has already been installed on a vehicle, turn on the power switch, check the fuel level from
the fuel gauge or check the fuel tank.
◆ Check the oil level
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Maintenance Manual of WP2.3 China V Diesel Engine

The oil level shall be between the H and L marks on the oil dipstick. Fill oil from the oil filler if necessary.
◆ Check whether the connections of various accessories of diesel engine are reliable and eliminate
abnormal phenomena. Check if the starting system circuit is connected normally, and the battery is fully charged.
After that, open the fuel tank valve and operate the hand pump on the primary fuel filter to exhaust the fuel
system.

1.8 Start
◆ Put the power switch and electric key in the starting position on the vehicle, put the shift lever in the
neutral position and start the engine.
◆ Depress the clutch pedal and accelerator pedal. Turn the electric key to start the diesel engine. If the
engine cannot be started within (5~10) s, wait for 1 min before the next start attempt. If three successive start
attempts fail, do not start the engine until the fault has been identified and eliminated. After the engine is
started, pay attention to the instrument readings, and check and make sure that the oil pressure gauge works
normally. Do not run a cold engine at a high speed. Instead, run it at an idle speed for a period of time. However,
do not idle it for too long.
◆In a cold environment, start the diesel engine with the starting aid. Activate the electronic heating flange
by a relay to ensure successful start at -30°C.

1.9 Running
◆After the diesel engine is started, run it at an idle speed for 3 min, and then accelerate it to 1,000 r/min -
1,200 r/min and add partial load. Only when the outlet water temperature is higher than 60°C and the oil
temperature is higher than 50°C, can the engine enter into full load operation. Increase the engine load and
speed gradually, and avoid abrupt loading or unloading as much as possible.
◆Within the running-in period of the first 60 h (or the mileage of the first 3,000 km), it is recommended to
run under medium load without a trailer.
◆Decelerate the engine in time on a slope. Do not keep running the engine at a large torque for a long
time, or do not apply too light load to it, because the rotating speed is too low at this time, and faults like oil
expelling are easy to occur.
◆ It is allowed to run the engine continuously at rated power and speed during normal use. However,
when the engine is running at 105% rated speed and 110% rated power, it should run for 20 min as the maximum.
Prior to stop, diesel engine should run at idle speed for 1 ~ 2 min after unloading.
◆Parameter values that should be paid attention to and parts to be checked at any time during use:
Pressure of main lubricating oil passage: 300 ~ 550 kPa; oil pressure at idle point: not less than 100 kPa;
Oil temperature of main oil passage ≤115°C;
Coolant outlet temperature 75~105°C
Turbine downstream exhaust gas temperature: ≤550°C
Intercooled intake air temperature 50±5°C
Check the exhaust color to identify the operation quality and load of the fuel injector. In case of serious
black smoke or white smoke, stop the engine for inspection.
Check the engine for water, gas and oil leakage. If any, stop it for troubleshooting.
◆ The operator should know the following characteristics of diesel engine:
A. The fuel consumption is low at the maximum torque, and the fuel consumption increases when the
rotating speed rises.
B. The maximum torque value will be achieved within the medium engine speed range (1900 r/min ~ 2100
r/min).
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Maintenance Manual of WP2.3 China V Diesel Engine

C. The engine power increases as the rotating speed rises, and reaches the calibrated value when the
calibrated rotating speed is achieved.
◆Precautions for running in a cold environment:
A. Fuel: select appropriate grade of diesel according to the outdoor temperature in winter.
B. Lubricating oil: select appropriate grade of lubricating oil according to different seasons.
C. Coolant: add anti-freeze into the cooling system, and determine the antifreeze grade and mixture ratio
according to the ambient temperature.
D. Start: Apply the starting aid in winter when necessary. After the diesel engine is started, do not run it
under a load or at a high speed until the oil pressure and water temperature are normal.
E. Battery: Before the cold season, check the electrolyte level, viscosity and unit voltage of battery. If the
diesel engine would not be used for a long time and would be kept at an extremely low temperature, remove the
battery and store it in a warm room.
F. Stop: To stop the engine in a cold weather, the load should be removed first. Then run the engine at an
idle speed for 1 min ~ 2 min, and shut it down after all temperature drop. Be careful not to discharge the coolant
with antifreeze additives after stop. If no antifreeze additive is added to the coolant, the water drain valves or
water plugs of the engine block, oil cooler cover, radiator, water inlet pipe, etc. must be opened or removed to
drain the coolant completely to prevent the engine from freezing and cracking.

1.10 Stop
Prior to engine shutdown, the load should be removed and the rotating speed should be gradually reduced,
and the diesel engine should be stopped after running at idle speed for several minutes. After shutdown, the
electric key should be disconnected to prevent the battery current from flowing backward into the excitation coil
of the silicon rectifier alternator and avoid the battery discharging.

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Maintenance Manual of WP2.3 China V Diesel Engine

Chapter II Maintenance Guidance

2.1 Fuel, lubricating oil, coolant, and auxiliary materials
2.1.1 Fuel
Summer: 0# diesel oil (GB252).
Winter: -10 # light diesel oil (GB252), generally. However, when the atmospheric temperature is lower than
-20°C, -20# diesel oil should be used, and when the outdoor temperature is lower than -30°C, -35# diesel oil
should be selected.
The fuel used must meet the requirements of Tab. C.6 in Annex C of national standard GB 17691-2005 of
China.
2.1.2 Lubricating oil
Weichai Power China V series diesel engines use Grade CH-4 engine oil. See Tab. 2-1 for specific standards.
Tab. 2-1 Selection criteria of special oil for Weichai Power engines

Category Product type Packing specification

10W-30
Diesel engine oil CJ-4 15W-40 4 L, 18 L, 170 kg
20W-50

Refer to Tab. 2-2 for viscosity of special oil according to temperature.

Tab. 2-2 Oil viscosity and applicable ambient temperature (continued)

Suitable ambient temperature

SAE viscosity grade
(°C)

0W-20 -35-20

5W-30 -30-30

10W-30 -25-30
15W-40 -20-40
20W-50 -15-45

Note:
1) Before starting the diesel engine, always check the oil level in the oil pan.
2) Never check the oil level when the diesel engine is running.
3) Special oil of Weichai Power is not allowed to be mixed with oil from other manufacturers.
See Tab. 2-3 for oil filling amount and number of filter elements of WP2.3 China V diesel engine.
Tab. 2-3 Oil filling amount and number of filter elements
Oiling filling Quantity of filter(s)
Model amount (L)
Diesel fuel
Oil filter
filter
WP2.3 6.5 1 1

2.1.3 Coolant
The special coolant for Weichai Power engines is available in three kinds of freezing points: -25°C, -35°C and
-40°C. Please select the coolant with appropriate freezing point according to the local ambient temperature.
Generally, the freezing point of the selected coolant should be 10°C below the ambient temperature. See Tab.
2-4.
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Maintenance Manual of WP2.3 China V Diesel Engine

Tab. 2- 4 Special coolant for Weichai Power heavy-duty engine

Packing
Category Product type
specification

HEC-II-25
Coolant for heavy-duty
HEC-II-35 4 kg, 10 kg
engine
HEC-II-40

Note:
1) Always check the coolant on a regular basis, and replace it in time as appropriate to avoid damage
from corrosion.
2) Never replace the engine coolant with water or coolant of poor quality.
2.1.4 Auxiliary materials
Tab. 2-5 Auxiliary materials for diesel engine

No. Item Color Purpose and application

Molykote Pulver (fine To be applied to smooth metal surfaces to prevent blocking

1 Black
molybdenum powder) E.g. external surface of cylinder liner
Molykote G-N-Uplus To be applied for lubrication before the pressure of lubricating oil
2 Dark grey builds up
(molybdenum disulfide oil
agent) E.g. intake valve stem

Tab. 2-6 Reference list of adhesive application for diesel engine

Grade Main purpose Examples of application position Comments

Camshaft thrust plate bolt

Camshaft timing gear bolt
Intermediate idler bolt
Front end cover bolt
Oil filter seat bolt
To be applied onto the thread for
locking and prevention of looseness Oil cooler bolt
Weichai special 242
due to vibration, with medium
Screw plug for oil cooler regulating valve
strength.
Oil pump return pipe fixing device bolt
As an option, DriLoc204
Air compressor shaft end thread thread-locking adhesive
can be used for
Suction filter bolt
pre-application.
Bolts for sensors and harness fixing
devices
To be applied onto the thread for
Weichai special 262 locking, sealing, and prevention of Cylinder head auxiliary bolt
looseness
Weichai special 271 For locking and tightening Bowl plug for oil holes
Weichai special 277 For sealing between core and hole Other bowl plugs
For sealing the top surface of the
Weichai special 270 Push rod tube - cylinder head
cylinder head
Joint surface between cylinder block and
Weichai special
To be applied to smooth metal crankcase
518(updated
surfaces for sealing
product of 510)) Front block and front end cover, rear end
face and flywheel housing connecting
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Maintenance Manual of WP2.3 China V Diesel Engine

Grade Main purpose Examples of application position Comments

plate
Joint surface of oil filter seat and
crankcase
Water pump rear cover - front end of
cylinder block
Flywheel housing connecting plate -
flywheel housing
Joint surface of cylinder block and oil
cooler cover
Joint surface of cylinder block and oil filler
cap
To be applied to smooth metal Joint surface of cylinder block and oil
Silica gel
surfaces for sealing cooler cover

2.1.5 Urea solution

2.1.5.1 Urea solution quality
The quality and performance of the urea solution, which is used as reducing agent, should conform to the
provisions of ISO22241. The requirements for concentration and composition of urea solution are presented in
Tab. 2-7. Substandard urea solution poses the risk of clogging the urea solution pump and nozzle, and may
contain the metal impurities that are prone to causing permanent poisoning of SCR catalyst and reducing the
efficiency of SCR catalytic converter thereafter. Urea solution shall be added through a specified channel or by a
designated unit. It is strictly forbidden to replace urea solution with any fluid during normal use.
Tab. 2-7 Requirements of urea solution components in ISO22241
Composition Unit Lower limit Upper limit
Weight percentage of urea % 31.8 33.2
3
Density at 20°C kg/m 1087 1093
Refractive index at 20°C - 1.3814 1.3843
Weight percentage of ammonia
% - 0.2
bases
Weight percentage of biuret % - 0.3
Acetaldehyde mg/kg - 5
Insoluble substances mg/kg - 20
Phosphate PO4 mg/kg - 0.5
Calcium mg/kg - 0.5
Iron mg/kg - 0.5
Copper mg/kg - 0.2
Zinc mg/kg - 0.2
Chromium mg/kg - 0.2
Nickel mg/kg - 0.2
Aluminum mg/kg - 0.5
Magnesium mg/kg - 0.5
Sodium mg/kg - 0.5
Potassium mg/kg - 0.5

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Maintenance Manual of WP2.3 China V Diesel Engine

2.1.4.2 Storage of urea solution

The urea solution for vehicle shall be stored in an enclosed light-resistant container at the ambient
temperature of 5°C-25°C, with the shelf life shown in Tab. 2-8.
Tab. 2-8 Shelf life of urea solution for vehicle
Shelf life of urea solution for vehicle
Ambient storage temperature °C Minimum shelf life (month)
≤10 36
a
≤25 18
≤30 12
≤35 6
b
>35
Note: The shelf life in the table is specified by giving major consideration to the ambient storage temperature
and initial alkalinity of urea solution besides the difference in evaporation between ventilated and
non-ventilated storage containers.
a
Avoid transporting or storing urea solution at a temperature above 25°C for a prolonged period of time, so as
to prevent decomposition.
b
Check whether each batch of urea solution is up to standard before use.

The materials of the urea solution storage containers should be properly compatible with vehicle urea
solution, without chemical reactions or impurity migration. Containers made of recommended materials in
accordance with ISO22241-3 such as austenitic alloys and additive-free teflon, polyethylene and polypropylene
should be used. When stored below 5°C, attention should be paid to leaving appropriate space in the storage
container, because the volume of urea solution increases by 7% when it solidifies compared with that when it is
liquid.
For the engine filled with urea solution, the effectiveness of urea solution shall be noted. The relationship
between the shelf life of urea solution and the ambient temperature during the inventory period of engine is as
shown in the above table. If the inventory period exceeds the shelf life, it is required to drain away urea
solution through the drain valve at the bottom of the urea solution tank and fill the tank with acceptable urea
solution before the delivery of engine. When the ambient temperature is greater than 35°C, it is necessary to
check if urea solution in the urea solution tank is still up to standard before delivery of the vehicle, and if not,
discharge the solution completely through the discharge valve at the bottom of the urea solution tank, and then
fill the tank with acceptable urea solution.

2.2 Daily maintenance

2.2.1 Daily maintenance
◆Check the level of coolant, oil and fuel; and check if there is sufficient grease at greasing positions.
◆Check for leakage of fuel/oil, coolant and air.
◆Check if external parts and attachments are properly connected and tightened.
◆ Check the fan and belts for overtension or undertension;
◆ Check the oil pressure of the diesel engine;
◆ Check the water temperature of the diesel engine;
◆Check whether the exhaust temperature, color, sound and vibration are normal, and whether the engine
speed is stable;
2.2.2 Daily maintenance
 Check the coolant level and temperature.
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Maintenance Manual of WP2.3 China V Diesel Engine

Check the coolant level through the glass sight hole on the expansion tank, and if the coolant is not enough,
open the filler cap for topping up.
Note: Always press down the exhaust button before opening the filler cap, so as to avoid scalding by hot
coolant when the diesel engine is hot.

Fig. 2-1 Exhaust button

Fig. 2-2 Expansion tank

 Check the oil level.

When the oil level is below the L mark or above the H mark, never start the diesel engine.
Always check the oil level at least 5 min after diesel engine shutdown, enabling the oil to return to the oil
pan.
The oil amount between the L mark and H mark of the oil dipstick is 3 liters.

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Maintenance Manual of WP2.3 China V Diesel Engine

Fig. 2-3 Oil dipstick

 Check the fuel level. See the figure below:

Fig. 2-4 Fuel gauge

 Check for leakage.

The whole engine should be free of water leakage, air leakage and oil leakage.
 Check the belt.
The belt of the engine is a V-belt, and the user checks the tension of the belt by pressing the belt by hand.
See Fig. 2-5.

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Maintenance Manual of WP2.3 China V Diesel Engine

Fig. 2-5 Check the belt Fig. 2-6 Check the exhaust

 Check whether the exhaust color is normal. See Fig. 2-6.

The exhaust color in normal operation is light gray. Color change should be checked and eliminated.
 Check whether the sound is normal.
 Check whether the rotating speed and vibration are normal.

2.3 Description of maintenance of all levels

In addition to daily maintenance, the following items should be added:
 Replace diesel engine oil. See Fig. 2-7.
Unscrew the drain plug at the bottom of oil pan to drain out oil, and then screw on the drain plug again.
Open the filler cap to fill oil through the filler; check the oil dipstick, and when the required level is reached,
refit the filler cap.

Fig. 2-7 Oil drain plug and oil filter

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Maintenance Manual of WP2.3 China V Diesel Engine

Fig. 2-8 Oil filter

 Replace of oil filter or oil filter element.

Replace the oil filter by the following steps:
A. Remove the old oil filter.
B. Fill the new filter with clean oil.
C. Apply oil to the rubber pad before installing the new oil filter.
D. After the rubber pad touches the base, tighten it for 3/4 ~ 1 turn for sealing.
E. Start the diesel engine to check for oil leakage.
Check and adjustment of intake valve clearance
Check and adjust the clearance of intake and exhaust valves according to the following steps:
A. When the diesel engine is cold, turn it forward (according to the running direction of the diesel engine)
to the top dead center of Cylinders 1# and 4#. At this moment, the OT mark of crankshaft pulley is aligned with
the pointer directly above it.
B. Remove the valve rocker arm cover on the cylinder head, and check that Cylinder 1# or Cylinder 4# is in
the compression stroke (there are clearances between the intake and exhaust valves and the rocker arm of the
cylinder in the compression stroke). See Fig. 2-9.

Fig. 2-9 Adjustment of valve clearance

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Maintenance Manual of WP2.3 China V Diesel Engine

C. Check the clearance between the valve upper plane and the valve rocker arm with a feeler gauge as
shown in Fig. 2-9. If the clearance is too large or too small, the required clearance may be achieved by adjusting
the adjusting bolt on the rocker arm. The intake valve clearance is required to be 0.35 mm in cold state and the
exhaust valve clearance is required to be 0.35 mm.
D. After checking Cylinder 1# or 4#, turn the engine forward for 360°, so that Cylinder 4# or Cylinder 1# is at
the top dead center of operating stroke, and check and make adjustment for the remaining valves.
Tab. 2-9 States of cylinders in compression stroke

Cylinder 1# Cylinder 2# Cylinder 3# Cylinder 4#

Compression stroke Intake and

Intake valve Exhaust valve Not adjustable
of Cylinder 1# exhaust valves
Compression stroke Intake and
Not adjustable Exhaust valve Intake valve
of Cylinder 4# exhaust valves

 Replacement of fuel filter element. See Fig. 2-10.

Replace the fuel filter element by the following steps:
A. Remove the old fuel filter element. If the water collector installed on the Primary fuel filter can be
reused, remove the water collector.
B. Lubricate the seal.
C. Screw the filter by hand until the seal fits the connection.
D. Continue to screw the filter until it is installed firmly (by about 3/4 circles).
E. Discharge the air until no bubbles appear.
F. Carry out a leakage test.

Fig. 2-10 Fuel filter

 Check of air intake system

Check if the intake hose is cracked due to aging, and if the hoop gets loosened. Fasten or replace parts if
necessary to ensure the tightness of the air intake system.

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Maintenance Manual of WP2.3 China V Diesel Engine

 Check of air filter element. Fig. 2-11 Schematic diagram of air filter

Fig. 2-11 Air filter

The max permissible intake resistance of the diesel engine is ≤3.5 kPa, and it shall be checked when the
diesel engine runs at rated speed and full load. When this max. permissible intake resistance is reached, clean or
replace the air filter element as specified by the manufacturer.
Note: Never run the diesel engine without an air filter; otherwise, dust and foreign matters may enter
the diesel engine to cause premature engine wear.
Remove the air filter element from the filter, and tap its end face to shake off the dust, or blow its end face
with compressed air from inside to outside. Fig. 2-12 Schematic diagram of air filter element cleaning

Fig. 2-12 Filter element cleaning

Note: Do not break the filter paper.

Do not wash the filter paper with water and oil.
Do not beat or knock the filter element with force.
 Check of urea solution pump filter element
During maintenance, remove the urea solution pump filter element, and clean it with water before refitting.
Do not beat or knock the filter element with force.
Note: Check the urea solution nozzle each time the urea solution nozzle is replaced or removed and refitted.
The nozzle gasket, if damaged or deformed, shall be replaced!
 Cleaning of urea solution tank and urea solution tank filter element
During maintenance, check the urea solution tank and filter element for any dirt, and clean them if
necessary.

2.4 Maintenance of diesel engine in long-term storage

 Clean diesel engine;
 Protection:
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Maintenance Manual of WP2.3 China V Diesel Engine

○ Warm up the engine, drain the engine oil away, clean the oil filter, and fill the engine with anti-rust
oil;
○ Empty the fuel tank, and then fill it with anti-rust oil mixture;
○ Empty the radiator and then fill it with coolant containing anti-rust agent;
○ Start the engine, and run it at an idle speed for 15~25 min;
○ Drain off the oil, fuel, and coolant;
○ Preserve other parts of the engine.
 Protection during storage:
○ Block inlets and outlets of fuel, oil, air and coolant by caps or plastic cloth; seal up the whole diesel
engine with VCI film.
 Pack the engine for handling where appropriate.

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Maintenance Manual of WP2.3 China V Diesel Engine

Chapter III Typical Faults and Troubleshooting

WP2.3 series diesel engines are designed and manufactured under a strict quality assurance system, and
have been subject to specified tests before delivery. Moreover, diesel engine is a precise machinery whose
lasting good performance is related closely to a proper maintenance. The premature failure of diesel engine is
generally resulted from:
◆Operation against regulations, improper management and misuse;
◆Failure to inspect and maintain the engine as specified, and more serious, replacement of maintenance
with repair;
◆Use of defective spare parts, or even counterfeit and shoddy parts due to their cheap price, which will
dramatically shorten the service life of diesel engine;
◆Use of fuel and lubricating oil with improper grade or poor quality.

3.1 Fault diagnostic methods

Methods commonly used for diagnosing diesel engine faults are:
◆ Observation: Determine the fault by observing the symptom of diesel engine, like smoking (as shown in
Fig. 3-1).
◆ Listening: Determine the fault location, symptom and severity by listening to the abnormal noise of
diesel engine (as shown in Fig. 3-2).

Fig. 3-1 Observation Fig. 3-2 Listening

◆ Cylinder cutoff: Cut off a cylinder from operation to determine whether the fault occurs in the cylinder.
Cylinder cutoff is usually to stop the fuel supply to the suspected cylinder, and then compare the diesel engine
states before and after the cutoff, so as to narrow down the scope for further identification of fault location or
cause.
◆ Comparison: Replace a certain assembly or component to determine whether it is faulty.
Note:
1. The diesel engine troubleshooting is a complicated work. Thus, do not disassemble or remove the
diesel engine at discretion before determining its basic fault cause; otherwise, the fault will not be eliminated,
and even more serious fault may occur due to improper refitting. 2. Key components of the engine such as
the high pressure fuel pump and turbocharger should be maintained and inspected by special apparatus and
based on certain experience. Therefore, users having no relevant experience and equipment are not allowed
to remove or adjust the engine at random.

3.2 General fault causes and troubleshooting methods

3.2.1 Diesel engine start failure
Cause Troubleshooting method

1. Fuel passages such as fuel inlet filter screen or Check and remove the dirt and check the cleanliness of fuel.

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Maintenance Manual of WP2.3 China V Diesel Engine

hose of fuel supply pump are blocked.

2. There is air in the fuel system. Bleed the air and check the tightness of the joint.
3. The high-pressure fuel pipe is damaged and
Repair and replace the part.
leaky.
4. The temperature is too low. Add starting assist equipment or measure.
5. The rail pressure sensor is broken. Unplug the rail pressure sensor connector and try to start again.
6. Connectors of engine wire harness and vehicle Check the installation of connectors, and use a multimeter (preferably
wire harness are not properly connected or the wire connected with a "circuit tester") to check the on-off of the circuits
harnesses are open or short-circuited. according to the pointer definition of the circuit diagram.
7. The crankshaft signal and camshaft signal is Check whether the sensor is damaged, the wire harness is properly
missing. connected and the sensor is loose.

3.2.2 Engine flameout soon after start

1. The fuel filter is blocked. Disassemble the filter, remove internal contaminates and moisture, and
replace the filter element if necessary.
2. Air enters the fuel system. Check the tightness of fuel pipes and joints, and check whether the air
bleed screws are tightened. Bleed the air in the pipes.
3. The fuel is of poor quality and contains too
Clean the filter and replace the fuel.
much moisture.

3.2.3 Underpower
Read the flash code through the flash code lamp, and check the flash code
1. The synchronization signal is incorrect.
table to find the specific cause.
Check the circuit and confirm that the fault occurs in the flow metering
2. The flow metering unit is faulted.
unit or the rail pressure sensor.
Check the sensors of intake temperature and pressure, water temperature
3. Sensor fails.
and rail pressure to see if the connectors are firmly connected.
4. The air intake (air filter) is blocked. Check air filter and intake manifold. Clean or replace the filter element.
Check the valve timing and check whether the exhaust pipe is blocked.
5. The exhaust back pressure is too high.
Make adjustment and fix the problem.
6. The booster system is underpressure. Check and eliminate leakage at pipeline joint.
Check the tightness of fuel pipes and pipe joints, the filter contamination
7. The fuel pipeline is leaky or blocked. and fuel pipe. Repair or remove the contamination or blockage, and
replace the filter element.
8. The fuel is of poor quality. Clean the fuel tank, filter parts and fuel pipes, and replace the fuel.
9. The oil level in the oil pan is too high. Check the dipstick and drain the excess oil.

3.2.4 Excessive fuel consumption

1. The air intake is blocked. Check the air filter and air intake pipeline.
2. The exhaust back pressure is too high. Check the exhaust pipe.
3. The fuel is of poor quality. Replace the fuel as required.
4. The fuel pipeline is blocked. Check and repair the part.
5. The fuel pipeline is leaky. Check and repair the part.

3.2.5 Unstable rotating speed

1. The fuel is of poor quality and contains moisture
Replace the fuel.
or wax.
2. Air enters the fuel suction pipe. Check the tightness of fuel pipes and joints, and bleed the air.

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Maintenance Manual of WP2.3 China V Diesel Engine

3. The atomization of fuel injector is unstable. Check and repair the part.
4. The turbocharger bearing is damaged. Replacement

3.2.6 Low oil pressure

1. The oil level of oil pan is too low or the pan is
Check the oil level and whether there is oil leakage, and add engine oil.
short of oil.
2. The main oil passage pressure-limiting valve is
Check and repair the part or replace the part directly.
faulty.
3. The suction filter, oil pipeline, sealing gasket, Check and repair the part or replace the part directly.
etc. are blocked or broken.
4. The oil grade is not in conformity with Replace engine oil according to regulations, and select oil of appropriate
regulations. grade.
5. The water temperature of the cooling system is
Check the cooling system, oil cooler and radiator.
too high, and the oil temperature is also too high.
6. The resistance of oil filter is excessive. Replace the filter element with a new one.
7. The oil cooler is blocked. Check and clean the oil cooler.
8. The bearing clearance is too large, or the
Check and replace.
bearing is damaged.

3.2.7 High cooling water temperature

1. The liquid level of expansion tank is too low. Check for leaks and add coolant.
2. The expansion tank is blocked. Check the expansion tank, and clean or repair it.
3. The water pump belt is slack. Adjust the belt tension according to regulations.
4. The water pump gasket is damaged and the
Check and repair the part or replace the part directly.
water pump impeller is worn.
5. Thermostat fails. Replacement
6. The water pipe is damaged and air enters the
Check water pipes, joints, gaskets, etc., and replace the damaged parts.
pipe.

3.2.8 Fast wearing of parts

1. The air filter element is of unacceptable quality
Check and replace the filter element with one of acceptable quality.
or is damaged.
2. The intake system is short circuited. Check the intake manifold, gasket and connecting pipe sleeve, and repair
or replace as necessary.
3. The oil level of oil pan is too low or the pan is
Check the oil level and oil leakage. Repair the damage and add oil.
short of oil.
4. The oil passage is blocked. Clean the oil passage.
5. The engine oil grade is not in conformity with
Change the oil as required.
regulations.
6. Piston rings are broken or worn. Replace the rings.
7. Cylinder liner or piston is worn or scratches the Disassemble and check the piston and cylinder liner. Repair or replace as
cylinder. necessary.
8. The oil filter element was not replaced in time. Replace as required.
9. Parts wear too much and need to be
Check the mileage and schedule overhaul.
overhauled.

3.2.9 Excessive noise

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Maintenance Manual of WP2.3 China V Diesel Engine

1. The fuel is of poor quality. Replace the fuel.

2. The cooling water temperature is too low. Check the thermostat and replace it if necessary.
3. The timing of air distribution or fuel supply is
Check and fix the problem by adjustment.
incorrect.
4. The atomization of fuel injector is not good. Check and fix the problem by adjustment.
5. The fuel supply amount of the high-pressure
Check and adjust (by professional factory).
fuel pump is too large.
Check for damage and check the connecting bolts. Replace the damaged
6. The damper is worn.
parts.
7. The valve is leaky or improperly adjusted. Disassemble and check the valve, and make adjustment accordingly.
8. The gear clearance is too large or the gear tooth
Check and replace the damaged parts.
is broken.
9. Cylinder liner or piston is worn or scratches the
Check and repair the part or replace the part directly.
cylinder.
10. The push rod is bent or broken. Replacement
11. Piston rings are broken or worn. Check or replace the damaged parts.
12. The bearing bush is excessively worn. Replacement
13. The thrust clearance of crankshaft is excessively
Replacement
large.
14. The main bearing bush is not concentric. Replacement
15. The driven main bearing of crankshaft is not
Check the mounting bracket bolts.
concentric.
16. The parts are excessively worn. Carry out overhaul.
Eliminate the fouling of compressor air passage and the carbon deposition
17. The turbocharger surges.
in exhaust passage.
18. The turbocharger seal ring is sintered. Replacement
19. The turbocharger bearing is damaged, and the
Replacement
rotating parts collides with the fixed parts.
20. Foreign matter enters the turbocharger turbine
Replacement
or compressor impeller.

3.2.10 Starter motor failure

1. The battery charging is insufficient. Check, charge or replace the battery.
2. The connecting wires are poorly connected. Ravel out the wires and tighten the terminal.
3. The fuse is blown. Replace the fuse.
4. The brush has poor contact. Clean the brush surface or replace the brush.
5. The starter motor is short-circuited. Check and repair the motor, or replace the assembly.

3.2.11 Starter underpower

1. The battery charging is insufficient. Charge or replace the battery.
2. The bearing bushing is worn. Replace the assembly.
3. The brush has poor contact. Clean the brush surface or replace the brush.
Remove the oil stains and grind the surface with sand paper, or replace
4. The commutator is dirty or singed.
the assembly.
5. Welding failure occurs at the end of wire. Re-weld the wire.

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Maintenance Manual of WP2.3 China V Diesel Engine

6. The switch is of poor contact. Check the switch and repair it.
7. The worn clutch slips. Adjust the clutch operating torque, or replace the clutch assembly.

3.2.12 Thorough alternator failure

1. The connecting wire is open or short circuited.
Check the wiring of alternator and ammeter, and fix the problems found.
The joint is loose.
2. Rotor and stator coils are open, short-circuited
Repair or replace the assembly.
or grounded.
3. The rectifying tube is damaged. Replace the assembly.
4. The terminal paper insulation is damaged, and
Repair it.
the wire is disconnected.
5. The regulator has an excessively low regulating
Repair it.
voltage.
6. The regulator contacts are melted. Repair or replace the assembly.

3.2.13 Insufficient charging of alternator

1. The connecting wire is open or short circuited.
Repair it.
The joint is loose.
2. Rotor and stator coils are open, short-circuited
Repair or replace the assembly.
or grounded.
3. The alternator belt is slack. Check and adjust the belt tension.
4. The rectifying tube of alternator is damaged,
Repair it.
and the battery has poor contact.
5. The regulator voltage is adjusted to an excessive
Adjust it properly.
low.
6. The regulator field coil or the resistor wire is
Repair or replace.
disconnected.
7. The battery contains insufficient electrolyte or is
Add electrolyte or replace the battery.
obsolete.

3.2.14 Unstable charging current

1. The stator or rotor coil is about to be open or
Repair or replace.
short circuited.
2. The brush has poor contact. Repair it.
3. The terminal is loose and has poor contact. Repair it.
4. The voltage regulator is damaged. Repair it.
5. The voltage regulation is improper. Check and adjust.

3.2.15 Excessive charging of alternator

1. The battery is internally short circuited. Repair or replace.
2. The regulator voltage is too high. Repair and adjust.
3. The regulator is improperly grounded. Repair it.
4. The regulator contact is inoperative or dirty, and
Repair or replace.
the voltage coil or resistor wire is disconnected.

3.2.16 Abnormal noise of alternator

1. The alternator is improperly installed. Repair it.
2. The bearing is damaged. Replace the bearing.

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Maintenance Manual of WP2.3 China V Diesel Engine

3. The rotating part has touched the fixed part. Repair or replace.
4. The rectifier is short circuited. Replacement
5. The stator coil is short circuited. Repair or replace.

