1001360669

Maintenance Manual of WP12/WP13 Four-valve

China IV/China V/Euro V Diesel Engine for Vehicle

Weichai Power Co., Ltd.

Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

WP12/WP13 China IV/China V/Euro V Diesel Engine

Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Foreword
This series is the high-speed engine independently developed by Weichai Power Co., Ltd. The series has
compact structure, high reliability, strong power, and good economy performance, as well as fast start, easy
operation and maintenance.

This manual mainly includes the precautions, maintenance methods, common inspection adjustments and
troubleshooting of common faults for the engine. In the process of preparation, we strive to be comprehensive,
simple and practical. It should be pointed out that judging engine failure is a careful work and requires a certain
amount of knowledge and experience. Please do not disassemble the engine before you understand the cause.
Otherwise, it will not only eliminate the fault, but will result in more serious failures because of improper
assembly and disassembly, especially for key components such as electronic control system and turbocharger. In
addition, the maintenance inspection of the engine must use special equipment, so users without experience
and conditions should not disassemble or adjust it.

With the increasing variants and continuous improvement of the series engine, this Manual will be subject
to change without notice. Weichai Power Co., Ltd. is authorized to carry out the after-sales service of this
product, and users can access relevant product information through the website of www.weichai.com.

You are welcome to suggest and comment on further improvements to the product.
Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Notice

 Before operation, please carefully read this Manual,

strictly observe the operation and maintenance
regulations specified in this Manual, and pay attention to
warning instructions and warning signs. Please pay
attention to the following issues because the engine
warranty will be invalidated if the operation is performed
not in accordance with the requirements of this Manual!

 As the engine has been tested in strict accordance with Please refer to this Manual
the test specifications upon delivery, it is not allowed to
adjust the fuel injection pump or ECU randomly.

 For the engine with a turbocharger, the rotor shaft of the

turbocharger is a precise high speed rotating part, please
keep any objects (such as hand, tool, cotton yarn) away
from the turbocharger when the engine is running, so as
to avoid personal injury or engine damage. Do not
disassemble the rotor component.

 Do not loosen or remove the main bearing bolt or the Do not touch the high-speed rotating part with hand
connecting rod bolt of the engine without permission as
they are subject to strict torque and rotation
requirements. For the torque and times of use of
important bolts, please refer to the annex in this Manual.

Tightening torque requirement

 Always fill the engine with the oil or fuel of grade specified
in this Manual, and filtered by a special filter; for the fuel,
subject it to a precipitation more than 72 h. Prior to start,
always check that the coolant and oil levels are
satisfactory, and if not, please fill the engine with fuel or
oil of grade specified in this Manual at an authorized
gasoline station.
 Before running a new engine, subject it to running-in for
Please refer to the relevant chapter in this Manual
50 h.
 Never run the engine without an air filter.
 After starting a cold engine, accelerate it slowly rather
than abruptly, and do not run it at an idle speed for a long
time.
 Regularly check the coolant, and never change the engine
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

coolant with water or coolant with poor quality. At a low

temperature, please select the coolant of the correct
grade in accordance with the requirements of this Manual.
 The engine has been preserved before delivery for
avoiding rust. The engine preservation period is one year,
and the engine should be checked and necessary
measures should be taken when this valid period expires.
 Always have the components of the electrical system
Please refer to the relevant chapter in this Manual
maintained by Weichai professional technicians.
 Please have the diesel engine disassembled and repaired
at the Weichai Power designated service station in case of
a fault. Do not use the spare parts not specified by
Weichai Power for maintenance; otherwise, Weichai will
not assume any responsibility for damage to the engine
therefrom.
 The maintenance of all parts of the electrical system must
be carried out by Weichai professional technicians.
 When replacing key components (turbocharger, fuel
injection pump, fuel injector, ECU, exhaust aftertreatment
system, EGR system) that affect emissions, it is necessary
Authentic Weichai spare parts
to ensure that the replaced parts are the same
manufacturer and model as the original parts, otherwise
for all the consequences, Weichai does not assume any
responsibility.
Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Warning Signs

Beware of electric
Wear gloves shock

Beware of
Wear protective clothing mechanical injury

Beware of being
Wear ear plugs stucked in

Beware of
suspended heavy
Wear goggles objects

Wear helmet Beware of steam

Wear safety shoes Beware of explosion

Wear protective mask Beware of corrosion

Keep ventilated Beware of scalding

Torque control Beware ofwinding

 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

No open
Checks required flame

Tools required No smoking

Serious warning No touching

Caution No smoking

Warning No touching

Most of accidents occurred during engine operation, maintenance and repair are caused by failure to observe
the safety rules and basic precautions. Only the well-trained operators with required skills and appropriate tools
can operate, maintain and repair the engine.
The violation of instructions in this Manual may lead to serious accident. Weichai Power Co., Ltd. cannot foresee
all potential hazards, and meanwhile, the rules and instructions specified in this Manual are not exhaustive.
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Precautions for Engine Disassembling, Assembling and Maintenance

 Prepare necessary common tools, special tools, measuring instruments, etc. before maintenance.
 Use a crane with sufficient hoisting capacity or jack to lift the engine, and use chains, cables or lifting belts
instead of ropes as hoisting tools.
 Use special tools to hoist and turnthe engine.
 Weichai original spare parts or the parts recommended by Weichai should be used; otherwise the service
life of the engine may be shortened or personal injury may be caused.
 Make sure that the workingsite and the surroundings are suitable for safe operation.
 Make sure that the workshop or the surrounding of the engine is clean and tidy.
 Before working, please take off your watch and other ornaments and wear well-fitted working clothes.
 Before working, check that the corresponding personal protective equipment (goggles, gloves, shoes, mask,
working clothes, helmet, etc.) are within the period of validity.
 Ensure that fire extinguishers are available near the maintenance area.
 Prevent the battery electrolyte from splashing to clothing, skin or eyes; Keep away from sparks and open
flames when charging the battery.
 When disassembling complicated components, make matching marks at the proper positions.
 Confirm whether the removed parts can be reused. Please refer to this Manual for details.
 Regularly calibrate the measuring instruments.
Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Declaration

Due to the diversified product variants of the company, the illustrations in this Manual are schematic and may
not match the real product you purchased. For the detailed structure, the real product shall prevail.
The symbols in the illustrations indicate the steps or conditions requiring your attention during operation!
Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Contents
Chapter I Operation Instructions of the Engine...........................................................................................1
1.1 Outline drawings.........................................................................................................................................1
1.2 Designation of engine model......................................................................................................................3
1.4 Hoisting........................................................................................................................................................4
1.5 Running........................................................................................................................................................5

Chapter II Maintenance....................................................................................................................................................7
2.1 Fuel, lubricating oil, coolant and auxiliary materials.................................................................................7
2.1.1 Fuel...................................................................................................................................................7
2.1.2 Lubricating oil...................................................................................................................................7
2.1.3 Engine coolant..................................................................................................................................8
2.1.4 Urea solution....................................................................................................................................8
2.1.5 Auxiliary materials.........................................................................................................................10
2.2 Daily maintenance.....................................................................................................................................11
2.2.1 Daily maintenance..........................................................................................................................11
2.2.2 Daily check......................................................................................................................................11
2.3 Maintenance items....................................................................................................................................12
2.3.1 Oil change.......................................................................................................................................12
2.3.2 Replace the oil filter or filter element...........................................................................................12
2.3.3 Replace the fuel filter and filter element.......................................................................................12
2.3.4 Check and adjust valve clearance..................................................................................................13
2.3.5 Check the air seal...........................................................................................................................14
2.3.6 Check the air filter element............................................................................................................14
2.4 Engine cleaning, protection and transportation.......................................................................................15
2.4.1 Cleaning and protection of engine.................................................................................................15
2.4.2 Protection during storage...............................................................................................................15
2.4.3 Oil sealing.......................................................................................................................................15
2.4.4 Transportation................................................................................................................................16

Chapter III Typical Faults and Troubleshooting..........................................................................................17

3.1 Overview....................................................................................................................................................17
3.1.1 Overview.........................................................................................................................................17
3.2 Fault diagnostic methods..........................................................................................................................17
3.2.1 Traditional fault diagnostic methods.............................................................................................17
3.2.2 On-board diagnostics (OBD)...........................................................................................................18
3.3 Typical fault and troubleshooting.............................................................................................................47
3.3.1 Engine start failure.........................................................................................................................47
3.3.2 Insufficient engine power...............................................................................................................49
3.3.3 High fuel consumption...................................................................................................................51
3.3.4 High oil consumption.....................................................................................................................53
3.3.5 Starter motor does not work.........................................................................................................54
3.3.6 Alternator does not work...............................................................................................................55
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

3.3.7 Air compressor failure....................................................................................................................56

3.3.8 High urea solution consumption....................................................................................................57
3.3.9 Low urea solution consumption or no consumption....................................................................58
3.3.10 Urea solution pressure build-up failure.......................................................................................59
3.3.11 Urea solution heating function not released...............................................................................60
3.3.12 Low NOx conversion efficiency....................................................................................................60
3.3.13 Urea crystallization.......................................................................................................................62

Chapter IV Introduction to Engine Systems...................................................................................................47

4.1 Lubricating system.....................................................................................................................................47
4.1.1 Overview.........................................................................................................................................47
4.2 Cooling system...........................................................................................................................................48
4.2.1 Overview.........................................................................................................................................48
4.3 Fuel system................................................................................................................................................48
4.3.1 Schematic diagram of fuel system.................................................................................................48

Chapter V Disassembling and assembling of engine.............................................................................50

5.1 Intake manifold assembly.........................................................................................................................50
5.1.1 Exploded view................................................................................................................................50
5.1.2 Disassembling tools and preparations...........................................................................................50
5.1.3 Disassembling steps.......................................................................................................................51
5.1.4 Inspection and maintenance..........................................................................................................51
5.2 Fan and hub assembly...............................................................................................................................52
5.2.1 Exploded view................................................................................................................................52
5.2.2 Disassembling tools and preparations...........................................................................................52
5.2.3 Disassembling steps.......................................................................................................................53
5.2.4 Inspection and maintenance..........................................................................................................53
5.2.5 Assembling steps............................................................................................................................53
5.3 Oil-gas separator assembly.......................................................................................................................53
5.3.1 Exploded view................................................................................................................................53
5.3.2 Disassembling tools and preparations...........................................................................................54
5.3.3 Disassembling steps.......................................................................................................................54
5.3.4 Inspection and maintenance..........................................................................................................54
5.3.5 Assembling steps............................................................................................................................55
5.4 Rear exhaust manifold assembly..............................................................................................................55
5.4.1 Exploded view................................................................................................................................55
5.4.2 Disassembling tools and preparations...........................................................................................55
5.4.3 Disassembling steps.......................................................................................................................56
5.4.4 Inspection and maintenance..........................................................................................................56
5.4.5 Assembling steps............................................................................................................................56
5.5 Turbocharger assembly.............................................................................................................................56
5.5.1 Exploded view................................................................................................................................56
5.5.2 Disassembling tools and preparations...........................................................................................57
5.5.3 Disassembling steps.......................................................................................................................57
5.5.4 Inspection and maintenance..........................................................................................................58
5.5.5 Assembling steps............................................................................................................................59
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

5.6 Low-pressure fuel pipe assembly..............................................................................................................60

5.6.1 Exploded view................................................................................................................................60
5.6.2 Disassembling tools and preparations...........................................................................................60
5.6.3 Disassembling steps.......................................................................................................................61
5.6.4 Inspection and maintenance..........................................................................................................61
5.6.5 Assembling steps............................................................................................................................61
5.7 Common rail pipe assembly......................................................................................................................62
5.7.1 Exploded view................................................................................................................................62
5.7.2 Preparations before disassembling................................................................................................62
5.7.3 Disassembling steps.......................................................................................................................63
5.7.4 Inspection and maintenance..........................................................................................................63
5.7.5 Assembling steps............................................................................................................................63
5.8 Fuel injector assembly...............................................................................................................................64
5.8.1 Exploded view................................................................................................................................64
5.8.2 Disassembling tools and preparations...........................................................................................64
5.8.3 Disassembling steps.......................................................................................................................64
5.8.4 Inspection and maintenance..........................................................................................................65
5.8.5 Assembling steps............................................................................................................................65
5.9 Air compressor assembly..........................................................................................................................66
5.9.1 Exploded view................................................................................................................................66
5.9.2 Disassembling tools and preparations...........................................................................................66
5.9.3 Disassembling steps.......................................................................................................................67
5.9.4 Inspection and maintenance..........................................................................................................67
5.9.5 Assembling steps............................................................................................................................67
5.10 Fuel injection pump assembly................................................................................................................68
5.10.1 Exploded view..............................................................................................................................68
5.10.2 Disassembling tools and preparations.........................................................................................69
5.10.3 Disassembling steps.....................................................................................................................69
5.10.4 Inspection and maintenance........................................................................................................69
5.10.5 Assembling steps..........................................................................................................................69
5.11 Fuel filter assembly.................................................................................................................................71
5.11.1 Exploded view..............................................................................................................................71
5.11.2 Disassembling tools and preparations.........................................................................................71
5.11.3 Disassembling steps.....................................................................................................................71
5.11.4 Inspection and maintenance........................................................................................................72
5.11.5 Assembling steps..........................................................................................................................72
5.12 Starter assembly......................................................................................................................................72
5.12.1 Exploded view..............................................................................................................................72
5.12.2 Disassembling tools and preparations.........................................................................................73
5.12.3 Disassembling steps.....................................................................................................................73
5.12.4 Assembling steps..........................................................................................................................73
5.13 Electronic control unit (ECU) assembly...................................................................................................74
5.13.1 Exploded view..............................................................................................................................74
5.13.2 Disassembling tools and preparations.........................................................................................74
5.13.3 Disassembling steps.....................................................................................................................74
5.13.4 Inspection and maintenance........................................................................................................75
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

5.13.5 Assembling steps..........................................................................................................................75

5.14 High-pressure fuel pipe assembly...........................................................................................................75
5.14.1 Exploded view of assembling.......................................................................................................75
5.14.2 Disassembling tools and preparations.........................................................................................75
5.14.3 Disassembling steps.....................................................................................................................75
5.14.4 Inspection and maintenance........................................................................................................76
5.14.5 Assembling steps..........................................................................................................................76
5.15 Oil filler pipe............................................................................................................................................76
5.15.1 Exploded view..............................................................................................................................76
5.15.2 Disassembling tools and preparations.........................................................................................77
5.15.3 Disassembling steps.....................................................................................................................77
5.15.4 Inspection and maintenance........................................................................................................77
5.15.5 Assembling steps..........................................................................................................................77
5.16 Air bleeding pipe assembly.....................................................................................................................78
5.16.1 Exploded view..............................................................................................................................78
5.16.2 Disassembling tools and preparations.........................................................................................78
5.16.3 Disassembling steps.....................................................................................................................78
5.16.4 Inspection and maintenance........................................................................................................78
5.16.5 Assembling steps..........................................................................................................................79
5.17 Oil cooler cover assembly.......................................................................................................................79
5.17.1 Exploded view..............................................................................................................................79
5.17.2 Disassembling tools and preparations.........................................................................................79
5.17.3 Disassembling steps.....................................................................................................................80
5.17.4 Inspection and maintenance........................................................................................................80
5.17.5 Assembling steps..........................................................................................................................80
5.18 Oil cooler assembly.................................................................................................................................80
5.18.1 Exploded view..............................................................................................................................80
5.18.2 Disassembling tools and preparations.........................................................................................80
5.18.3 Disassembling steps.....................................................................................................................81
5.18.4 Inspection and maintenance........................................................................................................81
5.18.5 Assembling steps..........................................................................................................................81
5.19 Oil pump assembly..................................................................................................................................81
5.19.1 Exploded view..............................................................................................................................81
5.19.2 Disassembling tools and preparations.........................................................................................81
5.19.3 Disassembling steps.....................................................................................................................81
5.19.4 Inspection and maintenance........................................................................................................82
5.19.5 Assembling steps..........................................................................................................................82
5.20 Oil filter assembly....................................................................................................................................82
5.20.1 Exploded view..............................................................................................................................82
5.20.2 Disassembling tools and preparations.........................................................................................82
5.20.3 Disassembling steps.....................................................................................................................83
5.20.4 Inspection and maintenance........................................................................................................83
5.20.5 Assembling steps..........................................................................................................................83
5.21 Exhaust manifold assembly.....................................................................................................................84
5.21.1 Exploded view..............................................................................................................................84
5.21.2 Disassembling tools and preparations.........................................................................................84
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

5.21.3 Disassembling steps.....................................................................................................................84

5.21.4 Inspection and maintenance........................................................................................................84
5.21.5 Assembling steps..........................................................................................................................85
5.22 Tensioner and belt assembly...................................................................................................................85
5.22.1 Exploded view..............................................................................................................................85
5.22.2 Disassembling tools and preparations.........................................................................................85
5.22.3 Disassembling steps.....................................................................................................................86
5.22.4 Inspection and maintenance........................................................................................................86
5.22.5 Assembling steps..........................................................................................................................86
5.23 Thermostat assembly..............................................................................................................................87
5.23.1 Exploded view..............................................................................................................................87
5.23.2 Disassembling tools and preparations.........................................................................................87
5.23.3 Disassembling steps.....................................................................................................................87
5.23.4 Inspection and maintenance........................................................................................................87
5.23.5 Assembling steps..........................................................................................................................88
5.24 Water pump assembly............................................................................................................................88
5.24.1 Exploded view..............................................................................................................................88
5.24.2 Disassembling tools and preparations.........................................................................................88
5.24.3 Disassembling steps.....................................................................................................................89
5.24.4 Inspection and maintenance........................................................................................................89
5.24.5 Assembling steps..........................................................................................................................89
5.25 Generator assembly................................................................................................................................89
5.25.1 Exploded view..............................................................................................................................89
5.25.2 Disassembling steps.....................................................................................................................90
5.25.3 Assembling steps..........................................................................................................................90
5.26 Fan bracket assembly..............................................................................................................................90
5.26.1 Exploded view..............................................................................................................................90
5.26.2 Disassembling tools and preparations.........................................................................................91
5.26.3 Disassembling steps.....................................................................................................................91
5.26.4 Inspection and maintenance........................................................................................................91
5.26.5 Assembling steps..........................................................................................................................91
5.27 Hoisting ring assembly............................................................................................................................92
5.27.1 Exploded view..............................................................................................................................92
5.27.2 Disassembling tools and preparations.........................................................................................92
5.27.3 Disassembling steps.....................................................................................................................92
5.27.4 Inspection and maintenance........................................................................................................92
5.27.5 Assembling steps..........................................................................................................................92
5.28 Cylinder head cover assembly................................................................................................................93
5.28.1 Exploded view..............................................................................................................................93
5.28.2 Disassembling tools and preparations.........................................................................................93
5.28.3 Disassembling steps.....................................................................................................................93
5.28.4 Inspection and maintenance........................................................................................................94
5.28.5 Assembling steps..........................................................................................................................94
5.29 Suction filter assembly............................................................................................................................94
5.29.1 Exploded view..............................................................................................................................94
5.29.4 Inspection and maintenance........................................................................................................95
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

5.29.5 Assembling steps..........................................................................................................................95

5.30 Electronic control wire harness and sensor assembly............................................................................96
5.30.1 Exploded view..............................................................................................................................96
5.30.2 Disassembling tools and preparations.........................................................................................96
5.30.3 Disassembling steps.....................................................................................................................96
5.30.4 Inspection and maintenance........................................................................................................97
5.30.5 Assembling steps..........................................................................................................................97
5.31 Valve train assembly................................................................................................................................97
5.31.1 Exploded view..............................................................................................................................97
5.31.2 Disassembling tools and preparations.........................................................................................98
5.31.3 Disassembling steps.....................................................................................................................98
5.31.4 Inspection and maintenance......................................................................................................100
5.31.5 Assembling steps........................................................................................................................101
5.32 Fuel injector assembly...........................................................................................................................105
5.32.1 Exploded view............................................................................................................................105
5.32.2 Disassembling tools and preparations.......................................................................................105
5.32.3 Disassembling steps...................................................................................................................106
5.32.4 Inspection and maintenance......................................................................................................106
5.32.5 Assembling steps........................................................................................................................106
5.33 Cylinder head assembly........................................................................................................................107
5.33.1 Exploded view............................................................................................................................107
5.33.2 Preparations before disassembling............................................................................................107
5.33.3 Disassembling steps...................................................................................................................107
5.33.4 Inspection and maintenance......................................................................................................108
5.33.5 Assembling steps........................................................................................................................110
5.34 Crankshaft pulley assembly...................................................................................................................112
5.34.1 Exploded view............................................................................................................................112
5.34.2 Disassembling tools and preparations.......................................................................................113
5.34.3 Disassembling steps...................................................................................................................113
5.34.4 Inspection and maintenance......................................................................................................113
5.34.5 Assembling steps........................................................................................................................113
5.35 Flywheel housing assembly..................................................................................................................114
5.35.1 Exploded view............................................................................................................................114
5.35.2 Disassembling tools and preparations.......................................................................................114
5.35.3 Disassembling steps...................................................................................................................115
5.35.4 Inspection and maintenance......................................................................................................115
5.35.5 Assembling steps........................................................................................................................115
5.36 Flywheel assembly................................................................................................................................116
5.36.1 Exploded view............................................................................................................................116
5.36.2 Disassembling tools and preparations.......................................................................................116
5.36.3 Disassembling steps...................................................................................................................116
5.36.4 Inspection and maintenance......................................................................................................116
5.36.5 Assembling steps........................................................................................................................117
5.37 Oil pump assembly................................................................................................................................117
5.37.1 Exploded view............................................................................................................................117
5.37.2 Disassembling tools and preparations.......................................................................................118
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

5.37.3 Disassembling steps...................................................................................................................118

5.37.4 Inspection and maintenance......................................................................................................118
5.37.5 Assembling steps........................................................................................................................118
5.38 Oil pan assembly...................................................................................................................................119
5.38.1 Exploded view............................................................................................................................119
5.38.2 Disassembling tools and preparations.......................................................................................119
5.38.3 Disassembling steps...................................................................................................................120
5.38.4 Inspection and maintenance......................................................................................................120
5.38.5 Assembling steps........................................................................................................................120
5.39 Suction filter assembly..........................................................................................................................121
5.39.1 Exploded view............................................................................................................................121
5.39.2 Disassembling tools and preparations.......................................................................................122
5.39.3 Disassembling steps...................................................................................................................122
5.39.4 Inspection and maintenance......................................................................................................122
5.39.5 Assembling steps........................................................................................................................122
5.40 Piston nozzle assembly..........................................................................................................................123
5.40.1 Exploded view............................................................................................................................123
5.40.2 Disassembling tools and preparations.......................................................................................123
5.40.3 Disassembling steps...................................................................................................................123
5.40.4 Inspection and maintenance......................................................................................................124
5.40.5 Assembling steps........................................................................................................................124
5.41 Piston connecting rod assembly...........................................................................................................124
5.41.1 Exploded view............................................................................................................................124
5.41.2 Disassembling tools and preparations.......................................................................................124
5.41.3 Disassembling steps...................................................................................................................125
5.41.4 Inspection and maintenance......................................................................................................125
5.41.5 Assembling steps........................................................................................................................126
5.42 Front end cover.....................................................................................................................................128
5.42.1 Exploded view............................................................................................................................128
5.42.2 Disassembling tools and preparations.......................................................................................128
5.42.3 Disassembling steps...................................................................................................................128
5.42.4 Inspection and maintenance......................................................................................................128
5.42.5 Assembling steps........................................................................................................................129
5.43 Oil seal assembly...................................................................................................................................129
5.43.1 Exploded view............................................................................................................................129
5.43.2 Preparations before disassembling............................................................................................130
5.43.3 Removal steps.............................................................................................................................130
5.43.4 Inspection and maintenance......................................................................................................130
5.43.5 Assembling steps........................................................................................................................130
5.44 Crankshaft assembly.............................................................................................................................130
5.44.1 Exploded view............................................................................................................................130
5.44.2 Disassembling tools and preparations.......................................................................................131
5.44.3 Disassembling steps...................................................................................................................131
5.44.4 Inspection and maintenance......................................................................................................131
5.44.5 Assembling steps........................................................................................................................132
5.45 Thrust plate assembly...........................................................................................................................135
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

5.45.1 Exploded view............................................................................................................................135

5.45.2 Disassembling tools and preparations.......................................................................................135
5.45.3 Disassembling steps...................................................................................................................135
5.45.4 Inspection and maintenance......................................................................................................136
5.45.5 Assembling steps........................................................................................................................136
5.46 Main bearing bush assembly................................................................................................................137
5.46.1 Exploded view............................................................................................................................137
5.46.2 Disassembling tools and preparations.......................................................................................137
5.46.3 Removal steps.............................................................................................................................138
5.46.4 Inspection and maintenance......................................................................................................138
5.46.5 Assembling steps........................................................................................................................138
5.47 Dipstick tube assembly..........................................................................................................................139
5.47.1 Exploded view............................................................................................................................139
5.47.2 Disassembling tools and preparations.......................................................................................139
5.47.3 Disassembling steps...................................................................................................................139
5.47.4 Inspection and maintenance......................................................................................................139
5.47.5 Assembling steps........................................................................................................................140
5.48 Engine block assembly..........................................................................................................................140
5.48.1 Exploded view............................................................................................................................140
5.48.2 Disassembling tools and preparations.......................................................................................141
5.48.3 Disassembling steps...................................................................................................................141
5.48.4 Inspection and maintenance......................................................................................................141
5.48.5 Assembling steps........................................................................................................................141
5.49 Urea pump.............................................................................................................................................142
5.49.1 Replacement steps.....................................................................................................................142
5.49.2 Installation..................................................................................................................................144
5.50 Urea nozzle............................................................................................................................................145
5.50.1 Installation..................................................................................................................................145
5.51 Urea tank...............................................................................................................................................146
5.51.1 Installation..................................................................................................................................146
5.52 Urea pipeline.........................................................................................................................................147
5.52.1 Installation..................................................................................................................................147
5.53 Sensor....................................................................................................................................................148
5.53.1 Installation..................................................................................................................................148
5.54 DeNOx 2.2 system.................................................................................................................................150
5.54.1 Usage and inspection.................................................................................................................150
5.54.2 Inspection and maintenance......................................................................................................151

Appendix A Diagnostic fault code table.........................................................................................................153

Appendix B Mating clearance of the main parts....................................................................................267

Appendix C Tightening torque of other main bolts..............................................................................269

Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle
 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Chapter I Operation Instructions of the Engine

1.1 Outline drawings

Fig. 1-1 Outline Drawing 1 of Engine (Intake Side)

No. Name No. Name No. Name No. Name

1 ECU 2 Alternator 3 Air inlet pipe 4 Common rail pipe

Fuel injection Fuel filter
5 6 7 Starter
pump assembly

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 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Fig. 1-2 Outline Drawing 2 of Engine (Exhaust Side)

No. Name No. Name No. Name No. Name

1 Air compressor 2 Turbocharger 3 Oil-gas separator 4 Oil cooler cap

5 Oil filter

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Fig. 1-3 Outline Drawing 3 of Engine (Fan End)

1.2 Designation of engine model

Product variant code

Emission level code

Power code

Application code

Product series code

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1.3 Main specifications

Table 1-1 Main Specifications

Item Specification
Type 4-stroke, water-cooled, electronical control and high-pressure common rail
Aspiration method Turbocharged and intercooled
126×155（WP12）
Bore × stroke (mm)
127×165（WP13）
Number of cylinders 6

11.596（WP12）
Displacement (L)
12.54（WP13）
Compression ratio 17:1
Firing order 1-5-3-6-2-4
Fuel system Electronical control and high-pressure common rail
Starting method Electric starter
Lubrication method Pressure lubrication
Cooling method Forced circulation water-cooling
Rating 350-550
Oil pressure (kPa)
Idling 130-250
Oil pan capacity (L) See Chapter II in this Manual for details
Rotation direction of crankshaft (viewed
Clockwise
from fan end)
Number of valves each cylinder 4
Emission standard China IV/China V/Euro V
Fuel supply advance angle -
Coolant outlet temperature (°C) 83~95
Turbocharger downstream exhaust gas
≤ 600
temperature (°C)

Intercooler downstream intake air

45~50
temperature (°C)

1.4 Hoisting
When hoisting the engine, keep the crankshaft centerline horizontal. Never hoist the tilted engine or hoist the
engine from one side. Hoist and lower the engine slowly to avoid damage.

Yes No

Fig. 1-4 Hoisting of the Engine

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1.5 Running
When the engine is running normally, the temperature and pressure shall meet the requirements specified in
Table 1-2.
Table 1-2 Main Specifications of Engine in Operation

Item Specification
Intake resistance (kPa) ≤3
≤7.5 (China III and non-road Stage III, or under)
Exhaust resistance (kPa) ≤20 (China IV and China V, with SCR box）
≤35 (China VI, with SCR box）
Oil pressure (kPa) See Table 1-1
Oil temperature (℃) 85~105
Coolant temperature (℃) See Table 1-1

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Chapter II Maintenance
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2.1 Fuel, lubricating oil, coolant and auxiliary materials

2.1.1 Fuel
The fuel used shall meet the standard GB 20891 and be selected based on the local ambient temperature:
5# automobile diesel fuel: used in areas where the risk of minimum temperature of 8°C is 10%;
0# automobile diesel fuel: used in areas where the risk of minimum temperature of 4°C is 10%;
-10# automobile diesel fuel: used in areas where the risk of minimum temperature of -5°C is 10%;
-20# automobile diesel fuel: used in areas where the risk of minimum temperature of -14°C is 10%;
-35# automobile diesel fuel: used in areas where the risk of minimum temperature of -29°C is 10%;
-50# automobile diesel fuel: used in areas where the risk of minimum temperature of -44°C is 10%.
2.1.2 Lubricating oil
Engine lubricating oil selection refers to Table 2-1.
Table 2-1 Selection Specifications of Weichai Power Special Oil

Product name Product category Packaging Specification

Diesel engine oil CK-4 4L, 18L, 170kg

Engine lubricating oil and viscosity refer to Table 2-2.

Table 2-2 Relationship between oil viscosity grade and ambient temperature

Applicable ambient Applicable ambient

Viscosity grade Viscosity grade
temperature (ºC) temperature (ºC)
0W -35~-15 10W-50 -25~50

0W-20 -35~20 15W-30 -20~30

0W-30 -35~30 15W-40 -20~40

0W-40 -35~40 15W-50 -20~50

5W -30~-10 20W-30 -15~30

5W-20 -30~20 20W-40 -15~40

5W-30 -30~30 20W-50 -15~50

5W-40 -30~40 20 -10~20

5W-50 -30~50 30 -5~30

10W-30 -25~30 40 5~40

10W-40 -25~40 50 15~50

Note: In the viscosity grade, the smaller the number before “W”, the better the low temperature performance of the oil; the
larger the number before “W”, the greater the viscosity of the oil. See standard GB 11122 for details.

CAUTION

1) Before starting the engine, check the oil level in the oil pan.
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2) Do not check the oil level while the diesel engine is running;
3) It is not allowed to mix the Weichai Power special oil with other oils.
See Table 2-3 for oil filling volume.
Table 2-3 Oil Filling Volume of the Engine

Number of filters

Oil filling volume Diesel engine

Engine model
(L) Fuel filter
Oil filter
Primary Secondary

WP12, WP13 25-28 2 1 1

Note：
1) The oil filling volume above is for reference only. The actual filling volume should base on the markings of oil dipstick.
2) If Weichai fuel system protector and fuel/water separator-filter is equipped, their filter elements shall be replaced when
replacing the diesel fuel filter.
3) The number of filters is for reference only, the actual number should base on the engine model.

2.1.3 Engine coolant

The freezing point specification of Weichai Power special coolant includes -25°C, -35°C, and -40°C. Please choose
the special coolant of different freezing points based on the local ambient temperature, and the freezing point
should be10°C below the local ambient temperature.
Table 2-4 Weichai Power special coolants for heavy-duty engine

Type Designation Packing capacity

HEC-II-25
Heavy-duty engine coolant HEC-II-35 4kg，10kg
HEC-II-40

CAUTION

1. Check the coolant regularly to prevent corrosion damage. Replace the coolant timely.
2. It is forbidden to use water or poor-quality coolant in the engine.
2.1.4 Urea solution
The quality and performance of urea solution used shall meet the requirements specified in standard GB29518.
The concentration and composition of the urea solution are listed in Table 2-5. Use of unqualified urea solution
has the risk of blocking the urea dosing pump and spray nozzle and the metal impurities contained will easily
lead to permanent intoxication of SCR catalyst and reduced the efficiency of SCR catalytic converter. Also, it is
strictly prohibited to use any other liquid instead of urea solution in normal use.
Table 2-5 Urea solution compositions (refer to standard ISO 22241)

Items Unit Minimum Maximum

Urea content % (m/m) 31.8 33.2
Density at 20°C kg/m³ 1,087 1,093
Refracting index at 20°C - 1.3814 1.3843
Alkalinity as NH3 % (m/m) - 0.2
Biuret % (m/m) - 0.3
Aldehydes mg/kg - 5
Insoluble matter mg/kg - 20
Phosphate (PO4) mg/kg - 0.5
Calcium mg/kg - 0.5

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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

Storage of urea solution

The urea solution for vehicle should be stored in an enclosed container at the ambient temperature of 5°C-25°C,
without direct sunlight, the shelf life is shown in Table 2-6.
Table 2-6 Shelf Life of urea solution for Vehicle

Shelf life of urea solution for vehicle

Ambient temperature, °C Minimum shelf life (month)
≤10 36
a
≤25 18
≤30 12
≤35 6
≥35 b
Note: The shelf life above is specified by giving major consideration to the ambient temperature and initial alkalinity of urea
solution besides the difference in evaporation between ventilated and non-ventilated storage containers.
Note a: In order to prevent decomposition, transporting or storing the urea solution for long hours at temperature above 25°C
shall be avoided.
Note b: Check whether the urea solution is up to standard before use.

The materials of the urea solution storage container should be properly compatible with the urea solution,
without chemical reactions or impurity migration. Container should be made of the recommended materials in
standard gb29518 such as austenitic alloys and additive-free Teflon, polyethylene and polypropylene without
additives. In case of storage below 5°C, a proper space should be reserved in the storage container as the volume
of urea solution in solidification state will be increased by about 7% compared to that in liquid state.
Please pay attention to the effectiveness of urea solution in the vehicle. The relationship between the shelf life of
urea solution and the ambient temperature during the inventory period of the vehicle is shown in Table 2-6. If
the inventory period exceeds the shelf life, it is required to drain away the urea solution through the drainage
valve at the bottom of urea solution tank and fill the tank with qualified urea solution before delivery. When the
ambient temperature is higher than 35°C, it is necessary to check if urea solution in the urea tank is still up to
standard before delivery of the vehicle, and replace with qualified when necessary.

CAUTION

1. Urea solution should be stored in the closed container, which should be stored in the cool and dry places,
far away from strong oxidizers. It is recommended to use special filling equipment to avoid splashing and
causing environmental pollution.
2. Urea solution is corrosive to the skin. If it contacts the skin or eyes accidentally when filling, wash with
water as soon as possible; if the pain continues, please seek medical help. If it is swallowed accidentally,
never induce vomiting but immediately seek medical treatment.
2.1.5 Auxiliary materials

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The auxiliary materials for the engine are shown in Table 2-7.
Table 2-7 Auxiliary Materials for the Engine

No. Name Color Purpose and application

To be applied to smooth metal surface to prevent seizing,
1 Molykote Pulver Black
e.g. external surface of cylinder liner
To be applied for lubrication before build-up of the
2 Molykote G-N pluspaste Dark grey
lubricating oil pressure, e.g. intake valve stem

The sealant application of engine is given in Table 2-8.

Table 2-8 Sealant Application of Engine

Designation Main purpose Application places Remarks

Camshaft timing gear bolt
Camshaft thrust plate fixing bolt
Flywheel housing bolt
Intermediate idler bolt
As an option,
Applied onto the Front cover bolt DriLoc204
threads to prevent Oil filter seat bolt
Weichai special sealant thread-locking
looseness due to
242 Oil cooler bolt adhesive can
vibration, with
Oil cooler adjustment valve bolt be used for
moderate strength
pre-coating.
Air compressor shaft end threads
Suction strainer bolt
Bolts for fuel pump return pipe fixing device
Bolts for sensor and wire harness fixing device
Applied on the outer
Weichai special sealant surface of the thread
Cylinder head auxiliary bolt
262 to lock, seal and
prevent shock
Applied on the top of
Weichai special sealant
cylinder head to seal Push rod body－cylinder head
270
the surface
Weichai special sealant
Fix and prevent shock Bowl plug for oil hole
271
Used for sealing
Weichai special sealant
between core and Other bowl plugs
277
hole
Cylinder block and crankcase joint surface
Engine front and front cover
Engine rear end face and flywheel housing connecting plate
Applied on the Water pump back cover – Engine front end
Weichai special sealant
shinymetal surface to
5188 (update for 510) Flywheel housing connecting plate - flywheel housing
seal
Cylinder block and oil cooler cover joint surface
Cylinder block and oil filler cap joint surface
Crankshaft gear and crankshaft rear end joint surface

2.2 Daily maintenance

2.2.1 Daily maintenance

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1. Check the coolant level, and open the filler cap to add
coolant when necessary.

CAUTION

Before opening the filler cap, make sure to press the

venting button to prevent personal injury due to the
hot coolant of the engine.

Fig. 2-1 Coolant filler cap

2. When the liquid level in the oil pan is below the “L” Oil dipstick
marking or above the “H” marking, never start the
engine.
Add oil through the oil filler timely.

CAUTION

Check the oil level at least 5 min after engine

shutdown, enabling the oil to return to the oil pan.
3. Check the fuel level, and add fuel timely.
4. Check the urea solution level Fig. 2-2 Markings of Oil Dipstick

The liquid level of the urea tank should be kept between

30% and 80% of the total volume of the urea tank.

2.2.2 Daily check

1. Check the coolant level, oil level and fuel level,
check and add grease when necessary.
2. Check for leakage of oil, water and air.
3. Check if the external parts and accessories are
connected and fastened securely.

Fig. 2-3 Checking of connections

4. Check the fan and belt;
5. Check if the exhaust temperature, color, engine
sound and vibration are normal, and if the engine
speed is stable;
6. Check the oil return pipe of turbocharger for
blockage and leakage;
7. Check the exhaust pipe for leakage and blockage.
Fig. 2-4 Checking of engine fan

2.3 Maintenance items

2.3.1 Oil change

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1. Unscrew the oil drain plug at the bottom of the oil
pan to drain the oil, and screw the oil drain plug back.

Oil drain plug

Fig. 2-5 Oil drain plug

2. Open the oil filler cap to add oil from the oil filler Oil filler cap
port. Observe the dipstick scale until the
requirements are met, and then put the oil filler cap
back on.

Fig. 2-6 Oil filler cap

2.3.2 Replace the oil filter or filter element

1. Use special tooling to remove the filter element. Pay attention to the oil inside the filter element to avoid oil
leakage that pollutes the environment. Do not discard the replaced oil filter.
2. Wipe the sealing surface of the joint surface with a clean rag to ensure that the sealing surface is free of
impurities so as not to affect the seal.
3. Apply a layer of oil film to the new seal ring, fill the filter with oil, lightly tighten the rubber ring to the sealing
surface, and tighten with a special wrench for 3/4 – 1 turn.
4. Start the engine to check for damage and oil leakage.

CAUTION

Unqualified diesel or oil filter will cause early wear of crankshaft bushing and other parts, which will increase the
risk of excessive emissions!

2.3.3 Replace the fuel filter and filter element

Follow these steps when replacing the fuel filter
element:
1. Remove the old fuel filter;
2. Lubricate the seal.
3. Screw on the filter by hand until the seal engages Fuel filter

the interface.
Fig. 2-7 Fuel filter
4. Continue to hand-screw the filter until the filter is
securely installed (approximately 3/4 turn).
5. Exhaust until no air bubbles appear.
6. Perform a leak test.
2.3.4 Check and adjust valve clearance
Valve clearance adjustment sequence:

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1. Turn the engine to the 1st cylinder compression top dead center (the flywheel housing observation window
marking is aligned with the flywheel groove).
2. Adjust the intake valve clearance of the 1st, 2nd, and 4th cylinder; the intake valve clearance is 0.4mm (see
Fig. 2-11 for the intake valve clearance adjustment method).

3. Adjust the brake clearance and exhaust valve

clearance of the 3rd cylinder (first adjust the brake
clearance, then adjust the exhaust valve clearance).
The brake clearance is 2.05mm. The exhaust valve
clearance is 3.0mm, and the adjustment method is
shown in Fig. 2-12.

Fig. 2-8 Flywheel marking

4. Turn the engine facing the flywheel end

counterclockwisely, align with the flywheel housing
observation window marking and the marking “1 6”
on the flywheel, and adjust the 6th cylinder brake
clearance and exhaust valve clearance (first adjust
the brake clearance, then adjust the exhaust valve
clearance). The brake clearance is 2.05mm, and the
exhaust valve clearance is 3.0mm. The adjustment
method is shown in Fig. 2-12.

Fig. 2-9 Flywheel marking

5. Turn the engine facing the flywheel end
counterclockwisely, align with the flywheel housing
observation window marking and the marking “2 5”
on the flywheel, adjust the brake clearance and
exhaust valve clearance of the 2nd cylinder (first
adjust the brake clearance, then adjust the exhaust
valve clearance). The brake clearance is 2.05mm, and
the exhaust valve clearance is 3.0mm. The
adjustment method is shown in Fig. 2-12.
6. Turn the engine facing the flywheel end
counterclockwisely, align with the flywheel housing
observation window marking and the marking “3 4” Fig. 2-10 Flywheel marking
on the flywheel.
7. Adjust the intake valve clearance of the 3rd, 5th
and 6th cylinder; the intake valve clearance is 0.4mm.
The adjustment method is shown in Fig. 2-11.
8. Adjust the brake clearance and exhaust valve
clearance of the 4th cylinder (first adjust the brake
clearance, then adjust the exhaust valve clearance).
The brake clearance is 2.05mm, and the exhaust valve
clearance is 3.0mm. See Fig. 2-12 for the adjustment
method.

9. Turn the engine facing the flywheel end counterclockwisely, align with the flywheel housing observation
window marking and the marking “1 6” on the flywheel, and adjust the 1 st cylinder brake clearance and exhaust

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valve clearance (first adjust the brake clearance, then adjust the exhaust valve clearance). The brake clearance is
2.05mm, and the exhaust valve clearance is 3.0mm. The adjustment method is shown in Fig. 2-12.
10. Turn the engine facing the flywheel end counterclockwisely, align with the flywheel housing observation
window marking and the marking “2 5” on the flywheel, adjust the brake clearance and exhaust valve clearance
of the 5th cylinder (first adjust the brake clearance, then adjust the exhaust valve clearance). The brake clearance
is 2.05mm, and the exhaust valve clearance is 3.0mm. The adjustment method is shown in Fig. 2-12.

Valve clearance adjustment method: Adjustment screw

Nut

1. Turn the engine to the corresponding position. Foot support

2. Intake valve clearance adjustment: Insert the feeler

gauge between the intake valve bridge and the intake
rocker arm. Adjust the valve clearance to 0.4mm, and
tighten the torque to (45±5)N•m.
3. Brake clearance adjustment: Insert the feeler
gauge between the exhaust valve bridge and the Fig. 2-11 Intake valve clearance adjustment method
small piston of the exhaust rocker arm, and adjust the
push rod side screw. The brake clearance is 2.05mm,
and the tightening torque is (45±5)N•m

4. Exhaust valve clearance adjustment: Insert the

feeler gauge between the exhaust valve bridge and Exhuast clearance

the foot support, and adjust the valve side screw. The
exhaust valve clearance is 3.0mm, and the tightening
torque is (45±5)N•m. Brake clearance
2.05mm

Fig. 2-12 Exhuast valve clearance adjustment method

2.3.5 Check the air seal

Check if the air intake hose is aging and cracked, and the clamp is loose. Fasten or replace parts as necessary to
ensure airtight system tightness.
2.3.6 Check the air filter element
The maximum allowable intake resistance of the engine is 6 kPa. The engine must be checked at the rated speed
and full load. When the intake resistance reaches the maximum allowable limit, the filter element should be
cleaned or replaced as specified by the manufacturer.

CAUTION

Never use the engine without an air filter, as dust and impurities entering the engine can cause early engine
wear!

Remove the filter element from the air filter, and tap
the end to allow the dust to fall, or use the
compressed air to blow from the inside out.

Fig. 2-13 Compressed air blow

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CAUTION

Unqualified air filter element can cause abnormal blockage of DPF, resulting in serious failures such as
excessive emissions and DPF damage!
2.3.7 Maintenance of after-treatment parts
Check the urea pump filter element:
The filter element of the urea pump needs to be removed and cleaned with water before installation for each
time of maintenance. Do not force or tap the filter element too hard.
CAUTION

The state of the urea nozzle needs to be checked each time the urea nozzle is replaced or disassembled. If it is
damaged or deformed, the urea nozzle needs to be replaced!
Clean the urea tank and urea tank filter element:
When doing maintenance, check the cleanliness of the urea tank and filter element and clean it if necessary.
CAUTION

After the engine is turned off (only T15 is cut off), the SCR system will automatically enter the reverse suction
state, and the urea solution in the urea pump and urea pipeline will be sucked back into the urea tank. This
phase will last for 2 minutes. During this period, it is forbidden to turn off the power supply of the vehicle.
Urea tank maintenance:
Regularly clean the urea tank every 60,000 km or 6 months to avoid the blockage and wear of the urea pump
caused by particulate impurities in the tank;
The urea tank sensor is an intelligent sensor that measures the liquid level and urea concentration and
corresponds to the data in the engine ECU. If the unmatched urea tank is replaced, it may cause OBD failure,
resulting in engine torque limit. If you need to replace it, please be sure to replace with the the same type of
urea tank as the original manufacturer’s.

