4J SERIES DIESEL ENGINE

Instruction for the operation

and maintenance of 4J Series diesel engine

ChengDu ChengFa Auto Engine CO.,Ltd.

2010.3

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Contents
1. Technical specification of engine

1.1 Main specification and parameter of engine

1.2 Full load performance curve of engine

1.3 Overall view of engine

2. Major parts and components construction of engine

2.1 Lubrication system

2.2 Cooling system

2.3 Fuel supply system

2.4 Engine electrical system

3. Engine start .run and stop

3.1 Preparation before start

3.2 Procedure for engine start

3.3 Engine cold start at temperature lower than -5℃

3.4 Check of engine at running

3.5 Engine stop

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4. Engine operation and maintenance

4.1 Points for attention when engine in operated

4.2 New engine run-in

4.3 Maintenance of engine lubrication system

4.4 Maintenance of engine cooling system

4.5 Maintenance of fuel injection pump

5. Maintenance and repair and adjustment of engine

5.1 Disassemble cylinder head cover dolt and cylinder head cover

5.2 Check and disassemble inlet and exhaust manifold

5.3 Clean and check oil pan and filter

5.4 Clean machine oil filter

5.5 Valve clearance adjustment

5.6 Caution for engine mount

6. Engine fault and correction

6.1 Hard starting

6.2 Unstable idling

6.3 Insufficient power

6.4 Dark or white exhaust smoke

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6.5 Overheating

6.6 Abnormal engine noise

6.7 Excessive oil consumption

6.8 Excessive fuel consumption

6.9 Engine lubrication system common trouble and correction method

6.10 Engine cooling system trouble and correction method

6.11 (diagnose) Trouble of electrical system ( attached is a 4JB1

engine electrical circuit drawing )

6.12 Turbocharger

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 1. Technical specifications of the engine
1.1 The main performance parameter of the engine
Engine model
4JB1TC 4JB1TI CF25TC
Engine type Water cooled,four-cycle,overhead valve
Combustion chamber type Direct injection
Cylinder liner type Dru type,chrome plated,stainless steel tube
No.of piston rings Compression rings:2/oil ring:1
Total piston displacement(L) 2.771 or 2.498
Compression ratio 17.5
Max.output(kW/rpm) 68/3600 75/3600 62/3600
Max.torque(N.m/rpm) 215/2000 235/2000 205/2000
Idling speed(rpm) 800±50
Engine weight(kg) 230～240
Fuel injection order 1-3-4-2
Fuel injection timing 8°～10°
Specified fuel type SAE No.0 diesel fuel(winter SAE No.-10 diesel fuel)
Intake/exhaust valve 0.40(at cold)
Intake valves open at(BTDC) 24.5°
Intake valves open at(ATDC) 55.5°
Exhaust valves open at(BTDC) 54.0°
Exhaust valves open at(ATDC) 26.0°
Lubrication method Pressurized circulation
Specified engine oil API CF-4 /SAE 15W/40
3.5～4.0(only instead of lubrication oil)
Lubrication oil capacity(L) 5～5.5
Lubrication oil pressure(kPa) ≥98(idling speed) ≥441(2000rpm)
Oil cooler type Water cooled
Min.fuel consumption rate(g/kW.h) 218
Injection pump type VE distributor
Injection nozzle type 5 holes
Injection nozzle opening(MPa) 19.5 or 27
Generator capacity(V-A) 14-70 or 14-80
Starter motor output(V-kW) 12-2.8

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1.2 Full load performance curve of engine

Meo(N.m) 240
230
220
210
200
190
180
Neo(kW) 70
60
50
40
30
20
Geo(g/kW.h) 250
240
230
220
210
1000 1500 2000 2500 3000 3500 4000
rate(rpm)

Fig.1 4JB1TI

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 Meo(N.m) 220
210
200
190
180
170
160
Neo(kW) 70
60
50
40
30
20
Geo(g/kW.h) 250
240
230
220
210
1000 1500 2000 2500 3000 3500 4000
rate(rpm)

Fig.2 4JB1TC

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 Meo(N.m) 210
200
190
180
170
160
Neo(kW) 70
60
50
40
30
20
Geo(g/kW.h) 250
240
230
220
210
1000 1500 2000 2500 3000 3500 4000
rate(rpm)

Fig.3 CF25TC

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1.3 Overall view of engine

A向旋转 B向旋转

Crankshaft center
line

Rubber hole
center line of
bracket

Fig.4 4JB1TI Front View(Fan not shown)

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Fig.5 4JB1TI Right View

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Fig.6 4JB1TI Left View

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 D向旋转 C向旋转

A点
B点

Crankshaft
center line

Rubber hole center

C B点 A点 D line of bracket

Fig.7 CF25TC Front View(Fan not shown)

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Fig.8 CF25TC Side View

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2. Major parts and components construction of engine

2.1 Lubrication system

Pressure and splash lubrication method is used in the lubrication system.

Machine oil pump

It is of gear type (oblique set type) and the case is aluminium alloy

casting, the machine oil pump is fixed on the engine with the two screws and

driven by the skew bevel gear on the camshaft. The rough filtering screen is

arranged below machine oil pump.

Machine oil filter:

It is of full flow cylindrical type. The paper changed filter element. On

the aluminium alloy seat mount the by-pass valve, pressure limit valve and

drain oil thread plug. When draining of oil is required only the drain oil plug

is turned outwards about 15mm, in this way the machine oil in the oil filter

cylinder will return to the oil pan through inside passage. Do not forget to

tighten the drain oil thread plug. Otherwise lubrication oil can not be

circulated in the engine.

By-pass valve:

When machine oil filter element was blocked, the oil from machine oil

pump flows directly in to main oil pipe and may not go through the machine

oil filter element. This prevents bearing from damaging. The open pressure of

by-pass valve is 0.8~1.2kgf/cm².

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Relieve valve:

When the pressure in the lubrication system exceeds permitted value, the

relieve valve can open automata and this make high pressure oil in the system

possible for returning to oil pan so as to adjust pressure to the normal range.

Viscosity of machine oil is great at cold state of engine and pressure of main

oil pipe can reach above 4.5~6kgf/cm².

After the engine temperature increases to about 60℃, the normal

pressure can be maintained. Work pressure of machine oil in summer time can

decrease to 1.5kgf/cm², but do not to be lower than 0.5kgf/cm².

Fig.9 Machine oil filter

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 Fig.10 Machine oil filter base

1.drain oil thread plug 2.by-pass valve open at

0.8~1.2kgf/cm²

3.dumy plug 4.open at 6kgf/cm²

5.pressure regulating valve

(relieve valve)

2.2 Cooling system

Cooling system is of pressurizing circulation type, it consists of radiator,

water pump, fan, thermostat and more, they are reasonably fitted on the

engine with the good warming engine performance and good cooling

performance. When water temperature is below 82℃, the cooling water flows

directly back water pump through by-pass hole and hose of thermostat so as to

form small circulation for warming engine. When water temperature reaches

82℃, temperature regulator is open, cooling water forms great circulation to

cool effectively engine.