3.3 Fault diagnosis and troubleshooting of after-treatment

3.3.1 Fault analysis of after-treatment components
3.3.1.1 Urea solution pump
a) Pressure build-up failure of urea solution pump
Fault symptom: MIL keeps being on. The urea solution pump stops rotating after working for a while. The
urea solution is not consumed.
Possible cause:
1) There is serious air leakage of urea solution inlet pipe.
2) There is urea solution leakage of urea solution inlet pipe.
3) The urea solution inlet and return pipe are connected reversely.
4) The urea solution inlet pipe is severely bent.
Solution:
Check whether the urea solution suction pipe is firmly connected and plugged, and whether the suction
pipe and the return pipe are connected reversely.
b) Abnormal temperature of urea solution pump
Fault symptom: MIL keeps being on. The temperature is significantly different from the ambient
temperature, and the after-treatment system cannot enter the normal working state.
Possible cause:
1) The power supply end of urea solution pump is open circuit.
2) The control end of urea solution pump is open circuit.
Solution:
Check the pins of urea solution pump, and check whether the connector terminal of urea solution pump is
inserted for only a little or virtually.
c) Urea solution injection pressure drop error
Fault symptom: MIL keeps being on. The urea solution pump stops working after a period of time. The urea
solution is never injected. The after-treatment system cannot enter the normal working state.
Possible cause:
The urea solution pressure pipeline is blocked.
Solution:
Remove the urea solution pipe, wash it with water, and the problem will be solved. Do not bend it during
assembling.
d) Open circuit of the urea reversing valve actuator high-end
Fault symptom: The fault indicator and MIL keep being on, and urea solution is not consumed.
Fault mechanism: The urea solution reversing valve is located in the 12-hole connector of urea solution
pump and controlled by ECU. It functions to prevent urea solution from remaining in the pipeline and pump. The
reversing valve works after each engine shutdown to suck the urea solution in the pipeline back to the urea
solution tank within 90 seconds. If multiple faults are reported at the same and in the same connector, it is
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Maintenance Manual of WP2.3 China V Diesel Engine

probably the faults lie in the connector. It may be the pin withdrawal caused by loose locking piece, or water
ingress in connector, etc.
Possible cause:
1) The connector is loose or the pin is withdrawn;
2) Water enters the connector;
3) The related wire harness is faulty.
Solution:
1) Check the connector of urea solution pump;
2) Check whether individual pins in the connector are withdrawn;
e) SCR urea pressure build-up error
Fault symptom: After the engine runs for several minutes to tens of minutes, the indicator lamp and MIL
keep being on. The fault of flash code 441SCR urea solution pressure build-up error will be reported, and urea
solution will never be consumed. Failure mechanism: Before urea solution injection, the urea solution pump
build up a urea solution pressure of 9 bar, which is detected by the pressure sensor in the urea solution pump.
After the engine is started, the urea solution pump tries to build up the urea solution pressure several times. If
the pressure keeps failing to 9 bar, this fault will be reported. Generally, the causes of this failure are: too little
urea solution, reverse connection of urea solution pipeline, blockage or leakage of suction pipe, leakage of
pressure pipe, etc. Very few of the faults can be caused by urea solution pump failure.
Possible cause:
1) There is too little urea solution;
2) The suction pipe is wrongly connected, blocked or leaky;
3) The pressure pipe is leaky;
4) The urea solution pump is blocked or there is a mechanical failure of urea solution pump.
Practical solutions and steps:
1) Check whether the urea solution amount is sufficient;
2) Check whether the urea solution pipeline is connected incorrectly or reversely;
3) Check whether the suction pipe is bent or blocked;
4) Check whether there is any leakage trace in the suction pipe and pressure pipe;
5) Check whether the urea solution pump interface is obviously blocked after all possibilities above are
ruled out.
3.3.1.2 Urea solution tank
The urea solution tank mainly consists of the tank housing and liquid level and temperature sensor. The
sensor is prone to failure such as inaccurate liquid level indication, abnormal temperature indication, and fault
indicator keeping on, and the fault of liquid level and temperature sensor may be reported. The main causes of
such faults are: sensor damage, sensor connector virtual connection, short circuit, and related wire harness
faults. Sometimes, the liquid level and temperature sensor does not comply with the electrical parameters
required by Weichai. For example, customers purchasing urea solution tanks independently without notifying
Weichai will cause abnormal liquid level and temperature, and even sensor fault report.

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Maintenance Manual of WP2.3 China V Diesel Engine

Fig. 3-1 Urea solution tank

Fig. 3-2 Urea solution tank connection

a) Urea level sensor voltage is above the upper limit

Fault symptom: The fault indicator and MIL keep being on, and the voltage of urea solution liquid level
sensor with flash code 445 is higher than the upper limit, and the urea solution liquid level indicated by the
instrument is in accurate. Failure mechanism: If the fault is not reported when the vehicle leaves the factory and
is reported after the vehicle has been running for a while, it is usually caused by the open circuit of the sensor
wire harness or connector. Please check whether PIN 1 of the sensor connector is open circuit or short circuited
to the power supply. If the fault cannot be eliminated thereby, further check other pins and wire harness for
faults.
Possible cause:
1) The pin is withdrawn from the sensor connector or the large plug of the vehicle wire harness;
2) The wire harness circuit is open or virtually connected;
3) PIN 1 is short-circuited to the power supply;
4) The sensor is damaged, or the sensor parameters do not meet the requirements of Weichai.
Practical solutions and steps:
1) Start from the easy part to check the places with the highest failure rate: sensor connectors and wire
harnesses;

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Maintenance Manual of WP2.3 China V Diesel Engine

2) After unplugging the sensor connector, check the pins;

3) Fix the pins.
b) The urea solution liquid level and temperature indications are not normal.
Fault symptom: The urea solution liquid level is indicated inaccurately. For example, when there is little
urea solution, the instrument indicates a 100% level, and the urea solution temperature is quite different from
the current ambient temperature, and no related sensor fault is reported. Failure mechanism: This fault is
generally caused by the mismatch between the urea solution tank sensor and that specified by Weichai, or the
urea solution tank on the vehicle has been replaced recently, but the sensor inside the urea solution tank is of
different model from the original one when the vehicle leaves the factory. The different sensor electrical
parameters lead to data calibration mismatch and liquid level and temperature indication error.
Possible cause:
1) The customer has replaced the original urea solution tank with a different one;
2) A self-purchased urea solution tank is used as the supporting accessory during OEM assembly, but
Weichai technicians are not informed for data recalibration;
3) The sensor or related wire harness is damaged. There is a little possibility that such damage may lead
to electrical parameter change, but it is still possible that sensor-related fault will not be reported;
Practical solutions and steps:
1) Check the urea solution tank and sensor to verify whether they are the same as the original ones;
2) Check whether urea solution tanks come from different manufacturers;
c) The urea solution liquid level and temperature indications are not normal.
Fault symptom:
The urea solution liquid level and temperature are indicated inaccurately. When there is little urea solution,
the instrument indicates a 100% level. When the ambient temperature measured by EOL is 21°C, the
temperature of urea solution tank reaches 42°C, which is obviously inconsistent. There is no other fault of the
urea solution level sensor. Failure mechanism: This fault is generally caused by the inconsistency between the
urea solution tank and Weichai's designated products. However, there are also special circumstances, such as
excessive resistance value of circuit, excessive internal resistance of ECU or other electrical apparatus failures.
Possible cause:
1) The urea solution tank does not conform to the products specified by Weichai;
2) There is excessive internal resistance of sensor related wire harness;
3) There is excessive internal resistance at both ends of ECU sensor pins;
Practical solutions and steps:
1) Check the urea solution tank and sensor to verify whether the urea solution tank is a Weichai
designation;
2) If the urea solution tank is found satisfactory, check the sensor wire harness: Connect the wire
harness normally, and check whether the resistance is normal;
3) Measure the resistance value of ECU urea solution level and temperature sensor;
3.3.1.3 Heating component
The freezing point of the urea solution is -11.5°C. When the system is working at low temperature, the urea
will freeze, resulting in the system’s failure to work. Therefore, the urea tank must be unfrozen. The urea tank is
unfrozen and heated by the cooling water of the engine. The heating water line direction is as shown in the
figure below.

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Fig. 3-3 Flowing direction of heating water passage

The heating system is composed of water heating of urea solution tank and electric heating of urea solution
pump and urea solution pipeline, in which the failure rate of electric heating is high due to more wire harnesses
and heating resistance wires. The main symptoms are relay damage, open circuit of heating resistance wire, open
circuit and short circuit of wire harness, etc.

吸液管加热电阻丝

尿素泵

尿素泵反向阀

发动机
ECU
回液管加热

尿素加热继电器

尿素泵加热电阻丝

压力管加热电阻丝

尿素液位传感器

尿素压力传感器

尿素喷嘴

尿素箱加热

Fig. 3-4 Circuit尿素加热继电器

diagram of urea solution heating system

Relay fault detection: ECU can detect whether the relay is installed correctly. If the relay is missing,
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damaged or has a circuit fault, it will report the fault of "heating relay open circuit, short circuit, etc.". If so, it is
necessary to check whether the relevant relays, wire harnesses and connectors are normal.
The faults of water heating mainly include: harness and connector faults of water heating solenoid valve;
mechanical fault of water heating solenoid valve, such as wear and seizure, which may lead to heating failure of
urea solution tank and low temperature of urea solution tank, and may also lead to continuous heating of urea
solution tank, excessively high urea solution temperature, and unacceptable emission caused by urea solution
volatilization; bending and blockage of water heating pipeline, leakage and blockage of pipeline and interface,
which will cause heating failure or coolant leakage.
a) Overheat of the urea tank
Fault symptom: After the vehicle is running for a while, the flash code lamp and MIL keep being on, and
the 446 urea solution tank overheating fault is reported. Fault mechanism: The urea solution tank carries out
heating with engine coolant and EDC17 controls the solenoid valve of water heating. As urea solution is volatile
at 75°C, the temperature of urea solution tank should not be too high. If the water heating solenoid valve cannot
be turned off normally, which causes the engine coolant to keep heating the urea solution tank, it may cause an
excessively high urea solution tank temperature, a fault will be reported. Other causes of high temperature of
urea solution tank will also lead to report of this fault.
Possible cause:
1) The heating water solenoid valve of urea solution tank is stuck and in a normally open state;
2) Urea tank temperature sensor failure
Practical solutions and steps:
1) Measure the actual temperature of urea solution tank to determine the authenticity of temperature
sensor;
2) Check the heating water solenoid valve of urea solution tank and check the on/off status.
b) The urea solution pipe heating relay is open circuit.
Fault symptom: The fault indicator and MIL keep being on, and the open circuit fault of urea solution
heating relay is reported.
Failure mechanism: If the urea solution heating relay is missing or the circuit is damaged, the open circuit
fault will be reported.
Possible cause:
1) The relay is not installed;
2) Relay-related wire harness and connector are faulted.
Practical solutions and steps:
1) Check the relay installation;
2) Install the relay correctly.
c) The heating resistance wire of urea solution pipe is open circuited.
Fault symptom: The fault indicator and MIL keep being on, and the fault of open circuit of urea solution
pipe heating resistance wire and urea solution pump heating resistance wire is reported.
Failure mechanism: If the urea solution pipeline and urea solution pump are only connected with heating
relay, but not with heating resistance wire, or the resistance wire is not completely connected according to the
requirements of pin diagram, ECU can also detect this fault.
Possible cause:
1) The heating resistance wire is not installed;
2) The wiring is not in accordance with the pin diagram, or there is an open circuit fault;
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3) Other wiring is not completely in accordance with the wiring requirements of the pin diagram.
Practical solutions and steps:
1) Check whether the resistance wire is installed, for example, whether the connector is loose during
installation;
2) Connect the resistance wire correctly, and check that the connection is correct.
3) There is open circuit inside the resistance wire. Replace the heating pipeline.

Fig. 3-5 Urea solution water heating valve

3.3.1.4 Urea solution nozzle

The structure of nozzle is relatively simple, so the faults involved are typical, mainly including: nozzle
solenoid valve fault: connector and harness damage, resulting in open circuit and short circuit; solenoid valve coil
burnout, which can be detected by measuring the resistance. Mechanical fault of nozzle: Due to poor quality of
urea solution added or aging of nozzle, wear of urea solution nozzle often leads to high urea solution
consumption. urea solution crystallization or other particulate matter may cause nozzle blockage. The nozzle may
be deformed or broken due to other reasons. All faults mentioned above that will affect urea solution injection
and discharging may limit engine torque.
a) SCR urea nozzle drive high end short circuit to the power supply
Fault symptom: The fault indicator and MIL keep being on, and the 453SCR fault that urea solution
nozzle driving high end is short-circuited to the power supply is reported.
Failure mechanism: The solenoid valve of urea solution nozzle has two pins, 1.96 and 1.23. They
correspond to connector 2 and 1. PIN 1.23 refers to the driving high end of solenoid valve, and PIN 1.96 is the
driving low end. This fault refers to the short circuit between PIN 1.23 and power supply. Please check PIN 1.23
connector and harness.
Possible cause:
1) The connector is faulted, resulting in short circuit of PIN 1.23 to power supply;
2) The related wire harness of PIN 1.23 is faulty, resulting in short circuit to external power supply.
Practical solutions and steps:
1) Check the nozzle connector for damage or short circuit;
2) Measure the voltage of PIN 1.23;
3) Check the large plug of the vehicle wire harness.
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b) The urea solution consumption is high.

Fault symptom: The urea solution consumption is high, and the ratio of urea solution consumption to fuel
consumption is far greater than 1/20. There is no other related fault.
Failure mechanism: If the failure is not reported, it shows that the wire harness and electrical components
of the after-treatment system are basically normal. Possible causes are leakage of urea solution pipeline, urea
solution pump, and urea solution tank, etc., and wear of urea solution nozzle, which leads to leakage of urea
solution from nozzle.
Possible cause:
urea solution leakage occurs in pipelines and related electrical components;
The nozzle is worn, which leads to the increase of urea solution injection amount.
Practical solutions and steps:
1) Check whether there are traces of urea solution leakage in urea solution tank, urea solution pump
and urea solution pipeline;
2) If there is no urea solution leakage, start the vehicle and keep it running at high power until the
exhaust temperature reaches the minimum temperature of 200°C for urea solution pump pressure build-up, and
then EOL detects the urea solution pump pressure until it is stable at about 9 bar;
3) Do not shut down the engine and keep the engine running at idle speed;
4) Take the urea solution nozzle out of the exhaust pipe and observe whether the nozzle leaks.
3.3.1.5 Diesel measuring unit
The diesel measuring unit is composed of a housing containing a shutoff valve, two pressure sensors, a
temperature sensor and an injection valve. The main faults involved are: diesel shutoff valve and nozzle solenoid
valve fault: connector and harness damage, resulting in open circuit and short circuit; solenoid valve coil burnout,
which can be detected by measuring the resistance. Sensor fault: open circuit and short circuit of sensor caused
by damage of connector and harness.
a) The diesel injection shutoff valve is short circuited to power supply.
Fault symptom: The fault indicator and MIL keep being on, and it is reported that the diesel injection
shutoff valve is short-circuited to the power supply, and the diesel measuring unit cannot supply fuel to the
diesel nozzle for injection.
Possible cause:
1) The connector is faulted, resulting in short circuit of PIN 1.45 to power supply;
2) The related wire harness of PIN 1.45 is faulty, resulting in short circuit to external power supply.
Practical solutions and steps:
1) Check the nozzle connector for damage or short circuit;
2) Measure the voltage of PIN 1.45;
3) Check the large plug of the vehicle wire harness.
b) The diesel injection valve is short circuited to power supply.
Fault symptom: The fault indicator and MIL keep being on, and it is reported that the diesel injection valve
is short-circuited to the power supply. The pressure sensor upstream the diesel measuring unit functions
normally but the diesel measuring unit cannot supply fuel to the diesel nozzle for injection.
Possible cause:
1) The connector is faulted, resulting in short circuit of PIN 1.24 to power supply;
2) The related wire harness of PIN 1.24 is faulty, resulting in short circuit to external power supply.
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Maintenance Manual of WP2.3 China V Diesel Engine

Practical solutions and steps:

1) Check the nozzle connector for damage or short circuit;
2) Measure the voltage of PIN 1.24;
3.3.1.6 Diesel nozzle
The diesel nozzle is a mechanical component, and the main faults involved are: diesel nozzle wear due to
poor fuel quality; particulate matter entering, resulting in nozzle blockage; or nozzle deformation and breakage
due to high temperature;
Fault symptom: Normal fuel injection cannot be performed.
Possible cause:
1) The diesel measuring unit is damaged.
2) There is fuel leakage in the fuel connecting pipe between the diesel measuring unit and the diesel
nozzle.
3) The diesel nozzle is damaged or blocked.
Practical solutions and steps:
1) Check whether the fuel connecting pipe between the diesel measuring unit and the diesel nozzle is
leaky.
2) Check whether the cooling pipeline of diesel nozzle is normal.
Check whether the diesel nozzle is blocked or damaged.
3.3.1.7 Urea solution pipeline
The after-treatment system consists of 3 sections of urea solution pipelines, which are most prone to 3
types of faults: pipeline blockage, pipeline leakage and pipeline bending. Pipeline blockage: It is usually caused by
urea solution crystallization or poor urea solution quality, which will affect urea solution injection and pressure
build-up, resulting in substandard emissions. Pipeline leakage: It can be caused by two major reasons. The model
of pipeline interface is inconsistent or the interface is not well sealed, which leads to urea solution leakage. The
pipeline is aged or worn, leading to urea solution leakage. Pipeline bending: It will cause urea solution pressure
build-up fault or injection fault, resulting in substandard emission.
a) SCR urea pressure build-up error
Fault symptom: The fault indicator and MIL keep being on. NOX emission exceeds the standard, and urea
solution cannot be injected normally. Failure mechanism: When the temperature of the exhaust manifold
reaches the minimum for pressure build-up, the urea solution pump starts to build up pressure. Check all urea
solution pipelines, urea solution pumps and nozzles for leakage and blockage. If the urea solution pressure does
not reach 9 bar for a long time, ECU will suspect urea solution leakage and will report this fault. The
after-treatment system stops working if so.
Possible cause:
1) The urea solution pipeline is connected incorrectly, or urea solution leaks from the suction pipe;
2) There is leakage in the pressure pipe;
3) Urea solution pump fault.
Practical solutions and steps:
1) Check the suction pipe for incorrect connection, leakage, and bending;
2) Check whether the pressure pipe leaks;
3) Check the sealing condition of pressure pipe and urea solution pump interface;
b) SCR was not emptied in the last driving cycle.
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Fault symptom: After T15 is powered on, the fault indicator and flash code lamp keep being on. The flash
code 447 is read and it shows that SCR is not emptied in the last driving cycle, and there was no such fault before.
Failure mechanism: In order to prevent urea solution residue from crystallizing in the pipeline and pump, causing
blockage or damage to the urea solution pump, the driver is required not to cut off the power supply of the
vehicle within 90 seconds after engine shutdown. Within the 90 seconds, the urea solution pump continues to
work, and the urea solution in the pipeline and urea solution pump is sucked back to the urea solution tank. If
the driver fails to operate as required, for example, the vehicle switch is turned off earlier than required, this
fault will be reported.
Possible cause:
The driver operates against the regulation.
Practical solutions and steps:
1) Check with the driver whether he/she waited for 90 seconds before turned off the vehicle switch
after engine shutdown in last driving;
2) The driver turned off the vehicle switch too early, much before 90 seconds;
3) Start the vehicle again. After engine shutdown in the next driving cycle, the driver should operate
correctly and wait for 90 seconds before cutting off the vehicle power supply.
3.3.1.8 After-treatment sensors
Sensors herein mainly refer to exhaust temperature sensor, ambient temperature sensor, NO X sensor and
differential pressure sensor.
Exhaust temperature sensor and ambient temperature sensor: They are subject to two main types of faults:
For the first type, the sensor voltage signal is higher than the upper limit or lower than the lower limit. The
former condition is usually caused by open circuit or short circuit to power supply of wire harness and connector,
while the latter condition is usually caused by short circuit between harness and connector and ground. The
other type of fault is inaccurate temperature indication. In cases like this, it is necessary to consider whether the
sensor is installed in place, whether the installation position is appropriate, or whether the sensor is damaged.
Faults of the ambient temperature sensor will affect the urea solution heating, resulting in urea solution
crystallization, urea solution pump blockage, etc. Faults of the exhaust temperature sensor will result in failure of
urea solution injection control, diesel injection control, and substandard exhaust emission. In a word, all the
faults that cause substandard emission will lead to torque limitation if they are not repaired in time.
NOX sensor: When this sensor fails, the nitrogen and oxygen concentration measured cannot be sent to
EDC17 through AT101 message, and "AT101 message timeout fault" will be reported. Generally, it is mainly
caused by wiring problems: The NOX sensor has 4 wires connected to the vehicle wire harness, which are power
positive, power negative, communication CAN ground and communication CAN high. Please check whether the
voltages of these four wire harnesses and connectors are normal, and whether the wire harnesses and
connectors are open or short circuited. On the premise of ensuring that the harnesses and connectors are not
faulty, NOX sensor damage may be considered, Try to confirm the theory by replacing the NOX sensor.
Faults of differential pressure sensor often lead to DPF regeneration fault or unreliable differential pressure.
It is usually caused by loose connector of differential pressure sensor and leakage of pipeline in sensor part. It is
necessary to check the circuit, both ends of differential pressure sensor and DPF housing in time to confirm
whether there is circuit fault or exhaust gas leakage, and whether DPF housing is damaged.
a) The exhaust temperature sensor voltage signal is higher than the upper limit.
Fault symptom: The fault indicator and flash code lamp keep being on, and the voltage signal of upstream
temperature sensor is reported to be higher than the upper limit. When EOL is used to measure the exhaust
temperature, the indication is obviously inaccurate and remains unchanged.
Failure mechanism: The exhaust temperature sensor, related circuits and connectors are faulty, which
leads to open circuit of the sensor. When this fault is detected, the exhaust temperature measured by EOL is the
default value.
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Possible cause:
1) The connector and circuit of exhaust temperature sensor are open;
2) The sensor is aged and damaged;
3) The large plug circuit of the sensor ECU is faulty, which leads to the open circuit of the sensor;
Practical solutions and steps:
1) Check the connector of exhaust temperature sensor;
2) Check whether the sensor wire harness is normally conductive;
b) The ambient temperature signal is not credible.
Fault symptom: After the vehicle runs for a period of time, the fault indicator and flash code lamp keep
being on, and the flash code 235 fault that the ambient temperature signal is not credible is reported.
Fault mechanism: The ambient temperature is used to measure the current atmospheric temperature. If
the ECU detects that the ambient temperature is obviously inconsistent, such as being too high or too low, it will
report this fault. Generally, the causes of this fault are: The ambient temperature sensor is installed in a wrong
position, such as in the engine compartment, too close to the heat source. The resistance of the sensor circuit is
abnormal. The sensor is faulted itself.
Possible cause:
1) The installation position of the ambient temperature sensor is wrong;
2) The circuit resistance of the sensor is too large;
3) The ambient temperature sensor is damaged;
Practical solutions and steps:
1) Check whether the installation position of the ambient temperature sensor meets the requirements;
2) Check whether the sensor is close to the heat source;
3) Adjust the installation position of the ambient temperature sensor as required.
c) CAN receiving frame AT101 timeout error is reported.
Fault symptom: The flash code lamp and MIL keep being on, and the timeout error 421CAN of receiving
frame AT101 is reported. Failure mechanism: After NOX concentration is measured by the NOx concentration
sensor, the measurement is continuously sent to ECU through AT101 message in CAN bus. If ECU does not
receive AT101 message, it will report this failure.
Possible cause:
1) The wiring of NOx sensor is faulted, resulting in AT101 message sending failure;
2) The NOx sensor is damaged;
3) CAN bus network is faulted.
Practical solutions and steps:
Check that the voltages of Pins 1, 2, 3 and 4 in the NOx sensor should be 24 V, 0 V, 2.2 V and 2.8 V
respectively, and determine whether there are faults such as wrong connection, open circuit and short circuit;

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Fig. 3-6 NOX sensor assembly

3.3.1.9 Summary
Generally, when the SCR system does not work, there are the following situations:
 The urea solution pipeline is leaky or is blocked by crystallization;
 The urea solution pipe joint is loose, and there is air leakage, but urea solution is not leaked;
 The urea solution injection pipeline and return pipeline are connected reversely;
 The wire harness connector of urea solution pump is short circuited, disconnected or wrongly
connected;
 Unreasonable placement of SCR system in the vehicle leads to bending of urea solution pipeline,
water ingress, or short circuit.
 The exhaust temperature sensor is not connected or disconnected, or connected incorrectly;
 The temperature sensor of urea solution tank is abnormal, which causes SCR system to stop;
 There is a problem with the ECU or ECU wire harness, and the ECU connector or sensor connector is
subject to pin withdraw;
 The urea solution heating resistance wire is burned out, and a heating related OL fault is reported;
 Components include nozzle, exhaust temperature sensor and urea solution level sensor.
3.3.2 Fault diagnosis and troubleshooting of after-treatment
3.3.2.1 Category I: urea solution pressure build-up failure
Step I: Read the flash code according to the flash code lamp. Determine where the fault locates according
to the DTC, and pay special attention to the function faults and component (e.g., nozzle, reversing valve, urea
solution pump, heating relay, heating resistance wire, exhaust temperature sensor, urea solution tank
temperature sensor, etc.) faults related to pressure build-up.
Step II: In a cold region, check urea solution heating components at first according to the DTC to ensure a
normal urea solution heating function.

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Step III: Based on relevant fault information obtained in Step I, if there are only component faults instead of
function faults related to pressure build-up, check the nozzle, reversing valve, urea solution pump, heating relay,
heating resistance wire, exhaust temperature sensor, urea solution tank temperature sensor, etc. and their
harnesses; component faults may be a possible reason why the system did not try to build up pressure, and the
upstream exhaust temperature required for pressurization is 180°C.
Step IV: Cut off power and restart. If the system still does not try to build up pressure, further check the
harness as the harness between components may be reversed.
Step V: Based on relevant fault information obtained in Step I, if there are only function faults instead of
component faults related to pressure build-up, check the installation of urea solution pipes for urea solution
leakage and clogging, since the system may have made an attempt to build up pressure.
Step VI: Power off and restart. If the system still fails to build up pressure, make further check if the harness
between components is connected reversely.
Step VII: Signal quality may also lead to pressure build-up failure of the system. Such signals include urea
solution level and urea solution temperature of urea solution pump.
Step VIII: Check the calibration data if necessary.
3.3.2.2 Category II: little urea solution consumption
Step I: Read the flash code according to the flash code lamp. Determine where the fault locates according
to the DTC, and pay special attention to the function faults and component (e.g., nozzle, reversing valve, urea
solution pump, heating relay, heating resistance wire, exhaust temperature sensor, urea solution tank
temperature sensor, etc.) faults related to pressure build-up.
Step II: In a cold region, check urea solution heating components at first according to the DTC to ensure a
normal urea solution heating function.
Step III: Check whether the urea solution pressure build-up is normal. If the pressure build-up fails, check
with reference to Category I.
Step IV: If the pressure build-up is done, further check the nozzle. Remove the nozzle and observe whether
the injection is normal. The mechanical blockage of the nozzle cannot be diagnosed.
Step V: Ask about the operating conditions of the vehicle. If the vehicle runs in the low load area most of
the time, it may lead to low exhaust temperature, and the urea solution injection will not be available (minimum
200°C).
Step VI: Further check the wire harness to see if the wire harness between components is connected
reversely.
Step VII: Check the calibration data if necessary.
3.3.2.3 Category III: OBD torque limit and code that cannot be cleared
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
functional faults and component faults that cause OBD torque limit and code that cannot be cleared. See Annex
A (Table of OBD Torque Limit and Code that Cannot Be Cleared) for details.
Step II: According to the result of the fault code investigation in Step I, refer to Tab. I to identify which fault
causes the OBD torque limit and code that cannot be cleared.
Step III: Check the calibration data if necessary.
Step IV: Check and rule out the faults with reference to the fault diagnosis manual.
3.3.2.4 Category IV: MIL
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
functional faults and component faults that cause MIL to light up.
Step II: According to the result of the fault code investigation in Step I, refer to Tab. I to identify which fault

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causes the MIL to light up.

Step III: Check the MIL and its wire harness to make sure that the MIL works normally.
Step IV: Check the calibration data if necessary.
Step V: Check and rule out the faults with reference to the fault diagnosis manual.
3.3.2.5 Category V: unavailable urea solution heating
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
faults related to urea solution heating and ambient temperature sensor.
Step II: Check the ambient temperature sensor and its harness if necessary based on the result obtained in
Step I to verify that the sensor works normally.
Step III: Check the urea solution heating relay, solenoid valve and their harnesses if necessary based on the
result obtained in Step I.
Step IV: Check the urea solution heating resistor and its harness, and urea solution tank heating coolant
pipeline if necessary based on the result obtained in Step I.
Step V: If a urea solution pump heater fault is reported, and this fault still exists after power-off and restart,
replace the urea solution pump if necessary.
Step VI: Check the calibration data if necessary.
Step VII: Check and rule out the faults with reference to the fault diagnosis manual.
3.3.2.6 Category VI: low NOx conversion efficiency
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
faults related to NOx conversion efficiency.
Step II: Carry out the following inspections in turn:
a) Check the NOx sensor and exhaust manifold. If the measurement signal of NOx sensor is large, a
conversion efficiency fault will occur.
b) Check the urea solution injection volume. If the urea solution injection volume is small, the
measurement signal of NOx sensor will be large, and a conversion efficiency fault will occur.
c) Check the nozzle. If the nozzle involve fault such as mechanical sticking or partially sticking which
cannot be detected by the system, the urea solution injection volume will be small, the measurement signal of
NOx sensor will be large, and a conversion efficiency fault will occur.
d) Check the urea solution pressure. If the urea solution pipeline is leaky, the control of urea solution
pressure will reduce, and the actual urea solution injection volume will be small, the measurement signal of NOx
sensor will be large, and a conversion efficiency fault will occur.
e) Check urea solution. If the quality of urea solution is not acceptable (low concentration, excessive
impurity, etc.), the measurement signal of NOx sensor will be large, which will lead to conversion efficiency
related fault.
f) Check if the urea solution is crystallized. If crystallization happens inside the SCR tank, the RPM
efficiency of the tank will decrease.
g) Check the engine and SCR tank. If the engine or SCR tank has aged seriously, the original emission of
NOx and the measurement signal of NOx sensor will be large, and a conversion efficiency fault will occur.
h) Check the factors related to the environment. If the ambient temperature and pressure sensor is
damaged, and the vehicle is running in an environment of high temperature, high pressure and high attitude, a
conversion efficiency fault will be reported. This is especially true in regions of high attitudes.
Step III: Check the rating data if necessary. If specific conditions for engine running are unreasonable, a
fault may be reported incorrectly.

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3.3.2.7 Category VII: unavailable NOx conversion efficiency monitoring

Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
faults related to NOx conversion efficiency.
Step II: Check the NOx sensor to confirm that the NOx sensor works normally, the ECU can read the NOx
measurement value, and the NOx sensor status is 1.
Step III: Check the availability conditions of urea solution injection, including: SCR status is in dose control
mode, urea solution pressure is about 9 bar, and the exhaust temperature is above 200°C. Make sure the urea
solution injection is available.
Step IV: Check the urea solution injection status to confirm that urea solution is actually being injected.
Step V: Check the ambient temperature and pressure sensors and their wire harness, and confirm that
these two sensors work normally, and the ambient pressure is greater than 900 hPa and the ambient
temperature is greater than 2°C.
Step VI: Make sure that the engine operating condition is within a suitable range. For example, the exhaust
temperature is greater than 300°C and the exhaust flow is greater than 500 kg/h.
Step VII: If necessary, check the calibration data. If the specific calibration for engine operating condition
availability is unreasonable, the NOx conversion efficiency monitoring will not be available.
3.3.2.8 Category VIII: inaccurate NOx measurement
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
faults related to NOx signal.
Step II: Check the NOx sensor and exhaust pipe to make sure that the exhaust pipe does not leak too much,
and the NOx sensor is installed correctly. See the supporting installation specifications of SCR after-treatment
system for details.
Step III: Check the harness of NOx sensor to confirm that the communication is normal and the power
supply is normal.
Step IV: Check the exhaust backpressure, which affects the number of NOx molecules entering the NOx
sensor, and then affects the NOx measurement.
Step V: Check the ratio of NO to NO2 in exhaust. If NO2 ratio is high, the NOx value measured will be high.
Step VI: If necessary, check the calibration data to confirm that the sending, receiving and availability of
NOx sensor related messages are correct.
3.3.2.9 Category IX: a whiff of ammonia
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
faults related to urea solution injection amount, including the faults of speed sensor, fuel injector, intake pressure
and temperature sensor, exhaust temperature sensor, nozzle, urea solution pressure sensor and other
components.
Step II: Check the speed sensor and its wire harness. The speed signal is one of the bases for calculating
urea solution injection amount.
Step III: Check the fuel injector. If the actual fuel injection amount is less than the amount set, the urea
solution injection amount will be relatively large.
Step IV: Check the intake pressure and temperature sensor and its wire harness. The intake air volume is
one of the bases for calculating urea solution injection amount.
Step V: Check the exhaust temperature sensor and its wire harness. The exhaust temperature signal is one
of the bases for calculating urea solution injection amount.
Step VI: Check the urea solution pressure sensor and its wire harness. If the measurement deviation of urea
solution pressure signal is too large, the correction of urea solution injection amount based on urea solution

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pressure will be too large, which will lead to excessive urea solution injection.
Step VII: Check the nozzle and its wire harness. If the nozzle is stuck in the normally open position, the urea
solution injection amount will exceed the set amount too much.
Step VIII: If necessary, check the calibration data to confirm that the calibration of the original emission and
intake air volume of the engine is accurate enough.
3.3.2.10 Category X: urea solution crystallization
Step I: Read the flash code according to the flash code lamp and determine the fault point. Focus on the
faults related to NOx conversion efficiency and NOx signal.
Step II: The excessive urea solution injection is one of the reasons for urea solution crystallization. Please
refer to the inspection methods and steps of Category IX.
Step III: Check the design and its materials of exhaust manifold.
Step IV: Check the design and material of nozzle base.
Step V: Check whether the spray orientation of the nozzle meets the technical requirements.
Step VI: If necessary, check the calibration data to confirm that the calibration of the original emission and
intake air volume of the engine is accurate enough.