2.4 Engine cleaning, protection and transportation

2.4.1 Cleaning and protection of engine
1. Warm up the engine, drain the lubricating oil, clean the oil filter, and add anti-rust oil;
2. Drain the fuel and add anti-rust oil mixture;
3. Drain the cooling water and add coolant containing anti-rust agent;
4. Start the engine and run it at idle speed for (15~25) minutes;
5. Drain off the lubricating oil, fuel and coolant completely;
6. Protect the other parts.
2.4.2 Protection during storage
Plug the oil, air and water inlet/outlet with lids or plastic cloth; cover and seal up the whole engine with VCI film.
2.4.3 Oil sealing
Generally the valid period of engine oil sealing is one year, and engine out of such period should be resealed as
follows:
1. The oil sealing should be operated in clean environment, and the diesel engine and related components
should clean without rust, oil stain and dust.
2. According to specific conditions, dipping, spraying, coating or filling methods can be used.
3. Oil seal positions: inlet/outlet port of turbocharger, inlet port of air compressor and intake pipe port.
2.4.4 Transportation
External packing should be provided during transportation.

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 Maintenance Manual of WP12/WP13 Four-valve China IV/China V/Euro V Diesel Engine for Vehicle

Chapter III Typical Faults and Troubleshooting

3.1 Overview
3.1.1 Overview
Engines of this series are designed and manufactured under a strict quality assurance system, and have
been subject to specified tests before delivery. Moreover, engine is the precise machinery whose lasting good
performance is related closely to a proper maintenance. The premature failure of engine is generally resulted

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from:
1. Operation against regulations, improper management and misuse;
2. Failure to inspect and maintain the engine as specified, and more serious, replacement of maintenance with
repair;
3. Use of defective spare parts, or even counterfeit and shoddy parts due to their cheap price, which will
dramatically shorten the service life of engine;
4. Use of fuel and lubricating oil with improper grade or poor quality.
CAUTION

1. The engine troubleshooting is a complicated work. Thus, do not disassemble or remove the engine at
discretion before determining its basic fault cause; otherwise, the fault will not be eliminated, and even
more serious fault may occur due to improper refitting.
2. Key components of the engine such as the high pressure fuel pump and turbocharger should be
maintained and inspected by special apparatus and based on certain experience. Therefore, users having
no relevant experience and equipment are not allowed to remove or adjust the engine at random.

3.2 Fault diagnostic methods

3.2.1 Traditional fault diagnostic methods

1. Observation: Determine the fault by observing

the symptom of diesel engine, such as smoke.

Fig. 3-1 Observation

2. Listening: Determine the fault location, symptom
and severity by listening to the abnormal noise
of diesel engine.

3. Comparison: Replace a certain assembly or

component to determine whether it is faulty.

Fig. 3-2 Listening

3.2.2 On-board diagnostics (OBD)

3.2.2.1 Check of MIL and SVS lamp

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1. MIL lamp is designed to indicate the faults related to

aftertreatment system. Under normal conditions, the MIL
lamp will stay on after the engine is powered on and will go
out automatically within 10s after the engine is started if the
engine has no fault.
1) If the MIL lamp is always on after the engine is started,
check if any DTC appears, if not, check if the driver circuit is
shorted to ground as per the pin diagram.
Fig. 3-3 OBD and SVS Lamps
2) If the MIL is flashing, check the driver circuit for false
connection.
3) If the MIL lamp does not go on during poweron self-test,
check the driver circuit and ensure that the bulb is normal.

Fig. 3-4 OBD Pins Diagram

2. SVS lamp is designed to indicate the faults related to

engine system, and it will go on and then go out quickly
during power on self-test.
1) If the lamp is always on after poweron, check if any DTC
appears; if not, check if this is caused by circuit fault;
2) If the SVS lamp does not go on during poweron self-test,
this may be caused by circuit fault or bulb damage.
Fig. 3-5 SVS Pins Diagram

3.2.2.2 DTC list

According to DTC, the name, related description, flash code(which can be checked through engine ECU) and P-
Code (which can be checkedif the engine is connected to ehicle) of engine fault, relatedfault components, fault
cause, solutions, etc. can be found to help quickly determine the cause of engine fault. The OBD fault diagnosis
methods are shown in the table below.

Table 3-1 OBD Fault Diagnosis Methods

Step Items Inspection methods

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Preliminarily judge the fault (mechanics, electrics, and

Preliminarily identify the fault and
1 components) according to the symptom and response of
location
vehicle; do not replace any component blindly.
DTC includeshistorical fault and present fault, and the
historical fault has no impact on vehicle performance. The
2 Read DTC (P code and flash code) location of fault that affects vehicle performance can be
determined by reading-recording-clearing-reading-recording
(analysis).
Check the engine step by step, do not replace any
component before identifying fault location. Most of DTCs
indicate the faulty location only rather than the faulty
component or sensor. Be sure to comprehensively identify
the fault point by taking the actual working process of
engine into consideration during troubleshooting.
3 Do troubleshooting based on DTC Troubleshooting scope of engineDTCs is classified as follows:
DTCs of fuel system: Fuel tank, filter, pipeline and joint, high-
pressure fuel pump and common rail, and fuel injector;
DTCs of air system: Air filter, pipeline, turbocharger, intake
air pressure and temperature sensor, intercooler, etc.;
Preliminary check of electrics: Harness, connector, sensor,
actuator, etc.
If no DTC can be read, check if the communication harness
between diagnosis tool and ECU is normal; if no DTC is read,
4 Do troubleshooting without DTC
do analysis and judgment based on experience and data
stream.

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3.3 Typical fault and troubleshooting

3.3.1 Engine start failure

Step Inspection items Inspection methods

Step 1 ...... Check of fuel quality ...... Check if the fuel is qualified.

Check of fuel level and fuel

Step 2 ...... ...... Check the fuel level in fuel tank, and check if the fuel gauge works normally.
gauge

Step 3 ...... Check of fuel tank ...... Check if the fuel tank is clean without any foreign matters and if the breather is not clogged.

Step 4 ...... Check of gear lever and ...... Check if the gear lever is set to neutral position and if the neutral switch works normally.
neutral switch

Step 5 ...... Check of auxiliary ...... Check if the auxiliary flameout switch is normal.
flameout switch

Step 6 ...... Check of battery voltage ...... Check if the battery voltage is normal (minimum starting voltage is 13~16 V).

Step 7 ...... Check of vehicle battery ...... Check if the vehicle battery is normal.

Step 8 ...... Check of starter relay ...... Check the starter relay harness for open circuit or incorrect connection and the starter relay for damage.

(1) If the starter motor does not work:

① Check if the vehicle key switch circuit is normal without intermittent connection;
② Check the starter relay harness for open circuit or incorrect connection and the
Check if the starter starter relay for damage, and eliminate circuit fault.
Check of starter
Step 9 ...... ...... motor works ......
motor (2) If the starter works:
normally.
① Check if the engine rotates smoothly;
② Check if the valve timing is correct;
③ The minimum cranking speed shall not be lower than 150 rpm.

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Check of low-pressure fuel Check the low-pressure line, coarse fuel filter and fine fuel filter for air accumulation, leakage or clogging; if the fuel
Step 10 ...... ......
line feed pump does not work, check the fuel feed pump piston, valve and fuel inlet filter for blockage.

The metering unit is normally open, the metering unit has no power supply due to incorrect harness connection and the
zero flow hole is blocked. Check the fuel pump: Loosen the fuel pump outlet and return port when the engine is shut
Check of high-pressure down. Normally, the pump will deliver fuel when the motor is started, which can be checked by reference to normal
Step 11 ...... ......
fuel line engine; in case of no or abnormal fuel delivery, the fuel pump may be abnormal: in this case, check if the fuel metering
unit is stuck at close position or small-opening position; the internal fuel passage or valve assembly is blocked by
particulate matters; in case of normal fuel delivery, check the fuel return volume of injector.

Check with diagnosis tester: Check if the rail pressure is built up normally. If the rail pressure is abnormal, it may be
Check with the fault caused by fuel injector, common rail, high-pressure fuel pump and ECU. Check if the four power lines between the
Step 12 ...... ......
diagnosis tester battery and the ECU are connected, and remove the vehicle harness connector from ECU to check for burning, which
may be caused by poor connection with ECU connector, water invasion due to seal failure or excessively high voltage.

Check of synchronization Check if the flywheel signal panel is synchronized with fuel pump cam signal panel by using diagnosis tester (signal 48).
between flywheel signal If they are not synchronized, check the crankshaft sensor or camshaft sensor for damage; if no damage is found, check
Step 13 ...... panel and fuel pump cam ...... the installation of crankshaft and camshaft speed sensors, the wire harness and the machining of flywheel ring gear. If
signal panel with the the crankshaft signal or camshaft signal is incorrect or there is no signal due to problems of mechanical assembly nd
diagnosis tester sensor harness, the synchronization will not be possible and the fuel injection will become abnormal.

1) Common DTCs:
Check DTCs with diagnosis tester. Common sync signal DTCs are as follows:
P0340: Camshaft signal lost
P0335: Crankshaft signal lost
P0341: Camshaft signal error
P0336: Crankshaft signal error
2) Check of camshaft and crankshaft signals:
Check of DTCs with scan Check the resistance of sensor (860±86 Ω at 20°C);
Step 14 ...... ......
tool Check if the sensor is installed in place (gap: 0.3~1.2 mm);
Check the wire harness between sensor and ECU for open circuit and short circuit; check the harness connector.
3) Check of sync signal:
Check for signal distortion due to sensor contamination;
Check for twisted pair and shielded cable, and check for electromagnetic interference caused by other signal lines
nearby;
Check if the relative position of crankshaft and camshaft is correct as per the timing drawing of engine;
Check the signal wheel for accurate machining, inconsistent height and width.

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4) Check of mounting position:

Mounting position of flywheel: When the piston of cylinder 1 is at TDC, the angle between the corresponding
crankshaft position of sensor and the position of notch shall be as specified in the factory design drawing.
Timing relationship of crankshaft and camshaft: Check the position of camshaft when the position of crankshaft is
fixed, in which case the relative position of crankshaft and camshaft must be as specified in the design drawing.

3.3.2 Insufficient engine power

Step Inspection items Inspection methods

Step 1 ...... Check of fuel quality ...... Check the fuel quality and grade are consistent with the specified, or if the fuel is of inferior quality.

Step 2 Check of throttle Check if the throttle cannot be opened to the 100% width due to obstacles or other physical factors.
...... ......
Check if the throttle feedback voltage is 100% when the accelerator pedal is depressed to the limit.

(1) Insufficient air intake:

① The air filter is dirty and blocked; the intake hose is leaky, blocked or deformation when the vehicle is
running at a high speed;
Check in the ② The turbocharger is not properly matched. Check the turbine side and compressor side for oil
following sequence: shortage or oil leakage, and if the blade is deformed or damaged;
air filter → intake
hose → ③ The intercooler is damaged, causing great resistance. Focus on checking of damage and blockage, and
turbocharger → check the connection of intake and exhaust hoses;
Step 3 ...... Check of air piping ...... intercooler → ...... ④ The intercooler is failed, causing excessively high intake temperature and reduced intake efficiency. It
combustion is necessary to check and remove the dirt from radiator and internal pipes to improve the radiation
chamber → exhaust effect.
pipeline (exhaust (2) High exhaust backpressure: If the backpressure of exhaust system is high due to blockage of exhaust
butterfly valve) → manifold, the residual exhaust gas in the cylinder will be increased, thus reducing the combustion rate of
muffler. the mixture, effective pressure of the cylinder and combustion efficiency. Focus on checking if the
exhaust pipeline is blocked, if serious carbon deposit occurs in the front and rear exhaust manifolds, if
the exhaust braking butterfly valve rotates smoothly, if the exhaust manifold and joint are properly
sealed and if the SCR tank and DPF are blocked.

Fuel tank → fuel (1) The fuel fails to be fed into fuel tank smoothly; tighten the fuel inlet and return pipe joints to avoid
coarse filter → gear leakage; the inner diameter of pipe shall not be small.
Check of low-pressure
Step 4 ...... ...... pump → fuel fine ...... (2) There shall be no residue and impurity deposits in the oil pan to avoid bloking the suction strainer.
fuel line
filter → high-
pressure fuel pump (3) The fuel inlet and return pipes involve problem, the fuel from fuel feed pump is insufficient, and the
fuel metering unit is damaged.
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(1) The high-pressure fuel pump is worn. The damage of high-pressure fuel pump, a component that
maintains the fuel supply pressure and a core component of the engine, will directly cause diesel engine
failure. Poor diesel fuel quality, filter damage and fuel feed pump damage will all result in wear of high-
pressure fuel pump plunger and control valve, reducing the fuel supply pressure.
High-pressure fuel (2) The common rail plays the role of fuel storage and pressure accumulation in common rail system, with
Check of high-
Step 5 ...... ...... pump → common ...... rail pressure sensor and pressure limiting valve as its key parts. Distortion of rail pressure sensor signal
pressure fuel line
rail → fuel injector and lax close of pressure limiting valve will reduce the fuel pressure in the pipe and directly decrease the
fuel injection.
(3) The needle valve is opened and closed under the control of solenoid valve to control fuel injection.
The main types of damage include serious carbon deposit of nozzle, needle valve stuck, and solenoid
valve damage.

Step 6 ...... Wrong configuration ...... Fuel injector, turbocharger, etc.

1) The cylinder gasket is leaky;

Check of tightness and
Step 7 ...... ...... 2) The valve and valve seat are improperly sealed;
valve clearance
3) The valve clearance is improper, resulting in an insufficient air intake volume.

Check of engine
Step 8 ...... ...... Check if overheating protection is activated due to excessive higher engine temperature in case of underpower.
overheating protection

Check of turbocharger Check if turbocharger protection is activated to limit the fuel injection when the working condition goes out of the
Step 9 ...... ......
protection working range of turbocharger.

Step 10 ...... Check of smoke limit ...... Check if the smoke limit is activated when the engine is working in a plateau region.

Step 11 ...... Aftertreatment system ...... 1) Nozzle fault;

fault 2) Urea dosing pump fault;
3) Urea pipeline fault;
4) Urea solution tank fault;
5) NOx sensor fault
The above faults will all cause the engine to trigger aftertreatment system torque limitation, which will limit the upper
threshold of output torque, and the user will feel insufficient power of engine. After finding out the fault location,
identify the faulty part or replace it with a new one, the fault will disappear, and the torque limit will be deactivated
automatically.
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Check of powertrain
Step 12 ...... ...... Check if the recommended configuration of powertrain is proper.
matching

Step 13 ...... Check of clutch ...... Check the clutch for serious wear, slipping, etc.

Check of chassis
Step 14 ...... ...... Check the chassis transmission system for excessive friction and check if the brake clearance is proper.
transmission system

Step 15 ...... Check of tire pressure ...... Check for tire burst or under-inflation.

Step 16 ...... Check of ECU data ...... The ECU data are not matched due to modification.

1) Demands for the engine: Power, economy and emission performance;

Step 17 ...... Inquiry of users ...... 2) Driving habits: engine speed during shifting, coasting in neutral;
3) Comparing mentality.

3.3.3 High fuel consumption

Step Inspection items Inspection methods

Make face-to-face communication with the user to verify the fault, and check if the fuel consumption is affected by
Step 1 ...... Inquiry of users ......
environment, special working condition and special time.

Check if the user has developed correct driving habits including shifting at reasonable speed range, abrupt acceleration
Step 2 ...... Check of driving habits ......
and deceleration, and always driving at a high engine speed.

Step 3 ...... Check of fuel quality ...... Check for fuel leakage, fuel grade and fuel quality.

Step 4 ...... Check of vehicle resistance ...... Check if the vehicle resistance is great. For example, large size items will cause great air resistance.

Step 5 ...... Check of odometer and ...... Check if the odometer and fuel gauge are normal.

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fuel gauge

(1) Insufficient air intake:

① The air filter is dirty and blocked; the intake hose is leaky, blocked or
deformation when the vehicle is running at a high speed;
② The turbocharger is not properly matched. Check the turbine side and
compressor side for oil shortage or oil leakage, and if the blade is deformed or
damaged;

Check in the following sequence: ③ The intercooler is damaged, causing great resistance. Focus on checking of
air filter → intake hose → damage and blockage, and check the connection of intake and exhaust hoses;
Check of air turbocharger → intercooler → ④ The intercooler is failed, causing excessively high intake temperature and
Step 6 ...... ...... ......
piping combustion chamber → exhaust reduced intake efficiency. It is necessary to check and remove the dirt from
pipeline (exhaust butterfly valve) → radiator and internal pipes to improve the radiation effect.
muffler. (2) High exhaust backpressure: If the backpressure of exhaust system is high
due to blockage of exhaust manifold, the residual exhaust gas in the cylinder
will be increased, thus reducing the combustion rate of the mixture, effective
pressure of the cylinder and combustion efficiency. Focus on checking if the
exhaust pipeline is blocked, if serious carbon deposit occurs in the front and
rear exhaust manifolds, if the exhaust braking butterfly valve rotates smoothly,
if the exhaust manifold and joint are properly sealed and if the SCR tank and
DPF are blocked.

(1) The fuel fails to be fed into fuel tank smoothly; tighten the fuel inlet and
return pipe joints to avoid leakage; the inner diameter of pipe shall not be
The inspection sequence is as small.
Check of low-
follows: Fuel tank → fuel coarse
Step 7 ...... pressure fuel ...... ...... (2) There shall be no residue and impurity deposits in the oil pan to avoid
filter → gear pump → fuel fine filter
line blocking the suction strainer.
→ high-pressure fuel pump.
(3) The fuel inlet and return pipes involve problem, the fuel from fuel feed
pump is insufficient, and the fuel metering unit is damaged.

Step 8 ...... Check of high- ...... High-pressure fuel ...... (1) The high-pressure fuel pump is worn. The damage of high-pressure fuel pump, a
pressure fuel line pump → common component that maintains the fuel supply pressure and a core component of the
rail → fuel injector engine, will directly cause diesel engine failure. Poor diesel fuel quality, filter damage
and fuel feed pump damage will all result in wear of high-pressure fuel pump plunger
and control valve, reducing the fuel supply pressure.
(2) The common rail plays the role of fuel storage and pressure accumulation in
common rail system, with the rail pressure sensor and pressure limiting valveas its key
parts. Distortion of rail pressure sensor signal and lax close of pressure limiting valve
will reduce the fuel pressure in the pipe and directly decrease the fuel injection.

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(3) The needle valve is opened and closed under the control of solenoid valve to
control fuel injection. The main types of damage include serious carbon deposit of
nozzle, needle valve stuck, and solenoid valve damage.

Step 9 ...... Check of ECU data ...... The ECU data are not matched due to modification.

1) The cylinder gasket is leaky;

Check of tightness and
Step 10 ...... ...... 2) Poor sealing between valve and valve seat;
valve clearance
3) Wrong valve clearance, resulting in insufficient air intake.

Step 11 ...... Check of cylinder fault ...... Check if engine cylinder is faulty, causing increased friction loss.

Step 12 ...... Check of drivetrain ...... Check if the drivetrain is not matched with the engine, or the drivetrain is faulty.

3.3.4 High oil consumption

Step Inspection items Inspection methods

Step 1 ...... Check of oil consumption ...... Check the oil consumption, and calculate the ratio of oil filling amount to mileage.

Check the engine for oil

Step 2 ...... ...... Check the engine for external oil leakage. Tighten the screw, pipe plug and joint. Replace the gasket timely.
leakage

Check of crankcase
Step 3 ...... ...... Check the crankcase ventilation system for leakage, and clean the ventilation system.
ventilation system

Check of air compressor

Step 4 ...... ...... Check if there is oil in air compressor pipeline.
pipeline

Step 5 ...... Check of oil dipstick ...... Check the oil dipstick marks.

Step 6 ...... Check of oil change interval ...... Check if the oil change interval is as specified.

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Check of oil for compliance

Step 7 ...... with the technical ...... Check if the oil meets the technical specifications under specific working condition. If not, replace the oil and filter.
specification

Check of turbocharger for

Step 8 ...... ...... Check the sealing elements and oil seals of turbocharger compressor and turbine for leakage.
leakage

Check of oil cooler for

Step 9 ...... ...... Check the oil cooler for leakage. Check if there is oil in the coolant.
leakage

Check of oil for

Step 10 ...... ...... Check if the oil is contaminated by coolant and fuel; analyze and identify contaminants in the oil.
contamination

Step 11 ...... Check of blow-by ...... In case of excessive blow-by, check if the piston rings are installed properly.

Check of condition inside

Step 12 ...... ...... Check the piston, cylinder liner and piston ring for wear and damage.
the cylinder

3.3.5 Starter motor does not work

Step Inspection items Inspection methods

Step 1 ...... Check of battery ...... Check if the battery runs low; check, recharge or replace the battery.

Step 2 ...... Check of fuse ...... Check if the fuse is burnt out; replace the fuse.

Step 3 ...... Check of connecting wire ...... Check if the connecting wire has poor contact; check the wire and tighten the terminal.

Step 4 ...... Check of starter motor ...... Check if the starter motor is short-circuited; repair the motor, or replace the assembly.

Step 5 ...... Check of electric brush ...... Check if the electric brush is in poor contact; clean the brush surface, and replace the assembly if necessary.

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Step 6 ...... Check of bearing bush ...... Check if the bearing bush is worn; replace the assembly.

Step 7 Check of commutator Check if the commutator is unclean or singed; clean the oil stains off and grind the surface with sand paper, or replace
...... ......
the assembly if necessary.

Step 8 ...... Check of connecting wire ...... Check if soldering failure occurs and solder again.

Step 9 ...... Check of switch ...... Check and repair the switch if the switch has poor contact.

Step 10 ...... Check of clutch ...... Check if clutch wear and slipping occur; adjust the torque of clutch, or replace the clutch assembly.

3.3.6 Alternator does not work

Step Inspection items Inspection methods

Step 1 ...... Check of connecting wire ...... Check the connecting wire of alternator and ammeter for open circuit, short circuit, and connector looseness.

Step 2 ...... Check of belt ...... Check if the alternator belt is slack; adjust the belt tension.

Check of rotor and stator Check if the rotor and stator coils are open-circuited, short-circuited or connected to vehicle body; if so, repair or
Step 3 ...... ......
coils replace the assembly.

Step 4 ...... Check of rectifying tube ...... Check if the rectifying tube is damaged; replace the assembly.

Check of binding post

Step 5 ...... ...... Check if the binding post paper insulation is damaged, causing wire disconnection.
paper

Step 6 ...... Check of regulating ...... Check if the regulator has an excessively low or high regulating voltage.
voltage of regulator

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Check of regulator
Step 7 ...... ...... Check if the regulator contactor is burnt; repair or replace the assembly.
contactor

Step 8 Check of rectifying tube Check if the rectifying tube of alternator is damaged, and the battery has poor contact.

Step 9 ...... Check of regulator ...... Check if the regulator field coil or the resistor wire is disconnected; repair or replace the assembly.

Step 10 ...... Check of electrolyte ...... Check the battery electrolyte, add electrolyte or replace the battery.

Step 11 ...... Check of electric brush ...... Check if the electric brush is in poor contact.

Step 12 ...... Check of binding post ...... Check if the binding post is loose and in poor contact.

Step 13 ...... Check of voltage regulator ...... Check if the voltage regulator is damaged.

Step 14 ...... Check of voltage ...... Check if the voltage regulation is improper.
regulation

Step 15 ...... Check the connection ...... Check if the regulator is properly connected with vehicle body.
between regulator and
vehicle body

Step 16 ...... Check of regulator ...... Check if the regulator contactor is inoperative or dirty, and the voltage coil or resistor wire is disconnected.
contactor

3.3.7 Air compressor failure

Step Inspection items Inspection methods

Step 1 ...... Check of pressure relief ...... Check if the pressure relief valve is stuck, and clean and replace the faulty part.
valve

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Step 2 ...... Check of valve plate ...... Remove the cylinder cover, check the valve plate, and replace the deformed or broken valve plate.

Step 3 ...... Check of valve seat plate ...... Remove the cylinder cover, and clean the valve seat plate.

3.3.8 High urea solution consumption

Step Inspection items Inspection methods

Check of ratio of urea
Communicate with the user to confirm the ratio of urea solution consumption to fuel consumption (recall the data
Step 1 ...... solution consumption to ......
stream with DiagSmart, and use the ratio of total urea solution consumption to total fuel consumption as a reference).
fuel consumption

If the ratio is smaller than 10%, tell the user that urea consumption is within normal range although it may not be the
Step 2 ...... Normal consumption ...... same as that of vehicles of other users. The possible reasons for this difference include vehicle model, working
condition, and driving habit.

If the ratio is greater than 10%, remove the spray nozzle from after-treatment box (remove the mounting bolts only,
Urea solution injection
Step 3 ...... ...... and do not remove the electrical connectors), connect DiagSmart software, network and actuator, and carry out
test
injection test with DiagSmart actuator.

Step 4 ...... Urea crystallization ...... In case of crystallization in exhaust pipe or after-treatment box, do troubleshooting referring to section 3.3.13.

Check the injection of urea spray nozzle:

(1) If columnar urea solution is injected continuously, the injection volume will be high and the spray nozzle should be
replaced.
Injection of urea spray
Step 5 ...... ...... (2) If urea solution is injected from three holes intermittently in atomization state and accompanied by click sound of
nozzle
the needle valve closure, it indicates that the injection is normal; wait for DiagSmart to display "End of Test". If urea
solution continuously leaks from the spray nozzle after injection stopped, replace the nozzle; if no leakage after it is
closed, check the pipeline for leakage.

Step 6 ...... Check of urea solution ...... If the urea solution consumption ratio is smaller than 10%, it is normal; if it is significantly greater than 10%, check the
consumption injection state of spray nozzle. If the nozzle hole is enlarged or serious crystallization occurs in the SCR tank due to the
use of inferior quality urea solution or addition of water in urea solution by the user, the warranty service will become
invalid.

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3.3.9 Low urea solution consumption or no consumption

Step Inspection items Inspection methods

Check of total urea
Communicate with the user to confirm the urea solution consumption (use DiagSmart to recall the total urea solution
Step 1 ...... solution consumption and ......
consumption and total fuel consumption from the data stream as a reference).
fuel consumption

Reading of ECU DTC with

Step 2 ...... ...... Read the ECU DTC with DiagSmart, and identify the fault cause based on DTC.
DiagSmart

Urea solution pressure

Step 3 ...... ...... If the urea solution pressure build-up failure is reported, do troubleshooting by referring to section 3.3.10.
build-up failure

Low NOx conversion

Step 4 ...... ...... If the low NOx conversion efficiency is reported, do troubleshooting by referring to section 3.3.12.
efficiency

In case of low consumption, communicate with the user to check if the fault is related to the working condition of
Communication with the vehicle. It is normal that urea solution consumption is low when the exhaust temperature is not high enough. If the
Step 5 ...... ......
user vehicle does not have any other faults, it indicates that this fault will not affect the fuel consumption and power of
vehicle.

Reading of DTC with In case of low or no urea solution consumption, then the total consumption value read by DiagSmart will be small.
Step 6 ...... ......
DiagSmart Connect DiagSmart, network, and actuator. If any DTC is read, do not clear it before troubleshooting.

If the ECU DTC shows that the fault lies in the components related to after-treatment system, such as open circuit or
Troubleshooting according
Step 7 ...... ...... short circuit of urea dosing pump, spray nozzle and SCR exhaust temperature sensor, do troubleshooting
to the DTC
correspondingly according to fault description until the fault is eliminated and no DTC is reported.

Step 8 ...... Urea solution injection ...... Check the working condition of urea solution injection system using DiagSmart.
test (1) If the urea solution injected from three holes of spray nozzle is in normal atomization state and click sound of
needle valve is accompanied, it indicates that the nozzle is normal.
(2) In case of no injection, check the pipeline for bending, leakage and reversed connection, eliminate pipeline fault; in
case of no pipeline fault, carry out injection test with DiagSmart, remove the urea dosing pump outlet pressure pipe,
and observe if any urea solution comes out from the outlet.

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If no urea solution comes out from dosing pump outlet, check if the suction pipe joint is blocked. Clean or replace the
joint when necessary.
If there is solution coming out from the dosing pump outlet, check if the spray nozzle is blocked. Clean the nozzle, and
Check of urea dosing
Step 9 ...... ...... repeat the urea injection test with DiagSmart. If the spray nozzle still fails to inject, replace the nozzle.
pump
In case of no urea consumption, do troubleshooting in sequence. Do not replace the dosing pump before verifying that
the pipeline is connected properly; and do not replace the spray nozzle before verifying that the dosing pump works
normally. Do troubleshooting step by step and correctly identify the fault location to avoid misjudgement.

3.3.10 Urea solution pressure build-up failure

Step Inspection items Inspection methods

Step 1 ...... Identification of fault ...... Identify the fault location according to DTC, and pay special attention to the function faults and component (e.g.,
location according to the nozzle, reversing valve, dosing pump, heating relay, resistive heater, exhaust temperature sensor, urea tank
DTC temperature sensor, etc.) faults related to pressure build-up.

Step 2 ...... Check of urea solution ...... In cold regions, check the heating components at first according to DTC to ensure normal heating function. If the faults
heating components related to heating exist at the same time, do troubleshooting by referring to section 3.3.11.

Step 3 ...... Check of related ...... Based on relevant fault information obtained in Step 1, if there is only component fault instead of function faults
component faults related to pressure build-up, check the nozzle, reversing valve, dosing pump, heating relay, resistive heater, exhaust
temperature sensor, urea tank temperature sensor, etc. and related wire harnesses; component faults may be the
possible reason why the system did not try to build up pressure, and the required SCR upstream exhaust temperature
for pressure release is 180°C.

Step 4 ...... Check of wire harness ...... Power off and restart. If the system still does not try to build up pressure, further check the harness between
components as it may be connected reversely.

Based on relevant fault information obtained in Step 1, if there is only function fault instead of component faults
Check of leakage and
Step 5 ...... ...... related to pressure build-up, which suggests that all components are not faulty, check the urea solution pipes for
clogging
leakage and clogging. The system may have made an attempt to build up pressure but failed.

Step 6 ...... Check of wire harness ...... Power off and restart. If the system still fails to build up pressure, further check the harness between components as it
may be connected reversely.

Step 7 ...... Check of urea tank liquid ...... Lack of urea solution in the tank may also result in pressure build-up failure. For relevant signals, please refer to the

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level liquid level.

Step 8 ...... Check of calibration data ...... Check the calibration data.

3.3.11 Urea solution heating function not released

Step Inspection items Inspection methods

...... Reading of DTC with ......
Read the DTC with DiagSmart to identify the fault location, and pay special attention to the faults related to urea
Step 1 DiagSmart for identification
solution heating and ambient temperature sensors.
of fault location

...... Check of ambient ......

Check the ambient temperature sensor and wire harness based on the result obtained in Step 1 to verify that the sensor
Step 2 temperature sensor and wire
works normally.
harness

...... Check of urea solution ......

Step 3 heating relay, solenoid valve Check the heating relay, solenoid valve and wire harness based on the result obtained in Step 1.
and wire harness

...... Check of urea solution ...... Check the heating resistor and wire harness, and urea tank heating pipeline based on the result obtained in Step 1.
Step 4 heating resistor and wire
harness

...... Check of dosing pump heater ...... If dosing pump heater fault is reported, and this fault still exists after power-off and restart, replace the dosing pump
Step 5
when necessary.

Step 6 ...... Check of calibration data ...... Check the calibration data.

3.3.12 Low NOx conversion efficiency

Step Inspection items Inspection methods

Step 1 ...... Identification of fault ...... Identify the fault location according to DTC, and pay special attention to faults related to NOx conversion efficiency.
location according to the

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DTC

Check of NOx sensor and Check the NOx sensor and exhaust pipe. If the measurement signal of NOx sensor is large, the conversion efficiency
Step 2 ...... ......
exhaust pipe fault will occur.

Check of urea solution Check the urea injection. If the injection volume is small, the measurement signal of NOx sensor will be large, and the
Step 3 ...... ......
injection volume conversion efficiency fault will occur accordingly.

Check the nozzle. If the nozzle involves fault (such as mechanical seizing or partially seizing which cannot be detected by
Step 4 ...... Check of spray nozzle ...... the system), the urea solution injection will be small, the measurement signal of NOx sensor will be large, and the
conversion efficiency fault will occur accordingly.

Check of urea solution Check the urea solution pressure. If the pipeline is leaky, the pressure will be low, the actual injection volume will be
Step 5 ...... ......
pressure small, and the measurement signal of NOx sensor will be large, causing conversion efficiency fault.

Check the urea solution. If the quality of urea solution is not acceptable (low concentration, high impurity, etc.), the
Step 6 ...... Check of urea solution ......
measurement signal of NOx sensor will be large, and conversion efficiency fault will occur accordingly.

Check of urea Check if the urea is crystallized. If crystallization happens inside the SCR tank, the conversion efficiency will decrease
Step 7 ...... ......
crystallization accordingly.

Check of engine and SCR Check the engine and SCR tank. If the engine or SCR tank has aged seriously, the original emission of NOx will be great
Step 8 ...... ......
tank or the measurement signal of NOx sensor will be large, and conversion efficiency fault will occur accordingly.

Check the factors related to the environment. If the ambient temperature and pressure sensor is damaged, and the
Check of factors related to
Step 9 ...... ...... vehicle is running in hot, plateau and cold environment, especially in regions of high altitude, the conversion efficiency
the environment
fault will occur.

Step 10 Check of calibration data Check the calibration data. If unreasonable conditions for releasing engine operating conditions exist, an error may be
...... ......
incorrectly reported.

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3.3.13 Urea crystallization

Step Inspection items Inspection methods

Step 1 ...... Check of crystallization ...... Check the exhaust pipe and after-treatment box for crystallization.

Step 2 ...... Check of connection ...... Check the exhaust pipe clamp for looseness and breakage, causing leakage.

Step 3 ...... Check of tightness Check the nozzle base for leakage.

Step 4 ...... Check of urea solution ...... Check if the urea solution used is up to standard with a standard concentration of 32.5%.

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Chapter IV Introduction to Engine Systems

4.1 Lubricating system

4.1.1 Overview
The lubrication system is essential for reliable operation of the engine, and it is also a key point in regular maintenance of
engine.
The lubrication system mainly functions for friction reduction, purging, cooling and rust protection, and the use of
lubricating oil shall conform to the enterprise standards of Weichai Power.
CAUTION

Notice: It is not allowed to use lubricating oils of grades CE, CD, CC, CB, or CA for the diesel engine. Remember to replace
the oil filter element while changing lubricating oil.
The oil pump suckslubricating oil from oil pan through suction strainer and then deliver it to oil filter passing through the
dirty oil passage of engine body, the filtered oil passes through the cooler to reach main oil passage. Small part of oil
reaches to rotor filter through the dirt oil passage, and then returns to oil pan. The oil in main passage reaches to the
lubricating positions through oil passages. A part of lubricatingoil reaches to main bearing through main oil passage, then
reaches to connecting rod bearing through the oil port in crankshaft. The piston cooling nozzle takes oil directly from the
main oil passage to lubricate and cool the piston and small end of connecting rod. A part of the oil reaches to front and rear
camshaft bearings (the first and seventh bearing) from main oil passage directly, then reaches rocker arm and rocker shaft
through oil holes in cylinder block and cylinder head.The oil reaching the front and rear camshaft bearings gets to the other
cam bearings via camshaft internal oil passage. Part of the oil in main oil passage reaches the gear chamber, rear PTO, air
compressor and fuel injection pumpthrough the oil passage at the rear end of engine body.The turbocharger takes oil
directly from the main oil passage (outside of the engine body) for lubrication.
The oil pressure of lubricating system is regulated through the pressure limiting valves in oil pump and the pressure limiting
valve in the main oil passage of oil cooling/filtering component. Also, oil cooler by-pass valve, oil filter by-pass valve and
rotor filter one-way valve are designed on oil cooling/filtering component.
The schematic diagram of oil passage of the engine is shown in the Fig. below:
Main oil passage
Oil cooler
High-pressure fuel
Camshaft bearing

Oil cooler
Air compressor

Bypass valve
Main bearing
Gear chamber

Turbocharger
PTO

pump

Cylinder head
Oil filter

Oil filter
Air intake rocker
Con-rod bearing

Bypass valve
Rocker arm shaft

arm Single-way valve

Air outlet rocker

arm
Piston cooling nozzle

Main oil passage

Oil pump

pressure limiting Centrifugal filter

valve

Oil pan

Fig. 4-1 Oil Passages of Diesel Engine

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4.2 Cooling system

4.2.1 Overview
The engine cooling system is mainly used to keep the engine in a proper temperature range under all working conditions.
The function of cooling system is to prevent the engine from overheating and overcooling. After the engine is started in cold
state, the cooling system shall ensure that the engine can be warmed up quickly, so as to reach the normal working
temperature as soon as possible. The engine cooling system is a forced circulation water cooling system, namely, the
coolant pump will be used to increase the coolant pressure and then force it to flow circularly in the engine. The coolant
circulation path of forced circulation water cooling system is as shown in the Fig. below:

Expansion Warm
water tank air

Water outlet
pipe
Thermostat

Cylinder head
Intercooler

Fan
Radiator

Cylinder block

Water tank Oil cooler

4.3 Fuel system

4.3.1 Schematic diagram of fuel system

Fig. 4-3 Schematic Diagram of Fuel System

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When the diesel engine works normally, the injection pump camshaft will drive the fuel delivery pump to suck fuel from
fuel tank. After the fuel flows throught the pump, it will be sent to the fuel filter after going through the ECU with the
pressure of（6-8）kg/cm2. The filtered fuel, after going through the fuel pump meaument module, will be partly sent to
the plunger chamber and partly to the fuel tank. When the plunger is moving up, the fuel in plunger chamber is
compressed and pumped into the common rail, and then flows into the injector through high pressure fuel pipe. The ECU
controls the opening and closing of injector by controlling on-off of solenoid valve on the injector. When the solenoid valve
is energized, the injector is opened, and the fuel is injected into the combustion chamber on the top of engine piston by the
injector.

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Chapter V Disassembling and assembling of engine

5.1 Intake manifold assembly

5.1.1 Exploded view

Fig. 5-1 Exploded view of intake manifold assembly

S/N Name S/N Name S/N Name S/N Name

1 Intake manifold 2 Grid heater relay 3 Intake manifold bolt 4 Bolt
5 Intake flow regulating 6 Intake flow regulating 7 Intake connecting pipe 8 Nut
valve valve gasket
9 Double-end stud 10 Grid heater 11 Grid heater gasket 12 Intake manifold
gasket
13 Temperature
pressure sensor

5.1.2 Disassembling tools and preparations

1. Disassembling tool
General tools required for maintenance and repair.

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5.1.3 Disassembling steps

1. Disassemble the intake flow regulating valve.

2. Disassemble the intake connecting pipe.
3. Disassemble the grid heater.

Fig. 5-2 Disassemble the intake flow regulating valve, intake

connecting pipe and grid heater
4. Disassemble the intake manifold bolt.
5. Disassemble the intake manifold.
6. Disassemble the intake manifold gasket.

Fig. 5-3 Disassemble the intake manifold bolt, intake

manifold and intake manifold gasket

5.1.4 Inspection and maintenance

1. Check the intake manifold for debris and dust, clean it if any
1) Check the intake manifold gasket for deformation, tearing, missing, etc. If any, it is necessary to replace it.
2) Check the grid heater for burnout, short circuit, etc. and replace it if any.
3) Ensure that the engine intake line is unobstructed, and the intake manifold is not cracked, etc. Tighten or replace it
to ensure the tightness of the intake system if necessary.
2. Connect the intake manifold to the intercooler line to avoid air leakage.
3. Check whether the intake pressure and temperature sensor wire harness connection and the sensor are damaged
and whether the measurement is normal.
5.1.5 Assembling steps
Assembling steps are in reverse of disassembling steps.

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5.2 Fan and hub assembly

5.2.1 Exploded view

Fig. 5-4 Exploded view of fan and hub assembly

S/N Name S/N Name S/N Name S/N Name

1 Hex flange bolt 2 Fan clutch assembly

5.2.2 Disassembling tools and preparations

1. Disassembling tools: equipped with a socket or wrench.

2. Preparation before disassembly: Ensure that the fan clutch wire harness is disconnected from the vehicle
before disassembly.

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5.2.3 Disassembling steps

1. Unscrew the flange bolts and remove the fan

clutch assembly and flange bolts.

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

5.2.4 Inspection and maintenance

Check the fan and clutch for cracks and other damage, and whether the clutch and fan rotate normally. Replace it with
an intact clutch fan assembly if any.

5.2.5 Assembling steps

Assembling steps is in reverse of disassembling steps.

5.3 Oil-gas separator assembly

5.3.1 Exploded view

Fig. 5-6 Exploded view of oil-gas separator assembly

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S/N Name S/N Name S/N Name S/N Name

1 Pre-separation oil 2 Hex flange bolt 3 Clamp 4 Oil-gas separator
return pipe return pipe
5 Hex flange bolt 6 Pipe clamp 7 Air hose 8 Oil-gas separator
assembly outlet pipe
9 Clamp 10 Oil-gas separator 11 Oil-gas pre- 12 Air hose
inlet pipe separator
13 Hex flange bolt 14 oil-gas separator 15 Bracket 16 Clamp
17 Hex flange bolt 18 Oil-gas separator 19 Clamp 20 Hinged bolt
return pipe
21 Assembled sealing 22 Pipe 23 Gasket 24 Joint
washer

5.3.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench or air wrench.

2. Preparation before disassembly: The engine is fixed and reliable, and other parts blocking the oil-gas separator are
disassembled.

5.3.3 Disassembling steps

1. Disassemble the clamps of the intake manifold 8, the exhaust manifold 12, the oil-gas pre-separator 11 and the
intake manifold 10 of the oil-gas separator, and remove the hoses.
2. Disassemble the clamps of the oil return pipe 4 and the oil return pipe 18 of the oil-gas separator, and remove the
hoses.
3. Disassemble the clamps that fix the oil-gas separator exhaust manifold and oil return pipe to the oil-gas separator,
and remove the hoses.
4. Disassemble the fixing nut and the hollow bolt 20 of the drive oil-inlet pipe 22 of the oil-gas separator, and remove
the oil-inlet pipe.
5. Disassemble the fixing bolt 13 of the oil-gas separator and remove the oil-gas separator.
6. Disassemble the oil-gas separator bracket fixing bolt 17 and remove the oil-gas separator bracket.

5.3.4 Inspection and maintenance

1. Check the appearance of each component to see whether there are any broken parts, cracked parts, etc., and the
hose is hardened and broken and fails in other mode. If there is any problem, replace the corresponding parts.
2. Check whether the oil-gas separator is unobstructed by inflating the intake manifold of the pre-separator. If the
airflow is not smooth, the oil-gas separator can be cleaned and unclogged by removing impurities and oil in the oil-gas
separator after the air with greater pressure passes through the pipe interfaces of the oil-gas separator. If the pre-separator
is still obstructed after the above operations, it needs to be replaced with a new pre-separator.
3. Check whether the oil-gas separator is unobstructed by inflating the intake manifold of the pre-separator. If the
airflow is not smooth, the oil-gas separator needs to be replaced with a new one.

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5.3.5 Assembling steps

1. The assembling steps of the oil-gas separator are the reverse of the disassembling steps. Ensure that the position of
each hose and each interface is correct according to the disassembling diagram. At the same time, see to it that the rotation
angle and fixing position of the hose are correct to ensure sufficient clearance with close parts.

5.4 Rear exhaust manifold assembly

5.4.1 Exploded view

Fig. 5-7 Exploded view of rear exhaust manifold assembly

S/N Name S/N Name S/N Name S/N Name

1 Assembly of exhaust 2 Bracket 1 3 Bracket 2 4 NOx sensor
connecting pipe heat
shield
5 NOx sensor bracket 6 Clamp band

5.4.2 Disassembling tools and preparations

1. Disassembling tool
General tools required for maintenance and repair.

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5.4.3 Disassembling steps

1. Remove the NOx sensor bracket.

2. Remove the NOx sensor.
3. Remove the bracket 2.
4. Remove the bracket 1.
5. Assembly of exhaust connecting pipe heat shield.

5.4.4 Inspection and maintenance

Be sure to install the NOx sensor on the exhaust connecting pipe with an intact, clean, dry tool. Do not install the
nitrogen oxide sensor if it is mechanically damaged.

5.4.5 Assembling steps

Assembling steps are in reverse of disassembling steps.

5.5 Turbocharger assembly

5.5.1 Exploded view

Fig. 5-8 Exploded view of turbocharger assembly

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S/N Name S/N Name S/N Name S/N Name

1 Assembly of 2 Clamp 3 Hose 4 Turbocharger
compressor intake
manifold
5 Turbocharger return 6 Double-end stud 7 Nut 8 Double-end stud
pipe
9 Nut 10 Turbocharger 11 Turbocharger inlet 12 Intake connecting
gasket pipe pipe
13 Clamp

5.5.2 Disassembling tools and preparations

1. Disassembling tool:
General tools required for maintenance and repair.
2. Preparations before disassembling:
Remove the air filter and connecting pipe, intercooler and exhaust tailpipe.

5.5.3 Disassembling steps

1. Disassemble the assembly of compressor intake

manifold.
2. Disassemble the intake connecting pipe.

Fig. 5-9 Disassemble the assembly of compressor intake

manifold and intake connecting pipe

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3. Disassemble the turbocharger return pipe.

4. Disassemble the turbocharger inlet pipe.
5. Disassemble the turbocharger.

Fig. 5-10 Disassemble the turbocharger inlet/return pipe

and turbocharger

5.5.4 Inspection and maintenance

1. Check for signs of looseness at the connection between the turbocharger and the engine line and clear it in time.
2. Check the turbocharger for air leakage and oil leaks and clear them in time.
3. Check the turbocharger fastening screw for looseness and clear it in time.
4. Check the air filter. If there is too much dust, it should be cleaned or replaced in time.
5. Push the air compressor impeller by hand lightly, and running one cycle or more means normal. If it stops quickly, it
means that the bearing has abnormal wear or there is collision or jam between the rotating part and the fixed part. It is
necessary to analyze the cause and clear the fault.

