——YNCR Series Electronic Control High-pressure Common Rail Diesel Engine

Contents
Introduction ....................................................................................................... III
Chapter I Main Technical Specification and Data for Electronic Control
High-pressure Common Rail Diesel Engine .................................. 1
(I) Main technical specifications................................................................... 1
(II) Specification of main accessories............................................................. 2
(III) Main technical data ................................................................................. 5
(IV) Main part size, fit clearance and abrasion limit ......................................... 6
Chapter II Disassembly of Diesel Engine......................................................... 9
(I) Maintenance requirements and attentions for engine ................................. 9
(II) Disassembly of engine assembly.............................................................10
(III) Disassembly of engine assemblies ..........................................................10
Chapter III Assembly of Diesel Engine ........................................................... 20
(I) Assembly of body ..................................................................................20
(II) Assembly of crankshaft, flywheel and clutch...........................................21
(III) Assembly of piston-connecting rod assembly ..........................................23
(IV) Assembly of camshaft and oil pump .......................................................25
(V) Assembly of gear chamber, fuel pump, oil pan, timing driving system ......26
(VI) Assembly of cylinder head part...............................................................27
(VII) Assembly of accessories .........................................................................31
(VIII) Installation, use and maintenance of electronic control high-pressure
common rail system ........................................................................................32
(IX) Assembly and adjustment of engine assembly .........................................52
Chapter IV Maintenance and Check of Diesel Engine ....................................... 53
(I) Body assembly.......................................................................................53
(II) Cylinder head part..................................................................................55
(III) Valve mechanism ...................................................................................56
(IV) Crankshaft, flywheel and clutch parts......................................................58
(V) Piston and connecting rod assembly........................................................60
(VI) Driving wheel system.............................................................................62
(VII) Lubrication system.................................................................................62
(VIII) Cooling system ......................................................................................64
(IX) Electronic control common rail system ...................................................65
(X) Electrical system....................................................................................66
I
 (XI) Intake and supercharging and intercooling system ...................................67
Chapter V Use of Diesel Engine.......................................................................... 74
I. Diesel oil ...............................................................................................74
II. Oil.........................................................................................................75
III. Coolant..................................................................................................76
IV. Starting of diesel engine .........................................................................77
V. Breaking-in of diesel engine ...................................................................77
VI. Running of diesel engine ........................................................................78
VII. Stopping of diesel engine .......................................................................78
Chapter VI Maintenance of Diesel Engine ......................................................... 80
1. First breaking-in mandatory maintenance................................................80
2. Regular mandatory maintenance .............................................................80
3. Routine maintenance..............................................................................82
4. Technical maintenance for using in winter...............................................83
Chapter VII Fault Diagnosis of Diesel Engine.................................................. 84

II
 Introduction
"Yunnei" brand YNCR series China III electronic control diesel engine is the new generation of diesel
engine suitable for light vehicle independently developed by adopting electronic control high
pressure common rail, supercharging intercooling, cylinder direct injection and other advanced
technologies, to further enhance the spare part and optimize the performance of diesel engine, and
meet the latest national environmental protection and emission regulation (China III) on the basis of
100 and 102 series supercharging and intercooling diesel engine. Characterized by low fuel
consumption, low noise, good acceleration performance, high reliability, low emission and
convenient use and maintenance, it's the ideal mating power for 2-3.75-ton truck and 19-25-seat
passenger car.
This Manual introduces main technical parameters, structure, principle, use, maintenance and
troubleshooting knowledge for YNCR series electronic control high-pressure common rail diesel
engine, which can be the basis for use, repairing and maintenance of the engine. Photos, pictures and
parameters in the Manual are only for reference, and actual object should be followed.
YN4EL089-33CR series engine belongs to 33CR series. Please refer to 33CR in this Manual for
repairing. There are several engine configurations and the main difference is the rated speed.

III
 Chapter I Main Technical Specification
and Data for Electronic Control
High-pressure Common Rail Diesel Engine
(I) Main technical specifications
TABLE I.
Model YN33CR-3 YN33CR-4 YN33CR-5 YN33CR-6 YN38CR-2
Direct injection, water cooling, four-stroke, supercharging and intercooling,
Type
high-pressure common rail
Cylinder number
x diameter x 4×100×105 4×102×115
stroke
Total
displacement L 3.298 3.76
of piston
Cylinder sleeve
Wet
type
Combustion
Direct injection
chamber type
Suction mode Supercharging and intercooling
Compression
18:1
ratio
Minimum
no-load stable 800
speed r/min
Maximum
no-load stable ≤3520 ≤3300
speed r/min
Rated
power/speed 79/3200 93/3200 73/3200 84/3200 95/3000
kW/r/min
Maximum 275 323 255 295 380
1
 Model YN33CR-3 YN33CR-4 YN33CR-5 YN33CR-6 YN38CR-2
torque/speed /1800-2200 /1800-2200 /1800-2200 /1800-2200 /1800-2200
N·m/r/min
Min. fuel
consumption ≤222
rate g/kW·h
Fuel-oil
consumption ≤0.2
ratio %
Working
sequence of 1-3-4-2
cylinder
Rotation
direction of Clockwise (from front of diesel engine)
crankshaft
Type of
Pressure and splashing mixed mode
lubrication
Cooling Method Forced circulation water-cooling
Oil capacity L 9.5 or 6.8
Stack Emission China III
Net mass kg 320-380 340-400

(II) Specification of main accessories

TABLE II.
Attachment Name Accessory specification
High-pressure Type In-line high pressure common rail pump
fuel pump Model CB18
High-pressure Type Hot forging rail
oil rail Model HFR-16
Type Electronic control type
Fuel injector
Model CRI 2.0
Type Paper filter element rotation type
Diesel oil filter
Model CUF0022
Oil-water Type Paper filter element rotation type

2
 Attachment Name Accessory specification
separator Model CUW0017, CUW0033
Type Paper filter element rotation type
Oil filter
Model JX0814D
Type Centrifugal
Water pump
Rated flow 180L/min, lift of 7m
Type Gear Pump
Oil pumps
Rated flow ≥ 48L/min (1500r/min)
Type DC deceleration
START
Model and
MOTOR QDJ2508 (24V/4.5kW)
Spec.
Type Silicon rectifier
Charging
Model and
generator JFWZ29 35A/28V
Spec.
Glow plug Model LM100-24V
Type Wax thermostat
Thermostat
Temperature Initial open 76±2℃, full open 86±2℃
Type 7PK poly V-belt
Fan Belts
Spec. 7PK1295, 7PK1320, 7PK1405, 7PK2165, 7PK2400, etc.
Technical Parameters for Main Parts of Electronic Control System Table III
Nominal voltage V 24
Operating voltage range V 8-32
Working ambient temperature ℃ -40-70
ECU
Maximum temperature inside ℃ 105
Atmospheric pressure
kPa 50-115
measurement range
Operating voltage V 5±0.15
Water temperature
Thermosensitive 20℃ kΩ 2.5±0.15
sensor
resistance 100℃ kΩ 0.186±0.004
(TF-W)
Working temperature ℃ -40-130
Crankshaft Coil resistance Ω 860±86 (below 20℃)
position sensor Working clearance of sensor mm 0.5-1.5
Camshaft position
Working temperature ℃ -40-150
sensor (DG6)

3
 Rated pressure MPa 140
Working temperature ℃ -40-120
Oil rail Maximum installation axial force kN 21
Working voltage of rail pressure
V 5±0.25
sensor
Intake temperature Operating voltage V 5±0.25
pressure Working temperature ℃ -40-130
Sensor
Pressure Range kPa 20-250
(LDF6T)
Rated voltage, V 24
Electric heating
Running current (20s) A 1.2-3.5
plug (LM100-24V)
Cold resistance Ω 1.3-4.0
Operating pressure MPa ≤0.2
Working temperature ℃ -40-120
Rated flow L/h 300
Voltage of water level sensor V 24
Oil-water separator Resistance of water level sensor kΩ 560±5.6
Filter element inlet and outlet
kPa 10 (rated flow)
pressure difference
Rupture pressure MPa ≥1
Oil-water separation efficiency ≥95％
Operating pressure MPa ≤0.2
Rated flow L/h 300
Diesel oil filter Filter element inlet and outlet
kPa 15 (rated flow)
pressure difference
Filter precision and efficiency 3-5μm；≥95.5％
Rated speed r/min 2000
Fuel injection Fuel supply of each cycle /rev 791
pump Rated rail pressure bar 1400
Direction of rotation Clockwise (from front end)
Working ambient temperature ℃ -30-120
Fuel injector
Flow cm3 450 (at 10MPa pressure, 30s)

4
(III) Main technical data
1. Valve timing (calculated by crankshaft rotation angle) Table IV
Intake valve open (BTDC) 33°
Intake valve close (ABDC) 55°
Exhaust valve open (BBDC) 68°
Exhaust valve close (ATDC) 32°
2. Valve Cold Clearance Table V
Intake valve 0.30-0.35mm
Exhaust valve 0.35-0.40 mm
3. Temperature and Pressure Scope of Diesel Engine Table VI
Model YN33CR YN38CR
Exhaust temperature at 15min power ≤ 650℃ ≤ 680℃
Oil temperature in nominal condition ≤ 115℃ ≤ 115℃
Cooling water outlet temperature in nominal
≤ 95℃ ≤ 95℃
condition
Oil pressure 200-600kPa 200-600kPa
Oil pressure at minimum speed of empty
≥ 80kPa ≥ 80kPa
vehicle
4. Tightening Torque of Main Bolts Table VII
Name Spec. Tightening torque N.m
Main bearing bolt M16 200-240
Connecting rod bolt M12 100-140
Fuel injection pump flange
M8 21-26
connecting bolt
Flywheel bolt M14×1.5 100-140
Cylinder cover bolt M14×1.5 160-200
Common rail assembly connecting
M8 15-20
nut
Common rail end high-pressure oil
M14×1.5 25-30
pipe connecting nut
Fuel injector end high-pressure oil
M12×1.5 25-30
pipe connecting nut
Fuel pump end high-pressure oil
M14×1.5 25-35
pipe connecting nut

5
 Name Spec. Tightening torque N.m
Fuel injector pressing plate
M10 47-52
compression bolt
Fuel pump shaft end compression
M14 90-95
nut
Flywheel housing bolt M12 70-110
Crankshaft pulley bolt M16×1.5 200-230
Glow plug M10×1.25 10-15
5. Main Installation Data Table VIII
Valve sinkage of new machine 1.0-1.4 mm
The nozzle head stretches out the bottom plane of 1.5-2.0mm
cylinder head
Clearance between crankshaft position sensor and 1.5-2.0mm
signal tooth
Clearance between camshaft position sensor and 0.5-1.5mm
signal tooth
6. Tightening Torque of General Bolt and Nut Table IX
Bolt Nominal diameter of bolt mm
strengt 6 8 10 12 14 16 18 20
h grade Tightening torque N.m
4.6 4-5 10-12 20-25 35-44 54-69 88-108 118-147 167-206
5.6 5-7 12-15 25-31 44-54 69-88 108-137 147-186 206-265
6.6 6-8 14-18 29-39 49-64 83-98 127-157 176-216 245-314
8.8 9-12 22-29 44-58 76-102 121-162 189-252 260-347 369-492
10.9 13-14 29-35 64-76 108-127 176-206 274-323 372-441 529-637
12.9 15-20 37-50 74-88 128-171 204-273 319-425 489-565 622-830

(IV) Main part size, fit clearance and abrasion limit

Table 10
Fit tolerance
S/N Parts Name Fit dimension mm Abrasion limit mm
mm
Crankshaft main bearing
φ80( +0.070
+0.135
)
1 bush hole 0.07-0.154 0.25
Crankshaft main journal φ80h6( −0.019 )
0

6
 Fit tolerance
S/N Parts Name Fit dimension mm Abrasion limit mm
mm
Connecting rod bush hole φ65( +0.052
+0.099
)
2 Crankshaft connecting 0.052-0.118 0.20
φ65h6( 0−0.019 )
rod journal
3 Crankshaft end play 0.07-0.262 0.40
Camshaft bushing inner
φ56H7( 0+0.046. )
4 hole 0.100-0.176 0.25
Camshaft journal φ56d7( −0.10
)
−0.13

Clearance between
5 0.095-0.318 0.50
camshafts
Timing gear meshing
6 0.14-0.31 0.50
clearance
Connecting rod small end
φ35F6( +0.025
+0.041
)
bush hole
7 0.025-0.048 0.10
Outer diameter of piston
φ35h4( −0.007 )
0

pin
Inner diameter of cylinder φ100 ( +0.03
)YN33CR
0

sleeve model
8 0.10-0.15 0.40
Outer diameter of piston φ100 ( −0.10
)YN33CR
−0.12

skirt model
Inner diameter of cylinder φ102 ( +0.03
)YN38CR
0

sleeve model
9 0.10-0.15 0.40
Outer diameter of piston φ102 ( −0.10
)YN38CR
−0.12

skirt model
Opening clearance of top
10 0.30-0.50 1.5
piston ring
Opening clearance of
11 0.50-0.75 1.5
second piston ring
Opening clearance of
12 0.30-0.55 1.5
third piston ring
13 Intake valve sinkage 1.0-1.4 2.5
14 Exhaust valve sinkage 1.0-1.4 2.5
Clearance between oil
15 0.06-0.125 0.30
pump gear upper end and
7
 Fit tolerance
S/N Parts Name Fit dimension mm Abrasion limit mm
mm
pump body end
Clearance between water
16 pump impeller and pump 0.10-0.55 1.0
body end
17 Compression clearance 0.6-1.1

8
 Chapter II Disassembly of Diesel Engine
(I) Maintenance requirements and attentions for engine
1. Non-professional maintenance personnel should not arbitrarily disassemble the engine for
repairing. For repairing, the customer shall consult the dealer or go to Yunnei special service station.
2. The operator shall be familiar with the diesel engine structure, technical data, spare part assembly
relation, disassembly technical requirement and master correct disassembly method and correct using
method of repairing tools. If the user fails to possess necessary technical condition, please contact
Yunnei special service station.
3. The disassembly sequence is generally from outside to inside and from assembly to parts. To
improve the assembly efficiency and ensure correct assembly, verify the marking and properly mark
it during disassembly. Clean the part disassembled, carefully check it and pile up the part that can be
used by assembly category, separate the precision part from general part and store it in clea n
container.
4. The assembly sequence is generally from inside to outside and from parts to assembly. During
assembly, pay attention to the assembly size, direction, fit clearance, tightening torque, etc.; avoid
omission and wrong assembly, scratch of part matching surface and foreign matter falling in the
engine. Use proper wrench to assemble the bolt and nut and apply even force. Properly use the
locking device and use proper cotter pin and spring washer as per regulation. In addition, during
assembly, verify the part number and assembly mark to ensure correct position and movement
relation of parts.
5. Ensure that the diesel engine is always in clean and intact condition. Before disassembling and
assembling the part, clean or wipe the part to ensure clean part and the assembly quality. Complicated
adjustment and repairing should be done indoor to prevent polluting the inside of diesel engine.
6. The engine adopts Bosch electronic control high-pressure common rail system. The battery
grounding must be at negative pole. The vehicle main power switch must control the positive pole.
For maintenance and repairing of diesel engine, be sure to power off the main power switch to prevent
damaging the ECU. The electronic control system parts should not be immersed in water or under
rain. The sensor should be free from impact and gravity.
7. For repairing or disassembly, pay attention to safety and prevent collision when the part is
running, crushing during disassembly or personal injury due to improper use of tool.
8. In the repairing process, be sure to use original part with quality meeting requirement for
replacement.

9
(II) Disassembly of engine assembly
To disassemble the engine from the vehicle, generally lift out the engine after the engine and
transmission are separated. (After disassembling all connecting mechanisms of transmission, it's
allowed to directly lift out the engine and transmission from the vehicle.)
For this, proceed as follows:
● Unscrew the oil drain bolt on the oil pan and drain the oil.
● Disassemble the battery grounding wire.
● Disassemble the engine inlet and outlet hose and open the water drain switch on the body to
empty the cooling water.
● Disassemble the generator, starter, sensor connector, oil temperature and water temperature
sensor power line.
● Close the fuel pipe, and unplug the oil inlet pipe and oil return pipe.
● Disassemble the connecting hose between intake piping and air filter.
● Loosen the radiator support and take out the radiator and intercooler with the fan guard.
● Loosen accelerator handle stay line and clutch stay line.
● For the engine with vacuum booster, air conditioner or inflation pump and disassemble
corresponding connecting pipe.
● Disassemble the connection between exhaust manifold and exhaust silencer pipe.
● Loosen the connecting bolt between engine and transmission and separate the transmission from
the engine.
● Loosen the fixing bolt of front support of engine and use the lifting device to hang the front and
rear lifting eye of engine and stably lower down the engine.

(III) Disassembly of engine assemblies

1. Disassembly of fuel injection system
● Disassemble the high-pressure oil pipe clamp and high-pressure oil pipe. When disassembling
the high-pressure oil pipe, use the wrench to clamp the joint of fuel injector and high-pressure
fuel pump to prevent joint loosening.
● Push away the fuel injector oil return pipe spring lock clamp and unplug the fuel injector oil
return pipe.
● Disassemble the oil rail, fuel injector pressing plate bolt and unplug the fuel injector. The copper
gasket on the fuel injector should be properly kept during disassembly.
● Disassemble the camshaft position sensor and properly keep the O-ring.
● Disassemble the fuel injector gear cover plate and loosen the high-pressure fuel pump gear
compression nut to disassemble the fuel injection pump gear assembly.
10
● Disassemble 3 high pressure oil pump compression nuts to disassemble the high-pressure fuel
pump. If the connection is too tight, use the copper rod to slightly knock the high-pressure fuel
pump camshaft; however, avoid damaging the thread of camshaft end. Properly keep the O-ring
on the high-pressure fuel pump.
Assemble the protective cap at the oil rail, fuel injector, high pressure oil pump inlet and outlet
joint to ensure clean inlet and outlet.

2. Disassembly of accessory system

● Disassemble the generator, fan belt and fan.
When disassembling the belt, firstly loosen the tensioning bolt and fixing bolt on the generator
adjusting support, push the generator inward to loosen the belt. After disassembly, never clean the
belt by water or gasoline and avoid applying oil to the belt to prevent belt slipping during running.
● Disassemble the air conditioner and support.
● Disassemble the power steering pump and inflation pump.
● Disassemble the starter.

11
3. Disassembly of cylinder head
When disassembling the cylinder head assembly, the intake pipe, intake connecting pipe,
exhaust pipe, supercharger, exhaust tail pipe and thermostat assembly should not be
disassembled. The valve rocker arm assembly should be disassembled as an assembly rather
than scattered parts. The electric heater plug must be unplugged; otherwise, it may be easily
broken. For disassembly:
● Disassemble the intake connecting pipe and intake pipe.
● Disassemble the exhaust pipe, supercharger oil inlet and return pipe, supercharger, exhaust
protective plate, exhaust pipe, etc.
● Disassemble the thermostat assembly.