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Chapter IV Disassembling and Assembling

4.1 Overview
When disassembling and assembling diesel engines, please strictly follow the instructions in this Manual,
and pay attention to the operations with signs to indicate danger and precautions in this Manual to ensure
personal safety and avoid accidents.
Since the disassembling and assembling procedures of diesel engine are opposite to each other, without
special instructions, only one of them will be illustrated in this Manual.
Special bolt tightening torques will be provided in relevant assembling procedures. If not specified, please
refer to Chapter V Standard Bolt Tightening Torque.
4.1.1 Danger sign
This sign is an internationally recognized warning sign. In this Manual, it is used to emphasize the
importance of the following information. Make sure that you understand the consequence of dangerous
conditions and the way to avoid such danger. Violation of warning information may result in property loss,
personal injury and even casualties.
The common danger signs are usually used for general warnings. In this Manual, warning messages are
divided into different types (minor injury, serious injury and death) according to the severity of possible
dangerous consequences.
This warning sign indicates a potential hazard which can lead to
serious injury even death or great property loss, if the occurrence
cannot be avoided.

This warning sign indicates a potential hazard which, if not being

avoided, can lead to slight injury or property loss. It can also be used
for hazardous operation warning.
The considerations in this Manual can indicate how to properly
operate and install the engine manufactured by the Company.
However, the potential hazards cannot be eliminated by simply
reading the Manual. The considerations will not be beneficial to the
correct use unless the implication is properly understood.
However, the warning information in this Manual does not cover all possible conditions! Before applying a
procedure or method not recommended in this Manual, make sure that the operation will never cause any
danger to you, others or the equipment.
4.1.2 Safety signs
Tab. 4-1 Safety signs
Icon Definition

Wear hand protection.

Wear ear protection.

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Wear eye protection.

Wear head protection.

Wear foot protection.

Wear protective mask.

Wear protective clothing.

No flame.

No smoking.

No mobile phone.

Danger! Battery electrolyte.

Danger of electric shock! Live cable.

Inflammables

Watch out! Heavy object in suspension.

Fire extinguishers nearby

During the use of diesel engines, there may be many potential dangers without warning. Therefore, this
Manual cannot warn against every potential danger. If the operation conducted is not within the special
recommended scope, please ensure that the operation safety and avoid property loss.
4.1.3 Tools
Tab. 4-2 Tools
Icon Definition

2.5 mm hexagon wrench

5mm hexagon wrench

8 mm sleeve

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Slotted screwdriver

Special tool

10 mm slotted hexagon wrench

If the method or tool used is not within the recommended scope of use in this Manual, the user must first
ensure his/her own safety, so as to avoid endangering people’s life, and at the same time ensure that the method
of use, maintenance or repair will not cause damage risk or safety threat.
4.1.4 Precautions for health protection
The following "Precautions for health protection" aims to reduce the risk of pollution.
a) Avoid repeated exposure to the used oil for a long time.
b) Wear the protective clothing and water-proof gloves properly, if available.
c) Do not place the oily rag in the pocket.
d) Avoid contaminating clothes especially underwear with oil.
e) Wash work clothes frequently. Throw away the oil-impregnated clothes and shoes that cannot be
cleaned up.
f) In case of cut and injury, take first-aid measures as soon as possible.
g) Before working, always apply some protective cream which will make it easier to remove the oil in
case that the skin is contaminated with mineral oil.
h) Use soap and hot water, or liquid soap and nail brush to wash hands for the convenience of removing
all oil stains. If the grease secreted by skin is washed off, the product containing lanum can substitute the grease
secreted by skin to moisturize the skin.
i) Do not clean the skin with any gasoline, kerosene, fuel, thinner or solvent.
j) Upon detection of skin irritation, please seek medical attention immediately.
k) Remove oil from the parts before transportation, if available.
l) Please use goggles or face guard masks when your eyes might be exposed to danger. Eye flush fluid
must be readily available.
m) During maintenance of the diesel engine, do not splash oil or other liquid on the floor. In the event of
accidental leakage of hydrocarbon or other liquid, please take all necessary measures to separate this area to
keep the environment clean and guard personnel against injuries.
n) The handling, storage and recovery of hydrocarbon, ethylene, glycol and petroleum must comply with
the safety and environmental standards of the local country.
4.1.5 Environmental protection measures
Regarding the treatment of waste oil and hydrocarbons, please abide by relevant environmental protection
laws and regulations. Please consult local officials for details.
4.1.6 Precautions for disassembling and assembling diesel engine
Most accidents related to the use, maintenance and repair of diesel engines are caused by failure to comply
with safety rules and basic precautions. Therefore, the dangers should be clearly understood and corresponding
preventive measures should be taken to avoid accidents. To operate, maintain and repair the diesel engine, the
operator needs to receive corresponding training, possess certain skills and should use appropriate tools.
Violation against the instructions in this Manual may cause serious accidents, and even lift threats. Weichai
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Maintenance Manual of WP2.3 China V Diesel Engine

Power Co., Ltd. cannot foresee all potential dangers. Similarly, the guidelines and instructions in this Manual are
not exhaustive enough to cover all possibilities.
Before continuing the maintenance or repair operation, put a sign saying "Do not use” or similar on the
starter switch.
Before using the barring rod, necessary preventive measures should be taken.
Make sure that the maintenance site and surrounding environment are suitable for safe operation.
Make sure that the maintenance shop or the area around the diesel engine is clean and tidy.
Take off the ring, necklace and watch before starting work. Please put on suitable overalls.
Before work, please check whether the corresponding protective articles (glasses, gloves, shoes, masks,
overalls, helmets, etc.) are within the validity period.
Do not use faulty or unsuitable tools.
Please shut down the diesel engine during maintenance or repair.

4.2 Engine block group

4.2.1 Disassembling and assembling
4.2.1.1 Exploded view
The engine block assembly mainly consists of engine block machining components, cylinder liners, plugs,
camshaft hole plugs, camshaft bushings, engine block reinforcing plates, main bearing caps and other
components. The assembling position of each part on the engine is shown in Fig. 4-1 and Fig. 4-2:

1. Cylinder liner 2. Cylinder block 3. Plug cover 4. Plug 5. Screw plug 6. Thrust main bearing cap 7. Main bearing bolt
8. Gasket for engine block reinforcing plate 9. Engine block reinforcing plate 10. Plug 11. Front bushing of camshaft

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Fig. 4-1 Exploded view 1 of engine block group

1. Plug cover 2. Plug cover of camshaft hole 3. Plug 4. Locating sleeve 5. Plug 6. Plug cover 7. Screw plug
8. Camshaft bushing 9. Oil inlet pipe joint 10. Plug 11. Main bearing cap 12. Screw plug
Fig. 4-2 Exploded view 2 of engine block assembly

4.2.2 Cylinder liner

[Assembling steps]
(1) Take out the cylinder liners and wipe them clean with a towel.
(2) Press the cylinder liners one by one into the cylinder holes of the engine block by hand, put the
special press-fitting tools in the cylinder liner holes, pull the press blocks to a certain height and then put them
down. Repeat this cycle twice and press the cylinder liners in place. Repeat the operations above and press the
cylinder liners of Cylinders 2#-4# in place in sequence.
[Disassembling steps] Operate in a reverse order of the assembling steps above.
[Note] The cylinder liner should be 0.04~0.12 mm higher than the upper plane of the engine block after
being pressed in, and the height difference between the four cylinder liners on the same engine block and the
upper plane of the engine block should be less than 0.05 mm. To install the cylinder liner, the pressure should be
uniform and act vertically on the end face of the cylinder liner.
4.2.3 Engine block screw plug
[Assembling steps]
(1) Align the engine block screw plug (the thread surface of the plug should be coated with thread sealant
evenly) with the mounting hole on the block, screw in 2-3 threads manually, and tighten the plug with a
pneumatic wrench.
[Disassembling steps] Operate in a reverse order of the assembling steps above.

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[Note] The plug of the engine block is assembled with adhesive , so be careful not to damage the thread
when disassembling.
4.2.4 Nozzle

1. Sealing ring 2. Cylindrical pin 3. Nozzle joint welding 4. Copper gasket 5. Nozzle valve group
Fig. 4-3 Exploded view of piston nozzle

[Assembling steps]
1. Install the nozzle group loosely on the cylinder block with a hollow bolt (nozzle valve group) separated by
a copper gasket, and tighten the hollow bolt (check whether the nozzle is unobstructed, check whether the joint
surface between the nozzle and the engine block has bumps and burrs, repair or replace if necessary, and use
locating pins to correct the location of the nozzle when screwing in the hollow bolt).
[Disassembling steps] Operate in a reverse order of the assembling steps above.
[Note] The nozzle must be checked for smoothness, and replace it with a new one if there is any blockage.

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4.2.5 Oil pan

4.2.5.1 Exploded view

Fig. 4-4 Explosion view of oil pan assembly

4.2.5.2 Disassembling steps

(1) Turn over the diesel engine to keep the oil pan upward;
(2) Disassemble the fastening bolts of oil pan;
(3) Scrape off the sealant with a scraper;
(4) Remove the oil pan and gasket;
(5) Remove the oil drain plug, sealing washer and screw plug support.
4.2.5.3 Inspection and maintenance
Point I: disassembling
Discharge the oil completely before removing the oil pan. Place the oil container under the oil drain plug of
the oil pan and unscrew the oil drain plug with a plug wrench to release the oil.
Point II: assembling
1) Apply adhesive along the inner edge of the screw hole on the engine block joint surface;
2) Move the oil pan and align it with the engine block joint surface. When the oil pan is in contact with
the engine block, it must be handled gently so as to avoid damaging the contact surface;
3) Insert bolts and gaskets, and tighten the oil pan bolts from the middle to both sides in turn.
4.2.5.4 Assembling steps
(1) Wipe the joint surface between the engine block and the oil pan with a towel. Apply 87 silicone
sealant on the joint surfaces between the engine block and the gear chamber cover, the rear oil cover, and apply
87 silicone sealant on the front and back sides of the gasket at the oil pump position.
(2) Place the oil pan gasket on the bottom surface of the engine block, take out the oil pan welding, align
the screw holes on the bottom surface of the engine block, and install the oil pan.
(3) Tighten the bolts and nuts with a pneumatic torque wrench, and tighten the bolts and nuts
symmetrically from the middle to both sides.
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[Note]
(1) To apply the adhesive, the adhesive trace must be continuous and uniform, and no breakpoints are
allowed.
4.2.6 Front and rear oil seals
4.2.6.1 Exploded view

1. Front oil seal 2. Rear oil seal gasket 3. Oil baffle 4. Locating sleeve 5. Rear oil seal
6. Hexagon flange bolt 7. Crankshaft front oil seal 8. Double-end stud
Fig. 4-5 Exploded view of oil seal assembly

4.2.6.2 Disassembling and assembling steps

[Assembling steps]
(1) Press the rear oil seal and the front oil seal in with special assembly tooling (before assembling,
evenly coat the front and rear sides of the oil seal with lubricating oil);
(2) Screw the double-end stud into the rear oil seal cover;
(3) Punch the locating sleeve to the bottom with a copper hammer;
(3) Put the oil baffle on the crankshaft, assemble the rear oil seal cover together with the gasket, and fix
it on the engine block with hexagonal flange bolts.
[Disassembling steps]
Operate in the reverse order of the assembling steps above for disassembling.
[Note]
(1) Check whether the gasket of the rear oil seal cover is damaged, whether the oil seal rubber is
damaged, whether the rear oil seal cover is clean and whether the machined surface is scratched;
(2) Clean the joint surface between the rear oil seal cover and the engine block before assembling, and
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wipe the joint surface clean;

(3) During disassembling, operate carefully to avoid scratching the crankshaft;
(4) Do not reuse the oil seals, and replace the rear oil seal and the front oil seal with new ones after
disassembling.
4.2.7 Flywheel housing
4.2.7.1 Exploded view

1. Hexagon bolt 2. Spring washer 3. Clutch housing 4. Cylindrical pin 5. Spring washer 6. Hexagon bolt 7. Cover
Fig. 4-6 Exploded view of flywheel housing assembly

4.2.7.2 Disassembling and assembling

[Assembling steps]
(1) Wipe the joint surface between the clutch housing and the engine block with a clean towel.
(2) Check the casting mark of the clutch housing manufacturer, and record the mark with a pen at the
corresponding parts on the assembling flow card, and correctly record the clutch housing manufacturer mark.
(3) Align the screw holes, install the clutch housing, and screw in 2-3 threads by hand.
(4) Start from the locating pin, use the starting wrench to tighten the bolts symmetrically and evenly in
2-3 times.
[Disassembling steps]
(1) Remove the cover fastening bolt (Item 6) and remove the cover (Item 7);
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(2) Loosen and remove the clutch housing fastening bolt (Item 1) in a diagonal sequence;
(3) Remove the clutch housing (Item 5) and the cylindrical pin (Item 4).
[Note] Remember to lubricating oil when assembling the clutch housing bolts. The clutch housing bolts can
be reused twice.
4.2.8 Gear chamber cover
4.2.8.1 Exploded view

1. Gear chamber cover gasket 2. Timing gear chamber cover 3. Hexagon bolt 4. Cylindrical pin
5. Hexagon nut 6. Double-end stud 7. Timing pointer 8. Front oil seal
Fig. 4-7 Exploded view of gear chamber cover

4.2.8.2 Disassembling and assembling

[Assembling steps]
(1) Insert the locating pin into the gear chamber cover.
(2) Install the gear chamber cover gasket and gear chamber cover, install and tighten the gear chamber
cover bolts in a diagonal sequence.
(3) Install the assembled washer and tighten the adjusting plug.
(4) Install the timing pointer.
[Disassembling steps] Operate in a reverse order of the assembling steps above.
[Note] The assembled washer should not be reused. Replace the assembled washer with a new one after
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disassembling.
4.2.9 Gear chamber
4.2.9.1 Exploded view

1. Timing gear chamber 2. Hexagon bolt 3. Spring washer 4. Hexagon bolt 5. cylindrical pin 6. Timing gear chamber gasket
Fig. 4-8 Exploded view of gear chamber

4.2.9.2 Disassembling and assembling

[Assembling steps]
(1) Drive the locating pin into the front end of the cylinder block (the locating pin should be free from
edge failure).
(2) Install the gear chamber gasket and gear chamber, and tighten the gear chamber bolts in a diagonal
sequence.
(3) Install the transition gear shaft, wipe the transition gear shaft clean, and check whether the transition
gear shaft is bumped or damaged. Install a pair of bearings, and apply a proper amount of clean lubricating oil.
Install the transition gear and the transition gear shaft pressure plate in turn.
(4) Install the bolts and tighten them in place.
[Disassembling steps] Operate in a reverse order of the assembling steps above.

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4.3 Crankshaft and connecting rod mechanism

4.3.1 Disassembling and assembling
4.3.1.1 Exploded view

1. Piston connecting rod group 2. Engine block 3. Flat key 4. Crankshaft timing gear 5. Oil pump gear 6. Hexagon bolt 7.
Signal plate 8. Cylindrical pin 9. Crankshaft pulley 10. Hexagon flange bolt 11. Gasket 12. Crankshaft 13. Main bearing
bush 14. Main bearing seat 15. Main bearing bolt 16. Thrust plate 17. Flywheel ring gear 18. Flywheel 19. Flywheel bolt
20. Deep groove ball bearing
Fig. 4-9 Exploded view of crankshaft and connecting rod mechanism

4.3.1.2 Crankshaft-connecting rod mechanism

[Disassembling steps]
1. Check before disassembling. Check the axial side clearance of connecting rod and the tightening
torque of connecting rod bolts. Tilt the engine,
turn the piston to be disassembled to BDC, and remove the connecting rod bolt and connecting rod cover.
Turn to TDC, knock out the piston with a wooden hammer,
and be careful to avoid the big end of connecting rod sticking to the cylinder block. Disassemble the
remaining pistons in the same way, and put them in serial numbers.
2. Screw out the hexagon flange bolts at the front end, and remove the crankshaft pulley, signal disc,
etc.
3. Unscrew the flywheel bolts, and remove the flywheel assembly, bearings and other components.
[Assembling steps]
The assembling steps are in reverse order of disassembling steps.

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4.3.2 Piston connecting rod assembly

4.3.2.1 Exploded view

1. Keystone barrel faced ring 2. Second gas ring 3. Combined oil control ring 4. Piston 5. Circlip for hole
6. Connecting rod bushing 7. Piston pin 8. Connecting rod body 9. Connecting rod cover 10. Connecting rod bush 11. Connecting
rod bolt
Fig. 4-10 Exploded view of piston connecting rod assembly

4.3.2.2 Disassembly steps

1. Tilt the engine, turn the piston to be disassembled to BDC, and remove the connecting rod bolt and
the connecting rod cover.
2. Turn to TDC, knock out the piston with a wooden hammer, and be careful to avoid the big end of
connecting rod sticking to the cylinder block.
3. Disassemble the remaining pistons in the same way, and put them in serial numbers.
4. Use the retainer ring pliers for hole to carefully remove the circlips on both sides of the piston and
push the piston pin out to remove the connecting rod body. Number the piston pin and the connecting rod
respectively and place them in sequence.
5. Use the piston ring mounting pliers to remove a ring, a second ring, and an oil ring, respectively, and
mark them separately;
4.3.2.3 Inspection and maintenance
1. Check that the big and small ends of the connecting rod are without burrs and bumps, and check the
bushing at the small end for crack, deformation and discoloration.
2. Mark the cylinder number at one end of connecting rod bolt, and mark the cylinder number at the
top of piston pointing to flywheel end.
3. Check that there are no burrs, oil dirt and bumps at the piston surface and the inner cavity, piston ring,
and piston pin surface.
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4. The grouping marks of weights of pistons for the same engine should be consistent, and the weight
difference of connecting rods for the same engine should not be greater than 12 g.
5. The grouping marks of piston sizes (Roman numerals I and II) and grouping marks of cylinder liners (A
and B) should be consistent.
6. The marks on the sides of connecting rod body and connecting rod cover must be consistent.
4.3.2.4 Assembling steps
1. Use the circlip pliers for hole to fit a circlip for hole into the piston retaining ring groove, and turn the
retaining ring to ensure complete installation.
The angular face of the retainer ring should be inward. The opening position of piston pin retainer ring
should be upward.
2. Insert the connecting rod small end into the inner piston cavity, align the connecting rod small end
with the piston pin hole, then install the piston pin, and
install the piston pin retainer ring on the other side at the end. Pay attention to the requirement that the
direction of the tapered cut of the connecting rod should be opposite to the direction of the oil inlet hole of the
piston cooling oil passage.
Apply a proper amount of clean lubricating oil to the connecting rod small end hole and the piston pin
before assembling.
3. Arrange the installed piston connecting rod components in the order of cylinder numbers, and then
install the oil control ring, the second gas ring and
the first gas ring into the piston ring groove in turn with a pair of piston ring installation pliers. The lettered
surface of piston ring should face upwards, and the ring should rotate in the ring groove
flexibly.
4. Wipe the inner wall of the cylinder, the crankshaft arm and the piston connecting rod member, and
apply clean lubricating oil to each auxiliary moving part.
5. Adjust the opening direction of each ring: the first ring opening is installed at a position offset by 30°
from the center line of the piston pin, the second ring opening is offset from the opening position of the first ring
by 120°, and the oil ring opening is offset from the first and second air ring opening by 120° respectively and is at
the vertical bisector of the center line of the piston pin.

Fig. 4-11 Schematic diagram of opening included angle of piston ring assembling

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4.3.3 Crankshaft
4.3.3.1 Exploded view

1. Hexagon flange bolt 2. Gasket 3. Crankshaft pulley 4. Cylindrical pin 5. Signal disc 6. Hexagon bolt 7. Oil pump gear 8. Crankshaft
timing gear 9. Flat key 10. Crankshaft 11. Deep groove ball bearing 12. Flywheel gear ring 13. Flywheel 14. Flywheel bolt
Fig. 4-12 Exploded view

4.3.3.2 Disassembling steps

1. Put the engine main bearing cover up, remove the main bearing bolts and put them in order.
2. Take down the crankshaft and flywheel, and take out the front and rear thrust plates and flywheel
end bearings. Take out the oil seal and place the crankshaft on a bracket
(if the crankshaft is left alone for too long, the crankshaft should be placed vertically).
3. All parts disassembled are placed as required.
4.3.3.3 Inspection and maintenance
1. Check the fillet parts of crankshaft main journal and connecting rod journal for cracks;
check the unblocking oil passage of the joint between the crankshaft and the bearing bush for cracks and
other abnormalities.
2. Check the wear of the main journal and the connecting rod journal, and whether there are line-like
abrasion pattern, metal peeling and cracking.
3. Check the wear on the front and rear oil seals.
4. Check the main bearing bolts for failure modes such as thread damage.
5. Check whether bolt holes on the front-end face and rear-end face for cracks.
6. Check the bending degree and distortion of crankshaft.
4.3.3.4 Assembling steps
1. Wipe the bottom hole of the main bearing of the cylinder block.
2. Press the upper bearing bushes into the bottom holes of the main bearing of the cylinder block in
order, and wipe off the foreign matters scraped off the bush edge.
2.1. Whether there is any bump on the upper bearing bush should be strictly checked before the upper
bearing bush is pressed in, and any bumped upper bearing bush is not allowed to be repaired and used again.
2.2. After the upper bearing bush is installed, it should be aligned with the oil hole and oil groove on the
cylinder block, and any upper bearing bush with its misalignment exceeding over 1/5-1/4 of the oil hole
is prohibited. The upper bearing bush should fully fit the bottom hole of the main bearing of the cylinder
block.
3. Apply a proper amount of clean lubricating oil to the inner surface of the upper bearing bush.
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4. Lift the crankshaft, purge the oil passage hole with compressed air and wipe off the main journal and
connecting rod journal with a towel,
and then gently let the crankshaft fall into the cylinder block. In this process, the crankshaft should be
without bump.
5. Wipe the upper thrust plate and press it into the cylinder block. The upper thrust plate oil groove
should face outward (toward the crankshaft).
6. Press in the lower main bearing bush, assemble the main bearing cover, and install the lower thrust
plate (the oil groove faces the crankshaft side).
7. On the basis of ensuring that the oil seal is flat without distortion, use special tooling to put the oil
seal flat into the sealing ring groove on the lower plane of the cylinder block. When the framework oil seal is
pressed in, the oil seal should not be skewed or uneven, and it should be ensured that the cutting edge of the oil
seal well fits with the journal.
8. Main bearing bolts: Tighten the main bearing cover with a torque wrench. Tighten bolts of the third
main bearing, the second and fourth bearings, and the first and fifth bearings in sequence, and apply lubricating
oil to the threaded parts and supporting surfaces. Two bolts of the same main bearing cover should be tightened
in twice. They should be tightened to 80 N∙m for the first time and be tightened to the specified (140 ~ 160) N∙m
for the second time. Before the last turns of bolts are tightened, the crankshaft should be rotated back and forth
to keep the upper and lower thrust plates on the same plane, and then the bolts should be tightened. The
tightening sequence is shown in the following figure.

Figure 4-13 Tightening sequence of main bearing bolts

4.3.4 Flywheel
4.3.4.1 Exploded view

1. Crankshaft 2. Deep groove ball bearing 3. Flywheel gear ring 4. Flywheel 5. Flywheel bolt
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Fig. 4-14 Exploded view

4.3.4.2 Disassembling steps

Disassembling steps is in reverse of assembling steps.
4.3.4.3 Inspection and maintenance
1. Whether flywheel bolts have failure modes such as thread breakage.
2. Whether there is crushing on the surface of the flywheel.
3. Whether the flywheel ring gear is damaged.
4.3.4.4 Assembling steps
1. Heat the flywheel gear ring to (180 ~ 200) °C and install it on the flywheel.
2. Hammer the deep groove ball bearing into the countersunk hole at the rear end of crankshaft.
3. The flywheel bolts are tightened symmetrically. The tightening sequence is shown in the following
figure. Bolts should be gradually tightened, and the tightening torque of the last bolt should be 60 ~ 70 N∙m.

Fig. 4-15 Tightening sequence of flywheel bolts

4.3.5 Crankshaft pulley

4.3.5.1 Exploded view

1. Hexagon flange bolt 2. Gasket 3. Crankshaft pulley 4. Cylindrical pin 5. Signal disc
6. Hexagon head bolt 7. Oil pump gear 8. Crankshaft timing gear 9. Flat key 10. Crankshaft
Fig. 4-16 Exploded view

4.3.5.2 Disassembling steps

Unscrew the hexagon bolt, remove the crankshaft pulley assembly, unscrew the signal disc bolt, and
remove the signal disc.
4.3.5.3 Inspection and maintenance
1. Check the crankshaft pulley for damage and the bolt for crushing.
2. Check the signal disc bolt for damage.
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3. Check whether the signal disc bolt tightening point is collapsed.

4.3.5.4 Assembling steps
After installing the crankshaft timing gear and the oil pump gear, install the signal disc and the crankshaft
pulley in turn.
1. Locate the signal disc through the cylindrical pin, and fasten the signal disc to the crankshaft pulley
with hexagon bolts. There are 4 hexagon bolts with the specification of Q1840610T1F3Q, and these hexagon
bolts are fastened to the test values.
2. Tighten the gasket and crankshaft pulley to the front end of the crankshaft with hexagon flange bolts.
The hexagonal flange bolt has the specification of 1×M14×1.5-12.9 and the tightening torque of (140 ~ 160) N·m.
4.3.6 Crankshaft bearing bush
4.3.6.1 Exploded view

Fig. 4-17 Explosion view of crankshaft bearing bush

4.3.6.2 Disassembling steps

The assembling steps are in reverse order of disassembling steps.
[Note]
(1) There are 5 lower main bearing bushes, and there should be no missed installation.
(2) The bearing bush fits with the cover and seat, and the bearing bush carrier is inserted into the gap of
the bearing hole.
4.3.6.3 Inspection and maintenance
Check whether the main bearing and the main bearing cover hole wall are clean. If any part is not clean, be
sure to clean it with a clean towel, and the boss on the lower main bearing bush should be embedded into the
groove for installing the bearing bush on the main bearing cover.
4.3.6.4 Assembling steps
1. Loosen the main bearing cover bolts with a pneumatic wrench, remove the main bearing cover, and
put crankshaft bearing bushes in to the process turnover box in an order of 1-2-3-4-5.
2. Take out 5 lower main bearing bushes (without oil holes) from the box and press them into the main
bearing cover.
3. Take out 5 upper main bearing bushes (with oil holes) from the box and press them into the engine
block.

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4.4 Cylinder head assembly

4.4.1 Cylinder head group
4.4.1.1 Exploded view

Fig. 4-18 Explosion view of cylinder head assembly

Fig. 4-19 Explosion view of cylinder head assembly

4.4.1.2 Disassembling and assembling

[Disassembling steps]
(1) Before disassembling, ensure that the coolant inside the engine has been drained through the water
drain valve.
(2) Before disassembling the cylinder head, always make sure that the components of the valve train
system (such as rocker arm shaft, push rod, etc.) installed on the cylinder head have been removed.
(3) Before disassembling the cylinder head, always make sure that the bolts of the fuel injector platen
have been disassembled, otherwise the short bolts of the cylinder head at the bottom of the bolts of the fuel
injector platen cannot be disassembled.
(4) Before disassembling the cylinder head, always make sure that the fuel injector installed on the
cylinder head has been removed to prevent the fuel injector nozzle head from being damaged when the cylinder
head is placed.
(5) Loosen the cylinder head bolts in turn. The WP2.3 China V diesel engine has 18 cylinder head bolts,
including 10 long bolts and 8 short bolts. Always make sure that all cylinder head bolts are loosened before
hoisting the cylinder head.

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(6) Remove the cylinder head, and put the removed cylinder head on a cardboard, template, plastic
board and other low-hardness items to prevent the base plane of the cylinder head from bumps and scratches.
(7) After the cylinder heads are removed, it is necessary to remove the coolant and other impurities on
the top surface of the engine block based on the actual condition, so as to prevent the coolant or other
impurities from entering the combustion chamber and causing other faults.
(8) Remove the cylinder head gasket.
(9) To remove the intake and exhaust valves, refer to the disassembling description of the valve train.
(10) Disassemble the valve oil seal;
(11) Schematic diagrams of the cylinder head assembly and its assembly position are shown in Fig. 4-18
and Fig. 4-19.
[Check]
(1) Cylinder head
Before removing the cylinder head, check whether the cylinder head for any trace of water leakage, oil
leakage, air leakage and other abnormal phenomena, so as to accurately identify the problem location and
analyze the problem.
Clean the cylinder head, focus on cleaning the combustion chamber surface, valve seat, intake and exhaust
valves, intake and exhaust passages, remove carbon deposit and adhesive on the surface, and check the surface
condition.
① Appearance inspection
Carefully check the cylinder head for discoloration and cracks, and if there is any crack, carry out
dye-penetration inspection.
② Valve sinkage
The valve sinkage is the vertical distance from the underside of the valve to the bottom plane of the
cylinder head. The difference between the measured value of the valve sinkage and the required value of the
valve sinkage can reflect the degree of wear of the valve and the valve seat. A depth micrometer can be used to
measure the valve sinkage, as shown in Fig. 4-20:

Fig. 4-20 Depth micrometer

Refer to Tab. 4-3 for the required value of the valve sinkage. If the valve sinkage exceeds the allowable
range, replace the cylinder head to ensure the reliability of the diesel engine. If the valve sinkage does not
exceed the allowable value, remove the valve to check the valve and valve seat ring sealing surface for obvious
wear and abnormal damage.
Table 4-3

Required value of valve sinkage (mm)

Intake valve 0.4±0.1

Exhaust valve 0.4±0.1

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③ Inner diameter of valve guide

The inner diameter of the valve guide refers to the diameter of the contact surface for the movement
between the valve guide and the valve. If the inner diameter of the valve guide exceeds the allowable value due
to wear, the guiding effect of the valve will be affected to degrade the reliability of the operation of the diesel
engine. The inner diameter dimension of the valve guide can be measured with an internal micrometer, as shown
in Fig. 4-21. The allowable range of the inner diameter of the valve guide is (8~8.022) mm. If the inner diameter
exceeds the allowable range, the valve guide has to be replaced to ensure the operation reliability of the diesel
engine.

Figure 4-21 Internal micrometer

(2) Cylinder head gasket

If there is air leakage, water leakage or oil leakage at the cylinder head gasket, it is necessary to check and
replace the cylinder head gasket.
For the removal method, see the description of cylinder head gasket removal above. Check the cylinder
head gasket for visible damage and analyze the cause. No matter whether there is any problem with the cylinder
head gasket, it is necessary to replace it with a new one once disassembled.
(3) Valve oil seal
The valve oil seal ensures the sealing performance of lubricating oil at the valve stem, while it ensures that
a certain amount of lubricating oil is evenly applied to the valve stem, to prevent adhesion between the valve
stem and the valve guide due to dry grinding. Before removing the valve, it is necessary to check whether all
valve oil seals fall off. After disassembling the valve, it is necessary to carefully check whether the valve oil seal is
intact, cracked and aged and check whether the spring on the valve oil seal is deformed. If the corresponding
valve and valve guide are seriously worn, the valve oil seal should be replaced together.
[Assembling steps]
(1) The valve oil seal and its installation are shown in Fig. 4-22.
① The valve oil seal is only allowed to be used once, and it must be replaced with new parts in case of
repair.
② Check the valve oil seal for defects and whether the valve oil seal spring is intact.
③ Install the valve oil seal on the valve guide.
④ Apply lubricating oil to the lip of valve oil seal.
⑤ Use the valve oil seal assembling tool and the rubber hammer to knock and install the valve oil seal.

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Fig. 4-22 Oil sealing

(2) Assembling the cylinder head gasket

① The cylinder head gasket can only be used once. In case of repair, it must be replaced with a new one,
as shown in the Fig.4-23.
② Wipe the inner wall of the cylinder liner, apply clean lubricating oil, wipe the upper surface of the
engine block, and then place the cylinder head gasket according to the corresponding locating pin bush.
③ Check whether the cylinder head gasket is installed correctly.