6. Check the operation of the turbocharger rotor

Place the dial indicator probe on the air compressor
end, push and pull the rotating shaft in the axial direction,
measure and record the difference value of the dial
indicator, as shown in Fig. 5–11. The rotor displacement
should be <0.09mm. If it exceeds this value, it means that
the thrust bearing plate or the thrust plate and the
bearing body are worn. The cause should be analyzed to
clear the fault.
Fig. 5-11 Rotor movement check

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7. Air compressor impeller radial clearance check

Press down or lift the air compressor impeller by
hand in the radial direction, as shown in Fig. 5-12. Use a
feeler gauge to measure the minimum and maximum
clearance between the air compressor impeller and the
air compressor casing. This value should be within the
range of (0.25~0.35) mm; if this range is exceeded, the
bearing should be checked to clear the fault.
Note: The above measurements should be made in
the cold state of the turbocharger. Fig. 5-12 Air compressor impeller radial clearance check
8. When the turbocharger is disassembled and
assembled, in case of a fault that cannot be cleared or
disassembly condition is not available, it should be
handed over to production or maintenance department
Note: The bolts and nuts for connecting the turbocharger to the exhaust manifold are made of special heat-resistant
steel materials, and ordinary bolts and nuts are not allowed to replace them.
Note: All gaskets are only allowed to be used once, and new parts are replaced during repair.
Note: Do not apply glue to the oil return gasket.
Note: Do not adjust the pressure of the turbocharger air release valve at will.
Note: For turbocharger that is left unused for a long period of time (more than 7 days), the turbocharger must be
removed and the oil inlet must be filled with oil before use.

5.5.5 Assembling steps

Assembling steps are in reverse of disassembling steps.

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5.6 Low-pressure fuel pipe assembly

5.6.1 Exploded view

S/N Name S/N Name S/N Name S/N Name

1 Hollow bolt 2 Sealing washer 3 Hex flange bolt 4 Fuel return pipe
assembly
5 Fuel return pipe 6 Hollow bolt 7 Sealing washer 8 Hollow bolt
assembly
9 Fuel return pipe 10 Hollow bolt 11 Pipe clamp 12 Hex flange bolt
assembly assembly
13 Fuel return pipe 14 Fuel return pipe 15 Sealing washer 16 Sealing washer
assembly assembly
17 Hollow bolt 18 Hollow bolt 19 Sealing washer

5.6.2 Disassembling tools and preparations

1. Disassembling tool:
Open end wrench.
2. Preparations before disassembling:
None.

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5.6.3 Disassembling steps

1. Remove the pipe clamp.

2. Remove the hollow bolt.
3. Remove the low-pressure fuel pipe.

5.6.4 Inspection and maintenance

1. Avoid kinks and bends in low-pressure lines, be careful when using rubber or plastic hoses.
2. Low-pressure lines, joints and hydraulic components must be reliably connected to avoid leakage.
3. Fuel pipes and connecting parts should avoid the use of copper, zinc, lead, tin and other metal materials.
4. The oil supply pipe and the oil return line should extend below the minimum oil level of the fuel tank, and the fuel
tank should be equipped with an air vent with a filter screen.
5. A certain distance between the mouths of oil-inlet pipe and oil return pipe should be ensured to prevent the air
bubbles entrained in the returned oil from being sucked into the oil-inlet pipe again, and at the same time, it is beneficial to
reduce the temperature of the sucked fuel.
6. The oil return pipe should extend below the minimum oil level of the fuel tank to prevent the air from entering the
oil pump along the oil return pipe after parking, and making the engine start difficult.
7. The ventilation system of the fuel tank should be equipped with a suitable air filter screen to prevent dust particles
and other pollutants from entering the fuel tank, reduce fuel pollution, increase the service life of the filter, and reduce the
wear of the high-pressure common rail system components. Check whether there is gas in the low-pressure circuit and
exhaust the air.
8. Exhaust method: Mainly discharge the air inside the primary filter. Unscrew the air bleeding bolt on the primary
filter and manually press the manual pump on the primary filter until oil continues to flow from the air bleeding bolt.

5.6.5 Assembling steps

Assembling steps is in reverse of disassembling steps.

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5.7 Common rail pipe assembly

5.7.1 Exploded view

Fig. 5-13 Exploded view of common rail pipe assembly

S/N Name S/N Name S/N Name S/N Name

1 Common rail pipe 2 Hex flange bolt

5.7.2 Preparations before disassembling

1. Disassembling tool:
Socket wrench;
2. Preparations before disassembling:
Remove the high-pressure fuel pipe assembly.

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5.7.3 Disassembling steps

1. Unscrew the hex flange bolts.

2. Disassemble the common rail pipe.

Fig. 5-14 Disassemble the common rail pipe

5.7.4 Inspection and maintenance

1. Check whether the joint between common rail pipe and high-pressure fuel pipe is in good condition, and replace it
with a new one if there is any damage.
2. Check whether the pins in the rail pressure sensor are in good condition.

5.7.5 Assembling steps

In reverse of disassembling steps.

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5.8 Fuel injector assembly

5.8.1 Exploded view

Fig. 5-15 Exploded view of fuel injector assembly

S/N Name S/N Name S/N Name S/N Name

1 Lock nut 2 High-pressure joint 3 Fuel injector 4 Fuel injector pressing
plate
5 Spherical washer 6 Hex bolt

5.8.2 Disassembling tools and preparations

1. Disassembling tool:
Socket wrench.
2. Preparations before disassembling:
Remove the rocker arm cover and high-pressure fuel pipe.

5.8.3 Disassembling steps

1. Remove the hex bolt for mounting fuel injector press block.

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2. Remove the fuel injector press block.

3. Remove the fuel injector assembly from the cylinder head.

5.8.4 Inspection and maintenance

1. Check the head of the nozzle for carbon deposit and clean if necessary.
2. Injector nozzle replacement must be conducted at a dedicated Bosch service station.
3. Pay attention to the injector nameplate mark and the fuel injectors of different part numbers are not
interchangeable.
4. Marking position: On the solenoid valve at the top of the injector.
5. Marking specifications: The first line: Fuel injector model, such as: WPCRIN2;
6. The second line: Weichai part number, such as: 611600080035;
7. The third line: Bosch part number, such as: 0445B29850.

Fig. 5-16 Fuel injector marking specifications

5.8.5 Assembling steps

Assembling steps are in reverse of disassembling steps.

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5.9 Air compressor assembly

5.9.1 Exploded view

Fig. 5-17 Exploded view of air compressor assembly

S/N Name S/N Name S/N Name S/N Name

1 Gasket 2 Hollow bolt 3 Air compressor water 4 Pipe clamp
return pipe
5 Hex flange bolt 6 Air compressor 7 Hollow bolt 8 Gasket
lubricating oil pipe
9 Supporting block 10 Pipe clamp 11 Air compressor gear 12 Air compressor water
inlet pipe
13 Hex flange bolt 14 Pipe clamp 15 Air pipe joint 16 Air hose
17 Clamp

5.9.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench or air wrench, open end wrench, etc.
2. Preparation before disassembly: Disconnect the air compressor exhaust manifold from the gas cylinder and remove
the air compressor lubricating pipe.

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5.9.3 Disassembling steps

1. Disassemble the water inlet/outlet pipe of air

compressor.

Fig. 5-18 Disassemble the water inlet/outlet pipe

2. Disassemble the bolt connecting air compressor to
engine block.
3. Take out the air compressor from the engine block
horizontally.

Fig. 5-19 Disassemble the air compressor

5.9.4 Inspection and maintenance

1. Check the air compressor gear for damage, replace it if it is damaged.

2. Check the sealing ring and replace it if there are signs of aging.
3. Check the lubricating pipe for signs of oil leaks and replace it if any.
4. Check the water inlet and outlet pipes for signs of leaks and replace them if any.

5.9.5 Assembling steps

1. Unscrew the air compressor nut, install the air compressor gear on the air compressor drive shaft and tighten it with
the air compressor nut. The tightening torque is (200+50) N·m. Apply the thread locker 242 to the air compressor shaft end
thread.
2. Remove the burrs on the joint surface of the air compressor and the gear chamber and wipe the joint surface.
3. Install an O-ring on the flange face of the air compressor.
4. Install the pre-assembled air compressor components on the flywheel housing connecting plate. Loosely install the
air compressor fastening bolts and tighten them.
5. Screw in the double pipe joints on the cylinder block and the air compressor and tighten them.
6. Blow off the inner cavity of the water inlet and outlet pipes by compressed air, and then place the clamp and the
pipe joint nut on both ends of the water inlet and outlet pipes.

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7. Install the air compressor water inlet and outlet pipes and tighten the pipe joint nut.
8. Blow off the inner cavity of the intake and exhaust manifolds by compressed air, and then place the clamp and the
pipe joint nut at the end where the air compressor intake and exhaust manifolds connect the air compressor.
9. Install the air compressor intake and exhaust manifolds and tighten the pipe joint nut.
10. Connect the air compressor oil pipe to the cylinder block and the air compressor with a hollow bolt and a sealing
washer, and tighten the hollow bolt.

5.10 Fuel injection pump assembly

5.10.1 Exploded view

Fig. 5-20 Exploded view of fuel injection pump assembly

S/N Name S/N Name S/N Name S/N Name

1 Fuel injection pump 2 Fuel injection pump 3 Fuel injection pump 4 Wave-shaped
gear flange rubber ring flange elastic gasket
5 Hex screw 6 Double-end stud 7 Hex socket head cap 8 Fuel injection pump
screw assembly
9 Type 2 hex nut

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5.10.2 Disassembling tools and preparations

1. Disassembling tool:
Socket wrench;
2. Preparations before disassembling:
Remove the connected low-pressure fuel pipe and high-pressure fuel pipe,

5.10.3 Disassembling steps

1. Unscrew the hex nuts between the fuel injection pump flange and the gear chamber.
2. Remove the fuel injection pump and gear assembly from the engine.
3. Disassemble the fuel injection pump lock nuts.
4. Unscrew the hex bolts between the fuel injection pump and the flange.
5. Disassemble the fuel injection pump flange.

5.10.4 Inspection and maintenance

The structure of the fuel injection pump is as shown in the Fig.. When the flywheel is rotated and the first cylinder of
the diesel engine is at the TDC of on the compression stroke, the marked line of the fuel injection pump should be aligned
with the marked line of the gear chamber.

5.10.5 Assembling steps

1. Install the fuel injection pump flange and apply a

small amount of lubricating oil to the rubber ring on the
fuel injection pump.

Fig. 5-21 Install the fuel injection pump flange rubber ring

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2. Install the hex bolts between the fuel injection

pump and the flange.

Fig. 5-22 Install the mounting nuts of fuel injection pump

3. Install the fuel injection pump gear. The fuel
injection pump gear lock nut is M24×1.5: tighten once to
(250～300) N·m.

Fig. 5-23 Install the fuel injection pump gear

4. Screw the three double-end studs for fixing pump
to engine block.

Fig. 5-24 Install the fuel injection pump to engine block

5. When the flywheel is rotated and the first cylinder
of the diesel engine is at the TDC of on the compression
stroke, the fuel injection pump gear is rotated. When the
marked line of the fuel injection pump gear is aligned with
the marked line of the fuel injection pump flange, the fuel
injection pump assembly is installed. Insert a Φ4 pin into
the corresponding hole in the intermediate flange and
gear, tighten the common rail pump assembly, pull out the
pin, and seal with the sealant-coated screw (M5).
6. Tighten the hex nuts between the fuel injection
pump and the gear chamber. The torque of injection Fig. 5-25 Fuel injection pump installation alignment mark
pump flange bolt is 51±5N.m

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5.11 Fuel filter assembly

5.11.1 Exploded view

Fig. 5-26 Exploded view of fuel filter assembly

S/N Name S/N Name S/N Name S/N Name

1 Screw 2 Fuel filter bracket 3 Hex flange bolt 4 Fuel filter
assembly
5 Hexagon head 6 Hex flange bolt 7 Hexagon head flange
flange bolt with bolt with tooth on the
tooth on the bearing surface
bearing surface

5.11.2 Disassembling tools and preparations

1. Disassembling tool:
Socket wrench.
2. Preparations before disassembling:
Remove the connected low-pressure fuel pipe.

5.11.3 Disassembling steps

1. Remove the low-pressure fuel pipe connecting to primary filter and secondary filter.
2. Remove the hexagon head flange bolt with tooth on the bearing surface for fixing filter base.

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3. Remove the hexagon head flange bolt for fixing filter base.
4. Remove the hexagon head flange bolt for fixing filter bracket.

5.11.4 Inspection and maintenance

Check the water level in the water cup of the primary fuel filter from time to time, and discharge the water, and
replace the fuel filter element every 60,000 kilometers.

5.11.5 Assembling steps

1. Remove the fuel primary filter and secondary filter with a suitable wrench.
2. Clean the filter base.
3. Apply oil on the new filter element seal gasket.
4. Screw the filter element into place by hand, subject to the sealing ring coming into contact with the filter seat
sealing surface.
5. Tighten the filter element 3/4-1 turn with a suitable wrench.
6. Unscrew the air bleeding screw of the primary fuel filter and pump the oil with the manual pump on the primary
fuel filter until the fuel flows out of the air bleeding screw and tighten the air bleeding screw.
7. Unscrew the hollow bolt at the fuel outlet of the fuel secondary filter and pump the oil with the manual pump on
the fuel supply pump until the fuel flows out of the loose hollow bolt and tighten the hollow bolt.

5.12 Starter assembly

5.12.1 Exploded view

Fig. 5-27 Exploded view of starter assembly

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S/N Name S/N Name S/N Name S/N Name

1 Double-end stud 2 Starter 3 Hex flange nut

5.12.2 Disassembling tools and preparations

1. Disassembling tools: Common tools such as socket wrench, air wrench or open end wrench, etc.
2. Preparations before disassembling: None.

5.12.3 Disassembling steps

1. Disassemble the hex nut.

2. Hold the starter with both hands to remove it along the axis of rotation of the starter gear.

5.12.4 Assembling steps

1. The starter gear should be coated with lithium-based grease for automobile.
2. Install the double-end stud
3. Install the starter.
4. Tighten the nuts.

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5.13 Electronic control unit (ECU) assembly

5.13.1 Exploded view

Fig. 5-28 Exploded view of electronic control unit (ECU) assembly

S/N Name S/N Name S/N Name S/N Name

1 ECU bracket 2 Hex flange bolt 3 Electronic control 4 Cover
unit (ECU)
5 Hex flange bolt 6 Hex flange bolt

5.13.2 Disassembling tools and preparations

1. Disassembling tool
2. Socket wrench;
3. Preparations before disassembling
4. Remove the fuel inlet pipe connecting to ECU.

5.13.3 Disassembling steps

1. Unscrew the bolts fixing ECU.

2. Disassemble the ECU.

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3. Unscrew the hex bolts fixing ECU bracket.

5.13.4 Inspection and maintenance

1. Check whether the bolts and screws that fix ECUs are reliably connected. If there is any looseness, tighten them with
a wrench.
2. Check whether the ECU pins are in good condition.

5.13.5 Assembling steps

In reverse of removal steps.

5.14 High-pressure fuel pipe assembly

5.14.1 Exploded view of assembling

Fig. 5-29 Exploded view of high-pressure fuel pipe assembly

S/N Name S/N Name S/N Name S/N Name

1 High-pressure fuel 2 High-pressure fuel 3 High-pressure fuel pipe
pipe assembly pipe assembly assembly

5.14.2 Disassembling tools and preparations

1. Disassembling tool:
Open end wrench
2. Preparations before disassembling:
Remove the intake manifold

5.14.3 Disassembling steps

1. Remove the bracket fixing high-pressure fuel pipe.

2. Remove the high-pressure fuel pipe.

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5.14.4 Inspection and maintenance

Check the high-pressure fuel pipe joint nut for looseness, and tighten it if any.
Check the high-pressure circuit for gas: Loosen a high-pressure fuel pipe of a cylinder, and use the starter to drive the
diesel engine until oil continues to flow from the high-pressure fuel pipe! (It is not recommended to remove high-pressure
fuel pipe joints frequently!).

5.14.5 Assembling steps

In reverse of disassembling steps.

Caution

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 high--pressure fuel rail end and pump end of high-pressure pump.

5.15 Oil filler pipe

5.15.1 Exploded view

Fig. 5-30 Exploded view of oil filler pipe assembly

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S/N Name S/N Name S/N Name S/N Name

1 Oil filler cap 2 Assembled sealing 3 Hex flange bolt 4 Cover
washer
5 Gasket

5.15.2 Disassembling tools and preparations

1. Disassembling tools: equipped with a socket or wrench.

5.15.3 Disassembling steps

Refer to the exploded drawing of the oil filling pipe assembly, disassemble the hex flange bolts that fix the cover and
gasket, and remove the cover and gasket.

5.15.4 Inspection and maintenance

1. After filling the oil, pay attention to the clockwise turning of the pull rod to tighten the pipe cover.

5.15.5 Assembling steps

1. Assembling steps of oil filler pipe are in reverse of disassembling steps.

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5.16 Air bleeding pipe assembly

5.16.1 Exploded view

Fig. 5-31 Exploded view of air bleeding pipe assembly

S/N Name S/N Name S/N Name S/N Name

1 Assembled washer 2 Air bleeding pipe 3 Assembled washer 4 Hollow bolt

5.16.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench.

2. Preparations before disassembling: Discharge the coolant in the engine firstly.

5.16.3 Disassembling steps

1. Unscrew the hollow bolts of air bleeding pipe in sequence.

2. Remove the air bleeding pipe and assembled washer.

5.16.4 Inspection and maintenance

1. Check the air bleeding pipe itself for cracks, wear, corrosion, and other damage. If there is a crack, replace the air
bleeding pipe. For corrosion that affects reliability, analyze the cause and replace it with a new air bleeding pipe.

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2. Check for water leakage at the hollow bolts. If there is water leakage, check the failure and replace them with new
hollow bolts.

5.16.5 Assembling steps

1. Clean the joint surface of the air bleeding pipe and the cylinder head and wipe the air bleeding pipe.
2. Install the assembled washer on one side of the hollow bolt on the hollow bolt and place the installed hollow bolt
and assembled washer into the air bleeding pipe.
3. Install the assembled washer on the other side on the hollow bolt, install the air bleeding pipe on the cylinder head,
and tighten the hollow bolt.

5.17 Oil cooler cover assembly

5.17.1 Exploded view

Fig. 5-32 Exploded view of oil cooler cover assembly

S/N Name S/N Name S/N Name S/N Name

1 Bolt 2 Supporting block 3 Oil cooler cover 4 O-ring
5 Washer 6 Water pipe joint 7 Hollow bolt

5.17.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench.

2. Preparations before disassembling: Discharge the coolant in the engine firstly.

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5.17.3 Disassembling steps

1. Unscrew the hollow bolt on the oil cooler cover and unscrew the oil cooler cover mounting bolt.
2. Remove the oil cooler cover and O-shape sealing ring.

5.17.4 Inspection and maintenance

1. Check the oil cooler cover for cracks and other damage. If there is any cracks, replace the oil cooler cover.
2. Check the O-ring for damage. If there is any signs of water seepage, check the failure and replace it with a new O-
ring.

5.17.5 Assembling steps

1. Clean the joint surface of the oil cooler cover and the engine block, and apply the special Weichai sealant and install
the oil cooler cover.
2. Install the oil cooler cover bolts and tighten them.
3. Install the outlet fitting and tighten the hollow bolts.

5.18 Oil cooler assembly

5.18.1 Exploded view

Fig. 5-33 Exploded view of oil cooler assembly

S/N Name S/N Name S/N Name S/N Name

1 Bolt 2 Oil cooler 3 O-ring

5.18.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench.

2. Preparations before disassembling: Discharge the coolant in the engine firstly.

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5.18.3 Disassembling steps

1. Unscrew the oil cooler mounting bolts.

2. Remove the oil cooler and O-ring.

5.18.4 Inspection and maintenance

1. Check the oil cooler itself for cracks and other damage, and replace the oil cooler if any.
2. Check the O-ring for damage. If there is any water leakage, analyze the failure and replace the O-ring with a new
one.

5.18.5 Assembling steps

1. Clean the joint surface of the oil cooler and the engine block and install the oil cooler.
2. Install the oil cooler bolts and tighten them.

5.19 Oil pump assembly

5.19.1 Exploded view

Fig. 5-34 Exploded view of oil pump assembly

S/N Name S/N Name S/N Name S/N Name

1 O-ring 2 Oil pump 3 Bolt 4 Locating pin

5.19.2 Disassembling tools and preparations

1. Disassembling tools: Socket or wrench.

5.19.3 Disassembling steps

1. Unscrew the oil pump mounting bolts.

2. Remove the oil pump and O-ring.

Fig. 5-35 Exploded view of oil pump

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5.19.4 Inspection and maintenance

1. Check the oil pump for cracking and replace the oil pump if any.
2. Check whether the oil pump drive gear rotates flexibly. If the rotation is not flexible, replace the oil pump.

5.19.5 Assembling steps

1. Check whether the oil pump drive gear rotates flexibly and is damaged before assembly.
2. Clean the joint surface of the oil pump and the crankcase, install the oil pump and tighten the bolts.

5.20 Oil filter assembly

5.20.1 Exploded view

Fig. 5-36 Exploded view of oil filter assembly

S/N Name S/N Name S/N Name S/N Name

1 Bolt 2 Oil filter seat 3 Gasket 4 Oil filter

5.20.2 Disassembling tools and preparations

1. Disassembling tools: Prepare a special disassembling tool for the oil filter, a sleeve or a wrench.

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5.20.3 Disassembling steps

1. Remove the oil filter first with special tooling.

Fig. 5-37 Removal diagram of oil filter

2. Unscrew the bolts that assemble the oil filter seat
and remove the oil filter seat and gasket.

Fig. 5-38 Removal diagram of oil filter seat

5.20.4 Inspection and maintenance

1. Check the oil filter for bumps, the oil filter seat and the oil filter joint surface for oil leaks, and replace if any.
2. Check the bolt threads for deformation and replace if any.

5.20.5 Assembling steps

1. Remove the spin-on oil filter element and loosely install it on the oil filter seat.
2. Install the oil filter seat on the crankcase and tighten the bolts.
3. Tighten the oil filter element with special tooling.

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5.21 Exhaust manifold assembly

5.21.1 Exploded view

Fig. 5-39 Exploded view of exhaust manifold assembly

S/N Name S/N Name S/N Name S/N Name

1 Exhaust manifold 2 Assembly of LH 3 Sealing ring 4 Assembly of
gasket exhaust manifold heat middle exhaust
shield manifold heat
shield
5 Exhaust manifold 6 Exhaust manifold bolt 7 Assembly of RH
sleeve exhaust manifold
heat shield

5.21.2 Disassembling tools and preparations

1. Disassembling tool
General tools required for maintenance and repair.

5.21.3 Disassembling steps

1. Unscrew the exhaust manifold bolts.

2. Disassemble the exhaust manifold sleeve.
3. Disassemble the assembly of exhaust manifold heat shield.
4. Disassemble the exhaust manifold gasket.
5. Disassemble the exhaust manifold sealing ring.

5.21.4 Inspection and maintenance

1. Check the exhaust system for debris.

2. 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.
3. Check the exhaust manifold flange for air leakage. If any, it is necessary to replace it with a new exhaust manifold
gasket.
4. Check the exhaust manifold gasket for deformation, tearing, missing, etc. If any, it is necessary to replace it.
5. The bolts and nuts used in the exhaust system are made of heat resistant steel and are not allowed to be replaced
by ordinary bolts and nuts.

5.21.5 Assembling steps

Installation of the exhaust pipes is in the reverse order of removal. Attention shall be given to the following:
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1. While installing the exhaust pipe seal rings, be careful not to cause damage to the exhaust pipe joint surface. See from
free end to flywheel end, the openings of 4 sealing rings should be toward left/toward right/toward up/toward down in
order.
2. The exhaust manifold bolts should be coated with molybdenum disulfide and the exhaust manifold bolts can be reused
up to 2 times.
3. Tighten the exhaust manifold bolts in three steps. Step 1,screw on the bolts but not tighten; Step 2 ，tighten the bolts
with the torque of 30N.m; Step 3，tighten the bolts to （65-80）N.m
4. For 2 bolts-structure manifold, tighten the exhaust manifold bolts from middle to both sides symmetrically.
5. For 3 bolts-structure manifold, tighten the exhaust manifold bolts as figure below

5.22 Tensioner and belt assembly

5.22.1 Exploded view

Fig. 5-40 Exploded view of tensioner and belt assembly

S/N Name S/N Name S/N Name S/N Name

1 Automatic 2 Hex flange bolt 3 Idle pulley 4 Idle pulley
tensioner
5 Automatic 6 Hex socket head 7 Multi-ribbed 8 Multi-ribbed
tensioner cap screw belt belt

5.22.2 Disassembling tools and preparations

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1. Disassembling tools: Socket wrench or air wrench, open end wrench, etc.
2. Preparations before disassembling: Remove the fan and hub assembly.

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5.22.3 Disassembling steps

1. Disassemble the outer tensioner assembly.

2. Disassemble the outer belt.
3. Disassemble the inner automatic tensioner.
4. Disassemble the inner belt.
5. Disassemble the idle pulley.

5.22.4 Inspection and maintenance

1. Check the belt for cracking, severe eccentric wear, and other forms of failures, and replace it with corresponding
parts in case of above problems.
2. Check the tensioner for no rotation, abnormal noise, blocking and other forms of failures, and replace it with
corresponding parts in case of above problems.
3. When replacing the belt, make sure that the belt is stayed in the groove to prevent abnormalities such as belt
slippage.

5.22.5 Assembling steps

1. Install the idle pulley and automatic tensioner. Loosely install the inner belt. The belt is freely placed around the
damper pulley, fan pulley, two idlers, air conditioning compressor, generator pulley and automatic tensioner without
tension. Use a square wrench to turn the automatic tensioner counterclockwise, place the belt, and tension the belt after
confirming that the belt is fully grooved.
2. Install the outer tensioner assembly and belt.

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5.23 Thermostat assembly

5.23.1 Exploded view

Fig. 5-41 Exploded view of thermostat assembly

S/N Name S/N Name S/N Name S/N Name

1 O-ring 2 Thermostat

5.23.2 Disassembling tools and preparations

1. Disassembling tools: equipped with a socket or wrench.

2. Preparations before disassembling: Discharge the coolant in the engine firstly.

5.23.3 Disassembling steps

1. Unscrew the flange bolts and remove the thermostat cap.

2. Remove the thermostat and O-ring.

5.23.4 Inspection and maintenance

1. Check the thermostat for damages such as cracking and not tight sealing etc., and it’s necessary to replace it with an
intact one if any.

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5.23.5 Assembling steps

1. Put the thermostat into water pump.

2. Install the two O-rings and then install the thermostat cover and tighten the bolts.

5.24 Water pump assembly

5.24.1 Exploded view

Fig. 5-42 Exploded view of water pump assembly

S/N Name S/N Name S/N Name S/N Name

1 Water pump 2 Heater joint 3 Pipe joint 4 Temperature
sensor
5 Temperature 6 Sealing 7 O-ring 8 Water pipe
sensor washer joint
9 Cover 10 Water pipe 11 Flange bolt 12 Plug
joint

5.24.2 Disassembling tools and preparations

1. Disassembling tools: equipped with a press-fit tool, socket or wrench.

2. Preparation before disassembly: Before disassembly, first release the antifreeze solution in the engine; remove the
belt, fan and the connecting pipe on the vehicle before disassembly.

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5.24.3 Disassembling steps

1. Remove the 5 bolts connecting the pump to the engine

block.
2. Remove the water pump.
3. Remove the O-shape sealing ring.

Fig. 5-43 Exploded view of water pump

5.24.4 Inspection and maintenance

1. Check the water pipe joints, plugs, temperature sensors for leaks, and replace them with intact water pipe joints,
plugs, and temperature sensors if any.
2. Check the water pump assembly for cracks and other damage, and whether there is any inflexibility, and replace it
with an intact water pump if any.

5.24.5 Assembling steps

1. Polish the joint surface of the front end of the cylinder block and the back cover of the water pump, and wipe it
clean and apply the 518 gasket sealant.
2. Place an O-ring in the O-ring groove of the water pump back cover.
3. Install the water pump assembly and fasten it with bolts. Check whether the pump pulley is flexible before assembly.

5.25 Generator assembly

5.25.1 Exploded view

Fig. 5-44 Exploded view of generator assembly

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S/N Name S/N Name S/N Name S/N Name

1 Cylinder 2 Cylindrical 3 Cylinder 4 Bowl plug
liner pin block
5 Hex bolt

5.25.2 Disassembling steps

1. Unscrew the short hex flange bolts.

2. Unscrew the long hex flange bolts.
3. Remove the generator.

5.25.3 Assembling steps

1. Straighten the generator.

2. Install the long bolt with the nut.
3. Lift the generator up and install the short bolt.
4. Tighten the bolts.

5.26 Fan bracket assembly

5.26.1 Exploded view

Fig. 5-45 Exploded view of fan bracket assembly

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S/N Name S/N Name S/N Name S/N Name

1 Fan bracket 2 Hex flange bolt 3 Fan pulley 4 Fan terminal
assembly pad
5 Spring washer 6 Hex socket head 7 Baffle 8 Hex bolt
cap screw

5.26.2 Disassembling tools and preparations

1. Disassembling tools: equipped with a socket or wrench;

2. Preparation before disassembly: The front wheel train, belt and fan clutch assembly must be removed before
disassembly.

5.26.3 Disassembling steps

Unscrew the bolts that secure the fan bracket assembly and remove the fan bracket assembly and fan pulley. If
necessary, remove the fan pulley firstly.

5.26.4 Inspection and maintenance

Check whether the bearing rotates normally and is not blocked, and there is any axial movement, and whether there is
any crushing on the bolt mounting surface. Replace the fan bracket assembly or bolts in time if there is any obvious
blocking, movement and crushing.

5.26.5 Assembling steps

In reverse of disassembling steps.

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5.27 Hoisting ring assembly

5.27.1 Exploded view

Fig. 5-46 Exploded view of hoisting ring assembly

S/N Name S/N Name S/N Name S/N Name

1 Hoisting ring

5.27.2 Disassembling tools and preparations

1. Disassembling tools: Torque wrench, open end wrench, socket wrench or air wrench.
2. Preparation before disassembly: The engine is fixed and reliable.

5.27.3 Disassembling steps

The hoisting ring is secured to the hoisting ring clamping block by the thread for lifting the engine. The hoisting ring
can be removed by loosening the thread during disassembly.

5.27.4 Inspection and maintenance

Disassemble and check the hoisting ring for cracks, large deformations, and other failure modes. If there is a failure
mode of the above type, replace the part with a new one for assembly to prevent a safety accident.

5.27.5 Assembling steps

The installing steps of engine hoisting ring are in reverse of disassembling steps.

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5.28 Cylinder head cover assembly

5.28.1 Exploded view

Fig. 5-47 Exploded view of cylinder head cover assembly

S/N Name S/N Name S/N Name S/N Name

1 Cylinder head 2 Locating sleeve 3 Cylinder head 4 Cylinder head
cover cover gasket cover
5 Hex flange bolt 6 Supporting block 7 Cylinder head 8 Cylinder head
cover cover gasket

5.28.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench or air wrench.

2. Preparation before disassembly: The engine is fixed and reliable, and the parts above the cylinder head cover are
disassembled.

5.28.3 Disassembling steps

Unscrew the cylinder head cover bolts and support screws in turn, and pull out the cylinder head cover, locating
sleeve, cylinder head cover gasket, etc. vertically.

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5.28.4 Inspection and maintenance

1. Check the cylinder head cover itself for cracks, large wear and other damage. If there is a crack, replace it with a new
cylinder head cover.
2. If there is oil leakage at the cylinder head cover gasket, check the cylinder head gasket for failure and the upper
plane of the cylinder head cover and the underside sealing surface of the cylinder head cover for surface wear degree. If
there is oil penetration and leakage, replace the cylinder head cover gasket with a new one and then check again for oil
penetration and leakage.

5.28.5 Assembling steps

1. The cylinder head cover gasket is only allowed to be used once, and it is replaced with a new one when reworked.
Before installing the cylinder head cover gasket, check that the new cylinder head cover gasket is not defective or damaged
in manufacturing and use.
2. Wipe the sealing surface of the cylinder head and cylinder head cover, and correctly assemble the cylinder head
gasket, cylinder head cover, locating sleeve, etc. in sequence.
3. Install the cylinder head cover bolts and tighten them.

5.29 Suction filter assembly

5.29.1 Exploded view

Fig. 5-48 Exploded view of suction filter assembly

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S/N Name S/N Name S/N Name S/N Name

1 Bolt 2 Washer 3 Oil suction 4 Gasket
filter

5.29.2 Disassembling tools and preparations

1. Disassembling tools: Socket or wrench.
2. Preparation before disassembly: Remove the oil pan firstly.
5.29.3 Disassembling steps
1. Unscrew the suction filter bolts.
2. Remove the suction filter and gasket from oil pump.

Fig. 5-49 Exploded view of suction filter mounting bolts

5.29.4 Inspection and maintenance

1. Check whether the suction filter screen is blocked.

2. Check whether the suction filter is installed securely.
3. Check the suction filter for cracking, breakage, etc.

5.29.5 Assembling steps

1. Apply the Weichai special 242 sealant to the threads of the suction filter fastening bolts.
2. Screw in the bolt with the washer and tighten it with a tightening torque of 50 N·m.

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5.30 Electronic control wire harness and sensor assembly

5.30.1 Exploded view

Fig. 5-50 Exploded view of electronic control wire harness and sensor assembly

S/N Name S/N Name S/N Name S/N Name

1 Engine wire harness 2 Hex bolt 3 Wire harness bracket 4 P-type pipe
clamp
5 Hex socket head cap 6 Clamp band 7 Hex bolt 8 P-type pipe
screw clamp
9 Hex socket head cap 10 Wire harness 11 Hex socket head cap 12 Wire harness
screw bracket screw bracket
13 Wire harness bracket

5.30.2 Disassembling tools and preparations

1. Disassembling tool:
Socket wrench;
2. Preparations before disassembling:
None.

5.30.3 Disassembling steps

1. Disassemble the engine wire harness fixing bracket.

2. Disassembling the engine wire harness.

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5.30.4 Inspection and maintenance

None

5.30.5 Assembling steps

In reverse of disassembling steps.

5.31 Valve train assembly

5.31.1 Exploded view

Fig. 5-51 Exploded view of valve train assembly

S/N Name S/N Name S/N Name S/N Name

1 Tappet 2 Push rod 3 Engine block 4 Exhaust valve
5 Cylinder head 6 Valve spring 7 Exhaust valve 8 Cylindrical pin
bridge
9 Rocker arm shaft 10 Rocker arm shaft 11 Brake rocker arm 12 Locating sleeve
seat assembly assembly
13 O-ring 14 EVB bracket 15 Hollow bolt 16 Hex socket head cap
assembly bolt

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S/N Name S/N Name S/N Name S/N Name

17 Assembled sealing 18 EVB lubricating oil 19 Solenoid valve 20 Hex socket head cap
gasket pipe assembly screw
21 Wire harness 22 Intake rocker arm 23 Rocker shaft seat 24 Intake valve bridge
bracket assembly assembly
25 Valve spring upper 26 Collet 27 Valve spring lower 28 Intake valve
seat seat
29 Flywheel housing 30 Hex bolt 31 Thrust plate 32 Hex bolt
connecting plate
33 Camshaft timing 34 Hex bolt 35 Cylindrical pin 36 Camshaft
gear

5.31.2 Disassembling tools and preparations

1. Disassembling tool:
Dial indicator, torque wrench, lubricating oilcan and lubricating oil, towel, camshaft guiding tool.
2. Preparations before disassembling:
1) Disassembly is performed on the assembly frame.
2) After the intermediate gear of flywheel housing is disassembled, disassemble the camshaft timing gear and the
camshaft.
3) After the camshaft is pulled out, remove the tappet from under the engine block
4) After the cylinder head cover is disassembled, disassemble the rocker arm and rocker arm shaft.
5) After the rocker arm and rocker are shaft are disassembled, take out the push rod
6) After the cylinder head is disassembled, remove the cylinder head from the engine block and then disassemble the
valves.

5.31.3 Disassembling steps

1. Disassemble the rocker arm and rocker arm shaft. See the disassembling steps of rocker arm and rocker arm shaft
for details.
2. Disassemble the push rod. See the disassembling steps of push rod for details.
3. Disassemble the intake and exhaust valves. See the disassembling steps of valve for details.
4. Disassemble the camshaft and camshaft timing gears. See the disassembling steps of camshaft and camshaft timing
gear for details.
5. Disassemble the tappet. See the disassembling steps of tappet for details.

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1. Disassembling steps of rocker arm and rocker arm

shaft
1) Turn the crankshaft to see if the rocker arm is
flexible.
2) Measure each valve clearance and check for valve
clearance changes.
3) If the rocker arm is not flexible or the valve
clearance changes greatly, loosen the hex screw, then
gently remove the EVB bracket, rocker arm shaft
assembly, intake and exhaust rocker arm, rocker arm
bracket, and mark them to avoid mixing the rocker arm of
each cylinder.

Fig. 5-52 Exploded view of rocker arm and rocker arm shaft
2. Disassembling steps of push rod
After the rocker arm and the rocker arm shaft are
disassembled, remove the push rods directly and place
them in order.

Fig. 5-53 Exploded view of push rod

3. Disassembling steps of valve
1) Use the valve spring compressor or valve spring
pressing plier or other tool to press the valve spring,
remove the valve collet, and remove the valve spring
upper seat and valve inner and outer spring.
2) Remove the valve from the valve seat.

Fig. 5-54 Exploded view of valve and spring

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4. Disassembling steps of camshaft

1) Turn the camshaft to check whether the camshaft
and timing gear are flexible and unblocked.
2) Use a dial indicator to check the camshaft for axial
displacement compared with the previous one.
3) Check the timing gear backlash.
4) On the engine mounting and dismounting table,
turn the crankshaft so that the camshaft timing gear is
located at the TDC of the first cylinder. Check the Fig. 5-55 Exploded view of camshaft
camshaft fixing hex bolt for looseness, etc., and remove
the camshaft timing gear hex bolt, camshaft timing gear
and locating pin.
5) Remove the camshaft thrust plate hex bolt,
remove the thrust plate and then remove the camshaft.
5. Disassembling steps of tappet
After the camshaft is taken out from the engine
block, take out the tappet from under the engine block .

Fig. 5-56 Exploded view of tappet

5.31.4 Inspection and maintenance

1. Inspection and maintenance points of rocker arm and rocker arm shaft
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 ball pin and rocker arm elephant foot 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.
6) Check the wear condition of EVB adjusting screw and whether there is cracking or wear of EVB bracket.
2. Inspection and maintenance points of valve
1) Check the valve stem and valve stem end faces for wear.

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2) Check the valve cone surface for wear or damage.

3) Check the valve cone surface and the arc surface for carbon deposit and sinter.
4) Check the upper end face of the valve bridge for wear marks and the parts that are in contact with the valve for
wear marks.
3. Inspection and maintenance points of tappet and push rod
1) Clean the push rod and tappet.
2) Check whether the tappet push rod oil circuit is unblocked.
3) Check the push rod for bending and the outer surface for wear.
4) Check the push rod ball head and the recess for wear.
5) Check the surface and underside of the tappet for wear.
6) Check the inner recess of the tappet for wear.
4. Inspection and maintenance points of camshaft
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) Check whether the timing gear fastening hex bolt is bent or deformed, the camshaft timing gear is broken or the
surface is seriously worn.

5.31.5 Assembling steps

1. Assemble the tappet. See the assembling steps of tappet for details.
2. Assemble the camshaft and camshaft timing gears. See the assembling steps of camshaft and camshaft timing gear
for details.
3. Assemble the push rod. See the assembling steps of 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 assembling steps of rocker arm and rocker arm shaft for
details.
Assembling steps of tappet
1. Check the tappet for problems and update if any. Before assembling the tappet, it must be blown off with
compressed air and check whether the oil hole is unblocked.
2. Apply clean lubricating oil evenly to the outer ring of the valve tappet and its underside.
3. Use the tappet mounting tool to install the tappet to the tappet hole from the bottom of the engine block. During
the installation process, the tappet and the tappet hole must not be bumped.
Assembling steps of camshaft assembly
1. Wipe the camshaft hole with a towel and check
the camshaft hole for bumps. Apply appropriate
amount lubricating oil to the inner circle of the
camshaft bushing with an oilcan. If the camshaft hole
is found to have a bump, it is not allowed to be used
after repair.

Fig. 5-57 Assembling diagram of camshaft assembly

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2. Place the camshaft guiding tool and the camshaft lubricating sleeve into the camshaft hole, wipe the camshaft and
check for bumps, align the cylinder of the tail of the guiding tooling with the cylinder of the head of the camshaft, and then
insert the camshaft into the camshaft hole. After the camshaft is installed, remove the camshaft guiding tool and the
camshaft sliding sleeve. Be careful to scratch the camshaft bushing when inserting the camshaft.
3. Install the camshaft thrust plate, apply clean lubricating oil on both sides of the camshaft thrust plate, turn the
camshaft, and the camshaft should rotate flexibly. Apply the 242 sealant to the threads of the thrust plate bolt, and
tightening torque should be (35±3)N•m.
4. Polish the rear end face of the cylinder block, wipe it clean after oil removal, and the joint surface should be smooth
and clean. Install the rear end face of the crankshaft into the cylindrical pin and then install the flywheel housing connecting
plate and tighten the four fastening bolts.
5. Apply special glue to the connecting plate, and the glue line should be continuous and uniform.
6. The camshaft thrust plate and the timing gear are bolted to the camshaft, and the counter bore on the connecting
plate must be aligned with the marked tooth on the camshaft timing gear.
Assembling steps of push rod
1. Check the push rod for problems and update if any.
2. After the cylinder head is assembled (see the assembling steps of cylinder head for details), blow off the push rod
with compressed air and check whether the oil hole is clear.
3. Apply clean lubricating oil to the push rod with and make sure the ball head and recess have sufficient oil.
4. Install the push rod with the spherical surface of the push rod facing down.
Assembling steps of valve and spring
Check the end face of the valve retainer for carbon deposits and sintering. If the valve is worn or the carbon deposit is
seriously sintered, it is necessary to replace with a new valve.
1. Evenly apply the molybdenum disulfide paste to the intake and exhaust valve stems, and then install the intake and
exhaust valves in the cylinder head to ensure that the intake and exhaust valves slide in the conduit without blocking.
2. The locating pins are driven into the upper plane of the cylinder head, and there are three locating pins for each
cylinder head, and it is required to be driven to the bottom.

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3. Install the intake valve spring lower seat, put the

valve stem protection sleeve on the intake and exhaust
valve guide rod, and then assemble the valve stem sealing
sleeve.
4. Note: Before assembling, it is necessary to check
whether the internal spring of the valve stem sealing
sleeve is in good condition.
5. Install the valve spring.
6. Install the valve spring upper seat, press down the
valve spring, and install the valve collet.
7. After the valve collet is installed, use the rubber
hammer to tap the intake and exhaust valve into the seat.
For the valve collet or the valve spring upper seat that is
not seated, find the cause and clear the fault.

Fig. 5-58 Assembling diagram of valve and spring

Assembling steps of rocker arm and rocker arm shaft

1. Place the rocker arm on the operating floor, screw in the adjusting screw on the rocker arm and loosely install the
nut for inspection.
2. A cylindrical pin is installed into the pin hole in the lower plane of the rocker arm shaft assembly, and the cylindrical
pin is driven to the end, and the cylindrical pin has no cracks.
3. Assemble the rocker arm bracket with the rocker arm shaft and tightly combine the rocker arm bracket and the
rocker arm shaft. After applying a small amount of lubricating oil to the rocker arm shaft, install the rocker arm assembly,
and the rocker arm assembly rotates flexibly. Install two hex socket head cap bolts into the rocker shaft seat.
4. Press the locating sleeve into the hole of the cylinder head, place the O-ring in the lower plane counterbore of the
EVB bracket, install the EVB bracket into the locating sleeve, and install the compression bolts so that the lower plane of the
EVB bracket is completely seated.
5. After installing the valve push rod (refer to the valve push rod assembly process for details), place the valve bridge
and exhaust valve bridge assembly on the intake and exhaust valves respectively.
6. Install the rocker arm member and pre-tighten it, and the pin hole on the lower side of the rocker arm bracket is
aligned with the locating pin on the upper plane of the cylinder head and completely seated; the rocker arm ball pin is
seated in the round hole of the valve push rod; a wire harness bracket also needs to be installed on the upper plane of the
rocker arm shaft assembly of 2-cylinder and 5-cylinder.
7. Tighten the rocker arm seat bolts.
8. Align the interfaces on both ends of the lubricating pipe assembly respectively with the oil inlet of the rocker arm
shaft and the oil inlet of the EVB bracket. At the same time, the upper and lower planes of the oil pipe joint are padded with
composite washers, and the two interfaces are screwed into the hollow bolts. The tightening torque is 20±3N.m.
9. Apply the lubricating oil to the O-ring of the solenoid valve and install it into the solenoid valve hole of the rocker
arm seat assembly and press the solenoid valve with a hex socket screw to fully seat the solenoid valve. The screw
tightening torque is 12±1.5N.m. Be careful not to let the push rod come into contact with the terminal of the solenoid valve.
10. Check and adjust the intake and exhaust valve clearance.