12
Generally, the intake pipe assembly, exhaust pipe assembly and thermostat assembly are not
disassembled. The disassembly process is as follows:
● Loosen the compression nut of cylinder head cover and take down the cylinder head cover.
● Remove glow plugs.

● Use the torque wrench to disassemble the cylinder head rocker arm compression bolt as per
specified sequence, completely lift down the valve rocker arm assembly to take down the push
rod.

13
● Use the torque wrench to disassemble the cylinder head compression bolt as per specified
sequence.
● Loosen the small circulation hose, supercharger oil inlet pipe and supercharger oil return pipe.
● Disassemble the fixing bolt of oil dipstick sleeve, unplug the oil level, separate the oil dipstick
sleeve support from the cylinder head and disassemble the oil dipstick sleeve.
● Confirm that the cylinder head is completely separated from the body, and lower the cylinder
head. There is a small O-ring at the matching surface between cylinder head and body, which
should be properly kept during disassembly.
● Use the valve spring special tool to press the valve spring seat, take out the valve lock clamp,
internal and external valve spring and valve seat ring and valve.
4. Disassembly of clutch assembly and flywheel
● Make the assembly mark on the clutch and flywheel
to prevent damaging the crankshaft dynamic balance
after re-assembly.
● Disassemble the clutch cover assembly and take out
the friction plate.
● Loosen the flywheel lock washer and bolt to
disassemble the flywheel.
Attention: To replace the crankshaft, disassemble the clutch assembly and flywheel. Otherwise,
it should not be disassembled.
5. Disassembly of oil pan parts

14
● Disassemble the oil dipstick pipe support and
unplug the oil dipstick and oil dipstick pipe.
● Disassemble all bolts of oil pan to take out
the oil pan.
Attention: To disassemble the body internal
parts like piston, piston cooling nozzle, oil
pump, etc., disassemble the oil pan.

6. Disassembly of gear chamber and body

● Disassemble the starting jaw, avoid following rotation in the disassembly process of crankshaft
flywheel assembly, and use the waste bolt or bearing bush to clamp the flywheel gear.
● Take out the crankshaft pulley, loosen the fastening bolt and nut of gear chamber cover and
disassemble the gear chamber cover. Pay attention not to damaging the front oil seal on the gear
chamber cover in the disassembly process.

● Loosen the fastening bolt of gear, take down the crankshaft gear, idle gear and camshaft thrust
plate and other internal parts of gear chamber cover plate.
● Loosen the fastening bolt and nut of gear chamber to disassemble the gear chamber.

15
● Disassemble the flywheel housing, and pay attention not to damaging the rear oil seal on the
flywheel housing in the disassembly process.

● Disassemble the oil pump assembly to take out the camshaft and tappet.
● To disassemble the camshaft, it's allowed not to disassemble the oil pan and oil pump assembly;
but it's required to disassemble the front and rear upper cover plate and air tube assembly, use the
wire clip or rubber ring to fix the tappet, keep the tappet away from the camshaft and take out the
camshaft from the front end.

16
7. Disassembly of piston-connecting rod assembly
● Use the torque wrench to disassemble the connecting rod bolt and take down the connecting rod
bearing cap (rotate the crankshaft in the disassembly process). Take out the piston-connecting rod
assembly from the cylinder in the cylinder head direction; the connecting rod and connecting rod
cover should be matched.
● Carefully disassemble top, second and third combination oil ring and use the clip forceps to take
down the piston pin lock ring. Heat the piston-connecting rod assembly to 60-80℃, push out the
piston pin and take down the connecting rod assembly. The piston mark, connecting rod
assembly mark and cylinder serial number should be consistent.

17
8. Disassembly of crankshaft
● Use the torque wrench to disassemble the main bearing bolt and take down the main bearing
cover and thrust plate to lower the crankshaft. Before disassembly, check the axial clearance of
crankshaft. Replace it if the specified clearance is exceeded.
● Disassemble the piston cooling nozzle.
● Disassemble the cylinder sleeve. During disassembly, use the wood to support the bottom of
cylinder sleeve and use the iron hammer to knock the wood. Never use iron block and other hard
objects to directly know the cylinder sleeve; otherwise, the cylinder sleeve may be damaged.

18
19
 Chapter III Assembly of Diesel Engine
(I) Assembly of body
● Use special tool to knock in the oil pump driving shaft sleeve,
keep the oil hole align with the oil hole on the body and keep
the groove outward.

● Put the water seal ring on the cylinder sleeve water sealing
groove, never distort it. For convenient assembly, apply soap
solution. The water seal ring should be replaced rather than
reused.

● Forcefully press the cylinder sleeve with the water seal ring in
the block hole by two hands; check the cylinder sleeve
shoulder protruding the upper level of 0.02-0.128mm and the
cylinder sleeve protruding height difference of same body
should not exceed 0.05mm. Before assembling the cylinder
sleeve, clean the slag and dirt at the joint of bore hole spigot
and water seal ring. If it's tight when the cylinder sleeve is
pressed in, use a clean wood and slightly knock it to place by a
hammer
● Use special tool to knock in the idler shaft and front and rear
locating pin of body, be sure to align the oil hole on the idler
shaft with the oil hole on the body.

● Assemble the camshaft bushing in the cylinder block camshaft

hole and align the oil hole on the bush with the oil hole on the
body. Meanwhile, the first bush should be level with the front
end of body and the rear bush should be level with the pit
bottom of rear end of body.

20
● Apply little lubricating oil to O-ring of rear blocking piece of
camshaft, assemble it in the rear end camshaft mounting hole.
The camshaft blocking piece should not be higher than the
rear end of body.

● Assemble the oil cooler connecting plate gasket, connecting

plate, oil cooler seal gasket and oil cooler assembly. Never
omit two rectangular seal rings at the inlet and outlet of oil
cooler.

(II) Assembly of crankshaft, flywheel and clutch

● Assemble the upper main bearing bush with oil groove in the main bearing hole of body, and
align the oil hole on the bearing bush with the oil way hole on the main bearing seat of body. The
upper and lower bearing bush should not be assembled reversely. The main bearing seat should
be corresponding to the main bearing cap slip groove and bearing bush. Apply little clean
lubricating oil. For assembly of bearing bush, it's prohibited to lay any metal or non-metal gasket.
● Put the crankshaft on the main bearing seat hole of body.
Before assembly of crankshaft in the body, carefully clean it
and pay special attention to the cleanliness of oil hole, journal
surface and bearing seat surface. After assembly, apply little
lubricating oil to the main journal.

● Assemble the crankshaft thrust plate to the last main bearing

seat. Keep the groove of thrust plate outward. Avoid reversely
assemble the thrust plate. There is a locating pin at two sides
of rear main bearing cap which plays the location function.

21
● As per the mark 1, 2, 3, 4 and 5 printed on the main bearing
cap, orderly assemble the main bearing cap from front (fan
end) to back (flywheel end). The arrow on the main bearing
cap should be ahead. The upper and lower locating lip should
be at the same side. During assembly, use the purple copper
rod to knock the main bearing cap in place. Symmetrically
tighten the main bearing bolt to 200-240 N.m from middle to
two sides by 3 times. Before assembly of main bearing bolt,
apply the thread fastening glue. After fastening, the crankshaft
can rotate flexibly and the axial clearance should be 0.07-
0.262mm).
● Assemble the crankshaft flat key and crankshaft timing gear
and keep the crankshaft timing gear mark outward.
● Press the crankshaft rear oil seal in the flywheel housing by a
special tool. Keep the rear oil seal main lip direction opposite
to the crankshaft.
● Apply little lubricating oil to the crankshaft and assemble the
flywheel housing in the crankshaft rear end smoothly by the
crankshaft rear oil seal installation guide sleeve. Avoid
damaging the rear oil seal lip and the main lip spring may not
fall off.
● Assemble the flywheel housing fastening bolt and tighten the flywheel housing bolt to 100-
140N.m by 3 times.
● Assemble the flywheel at the crankshaft rear end, assemble the flywheel locking gasket and
flywheel bolt, diagonally and symmetrically tighten the flywheel bolt to 70-110N.m by 3 times
and lock the flywheel locking gasket.
Before assembling the flywheel on the crankshaft, use clean towel
to wipe off the dirt on the crankshaft flange end and flywheel
spigot. To replace the damaged flywheel gear ring, evenly heat the
gear ring to 150-200℃ and lightly disassemble it. (To assemble the
gear ring, heat it to 150-200℃ and insert it on the flywheel
external circle in the specified direction at room temperature.) 。
● Press the bearing in the crankshaft rear end. Apply lubricating
grease before pressing and the direction should not be reverse.

22
● Use special locating spline shaft and use the rear bearing hole
for locating, assemble the clutch pressing disc and clutch
cover assembly and keep the clutch pressing disc spline
groove outward.
The crankshaft, flywheel and clutch assembly have received
dynamic balance treatment at delivery. During assembly, refer to
the mark made during disassembly and the flywheel end and
clutch pressing disc end should be free of oil stain and foreign
matter.
The clutch pressing disc and cover assembly have been carefully
adjusted at delivery and careful adjustment should be made after
exchange assembly.
● Assemble the clutch housing bottom cover.

(III) Assembly of piston-connecting rod assembly

There is a necking direct injection ω combustion chamber on
the top of piston and there are two pits (big and small) to avoid
the valve. During assembly, the big intake valve pit should
face the front end of engine and the combustion chamber pit
should face the fuel injection pump. To improve the piston
strength, adopt wedge connecting rod.
● Press the connecting rod copper sleeve in the connecting
rod body by interference fit and align the copper sleeve oil
hole with the oil hole of connecting rod body (the newly
purchased connecting rod copper sleeve is generally
assembled).
● Assemble the piston pin lock ring at one side of piston.
● Heat the piston to 40-100℃, put on the connecting rod,
align the piston with connecting rod pin hole, press the
piston pin and keep the connecting rod big end hole
groove in the same eccentric direction as the piston
combustion chamber.

23
● Assemble the piston pin lock ring at the other side of
piston.
There are three piston rings. After the piston rings are
assembled in the cylinder sleeve in normal temperature, proper
clearance is reserved at the opening, which is the "opening
clearance". Put the piston ring in the new cylinder sleeve and
use the feeler gauge to measure the opening clearance of piston
ring. The standard opening clearance of piston ring: top ring:
0.30-0.50mm, second ring: 0.50-0.75mm, oil ring: 0.30-
0.55mm. The abrasion limit is 1.5mm; replace it if the limit is
exceeded.
● Use special tool to assemble the piston ring in the piston
groove;
● If there is no piston ring special tool, wear the glove and
pull the piston ring from the opening, assemble the piston
ring in the ring groove and avoid scratching the piston
surface. Assemble the oil cup, keep the oil ring opening in
opposite direction to the support ring joint (put the support
ring in the piston ring groove), assemble the second ring
and the top ring. The upper and lower face of ring should
not be assembled wrongly. Keep the face with "TOP"
facing the piston top. The ring opening should be
staggered by 120° and staggered with the pin hole
direction. The piston ring in the ring groove should rotate
flexibly.
● Apply little oil to the piston ring, connecting rod bush,
piston pin, etc.
● Use special tool to assemble the piston-connecting rod
assembly in corresponding cylinder sleeve. When
disassembly and assembly of piston-connecting rod
assembly, pay attention to the corresponding relation with
cylinder and never exchange the piston-connecting rod
assembly.

24
● Assemble the connecting rod cap and connecting rod bolt;
before screwing the connecting rod bolt, apply little
lubricating oil to the working face of bearing bush and
alternatively tighten it to final tightening torque of 100-
140N.m.
To ensure stable working of engine, the quality of piston-
connecting rod assembly should be strictly controlled. To
replace the connecting rod, the difference between mass of
new piston-connecting rod assembly and mass of piston-
connecting rod assembly of the diesel engine should be
no more than 25g.
The connecting rod body and cover are processed in group and there is a matching mark on it. Avoid
wrong and reverse assembly. After assembly, check the clearance between two sides of the
connecting rod big end and crankshaft, the crankshaft shall rotate flexibly without blockage.
● Assemble the piston cooling nozzle. When assembling the
piston cooling nozzle, assemble the locating pin on the
piston cooling nozzle in the pin hole and align the piston
cooling nozzle with the cooling cavity oil inlet hole in the
piston.

(IV) Assembly of camshaft and oil pump

● Apply little clean lubricating oil to the tappet and
assemble it in the tappet hole
● Apply little clean lubricating oil to the camshaft bushing,
assemble the camshaft from the front end of body and
assemble the camshaft flat key. Slightly rotate the
camshaft and avoid damaging the camshaft bushing.
● Assemble the camshaft thrust plate, keep the surface with
oil groove outward, and tighten the camshaft thrust plate
bolt.

25
● Overturn the body for 180°, assemble the oil pump drive
gear shaft and upper sleeve cap on the body from the
upper end and fasten it.
● Insert the oil pump assembly in the oil pump mounting
hole, rotate the oil pump driving shaft to insert it in the oil
pump driving shaft groove and fasten the oil pump
mounting bolt. Pay attention that the two ends of oil outlet
pipe part should be laid with seal gasket without omission.
● After assembly, the camshaft and oil pump driving gear
shaft can rotate flexibly.

(V) Assembly of gear chamber, fuel pump, oil pan, timing driving
system
● Assemble the gear chamber gasket and gear chamber and align the locating pin hole of gear
chamber with the locating pin on the body.
● Use special tool and sleeve (or copper rod to slowly knock) to press the camshaft timing gear on
the camshaft, keep the mark outward and add retainer ring and bolt for fastening.
● Assemble the high-pressure fuel pump on the gear chamber of engine by three M8 studs. Before
assembly of high-pressure fuel pump, keep the sealing surface clean, without oil stain and
impurity and check whether the O-ring is complete. Assemble the stud in the gear chamber and
apply thread sealant and tighten the nut with torque of 22-25N.m.
● The fuel injection pump is assembled on the high-pressure
fuel pump shaft. Assemble the woodruff key. Tighten the
nut with torque of 90-95N.m.

● Assemble the camshaft speed signal panel and cushion block on the fuel pump gear, and never
reversely assemble two locating pins.

26
● When assembling the idler system, keep the gear system
mark outward and the meshing gear marks should be
matched. After assembly, the gear can rotate flexibly
without blockage. When assembling the camshaft and
idler shaft pressing plate bolt, pay attention to
distinguishing the bolt length; the long bolt is used for
camshaft pressing plate and short bolt is for idler shaft
pressing plate; no mistake is allowed.
● Press the crankshaft front oil seal in the gear chamber
cover by a special tool. Keep the front oil seal lip directio n
opposite to the crankshaft.
● Assemble the gear chamber cover gasket and gear
chamber cover and fasten the bolt. Before assembly, never
forget the crankshaft front retainer oil ring and check it for
omission or impurity.
● Knock the crankshaft belt pulley in the crankshaft,
assemble the starting jaw bolt and tighten it to 200-
230N.m. Before assembling the starting jaw, apply the
thread fastening glue.
● Assemble the oil pan and oil pan pressing plate and fasten
them. Before fastening, keep the mounting surface of oil
pan and cylinder block clean and smooth, scrape off the
paper pad at the joint of gear chamber cover, gear chamber
and front end of body and rear end of body, and apply
sealant. Before assembling the oil pan, check it for
omission or impurity.
● Assemble the drain plug and reliably fasten it.

(VI) Assembly of cylinder head part

Assembly of rockshaft assembly
● Assemble the bowl-shaped plug at two ends of rockshaft and keep the concave surface outward.
● During assembly, firstly wipe the rocker arm, rockshaft and rocker arm seat and apply oil to
lubricating the mating surface.
● The rockshaft with oil inlet hole should be assembled in the front and avoid reversely assembly.
The lubricating oil from the cylinder head is to lubricate all rocker arms by the rockshaft. When

27
 the diesel engine is working, check whether the lubricating oil on the rockshaft is properly
supplied.
● The assembly sequence of rocker arm seat: assemble the shaft retainer ring on one end of
rockshaft, assemble the washer, rocker arm assembly, rocker arm seat, rocker arm assembly,
washer, spring, washer, rocker arm assembly, rocker arm seat, rocker arm assembly, washer,
spring, etc. till sufficient cylinder is assembled. The sequence of final cylinder is washer, rocker
arm assembly, rocker arm seat, rocker arm assembly, washer and shaft retainer ring. It is shown in
the above photo.

1. Front auxiliary rocker arm seat, 2. Rocker arm seat, 3. Valve rocker arm assembly, 4. Valve
clearance adjusting screw, 5. Nut, 6. Rockshaft, 7. Rockshaft spring, 8. Washer, 9. Shaft retainer ring,
10, Rear auxiliary rocker arm seat, 11, Bowl-shaped plug
Assembly of cylinder head and valve mechanism:
● Use a proper punch, carefully knock the punch along
the central direction of guide and assemble the valve
guide on the cylinder head. In the process, avoid
damaging the valve guide hole. The distance of valve
guide top surface protruding the valve spring seat
surface on the cylinder head shall meet the regulation.

● Assemble the valve seat ring on the specially made

mandrel, insert the mandrel in the valve guide, by the
valve guide, and slightly knock the mandrel to
completely insert the valve seat ring in the seat ring
hole.

28
● Use the 90° reamer to ream the intake and exhaust Valve sinkage

valve seat ring sealing tape and pay attention that the
width of sealing tape is 1.35-1.45mm and valve
sinkage is 1.0-1.4mm. When the valve sinkage exceeds
the abrasion limit of 2.5mm, replace the valve seat and Sealing tape Valve taper angle 90℃

valve.
● The intake and exhaust valve and valve seat ring
should be grinded in pairs. It should not be exchanged
during disassembly and assembly. After grinding,
perform leakage test. The valve should be free of
leakage.
● Put the valve stem oil seal on the valve guide by the
special tool and assemble it in place and never damage
the oil seal lip.

● Put in the intake and exhaust valve and valve spring,

and use special disassembly tool to press in the valve
lock clamp and valve spring seat. After assembling the
lock clamp, use the rubber hammer to lightly knock it
to ensure reliable assembly. There are internal and
external valve springs. During assembly of valve
spring, keep the end with small thread pitch at the
cylinder head and avoid reverse assembly. There is a
groove at the valve stem end, Two half taper locking
plates are embedded in it to fasten the spring seat and
valve spring.
● Properly put the cylinder gasket and cylinder head,
assemble the O-ring (15x3) at the body oil hole, there
are two locating sleeves on the block which will
automatically locate the cylinder head;

29
● Diagonally and symmetrically tighten the cylinder
head bolt to 160-200N.m by 3 times and apply the
thread fastening glue before assembling the cylinder
head bolt.