Figure 4-23 Cylinder head gasket

(3) Assembling the cylinder head

① Carefully wipe the cylinder head to ensure that there are no dust, debris, sand and other dirt, and
then clean the lower surface of the cylinder head.
② Check and make sure that there is no foreign matter in the cylinder, and the cylinder head gasket and
the lower surface of cylinder head are clean.
③ Before the cylinder head bolts are fastened, the cylinder head is positioned with two locating pin
sleeves on the engine block and the contact surface between the cylinder head and the engine block.
④ Assemble the cylinder head.
(4) Assemble the cylinder head bolts
① There are two types of cylinder head bolts, short and long bolts, as shown in Fig. 4-24.
② The cylinder head bolts are allowed to be used 3 times, and the tightening sequence of the cylinder
head bolts is shown in Fig. 4-25.
③ Align the cylinder heads in sequence, apply lubricating oil to the threaded parts and pressure-bearing
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surfaces of the cylinder head bolts, and tighten them gradually in 2 ~ 3 times. The last tightening torque is 95 ~
105 N∙m. Any bolt which cannot be tightened to the specified torque has to be unscrewed and should be
replaced with a new one. The new bolt should be tightened to the specified torque.

Fig. 4-24 Cylinder head bolt

Fig. 4-25 Tightening sequence

4.4.2 Lifting ring

4.4.2.1 Exploded view

Fig. 4-26 Exploded view of hoisting ring assembly

4.4.2.2 Lifting ring

[Disassembling steps]
(1) Loosen two M8×16 bolts fastening the engine hanger plate (front) at the front end of the engine, and
remove the engine lifting lug (front).
(2) Loosen two M8×16 bolts fastening the engine hanger plate (rear) at the rear end of the engine, and
remove the engine lifting lug (rear).
[Check]
(1) Check the engine lifting lug for cracks and bends.

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(2) Check whether the fastening bolts of lifting lugs fail, and replace them with new bolts if they fail.
[Assembling steps]
(1) Tighten the M8 hexagon flange bolts on the front and rear hanger plates of the engine.
(2) ②The assembling position of engine hanger plate (front and rear ends of cylinder head) and the
fastening bolts are shown in Fig. 4-26.
4.4.3 Cylinder head cover
4.4.3.1 Exploded view

Fig. 4-27 Exploded view of cylinder head cover

4.4.3.2 Disassembling and assembling

[Disassembling steps]
①Loosen the compression nut on the cylinder head cover — the sealing cover of cylinder head cover —
the conical washer in turn, and take out the cylinder head cover and the cover sealing ring upwards.
[Check]
(1) Before disassembling, check whether there is oil leakage at the cylinder head cover sealing ring.
Please carefully check the relevant components if necessary.
(2) Check the cylinder head cover for oil leakage, cracks, damage, etc. before disassembling, and replace
it with a new one if necessary.
(3) Check whether there is oil leakage at the oil filler before disassembling. Please carefully check the
relevant components if necessary.
(4) If there is oil leakage at the cylinder head cover sealing ring, when disassembling the lower cylinder
head cover and the cylinder head sealing ring, it is necessary to check whether the cylinder head sealing ring fails,
whether the sealing surface of the cylinder head is scratched, and whether the sealing surface of the cylinder
head is greatly deformed. If the cylinder head sealing ring leaks oil, replace it with a new cylinder head sealing
ring; if the cylinder head cover itself is greatly deformed or scratched, replace the cylinder head cover with a new
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one.
(5) If there is oil leakage at the oil filler, check whether the thread and sealing gasket of the oil filler fail
when disassembling the lower oil filler cap, and replace the oil filler cap with another one if it fails. If oil seepage
is caused by scratches on the sealing surfaces of the cylinder head cover and the oil filler cap, replace the
cylinder head cover.
[Assembling steps]
(1) Before installing the cylinder head cover sealing ring, check the new head cover sealing ring to ensure
that there is no manufacturing defect or damage.
(2) Clean up the upper surface of the cylinder head, and install the head cover sealing ring correctly.
(3) Clean up the cylinder head cover and install it on the cylinder head correctly.
(4) Install the conical washer, sealing cover of cylinder head cover and cap nut, and tighten the cap nut.
(5) Clean up the oil filler cap and the corresponding sealing surface of the cylinder head cover, and
tighten the oil filler cap.

4.5 Valve train

4.5.1 Disassembling and assembling
4.5.1.1 Exploded view

1. Engine block assembly 2. Exhaust valve 3. Cylinder head assembly 4. Inner valve spring 5. Outer valve spring 6. Valve spring upper
seat 7. Valve collet 8. Push rod 9. Rocker arm and rocker shaft group 10. Standard elastic washer 11. Hexagon screw 12. Hexagon
bolt 13. Intake valve 14. Camshaft 15. Ordinary flat key 16. Camshaft thrust plate 17. Standard elastic washer 18. Hexagon bolt 19.
Tappet
Fig. 4-28 Exploded view of valve train

4.5.1.2 Disassembling steps

1) Disassemble the rocker arm and rocker arm shaft group. See the disassembling steps of rocker arm
and rocker arm shaft for details.
2) Disassemble the intake and exhaust valves. See the disassembling steps of valve for details.
3) Disassemble the tappet and the push rod. See the disassembling steps of the tappet and push rod for
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details.
4) Disassemble the gear train. See the gear train disassembling steps for details;
5) Disassemble the camshaft. See the camshaft disassembling steps for details.
4.5.1.3 Assembling steps
1) Assemble the camshaft. See the camshaft assembling steps for details.
2) Assemble the gear. See the intermediate gear assembling steps for details.
3) Assemble the tappet and the push rod. See the assembling steps of tappet and push rod for details.
4) Assemble the intake and exhaust valve. See the assembling steps of intake and exhaust valve for
details.
5) Assemble the rocker arm and rocker arm shaft. See the assembly of rocker arm and rocker arm shaft
for details.
4.5.2 Camshaft
4.5.2.1 Exploded view

1. Engine block assembly 2. Camshaft 3. Ordinary flat key 4. Camshaft thrust plate 5. Standard elastic washer 6. Hexagon bolt
Fig. 4-29 Exploded view of camshaft

4.5.2.2 Disassembling steps of camshaft

1) Before disassembling the gear train, turn the camshaft to check whether the camshaft and timing
gear are flexible and unblocked.
2) Check the axial displacement of camshaft with a dial indicator;
3) On the engine installation and removal bench, after disassembling the push rod cylinder head
assembly, check whether the hexagon bolt of the camshaft thrust plate fixed on the camshaft is loose, etc.
Disassemble the camshaft thrust plate (4), the standard elastic washer (5) and the hexagon bolt (6) in turn, and
take out the camshaft (2) gently to avoid bumping against the camshaft bearing bush.
4.5.2.3 Inspection and maintenance
1) Check the surface of the cam that is in contact with the tappet for wear and check whether the main
journal is stuck and worn.
2) Measure the camshaft lift of each cylinder.
4.5.2.4 Assembling steps

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After disassembly, check the camshaft (2), and replace it with a new one if it is worn or other parameters
have large deviation.
1) Check the camshaft for burrs and bumps, and ensure that the surface is without rust, scratches, iron
filings and other impurities;
2) Apply a proper amount of clean engine oil to the camshaft hole and the tappet hole, and install the
tappet. See the tappet assembling steps for details. Install the camshaft (2). Apply uniform force to the camshaft
(2) during pushing, and the camshaft (2) surface and the engine block hole should not be damaged.
3) Install the camshaft thrust plate (4), put the standard elastic washer (5) on the hexagon bolt (6),
tighten the camshaft thrust plate on the engine block assembly (1) through the thrust plate hole, and seal it with
paint after tightening.
4) After tightening the camshaft thrust plate, check the axial clearance of camshaft. If the axial clearance
of camshaft is too small, check whether there is burr between the camshaft and the sector plate. If the axial
clearance of camshaft cannot be adjusted to the range above after burr removal, replace the camshaft (2).
5) Turn the crankshaft after assembly, and observe whether the camshaft (2) rotates flexibly.
4.5.3 Rocker arm and rocker arm shaft
4.5.3.1 Exploded view

1. Cylinder head assembly 2. Rocker arm and rocker arm shaft group 3. Hexagon bolt 4. Hexagon bolt 5. Standard elastic washer
Fig. 4-30 Exploded view of rocker arm and rocker arm shaft

4.5.3.2 Inspection and maintenance

1) Clean the rocker arm and observe the appearance of the rocker arm for defects such as cracking.
2) Check the inner hole of the rocker arm for wear and scratches and measure the diameter.
3) Check the rocker arm adjusting screw and the arc surface on the other side of the rocker arm for
wear.
4) Check whether the oil passages are unblocked.
5) Measure the diameter of the rocker arm and the diameter of the rocker arm shaft to calculate the fit
clearance.
4.5.3.3 Assembling steps of rocker arm and rocker arm shaft

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1) Check whether the assembled parts are clean without bump, scratch and rust.
2) Put the rocker arm and rocker shaft (2) gently on the cylinder head group (1), put the standard elastic
washer on the group, and install the hexagon bolts (3) and (4) loosely;
3) Tighten hexagon bolts (3) and (4) in the following sequence as shown in Fig. 4-31 below.

Fig. 4-31 Tightening sequence

 Check and adjustment of intake valve clearance

① Turn the crankshaft to the position where the phase pointer points to the phase disk “0” point, and
observe that the crankshaft timing gear “0” point engages with the camshaft gear “0” point. At this time, adjust
the valve clearance to (0.35±0.04) mm from the front rocker arm No. 1-2-3-6.
② Turn the crankshaft again to the position where the phase pointer points to the phase disk “0” point,
and observe that the crankshaft timing gear “0” point engages with the 180° point of the camshaft gear “0” point.
At this time, adjust the valve clearance from the front rocker arm No. 4-5-7-8. The method is the same as that in
①.
After adjustment, check the valve timing of Cylinder 1 in cold state:
The intake valve is open at 16° before TDC, and the intake valve is closed at 42° after BDC.
The exhaust valve is open at 60° before BDC, and the exhaust valve is closed at 10° after TDC.
4.5.4 Tappet and push
4. 5.4.1 Exploded view

Fig. 4-32 Exploded view of tappet and push rod

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4.5.4.2 Disassembling steps

1) After the rocker arm and the rocker arm shaft are disassembled, remove the push rods (4) directly
and place them in order.
2) After the camshaft is disassembled, take out the tappets (5) from the lower side of the engine block
and place them in order.
4.5.4.3 Inspection and maintenance
1) Clean the push rod (4) and tappet (5).
2) Check whether the tappet push rod (4) oil circuit is unblocked.
3) Check the push rod (4) for bending and the outer surface for wear.
4) Check the push rod (4) ball head and the recess for wear.
5) Check the surface and underside of the tappet (5) for wear.
6) Check the inner recess of the tappet (5) for wear.
4.5.4.4 Assembling steps
1) Check whether there is any problem with the tappet (5) and push rod (4), and renew them if there is
any problem. Before assembling the tappet (5), be sure to purge the tappet with compressed air, and check
whether the oil hole is unblocked.
2) Apply clean lubricating oil evenly to the engine block tappet (5) hole and the valve tappet excircle.
3) Gently put the tappet (5) into the tappet hole from the lower side of the engine block, and the tappet
(5) rotates freely in the tappet hole with uniform hand resistance. Assemble the camshaft. See the camshaft
assembling steps for details.
4) Loosely install the rocker arm seat on the cylinder head, and check whether the push rod (4) is clean
and the welding is intact.
5 Apply clean lubricating oil to the push rod (4) with and make sure the ball head has sufficient oil.
6) Install the push rod (4), and put the push rod (4) into the tappet gently through the cylinder head.
4.5.5 Valve
4.5.5.1 Exploded view

1. Exhaust valve 2. Cylinder head assembly 3. Inner valve spring

4. Outer valve spring 5. Upper valve spring seat 6. Valve collet 7. Intake valve

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Fig. 4-33 Exploded view of valve

4.5.5.2 Disassembling steps

1) Use the valve spring compressor or valve spring pressing plier or other tool to press the valve spring,
remove the valve collet (6), and remove the valve spring upper seat (5) and valve inner (3) and outer spring (4).
2) Remove the valves (1) and (7) from the valve seat.
4.5.6 Gear train
4.5.6.1 Exploded view

1. Camshaft timing gear 2. Camshaft gear platen 3. Spring washer 4. Camshaft gear platen bolt
5. Intermediate gear shaft 6. Intermediate gear 7. Intermediate gear baffle plate 8. Flat washer 9. Intermediate gear bolt
Fig. 4-34 Exploded view of gear train

4.5.6.2 Disassembling and assembling

1) Disassemble the fuel injection pump. See the description of fuel system disassembling for details;
2) Turn the crankshaft to check whether the camshaft assembly and camshaft timing gear are flexible
and unblocked.
3) Use a dial indicator to check the camshaft for axial displacement compared with the previous one.
4) Check the side clearance between the camshaft timing gear and the intermediate gear side as well as
the side clearance between the intermediate gear and the crankshaft timing gear;
5) Check whether the camshaft gear platen bolt is loose, etc., and disassemble the camshaft gear platen
bolt and the camshaft timing gear;
6) Check the mark of intermediate gear mounting bolt to confirm whether the bolt rotates. Disassemble
the 2 hexagon bolts of the intermediate gear, take off the gasket and the intermediate gear, and then take off the
intermediate gear shaft.
4.5.6.3 Inspection and maintenance
1) Whether the mounting bolt thread in good condition.
2) Whether each gear has tooth surface peeling, broken teeth, whether the bolt bearing surface is
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crushed, whether the threaded hole or the through hole on the gear is deformed;
3) Check for abnormal wear between the intermediate gear shaft and the intermediate gear bushing.
Check whether each oil hole is blocked by dirty foreign matter.

4.6 Intake and exhaust system

4.6.1 Intake manifold
4.6.1.1 Exploded view

Fig. 4-35 Exploded view of intake manifold

4.6.1.2 Disassembling and assembling

[Disassembling steps]
(1) Unscrew the intake manifold bolts in turn, and then remove the intake manifold and gasket.
(2) Loosen the fastening nut of the intake connecting pipe, and remove the intake connecting pipe, air
intake heater and air intake connecting pipe gasket.
(3) Loosen the bolts of EGR cover plate at the air intake end, and remove the cover plate and the EGR
valve gasket.
[Check]
(1) Check whether there are cracks, deformation and other damage on the intake manifold body, and
replace the intake manifold with a new one if any.
(2) Check whether the intake manifold gasket, end cover gasket, and EGR valve gasket are deformed, torn,
missing, etc.
If any part gets defected, replace it with a new one.
(3) Check the grid heater for burnout, short circuit, etc. and replace it if any.
[Assembling steps] The assembling steps are in reverse order of the disassembling steps.
4.6.2 Exhaust manifold
4.6.2.1 Exploded view

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Fig. 4-36 Exploded view of exhaust manifold

4.6.2.2 Disassembling and assembling

[Disassembling and assembling steps]
(1) Firstly, remove the heat insulation layer of exhaust manifold.
(2) Loosen the exhaust manifold bolts, and remove the bolt sleeve, exhaust manifold and exhaust
manifold gasket in turn.
[Check]
(1) Check the exhaust manifold body for damage such as cracking, and the flanges for deformation. If any,
it is necessary to replace it with a new exhaust manifold.
(2) Check the exhaust manifold flange for air leakage. If any, it is necessary to replace it with a new
exhaust manifold gasket.
(3) Check the exhaust manifold gasket for deformation, tearing, missing, etc. If any, it is necessary to
replace it.
(4) Check the exhaust manifold for sintering, rust, carbon deposit, etc. If it gets defected, replace it.
[Assembling steps] The assembling steps are in reverse order of the disassembling steps. The following
points should be noted during assembling:
① Apply anti-bite agent (molybdenum disulfide) to the exhaust manifold bolts, and tighten the bolts to
the torque of 65 N·m - 80 N·m. The exhaust manifold bolts can be reused up to twice.

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4.6.3 Turbocharger system

4.6.3.1 Exploded view

Fig. 4-37 Exploded view of turbocharger system

4.6.3.2 Disassembling and assembling

[Disassembling and assembling steps]
1. Loosely install one end of the pre-installed turbocharger oil inlet pipe on the oil filter. Pay attention to
adjusting the position of the oil inlet pipe for connecting the turbocharger.
2. Install the turbocharger gasket on the exhaust manifold flange.
3. Install the turbocharger return pipe and the double-end stud on the turbocharger, and apply the
double-end stud with molybdenum disulfide 0# + clean lubricating oil. Torque of oil return pipe bolts should be
controlled at 22 N·m - 29 N·m.
4. Install the turbocharger on the exhaust manifold flange surface separated with a turbocharger gasket,
and loosely install Type-2 all-metal hexagon lock nut and tighten it.
5. Pour a proper amount of clean lubricating oil into the oil inlet of the turbocharger, and wipe off the
spilled lubricating oil.
6. Install the oil inlet pipe of turbocharger, tighten the hollow bolt, and fix the oil inlet pipe group. The
turbocharger impeller should be rotated flexibly without blocking.
7. Install the oil return hose and hose clamp of turbocharger and tighten them. Pay attention to that the
two clamps should be in the same direction, and the oil return pipe should be aligned.
8. Install gaskets and clamps and tighten them.
9. All gaskets are only allowed to be used once. New parts are replaced during repair.
[Check]
1. Check the operation of the rotor
Push the air compressor impeller by hand lightly. It is normal if it rotates for more than revolution. If it
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stops quickly, it indicates the abnormal wear of the bearing or the collision or jam between the rotating part and
the fixed part.
The causes should be analyzed and the faults eliminated.
2. Rotor movement check
Put the measuring head of the dial indicator on the compressor end, push and pull the rotating shaft by
hand along the axial direction, and measure and record the difference between the indicator readings, as shown
in the figure below:

Fig. 4-38

The rotor movement should be within 0.088 mm ~ 0.118 mm. If this value is exceeded, it means that the
thrust bearing plate or thrust plate and bearing body are worn. The causes should be analyzed and the faults
eliminated.
3. Air compressor impeller radial clearance check
Press down or lift the air compressor impeller in the radial direction by hand, and measure the minimum
and maximum clearance values between the air compressor impeller and the air compressor volute with a feeler
gauge, as shown in the figure:

Fig. 4-39
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This value should be within 0.4 mm ~ 0.8 mm. If it is beyond this range, the bearing should be checked to
eliminate the fault.
Note: The above measurements should be made in the cold state of the turbocharger.
[Daily maintenance]:
1. Check whether the connection between the turbocharger and the engine pipe is loose, and tighten it
if it gets loose.
2. Check the turbocharger for air leakage and oil leakage, and eliminate the fault in time.
3. Check whether the fastening screws of the turbocharger are loose, and tighten them in time if loose.
4. Check the air filter. In case of excessive dust deposit, clean it in time.
[Assembling steps]
Disassembling steps is in reverse of assembling steps.
4.6.3.3 Daily inspection
1. Check whether the air filter is blocked;
2. Check whether the pipeline and clamp connecting the air filter to the inlet of the air compressor
housing of the turbocharger are loose;
3. Check whether the pipeline and clamp connecting the air compressor housing of the turbocharger to
the intercooler are loose;
4. Check the clamp or other connecting screws at the connection between the turbocharger volute and
the engine exhaust manifold for looseness;
5. Check the oil level of the engine crankcase. If it is too low, add oil. If it is too high, drain the excess oil
to ensure a normal oil level.
6. Check whether there is any leakage of lubricating oil at the connection of turbocharger housing. If
there is any leakage, find out the cause and eliminate the fault.
7. Check the lubricating oil inlet pipe and return pipe for damage or throttling;
8. Check the turbocharger housing for overheating, discoloration, cracks or damage, and replace it in
time if any fault above exists.
9. When the turbocharger generates any abnormal noise, it can never be used continuously. The
turbocharger should be shut down and inspected for the cause.

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4.7 Fuel system

4.7.1 Fuel injection pump
4.7.1.1 Exploded view

Fig. 4-40 Exploded view of fuel injection pump

4.7.1.2 Disassembling and assembling

[Disassembling steps]
(1) Disassemble the wire harness connected to the fuel injection pump;
(2) Disassemble the lubricating oil pipe of the fuel injection pump;
(3) Disassemble the hollow bolt connecting the fuel injection pump and the low-pressure fuel pipe;
(4) Disassemble the bolts and gaskets connecting the fuel injection pump flange and the gear chamber
cover;
(5) Disassemble the locking nut and gear of the fuel injection pump;
(6) Disassemble the bolt and cylindrical pin connected to the signal disc;
(7) Disassemble the bolts connecting the fuel injection pump flange and the fuel injection pump.
[Check]
(1) Check the fuel injection pump appearance for cracks and oil leakage. If any, it is necessary to replace
the defective pump with a new one and feed the check result back to the manufacturer through the
corresponding process;
(2) The engraving marks of the fuel injection pump gear should be aligned with the corresponding
engraving marks.
[Assembling steps]
Assembling steps is in reverse of disassembling steps.
4.7.2 Fuel injector
4.7.2.1 Exploded view

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Fig. 4-41 Exploded view of fuel injector

4.7.2.2 Disassembling and assembling

[Disassembling steps]
(1) Remove the wire harness connected to the fuel injector;
(2) Remove the fuel injector return pipe from the fuel injector of each cylinder;
(3) Remove the fastening bolts of the fuel injector press block and take down the fuel injector press
block.
(4) Remove the fuel injector from the cylinder head with special tooling.
[Check]
(1) Check the sealing copper washer, and replace it if it is excessively deformed or suffered other damage.
At the same time, clean the surface of the fuel injector seat hole and remove the carbon deposit and other
sundries on it to ensure the sealing performance. Each fuel injector, sealing washer and the adjusting gasket on
the sealing washer should be installed incorrectly to ensure that the extension of the lower cone and tip of the
nozzle body meets the requirements.
(2) Check the oil return pipe appearance of the fuel injector for damage and oil leakage. If the
appearance is damaged or leaks oil, replace the oil return pipe.
[Assembling steps]
Assembling steps is in reverse of disassembling steps.
4.7.3 Low-pressure fuel pipe
4.7.3.1 Exploded view

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Fig. 4-42 Exploded view of low-pressure fuel pipe

4.7.3.2 Disassembling and assembling

[Disassembling steps]
(1) Remove bolts securing the oil pipe clamp and then remove the pipe clamp;
(2) Loosen the hollow bolt and hose clamp at the end of the oil pipe;
(3) Remove all low-pressure pipelines in turn.
[Check]
(1) Check the low-pressure fuel pipe appearance for fuel leakage. If any, it is necessary to replace the
defective pipe with a new one and feed the check result back to the manufacturer through the corresponding
process;
(2) Check the interfaces at both ends of the low-pressure fuel pipe for fuel leakage. If any, it is necessary
to replace the hollow bolt sealing washer.
[Assembling steps]
Assembling steps is in reverse of disassembling steps.

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4.7.4 Fuel filter

4.7.4.1 Exploded view

Fig. 4-43 Exploded view of fuel filter assembly

4.7.4.2 Disassembling and assembling

[Disassembling steps]
(1) Disassemble the two bolts fixing the fuel filter;
(2) Disassemble the fuel filter.
[Check]
(1) Check whether the fuel filter appearance is intact. ;
(2) Check whether there is oil leakage at the joint between the fuel filter and the filter seat, and replace
any affected part if there is oil leakage;
(3) Check whether the fuel filter is blocked, and replace the filter element if it is blocked. During
replacement of the filter element, remove the filter element, fill in the new filter element with clean diesel, and
at the same time keep the filter base clean and apply lubricating oil to the rubber pad. After the rubber pad
contacts the base, tighten the rubber pad for 3/4 ~ 1 turn to make it sealed. Finally, remove the air bleed screw
on the filter seat and press the hand pump on the primary filter to exhaust air from the filter.
[Assembling steps]
Assembling steps is in reverse of disassembling steps. However, it should be noted that, during replacement
of the filter element, it is necessary to fill in the new filter element up with clean diesel, and at the same time
keep the filter base clean and apply lubricating oil to the rubber pad. After the rubber pad contacts the base,
tighten the rubber pad for 3/4 ~ 1 turn to make it sealed. Finally, remove the air bleed screw on the filter seat
and press the hand pump on the primary filter to exhaust air from the filter.

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4.7.5 High-pressure fuel pipe

4.7.5.1 Exploded view

Fig. 4-44 Exploded view of high-pressure fuel pipe assembly

4.7.5.2 Disassembling and assembling

[Disassembling steps]
(1) Remove the nut connecting the high-pressure fuel pipe with the pump;
(2) Remove the nut connecting the high-pressure fuel pipe and the fuel injector;
(3) Remove the nut connecting the high-pressure fuel pipe with the common rail pipe, and then the
high-pressure fuel pipe can be completely removed.
[Check]
(1) Check the high-pressure fuel pipe appearance for cracks, oil leakage, etc. If any, it is necessary to
replace the high-pressure fuel pipe and feed the check result back through the corresponding process;
(2) Check the conical surfaces of joints at both ends of the high-pressure fuel pipe to make sure that the
conical surfaces are intact.
[Assembling steps]
Assembling steps is in reverse of disassembling steps. However, it is necessary to note that the
high-pressure fuel pipe should be clean and intact. High-pressure fuel pipe fastening nut tightening torque is
(30~40) N•m at the fuel injector end and (30~40) N•m at the rail end and fuel pump end.

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4.7.6 Common rail pipe

4.7.6.1 Exploded view

Fig. 4-45 Exploded view of common rail pipe assembly

4. 7.6.2 Disassembling and assembling

[Disassembling steps]
(1) Disassemble the connector connecting the common rail pipe wire harness;
(2) Disassemble the bolts fixing the common rail pipe and the high-pressure fuel pipe;
(3) Disassemble the bolts fixing the common rail pipe and the common rail pipe bracket.
[Check]
Check whether the connection between the common rail pipe and the high-pressure fuel pipe is damaged.
The new common rail pipe should be protected by a protective cover which should be removed during
assembling.
[Assembling steps]
Assembling steps is in reverse of disassembling steps.

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4.7.7 Wire harness

4.7.7.1 Exploded view

Fig. 4-46 Exploded view of wire harness

4.7.7.2 Wire harness assembly

[Disassembling steps]
(4) Disassemble the connectors connecting wire harnesses with sensors and actuators;
(5) Disassemble the wire harness and fix the wire harness routing;
[Check]
Check the wire harness appearance and connectors for damage, and further check whether circuits are
connected or not with a multimeter.
[Assembling steps]
Assembling steps is in reverse of disassembling steps.

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4.8 Cooling system

4.8.1 Front cover
4.8.1.1 Exploded view

Fig. 4-47 Exploded view of front cover

4.8.1.2 Disassembling and assembling

[Disassembling steps]
(1) Loosen four bolts in turn and remove the gasket.
(2) Remove the heater joint and plug in turn, and put away the flange bolts by classification.
[Check]
(1) Check the gasket, and replace it with a new one if there are such problems as indentation.
(2) Check the front cover, and replace it with a new one if there are such problems as cracks.
[Assembling steps]
Disassembling steps are in reverse of assembling steps.

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4.8.2 Water pump

4.8.2.1 Exploded view

Fig. 4-48 Exploded view of water pump

4.8.2.2 Disassembling and assembling

[Disassembling steps]
(1) Remove the fan assembly. See the fan assembly disassembling steps for details.
(2) Remove the water pump pulley and intermediate cushion block.
(3) Move the water pipe joint upward to a certain displacement.
(4) Loosen four flange bolts in turn, while removing the water pump and gasket.
(5) All components should put properly by classification.
[Check]
(1) Check whether the water pump gasket is intact, and replace it with a new one if there are such
problems as indentation.
(2) Check the O-ring to ensure that there are no such problems as crack. If any, replace the O-ring with a
new one.
(3) Check the water pump to ensure that the water pump operates flexibly without sticking, otherwise
replace the water pump with a new one.
(4) Check the water pipe joint to ensure that there is no burr, etc., otherwise replace the water pipe joint
with a new one.
[Assembling steps]
In reverse of disassembling steps.

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4.8.3 Drain valve

4.8.3.1 Exploded view

Fig. 4-49 Exploded view of drain valve

4.8.3.2 Disassembling and assembling

[Disassembling steps]
(1) Loosen the clamp and remove the clamp and water outlet pipe;
(2) Unscrew the water drain valve from the engine block;
[Check]
(1) Check the water outlet pipe for water leakage. If any water leaks, replace it with a new water outlet
pipe.
(2) Check the connecting thread of the water drain valve for scratch and other defects. If any defect exists,
replace it with a new water drain valve.
[Assembling steps]
In reverse of disassembling steps.

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4.8.4 Thermostat
4.8.4.1 Exploded view

Fig. 4-50 Exploded view of thermostat

4.8.4.2 Disassembling and assembling

[Disassembling steps]
Loosen three flange bolts in turn, and remove the gasket, thermostat cover and thermostat respectively.
[Check]
(1) Check whether the gasket is intact, and replace it with a new gasket if there are such problems as
indentation.
(2) Check the connecting thread of the bolt for scratch and other defects. If any defect exists, replace it
with a new bolt.
[Assembling steps]
In reverse of disassembling steps.

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4.8.5 Fan
4.8.5.1 Exploded view

Fig. 4-51 Exploded view of fan

4.8.5.2 Disassembling and assembling

[Disassembling steps]
Loosen four flange bolts in turn, and remove the fan and the intermediate cushion block respectively.
[Check]
Check the connecting thread of the bolt for scratch and other defects. If any defect exists, replace it with a
new bolt.
[Assembling steps]
In reverse of disassembling steps.

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4.8.6 Water inlet pipe of water pump

4.8.6.1 Exploded view

Fig. 4-52 Exploded view of water pump water inlet pipe

4.8.6.2 Disassembling and assembling

[Disassembling steps]
(1) Remove clamps from the assembly in turn, and remove the water outlet elbow, the inlet pipe and the
water outlet pipe of oil cooler water respectively.
(2) Loosen three flange bolts in turn and remove the cooler return pipe.
(3) Properly place all components by classification.
[Check]
(1) Check the connecting thread of the bolt for scratch and other defects. If any defect exists, replace it
with a new bolt.
(2) Check three rubber pipes to ensure no water leakage, otherwise replace the rubber pipes with new
ones.
[Assembling steps]
In reverse of disassembling steps.

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4.9 After-treatment system

4.9.1 Overview
The after-treatment system of WP2.3 China V diesel engine includes two parts, i.e., SCR tank and urea
solution supply system. It mainly functions to reduce NO x and PM in engine exhaust so as to improve the engine
emission.
4.9.2 Requirements for installation matching of after-treatment assembly
2.1 Installation and fixing methods and installation requirements of after-treatment Assembly
(1) The SCR tank of WP2.3 China V diesel engine is a cylindrical catalytic converter. The catalytic converter
can be fixed on the whole vehicle with steel belts like the traditional silencer. However, the binding position of
steel belts should be determined as required and reliably limited. A wrong binding position will cause damage to
the surface insulation layer and unstable fixation.
(2) An elastic damper is required for the connection between the catalytic converter bracket and the
vehicle crossbeam, thus preventing the internal ceramic catalytic converter core from violent vibration.
(3) As the catalytic converter is much heavier than the traditional silencer, the vehicle manufacturer
should check the strength of the previous silencer installation system and update the design if necessary.
(4) As the chemical reaction in the catalytic converter depends on the temperature (180 °C at least), the
catalytic converter should be as close to the engine as possible, and the exhaust manifold should be wrapped
with an insulation layer as much as possible. For a bus, the conversion efficiency of NO x can be improved for the
exhaust manifold that has been subject to heat preservation treatment. Therefore, the exhaust manifold from
the engine to the catalytic converter generally requires heat preservation and heat insulation.
(5) The exhaust system pipeline from the position 200 mm from the upstream urea solution nozzle to the
downstream catalytic converter must be made of Grade 304 or 439 stainless steel. As the urea solution is
corrosive, under the influence of high temperature, low-carbon steel parts will be eroded rapidly.
(6) The turbocharger outlet should be connected with the catalytic converter with a metal hose, so as to
prevent the vibration of the engine from being transmitted to the catalytic converter and thus avoid the vibration
of the catalytic converter.
(7) Under full load and rated speed, the maximum exhaust back pressure of the system measured at the
turbocharger exhaust outlet should not exceed 20 kPa. .