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11. After the cold-state clearance of the intake valve, the brake clearance, and the cold-state clearance of the exhaust
valve are adjusted, check the intake open and exhaust close of 1st-cylinder and record on the record card.
12. Check the valve timing of 1st-cylinder at the cold state. If the camshaft part number is 1000053446, the intake
valve open is before the TDC (20±5)°, and the exhaust valve close is after the TDC (8±5)°. If the camshaft part number is
1001672478, the intake valve open is before TDC (20±5)°, and the exhaust valve close is after the TDC (22±5)°.
Adjustment sequence and method of valve clearance
Valve clearance adjustment sequence, (see the diagram of flywheel marked lines)
1. Manually rotate the crankshaft until the 1st-cylinder is at the TDC of the compression stroke (the flywheel housing
observation window scale line is aligned with the flywheel groove).
2. Adjust the intake valve clearance of 1, 2 and 4-cylinder; Intake valve clearance is (0.4±0.03) mm.
3. Adjust the brake clearance and exhaust valve clearance of the 3-cylinder (firstly adjust the brake clearance, then
adjust the exhaust valve clearance).
4. Facing the flywheel end, manually rotate the
crankshaft counterclockwise until the flywheel housing
inspection window scale line is aligned with the scale line
marked “16” on the flywheel and adjust the brake
clearance and exhaust valve clearance of the 1-cylinder
(firstly adjust the brake clearance, then adjust the exhaust
valve clearance). Fig. 5-59 Diagram of flywheel marked lines
5. Facing the flywheel end, manually rotate the
crankshaft counterclockwise until the flywheel housing
inspection window scale line is aligned with the scale line
marked “25” on the flywheel and adjust the brake
clearance and exhaust valve clearance of the 2-cylinder
(firstly adjust the brake clearance, then adjust the exhaust
valve clearance).
6. Facing the flywheel end, manually rotate the crankshaft counterclockwise until the flywheel housing inspection
window scale line is aligned with the scale line marked “34” on the flywheel.
7. Adjust the intake valve clearance of 3, 5 and 6-
Adjusting Adjust the position of Elephant foot Adjust the position
cylinder. Intake valve clearance is (0.4±0.03) mm. bolt at push the brake clearance adjusting bolt of the exhaust
8. Adjust the brake clearance and exhaust valve rod side feeler gauge clearance feeler
gauge
clearance of the 4-cylinder (firstly adjust the brake
clearance, then adjust the exhaust valve clearance).
9. Facing the flywheel end, manually rotate the
crankshaft counterclockwise until the flywheel housing
inspection window scale line is aligned with the scale
line marked “16” on the flywheel and adjust the brake
clearance and exhaust valve clearance of the 1-cylinder
(firstly adjust the brake clearance, then adjust the
exhaust valve clearance). Fig. 5-60 Diagram of clearance adjustment
10. Facing the flywheel end, manually rotate the crankshaft counterclockwise until the flywheel housing inspection
window scale line is aligned with the scale line marked “25” on the flywheel and adjust the brake clearance and exhaust
valve clearance of the 5-cylinder (firstly adjust the brake clearance, then adjust the exhaust valve clearance).
Exhaust valve clearance and brake clearance adjustment method: (see the diagram of exhaust valve clearance
adjustment).
1. Manually rotate the crankshaft to the corresponding adjustment position (see the diagram of exhaust valve
clearance adjustment).

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2. Brake clearance adjustment: Insert the feeler gauge between the exhaust valve bridge and the small piston of the
exhaust rocker arm, and adjust the adjusting bolt at push rod side to maintain the brake clearance of 2.05±0.03mm.
3. Exhaust valve clearance adjustment: Insert the feeler gauge between the exhaust valve bridge and the pad, and
adjust the exhaust valve clearance to 3.00±0.03mm.
4. Tightening torque of the adjusting nut at exhaust push rod side (M10): (45 ± 5) N•m. Tightening torque of exhaust
valve clearance adjusting nut (M10): (45±5) N·m. Tightening torque of intake valve adjusting nut is (45±5) N·m.

5.32 Fuel injector assembly

5.32.1 Exploded view

Fig. 5-61 Exploded view of fuel injector assembly

S/N Name S/N Name S/N Name S/N Name

1 Lock nut 2 High- 3 Fuel injector 4 Fuel injector
pressure pressing
joint plate
5 Spherical 6 Hex bolt
washer

5.32.2 Disassembling tools and preparations

1. Disassembling tool:

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Socket wrench.
2. Preparations before disassembling:
Remove the rocker arm cover and high-pressure fuel pipe.

5.32.3 Disassembling steps

1. Remove the hex bolt for mounting fuel injector press block.
2. Remove the fuel injector press block.
3. Remove the fuel injector assembly from the cylinder head.

5.32.4 Inspection and maintenance

1. Check the head of the nozzle for carbon deposit and clean if necessary.
2. Injector nozzle replacement must be conducted at a dedicated Bosch service station.
3. Pay attention to the injector nameplate mark and the fuel injectors of different part numbers are not
interchangeable.
4. Marking position: On the solenoid valve at the top of the injector.
5. Marking specifications: The first line: Fuel injector model, such as: WPCRIN2;
6. The second line: Weichai part number, such as: 611600080035;
7. The third line: Bosch part number, such as: 0445B29850.

Fig. 5-62 Fuel injector marking specifications

5.32.5 Assembling steps

Assembling steps are in reverse of disassembling steps.

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5.33 Cylinder head assembly

5.33.1 Exploded view

Fig. 5-63 Exploded view of cylinder head assembly

S/N Name S/N Name S/N Name S/N Name

1 Cylinder head 2 Cylinder head 3 Cylinder head 4 Hoisting ring
gasket auxiliary bolt assembly clamping
block
5 Valve stem sealing 6 Valve stem sealing 7 Cylinder head 8 Cylinder
sleeve-Intake sleeve-Exhaust bolt head nut
9 Clamping block 10 Assembled sealing 11 Rocker arm 12 Hollow bolt
washer lubricating oil
pipe

5.33.2 Preparations before disassembling

1. Equipment conditions: Socket wrench or air wrench, torque wrench, open end wrench.
2. Preparations before disassembling: It is necessary to disassemble the cylinder head cover, intake manifold, exhaust
manifold, water outlet pipe, high-pressure fuel pipe, high-pressure connector, oil-gas separator and other parts that may be
fixed on the cylinder head or interfere with the disassembly of the cylinder head in advance.

5.33.3 Disassembling steps

1. Unscrew and remove the hoisting ring screws at both ends of the engine. Loosen the lubricating pipe between the
cylinder heads at the intake side for the brake type.

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2. Unscrew the cylinder head auxiliary bolts and nuts and remove the clamping block. The clamping block has two
structures: the first one is a cylindrical clamping block assembled between the two cylinder heads, which is mounted on an
auxiliary bolt; the second one is a clamping block that is assembled on both ends of the engine and is only mounted on one
cylinder head, which is mounted on two auxiliary bolts and can install with a hoisting ring connecting block.
3. Unscrew the cylinder head main bolt and remove the main bolt and place it in place.
4. Disassemble the fuel injector. Since the injector nozzle protrudes from the bottom surface of the cylinder head,
make sure that the injector is removed before disassembling the cylinder head. Otherwise, the injector head is easily
damaged when placing the cylinder head.
5. Disassemble the cylinder head and place the disassembled cylinder head on the cardboard to avoid wearing the
upper surface of the combustion chamber and other sealing surfaces. If multiple cylinder heads are required to be
disassembled, mark the cylinder serial number on the cylinder head for subsequent problem analysis and solving.
6. Disassemble the cylinder head gasket. If multiple cylinder head gaskets are disassembled, the cylinder number
should be indicated on the cylinder head gasket for subsequent analysis.
7. If the cylinder head auxiliary bolts need to be replaced, or the check is required, disassemble the cylinder head
auxiliary bolts.
8. Disassemble the rocker arm seat, intake and exhaust valves and other valve train.
9. If you need to check or replace the valve stem sealing sleeve, disassemble the valve stem sealing sleeve. Use the
special tooling to disassemble the valve stem sealing sleeve, or use the pliers to clamp the outer side wall of the valve stem
sealing sleeve, and remove the valve stem sealing sleeve by rotating and lifting. The disassembled valve stem sealing sleeve
is scrapped and cannot be used multiple times.

5.33.4 Inspection and maintenance

1. Before disassembling the cylinder head, check whether there is any water leakage, oil leaks, air leakage and other
abnormalities at the joint between the cylinder head and the engine block. If there is such a problem, replace the cylinder
head gasket with a new one to check whether the problem is solved. The disassembling and assembling method of the
cylinder head gasket is shown in this section.
2. Check the appearance of cylinder head, carefully check the cylinder head for discoloration and cracking. If cracking
are found, check for dye detection.
3. Check the lubricating oil-inlet pipe for any oil leaks before disassembly, and check the lubricating oil-inlet pipe itself
for cracks, wear, corrosion, and other damage. If there is a crack, replace the lubricating oil-inlet pipe. Analyze the cause of
the corrosion that affects reliability and replace the lubricating oil-inlet pipe with a new one. If the oil leaks appear at the
hollow bolts, replace the hollow bolts and the assembled sealing washers, and tighten them and check again for oil leaks.

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4. Before disassembling the valve train, check the

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 indirectly. The valve sinkage can be
measured using a depth micrometer shown in the Fig..
5. Refer to the required value of the valve sinkage. If
the valve sinkage exceeds the permissible range, confirm
the wear of the valve and the valve seat. Check the valve
seat wear by measuring the valve sinkage after an unused
valve is installed. If the valve sinkage still exceeds the Fig. 5-64 Depth micrometer
required value, the cylinder head needs to be replaced to
ensure the reliability of the diesel engine. If the valve
sinkage does not exceed the allowable value, disassemble
the valve to check valve and valve seat sealing surface to
see if there is any obvious wear and abnormal damage.

Table 5–1 Required value of valve sinkage

Position Required value of valve sinkage (mm)

Intake -0.2~0.2
Exhaust -0.2~0.2

6. After disassembling the valve train, check the inside of intake and exhaust passages of the cylinder to check for
water leakage. If there is such a problem, clean the passages and conduct dye-penetration inspection to confirm the
problem position and replace the cylinder head with a new one.
7. 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.

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8. Check the inner diameter of the valve guide. The

inner diameter of the valve guide is 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 steering effect of the
valve will be affected to reduce the reliability of the
operation of the diesel engine. The internal diameter of
the valve guide can be measured using an internal
micrometer as shown in the Fig.. The allowable range of
the inner diameter of the valve guide is: (9.0 - 9.015) mm.
The cylinder head needs to be replaced if exceeding the
allowable range to ensure the reliability of the diesel
engine.
9. Disassemble the cylinder head gasket and 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.
10. Before disassembling, check the valve stem
sealing sleeves for any abnormalities such as rubber lip
damage, spring failure, etc., but once the valve stem Fig. 5-65 Internal micrometer
sealing sleeves are disassembled, they needs to be
replaced with new ones.

5.33.5 Assembling steps

1. Assemble the cylinder head auxiliary bolts

1) The cylinder head auxiliary bolts are allowed to be used 3 times, and they should be replaced with new ones after 3
times.
2) Apply the anaerobic thread locker 262 to the screw-in end (the shorter thread end) of the cylinder head auxiliary
bolts.
3) Clean the threaded hole on the cylinder block.
4) Tighten the bolts and tightening torque is (25±3) N.m.
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.
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 pin hole.
3) Check whether the holes on the cylinder head
gasket are aligned with the holes on the cylinder block
and check whether the cylinder head gaskets are
assembled correctly.

Fig. 5-66 Cylinder head gasket

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3. Assemble the valve stem sealing sleeve

1) The valve stem sealing sleeve is only allowed to be
used once, and it must be replaced with new parts in case
of repair.
2) Check the valve stem sealing sleeve for defects
and whether the valve stem sealing sleeve spring is in
good condition.
3) Install a valve stem sealing sleeve on the valve
guide. Fig. 5-67 Valve stem sealing sleeve
4) Apply lubricating oil to the lip of the valve stem
sealing sleeve.
5) Use the valve stem sealing sleeve assembly tools
and rubber hammer to install the valve stem sealing
sleeve.
4. Assembling the cylinder head
1) Before assembling the cylinder head, confirm that
the valve parts such as the valve, valve spring and lock are
installed in place.
2) 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.
3) Check that there are no foreign matter in the air
passage and water passage of the cylinder head, check
that there are no foreign matter in the cylinder, the Fig. 5-68 Valve stem sealing sleeve installer
cylinder head gasket and the lower surface of the cylinder
head are clean.
4) Prior to the tightening of the cylinder head bolts,
the cylinder head is pin-to-face positioned.
5) Assemble the cylinder head.
5. Assemble the clamping blocks
1) Wipe the clamping blocks.
2) After applying the clean lubricating oil to the
support surface of the clamping block, clamp the clamping
blocks on the cylinder head in sequence, and apply the oil
in an appropriate amount to prevent the lubricating oil
from flowing into the gap between the cylinder heads.
3) The clamping block is clamped so that the
direction of the groove is the same as the direction of the
gap between the cylinder heads.
4) Screw the cylinder head auxiliary bolts and nuts
into the cylinder head auxiliary bolts by hand.

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6. Assemble the cylinder head bolts and auxiliary

bolts
1) Tighten the M12×1.5 cylinder head auxiliary bolts
(double-end stud) numbered 1 to 14; tighten the M14×2
main bolts numbered 15 to 38; the cylinder head bolts
and the auxiliary bolts are allowed to be used 3 times.
2) Place the cylinder heads in order, apply the
appropriate amount of clean lubricating oil to the cylinder Fig. 5-69 Tightening diagram of cylinder head bolts
head main bolt threads and the shoulder bearing surfaces
and shoulder nuts, and install them on the cylinder head,
cylinder head auxiliary bolts and clamping blocks
respectively.
3) Tighten the main bolts with tightening torque of
(60±6) N.m.
4) Tighten the auxiliary bolts and nuts with
tightening torque of (25±3) N.m.
5) Tap each clamping block to seat it all in place.
6) Screw the auxiliary nuts with the angle of 120°±5°.
Mark its position with a color point.
7) Screw the auxiliary nuts with the angle of 120°±5°.
Mark its position with a color point.
8) Then screw the auxiliary nuts with the angle of
120°±5°. Mark its position with a color point.
9) Then screw the main bolts with the angle of
120°±5°. Mark its position with a color point.
7. Use a torque wrench to assemble the rocker arm oil-inlet pipes, hollow bolts, and assembled sealing washers.

5.34 Crankshaft pulley assembly

5.34.1 Exploded view

Fig. 5-70 Exploded view of crankshaft pulley assembly

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S/N Name S/N Name S/N Name S/N Name

1 Hex flange bolt 2 Crankshaft pulley 3 Torsional vibration 4 Damper bolt
damper
5 crankshaft assembly

5.34.2 Disassembling tools and preparations

1. Equipment conditions: Torque wrench, auto tightening machine, etc.

2. Preparations before disassembling: The belt must be removed before disassembling the crankshaft pulley assembly.

5.34.3 Disassembling steps

Firstly unscrew the hex flange bolts to remove the crankshaft pulley and torsional vibration damper from the front end
of the crankshaft. Next, unscrew the damper bolts and remove the damper from the crankshaft pulley.

5.34.4 Inspection and maintenance

1. Check the damper for bumps, radiator loss, deformation, etc.

2. Check the pulley for damage and the bolt for crushing.
3. Check the damper bolts and hex flange bolts for damage.

5.34.5 Assembling steps

1. Assemble the torsional vibration damper

1) Assemble the torsional vibration damper to the
crankshaft pulley by 6 M10×1.5 damper bolts, and tighten
them with the tightening torque of (60-70) N.m after
pretensioning diagonally.
2) Apply a small amount of lubricating oil to the head Fig. 5-71 Assembling diagram of crankshaft pulley assembly
of the damper bolts before assembly.
2. Install the crankshaft pulley.
3. Assemble the crankshaft pulleys to the crankshaft with 6 M12×1.5 hex flange bolts, and tighten them after
pretensioning diagonally. First tighten them with a torque of 45N.m and second rotate them with an angle of (135±5)°.

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5.35 Flywheel housing assembly

5.35.1 Exploded view

Fig. 5-72 Exploded view of flywheel housing assembly

S/N Name S/N Name S/N Name S/N Name

1 Hex bolt 2 Hex flange bolt 3 Hex socket head cap 4 Flywheel housing
screw connecting plate
5 Cylindrical pin 6 Speed sensor 7 Hex socket head cap 8 Flywheel housing
screw
9 Hex bolt 10 "Hex flange bolt-big- 11 Spring washer 12 Type 1 hex nut
size series"
13 Double-end stud 14 Hex bolt 15 Wave-shaped elastic 16 Inspection hole cap
gasket

5.35.2 Disassembling tools and preparations

1. Disassembling tools: Sleeve, wrench, oil seal press-fit tool.

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2. Preparations before disassembling: Remove the gearbox and clutch and remove the flywheel.

5.35.3 Disassembling steps

1. Disassemble the speed sensor.

2. Disassemble the inspection hole fastening bolts and remove the inspection hole cap.
3. Disassemble the double-end studs on the outer edge of the flywheel housing.
4. Unscrew the flywheel housing fastening bolts in the diagonal disassembly sequence.
5. Remove the flywheel, cylindrical pin and connecting plate.

5.35.4 Inspection and maintenance

1. Check whether the parts are complete according to the parts list.
2. Check the status of the connecting plate, flywheel housing and engine block.
3. Pre-apply glue to the flywheel housing bolts, tighten them in a symmetrical order, and apply oil to the flange surface
of the bolt before assembly. The flywheel housing bolts can be reused twice.
4. When installing, apply sealant uniformly on the joint surface of the cylinder block and the flywheel housing, and the
sealant should be continuous and uniform. Lift the flywheel housing to prevent bumps.

5.35.5 Assembling steps

1. Install a cylindrical pin on the lower part of the rear end of the pre-assembled engine block, and co-locate with the
idler shaft (located in the gear transmission combination group), and hoist the flywheel housing connecting plate to an
appropriate position.
2. Caution: The cylindrical pin must be driven to the end.
3. Check whether the flywheel housing connecting plate and the joint surface of the pre-assembled engine block and
the flywheel housing are clean and burr-free, and remove the oil, then apply the sealant.
4. Caution: The glue line should be continuous and uninterrupted.
5. Note: After the installation of the flywheel housing connecting plate, the assembly of the gear drive assembly is
required. See the assembling steps of the gear drive assembly for details.
6. Install a cylindrical pin on the upper part of the rear end of the pre-assembled engine block, co-locate with the
cylindrical pin in the lower part, hoist the flywheel housing to an appropriate position, install the bolts, and tighten the
flywheel housing fastening bolts in a diagonal order.
7. Install the double-end studs on the outer edge of the flywheel housing.
8. Install the inspection hole cap to the flywheel housing with two hex bolts and tighten the bolts.
9. Install the speed sensor.

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5.36 Flywheel assembly

5.36.1 Exploded view

Fig. 5-73 Exploded view of flywheel assembly

S/N Name S/N Name S/N Name S/N Name

1 Crankshaft 2 Crankshaft timing 3 Cylindrical pin 4 Flywheel ring gear
gear
5 Flywheel 6 Double-end stud 7 Hex bolt 8 Washer
9 Deep groove ball 10 Circlip for hole 11 Flywheel bolt
bearing

5.36.2 Disassembling tools and preparations

1. Disassembling tool:
2. Torque wrench, auto tightening machine, guide studs, nipper pliers, etc.
3. Preparations before disassembling:
4. Before disassembling the flywheel assembly, it is necessary to disassemble the flywheel output connection, such as
a clutch.

5.36.3 Disassembling steps

Disassemble the flywheel bolts and remove the flywheel assembly. Loosen the hex bolt and double-end stud, take out
the flywheel ring gear.

5.36.4 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. Whether there is any problem such as cracking on the contact surfaces of the flywheel and the clutch.

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5.36.5 Assembling steps

1. Assemble the flywheel gear ring to the

flywheel with hex bolts and double-end studs, and
then install the retaining ring and bearing.
2. Insert a cylindrical pin at the rear end of the
crankshaft to hit the cylinder pin to the end and
install the crankshaft timing gear.
3. Install the crankshaft rear oil seal on the
crankshaft flange, and press the rear oil seal in by the
rear oil seal pressing tool. Fig. 5-74 Assembling diagram of flywheel assembly
4. Install the flywheel.
1) The inner machined surface of the flywheel is
coated with anti-rust oil, and the flywheel guide rod
is inserted into two symmetric bolt holes on the
crankshaft;
2) Pass the flywheel through the guide bar into
the flywheel housing.
5. Use flywheel bolts to install the flywheel and
crankshaft timing gear and assemble the flywheel
onto the crankshaft.
1) Apply clean lubricating oil to the threaded
part of the flywheel bolt and the bolt support
surface;
2) Tighten after pre-tightening diagonally: first
tighten with a torque of 100 N•m diagonally; second
rotate with an angle of (210° ± 5°) in sequence.

5.37 Oil pump assembly

5.37.1 Exploded view

Fig. 5-75 Exploded view of oil pump assembly

S/N Name S/N Name S/N Name S/N Name

1 O-ring 2 Oil pump 3 Bolt 4 Locating pin

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5.37.2 Disassembling tools and preparations

1. Disassembling tools: Socket or wrench.

5.37.3 Disassembling steps

1. Unscrew the oil pump mounting bolts.

2. Remove the oil pump and O-ring.

Fig. 5-76 Exploded view of oil pump

5.37.4 Inspection and maintenance

1. Check the oil pump for cracking and replace the oil pump if any.
2. Check whether the oil pump drive gear rotates flexibly. If the rotation is not flexible, replace the oil pump.

5.37.5 Assembling steps

1. Check whether the oil pump drive gear rotates flexibly and is damaged before assembly.
2. Clean the joint surface of the oil pump and the crankcase, install the oil pump and tighten the bolts.

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5.38 Oil pan assembly

5.38.1 Exploded view

Fig. 5-77 Exploded view of oil pan assembly

S/N Name S/N Name S/N Name S/N Name

1 Washer 2 Oil pan assembly 3 Oil pan support block 4 Hex flange bolt
5 Oil drain plug 6 Sealing washer 7 Oil pan support block

5.38.2 Disassembling tools and preparations

1. Disassembling tools: Socket or wrench.

2. Preparation before disassembly: Remove the dipstick firstly.

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5.38.3 Disassembling steps

1. 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.

Fig. 5-78 Exploded view of oil pan oil drain plug

2. Use a wrench to remove the bolts of the joint
surface of the oil pan and the engine block.
3. After separating the oil pan, check whether it is flat
and free from damage.

Fig. 5-79 Disassembling diagram of oil pan bolts and

support blocks

5.38.4 Inspection and maintenance

1. Check the sealing washer at the oil drain plug for damage.
2. Check the sealing ring on the oil pan that is in contact with the engine block for damage.
3. Check the compression surface of the bolt and the block for crushing or damage.

5.38.5 Assembling steps

1. Insert an O-ring seal on the oil pan assembly:

1) The O-ring seal should be flat and not allowed to twist.
2) The sealing gasket joint should be on the straight side of the oil pan and not at the circular arc transition.

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3) The front end cover, the engine block, the triangle of the oil pan, the flywheel housing, the triangle of the oil pan of
the engine block should be applied with silicone sealant.
2. Insert the hex flange bolts to the oil pan support blocks to loosly install the oil pan assembly to the cylinder block.
The oil pan bolts should be M8 and the quantity should be 14.
1) Check whether there is any foreign matter in the cylinder before installing. The tightening torque of the oil pan bolt
is: (28~32) N·m.
2) Manually rotate the crankshaft 360° in the direction of the flywheel rotation to check whether the crankshaft arm
and the oil pump gear interfere with the oil pan. If it is found, it should be treated.
3) Tighten the oil pan fastening bolts symmetrically.
3. Screw in the magnetic screw plug assembly with a sealing ring.
Wipe the magnetic plug assembly before installing.

5.39 Suction filter assembly

5.39.1 Exploded view

Fig. 5-80 Exploded view of suction filter assembly

S/N Name S/N Name S/N Name S/N Name

1 Bolt 2 Washer 3 Oil suction filter 4 Gasket

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5.39.2 Disassembling tools and preparations

1. Disassembling tools: Socket or wrench.

2. Preparation before disassembly: Remove the oil pan firstly.

5.39.3 Disassembling steps

1. Unscrew the suction filter bolts.

2. Remove the suction filter and gasket from oil
pump.

Fig. 5-81 Exploded view of suction filter mounting bolts

5.39.4 Inspection and maintenance

1. Check whether the suction filter screen is blocked.

2. Check whether the suction filter is installed securely.
3. Check the suction filter for cracking, breakage, etc.

5.39.5 Assembling steps

1. Apply the Weichai special 242 sealant to the threads of the suction filter fastening bolts.
2. Screw in the bolt with the washer and tighten it with a tightening torque of 50 N·m.

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5.40 Piston nozzle assembly

5.40.1 Exploded view

Fig. 5-82 Exploded view of piston nozzle assembly

S/N Name S/N Name S/N Name S/N Name

1 Nozzle spring 2 O-ring 3 Piston nozzle locating 4 Hexagon socket set
plate screw
5 Cooling nozzle pipe 6 Nozzle body 7 Retaining ring 8 Steel ball

5.40.2 Disassembling tools and preparations

1. Disassembling tool:
Socket wrench.
2. Preparations before disassembling:
Remove the crankshaft and other parts.

5.40.3 Disassembling steps

1. Remove the hollow bolt.

2. Remove the nozzle assembly.

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5.40.4 Inspection and maintenance

The nozzle must be checked for smoothness, and replace it with a new one if there is any blockage.

5.40.5 Assembling steps

Assembling steps is in reverse of disassembling steps.

5.41 Piston connecting rod assembly

5.41.1 Exploded view

Fig. 5-83 Exploded view of piston connecting rod assembly

S/N Name S/N Name S/N Name S/N Name

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

5.41.2 Disassembling tools and preparations

1. Disassembling tools: Torque wrench, auto tightening machine, overhead crane, nipper pliers, etc.
2. Preparations before disassembling: Before disassembling the piston connecting rod assembly, the cylinder head,
valve train, oil pan and so on should be removed.

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5.41.3 Disassembling steps

1. Carefully remove carbon deposit from the top of

the cylinder without damaging the inside of the cylinder.
Tilt the engine and turn the engine so that the piston is at
BDC, and remove the connecting rod bolt and the
connecting rod cover. Then turn the engine so that the
piston is at the TDC and knock the piston out with a
wooden hammer. Be careful to avoid the big end of the
connecting rod from getting stuck in the cylinder. Position Fig. 5-84 Exploded view of connecting rod big end
the bearing bushes and connecting rod covers in the
original order.
2. Use the retaining ring pliers for hole to carefully
remove the circlip on both sides of the piston and push
the piston pin out to remove the connecting rod body. The
connecting rod bodies are numbered separately and
placed in order;
3. Use the piston ring mounting pliers to remove a
ring, a second ring, and an oil ring, respectively, and mark
them separately; Fig. 5-85 Exploded view of piston pin and connecting rod
4. Apply radial and tangential forces to the bushing
connecting rod bearing bush to disengage the bearing
bush from the assembled position and remove the bearing
bush. Note that they are numbered according to cylinder
numbers and placed in order.

5.41.4 Inspection and maintenance

1. Check that there are no burrs, oil dirt and bumps at the surface of the piston and the inner cavity, piston ring, piston
pin surface; check whether there is a crack at the fillet at the throat of the combustion chamber and the piston pin seat.
Replace them if any.
2. Check whether the outer ring wear of the piston ring is abnormal; check whether the upper and lower end faces of
the piston ring are worn abnormally.
3. The weight difference of the aluminum piston is not more than 10 grams per group. The pistons of the same weight
are installed on the same diesel engine and must not be mixed.
4. After the piston ring is assembled to the piston, collisions between the pistons are not allowed.
5. Check that there are no burrs or bumps on the big and small ends of the connecting rod, and check that there are no
cracks, deformation and discoloration on the oil holes around the small end bearing bushes.
6. Check whether the side wear of the connecting rod is abnormal, and check the bending of the connecting rod shaft.
7. Check whether the alloy layer of the connecting rod bushing is worn properly, and whether there is peeling
phenomenon, etc.;
8. The cylinder number on the connecting rod body and the connecting rod cover must be identical; the weight
identification of the same connecting rod should be identical.
9. If there is any scratch or damage on the connecting rod body, the connecting rod should be replaced;
10. The connecting rod bolts can be used up to 3 times and the bolt length cannot exceed 75.3mm.
11. Check the appearance of the connecting rod to check whether the surface of the bearing bush has nicks or burrs.
12. Before installing the connecting rod bearing bush, clean the bottom hole and the bush, and do not apply
lubricating oil to the bottom hole and the back of the bush.
13. If there is corrosion, cavitation, erosion and abrasion on the surface of the connecting rod bearing bush, it is
necessary to replace the connecting rod.
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14. Check the wear of the connecting rod bearing bush, whether the alloy layer has discoloration, peeling, slipping and
so on.

5.41.5 Assembling steps

1. Apply radial force and tangential force to the

connecting rod bearing bush, so that the bearing bush
avoids the edge of the rising section and enters the
assembly position to avoid scratching the steel back.
Ensure that the locating lip on the connecting rod bearing
bush is positioned in the groove on the big end of the
connecting rod and the connecting rod cover. Pay
attention to the applying of lubricating oil to the surface of
bearing bush after installation.
2. 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.
Fig. 5-86 Installation diagram of connecting rod bushing
3. The small end of the connecting rod is fed into the
inner cavity of the piston, and the small end of the
connecting rod is aligned with the pin hole of the piston,
and then the piston pin is inserted, and finally the piston
pin retaining ring of the other side is installed. The
retaining ring opening is offset by 30° from the centerline
of the piston, and the two retaining rings are offset by 60°.
Clean the small hole of the connecting rod and the piston
pin and apply proper amount of clean lubricating oil
before assembly. The emblem mark on the connecting rod
is on the same side as the direction mark of the piston.
The connecting rod and the piston of the same machine
are in the same quality group respectively.
Fig. 5-87 Installation diagram of piston pin
4. The assembled piston connecting rods are hung on
the tray in the order of the cylinder numbers, and the coil
spring loaded oil-control ring, the twisted taper faced ring
and the keystone barrel faced ring are sequentially
installed into the piston ring groove by using the piston
ring mounting pliers. Ensure that the piston rings are
assembled in parallel in the ring groove and no distortion Fig. 5-88 Installation diagram of piston ring
is allowed. The "TOP" face of the piston ring faces up, and
the ring should rotate flexibly in the ring groove.

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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.
6. 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.
7. The barring makes the 1 and 6-cylinder near the
BDC position respectively. When the direction mark of the
piston is directed to the front end of the engine, the piston
and the connecting rod assembly are gently placed into
the cylinder liner. Hold the piston ring compressor against
the cylinder liner. Push the piston through the compressor
into the cylinder liner. Then pull the connecting rod
downward to install it to the crankshaft journal.
Connecting rod bolt: pre-tighten 35N·m for the first time,
screw 120° at second time.
Note
The number of the piston cylinder is the same as
that of the cylinder. The connecting rod cover is used in
conjunction with the connecting rod body. Apply clean
lubricating oil to connecting rod bolts before installation.
Install the remaining cylinders in the same way.

Fig. 5-89 Installation diagram of connecting rod assembly

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5.42 Front end cover

5.42.1 Exploded view

Fig. 5-90 Exploded view of front end cover assembly

S/N Name S/N Name S/N Name S/N Name

1 Front end cover 2 Pipe joint 3 Hex flange bolt 4 Hex flange bolt
5 Hex flange bolt-big- 6 Hex bolt 7 Fixing bracket 8 Hex flange bolt-
size series big-size series
9 Fixing bracket 10 Cylindrical pin

5.42.2 Disassembling tools and preparations

1. Disassembling tools: Socket, wrench.

2. Preparation before disassembly: Remove parts such as fans and hubs, tensioners and belts, crankshaft pulleys and
torsional dampers.

5.42.3 Disassembling steps

1. Disassemble the two fastening brackets of front end cover.

2. Unscrew front end cover the fastening bolts to remove the front end cover.
3. Remove the locating cylindrical pin of front end cover.

5.42.4 Inspection and maintenance

1. Use pre-coated bolts as the front end cover fastening bolts.

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2. Apply a uniform sealant on the joint surface of the cylinder block and the front end cover to prevent the bumps of
the front end cover and the binding face of the engine block and the oil pan.

5.42.5 Assembling steps

1. Drive 2 locating cylindrical pins into the front end of the cylinder block. (Tooling name: Copper hammer)
2. Caution: The cylindrical pin must be driven to the end.
3. Check that the joint surface of the cylinder block and the front end cover is clean and free of burrs, and remove the
oil, then apply the sealant.
4. Caution: The glue line should be continuous and uninterrupted.
5. Install the front end cover and screw the fastening bolts.

5.43 Oil seal assembly

5.43.1 Exploded view

Fig. 5-91 Exploded view of oil seal assembly

S/N Name S/N Name S/N Name S/N Name

1 Front oil seal 2 Front end cover 3 Flywheel housing 4 Rear oil seal

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5.43.2 Preparations before disassembling

1. Disassembling tools: Special disassembling tools.

2. Preparations before disassembling: Remove the damper and remove the flywheel.

5.43.3 Removal steps

Use special tooling to remove the front and rear oil seals and avoid scratching the crankshaft during the disassembly
process.

5.43.4 Inspection and maintenance

1. The mounting holes and oil seals must be cleaned before installing the oil seals, and no dirt is allowed. Use a special
tool to install the oil seals and smoothly press the oil seal. Oil seals and press tools must be lubricated before assembly.
2. The oil seal should be no longer used after removal.

5.43.5 Assembling steps

Use the oil seal tooling to slowly press the front oil seal into the front end cover and slowly press the rear oil seal into
the flywheel housing.

5.44 Crankshaft assembly

5.44.1 Exploded view

Fig. 5-92 Exploded view of crankshaft assembly

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S/N Name S/N Name S/N Name S/N Name

1 Engine block 2 Main bearing upper 3 Main bearing lower 4 Crankcase
bushing bushing
5 Main bearing bolt 6 Lower thrust plate 7 crankshaft assembly 8 Crankshaft timing
gear
9 Upper thrust plate

5.44.2 Disassembling tools and preparations

1. Disassembling tool:
Torque wrench, auto tightening machine, overhead crane, guide studs, etc.
2. Preparations before disassembling:
1) Before disassembling the crankshaft pulley, the belt must be disassembled;
2) Before disassembling the crankshaft assembly, the flywheel, flywheel housing, front end cover, crankshaft pulley,
crankcase, and piston connecting rod, etc. must be disassembled.

5.44.3 Disassembling steps

1. Before disassembling the crankshaft assembly, the

crankshaft pulley assembly, front end cover assembly,
piston connecting rod assembly, flywheel assembly,
flywheel housing assembly, etc. should be removed. Turn
the engine block upside down, remove the main bearing
bolts, remove the crankcase and the main bearing lower
bushings, and place them in order.
2. Remove the front and rear thrust plates and take
out the oil seal. Use the overhead crane to hoist the
crankshaft assembly and place the crankshaft on the
bracket (if the time is too long, the crankshaft should be
placed vertically), take out the main bearing upper
bushings, and place them in order.
3. All parts disassembled are placed as required.

Fig. 5-93 Disassembling steps view of crankshaft assembly

5.44.4 Inspection and maintenance

1. Whether there is cracking in the main journal of the crankshaft, the connecting rod journal and the filleted corners;
check the unblocking oil passage for cracking 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.

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3. Check the wear on the oil seal.

4. Check the main bearing bolts for failure modes
such as thread damage.
5. Whether there is cracking in the bolt holes on the
front and rear end faces of the crankshaft, and whether
the thread profiles are damaged or not.
6. The amount of crankshaft journal wear, crankshaft
bending and distortion.
7. Whether the front and rear end faces of the
crankshaft are worn.

5.44.5 Assembling steps

1. Hoist the crankshaft to the support frame to avoid

bumps.
2. Check the crankshaft mating surface and the inner
cavity of oil passage.
1) Check the mating surfaces of the crankshaft for
bumps, and replace if necessary;
2) Blow off the inner cavity of oil passage with
compressed air to ensure that the inner cavity of oil
passage is clean and unobstructed.
3. Wipe the main bearing upper bushings and the
bottom holes of the engine block, and press the main
bearing upper bushings into the bottom holes of the
engine block.
1) Before the bushing is pressed in, check for bumps,
and the bearing bush is not allowed to be used after
repair.
2) After the bushing is pressed in, the oil hole should
be aligned with the oil hole of the engine block;
3) Wipe the foreign matter scraped off by the
bushing edge.
4. Apply clean lubricating oil to the inner surface of
the upper bearing bush.
5. Hoist the crankshaft components, wipe the main
journal and the connecting rod journal with a towel, and
then gently drop into the engine block.
1) Strictly prevent bumps during hoisting;
2) Apply clean lubricating oil to each main journal
after seating.
6. The upper thrust plate is installed into the thrust
plate groove between the engine block and the
crankshaft. Fig. 5-94 Assembling diagram of crankshaft
1) The oil groove of the upper thrust plate should
face outward (toward the crankshaft).
7. Wipe the main bearing lower bushing and the
crankcase, press the main bearing lower bushing into the
crankcase and install the lower thrust plates.
1) The lower thrust plate oil groove should face
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outward (toward the crankshaft);

2) Carefully check the bearing bush and the lower
thrust plate for bumps before installing;

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3) Apply lithium-based grease for automobile inside

the lower thrust plate;
4) Wipe the foreign matter scraped off by the
bushing edge.
8. Install the crankcase on the engine block.
9. Install the main bearing bolts.
1) Before installing the main bearing bolts, carefully
check whether there is any foreign matter on the joint
surface of the main bearing bolt and the crankcase, avoid
the foreign material from scratching the main bearing cap,
and check whether there is burr on the chamfer of the
bearing surface of the bolt by hand. Replace the bolt if
necessary;
2) Apply clean lubricating oil to the bearing surface of
the main bearing bolt and the threads of the main bearing
bolt.
10. Tighten the main bearing bolts.
1) Tighten the main bearing bolts M18 (14 pieces) in
numerical order as shown in the Fig., and apply the
lubricating oil on the threads of the bolts and the bearing
surfaces before assembly. After the bolts are screwed,
they are tightened four times in order. First, the pre-
tightening torqure reaches 80 N•m; second, the pre-
tightening torqure reaches 140 N•m; third, rotate them Fig. 5-95 Tightening sequence diagram of main bearing
90° in order; fourth, rotate them 60° in order again; bolts
2) The crankshaft is flexible and unblocked.
11. Check the crankshaft axial clearance.
1) The axial clearance of the crankshaft is (0.052 to
0.255) mm.

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5.45 Thrust plate assembly

5.45.1 Exploded view

Fig. 5-96 Exploded view of thrust plate assembly

S/N Name S/N Name S/N Name S/N Name

1 Engine block 2 Main bearing upper 3 Main bearing lower 4 Crankcase
bushing bushing
5 Main bearing bolt 6 Lower thrust plate 7 crankshaft assembly 8 Crankshaft timing gear
9 Upper thrust plate

5.45.2 Disassembling tools and preparations

1. Disassembling tools: Torque wrench, auto tightening machine, overhead crane, guide studs, nipper pliers, etc.
2. Preparations before disassembling: Before disassembling the thrust plate assembly, the crankshaft pulley, front end
cover, flywheel, flywheel housing, gear set, piston connecting rod, etc. need to be disassembled.

5.45.3 Disassembling steps

1. Take the lower thrust plate out from the side of the sixth gear of the crankcase.
2. Remove all crankcases and lower bearing bushes and hoist the crankshaft assembly to the bracket.

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3. Take the upper thrust plate from the side of the sixth gear of the engine block.

5.45.4 Inspection and maintenance

1. Check whether the thrust plate is complete and has no bumps.

2. Check the thrust plate for damage, peeling, deformation, crushing, etc.

5.45.5 Assembling steps

1. Wipe the main bearing upper bushing and the

bottom hole of the engine block, press the main bearing
upper bushing into the bottom hole of the engine block,
apply the clean lubricating oil on the inner surface of the
upper bearing bush, hoist the crankshaft components, and
then gently drop into the engine block.
2. The upper thrust plate is installed into the thrust
plate groove between the engine block and the
crankshaft.
1) The oil groove of the upper thrust plate should
face outward (toward the crankshaft);
3. Wipe the main bearing lower bushing and the
main bearing cap, press the main bearing lower bushing
into the crankcase and install the lower thrust plates.
1) The lower thrust plate oil groove should face
outward (toward the crankshaft);
2) Carefully check the lower thrust plate for bumps
before installing;
3) Apply lithium-based grease for automobile inside
the lower thrust plate.
4. Install the crankcase on the engine block, install Fig. 5-97 Assembling diagram of thrust plate assembly
the main bearing bolts, and measure the axial clearance
of the crankshaft (0.052 - 0.255) mm.

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5.46 Main bearing bush assembly

5.46.1 Exploded view

Fig. 5-98 Exploded view of main bearing bush assembly

S/N Name S/N Name S/N Name S/N Name

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

5.46.2 Disassembling tools and preparations

Equipment conditions: torque wrench, auto tightening machine, overhead crane tools, etc.
Before disassembling the crankshaft bearing bush, the flywheel housing, flywheel, front end cover, crankshaft pulley,
main bearing cap, piston connecting rod, etc. must be disassembled.

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5.46.3 Removal steps

1. The bearing bush is pushed out from the side by

hand, and the removed bearing bush is marked,
corresponding to the engine block and the seat hole of the
main bearing cap.

Fig. 5-99 Removal diagram of main bearing lower bushing

5.46.4 Inspection and maintenance

1. Clean the bearing bush and check the wear of the bearing bush.
2. Check the bearing bush for metal peeling, locating lip damage and lateral cracks.

5.46.5 Assembling steps

1. First clean the main bearing bush and the bottom

hole and wipe it clean.
2. In case of no new bearing bush replacement, the
assembly should be installed into the engine block (upper
bushing) and the main bearing cap (lower bushing) in the
order when the original bearing bush is removed.
Distinguish the upper and lower bushings, and the upper
bushing is the one with the oil groove; in case of new
bearing bush replacement, install directly. Align the lip
when installing and apply a small amount of oil.
Fig. 5-100 Diagram of main bearing upper bushing

Fig. 5-101 Diagram of main bearing lower bushing

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5.47 Dipstick tube assembly

5.47.1 Exploded view

Fig. 5-102 Exploded view of dipstick tube assembly

S/N Name S/N Name S/N Name S/N Name

1 Oil dipstick 2 Dipstick tube joint

5.47.2 Disassembling tools and preparations

1. Disassembling tools: Prepare the dipstick head disassembling tooling.

5.47.3 Disassembling steps

1. Pull out the oil dipstick.

2. Remove the dipstick tube joint.

Fig. 5-103 Removal diagram of dipstick tube

5.47.4 Inspection and maintenance

1. Check whether the oil dipstick O-ring falls off.

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2. In order to ensure the height of the oil level accurate, the dipstick tube should be installed below the oil level, and
no gap is allowed. After the dipstick tube is fixed as required, check whether the oil dipstick is easy to insert or remove.

5.47.5 Assembling steps

In reverse of disassembling steps.

5.48 Engine block assembly

5.48.1 Exploded view

Fig. 5-104 Exploded view of engine block assembly

S/N Name S/N Name S/N Name S/N Name

1 Cylinder liner 2 Cylindrical pin 3 Cylinder block 4 Bowl plug
5 Hex head plug 6 Assembled sealing 7 Dipstick pipe plug 8 O-ring
washer
9 Internal threaded 10 Crankcase 11 Main bearing bolt 12 Hex bolt
cylindrical pin
13 Hex bolt 14 Hex socket head cap 15 Washer 16 Hex socket plug
screw
17 Cylindrical pin 18 O-ring 19 Rear camshaft 20 Sealing washer
bushing
21 Pressure and 22 Sealing washer 23 Hex head plug 24 Bowl plug
temperature sensor

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S/N Name S/N Name S/N Name S/N Name

25 Pulling rivet 26 Cover 27 Camshaft bushing 28 Bowl plug
29 Bowl plug

5.48.2 Disassembling tools and preparations

1. Disassembling tools: Socket wrench, copper hammer, etc.

2. Preparations before disassembling: Remove the gearbox, clutch, flywheel, flywheel housing, front end cover, oil pan,
etc.

5.48.3 Disassembling steps

1. Remove the internal threaded cylindrical pin.

2. Remove the camshaft bushing.
3. Disassemble the main bearing bolts: Use a socket wrench, manual wrench or air wrench to remove the main bearing
bolts.
4. Disassemble the crankcase.
5. Disassemble the cylinder liner.

5.48.4 Inspection and maintenance

Check whether the parts are complete according to the parts list. Check the state of the engine block assembly, and do
not allow burrs, oil, bumps, etc. on each joint surface.
1. The cylinder liner should be carefully inspected before assembly to see if there are cracking defects and cleaned up.
2. Use a special tool to remove the camshaft bushing and take care to protect the other bushings during the
disassembly process.
3. Carefully check the inner surface of the camshaft bushing for scratches before assembly and replace it if necessary.
The oil hole of the camshaft bushing is aligned with the oil hole of the bottom hole of the engine block camshaft.
4. Pay attention to cleaning the upper plane of the crankcase and the lower plane of the cylinder block before
assembly. The upper plane of the crankcase should be coated with sealant.
5. When assembling the main bearing bolts, tighten
them symmetrically in order as shown in the Fig.. Apply
clean lubricating oil to the bearing surface of the
crankcase and the threads of the main bearing bolt before
assembly.
6. Torque control: first, tighten with a low torque
pneumatic impact wrench; second, the torque reaches
80N·m; third, the torque reaches 140N·m; fourth, rotate Fig. 5-105 Tightening sequence of main bearing bolts
90° in order; fifth, rotate 60° in order again.

5.48.5 Assembling steps

Assembling steps is in reverse of disassembling steps.