● Assemble the valve push rod, valve rocker arm

assembly, and assemble the valve push rod lower end
ball head in the tappet upper end ball socket correctly;
and assemble the valve clearance adjusting screw
lower end ball head in the valve push rod upper end
ball socket correctly. When assembling the valve
rocker arm assembly, rotate the rockshaft, align the
concave surface of half circle with the rocker arm seat
hole to properly assemble the valve rocker arm
assembly in place. Tighten the cylinder head bolt and
rocker arm support compression nut.
● Tighten the cylinder head bolt and adjust the valve
clearance. Steps for adjusting the valve clearance:
Rotate the crankshaft to make the 1# cylinder at
compression top dead center (as per the movement of
rocker arm, 2# cylinder exhaust valve rocker arm and 3#
cylinder intake rocker arm are moving), align the "0" scale
line on the external circle of crankshaft belt pulley with the
arrow on the gear chamber, loosen the lock nut, use the
screwdriver to rotate the adjusting screw, and insert the
feeler gauge between the valve end and rocker arm head.
Adjust 1, 2 3 and 6 valves, and rotate the crankshaft for a
circle (360°) along the moving direction of diesel engine,
keep the 4# cylinder at compression top dead center and
adjust 4, 5, 7 and 8 valves.
● Assemble the cowl hood and oil filler cap and fasten them.
Adjustable valve
Working stroke of piston 1 2 3 4 5 6 7 8
In ROWS In ROWS In ROWS In ROWS

30
1# cylinder at compression top dead
√ √ √ √
center
4# cylinder at compression top dead
√ √ √ √
center

● Assemble the preheating plug. To ensure low-temperature

starting performance, assemble ceramic glow plug near the fuel
injector. The tightening torque of ceramic glow plug is 10-15
N.m. After assembling the glow plug in place, use the
resistance gauge to measure the resistance within 4Ω, and
replace the glow plug exceeding the resistance.
● Assemble the cylinder head front cover plate, thermostat
assembly, small circulation hose and cylinder head rear cover
plate.
● Assemble the intake pipe and intake connecting pipe.
● Assemble exhaust pipe, exhaust protective plate, supercharger,
exhaust tail pipe, supercharger oil inlet pipe and supercharger
oil return pipe. As shown in the right figure.
Attention: during assembly, avoid foreign matters falling in the
intake and exhaust pipe and avoid damaging the diesel engine.

(VII) Assembly of accessories

● Assemble the water pump, water pump pulley and fan. The fan fastening bolt is equipped with
lock gasket for locking.
● Assemble the oil filter, diesel oil filter, drain connector and
drain cock.
● Assemble the decelerating starter and generator.
● Assemble the transition gear assembly on the gear chamber
cover and the transition gear shaft bolt has reverse-tooth
thread.

● Assemble the gear inflation pump (air cooling, with driving gear) on the rear end of gear chamber
and it's no need to mark the gear. To assemble the gear driven power steering pump, assemble the
power steering pump connecting plate on the gear inflation pump driving wheel.

31
● Assemble the power steering pump on the front end of gear chamber cover and insert the spline in
the power steering pump connecting plate groove.
● Assemble the A/C support and A/C.
● Assemble the fan belt as shown in the figure. The fan belt adopts 7PK poly-V belt, which can
greatly increase the service life of fan belt. Adjust the generator tension adjusting bolt and tighten
the fan belt. The tightness of fan belt: apply the force of 50N to the middle part of water pump
and generator belt, the belt moves 6-15mm toward the force direction.

(VIII)Installation, use and maintenance of electronic control high-

pressure common rail system
The electronic control system of diesel engine mainly consists of sensor, ECU, executor and harness.
Their relations and functions are shown in the figure below. The executor mainly includes fue l
injector, high-pressure fuel pump, etc. The sensor mainly consists of crankshaft position sensor,
camshaft position sensor, water temperature sensor, intake temperature pressure sensor, accelerator
pedal, rail pressure sensor, etc.

 Receive and analyze the input  Receive ECU order

information  Inject the fuel as per order
 Decide the control parameter
 Monitor the working
condition of engine  Send out the order to executor
 Send the information to
ECU

Sensor ECU control unit ACTUATORS

Wire Wire
harness harness

ENGINE

Schematic Diagram for Electronic Control System

YN33CR and YN38CR electronic control China III series diesel engine adopts BOSCH economic
electronic control high-pressure common rail fuel injection system. Due to high manufacturing and
processing precision of high-pressure fuel pump and fuel injector and small fuel injection nozzle,
there is high requirement on the diesel oil quality and cleanliness. Be sure to use the diesel oil o f
normal gas station and effectively filter it; otherwise, the electronic control system may be damaged
and Yunnei will assume no responsibility.
Main control functions of electronic control system are as follows:
1. Starting control

32
The electronic control engine is directly controlled by the electronic control system. At the starting
condition, the starting fuel volume control module provides sufficient fuel to ensure quick startup
without black smoke.
At startup, the driver shall not press the accelerator.
2. Torque output control
It delivers the driver's intention to the control unit as per the electronic throttle opening and its change,
combines the transmission ratio to control the change of output torque, and controls the acceleration
of vehicle, including acceleration smoke limit, driver's feeling at sudden acceleration and
deceleration, maximum no- load stable speed control, torque reduction when the engine cooling water
temperature is too high, etc.
3. Idle speed closed-loop control
The engine idle speed control refers to that ECU can automatically adjust the idle running speed as
per the temperature, battery voltage and air conditioner request, and keep the engine running at setting
idle speed through the closed- loop control of ECU control unit. If the cooling water temperature is
low, the engine idle speed is high; at idle speed, turn on the A/C, the engine speed will rise quickly.
4. Starting pre-heating control
The electronic control system preheating control module will heat the engine at cold starting
condition to accelerate the starting process. Under the control by electronic control system, the
preheating module will heat the engine of different degrees at cold starting condition to prevent
engine flameout in the starting or running process. When the preheating module is working, the
preheating indicator on the instrument panel of vehicle will illuminate to remind the driver that the
preheating module is working.
5. Exhaust brake control (optional)
The exhaust brake module provides certain reactive force to lower the vehicle speed when the engine
is working properly.
To implement execution brake, the driver can turn on the exhaust brake request switch on the
instrument panel (or press the exhaust brake switch by foot), the electronic control system will control
the exhaust brake valve as per the driver's request and running condition of engine. Once the exhaust
brake function is activated, the engine stops supplying oil.
If the driver stops the exhaust brake, turn off the exhaust brake request switch (or release the foot
exhaust brake switch), ECU will supply fuel to the engine as per the control signal.
6. Electronic accelerator pedal control
As the common mechanical engine, the driver shall control the engine by the accelerator. But the
electronic control system adopts electronic accelerator pedal. The electronic accelerator feeds back
the driver's intention (throttle opening) to ECU by the control harness. The accelerator fuel volume

33
control module will calculate the fuel volume as per the throttle opening and engine speed so that the
driver can control the engine speed and running speed of vehicle.
7. Limp home function and failure protection control strategy
In case of serious fault of electronic control system or harness, ECU will enter the failure protection
mode, which can protect the engine and avoid malfunction in the half way. In this mode, the system
upgrades and limits the maximum power, torque and speed. In this condition, the driver shall drive the
vehicle to the nearest service station for repairing in time.
In case of serious fault of electronic accelerator pedal output signal or harness, ECU will enter the
limp home control mode. In this mode, the electronic accelerator pedal signal will be replaced by the
normal accelerator pedal of the driver as per the fault default set in the ECU (at this time, the
electronic accelerator pedal deactivates), and the engine will lower the power and maintain constant
speed. In this case, the driver shall drive the vehicle to the nearest service station for repairing in time.
In case of serious safety accident, ECU will mandatorily stop the vehicle.
8. Thermal protection control
In the electronic control system, when the engine cooling water temperature and fuel temperature
exceed the permissible scope, ECU will protect the engine from being damaged and enter the thermal
protection control mode. At this time, the maximum power, torque and speed may be limited, the
vehicle can be still running, by the speed and acceleration property are limited. Once the temperature
is lowered, the engine returns to normal. If this condition appears frequently, the driver shall drive the
vehicle to the nearest service station for repairing in time.
9. Speed reduction and fuel cut control
When the engine is running at high speed, suddenly release the accelerator pedal, under speed
reduction and fuel cut condition, the engine enters speed reduction and fuel cut control mode. At this
time, ECU will stop fuel injection and the vehicle will slide by inertia or slide down the slope.
The engine speed is gradually lowered, when the speed lowers to a setting value, ECU recovers
supplying fuel and maintains the working of engine. Adopt speed reduction and fuel cut control
strategy to lower fuel consumption and change the emission pollution caused by instable combustion.
Add the brake function of engine.
10. A/C control (optional)
When the A/C request switch on the instrument panel is pressed, ECU will detect the request signal of
turning on the air conditioner, so as to maintain normal working of engine.
At idle speed, if the air conditioner is turned on, ECU will increase the target idle speed of engine;
once the air conditioner is turned off, ECU will lower the target idle speed of engine. For the vehicle
whose air conditioner clutch is controlled by the ECU (subject to the operating manual of vehicle),
ECU receives the A/C order and controls the relay to operate the A/C clutch. For example: when the

34
vehicle is running at high load or the water temperature is high, ECU will automatically turn off the
A/C to ensure sufficient output power of engine.
11. Noise control
YN33CR and YN38CR China III electronic control engine adopt several injection and fuel injection
pressure closed control, which can effectively lower the noise of engine.
12. Fault diagnosis control
The electronic control system monitors the running state of engine in real time and diagnoses faults to
protect the engine and improve the driving safety. When the system detects fault, the engine detection
lamp on the instrument panel will illuminate to remind the driver of checking the engine. The fault
code is saved in the ECU for the service personnel to read the fault information.
The high pressure common rail fuel system consists of oil tank, diesel oil filter, high pressure fue l
pump, high pressure oil rail, fuel injector, high pressure fuel pipe and low pressure fuel return pipe
and so on.
The working process of fuel system is as follows:
The diesel oil is sucked out from the fuel tank, through the oil-water separator assembly (coarse filter)
and diesel oil filter assembly (fine filter) with high-efficient water separation function, enters the high
pressure oil pump. It turns to high-pressure diesel oil under the influence of high-pressure fuel pump.
As per the working state of diesel engine, deliver the diesel oil to each fuel injector through the
high-pressure oil pipe and common rail pipe at fixed time and fixed quantity and inject the oil to the
combustion chamber under atomization of fuel injector. Remaining diesel oil from the fuel injector
and high-pressure fuel pump overflow flows back to the fuel tank through the fuel return pipe.
The low-pressure oil inlet pipe and oil return pipe must be smooth without bending and blockage. All
joints must be firmly connected and sealed to prevent air enters the oil way. To ensure the oil inlet
pressure of fuel delivery pump of high pressure fuel pump, the inner diameter of connecting pipe of
low pressure oil pipe should be no less than φ8 and the oil pressure vacuum degree at the high-
pressure fuel pump inlet joint should be no more than 50kPa. The inner diameter of high-pressure
fuel pump oil return pipe is φ4 and it should not be too big; otherwise, it may cause starting
difficulty.

35
 Rail pressure sensor

High-pressure
oil pump Oil rail

Diesel oil filter and

oil-water separator
ACTUATORS
Sensor
Fuel injector

Fuel tank Control unit

with filter ECU

High pressure Low Voltage

Schematic Diagram for High-pressure Common Rail Fuel System
For oil inlet pipe and oil return pipe, avoid using copper, copper alloy, zinc, lead and tin, which may
lower the service life of fuel injector.
The fuel tank must be open to atmosphere. The oil inlet pipe and oil return pipe of fuel tank should be
inserted to the bottom of fuel tank. The fuel tank should be made of plastic or stainless steel.
The diesel oil filter must be replaced regularly and the fuel tank should be cleaned regularly to ensure
the cleanliness of fuel system. During repairing, especially when the user repairs the low oil way,
clean the external clean dust and oil stain and other impurities, do inspection and repairing and be sure
to clean the parts before re-assembly.
The oil-water separator assembly with hand pump is assembled on the frame. The alarm will be given
out when the water of oil-water separator exceeds the volume, immediately drain the water in the
oil-water separator.
Attention: the electronic control high-pressure common rail fuel system must be
adjusted by professional serviceman by using special tool, which should not be
arbitrarily disassembled and adjusted by the user. For repairing and replacing the
fuel pipe, use the original parts of automobile factory and never randomly purchase
the part!
1. High-pressure fuel pump
The assembly of high-pressure fuel pump is described in (V).
The high-pressure fuel pump should be adjusted by special technology, no arbitrary adjustment is
allowed, in case of fault; send it to the local service center of Yunnei for repairing.
Main parameters of CB18 high-pressure fuel pump: transmission ratio of 1/2; clockwise rotating,
rated rail pressure of 1,400bar, rated speed of 2,000r/min, and theoretical displacement of
791mm3 /rev. The fuel pump is equipped with fuel volume control unit to control the fuel supply

36
 volume. It's integrated with vane type fuel transfer pump and mechanical pressure limiter (overflow
valve, opening at 1,600bar). The fuel pump is inline plunger pump with 2 plunger pairs. The fuel
pump mounting flange face is equipped with O-ring. The high-pressure fuel pump is equipped with
thrust bearing, so it can withstand axial force.
After assembly of fuel injection pump, before starting the engine, press the manual fuel delivery
pump on the oil-water separator by hand and exhaust air in the fuel injection pump. To replace the
fuel injection pump, be sure to fill clean diesel oil of 15ml in the fuel delivery pump.

Assemble the high-pressure fuel pump on the gear chamber base plate of engine by three M8 studs.
Before assembly of fuel injection pump, keep the sealing surface clean, without oil stain and impurity
and check whether the O-ring is complete. Assemble the stud in the gear chamber and apply thread
sealant and tighten the nut with torque of 22-25N.m.
The fuel pump gear is assembled on the high-pressure fuel pump shaft. Assemble the woodruff key.
Tighten the nut with torque of 90-95N.m.
The wiring between fuel control unit on the high-pressure fuel pump
and ECU is shown in the figure. There are 2 leads for connector:
power line (pin 19) on the ECU and signal line (pin 49). The pin is
the one connecting ECU, and the following are the same. Control the
fuel injection volume as per the signal from ECU.
When ECU fault lamp illuminates, the diagnostic instrument detects
the fault code and displays the fuel injector pump fault; be sure to
turn off the ignition switch and check whether the connector is loose.
Use the multimeter to measure two ends of wire and check whether
the wire is disconnected. In case of mechanical fault, replace the high-
pressure fuel pump.
Warning: High-pressure fuel pump belongs to high technology precise coupling assembly. In
case of fault, never randomly disassemble it but notify Yunnei service pe rsonnel and send it to
Yunnei service center for repairing.

37
 YN4EL 机型高压油泵安装图解

YN4EL high pressure oil pump installation diagram

① 将高压油泵按图示位置与齿轮室用螺栓连接

Bolt the high-pressure oil pump to the gear chamber according to

the position shown in the figure

螺母

nut 三颗法兰面螺栓

Three flange bolts

（前端面 Front face）

（后端面 Rear face）

② 取下①前端面图中的螺母

Remove the nut from the front view

（取下螺母后
After removing the nut）

③ 压入油泵齿轮并上紧②中取下的螺母（高压油泵与齿轮无键连

接，利用接触的锥面配合来传动）

Press in the oil pump gear and tighten the nut removed in ②

（The high-pressure oil pump is keylessly connected to the

gear, Drive with conical mating contact）

四个螺栓孔均布
Four bolt holes are
evenly distributed
④ 若是拖拉机，则将四颗螺栓穿入下图零部件后与压入③的油泵

齿轮上四个螺栓孔连接，

If it is a tractor, pass the four bolts into the parts shown in the

figure and connect with the four bolt holes on the oil pump

gear pressed into ③.

⑤ 完成 complete
2. Fuel injector
The fuel injector is electronic control 6-hole fuel injector. It mainly consists of fuel injector body, fue l
injector coupling part, solenoid valve assembly, oil inlet joint (with filter), etc.
The fuel injector is to control the opening and closing of electromagnetic valve through the contro l
signal from ECU, and inject the fuel in the high-pressure oil rail to the combustion chamber of diese l
engine at the optimal fuel injection timing, fuel injection volume and fuel injection speed.
VALVE ASSY,
SOLENOID

Fuel injector
body
Oil inlet joint
(with filter)
Fuel injector
coupling part

Fuel injector

The rail pressure when the fuel injector works properly: the rail pressure is between 25MPa and
145MPa, and the maximum fuel injection pressure of fuel injector is 1,400 bar. Power parameter for
normal working at 20℃ to 70℃: peak current: (18±0.5)A; holding current: (12±0.5) A, resistance
(0.255±0.040)Ω. The oil return pressure of fuel injector is 0.3-0.8bar (relative pressure). The driving
voltage of fuel injector is the battery voltage (24V). The fuel injector adopts correction code (IQA) to
correct the fuel injection characteristic of each fuel injector, maintain minimum difference of fue l
injection, and maintain even fuel injection and good low-speed balance ability. When replacing the
fuel injector, use the diagnostic instrument to input the fuel injector IQA code in ECU so as to keep
balance fuel volume.
The wiring diagram of fuel injector is shown in the figure below. The wiring pin 17, 01, 02 and 16 of
fuel injector plug-in are high level and pin 33, 46, 31 and 47 are low level.

38
 Cabling Diagram of Fuel Injector Plug-in
Before assembling the fuel injector, check whether the pin of fuel injector solenoid valve is good and
whether there is bruise mark on the surface of fuel injector. During assembly, firstly assemble O-ring
in the groove, put the copper gasket (thickness of 2mm) on the coupling part of fuel injector. Before
assembling the cylinder head cover, apply little lubricating oil or grease surrounding the O-ring. Push
the fuel injector in the mounting hole of cylinder head fuel injector by hands, assemble the fuel
injector pressing plate and bolt and try to keep the fuel injector at the middle position, tighten the fuel
injector pressing plate bolt by hands and use the wrench to gradually tighten the fuel injector pressing
plate bolt to 47-52N.m. After assembly, keep the height of fuel injector head stretching out the bottom
of cylinder head at 1.5-2.0mm.
The fuel injector oil return joint has a lock clamp. When assembling the fuel injector oil return pipe,
forcefully press the oil return pipe joint to place. To disassemble the fuel injector oil return pipe,
firstly open the fuel injector oil return pipe spring lock clamp to pull out the fuel injector oil return
pipe.
Whether the height of fuel injector nozzle protruding the cylinder head meets the design requirement
has great influence on the performance of engine. When disassembling and re-assembling the fue l
injector, assemble the fuel injector and fuel injector gasket (with thickness properly adjusted at
delivery) to the original position and avoid mixing. To replace the fuel injector gasket, select the
gasket with same thickness; otherwise the protruding height of nozzle and engine performance ma y
be influenced.
When the fuel injector is blocked and leaked, but the engine ECU is unable to detect the fault, and the
fault diagnostic instrument is unable to read the fault information. At this time, check whether the
cable socket and plug of each fuel injector are properly connected and whether the connection is firm.
Start the engine, and use the mechanical stethoscope to check the working of fuel injector; if clear and
urgent "click" sound can be heard, it means that the fuel injector works properly. If the fuel injector is
blocked, send it to the service center specified by Yunnei for ultrasonic wave cleaning.
3. Oil rail and high-pressure oil pipe

39
The oil rail is the hot forging part, there are 4 oil outlets and 2 oil inlets; one end of oil rail is integrated
with rail pressure sensor and the other end has a plug. It's not allowed to disassemble the rail pressure
sensor reversely and plug. The maximum permissible axial force is 21kN. The cable wiring of rail
pressure sensor on the high-pressure oil rail is shown in the figure below. There are 3 leads of rail
pressure senor, respectively connecting the grounding wire (pin 26), signal line (pin 43) and
grounding wire (pin 08). The rated rail pressure is 140MPa. Use two M8 bolts to fix the common rail
on the engine intake pipe.