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 On the temperature regulator case mount the hot water outlet pipe and

water returning pipe, which are used in the mounting of warming device. If

engine is not operated for whole night in the north winter, the drain water plug

at left side of cylinder block should be turned on to drain away cooling water

completely so as to prevent cylinder block fromicing and cracking of freezing.

Water pump:

The water pump is of centrifugal impeller type with six impellers. The

case is the aluminium alloy die casting. In the case mount the bearing unit and

rubber water seal. On the end of impeller mount the acid resistant ceramic

water seal friction plate and on the rear end of shaft mount the cooling fan

center.

Water pump flow rate is 100L/min. it is not permitted to operate the

pump under the situation of cutting off water in order to prevent water seal

from damage.

O-rubber sealing ring is fitted in the contacting surfaces between the

water pump and timing gear case.

Cooling fan:

4J series diesel engine is equipped with the resin fan with silicon oil

clutch in the energy economy and reduction of noise. There is a dual metal

temperature sensor on the silicon oil clutch, and connection and disconnection

of cooling fan is controlled depend on the airflow temperature of engine

radiator which is sensed by temperature sensor.

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Cooling fan belt:

The less deformation and fatigue resistant cutting belt is used. Please

make sure of inspecting tension when the belt is fitted.

Thermostat:

The wax ball shape of thermostat is used in the cooling system. The

bottom is the by-pass construction. Fit a valve which can open at 80℃ of

temperature. The open and close of valve is dependent on expansion of heated

wax sealed in the cylinder and spring force.

Fig.11 Characteristics of fan clutch

1. connection(below 65℃) 2. disconnection(below55℃)

2.3 Fuel supply system

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 Fig.12 4JB1 fuel supply system

1.CDS solenoid valve 2.Oil injection nozzle

(Cold start solenoid valve)

3. fuel cut off solinoid valve 4.VE type-injection pump

5. fuel filter 6.fuel and water separator

7. fuel tank

The fuel supply system of 4J series diesel engine consists of fuel tank,

fuel and water separator, fuel filter, high pressure fuel pump and fuel injection

nozzle

Fuel and water separator:

It is used to separate the moisture content in the fuel to prevent the water

in the fuel from entering into high pressure fuel pump and causing corrosion

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of components and damage of paper fuel filter element. Unscrew the drain

plug with plastic pipe under the fuel and water separator and press the valve of

water exhaust system and gas exhaust on the separator for several times, this

can eliminate the water and air in the fuel pipe

High pressure fuel pump:

4J series diesel engine is equipped with single plunger Bosch VE type

distributing pump driven by the end face cam.

Timing marks is engraved on the front end circular tale of crankshaft

damper pulley, Turn the crankshaft clockwise to see the TDC mark of the

crank pulley to the pointer, and then bring the No. 1 cylinder to the TDC on

the compression strode in the condition above with the injection pump gear

mark “o” set to the pointer of the check hole install the injection pump

assembly。The two V-shape slots right side are the BTDC14°and BTDC16°

Fig.13 Crankshaft damper pulley

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 Each adjusting screen on the fuel pump has been adjusted well before

leaning the factory do not adjust as one pleases during operating of fuel pump

On the VE pump, mount the CSD cold start solenoid valve and fuel cutting off

solenoid valve.

CSD cold start solenoid valve:

When the temperature sensed by thermosensor of thermostat is less than

0℃, the solenoid valve circuit is in the energized state, solenoid valve body is

drawn back by magnetic force, the main overflow passage is in the disconnect

position, under the action of fuel transfer pump inside pump body of high

pressure fuel pump the pressure in the fuel pump goes up and fuel injection

timing unit starts ahead of time so as to start easily the engine.

When the temperature sensed by thermosensor of thermostat is more than

0℃,the solenoid valve circuit is in disconnect state, and solenoid valve body

is pushed by the valve body spring to the position where the main overflow

passage is energized, and normal overflow of VE pump is realized.

Fuel cutting off solenoid valve:

When it is energized, the valve is sucked, the fuel inlet hole is open, the

fuel comes into fuel pump pressure chamber and high pressure fuel pump is in

the fuel supply state

If you want to stop the engine, only cut off the power supply, under the

action of spring, valve closed the fuel inlet hole and fuel can not come into

pressure chamber, the fuel pump stop fuel supply at once, so the engine stops

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at once.

Fuel injector:

Type P and five holes low inertia fuel injector is used on the 4JB1 engine.

Diameter of orifice is φ0.25.

Fuel injector is a component which is easy to produce the trouble on the

diesel engine, the possible cause is the wear, fuel leakage, needle valve been

seized, injection pressure reduce poor atomization, orifice been blocked up. In

which the wear will lead to the enlarging of fuel out orifice, the fuel can not

form atomization state, like the running water. At this very moment the fuel

injection nozzle should be replaced and fuel injection pressure should be

adjusted.

2.4 Engine electrical system

Engine electrical system is shown in the schematic circuit diagram of 4J

series diesel engine.

Electric generator:

The A.C electric generator with vacuum pump which the IC d.c

integration regulator mechanism is mounted inside is used.

Capacity 14V-70A or 28V-35A

Motor specifications:

Rated voltage 14V

Rated current 70A

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 Rated speed 5000r/min

Adjustable voltage 14.4～15V

Operating speed 900～11000r/min

Rotating direction Clockwise (As viewed back from front)

Polarity Negative ground connection

Working mode Continuous rating mode

Type of regulator IC regulator

Fig.14 Electric generator

1. Regulator 2. Vacuum output pipe

3. Vacuum pump 4. Fuel inlet pipe connector

5. Socket 6. IG switch]

7. Charging relay 8. Magnetic field

9. B armature (terminal) 10.Fuel return pipe

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Vacuum pump specifications:

Working mode Continuous rating mode

Operating speed 900～11000r/min

Max vacuum level 680mmHg

Time for up to 500mmHg of vacuum Below 35s is required at 1000r/min

Vacuum level decrease Below 10s is required at 5000r/min

Stop at 400mmHg Vacuum level decreases by less than 20mmHg after 15s

There is a three core electrical socket and plug on the generator. Refer to

the circuit diagram for the connecting method.

Starter:

Deceleration type starter with low speed and great torque is used. Output

power is 2～2.8kw. Each operating time does not exceed 5s.

There is a plug and copper terminal on the starter.

When engine leaves factory, the starter was fixed on the

rear cover by using of two short dummy bolts, the original long bolts are

placed in the plastic bag in the packing box, they will be used when the gear

shift is mounted.

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 Fig.15 Starter

1. Connect to the start relay switch.

2. Connect to the positive pole of battery.

Starter performance and parameters:

Voltage 12V

Output power 2-2.8kw(optional)

Back rotating direction clockwise as viewed from pinion gear

Tooth number of pinion gear 9

Modulus of pinion gear 2.75

Gear ratio 108/9

Performance without load Voltage 11.5V Current below 120A

back rotating speed over 4000r/min.

.
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3. Engine start, run and stop

To operate the engine correctly is not only to keep engine normal

operating but also to extend the working life of engine.