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5.49 Urea pump

5.49.1 Replacement steps

When the urea pump wire harness is fixed, the distance from the first fixed point of the wire harness to the joint is
required to be less than 200 mm, and the fixed point needs to be on the same vibration source as the fixed component.
1. Unscrew the filter cover with the wrench size of
27mm
(DIN3124/SO2725-1)

Fig. 5-106 Unscrew the filter cover

2. Take out the balancer

Fig. 5-107 Take out the balancer

3. Observe the color of the filter element. If it is gray,
use the gray end of the professional tool. If it is black, use
the black end. Insert the correct tool end into the filter
element until you hear a click, indicating that the tool is in
place.

Fig. 5-108 Tool using method

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4. Pull out the filter element and use the tool slot
with the help of other tools to help pull it out if necessary.

Fig. 5-109 Pull out the filter element

5. Clean the outer surface of the filter element cover
with water.

Fig. 5-110 Clean the filter element

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6. After lubricating the O-rings on both ends of the

HCF filter element, install the filter element.
(MobilVelocite No.6 is recommended, and the use of
other lubricating oil may present a risk of failure)

Fig. 5-111 Install the filter element

7. Tighten the filter cover, with the torque of (20+5)
N·m, and the wrench size of 27mm (DIN3124/ISO2715-1)

Fig. 5-112 Tighten the filter cover

5.49.2 Installation

1. The urea pump has very high cleanliness

requirements, as shown in Fig. 5-114. All protective caps
can only be removed before installation.
2. In order to ensure that the system works normally
and efficiently, the urea pump needs to be properly
installed on the vehicle. With the Weichai integrated urea
tank, the urea pump can be directly installed in the Fig. 5-113 Remove the protective caps before installation
corresponding position of the urea tank to meet the urea
pump installation requirements.

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3. There are 3 mounting holes on the urea pump.

Refer to Fig. 5-115 for the specific locations. The minimum
length of the mounting bolt can be 90mm. The shockproof
Mounting Mounting
gasket is required. The surface contact pressure is hole #1 hole #2

260N/mm2. The mounting torque is recommended to be

19Nm±20%.
Mounting
hole #3

Fig. 5-114 Urea pump mounting hole positions and size

5.50 Urea nozzle

5.50.1 Installation

1. The urea nozzle has very high cleanliness

requirements. As shown on the right Fig., all protective
caps can only be removed before installation.
2. In order to ensure that the system works normally
and efficiently, the urea nozzle needs to be properly
installed on the vehicle. When using the Weichai
integrated DOC-DPF-SCR assembly, the urea nozzle can be
directly installed in the corresponding position of the Fig. 5-115 Remove the protective caps before installation
DOC-DPF-SCR assembly to meet the urea nozzle
installation requirements.
3. The correct installation sequence of the urea
nozzle is as shown in the Fig. on the right. First fix the Mounting
hole #1
mounting hole #1, and then the rear mounting hole #2,
#3. The minimum diameter of the contact surface (nut or
gasket) is 12mm and the maximum contact pressure is
180N/mm². The mounting torque is recommended to be Mounting
hole #2
(8±2) N·m (the reference value of friction coefficient is Mounting hole #3
0.14), and the minimum screw length is 20mm.
Fig. 5-116 Urea nozzle installation sequence
4. The gasket seal at the bottom of the urea nozzle is
a disposable part and must be replaced after each
disassembly. The right is the diagram of the urea nozzle
gasket replacement process. Do not use sharp tools to pry
up edges when replacing. Use the tweezers to push the
three disc contacts. After removing, clean the sealing area
but avoid touching the urea nozzle and reinstall a new
gasket seal.

Fig. 5-117 Diagram of urea nozzle gasket replacement

process

Caution

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When the urea nozzle wire harness is fixed, the distance from the first fixed point of the wire harness to the joint is less
than 100mm, and the wire harness mounting position must maintain the same vibration level as the urea nozzle.

5.51 Urea tank

5.51.1 Installation

1. Before installing the urea tank, make sure that the

various interfaces of the liquid level and temperature
sensor are well protected as shown in the right Fig., to
prevent debris from entering the system pipeline, so that
the system cannot work.
2. When the urea tank is installed on the vehicle, it
should be kept away from the heat source. Try to avoid
the risk of urea solution deterioration caused by the
radiation effect of the heat source such as the engine,
gearbox, SCR catalytic converter and exhaust manifold on
the urea tank.

Fig. 5-118 Good protection of liquid level and temperature

sensor interfaces
3. The freezing point of the urea solution is -11.5°C.
When the system is working at low temperature, the urea The water intake Water through
position is after the solenoid valve
will freeze, resulting in the system’s failure to work. water pump, before
the thermostat
on the arrow
direction

Therefore, the urea tank must be unfreezed. The urea Water outlet Solenoid valve

tank is unfreezed and heated by the cooling water of the Water return Heating water
inlet
engine. The heating water line direction is as shown in the Heating water
The return water outlet
right Fig.. position is in the
negative pressure
zone of the water
inlet of the pump

Fig. 5-119 System heating water line direction

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5.52 Urea pipeline

5.52.1 Installation

1. The urea pipeline is the passage of urea. Ensure

that the two ends are well protected before installation as
shown in the right Fig. to prevent dirt and impurities from
entering the pipeline and then entering the system,
resulting in system failure.
2. The urea pipeline installation should be correct
correspondingly and incorrect installation will result in the
system’s failure to work. Confirm the size of the urea pipe
joint before installation. The model of each quick
connector matches correctly with the model on the tank,
pump and urea nozzle. The table below is the matching
table for the urea pipe and the pump and urea tank.
Fig. 5-120 Confirm good protection before installation

Name Pipe diameter/mm Joint specification Description Description

Straight at the tank
Outer diameter 8,
Urea inlet line SAE J2044 3/8'' 3/8 straight with bent end, bent at the
inner diameter 6
pump end
Straight at the pump
Outer diameter 8, 5/16 straight with
Urea pressure line SAE J2044 5/16'' end, bent at the
inner diameter 7 bent
nozzle end
SAE J2044 5/16'' Straight at the tank
Outer diameter 8,
Urea return line 3/8 bent 5/16 straight end, bent at the
inner diameter 7 SAE J2044 3/8''
pump end

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3. The urea pipe cannot be bent during installation. If

the pipeline is bent as shown in the right Fig., severe
bending will cause the system’s failure to work.

Fig. 5-121 Urea pipeline is severely bent

5.53 Sensor
5.53.1 Installation

In addition to the liquid level and temperature sensor integrated in the urea tank, the sensors of DeNOx2.2 system
related to the after-treatment include the exhaust temperature sensor, the NOx sensor and the ambient temperature
sensor.
1. The installation direction of the NOX sensor and the exhaust temperature sensor is perpendicular to the direction of
the airflow. Before the sensors are integrated and installed, sufficient clearance is left for disassembly; the tightening torque
of the NOx sensor probe is 50N·m during installation, the wire harness should be protected from contact with high-
temperature objects; the installation torque for the exhaust temperature sensor is 45N·m±5N·m.
2. The ambient temperature sensor is required to be installed in a position that can objectively reflect the ambient
temperature to avoid the influence of the vehicle heat source on the sensor measurement.

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3. The NOx sensor is installed at the outlet of the

exhaust pipe and the after-treatment tank. The
installation direction should be perpendicular to the
exhaust manifold between -80° and 80°. The right Fig. is
the diagram of the NOX sensor and the installation angle.

Fig. 5-122 Diagram of the NOX sensor installation angle

4. In order to avoid the looseness and damage of the
connectors of the wire harness caused by the vibration of
the vehicle during the running of the vehicle, resulting in
the interruption and failure of the signal transmission and
then the abnormal operation of the system, the margin Wire harness
fixed point
wire harness is fixed by the clamp. When fixing, the
bending angle of the wire harness should not be too large,
Wire harness
otherwise the wire will be easily damaged after long time
running. The fixing requirements of the wire harness are:
L1>10mm, the length of the arc is L2>50mm, and the α is
between 45°~135°. The definition of each parameter is as
shown in the right Fig.. Fig. 5-123 Fixing requirements for sensor and actuator wire
harnesses
5. Pay attention to the following when mounting the wire harness:
1) The connection of the wire harness cable to the
connector shall be such that no visible conductors are
exposed to the air and the insulating sheath should be
intact. When the wiring wire harness is arranged on the
vehicle, adequate protection measures should be taken.
During arrangement, keep away from the sharp edges of
the vehicle, and prevent the wear of the wire harness
during the long-term operation of the vehicle, and
resulting in short circuit and other situations. The
connector is required to be inserted into the position to
avoid the phenomenon of false insertion, which brings
unnecessary trouble to the work of the vehicle off-line Fig. 5-124 Wire harness wrapping protection layer
and the diagnosis. At the same time, in order to ensure
the reliability of the signal communication, the wire
harness should be bundled and fixed in an orderly
manner.

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2) At the wire harness connector, the wire harness

should not be bent excessively, and the wire joint should
not be affected by impurities such as oil dirt, water,
debris, mud, etc. If the metal wire head is exposed, it
should be wrapped with tape to avoid short circuit. The
right Fig. is the diagram of the fixing method of the
exhaust temperature and NOX sensor wire harness.

Fig. 5-125 Correct wire harness fixing method

5.54 DeNOx 2.2 system

5.54.1 Usage and inspection

According to the current China IV OBD regulations, when the urea tank liquid level is lower than 10%, the
corresponding indicator of the instrument panel flashes as a warning. At this time, the urea solution should be filled in time.
The urea solution needs to be purchased from an authorized retailer or a professional manufacturer. Since the current
infrastructure for filling the urea solution is not yet fully constructed, in order to prevent the engine torque from being
limited by the lack of urea, an appropriate amount of urea solution may be reserved. It is forbidden to use a privately-
prepared or nonconforming urea solution, as well as other alternative liquids as impurities and metal ions can affect the
normal operation of the system and shorten the life of the system. The resulting losses are not covered by the warranty.
When starting the diesel engine, after the engine speed and exhaust temperature reach the set value, the DeNOx 2.2
system starts to work. After the engine stops, the system enters the reverse pumping stage, and the urea solution in the
system is released. This stage will last for two to three minutes. Do not disconnect the main power switch while the system
is still working.
After the DeNOx 2.2 system is normally turned off (the entire reverse pumping process is completed), it can be shut
down for 4 months in the environment of -40~25°C without disassembly and storage. At higher temperature, the upper
limit of downtime without disassembly will be shortened accordingly. However, the hydraulic and electrical connections
must not be disconnected during this period; evaporation of the urea water vapor in the urea nozzle and pump should be
avoided. It is recommended to fill the urea tank before shutdown to reduce evaporation in the pipeline.
After the time limit is exceeded, the system should be pre-run before starting the system to ensure normal startup. The
steps are as follows:
1. Refill the urea tank with the urea solution;
2. Replace the filter in the pump;
3. Start the DeNOx 2.2 system;
If the system starts abnormally, turn off the system. After the DCU/ECU main relay stops (the stop time varies from
application to application), restart the system. If the startup still fails, seek assistance from service station.

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5.54.2 Inspection and maintenance

During the driving process, when the cab MIL lamp is found to be on, promptly go to the nearest service station for
professional maintenance.
A professional diagnostic instrument is required to service the DeNOx 2.2 system, which should be available at each
service station.
A simple visual examination can be performed without a diagnostic instrument. The urea tank lamp on the instrument
panel of the cab is bright, indicating that the remaining urea solution is less than 10% and should be filled in time.
If it is necessary to replace/remove the urea nozzle, it must be carried out after the engine is completely stopped for
one hour and the exhaust manifold is cooled. Also note that the gasket seal at the bottom is a disposable device and must
be replaced after each assembly.
After the vehicle is used every three years or after driving for 100,000 kilometers, replace the filter element of the urea
pump.

S/N Parts Parts No. Supply No. Qty

1 Urea nozzle 1
2 Cooling pipe joint kit 3/8" 2
3 Pressure pipe joint kit 5/16" 1
4 Gasket seal 1
5 Urea pump 1
6 Return pipe joint kit 3/8" 1
7 Inlet pipe joint kit 3/8" 1
8 Electrical interface protection cap 1
9 Filter kit 1
10 ECU 1

Characteristic Parameter
Size
Urea pump About 220 × 209 × 134 mm
Urea nozzle About 100×60×110 mm
ECU About 205×203×38 mm
Operating condition
Working voltage 12V or 24V
Injection system pressure 9Bar
Injection frequency 1 Hz
Urea pump heating type Electric heating

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Characteristic Parameter
Service life
Urea pump 15,000 hours
Urea nozzle 15,000 hours
ECU 30,000 hours
Number of system start/stop 70,000 times
Interface
Urea solution joint SAE J2044 standard, outer diameter 3/8" or 5/16"
Urea pump electrical interface TYCO, 12 pin
Bosch compackt 1928403874 or 1928404072
Urea nozzle electrical interface Silver plated joint 1 928 498 058
Sealed joint 1 928 300 599
Emission target China IV/China V/Euro VI, US10, JNPLT, TIER 4 etc.
Diagnosis OBD diagnosis for the China IV standard, US13 etc.

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Appendix A Diagnostic fault code table

DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_IVDiaShCirGn- Fuel injection 151 P062D Fuel injectors 1, 2, 3 Fuel injectors 1, 2, 3 1, 2 and 3-cylinder fuel Check the wire harness of
dToutBnk_0 capacitor 1 is short- do not work, which injector wire harness high- the 1, 2 and 3-cylinder fuel
circuited to ground affect the engine end short circuit to earth injectors, and unplug the
performance (ground) engine end wire harness
(small end) connector on the
ECU to measure the high-
end pins of 1, 2 and 3-
cylinder (the 1-cylinder fuel
injector high-end pin A33,
the 2-cylinder fuel injector
high-end pin A48, the 3-
cylinder fuel injector high-
end pin A47) resistance to
ground. If the value of
resistance is greater than
1MΩ, it indicates that the
wire harness is normal.
DFC_IVDiaShCirGn- Fuel injection 151 P062E Fuel injectors 4, 5, 6 Fuel injectors 4, 5, 6 4, 5 and 6-cylinder fuel Check the wire harness of
dToutBnk_1 capacitor 2 is short- do not work, which injector wire harness high- the 4, 5 and 6-cylinder fuel
circuited to ground affect the engine end short circuit to earth injectors, and unplug the
performance (ground) engine end wire harness
(small end) connector on the
ECU to measure the high-
end pins of 4, 5 and 6-
cylinder (the 1-cylinder fuel
injector high-end pin A46,
the 2-cylinder fuel injector
high-end pin A31, the 3-
cylinder fuel injector high-

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
end pin A32) resistance to
ground. If the value of
resistance is greater than
1MΩ, it indicates that the
wire harness is normal.
DFC_IVDiaShCirGn- Fuel injection 426 P1581 Fuel injectors 1, 2, 3 Fuel injectors 1, 2, 3 1, 2 and 3-cylinder fuel Check the wire harness of
dTstBnk_0_C capacitor 1 earthing do not work, which injector wire harness high- the 1, 2 and 3-cylinder fuel
short circuit test affect the engine end short circuit to earth injectors, and unplug the
error performance (ground) engine end wire harness
(small end) connector on the
ECU to measure the high-
end pins of 1, 2 and 3-
cylinder (the 1-cylinder fuel
injector high-end pin A33,
the 2-cylinder fuel injector
high-end pin A48, the 3-
cylinder fuel injector high-
end pin A47) resistance to
ground. If the value of
resistance is greater than
1MΩ, it indicates that the
wire harness is normal.
DFC_IVDiaShCirGn- Fuel injection 426 P1582 Fuel injectors 4, 5, 6 Fuel injectors 4, 5, 6 4, 5 and 6-cylinder fuel Check the wire harness of
dTstBnk_1_C capacitor 2 earthing do not work, which injector wire harness high- the 4, 5 and 6-cylinder fuel
short circuit test affect the engine end short circuit to earth injectors, and unplug the
error performance (ground) engine end wire harness
(small end) connector on the
ECU to measure the high-
end pins of 4, 5 and 6-
cylinder (the 1-cylinder fuel
injector high-end pin A46,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
the 2-cylinder fuel injector
high-end pin A31, the 3-
cylinder fuel injector high-
end pin A32) resistance to
ground. If the value of
resistance is greater than
1MΩ, it indicates that the
wire harness is normal.
DFC_RailPRV8 PRV valve open 136 P0088 High/low-pressure The rail pressure PRV valve has fault and can 1. Check whether the oil
error (it should be circuit and related remains high and the not be opened. circuit is bent and blocked;
opened, but not parts PRV valve cannot be 2. Check whether the
actually opened) opened metering unit is stuck or
damaged;
3. Check whether the fuel
injector or high pressure oil
pump return oil is blocked;
4. Check whether the fuel
injector has fault.
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line
interference;
6. Check common rail pipe
DFC_RailPRV9 The high pressure 136 P0088 High/low-pressure Engine power is Fuel temperature is over Check the fuel line, and
oil pump always circuit and related reduced high whether there is a problem
works at the parts of connection between the
maximum pump oil oil return line and the oil-
level (causing the inlet pipe; check whether the
fuel temperature fuel in the tank is too little,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
too high) so that the return oil is
quickly re-pressed and
supplied to the fuel system.
DFC_AirHt_ TstOffHi Voltage signal is 323 P2609 Grid heater grill Grid heater works Grid heater grill works 1. Check that the resistance
high when closing abnormally abnormally; Grid heater grill of grid heater grill is about
grid heater grill drive circuit works 0.4Ω;
abnormally 2. Check the related wire
harness of grid heater grill
drive circuit
DFC_AirHt_ TstOffLo Voltage signal is low 323 P2609 Grid heater grill Grid heater works Grid heater grill works 1. Check that the resistance
when closing grid abnormally abnormally; Grid heater grill of grid heater grill is about
heater grill drive circuit works 0.4Ω;
abnormally 2. Check the related wire
harness of grid heater grill
drive circuit
DFC_AirHt_ TstOnHi Voltage signal is 323 P2609 Grid heater grill Grid heater works Grid heater grill works 1. Check that the resistance
high when opening abnormally abnormally; Grid heater grill of grid heater grill is about
grid heater grill drive circuit works 0.4Ω;
abnormally 2. Check the related wire
harness of grid heater grill
drive circuit
DFC_AirHt_ TstOnLo Voltage signal is low 323 P2609 Grid heater grill Grid heater works Grid heater grill works 1. Check that the resistance
when opening grid abnormally abnormally; Grid heater grill of grid heater grill is about
heater grill drive circuit works 0.4Ω;
abnormally 2. Check the related wire
harness of grid heater grill
drive circuit
DFC_AirHtStickOn Grid heater grill is 322 P2609 Grid heater grill, Grid heater does not Grid heater grill works 1. Connect the grid heater
always on control relay work/wire harness abnormally; Grid heater grill flange
burnout drive circuit works 2. Check the heating flange
abnormally circuit for open circuit or

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
short circuit
DFC_AirTMonPlaus_ 0 Temperature _0 is 481 P1000 Water temperature Cold starting does not Water temperature sensor 1. Check the water
not reliable at cold sensor work fault temperature sensor wire
start harness and connector
(detect the on-off of the
connector to A28, A29, check
whether the A28 voltage to
ground is 5V)
2. Replace the water
temperature sensor and
normal resistance of water
temperature sensor is about
several KΩ
DFC_AirTMonPlaus_ 1 Temperature _1 is 481 P1001 Upstream Cold starting does not Upstream temperature 1. Check the upstream
not reliable at cold temperature sensor work sensor fault exhaust temperature sensor
start wire harness and connector
(detect the on-off of the
connector to K81, K82, check
whether the K81 voltage to
ground is 5V)
2. Replace the upstream
exhaust temperature sensor
(the normal resistance value
of the exhaust temperature
sensor is about several
hundred Ω)
DFC_AirTMonPlaus_ 2 Temperature _2 is 481 P1002 Intake temperature Cold starting does not Intake temperature sensor 1. Check the intake air
not reliable at cold sensor work fault temperature sensor and
start connector (check the on-off
of the connector to A27,
A42, A09, A43, check

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
whether the A09, A27
voltage to ground is 5V)
2. Replace the intake
temperature sensor
(resistance between 1 and 2
pin is about 2KΩ)
DFC_AirTMonPlaus- Tot Multiple 481 P1005 Water temperature, Cold starting does not Water temperature, 1. Check intake temperature,
temperatures are upstream exhaust work upstream exhaust upstream exhaust
not reliable during temperature, intake temperature, intake temperature, water
cold start temperature sensor temperature sensor fault temperature sensor and
connector
2. Replace intake
temperature, water
temperature, upstream
exhaust temperature sensor
DFC_ARlySCB_0 Actuator_0 short 114 P0659 Grid heater relay, Related lamps or K68, K29, and A45 are used 1. Plug and unplug the
circuit to power cold start lamp, solenoid valve do not for the output power of the relevant sensor or relay, and
supply OBD lamp, start work ECU, and should not be power on T15 again to see if
relay, water in fuel connected to the vehicle it can become a historical
lamp, exhaust brake electricity. fault and clear it. If it can be
solenoid valve, cleared, it is the problem of
electric control fan the sensor and its line.
solenoid valve 2. If the fault still exists,
check whether K68, K29, and
A45 still have voltage after
the vehicle T15 is powered
off. If any, check the voltage
source and change the
vehicle circuit.
3. If the reason still can't be
found, check whether the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
K68, K29, and A45 are short-
circuited on the power
supply module of other ECUs
by the lead method to
measure the on-off under
the condition of T15 power
on.
DFC_ARlySCB_1 Actuator_1 short 115 P2671 Urea heating main Related lamps or K94, K92, K50, K25, K26 and 1. Plug and unplug the
circuit to power relay, pressure tube solenoid valve do not vehicle voltage input relevant sensor or relay, and
supply heating relay, inlet work power on T15 again to see if
pipe relay, return it can become a historical
pipe relay, urea fault and clear it. If it can be
pump heating relay, cleared, it is the problem of
urea tank heating the sensor and its line.
solenoid valve 2. If the fault still exists,
check whether K90 still has
voltage after the vehicle T15
is powered off. If any, check
the voltage source and
change the vehicle circuit.
3. If the reason still can't be
found, check whether the
K90 is short-circuited on the
power supply module of
other ECUs by the lead
method to measure the on-
off under the condition of
T15 power on.
DFC_ARlySCB_2 Actuator_2 short 116 P2686 Urea pump Urea pump cannot K93 has vehicle voltage 1. Plug and unplug the
circuit to power establish urea input relevant sensor or relay, and
supply pressure power on T15 again to see if

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
it can become a historical
fault and clear it. If it can be
cleared, it is the problem of
the sensor and its line.
2. If this fault still exists,
check whether K73 still has
voltage after the vehicle T15
is powered off. If any, check
the voltage source and
change the vehicle circuit.
3. If the reason still can't be
found, check whether the
K73 is short-circuited on the
power supply module of
other ECUs by the lead
method to measure the on-
off under the condition of
T15 power on.
DFC_ARlySCG_0 Actuator_0 short 114 P0658 Grid heater relay, Related lamps or K68, K29, and A45 are used 1. Plug and unplug the
circuit to ground cold start lamp, solenoid valve do not for the output power of the relevant sensor or relay, and
OBD lamp, start work ECU, and should not be power on T15 again to see if
relay, water in fuel connected to the vehicle it can become a historical
lamp, exhaust brake electricity. fault and clear it. If it can be
solenoid valve, cleared, it is the problem of
electric control fan the sensor and its line.
solenoid valve 2. If this fault still exists,
check the K68, K29, A45 and
other related actuator
sensors corresponding pins
for grounding or short
circuit.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_ARlySCG_1 Actuator_1 short 115 P2670 Urea heating main Related lamps or K94, K92, K50, K25, K26 and 1. Plug and unplug the
circuit to ground relay, pressure tube solenoid valve do not vehicle voltage input relevant sensor or relay, and
heating relay, inlet work power on T15 again to see if
pipe relay, return it can become a historical
pipe relay, urea fault and clear it. If it can be
pump heating relay, cleared, it is the problem of
urea tank heating the sensor and its line.
solenoid valve 2. If this fault still exists,
check the K90, K94, K92,
K50, K25 and K26 for
grounding or short circuit.
DFC_ARlySCG_2 Actuator_2 short 116 P2685 Urea pump Urea pump cannot K93 has vehicle voltage 1. Plug and unplug the
circuit to ground establish urea input relevant sensor or relay, and
pressure power on T15 again to see if
it can become a historical
fault and clear it. If it can be
cleared, it is the problem of
the sensor and its line.
2. If this fault still exists,
check the K73 and K93 for
grounding or short circuit.
DFC_BattUHi Battery voltage over 124 P0563 Generator, battery ECU is damaged and Battery voltage over high 1. Check the battery
high engine can not be 2. Check the generator
started
DFC_BattULo Battery voltage over 124 P0562 Generator, battery ECU can not work Battery voltage over low 1. Check the battery
low normally and the 2. Check the generator
engine is stopped
DFC_BattUSRCMax Battery voltage 124 P0563 Generator, battery ECU is damaged and Battery voltage over high 1. Check the battery
signal over high engine can not be 2. Check the generator
started
DFC_BattUSRCMin Battery voltage 124 P0562 Generator, battery ECU can not work Battery voltage over low 1. Check the battery

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
signal over low normally and the 2. Check the generator
engine is stopped
DFC_BrkNpl The main and 223 P0504 Brake or brake wire 1. Unable to judge the Main and auxiliary brake Check the main and auxiliary
auxiliary brake harness brake switch wire harness fault; brakes (when the main brake
signals are not in 2. Cruise control can main and auxiliary brake is pressed, the K41 end is
the same state not be realized signals are not synchronized 24V, the K14 end is 0V when
3. BOS has failure the auxiliary brake is
pressed, and the two are
synchronized), and the
relevant wire harness (check
the on-off of the connector
to K41, K14)
DFC_BrkSig Brake signal error 223 P0571 CAN message Brake signal from CAN Brake switch or related wire Check whether the main and
bus fault harness fault auxiliary brakes are
synchronized and the
relevant wire harness is on
and off.
DFC_BusDiagBusOf- CAN node A bus 411 U0073 ECU/vehicle CAN 1. Affecting the "CAN node A bus error" is 1. The vehicle CAN line is
fErrPasNodeA error network parameters such as not the fault of the ECU short-circuited, open-
speed, water itself, and basically it is the circuited or disturbed: check
temperature and oil abnormality of the CAN whether the CAN high and
pressure on the CAN network voltage of the low voltages are normal, and
meter: it causes the vehicle, and the CAN whether the on-off is
CAN instrument to network interference caused normal. Generally, CAN high
display abnormality, by other CAN control faults. voltage is about 2.8V, and
but does not affect the CAN low voltage is about
the mechanical 2.2V, as the voltage is slightly
instrument. different due to the use
2. Affecting the condition;
shifting gear of the 2. CAN network controller or
automatic gearbox, vehicle CBCU itself fault:

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
etc.: it may cause the cause abnormal CAN line
automatic gearbox to voltage, and large
shift gear irregularly, fluctuations, check CBCU,
and the setting is vehicle CAN control module,
invalid; etc.;
3. NOx sensor or CAN
instrument, ABS/ASR
controller, AMT controller
fault, causing CAN line
instability: disconnect the
above controllers in
sequence, check its
interference with CAN
voltage, and check its related
CAN line. Troubleshooting
skills: not caused by ECU
fault, but caused by the
vehicle CAN network or
other CAN control fault.
DFC_BusDiagBusOf- CAN node A bus 411 U0073 ECU/vehicle CAN 1. Affecting the "CAN node A bus error" is 1. The vehicle CAN line is
fNodeA closing error network parameters such as not the fault of the ECU short-circuited, open-
speed, water itself, and basically it is the circuited or disturbed: check
temperature and oil abnormality of the CAN whether the CAN high and
pressure on the CAN network voltage of the low voltages are normal, and
meter: it causes the vehicle, and the CAN whether the on-off is
CAN instrument to network interference caused normal. Generally, CAN high
display abnormality, by other CAN control faults. voltage is about 2.8V, and
but does not affect the CAN low voltage is about
the mechanical 2.2V, as the voltage is slightly
instrument. different due to the use
2. Affecting the condition;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
shifting gear of the 2. CAN network controller or
automatic gearbox, vehicle CBCU itself fault:
etc.: it may cause the cause abnormal CAN line
automatic gearbox to voltage, and large
shift gear irregularly, fluctuations, check CBCU,
and the setting is vehicle CAN control module,
invalid; etc.;
3. NOx sensor or CAN
instrument, ABS/ASR
controller, AMT controller
fault, causing CAN line
instability: disconnect the
above controllers in
sequence, check its
interference with CAN
voltage, and check its related
CAN line. Troubleshooting
skills: not caused by ECU
fault, but caused by the
vehicle CAN network or
other CAN control fault.
Engine coolant
steady-state
DFC_CEngDsTAbsT- st 242 P0116
temperature is not
This fault will not be
reliable Engine water Engine torque limit, Water temperature sensor
reported and does not need
Engine coolant temperature store flash code error
to be processed
dynamic
DFC_CEngDsTDynT- st 242 P0116
temperature is not
reliable
Engine coolant Can't get water CAN bus does not have this 1. Find the vehicle
DFC_CEngDsTSig 241 U0116 CAN bus
temperature error temperature, store message, message error or technology agreement and

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
identify the signal source of
water temperature sensor
from CAN signal flash code the water temperature
error
sensor.
Engine coolant 1. Check the water
temperature original Water temperature temperature sensor line
DFC_ CEngDsTSRC-Max 241 P0118
voltage is above the sensor connection, unplug the
upper limit sensor plug, measure the
sensor plug sensor terminal
voltage, and A37 should be
5V;
Engine torque limit,
Circuit connecting error 2. Measure the water
Engine coolant MIL lamp is on
temperature sensor
temperature original Water temperature
DFC_ CEngDsTSRC-Min 241 P0117 resistance, and the water
voltage is below the sensor
temperature resistance value
lower limit
at room temperature is
about 300Ω;
3. Measure the on-off of the
A50 wire harness
Engine coolant
temperature is not
reliable (the
deviation of this The water temperature does
Water temperature Engine water No need to process, the data
DFC_CEngDsTVDPl- aus temperature from 242 P0116 not reach the set value at
sensor temperature error has been blocked
the selected second startup
temperature is
above the upper
limit)
DFC_ClthNpl The clutch signal is 222 P0704 Clutch signal Can not exit cruise Clutch switch has bad 1. The clutch switch is not
not reliable (the when stepping on the contact connected, or the normally
gear position has clutch, and the fault open switch is selected (the
changed, but the lamp is on after three normally closed type should

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
clutch signal has not driving cruises be selected): check whether
changed the clutch switch is installed,
accordingly) whether it is a normally
closed switch; check
whether the relevant line of
the clutch switch is open-
circuited or short-circuited;
2. Clutch switch sensor
problem: Check whether the
clutch switch function is
normal;
3. The gas circuit fault of
pushing the clutch switch:
Check whether the drive gas
circuit of the clutch switch is
normal; troubleshooting
skills: basically caused by the
missing of the switch, and
the selection of wrong
model; it may also be the
problem of sensor and gas
circuit.
DFC_ClthSig Clutch signal from 222 U1400 Clutch signal Cannot enter cruise, Message address and Check the CAN controller
CAN error and the fault lamp is contents error
on after three driving
cruises
DFC_CoVehPrfmLim- OBD torque limit 511 P1007 Torque limiter Engine torque limit Multi-layer torque limiter Fault removal caused by
Act activation error works, not shown correctly torque limitation
DFC_CrCUIModeNpl Cruise control 341 P0575 Multifunctional The vehicle cannot Two or more keys of the 1. Use the data stream to
switch combination switch enter the cruise and multi-function switch are check the switch status
error store the fault code. pressed at the same time, 2. Check whether there is a

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
resulting in a state conflict problem with the switch wire
harness, pins
K18/K37/K12/K32.
DFC_DevLibBattUHi Battery voltage over 124 P0563 Battery Actuator pin power Battery leakage or poor line 1. Check the battery
high diagnosis is all turned contact 2. Check the generator
off, storing fault codes
DFC_DevLibBattULo Battery voltage over 124 P0562 Battery Actuator pin power Battery leakage or poor line 1. Check the battery
low diagnosis is all turned contact 2. Check the generator
off, storing fault codes
DFC_EBrkPreSelPla- us Exhaust brake is not 342 P1500 Exhaust brake Exhaust brake does Exhaust brake solenoid valve This fault will not be
reliable solenoid valve not work, storing fault fault, exhaust brake circuit reported and does not need
codes to be processed
DFC_ECBtnStopSig The off-vehicle stop 343 P2536 Off-vehicle stop The off-vehicle stop The off-vehicle stop switch 1. Check whether the switch
switch signal is not switch function does not has been pressed for too is stuck, check the line for
reliable work, storing the fault long short circuit, and pin K31.
code
DFC_ECBtnStrtSig The off-vehicle 343 P2536 Off-vehicle starting The off-vehicle The off-vehicle starting 1. Check whether the switch
starting switch switch starting function does switch has been pressed for is stuck, check the line for
signal is not reliable not work, storing fault too long short circuit, and pin K67.
codes
DFC_EEPEraseErr EEP erase error 117 P062F ECU internal ECU fault; Store the ECU internal error 1. Re-write-in data;
memory fault code
DFC_EEPRdErr EEP reading error 117 P062F ECU internal Read data error, use ECU internal error 1. Re-write-in data;
memory substitute values, and
store fault codes
DFC_EEPWrErr EEP writing error 117 P062F ECU internal ECU fault; Store the ECU internal error 1. Re-write-in data;
memory fault code
DFC_EngICO Engine shut-off 512 P1008 Fuel injector, engine Engine flameout, fault Does not appear during
request causes oil turning off system lamp ON normal engine operation
injection cut-off
DFC_EngPrtOvrSpd Engine over-speed 513 P0219 Engine speed Engine entering the Engine speed exceeds the 1. The vehicle engine does

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
controller limp home mode; max allowable value not need to be processed,
Store the flash code and will be resolved
automatically after the speed
drops to the lowest value.
2. Restart power generation
equipment, etc. after fault
removal
DFC_EngPrtTMFWS- Engine protection 514 P1009 This fault will not be
hOff activated reported and does not need
to be processed.
DFC_EngSpdOL Engine speed output 344 P100A Engine speed The engine speed Short circuit, open circuit on Measure the voltage at the
has no load output pin signal cannot be the line connected to the K49 terminal of the wire
correctly obtained speed output pin harness
through this pin, and
the flash code is
stored.
DFC_EngSpdOvrTe- mp Engine speed output 344 P100B Engine speed The engine speed Short circuit, open circuit on Measure the voltage at the
temperature over output pin signal cannot be the line connected to the K49 terminal of the wire
high correctly obtained speed output pin harness
through this pin, and
the flash code is
stored.
DFC_EngSpdSCB Engine speed output 344 P100C Engine speed The engine speed Short circuit, open circuit on Measure the voltage at the
short circuit to output pin signal cannot be the line connected to the K49 terminal of the wire
power supply correctly obtained speed output pin harness
through this pin, and
the flash code is
stored.
DFC_EngSpdSCG Engine speed output 344 P100D Engine speed The engine speed Short circuit, open circuit on Measure the voltage at the
short circuit to output pin signal cannot be the line connected to the K49 terminal of the wire
ground correctly obtained speed output pin harness

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
through this pin, and
the flash code is
stored.
DFC_EnvPSig Ambient pressure 232 U1401 Ambient pressure The fault lamp is ECU internal atmosphere Replace the ECU
CAN message error sensor (in the ECU) normally on, and pressure sensor damaged
there is insufficient
power and smoke in
the plateau.
DFC_EnvPSRCMax Ambient pressure 232 P2229 Ambient pressure The fault lamp is ECU internal atmosphere Replace the ECU
sensor voltage is sensor (in the ECU) normally on, and pressure sensor damaged
above the upper there is insufficient
limit power and smoke in
the plateau.
DFC_EnvPSRCMin Ambient pressure 232 P2228 Ambient pressure The fault lamp is ECU internal atmosphere Replace the ECU
sensor voltage is sensor (in the ECU) normally on, and pressure sensor damaged
below the lower there is insufficient
limit power and smoke in
the plateau.
DFC_EnvTAmbTem- Ambient 235 P0071 Ambient The after-treatment The temperature difference 1. Check the ambient
pMon temperature is not temperature sensor system does not work between the ambient temperature sensor line
reliable properly, and the fault temperature sensor and the connection, unplug the
code is stored. intake air flow sensor is too sensor plug, measure the
large sensor plug sensor terminal
voltage, which should be 5V
for k39;
2. Measure the ambient
temperature sensor
resistance, and the
resistance of the ambient
temperature sensor at
normal temperature is 3kΩ;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
3. Measure the on-off of the
k60 wire harness
DFC_EnvTSRCMax Ambient 235 P0073 Ambient The ambient Circuit short circuit to power 1. Check the ambient
temperature sensor temperature sensor temperature sensor is supply and ground temperature sensor line
voltage is above the not properly acquired connection, unplug the
upper limit and the MIL lamp is sensor plug, measure the
on sensor plug sensor terminal
DFC_EnvTSRCMin Ambient 235 P0072 Ambient The ambient Circuit short circuit to power voltage, which should be 5V
temperature sensor temperature sensor temperature sensor is supply and ground for k39;
voltage is below the not properly acquired 2. Measure the ambient
lower limit and the MIL lamp is temperature sensor
on resistance, and the
resistance of the ambient
temperature sensor at
normal temperature is 3kΩ;
3. Measure the on-off of the
k60 wire harness
DFC_EpmCaSI1Err- Sig Camshaft signal 123 P0341 Camshaft speed Difficult to start, lack Camshaft speed sensor 1. High-pressure oil pump
error sensor of power, fault lamp damaged; timing error: caused by too
on large high-pressure oil pump
gear timing deviation, need
to re-correct time, install the
oil pump;
2. Camshaft sensor line
faults, such as short circuit,
electromagnetic
interference, etc.: Check
whether the camshaft sensor
is properly installed, whether
the line connection is
normal, and whether the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
shielding measures are
normal;
3. Camshaft mounting
problems, such as too small
or too large clearance
between sensor and
camshaft: re-install the
sensor correctly
4. Sensor fault or quality
problems, or camshaft
installation, machining
problems: Check whether
the sensor is normal, the
quality meets the
requirements, and the
camshaft is normal.
Troubleshooting skills: If the
engine has been repaired,
then the main cause is the
wrong timing of the
installation of the oil pump;
if there is no repair, then the
main cause is fault of the
sensor and the wiring wire
harness; if there is no
problem after the above
situation is checked, then it
may be the problem of
camshaft installation,
processing, etc. If this fault
occurs on the P7 engine, try

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
replacing the BOSCH sensor
to test.
DFC_EpmCaSI1No- Sig Camshaft signal 123 P0340 Camshaft speed Difficult to start, lack Camshaft speed sensor 1. High-pressure oil pump
missing sensor of power, fault lamp damaged; circuit shorted timing error: caused by too
on large high-pressure oil pump
gear timing deviation, need
to re-correct time, install the
oil pump;
2. Camshaft sensor line
faults, such as short circuit,
electromagnetic
interference, etc.: Check
whether the camshaft sensor
is properly installed, whether
the line connection is
normal, and whether the
shielding measures are
normal;
3. Camshaft mounting
problems, such as too small
or too large clearance
between sensor and
camshaft: re-install the
sensor correctly
4. Sensor fault or quality
problems, or camshaft
installation, machining
problems: Check whether
the sensor is normal, the
quality meets the
requirements, and the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
camshaft is normal.
Troubleshooting skills: If the
engine has been repaired,
then the main cause is the
wrong timing of the
installation of the oil pump;
if there is no repair, then the
main cause is fault of the
sensor and the wiring wire
harness; if there is no
problem after the above
situation is checked, then it
may be the problem of
camshaft installation,
processing, etc. If this fault
occurs on the P7 engine, try
replacing the BOSCH sensor
to test.
DFC_EpmCaSI1Ofs- Err Camshaft signal 123 P0340 Camshaft speed Difficult to start, lack Assembling problems of Replace the camshaft speed
deviation error sensor of power, fault lamp crankshaft and camshaft sensor
on
DFC_EpmCrSErrSig Crankshaft signal 122 P0336 Crankshaft speed Difficult to start, Improper installation of the 1. Installation phase error, or
error sensor insufficient engine crankshaft speed sensor, crankshaft signal sensor, line
power wire harness disconnection, fault: check whether the
flywheel processing problem sensor and line is normal,
whether there is open
circuit, short circuit and
other conditions, whether
the line is damaged, causing
interference, etc.; if repaired,
check whether the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
installation phase is correct;
2. Too large or too small
clearance of sensor
installation: check whether
the sensor installation
clearance is normal;
3. Flywheel housing
processing and installation
problems: The flywheel
housing processing process is
noconforming, which may
result in difficulty in sensor
signal acquisition;
4. Flywheel, gear ring,
crankshaft hardware fault,
causing the flywheel to
shake and resulting in signal
loss: check whether the gear
ring, the flywheel is secure,
whether the crankshaft axis
is displaced, whether the
main bearing bolt is broken,
causing the crankshaft to
shake; troubleshooting skills:
if the engine is repaired,
then the main cause is the
flywheel installation timing
error; if there is no repair,
then the main cause is the
fault of the sensor and the
wiring wire harness; if there

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is no problem after the
above situation is checked,
then it may be caused by the
flywheel, ring gear,
crankshaft vibration, and
sometimes the main bearing
bolt, thrust plates, etc. need
to be checked.
DFC_EpmCrSNoSig Crankshaft signal 122 P0335 Crankshaft speed Difficult to start, Improper installation of the 1. Installation phase error, or
missing sensor insufficient engine crankshaft speed sensor, crankshaft signal sensor, line
power wire harness disconnection, fault: check whether the
flywheel processing problem sensor and line is normal,
whether there is open
circuit, short circuit and
other conditions, whether
the line is damaged, causing
interference, etc.; if repaired,
check whether the
installation phase is correct;
2. Too large or too small
clearance of sensor
installation: check whether
the sensor installation
clearance is normal;
3. Flywheel housing
processing and installation
problems: The flywheel
housing processing process is
noconforming, which may
result in difficulty in sensor
signal acquisition;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
4. Flywheel, gear ring,
crankshaft hardware fault,
causing the flywheel to
shake and resulting in signal
loss: check whether the gear
ring, the flywheel is secure,
whether the crankshaft axis
is displaced, whether the
main bearing bolt is broken,
causing the crankshaft to
shake; troubleshooting skills:
if the engine is repaired,
then the main cause is the
flywheel installation timing
error; if there is no repair,
then the main cause is the
fault of the sensor and the
wiring wire harness; if there
is no problem after the
above situation is checked,
then it may be caused by the
flywheel, ring gear,
crankshaft vibration, and
sometimes the main bearing
bolt, thrust plates, etc. need
to be checked.
DFC_ExhFlpLPOL Exhaust brake 311 P0475 Exhaust brake Exhaust brake does Exhaust brake solenoid valve Check the circuit, pins K47,
solenoid valve has solenoid valve not work, and the is not properly connected K29.
no load fault lamp is on after
three driving cruises
DFC_ExhFlpLPOvrT- Exhaust brake 311 P0475 Exhaust brake Exhaust brake does Exhaust brake solenoid valve Replace the solenoid valve

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
emp solenoid valve solenoid valve not work, and the is damaged
overheats fault lamp is on after
three driving cruises
DFC_ExhFlpLPSCB Exhaust brake 311 P0478 Exhaust brake Exhaust brake does Exhaust brake line is short- Check exhaust brake line
solenoid valve short solenoid valve not work, and the circuited
circuit to the power fault lamp is on after
supply three driving cruises
DFC_ExhFlpLPSCG Exhaust brake 311 P0477 Exhaust brake Exhaust brake does Exhaust brake line is short- Check exhaust brake line
solenoid valve short solenoid valve not work, and the circuited
circuit to ground fault lamp is on after
three driving cruises
DFC_ExhFlpLPStLn- Npl Exhaust brake 311 P0476 Exhaust brake Exhaust brake failure The detection pulse for the 1. Check the exhaust brake
solenoid valve status solenoid valve exhaust brake solenoid valve solenoid valve wiring
is not reliable is nonconforming (K29/K47);
2. Check the exhaust brake
solenoid valve for damage.
DFC_ExhFlpLPStLn- Sig Exhaust brake 311 P0475 Exhaust brake Exhaust brake failure The detection pulse for the 1. Check the exhaust brake
solenoid valve status solenoid valve exhaust brake solenoid valve solenoid valve wiring
error is nonconforming (K29/K47);
2. Check the exhaust brake
solenoid valve for damage.
DFC_ FanDIOOL_0 Fan solenoid valve 1 312 P0480 Electromagnetic fan Electromagnetic fan Electromagnetic fan relay 1 1. Check whether it is a
has no load coil 1 does not work is not properly connected electromagnetic fan;
2. Check whether the wire
harness connection is normal
(the electromagnetic fan
relay ECU terminal voltage is
both 24V for two pins A45
and A35, when T15 power-
on fan does not work;
unplug the electromagnetic