The high-pressure fuel pump is the passage connecting high-pressure fuel pump and oil rail, oil rail
and fuel injector, which can withstand the impact wave of high pressure fuel of above 1,400bar for a
long term. The high-pressure fuel pipe adopts imported steel pipe with outer diameter of φ6.35mm
and inner diameter of φ3mm.
Assembly sequence of high-pressure fuel pipe and oil rail and requirements:
1) Fasten the fuel injection pump, fuel injector and oil rail on the assembly parts at final torque
specified.
2) Disassemble the high-pressure joint protective cap on the fuel injector and oil rail and fasten the
high-pressure fuel pipe connecting nut on the fuel injector and oil rail assembly.
3) Disassemble the high-pressure joint protective cap on the fuel injection pump and oil rail and
fasten the high-pressure fuel pipe connecting nut on the fuel injector and oil rail assembly.
4) Tighten the high-pressure oil pipe connecting nut at the fuel injector end to final torque of 25-30
N.m.
5) Tighten the high-pressure oil pipe connecting nut at the oil rail end to final torque of 25-30 N.m.
6) Tighten the high-pressure oil pipe connecting nut at the fuel pump end to final torque of 25-
35N.m.
The tightening torque of high-pressure fuel pipe nuts should not be too big; otherwise, the commo n
rail parts may be damaged. The high-pressure fuel pipes should be closely connected without leakage.
During assembly, firstly disassemble the high-pressure fuel pipe nut at the oil rail end and then the
high-pressure fuel pipe nut at the fuel injector and high-pressure fuel pump end. When disassembling
the high-pressure fuel pipe nut at the high-pressure fuel pump and fuel injector end, be sure to use a
tool to fix the connector of high-pressure fuel pump or fuel injector to avoid loosening the connector.

40
There is a hole in the rail pressure sensor. When water inflows, the sensor may be rusty, resulting in
sensor malfunction. Meanwhile, the vent hole is blocked by paint or other objects, resulting in sensor
malfunction. Therefore, properly keep the connector rubber ring and never directly flush the joint by
water. Use plastic paper or rubber tape to wrap the harness and sensor to prevent water inflowing.

Warning: when the oil pressure in the common rail pipe reaches 1,400bar, never loosen the
high-pressure oil pipe joint nut at the high-pressure fuel pump, rail and nozzle end. During
repairing, it's not allowed to do welding and repairing on the common rail pipe.
4. Oil-water separator
The oil-water separator structure is shown in the figure below. Main technical parameters of oil- water
separator: rated flow≥300L/h; filtration precision 30μm, filtration efficiency≥99%; water separation
rate ≥93%; clogging capacity≥100g; at rated flow, the inlet and outlet voltage drop ≤10kPa. The oil-
water separator should be firmly fixed on the frame rather than on the engine; otherwise, the water
filtration effect may be greatly lowered.
Principle of oil- water separator: the diesel oil enters the oil- water separator through the oil inlet and
flows out from the oil outlet after being filtered. The filter element adopts imported water-
preventing filter element with two functions: impurity filtration and oil-water separation. When water
in diesel oil flows through the filter element, it adheres to the external surface of filter paper and it's
condensed into water drop falling in the water cup under the gravity.
The oil-water separator is assembled a water level sensor below. When water reaches certain level,
the water temperature sensor gives out signal to ECU for alarming; at this time, unscrew the lower
drain plug for draining water.
The oil-water separator adopts spin-on filter tank and filter tank, which is easy for replacing the filter
element. Before assembling the oil-water separator on the vehicle, ensure that the joint is not

41
damaged. After assembly, the dip angle in vertical direction should be less than 10º.
Replace the filter tank and filer element:
1） Thoroughly clean the external surface of filter assembly and use a wrench or proper tool to
loosen and disassemble the filter tank and filer element.
2） Ensure that the thread joint is fastened on the filter seat and the filter seat is clean.
3） Apply little clean fuel to the seal ring of new filter tank and filer element. Twist the filter tank and
filer element on the filter seat by hands till the resistance is felt.
4） Use a wrench to tighten the filter tank and filer element. Release the oil way and check the
leakage condition.
Please replace the filter tank and filer element as per the operating manual!

Filter seat with hand pump

Filter element assembly

Heaters

Water cup
Sump oil
Drain screw and water level Pure oil
Water/sump oil

Structure and Principle of Oil-water Separator

Exhaust air in the low-pressure fuel pipe
If there is air in the fuel pipe, be sure to use the hand oil pump on the diesel oil filter to exhaust air in
the fuel pipe and high-pressure fuel pump. Fill fuel in the fuel pipe and high-pressure fuel pump and
start the engine.
Attention: the air in the high-pressure fuel pipe and fuel rail will be automatically drained back
to the fuel tank whe n the high-pressure fuel pump is working. It's not allowe d to unscrew the
high-pressure fuel pipe bolt to exhaust air.

42
 Unscrew the vent
screw on the filter.

Exhaust air in the oil-water separator and filter

Exhaust steps and attentions are as follows:
1） Unscrew the vent screw on the diesel oil filter.
2） Repeatedly press and loosen the hand pump to pump oil till that there is no air at the vent screw.
3） Tighten the exhaust screw on the diesel oil filter and unscrew the vent screw on the oil-water
separator.
4） Repeatedly press and loosen the hand pump to pump oil till that there is no air at the vent screw.
5） Tighten the vent screw and use the hand pump to pump fuel till the fuel injection pump is filled
with fuel.
Water in diesel oil may cause corrosion and abrasion of high-pressure fuel pump, fuel rail and fuel
injector. If the diesel oil filter water level alarm indicator on the instrument panel illuminates, it means
that the diesel oil filter is filled with water which should be drained in time.
Drainage step:
1） Loosen the drain plug (but not unscrew it), drain water till the
diesel oil flows out.
2） After drainage, tighten the drain plug and press the manual
Unscrew (never
fuel delivery pump for several times. screw off) the plug
3） Start the diesel engine and confirm no oil leakage at the drain to drain water and
screw it down after
plug, and check whether the oil-water separator indicator drainage.

goes out.
Oil-water separator drains water

Attention: Water in fuel may greatly endanger the fuel system! When the diesel oil
filter water level alarm indicator on the instrument panel illuminates, please drain
water in time!
5. Diesel oil filter
The diesel oil filter is high-pressure common rail special filter and the diesel oil filter is assembled

43
with vent screw. Main technical parameters of diesel oil filter: rated flow≥300L/h; filtration precision
3-5μm, filtration efficiency≥95.5%; clogging capacity≥30g; at rated flow, the inlet and outlet voltage
drop ≤15kPa.
The diesel oil requires high filtration precision. It couldn't be replaced by common diesel oil filter
element; otherwise, the service life of common rail system part may be greatly influenced.
The effective life of diesel filter is related to the oil quality. It's generally 10,000-15,000km. The user
should replace the filter regularly as per the maintenance requirements.
6. ECU control unit
ECU is the "brain" of the electronic control system, and it's composed of hardware and software.
During assembly, keep the engine and vehicle away from the high temperature zone and keep good
ventilation. No coverage is permitted on the ECU. Avoid dust accumulation for a long time. Collisio n
and dropping are prohibited in the using and repairing process.

ECU control unit pin

ECU pin connection: it consists of 60-engine harness A and 94-pin harness K and totally 154-pin. The
ECU pin diagram is shown above.
When disassembling ECU connector, firstly turn the black locking device to the ultimate position,
unplug the connector; when assembling the connector, maintain the disassembled state and pull the
black locking device downward till clear click is heard, it means that it's at the locking device. During
disassembly, if it's hard to unplug or plug it, never forcefully unplug or plug it; firstly check whether
the locking device is in place, and whether there is foreign matter in the connector; otherwise ECU
pin and connector may be damaged. Attention: be sure to firstly turn off the ECU master power
switch when disassembling ECU connector.
When disassembling ECU connector, check whether the pin is bending to ensure that all contacts are
properly connected. Slightly shake the pin on the socket by hands to check whether it's loose. Check
whether the pin is corrosive, if so, replace the plug or sealing element.
The ECU cannot receive overhaul and repairing but receive basic check. The ECU fault should be
diagnosed by special diagnostic instrument or diagnosis software; otherwise ECU may be damaged.

44
Attention: ECU controller must be assembled in the cab, the
assembly position should be waterproof, oilproof and
vibration-proof. The ECU housing and body must be
properly grounded.

7. Sensor:
● Crankshaft position sensor and camshaft position sensor
The crankshaft position sensor and camshaft position sensor of Yunnei China III diesel engine
electronic control system are the same and the model is DG6. The crankshaft position sensor and
camshaft position sensor are magneto electric sensors consisting of permanent magnet and coil. The
sensor continuously detects the change of signal tooth and coverts it into voltage signal and outputs it
to ECU.

Crankshaft position sensor or camshaft position

sensor DG6 Sensor mounting clearance
The crankshaft position sensor is assembled on the flywheel housing and the camshaft position sensor
is assembled on the gear chamber cover. After assembly, the clearance between sensor and signal
panel tooth top is 0.5-1.5mm. When assembling the crankshaft position sensor and camshaft position
sensor, apply little lubricating oil on the O-ring, press the sensor to the bottom by hands and assemble
the fixing bolt and never fasten the bolt when the sensor is not assembled to the bottom.
The crankshaft position sensor is connected with ECU pin 27 and 12, the camshaft position sensor is
connected with ECU pin 50 and 10. Pin 12 and 10 are high level positive; pin 27 and 50 are low level
negative. The connecting wire has shielding layer and is connected with the grounding wire to
prevent interference.

45
Crankshaft position sensor monitors the tooth
number and tooth missing position of flywheel to get
the speed and crankshaft position signal of diesel
engine and confirm the fuel injection time and
sequence.
Camshaft position sensor monitors the boss position Camshaft position sensor
Crankshaft position
of camshaft timing gear to get the camshaft position sensor

signal of diesel engine and confirm the fuel injection

time and sequence. The camshaft position sensor is
assembled on the gear chamber cover, as the oil
pump gear and camshaft gear tooth are the same, the
sensor monitors the fuel injection pump gear position
to get the camshaft gear position.
The sensor connecting wire is twisted and wrapped by shielding layer and connected with the
grounding wire to prevent interference. The sensor fault may cause that the diesel engine is unable to
start or work properly.
The fault of crankshaft position sensor and camshaft position sensor may cause that the diesel engine
is unable to start or work properly.
Fault detection method for crankshaft position sensor and camshaft position sensor:
(1) Check the sensor
1) Multimeter: measure the resistance of two pins of sensor and the coil resistance is about
(860±86)Ω under 20℃.
2) Oscilloscope: use the oscilloscope to observe the pulse waveform and each tooth (or groove)
generates an electric pulse.
(2) Check the connecting wire
Turn off the ignition switch and unplug A line plug on ECU. Use the multimeter to check the wire
connection between speed sensor plug and ECU plug. If the wire is broken, replace the harness.
● Intake temperature pressure sensor
Yunnei China III diesel engine adopts the intake temperature
pressure sensor integrating intake temperature and intake
pressure sensor, which can measure the intake temperature and
the intake pressure. It's fixed on the intake connecting pipe of
engine to measure the pressure and temperature of intake pipe.
The pressure measuring scope of intake temperature pressure
sensor is 20-250kPa and the temperature measuring scope is

46
-40-130℃.
The intake temperature pressure sensor is assembled on the
intake pipe. During assembly, apply little lubricating oil to O-
ring, press the sensor to the bottom by hands, assemble the
fixing bolt and never fasten the bolt when the sensor is not
assembled to the bottom.
The fault of intake temperature pressure sensor may cause too
thick or thin flammable mixed gas, which may increase the fuel
consumption and unstable running of diesel engine.
There are 4 leads for intake temperature pressure sensor, power
supply (pin 14), pressure signal (pin 40), temperature signal (pin
53) and grounding wire (pin 23).
Fault detection method of intake temperature pressure sensor:
(1) Ohmmeter: use the ohmmeter to test the resistance between
pin 53 and pin 23. As per the relation between intake
temperature and resistance of diesel engine, refer to the
resistance-temperature property table to judge whether the
intake temperature pressure sensor is normal.
(2) Voltmeter: assemble the intake temperature pressure sensor on the diesel engine, start the diesel
engine and connect the voltmeter on the sensor signal line pin 53. Corresponding to different intake
temperature, the voltmeter will display corresponding voltage drop. The voltage drops with the rising
of temperature.
Table for electrical property of intake temperature pressure sensor
Table for resistance-temperature property
TEMPERATURE ℃ R minimum (Ω) R nominal (Ω) R maximum (Ω)
-40 45301 48153 51006
-30 25350 26854 28359
-20 14785 15614 16443
-10 8951 9426 9901
0 5605 5887 6168
10 3618.7 3791.1 3963.5
20 2401.9 2510.6 2619.3
30 1644.7 1715.4 1786.2
40 1152.4 1199.6 1246.7
50 819.1 851.1 883.0
47
 60 590.3 612.3 634.2
70 431.0 446.3 461.6
80 318.68 329.48 340.27
90 238.43 246.15 253.86
100 180.42 186.00 191.58
110 137.63 142.08 146.52
120 106.09 109.65 113.21
130 82.58 85.45 88.32
The electrical property of intake temperature pressure sensor is shown in the figure below.
The fault of intake temperature pressure sensor may cause too thick or thin flammable mixed gas,
which may increase the fuel consumption and unstable running of diesel engine.
The maximum input voltage of intake temperature pressure sensor should not exceed 16V, the
maximum pressure should not exceed 500kPa; otherwise, the sensor may be damaged.
Output voltage (V)

Absolute pressure

Electrical property of intake temperature pressure sensor

● Water temperature sensor
The water temperature is assembled on the thermostat housing and its working principle is the same
as that of intake temperature sensor. It's mainly used to convert the coolant temperature change into
the resistance change, transmits it to ECU and make dynamic adjustment of fuel injection volume of
diesel engine.
The resistance property of water temperature sensor is shown in the table below. The overall
dimension and cable wiring is shown in the figure below.

48
The water temperature sensor has two leads, signal line (pin 58) and grounding wire (pin 41).
Fault detection method of water temperature sensor:
(1) Ohmmeter method: use the ohmmeter to test the resistance. As per the relation of diesel engine
coolant temperature in Table 2-2, judge whether the water temperature sensor works properly.
Disassemble the water temperature sensor, and put the sensor in the water for heating, as shown in
Table 2-2. Corresponding to different temperature, the sensor has fixed resistance.
(2) Voltmeter: assemble the water temperature sensor on the diesel engine, start the diesel engine and
connect the voltmeter on the sensor signal line. Corresponding to different coolant temperature, the
voltmeter will display corresponding voltage drop.
Table for Temperature and Resistance Property of Water Temperature Sensor
Resistance Resistance Resistance
TEMPERATURE ℃ TEMPERATURE ℃ TEMPERATURE ℃
(kΩ) (kΩ) (kΩ)
-40 45.313 20 2.500 100 0.186

-30 26.114 25 2.057 120 0.113

-20 15.462 40 1.175 140 0.071

-10 9.397 60 0.596

0 5.896 80 0.323
● Electronic accelerator pedal
The electronic accelerator pedal transmits the driver's
intention to ECU. By monitoring the accelerator signal,
calculate and decide the fuel injection volume and fuel
injection timing.
The electronic accelerator pedal adopts double
potentiometer signal output (proportion type) to ensure
high driving safety. The working temperature is -40-80℃
and the working voltage Vcc is 5±0.3V.

49
The electronic accelerator pedal temperature sensor wire is
connected with the ECU vehicle harness K. There are
totally 6 leads, sensor 1 signal line (K09 pin), sensor 1
grounding wire (K30 pin), sensor 1 power supply (K22
pin), sensor 2 signal line (K08 pin), and sensor 2 grounding
wire (K31 pin). Sensor 2 power supply (K46 pin).

Briefly, the electronic accelerator pedal is a double sliding resistant and the two signal output of
electronic accelerator pedal is in multiple relation, i.e. signal 1 voltage is 2 times as much as the signal
2 voltage.
Fault detection method of electronic accelerator pedal sensor: assemble the electronic accelerator
pedal sensor and connector, start the diesel engine, press the electronic accelerator pedal, connect the
voltmeter on the sensor signal line. Corresponding to different opening degrees of accelerator, the
voltmeter will display corresponding voltage drop.
Electrical property of electronic accelerator pedal
Accelerator
APP1 sensor voltage (V) APP2 sensor voltage (V)
opening %
0 (0.15±0.03)Vcc (0.075±0.03)Vcc
100 (0.768±0.05)Vcc (0.384±0.06)Vcc

50
 Output voltage rate (%VCC)

Throttle opening (%)

7. Harness
The harness is very important for the whole common rail system. It's the bridge for power, ECU,
sensor and executor and it's the passage delivering various information. The harness should be made
by special wire with minimum resistance. The harness making requirement is shown in Table 7. In
any condition, the harness connector should be dry without water, oil and dust to prevent short circuit.
Although some protective measures are taken for the harness part connector, it's not allowed to
directly the engine electrical part and connector by water. Harness diagram is shown in Appendix II.
It would be best to adopt the main relay with diode. When the main relay stops supplying power, the
solenoid coil will generate high dynamic potential, which may damage the ECU if it's applied on the
ECU. If the main relay with resistance is adopted, the dynamic potential may be consumed by other
electrical components so the resistance consumption effect is not as good as that of diode.
Table: harness making requirement
Wiring harness name Does it need shielding? Does it need twisted harness?
Fuel injector control harness No yes

Crankshaft position sensor harness yes yes

Camshaft position sensor harness yes yes

Rail pressure sensor harness No yes

High-pressure fuel pump measuring unit harness No yes

Speed signal input harness No yes

Exhaust brake valve harness No yes

51
(IX) Assembly and adjustment of engine assembly
● The engine assembly should be assembled as per the sequence contrary to the disassembly.
● After the engine assembly is assembled, fill cold water in the radiator; fill soft water otherwise
serious scale may be generated to block the hole and influence the radiating effect.
● Unscrew the oil filler cap, fill oil to the specified height and the oil level should be between two
scale lines of oil dipstick. Fill Yunnei special A3/B4 oil.
● Connect the fuel pipe and eliminate air by following method: firstly check the connecting pipe
for no leakage, loosen the diesel oil filter bolt, use the hand pump to pump out oil and fasten the
bolt when the oil flows out.
● Check and confirm that the engine is properly connected, start the engine, check and eliminate oil,
water and gas leakage.