3.1 Preparation before start of engine

The following items must be checked before start of engine.

3.1.1 Before the new diesel engine starts first time, check carefully to see

that fastening connection of each part is loose, accessories are complete and

control mechanism is flexible.

3.1.2 Check the water level hight of cooling water in the radiator, the

fastening state of water pipe connector and tension of fan belt.

3.1.3 Check the lubrication oil level high in the oil pan.For the new engine

and engine not worked for a long time, the machine oil must be filled to upper

scale of dip stick.

3.1.4 Check the diesel oil level in the diesel oil tank and each pipe and

connector of oil supply system. If leakage is found, repair it.

3.1.5 Check the liquid high of electrolyte in the storage battery.

3.2 Procedure for engine start

3.2.1 Move the speed changing lever of gear box too the neutral

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position.

3.2.2 For the new engine and engine stayed for a long time the air in oil

lines must be exhausted.

3.2.3 Switch off the clutch so as to reduce thee load of engine start.

3.2.4 Turn the switch key clockwise to the start position, so that the starter

pinion gear engages with gear ring of fly wheel and this drive the engine to

start. However, the starting time can not exceed 5 seconds. When the engine is

cold started in winter, the switch key can be turned to pre-heating position,

energize the pre-heating system circuit , then start the engine at once after

pre-heating for 15~30 seconds.

3.2.5 After engine starts, release the switch key immediately so that the key

returns back to working position (45°of angle in clockwise).

If the engine starts for three times(interval for each starting time must be

over 20 seconds), engine still does not turn over, at this moment must find out

the cause, then start the engine again after eliminate the trouble.

3.3 Engine cold start at temperature below than –5℃

Before start the engine at the low temperature, beside the above works to

be done well the engine shall be pre-heated to increase the engine temperature,

so that the machine oil viscosity tends to the normal, crankshaft is easily

rotated and forming of mixed gas in engine cylinder is in good condition.

3.3.1 Assure the engine crankshaft easy rotate.

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In order to easy start the engine in the winter, the winter lubrication oil with

less viscosity shall be used , at the same time, the engine, cylinder block, cy

inder head cover, water pump and more components must be pre-heated so as

to reduce the resistance at engine start.

3.3.2 The procedures for pre-heating engine:

Pour the hot machine oil into engine, after the engine was stopped to operate,

drain the machine oil in the engine immediately, and store the machine oil in

the clean container. When you want to start engine again, heat the machine oil

to 80±5℃ of temperature, then fill into the engine, do not get the machine oil

dirty.

Pre-heat the engine with boiled water, fill the above 90℃ of hot water into the

radiator, drain it through the water jacket after the water became cold, then

reheat the water till the crankshaft can be easily rotated. In the meantime,

pre-heat suitably the water pump with hot water.

3.3.3 In addition to starting of engine according to the above procedure, the

following items must be taken, after engine was preheated.

(1) Rotate the crankshaft several revolutions, check to see that

rotation of crankshaft is normal, at the same time, spray a little of fuel into

cylinder of engine first. Turn off power supply after energizing pre-heat glow

plug for 20 seconds, then start engine rapidly.

(2) After engine started, as the valve of thermostat is closed during

pre-heating and the circulation of cooling water does not go through the

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radiator, in order to decrease the possible cause which cooling water will be

iced in the radiator, try to use hot water and put the wind curtain in front of

radiator.

(3) The engine can be run at low load after starting for 2~3 minutes. It

is not permitted to operate engine at high speed and also not permitted to

operate engine in exceeding five minutes at idling speed.

3.4 Check of engine at running

The following items should be checked often during engine run.

3.4.1 Make sure that there are the noise of strike, loosening and abnormal

working in the parts and components.

3.4.2 Make sure that abnormal burnt smell which the generator or other

electrical equipments produced due to the high heat.

3.4.3 Make sure that there is a leakage situation on the fuel , cooling and

lubricating system.

3.4.4 Make sure that indications of instruments for machine oil pressure, water

temperature, current and diesel oil are correct.

3.5 Engine stop

When the engine is running at great load, if you want to stop the work,

first decrease to low speed and run for 2~3 minutes then turn off the power

supply, and engine stopped. The purpose is to let the engine cooled gradually,

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so as to prevent some parts and components from deformation caused by rapid

cooling.

In the winter season, drain the cooling water away in the engine after

engine stopped.

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4 Engine operation and maintenance

4.1 Points for attention when engine in operated

4.1.1 When you operate the engine, you should make adjustment and

maintenance according to the maintenance methods and each requirement

specified in the instruction.

4.1.2 Check the polarity of storage battery ground, The negative pole ground

must be used on the 4JB1 diesel engine.

4.1.3 Before operate the new engine, run-in must be performed as per

requirements, do not operate the engine at sudden acceleration speed.

4.1.4 Keep the normal water temperature (80±5℃). On the medium travel

speed, the normal machine oil pressure shall be more than 441.3 KPa

(4.5kgf/cm2).

4.1.5 The light diesel oil shall be selected to be fuel for the engine according

to the environmental temperature where the engine is operated.

4.1.6 When the water in the cooling system is drained, the cover of radiator

must be opened first(drain it after water temperature decreased, otherwise the

hot water in and out will cause the scald), then turn on the water drain

threaded plug on the left side of engine.

4.2 New engine run-in

The initial working situation of engine is related greatly to the working

life if engine, the new engine shall be run-in on the truck for 2500 kilometer
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as per run-in specification (see table 1)

Table1 Run-in specification for new engine:

Distance of travel Load Speed of a motor vehicle

(kilometer)

0~200 Unload Not exceed the 50% of

corres-ponding rated speed

of engine.

200~800 Not more than Not exceed the 50% of

50% of rated corres-ponding rated speed

load of engine.

800~1500 Not more than Not exceed the 75% of

75% of rated corres-ponding rated speed

load of engine.

1500~2500 Full load Not exceed the highest

rated speed.

Caution for the new engine running in:

1. Check to see that machine oil、water、diesel oil、electricity and so on are

sufficient and the leakage must be eliminated.

2. The engine crankshaft rotated for several revolutions and then engine

starts.

3. When the engine is fit on the truck for running-in, the truck shall travel on

the level 1 and 2 road. It is not permitted to travel on the bad condition

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 road (especially on the sandy beach).

4. After the truck travels first by 1000 kilometers, the machine oil shall be

replaced and filter element shall be cleaned or replaced. The machine oil

shall be replaced every 3000 kilometers of travel here after.

Fig16. Schematic diagram of lubrication system

1. Battery 11. Idle gear shaft

2. Indicator light 12. Machine oil pump

3. Oil pressure switch 13. Timing gear

4. Cylinder body oil gallery 14. Crankshaft bearing

5. Machine oil filter 15. Connecting rod bearing

6. Filter element 16. Crankshaft bearing

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7. Safety valve 17. Rocker arm shaft

8. Machine oil pump 18. Rocker arm

9. Pressure limiting valve 19. Vacuum pump

10. Throttle orifice

4.3 Maintenance of engine lubricating system

4.3.1 Main data and specifications for lubricating system:

Item Data

Oil pump type Gear oblique

setting type)

Flow ratio(actual lowest displacement) Lit /min 19.9

Pump speed r/min 1000

Outlet pressure kgf/cm2 4

Oil SAE30……

Open pressure of pressure relief valve kgf/cm2 4.3~4.7

Open pressure of safety valve kgf/cm2 0.8~1.2

Rated displacement Lit /min 23

4.3.2 Selection if oil and oil level measurement of oil:

Recommend to use the API CC or CD diesel engine oil.