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
fan relay, at the moment the
A35 pin is suspended in
midair, and the voltage is
3.5V for A35 pin);
DFC_ FanDIOOL_1 Fan solenoid valve 2 312 P0480 Electromagnetic fan Electromagnetic fan Electromagnetic fan relay 2 1. Check whether it is a
has no load coil 2 does not work is not properly connected electromagnetic fan;
2. Check whether the wire
harness connection is normal
(the electromagnetic fan
relay ECU terminal voltage is
both 24V for two pins A45
and A15, when T15 power-
on fan does not work;
unplug the electromagnetic
fan relay, at the moment the
A15 pin is suspended in
midair, and the voltage is
3.5V for A35 pin);
DFC_FanDIOOvrTe- Fan solenoid valve 1 312 P0480 Electromagnetic fan Electromagnetic fan Electromagnetic fan relay is 1. Check whether the
mp_0 overheats coil 1 does not work damaged or the resistance is electromagnetic fan relay is
too small damaged;
2. Check whether the
electromagnetic fan relay
matching (resistance) is
appropriate;
3. Check whether the two
control terminals of the relay
are short-circuited
DFC_FanDIOOvrTe- Fan solenoid valve 2 312 P0480 Electromagnetic fan Electromagnetic fan Electromagnetic fan relay is 1. Check whether the
mp_1 overheats coil 2 does not work damaged or the resistance is electromagnetic fan relay is
too small damaged;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
2. Check whether the
electromagnetic fan relay
matching (resistance) is
appropriate;
3. Check whether the two
control terminals of the relay
are short-circuited
DFC_ FanDIOSCB_0 Fan solenoid valve 1 312 P0692 Electromagnetic fan Electromagnetic fan Control end of coil 1 short- 1. Unplug the
short circuit to the coil 1 does not work circuit to the power supply electromagnetic fan relay
power supply and measure whether the
voltage is 3.5V for A15;
2. If it is 24V, then continue
to measure the voltage of
A35 pin after T15 is powered
off, and determine the
source of short circuit
DFC_ FanDIOSCB_1 Fan solenoid valve 2 312 P0692 Electromagnetic fan Electromagnetic fan Control end of coil 2 short- 1. Unplug the
short circuit to the coil 2 does not work circuit to the power supply electromagnetic fan relay
power supply and measure whether the
voltage is 3.5V for A15;
2. If it is 24V, then continue
to measure the voltage of
A35 pin after T15 is powered
off, and determine the
source of short circuit
DFC_ FanDIOSCG_0 Fan solenoid valve 1 312 P0691 Electromagnetic fan Electromagnetic fan Control end of coil 1 short- 1. Unplug the connector of
short circuit to coil 1 does not work circuit to ground the coil 1 and measure
ground whether the resistance
between the A35 and the
common ground is not
infinite;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_ FanDIOSCG_1 Fan solenoid valve 2 312 P0691 Electromagnetic fan Electromagnetic fan Control end of coil 2 short- 1. Unplug the connector of
short circuit to coil 2 does not work circuit to ground the coil 2 and measure
ground whether the resistance
between the A15 and the
common ground is not
infinite;
DFC_ FanPWMOL Fan PWM drive has 312 P0481 Electronically Fan does not work Electronically controlled 1. Check whether it is a
no load controlled silicone silicone oil fan solenoid electromagnetic silicone oil
oil fan valve is open-circuited fan;
2. Check whether the wire
harness connection is normal
(When the fan does not
work, the electromagnetic
silicone oil fan relay ECU
terminal voltage is 24V for
both pins; unplug the
electromagnetic fan relay, at
this time the A35 pin is
suspended, and the pin
voltage is 3.5V for A35);
DFC_FanPWMOvrT- Fan PWM drive over 312 P0481 Electronically Fan does not work Electric control fan coils Use 24V relay to test
emp temperature controlled silicone damaged whether there is still a
oil fan fault,and replace the fan
clutch if not
DFC_ FanPWMSCB Fan PWM drive 312 P0694 Electronically Fan does not work Electronically controlled 1. Check whether it is an
short circuit to controlled silicone silicone oil fan solenoid electronically controlled
power supply oil fan valve PWM signal terminal is silicone oil clutch;
short-circuited to power 2. Unplug the
supply electromagnetic fan relay
and measure whether the
voltage is 3.5V for A15;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
3. If it is 24V, then continue
to measure the voltage of
A35 pin after T15 is powered
off, and determine the
source of short circuit
DFC_ FanPWMSCG Fan PWM drive 312 P0693 Electronically Fan does not work Electronically controlled 1. Check whether it is an
short circuit to controlled silicone silicone oil fan solenoid electronically controlled
ground oil fan valve PWM signal terminal is silicone oil clutch;
short-circuited to ground 2. Check whether the fan
relay PWM end is short
circuit to ground
DFC_FanSpdLonPer Fan speed signal 316 P0480 Electronically No fan speed The time interval for two 1. Check whether the
time interval is too controlled silicone pulses of fan speed is too electronically controlled
long oil fan short silicone oil clutch can rotate
under normal conditions;
2. Check whether the
electronically controlled
silicone oil clutch speed
sensor is damaged.
DFC_FanSpdSRCHi- gh Fan speed exceeds 316 P0495 Electronically Fan speed is not Broken sensor or data 1. Check whether the
the max value controlled silicone accurate mismatch electronically controlled
oil fan silicone oil fan speed sensor
is damaged;
2. Check whether the
transmission ratio of the fan
to the crankshaft is too large;
3. Check the data.
DFC_FanSpdSRCLo- w Fan speed is lower 316 P0494 Electronically Fan speed is not Broken sensor or data 1. Check whether the
than the minimum controlled silicone accurate mismatch electronically controlled
value oil fan silicone oil fan speed sensor
is damaged;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
2. Check whether the
transmission ratio of the fan
to the crankshaft is too
small;
3. Check the data.
DFC_ FlFWLvlSRCM-ax The water in fuel 214 P2267 Primary filter or fuel Store the flash code Sensor is not connected 1. Check whether the three
sensor voltage system protector wires of the water in fuel
signal is above the sensor are connected
upper limit. properly and are normally
turned on;
2. Check whether the three
pin voltages are normal.
DFC_ FlFWLvlSRCM-in The water in fuel 214 P2266 Primary filter or fuel Store the flash code Sensor signal cable short 1. Check whether the three
sensor voltage system protector circuit to ground wires of the water in fuel
signal is below the sensor are connected
lower limit. properly and are normally
turned on;
2. Check whether the three
pin voltages are normal.
DFC_FlSys_ WtDet There is too much 211 P2269 Primary filter or fuel The diesel entering The water level of the Primary fuel filter water cup
water in the fuel system protector the engine has a high primary filter water cup is drains off water
water content high
DFC_GbxNPosSig Neutral gear CAN 227 U1402 Neutral gear signal Store the flash code The neutral position There is no such fault at the
input signal error obtained from the CAN bus moment, and it needs to be
is incorrect closed in the program if any.
DFC_GlwLmpOL Grid heater lamp 332 P0381 Grid heater lamp Grid heater lamp has Grid heater lamp is not 1. Make sure the indicator is
has no load no action connected or is open- from the hardware;
circuited 2. Check whether the grid
heater lamp is connected or
damaged, unplug the
connector, and measure the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
resistance of the lamp
terminal to be about 2kΩ.
3. Unplug the connector,
measure the line voltage of
the ECU terminal when T15
is powered on, and the
voltage is 24V for K68, and
the voltage is about 3.65V
for K48 (K68/K48);
4 Check the on-off of the
ECU end wire harness.
DFC_GlwLmpOvrTe- Grid heater lamp is 332 P0381 Grid heater lamp Grid heater lamp has Improper matching of grid 1. Make sure the indicator is
mp overheated no action heater lamp or line problem from the hardware;
2. Check whether the grid
heater lamp is connected or
damaged, unplug the
connector, and measure the
resistance of the lamp
terminal to be about 2kΩ.
DFC_GlwLmpSCB Grid heater lamp 332 P0381 Grid heater lamp Grid heater lamp has Grid heater lamp wiring 1. Make sure the indicator is
short circuit to the no action problem from the hardware;
power supply 2. Check whether the grid
heater lamp is connected or
damaged, unplug the
connector, and measure the
resistance of the lamp
terminal to be about 2kΩ.
3. Check whether the signal
terminal K48 of the grid
heater lamp is short-
circuited to the power supply

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_GlwLmpSCG Grid heater lamp 332 P0381 Grid heater lamp Grid heater lamp has Grid heater lamp wiring 1. Make sure the indicator is
short circuit to no action problem from the hardware;
ground 2. Check whether the grid
heater lamp is connected or
damaged, unplug the
connector, and measure the
resistance of the lamp
terminal to be about 2kΩ.
3. Check whether the signal
terminal K48 of the grid
heater lamp is short-
circuited to ground
(grounding)
DFC_IAirHtOL Grid heater has no 321 P0110 Grid heater relay Grid heater failure Grid heater relay is not 1. Check whether the wiring
load connected or open-circuited of the grid heater relay is in
good condition, whether it is
connected with the ECU
(K68/K72), and when the
grid heater relay is not
working, the voltage is 24V
for K68 pin and the K72 pin;
2. Measure the resistance of
the 85 and 86 pins of the
grid heater relays to
determine whether the grid
heater relay is damaged and
the resistance value is
approximately 10Ω.
DFC_IAirHtOvrTemp Grid heater is 321 P0110 Grid heater relay Grid heater failure Improper matching of grid 1. Measure the resistance of
overheated heater relay or line problem the 85 and 86 pins of the
grid heater relays and the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
resistance value is
approximately 10Ω.
DFC_IAirHtSCB Grid heater short 321 P0113 Grid heater relay Grid heater failure Grid heater relay wiring 1. Check whether the grid
circuit to the power problem heater relay control terminal
supply K72 is short-circuited to the
power supply
DFC_IAirHtSCG Grid heater short 321 P0112 Grid heater relay Grid heater failure Grid heater relay wiring 1. Check whether the grid
circuit to ground problem heater relay control terminal
K72 is short-circuited to
ground
DFC_InjCrvInjLimCh- The number of 324 P100E ECU Fault lamp ON ECU power supply voltage 1. Check battery power and
rgBal injections exceeds low power supply conditions;
the drive circuit limit 2. Check the generator's
power generation status.
DFC_InjCrvInjLimQn- The number of 324 P100F High pressure oil Fault lamp ON The flow rate of the high 1. Check whether the
tBal injections exceeds pump, common rail pressure oil pump is too metering unit is damaged;
the high pressure pipe large, and the positive
pump limit deviation of the rail pressure
exceeds 50MPa.
DFC_InjCrvInjLimSys The number of 324 P1010 ECU Fault lamp ON More than 5 injections Check the data calibration
injections exceeds
the system limit
DFC_InjCrvNumInjR- The number of 324 P1011 ECU Fault lamp ON More than 5 injections Check the data calibration
tmLim injections exceeds
the system limit
DFC_InjVlvPresMin The rail pressure is 276 P0087 ECU/fuel injector Fault lamp ON Rail pressure is lower than 1. Check the fuel tank
too low, less than the minimum injection quantity, and whether the oil
200bar, stop the pressure quantity is too low
injection 2. Check whether the suction
filter is blocked and the fuel
line is bent.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_ IVDiaBnkShCi- Fuel injection 151 P062D Fuel injector The fault lamp is The wire harness in the 1- 1. Check whether the fuel
r_0 capacitor 1 is short- normally on; the cylinder, 2-cylinder and 3- injector wire harnesses of
circuited relevant fuel injector cylinder fuel injector has the 1-cylinder, 2-cylinder and
stops injection, and short circuit 3-cylinder are grounded
the power is 2. Check whether the wire
insufficient harness at the injector
terminal is loose
DFC_ IVDiaBnkShCi- Fuel injection 151 P062E Fuel injector The fault lamp is The wire harness in the 4- 1. Check whether the fuel
r_1 capacitor 2 is short- normally on; the cylinder, 5-cylinder and 6- injector wire harnesses of
circuited relevant fuel injector cylinder fuel injector has the 4-cylinder, 5-cylinder and
stops injection, and short circuit. 6-cylinder are grounded
the power is 2. Check whether the wire
insufficient. harness at the injector
terminal is loose
DFC_IVDiaChp_0 Fuel injection chip 153 P062B ECU Engine flameout ECU internal CY33X chip 1. Check ECU, write-in data
error error
DFC_IVDiaCylNoLd_ 0 Fuel injector 1 open 141 P0201 Fuel injector The fault lamp is The 1-cylinder fuel injector 1. Check whether the 1-
circuit normally on, and a wire harness is not cylinder fuel injector
certain cylinder of the connected properly terminal connection is
engine will catch fire, secure;
resulting in 2. Check whether the wire
insufficient power. harness connectors A33 and
A16 are connected to the
ECU pins
DFC_IVDiaCylNoLd_ 1 Fuel injector 5 open 142 P0205 Fuel injector The fault lamp is The 5-cylinder fuel injector 1. Check whether the 5-
circuit (the injector normally on, and a wire harness is not cylinder fuel injector
3 for the 4-cylinder certain cylinder of the connected properly (the connection is secure (the
engine) engine will catch fire, injector 3 for the 4-cylinder injector 3 for the 4-cylinder
resulting in engine) engine)
insufficient power. 2. Check whether the wire
harness connectors A31 and

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
A01 are connected to the
ECU pins.
DFC_IVDiaCylNoLd_ 2 Fuel injector 3 open 143 P0203 Fuel injector The fault lamp is The 3-cylinder fuel injector 1. Check whether the 3-
circuit (the injector normally on, and a wire harness is not cylinder fuel injector
2 for the 4-cylinder certain cylinder of the connected properly (the connection is secure (the
engine) engine will catch fire, injector 2 for the 4-cylinder injector 2 for the 4-cylinder
resulting in engine) engine)
insufficient power. 2. Check whether the wire
harness connectors A47 and
A17 are connected to the
ECU pins.
DFC_IVDiaCylNoLd_ 3 Fuel injector 6 open 144 P0206 Fuel injector The fault lamp is The 6-cylinder fuel injector 1. Check whether the 6-
circuit (the injector normally on, and a wire harness is not cylinder fuel injector
4 for the 4-cylinder certain cylinder of the connected properly (the connection is secure (the
engine) engine will catch fire, injector 4 for the 4-cylinder injector 4 for the 4-cylinder
resulting in engine) engine)
insufficient power. 2. Check whether the wire
harness connectors A32 and
A02 are connected to the
ECU pins.
DFC_IVDiaCylNoLd_ 4 Fuel injector 2 open 145 P0202 Fuel injector The fault lamp is The 2-cylinder fuel injector 1. Check whether the 2-
circuit normally on, and a wire harness is not cylinder fuel injector
certain cylinder of the connected properly terminal connection is
engine will catch fire, secure
resulting in 2. Check whether the wire
insufficient power. harness connectors A48 and
A18 are connected to the
ECU pins.
DFC_IVDiaCylNoLd_ 5 Fuel injector 4 open 146 P0204 Fuel injector The fault lamp is The 4-cylinder fuel injector 1. Check whether the 4-
circuit normally on, and a wire harness is not cylinder fuel injector
certain cylinder of the connected properly terminal connection is

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
engine will catch fire, secure
resulting in 2. Check whether the wire
insufficient power harness connectors A46 and
A03 are connected to the
ECU pins
DFC_ IVDiaCylShCir_0 Fuel injector 1 short 141 P0262 Fuel injector The fault lamp is Fuel injector 1 is short- Check the fuel injector 1 wire
circuit normally on, and a circuited at high and low harness (A16, A33)
certain cylinder of the ends or the fuel injector is
engine will catch fire, short-circuited to the power
resulting in supply
insufficient power.
DFC_IVDiaCylShCir_ 1 Fuel injector 5 short 142 P0274 Fuel injector The fault lamp is Fuel injector 5 is short- Check the fuel injector 5 wire
circuit (the injector normally on, and a circuited at high and low harness (A31, A01) (the
3 for the 4-cylinder certain cylinder of the ends or the fuel injector is injector 3 for the 4-cylinder
engine) engine will catch fire, short-circuited to the power engine)
resulting in supply (the injector 3 for the
insufficient power. 4-cylinder engine)
DFC_IVDiaCylShCir_ 2 Fuel injector 3 short 143 P0268 Fuel injector The fault lamp is Fuel injector 3 is short- Check the fuel injector 3 wire
circuit (the injector normally on, and a circuited at high and low harness (A47, A17) (the
2 for the 4-cylinder certain cylinder of the ends or the fuel injector is injector 2 for the 4-cylinder
engine) engine will catch fire, short-circuited to the power engine)
resulting in supply (the injector 2 for the
insufficient power. 4-cylinder engine)
DFC_IVDiaCylShCir_ 3 Fuel injector 6 short 144 P0277 Fuel injector The fault lamp is Fuel injector 6 is short- Check the fuel injector 6 wire
circuit (the injector normally on, and a circuited at high and low harness (A32, A02) (the
4 for the 4-cylinder certain cylinder of the ends or the fuel injector is injector 4 for the 4-cylinder
engine) engine will catch fire, short-circuited to the power engine)
resulting in supply (the injector 4 for the
insufficient power. 4-cylinder engine)
DFC_IVDiaCylShCir_4 Fuel injector 2 short 145 P0265 Fuel injector The fault lamp is Fuel injector 2 is short- Check the fuel injector 2 wire
circuit normally on, and a circuited at high and low harness (A48, A18)

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
certain cylinder of the ends or the fuel injector is
engine will catch fire, short-circuited to the power
resulting in supply
insufficient power.
DFC_ IVDiaCylShCir_5 Fuel injector 4 short 146 P0271 Fuel injector The fault lamp is Fuel injector 4 is short- Check the fuel injector 4 wire
circuit normally on, and a circuited at high and low harness (A46, A03)
certain cylinder of the ends or the fuel injector is
engine will catch fire, short-circuited to the power
resulting in supply
insufficient power.
DFC_IVDiaCylShCir- Fuel injector 1 low 141 P0261 Fuel injector The fault lamp is Fuel injector 1 is short- Check whether the fuel
HSLS_0 end and high end normally on, and a circuited at high and low injector 1 wire harness (A16,
short circuit certain cylinder of the ends A33) is short-circuited
engine will catch fire,
resulting in
insufficient power.
DFC_ IVDiaCylShCir- Fuel injector 5 low- 142 P0273 Fuel injector The fault lamp is Fuel injector 5 high and low- Check whether the fuel
HSLS_1 end and high-end normally on, and a end short circuit (the injector 5 wire harness (A31,
short circuit (the certain cylinder of the injector 3 for the 4-cylinder A01) is short-circuited (the
injector 3 for the 4- engine will catch fire, engine) injector 3 for the 4-cylinder
cylinder engine) resulting in engine)
insufficient power.
DFC_ IVDiaCylShCir- Fuel injector 3 low- 143 P0267 Fuel injector The fault lamp is Fuel injector 3 high and low- Check whether the fuel
HSLS_2 end and high-end normally on, and a end short circuit (the injector 3 wire harness (A47,
short circuit (the certain cylinder of the injector 2 for the 4-cylinder A17) is short-circuited (the
injector 2 for the 4- engine will catch fire, engine) injector 2 for the 4-cylinder
cylinder engine) resulting in engine)
insufficient power.
DFC_ IVDiaCylShCir- Fuel injector 6 low- 144 P0276 Fuel injector The fault lamp is Fuel injector 6 high and low- Check whether the fuel
HSLS_3 end and high-end normally on, and a end short circuit (the injector 6 wire harness (A32,
short circuit (the certain cylinder of the injector 4 for the 4-cylinder A02) is short-circuited (the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
injector 4 for the 4- engine will catch fire, engine) injector 4 for the 4-cylinder
cylinder engine) resulting in engine)
insufficient power.
DFC_IVDiaCylShCir- Fuel injector 2 low 145 P0264 Fuel injector The fault lamp is Fuel injector 2 is short- Check whether the fuel
HSLS_4 end and high end normally on, and a circuited at high and low injector 2 wire harness (A48,
short circuit certain cylinder of the ends A18) is short-circuited
engine will catch fire,
resulting in
insufficient power.
DFC_IVDiaCylShCir- Fuel injector 4 low 146 P0270 Fuel injector The fault lamp is Fuel injector 4 is short- Check whether the fuel
HSLS_5 end and high end normally on, and a circuited at high and low injector 4 wire harness (A46,
short circuit certain cylinder of the ends A03) is short-circuited
engine will catch fire,
resulting in
insufficient power.
DFC_MaxPTOSwt PTO switch voltage 345 P251C Economic mode Store the flash code Economic mode switch 1. Remove the economic
is above the upper switch (multi-state switch) is not mode switch and check that
limit properly connected the ECU end K79 voltage
should be 5V.
2. Check the connection
between K79 and K74 and
the economic mode switch
pins
DFC_MeUnIntCtct Poor contact 133 P0251 Metering unit The fault lamp is Poor contact of the Check whether the metering
between ECU and normally on, the Limp metering unit wire harness unit wire harness is reliably
the metering unit Home Mode of the fixed
engine is activated
DFC_MeUnOL Open circuit of the 133 P0251 Metering unit The fault lamp is Improper connection of the 1. Plug the metering unit
metering unit normally on, the Limp metering unit connector in place
Home Mode of the 2. Check whether the wire
engine is activated harness is open-circuited

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_MeUnOT Overtemperature of 133 P0252 Metering unit The fault lamp is Damage of the metering Replace the metering unit
the metering unit normally on, the Limp unit
Home Mode of the
engine is activated
DFC_MeUnShCirHS- Metering unit high- 133 P0254 Metering unit The fault lamp is A04 voltage higher than Check the A04 line
Batt end short circuit to normally on, the Limp battery voltage connection, and unplug the
the power supply Home Mode of the metering unit connector,
engine is activated which should be 24V
DFC_MeUnShCirHS- Metering unit high- 133 P0253 Metering unit The fault lamp is A04 voltage short circuit to Check whether the A04 wire
Gnd end short circuit to normally on, the Limp ground harness is grounded, and
ground Home Mode of the unplug the oil metering unit
engine is activated connector, which should be
24V
DFC_MeUnShCirLS- Metering unit low- 133 P0254 Metering unit The fault lamp is A04 voltage short circuit to 1. Unplug the metering unit
Batt end drive short normally on, the Limp power supply connector and measure the
circuit to the power Home Mode of the voltage, which should be
supply engine is activated 3.5V for A05
DFC_MeUnShCirLS- Metering unit low- 133 P0253 Metering unit The fault lamp is A04 short circuit to ground 1. Unplug the metering unit
Gnd end drive short normally on, the Limp connector and measure the
circuit to ground Home Mode of the voltage, which should be
engine is activated 3.5V for A05
DFC_MeUnSRCMax The current 133 P0254 Metering unit The fault lamp is Improper connection of the 1. Unplug the metering unit
feedback voltage normally on, the Limp metering unit connector and measure the
signal of the Home Mode of the voltage, which should be
metering unit is engine is activated 3.5V for A05, and 24V for
above the upper A04.
limit
DFC_MeUnSRCMin The current 133 P0253 Metering unit, Lime home mode The pressure limiting valve is 1. Check whether the
feedback voltage pressure limiting open, the oil circuit is pressure limiting valve is
signal of the valve, common rail damaged, and the oil-inlet normal
metering unit is pipe, oil circuit pipe is blocked. 2. Oil passage inspection

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below the lower
limit
DFC_MILOL The MIL lamp has 331 P0650 OBD lamp OBD fault indicator 1. The MIL lamp is not 1. Check whether the MIL
no load lamp does not work connected or damaged lamp is normal
properly 2. Single-ended control 2. Turn off the MIL lamp
diagnosis
DFC_MILOvrTemp MIL lamp over 331 P0650 OBD lamp OBD fault indicator OBD fault indicator drive Check OBD MIL and line
temperature lamp does not work circuit is overloaded
properly
DFC_MILSCB MIL lamp short 331 P0650 OBD lamp OBD fault indicator OBD fault indicator drive 1. Use a multimeter to check
circuit to power lamp does not work circuit short circuit to power whether the MIL lamp is
supply properly supply connected to the power line
2. Rewire
DFC_MILSCG MIL lamp short 331 P0650 OBD lamp OBD fault indicator OBD fault indicator lamp 1. Use a multimeter to check
circuit to ground lamp does not work drive circuit short circuit to whether the MIL lamp line is
properly ground grounded.
2. Rewire
DFC_MinPTOSwt PTO switch voltage 345 P251B Multi-state switch Multi-state switch 1. Fuse damaged, wire 1. Check whether power
is below the lower and its wire harness (Economic mode harness damaged and supply is normal
limit (multi-state and connector switch) cannot be connectors damaged 2. Check whether circuit is
switch) used 2. Switch damaged normal
2. Check whether the switch
resistance is normal
DFC_ MoCADCNTP Digital to analog 262 P060B ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
conversion error error 2. Check ECU, write-in data
DFC_MoCADCTst Digital to analog 262 P060B ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
conversion error error 2. Check ECU, write-in data
DFC_MoCADCVltgR- Analog-to-digital 262 P060B ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
atio conversion scale error 2. Check ECU, write-in data
factor error
DFC_MoCComErrC- nt Communication 262 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_MoCComSPI Communication 262 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCROMErrX-Pg ECU memory fault 262 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
error 2. Check ECU, write-in data
DFC_ MoCSOPErrM- Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
MRespByte error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPErrN- Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
oChk error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPErrR- Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
espTime error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPErrS- PI Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPLoLi Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPMM Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
error between CPU error 2. Check ECU, write-in data

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and monitoring
module
DFC_ MoCSOPOSTi- Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
meOut error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPPsvT- Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
stErr error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_MoCSOPTime- Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
Out error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_ MoCSOPUpLi Communication 263 P060C ECU Fault lamp ON ECU internal monitoring 1. Power off and restart;
error between CPU error 2. Check ECU, write-in data
and monitoring
module
DFC_MoFAPP Two voltages for 264 P1012 Throttle pedal, wire Accelerator pedal Throttle pedal fault, ECU 1. Check whether the voltage
accelerator pedals harness, ECU failure internal fault of the throttle pedal APP1 is
are inconsistent double that of APP2
2. Replace the throttle pedal
3. Check whether the pedal
related wire harness has a
short circuit or open circuit
fault
4. Replace the ECU
DFC_MoFESpd Engine speed is not 264 P1013 Speed signal Fault lamp always on
reliable
DFC_MoFInjDatET Fuel injector power- 264 P1014 ECU/fuel injector Fault lamp always on ECU internal fault Turn off the vehicle power
on time is not supply for more than 30s,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
reliable and check whether the next
driving cycle is normal.
DFC_MoFInjDatPhi The injection angle 264 P1015 Fault lamp always on Turn off the vehicle power
of advance is not supply for more than 30s,
reliable and check whether the next
driving cycle is normal.
DFC_MoFOvR The power-on time 261 P101A ECU Fault lamp always on ECU internal fault 1. Turn off the vehicle power
exceeds the supply for more than 30s,
maximum value at and check whether the next
the time of Overrun driving cycle is normal.
2. Replace the ECU
DFC_MoFOvRHtPrt The fuel injector 261 P101A ECU Fault lamp always on ECU internal fault 1. Turn off the vehicle power
power-on time supply for more than 30s,
exceeds the and check whether the next
maximum allowable driving cycle is normal.
value at the time of 2. Replace the ECU
Overrun
(overtemperature
protection for the
fuel injector)
DFC_MoFRailP Rail pressure error 264 P101C Rail pressure Affect the normal Above-mentioned related Turn off the vehicle power
sensor, high operation of the parts fault supply for more than 30s,
pressure oil pump, vehicle or activate the and check whether the next
metering unit, high- Limp Home Mode driving cycle is normal.
pressure circuit,
low-pressure circuit
DFC_MoFRmtAPP Two voltages for 264 P1045 Remote throttle Remote accelerator Remote throttle pedal fault, 1. Check whether the remote
remote accelerator pedal, wire harness, pedal failure ECU internal fault throttle pedal APP1 and
pedals are ECU APP2 voltage are twice the
inconsistent relationship
2. Replace the remote

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
throttle pedal
3. Check whether the remote
pedal related wire harness
has a short circuit or open
circuit fault 4. Replace the
ECU
DFC_MonUMaxSup- Power supply 265 P1600 ECU, battery and ECU is not working supply1 power supply 1. Check whether the 30A
ply1 module 1 voltage alternator properly, affecting voltage over high fuse of the power supply
over upper limit normal operation module 1 is normal.
2. Check the related wire
harness
3. Check the vehicle battery
and alternator
4. Replace the ECU
DFC_MonUMinSupp- Power supply 265 P1601 ECU, battery and ECU is not working supply1 power supply 1. Check whether the 30A
ly1 module 1 voltage is alternator properly, affecting voltage over low fuse of the power supply
below the lower normal operation module 1 is normal.
limit 2. Check the related wire
harness
3. Check the vehicle battery
and alternator
4. Replace the ECU
DFC_MRlyErlyOpng The main relay is 125 P068A ECU Fault lamp ON The main relay inside the 1. Check the ECU;
turned on too early ECU is not working properly 2. ECU power off and restart
after the ECU is
powered on.
DFC_MRlyStk The main relay 125 P068B ECU Store the fault code The main relay inside the 1. Check the ECU
cannot be ECU is not working properly. 2. Replace the ECU
disconnected
DFC_OilPMin Oil pressure signal 243 P0524 Digital oil pressure After 3 driving cycles, Oil pressure low Feedback to Weichai
error sensor the fault lamp is on Headquarters

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
and the Limp Home
Mode of the engine is
activated
DFC_OilPNpl Oil pressure signal is 243 P0521 Digital oil pressure After 3 driving cycles, After the engine is turned Feedback to Weichai
not reliable sensor the fault lamp is on off, the oil pressure still Headquarters
and the Limp Home exists.
Mode of the engine is
activated
DFC_OilPSwmpPhy- Oil pressure higher 243 P0523 Analog oil pressure Fault lamp always on Oil pressure over high 1. Use the diagnostic
sRngHi than upper limit sensor instrument to check whether
the oil pressure value
exceeds the allowable value
WP5&WP7&W-P10&WP12:
7,800hPa WP4&WP6&W-
P13: 10,000hPa
2. Replace the oil pressure
sensor
3. Check whether the oil
pump and oil passage
pressure relief valve are
damaged
DFC_OilPSwmpPhy- Oil pressure is below 243 P0524 Analog oil pressure Fault lamp always on Oil pressure over low 1. Use the diagnostic
sRngLo the lower limit sensor instrument to check whether
the oil pressure value is
below the allowable value of
1600hPa
2. Replace the oil pressure
sensor
3. Check whether the oil
pump and oil passage
pressure relief valve are

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damaged.
DFC_OilPSwmpSig Oil pressure CAN 243 P0520 Analog oil pressure Store the flash code, The fault is not closed in the 1. Write-in the program and
signal error sensor and the engine is program, and the engine oil close the fault
entering limp home pressure signal is connected
mode to the ECU through the real
sensor.
DFC_OilPSwmpSR- Oil pressure voltage 243 P0523 Analog oil pressure After 3 driving cycles, A44 pin voltage is higher 1. Check whether the oil
CMax signal higher than sensor the fault lamp is on than 4.5V pressure sensor connector is
upper limit loose
2. Check the on-off of the
A44 pin and the ECU end
3. Whether the A44 pin is
short circuited to a power
line higher than 5V
4. Replace the sensor
DFC_OilPSwmpSR- Oil pressure voltage 243 P0522 Analog oil pressure After 3 driving cycles, A44 pin voltage is lower 1. Check whether A4 pin is
CMin signal is below the sensor the fault lamp is on than 215mV short circuit to ground
lower limit 2. Replace the sensor
DFC_OilTNplHigh Oil temperature 244 P0196 Oil temperature Store the flash code Oil temperature exceeds 1. Check whether the actual
signal is above the sensor allowable value 125°C oil temperature is too high
upper limit 2. Replace the oil
temperature sensor
DFC_OilTSig Oil temperature 244 U1403 Oil temperature Store the flash code The oil temperature The ECU does not obtain the
CAN signal error sensor obtained from the CAN bus oil temperature from the
is equal to 0°C CAN bus. Write-in the
program, and close the fault.
DFC_OilTSRCMax Oil temperature 244 P0198 Oil temperature After 3 driving cycles, A59 pin voltage is higher 1. Check whether the oil
voltage signal higher sensor the fault lamp is on than 4.97V temperature sensor
than upper limit connector is loose
2. Check the on-off of the
A59 pin and the ECU end

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
3. Whether the A59 pin is
short circuited to a power
line higher than 5V
4. Replace the sensor
DFC_OilTSRCMin Oil temperature 244 P0197 Oil temperature After 3 driving cycles, A59 pin voltage is lower 1. Check whether A59 pin is
voltage signal is sensor the fault lamp is on than 144mV short circuit to ground
below the lower 2. Replace the sensor
limit
DFC_OilTVDPlaus Oil temperature 244 P0196 Oil temperature Store the flash code The difference value 1. Monitor the oil
signal is not reliable sensor between the oil temperature, water
temperature and other temperature, and intake air
temperatures exceeds the temperature for
allowable value. abnormalities
2. According to the first step,
check the corresponding
sensor
DFC_PhyModNonM- Oil torque 245 P1031 ECU calibrating data Store the flash code Data calibration is not Contact the headquarters,
onMapNpl conversion is not monotone check the data, write-in after
monotone correction
DFC_PIntkVUsPlsHi The upstream intake 231 P006D Upstream intake Fault lamp ON The intake pressure is 1. Check whether the
pressure is too high pressure 200hPa higher than the atmospheric pressure value
compared to the atmospheric pressure when matches the local
atmospheric parking atmospheric pressure and
pressure, and the replace the ECU if the
upstream intake difference is too large.
pressure is not 2. Check whether the intake
reliable. pressure value matches the
local atmospheric pressure
and replace the sensor if the
difference is too large.
DFC_PIntkVUsPlsLo The upstream intake 231 P006D Upstream intake Fault lamp ON The intake pressure is 1. Check whether the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
pressure is too small pressure 200hPa lower than the atmospheric pressure value
compared to the atmospheric pressure when matches the local
atmospheric parking atmospheric pressure and
pressure, and the replace the ECU if the
upstream intake difference is too large.
pressure is not 2. Check whether the intake
reliable pressure value matches the
local atmospheric pressure
and replace the sensor if the
difference is too large.
DFC_PIntkVUsSRC- Max Upstream intake 231 P0238 Upstream intake Fault lamp ON A43 pin voltage is higher 1. Check whether the intake
pressure voltage pressure than 4.92V pressure sensor connector is
signal higher than loose
upper limit 2. Check the on-off of the
A43 pin and the ECU end
3. Whether the A43 pin is
short circuited to a power
line higher than 5V
4. Replace the sensor
DFC_PIntkVUsSRC- Min Upstream intake 231 P0237 Upstream intake Fault lamp ON A43 pin voltage is lower 1. Check whether A43 pin is
pressure voltage pressure than 202mV short circuit to ground
signal is below the 2. Replace the sensor
lower limit
DFC_PRVctOpnMax The number of 134 P0089 Fuel circuit Fault lamp always on The number of times the 1. Check whether the oil
times the pressure pressure in the common rail circuit is bent and blocked;
limiting valve opens pipe exceeds the allowable 2. Check whether the
reaches or exceeds value is more than 50 times metering unit is stuck or
the maximum value damaged;
3. Check whether the fuel
injector or high pressure oil
pump return oil is blocked;

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4. Check whether the fuel
injector has fault.
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line
interference;
6. After confirming the cause
of the fault, use the "Vehicle
Calibration" - "Advanced
Calibration" - "Common Rail
Pipe" interface in the
DiagSmart, click "Set", and
the fault can be cleared
DFC_PRVFrOpnPre- Excessive rail 137 P0089 Fuel circuit Engine Limp Home Pressure in common rail 1. Check whether the oil
sInc pressure causes the Mode exceeds the allowable value circuit is bent and blocked;
pressure limiting 2. Check whether the
valve to open metering unit is stuck or
damaged;
3. Check whether the fuel
injector or high pressure oil
pump return oil is blocked;
4. Check whether the fuel
injector has fault.
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line
interference;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_PRVFrOpnPre- Rail pressure 138 P0089 Fuel circuit Engine Limp Home Pressure in common rail 1. Check whether the oil
sShck oscillation causes Mode exceeds the allowable value circuit is bent and blocked;
the pressure limiting 2. Check whether the
valve to open metering unit is stuck or
damaged;
3. Check whether the fuel
injector or high pressure oil
pump return oil is blocked;
4. Check whether the fuel
injector has fault
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line
interference;
DFC_PRVOpn The pressure 135 P0089 Fuel circuit The fault lamp is Pressure in common rail 1. Check whether the oil
limiting valve is normally on, the Limp exceeds the allowable value circuit is bent and blocked;
open Home Mode of the 2. Check whether the
engine is activated metering unit is stuck or
damaged;
3. Check whether the fuel
injector or high pressure oil
pump return oil is blocked;
4. Check whether the fuel
injector has fault.
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
interference;
DFC_PRVQBalChk Oil balance error 136 P1036 Fuel circuit The fault lamp is The fuel injection is Contact the headquarters,
when the pressure normally on, the Limp excessive, and the common check the data, write-in after
limiting valve is Home Mode of the rail pipe pressure cannot be correction
opened engine is activated built up quickly.
DFC_ PRVRPOutOf-Rng The PRV valve is 136 P1037 Fuel circuit The fault lamp is After the PRV valve is 1. Check for rail pressure
opened and the normally on, the Limp opened, the average rail sensor fault and metering
average rail pressure Home Mode of the pressure is not in the range unit fault
is beyond engine is activated of 600bar~900bar. 2. Replace the common rail
permissible range pipe
DFC_PRVtiOpnMax The opening time of 136 P0089 Fuel circuit Fault lamp always on The opening time of the 1. Check whether the oil
the pressure limiting pressure limiting valve of circuit is bent and blocked;
valve reaches the the common rail pipe 2. Check whether the
limit exceeds more than 300 metering unit is stuck or
minutes damaged;
3. Check whether the fuel
injector or high pressure oil
pump return oil is blocked;
4. Check whether the fuel
injector has fault
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line
interference;
6. After confirming the cause
of the fault, use the "Vehicle
Calibration" - "Advanced
Calibration" - "Common Rail
Pipe" interface in the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DiagSmart, click "Set", and
the fault can be cleared
DFC_R2S2_MscComm1 ECU internal power 111 P060C ECU Fault lamp always on ECU internal fault Replace the ECU
supply monitor
module error
DFC_RailMeUn0 The actual rail 251 P0251 Fuel circuit The fault lamp is The actual value of the rail 1. Check whether the low-
pressure value is too normally on, the Limp pressure is too low, 200 bar pressure circuit oil-inlet pipe
low compared to Home Mode of the less than the rail pressure is bent or blocked
the rail pressure engine is activated setting value. 2. Check the high-pressure
setting value circuit for leakage
3. Check whether the oil
inlet and return pipe of the
fuel tank inversely connected
4. Check whether the
metering unit is stuck and
replace the high pressure oil
pump
DFC_RailMeUn10 The oil pumped by 252 P0251 Fuel circuit The fault lamp is The oil supplied by the high 1. Check the high pressure
the high pressure oil normally on, the Limp pressure oil pump exceeds oil pump and high-pressure
pump is above the Home Mode of the the oil supply upper limit of circuit for leaks
upper limit, and engine is activated the oil pump 2. Replace the high-pressure
there is leakage oil pump
3. Check the oil quality
DFC_RailMeUn2 The actual rail 255 P0251 Fuel circuit The fault lamp is The actual value of the rail 1. Check whether the return
pressure value is too normally on, the Limp pressure is too high, 200 bar line is bent or blocked (oil
high compared to Home Mode of the higher than the rail pressure return pressure is less than
the rail pressure engine is activated setting value. 1.2 bar)
setting value 2. Check whether the zero oil
volume hole is blocked or
the pressure is too high
behind the zero oil volume

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
hole
3. Check whether the
pressure before the gear
pump is too high (less than
9bar)
DFC_RailMeUn22 The actual rail 253 P0251 Fuel circuit The fault lamp is The actual value of the rail 1. Check whether the return
pressure value is too normally on, the Limp pressure is too high, 200 bar line is bent or blocked (oil
high compared to Home Mode of the higher than the rail pressure return pressure is less than
the rail pressure engine is activated setting value. 1.2 bar)
setting value 2. Check whether the zero oil
volume hole is blocked or
the pressure is too high
behind the zero oil volume
hole
3. Check whether the
pressure before the gear
pump is too high (less than
9bar)
DFC_RailMeUn3 The actual rail 256 P0087 High-pressure The fault lamp is There is too much inlet 1. Check the fuel tank
pressure is too low, circuit, low-pressure normally on, the resistance, and high- quantity
less than 200bar circuit engine is shut down, pressure circuit leaks 2. Check whether the oil-
the start-up is inlet pipe is blocked and
difficult, and Limp replace the diesel filter
Home Mode is element
activated.
DFC_RailMeUn4 Rail pressure is too 271 P0088 Metering unit and Lime home mode The metering unit is Check the zero flow hole, the
high, exceeding its wire harness normally open, and the metering unit and its wire
1,700bar metering unit has no power harness
supply and the zero flow
hole is blocked due to wire
harness connection error.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_RailMeUn42 Rail pressure is too 272 P0088 Metering unit and Lime home mode The metering unit is 1. Check whether the oil
high, exceeding its wire harness normally open, and the return pipeline is bent
1,700bar metering unit has no power 2. Check whether the oil
supply and the zero flow return pressure is too high
hole is blocked due to wire (less than 1.2 bar)
harness connection error. 3. Check whether the
metering unit is stuck in the
normally open position
DFC_RailMeUn7 The high pressure 273 P1050 High pressure oil Lime home mode The fuel injector and Check the oil circuit of the
oil pump sets the pump, fuel injector, pressure limiting valve are engine (high-pressure oil
pump oil above the pressure limiting normally open circuit and low-pressure oil
upper limit at the valve circuit)
time of OverRun
DFC_RailMeUn8 Oil supply of the 274 P0251 High pressure oil Lime home mode Fuel injector, pressure 1. Check the high-pressure
high pressure oil pump, fuel injector, limiting valve leakage, high oil pump for leakage
pump is above the pressure limiting pressure oil pump fault 2. Check whether the fuel
upper limit at low valve injector has leakage
idle speed 3. Replace the high-pressure
oil pump
DFC_RailPGradMon The number of 275 P0194 Common rail pipe Causing the pressure Low-pressure circuit is Replace the common rail
times the change in pressure relief relief valve to open obstructed (including oil pipe
rail pressure valve, low-pressure frequently or open for inlet and oil return)
exceeds the upper circuit a long period of time,
limit is above the and the damage of
upper limit. the pressure relief
valve
DFC_RailPOfsTstMa- x The positive voltage 132 P0191 High-pressure The start-up is The metering unit is Check the zero flow hole, the
deviation of the rail circuit, low-pressure difficult, the Limp normally open, and the metering unit and its wire
pressure sensor is circuit Home Mode is metering unit has no power harness
above the upper activated, the supply and the zero flow
limit pressure limiting valve hole is blocked due to wire

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
is open, a lot of high harness connection error.
pressure oil leaks, and
the oil return
temperature rises.
DFC_RailPOfsTstMin The negative voltage 132 P0191 High-pressure The start-up is There is too much intake Check the oil circuit of the
deviation of the rail circuit, low-pressure difficult, the Limp resistance; there is a leak in engine and replace the filter
pressure sensor is circuit Home Mode is the oil-inlet pipe; There is and pipe if necessary.
below the lower activated, the too much oil return
limit pressure limiting valve resistance
is open, a lot of high
pressure oil leaks, and
the oil return
temperature rises.
DFC_RailPRV4 The rail pressure 136 P0088 High-pressure Lime home mode The pressure limiting valve 1. Check whether the oil
exceeds the limit, circuit, low-pressure or the overflow valve is circuit is bent and blocked;
the PRV valve is not circuit damaged; the oil return pipe 2. Check whether the
open normally, and is blocked metering unit is stuck or
the rail pressure is damaged;
greater than 3. Check whether the fuel
1,750bar. injector or high pressure oil
pump return oil is blocked;
4. Check whether the fuel
injector has fault.
5. Check whether there is
any fault in the rail pressure
sensor and wire harness, and
there is any electromagnetic
interference and the line
interference;
DFC_RailPSRCMax The rail pressure 131 P0193 Rail pressure sensor Lime home mode The rail pressure sensor is 1. Check whether the rail
sensor voltage and its wire harness damaged or its wire harness pressure sensor connector is

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
signal exceeds the is damaged or connected in loose
upper limit a wrong way. 2. Check the on-off of the
A26 pin and the ECU end
3. Whether the A26 pin is
short circuited to a power
line higher than 5V
4. Replace the common rail
pipe
DFC_RailPSRCMin Rail pressure sensor 131 P0192 Rail pressure sensor Lime home mode The rail pressure sensor is 1. Check whether A26 pin is
voltage signal is and its wire harness damaged or its wire harness short circuit to ground
below the lower is damaged or connected in 2. Replace the sensor
limit a wrong way.
DFC_RdcAgQlDetFa- il Urea injection 434 P203B
volume adjustment
error
DFC_SigPTOSwt PTO switch CAN 345 U1404 Multi-state switch Multi-state switch The controller sending the Check the controller
message error and its wire harness status is incorrect economic mode switch
and connector status to the ECU is
incorrect.
DFC_ SRCHighAPP1 Pedal 1 voltage 221 P0123 Throttle pedal Lime home mode Throttle pedal or its wire 1. Unplug the throttle pedal
higher than upper harness connector damaged connector and measure the
limit pin voltage of the 5V power
supply end (K45) and signal
end (K61) of the ECU end,
which should be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
throttle pedal.
DFC_ SRCHighAPP2 Pedal 2 voltage 221 P0223 Throttle pedal Lime home mode Throttle pedal or its wire 1. Unplug the throttle pedal

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higher than upper harness connector damaged connector and measure the
limit pin voltage of the 5V power
supply end (K44) and signal
end (K83) of the ECU end,
which should be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
throttle pedal.
DFC_SRCHighRmtA- Remote pedal 1 229 P1501 Remote throttle Enter the Limp Mode Throttle pedal or its wire 1. Unplug the remote
PP1 voltage is above the pedal when using the harness connector damaged throttle pedal connector and
upper limit remote throttle pedal measure the pin voltage of
the 5V power supply end
(K45) and signal end (K63) of
the ECU end, which should
be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
remote throttle pedal.
DFC_SRCHighRmtA- Remote pedal 2 229 P1502 Remote throttle Enter the Limp Mode Throttle pedal or its wire 1. Unplug the remote
PP2 voltage is above the pedal when using the harness connector damaged throttle pedal connector and
upper limit remote throttle pedal measure the pin voltage of
the 5V power supply end
(K44) and signal end (K85) of
the ECU end, which should
be 5V;
2. Measure the resistance
value of the power supply