52
 Chapter IV Maintenance and Check of
Diesel Engine
(I) Body assembly
1. Clean and check the body:
Disassemble the lubricating oil way plug and clean all oil ways. Blow away impurity by the
compressed air and dry the oil way. Clean and check the thread hole fixing the cylinder head. Use the
screw tap to repair the thread hole and clear the impurity. Clean and blow off all thread holes on the
cylinder block (thread hole with impurity may cause bolt blockage, which may be wrongly deemed as
that the tightening torque of bolt exceeds the specified value).
After cleaning the body, carefully check the block for crack. Perform water pressure test. Test method:
Assemble the cylinder head and liner on the block, seal all jacket openings and apply the water
pressure of 392kPa for 2min and check the cylinder block for leakage. If the thread is not serious,
repair the crack by bonding or welding as per the crack size and degree. If it's unable to repair, replace
the body.
Check the mating surface between body and cylinder head and other mechanical processing surface
for burr, scratch, groove and corrosion. Light damage can be grinded by a very thin grinding bar.
Check the flatness of body mating surface. The
maximum permissible deviation of flatness is 0.1mm. I f
the deviation exceeds the specified value, grind the bod y
mating surface. Before grinding, take out all cylinder
liners. Use the flat grinder to grind it and the meta l
thickness grinded should not exceed 0.25mm. To ensure
the verticality of cylinder axis, for body grinding, select
the centerline of body main bearing as the benchmark. I f
the body bottom surface is subject to small deformatio n
but flat, do grinding as the benchmark. Otherwise, the
compression ratio may be changed.

53
Check the cylinder sleeve shoulder protruding the upper
level of 0.02-0.128mm and the cylinder sleeve
protruding height difference of same body should not
exceed 0.05mm.
2. Check and repair the cylinder sleeve:
When the engine cylinder hole abrasion reaches certain
degree, the technical performance of engine is obviously
deteriorated, the power is lowered, and the fuel and
lubricating oil consumption is obviously increased.
Generally, the abrasion degree of cylinder hole should
be main basis for overhaul of engine. The cylindricity
and roundness after cylinder abrasion should be the
mark of overhaul of engine.
Measurement method of cylindricity and roundness of
cylinder sleeve:
1) As per the diameter of cylinder hole, select proper
extension bar and fix it at the lower end of cylinder bore
gauge.
2) Verify the size of cylinder bore gauge.
3) Use the cylinder bore gauge to respectively measure the upper edge, middle and lower edge of
cylinder sleeve. Respectively measure the direction parallel and vertical to the crankshaft from each
section.
Attention: when the cylinder bore gauge is used for measurement, the measuring bar should be
vertical to the cylinder axis; otherwise, the measurement is not accurate.
4) Calculate the error of cylindricity and roundness as per the measured results.
The roundness error is the half of difference between maximum and minimum diameter of the same
section measured.
The cylindricity error is the half of difference between maximum and minimum diameter measured in
any direction of cylinder surface. When the roundness of cylinder exceeds 0.04mm and the
cylindricity exceeds 0.08mm, replace the cylinder sleeve.
If there is slight scratch on the cylinder wall, the roundness and cylindricity don't exceed the limit,
grind it by the grinding bar.
If there is serious scratch, burn and scuffing on the cylinder wall, replace the cylinder sleeve.
To calculate the clearance between cylinder and piston, use the micrometer to measure the maximum
diameter at piston skirt. The difference between this value and maximum diameter of cylinder

54
measured above is the clearance between piston and cylinder. The clearance should not exceed
0.195mm.

(II) Cylinder head part

1. Clean and check the cylinder head: use the scraper and wire brush to clear the carbon deposit in
the combustion chamber and valve. To protect the valve seat, don't disassemble the valve but avoid
scratching the assembly surface of cylinder head. After cleaning the carbon deposit, disassemble the
valve and clean the valve guide pipe hole. After mechanically cleaning the carbon deposit, wash the
recessed and oil fouling on the cylinder head by alkaline water (gasoline or pure alcohol) and dry it.
Check the cylinder head assembly surface for damage. Slight scratch can be grinded by the thin
grinding bar.
2. Check and repair the deformation of cylinder head and body mating face: Put a ruler on the plane,
use the feeler gauge to measure the clearance between ruler and plane and use the flatness inspection
instrument to measure the clearance. The standard is that the flatness error at the lower surface of
cylinder head is no more than 0.10mm. If it's over 0.10mm, grind the plane. There are two repairing
methods for deformation of cylinder head plane: When the plane is greatly deformed, partially press it
and do scraping to grind the plane. Put the sizing block of 0.5-0.7mm at two ends of cylinder head, fix
the middle part on the flat plate, apply pressure to the middle part and heat it to 300℃. Gradually
knock the cylinder casting surface by a small hammer and stop for 5min. Move the pressing plate to
1/3 of total length of cylinder head, proceed to above processes, loosen the compression device, take
out the cylinder head to check the correction condition. If the technical requirement is not met, do
scraping to grind the plane.
The other method is plane milling method: For milling, put the cylinder head on the support with
plane facing upward, fasten it after alignment. Do milling as per selected milling specification.
Ensure that the height of cylinder head is no less than 91.89mm after grinding, otherwise, replace the
cylinder head.
3. Check and repair the deformation of mating surface of cylinder head and intake and exhaust
manifold: The method to check the deformation of mating surface of cylinder head and intake and
exhaust manifold is the same as the method to check the mating surface of cylinder head and cylinder
block. The flatness tolerance is 0.15mm if it's above 0.15mm, do grinding. The grinding should not
exceed 1mm.
4. Check and repair the cylinder head crack: Perform the hydraulic test to check the cylinder head
crack. If the conditions are not met, test the thin crack not visible by naked eyes: apply the mixture of
75% oil and 25% kerosene to the part with crack, wipe off the mixture by cotton yarn, and
immediately apply a layer of methanol solution of zinc oxide. If there is crack, the solution at crack

55
may change color. Be sure to replace the cylinder head with crack.
5. Check the valve seat for excessive abrasion and crack and whether the exhaust valve seat ring is
loose
The intake and exhaust valve seat are pressed on the cylinder head
by interference fit and match with the valve by the conical sealing
tape with 90o taper angle. The width of sealing tape should be
1.35-1.55mm. The valve sinkage is 1.0-1.4mm. If the sealing tape
is burnt, do reaming for repairing. The abraded metal can properly
eliminate the scratch and deviation. If the valve seat exceeds the
deviation or the valve sinkage exceeds the abrasion limit, replace
the valve seat and valve. For replacement, adopt dry- ice cooling
valve seat ring, quickly press it in the seat hole, use hot water to
heat the cylinder head to 80-90℃, take out the cylinder head from
hot water and immediately do operation so as to assemble the valve
seat ring when the cylinder head is hot.
Check the sealing condition after grinding and matching of valve and valve seat, perform gas leakage
test or fill kerosene in the valve pit and observe it for leakage and judge the sealing effect.

(III) Valve mechanism

1. Camshaft assembly
The camshaft is at the left lower part of cylinder and it's mainly equipped with intake and exhaust cam
and oil pump driving gear. The sequence of intake and exhaust cam should be intake exhaust intake
exhaust.
Check and repair the camshaft and bushing: clean and wipe the camshaft. Check the cam surface for
pit, scratch and abnormal abrasion. Check the abrasion condition of oil pump driving gear and
observe the gear tooth for breakage or peeling off. The slight scratch of cam surface can be grinded by
the thin grinding bar. If the cam abrasion is serious and the lift exceeds the limit, be sure to replace the
camshaft.
Check the cam lift: use the micrometer to measure the cam height
at the peach tip direction of cam, measure the diameter of ca m
base circle in the base circle direction of cam and the difference o f
two is the cam lift. The intake cam lift should be 7.42-7.22mm but
no less than 7.0mm (abrasion limit). The exhaust cam lift should
be 8.05-7.85mm but no less than 7.60mm (abrasion limit). If the
abrasion limit is exceeded, replace the cam.

56
Check the clearance between the camshaft journal and bushing,
use the dial gauge to measure the diameter of camshaft journal
and use the inner diameter dial gauge to measure the bushing bore
and the difference of two is the bearing clearance.
If the clearance between the camshaft journal and bushing exceeds the abrasion limit, replace the
camshaft or bushing.
Check the coaxiality of camshaft: use V-gauge and dial meter to check the coaxiality of camshaft, if it
exceeds 0.04mm, replace the camshaft.
To replace the camshaft due to damage, if the clearance between the new camshaft journal and old
bushing hole fails to exceed 0.1-0.176mm, never replace the bushing; if the clearance exceeds the
above specified value, replace the old bushing with the standard bore bushing.
When the engine is assembled on the vehicle, check the cam lift as per following procedures :
Disassemble the cowl head and disassemble the rocker arm component. Check whether the push rod
is correctly assembled in the recess of tappet. Assemble the dial gauge and keep the contact in the
push rod end recess and in the same direction with the push rod axis. Slowly rotate the crankshaft and
keep the tappet contact with the cam base circle. At this time, the push rod is at the lowest position.
The dial gauge pointer points at zero. Keep rotating the crankshaft till the push rod reaches the highest
position. Record the cam lift indicated by the dial gauge. Keep rotating the crankshaft to keep the dia l
gauge pointer point at zero and check whether the first reading is accurate. Use the same method to
measure the cam lift.
In case of scratch, crack, peeling off or excessive abrasion of tappet, replace it. Before assembly of
new tappet, make following preparations: clean the tappet by acetone or industrial alcohol and
completely clear the grease on the surface.
Check the axial clearance of camshaft as per following operations: Assemble the dial gauge and keep
the contact of dial gauge block the screw of camshaft end. Push the camshaft toward the back of
engine to block it; the dial gauge pointer points at zero. Pull the camshaft toward the front of engine to
block it, record the reading of dial gauge and the reading is the axial clearance of camshaft. The
clearance should be within 0.095-0.318mm.
2. Check and repair the rockshaft assembly: Before inspection, clean all parts. After cleaning, check
whether the lubricating oil duct is complete. Check the rocker arm aperture and axial diameter of
rockshaft with rocker arm, and calculate the clearance. The maximum clearance between rockshaft
and rocker arm hole exceeds the permissible abrasion limit (0.15mm), as per the part abrasion
condition, replace the rockshaft or rocker arm, or replace one.
Check the rockshaft and rocker arm hole for crack and other damages. Slight surface scratch can be
grinded by the thin grinding bar.

57
If there is concavity caused by excessive abrasion of an end of rocker arm compression valve, replace
the rocker arm and never grind the concavity for continuous use.
Check whether the thread of adjusting screw and screw hole of rocker arm are complete. Check the
adjusting screw bulb for crack, scratch and excessive abrasion.
Check the retaining spring for damage. In case of above damage, replace the part.
3. Check the push rod: When the push rod is assembled on the engine, the valve is closed, rotate the
push rod by hands and visually check its straightness. Use the dial gauge to perform strict inspection:
on the special tester with dial gauge, use the two ends of push rod for fixing and check the bending
degree. The permissible bending degree of full length of push rod is 0.5mm. When the bending
degree is above 0.5mm, if it's within 3.0mm, put the push rod on the press for straightening. If the
bending degree is big, be sure to replace the push rod.
Check the bulb and recess at two ends of push rod for scratch, crack and excessive abrasion. In case o f
damage, replace the push rod.
4. Check and repair the valve assembly: before inspection, use fine wire brush to clear the carbon
deposit on the valve and do cleaning. Check the valve head, sealing cone and other parts for burnout,
corrosion, scratch, bending and crack. The slight scratch can be repaired, if not, replace a new one.
Check the valve stem for scratch and excessive abrasion. The conical angle of valve and diameter of
valve stem should be measured by the multimeter. The maximum permissible radial runout of valve
head cone is 0.02mm and the maximum permissible straightness of stem is 0.01mm.
5. Check and repair the valve guide: To check the clearance between valve and valve guide, insert
the valve in corresponding guide. Measurement: put the special survey meter on the valve stem end
and fix it by the screw. Push the valve downward to separate the valve head from the valve seat and
measure the contact between survey meter and valve guide. Put the dial gauge support on the cylinder
head, keep the contact between dial gauge and ball part of survey meter and form an angle of 90o with
the valve stem. Shake the survey meter toward the dial gauge direction, keep the valve stem cling to
the guide wall and record the reading of dial gauge. Push the survey meter toward the direction awa y
from the dial gauge and record the reading at ultimate position (never lift the survey meter from the
valve guide end). The effective clearance between valve stem and guide is the movement distance o f
dial gauge dividing 2.
If the clearance between valve guide and valve stem exceeds the limit due to abrasion, replace the
valve guide.

(IV) Crankshaft, flywheel and clutch parts

1. Structure of crankshaft, flywheel and clutch
The crankshaft is full support casting crankshaft, which is casted into integral structure with the

58
balance block. The flywheel is assembled at the back of crankshaft. The flywheel is positioned by the
locating pin and connected by the flywheel bolt. The main bearing bush is steel back high tin
aluminum alloy thin wall bearing bush. The crankshaft, flywheel and clutch assembly have received
dynamic balance treatment before delivery, after shipping, carefully make adjustment.
2. Clean and check the crankshaft: wipe and wash the crankshaft by the detergent and dry it by the
compressed air. Pay attention to protecting the crankshaft journal processing surface from damage.
Check the main journal and connecting rod journal for pit, scratch and crack. The crankshaft crack is
generally at the transition round corner between crank arm and journal and the oil hole. The former
one is transverse crack, in case of crack, replace the crankshaft; the latter one is axial crack, if
necessary, replace the crankshaft. Perform magnetic crack detection and fluorescent flaw detection to
test the crankshaft crack. The slight scar can be grinded by a very thin grinding bar. Large damage
must be repaired by grinding or replacing the crankshaft.
Check the cylindricity of main journal and connecting rod journal, if it's above 0.01mm, grind the
crankshaft journal.
3. Check the lower surface of bearing bush: ① the abrasive resistant material of bearing should be
free of scratch or impurity; ② it's free of bearing bush blockage or falling of abrasive resistance
material due to poor lubrication; ③ there is no partial spot on the bearing bush surface due to
improper assembly; ④ the abrasive resistant material of bearing may not be extruded to one side due
to the taper of journal; ⑤ the bearing bush surface should be free of wrinkle and crack betwee n
abrasive resistant material and steel belt due to fatigue.
4. Check the bearing clearance and replace the bearing bush: measure the clearance between the
crankshaft main journal and bearing bush, assemble the bearing cap and bearing bush on the bearing
seat and apply specified torque to fasten the bolt. Use the inner diameter dial gauge to measure the
hole diameter and use the micrometer to measure the diameter of connecting rod journal to check
whether the bearing clearance exceeds the abrasion limit. If the cylindricity of one or more
connecting rod journals and bearing clearance exceed the abrasion limit, replace new bearing
connecting rod bush.
When measuring the clearance between connecting rod journal and bearing bush, assemble all
bearing bushes and bearing caps on corresponding connecting rod and apply specified torque to
tighten the fastening bolt of bearing cap. Use the inner diameter dial gauge to measure the inner
diameter of connecting rod bearing hole and use the micrometer to measure the diameter o f
connecting rod journal to check whether the bearing clearance exceeds the abrasion limit.
If the cylindricity of connecting rod journal and bearing clearance exceed the abrasion limit, replace
new connecting rod bush.
5. Check the flywheel: check the abrasion condition of flywheel and clutch contact surface; in case

59
of abrasion or damage, replace the flywheel. Use the dial gauge to check the runout of flywheel and
clutch contact surface, if it's above 0.2mm, replace the flywheel. Check the flywheel gear tooth for pit,
fracture, abrasion and other defects. If necessary, replace the flywheel gear ring.
6. Check the runout of flywheel and clutch contact surface: keep the dial gauge contact support the
flywheel working surface, maintain the crankshaft on the position with front and rear axial clearance
eliminated to avoid taking the axial clearance as the runout of flywheel. Rotate the flywheel and use
the dial gauge to measure the end runout of flywheel at the radius of 150mm, which should not exceed
0.2mm. If the dial gauge reading exceeds the specified value, replace the flywheel.
7. Check the axial clearance of crankshaft: Assemble the dial gauge at the
back of engine, keep the dial gauge measuring rod parallel with the
crankshaft axis, and the contact of measuring rod supports the crankshaft
flange of flywheel. Push the crankshaft toward the back of engine to keep it
block with the rear end of rear main bearing bush. The dial gauge pointer
points at zero. Push the crankshaft toward the front of engine to keep it
block with the rear end of rear main bearing bush and record the axial
clearance in the dial gauge. The clearance should be 0.07-0.262mm. If the
clearance is too big, be sure to replace the thrust plate. If the clearance is
too small, disassemble the bearing bush, and check the end for damage,
sharp edge and dirt. If the bearing bush end is clean and smooth, the small
clearance may be caused by misalignment of thrust plate.

(V) Piston and connecting rod assembly

1. Structure of piston and connecting rod assembly
The piston top is ω combustion chamber. There are three ring grooves on the piston head. The skirt is
oval. There are two gas rings and one oil ring of piston ring. The top gas ring is barrel surface plating
chromium keystone ring, the second gas ring is taper surface distortion ring and the oil ring is spiral
spring expansion ring. The connecting rod is forged part. To improve the piston strength, adopt wedge
connecting rod. There is a small oil hole on the connecting rod, which is used for lubricating the
connecting rod bushing and piston pin.
2. Clean and check the piston-connecting rod assembly
Clean and check the connecting rod: before washing, disassemble the bushing from the connecting
rod body and bearing cap. If the bushing can be reused, mark the bushing and assemble it back to the
original position. Wash the connecting rod body, big head and small end (it's prohibited to use
corrosive solution). Blow off the oil way by the compressed air.
Check the connecting rod for crack and fracture, if so, replace it.

60
Check the bending and distortion of connecting rod. The bending and distortion limit of connecting
rod is no more than 0.05mm for the length of 100mm. If the limit is exceeded, straighten or replace
the connecting rod.
Check the connecting rod big end bushing for abrasion, scratch, defect and check the cylindricity. The
clearance abrasion limit for bushing and crankshaft connecting rod journal is 0.20mm. If the abrasion
limit is exceeded, replace the connecting rod bushing.
Check the connecting rod bushing hole for abrasion, scratch, defect and check the cylindricity. The
clearance abrasion limit for connecting rod bushing and piston pin is 0.10mm. If the abrasion limit is
exceeded, replace the bushing. Press the new bushing in the connecting rod small end hole and do
reaming.
Carefully check the connecting rod bolt and nut, if damaged, replace them.
3. Clean and check the piston: Clear the carbon deposit inside and outside of the piston top. Clear
the carbon deposit at the piston skirt by the detergent. Never use corrosive solution and wire brush to
wash the piston. Use the special ring groove cleaning tool to clear the carbon deposit in the piston ring
groove, clean the oil way and oil hole. Check whether there is big step in the piston ring groove. If
there is step, the piston ring edge gap may be too big and the piston ring may be damaged. Therefore,
if there is big step, replace the piston. Check whether there is pit near the skirt part of piston ring edge
and piston pin seat. Check the piston skirt for damage and corrosion. In case of excessive abrasion of
piston, ring edge deformation, piston top edge fracture or pit and corrosion, replace the piston. Check
the clearance between piston and cylinder and the clearance limit should be 0.17mm. If the limit is
exceeded, replace the piston.
4. Clean and check the piston pin: clean the piston ring by the detergent. Check the clearance
between piston pin and pin seat hole and connecting rod small end bushing hole. The clearance
abrasion limit between piston pin and pin seat hole is 0.04mm. If the clearance exceeds the limit,
replace the piston and piston pin. The cylindricity of piston pin should not exceed 0.003mm, if the
value is exceeded, replace it. If the piston pin has pit, crack and abnormal abrasion, replace it.
5. Clean and check the piston ring: wash the piston ring by the
detergent. Check the piston ring, if there is corrosion or pit,
replace it. For overhaul of engine, replace the piston ring. Use
the feeler gauge to check the opening clearance of ring groove.
The top ring is 0.30-0.50mm, the second ring is 0.5-0.75mm and
the oil ring is 0.3-0.55mm. The abrasion limit is 1.5mm, replace
it if the limit is exceeded.