Universal use in summer SAE 40 (more than 25℃ of temperature)

Use in warm season SAE 30(0~30℃ of temperature)

Winter use in the plateau SAE10W or SAE10W30

Frigid zone:

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 Oil level position if oil in the oil pan is measured with the oil dipstick

mounted on the left side of engine. When the running , the oil level position is

measured, the engine shall stop the running, the oil dipstick is taken out after

the oil level was stationary, and wipe the oil on the oil dipstick with clear

cotton yarn , then put the oil dipstick into oil pan . Make sure that oil dipstick

must be inserted to the bottom of oil pan, and take out the oil dipstick and

check for oil level high.

There are two scale lines on the oil dipstick. Oil level of oil can not be

below lower scale line. If the oil level is below the lower scale line, oil supply

will stop, while it is not proper that oil level exceeds upper scale line, because

the major end of connecting rod will impact the oil level in that situation, to

form the excessive oil spray and splashed oil drop in the crankshaft case, thus

this caused the serious carbon-deposit on the piston top and combustion

chamber wall. In addition, piston ring will be seared due to the coking oil, this

will cause the trouble of smoke and oil leakage of oil sealing produced by

engine. So it must often have taken care of oil pressure and the high of oil level

checked before start to go on road and every 300~500 kilometers of travel

distance.

4.3.3 Replace with mew oil and replace the oil filter elements.

After the oil has been used for a long time, as there is oxidation,

dissipation of additive and contamination of foreign substance, the impurity,

dust and dirt will be produced. As mixing some fuel into the oil, the oil

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becomes thin. The acid anhydride will be brought in at the same time when

the part of exhaust gas intruded into oil, this leads to the deterioration of oil

and corrosion of the parts. So if the oil has been used for a long time, all oil

must be drained away and mew oil will be filled.

If the great number of impurity material deposits in the oil pan, when the

mew engine is run-in, lubricating system shall be cleaned with NO.5 or NO.7

oil (light bobbin oil), is not absolutely permitted to clean with gasoline and

kerosene.

When clean the inner part of engine, fill the 3Litres of NO.5or NO.7oil

into the oil pan, remove the all glow plugs and rotate engine crankshaft with

rocking handle for 2~3mins then drain the cleaning oil quickly.

After replacing with new oil each time, the engine shall be operated for a

while in short time without load, in order to ensure that lubricating system and

positions to be oil supplied can all have the sufficient oil.

When you fill the oil from the oil filling hole on the valve chamber cowl,

the edge of oil filling hole shall be cleaned to prevent from mixing the

impurity material. After oil filling was finished, cover the holes well with oil

filler cap. The filled oil can flow into the oil pan through the push rod hole on

the cylinder head cover and hole on one side of push rod on cylinder head, so

the oil level high of oil can be measured 5 minutes later.

4J series diesel engine is equipped with full flowing oil filter. Before

replace with new oil, turn the oil drain plug on the filter seat to open about

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15mins, drain the engine oil into the engine crankshaft case, wait for several

minutes, then tighten the oil drain plug (shown as Fig.17).

Fig.17 Oil drain pulp

For the replacing of oil filter element and lubrication positions and

intervals of engine. Refer to the maintenance period table. When the new

engine works for 1000 kilometers the oil filter element shall be replaced.

Whenever element is replaced, o-ring and sealing washer must be replaced.

And make sure the mounting direction of element.

Maintenance Period Table

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1: Perform the inspection, calibration and Replacement according to

requirements; A: Adjustment; R: Replacement or changement; I: Cherk、clear、

replacement according to the request. 2: no sign is the same with 4J series

diesel engine;“ ”is the same with 4JB1;“ ”is the same with 4JB1T

and 4JB1TL.

*Mark: If the trucks are used at the bad situations they will be more required

to be maintained often. So the user shall refer to the other manuals such as

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“Maintenance procedures for the trucks to be used at bad situation”.

4.3.4 Recommendatory designations of lubricating oil and diesel oil:

In order to get the super performance and longest wording life for your

4J series engine it is very important to select the proper lubrication oil and

diesel oil

Antifreezing solution for Ethylene glycol type antifreezing

engine cooling system solution shall contain the antirust
additive
Specified fuel type SAE No.2 diesel fuel

Oil viscosity table

〔single grade〕 Eng oil viscosity grade environmental temperature.

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4.4 Maintenance of engine cooling system

When engine is running there must be sufficient cooling Water in the

cooling system in order to ensure the normal Working of engine. So before

start of travel each time, careful check must be done and clean soft Water is

supplemented in time. It is forbidden to use the hard Water which contains

great alkali and very much mineral in the cooling system. Check and adjust

the tension of fan belt under the 68.6-98 N (7-10kgf) of pressure the belt will

subside about 6-8 mm, this will be proper.

4.5 Maintenance of fuel injection pump

4J series diesel engine is equipped with VE type distribution pump .As

VE pump is lubricated with fuel it is very important to keep the fuel clean To

perform properly technical maintenance on the fuel injection pump can

enhance the working life.

4.5.1 Fuel filter’s filter elements shall be replaced with new part every

18000 kilometers of travel.

4.5.2 Often check the sealing of oil lines, carefully check to see that there

are local overheating and abnormal noise.

4.5.3 Check to see that fixing screw of fuel pump loose at condition

which the diesel engine works for 200 hours.

4.5.4 User can not disassemble the fuel injection pump assembly when

concerned test requirements can not be met

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5. Maintenance and repair and adjustment of engine
Torque Specification

(1) Standard bolt (unit : kg f﹒m)

Torque value given in following table is used at time when torque is not

indicated specially.