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end and the signal end of the
throttle pedal 1 at the
remote throttle pedal.
DFC_ SRCLowAPP1 Pedal 1 voltage is 221 P0122 Throttle pedal Lime home mode Throttle pedal or its wire 1. Unplug the throttle pedal
below the lower harness connector damaged connector and measure the
limit pin voltage of the 5V power
supply end (K45) and signal
end (K61) of the ECU end,
which should be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
throttle pedal.
DFC_ SRCLowAPP2 Pedal 2 voltage is 221 P0222 Throttle pedal Lime home mode Throttle pedal or its wire 1. Unplug the throttle pedal
below the lower harness connector damaged connector and measure the
limit pin voltage of the 5V power
supply end (K44) and signal
end (K83) of the ECU end,
which should be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
throttle pedal.
DFC_SRCLowRmtA- PP1 Remote pedal 1 229 P1503 Remote throttle Enter the Limp Mode Throttle pedal or its wire 1. Unplug the remote
voltage is below the pedal when using the harness connector damaged throttle pedal connector and
lower limit remote throttle pedal measure the pin voltage of
the 5V power supply end
(K45) and signal end (K63) of
the ECU end, which should

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
remote throttle pedal.
DFC_SRCLowRmtA- PP2 Remote pedal 2 229 P1504 Remote throttle Enter the Limp Mode Throttle pedal or its wire 1. Unplug the remote
voltage is below the pedal when using the harness connector damaged throttle pedal connector and
lower limit remote throttle pedal measure the pin voltage of
the 5V power supply end
(K44) and signal end (K85) of
the ECU end, which should
be 5V;
2. Measure the resistance
value of the power supply
end and the signal end of the
throttle pedal 1 at the
remote throttle pedal.
DFC_SRCMaxUTnk- Lvl Urea liquid level 445 P203D Urea liquid level 1. OBD lamp will be Principle: When the voltage 1. Check the sensor end:
sensor voltage is sensor on immediately in the of the urea liquid level Check whether the
above the upper event of a fault; sensor pin K57 at the ECU connector is missing, and
limit 2. Limit the torque end is greater than 4.5V, the check the pin for false
after the fault occurs fault is reported. connection, pin breakage,
50 hours. 1. Sensor wire harness pin corrosion, water ingress
connector open circuit: and other problems.
connector pin breakage, pin 2. Check the ECU end: Check
withdrawal, false whether the ECU end
connection, corrosion and connector is missing, and
wire harness disconnection; check the pin and the wire
2. Pin withdrawal, false harness for false connection,
connection, pin breakage, pin breakage, pin corrosion,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
etc. of the ECU connector water ingress, and other
K57; problems.
3. The sensor wire harness 3. Use a multimeter to select
connector is shorted- the multimeter on-off
circuited to a high level position, and measure the
(voltage: 4.5V); 4. Sensor on-off of the wire harness
body fault; between the urea liquid level
sensor 1# and ECU controller
K57, 2# pin and ECU
controller K52 pin
respectively (normal state:
conduction).
4. Use a multimeter to select
the voltage position, turn the
key to the ON position,
normally connect the urea
liquid level sensor, and
detect the signal line voltage
of the urea liquid level
sensor by the lead method
or the pin method (normal
range 0.5V<U<4.5V).
5. Visual inspection: Check
the urea liquid level sensor
for mechanical damage
6. Use a multimeter to select
the resistance position,
measure the resistance
between the sensor 4-hole
connector 1#, 2# (normal
range of Weichai: about

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
1.15KΩ~16.2KΩ), and try to
replace the urea liquid level
sensor if the resistance
deviation is large after
repeated confirmation of the
correct operation
DFC_SRCMinUTnkL- vl Urea liquid level 445 P203C Urea liquid level 1. OBD lamp will be Principle: When the voltage 1. Check the sensor end:
sensor voltage is sensor on immediately in the of the urea liquid level Check the pins for pin
below the lower event of a fault; sensor pin K57 at the ECU corrosion, water ingress,
limit 2. Limit the torque end is smaller than 0.3V, the urea seepage and other
after the fault occurs fault is reported. 1. Short problems.
50 hours. circuit to ground of the 2. Check the ECU end: Check
sensor wire harness the ECU end connector pins
connector: the connector for corrosion, water ingress
pins are short-circuited, the and other problems.
wire harness is short- 3. Use a multimeter to select
circuited to ground caused the voltage position, turn the
by wear, the signal line is key to the ON position,
shorted-circuited to the normally connect the urea
ground wire, and the like; liquid level sensor, and
2. Sensor body fault; detect the signal line voltage
of the urea liquid level
sensor by the lead method
or the pin method (normal
range 0.5V<U<4.5V).
4. Visual inspection: Check
the urea liquid level sensor
for mechanical damage.
5. Use a multimeter to select
the resistance position,
measure the resistance

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
between the sensor 4-hole
connector 1#, 2# (normal
range: 1.15KΩ~16.2KΩ), and
try to replace the urea liquid
level sensor if the resistance
deviation is large after
repeated confirmation of the
correct operation
DFC_SSpMon1 Sensor power 112 P0643 ECU internal sensor Underpower and ECU internal error or the Check whether the
supply 1 error power supply black smoke of the power supply error of fan corresponding wire harness
module engine speed sensor, throttle pedal and ECU pin voltage of each
2 sensor, oil pressure and sensor are normal.
temperature sensor, intake
pressure and temperature
sensor, short-circuited to the
vehicle power supply or
grounding.
DFC_SSpMon2 Sensor power 112 P0653 ECU internal sensor Underpower and The power supply error of Check whether the
supply 2 error power supply black smoke of the the throttle pedal 1 sensor, corresponding wire harness
module engine short-circuited to the vehicle and ECU pin voltage of each
power supply or grounding. sensor are normal.
DFC_SSpMon3 Sensor power 112 P0699 ECU internal sensor Underpower and The power supply of the rail Check whether the
supply 3 error power supply black smoke of the pressure sensor or the corresponding wire harness
module engine DNOX module is short- and ECU pin voltage of each
circuited to the vehicle sensor are normal.
power supply or grounding.
DFC_StrtOL The starter drive has 121 P0615 Starter relay and its Engine can not be The starter relay wire 1. Check the on-off of the
no load wire harness started harness is open-circuited, ECU end K29, K71 pins and
the starter relay wire starter relay;
harness is connected in a 2. Check that K29, K71 pins
wrong way, and the starter are not connected in a

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
relay is damaged. wrong way, missed, short-
circuited;
3. Check whether the starter
relay is damaged;
4. Turn the T50 signal and
read the T50 signal through
the data stream. Under
normal conditions, and the
voltage is 24V for the K29 pin
and 0V for the K71 pin.
DFC_StrtOvrTemp Overtemperature of 121 P0615 Starter relay and its Engine can not be The starter relay wire 1. Check the on-off of the
the starter drive wire harness started harness is open-circuited or ECU end K29, K71 pin and
short-circuited, the starter starter relay;
relay wire harness is 2. Check that K29, K71 pins
connected in a wrong way, are not connected in a
and the starter relay is wrong way, missed, short-
damaged. circuited;
3. Check whether the starter
relay is damaged;
4. Turn the T50 signal and
read the T50 signal through
the data stream. Under
normal conditions, and the
voltage is 24V for the K29 pin
and 0V for the K71 pin.
DFC_StrtSCB Starter relay short 121 P0617 Starter relay and its Engine can not be The starter relay wire 1. Check the on-off of the
circuit to power wire harness started harness is short-circuited, ECU end K29, K71 pins and
supply the starter relay wire starter relay;
harness is connected in a 2. Check that K29, K71 pins
wrong way, and the starter are not connected in a
relay is damaged. wrong way, missed, short-

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
circuited;
3. Check whether the starter
relay is damaged;
4. Turn the T50 signal and
read the T50 signal through
the data stream. Under
normal conditions, and the
voltage is 24V for the K29 pin
and 0V for the K71 pin.
DFC_StrtSCG Starter relay short 121 P0616 Starter relay and its Engine can not be The starter relay wire 1. Check the on-off of the
circuit to ground wire harness started harness is short-circuited, ECU end K29, K71 pins and
the starter relay wire starter relay;
harness is connected in a 2. Check that K29, K71 pins
wrong way, and the starter are not connected in a
relay is damaged. wrong way, missed, short-
circuited;
3. Check whether the starter
relay is damaged;
4. Turn the T50 signal and
read the T50 signal through
the data stream. Under
normal conditions, and the
voltage is 24V for the K29 pin
and 0V for the K71 pin.
DFC_SVSOL Diagnostic lamp 333 P1604 Diagnostic lamp and Diagnostic lamp Diagnostic lamp wire 1. Make sure the indicator is
drive has no load its wire harness indication function harness is open-circuited or from the hardware;
cannot be realized connected in a wrong way, 2. Check whether the grid
or the diagnostic lamp is heater lamp is connected or
damaged damaged, unplug the
connector, and measure the
resistance of the lamp

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
terminal to be about 2kΩ.
3. Measure the on-off
voltage of the ECU end line
(K70/K65)
DFC_SVSOvrTemp Overtemperature of 333 P1605 Diagnostic lamp and Diagnostic indicator Diagnostic lamp wire 1. Check whether the grid
the diagnostic lamp its wire harness power supply stops harness is short-circuited or heater lamp is connected or
drive connected in a wrong way, damaged, unplug the
or the diagnostic lamp is connector, and measure the
damaged resistance of the lamp
terminal to be about 2kΩ.
DFC_SVSSCB Diagnostic lamp 333 P1606 Diagnostic lamp Diagnostic lamp Diagnostic lamp wire 1. Make sure the indicator is
drive short circuit to wire harness indication function harness is damaged or from the hardware;
the power supply cannot be realized connected in a wrong way 2. Measure whether the ECU
end K70 line is connected to
the power supply.
3. Measure the voltage of
the K70 pin after the T15 is
powered off
DFC_SVSSCG Diagnostic lamp 333 P1607 Diagnostic lamp Diagnostic lamp Diagnostic lamp wire 1. Make sure the indicator is
drive short circuit to wire harness indication function harness is damaged or from the hardware; 2.
ground cannot be realized connected in a wrong way Measure whether the ECU
end K70 line is grounded
DFC_SyncAPP The voltage signal 221 P2135 Throttle pedal Lime home mode The throttle pedal or its wire 1. Connect the DiagSmart,
deviation between harness connector is measure the original voltage
pedal 1 and pedal 2 damaged or the throttle value of the throttle pedal 1
is too large pedal itself is and the throttle pedal 2, and
nonconforming the voltage value of the
throttle pedal 1 is about
800mv-3,800mv, and the
voltage value of the throttle
pedal 2 is about 400mv-

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
1,900mv;
2. Determine the
problematic pedal and
measure the corresponding
pedal wire harness voltage
value
DFC_SyncAPPDblP- The voltage signal 221 P2135 Throttle pedal 1, The engine has a Excessive deviation of the Not start using
otLIS between pedal 1 throttle pedal 2 constant speed of throttle pedal voltage signal
and pedal 2 and the 1,000rpm, the throttle at the low idle speed when
low idle speed pedal malfunctions, using single-modulus
switch are not store the flash code, accelerator
reliable and activate the fault
lamp
DFC_SyncRmtAPP The voltage signal 229 P1505 Remote throttle The engine has a The difference between the 1. Check whether the remote
deviation between pedal 1 and 2 constant speed of half of the voltage value of throttle pedal is normal and
remote pedal 1 and 1,000rpm, the remote the remote throttle pedal 1 replace the remote throttle
remote pedal 2 is throttle pedal and the voltage value of the pedal
too large malfunctions, store remote throttle pedal 2 is 2. Check the remote throttle
the flash code, and greater than 0.18V. pedal related lines and
activate the fault connectors for short circuit
lamp or open circuit
3. Check whether the remote
throttle line is interfered by
other lines
DFC_T50Err T50 switch error 345 P2530 T50 switch Store the flash code, T50 is closed for more than 1. Troubleshoot whether the
activate the fault 20 seconds T50 is energized for a long
lamp period of time due to the
design problem of the
vehicle line;
2. Check whether the T50
switch can be returned and

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
whether it is stuck;
3. Check whether the T50
switch is short-circuited to
the power supply due to the
line;
4. Check the T50 switch
status with the DiagSmart for
troubleshooting.
DFC_TCACDsSig CAN communication 233 P0099 CAN bus The value of the Loss of the intake air Check the voltage of the
error of the intake intake air temperature downstream to communication CAN with a
air temperature temperature the intercooler signal from multimeter. About 2.8V for
downstream to the downstream to the the CAN bus CANH, and about 2.3V for
intercooler signal intercooler should be CANL under normal
the last normal value circumstances. If the voltage
or the default value; is abnormal, check whether
the engine the CAN wire harness is
combustion is short-circuited, open-
affected, and even circuited, or interfered by
there is black smoke other wire harnesses.
or underpower; store
the flash code, and
activate the fault
lamp
DFC_ TCACDsSRC-Max The voltage signal of 233 P0098 Intake air The value of the The voltage signal of intake 1. Check whether the intake
intake air temperature sensor intake air air temperature sensor air temperature sensor
temperature sensor downstream to the temperature downstream to the connector is loose
downstream to the intercooler downstream to the intercooler is higher than 2. Check the on-off of the
intercooler is above intercooler should be 4.978V A27 pin and the ECU end
the upper limit the last normal value 3. Whether the A27 pin is
or the default value; short circuited to a power
the engine line higher than 5V

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
combustion is 4. Replace the common rail
affected, and even pipe
there is black smoke
or underpower; store
the flash code, and
activate the fault
lamp
DFC_ TCACDsSRC-Min The voltage signal of 233 P0097 Intake air The value of the The voltage signal of intake 1. Check whether the A27
intake air temperature sensor intake air air temperature sensor pin is short-circuited to
temperature sensor downstream to the temperature downstream to the ground wire
downstream to the intercooler downstream to the intercooler is below 0.137V 2. Replace the sensor
intercooler is below intercooler should be
the lower limit the last normal value
or the default value;
the engine
combustion is
affected, and even
there is black smoke
or underpower; store
the flash code, and
activate the fault
lamp
DFC_ TCACDsVDPl-aus The intake air 233 P0096 Intake air The value of the The difference between the Check whether the
temperature temperature sensor intake air two consecutive intercooled intake air
downstream to the downstream to the temperature temperatures acquired by temperature sensor is
intercooler is not intercooler downstream to the the intake air temperature normal, check whether the
reliable intercooler should be sensor downstream to the sensor and related lines are
the last normal value intercooler exceeds 40°C. short-circuited, open-
or the default value; circuited, or interfered by
the engine other lines.
combustion is

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
affected, and even
there is black smoke
or underpower; store
the flash code, and
activate the fault
lamp
DFC_ TECUSRCMax ECU internal 119 P0669 ECU internal ECU internal ECU internal temperature Replace the ECU
temperature sensor temperature sensor temperature value sensor voltage signal is
voltage signal is should be the last higher than 2.847V
above the upper normal value or
limit default value
DFC_ TECUSRCMin ECU internal 119 P0668 ECU internal ECU internal ECU internal temperature Replace the ECU
temperature sensor temperature sensor temperature value sensor voltage signal is
voltage signal is should be the last lower than 0.7034V
below the lower normal value or
limit default value
DFC_TIntkVUsSRC- Max Intake valve 236 P0113 Upstream intake The upstream intake Upstream intake Check whether the upstream
upstream temperature sensor air temperature value temperature sensor voltage intake air temperature
temperature sensor should be the last signal is higher than 3.2V sensor is normal. Use a
voltage exceeds the normal value or multimeter to measure the
maximum value default value; the pin voltage of the upstream
engine combustion is intake air temperature
affected, and even sensor to determine whether
there is black smoke it is short-circuited to the
or underpower; store external power supply. Check
the flash code, and the relevant wire harness
activate the fault and connector for short
lamp circuit or open circuit caused
by damage.
DFC_TIntkVUsSRC- Min Intake valve 236 P0112 Intake valve The upstream intake Upstream intake Check whether the upstream
upstream upstream air temperature value temperature sensor voltage intake air temperature

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
temperature sensor temperature sensor should be the last signal is lower than 0.2V sensor is normal. Use a
voltage is lower normal value or multimeter to measure the
than the minimum default value; the resistance of the upstream
value engine combustion is intake air temperature
affected, and even sensor pin to the vehicle
there is black smoke floor and determine whether
or underpower; store it is short-circuited to
the flash code. ground. The normal
Activate the fault resistance is > 1MΩ. Check
lamp the relevant wire harness
and the connector for short
circuit caused by damage.
DFC_UCatDsTSig CAN communication 448 U0113 CAN bus SCR catalyst Loss of the SCR catalyst Check the voltage of the
error of SCR catalyst downstream downstream temperature communication CAN with a
downstream temperature should signal from CAN bus multimeter. About 2.8V for
temperature sensor be the last normal CANH, and about 2.3V for
signal value or default value CANL under normal
circumstances. If the voltage
is abnormal, check whether
the CAN wire harness is
short-circuited, open
circuited, or interfered by
other wire harnesses.
DFC_ UCatDsTSRC-Max The SCR catalyst 448 P0428 Downstream SCR catalyst The downstream exhaust Check whether the
downstream exhaust downstream temperature sensor voltage downstream temperature
temperature sensor temperature sensor temperature should signal is higher than 4.75V sensor is normal. The normal
voltage is above the of the exhaust pipe be the last normal resistance is about 180Ω at
upper limit value or default value normal temperature. Use a
multimeter to measure the
voltage of the pins K55 and
K56 to determine whether it

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
is short-circuited to the
external power supply. Check
whether the relevant wire
harness and connector are
short-circuited to the
external power supply
caused by breakage
DFC_ UCatDsTSRC-Min The SCR catalyst 448 P0427 Downstream SCR catalyst The downstream exhaust Check whether the
downstream exhaust downstream temperature sensor voltage downstream exhaust
temperature sensor temperature sensor temperature should signal is below 0.3V temperature sensor is
voltage is below the of the exhaust pipe be the last normal normal, and the normal
lower limit value or default value resistance is about 180Ω at
normal temperature. Use a
multimeter to measure the
resistance of the pins K55
and K56 to the vehicle floor,
and determine whether it is
short-circuited to ground.
The normal resistance is
>1MΩ. Check whether the
relevant wire harness and
connector are short-circuited
caused by damage.
DFC_UCatUsTSig CAN communication 448 U0113 CAN bus The SCR catalyst Loss of the SCR catalyst Check the voltage of the
error of SCR catalyst upstream upstream temperature communication CAN with a
upstream temperature should signal from CAN bus multimeter. About 2.8V for
temperature sensor be the last normal CANH, and about 2.3V for
signal value or default value; CANL under normal
store the flash code, circumstances. If the voltage
and activate the fault is abnormal, check whether
lamp and the OBD the CA wire harness is short-

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lamp circuited, open-circuited, or
interfered by other wire
harnesses.
DFC_ UCatUsTSRC-Max The SCR catalyst 448 P042D Upstream exhaust 1. OBD lamp will be Principle: The upstream 1. Use a multimeter to
upstream temperature sensor on immediately in the exhaust temperature sensor detect the resistance and
temperature sensor of the exhaust pipe event of a fault and related lines and measure the resistance
voltage is above the 2. Immediate torque connectors are faulty, between the two pins 1# and
upper limit limit of the engine causing the sensor open 2# of the sensor, which is
3. No consumption of circuit or short circuit to the about 200±20Ω at normal
urea power supply. The voltage of room temperature. If the
K81 is 4.7V. resistance is 0Ω, replace the
1. The missing or pin sensor
withdrawal, pin breakage, 2. Unplug the sensor
corrosion, etc. of the connector, turn the key to
connector the ON position, and
2. The vehicle wire harness measure the voltage value of
is disconnected or short- the K81 line with a
circuited to the power multimeter. The voltage
supply; should be 5V normally. If the
3. The false connection and voltage is above 5V, it means
pin withdrawal of the ECU that the K81 line is short-
end K81 pin or the open circuited to other power
circuit of the corresponding lines, and the wire harness
wire harness; should be repaired;
4. Sensor internal fault 2. Check whether the
relevant wire harness and
connector are short-circuited
to external power supply
caused by breakage
DFC_ UCatUsTSRC-Min The SCR catalyst 448 P042C Upstream exhaust 1. OBD lamp will be Principle: The voltage of the 1. Turn the key to the ON
upstream temperature sensor on immediately in the wire harness end K81 is position and use a

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
temperature sensor of the exhaust pipe event of a fault <0.3V multimeter to measure the
voltage is below the 2. Immediate torque 1. The sensor connector is voltage value of the K81 line
lower limit limit of the engine damaged or the two pins when the sensor connector
3. No consumption of are short-circuited; is normally connected. The
urea 2. The vehicle wire harness voltage should be greater
is grounding caused by than 0.3V normally. If the
wear; voltage is below 0.3V, it
3. Sensor internal fault means that the K81 wire
harness is short-circuited to
ground, and the wire harness
should be repaired.
2. Check the sensor for
mechanical damage, and
replace the sensor if any
3. Check whether the
relevant wire harness and
connector are short-circuited
to external ground caused by
breakage
DFC_UDCRdcAgRm- n Low urea liquid level 445 P203F Urea tank, urea 1. OBD lamp will be 1. Insufficient actual urea 1. Check the urea liquid level
liquid level sensor on immediately in the quantity and fill urea in time;
event of a fault 2. Liquid level sensor float 2. Check whether the actual
2. Immediate torque stuck liquid level matches the
limit of the engine 3. The liquid level reading. If the deviation is
temperature sensor is not large, check the urea liquid
replaced with the one with level sensor to see whether
the same part number the float floats normally;
during maintenance (the 3. Check whether the sensor
ECU program does not connector is rusted;
match the urea tank) 4. Check whether the
replaced sensor matches the

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original configuration. In
case of a replacement of the
urea liquid level sensor,
check whether the sensor
matches the Weichai system
DFC_UDosVlvEPHi SCR urea nozzle 453 P2049 Urea nozzle Easy to damage the Urea nozzle current exceeds Check whether the urea
current exceeds the urea nozzle, excessive the maximum allowable nozzle is working normally,
maximum limit urea injection; store current and measure whether the
the flash code, and urea nozzle solenoid valve is
activate the fault short-circuited or damaged.
lamp and OBD lamp The normal resistance is
about 13Ω.
DFC_UDosVlvOvrTe- Overtemperature of 453 P3009 Urea nozzle drive The ECU Overtemperature of ECU The ECU is powered off and
mp SCR urea nozzle power supply automatically cuts off internal urea nozzle drive cooled to ensure that the
module the urea nozzle drive power supply module ECU is installed in a position
power supply module, of good ventilation and heat
and the urea nozzle dissipation. If this fault still
stops working; store occurs frequently, replace
the flash code, and the ECU
activate the fault
lamp and the OBD
lamp
DFC_UDosVlvSCBL- S SCR urea nozzle 453 P2049 Urea nozzle When illuminating The urea nozzle drive low 1. Check the urea nozzle
drive short circuit to OBD lamp has fault end (2# pin) is short- connector for pin corrosion
the power supply during the current circuited to the power and water ingress and other
driving cycle, supply (usually connected to problems;
immediately limit the the 24V power supply); the 2. Check whether the ECU
torque; the urea wire harness corresponding end K09 pin voltage is
nozzle does not work, to the vehicle wire harness normal (only 8.5V when the
and the after- K09 pin is short-circuited to key is powered on);
treatment does not the power supply; 3. Check whether the

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work resistance between the urea
nozzle pins is 12-13Ω; the
resistance value of the
K09/K10 pins to the frame is
greater than 1 MΩ;
DFC_UDosVlvSCBO- SCR urea nozzle 453 P2049 Urea nozzle When illuminating The urea nozzle drive high 1. Check the urea nozzle
LHS drive high end short OBD lamp has fault end (1# pin) is short- connector for pin corrosion,
circuit to the power during the current circuited to power supply water ingress, etc.
supply driving cycle, (usually connected to the 2. The key is turned to the
immediately limit the 24V power supply); the wire ON position, and when the
torque; the urea harness corresponding to connector is connected well,
nozzle does not work, the vehicle wire harness K10 the voltage of the urea
and the after- pin is short-circuited to nozzle connector K10 to the
treatment does not power supply; ground is detected by the
work lead method or the pin
method (only 8.5V when the
key is powered on);
3. Check whether the
resistance between the urea
nozzle pins is 12-13Ω; the
resistance of the K09/K10
pins to the vehicle floor is
greater than 1 MΩ;
DFC_UDosVlvSCG- SCR urea nozzle 453 P2048 Urea nozzle When illuminating The urea nozzle drive low 1. Check the urea nozzle
OLLS drive short circuit to OBD lamp has fault end (2# pin) is short- connector for false
ground during the current circuited to ground; the wire connection, pin breakage,
driving cycle, harness corresponding to pin corrosion, water ingress
immediately limit the vehicle wire harness K09 pin and other problems;
torque; the urea is short-circuited to ground; 2. Check whether the ECU
nozzle does not work, end K09 pin voltage is
and the after- normal (only 8.5V when the

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
treatment does not key is powered on);
work 3. Check whether the
resistance between the urea
nozzle pins is 12-13Ω; the
resistance of the K09/K10
pins to the vehicle floor is
greater than 1 MΩ;
DFC_UDosVlvSCHS SCR urea nozzle 453 P2047 Urea nozzle When illuminating The urea nozzle drive high- 1. Check whether the urea
drive high-end short OBD lamp has fault end (1# pin) is short- nozzle connector is plugged
circuit during the current circuited to ground; the wire in properly, and there are
driving cycle, harness corresponding to any problems such as false
immediately limit the vehicle wire harness K10 pin connection, pin breakage,
torque; the urea is short-circuited to ground; pin corrosion, and water
nozzle does not work, ingress;
and the after- 2. The key is turned to the
treatment does not ON position, and when the
work connector is connected well,
the voltage of the urea
nozzle connector K10 to the
ground is detected by the
lead method or the pin
method (only 8.5V when the
key is powered on);
3. Check whether the
resistance between the urea
nozzle pins is 12-13Ω; the
resistance of the K09/K10
pins to the vehicle floor is
greater than 1 MΩ;
DFC_VehVCANSig Speed signal CAN 224 U1405 CAN bus ECU speed should be Loss of vehicle speed signal 1. Check the voltage of the
communication the default value of 0 from CAN bus communication CAN with a

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
error multimeter. About 2.8V for
CANH, and about 2.3V for
CANL under normal
circumstances;
2. If the voltage is abnormal,
check whether the CAN wire
harness is short-circuited,
open-circuited, or interfered
by other wire harnesses;
3. Check whether the CAN
instrument is damaged and
replace it to verify if
necessary.
DFC_VehVMax Speed exceeds the 224 P0279 Speed sensor, ECU speed should be Speed exceeds 170km/h Check whether the speed of
upper limit speedometer the default value of 0; the vehicle exceeds 170km/h
module the flash code is with related equipment such
stored as DiagSmart.
Troubleshooting:
1. Check whether the vehicle
speed sensor is installed
correctly;
2. Check whether the vehicle
speed sensor is interfered by
other wire harnesses and
components (such as
instruments), affecting the
stability of the vehicle speed
signal and resulting in the
vehicle speed error;
3. Whether the speed value
sent by the CAN instrument

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
is accurate?
DFC_VehVNplMon Vehicle speed 224 P2162 Speed sensor, ECU speed should be The maximum of the vehicle 1. Check whether the vehicle
sensor voltage speedometer the default value of 0; speed signal linear voltage is speed sensor is properly
signal is not reliable module the flash code is <4.7V, or the minimum of installed, resulting in the low
stored the vehicle speed signal maximum voltage or the
linear voltage is >4.36V high minimum voltage.
2. Check whether the speed
sensor is interfered by other
wire harnesses or
components (such as
instruments), resulting in the
low maximum voltage or the
high minimum voltage.
DFC_VehVPlaus The engine speed 224 P0501 Speed sensor, ECU speed should be When the engine speed is 1. Determine whether the
and torque are not speedometer the default value of 0; greater than 5,000rpm and ECU speed is from hardware;
consistent with the module the flash code is the torque is greater than 2. Check whether the signal
vehicle speed stored 300Nm, the vehicle speed is is unstable or lost caused by
less than 10km/h (the improper installation of the
current rated engine speed speed sensor, resulting in a
lower limit is 5,000rpm, vehicle speed error.
which is impossible to reach 3. Check whether the vehicle
under normal conditions) speed sensor is interfered by
other wire harnesses and
components (such as
instruments), affecting the
stability of the vehicle speed
signal and resulting in the
vehicle speed error.
DFC_VehVSRCHi Speed sensor 224 P0503 Speed sensor ECU speed should be After the engine runs 1. Determine whether the
voltage signal higher the default value of 0; normally for a certain period ECU speed is from hardware;
than upper limit the flash code is of time, the linear voltage 2. Check whether the speed

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
stored signal of the vehicle speed sensor is installed correctly
sensor is above the high 3. Check whether the speed
level upper limit of 12V. sensor is interfered by other
wire harnesses or
components (such as
instruments), resulting in
high or unstable voltage;
4. Check whether K34 pin is
short circuit to power supply
DFC_VehVSRCLo Speed sensor 224 P0502 Speed sensor ECU speed should be After the engine runs 1. Determine whether the
voltage signal is the default value of 0; normally for a certain period ECU speed is from hardware;
below the lower the flash code is of time, the linear voltage 2. Check whether the sensor
limit stored signal of the vehicle speed is not connected properly,
sensor is below the lower affecting the normal
limit of the low level (the reception of the vehicle
current rated lower limit of speed signal.
the low level is 0, so this 3. Check whether the sensor
fault will not occur) is not installed in place,
resulting in weak induction
voltage
4. Check whether the speed
sensor is interfered by other
wire harnesses or
components (such as
instruments), resulting in low
or unstable voltage;
5. Check whether K34 pin is
short circuit to ground
DFC_VehVTachMax Vehicle speed 225 P2158 Speed sensor, ECU speed should be After the engine runs 1. Determine whether the
sensor signal pulse speedometer the default value of 0; normally for a certain period ECU speed is from hardware;
width is above the module the flash code is of time, the vehicle speed 2. Check whether the sensor

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
upper limit stored signal pulse width is more is not connected properly,
than 5000μs affecting the normal
reception of the vehicle
speed signal.
3. Check whether the sensor
is installed in place, resulting
in weak induction voltage
signal
4. Check whether the speed
sensor and speedometer are
interfered by other wire
harnesses and components
(such as instruments),
resulting in loss of vehicle
speed pulse voltage signal
DFC_VehVTachMin Vehicle speed 225 P2160 Speed sensor, ECU speed should be After the engine runs 1. Determine whether the
sensor signal pulse speedometer the default value of 0; normally for a certain period ECU speed is from hardware;
width is below the module the flash code is of time, the vehicle speed 2. Check whether the speed
lower limit stored signal pulse width is less sensor, speedometer and
than 400μs related wire harness are
interfered by other wire
harnesses and components
(such as instruments),
resulting in the high
frequency oscillation of
vehicle speed signal.
3. Check whether
speedometer works normally
DFC_VehVTachSig Vehicle speed 225 P2161 Speed sensor, ECU speed should be After the engine runs This fault will not be
sensor signal period speedometer the default value of 0; normally for a certain period reported and does not need
is below the lower module the flash code is of time, the pulse period of to be processed

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
limit stored the vehicle speed signal is
below the minimum period
(the current rated minimum
period is 0, so this fault does
not occur)
DFC_WrnLmpOL Warning lamp open 336 P1613 Fault lamp The fault lamp is not The fault lamp pin has no 1. Make sure the indicator is
circuit illuminated when the load from the hardware;
ECU is powered on; 2. Check whether the water
the fault lamp is not in fuel lamp is connected or
illuminated when the damaged. Unplug the
fault request switch is connector and measure the
pressed; the flash lamp end resistance to be
code is stored. about 2kΩ;
3. Measure the on-off
voltage of the ECU end line,
and normally the voltage is
24V for K29, and about
3.65V for the K27 (K29/K27);
4 Check the on-off of the
ECU end wire harness.
DFC_WrnLmpOvrTe- Overtemperature of 336 P1614 ECU internal fault The ECU Overtemperature of ECU 1. Make sure the indicator is
mp warning lamp lamp power supply automatically cuts off internal fault lamp power from the hardware;
module the fault lamp power supply module 2. Check whether the water
supply module, and in fuel lamp is connected or
the fault lamp stops damaged. Unplug the
working; the flash connector and measure the
code is stored lamp end resistance to be
about 2kΩ;
DFC_WrnLmpSCB Warning lamp short 336 P1615 Fault lamp The fault lamp is still Fault lamp pin wire harness 1. Make sure the indicator is
circuit to power normally on when is short-circuited to the from the hardware;
supply there are no other external power supply 2. Check whether the water

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
faults; the flash code in fuel lamp is connected or
is stored damaged. Unplug the
connector and measure the
lamp end resistance to be
about 2kΩ;
3. Check whether the signal
terminal K29 of the grid
heater lamp is short-
circuited to the power supply
4. Measure the voltage of
the K29 pin after the T15 is
powered off.
DFC_WrnLmpSCG Warning lamp short 336 P1616 Fault lamp The fault lamp is not Fault lamp power supply pin 1. Make sure the indicator is
circuit to ground illuminated when the is short-circuited to external from the hardware;
ECU is powered on; ground 2. Check whether the water
the fault lamp is not in fuel lamp is connected or
illuminated when the damaged. Unplug the
fault request switch is connector and measure the
pressed; the flash lamp end resistance to be
code is stored. about 2kΩ;
3. Check whether the signal
terminal K29 of the grid
heater lamp is grounded
DFC_SCRChkEta The actual average 430 P0420 Emission control OBD torque limit, and Emissions exceeding the Replace the engine emission
conversion monitor module unclearable code national emission standard related components (mainly
efficiency of SCR is at phase-5 or phase-7; the fuel system); replace the SCR
low original engine emission is conversion tank, or
degraded; the SCR reactivate the SCR
conversion tank is degraded; conversion tank; replace the
the urea injection dose error urea injection system
is too big; the calibrated components (such as nozzle,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
data is incorrect. urea pump, etc.); replace the
diesel with good one; check
the calibrated data;
DFC_SCRChkEta1 The actual average 431 P0420 Emission control Unclearable code The emission exceeds the Replace the engine emission
conversion monitor module national emission standard related components (mainly
efficiency of SCR is at phase-5; the original fuel system); replace the SCR
below the threshold engine emission is conversion tank, or
1, and the emission degraded; the SCR reactivate the SCR
exceeds the national conversion tank is degraded; conversion tank; replace the
emission standard the urea injection dose error urea injection system
at phase-5 is too big; the oil is not components (such as nozzle,
good; the calibrated data is urea pump, etc.); replace the
incorrect. diesel with good one; check
the calibrated data;
DFC_SCRChkEta2 The actual average 432 P0420 Emission control When illuminating The urea pump works Check the quality of the
conversion monitor module OBD lamp has fault normally. The concentration urea; check the quality of the
efficiency of SCR is during the current of NOx in the exhaust gas oil; test the injection system,
below the threshold driving cycle, passing through the SCR remove the nozzle to the
2, and the emission immediately limit the tank is greater than the ground, check whether the
exceeds the national torque requirements of China IV injection state of the nozzle
emission standard regulations (7g/kwh); the is normal, and the problem
at phase-7 urea quality is poor, the oil is of the injection system is
poor; the SCR tank is generally reported as "SCR
degraded; the urea injection urea pressure build-up
dose error is too big; the error"; after the nozzle is
original engine emission is removed, follow the nozzle
deteriorated. mounting hole of the SCR
tank, check whether there is
obvious crystallization
abnormality inside the SCR
catalytic muffler; check for

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
oil/urea replacement/vehicle
refitting/urea consumption
abnormality, etc.
DFC_ SCRChkNOxD- SCR downstream 421 P2214 Emission control The OBD lamp is The measured value of the 1. Check whether the NOx
sPeakErr NOx sensor signal monitor module illuminated nitrogen oxide sensor does sensor is properly installed
peak detection is immediately in the not change when the engine on the SCR tank;
not reliable event of a fault; the operating conditions 2. Check whether the NOx
engine torque is change, and the fault is sensor probe is loose;
limited after 50 hours reported as incorrect 3. Check the exhaust pipe for
of fault installation position of NOx blockage and the Nox sensor
sensor (not connected to probe for covering.
the exhaust line); the NOx 4. The engine runs at high
sensor NOx signal is slow in load for 30 minutes or runs
response; the NOx sensor normally for a period of
malfunctions; the exhaust time. If the fault no longer
line is blocked inside; occurs, it means that the
fault has been solved.
DFC_ SCRChkTTCL Urea injection is not 436 P3042 Emission control OBD torque limit after Nozzle electrical fault; the Check the nozzle and replace
released monitor module 50 hours, and nozzle is stuck in normally if necessary; replace the
unclearable code closed position; ECU nozzle; replace the ECU.
hardware fault
DFC_SCRMonDetM- Urea return line is 441 P3050 Urea pump and 1. The OBD lamp is 1. The return pipe is bent; 1. Check whether the return
odeBLPlaus blocked or bent return pipe immediately 2. The urea pump return pipe is bent;
illuminated in the pipe joint is blocked; 2. Check whether the urea
event of a fault in the 3. The return line is blocked pump return pipe joint is
current driving cycle; or thawing is not complete. blocked, and remove the
2. No injection of the crystal with hot water if any;
urea. 3. Check whether the return
pipe is blocked, and remove
the crystal with hot water if
any.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_SCRMonDetM- Urea pump injection 441 P3053 Urea pump and 1. The OBD lamp is 1. The pressure pipe is bent 1. Check whether the
odePresChk pressure can not be pressure pipe immediately or blocked; pressure pipe is bent or
reduced illuminated in the 2. The urea pump pressure blocked, and remove the
event of a fault in the pipe joint is blocked; crystal with hot water if any;
current driving cycle; 3. The urea nozzle is 2. Check whether the
2. No injection of the blocked. pressure pipe joint is
urea. blocked, and remove the
crystal with hot water if any;
3. Check whether the urea
nozzle is blocked, and
remove the crystal with hot
water if any.
DFC_SCRMonDetM- Urea pump injection 441 P3054 Urea pump and 1. The OBD lamp is 1. Pipe joint leakage; 1. Check the pipe joints for
odePresStab pressure instability pressure pipe immediately 2. The urea line is damaged leakage;
error illuminated in the or blocked. 2. Check the urea line for
event of a fault in the damage or blockage.
current driving cycle;
2. No injection of the
urea.
DFC_ SCRMonECU- ECU internal 119 P0669 ECU The SCR system is ECU temperature over high Check the various reasons
OvrTemp temperature higher shut down and urea is for overheating
than upper limit not injected.
DFC_SCRMonLdSt- SCR is not drained at 447 P3015 Hydraulic line No effect on system No complete reverse Complete reverse pumping
OvrThres the end of the operation pumping
previous driving
cycle
DFC_SCRMonMetCt- Urea injection 442 P3039 Hydraulic line The system is There is a blockage Check the hydraulic line
lOvrPresErr pressure for SCR overpressured and
urea metering the torque is limited
control is too high after 50 hours.
DFC_SCRMonMetCt- Urea injection 443 P3056 Hydraulic line If the urea is not There is a leakage Check whether the hydraulic

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
lUndrPresErr pressure for SCR inject which caused line leaks
urea metering by too low system
control is too low pressure, immediately
limit the torque.
DFC_SCRMonOvrPr- Urea injection 442 P3039 Hydraulic line The system pressure There is a blockage Check whether the hydraulic
esErr pressure is too high is too high and urea is line is blocked
after SCR urea pump not injected.
is frozen
DFC_SCRMonPres- SCR urea pressure 441 P3040 Urea pump, urea 1. The OBD lamp is 1. Bending of urea line: 1. Visually check whether the
BuildUpErr build-up error nozzle, urea pipe, illuminated check whether the intake urea pipe is bent or reversed,
urea tank immediately in the pipe, the return pipe and and whether there is
event of a fault; the the injection pipe are bent; excessive binding. If any,
fault becomes a 2. Check whether the urea organize and re-arrange and
historical fault after pump intake and return bind up the pipeline to
the vehicle is shut lines are installed reversely; ensure that the pipeline runs
down and is powered 3. The urea pump pipe joint smoothly and is securely
on again; even if it is a breakage or the joint filter fixed.
historical fault, it screen blockage: check 2. Visually check whether the
needs to be checked. whether the urea pump urea pump pipe joint leaks or
2. Immediately limit intake pipe joint leaks and is blocked; if there is liquid
the torque in the the joint filter is blocked. leakage or crack at the joint,
event of a fault. 4. Excessive impurities in the replace the corresponding
urea tank: check whether urea pump pipe joint.
the impurities inside the 3. Open the urea tank and
urea tank are too much, observe the impurities in the
resulting in the urea pump urea tank. Fill the
blockage; conforming urea, clean the
5. Check whether the urea urea tank and filter screen
nozzle for leak through and according to the situation.
the problem of normally- Be sure to fill the conforming
open urea of regular channels.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
6. Urea pump fault or too 4. Check the nozzle and urea
dirty filter element: check pump;
the urea pump and filter 5. Confirmation of the
element for cleanliness troubleshooting results: The
first method: use the
DiagSmart for urea injection
test to observe whether the
urea pump and nozzle can
work normally; the second
method: use the DiagSmart
in the vehicle to view the
data stream, and observe
whether the urea pressure
reaches 9bar after the
upstream exhaust
temperature reaches 180°C.
If the urea pump
malfunctions, replace the
urea pump; if the nozzle is
abnormal, first soak it in hot
water and repeat the test,
and replace the nozzle that
cannot be repaired. If
abnormal, go back to steps 1,
2, 3, and 4.
DFC_SCRMonPres- SCR urea pressure 441 P3049 Urea pump and The pressure relief is Partial urea thawing is Continue to thaw
DropChk step-down error hydraulic line unsuccessful and the unsuccessful
SCR system stops
working. Limit the
torque 50 hours later.
DFC_SCRMonPres- After step-down, the 441 P3041 Urea pump and The pressure does not Reversing valve failure or Check whether the reversing

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
RdcErr SCR urea pressure is hydraulic line drop to the target blockage of the pipeline valve and piping are blocked
not below the limit value and the SCR
system stops working.
DFC_ SCRPODMon- Overheat of the 446 P2043 Urea tank The urea is not Urea tank temperature Stop heating; cool down;
TnkT urea tank injected; if the SCR_tUTnkT continues to be
temperature is too the upper limit SCRPOD_
high, the state tMonTnkTemp- Max_C;
machine switches to
the state of pressure-
free control
DFC_SCRRCntErr The number of 438 P2068 Urea The urea injection The urea tank liquid level is Refill the urea so that the
times the SCR urea volume initialization is below a certain limit. liquid level is no longer
solution is not filled prohibited; below the fault limit
in time exceeds the
maximum allowable
value.
DFC_SRCMaxUTnk- Lvl Urea liquid level 445 P203D Urea liquid level Limit the torque after Poor contact or open circuit 1. Tighten or replace the
sensor voltage is sensor 50h or short circuit to the power connector or wire harness;
above the upper supply fo the sensor 2. Replace the sensor
limit connector; the sensor raw 3. Check whether the voltage
voltage SCR_uRawUTnkLvl is upper limit rating is correct
greater than voltage upper
limit
SCR_SRCUTnkLvl.uMax_C
DFC_SRCMinUTnkL- vl Urea liquid level 445 P203C Urea liquid level Limit the torque after The sensor connector is 1. Replace the connector;
sensor voltage is sensor 50h short- circuited to the 2. Replace the sensor
below the lower ground; the sensor raw 3. Check whether the voltage
limit voltage SCR_uRawUTnkLvl is lower limit rating is correct
less than the voltage lower
limit
SCR_SRCUTnkLvl.uMin_C

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DFC_SMHtrTDycFail SCR urea pump 455 P3029 SCR urea pump Urea pump cannot The SCR urea pump heater 1. Check the on-off of the
heater temperature heater heat temperature duty cycle is line between the urea supply
duty cycle is in the less than the upper limit and module circuit wire harness
wrong range greater than the lower limit, ECU pin K93 and the urea
i.e. SCR_rSMFailMin_ C<= pump pin PIN10
SCR_ rSMHtrT<= SCR_ 2. Replace the urea supply
rSMFailMax_C module
DFC_SMHtrTDycInvl- d SCR urea pump 455 P3029 SCR urea pump Urea pump cannot The SCR urea pump heater 1. Check the on-off of the
heater temperature heater heat temperature duty cycle is line between the urea supply
duty cycle is in the not within the valid range or module circuit wire harness
invalid range is not within the wrong ECU pin K93 and the urea
range, i.e. (SCR_rSMHtrT pump pin PIN10
<SCR_rSMHtrTVldMi- 2. Replace the urea supply
n_C)OR(SCR_rSMHtrTVldMa module
- x_C < SCR_r- SMHtrT <
SCR_ rSMFailMin_C)
OR(SCR_ rSMHtrT>
SCR_rSMFailMax_C)
DFC_SMNoAvl SCR urea pump 454 P3038 SCR urea pump Unable to obtain the The temperature 1. Check the on-off of the
temperature temperature urea pump measurement unit line between the urea supply
measurement measurement temperature malfunctions; the module circuit wire harness
module failure module temperature measurement ECU pin K93 and the urea
is still invalid after the pump pin PIN10
number of start-ups exceeds 2. Replace the urea supply
the maximum rating value. module
1. The controller does not
receive the signal
transmitted by the urea
supply module (interfered)
2. SM signal line is short-
circuited to the power