61
(VI) Driving wheel system
It consists of crankshaft timing gear, camshaft timing gear, fuel injection pump timing gear and idle
gear.
Check the timing gear: clean the timing gear by gasoline. Check the tooth shape; even if the gear tooth
is damaged and unevenly abraded, replace the gear in pairs. Use the multimeter to check the meshing
clearance of timing gear. During inspection, fix the gear, swing the other gear, and record the
clearance measured by the multimeter. The clearance should be 0.14-0.31mm.

(VII) Lubrication system

1. Structure of lubrication system
The lubrication system of diesel engine adopts the compound lubrication of traditional pressure
lubrication and splash lubrication. The oil pump adopts traditional gear oil pump and the oil pump is
driven by the camshaft.
The oil way of lubrication system is shown in the figure below. The oil in oil pan enters the oil pump
through the suction filter. After the oil flows out by the oil pump, the oil flows through the filter and
oil cooler, enters the main oil way of engine body and then to the crankshaft bearing, connecting rod
bearing, etc. by several branch oil ways for lubrication. In addition, oil in main oil way will flow to
the oil way of cylinder head for lubricating the camshaft. After lubrication, the oil flows back the oil
way and the oil pan.
Check the oil pan for crack and gap, check the drain plug thread for integrity and check the oil pan
assembly surface for crack and bending. Repair the damaged oil pan, if it's unable to repair, replace
the oil pan.

62
 Lubrication system
1. Clean and check the oil pump:
Clean all parts by the detergent and wipe up. Use the hairbrush to clean the inside of oil pump, clean
the pressure limiting valve and clear away metal scrap and sediment. Check the inside of oil pump,
driving and driven gear for damage or excessive abrasion.
Check the distance between the gear end and pump cover end and check the end clearance. Commo n
method: Use the feeler gauge and dimension gauge or add a lead wire between the driving gear end
and pump cover, assemble the pump cover, tighten the screw, disassemble the pump cover, and
measure the thickness of compressed lead wire, which is the end clearance of 0.06-0.125mm. If the
clearance is improper, add the cushion between pump cover and pump to make adjustment. If the
limit is exceeded, replace the gear pair or pump body.
Use the feeler gauge to check the meshing clearance of oil pump gear and the gear top clearance
between gear top and pump housing; if the limit is exceeded, replace the gear or housing; it would be
better to replace the gear in pairs.
If there is a pressure limiting valve, check whether the pressure limiting valve is properly matched,
whether the oil duct is blocked, whether the sliding surface is damaged, if necessary, replace the valve.
Check whether the pressure limiting valve is damaged, the elasticity is reduced, if necessary, replace
it. Check the clearance between oil pump shaft and bearing. If the limit is exceeded, repair the size or
add the bush to do repairing.
Check the performance of oil pump. After assembling the oil pump, test the assembly and confirm the
working performance. Simple method: Put the assembled oil pump in the oil and manually rotate the
gear, the oil continuously pumps out, block the oil outlet by hands, rotate the driving gear; if it's
unable to rotate the driving gear shaft, it means that the oil pump is good.
2. Clean and check the oil intercooler
Disassemble the oil cooler, check it for leakage, and clean the water scale on the oil cooler cooling
element.
3. Oil filter
The diesel engine oil filter consists of paper filter element and spin-on type. The paper filter element
has two sealed cavities. There are two valves (safety valve and pressure regulating valve) on the filter
seat. The pressure regulating valve is to control the oil pressure and maintain oil pressure of 200-
500kPa when the diesel engine is working (the pressure should be higher than 80kPa at minimum idle
stable speed); if the requirement is not met, adjust the pressure regulating valve. When the filter
element is blocked, the oil viscosity is too big or the filter element is blocked, and the oil is unable to
flow through the filter element, the pressure is raised, the pressure on the safety valve exceeds certain
value, open the safety valve to make the oil directly flow to main oil way not through the filter

63
element, so as to ensure the minimum lubrication of diesel engine. The overall flow spin-on filer is
the disposable oil filter. It's assembled in the lubricating oil circuit in series. The oil from the oil pump
should enter the main oil way through the filter.
Generally, the oil filter should be replaced (or cleaned) once every 10,000km. The user can make
proper adjustment as per the using condition.

(VIII) Cooling system

1. Structure of cooling system
The cooling system is closed forced circulation water cooling type. It mainly consists of radiator
(water tank), water pump, fan, wind scooper, thermostat, cooling water sleeve, pipe, etc. as shown in
the figure. The cooling system is to ensure that the diesel engine is working at proper temperature.
Too high or low temperature may influence the normal working of diesel engine, accelerate abrasion,
cause excessive heat loss and lower the economy.
When the diesel engine is running properly, the cooling water temperature is 75-95℃.
2. Structure of water pump and disassembly for
examination
Structure of water pump: The water pump is
traditional centrifugal water pump consisting of
water pump body, water pump shaft, bush, water
pump impeller, seal gasket, bearing sleeve, gasket,
water pump cover plate, water pump hub, etc.
Check the disassembled parts of water pump one by
one, if the bearing is damaged, replace it. if the
bearing seat hole and water seal seat hole are
abraded, recover it by brushing plating. If the
bearing is abraded, recover it by electroplating
method or replace it in serious condition. If the
water seal is not tight, replace the water seal
assembly.

64
Assembly of water pump:
To assemble the water pump, assemble the water
pump shaft lock ring on the water pump shaft.
Assemble the bearing snap ring on the end of water
pump body close to the impeller. Assemble the first
bearing and keep the sealing surface toward the
impeller chamber. Assemble the bearing sleeve.
Assemble the second bearing and the water pump
hub. Press the water pump shaft in the bearing hole.
Use the mandrel to press the water seal in the water 1. Bolt, 2, water pump cover plate, 3, gasket, 4.
pump body. On the hand press, use the mandrel to water pump impeller, 5. water seal assembly,
press the water pump shaft in the impeller, keep 6. water pump shaft, 7, water pump body, 8,
specified clearance, assemble the gasket on the bearing, 9. bearing sleeve, 10. water pump
water pump body and tighten the fastening screw. hub, 19, small circulation hose, 20, clamp, 21,
Apply a thin layer of oil to the assembly surface filling cup, 22, woodruff key
before the press fitting operation. Assemble the
water pump on the engine, keep the water pump
gasket cling to the water pump assembly surface
and assemble the water pump.
3. Thermostat
The diesel engine thermostat is wax-type
thermostat. Check whether the thermostat works
properly. Put the thermostat and thermometer in the
container with hot water, gradually heat it and
observe the thermometer. It's opened when the
water temperature is 76 土 2℃.
When the water temperature is low, the thermostat
is closed, the cooling water may not flow to the
radiator but flow back to the water pump. When the
water temperature reaches above 76℃, the
thermostat is gradually opened, cooling water flows
to the radiator for cooling.

(IX) Electronic control common rail system

Refer to Chapter III for the attentions for use of electronic control common rail system.

65
(X) Electrical system
1. Generator
The generator is silicon rectification generator. Pay attention to negative grounding and never
reversely connect the wire. As per the matching requirement, the vacuum pump can be assembled
behind the generator, as the vacuum booster auxiliary device of brake system. The wiring diagram is
as follows. The vacuum pump behind the generator, the joint between lubricating oil and oil inlet joint,
connection between vacuum drum and exhaust joint, connection between oil return joint and
crankcase should be tight. In the using process, ensure the cleanliness and proper viscosity of
lubricating oil. It's prohibited to work without oil; otherwise, the vacuum pump may be seriously
damaged.
The voltage regulator in the generator should be used with battery of corresponding voltage and
capacity. The diesel engine and automobile frame should be connected with a grounding wire firmly
and correctly.
When disassembling the charging generator, unscrew 3 interlocking bolts and rear end cover bearing
nuts, slightly knock the front end cover to separate it and gradually disassemble it to clear the dirt.
Generally, never randomly disassemble it.
To check the generator fault, firstly open the rear cover plate, use the multimeter to measure the diode
or integrated circuit adjuster (never use the megameter or AC power of above 110V to do the test).

Extraction joint

Oil inlet joint

Oil
return
joint

2. Starter
Adopt the starting motor with speed reducer and the power is 4.2kW.
The line connection of starter is shown in the figure below. The section area of copper lead connecting
the battery should be no less than 25mm2 and the length should not exceed 2m. The section area of
copper lead connecting the electromagnetic switch power supply circuit should be no less than 4mm2
and the length should not exceed 6m.
When cleaning the automobile or diesel engine, it's prohibited to flush the generator and starter by
water to prevent damage due to water.
66
 Starting switch

Starting relay

M agnetic
Switches

Battery

Starting pole

(XI) Intake and supercharging and intercooling system

The intake system can ensure the sealing reliability of pipe
and avoid damage and leakage.
1. Air filter
The air filter is cyclone dust collection paper filter. The air
filter and intake pipe should be reliably sealed and
connected. The air inlet of air filter should be at the place
with clean air. For disassembly and maintenance, pay
special attention to the sealing at two ends of paper
element, never damage the sealing part or damage or 1. Butterfly nut, 2. shroud, 3, filter
pollute the paper element. In the using process, it's element part, 4. housing part, 5. locking
prohibited to contact oil, water and fire. bolt, 6, square nut, 7. clamp
To ensure the air filtering effect, regularly maintain the air filter as per the technical maintenance
requirements. Frequently check the airtightness of joints of intake system to prevent air unfiltered
enters the cylinder through the gap.
2. Supercharging and intercooling system
The supercharging and intercooling system consists of intake pipe, exhaust pipe, intake connecting
pipe, supercharger, intercooler, etc. The exhaust turbine and air compressor of supercharger are
assembled on the same axis. The exhaust turbine is driven by the exhaust from the engine, the air
compressor compresses the air inhaled through the air filter so as to increase the air density in the
cylinder, increase the air volume, fuel supply of fuel pump and improve the output efficiency of
engine.
(1) Intake and exhaust pipe, intake connecting pipe
The intake pipe is to respectively supply air to all cylinders of diesel engine; the exhaust pipe is to

67
drain exhaust of all cylinders.
Frequently check the intake and exhaust pipe:
① Check the bolt for looseness.
② Check the intake and exhaust pipe gasket for erosion and leakage.
③ Check the pipe from air compressor to cylinder head for leakage. As the pipe leakage may
directly influence the normal working of diesel engine, be sure to keep leakproofness.
(2) Turbocharger
The supercharger is mainly composed of turbine, air compressor, intermediate housing and blow-
down valve (as shown in the figure below).

Air compressor

Blow-down valve

Intermediate housing
Turbine

◆ Turbine part
The turbine part mainly consists of turbine housing, single-stage radial turbine, as an energy converter.
The exhaust from diesel engine enters the nozzle through the turbine housing and injects toward the
impeller in a direction, convert the exhaust heat and pressure energy into kinetic energy so as to keep
the turbine rotate at high speed.
◆ Mid-body
The mid-body is the intermediate support body supporting the rotor assembly and fixing the turbine
housing and air compressor housing, as well as the lubricating oil tank for lubricating and cooling
floating bearing rotor.
◆ Air compressor

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The air compressor mainly consists of single-stage centrifugal air compressor impeller, diffuser and
air compressor housing. The air is sucked by high-speed rotating air compressor through the air filter,
so the air flow speed is increased, the pressure is raised; the air passes through the diffuser and air
compressor housing to convert the air flow kinetic energy into pressure energy; the pressure is further
raised, the air enters the cylinder through the diesel engine intake pipe so as to increase the air density
in the diesel engine cylinder.
The turbine shaft and turbine are welded together by the friction welding. The air compressor
impeller is assembled on the turbine shaft by transition fit and tightened by the self- locking nut. The
whole rotor assembly receives accurate dynamic balance treatment to ensure normal working under
high speed.
The rotor assembly adopts internal support. i.e. Two floating bearing are arranged on the mid-body
between two impellers. The thrust bearing device fixed on the mid-body withstands the axial force of
rotor.
◆ Blow-down valve
The supercharger adopts blow-down valve
to ensure maximum matching effect of
turbocharger in low and medium speed of
diesel engine so as to maintain sufficient air
of diesel engine, corresponding to the
increasing fuel supply, increase the low-
speed torque, improve the fuel
consumption, exhaust air (exhaust directly
enters the exhaust pipe not through the
turbine) at high speed scope, to avoid
supercharger rotor overspeed or big
combustion pressure in the cylinder and
increase the mechanical load of diesel
engine due to high supercharging pressure.
In other words, the turbocharger adopts
exhaust vent valve, which is mainly to 1-adjusting nut; 2-blow-down valve; 3-rocker arm, 4-
improve the low-speed torque property of pin shaft; 5-exhaust manifold; 6- gear; 7-air
diesel engine and combine the performance compressor impeller; 8- intake pipe; 9- induction pipe;
indicator and using reliability of diesel 10-sealed pressure pipe; 11-diaphgram; 12-spring; 13-
engine at high speed. linkaged push rod; A- exhaust inlet; B-exhaust
outlet; C-fresh air; D- supercharging air

69
The vent valve is a diaphragm valve consisting of two cavities. One cavity is connected with the air
compressor outlet and the other cavity is to the atmosphere. The opening and closing of vent valve are
automatically controlled by the supercharging pressure. When the supercharging pressure reaches or
exceeds the specified value, the diaphragm will overcome left spring force and move leftward with
the linkage push rod, push the rocker arm to rotate around the pin shaft, open the vent valve, realize
the exhaust valve bypass air bleeding and control the speed reduction of supercharger.
Attention:
a) The opening pressure of blow-down valve is set by the manufacturer, the user should not adjust it;
otherwise, it may seriously damage the dynamic property, economy and reliability of diesel
engine.
b) In any case, never take the blow-down valve push rod as the handle.
c) In the using process, in case of intake pipe leakage or inflexible blow-down valve push rod, stop
to eliminate the fault.
d) The blow-down valve and airtight pressure chamber couldn't be repaired but replaced in case of
damage.
(3) Maintenance of supercharger
To ensure the effective and reliable working of supercharging diesel engine, in addition to proper
operation, be sure to perform regular maintenance on the supercharger. However, the turbocharger is
precise high-speed rotary machine, its maximum speed is 160,000r/min or above, never randomly
disassemble the supercharger assembly, if not necessary. Too much dirt or carbon deposit on the
supercharger may cause inflexible rotation of rotor or poor performance of diesel engine, simply
clean and wash the supercharger rather than complete disassembly, the specific methods are as
follows:
a) Clean the dust and oil stain on the surface of supercharger.
b) Disassemble the supercharger from the diesel engine and never lift the supercharger by holding
the blow-down valve push rod.
c) Firstly disassemble the intake pipe and then the blow-down valve adjuster.
d) Disassemble the air compressor housing, turbine housing, oil inlet pipe, oil return pipe and
coolant pipe connecting parts.
e) Clean and wash the air compressor housing, turbine housing and two impellers. At the same time,
check the impeller for damage and polishing.
f) Fill proper clean detergent from the oil filler, rotate the impeller by hands and repeatedly operate
it till it can flexibly rotate.
g) Assemble the supercharger and assemble it on the diesel engine. When assembling the
supercharger, replace all sealing parts connected with the supercharger and fill clean lubricating

70
 oil in the supercharger oil inlet for pre-lubrication.
● Warning: When disassembling and cleaning the supercharger, never collide with the impeller, if
so, correct the deformed impeller before use. The detergent may be kerosene, gasoline or high
quality diesel oil.
(4) Check of supercharger
Check the radial clearance of rotor: Use two hands to radially press the air compressor impeller and
turbine impeller and use the feeler gauge to measure the minimum clearance between air compressor
impeller and housing, which should be no less than 0.1mm. If it's below the value, replace the floating
bearing (if it's unable to do repairing, replace the supercharger).
Check the axial clearance of rotor: Use the magnetic base to fix it on the turbine housing outlet flange,
keep the multimeter contact with the turbine rotor shaft end, push or drag the turbine rotor along the
axis and measure the difference, which is the axial clearance. The axial clearance of new supercharger
rotor should be≤0.111mm and the operating limit is ≤0.25mm. When the axial clearance of
supercharger rotor exceeds the operating limit, disassemble the assembly and replace the abraded
parts (if it's unable to do repairing, replace the supercharger).
Before confirming and eliminating the damage reason of supercharger, never replace the new
supercharger.
(5) Air-air intercooler
The air-air intercooler is assembled in front of the water tank radiator, generally at upper front of
water tank radiator rather than the lower front of water tank radiator. Leave proper distance below the
radiator to ensure cooling effect of water tank radiator.
There is no other cooling radiator (e.g. A/C radiator, etc.)
in front of the intercooler, keep certain distance from the
vehicle body parts to maintain air circulation. The face Intercooler

area of intercooler should not too big or small, generally

3/5 of face area of radiator. If it's too small, the Radiator

intercooling effect is poor, which may influence the

engine performance; if it's too big, the cooling water
radiation effect is poor, which may cause high water
temperature of engine. For the model with engine
assembled at back, due to the structure, the face area of
intercooler may be equal to the face area of water tank
radiator.
The radiation area of air-air intercooler should meet the
resistance and outlet temperature. The resistance of

71
air-air intercooler is generally ≤5kPa and the temperature
after intercooling is ≤75℃. The connecting hose of
intercooler and engine must be silicone rubber tube lined
with cloth. No failure is allowed under temperature of
-40℃-200℃ and pressure of 300kPa.