The bolt with star is used for inner screw of casting iron material

- 41 -
 Bolt 4. 7
materia 9
l 4T 7T 9T
Bolt
(low carbon steel )
(high carbon steel) (Alloy steel )

M6×1.0 0.4-0.8 0.5-1.0

M8×1.25 0.8-1.8 1.2-2.3 1.7-3.1

M10×1.25 2.1-3.5 2.8-4.7 3.8-6.4

* M10×1.5 2.0-3.4 2.8-4.6 3.7-6.1

M12×1.25 5.0-7.5 6.7-9.3 7.7-11.6

* M12×1.25 4.6-7.0 5.8-8.6 7.3-10.9

M14×1.5 7.8-11.7 9.5-14.2 11.6-17.4

* M14×2.0 7.3-10.9 9.0-13.2 10.9-16.3

M16×1.5 10.6-16.0 13.8-20.8 16.3-24.5

* M16×2.0 10.2-15.2 13.2-19.8 15.6-23.4

M18×1.5 15.4-23.0 19.9-29.9 23.4-35.2

M20×1.5 21.0-31.0 27.5-41.3 32.3-48.5

M122×1.5 25.6-42.2 37.0-55.5 43.3-64.9

M24×2.0 36.6-55.0 43.9-72.5 56.5-84.7

- 42 -
(2) Non standard bolt (unit : kg﹒m)

Fixed bolt for cylinder head cover 0.8-1.8

Fixed bolt for rocker arm bracket 5.0-6.0

Adjustable bolt for valve gap 1.6-2.0

Bolt for cylinder head 10-11

Fixed bolt for exhaust manifold 1.4-2.4

Fixed bolt for inlet pipe 2.8-4.8

Fixed bolt for water outlet pipe 1.4-2.4

Fixed bolt for water inlet pipe 1.4-2.4

Fixed bolt for bearing cap 16-18

Fixed bolt and nut for oil pan 1.4-2.4

Fixed bolt for post plate 7.6-9.2

Fixed bolt for oil pump 1.4-2.4

Fixed bolt for oil filter 1.4-2.4

Fixed bolt for water pump 1.5-2.5

Fixed bolt for timing gear chamber 1.5-2.3

Fixed bolt for timing gear 10-12

Fixed bolt for thrust plate or camshaft 1.5-2.3

Fixed bolt for idler B 10-12

Bolt for connecting rod 8-9

Fixed bolt for damping pulley 17-27

Fixed bolt for fly wheel 11.5-12.5

- 43 -
Nut for high pressure oil pipe 2-4

Nut for clamp plate or full injector 3.2-4.4

Adjustable nut for front bracket of fuel injection pump 1.7-2.3

Screw for carrier frame of fuel pump 1.4-2.4

Fixed nut for gear of fuel injection pump 6-7

5.1 Disassembling of cylinder head bolt and cylinder head

In order to prevent the cylinder body gasket of engine from air leaking

and water leaking. When the new truck travels for 500 kilometer and 1000

kilometer, check the tighten moment force of cylinder head bolt with torque

wrench, the tighten moment of force shall be 80.4~90.2 Newton. meter

(8.2~9.2 Kg. m). For the disassembly engine ,the tighten moment of force

shall be 10-11kg﹒m. Tighten the bolt after engine was cooled.

When the cylinder head must be dismounted in order to remove the

carbon deposit (truck travels every 16000 kilometer) or to dismount the piston,

drain the water deposit in the cooling system away. Dismount the connection

parts to cylinder head (It is not necessary to dismount the inlet and exhaust

manifold) and screw the cylinder head off stably. Be careful not to damage the

two mating faces lf cylinder head and cylinder body to avoid affecting the

sealing .At the same tine ,check the cylinder head for the crack or deformation,

and check the cylinder head gasket for damage and crack.

5.2 Check and disassemble inlet and exhaust manifold

- 44 -
 After the truck traveled for 1000 kilometers, check the inlet and exhaust

manifold as follows:

1. Check to see that the nut each position is loose.

When tighten the nut of inlet and exhaust manifold, the torque shall be

even, otherwise it win cause the air leakage.

2. Check to see that there are cracks and opening or hole on the inlet and

exhaust manifold, and check the gasket for damage or corrosion.

5.3 Clean and check oil pan and filter

To check the oil pan for oil leakage shall be performed at the time when

engine is running at warm engine state. If there is a leakage appearance

tightened the relevant position nut. If the leakage is still not eliminated,

remove the oil pan and check or replace the oil pan gasket.

In order to prevent from blocking and affecting the lubrication and

filtering effect, clean periodicity the oil connection filter.

5.4 Cleaning machine oil filter

After truck traveled every 18000 kilometers, replace the oil filter’s filter

elements. The limited pressure in the pressure limiting valve of oil filter is

441±20Kp (4.5±0.2kgf/cm2). Before the engine is delivered the pressure

limiting valve of oil filter has been adjusted well, so do not dismount and

torch it in normal situation. When dismount and assemble the oil filter, make

- 45 -
sure that rubber seal ring was fit correctly, to avoid causing oil leakage due to

poor sealing.

5.5 Valve clearance adjustment

More or less valve clearance would influence whether engine is running

normally, and also influence the dynamic characteristics and economy. So

often pay attention to the variation of valve clearance, and it is necessary job

to perform inspection and adjustment of valve clearance at right time in

accordance with above methods and requirements.

First check the bolt of rocker arm bracket, and tighten it to the specified

torque of 5~6kgf.m. Rotate the crankshaft clockwise to make the piston of

No.1 cylinder to locate at top dead center of compressed stroke, adjust the

1,2,3,6 valves numbered from front and adjust correspondingly the clearance

to specified value in order. Rotate crankshaft one circle, so that No.4 cylinder

located at top dead center of compressed stroke, then adjust correspondingly

the 4,5,7,8 valves.

Fig.18 Adjustment of valve clearance

- 46 -
5.6 Caution for engine mount

1. There is a facing front “-”notch mark on the piston top, be sure not to

install it in reversal.

2. One side with protrusive word on the rod portion of connecting rod is

towards front n and one side with boss on the connecting rod bearing

is towards front.

3. The arrow mark on the main bearing cap shall point to the front.

4. Main bearing with oil slot is upper bearing.

5. The first step of piston ring is of barrel, the side with “TOP” or “O”

mark is a facing up. One side with notch on second step of piston ring

is a facing down.

6. The oil hole on the idler a shaft must be on the above when engine

installed.

7. The fitting mark X.Y.Z and V of timing gear shall be aligned

respectively.

8. Install the cylinder head gasket with mark “TOP” facing up, and

“FRONT” facing front.

9. Before install the oil pan , coat the No.5 main bearing cap and mating

parts of bottom of timing gear chamber and oil pan gasket with 587,

silicone jelly and room temperature cured silicon rubber so as to

increase sealing performance.

10. When install the valve spring, one end with small pitch and stamped

- 47 -
 pink mark is a facing down.