Fig. 1 Fig. 2

4.9.3 Urea solution supply unit

4.9.3.1 Requirements
The urea solution supply unit (urea solution pump) weighs about 2.6 kg and has a working voltage of 12 V.
The urea solution supply unit is equipped with a main filter, an inlet filter and a reflux filter. The replacement
period of the main filter is generally 100,000 kilometers or 3 years. However, if the cleanliness of urea solution
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flowing into the urea solution metering unit fails to meet the requirements, the replacement period may be
shortened. The filtration efficiency of the main filter of urea solution pump is based on the regulation of single
pass efficiency in SAE J1985. The mass of aqueous urea solution in the urea solution pump should meet the
requirements specified in ISO 22241. At the same time, before using the urea solution pump, check whether the
joints of urea solution hydraulic pipelines and electrical appliances are installed with protective caps and are kept
clean. If there is no protective cap or the protective cap is polluted, the use requirements will not be met. In
addition, painting on the urea solution pump surface is not allowed, and protective measures should be taken for
the urea solution pump during painting operations.
4. 9.3.2 Installation and protection
a. Requirements for installation and protection on vehicle: The urea solution supply unit generally does not
need special protection. However, it should be installed at a position to avoid potential failure risks such as rain
wash, sludge splashing, stone impact, etc. and to prevent accidental damage to connectors. If there is a
possibility of sand and stone impact or accidental collision, a baffle plate should be installed at the bottom (the
distance between the non-detachable baffle plate and the bottom of the main filter of urea solution pump
should be greater than 170 mm), and a protective cover plate should be used.
b. After the urea solution pump is installed on the frame, its vibration level should meet the requirements
when the vehicle is running (because special test roads and test equipment are needed, the prototype vibration
test is generally arranged after RBCD).
c. Installation height requirements: There is no strict requirement for the relative position between the
urea solution supply unit and the urea solution tank. However, when the urea solution supply unit is installed
below the urea solution tank, the highest point of the solution inlet pipe should be higher than that of the urea
solution level, the vertical distance between the highest point of the solution inlet pipe and the internal solution
suction port of the urea solution tank should not exceed 1 m, and the height difference between the internal
solution suction port of the urea solution tank and the solution inlet port of the supply unit should not exceed 1
m, so as to reduce the pressure used for the urea solution pump to suck urea solution backwards after the
vehicle shutdown. When the urea solution supply unit is installed higher than the urea solution tank, the vertical
distance between the reference point of the urea solution supply unit and the internal solution suction port of
the urea solution tank should not exceed 1 m, so as to avoid the difficulty in pressure building.
d. To reduce the possibility of intercepting air in the hydraulic pipeline, the hydraulic pipeline should be as
short as possible. Therefore, the urea solution supply unit should be installed close to the urea solution tank. A
smooth transition should be made for the urea solution pipeline, to avoid local arching, dead fold, or air
interception area, etc.
e. When the urea solution pump is fixed on the whole vehicle, it should be controlled within -45°~45° from
both directions. The M8 bolt fixing the urea solution pump has the tightening torque of 19 N•m (±20%). The
device for disassembling and assembling the main filter cover has a width of 27 mm and the tightening torque of
19 N•m (5 N•m). The bottom of the main filter of urea solution pump should be designed to ensure that there is
a disassembling and assembling space with a distance of more than 170 mm down the center line of the filter, so
as to facilitate the maintenance and replacement of the filter element of urea solution pump.
f. Pin definition of urea solution pump electrical interface and waterproof and fixing requirements of
connector: See Tab. 1 for the pin definition of urea solution pump electrical interface and Fig. 3 for the pin
sequence. PIN 1 and PIN 7 are unoccupied pins, PIN 5 is connected with the after-treatment main relay, PIN 6 is
connected with the heating relay of urea solution pump, and other pins are connected with ECU. Connectors
corresponding to PIN 1 and PIN 7 should be sealed by blind plugs.

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Fig. 3 Urea solution pump fixing and pin layout

Tab. 1 Urea solution pump fixing and pin layout
Urea solution Urea solution
ECU pin Pin definition ECU pin Pin definition
pump pin pump pin
PIN 1 None -- PIN 7 None --
PIN 2 1.68 Pressure sensor (positive) PIN 8 1.89 Urea pump motor (ground)
Urea pump motor
PIN 3 1.07 Pressure sensor (signal) PIN 9 1.50
(positive)
Urea solution pump motor
PIN 4 1.39 Pressure sensor (ground) PIN 10 1.84
(PWM)
PIN 5 V1 Heater PIN 11 1.50 Reversing valve
PIN 6 1.02 Heater (signal) PIN 12 1.85 Reversing valve (signal)

Note: The V1 terminal is connected to the main power switch of the whole vehicle, and the main power
switch is connected to the positive electrode of the battery of the whole vehicle.
To prevent a system fault caused by water ingress to the urea solution pump connector, the connector,
sealing plug and conductor diameter should be selected strictly according to the requirements of Weichai in the
wire harness manufacturing process of the whole vehicle. Conductors of wire harnesses of the whole vehicle
must not be exposed to air, a 90° or 180° protective cover must be installed between the connector and the wire
harness, and the connector should be tied tightly with the wire harness by using a tie to prevent rainwater from
falling into the connector from the joint surface. During the arrangement of the whole vehicle, the wire harness
of the whole vehicle should be inserted into the urea solution pump and then be routed downwards at first to
ensure that there is a lowest point between the wire harness and the connector and prevent rainwater from
flowing into the connector downstream along the conductor.
4.9.4 Urea solution injection unit
The urea solution injection unit (urea solution nozzle) weighs about 0.24 kg. It consists of urea solution
pipe joint, cooling water pipe joint, heat insulation plate, electronic joint of injection valve and cooler body, as
shown in Fig. 4.
The urea solution injection unit is fixed on the nozzle base on the exhaust manifold, and the installation of
the injection unit depends on the installation position and angle of the nozzle base on the exhaust manifold. See
the design requirements of nozzle base on the intermediate exhaust manifold for the angle and size
requirements of injection unit relative to exhaust manifold. The tightening torque of nozzle base M6 bolt is 8
N•m (±2 N•m).

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Fig. 4 DeNOx2.2 system nozzle structure

The wire harness connector of urea solution nozzle includes two pins without positive and negative
electrodes. To prevent a system fault caused by water ingress in the nozzle connector during use, the conductor
sealing plugs should be used at pins of the urea solution nozzle wire harness connector, extra sealing rings should
be installed inside the connector housing, and a protective sleeve should be installed outside the wire harness to
avoid exposure of the wire harness and prevent the increase of the water ingress risk. Requirements for the
protection of whole-vehicle wire harness connectors of the urea solution nozzle are shown in Fig. 5.

Fig. 5 Requirements for the protection of whole-vehicle wire harness connectors of urea solution nozzle

Before using the urea solution nozzle, check whether the joints of urea solution hydraulic pipelines and
electrical appliances are installed with protective caps and are kept clean. If there is no protective cap or the
protective cap is polluted, the use requirements will not be met. In addition, painting on the urea solution nozzle
surface is not allowed. Therefore, protective measures should be taken for the urea solution nozzle during
painting operations.
There is no requirement for the flow direction of cooling water of the urea solution nozzle, only a certain
pressure difference should be kept for the cooling water, and the waterway should be kept unblocked during the
operation of diesel engine.
Disassembling and assembling sequence of urea solution nozzle connector: The urea solution nozzle should
be installed at a position of the whole vehicle to facilitate the installation and disassembly of the urea solution
hydraulic pipelines and electric appliances. In order to prevent the possibility of pollution to the electrical
interface during disassembly and assembly of the urea solution pipeline, the disassembling and assembling
sequence of the urea solution pipeline joint and electrical connector is as follows: (1) When installing, firstly
install the electrical connector, and then install the urea solution pipeline joint. (2) When disassembling, firstly
disassemble the urea solution pipeline connector, and then disassemble the electrical connector.
4.9.5 Matching requirements of urea solution tank
4.9.5.1 Matching requirements of urea solution tank
The sensor assembly is installed at the top of the urea solution tank, and a residual liquid release plug hole
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is installed at the bottom. Sensors in the sensor assembly include the liquid level sensor and the temperature
sensor, which are used for sensing the liquid level and temperature. The heat exchanger integrated on the sensor
assembly can unfreeze the frozen urea in cold weather by using the heat of engine cooling water, as shown in Fig.
6. Experience shows that particles smaller than 70 µm are allowed for the filter of urea solution tank. Therefore,
a urea primary filter should be installed at the inlet of urea hydraulic pipe in urea solution tank to prevent
impurities larger than 70 µm from entering the injection system. The urea solution tank should have ventilation
function during use or filling, so as to ensure the pressure balance between inside and outside the tank at all
times. During the filling process, the pressure balance inside and outside the tank should be maintained to
ensure that urea can be filled smoothly. During use, maintaining the pressure balance inside and outside the tank
can prevent the tank from bulging due to the pressure rise in the tank caused by heating in cold regions, and
avoid the difficulty of system pressure building due to the low pressure in the tank caused by urea consumption.
In addition, the bottom of the urea solution tank should be provided with a residual liquid release plug hole, and
the design of the filler of the urea solution tank should comply with the provisions of DIN 70070 standard.
Non-metallic materials are recommended for the urea solution tank cover, and materials which are easy to
rust are not allowed, thus preventing the pollution of urea solution. Before the urea solution tank is used, it is
necessary to check whether there are impurities in the urea solution tank, such as plastic chips, which have not
been removed during processing. If there are, they should be rinsed thoroughly to avoid blockage of the injection
system during use.
When installing the urea solution tank to the vehicle, try to avoid the urea solution tank being affected by
the radiation from the engine, transmission, SCR catalytic converter, exhaust pipe and other heat sources, and
avoid the deterioration of urea solution caused by the ambient temperature of the urea solution tank being
higher than 70°C. To facilitate urea filling, the urea solution tank can be installed on the same side as that of the
fuel tank, and attention should be paid to the protection of the bottom of the urea solution tank during
installation of the urea solution tank.
To prevent diesel or other liquids from being filled into the urea solution tank, it is necessary to mark
warning signs at conspicuous positions on the urea solution tank and cover, which should be visible after the
urea solution tank is correctly installed to the vehicle. At low temperature, the frozen volume of urea expands by
about 8%. During filling of urea solution, it should not be overfilled, and a certain expansion volume should be
reserved at the top of the tank to prevent the tank from cracking or the liquid level and temperature sensor from
being crushed due to the increase of frozen urea volume at low temperature. The maximum filling amount of
Weichai 35 L urea solution tank (with a total volume of about 40 L) should not exceed 36 L, and the maximum
filling amount of Weichai 50 L urea solution tank (with a total volume of about 60 L) should not exceed 52 L.
During use, if the urea level is too low (less than 5%), the system will report the low urea level fault. It is required
to add enough urea when the vehicle is put into storage, so as to ensure that the vehicle runs for a certain
mileage without reporting the fault of low liquid level.
The urea liquid level sensor is a float type sliding resistance sensor. During urea filling, the displayed liquid
level changes discontinuously, and the displayed value of the liquid level jumps once every 2 L~4 L is filled. Tab. 2
shows the relationship between the filling quantity and the liquid level display of Weichai 35 L and 50 L urea
solution tanks.
Tab. 2 Relationship Between Filling Quantity and Liquid Level Display of 35 L and 50 L Urea Solution Tanks
35 L urea solution tank 50 L urea solution tank
Liquid level Liquid level
Filling quantity/L Filling quantity/L
display display
0 0% 0 0%
5.5 5% 7 5%
8 11% 8.8 11%
10.5 17% 12 17%
13 23% 15 24%
16 29% 18.5 29%

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35 L urea solution tank 50 L urea solution tank

Liquid level Liquid level
Filling quantity/L Filling quantity/L
display display
18 35% 21.5 35%
20 40% 25 40%
21.5 46% 28 47%
23.5 53% 32 53%
25 57% 35 57%
26.5 62% 38.5 63%
28.5 68% 41 69%
30 76% 43 77%
31.5 82% 45 83%
33 90% 47.5 91%
34.5 95% 49 95%
36 100% 52 100%

(a) Ordinary heating type (b) Enhanced heating (c) Sensor interface of heating type urea solution tank
type

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Fig. 6 Sensor Group of Integrated Urea Solution Tank and Heating Type Urea Solution Tank

The liquid level and temperature sensor group of the urea solution tank is classified into the non-heating
type urea solution tank sensor group and the heating type urea solution tank sensor group according to whether
the urea heater is integrated or not. There is no urea heater integrated on the non-heating type urea solution
tank sensor group, which is suitable for use in non-cold regions (the lowest temperature is not lower than -7°C).
The urea heater is integrated on the heating type urea solution tank sensor group, which is divided into the
ordinary heating type urea solution tank sensor group and the enhanced heating type urea solution tank sensor
group (the heater is of a spiral structure) according to the heating effect. The ordinary heating type urea solution
tank sensor group is suitable for use in cold regions where the lowest temperature is not lower than -25°C, and
the enhanced heating type urea solution tank sensor group is suitable for use in cold regions where the lowest
temperature is lower than -25°C.
4.9.5.2 Matching requirements of urea solution pipeline
DeNOx6.5 system includes three urea solution hydraulic pipelines:
 Suction Line (SL): from urea solution tank to urea solution pump
 Backflow Line (BL): from urea solution pump to urea solution tank
 Pressure Line (PL): from urea solution pump to urea solution nozzle
During installation on the vehicle, ensure that the urea solution pump and various hydraulic joints have no
leakage, so as to prevent urea crystallization pollution. The urea solution pipeline should be arranged to avoid
being affected by other heat sources whenever possible, especially to avoid being bound together with the
engine coolant pipeline used to cool the nozzle. The pipeline layout should ensure that the pressure drop of each
pipeline does not exceed 100 hPa, and the shorter the length, the better. The length of suction pipes and return
pipes should not exceed 3 m, and it is suggested that the length of pressure pipes should not exceed 5 m.
For the layout of urea solution pipes, the correct connection should be first ensured, especially the
connection between the urea solution suction pipe and the return pipe and the urea solution pump, so as to
prevent the two urea solution pipes from being reversely connected with the liquid inlet and return joints of urea
solution pump, and bending of pipes should be avoided. As shown in Fig. 17, the suction pipe is connected with
an arrow pointing to the direction of urea solution pump at the urea solution tank end, and is connected with a
gray joint marked with the word "INLET" at the pump end. The return pipe is connected with the arrow marked
with the direction opposite to the urea solution pump at the urea solution tank end and with the white joint
marked with the word "BACKFLOW" at the pump end. The reverse connection or serious bending of the pipeline
will cause the system failure to enter the normal working state.
If the integrated structure is adopted for the urea solution tank and the urea solution pump, and the urea
solution suction pipe and return pipe are short, the formed pipe must be adopted to prevent the urea solution
pipe from being reversely connected with the inlet/return joint of the urea solution pump, and avoid the serious
bending of the ordinary straight pipe after connection, which will affect the operation of the injection system.

Fig. 7 Precautions for Urea Solution Pipe Layout

When the urea solution pipe is a heating type urea solution pipe, the relationship between the length of
the urea solution pipeline and the heating power should be considered, the working current should be
determined, and appropriate relays and fuses should be selected for the after-treatment heating system.
For the layout of the urea solution hydraulic pipeline and the engine coolant pipeline, extra heat transfer
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should be avoided as much as possible, so it is recommended to install heat insulation materials on their outer
surfaces. The distance between the first fixed point of the three urea solution pipes and the joint should not
exceed 200 mm, and the fixed point should be selected on the basis of the same vibration source as that of the
fixed parts.
The material of urea solution pipes used in the SCR system is required to be resistant to urea corrosion, and
at the same time should have certain strength to avoid being flattened due to vacuum generated by suction.
Special pipe joints should be used at the connections between the urea solution pipe and the urea solution tank,
between the urea solution pump and the nozzle to prevent leakage. The specifications of hydraulic pipelines and
joints of the system should meet the requirements in Tab. 3.
As the size of quick-release joints of urea solution suction pipelines and urea solution return pipelines are
both 3/8 in., in order to prevent mis-installation, not only the assembly process should be explained, but also
distinguishing measures should be taken. For example, the color of quick-release joint or urea solution pipeline
should correspond to that of the urea solution pump joint (the colors of the suction pipe joint and the return
pipe joint on the urea solution pump currently used are black and gray-white, respectively).
Tab. 3 Specifications of System Liquid Pipelines and Joints

Pipe diameter
Number of
Item (Inner Joint (SAE J2044) Remarks
joints
diameter)
Urea solution suction
6~8 mm 3/8 inch (9.5 mm) joint 2
pipeline
Urea solution pressure
6~8 mm 5/16 in (8mm) joint 2
pipeline
Urea solution pump end:
3/8 in (9.5 mm) joint 1
Urea solution return 3/8 in
6~8 mm
pipeline Urea solution tank end:
5/16 in (8mm) joint 1
5/16 in

4.9.6 Matching requirements of urea solution heating system

DeNOx6.5 heating system is mainly used in cold weather, and is used to unfreeze the frozen urea solution
and ensure that the SCR after-treatment system can still work normally in cold weather. Under the condition that
urea will not freeze in non-cold weather, there is no need to use the heating function. As there is a difference in
freezing point temperature between ordinary water and urea solution, and the calibration of the heating system
is based on standard urea solution, it is possible to cause abnormal operation of the system if the temperature is
lower than 0°C, and water is added into the urea solution tank or urea solution that does not meet the
requirements is added.
4.9.6.1 Requirements of cooling water pipeline for heating
It is recommended to use fiber reinforced ethylene propylene diene monomer (EPDM) pipes for cooling
water pipes for heating, with inner and outer diameters of Φ14 mm and Φ18 mm respectively. The joints are
respectively installed on the sensor of urea solution tank and the solenoid valve of coolant switch, and are
fastened by clamps.
4.9.6.2 Layout of cooling system for heating
(1) Heating arrangement of cooling water in urea solution tank
When ECU judges through the urea solution tank temperature sensor and the ambient temperature sensor
that urea solution needs to be unfrozen (the temperature point is lower than the set value), and the engine
coolant temperature reaches the set temperature, ECU will turn on the coolant solenoid valve and the hot
coolant will flow into the heat exchanger of the urea solution tank to unfreeze urea solution. In order to avoid
the problems caused by pipeline icing or urea crystallization in cold weather, the SCR system will also heat up
during cold weather operation, and repeatedly open/close the coolant solenoid valve to keep the liquid
temperature in the urea solution tank within a certain range. However, the engine coolant needs to continuously
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cool the urea solution nozzle to keep it in a safe working temperature range.
The water inlet and return positions of the cooling system for heating should be selected to ensure
sufficient pressure difference between the two positions. The water inlet position is arranged in the
high-pressure water area behind the engine water pump, and the water return position is arranged in the
low-pressure water area. It is recommended that the water inlet position be arranged on the water outlet pipe in
front of the oil cooler cover or thermostat, and the water return position be arranged in the negative pressure
area at the inlet of the engine water pump. The water pipe runs smoothly without serious bending.
The engine coolant cooling the urea solution nozzle flows out through the engine, flows into the urea
solution nozzle through one of the cooling water pipe joints at the top of the urea solution nozzle, and flows out
from the other cooling water pipe joint after completing the cooling cycle. There is no sequential priority
between the two water pipe joints. As long as the engine is running, the coolant will keep cooling the urea
solution nozzle continuously. Engine coolant for heating urea solution in the urea solution tank should first pass
through the open solenoid valve of coolant switch, then enter the urea solution tank through the heat exchange
pipe joint of the urea solution tank, complete the heat exchange with urea solution, and then flow out of the
urea solution tank and back to the engine cooling system. Only when the urea solution temperature in the urea
solution tank is lower than a certain value, will the coolant solenoid valve open, and the engine cooling water will
flow into the urea solution tank to heat the urea solution. The schematic diagram of the cooling water pipeline
layout of the system is shown in Fig. 8.

Fig. 8 Schematic diagram of engine cooling water pipeline layout of DeNOx6.5 system

The cooling water pipe needs to be fixed when it is well connected. The distance between the first fixed
point of the water pipe and the joint should not exceed 200 mm. The fixed point should be selected on the basis
of the same vibration source as that of the fixed parts.
(2) Electric heating arrangement of urea solution pump and pipeline
DeNOx6.5 system uses electric heating for the urea solution pump and the urea solution pipeline. The urea
solution pump has the built-in electric heating device, and the urea solution pipe is wrapped by the heating
resistive element. According to the signals from the temperature and ambient temperature sensors of the urea
solution pump, ECU judges whether electric heating needs to be started. When electric heating is needed,
corresponding relays are started, and the heating elements of the parts to be heated are fed by 12 V power
supply, thus heating the urea solution pump and the urea solution pipeline. The connection methods among
relay, heating wire and ECU pins are shown in Fig. 9.
The heating of the urea solution pump and the urea solution pipeline share a fuse and a relay, and the fuse
should be installed outside the relay box, close to the battery. When ECU judges that heating is needed according
to the signals from the temperature and ambient temperature sensors of urea solution pump, firstly, pin 1.93 of
ECU outputs a low-level signal to drive the relay to close the switch; then the urea heating control strategy
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decides which pipeline to be heated, and the corresponding pins of the pipeline output low-level signals, the
circuit is connected, and the resistance wire starts heating.
Determination of fuse size: It needs to be determined according to the maximum current of the entire
after-treatment heating system, and the maximum current passing through the fuse is the sum of the maximum
currents of three urea solution pipes and the urea solution pump. It is required that the maximum current that
the fuse can bear should not be less than 1.5 times of the total currents of the four branches; otherwise, the fuse
may be blown out. At the same time, the fuse can be blown out smoothly when any circuit is short-circuited;
otherwise, the fuse cannot play a protective role.
At present, PTC material is the main heating material for urea solution pipes in China, which is
characterized by low resistance at low temperature, and the maximum current of heating wire for urea solution
pipes should be calculated according to the initial heating current at -40°C. According to the application
experience of heating type urea solution pipes in the market, the heating power is between 20 W/m and 30
W/m at room temperature and under 12 V power supply. At low temperature, the resistance of heating wire of
the urea solution pipe decreases and the heating power increases. At -40°C, the initial heating power of the urea
solution pipe is about 60 W/m. In consideration of the voltage change of the vehicle, the maximum heating
current per meter of the urea solution pipe is about 2 A~3.5 A. The longer the urea solution pipe is, the larger the
heating current will be. In the practical application process, customers need to determine the maximum heating
current of the urea solution pipe according to the actual length of the urea solution pipe and the electrical
parameters, so as to select suitable relays and fuses for the after-treatment heating system.

Fig. 9 Schematic diagram of electrical connection arrangement of DeNOx6.5 system electrical heating

In consideration of the resistance characteristics of PTC heating material of the urea solution pipe, during
use in cold regions, the current is relatively large during the vehicle start-up or initial heating process, and the
longer the urea solution pipe is, the more obvious this characteristic will be. Therefore, when the PTC heating
material is adopted for urea solution pipes, it is necessary to fully evaluate the current in extreme cases. At the
same time, it is suggested that when the urea heating pipe is long, the heating material should be a pure resistor
material to avoid the damage of the relay and the fuse due to excessive current.

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4.10 Lubricating system

4.10.1 Oil cooler and filter
4.10.1.1 Exploded view

Fig. 4-53 Exploded view of oil cooler and filter

4.10.1.2 Disassembling and assembling

[Disassembling steps]
Loosen the two flange bolts and remove the gasket, oil cooler and filter assembly.
[Check]
(1) Check whether the gasket is intact, and replace it with a new gasket if there are such problems as
indentation.
(2) Check the connecting thread of the bolt for scratch and other defects. If any defect exists, replace it
with a new bolt.
[Assembling steps]
In reverse of disassembling steps.

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4.10.2 Oil suction filter

4.10.2.1 Exploded view

Fig. 4-54 Exploded view of oil suction filter

4.10.2.2 Disassembling steps

(1) Remove the oil pan.
(2) Remove 3 hexagon flange bolts.
4.10.2.3 Inspection and maintenance
Check the suction filter for cracks and other damage, and if any, replace the suction filter with a new one.
4.10.2.4 Assembling steps
(1) Before assembling, check the suction filter for manufacturing defects and damage to ensure that it is in
good condition.
(2) Clean the inner cavity of the suction filter.
(3) Install the suction filter group.
(4) Install the filter group to the engine block, and tighten the hexagon flange bolts.

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4.10.3 Oil dipstick

4.10.3.1 Exploded view

Fig. 4-55 Exploded view of dipstick

4.10.3.2 Disassembling and Assembling

1) Pull out the oil dipstick.
4.10.3.3 Inspection
1) Check whether the oil dipstick cap is loose and falls off, and if so, replace it with a new one.
2) In order to ensure the high accuracy of oil level, the oil dipstick tube should be installed to the
component under the oil dipstick pipe, and no gap should be left. After the dipstick tube is fixed as required,
check whether the dipstick is easy to insert or remove.

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4.11 Starting system

4.11.1 Starting system
4.11.1.1 Exploded view

1. Starter 2. Spring washer 3. Bolt

Fig. 4-56 Exploded View of Starting System

4.11.1.2 Disassembling steps

①Remove hexagon bolts and spring washers.
②Hold the starter with both hands to remove it along the axis of rotation of the starter gear.
4.11.1.3 Inspection and maintenance
Check whether the starter gear teeth are damaged, and replace them if damaged.
4.11.1.4 Assembling steps
Assembling steps is in reverse of disassembling steps.

4.12 Vehicle accessory system

4.12.1 Disassembling and assembling of engine bracket
4.12.1.1 Exploded view

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Fig. 4-57 Exploded view of engine bracket assembly

4.12.1.2 Disassembling steps

①Remove hexagon bolts and spring washers.
②Hold the engine bracket with both hands and remove it.
4.12.1.3 Inspection and maintenance
Check whether the engine bracket is tightened, and if not, tighten it in time.
4.12.1.4 Assembling steps
Assembling steps is in reverse of disassembling steps.
4.12.2 Alternator
4.12.2.1 Exploded view
The alternator is a 14 V silicon controlled rectifier (SCR) alternator. When using, pay attention to grounding
the negative pole, and do not connect it reversely. The rear end of this alternator can also be equipped with a
vacuum pump, which can be used as a vacuum booster for the brake system.

1- Hexagon flange bolt 2- Alternator 3- Hexagon flange bolt 4-Type 1 hexagon nut
Fig. 4-58 Exploded View of Alternator

4.12.2.2 Disassembling and assembling

[Disassembling and assembling steps]
(1) Loosen the alternator adjusting frame and remove the front belt of the alternator.
(2) Remove the adjusting bolt whose upper end is installed on the alternator adjusting frame.
(3) Remove the fixing bolt whose lower end is installed on the alternator bracket, and remove the
alternator.
Note: The disassembling and repair of the alternator must be carried out by professionals. During
installation, check whether the insulation pads and sleeves are in good condition, and replace the damaged ones.
The positive pole of the alternator and the shell should not be short-circuited; otherwise, it is forbidden to install
the alternator to the vehicle for fear of serious accidents.
[Assembling steps]
(1) Place the alternator on the alternator bracket and install the alternator fixing bolts.
(2) Loosely install the alternator on the adjusting frame.
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(3) Install the front belt of the alternator.

(4) Use the alternator adjusting frame to tension the belt at the front end of the alternator and tighten the
bolts of the alternator adjusting frame.
4.12.2.3 Inspection and maintenance
①Alternator fault judgment process
Before users decide to enjoy the warranty service, they should first test on the vehicle whether it is a
alternator fault.
②Methods for fault diagnosis and removal of charging system
a) Charging failure
Fault 1: charging failure
Symptom Inspection Fault handling
(1) When the a Check the charging ① Detect whether the alternator indicator lamp has voltage to the
ignition is turned indicator ground, and if not, replace the indicator lamp or check the circuit
on, the charging
indicator does not B Check whether the ② If yes, the alternator regulator or rotor fails; repair or replace
light up. excitation circuit is open the alternator.

(2) The charging a The indicator has low

indicator does not power or the parallel ① It is recommended to use 2-6 W bulbs or repair the circuit
go out when the excitation resistor is loose
② Adjust the engine idle speed
engine is idling, but
goes out when it is b Engine idle speed
at high speed. extremely low

① If the terminal voltage of the indicator of the alternator is very

low, it means that the power of the indicator of the excitation line
is too small or the line has a virtual connection. Adjust the indicator
power or check the line connector and connection point.
a. Check whether the
② If the terminal voltage of the alternator indicator is zero, it
voltage to ground at
means that there is a short circuit point to the ground at the
excitation end of
alternator end of the excitation line, so check the line.
alternator is between 1-3
V ③ If the terminal voltage of the alternator indicator is the battery
voltage, it means that there is a problem with the excitation circuit
of the vehicle, and the alternator regulator and excitation tube may
be damaged at the same time, so it is necessary to correct the
excitation circuit before connecting the repaired alternator.
(3) When the
① If the voltage of B+ to ground is zero, check whether the
engine is working,
positive and negative leads between the alternator and the battery
the charging
are conducted.
indicator does not
go out ② If the voltage of B+ to ground is obviously lower than the
battery voltage, check whether the contacts of positive and
negative leads between the alternator and the battery are loose or
whether the battery is damaged.
b Detect whether the
voltage of alternator Recommended detection method: Connect 2W indicator between
output terminal B+ to alternator output terminal B+ and excitation terminal D+/L, and
ground is about 12 V observe the working condition of indicator.
battery voltage
Fault handling:
① The brightness of indicator is normal. After the engine is
started, the indicator light goes out and the alternator output
voltage is 12 V. The vehicle excitation circuit is faulty and needs to
be repaired.
② The brightness of the indicator is normal, the indicator light
does not go out after the engine is started, and the output voltage

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of the alternator is about 12 V. The alternator regulator is faulty

and needs to be replaced.
③ The brightness of the indicator is normal, the indicator does
not go out after the engine is started, and the output voltage of the
alternator is the battery voltage; the alternator regulator, rectifier
bridge, stator or internal wiring may be faulty and need to be
repaired or replaced.

b) The charging voltage is too low

Fault 2: The charging voltage is too low
Symptom Inspection Fault handling
Understand whether the
Measure the B+ terminal voltage of alternator, which should
matching between
usually be around 12 V. If the voltage is normal, there is a problem
alternator output power
with the voltmeter or the voltmeter sampling point, which needs to
and the vehicle electrical
be repaired or replaced
equipment is reasonable
② It is recommended that the idle speed of alternator under no
a Check whether the
load should be greater than 1600 RPM.
voltmeter is damaged
③ When the alternator works with high-power loads such as the
b Check the alternator
air conditioner, the speed should be not less than 2000 rpm or the
speed
voltage should be around 12 V.
① Check the quality of the alternator and related gear train belts,
and replace the belts with coking, missing teeth, fracture,
c Check the quality and
deformation and falling to the bottom of the groove.
tension of the alternator
and related gear train ② Re-tension belts of the alternator and related gear train
drive belts.
★ Note: If the system requiring belt replacement involves double
belt drive, both belts must be replaced at the same time.
d Check the alternator
If it is loose, it needs to be tightened
pulley
The battery is often
under-charged, the ① If the voltage difference is greater than 1 V under the working
charging voltage is e Check whether the condition of heavy load (the voltage drop is large due to the thin
low, and the wires are used properly wire), replace the wire
voltage drops and measure the terminal 2 2
S ≥ 6mm in 35A and S ≥12mm in 70A
obviously when the voltage of alternator and
2 2
load is turned on. battery S ≥ 20mm in 100A and S ≥25mm in 150A
② If the heating of the wire or connector is obvious under heavy
load conditions, it is necessary to replace the wire or connector.

f Check whether the ① Grind the surface of the oxidized lead piece and the grounding
connection of the bolt shell before reinstallation.
charging system wires
② Re-tighten the loose nuts and lugs, and re-insert the connectors
and bolts are loose,
tight.
oxidized and
disconnected and ★ Note: After reinstalling or re-tightening, check whether there is
whether high heat is still high heat after the engine runs under heavy load conditions for
generated 3 ~ 5 min.
g Detect the output
If there is a big difference between the output voltage of the phase
voltage of the phase
terminal (W/R/AC) and the normal output value, there is a problem
terminal of the alternator
with the rectifier bridge or stator of the alternator, which should be
(it should be about half of
repaired or replaced.
the output voltage at B+)
If the charging current drops to about 10 A after charging for 10
h Check whether the
min, and if the charging current keeps being 30-70 A for a long
battery is charged
time, the battery may be damaged and needs to be repaired or
normally
replaced.