Intercoolers Compressed air

Engine

Turbocharger

Air suction
Exhaust

Exhaust from engine

(6) Matching requirement of supercharging and intercooling diesel engine

a) The air filter should be dry filter rather than oil-bath filter. The flow of air filter is ≥600m3 /h and
resistance is ≤2.4kPa; the inner diameter of intake pipe should be no less than Φ60mm; maintain
clean and smooth inner wall and the pipe system joint should be free from leakage; the
connecting hose should adopt rubber hose lined with steel wire to avoid that the hose is flat under
high speed air flow, and the air may be insufficient, the power may be lowered, the smoke may be
generated, resulting in oil leakage of supercharger air compressor. The intake vacuum of intake
pipe from the air filter outlet to air compressor inlet should be ≤4kPa; replace the air filter
element when the vacuum reaches 6.5kPa. If permissible, assemble the intake vacuum alarm
behind the air filter outlet to test the intake resistance, ensure the intake volume of diesel engine
and remind the operator to maintain and replace the air filter element.
b) The inner diameter of exhaust pipe should be no less than Φ54mm. If the silencer meets the noise
elimination quantity, the permissible exhaust resistance is 15kPa and the power loss of diesel
engine should not exceed 3-4%.
c) Generally adopt Φ450 induced cooling fan. For the model with tense arrangement, properly
reduce the cooling fan, but take other measures to meet the cooling requirement.
d) The face area of intercooler should not too big or small, generally 3/5 of face area of radiator. The
resistance of air-air intercooler is generally ≤5kPa and the temperature after intercooling is ≤75℃.
The connecting hose of intercooler and engine must be silicone rubber tube lined with cloth. No
failure is allowed under temperature of -40℃-200℃ and pressure of 300kPa.

72
e) The radiation area of radiator should be ≥20m2 ; Be sure to assemble the wind scooper. The radial
clearance between wind scooper and fan should be about 20mm. The distance between front end
of fan and radiator should be about 30-60mm.
(7) Use and maintenance of supercharging and intercooling diesel engine
a) Be sure to maintain the oil filter and replace the oil as per the operating manual.
b) Frequently clear impurity attached on the intercooler and water tank and flush the dust by high-
pressure water; otherwise, it may directly influence the performance and service life of diesel
engine.
c) After starting, it's not allowed to immediately run under load, keep it idle running for 3-5 minutes
to ensure poor lubrication.
d) It's not allowed to immediately shut down the diesel engine after working under high load, keep it
idle running for 3-5 minutes; it's prohibited to shut it down at downslope.
e) Avoid long-term idle running of diesel engine. If the idle speed is too long, the oil may flows to
the supercharger.
f) When the diesel engine is not used for a long term or the new supercharger is replaced, fill little
oil at the supercharger oil filler.
g) When the diesel engine is hot, it's prohibited to touch the supercharger and its connecting pipe to
avoid getting a burn.

73
 Chapter V Use of Diesel Engine
I. Diesel oil
The diesel oil grade is related to the ambient temperature. When the ambient temperature lowers, the
paraffin flows out from the diesel oil, which may block the fuel pipe. Therefore, in different regions
and seasons, select the oil with different grades as per different ambient temperature. Otherwise, it
may cause starting difficulty of diesel engine.
Ambient
Above 5℃ Above -5℃ Above -10℃ Above -25℃
temperature
0# light diesel
Diesel grade -10# light diesel oil -20# light diesel oil -35# light diesel oil
oil
1. Requirement of diesel oil cleanliness
Compared with the traditional mechanical fuel system, the electronic control system has strict
requirement on the fuel cleanliness. The electronic control system requires high fuel pressure,
accurate control and more precise matching of internal moving parts. Unclean fuel may shorten the
service life of fuel injection pump and fuel injector.
1) The oil filter is the key part to maintain the diesel oil cleanliness. The electronic control high-
pressure common rail diesel engine adopts two-stage special and high-efficient diesel filter,
i.e. oil-water separator (coarse filter) assembled on the vehicle and diesel oil filter (fine filter)
assembled on the engine.
2) The diesel oil filter and oil-water separator must be special supporting parts of Yunnei. Starting
difficulty, underpower and fuel system part abrasion and other faults caused by using poor quality
diesel oil filter and oil-water separator may be beyond the warranty of Yunnei.
3) Please be sure to regularly change the diesel oil filter element as per the maintenance regulations.
Attention: please fill diesel oil in normal gas station. Because that the poor quality
diesel oil may cause diesel engine fault and you may not enjoy the quality warranty
right.

74
2. Oil-water separation requirement
Water in the diesel oil may cause serious danger to the
common rail system!
Water in diesel oil may cause corrosion and abrasion of high-
pressure fuel pump, fuel rail and fuel injector. If the diesel oil
filter water level alarm indicator on the instrument panel
Unscrew (never screw off) the
illuminates, it means that the diesel oil filter is filled with water plug to drain water and screw
it down after drainage.
which should be drained in time.
Drainage step:
1) Loosen the drain plug (but not unscrew it), drain water till
the diesel oil flows out.
2) After emptying the water, tighten the drain plug.

Attention: When the diesel oil filter water level alarm indicator on the instrument
panel illuminates, please drain water in time!
3. Exhaust air in the fuel pipe
If there is air in the fuel pipe, be sure to use the hand oil pump on the
diesel oil filter to exhaust air in the fuel pipe and high-pressure fuel
pump. Fill fuel in the fuel pipe and high-pressure fuel pump to start
the engine.
Attention: the air in the high-pressure fuel pipe and fuel rail will
be automatically drained back to the fuel tank when the high-
pressure fuel pump is working. It's not allowe d to unscre w the
high-pressure fuel pipe bolt to exhaust air.
Exhaust steps and attentions are as follows:
1） Loosen the vent screw on the diesel oil filter, repeatedly press
and loosen the hand pump to pump oil till that there is no air at
the vent screw, tighten the vent screw again.
2） Loosen the vent screw on the oil-water separator, repeatedly press and loosen the hand pump to
pump oil till that there is no air at the vent screw, tighten the vent screw again.
3） Use the hand pump to pump fuel till the fuel injection pump is filled with fuel.

II. Oil
Attention: Be sure to use special oil for A3/B4 diesel engine specified by Yunnei
Power; otherwise, you may not enjoy the quality warranty right.

75
The oil viscosity is related to the ambient temperature. When the ambient temperature lowers, the oil
viscosity is increased so the starting resistance is increased, and the diesel engine may not easily reach
the speed, resulting in starting difficulty. Therefore, in different regions and seasons, select the oil
with different viscosities (grades) from the table below as per different ambient temperature.
Ambient Above -10℃ Above -20℃ Above -30℃ Extremely cold
temperature region
Oil grade 15W/40 10W/40 5W/30 0W/30
Check the oil level:
1） At normal temperature, shut down the engine and
wait for 5 minutes
2） Take out the oil dipstick, wipe it by a piece of cloth Upper scale
line
and re-insert the oil dipstick to the bottom.
3） Take out the oil dipstick again and observe the oil
level. Check whether the oil level is between the Lower scale
line
upper and lower scale line of oil dipstick; if not, fill
oil.
Change oil
Please be sure to regularly replace the engine oil and oil
filter element as per the maintenance regulations. Attention: To measure the oil level, the vehicle
must be at put horizontally. Shut down the engine
Frequent starting and running at high speed and load may and wait for about 5 minutes so that the oil flows
back
shorten the oil changing period.
Attention: Be sure to check the engine oil level and replace the oil. Imme diately find out the
cause if the coolant level is raised or lowered suddenly.

III. Coolant
Please be sure to use the auto coolant with antifreezing, anti-boiling, anti-corrosion and antiscale
performance.
1) Use the coolant all the year round and pay attention to the using continuity of coolant. Never
ignore the anti-corrosion, anti-boiling and antiscale function but only focus on the antifreezing
function of coolant.
2) As per the temperature at the using place, select the coolant with different ice points. The ice
point of coolant should be at least 10℃ lower than the minimum temperature of the region to
maintain the antifreezing function.
3) Buy qualified coolant product. Never buy the coolant with poor quality to prevent damaging the
engine and causing unnecessary economic loss.

76
4) Immediately find out the cause if the coolant level is lowered suddenly.
5) Never open the coolant compensation tank or radiator cover when the engine is hot. Otherwise, it
may cause burn risk!

IV. Starting of diesel engine

Attention: When starting, never press the accelerator, and never immediately keep the diesel
engine running at high speed after starting!
 Starting steps at normal temperature and attentions:
1） Turn off the main power switch.
2） Use the key to turn on the power supply and observe whether the electrical instrument indicates
properly.
3） After powering on, the system performs self-inspection on the fault lamp circuit and the fault
lamp illuminates. If the system is free of fault, the fault lamp will go out 2s later. If the electronic
control system is faulty, the indicator illuminates but it's not flashing; if the electronic control
system is seriously faulty, the indicator illuminates and is flashing.
Attention: When the fault indicator on the instrument panel illuminates, please go to the
special service station for repairing in time.
4） Start the diesel engine: turn the key to "start" position, the diesel engine can smoothly start and
the starting time of starter should not exceed 5s. If it's unable to start, restart it 10-15s later.
Cold start in winter: when the ambient temperature is below the warm-up setting temperature, tur n
the key to "ON", the warm- up indicator on the instrument panel illuminates; the indicator is flashing
after the warm-up and it's able to start the engine when the warm- up indicator is flashing. If it's
unable to start or the warm-up indicator goes out , be sure to turn the key switch to "OFF"
position for reset, 8s later, perform warm-up and starting for the second time as per above
operation.
5） After starting the diesel engine, immediately loosen the key switch; completely separate the
starter gear from the flywheel gear ring to avoid damaging the starter due to reversely dragging.
6） After starting, never immediately keep the diesel engine running at high speed, check whether the
oil pressure indication is normal. At low ambient temperature, warm up the engine after starting.

V. Breaking-in of diesel engine

For new vehicle or diesel engine subject to overhaul, be sure to do breaking- in, which may realize
good matching of surfaces of moving parts of diesel engine and avoid abnormal abrasion and damage.
The service life, working reliability and economy of diesel engine greatly depend on the initial
breaking in, so the breaking-in should be done in strict line with the breaking-in specification.

77
The breaking- in of diesel engine can be done with the vehicle. Calculated by driving mileage, the
breaking- in mileage is 4,000-5,000km. In the breaking- in period, never drive the vehicle at maximum
speed. The speed should be no more than 60km/h and never keep the diesel engine running at high
speed. Never drive the vehicle at too high or low speed for a long time. Regardless of fast and slow
speed, frequently change the speed.
After breaking- in maintenance, please go to special service station for performing "mandatory
breaking-in maintenance" of diesel engine.

VI. Running of diesel engine

In the running process, please note whether the instrument displays normally. If it's abnormal,
immediately stop the vehicle for inspection.
1） In the running process, if the fault indicator on the instrument panel illuminates, please go to the
special service station for repairing.
2） Attentions for driving across water: When driving across water, in principle, the control unit and
harness should be 200mm above the water to avoid damaging the electronic control system due
to water.
3） When the water temperature is too high (above 90℃), the engine enters thermal protection
state, the ECU will automatically lower the engine output power. In serious condition (water
temperature ove r 100℃), the engine will automatically stops; at this time, the user should
carefully check the cause and eliminate the fault.
4） Limp home function: In some non-fatal fault condition, the engine fault indicator illuminates.
To ensure driving safety and convenient repairing, the control unit activates the limp home
function of engine, i.e. the engine is running at low speed and small load so as to slowly drive the
vehicle to nearby service station for troubleshooting.

VII. Stopping of diesel engine

Before the engine stops, keep it idle running for 3 minutes. Never suddenly stop the engine at
extremely high temperature and excessive load; otherwise, the turbocharger and engine may be
damaged.
Turn off the key switch.
Turn off the key switch, 15s later, turn off the main power switch of vehicle. After the key switch is
turned off, the electronic control unit (ECU) needs a certain period of time to save the running state
parameters of engine.
Safety Warnings
1. When the diesel engine is running, never touch the fan rotation plane, pulley and belt exposed

78
rotary part to avoid being injured by the rotary part.
2. When the diesel engine is hot, never touch the exhaust pipe and other high temperature parts to
avoid burning.

79
 Chapter VI Maintenance of Diesel Engine
1. First breaking-in mandatory maintenance
Attention: If no first breaking-in mandatory maintenance is performed, you may not
enjoy the quality warranty right.
From the date of buying the vehicle (subject to the invoice issue date), and driving for 4,000-5,000km
or 3 months (whichever is earlier), please drive the vehicle to special service station for breaking- in
maintenance. Maintenance content is as follows:
1) Replace the oil and oil filter tub.
2) Replace the diesel filter tub and oil-water separator tub.
3) Replace the air filter element or use the compressed air to clean the air filter element.
4) Check the intake pipe for leakage and damage.
5) Check the water tank and maintain the coolant at the specified level.
6) Check the leakage of fuel, oil, coolant and sealing surface and eliminate it.
7) Check and adjust the belt tightening degree and visually check the belt for abnormal abrasion.
8) Check whether external parts of diesel engine are reliably connected or loosened.
9) Check whether the engine ECU and harness are reliably fastened without looseness.
10) Check the engine idle speed, slowly accelerate it till abnormal noise from the engine is heard.
11) Inquire the electronic control diagnosis system fault memory and clear the fault code saved.
Attention: Before plugging the harness connector, firstly turn off the ignition switch and
battery main switch!
For electric welding operation, be sure to turn off the main power switch, and unplug all
connectors on the ECU and sensor!

2. Regular mandatory maintenance

Attention: If no mandatory maintenance is performed, you may not enjoy the quality
warranty right.
After the first breaking- in maintenance, in addition to daily maintenance, please drive the vehicle to
special service station for regular mandatory maintenance after driving 10,000km or 6 months
(whichever is earlier). Regular mandatory maintenance is as follows:
1) Replace the oil and oil filter tub.
2) Replace the diesel filter tub and oil-water separator tub.
3) Replace the air filter element or use the compressed air to clean the air filter element.
4) Clean the fuel tank.
5) Check the intake pipe for leakage and damage.

80
Fault code Fault description Failure diagnosis
Accelerator pedal potentiometer 1 The harness is short to high level and the sensor
X071 fault: voltage exceeds the upper internal is short circuit. Check the harness
limit relating to K22, K09 and K30 and its sensor 1.
Harness and sensor are open circuit or loosely
Accelerator pedal potentiometer 1 connected or short to low level. Check the
X072 fault: voltage is lower than the harness relating to K22, K09 and K30 and
lower limit sensor 1. The idle speed rises to 1100rpm and
torque is limited.
Accelerator pedal potentiometer 1
fault: it's unbelievable when The sensor internal fault may be caused. Check
X078 comparing accelerator pedal the sensor 1. The idle speed rises to 1100rpm
potentiometer 1 with potentiometer and torque is limited.
2
Accelerator pedal potentiometer 2 The harness is short to high level and the sensor
X081 fault: voltage exceeds the upper internal is short circuit. Check the harness
limit relating to K46, K31 and K08 and its sensor 2.
Harness and sensor are open circuit or loosely
Accelerator pedal potentiometer 2
connected or short to low level. Check the
X082 fault: voltage is lower than the
harness relating to K46, K31 and K08 and its
lower limit
sensor 2.
Accelerator pedal potentiometer 2
fault: it's unbelievable when The sensor internal fault may be caused. Check
X088 comparing accelerator pedal the sensor 2. The idle speed rises to 1100rpm
potentiometer 2 with and torque is limited.
potentiometer 1
Atmospheric pressure sensor signal
X091 error: voltage exceeds the upper It's integrated in ECU
limit
Atmospheric pressure sensor signal
X092 error: voltage is lower than the It's integrated in ECU
lower limit
Atmospheric pressure sensor signal
X098 error: it's unbelievable compared It's integrated in ECU
with boost pressure sensor signal
81
 Accelerator and brake signal ECU receives accelerator and brake pedal
X0B8 credibility error: accelerator signal signal. Check the accelerator pedal sensor and
is unbelievable brake switch.
Air heater is always on:
X0E1
multichannel signal error
Relevant harness is short to high level or
Air heater 1 executor power-on
connected improperly; and the executor is short
X111 error: the control line is short to
circuit. Check the harness connecting K07 and
power supply
K68 and its relay.
Air heater 1 executor power-on
Air heater 1 executor power-on error: the
X112 error: the control line is short to
control line is short to ground
ground
Air heater 1 executor power-on
Air heater 1 executor power-on error: the
X114 error: the control line is
control line is disconnected
disconnected
6) Check the water tank and expansion tank and maintain the coolant at the specified level.
7) Check the leakage of fuel, oil, coolant and sealing surface and eliminate it.
8) Check and adjust the belt tightening degree and visually check the belt for abnormal abrasion.
9) Check whether external parts of diesel engine are reliably connected or loosened.
10) Check whether the engine ECU and harness are reliably fastened without looseness.
11) Check the engine idle speed, slowly accelerate it till abnormal noise from the engine is heard.
12) Inquire the electronic control diagnosis system fault memory and clear the fault code saved.

3. Routine maintenance
In addition to first breaking-in mandatory maintenance and regular mandatory maintenance, the user
shall check the following aspects in daily maintenance:
1) Check whether the oil is between the upper and lower scale of oil dipstick, fill oil if it's
insufficient.
2) Check the oil for deterioration, if so, replace it in time.
3) Regularly (in one week) empty water in the oil-water separator water cup.
4) Use the compressed air to clean the air filter element. Due to great difference of vehicle usage and
applications, flexibly adjust the maintenance and replacement cycle.
5) Check the intake pipe for leakage and damage.
6) Check whether the ECU harness and sensor connector are reliably connected. Maintain the
electronic control harness and connector dry and clean. It's prohibited to directly flush the engine
electric control parts and connector by water.
82
4. Technical maintenance for using in winter
In winter, pay special attention to:
When the ambient temperature is below 0℃, paraffin will be separated out from the diesel oil so the
diesel oil is thick; the diesel oil mobility is lowered. If the summer diesel oil is used in winter, it ma y
cause fault.
Use the fuel and oil for winter and pay attention to the water content in the fuel to avoid freezing.
1） The cooling system must be filled with antifreezing solution suitable for ambient temperature.
2） In cold season and region, the vehicle should not be parked outside.
3） For cold starting, start the engine when the warm-up indicator changes from illumination to
flashing.
The use and maintenance requirements for diesel engine are mentioned above. The user should
carefully read the requirements. Reasonable and effective maintenance in regular time, keep the
engine at optimal state, reduce unnecessary maintenance, lower the suspension loss and finally save
cost but increase efficiency.