Service standard and service limit for main easy

damaged parts of 4JB1 engine

unit (mm)
Part Name Standard Limit
Contact width of valve to
valve seat insert
Inlet valve 1.7 2.2
Exhaust valve 2.0 2.5
Valve depression
Inlet valve 0.73 1.28
Exhaust valve 0.70 1.20
15°
Valve cutter angle 45°
45°

Diameter of valve stem

Inlet valve 7.946-7.961 7.88
Exhaust valve 7.921-7.936 7.85
Valve clearance 0.039-0.068 0. 2
Exhaust clearance 0.064-0.096 1. 0.25
Free height of valve spring 48.0 47.1
Squareness of valve spring 1.7
Outside diameter of idler 440945-44.975 440845
A shaft
Inside diameter of idler 45.00-45.03 45.10
A bearing
Clearance 0.025-0.085 0.02
Cylinder liner inside 93.021-93 93.01
diameter 0-0.1
End height of cylinder liner
from cylinder block
Piston diameter
Group A 92.985-93.994
Group B 93.995-93.004
Group C 93.005-93.014
Group D 93.015-93.024
Clearance between piston 0.025-0.045
and cylinder liner

- 48 -
Piston ring gap 1.5
1 st-2 nd 0.2-0.4
0：1 ring 0.1-0.3
Piston ring clearance
1 st ring 0.09-0.125 0.15
2 nd ring 0.05-0.075 0.15
0：1 ring 0.03-0.07 0.15
Tappet outside diameter 12.977-12.99 12.95
Oil clearance between tappet 0.03 0.10
And cylinder body
Push rod run out 0.3
Rocker shaft run out 0.3
Rocker shaft run outside 18.98-19.00 18.90
Diameter
Clearance between rocker 0.1-0.05 0.20
arm and rocker shaft

Camshaft end play 0.05-0.11 0.20

Journal diameter of camshaft 49.945-49.975 49.60
Cam lobe height 42.08 41.65
Camshaft bearing inside 50.00-50.03 50.08
diameter
Camshaft bearing 0.05 0.12
Clearance
Camshaft bearing run out 0.02 0.10
Piston pin diameter 30.995-31.00 30.97
Piston pin hole 31.002-31.010
Clearance between piston 0.002-0.015
Pin and pin hole

Connecting rod thrust 0.230 0.35

clearance
Clearance between piston pin 520915-52.930 52.906
and connecting rod bushing
Rated diameter of connecting 53
Rod bearing hole
Crankshaft journal and 0.029-0.066 0.10
bearing clearance
Main journal 69.92-69.93 69.91
Main journal and main 0.035-0.080 0.11
bearing clearance

- 49 -
6. Troubleshooting of engine

6.1 Hard starting

If the start power is enough, compression force is enough to high,

preheating system works normally and fuel quantity is also normal, the engine

should easy start without trouble of hard starting.

When check the engine for hard starting, first dismount the fitting of full

injection nozzle end, and check to see that fuel has flowed through. In some

cases, it is necessary to check the fuel injection condition of fuel nozzle and

fuel injection timing. When no fault was found after performed these check. It

is required to measure the compression pressure, so as to confirm the

operation situation of valve and piston ring.

A1 though the engine can start, it stopped immediately after starting and

can not restarts, this is possibly caused by the fact which the air is mixed into

fuel system.

Start performance of engine will be affected more or less by the

environmental temperature.

- 50 -
 Hard starting

Check the fuel level of fuel in the fuel tank with fuel gauge

Check to see that notch line of fuel injection pump flange is aligned correctly

Check to see that fuel come up to the fuel injection nozzle

Yes No

Connection of fuse, glow plug

Check the operation of Check to see that air in the
and glow plug relay
preheating loop fuel filter is drained
completely

Check the fuel injection Fuel spray form, fuel

nozzle injection opening puessure: Check to see that air
18.1MP (185kgf /cm2 ) enters into fuel line from
leakage area of fitting

Inlet valve：0.4mm Exhaust Check the working condition

Check the valve clearance
valve：0.40mm of fuel cut solenoid valve

Check the throttle

condition fuel line
Rated value: 3MP
Check the compressed
(31kgf/cm2)
pressure of cylinder
Value pressure is required Check the throttle
for working: 2.2~2.3MP condition of fuel fitter
(22~23kgf/cm2) element

Check the compressed Rated valve ： 3MP(31kgf/ Check the throttle condition
pressured cylinder cm2) pressure valve is of fuel fitter element
required for
working:2.2~2.3MP
Check the throttle condition
(22~23kgf/ cm2)
of fuel line

- 51 -
Check to see that there is a
defect for timing gear system
Check the timing gear Check delivery valve for
seizure

Replace or adjust fuel pump

6.2 Unstable idling

The engine unstable idling may cause the engine surging and rapid

deceleration and stop. If engine runs normally at medium and high speed, first

check the fuel injection pump and related parts then check the engine idling.

Engine speed is unstable probably the reason is too low idling. Fuel

injection pump plunger works unstably and delivery valve bracket was

screwed too tight.

When rapid deceleration and stop of engine occurred probably idling setting is

too low.
Engine unstable idling

Check to see that idling is lower the specified value

Check the quick idling control device of vehicle with air conditioner

Check to see that quick speed control cable is twisted

Check to see that acceleration rod is loose

- 52 -
Check to see that air and water was drained off from fuel filter
 6.3 Insufficient power

Engine insufficient power is probably caused by the insufficient fuel

injection quantity, insufficient air intake quantity and insufficient compression

force. If the trouble is caused by the insufficient fuel injection quantity, check

to see that fuel filter element is clogged and air is in the fuel system.

If no abnormality is found after above checking was made, check the fuel

injection pump and speed regulator further with fuel injection pump tester.

When air intake quantity is insufficient, check to see that air cleaner filter

element is clogged and exhaust pipe is clogged

Engine in sufficient power

Check to see that air cleaner is clogged

Check to see that acceleration control cable is twisted

Check the maximum speed stop screw and full load adjusting screw for seals

Check to see that acceleration control lever contact with the maximum speed stop screw.

Check to see that exhaust manifold and pipes are clogged

Check to see that air in the fuel filter is completely drained

- 53 -
 Check to see that fuel pipe is twisted and fitting is blocked

Check to see that vent hole of fuel tank is clogged

Check to see that used fuel is a poor quality of fuel

Fuel injection form. Fuel

Check fuel injection
Check fuel injection injection starting pressure
timing
nozzle 18.1MP(1.85 Kgf/cm2)

Inlet valve: 0.40mm

Check each cylinder for Check valve
Exhaust valve: 0.40mm
Compression force clearance

Rated value: 3MP (31Kgf/cm2)

Value to be required in the working:
2.2~2.3MP(22~23 Kgf/cm2)

Check to see that delivery

Adjust and replace fuel injection pump
valve is seized

6.4 Dark or white exhaust smoke

Excessive fuel injection volume insufficient air intake volume, poor fuel

injection condition, advanced fuel injection timing and fuel not complete

burning resulting in the engine great number of dark exhaust smoke.

When find out the cause, first check the fuel injection pump for seal,

compression pressure, air cleaner and fuel injection nozzle spray conditions,

check the fuel injection timing.

- 54 -
 Abnormal exhaust smoke

Check to see that engine is sufficiently warmed

Check to see that air cleaner is clogged

Check to see that the air and water in the fuel filter are completely drained away

Check the full load adjusting screw for seal

Check to see that exhaust manifold pipes are blocked

Check to see that used fuel is poor quality of fuel

Check the fuel injection timing

Fuel injection spray condition.

Check fuel injection nozzle
Fuel injection starting
pressure:18.1MP(185kgf/cm2)

Check the valve clearance Inlet valve:0.40mm

Exhaust valve:0.40mm
Check each cylinder for
compression pressure Rated value:3MP(31 kgf/cm2)value of
work to he required:(22~2.3MP)

Check to see that timing gear is Installation of timing gear

defective

Check valve guide and seal Check to see that valve is seized
condition

Adjust or replace the full injection pump

- 55 -
6.5 Overheating

When you find out the cause of engine overheating, you must make sure

that it is really engine overheating or defective temperature meter indication.