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c) Charging voltage extremely high

Fault 3: charging voltage extremely high
Symptom Inspection Fault handling
Measure the B+ terminal voltage of alternator, which should
a Check whether the usually be around 12 V. If the voltage is normal, it means that the
voltmeter is damaged voltmeter calibration value has a large error and the voltmeter
needs to be repaired or replaced.
b Check the wires and
connecting parts of the
charging system, and
check whether the ① If re-tightening is required for poor contact and loose
connecting bolts are connecting parts, the connector needs to be re-inserted tight.
loose, disconnected and
produce high heat, and ② If there is a short circuit, reconnect the wires.
whether the wires are
short-circuited with the
alternator housing.
The voltmeter ① Observe whether the charging current value of the battery
shows high voltage changes greatly in a short time during charging. If not, consider
c Check whether the replacing the battery as soon as possible.
working state of the
battery is normal ② Observe whether the surface of the battery is clean and dry,
and whether the terminal and clamp fit well. If there is damage,
replacement should be done as soon as possible.
d Detect the output If there is a big difference between the output voltage of the phase
voltage of the phase terminal (W/R/AC) and the normal output value, and if the voltage
terminal of the alternator drop is great during alternator operation under load conditions,
(it should be about half of there is a problem with the rectifier bridge or stator of the
the output voltage at B+) alternator, which should be repaired or replaced.
e After the above
inspection is completed,
Replace the alternator regulator, rotor or the entire alternator.
the fault symptom has
not been eliminated

d) Unstable charging voltage

Fault 4: unstable charging voltage
Symptom Inspection Fault handling
When the engine is a Belts of alternator or related gear train are Tension belts of the alternator and related
running normally, extremely loose and jump gear train
the voltmeter
indicates charging, b Each connection of charging line is loose and Check and tighten each connection of the
but the pointer has poor contact charging circuit
swings from side to c The collector ring is polluted, or the brush is
side, and the Clear stains, or replace brushes and brush
excessively worn, or the brush spring is too soft
reading cannot be springs
and broken
seen clearly (or the
charging indicator
lights up and goes d The regulator is damaged Replace the regulator
out)

d) Abnormal sound of alternator

Fault 4: unstable charging voltage
Symptom Inspection Fault handling

The alternator has a The alternator bracket is deformed or too Improve the strength of the mounting bracket
abnormal noise close to other machines and adjust the mounting state

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during operation B The alternator belt is loose and slips Replace the alternator belt
C Loose pulley of alternator Tighten the pulley
d The alternator bearing is lacking in oil or
Replace the alternator bearing
damaged
e The alternator has a deep abnormal sound
The stator coil is short-circuited; replace it
inside
It is the noise generated when the stator core
f The alternator has a howling noise inside,
vibrates. Replace the stator group if
which changes with the alternator speed
necessary.

4.12.3 Hydraulic pump

4.12.3.1 Exploded view

1- Hex flange bolt 2- Sleeve 3- Hex flange bolt 4- Hydraulic pump bracket 5- Hydraulic pump adjusting bracket 6- Hex
flange bolt 7- Hydraulic pump 8- Hexagon flange bolt 9- Hexagon flange bolt
Fig. 4-59 Exploded View of Hydraulic Pump

4.12.3.2 Disassembling and assembling

[Disassembling steps]
(1) Remove the hexagon flange bolts connecting the hydraulic pump and the hydraulic pump adjusting
bracket.
(2) Rotate the hydraulic pump body and remove the belt at the front end of the hydraulic pump.
(3) Remove the hexagon flange bolts and sleeves on the lower part of the hydraulic pump, and remove the
hexagon flange bolts, sleeves and hydraulic pump.
[Assembling steps]
Follow the reverse order of the above disassembling steps.
4.12.4 A/C compressor
4.12.4.1 Exploded view

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1- A/C compressor 2- Type 1 hexagon nut 3- A/C compressor bracket 4- Hexagon bolt 5- Hexagon flange bolt
6- Type 1 hexagon nut 7- Hexagon flange bolt 8- A/C compressor bracket 9- Hexagon flange bolt 10- Hexagon flange
bolt 11- Hexagon flange bolt 12- Hexagon flange bolt
Fig. 4-60 Exploded View of A/C Compressor Assembly

4.12.4.2 Disassembling and assembling

[Disassembling steps]
(1) Remove the hexagon flange bolts, hexagon bolts and nuts connecting the A/C compressor and the
A/C compressor bracket.
(2) Remove the front belt of the A/C compressor.
(3) Remove the A/C compressor.
[Installation steps] Follow the reverse order of the above disassembling steps.

Annex A OBD Torque Limit and Unclearable Code List

Clearable or
DFC Chinese description Torque limit
unclearable

Torque limit
DFC_ComAT1OG1TO CAN receive frame AT1O1 timeout error Clearable
within 50 hours

The actual average conversion efficiency of SCR

is below the threshold 2, and the emission Immediately limit
DFC_SCRChkEta2 Unclearable
exceeds the national emission standard at the torque
phase-7

Immediately limit
DFC_SCRMonPresBuildUpErr SCR urea pressure build-up error Clearable
the torque

Urea liquid level sensor voltage is above the Torque limit

DFC_SRCMaxUTnkLvl Clearable
upper limit within 50 hours

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Urea liquid level sensor voltage is below the Torque limit

DFC_SRCMinUTnkLvl Clearable
lower limit within 50 hours

Immediately limit
DFC_UDCRdcAgRmn Low urea level Unclearable
the torque
SCR urea nozzle drive short circuit to the power Immediately limit
DFC_UDosVlvSCB Clearable
supply the torque

SCR urea nozzle drive high end short circuit to Immediately limit
DFC_UDosVlvSCBHS Clearable
the power supply the torque

Immediately limit
DFC_UDosVlvSCG SCR urea nozzle drive short circuit to ground Clearable
the torque

Immediately limit
DFC_UDosVlvSCGHS SCR urea nozzle drive high-end short circuit Clearable
the torque

Immediately limit
DFC_UPmpMotOL Open circuit of the urea pump motor drive Clearable
the torque
Short circuit to the power supply of the urea Immediately limit
DFC_UPmpMotSCB Clearable
pump motor drive the torque

Short circuit to ground of the urea pump motor Immediately limit

DFC_UPmpMotSCG Clearable
drive the torque

Urea pump pressure sensor voltage signal is Immediately limit

DFC_UPmpPPhysRngHi Clearable
above the upper limit the torque

Urea pump pressure sensor voltage signal is Immediately limit

DFC_UPmpPPhysRngLo Clearable
below the lower limit the torque

Upstream exhaust temperature sensor open Immediately limit

DFC_UCatUsTSRCMax Clearable
circuit the torque

Upstream exhaust temperature sensor short Immediately limit

DFC_UCatUsTSRCMin Clearable
circuit the torque

Torque limit
DFC_SCRChkNOxDsPeakErr NOx sensor in the air Clearable
within 50 hours

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Annex B Diagnostic Fault Code Table

NO Fault name Chinese description P-Code(HEX)

1 DFC_AFSBattErr Supply voltage failure of air flow meter (HFM) P0100(0100)

Offset correction value 0 of air flow meter (HFM)
2 DFC_AFSDrftAdjVal_0 P0100(0100)
higher than upper limit value
Offset correction value 1 of air flow meter (HFM)
3 DFC_AFSDrftAdjVal_1 P0100(0100)
higher than upper limit value
4 DFC_AFSScg HFM sensor short circuit to ground P0100(0100)
Deviation value of air flow meter (HFM) higher than
5 DFC_AFSSetyDrftMax P0100(0100)
upper limit value
Deviation value of air flow meter (HFM) lower than
6 DFC_AFSSetyDrftMin P0100(0100)
lower limit value
7 DFC_AFSSigErr Hardware fault of air flow meter (HFM) P0103(0103)
Periodic signal of air flow meter (HFM) higher than
8 DFC_AFSSRCRawMax P0103(0103)
upper limit
Periodic signal of air flow meter (HFM) lower than
9 DFC_AFSSRCRawMin P0102(0102)
lower limit
Analog voltage signal of A/C pressure sensor higher
10 DFC_AirCClntPAnaSRCMax P0530(0530)
than upper limit value
Analog voltage signal of A/C pressure sensor lower
11 DFC_AirCClntPAnaSRCMin P0530(0530)
than lower limit value
Duty cycle signal of A/C pressure sensor higher than
12 DFC_AirCClntPdcycSRCMax P0530(0530)
upper limit value
Duty cycle signal of A/C pressure sensor lower than
13 DFC_AirCClntPdcycSRCMin P0530(0530)
lower limit value
Periodic signal of A/C pressure sensor higher than
14 DFC_AirCClntPPerSRCMax P0530(0530)
upper limit value
Periodic signal of A/C pressure sensor lower than lower
15 DFC_AirCClntPPerSRCMin P0530(0530)
limit value
16 DFC_AirCCmprOL AC compressor open circuit P0645(0645)
A/C compressor driver chip in electronic control unit
17 DFC_AirCCmprOvrTemp P0645(0645)
(ECU) overheated
Variable displacement A/C compressor drive circuit
18 DFC_AirCCmprRedTrqOL P0645(0645)
open
Variable displacement A/C compressor driver chip
19 DFC_AirCCmprRedTrqOvrTemp P0645(0645)
overheated
Drive circuit of variable displacement A/C compressor
20 DFC_AirCCmprRedTrqSCB P0647(0647)
short-circuited to power supply
Drive circuit of variable displacement A/C compressor
21 DFC_AirCCmprRedTrqSCG P0646(0646)
short-circuited to ground
Drive circuit of A/C compressor short-circuited to
22 DFC_AirCCmprSCB P0647(0647)
power supply
Drive circuit of A/C compressor short-circuited to
23 DFC_AirCCmprSCG P0646(0646)
ground
24 DFC_AirCSwtNpl A/C switch CAN signal not reliable U0424(C424)
25 DFC_AirCSwtSig A/C switch CAN signal reception timeout (A/C switch U0466(C466)

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CAN message not received within the specified time)

Difference between set air quantity and actual fresh
26 DFC_AirCtlGovDvtEOMMax intake air quantity higher than upper limit value in P0101(0101)
regeneration mode (fresh intake air quantity too small)
Difference between set air quantity and actual fresh
27 DFC_AirCtlGovDvtEOMMin intake air quantity lower than lower limit value in P0101(0101)
regeneration mode (fresh intake air quantity too large)
Difference between set air quantity and actual fresh
28 DFC_AirCtlGovDvtMax intake air quantity higher than upper limit value (fresh P0402(0402)
intake air quantity too small)
Difference between set air quantity and actual fresh
29 DFC_AirCtlGovDvtMin intake air quantity lower than lower limit value (fresh P0401(0401)
intake air quantity too large)
Excessively long time for exhaust gas recirculation
30 DFC_AirCtlRmpTOut (EGR) control to switch from regeneration state to P04D8(04D8)
normal state
Excessively long time for air system to enter
31 DFC_AirCtlTimeToClsLop P04D8(04D8)
closed-loop control
Scale deposition in EGR line causing decrease in
32 DFC_AirMonEGRRed P0403(0403)
recirculated exhaust gas quantity
Unreasonable signal fault of accelerator pedal and
33 DFC_APPPlausBrk P2299(2299)
brake pedal
34 DFC_BattUSRCMax ECU internal battery voltage signal too high P0563(0563)
35 DFC_BattUSRCMin ECU internal battery voltage signal too low P0562(0562)
36 DFC_BrkMaiStuckErr Main brake pedal signal failure P0571(0571)
Brake signal not reliable, and main brake signal and
37 DFC_BrkPlausChk P0504(0504)
auxiliary brake signal not changing simultaneously
38 DFC_BrkRdntStuckErr Auxiliary brake pedal signal failure P0703(0703)
39 DFC_BusDiagBusOffErrPasNodeA Passive fault of CAN A U0073(C073)
40 DFC_BusDiagBusOffErrPasNodeC Passive fault of CAN C U0046(C046)
41 DFC_BusDiagBusOffNodeA CAN A communication interrupted U0073(C073)
42 DFC_BusDiagBusOffNodeC CAN C communication interrupted U0046(C046)
43 DFC_CAClgEta Low efficiency of turbocharged intercooler P026A(026A)
Rationality detection fault of water temperature
44 DFC_CEngDsTAbsTst sensor absolute value (water temperature not reaching P0116(0116)
threshold value within a certain time)
Rationality detection fault of water temperature
45 DFC_CEngDsTDynTst sensor dynamic value (water temperature rise not P0116(0116)
reaching threshold value within a certain time)
46 DFC_CEngDsTPhysRngHi Engine water temperature higher than upper limit P0115(0115)
47 DFC_CEngDsTPhysRngLo Engine water temperature lower than lower limit P0115(0115)
Water temperature sensor voltage higher than upper
48 DFC_CEngDsTSRCMax P0118(0118)
limit value
Water temperature sensor voltage lower than lower
49 DFC_CEngDsTSRCMin P0117(0117)
limit value
50 DFC_ClthNpl Plausibility check for Clutch P0704(0704)
51 DFC_ClthSig Clutch signal failure (CAN signal error) U1400(D400)

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Error in CAN signal frame length of upstream NOx

52 DFC_ComAT1IG1DLC U0113(C113)
sensor
Upstream NOx sensor CAN signal reception timeout
53 DFC_ComAT1IG1TO U0113(C113)
(i.e. signal loss)
Error in CAN signal frame length of downstream NOx
54 DFC_ComAT1OG1DLC U0113(C113)
sensor
Downstream NOx sensor CAN signal reception timeout
55 DFC_ComAT1OG1TO U0113(C113)
(i.e. signal loss)
CAN communication between ECU and NOx sensor
56 DFC_ComEEC3TO U0100(C100)
interrupted
57 DFC_ComFLS01DLC 00 Y
58 DFC_ComFLS01TO 00 Y
59 DFC_ComICM2DLC 00 Y
60 DFC_ComICM2TO 00 Y
61 DFC_ComNOX1DLC 00 Y
62 DFC_ComNOX1TO 00 Y
63 DFC_ComNOX2DLC 00 Y
64 DFC_ComNOX2TO 00 Y
NOxNoCat2Ds CAN information content beyond the
65 DFC_ComNOxNoCat2DsSAE U0113(C113)
reasonable range specified by SAE
NOxNoMCatDs CAN information content beyond the
66 DFC_ComNOxNoMCatDsSAE U0113(C113)
reasonable range specified by SAE
O2NoCat2Ds CAN information content beyond the
67 DFC_ComO2NoCat2DsSAE U0113(C113)
reasonable range specified by SAE
O2NoMCatDs CAN information content beyond the
68 DFC_ComO2NoMCatDsSAE U0113(C113)
reasonable range specified by SAE
SensNOxNoMCatDs CAN information content beyond
69 DFC_ComSensNOxNoMCatDsSAE U0113(C113)
the reasonable range specified by SAE
SensNOxStabNoCat2Ds CAN information content
70 DFC_ComSensNOxStabNoCat2DsSAE U0113(C113)
beyond the reasonable range specified by SAE
SensO2NoMCatDs CAN information content beyond
71 DFC_ComSensO2NoMCatDsSAE U0113(C113)
the reasonable range specified by SAE
SensO2StabNoCat2Ds CAN information content
72 DFC_ComSensO2StabNoCat2DsSAE U0113(C113)
beyond the reasonable range specified by SAE
SensPwrNoMCatDs CAN information content beyond
73 DFC_ComSensPwrNoMCatDsSAE U0113(C113)
the reasonable range specified by SAE
SensPwrRngNoCat2Ds CAN information content
74 DFC_ComSensPwrRngNoCat2DsSAE U0113(C113)
beyond the reasonable range specified by SAE
SensTempNoCat2Ds CAN information content beyond
75 DFC_ComSensTempNoCat2DsSAE U0113(C113)
the reasonable range specified by SAE
SensTempNoMCatDs CAN information content beyond
76 DFC_ComSensTempNoMCatDsSAE U0113(C113)
the reasonable range specified by SAE
Communication between ECU and CAN instrument
77 DFC_ComTI1TO U1103(D103)
disconnected
78 DFC_CoVehPrfmLim0 Whole vehicle performance limit 0 activated P110A(110A)
79 DFC_CoVehPrfmLim1 Whole vehicle performance limit 1 activated P110B(110B)

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80 DFC_CoVehPrfmLim2 Whole vehicle performance limit 2 activated P110C(110C)

81 DFC_CoVehPrfmLim3 Whole vehicle performance limit 3 activated P110D(110D)
82 DFC_CoVehPrfmLimAct Vehicle performance limit function activated P110E(110E)
83 DFC_CrCLmpSetOL Cruise indicator driver circuit open P1680(1680)
84 DFC_CrCLmpSetOvrTemp Cruise indicator driver chip in ECU overheated P1681(1681)
85 DFC_CrCLmpSetSCB Cruise indicator driver circuit short-circuited to power P1682(1682)
86 DFC_CrCLmpSetSCG Cruise indicator driver circuit short-circuited to ground P1683(1683)
87 DFC_CrCsVDiscIntMnf Pipe between crankcase and intake manifold falling off P04DB(04DB)
88 DFC_CrCUIModeNpl Cruise control key signal unreasonable P0575(0575)
Temperature diagnosis (thermal management system)
89 DFC_CtT P07CB(07CB)
failure
90 DFC_Cy327SpiCom Communication failure of internal chip Cy327 of ECU P0607(0607)
High battery voltage causing related components to
91 DFC_DevLibBattUHi P0563(0563)
stop working
Low battery voltage causing related components to
92 DFC_DevLibBattULo P0562(0562)
stop working
93 DFC_ECBVlvOL EGR cooling bypass valve actuator circuit open P00E3(00E3)
94 DFC_ECBVlvOvrTemp EGR cooling bypass valve driver chip in ECU overheated P00E3(00E3)
EGR cooling bypass valve drive circuit short-circuited to
95 DFC_ECBVlvSCB P00E3(00E3)
power supply
EGR cooling bypass valve drive circuit short-circuited to
96 DFC_ECBVlvSCG P00E3(00E3)
ground
97 DFC_EEPEraseErr Erase fault of memory unit EEPROM area in ECU P062F(062F)
98 DFC_EEPRdErr Reading fault of memory unit EEPROM area in ECU P062F(062F)
99 DFC_EEPWrErr Writing fault of EEPROM area of memory unit in ECU P062F(062F)
100 DFC_EGRClgMonEta Low cooling efficiency of EGR cooler P2457(2457)
101 DFC_EGRClgMonVlv EGR cooling bypass valve stuck P245A(245A)
102 DFC_EGRVlvCurrLim Operating current of EGR valve limited P0403(0403)
Self-learning value of EGR valve at fully closed position
103 DFC_EGRVlvDrftClsd P0404(0404)
exceeding limit
Self-learning value of EGR valve at full open position
104 DFC_EGRVlvDrftOpn P0404(0404)
exceeding mechanical point of valve
Self-learning value of EGR valve at mechanical closing
105 DFC_EGRVlvDrftRng P0404(0404)
position deviating beyond mechanical point of valve
EGR valve control deviation exceeding limit (due to low
106 DFC_EGRVlvGovDvtCld P0404(0404)
temperature during cold start)
Difference between set value of EGR valve opening and
107 DFC_EGRVlvGovDvtMax actual value higher than upper limit value (positive P0401(0401)
deviation too large)
Difference between set value of EGR valve opening and
108 DFC_EGRVlvGovDvtMin actual value lower than lower limit value (negative P0402(0402)
deviation too large)
109 DFC_EGRVlvHBrgOpnLd EGR H-bridge drive circuit open P213A(213A)
110 DFC_EGRVlvHBrgOvrCurr Excessive drive current of EGR H-bridge P213A(213A)

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111 DFC_EGRVlvHBrgOvrTemp EGR H-bridge driver chip in ECU overheated P213A(213A)

EGR H-bridge drive circuit high end short-circuited to
112 DFC_EGRVlvHBrgShCirBatt1 P2142(2142)
power supply
EGR H-bridge drive circuit low end short-circuited to
113 DFC_EGRVlvHBrgShCirBatt2 P213D(213D)
power supply
EGR H-bridge drive circuit high end short-circuited to
114 DFC_EGRVlvHBrgShCirGnd1 P2141(2141)
ground
EGR H-bridge drive circuit low end short-circuited to
115 DFC_EGRVlvHBrgShCirGnd2 P213C(213C)
ground
116 DFC_EGRVlvHBrgShCirOvrLd Excessive drive current of EGR H-bridge P213A(213A)
117 DFC_EGRVlvHBrgTempOvrCurr EGR H-bridge driver chip in ECU overheated P213A(213A)
118 DFC_EGRVlvHBrgUndrVltg EGR H-bridge drive circuit voltage too low P213A(213A)
119 DFC_EGRVlvJamVlvClsd EGR valve stuck closed P042F(042F)
120 DFC_EGRVlvJamVlvOpn EGR valve stuck open P042E(042E)
Self-learning value of EGR valve at fully closed position
121 DFC_EGRVlvLonTimeDrftClsd deviating too much from the value of the first time in P0404(0404)
this round in the self-learning process
Self-learning value of EGR valve at fully open position
122 DFC_EGRVlvLonTimeDrftOpn deviating too much from the value of the first time in P0404(0404)
this round in the self-learning process
EGR valve position sensor physical value higher than
123 DFC_EGRVlvPhysSRCMax P0409(0409)
upper limit
EGR valve position sensor physical value lower than
124 DFC_EGRVlvPhysSRCMin P0409(0409)
lower limit
Value of EGR valve at fully closed position deviating
125 DFC_EGRVlvShrtTimeDrftClsd over the limit in a short time in the self-learning P0404(0404)
process
Value of EGR valve at fully open position deviating over
126 DFC_EGRVlvShrtTimeDrftOpn P0404(0404)
the limit in a short time in the self-learning process
127 DFC_EGRVlvSprgBrk EGR valve spring failure P0403(0403)
EGR valve position sensor voltage higher than upper
128 DFC_EGRVlvSRCMax P0406(0406)
limit value
EGR valve position sensor voltage lower than lower
129 DFC_EGRVlvSRCMin P0405(0405)
limit value
130 DFC_EGRVlvTmpErr Poor contact of EGR valve drive circuit P0403(0403)
131 DFC_EngICO Injection cut-off request indication P1008(1008)
132 DFC_EngPrtOvrSpd Engine overspeed indication P0219(0219)
133 DFC_EngSpdOL Speed output drive open circuit P0725(0725)
134 DFC_EngSpdOvrTemp Speed output driver chip in ECU overheated P0725(0725)
135 DFC_EngSpdSCB Speed output drive short circuit to power supply P0725(0725)
136 DFC_EngSpdSCG Speed output drive short circuit to ground P0725(0725)
Exhaust temperature 1 higher than upper limit value of
137 DFC_EnhSRCMaxT1ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 2 higher than upper limit value of
138 DFC_EnhSRCMaxT2ExhTMon P2031(2031)
physical reasonable range
139 DFC_EnhSRCMaxT3ExhTMon Exhaust temperature 3 higher than upper limit value of P2031(2031)

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physical reasonable range

Exhaust temperature 4 higher than upper limit value of
140 DFC_EnhSRCMaxT4ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 5 higher than upper limit value of
141 DFC_EnhSRCMaxT5ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 6 higher than upper limit value of
142 DFC_EnhSRCMaxT6ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 1 lower than lower limit value of
143 DFC_EnhSRCMinT1ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 2 lower than lower limit value of
144 DFC_EnhSRCMinT2ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 3 lower than lower limit value of
145 DFC_EnhSRCMinT3ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 4 lower than lower limit value of
146 DFC_EnhSRCMinT4ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 5 lower than lower limit value of
147 DFC_EnhSRCMinT5ExhTMon P2031(2031)
physical reasonable range
Exhaust temperature 6 lower than lower limit value of
148 DFC_EnhSRCMinT6ExhTMon P2031(2031)
physical reasonable range
Ambient temperature sensor voltage signal is above
149 DFC_EnvTSRCMax P0073(0073)
the upper limit
Ambient temperature sensor voltage signal is below
150 DFC_EnvTSRCMin P0072(0072)
the lower limit
151 DFC_EpmCaSI1ErrSig Interference or loss of camshaft signal P0341(0341)
152 DFC_EpmCaSI1NoSig Camshaft signal not detected P0340(0340)
Excessive deviation between camshaft signal and
153 DFC_EpmCaSI1OfsErr P0340(0340)
crankshaft signal
154 DFC_EpmCrSErrSig Interference or loss of crankshaft signal P0336(0336)
155 DFC_EpmCrSNoSig No crankshaft signal detected P0335(0335)
Power-on time of injector of cylinder 1 in ignition
156 DFC_ETClbETFltMax_0 sequence higher than upper limit value (when ZFC P020A(020A)
function active)
Power-on time of injector of cylinder 2 in ignition
157 DFC_ETClbETFltMax_1 sequence higher than upper limit value (when ZFC P020C(020C)
function active)
Power-on time of injector of cylinder 3 in ignition
158 DFC_ETClbETFltMax_2 sequence higher than upper limit value (when ZFC P020D(020D)
function active)
Power-on time of injector of cylinder 4 in ignition
159 DFC_ETClbETFltMax_3 sequence higher than upper limit value (when ZFC P020B(020B)
function active)
Power-on time of injector of cylinder 1 in ignition
160 DFC_ETClbETFltMin_0 sequence lower than lower limit value (when ZFC P020A(020A)
function active)
Power-on time of injector of cylinder 2 in ignition
161 DFC_ETClbETFltMin_1 sequence lower than lower limit value (when ZFC P020C(020C)
function active)

162 DFC_ETClbETFltMin_2 Power-on time of injector of cylinder 3 in ignition P020D(020D)

sequence lower than lower limit value (when ZFC

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function active)
Power-on time of injector of cylinder 4 in ignition
163 DFC_ETClbETFltMin_3 sequence lower than lower limit value (when ZFC P020B(020B)
function active)
Small closed-loop control deviation of exhaust
164 DFC_ETCtlInrLopCtVMax temperature higher than upper limit value (low P20CB(20CB)
exhaust temperature)
Small closed-loop control deviation of exhaust
165 DFC_ETCtlInrLopCtVMin temperature lower than lower limit value (high exhaust P20CB(20CB)
temperature)
Fault of too long reaction time in internal control cycle
166 DFC_ETCtlInrLopRpT P24C2(24C2)
of exhaust temperature
Large closed-loop control deviation of exhaust
167 DFC_ETCtlOutrLopCtVMax temperature higher than upper limit value (low P24C2(24C2)
exhaust temperature)
Large closed-loop control deviation of exhaust
168 DFC_ETCtlOutrLopCtVMin temperature lower than lower limit value (high exhaust P24C2(24C2)
temperature)
Fault of too long reaction time in external control cycle
169 DFC_ETCtlOutrLopRpT P24C2(24C2)
of exhaust temperature
170 DFC_ExhFlpLmpOL Exhaust brake lamp drive circuit open P1502(1502)
171 DFC_ExhFlpLmpOT Exhaust brake lamp driver chip in ECU overheated P1503(1503)
Exhaust brake lamp drive circuit short-circuited to
172 DFC_ExhFlpLmpSCB P1504(1504)
power supply
Exhaust brake lamp drive circuit short-circuited to
173 DFC_ExhFlpLmpSCG P1505(1505)
ground
174 DFC_ExhFlpRlyOL Exhaust brake control relay drive circuit open P04D4(04D4)
Exhaust brake control relay driver chip in ECU
175 DFC_ExhFlpRlyOT P04D4(04D4)
overheated
Exhaust brake control relay drive circuit short-circuited
176 DFC_ExhFlpRlySCB P04D4(04D4)
to power supply
Exhaust brake control relay drive circuit short-circuited
177 DFC_ExhFlpRlySCG P04D4(04D4)
to ground
Signal of exhaust temperature sensor unreliable at low
178 DFC_ExhTMonPlaus_0 P0544(0544)
temperature (combination 1)
Signal of exhaust temperature sensor unreliable at low
179 DFC_ExhTMonPlaus_1 P2031(2031)
temperature (combination 2)
Signal of exhaust temperature sensor unreliable at low
180 DFC_ExhTMonPlaus_2 P242A(242A)
temperature (combination 3)
Signal of exhaust temperature sensor unreliable at low
181 DFC_ExhTMonPlaus_3 P246E(246E)
temperature (combination 4)
Signal of exhaust temperature sensor unreliable at low
182 DFC_ExhTMonPlaus_4 P2480(2480)
temperature (combination 5)
Signal of exhaust temperature sensor unreliable at low
183 DFC_ExhTMonPlaus_5 P1410(1410)
temperature (combination 6)
Exhaust temperature signal unreliable at low
184 DFC_ExhTMonPlausGen P1411(1411)
temperature
Measured value of exhaust temperature 1 not reliable
185 DFC_ExhTMonPlausPos1 P0544(0544)
compared with the simulated value

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Measured value of exhaust temperature 2 not reliable

186 DFC_ExhTMonPlausPos2 P2031(2031)
compared with the simulated value
Measured value of exhaust temperature 3 not reliable
187 DFC_ExhTMonPlausPos3 P242A(242A)
compared with the simulated value
Measured value of exhaust temperature 4 not reliable
188 DFC_ExhTMonPlausPos4 P246E(246E)
compared with the simulated value
Measured value of exhaust temperature 5 not reliable
189 DFC_ExhTMonPlausPos5 P2480(2480)
compared with the simulated value
Measured value of exhaust temperature 6 not reliable
190 DFC_ExhTMonPlausPos6 P1412(1412)
compared with the simulated value
191 DFC_FanDIOOL_0 Switch-type low-speed fan control circuit open P0480(0480)
192 DFC_FanDIOOL_1 Switch-type high-speed fan control circuit open P0480(0480)
Switch-type low-speed fan control driver chip in ECU
193 DFC_FanDIOOvrTemp_0 P0480(0480)
overheated
Switch-type high-speed fan control driver chip in ECU
194 DFC_FanDIOOvrTemp_1 P0480(0480)
overheated
Switch-type low-speed fan control circuit
195 DFC_FanDIOSCB_0 P0692(0692)
short-circuited to power supply
Switch-type high-speed fan control circuit
196 DFC_FanDIOSCB_1 P0694(0694)
short-circuited to power supply
Switch-type low-speed fan control circuit
197 DFC_FanDIOSCG_0 P0691(0691)
short-circuited to ground
Switch-type high-speed fan control circuit
198 DFC_FanDIOSCG_1 P0693(0693)
short-circuited to ground
Oil quantity correction (FBC) of cylinder 1 in ignition
199 DFC_FBCMon_0 P0611(0611)
sequence exceeding limit
Oil quantity correction (FBC) of cylinder 2 in ignition
200 DFC_FBCMon_1 P0611(0611)
sequence exceeding limit
Oil quantity correction (FBC) of cylinder 3 in ignition
201 DFC_FBCMon_2 P0611(0611)
sequence exceeding limit
Oil quantity correction (FBC) of cylinder 4 in ignition
202 DFC_FBCMon_3 P0611(0611)
sequence exceeding limit
203 DFC_FlCDsplOL Fuel consumption rate display drive circuit open P0001(0001)
Fuel consumption rate display driver chip in ECU
204 DFC_FlCDsplOT P0001(0001)
overheated
Fuel consumption rate display drive circuit
205 DFC_FlCDsplSCB P0001(0001)
short-circuited to power supply
Fuel consumption rate display drive circuit
206 DFC_FlCDsplSCG P0001(0001)
short-circuited to ground
207 DFC_FlFltHtOL Fuel filter heater drive circuit open P2687(2687)
208 DFC_FlFltHtOvrTemp ECU fuel filter heater driver chip overheated P2687(2687)
Fuel filter heater drive circuit short-circuited to power
209 DFC_FlFltHtSCB P2687(2687)
supply
210 DFC_FlFltHtSCG Fuel filter heater drive circuit short-circuited to ground P2687(2687)
211 DFC_FlLvlSig Malfunction of fuel level signal from CAN bus P0656(0656)
212 DFC_FlLvlSRCMax Fuel level sensor voltage signal higher than upper limit P0460(0460)