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
supply (short time)
DFC_SMPerPwm The PWM period 454 P2062 SCR urea pump Signal cannot be The PWM period received 1. Check the on-off of the
received by the SCR acquired by the SCR urea pump is line between the urea supply
urea pump is in the outside the range of 150ms module circuit wire harness
invalid range and 250ms. ECU pin K93 and the urea
pump pin PIN10
2. Replace the urea supply
module
DFC_SMPwm SCR urea pump 454 P2062 SCR urea pump Signal cannot be Check or replace the urea
PWM signal error acquired pump
DFC_SMTDycFail SCR urea pump 456 P3029 SCR urea pump Immediately limit the The urea pump temperature Check or replace the urea
temperature duty torque; signal cannot duty cycle is within the pump
cycle is within the be acquired wrong range, i.e. SCR_
wrong range rSMFailMin_ C<= SCR_ rSMT
<= SCR_rSMFailMax_C
DFC_SMTDycInvld SCR urea pump 456 P3029 SCR urea pump Immediately limit the The urea pump temperature Check or replace the urea
temperature duty torque; signal cannot duty cycle is within the pump
cycle is in the invalid be acquired invalid range, i.e.
range (SCR_rSMT<
SCR_rSMTVldMin_C) or
(SCR_rSMTVldMax_C<
SCR_rSMT
<SCR_rSMFailMin_C) or
(SCR_rSMT>
SCR_rSMFailMax_C)
DFC_UTnkTSig Urea tank 446 P205A Urea tank Cannot read the The information read from Check ECU communication;
temperature CAN temperature sensor temperature of the Com_tUTnkT is equal to replace the urea tank
information error urea tank 0x7FFF temperature sensor
DFC_UTnkTSRCMax Urea tank 446 P205D Urea tank OBD lamp will be on 1. Missing, pin withdrawal 1. Check the connector for
temperature sensor temperature sensor immediately in the of the connector; pin problems such as missing,
voltage signal is event of a fault breakage, corrosion, water false connection, pin

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
above the upper ingress of the connector and breakage, and pin corrosion.
limit the line wear and short Multimeter: the negative
circuit to the high level; pole is grounded, and in case
2. Pin withdrawal, false of ensuring the normal
connection and short circuit connection of the line,
of ECU connector K80; detect whether the ECU end
3. Urea tank temperature K80 voltage is normal with
sensor has faulty. the positive pole (normal
range 0.5 ~ 4.5V)
2. Detect the on-off of the
wire from K80 to the sensor
end 3# pin
3. Check the urea tank
temperature sensor and
connector for mechanical
damage or pin breakage. The
resistance position is
selected in the multimeter to
measure the resistance
between the Pin3 and Pin4
of the connector (the normal
range of Weichai is about
0.6-7kΩ)
DFC_UTnkTSRCMin Urea tank 446 P205C Urea tank The OBD lamp is 1. The urea tank 1. Check whether the urea
temperature sensor temperature sensor immediately temperature liquid level tank temperature and liquid
voltage signal is illuminated in the sensor connector has level sensor connector has
below the lower event of a fault in the problems such as missing, problems such as missing,
limit current driving cycle water ingress, corrosion, water ingress, corrosion,
etc., or there is a broken etc., and whether the line is
short circuit in the line; damaged or short-circuited;
2. The multimeter detects 2. Use a multimeter to

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the voltage of the K80 pin of detect the voltage of the K80
the ECU end, and the pin of the ECU end, which
voltage value is below 0.5V; should be higher than 0.5V
3. The connector is under normal conditions;
damaged. 3. Check the connector for
damage.
DFC_UTnkTVDPlau- Urea tank 446 P205B Urea tank OBD lamp will be on Principle: After the engine 1. Check whether the sensor
sTempMax temperature is not temperature sensor, immediately in the stops for a long time, when part number is consistent
reliable (too high) ambient event of a fault the temperature of the urea with the matching manual
temperature sensor tank is over 15°C above the part number;
ambient temperature during 2. Use the DiagSmart to read
cold start, report the fault; the sensor measured value
1. The urea tank heating and whether the actual
water solenoid valve is measurement is correct;
normally opened, and the 3. Touch the urea tank with
urea is overheated. your hand to determine
2. The replaced sensor does whether the temperature is
not match the original higher than the current
configuration; ambient temperature.
3. Internal fault of the 4. Visually check whether the
ambient temperature sensor ambient temperature sensor
or urea tank temperature is installed away from the
sensor; heat source;
4. The ambient temperature 5. Use the DiagSmart to read
sensor is not installed the sensor measured value
properly and does not and whether the actual
accurately reflect the measurement is correct;
ambient temperature. 6. Confirmation of the
inspection results: the
vehicle is fully cooled and
then started. If the fault no

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longer occurs, it means that
the fault is solved.
DFC_UTnkTVDPlau- Urea tank 446 P205B Urea tank OBD lamp will be on Principle: After the engine 1. Check whether the sensor
sTempMin temperature sensor temperature sensor, immediately in the stops for a long time, when part number is consistent
signal is below the ambient event of a fault the temperature of the urea with the matching manual
lower limit temperature sensor tank is over 15°C below the part number;
ambient temperature during 2. Use the DiagSmart to read
cold start, report the fault; the sensor measured value
1. The replaced sensor does and whether the actual
not match the original measurement is correct;
configuration; 3. Visually check whether the
2. Internal fault of the ambient temperature sensor
ambient temperature sensor is installed away from the
or urea tank temperature heat source;
sensor; 4. Use the DiagSmart to read
3. The ambient temperature the sensor measured value
sensor is not installed and whether the actual
properly and does not measurement is correct
accurately reflect the
ambient temperature.
DFC_UHCEnfShOff- Pressure pipe 433 P3025 Urea line connector 1. The SVS fault lamp 1. The pressure pipe needs 1. Check the connectors of
WiEmp heating error is immediately to be heated, but the the pipelines such as the
illuminated in the current fault causes the pressure pipe for missing,
event of a fault in the pressure pipe not be heated false connection, pin
current driving cycle; normally. In order to breakage, pin corrosion,
2. No injection of the prevent the urea in the damage and other problems;
urea. pressure tube from being 2. If the ambient
frozen, the urea in the temperature is high, the urea
pressure pipe is emptied tank will not be re-frozen.
and the fault is reported; Check the connector of the
2. In the urea injection urea tank temperature

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
process, the urea tank sensor for missing, false
temperature sensor connection, pin breakage,
measured value is very low pin corrosion, damage, and
and thawing is required. In other problems.
order to prevent the urea in
the pressure pipe from
being frozen, the urea in the
pressure pipe is emptied
and the fault is reported.
DFC_UHtrBLLdFdBk- Urea pipe (pump to 461 P3069 Urea pipe (pump to The lamp is Principle: When the fault 1. Use a multimeter to
Plaus tank) heater tank) heater illuminated feedback signal of the K36 measure the resistance value
resistance wire resistance wire immediately in the pin of the return pipe of the heater resistance wire
feedback is not event of a fault and heating unit is between 7.2V of the return pipe, and the
reliable the urea pipe does and 21.6V, the fault will be normal resistance value is
not heat up properly reported. greater than 9Ω;
1. The resistance value of 2. Check whether the heater
the return pipe heater resistance wire of the return
resistance wire is too low; pipe is grounded;
2. The resistance value of 3. Use a multimeter to
the common ground wire of measure the resistance value
the heating circuit is too of the common ground wire;
large, and the resistance 4. Connect according to the
value of the common heating circuit schematic
ground wire is close to 0Ω; diagram.
3. The heating line is not
connected properly;
DFC_ UHtrBLLdOL Open circuit of the 461 P3070 Urea pipe (pump to The lamp is Principle: When the after- 1. Replace with an intact and
urea pipe (pump to tank) heater illuminated treatment heating main conforming relay;
tank) heater resistance wire immediately in the relay is closed, the return 2. Use a multimeter to
resistance wire event of a fault and pipe heater resistance wire measure whether the
the urea pipe does is in the heating state. ground wire of the heater

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
not heat up properly Report the fault when resistance wire is open-
detecting that the K36 pin circuited, and measure
feedback voltage is close to whether the ground terminal
24V. of the relay output end is
1. Return pipe heater relay connected to the ground. In
damaged; case of open circuit,
2. The ground wire of return reconnect the wire harness.
pipe heater resistance wire 3. Observe or use a
is disconnected; multimeter to check whether
3. The ground wire fuse is the ground end fuse is burnt
burnt out; out;
4. The heating line is not 4. Connect according to the
connected properly. heating circuit schematic
diagram.
DFC_ UHtrBLLdSCG- OL Short circuit to 461 P3071 Urea pipe (pump to The lamp is Principle: When the heating 1. Use a multimeter to check
ground or open tank) heater illuminated main relay is closed, the the resistance value of the
circuit of the urea resistance wire immediately in the heater resistance wire of the heater resistance wire. If the
pipe (pump to tank) event of a fault and return pipe is not in the resistance value is infinite, it
heater resistance the urea pipe does heating state. Report the means an open circuit.
wire not heat up properly fault when detecting that Replace the heating pipe
the K36 pin feedback again or reconnect the
voltage is close to 0V. connector properly;
1. The heater resistance 2. Use a multimeter to check
wire of the return pipe is whether the common
open-circuited, and the ground wire of the resistance
heater resistance wire wire is connected to the
connector is missing; ground. In case of open
2. The return pipe heater circuit, reconnect the ground
resistance wire is short- wire.
circuited to ground; 3. Observe or use a
3. The main fuse of the multimeter to check whether

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
heating circuit is burnt out; the main heating fuse is
4. The heating circuit is not burnt out;
connected properly. 4. Connect according to the
heating circuit schematic
diagram.
DFC_ UHtrBLOL Open circuit of the 461 P3021 Urea return pipe The fault lamp is 1. The urea return line 1. Check whether the pipe of
urea return pipe (pump to tank) illuminated (pump to tank) heater relay the urea return pipe heater
(pump to tank) heater relay immediately in the line is disconnected; relay terminal is
heater relay event of a fault; the 2. Urea return pipe (pump disconnected, falsely
urea return line to tank) heater relay fault. connected, corroded, etc.
(pump to tank) does 2. Check whether the K50
not heat properly. pin terminal of the ECU is
disconnected, falsely
connected, corroded, etc.
3. Replace the urea return
pipe heater relay to see
whether the fault has
disappeared.
DFC_UHtrBLOvrTe- mp Overtemperature of 461 P3072 Urea return pipe The power supply of 1. Relay terminal water 1. Check the urea return pipe
the urea return pipe (pump to tank) heater relay is turned ingress, line short circuit, heater relay terminal pin for
(pump to tank) heater relay off; all urea lines etc.; short circuit or lap joint;
heater relay drive cannot be heated. 2. The wire harness of K50 is 2. Check whether the
short-circuited to other resistance at both ends of
positive wire harnesses, the relay coil is normal
etc.; 3. Replace the urea return
3. Urea return pipe heater pipe heater relay to see
relay fault. whether the fault has
disappeared.
DFC_ UHtrBLSCB Short circuit to the 461 P3023 Urea return pipe The fault lamp is 1. Relay terminal water 1. Check the urea return pipe
power supply of the (pump to tank) illuminated ingress, line short circuit, heater relay terminal pin for
urea return pipe heater relay immediately in the etc.; short circuit or lap joint;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
(pump to tank) event of a fault; the 2. The wire harness of K50 is 2. Replace the urea return
heater relay urea return line short-circuited to other pipe heater relay to see
(pump to tank) does positive wire harnesses, whether the fault has
not heat properly. etc.; disappeared.
3. Urea return pipe heater
relay fault.
DFC_ UHtrBLSCG Short circuit to 461 P3022 Urea return pipe The fault lamp is 1. Short circuit to ground of 1. Check the urea return pipe
ground of the urea (pump to tank) illuminated the urea return pipe (pump heater relay terminal for
return pipe (pump heater relay and its immediately in the to tank) heater relay false connection, short
to tank) heater relay terminals event of a fault; the interface or interior circuit, water ingress,
urea return line 2. Short circuit to ground, corrosion, etc.
(pump to tank) does water ingress, corrosion, 2. Check whether the fault
not heat properly. etc. of the K50 pin terminal disappears after replacing
of the ECU. the urea return pipe heater
relay.
DFC_UHtrPLLdFdBk- Urea pressure pipe 462 P3073 Urea pressure pipe The fault lamp is The urea pressure pipe 1. Check the urea pressure
Plaus (pump to nozzle) (pump to nozzle) illuminated (pump to nozzle) heater pipe heater resistance wire
heater resistance immediately in the resistance wire voltage is terminal for false
wire feedback event of a fault; the not within the normal range, connection, corrosion, etc.
voltage is not urea pressure pipe below a few millivolts. 2. Check whether the K58
reliable (pump to nozzle) does and K92 pin terminals are
not heat properly. normal;
3. Replace the urea pressure
pipe to see whether the fault
has disappeared.
DFC_ UHtrPLLdOL Open circuit of the 462 P3074 Urea pressure pipe The fault lamp is 1. Disconnection of the urea 1. Check the urea pressure
urea pressure pipe (pump to nozzle) illuminated pressure pipe (pump to pipe heater relay terminal
(pump to nozzle) heater relay immediately in the nozzle) heater relay terminal for disconnection, false
heater relay event of a fault; the line; connection, corrosion, etc.
urea pressure pipe 2. Urea pressure pipe (pump 2. Check whether the K58
(pump to nozzle) does to nozzle) heater relay fault. pin terminal of the ECU is

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
not heat properly. disconnected, falsely
connected, corroded, etc.;
3. Replace the urea pressure
pipe heater relay to see
whether the fault has
disappeared.
DFC_ UHtrPLLdSCG- OL Short circuit to 462 P3075 Urea pressure pipe The fault lamp is 1. Urea pressure pipe (pump 1. Check the urea pressure
ground or open (pump to nozzle) illuminated to nozzle) heater relay pipe heater relay terminal
circuit of the urea heater relay immediately in the terminal line is short- for short circuit to ground,
pressure pipe (pump event of a fault; the circuited to ground; water ingress, corrosion, etc.
to nozzle) heater urea pressure pipe 2. K58 wire harness is short- 2. Check the K58 pin
relay (pump to nozzle) does circuited to ground, etc.; terminal for short circuit to
not heat properly. 3. Urea pressure pipe (pump ground, false connection,
to nozzle) heater relay fault. corrosion, etc.
3. Check whether the fault
disappears after replacing
the urea return pipe heater
relay.
DFC_ UHtrPLOL Open circuit of the 462 P3024 Urea pressure pipe The fault lamp is 1. Disconnection of the urea 1. Check whether the urea
urea pressure pipe (pump to nozzle) illuminated pressure pipe (pump to pressure pipe heater relay
(pump to nozzle) heater relay immediately in the nozzle) heater relay line; terminal circuit is
heater relay event of a fault; the 2. Urea pressure pipe (pump disconnected, falsely
urea pressure pipe to nozzle) heater relay fault. connected, corroded, etc.
(pump to nozzle) does 2. Check the K92 pin
not heat properly. SCR terminal of the ECU for
system does not disconnection, false
work. connection, corrosion, etc.
3. Replace the urea pressure
pipe heater relay to see
whether the fault has
disappeared.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_UHtrPLOvrTe- mp Overtemperature of 462 P3076 Urea pressure pipe The power supply of 1. Relay terminal water 1. Check the urea pressure
the urea pressure (pump to nozzle) heater relay is turned ingress, line short circuit, pipe heater relay terminal
pipe (pump to heater relay off; all urea lines etc.; pin for short circuit or lap
nozzle) heater relay cannot be heated. 2. The wire harness of K92 is joint;
drive short-circuited to other 2. Replace the urea pressure
positive wire harnesses, pipe heater relay to see
etc.; whether the fault has
3. Urea pressure pipe heater disappeared.
relay fault.
DFC_ UHtrPLSCB Short circuit to the 462 P3027 Urea pressure pipe The fault lamp is 1. Relay terminal water 1. Check the urea pressure
power supply of the (pump to nozzle) illuminated ingress, line short circuit, pipe heater relay terminal
urea pressure pipe heater relay immediately in the etc.; pin for short circuit or lap
(pump to nozzle) event of a fault; the 2. The wire harness of K92 is joint;
heater relay urea pressure pipe short-circuited to other 2. Replace the urea pressure
(pump to nozzle) does positive wire harnesses, pipe heater relay to see
not heat properly. SCR etc.; whether the fault has
system does not 3. Urea pressure pipe heater disappeared.
work. relay fault.
DFC_ UHtrPLSCG Short circuit to 462 P3026 Urea pressure pipe The fault lamp is 1. Urea pressure pipe (pump 1. Check the urea pressure
ground of the urea (pump to nozzle) illuminated to nozzle) heater relay pipe heater relay terminal
pressure pipe (pump heater relay and its immediately in the interface or interior is short- for false connection, short
to nozzle) heater terminals event of a fault; the circuited to ground; circuit, water ingress,
relay urea pressure pipe 2. Short circuit to ground, corrosion, etc.
(pump to nozzle) does water ingress, corrosion, 2. Replace the urea pressure
not heat properly. SCR etc. of the K92 pin terminal pipe heater relay to see
system does not of the ECU. whether the fault has
work. disappeared.
DFC_UHtrRlyLdSCB Short circuit to the 463 P3077 Urea heating main Urea heating main 1. Relay terminal water 1. Check the urea heating
power supply of the relay relay is normally ingress, line short circuit, main relay terminal pin for
urea heating main closed etc.; water ingress, short circuit,
relay load terminal 2. The internal switch of the corrosion, etc.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
relay is short-circuited. 2. Replace the urea heating
main relay to see whether
the fault has disappeared.
DFC_UHtrRlyOL Open circuit of the 463 P3043 Urea heating main The lamp is 1. Missing of the urea 1. Check the relay: Check
urea heating main relay illuminated heating main relay; whether the urea heating
relay immediately in the 2. Open circuit of the urea main relay is installed;
event of a fault and heating main relay related 2. Check the wire harness:
the urea pipe does wire harness; use a multimeter to detect
not heat up properly 3. The main relay resistance the on-off of the wire
value is not suitable. harness between the urea
4. The malfunction of open heating main relay control
circuit is reported for all pin and the ECU controller
other T pipes, indicating that K94 and K90 pins;
the main relay is open- 3. Check the ECU connector:
circuited. Check the ECU connector for
pin breakage, pin
withdrawal, false
connection, etc.;
4. Use a multimeter to
measure the value of the
resistance between the pins
of the main heating relay
control coil, ranging from
(100-3,000) Ω.
DFC_UHtrRlyLdSCB Short circuit to the 463 P3077 Urea heating main Urea heating main 1. Relay terminal water 1. Check the urea heating
power supply of the relay relay is normally ingress, line short circuit, main relay terminal pin for
urea heating main closed etc.; water ingress, short circuit,
relay load terminal 2. The internal switch of the corrosion, etc.
relay is short-circuited. 2. Replace the urea heating
main relay to see whether
the fault has disappeared.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_UHtrRlyOvrTe- mp Overtemperature of 463 P3044 Urea heating main The power supply of 1. Relay terminal water 1. Check the terminal pin of
the urea heating relay heater relay is turned ingress, line short circuit, the urea main heater relay
main relay drive off; all urea lines etc.; for short circuit or lap joint;
cannot be heated. 2. The wire harness of K94 is 2. Replace the urea main
short-circuited to other heater relay to see whether
positive wire harnesses, the fault has disappeared.
etc.;
3. Urea main heater relay
fault.
DFC_UHtrRlySCG Short circuit to 463 P3046 Urea heating main All urea pipes cannot Urea heating main relay or 1. Check the K90 terminal for
ground of the urea relay be heated up its wire harness is short- short circuit to ground,
heating main relay circuited to ground corrosion, water ingress, etc.
2. Replace the urea heating
main relay to see whether
the fault has disappeared.
DFC_UHtrSLLdFdBk- Urea inlet line (tank 464 P3078 Urea inlet line (tank The fault lamp is The feedback resistance 1. Check the urea inlet line
Plaus to pump) heater to pump) illuminated value of the urea inlet line heater resistance wire
resistance wire immediately in the (tank to pump) heater terminal for false
feedback is not event of a fault; the resistance wire (the voltage connection, corrosion, etc.
reliable urea inlet line (tank to between k20 and ground) is 2. Check whether the K26
pump) cannot be very small, within a few and K20 pin terminals are
heated up normally. millivolts. normal;
3. Replace the urea inlet line
to see whether the fault has
disappeared.
DFC_ UHtrSLLdOL Open circuit of the 464 P3079 Urea inlet line (tank The fault lamp is 1. False connection, 1. Check the K20 terminal for
urea inlet line (tank to pump) heater illuminated disconnection, corrosion, false connection,
to pump) load end relay immediately in the etc. of the K20 terminal pin disconnection, corrosion,
event of a fault; the of the ECU; etc.
urea inlet line (tank to 2. False connection, 2. Check the terminal of the
pump) cannot be disconnection, corrosion, urea inlet line heater relay

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
heated up normally. etc. of the urea inlet pipe for false connection,
heater resistance wire; disconnection, corrosion,
3. Urea inlet line (tank to etc.;
pump) fault. 3. Replace the urea inlet line
heater relay to see whether
the fault has disappeared.
DFC_ UHtrSLLdSCG- OL Short circuit to 464 P3080 Urea inlet line (tank The fault lamp is 1. Short circuit to ground, 1. Check the urea inlet line
ground or open to pump), urea inlet illuminated water ingress, corrosion, heater resistance wire
circuit of the urea line heater relay, immediately in the etc. of the urea inlet line terminal for short circuit to
inlet line (tank to terminal event of a fault; the (tank to pump) heater ground, water ingress ,
pump) heater urea inlet line (tank to resistance wire terminal; corrosion, etc.
resistance wire pump) cannot be 2. Short circuit, water 2. Check the K20 pin for
heated up normally. ingress, corrosion, etc. of short circuit to ground or pin
the urea inlet line heater lap joint;
relay pin; 3. Check the terminals of the
3. Urea inlet line heater urea inlet line heater relay
relay interior short circuit. for short circuit, water
ingress, corrosion, etc.;
4. Replace the urea inlet line
heater relay to see whether
the fault has disappeared.
DFC_ UHtrSLOL Open circuit of the 464 P3028 Urea inlet line (tank The fault lamp is 1. Disconnection of the urea 1. Check the line of the urea
urea inlet line (tank to pump) heater illuminated inlet line (tank to pump) inlet line heater relay
to pump) heater relay immediately in the heater relay line terminal for disconnection,
relay event of a fault; the 2. Urea inlet line (tank to false connection, corrosion,
urea inlet line (tank to pump) heater relay fault. etc.
pump) cannot be 2. Check the K26 pin
heated up normally. terminal of the ECU for
disconnection, false
connection, corrosion, etc.
3. Replace the urea inlet line

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
heater relay to see whether
the fault has disappeared.
DFC_UHtrSLOvrTe- mp Overtemperature of 464 P3081 Urea inlet line (tank The power supply of 1. Relay terminal water 1. Check the terminals of the
the urea inlet line to pump) heater heater relay is turned ingress, line short circuit, urea inlet line heater relay
(tank to pump) relay off; all urea lines etc.; terminal for short circuit or
heater relay drive cannot be heated. 2. The wire harness of K26 is lap joint;
short-circuited to other 2. Replace the urea inlet line
positive wire harnesses, heater relay to see whether
etc.; the fault has disappeared.
3. Urea inlet line heater
relay fault.
DFC_ UHtrSLSCB Short circuit to the 464 P3032 Urea inlet line (tank The fault lamp is 1. Relay terminal water 1. Check the terminals of the
power supply of the to pump) heater illuminated ingress, line short circuit, urea inlet line heater relay
urea inlet line (tank relay immediately in the etc.; terminal for short circuit or
to pump) heater event of a fault; the 2. The wire harness of K26 is lap joint;
relay urea inlet line (tank to short-circuited to other 2. Replace the urea inlet line
pump) cannot be positive wire harnesses, heater relay to see whether
heated up normally. etc.; the fault has disappeared.
3. Urea inlet line heater
relay fault.
DFC_ UHtrSLSCG Short circuit to 464 P3031 Urea inlet line (tank The fault lamp is 1. Short circuit to ground of 1. Check the terminal of the
ground of the urea to pump) heater illuminated the urea inlet line (tank to urea inlet line heater relay
inlet line (tank to relay and its immediately in the pump) heater relay interface for false connection, short
pump) heater relay terminals event of a fault; the or interior; circuit, water ingress,
urea inlet line (tank to 2. Short circuit to ground, corrosion, etc.
pump) cannot be water ingress, corrosion, 2. Replace the urea inlet line
heated up normally. etc. of the K26 pin terminal heater relay to see whether
of the ECU. the fault has disappeared.
DFC_UHtrSMLdFdB- Urea pump heater 465 P3082 Urea pump heater Cannot heat up Diagnostic failure of the 1. Check the urea pump
kPlaus resistance wire resistance wire relay load; the urea pump heater resistance wire
feedback is not heater resistance wire terminal for short circuit to

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
reliable feedback voltage ground, water ingress,
UHC_uSMFdBk is between corrosion, etc.
UHC_uADCLow_C and 2. Check whether the line
UHC_uADCHigh_C from K33 to the ground is
too long, the wire diameter
is too thin, and the line
specifications are in line with
norms;
3. Replace the line from the
urea pump heater resistance
wire to the ground
DFC_ UHtrSMLdOL Open circuit of urea 465 P3083 Urea pump heater Cannot heat up Disconnection of the urea 1. Check the urea pump
pump heater resistance wire pump heater resistance wire heater resistance wire
resistance wire line terminal for short circuit to
ground, water ingress,
corrosion, etc.
2. Check the on-off of the
line from the K33 to the
resistance wire end, check
the on-off of various lines
from the resistance wire to
the power supply end, and
whether there is a false
connection, and whether the
open circuit voltage is 24V;
3. Replace the urea pump
heater resistance wire.
DFC_ UHtrSMLdSC- Short circuit to 465 P3084 Urea pump heater Cannot heat up Short circuit to ground of 1. Check the urea pump
GOL ground or open resistance wire the urea pump heater heater resistance wire
circuit of the urea resistance wire terminal for short circuit to
pump heater ground, water ingress,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
resistance wire corrosion, etc.
2. Check the line from the
resistance wire to the ground
for on-off, and check the line
from the K33 pin to the
ground for grounding;
3. Replace the urea pump
heater resistance wire
DFC_ UHtrSMOL Open circuit of the 465 P3033 Urea pump heater Cannot heat up Disconnection of the urea 1. Check the urea pump
urea pump heater relay pump heater relay line K25 heater relay for short circuit
relay to ground, water ingress,
corrosion, etc.
2. Check various lines from
the K25K90 to the relay end
for on-off, and the open
circuit voltage of the K25 pin
is 3.5V;
3. Replace the urea pump
heater relay.
DFC_UHtrSMOvrTe- mp Overtemperature of 465 P3085 Urea pump heater Cannot heat up High temperature of the 1. Check whether there is a
the urea pump relay urea pump heater relay broken cable sheath and
heater relay leakage of electricity of the
lines from the K90 and K25
to the urea pump heater
relay circuit, and check the
ECU pin for short circuit to
ground or pin lap joint if
necessary.
2. Replace the urea pump
heater relay.
DFC_ UHtrSMSCB Short circuit to the 465 P3037 Urea pump heater Cannot heat up Short circuit to the power 1. Check the urea pump

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
power supply of the relay supply of the urea pump heater relay for short circuit
urea pump heater heater relay K25 to ground, water ingress,
relay corrosion, etc.
2. Check the line from the
K25 to relay terminal for
grounding, connection in a
wrong way;
3. Replace the urea pump
heater relay.
DFC_ UHtrSMSCG Short circuit to 465 P3036 Urea pump heater Cannot heat up Short circuit to ground of 1. Check the urea pump
ground of the urea relay the urea pump heater relay heater relay for short circuit
pump heater relay K25 to ground, water ingress,
corrosion, etc.
2. Check the line from the
K25 to relay terminal for
grounding, connection in a
wrong way;
3. Replace the urea pump
heater relay.
DFC_UHtrTnkOL Open circuit of the 466 P3016 Urea tank heating The urea tank cannot Disconnection of the urea 1. Check whether the on-off
urea tank heating solenoid valve be heated up tank heating solenoid valve and feedback voltages of the
solenoid valve line K28/K89 urea heating solenoid valves
K89 and K28 are abnormal,
whether there is a broken
cable sheath and leakage of
electricity of the line, and
check the ECU pins for short
circuit to ground or pin lap
joint if necessary.
2. Replace the urea tank
heating solenoid valve.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
DFC_UHtrTnkOvrTe- Overtemperature of 466 P3018 Urea tank heating The urea tank cannot High temperature of the 1. Check whether the on-off
mp the urea tank solenoid valve be heated up urea tank heating solenoid and feedback voltages of the
heating solenoid valve urea heating solenoid valves
valve K89 and K28 are abnormal,
whether there is a broken
cable sheath and leakage of
electricity of the line, and
check the ECU pins for short
circuit to ground or pin lap
joint if necessary.
2. Replace the urea tank
heating solenoid valve.
DFC_UHtrTnkSCB Short circuit to the 466 P3020 Urea tank heating The urea tank cannot Short circuit to the power 1. Check whether the on-off
power supply of the solenoid valve be heated up supply of the urea tank and feedback voltages of the
urea tank heating heating solenoid valve K28 urea heating solenoid valves
solenoid valve K89 and K28 are abnormal,
whether there is a broken
cable sheath and leakage of
electricity of the line, and
check the ECU pins for short
circuit to ground or pin lap
joint if necessary.
2. Replace the urea tank
heating solenoid valve.
DFC_UHtrTnkSCG Short circuit to 466 P3019 Urea tank heating The urea tank cannot Short circuit to ground of 1. Check whether the on-off
ground of the urea solenoid valve be heated up the urea tank heating and feedback voltages of the
tank heating solenoid valve K28 urea heating solenoid valves
solenoid valve K89 and K28 are abnormal,
whether there is a broken
cable sheath and leakage of
electricity of the line, and

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
check the ECU pins for short
circuit to ground or pin lap
joint if necessary.
2. Replace the urea tank
heating solenoid valve.
DFC_UPmpMotNDvt Urea pump motor 451 P3001 Urea pump No injection of the Urea pump motor damaged Check or replace the urea
speed deviation urea pump
error
DFC_UPmpMotNDvt- Permanent error of 451 P3086 Urea pump No injection of the Urea pump motor damaged Check or replace the urea
Perm urea pump motor urea pump
speed deviation
DFC_UPmpMotNoA- vl Urea pump motor 451 P3002 Urea pump No injection of the Urea pump damaged Check or replace the urea
cannot be driven urea pump
DFC_UPmpMotOL Open circuit of the 451 P3006 Urea pump motor The OBD lamp is Missing and pin withdrawal 1. Check the urea pump
urea pump motor drive illuminated of the urea pump connector for missing, false
drive immediately in the connector; disconnection of connection, pin breakage,
event of a fault; the line at the urea pump pin corrosion, water ingress,
immediately limit the motor drive end (the urea etc.
engine torque after pump end Pin10 and the 2. Grounding of the negative
the fault occurs ECU end K93 pin); internal pole of the multimeter, and
damage of the urea pump. power on of the T15: When
the line is normally
connected, detect the
voltage of K93 at ECU end by
the lead method or the pin
method. If the voltage value
is 3.5V, it means open circuit
(the normal voltage is 8.5V
only when the T15 is
powered on);
3. Check the urea pump

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
housing and connector for
mechanical damage
DFC_UPmpMotOvrT- Overtemperature of 451 P3003 Urea pump No injection of the 1. Water ingress of the 1. Check the urea pump
emp the urea pump urea connector, short circuit of connector for missing, false
motor drive the line, etc.; connection, pin breakage,
2. Urea pump or internal pin corrosion, water ingress,
motor fault. etc.;
2. Check or replace the urea
pump.
DFC_UPmpMotSCB Short circuit to the 451 P3004 Urea pump motor The OBD lamp is Water ingress of the 1. Check the urea pump
power supply of the drive illuminated connector, short circuit of connector for pin corrosion,
urea pump motor immediately in the the line, etc.; short circuit of water ingress, etc.
drive event of a fault; the K93 wire harness and 2. Grounding of the negative
immediately limit the other positive wire harness, pole of the multimeter, and
engine torque after etc.; urea pump or internal power on of the T15: When
the fault occurs. motor fault. the line is normally
connected, detect the
voltage of K93 at ECU end by
the lead method or the pin
method with the multimeter
positive pole. If the voltage
value is 24V, it means short
circuit (the normal voltage is
8.5V only when the T15 is
powered on);
3. Check the urea pump
housing and connector for
mechanical damage
DFC_UPmpMotSCG Short circuit to 451 P3005 Urea pump motor The OBD lamp is Water ingress of the 1. Check the urea pump
ground of the urea drive illuminated connector, short circuit of connector for missing, false
pump motor drive immediately in the the line, etc.; short circuit of connection, pin breakage,

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
event of a fault; the K93 wire harness and pin corrosion, water ingress,
immediately limit the other positive wire harness, etc.
engine torque after etc.; urea pump or internal 2. Grounding of the negative
the fault occurs motor fault. pole of the multimeter, and
power on of the T15: When
the line is normally
connected, detect the
voltage of K93 at ECU end by
the lead method or the pin
method with the multimeter
positive pole. If the voltage
value is 0V, it means short
circuit to ground (the normal
voltage is 8.5V only when
the T15 is powered on);
3. Check the urea pump
housing and connector for
mechanical damage
DFC_UPmpPPlaus- Max Urea pump pressure 451 P3007 Urea pump Immediately limit the Pipeline blocking; nozzle Check whether the urea line
is above the upper pressure sensor torque blocking; urea pump is blocked; check whether
limit pressure the nozzle is blocked;
SCR_pUPmpPPlaus-Diff_mp
is greater than the upper
limit
_pUPmpPPlausMaxDiff_mp
DFC_UPmpPPlaus- Min Urea pump pressure 451 P3007 Urea pump Immediately limit the There is gas or leakage in Check whether there is gas
is below the lower pressure sensor torque the pipeline; the urea pump or gas leakage in the urea
limit pressure pipeline; whether the urea
SCR_pUPmpPPlaus-Diff_mp pipeline is connected in a
is below the lower limit wrong way
SCR_pUPmpPPlaus-

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
MinDiff_mp;
DFC_UPmpPSig Urea pump pressure 451 P204E Urea pump Unable to acquire The signal from Check the communication of
signal CAN pressure sensor signals; unable to Com_pAbsUpmpP on the ECU and pump; check the
communication inject urea pump pressure is equal connection
error to 0x7FFF
DFC_ UPmpPSRCM-ax Urea pump pressure 451 P204D Urea pump The OBD lamp is 1. Check whether the urea 1. Check whether the urea
sensor voltage pressure sensor illuminated pump connector has any pump connector has any
signal is above the immediately in the problems such as missing, problems such as missing,
upper limit event of a fault; water ingress, corrosion, water ingress, corrosion, etc.
immediately limit the etc. and whether the line is and whether the line is
engine torque after damaged or short-circuited damaged or short-circuited
the fault occurs 2. Use a multimeter to 2. Use a multimeter to
detect the voltage of the detect the voltage of the K78
K78 pin at the ECU end, pin at the ECU end, which
which should be below 4.5V should be below 4.5V under
under normal conditions; normal conditions;
3. Check the urea pump 3. Check whether the urea
housing and connector for pump pressure sensor pins
mechanical damage. (K24, K78, K77) and the wire
harness are in good contact;
4. Check the urea pump
housing and connector for
mechanical damage.
DFC_ UPmpPSRCMi-n Urea pump pressure 451 P204C Urea pump The OBD lamp is 1. Check whether the urea 1. Check whether the urea
sensor voltage pressure sensor illuminated pump connector is pump connector has water
signal is below the immediately in the corroded, etc., and the line ingress and the circuit is
lower limit event of a fault; is damaged or short- damaged or short-circuited.
immediately limit the circuited 2. Use a multimeter to
engine torque after 2. Use a multimeter to detect the voltage of the K78
the fault occurs detect the voltage of the pin at the ECU end, which
K78 pin at the ECU end, should be above 0.5V under

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
which should be above 0.5V normal conditions;
under normal conditions; 3. Check whether the urea
3. Check the urea pump pump pressure sensor pins
housing and connector for (K24, K78, K77) and the wire
mechanical damage. harness are in good contact;
4. Check the urea pump
housing and connector for
mechanical damage.
DFC_URevVlvHSOL Open circuit of the 452 P3047 Urea reversing valve Urea pressure cannot Disconnection of the urea 1. Check the circuit on-off of
urea reversing valve actuator be built up reversing valve actuator the K30 pin and the Pin11
actuator high-end high-end line pin on the urea pump;
2. Replace the urea pump
DFC_URevVlvHSOv- Overtemperature of 452 P3048 Urea reversing valve Urea pressure cannot 1 Overtemperature of the Check and replace the urea
rTemp the urea reversing actuator be built up high-end control drive supply module and control
valve actuator high- circuit of the urea drive circuit wire harness
end conversion valve.
2 Overtemperature of the
ECU
DFC_URevVlvHSSC- B Short circuit to the 452 P3049 Urea reversing valve Urea pressure cannot Short circuit to the power 1. Check the circuit on-off of
power supply of the actuator be built up supply of the urea the K30 pin and the Pin11
urea reversing valve conversion valve high-end pin on the urea pump;
actuator high end control drive circuit (K30) 2. Replace the urea pump
DFC_URevVlvHSSC- G Short circuit to 452 P3050 Urea reversing valve Urea pressure cannot Short circuit to ground of 1. Check the circuit on-off of
ground of the urea actuator be built up the urea conversion valve the K30 pin and the Pin11
reversing valve high-end control drive pin on the urea pump;
actuator high-end circuit (K30) 2. Replace the urea pump
DFC_URevVlvOL Open circuit of the 452 P3010 Urea reversing valve The OBD lamp is 1. Pin breakage, false 1. Check the urea reversing
urea reversing valve actuator illuminated connection, and pin valve actuator connector for
actuator immediately in the withdrawal of the urea pin withdrawal, pin
event of a fault; urea reversing valve actuator breakage, false connection,
pressure cannot be connector; etc.;

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
built up 2. Open circuit of the urea 2. Check the ECU connector
reversing valve wire harness, K08 pin for pin withdrawal,
etc.; 2. Pin breakage, pin pin breakage and false
withdrawal, false connection;
connection, etc. of the ECU 3. Use a multimeter to
connector K08 pin; measure the on-off of the
3. Urea reversing valve wire harness between the
actuator fault; urea reversing valve actuator
12# pin and the ECU
controller K57 pin (normal
state: conduction, resistance
approaching to 0Ω);
4. Multimeter: Select the
multimeter resistance
position to measure the
value of resistance between
the 12# pin and the 11# pin
of the urea reversing valve
actuator (normal resistance:
20Ω or so)
DFC_URevVlvOvrTe- Overtemperature of 452 P3011 Urea reversing valve Urea pressure cannot High temperature of the 1. Check the on-off of the
mp the urea reversing actuator be built up urea reversing valve circuit of the K08 pin and the
valve actuator actuator Pin12 pin on the urea pump.
2. Replace the urea pump
DFC_URevVlvSCB Short circuit to the 452 P3013 Urea reversing valve Urea pressure cannot Short circuit to the power 1 Check the on-off of the
power supply of the actuator be built up supply of the urea circuit of the K08 pin and the
urea directional conversion valve low-end Pin12 pin on the urea pump.
valve actuator control drive circuit (K08) 2. Replace the urea pump
DFC_URevVlvSCG Short circuit to 452 P3012 Urea reversing valve Urea pressure cannot Short circuit to the power 1 Check the on-off of the
ground of the urea actuator be built up supply of the urea circuit of the K08 pin and the
reversing valve conversion valve low-end Pin12 pin on the urea pump.

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DFC name Chinese description Flash code P-Code Related parts Caused problems Causes Solutions
actuator control drive circuit (K08) 2. Replace the urea pump
DFC_ComAT1OG1D- LC CAN received frame 421 U0113 NOx sensor Nox concentration 1. Electrical signal 1. Check wire harness and
AT1O1 data length measured value is not interference; battery power to eliminate
error accurate 2. NOx sensor or wire interference;
harness damaged. 2. Replace the NOx sensor
DFC_ComAT1OG1T- O CAN receive frame 421 U0113 NOx sensor 1. OBD lamp will be 1. NOx sensor wire harness 1. Check for problems such
AT1O1 timeout error on immediately in the problem or connection as water ingress, pin
event of a fault error; withdrawal, false
2. Limit the torque 2. NOx sensor fault. connection, pin breakage,
after the fault occurs and pin corrosion.
50 hours 2. Use a multimeter to check
whether the supply voltage
of each pin of the NOx
vehicle wire harness is
normal. The voltage value is
shown in the Fig.;
3. Check the NOx sensor and
connector for mechanical
damage, burnout, etc.

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Engine Repair Manual

Appendix B Mating clearance of the main parts

S/N Item Theoretical value / mm
1 Main bearing clearance 0.063～0.138
2 Connecting rod bearing clearance 0.050～0.125
3 Crankshaft axial clearance 0.052～0.255
4 Connecting rod plane axial clearance 0.15～0.35
5 Clearance between connecting rod 0.04～0.060
small head bushing and piston pin
6 Idle gear bearing 0.05～0.094
7 Cold piston ring opening working
clearance 0.35～0.55
First ring 0.60～0.70
Second ring 0.30～0.50
Oil ring
8 Clearance between piston and cylinder 0.105～0.182
liner
9 Clearance between piston and cylinder 1.15
head (TDC)
10 Clearance between intake valve stem 0.023～0.052
and valve guide
11 Clearance between exhaust valve stem 0.045～0.072
and valve guide
12 Value for the bottom surface of the ±0.2/±0.2
valve recessed into the cylinder head
plane
Exhaust/intake
13 Value for the top of the cylinder liner 0.05～0.10
higher than the plane value on the
engine block
14 Camshaft axial clearance 0.1～0.4
15 Camshaft bearing clearance 0.04～0.12
16 Clearance between tappet and tappet 0.025～0.089
hole
17 Interference and clearance between －0.02～0.023
the outer diameter of the cylinder
liner and the cylinder liner hole
18 Rocker arm and rocker arm shaft 0.012~0.066
clearance
19 Rocker arm and rocker arm shaft 0.022~0.082
clearance (Ennova)
20 Valve clearance, intake/exhaust (cold 0.4/0.6
state)
21 EVB system 0.4
22 Clearance between crankshaft speed 1.0±0.5
sensor and flywheel
23 The distance of the fuel injector 2.53（-0.3, +0.45）
protruding from the cylinder head
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surface
Note: Piston clearance calculation: cylinder liner bottom hole diameter - 2 * cylinder liner thickness - piston diameter
(measure - φDN in the piston skirt perpendicular to the piston pin axis).

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Engine Repair Manual

Appendix C Tightening torque of other main bolts

Allowed usages
Bolt name Bolt specification Tightening technical requirements Bolt length mm (including first
installation)
Manual tightening: low torque tightening 4 (the length of
Main bearing +(80±5)N•m+(140±5)N•m+(90±5)°+(60±5)° the bolt after
M18-10.9 169
bolt stretch should be
Automatic tightening: 140N•m+(150±5)°
less than 172mm)
Crankcase
DIN 912; M8-8.8 (20～25)N•m 25, 110 2
auxiliary bolt
Cylinder head
M14-10.9 60N•m+2×(120±5)° 185 3
main bolt
195, at least
Cylinder head 175mm beyond
M12×1.5-8.8 (20+10)N•m sealed with Loctite 262 3
auxiliary bolt the engine
block
Cylinder head
25N•m+2×(120±5)° 3
auxiliary nut
Crankshaft
M12×1.5-10.9 45N•m+(135±5)° 75 2
pulley bolt
Torsional
DIN 933 M10-
vibration (60-70)N•m 30 2
10.9
damper bolt
Flywheel bolt M16×1.5-10.9 105N•m+(180±5)° 120 2
Flywheel bolt M16×1.5-12.9 100N•m+(210±5)° 100, 110, 120 2
Connecting
rod bolt for
Manual tightening: 115N•m+(90±5)°
toothed M14×1.5 67.5 1
Automatic tightening: 80N•m+(153±5)°
connecting
rod
Connecting 3 (The bolt has
rod bolt for been used once
(80±2) N•m +(90°±5°) reaching (180～
cracked M14×1.25 65.5 during the
290)N•m
connecting connecting rod
rod machining)
Air 1×30 plate,
DIN 912; M10-
compressor 40N•m 2×40 flywheel
8.8
fastening bolt housing
Air
compressor
gear fixing
M20×1.5 (200+50)N•m 2
nut (1-
cylinder and
2-cylinder)

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Allowed usages
Tightening technical
Bolt name Bolt specification Bolt length mm (including first
requirements
installation)
Idle gear bolt M12×1.5-10.9 105N•m 90
Common rail pump gear
M24 (250+50)N•m 2
fixing nut
Fuel injector clamping
M8-8.8 8N•m+(90±5)° 50 3
bolt
Camshaft gear bolt M8-10.9 8N•m+(120±5)° 30 2
Piston cooling nozzle
M14×1.5-8.8 30N•m 25
bolt
Water pump bolt
(connecting water pump DIN 931; M10- 8.8 (40～46)N•m 4×80
housing - middle case)
Exhaust manifold bolt M10 (60～75)N•m 65 2
Connecting nut for
turbocharger and M10×1.5 (55~60)N•m
exhaust pipe
Turbocharger oil-inlet
M18×1.5 (75±5)N•m
pipe coupling nut
Air compressor water
M18×1.5 (75±5)N•m
pipe coupling nut
Tensioner bolt (pre-
M10×1.5 (62±5)N•m
coated)
Double pipe joint M16×1.5 (50±5)N•m
Double pipe joint M26×1.5 (80±5)N•m
Cast aluminum flywheel M8-8.8 (20±2)N•m
housing bolts (fixed M10-8.8 (40±3)N•m
torque wrench must be M12-8.8 （70±5）N•m
used) M14×1.5-8.8 （110±6）N•m

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Quality Standard

XK06-002-00156

WEICHAI POWER CO., LTD

Address: 197 A, East Fushou Street, High-Tech Development Zone, Weifang, Shandong Province
Postcode: 261061
Tel: 0536-8197777
Fax: 0536-8231074
E-mail: [email protected]
Web: http://www.weichai.com
Hotline: 400 618 3066

This material is for reference only. Product parameters or images are subject to change without prior notice, which are
subject to the actual product.

272