In order to find out the real cause, measure the cooling temperature of

engine coolant on the top of radiator and compare the measured value with the

indication value of temperature meter on the instrument panel, thus check to

see that temperature meter indication is accurate.

Engine overheating

Check the radiator for level of coolant

Check the cooling condition Contamination of coolant ,content of

anti-freezing fluid and oil leaking into
the coolant

Check to see that the hose is leakage

Hose deteriorated and snap ring loose

Check to see that water pump is leakage

Check to see that cylinder bead and cylinder body sealing cap were damaged

Finger pressed flexibility: about 10 mm

Check the fan belt

Check the fan clutch for working condition

- 56 -
Check to see that the water filling port cover of radiator worked normally

Check the thermostat for working

condition

Check fuel injection timing

Check fuel injection nozzle Fuel injection form injection starting

pressure: 18.1 MP (185kgf/cm2)

Check the water pump impeller

Check the oil quality in the engine

Check to see that carbon deposit is in the Adjust and replace the fuel injection pump
combustion chamber

After finding out the cause from following checkpoint and start the items

which is easy to be checked.

The general reason caused engine overheating is listed as follows in the

light of more or less possibility:

As the cold water leakage in the water pump, radiator and hose,

defective thermostat and unstable water flow in the water line occurred, this

reduced the cooling capability.

Sealing cap damaged causing air into cooling water circulation loop ,

over fuel injection volume, uncorrected fuel injection timing ,carbon powder

- 57 -
 deposit in the combustion chamber and so on , are all considered as the causes

of engine overheating.

6.6 Abnormal engine noise

Abnormal engine noise covers the knocking noise and slapping noise.

Abnormal engine noise

Engine slapping Gas leakage noise Continuous noise Knocking noise

Check to see that Loosely connected

Fan belt finger Valve clearance inlet
the engine has exhaust pipe or
pressed valve:0.4mm,
been thoroughly leaked exhaust pipe
Flexibilit: about Exhaust valve:0.4
warmed up
10 mm mm

Check fuel infection

Check fuel injection Loosen cooling fan Defective and
nozzle and glow plug
timing damaged rocker
for installation
arm

Fuel injection nozzle Check to see that Check to see that Check to see that
cylinder body water pump bearing fixing bolt of
Proper injection nozzle sealing cap was was worn or damaged flywheel was
spray condition .Full damaged worn or damaged
injection starting
pressure:
18.1MP(185kgf/cm2)

Check each cylinder

Check valve for Check the generator Check see that
block for compression
clearance and vacaum pump for crank shaft and
force
Working condition thrust bearing were
Inlet valve:0.40mm
Rated worn or damaged
Exhaust
value:3MP(31kgf/cm2)
vaeve:0.40mm
value to be required in
theworking:2.2~2.3MP - 58 -
22~23(kgf/cm2)
 Check each cylinder Check valve for
block for clearance
compression force
Check the main
bearing for clearance

Check the connecting

Inlet valve:1.40mm
rod bushing for
Exhaust
clearance
valve:0.40mm

` Check the connecting

rod bearing for
clearance

Check the clearance

between piston and
cylinder wall

Engine knocking noise is caused by the fuel quick combusting, and

mainly caused by the fact which fuel injection timing is too fast or fuel

injection spray condition is bad.

After engine starting Knocking noise occurred immediately with

increasing of engine temperature.

When engine continuous noise occurred, it is required to perform

checking of each system so as to determine the noise source. If the noise

comes from the accessory such as generator, water pump and so on, it is

eliminated by means of removal of bolt, So that it is more convenient to check

the engine noise.

If engine slapping noise occurred, for example piston slapping noise,

piston pin and connecting rod bearing noise from cylinder block, unscrew the

fitting of fuel injection pipe in orders and cut off fuel flow inspection.
- 59 -
 The noise from engine crankshaft can be checked by means of operating

step of clutch down and up.

If the noise is caused by the crankshaft movement, when operate clutch,

the noise will variety.

6.7 Excessive oil consumption

The main reasons for excessive oil consumption are the oil leakage out,

oil combustion and piston oil leaking. These possible causes can be directly

inspected with eyes.

Excessive oil consumption

Oil leakage Oil combustion

Check the oil for level Check the oil quality inside engine

Check to see that drain cock is Check valve rod for sealing
loose

Check to see that oil pipes is Check to see that valve guide and
leakage valve rod are worn

Check to see that sealing fixed Check to see that cylinder body
unit and oil filter seat sealing sealing cap was damaged
gasket were leakage

Check piston ring for installation

Check to see that forced vent valve of
crankshaft box and forced ventilation
system one-way valve of crank shaft
box were worn or leakage
- 60 -
 Check to see that piston ring was
seized

Check to see that cylinder head rubber

Check to see that piston ting was
sealing cap. Oil pan and oil pump for oil
worn
were leaked

Check to see that piston ring

Check to see that cylinder head
groove on t he piston was worn
cover was leaked

Check to see that cylinder wall

Check to see that sealing was leaked
was worn or scratched

In order to make sure of oil combustion or oil leakage through piston,

you can start the engine, and operate the engine at idling speed for several

minutes, then dismount cylinder head cover for inspection. If it is oil

combustion, there should be the trace around piston. If it is inner leakage,

normally there is the oil trace around valve head and there is the carbon

deposit.

6.8 Excessive fuel consumption

Before perform checking of engine according to the trouble shooting

procedures, be sure of that how great fuel consumption the vehicle has at what

kind of driving conditions, because fuel consumption rate will change with

combination situations of driving customs, vehicle loading and roads to a

great extent.

- 61 -
 Excessive fuel consumption

Check to see that air cleaner is blocked

Check to see that full load adjustable bolt sealing is in

good condition

Check to see that fuel pipe is leaked

Check to see that the exhaust manifold and pipes are clogged

Check the engine for idling speed

Check to see that used fuel is poor quality of fuel

Check the fuel injection timing

Fuel injection spray condition, fuel injection

Check the fuel injection nozzle starting pressure: 18.1MP(185 Kgf/cm2)

Inlet valve: 0.40mm

Check valve for clearance
Exhaust valve: 0.40mm

Check the each cylinder block Rated value:3MP (31 Kgf/cm2)

for compression force Required value in the work:
2.2~2.3MP (22~23185 Kgf/cm2)

Check to see that delivery valve is seized

Adjust or replace the fuel injection pump

- 62 -
 First check to see that air cleaner and exhaust manifold are blocked, then

check to see the compression force of cylinder block is correct, perform the

road driving test so as to inspect whether engine works normally and

acceleration is normal or not.

If the road driving test is acceptable, the trouble probable is in the fuel

system.

For the working condition of fuel system, the fuel injection nozzle tester

shall be used for checking the fuel injection spray condition and fuel injection

starting pressure.

6.9 Engine lubrication system common trouble and correction method

Refer to the tables for engine lubrication system common trouble,

possible cause and correcting method.