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213 DFC_FlLvlSRCMin Fuel level sensor voltage signal lower than lower limit P0460(0460)
214 DFC_FlSysTnkLo Low fuel level P0460(0460)
215 DFC_FlWLmpOL Oil-water separation indicator drive circuit open P226A(226A)
Oil-water separation indicator driver chip in ECU
216 DFC_FlWLmpOvrTemp P226A(226A)
overheated
Oil-water separation indicator drive circuit
217 DFC_FlWLmpSCB P226A(226A)
short-circuited to power supply
Oil-water separation indicator drive circuit
218 DFC_FlWLmpSCG P226A(226A)
short-circuited to ground
Self-check failure of oil-water separation sensor
219 DFC_FlWLvlSensDefSig P2264(2264)
(sensor damage)
220 DFC_FlWLvlSig Oil-bearing fault P2269(2269)
Temperature measured by fuel temperature sensor
221 DFC_FuelTPhysRngHi P0180(0180)
higher than upper limit
Temperature measured by fuel temperature sensor
222 DFC_FuelTPhysRngLo P0180(0180)
lower than lower limit
Fuel temperature sensor voltage signal higher than
223 DFC_FuelTSRCMax P0183(0183)
upper limit
Fuel temperature sensor voltage signal is below the
224 DFC_FuelTSRCMin P0182(0182)
lower limit
225 DFC_FuelTVDPlaus Fuel temperature sensor signal is not reliable P0181(0181)
226 DFC_GbxNPosNPL GNS signal not reliable P084F(084F)
227 DFC_GbxNPosSig Transmission signal failure from CAN bus U1402(D402)
228 DFC_GlwLmpOL Preheating indicator driver circuit open P0381(0381)
229 DFC_GlwLmpOvrTemp Preheating indicator driver chip in ECU overheated P0381(0381)
Preheating indicator driver circuit short-circuited to
230 DFC_GlwLmpSCB P0381(0381)
power supply
Preheating indicator driver circuit short-circuited to
231 DFC_GlwLmpSCG P0381(0381)
ground
Glow plug controller (GCU) decoding failure: decoding
232 DFC_GlwPlg2of3 P064C(064C)
mismatch
Glow plug controller (GCU) decoding failure: data
233 DFC_GlwPlgDiagErr P064C(064C)
transmission failure
Glow plug controller (GCU) decoding failure: different
234 DFC_GlwPlgDiff P064C(064C)
decodes received in one decoding cycle
235 DFC_GlwPlgGCU4ComErr Glow plug control unit (VCI) CAN frame error P064C(064C)
236 DFC_GlwPlgGCU4CPUV GCU charger pump voltage too low P064C(064C)
Glow plug in cylinder 1 of ignition sequence
237 DFC_GlwPlgGCU4MOSFETErr_0 P0671(0671)
short-circuited to high level
Glow plug in cylinder 2 of ignition sequence
238 DFC_GlwPlgGCU4MOSFETErr_1 P0673(0673)
short-circuited to high level
Glow plug in cylinder 3 of ignition sequence
239 DFC_GlwPlgGCU4MOSFETErr_2 P0674(0674)
short-circuited to high level
Glow plug in cylinder 4 of ignition sequence
240 DFC_GlwPlgGCU4MOSFETErr_3 P0672(0672)
short-circuited to high level
241 DFC_GlwPlgGCU4OL_0 Open circuit of glow plug of cylinder 1 in ignition P0671(0671)

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sequence
Open circuit of glow plug of cylinder 2 in ignition
242 DFC_GlwPlgGCU4OL_1 P0673(0673)
sequence
Open circuit of glow plug of cylinder 3 in ignition
243 DFC_GlwPlgGCU4OL_2 P0674(0674)
sequence
Open circuit of glow plug of cylinder 4 in ignition
244 DFC_GlwPlgGCU4OL_3 P0672(0672)
sequence
245 DFC_GlwPlgGCU4OT Glow plug control driver chip in ECU overheated P064C(064C)
Excessive current of glow plug of cylinder 1 in ignition
246 DFC_GlwPlgGCU4OvrLd_0 P0671(0671)
sequence
Excessive current of glow plug of cylinder 2 in ignition
247 DFC_GlwPlgGCU4OvrLd_1 P0673(0673)
sequence
Excessive current of glow plug of cylinder 3 in ignition
248 DFC_GlwPlgGCU4OvrLd_2 P0674(0674)
sequence
Excessive current of glow plug of cylinder 4 in ignition
249 DFC_GlwPlgGCU4OvrLd_3 P0672(0672)
sequence
250 DFC_GlwPlgGCU4OvrVltg GCU high voltage fault P064C(064C)
251 DFC_GlwPlgGCU4PRFlgErr Error in PRflag of GCU P064C(064C)
Glow plug in cylinder 1 of ignition sequence
252 DFC_GlwPlgGCU4ShrtCir_0 P0671(0671)
short-circuited to low level
Glow plug in cylinder 2 of ignition sequence
253 DFC_GlwPlgGCU4ShrtCir_1 P0673(0673)
short-circuited to low level
Glow plug in cylinder 3 of ignition sequence
254 DFC_GlwPlgGCU4ShrtCir_2 P0674(0674)
short-circuited to low level
Glow plug in cylinder 4 of ignition sequence
255 DFC_GlwPlgGCU4ShrtCir_3 P0672(0672)
short-circuited to low level
GCU-T T30 signal loss fault: No electrical signal at T30
256 DFC_GlwPlgGCU4T30Miss P064C(064C)
when GCU activated
257 DFC_GlwPlgGCU4Var GCU variable information failure P064C(064C)
GCU-R fault: Relay fault/glow plug fault/short circuit or
258 DFC_GlwPlgGCURErr1 P064C(064C)
overload
259 DFC_GlwPlgGCURErr2 GCU-R fault: Relay stuck/short circuit or overload P064C(064C)
260 DFC_GlwPlgLVSOL Open circuit of glow plug low pressure system P0380(0380)
Glow plug low-voltage system driver chip in ECU
261 DFC_GlwPlgLVSOvrTemp P0380(0380)
overheated
Glow plug low-voltage system short-circuited to power
262 DFC_GlwPlgLVSSCB P0380(0380)
supply
Glow plug low-voltage system short-circuited to
263 DFC_GlwPlgLVSSCG P0380(0380)
ground
264 DFC_GlwPlgOL Open circuit of glow plug control drive circuit P0380(0380)
265 DFC_GlwPlgOvrTemp Glow plug control driver chip in ECU overheated P0380(0380)
Glow plug of cylinder 1 in ignition sequence driven by
266 DFC_GlwPlgPLUGErr_0 P0671(0671)
glow plug controller (GCU-T) fails
Glow plug of cylinder 2 in ignition sequence driven by
267 DFC_GlwPlgPLUGErr_1 P0673(0673)
glow plug controller (GCU-T) fails
268 DFC_GlwPlgPLUGErr_2 Glow plug of cylinder 3 in ignition sequence driven by P0674(0674)

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glow plug controller (GCU-T) fails

Glow plug of cylinder 4 in ignition sequence driven by
269 DFC_GlwPlgPLUGErr_3 P0672(0672)
glow plug controller (GCU-T) fails
Short circuit of glow plug of cylinder 1 in ignition
270 DFC_GlwPlgPLUGSC_0 P0671(0671)
sequence driven by glow plug controller (GCU-T)
Short circuit of glow plug of cylinder 2 in ignition
271 DFC_GlwPlgPLUGSC_1 P0673(0673)
sequence driven by glow plug controller (GCU-T)
Short circuit of glow plug of cylinder 3 in ignition
272 DFC_GlwPlgPLUGSC_2 P0674(0674)
sequence driven by glow plug controller (GCU-T)
Short circuit of glow plug of cylinder 4 in ignition
273 DFC_GlwPlgPLUGSC_3 P0672(0672)
sequence driven by glow plug controller (GCU-T)
274 DFC_GlwPlgSCB Glow plug driver circuit short-circuited to power supply P0380(0380)
275 DFC_GlwPlgSCG Glow plug drive circuit short-circuited to ground P0380(0380)
GCU-T T30 signal loss fault: No electrical signal at T30
276 DFC_GlwPlgT30Miss P064C(064C)
when GCU activated
277 DFC_GlwPlgUnErr GCU-T preheating module failure P064C(064C)
NOx1 sensor enters heating mode after diagnosis
278 DFC_HegnHtrAvlB1S1 P2205(2205)
release, but fails within a specific heating time
NOx2 sensor enters heating mode after the diagnosis
279 DFC_HegnHtrAvlB1S2 P22A3(22A3)
released, but fails within a specific heating time
NOx1 sensor enters heating mode after diagnosis
280 DFC_HegnHtrRdnB1S1 P2205(2205)
release, but fails within a specific heating time
NOx2 sensor enters heating mode after the diagnosis
281 DFC_HegnHtrRdnB1S2 P22A3(22A3)
released, but fails within a specific heating time
282 DFC_HegnNoxAvlDiagB1S1 Availability of Nox sensor 1 signal P2200(2200)
283 DFC_HegnNoxAvlDiagB1S2 Availability of Nox sensor 2 signal P229E(229E)
When the fault occurs, the dynamic response of Nox
284 DFC_HegnNoxDynChkHighB1S1 P2200(2200)
sensor signal will be enhanced
When the fault occurs, the dynamic response of Nox
285 DFC_HegnNoxDynChkLowB1S1 P2200(2200)
sensor signal will be weaken
286 DFC_HegnNoxOffsMaxB1S1 Nox1 sensor signal deviation exceeding the upper limit P2200(2200)
287 DFC_HegnNoxOffsMaxB1S2 Nox2 sensor signal deviation exceeding the upper limit P229E(229E)
288 DFC_HegnNoxOffsMinB1S1 Nox1 sensor signal deviation exceeding the lower limit P2200(2200)
289 DFC_HegnNoxOffsMinB1S2 Nox2 sensor signal deviation exceeding the lower limit P229E(229E)
290 DFC_HegnNoxOffsUshtB1S1 Signal undershoot of Nox sensor before catalyst P225D(225D)
291 DFC_HegnNoxOffsUshtB1S2 Signal undershoot of Nox sensor after catalyst P225F(225F)
292 DFC_HegnNOxSRCMaxB1S1 No relevant Chinese description P2200(2200)
293 DFC_HegnNOxSRCMaxB1S2 No relevant Chinese description P229E(229E)
294 DFC_HegnNOxSRCMinB1S1 No relevant Chinese description P2200(2200)
295 DFC_HegnNOxSRCMinB1S2 No relevant Chinese description P229E(229E)
296 DFC_HegnO2PlausFullLoadB1S1 Oxygen sensor signal distortion at full load P014D(014D)
297 DFC_HegnO2PlausFullLoadB1S2 Oxygen sensor signal distortion at full load P013B(013B)
298 DFC_HegnO2PlausOvrRunB1S1 Oxygen sensor signal distortion during OverRun P014D(014D)
299 DFC_HegnO2PlausOvrRunB1S2 Oxygen sensor signal distortion during OverRun P013B(013B)

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300 DFC_HegnO2PlausPartLoadB1S1 Oxygen sensor 1 signal distortion at partial load P014D(014D)

301 DFC_HegnO2PlausPartLoadB1S2 Oxygen sensor 2 signal distortion at partial load P013B(013B)
302 DFC_HegnOpCirB1S1 No relevant Chinese description P2200(2200)
303 DFC_HegnOpCirB1S2 No relevant Chinese description P229E(229E)
Error in self-diagnosis detection of NOx1 sensor:
304 DFC_HegnSelfDiagAbrtB1S1 P06EA(06EA)
sensor stopped
Error in self-diagnosis detection of NOx2 sensor:
305 DFC_HegnSelfDiagAbrtB1S2 P06EB(06EB)
sensor stopped
Error in self-diagnosis detection of NOx1 sensor:
306 DFC_HegnSelfDiagB1S1 P06EA(06EA)
corrected average value exceeding limit
Error in self-diagnosis detection of NOx2 sensor:
307 DFC_HegnSelfDiagB1S2 P06EB(06EB)
corrected average value exceeding limit
Error in self-diagnosis detection of NOx1 sensor: signal
308 DFC_HegnSelfDiagTimeoutB1S1 P06EA(06EA)
timeout (invalid)
Error in self-diagnosis detection of NOx2 sensor: signal
309 DFC_HegnSelfDiagTimeoutB1S2 P06EB(06EB)
timeout (invalid)
310 DFC_HegnShCirB1S1 No relevant Chinese description P2200(2200)
311 DFC_HegnShCirB1S2 No relevant Chinese description P229E(229E)
312 DFC_HegnSnsrSigRdnB1S1 Nox sensor 1 signal ready state P2208(2208)
313 DFC_HegnSnsrSigRdnB1S2 Nox sensor 2 signal ready state P22A6(22A6)
314 DFC_HegnSRCBinMaxB1S1 No relevant Chinese description P2201(2201)
315 DFC_HegnSRCBinMaxB1S2 No relevant Chinese description P2215(2215)
316 DFC_HegnSRCBinMinB1S1 No relevant Chinese description P2201(2201)
317 DFC_HegnSRCBinMinB1S2 No relevant Chinese description P2216(2216)
318 DFC_HegnSRCLinMaxB1S1 No relevant Chinese description P2201(2201)
319 DFC_HegnSRCLinMaxB1S2 No relevant Chinese description P2215(2215)
320 DFC_HegnSRCLinMinB1S1 No relevant Chinese description P2201(2201)
321 DFC_HegnSRCLinMinB1S2 No relevant Chinese description P2216(2216)
322 DFC_HegnWireDiagB1S1 No relevant Chinese description P2201(2201)
323 DFC_HegnWireDiagB1S2 No relevant Chinese description P2201(2201)
Engine speed exceeding upper limit when high and low
324 DFC_HLSDem_MonOBDMax P0507(0507)
idle speed adjustment activated
Engine speed exceeding lower limit when high and low
325 DFC_HLSDem_MonOBDMin P0506(0506)
idle speed adjustment activated
Positive deviation of rail pressure control exceeding
326 DFC_HPUnTqLimn P1085(1085)
limit
Indication of injector injection times restrained by
327 DFC_InjCrvInjLimInjVlv P1086(1086)
system
Indication of injector injection times restrained by fuel
328 DFC_InjCrvInjLimQntBal P100F(100F)
balance limit of high pressure fuel pump
Indication of injector injection times restrained by
329 DFC_InjCrvInjLimSys P1010(1010)
system
Indication of injector injection times restrained by
330 DFC_InjCrvNumInjRtmLim P1011(1011)
runtime

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Fuel injection quantity exceeds maximum control fuel

331 DFC_InjCtlMonMax P026D(026D)
quantity
Fuel injection quantity lower than minimum control
332 DFC_InjCtlMonMin P026C(026C)
fuel quantity
333 DFC_InjUnStrtPres Rail pressure cannot be established during startup P1066(1066)
334 DFC_InjUnStrtTst Engine failed to start P0A0F(0A0F)
Open circuit of injector drive circuit of cylinder 1 in
335 DFC_InjVlv_DI_NoLd_0 P0201(0201)
ignition sequence
Open circuit of injector drive circuit of cylinder 2 in
336 DFC_InjVlv_DI_NoLd_1 P0203(0203)
ignition sequence
Open circuit of injector drive circuit of cylinder 3 in
337 DFC_InjVlv_DI_NoLd_2 P0204(0204)
ignition sequence
Open circuit of injector drive circuit of cylinder 4 in
338 DFC_InjVlv_DI_NoLd_3 P0202(0202)
ignition sequence
339 DFC_InjVlv_DI_ScBnk_0 Short circuit of injection control module 0 (harness) P062D(062D)
340 DFC_InjVlv_DI_ScBnk_1 Short circuit of injection control module 1 (harness) P062E(062E)
Short circuit of injector harness of cylinder 1 in ignition
341 DFC_InjVlv_DI_ScCyl_0 sequence (short-circuited to power supply or ground at P0262(0262)
high end or low end)
Short circuit of injector harness of cylinder 2 in ignition
342 DFC_InjVlv_DI_ScCyl_1 sequence (short-circuited to power supply or ground at P0268(0268)
high end or low end)
Short circuit of injector harness of cylinder 3 in ignition
343 DFC_InjVlv_DI_ScCyl_2 sequence (short-circuited to power supply or ground at P0271(0271)
high end or low end)
Short circuit of injector harness of cylinder 4 in ignition
344 DFC_InjVlv_DI_ScCyl_3 sequence (short-circuited to power supply or ground at P0265(0265)
high end or low end)
Low end of harness of cylinder 1 in ignition sequence
345 DFC_InjVlv_DI_ScHsLs_0 P0261(0261)
short-circuited to high end
Low end of harness of cylinder 2 in ignition sequence
346 DFC_InjVlv_DI_ScHsLs_1 P0267(0267)
short-circuited to high end
Low end of harness of cylinder 3 in ignition sequence
347 DFC_InjVlv_DI_ScHsLs_2 P0270(0270)
short-circuited to high end
Low end of harness of cylinder 4 in ignition sequence
348 DFC_InjVlv_DI_ScHsLs_3 P0264(0264)
short-circuited to high end
Cylinder 1 of ignition sequence not having injector fuel
349 DFC_IVAdjDiaIVAdj_0 P062B(062B)
quantity correction (IQA) code
Cylinder 2 of ignition sequence not having injector fuel
350 DFC_IVAdjDiaIVAdj_1 P062B(062B)
quantity correction (IQA) code
Cylinder 3 of ignition sequence not having injector fuel
351 DFC_IVAdjDiaIVAdj_2 P062B(062B)
quantity correction (IQA) code
Cylinder 4 of ignition sequence not having injector fuel
352 DFC_IVAdjDiaIVAdj_3 P062B(062B)
quantity correction (IQA) code
353 DFC_LLim_EEPErr Fault indication of ECU software during reading/writing P062F(062F)
354 DFC_MaxPTOSwt PTO switch voltage signal too high P251C(251C)
Loose joint of high pressure fuel pump fuel metering
355 DFC_MeUnIntCtct P0251(0251)
unit (MeUn)

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Open circuit of fuel metering unit (MeUn) drive circuit

356 DFC_MeUnOL P0251(0251)
of high pressure fuel pump
Fuel metering unit (MeUn) driver chip in ECU
357 DFC_MeUnOT P0252(0252)
overheated
Fuel metering unit (MeUn) drive circuit short-circuited
358 DFC_MeUnSCB P0251(0251)
to power supply
Fuel metering unit (MeUn) drive circuit short-circuited
359 DFC_MeUnSCG P0251(0251)
to ground
Drive current of high pressure fuel pump fuel metering
360 DFC_MeUnSRCMax P0254(0254)
unit (MeUn) too large
Drive current of high pressure fuel pump fuel metering
361 DFC_MeUnSRCMin P0253(0253)
unit (MeUn) too small
362 DFC_MILOL MIL lamp (OBD lamp) drive circuit open P0650(0650)
363 DFC_MILOvrTemp MIL lamp (OBD lamp) driver chip in ECU overheated P0650(0650)
MIL lamp (OBD lamp) drive circuit short-circuited to
364 DFC_MILSCB P0650(0650)
power supply
MIL lamp (OBD lamp) drive circuit short-circuited to
365 DFC_MILSCG P0650(0650)
ground
366 DFC_MinPTOSwt Low voltage signal of PTO switch P251B(251B)
367 DFC_MisfDetMisfireCyl_0 Misfire of cylinder 1 in ignition sequence P0301(0301)
368 DFC_MisfDetMisfireCyl_1 Misfire of cylinder 2 in ignition sequence P0303(0303)
369 DFC_MisfDetMisfireCyl_2 Misfire of cylinder 3 in ignition sequence P0304(0304)
370 DFC_MisfDetMisfireCyl_3 Misfire of cylinder 4 in ignition sequence P0302(0302)
371 DFC_MisfDetMisfireMul Multi-cylinder misfire P0300(0300)
ECU internal software and hardware bottom layer
372 DFC_MoCADCNTP P060B(060B)
monitoring error (MoC)
ECU internal software and hardware bottom layer
373 DFC_MoCADCTst P060B(060B)
monitoring error (MoC)
ECU internal software and hardware bottom layer
374 DFC_MoCADCVltgRatio P060B(060B)
monitoring error (MoC)
ECU internal software and hardware bottom layer
375 DFC_MoCComErrCnt P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
376 DFC_MoCComSPI P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
377 DFC_MoCROMErrXPg P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
378 DFC_MoCSOPErrMMRespByte P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
379 DFC_MoCSOPErrNoChk P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
380 DFC_MoCSOPErrRespTime P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
381 DFC_MoCSOPErrSPI P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
382 DFC_MoCSOPLoLi P060C(060C)
monitoring error (MoC)

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ECU internal software and hardware bottom layer

383 DFC_MoCSOPMM P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
384 DFC_MoCSOPOSTimeOut P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
385 DFC_MoCSOPPsvTstErr P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
386 DFC_MoCSOPTimeOut P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
387 DFC_MoCSOPUpLi P060C(060C)
monitoring error (MoC)
ECU internal software and hardware bottom layer
388 DFC_MoFAPP P1012(1012)
monitoring error (MoF)
ECU internal software and hardware bottom layer
389 DFC_MoFESpd P1013(1013)
monitoring error (MoF)
ECU internal software and hardware bottom layer
390 DFC_MoFInjDatET P1014(1014)
monitoring error (MoF)
ECU internal software and hardware bottom layer
391 DFC_MoFInjDatPhi P1015(1015)
monitoring error (MoF)
ECU internal software and hardware bottom layer
392 DFC_MoFInjQnt P1016(1016)
monitoring error (MoF)
ECU internal software and hardware bottom layer
393 DFC_MoFMode1 P1017(1017)
monitoring error (MoF)
ECU internal software and hardware bottom layer
394 DFC_MoFMode2 P1018(1018)
monitoring error (MoF)
ECU internal software and hardware bottom layer
395 DFC_MoFMode3 P1019(1019)
monitoring error (MoF)
ECU internal software and hardware bottom layer
396 DFC_MoFModeEom P1090(1090)
monitoring error (MoF)
ECU internal software and hardware bottom layer
397 DFC_MoFModeTotQntBnd P1091(1091)
monitoring error (MoF)
ECU internal software and hardware bottom layer
398 DFC_MoFOvR P101A(101A)
monitoring error (MoF)
ECU internal software and hardware bottom layer
399 DFC_MoFQntCor P101B(101B)
monitoring error (MoF)
ECU internal software and hardware bottom layer
400 DFC_MoFRailP P101C(101C)
monitoring error (MoF)
ECU internal software and hardware bottom layer
401 DFC_MoFStSys P0000(0000)
monitoring error (MoF)
ECU internal software and hardware bottom layer
402 DFC_MoFTrqCmp P101D(101D)
monitoring error (MoF)
ECU internal software and hardware bottom layer
403 DFC_MonLimCurr P101E(101E)
monitoring error (Mon)
ECU internal software and hardware bottom layer
404 DFC_MonLimLead P101F(101F)
monitoring error (Mon)
ECU internal software and hardware bottom layer
405 DFC_MonLimSet P1020(1020)
monitoring error (Mon)
ECU internal software and hardware bottom layer
406 DFC_MonUMaxSupply1 P1600(1600)
monitoring error (Mon)

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ECU internal software and hardware bottom layer

407 DFC_MonUMinSupply1 P1601(1601)
monitoring error (Mon)
408 DFC_MRlyErlyOpng Failure of premature disconnection of main relay P068A(068A)
409 DFC_MRlyStk Main relay stuck P068B(068B)
Pipeline connection fault of differential pressure
410 DFC_NplHsChngPPFltDiff P244A(244A)
sensor of diesel particulate filter (DPF)
Unreliable signal of differential pressure sensor of
411 DFC_NplPresSensPPFltDiff P2452(2452)
diesel particulate filter (DPF)
412 DFC_NplPresSensPPMCatDiff 99 Y
413 DFC_NplPTOSwt Unreasonable PTO switch voltage signal P251A(251A)
414 DFC_OilTNpl Oil temperature sensor signal is not reliable P0196(0196)
415 DFC_OilTPhysRngHi Oil temperature is above the upper limit P0195(0195)
416 DFC_OilTPhysRngLo Oil temperature below lower limit P0195(0195)
Oil temperature sensor voltage signal higher than
417 DFC_OilTSRCMax P0198(0198)
upper limit
Oil temperature sensor voltage signal is below the
418 DFC_OilTSRCMin P0197(0197)
lower limit
419 DFC_OxiCatMonActvMin HC conversion efficiency lower than limit P0422(0422)
420 DFC_OxiCatMonPasMin Low efficiency of diesel oxidation catalyst (DOC) P0422(0422)
421 DFC_OxiCatMonRHU Low efficiency of diesel oxidation catalyst (DOC) P0423(0423)
Boost pressure sensor signal not reliable (compared
422 DFC_PCACDsEnvPPls P0069(0069)
with atmospheric pressure sensor)
423 DFC_PCACDsPhysRngHi Boost pressure higher than upper limit P023D(023D)
424 DFC_PCACDsPhysRngLo Boost pressure lower than lower limit P023D(023D)
Boost pressure sensor voltage signal higher than upper
425 DFC_PCACDsSRCMax P0235(0235)
limit
Boost pressure sensor voltage signal is below the lower
426 DFC_PCACDsSRCMin P0235(0235)
limit
Deviation value of boost pressure regulating controller
427 DFC_PCRGovDvtMax (boost pressure set value minus actual value) higher P2263(2263)
than upper limit (positive deviation too large)
Boost pressure control deviation exceeding the upper
428 DFC_PCRGovDvtMaxCol P2263(2263)
limit
During open-loop control of boost pressure, pressure
429 DFC_PCRGovDvtMaxNoCtl P2263(2263)
deviation exceeding upper limit
In partial load area, boost pressure control deviation
430 DFC_PCRGovDvtMaxPartLd P2263(2263)
exceeding upper limit
Deviation value of boost pressure regulating controller
431 DFC_PCRGovDvtMin (boost pressure set value minus actual value) lower P2263(2263)
than lower limit (negative deviation too large)
Boost pressure control deviation exceeding the lower
432 DFC_PCRGovDvtMinCol P2263(2263)
limit
During open-loop control of boost pressure, pressure
433 DFC_PCRGovDvtMinNoCtl P2263(2263)
deviation exceeding lower limit
In partial load area, boost pressure control deviation
434 DFC_PCRGovDvtMinPartLd P2263(2263)
exceeding lower limit

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435 DFC_PCRSlwResp Dynamic fault of turbocharger P2263(2263)

436 DFC_PCRTiToCtl PCR monitoring not reactivated within the time limit P259C(259C)
After engine started, PCR monitoring not reactivated
437 DFC_PCRTiToStrtCtl P056E(056E)
within the time limit for the first time
Learning coefficient of (rail pressure) pressure control
438 DFC_PCVfacAdaptMax P009B(009B)
valve (PCV) too high
Learning coefficient of (rail pressure) pressure control
439 DFC_PCVfacAdaptMin P009B(009B)
valve (PCV) too low
(Rail pressure) pressure control valve (PCV) drive circuit
440 DFC_PCVOL P009B(009B)
open
(Rail pressure) pressure control valve (PCV) driver chip
441 DFC_PCVOT P009B(009B)
in ECU overheated
(Rail pressure) pressure control valve (PCV) drive circuit
442 DFC_PCVSCB P009B(009B)
short-circuited to power supply
(Rail pressure) pressure control valve (PCV) drive circuit
443 DFC_PCVSCG P009B(009B)
short-circuited to ground
Drive current of (rail pressure) pressure control valve
444 DFC_PCVSRCMax P009B(009B)
(PCV) too large
Drive current of (rail pressure) pressure control valve
445 DFC_PCVSRCMin P009B(009B)
(PCV) too small
446 DFC_PEnvRngChkMax Atmospheric pressure value higher than upper limit P2226(2226)
447 DFC_PEnvRngChkMin Atmospheric pressure value lower than lower limit P2226(2226)
Atmospheric pressure sensor voltage signal higher
448 DFC_PEnvSigRngMax P2229(2229)
than upper limit
Atmosphere pressure sensor voltage signal is below
449 DFC_PEnvSigRngMin P2228(2228)
the lower limit
450 DFC_PEnvSnsrPlaus Ambient pressure sensor reliability failure P2227(2227)
451 DFC_PFltDstrMin Diesel particulate filter (DPF) removed or failed P226D(226D)
Fault indication of torque-fuel conversion MAP not
452 DFC_PhyModNonMonMapNpl P1031(1031)
monotone
453 DFC_PMCatBlk Diesel oxidation catalyst (DOC) blocking Fault P2002(2002)
454 DFC_PMCatRmv Diesel oxidation catalyst (DOC) removal fault P2002(2002)
Pressure difference between two ends of the adjusted
455 DFC_PPFltDiffEnhSRCMax diesel particulate filter (DPF) higher than upper limit P244A(244A)
value
Pressure difference between two ends of the adjusted
456 DFC_PPFltDiffEnhSRCMin diesel particulate filter (DPF) lower than upper limit P244A(244A)
value
Dynamic testing fault of differential pressure sensor of
457 DFC_PPFltDiffNplDyn P2452(2452)
diesel particulate filter (DPF)
Diesel particulate filter (DPF) differential pressure
458 DFC_PPFltDiffNplHsLn P2452(2452)
sensor Hoseline fault
Diesel particulate filter (DPF) differential pressure
459 DFC_PPFltDiffSot P2452(2452)
sensor Hoseline fault
Voltage signal of diesel particulate filter (DPF)
460 DFC_PPFltDiffSRCMax P2452(2452)
differential pressure sensor higher than upper limit
461 DFC_PPFltDiffSRCMin Voltage signal of diesel particulate filter (DPF) P2452(2452)

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differential pressure sensor lower than lower limit

Pressure difference between two ends of diesel
462 DFC_PPMCatPhysRngChkHi P2455(2455)
oxidation catalyst (DOC) higher than upper limit
Pressure difference between two ends of diesel
463 DFC_PPMCatPhysRngChkLo P2454(2454)
oxidation catalyst (DOC) lower than lower limit
Diesel oxidation catalyst (DOC) differential pressure
464 DFC_PPMCatPlaus P2453(2453)
sensor signal not reliable
Diesel oxidation catalyst (DOC) differential pressure
465 DFC_PPMCatSig U0100(C100)
sensor signal fault from CAN bus
Diesel oxidation catalyst (DOC) differential pressure
466 DFC_PPMCatSRCMax P2455(2455)
sensor voltage signal higher than upper limit
Diesel oxidation catalyst (DOC) differential pressure
467 DFC_PPMCatSRCMin P2454(2454)
sensor voltage signal lower than lower limit
468 DFC_PSPOL Pre-supply pump (PSP) drive circuit open P0627(0627)
Fuel pre-supply pump (PSP) driver chip in ECU
469 DFC_PSPOvrTemp P0627(0627)
overheated
Pre-supply pump (PSP) drive circuit short-circuited to
470 DFC_PSPSCB P0627(0627)
power supply
Pre-supply pump (PSP) drive circuit short-circuited to
471 DFC_PSPSCG P0627(0627)
ground
Exhaust pressure upstream of turbine exceeding upper
472 DFC_PTrbnUsPhysRngHi P0544(0544)
limit
Exhaust pressure upstream of turbine exceeding lower
473 DFC_PTrbnUsPhysRngLo P0544(0544)
limit
474 DFC_PTrbnUsSRCMax Turbine pressure sensor signal exceeding upper limit P0470(0470)
475 DFC_PTrbnUsSRCMin Turbine pressure sensor signal exceeding lower limit P0470(0470)
Negative deviation of rail pressure control exceeding
476 DFC_RailColl0Neg P228C(228C)
limit
Positive deviation of rail pressure control exceeding
477 DFC_RailColl0Pos P228D(228D)
limit
Negative deviation of rail pressure control exceeding
478 DFC_RailColl1Neg P229B(229B)
limit
Positive deviation of rail pressure control exceeding
479 DFC_RailColl1Pos P229A(229A)
limit
Negative deviation of rail pressure control exceeding
480 DFC_RailColl2Neg P0090(0090)
limit
Positive deviation of rail pressure control exceeding
481 DFC_RailColl2Pos P0090(0090)
limit
Unreliable set value of pressure control valve (PCV)
482 DFC_RailCPC1 P009B(009B)
during rail pressure control
Rail pressure too low during rail pressure control of
483 DFC_RailCPC3 P009B(009B)
pressure control valve (PCV)
Rail pressure too high during rail pressure control of
484 DFC_RailCPC4 P009B(009B)
pressure control valve (PCV)
During cold start, positive deviation of rail pressure
485 DFC_RailDvtMaxCSERS P053F(053F)
exceeding limit under working mode of Rapid heat up
During cold start, negative deviation of rail pressure
486 DFC_RailDvtMinCSERS P053F(053F)
exceeding limit under working mode of Rapid heat up

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Positive deviation of rail pressure exceeding limit