83
 Chapter VII Fault Diagnosis of Diesel
Engine
Fault code Fault description Failure diagnosis
Accelerator pedal potentiometer 1 The harness is short to high level and the sensor
X071 fault: voltage exceeds the upper internal is short circuit. Check the harness
limit relating to K22, K09 and K30 and its sensor 1.
Harness and sensor are open circuit or loosely
Accelerator pedal potentiometer 1 connected or short to low level. Check the
X072 fault: voltage is lower than the harness relating to K22, K09 and K30 and
lower limit sensor 1. The idle speed rises to 1100rpm and
torque is limited.
Accelerator pedal potentiometer 1
fault: it's unbelievable when The sensor internal fault may be caused. Check
X078 comparing accelerator pedal the sensor 1. The idle speed rises to 1100rpm
potentiometer 1 with potentiometer and torque is limited.
2
Accelerator pedal potentiometer 2 The harness is short to high level and the sensor
X081 fault: voltage exceeds the upper internal is short circuit. Check the harness
limit relating to K46, K31 and K08 and its sensor 2.
Harness and sensor are open circuit or loosely
Accelerator pedal potentiometer 2
connected or short to low level. Check the
X082 fault: voltage is lower than the
harness relating to K46, K31 and K08 and its
lower limit
sensor 2.
Accelerator pedal potentiometer 2
fault: it's unbelievable when The sensor internal fault may be caused. Check
X088 comparing accelerator pedal the sensor 2. The idle speed rises to 1100rpm
potentiometer 2 with and torque is limited.
potentiometer 1
Atmospheric pressure sensor signal
X091 error: voltage exceeds the upper It's integrated in ECU
limit
X092 Atmospheric pressure sensor signal It's integrated in ECU
84
Fault code Fault description Failure diagnosis
error: voltage is lower than the
lower limit
Atmospheric pressure sensor signal
X098 error: it's unbelievable compared It's integrated in ECU
with boost pressure sensor signal
Accelerator and brake signal ECU receives accelerator and brake pedal
X0B8 credibility error: accelerator signal signal. Check the accelerator pedal sensor and
is unbelievable brake switch.
Air heater is always on:
X0E1
multichannel signal error
Relevant harness is short to high level or
Air heater 1 executor power-on
connected improperly; and the executor is short
X111 error: the control line is short to
circuit. Check the harness connecting K07 and
power supply
K68 and its relay.
Air heater 1 executor power-on
Air heater 1 executor power-on error: the
X112 error: the control line is short to
control line is short to ground
ground
Air heater 1 executor power-on
Air heater 1 executor power-on error: the
X114 error: the control line is
control line is disconnected
disconnected
Boost pressure sensor signal error: Boost pressure sensor signal error: voltage
X151
voltage exceeds the higher limit exceeds the higher limit
Boost pressure sensor signal error: Boost pressure sensor signal error: voltage is
X152
voltage is lower than the lower limit lower than the lower limit
Boost pressure sensor signal error: Boost pressure sensor signal error:
X158
unbelievable unbelievable
Brake signal error: brake signal is
X174 Brake signal error: brake signal is incorrect
incorrect
Brake signal error: brake signal is
X178 Brake signal error: brake signal is unbelievable
unbelievable
Cold start indicator error: the
Cold start indicator error: the control line is
X1B1 control line is short to positive pole
short to positive pole of power supply
of power supply
X1B2 Cold start indicator error: the Cold start indicator error: the control line is
85
Fault code Fault description Failure diagnosis
control line is short to ground short to ground
Cold start indicator error: open
X1B4 Cold start indicator error: open circuit
circuit
Cold start indicator error: ECU
Cold start indicator error: ECU internal driving
X1B8 internal driving module is
module is overheating
overheating
Coolant temperature sensor signal
Coolant temperature sensor signal error:
X1C1 error: voltage exceeds the upper
voltage exceeds the upper limit
limit
Coolant temperature sensor signal The control line is short to low level or the
X1C2 error: voltage is lower than the sensor is short circuit. Check the harness
lower limit relating to A58 and A41 and its sensor.
Main clutch signal error diagnosis: The clutch switch is faulty and relevant harness
X288 the clutch state signal is is disconnected. Check above parts relating to
unbelievable K40.
Only at the working mode with
Crankshaft sensor and corresponding harness
camshaft signal, the engine
X341 are disconnected. Check above parts relating to
activates the fault setting: activate
A27 and A12.
standby operating mode
Camshaft sensor and corresponding harness are
Camshaft signal failure error: no
X351 disconnected. Check above parts relating to
camshaft signal
A10 and A50.
The camshaft sensor and corresponding
Camshaft signal failure error: harness are disconnected or loosely connected.
X352
camshaft signal error Check above parts relating to A10 and A50.
The engine torque and speed are limited.
Crankshaft sensor and corresponding harness
Crankshaft signal failure error: no
X361 are disconnected. Check above parts relating to
crankshaft signal
A27 and A12.
The crankshaft sensor and corresponding
Crankshaft signal failure error:
X362 harness are disconnected or loosely connected.
crankshaft signal error
Check above parts relating to A27 and A12.
The electronic control line on the Relevant harness is short to high level or
X391
exhaust brake valve executor is connected improperly; and the executor is short
86
Fault code Fault description Failure diagnosis
short to power supply: the control circuit. Check the harness relating to A29 and
line is short to the positive pole of A45 and its relay.
power supply or the ECU internal
driving module is overheating.
Relevant harness is loosely connector or short
The exhaust brake valve executor
to low level; even open circuit and the executor
X3A2 power-on control line is short to
is open circuit. Check the harness relating to
ground
A29 and A45 and its relay.
The exhaust brake valve executor It's the harness relating to A29 and A45 and the
X3B4
power-on control line is open circuit relay is open circuit.
Relevant harness is short to high level or
The ECU internal driving mode of
connected improperly; and the executor is short
X3B8 exhaust brake valve executor
circuit. Check the harness relating to A29 and
power-on control line is overheating
A45 and its relay.
Relevant harness is loosely connected or open
Fuel filter water level sensor signal
X451 circuit or the sensor is open circuit. Check
error: voltage exceeds upper limit
above parts relating to A63 and A64.
Fuel filter water level sensor signal The control line is short to high level or sensor
X462 error: voltage is lower than the is short circuit. Check above parts relating to
lower limit A63 and A64.
Gen3 indicator power-on fault: Relevant harness is short to high level or
X651 control line is short to positive pole indicator is short circuit. Check the harness
of power supply connecting K73 and K94 and its executor.
Relevant control line and executor are loosely
Gen3 indicator power-on fault:
X652 connected or open circuit. Check the harness
control line is short to ground
connecting K73 and K95 and its indicator.
Gen3 indicator power-on fault: Check the harness connecting K73 and K95
X654
control line is open circuit and its indicator.
Relevant harness is loosely connected or open
Air temperature sensor signal error:
X6E1 circuit or the sensor is open circuit. Check
voltage exceeds the upper limit
above parts relating to A23 and A53.
The control line is short to low level The control line is short to low level or the
X6E2 or the sensor is short circuit. Check sensor is short circuit. Check above parts
above parts relating to A23 and relating to A23 and A53.
87
Fault code Fault description Failure diagnosis
A53.
Relevant harness is short to high
Relevant harness is short to high level or
level or connected improperly; and
connected improperly; and the executor is short
X761 the executor is short circuit. Check
circuit. Check the harness connecting A47 and
the harness connecting A47 and
A16 and its fuel injector
A16 and its fuel injector
Check the harness connecting A47 Check the harness connecting A47 and A16
X774
and A16 and its fuel injector and its fuel injector
Relevant harness is short to high
Relevant harness is short to high level or
level or connected improperly; and
connected improperly; and the executor is short
X781 the executor is short circuit. Check
circuit. Check the harness connecting A31 and
the harness connecting A31 and
A02 and its fuel injector
A02 and its fuel injector
Check the harness connecting A31 Check the harness connecting A31 and A02
X794
and A02 and its fuel injector and its fuel injector
Relevant harness is short to high
Relevant harness is short to high level or
level or connected improperly; and
connected improperly; and the executor is short
X7A1 the executor is short circuit. Check
circuit. Check the harness connecting A01 and
the harness connecting A01 and
A46 and its fuel injector
A46 and its fuel injector
Check the harness connecting A01 Check the harness connecting A01 and A46
X7B4
and A46 and its fuel injector and its fuel injector
Relevant harness is short to high
Relevant harness is short to high level or
level or connected improperly; and
connected improperly; and the executor is short
X7C1 the executor is short circuit. Check
circuit. Check the harness connecting A17 and
the harness connecting A17 and
A33 and its fuel injector
A33 and its fuel injector
Check the harness connecting A17 Check the harness connecting A17 and A33
X7D4
and A33 and its fuel injector and its fuel injector
Relevant control line and executor
Relevant control line and executor are short to
are short to high level. Check the
X851 high level. Check the harness connecting K72
harness connecting K72 and its
and its relay.
relay.
X852 Relevant control line and executor Relevant control line and executor are loosely
88
Fault code Fault description Failure diagnosis
are loosely connected; Check the connected; Check the harness connecting K72
harness connecting K72 and its and its relay.
relay.
Relevant control line and executor
Relevant control line and executor are short to
are short to high level. Check the
X871 high level. Check the harness connecting K72
harness connecting K72 and its
and its executor.
executor.
Relevant control line and executor
Relevant control line and executor are loosely
are loosely connected; Check the
X882 connected; check the harness connecting K73
harness connecting K73 and its
and its relay
relay.
Relevant control line and executor
are loosely connected or open Relevant control line and executor are loosely
X9D1 circuit. Check the harness connected or open circuit. Check the harness
connecting K55 and the system fault connecting K55 and the system fault lamp
lamp
Probably relevant harness is short to
ground or the executor is short Probably relevant harness is short to ground or
X9D2 circuit. Check the harness the executor is short circuit. Check the harness
connecting K56 and the system fault connecting K56 and the system fault lamp
lamp
System fault lamp power-on fault: System fault lamp power-on fault: the control
X9D4
the control line is open circuit line is open circuit
System fault lamp power-on fault: System fault lamp power-on fault: the ECU
X9D8 the ECU internal control module of internal control module of control line is
control line is overheating overheating
T15 terminal fault: (including
T15 terminal fault: (including unbelievable
X9E4 unbelievable fault or T15 terminal
fault or T15 terminal signal is not detected)
signal is not detected)
Speed signal error: the voltage Speed signal error: the voltage monitoring SRC
XA51
monitoring SRC is too big is too big
Speed signal error: the voltage Speed signal error: the voltage monitoring SRC
XA52
monitoring SRC is too small is too small
XA58 Speed signal error: the voltage Speed signal error: the voltage monitoring
89
Fault code Fault description Failure diagnosis
monitoring signal is unbelievable signal is unbelievable
A/C power-on fault: the control line
A/C power-on fault: the control line is short to
XAA1 is short to positive pole of power
positive pole of power supply
supply
A/C power-on fault: the control line
A/C power-on fault: the control line is short to
XAA2 is short to positive pole of power
positive pole of power supply
supply
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XAA4
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XAA8
is short to ground ground
Fuel gauge MeUn power-on error:
Check the harness connecting A19 and A49
XAD4 the output control line of fuel gauge
and its relay
is disconnected
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XAD8
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XAE1
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XAF2
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XB31
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XB32
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XB51
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XB61
is short to ground ground
A/C power-on fault: the control line A/C power-on fault: the control line is short to
XB81
is short to ground ground
Note: X=0, 4, 8 or C

90
 Overall Connection Dimension Diagram for YN33CR

不带转向助力泵尺寸 Size (without power steering pump)_

出水口 Water outlet
气泵排气口 Air pump outlet

91
气泵进气口 Air pump inlet
转向泵进油口 Steering pump oil inlet
转向泵出油口 Steering pump oil outlet
曲轴中心线 Crankshaft centerline
轴承 Bearing
轴承端面至飞轮壳端面 Bearing end face to flywheel housing end
face
机体后端面 Body rear end face
暖风进水螺套 Warm air water inlet threaded sleeve
暖风回水螺套 Warm air water return threaded sleeve
向 Direction
水泵进水口 Water pump water inlet
飞轮连接尺寸 Flywheel connection size
军部

92
 Engine Harness Diagram-A Line

喷油器 Fuel injector

插 件 Plug-in
端 子 Terminal
防水塞 Waterproof plug

93
护套 Sheath
共轨压力 Common rail pressure
视图 View
转速 Speed
压力/温度 Pressure/temperature
冷却液温度 Coolant temperature
凸轮相位 Cam phase
高压油泵 High-pressure fuel pump
排气 Exhaust
接口 Interface
插接器 Connector
端子 Terminal
端子 Terminal
防水棒 Waterproof stick
尺寸测量基准端 Size measuring benchmark
导线 Conductor
插接线 Patch cord
插接器观测方向如图所示 The observation direction of connector
is shown in the figure.
插接器（除 ECU 外）尺寸测量基准如图所示 The size measuring benchmark of
connector (excluding ECU) is shown in
the figure.
图例 Legend
未加保护的导线 Unprotected conductor
PVC 胶带密缠的导线 Conductor wrapped by PVC adhesive
tape
波纹管 Corrugated pipe
测量基准点 Measuring benchmark
波纹管内径 Inner diameter of corrugated pipe
线号 Line No.
位置 Position
端子 Terminal
规格 Specification
颜色 Color

94
防水塞 Waterproof plug
备注 Remark
转速 Speed
共轨压力凸轮相位 Common rail pressure cam phase
压力温度 Pressure temperature
冷却液温度 Coolant temperature
排气制动 Exhaust brake
传感器端剪断 Sensor end is cut off
绿黑 Green black
白 White
黑 Black
红 Red
白黑 White black
绿 Green
白黄 White yellow
绿白 Green white
蓝 Blue
白蓝 White blue
黄黑 Yellow black
蓝 Blue
灰 Grey
双绞 Twisted pair
屏蔽绞合 Shield stranding
三绞 Three stranded
技术要求 Technical requirement
1、导线有效长度允许偏差 1. The effective length of conductor
may have allowable deviation
有效长度 Effective length
偏差 Deviation
2、波纹管内的导线用 PVC（胶带 BTK1915 SW33 进 2. The conductor in the corrugated pipe
行间缠 should be wrapped by PVC adhesive
3、中铆点用双层热缩管热缩。 tape BTK1915 SW33.
4、线束执行标准为 QC/T29106《汽车用低压电线束技 3. The middle riveting point should be
术条件》 subject to thermal sinkage by the

95
5、导线采用 C3ZH 型 two-layer heat shrink tubing.
6、定为钉,扎带视图方向装配 4. The harness executive standard is
7、屏蔽绞合采用 AESSXF-SB 型 QC/T29106 Technical Specification of
8、在适当位置标示商代码及物料编码：HA1223 Low-voltage Electric Harness for
Motor Vehicles
5. The conductor adopts C3ZH.
6. The locating pin and ribbon should
be assembled in the view direction.
7. The shield stranding adopts
AESSXF-SB.
8. Mark the supplier code and material
code at proper position: HA1223
更改标记 Change mark
处数 No.
文件号码 Document No.
签字 Signature
日期 Date
设计 Design
绘图 Drawing
审核 Review
工艺审查 Process review
标准审查 Standard checked by
审定 Reviewed by
批准 Approved by
发动机线束 Engine harness
金事达（2.2m） Jinshida (2.2m)
重要度分级 Importance classification
图号 Drawing No.
图样标记 Sketch marking
重量 Weight
比例 Scale
共 张 Total Sheet(s)
第 张 Sheet
昆明云内动力股份有限公司 Kunming Yunnei Power Co., Ltd.
登记号 Registration No.
96
图 Fig.
继电器图示 Schematic Diagram for Relay

97
 Vehicle Harness Diagram-K Line

登记号 Registration No.

图 Drawing
继电器图示 Schematic diagram for relay
扎带 Ribbon

98
插件 Plug-in
端子 Terminal
防水棒 Waterproof stick
诊断接口 Diagnostic interface
插件 Plug-in
端子 Terminal
端子 Terminal
插接器 Connector
端子 Terminal
预热对接口 Preheating interface
接蓄电池正极 To battery+
插接器 Connector
端子 Terminal
接电源对接口 To power interface
蓝色易燃线 Blue flammable line
电源对接口 Power interface
插接器 Connector
端子 Terminal
接驾驶区线束 To harness in the driving region
插接器 Connector
端子 Terminal
防水上 Waterproof upper
盲堵 Blind plug
接蓄电池负极 To battery-
绞合线示意图 Schematic diagram for twisted wire
中铆点示意图 Schematic diagram for middle riveting point
图例 Legend
未交保护的导线 Unprotected conductor
波纹管 Corrugated pipe
测量基准点 Measuring benchmark
波纹管内径 Inner diameter of corrugated pipe
插接器观测方向为入线端 The observation direction of connector is the
entry end.
尺寸测量基准端 Size measuring benchmark

99
导线 Conductor
插接件 Connector
辅刹继电器 Auxiliary brake relay
空调继电器 Air conditioner relay
预热继电器 Pre-heating relay
主继电器 Main relay
保险 Fuse
油门踏板传感器 Accelerator pedal sensor
接蓄电池负极 To battery-
继电器座 Relay seat
端子 Terminal
继电器：JQ202S-(贵州天仪)4 个 Relay: JQ202S-(Guizhou Tianyi) 4
保险座 Fuse holder
端子 Terminal
离合器开关 Clutch switch
护套 Sheath
线号 Line No.
位置 Position
端子 Terminal
规格 Specification
颜色 Color
防水塞 Waterproof plug
备注 Remark
焊点 Welding point
保险 Fuse
电瓶负 Battery-
辅刹继电器 Auxiliary brake relay
诊断 Diagnosis
空调继电器 Air conditioner relay
预热继电器 Pre-heating relay
油门踏板 Accelerator pedal
接驾驶区线束 To harness in the driving region
离合开关 Clutch switch
电瓶正 Battery +

100
与 95 合并 Combined with 95
红 Red
黑 Black
棕 Brown
黄 Yellow
蓝 Blue
红白 Red white
绿 Green
黑白 Black white
黑红 Black red
红黄 Red yellow
棕 Brown
红白 Red white
红蓝 Red blue
双绞 Twisted pair
技术要求 Technical requirement
1、导线附近的数字为相应节点到插接件入线 1. The figure near the conductor should be the
端的有效尺寸； effective size of conductor from corresponding
2、导线有效长度允许偏差 node to connector entry end.
2. The effective length of conductor may have
allowable deviation
大于 ＞
小于等于 ≤
主干结点间 Between main nodes
分支 Branch
卡子间 Between clips
3 、 波 纹 管 内 的 导 线 其 节 点 用 PVC 胶 带 2. The conductor and its node in the corrugated
BTK1915 SW33 19MM 捆扎 pipe should be wrapped by PVC adhesive tape
4、中铆点用双层热缩管热缩。 BTK1915 SW33 19MM.
5、线束执行标准为 QC/T29106《汽车用低压 3. The middle riveting point should be subject to
电线束技术条件》 thermal sinkage by the two- layer heat shrink
6、定为钉,扎带视图方向装配 tubing.
6、导线采用 FLRY-B 型导线；
4. The harness executive standard is QC/T29106

101
7 、 在 适 当 位 置 标 示 商 代 码 及 物 料编码： Technical Specification of Low-voltage Electric
HA1 2 2 2 Harness for Motor Vehicles
5. The conductor adopts C3ZH.
6. The locating pin and ribbon should be
assembled in the view direction.
7. The shield stranding adopts FLRY-B.
8. Mark the supplier code and material code at
proper position: HA1222
更改标记 Change mark
处数 No.
文件号码 Document No.
签字 Signature
日期 Date
图号 Drawing No.
图样标记 Sketch marking
重量 Weight
比例 Scale

102
Schematic Wiring Diagram for ECU

103
Operating Manual for YNCR Series High-Pressure Common Rail Electronic Control Diesel Engine

Creating integrity Improving quality

KUNMING YUNNEI POWER CO., LTD.

Address: No. 715 Chuanjin Road, Kunming City, China

Tel: 0871-5633185
Fax: 0871-5633176
Zip Code: 650224
Website: www. Yunneidongli.com.cn

104