Lubrication system common trouble ,cause and correction:

- 63 -
Trouble Possible cause correction
Excessive Unacceptable oil was used . Drain unacceptable oil away
Oil fill the specified oil.
Consumption One –way valve in the crank Clean or replace one-way
Volume shaft case. valve.
volume Ventilation system was leaked.
Defective oil seating gasket. Repair
Worn piston ring or ring groove. Replace piston ring or piston
Piston ring seizure Replace piston ring or piston.
Worn valve rod sealing valve Replace oil sealing cap ,valve
guide and valve rod. or valve guide.
Worn cylinder liner Replace the cylinder liner.
Insufficient oil Unacceptable oil was used Drain the unacceptable oil
pressure away ,fill the specified oil .
Safety valve seizure Replace safety valve.
Clogged screen filter of oil Clean or replace the screen
pump . filter.
Replace oil pump assembly.
Worn driving and driven gear of
oil pump. Repair or replace
Broken, splited oil pipe or loosen
Connectors. Replace oil pump assembly
Defective oil pump Replace
Excessively worn crankshaft
bearing and connecting rod
bearing. Repair or replace
Defective ail pressure gauge and
defective sensor

Oil quick Clogged oil filter. Replace filter element replace

consumption Gas leakage. piston ring and cylinder liner.
Unacceptable oil was used Drain unacceptable oil off, and
fill the specified oil.
Oil not enter into Clogged oil hole on the cylinder Clean or repair
valve system head ant cylinder head cover

Clogged oil hole on the rocker Clean or repair

arm shaft

Clogged oil hole on the rocker Clean or repair

arm shaft support

Clogged oil hole on the rocker Clean or repair

arm

- 64 -
6.10 Engine cooling system trouble and correction method

Refer to the table 4 for the engine cooling system trouble, possible cause

and correction method.

Cooling system trouble, cause and correction:

- 65 -
Trouble Possible Cause Correction
Cooling water level too low Replenish cooling water.
Engine overheating If leakage occurred.
Pressure spring force of Repair it as per
radiator cap weak requirement.
Loose or broken fan belt Replace water port cap
Slopped fan belt assembly
Faulty thermostat Adjust or replace fan belt
(Valve not open) Replace fan belt
faulty water pump Replace thermostat

Scale accumulation Replace water pump

causing water line clogged. assembly
Fuel injection timing not Clean radiator and water
correct line.
Clogged radiator element
Worn cylinder head cover Fuel injection timing
sealing cap properly adust
Causing gas leaked into Clean radiator
water jacket Inspect cylinder head
cover and replace
Sealing gasket

Engine too cold Faulty thermostat (valve Replace thermostat

not closed completely)
Often to replenish cooling Leakage of radiator. Repair or replace.
water is required Loose hose connector of Tighten the snap ring or
radiator and damaged replace hose.
hose. Repair of replace water
Radiator cap valve spring filling port cap assembly.
tension force weak. Replace water pump
Water pump leakage assembly.
Tighten or replace hose
Loose hose connector of
warmer or damaged hose. Inspect cylinder head
Cylinder head cover cover and replace sealing
sealing cap leaked. cap.
SPlited cylinder head cover Replace cylinder head
and cylinder block cover or cylinder block
Cooling system noise Faulty water pump Replace cylinder head
bearing cover or cylinder block
Tighten or replace fan
Loose or bent fan fixing assembly
Replace fan assembly
Unbalanced fan Replace fan belt
Faulty fan belt - 66 -
6.11 Electricity system trouble diagnosis
1). Problems when the water temperature of engine is 0℃ or 0℃below:
Condition Possible cause

Glow plug relay will Bad connection of FLW between battery and starter.
not be lit Bad connection or disconnection of starter SW circuit.
Bad connection or disconnection of
Fuse No.8 , Malfunction of other circuits occurred
simultaneously.
Faulty starter switch
Bad connection of glow plug relay terminal
Disconnection of glow plug relay excitation coil.
Disconnection of circuit between glow
Plug relay and timer.
Faulty glow plug relay (the main contact does not pass
electricity).
Bad connection of timer.
Faulty timer
Bad earth circuit of timer
Faulty thermostat switch .(It remains on even in water
temperature below 0℃ ).
Earth short –circuiting of thermostat SW.
Through glow plug Bad connection of FLW between battery and glow relay.
relay turns ON, Bad connection or disconnection in preheating circuit of
preheating is not done. glow relay main contact terminal connector.
Bad connection between connector and preheating circuit.
Glow plug relay turns Bad timer.
ON ,but does not go Bad timer. Short circuiting in circuit or earth between 5
OFF terminals and glow relay.
Faulty glow plug relay.
Indication lamp is not Bad timer
lit. Burning-out of light bulb.

2).problems when the water temperature of the engine is 0℃or above:

Indicator lamp is not Bad timer
lit Burning-out bulb.
Turn glow relay ON Defective thermostatswitch or disconnection of thermo SW
circuit (Glow plug timer indicator will light for 15 second,
and QOSII timer indicator will light for 3.5 seconds.)
Defective timer.
Short-circuiting in circuit or earth between terminals 5 and
glow relay.

- 67 -
 3).Burning-out of glow plug:

When only one line is burned out, it has on effect on the start up of the

engine. Even if one line is burned out, judging from the characteristics of

glow plug, the impressed voltage will change only slightly. Therefore, no

judgment can be made by normal testing while the glow plug is installed. In

order to check for disconnection and burn-outs, the glow plugs will have to be

removed from the connectors and checked one by one for continuity.

4).Charging and noise problems:

Battery is not charged

Check the terminal and connector

Disconnection or
Terminal and connector are
faulty
normal

Repair
Check earth condition
of parts

Bad earth Good earth

Check the brush and

Repair
sliding ring for
contacting

Poor contact of brush Good contact of brush

with sliding ring

Repair or replace Check stator coil

- 68 -
Disconnection or Stator coil is normal
burning-out of coil

Repair or replace Check rotor coil

Disconnection or Rotor coil is normal

burning-out of coil
Check diode
Repair or replace

Diode is normal
Failure Check the stabilizator

Failure
Replace
Replace

Overcharging of battery

Check B and F terminal circuit

Short-circuit Terminal circuit is normal

Check the stabilizator

Stabilized voltage is too high

Adjust or replace

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 Battery in the charging

Check the terminal

Loose connector Terminal is normal

Tighten Check V belt

Slipping V belt is normal

Adjust or replace
Check contact of brush with slip
ring

Bad contact of brush with Contact of brush is

slip ring normal

Repair replace brush frame

assembly
Check rotor coil

Short-circuit
Rotor coil is normal

Repair or replace

Check stator coil

Disconnection or
Stator coil is normal
short circuit of coil

Check diode
Repair or replace

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 Failure Diode is normal

6.12 Turbocharger

1) Engine has less than normal power

Checkpoint Trouble Cause Countermeasure

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2) Blue or black smoke

- 72 -
- 73 -
3) Excessive oil consumption

- 74 -
4) Excessive turbocharger noise

- 75 -
- 76 -
5) Excessive rotating part wear

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