487 DFC_RailMeUn0 (actual rail pressure lower than set value) (MeUn P0087(0087)
scheme)
When the fuel metering unit (MeUn) fuel supply
reaches the maximum set flow rate, the positive
488 DFC_RailMeUn1 P1092(1092)
deviation of rail pressure exceeding limit value (actual
rail pressure lower than set value)
When the fuel metering unit (MeUn) fuel supply
reaches the minimum set flow rate, the negative
489 DFC_RailMeUn2 P0087(0087)
deviation of rail pressure exceeding limit value (actual
rail pressure higher than set value)
Actual rail pressure lower than minimum rail pressure
490 DFC_RailMeUn3 P0087(0087)
value (MeUn scheme)
Actual rail pressure higher than maximum rail pressure
491 DFC_RailMeUn4 P0088(0088)
(MeUn scheme)
In Overrun condition, rail pressure higher than
492 DFC_RailMeUn9 P1093(1093)
maximum limit (MeUn scheme)
493 DFC_RailMonInjRls Error in minimum rail pressure P213E(213E)
Time for entering rail pressure closed-loop control
494 DFC_RailMonTTC P015E(015E)
exceeding limit
During cold start, negative deviation of rail pressure
495 DFC_RailNegDvtCSERS P053F(053F)
exceeding limit under working mode of Rapid heat up
496 DFC_RailOverPresAlrm Rail pressure exceeding system limit (to a lesser extent) P228D(228D)
Rail pressure exceeding system limit (to a greater
497 DFC_RailOverPresImdt P016E(016E)
extent)
Excessive rail pressure fault (system needs to be
498 DFC_RailOverPresReact P228A(228A)
started for response)
499 DFC_RailOverPresReactMaxCnt Fault times of high rail pressure exceeding limit P228A(228A)
Positive deviation of rail pressure exceeding limit value
500 DFC_RailPCV0 (actual rail pressure lower than set value) (PCV of rail P018F(018F)
pressure control valve)
Positive deviation of rail pressure control based on set
value of rail pressure control valve (PCV) exceeding
501 DFC_RailPCV1 P018F(018F)
upper limit value (actual rail pressure lower than set
value)
Rail pressure control valve (PCV) normally closed,
502 DFC_RailPCV2 causing negative deviation of rail pressure control P018F(018F)
exceeding lower limit value
Rail pressure lower than minimum allowable rail
503 DFC_RailPCV3 pressure value (PCV scheme of rail pressure control P018F(018F)
valve)
Rail pressure higher than maximum allowable rail
504 DFC_RailPCV4 pressure value (PCV scheme of rail pressure control P018F(018F)
valve)
505 DFC_RailPGradMon Rail pressure sensor signal intermittent P0194(0194)
Drift correction of rail pressure sensor exceeding upper
506 DFC_RailPOfsTstCorMax P0190(0190)
limit
Drift correction of rail pressure sensor exceeding lower
507 DFC_RailPOfsTstCorMin P0190(0190)
limit
508 DFC_RailPOfsTstMax Rail pressure sensor signal drift fault (high voltage) P0191(0191)

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509 DFC_RailPOfsTstMin Rail pressure sensor signal drift fault (low voltage) P0191(0191)
During cold start, positive deviation of rail pressure
510 DFC_RailPosDvtCSERS P053F(053F)
exceeding limit under working mode of Rapid heat up
Rail pressure sensor voltage signal higher than upper
511 DFC_RailPSRCMax P0193(0193)
limit
Rail pressure sensor voltage signal is below the lower
512 DFC_RailPSRCMin P0192(0192)
limit
Frequency of switching to CPC working mode
513 DFC_RailSwtCPCMax P018F(018F)
exceeding limit
514 DFC_RdcAgQlDetFail Poor urea solution quality P203B(203B)
515 DFC_SCRChkAdapMax Long-term correction of SCR system too large P20FE(20FE)
516 DFC_SCRChkAdapMin Long-term correction of SCR system too small P20FE(20FE)
517 DFC_SCRChkEta1 Fault of engine NOx emission exceeding 3.5g/kW.h P20EE(20EE)
518 DFC_SCRChkEta2 Fault of engine NOx emission exceeding 7.0g/kW.h P20EE(20EE)
In range 3, actual catalyst conversion efficiency lower
519 DFC_SCRChkEta3 P20EE(20EE)
than set limit
520 DFC_SCRChkEta Fault of engine NOx emission exceeding standard P20EE(20EE)
Downstream NOx sensor rationality check failure (peak
521 DFC_SCRChkNOxDsPeakErr P2214(2214)
check)
Downstream NOx sensor rationality check fault
522 DFC_SCRChkNOxDsStkErr P2214(2214)
(incremental check)
Upstream NOx sensor rationality check fault (NOx
523 DFC_SCRChkNOxUsPlausMax P2201(2201)
value high)
Upstream NOx sensor rationality check fault (NOx
524 DFC_SCRChkNOxUsPlausMin P2201(2201)
value low)
Time from start-up to release urea solution injection of
525 DFC_SCRChkTTCL P249C(249C)
SCR system too long
526 DFC_SCRFBCMon SCR system closed-loop control correction closed P3065(3065)
527 DFC_SCRMonDetModeBLPlaus Blockage of urea solution return pipe in SCR system P20A0(20A0)
Blockage of urea solution pressure pipe or urea
528 DFC_SCRMonDetModePresChk P3053(3053)
solution injection unit in SCR system
529 DFC_SCRMonDetModePresStab Excessive pressure fluctuation of SCR system P3054(3054)
530 DFC_SCRMonMetCtlOvrPresErr Excessively high pressure during SCR system injection P20FE(20FE)
531 DFC_SCRMonMetCtlUndrPresErr Excessively low pressure during SCR system injection P20FE(20FE)
532 DFC_SCRMonOvrPresErr SCR system pressure too high P20E9(20E9)
533 DFC_SCRMonPresBuildUpErr SCR system failure to build pressure P3040(3040)
534 DFC_SCRPODDnoxRlyStuckClsd DNOX relay stuck in closed position P21C7(21C7)
535 DFC_SCRPODDnoxRlyStuckOpend DNOX relay stuck in open position P21C7(21C7)
536 DFC_SCRPODFilFull Filter blockage detected P3070(3070)
537 DFC_SCRPODLeakDetnNoDos Non-injection leakage detected P3091(3091)
Physical Range Check high for Urea tank temperature
538 DFC_SCRPODMonTnkT P2043(2043)
Sensor
Upstream temperature in dynamic reliability detection
539 DFC_SCRPODPlausUCatUsTMax of upstream temperature sensor of SCR catalyst too P0426(0426)
high

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Upstream temperature in dynamic reliability detection

540 DFC_SCRPODPlausUCatUsTMin of upstream temperature sensor of SCR catalyst too P0426(0426)
low
Static reliability detection fault of upstream
541 DFC_SCRPODPlausUCatUsTStat P0426(0426)
temperature sensor of SCR catalyst
Failure of injection valve of urea solution injection unit
542 DFC_SCRPODPlausUDosVlv P2047(2047)
(sticking)
543 DFC_SCRPODPlausUDosVlvULo At low voltage, Dosing valve fails P2047(2047)
Urea solution tank level sensor failure (high measured
544 DFC_SCRPODPlausUTnkLvlHi P20F5(20F5)
value)
Urea solution tank level sensor failure (low measured
545 DFC_SCRPODPlausUTnkLvlLo P20F4(20F4)
value)
546 DFC_SCRPODPRednErr Reduced pressure failure P20A6(20A6)
547 DFC_SCRPODPSnsrPlausHi Measured value exceeding upper limit value P204A(204A)
548 DFC_SCRPODPSnsrPlausLo Measured value lower than lower limit value P204A(204A)
549 DFC_SCRPODSMHtr Fault of urea solution supply unit heater P3057(3057)
Dynamic monitoring by temperature sensor of urea
550 DFC_SCRPODSMHtrT P3058(3058)
solution supply unit heater not reliable
Cold starting by temperature sensor of urea solution
551 DFC_SCRPODSMHtrTCldStrt P20B1(20B1)
supply unit heater not reliable
Dynamic monitoring by temperature sensor of urea
552 DFC_SCRPODSMT P3060(3060)
solution supply unit not reliable
Cold starting by temperature sensor of urea solution
553 DFC_SCRPODSMTCldStrt P05EB(05EB)
supply unit not reliable
554 DFC_SCRPODTnkTempResp Urea solution tank temperature sensor not reliable P203B(203B)
555 DFC_SCRRlyOL Open circuit of external relay P21C7(21C7)
556 DFC_SCRRlyOT Overheating fault of external relay P21C7(21C7)
557 DFC_SCRRlySCB External relay short-circuited to battery P21C7(21C7)
558 DFC_SCRRlySCG External relay short-circuited to ground P21C7(21C7)
559 DFC_SiaEEPEolData Immobilizer (immo) reading fault response P0633(0633)
560 DFC_SiaRls Simple anti-theft fault (loop function) P1643(1643)
561 DFC_SigPTOSwt PTO switch CAN signal fault U0117(C117)
562 DFC_SigUPmpP Urea solution pump CAN communication error U010E(C10E)
563 DFC_SigUTnkLvl Error in urea solution tank liquid level can signal P203A(203A)
Accelerator pedal sensor 1 voltage signal higher than
564 DFC_SRCHighAPP1 P0123(0123)
upper limit value
Accelerator pedal sensor 2 voltage signal higher than
565 DFC_SRCHighAPP2 P0223(0223)
upper limit value
Accelerator pedal sensor 1 voltage signal lower than
566 DFC_SRCLowAPP1 P0122(0122)
lower limit value
Accelerator pedal sensor 2 voltage signal lower than
567 DFC_SRCLowAPP2 P0222(0222)
lower limit value
Fault diagnosis and detection of high urea solution
568 DFC_SRCMaxUPmpP P249E(249E)
injection
569 DFC_SRCMaxUTnkLvl Urea tank level sensor voltage signal is above the P203D(203D)

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upper limit
Fault diagnosis and detection of low urea solution
570 DFC_SRCMinUPmpP P249D(249D)
injection
Urea tank level sensor voltage signal is below the lower
571 DFC_SRCMinUTnkLvl P203C(203C)
limit
572 DFC_SSpMon1 Sensor power supply module 1 fault P0643(0643)
Sensor power supply module 1 voltage exceeding
573 DFC_SSpMon1OV P0643(0643)
upper limit
Sensor power supply module 1 short-circuited to
574 DFC_SSpMon1SCG P0641(0641)
ground
Sensor power supply module 1 voltage exceeding
575 DFC_SSpMon1UV P0642(0642)
lower limit
576 DFC_SSpMon2 Sensor power supply module 2 fault P0653(0653)
Sensor power supply module 2 voltage exceeding
577 DFC_SSpMon2OV P0653(0653)
upper limit
Sensor power supply module 2 short-circuited to
578 DFC_SSpMon2SCG P0651(0651)
ground
Sensor power supply module 2 voltage exceeding
579 DFC_SSpMon2UV P0652(0652)
lower limit
580 DFC_SSpMon3 Sensor power supply module 3 fault P0699(0699)
Sensor power supply module 3 voltage exceeding
581 DFC_SSpMon3OV P0699(0699)
upper limit
Sensor power supply module 3 short-circuited to
582 DFC_SSpMon3SCG P0697(0697)
ground
Sensor power supply module 3 voltage exceeding
583 DFC_SSpMon3UV P0698(0698)
lower limit
Sensor power supply module voltage exceeding upper
584 DFC_SSpMonOT P0643(0643)
limit
585 DFC_SSwtSVarMngDatasetIdErr Invalid variant data identification code P062F(062F)
586 DFC_SSwtSVarMngDatasetSwtErr Variant data switching failure P062F(062F)
587 DFC_SSwtSVarMngEEPErr EEPROM code reading failure P062F(062F)
588 DFC_StopCntTmr Engine down time timer counting failure P060C(060C)
589 DFC_StrtCoilHSSCB 00 Y
590 DFC_StrtDummy Virtual starter indication P0615(0615)
Starter relay control terminal high-end driver chip of
591 DFC_StrtHSOvrTemp P0615(0615)
ECU overheated
Starter relay control terminal high end short-circuited
592 DFC_StrtHSSCB P0615(0615)
to power supply
Starter relay control terminal high end short-circuited
593 DFC_StrtHSSCG P0615(0615)
to ground
Starter relay control terminal low-end driver chip of
594 DFC_StrtLSOvrTemp P26E4(26E4)
ECU overheated
Starter relay control terminal low end short-circuited
595 DFC_StrtLSSCB P26E4(26E4)
to power supply
Starter relay control terminal low end short-circuited
596 DFC_StrtLSSCG P26E4(26E4)
to ground

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597 DFC_StrtOL Open circuit of starter relay control terminal P0615(0615)

598 DFC_SVSOL System lamp (SVS) drive circuit open P1604(1604)
599 DFC_SVSOvrTemp System lamp (SVS) driver chip in ECU overheated P1605(1605)
System lamp (SVS) drive circuit short-circuited to
600 DFC_SVSSCB P1606(1606)
battery
System lamp (SVS) drive circuit short-circuited to
601 DFC_SVSSCG P1607(1607)
ground
602 DFC_SWReset_0 ECU_SWReset_0 P1608(1608)
603 DFC_SWReset_1 ECU_SWReset_1 P1609(1609)
604 DFC_SWReset_2 ECU_SWReset_2 P160A(160A)
Signal rationality failure of accelerator pedal 1 and
605 DFC_SyncAPP P2135(2135)
accelerator pedal 2
606 DFC_T50Err Wrong T50 switch operation P2530(2530)
Duty cycle signal of air flow meter (HFM) air
607 DFC_TAFSDtyCycHi P0113(0113)
temperature sensor higher than upper limit
Duty cycle signal of air flow meter (HFM) air
608 DFC_TAFSDtyCycLo P0112(0112)
temperature sensor lower than lower limit
Periodic signal of air flow meter (HFM) air temperature
609 DFC_TAFSPerHi P0113(0113)
sensor higher than upper limit
Periodic signal of air flow meter (HFM) air temperature
610 DFC_TAFSPerLo P0112(0112)
sensor lower than lower limit
Measured temperature of air flow meter (HFM) air
611 DFC_TAFSPhysRngHi P0100(0100)
temperature sensor lower than lower limit
Measured temperature of air flow meter (HFM) air
612 DFC_TAFSPhysRngLo P0100(0100)
temperature sensor higher than upper limit
613 DFC_TAFSVDPlaus Rationality failure of air temperature sensor P00AB(00AB)
Intake air temperature higher than upper limit after
614 DFC_TCACDsPhysRngHi P007A(007A)
turbocharging and intercooling
Intake air temperature lower than lower limit after
615 DFC_TCACDsPhysRngLo P007A(007A)
turbocharging and intercooling
The voltage signal of intake air temperature sensor
616 DFC_TCACDsSRCMax downstream to the turbocharger and intercooler is P0098(0098)
above the upper limit
The voltage signal of intake air temperature sensor
617 DFC_TCACDsSRCMin downstream to the turbocharger and intercooler is P0097(0097)
below the lower limit
618 DFC_TClntDsplOL Water temperature indicator driver circuit open P0655(0655)
Water temperature indicator driver chip in ECU
619 DFC_TClntDsplOvrTemp P0655(0655)
overheated
Water temperature indicator driver circuit
620 DFC_TClntDsplSCB P0655(0655)
short-circuited to power supply
Water temperature indicator driver circuit
621 DFC_TClntDsplSCG P0655(0655)
short-circuited to ground
622 DFC_TECUPhysRngHi Temperature value in ECU higher than upper limit P0666(0666)
623 DFC_TECUPhysRngLo Temperature value in ECU lower than lower limit P0666(0666)
624 DFC_TECUSigRngMax Voltage signal of temperature sensor in ECU higher P0669(0669)

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than upper limit

Voltage signal of temperature sensor in ECU lower than
625 DFC_TECUSigRngMin P0668(0668)
lower limit
626 DFC_TECUSnsrPlaus Reliability failure of ECU temperature sensor P0666(0666)
Temperature downstream of EGR valve cooler higher
627 DFC_TEGRClrDsPhysRngHi P24F2(24F2)
than upper limit
Temperature downstream of EGR valve cooler lower
628 DFC_TEGRClrDsPhysRngLo P24F2(24F2)
than lower limit
EGR valve cooler downstream temperature sensor
629 DFC_TEGRClrDsSRCMax P040D(040D)
voltage signal higher than upper limit
EGR valve cooler downstream temperature sensor
630 DFC_TEGRClrDsSRCMin P040C(040C)
voltage signal lower than lower limit
Rationality failure of EGR Cooler downstream
631 DFC_TEGRClrDsVDPlaus P040B(040B)
temperature sensor
632 DFC_ThrVlvCurrLim Drive current of throttle valve (TVA) limited P2100(2100)
Self-learning value of electronic throttle valve (TVA) at
633 DFC_ThrVlvDrftClsd P2108(2108)
fully closed position deviating beyond limit
Self-learning value of electronic throttle valve (TVA) at
634 DFC_ThrVlvDrftOpn P2108(2108)
fully open position deviating beyond limit
Self-learning value of electronic throttle valve (TVA) at
635 DFC_ThrVlvDrftRng P2108(2108)
mechanical closing position deviating beyond limit
Throttle valve (TVA) controller deviating during cold
636 DFC_ThrVlvGovDvtCld P2112(2112)
start
Throttle valve (TVA) controller generating permanent
637 DFC_ThrVlvGovDvtMax P2112(2112)
positive deviation
Throttle valve (TVA) controller generating permanent
638 DFC_ThrVlvGovDvtMin P2111(2111)
negative deviation
639 DFC_ThrVlvHBrgOpnLd Throttle valve (TVA) H-bridge drive open P2100(2100)
Overload of drive current of throttle valve (TVA)
640 DFC_ThrVlvHBrgOvrCurr P2100(2100)
H-bridge
Throttle valve (TVA) H-bridge driver chip in ECU
641 DFC_ThrVlvHBrgOvrTemp P2100(2100)
overheated
Throttle valve (TVA) H-bridge drive circuit high end
642 DFC_ThrVlvHBrgShCirBatt1 P2100(2100)
short-circuited to power supply
Throttle valve (TVA) H-bridge drive circuit low end
643 DFC_ThrVlvHBrgShCirBatt2 P2100(2100)
short-circuited to power supply
Throttle valve (TVA) H-bridge drive circuit high end
644 DFC_ThrVlvHBrgShCirGnd1 P2100(2100)
short-circuited to ground
Throttle valve (TVA) H-bridge drive circuit low end
645 DFC_ThrVlvHBrgShCirGnd2 P2100(2100)
short-circuited to ground
Throttle valve (TVA) H-bridge drive circuit short-circuit
646 DFC_ThrVlvHBrgShCirOvrLd P2100(2100)
overload
647 DFC_ThrVlvHBrgTempOvrCurr Throttle valve (TVA) H-bridge drive circuit overheated P2100(2100)
Low voltage of throttle valve (TVA) H-bridge drive
648 DFC_ThrVlvHBrgUndrVltg P2100(2100)
circuit
649 DFC_ThrVlvJamVlvClsd Throttle valve (TVA) stuck in closed position P2112(2112)
650 DFC_ThrVlvJamVlvOpn Throttle valve (TVA) stuck in open position P2111(2111)

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Difference between self-learning value at fully closed

651 DFC_ThrVlvLonTimeDrftClsd position of electronic throttle valve (TVA) and the first P2108(2108)
value of this round too large
Difference between self-learning value at fully open
652 DFC_ThrVlvLonTimeDrftOpn position of electronic throttle valve (TVA) and the first P2108(2108)
value of this round too large
Electronic throttle valve (TVA) signal exceeding
653 DFC_ThrVlvPhysSRCMax P2101(2101)
mechanical maximum position
Electronic throttle valve (TVA) signal exceeding
654 DFC_ThrVlvPhysSRCMin P2101(2101)
mechanical minimum position
Difference between two self-learning values at fully
655 DFC_ThrVlvShrtTimeDrftClsd closed position of electronic throttle valve (TVA) too P2108(2108)
large
Difference between two self-learning values at fully
656 DFC_ThrVlvShrtTimeDrftOpn open position of electronic throttle valve (TVA) too P2108(2108)
large
657 DFC_ThrVlvSprgBrk TVA valve spring failure P212A(212A)
Throttle valve (TVA) position feedback sensor value
658 DFC_ThrVlvSRCMax P2622(2622)
higher than upper limit value (analog signal)
Throttle valve (TVA) position feedback sensor value
659 DFC_ThrVlvSRCMin P2621(2621)
lower than lower limit value (analog signal)
660 DFC_ThrVlvTmpErr Temporary failure of throttle valve (TVA) P2620(2620)
661 DFC_Tprot_Rttp Incorrect adjustment of ESP P1744(1744)
662 DFC_TrbChOL Turbocharger drive circuit open P0045(0045)
663 DFC_TrbChOvrTemp Turbocharger driver chip in ECU overheated P0045(0045)
Turbocharger drive circuit short-circuited to power
664 DFC_TrbChSCB P0048(0048)
supply
665 DFC_TrbChSCG Turbocharger control circuit short-circuited to ground P0047(0047)
Rationality failure of turbine upstream temperature
666 DFC_TTrbnUsNpl P0544(0544)
sensor
667 DFC_TTrbnUsPhysRngHi Turbine upstream temperature exceeding lower limit P2428(2428)
668 DFC_TTrbnUsPhysRngLo Turbine upstream temperature exceeding upper limit P2428(2428)
Turbine upstream temperature sensor signal exceeding
669 DFC_TTrbnUsSRCMax P0544(0544)
upper limit
Turbine upstream temperature sensor signal exceeding
670 DFC_TTrbnUsSRCMin P0544(0544)
lower limit
Rationality failure of downstream temperature of urea
671 DFC_UCatDsTNpl P043A(043A)
solution catalyst
Temperature sensor signal voltage downstream of SCR
672 DFC_UCatDsTSRCMax P043A(043A)
catalyst too high
Temperature sensor signal voltage downstream of SCR
673 DFC_UCatDsTSRCMin P043A(043A)
catalyst too low
Rationality failure of upstream temperature of urea
674 DFC_UCatUsTNpl P0425(0425)
solution catalyst
Temperature sensor signal voltage upstream of SCR
675 DFC_UCatUsTSRCMax P0435(0435)
catalyst too high
Temperature sensor signal voltage upstream of SCR
676 DFC_UCatUsTSRCMin P0435(0435)
catalyst too low

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Physical Range Check low for Urea Tank Level Module

677 DFC_UDCRdcAgRmn P203F(203F)
Sensor
678 DFC_UDosVlvOL Failure of injection valve of urea solution injection unit P2047(2047)
Urea solution injection unit driver chip in ECU
679 DFC_UDosVlvOvrTemp P2047(2047)
overheated
680 DFC_UDosVlvSCB Urea solution injection unit short-circuited to battery P2047(2047)
Urea solution injection unit high end short-circuited to
681 DFC_UDosVlvSCBHS P2047(2047)
battery
682 DFC_UDosVlvSCG Urea solution injection unit short-circuited to ground P2047(2047)
Urea solution injection unit high end short-circuited to
683 DFC_UDosVlvSCGHS P2047(2047)
ground
When heated, SCR system stops due to failure of
684 DFC_UHCEnfShOffWiEmp P05F8(05F8)
heating parts
685 DFC_UHCMonCirc2OpenLoadErr Urea solution heating relay 2 open to ground P20B9(20B9)
Urea solution heating relay 2 short-circuited to ground
686 DFC_UHCMonCirc2ScgOrOpenLoadErr P20B9(20B9)
or open circuit
687 DFC_UHCMonCirc3OpenLoadErr Urea solution heating relay 3 open to ground P20BD(20BD)
Urea solution heating relay 3 short-circuited to ground
688 DFC_UHCMonCirc3ScgOrOpenLoadErr P20BD(20BD)
or open circuit
689 DFC_UHCMonCirc4OpenLoadErr Urea solution heating relay 4 open to ground P20C1(20C1)
Urea solution heating relay 4 short-circuited to ground
690 DFC_UHCMonCirc4ScgOrOpenLoadErr P20C1(20C1)
or open circuit
691 DFC_UHCMonCirc5OpenLoadErr Urea solution heating relay 5 open to ground P20C5(20C5)
Urea solution heating relay 5 short-circuited to ground
692 DFC_UHCMonCirc5ScgOrOpenLoadErr P20C5(20C5)
or open circuit
Urea solution heating relay short-circuited to positive
693 DFC_UHCMonScbErr P202A(202A)
pole of power supply
694 DFC_UHtrBLLoadFbPlaus Return pipe heating ADC signal conversion error P2089(2089)
Open circuit of heating relay control terminal of urea
695 DFC_UHtrBLOL P20B9(20B9)
solution return pipeline
Urea solution return pipeline heating relay control
696 DFC_UHtrBLOvrTemp P20B9(20B9)
terminal driver chip in ECU overheated
Urea solution return pipeline heating relay control
697 DFC_UHtrBLSCB P20B9(20B9)
terminal short-circuited to power supply
Urea solution return pipeline heating relay control
698 DFC_UHtrBLSCG P20B9(20B9)
terminal short-circuited to ground
699 DFC_UHtrPLLoadFbPlaus Pressure pipe heating ADC signal conversion error P20BD(20BD)
Open circuit of heating relay control terminal of urea
700 DFC_UHtrPLOL P20BD(20BD)
solution pressure pipeline
Urea solution pressure pipeline heating relay control
701 DFC_UHtrPLOvrTemp P20BD(20BD)
terminal driver chip in ECU overheated
Urea solution pressure pipeline heating relay control
702 DFC_UHtrPLSCB P20BD(20BD)
terminal short-circuited to power supply
Urea solution pressure pipeline heating relay control
703 DFC_UHtrPLSCG P20BD(20BD)
terminal short-circuited to ground
704 DFC_UHtrRlyOL Open fault of SCR system heating main relay control P3043(3043)

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terminal
SCR system heating main relay control terminal driver
705 DFC_UHtrRlyOvrTemp P3044(3044)
chip in ECU overheated
SCR system heating main relay control terminal
706 DFC_UHtrRlySCB P3045(3045)
short-circuited to power supply
SCR system heating main relay control terminal
707 DFC_UHtrRlySCG P3046(3046)
short-circuited to ground
708 DFC_UHtrSLLoadFbPlaus Suction pipe heating ADC signal conversion error P20C1(20C1)
Open circuit of heating relay control terminal of urea
709 DFC_UHtrSLOL P20C1(20C1)
solution suction pipeline
Urea solution suction pipeline heating relay control
710 DFC_UHtrSLOvrTemp P20C1(20C1)
terminal driver chip in ECU overheated
Urea solution suction pipeline heating relay control
711 DFC_UHtrSLSCB P20C1(20C1)
terminal short-circuited to power supply
Urea solution suction pipeline heating relay control
712 DFC_UHtrSLSCG P20C1(20C1)
terminal short-circuited to ground
Urea solution pump heating ADC signal conversion
713 DFC_UHtrSMLoadFbPlaus P263D(263D)
error
Open circuit of heating relay control terminal of urea
714 DFC_UHtrSMOL P263D(263D)
solution supply unit
Urea solution supply unit heating relay control
715 DFC_UHtrSMOvrTemp P263D(263D)
terminal driver chip in ECU overheated
Urea solution supply unit heating relay control
716 DFC_UHtrSMSCB P263D(263D)
terminal short-circuited to power supply
Urea solution supply unit heating relay control
717 DFC_UHtrSMSCG P263D(263D)
terminal short-circuited to ground
718 DFC_UHtrTnkOL Urea solution tank heating valve drive circuit open P202A(202A)
Urea solution tank heating valve driver chip in ECU
719 DFC_UHtrTnkOvrTemp P202A(202A)
overheated
Urea solution tank heating valve drive circuit
720 DFC_UHtrTnkSCB P202A(202A)
short-circuited to power supply
Urea solution tank heating valve drive circuit
721 DFC_UHtrTnkSCG P202A(202A)
short-circuited to ground
722 DFC_UPmpMotComRxFail Urea solution supply unit CAN communication fault U010E(C10E)
Motor speed deviation fault of urea solution supply
723 DFC_UPmpMotNDvt P05EE(05EE)
unit
Permanent fault of motor speed deviation of urea
724 DFC_UPmpMotNDvtPerm P05EE(05EE)
solution supply unit
725 DFC_UPmpMotOL Urea solution supply unit drive circuit open P05EE(05EE)
Urea solution supply unit driver chip in ECU
726 DFC_UPmpMotOvrTemp P05EE(05EE)
overheated
Duty cycle of urea solution pump control higher than
727 DFC_UPmpMotratdcPmpMax P208A(208A)
effective range
Duty cycle of urea solution pump control lower than
728 DFC_UPmpMotratdcPmpMin P208A(208A)
effective range
Temperature of urea solution pump heating module
729 DFC_UPmpMotratHTMax P208A(208A)
greater than maximum limit

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Temperature of urea solution pump heating module

730 DFC_UPmpMotratHTMin P208A(208A)
lower than minimum limit
Urea solution pump motor speed duty cycle higher
731 DFC_UPmpMotratnPmpMax P208A(208A)
than upper limit value
Urea solution pump motor speed duty cycle lower than
732 DFC_UPmpMotratnPmpMin P208A(208A)
lower limit value
Urea solution pump temperature duty cycle higher
733 DFC_UPmpMotratSMTMax P208A(208A)
than upper limit value
Urea solution pump temperature duty cycle lower than
734 DFC_UPmpMotratSMTMin P208A(208A)
lower limit value
Urea solution supply unit drive circuit short-circuited
735 DFC_UPmpMotSCB P05EE(05EE)
to power supply
Urea solution supply unit drive circuit short-circuited
736 DFC_UPmpMotSCG P05EE(05EE)
to ground
737 DFC_UPmpPPhysRngHi Urea solution pressure exceeding upper limit P204A(204A)
738 DFC_UPmpPPhysRngLo Urea pressure is below the lower limit P204A(204A)
Open circuit of urea solution return pump PWM
739 DFC_UrBackFlowPmpOL P20A0(20A0)
output module
Excessively high temperature of urea solution return
740 DFC_UrBackFlowPmpOT P20A0(20A0)
pump PWM output module
Urea solution return pump PWM output module
741 DFC_UrBackFlowPmpSCB P20A0(20A0)
short-circuited to power supply
Urea solution return pump PWM output module
742 DFC_UrBackFlowPmpSCG P20A0(20A0)
short-circuited to ground
Urea solution tank liquid level sensor signal exceeding
743 DFC_UTnkLvlPhysRngHi P203A(203A)
upper limit diagnostic testing
Urea solution tank liquid level sensor signal exceeding
744 DFC_UTnkLvlPhysRngLo P203A(203A)
lower limit diagnostic testing
Urea solution tank temperature sensor signal
745 DFC_UTnkTPhysRngHi P205A(205A)
exceeding upper limit diagnostic testing
Urea solution tank temperature sensor signal
746 DFC_UTnkTPhysRngLo P205A(205A)
exceeding lower limit diagnostic testing
Error of urea solution tank temperature signal received
747 DFC_UTnkTSig P205A(205A)
by ECU from CAN bus
Urea solution tank temperature sensor signal voltage
748 DFC_UTnkTSRCMax P205D(205D)
too high
Urea solution tank temperature sensor signal voltage
749 DFC_UTnkTSRCMin P205C(205C)
too low
Signal rationality failure of urea solution tank
750 DFC_UTnkTVDPlausTempMax P205B(205B)
temperature sensor (measured value too high)
Signal rationality failure of urea solution tank
751 DFC_UTnkTVDPlausTempMin P205B(205B)
temperature sensor (measured value too low)
Speed signal measured by speed sensor higher than
752 DFC_VehVPhysRngHi P0500(0500)
upper limit
Speed signal measured by speed sensor lower than
753 DFC_VehVPhysRngLo P0500(0500)
lower limit
754 DFC_VehVPlausFco Unreasonable speed due to engine injector fuel cut-off P062C(062C)
755 DFC_VehVPlausPwr Vehicle speed signal unreasonable P0501(0501)

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Unreasonable speed fault due to reference signal

756 DFC_VehVPlausRef P062C(062C)
check
Unreasonable speed fault due to unreasonable vehicle
757 DFC_VehVPlausV2N P062C(062C)
speed and engine speed ratio
758 DFC_VehVWhlErr Wheel failure P215A(215A)

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Annex C Tightening Torque for General Bolts of Diesel Engine

Item Bolt specification Tightening torque

M8-8.8 (25±2) Nm
Standard bolt for peripheral
M10-8.8 (50±5) Nm
part
M12-8.8 (75±5) Nm
Copper hexagon head
M10X1 (13±2) Nm
hollow bolt
M10X1 (21±3) Nm

Steel hexagon head hollow M14X1.5 (27±3) Nm

bolt M16X1.5 (40±5) Nm
M6X1 (6±1) Nm
M10 (20±3) Nm
M12 (28±3) Nm
Flange hollow bolt
M14 (32±3) Nm
M16 (36±3) Nm

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Annex D Fit Clearance for Main Parts of Diesel Engine

No. Item Theoretical value (mm)

1 Main bearing clearance 0.059~0.117

2 Connecting rod bearing clearance 0.050~0.109
3 Axial clearance of crankshaft 0.075~0.235
4 Connecting rod plane axial clearance 0.1~0.3
Clearance between connecting rod small head
5 0.025~0.043
bushing and piston pin
6 Clearance between piston pin seat and piston pin 0.005~0.019
First ring 0.20~0.35
Cold piston ring opening
7 Second ring 0.40~0.60
working clearance
Oil control ring 0.20~0.45
First ring 0.08~0.13
Cold piston ring end
8 Second ring 0.06~0.1
clearance
Oil control ring 0.04~0.08
Clearance between intake valve stem and valve
9 0.025~0.062
guide
Clearance between exhaust valve stem and valve
10 0.04~0.077
guide
11 Valve depression 0.4±0.1
Clearance between camshaft front journal and
12 0.089~0.139
bushing inner diameter
13 Rocker arm and rocker arm shaft clearance 0.016~0.045
14 Tappet and engine block tappet hole 0.016~0.052

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