Manual de Reparacion Motor Jac 4da1 Parte 1

SHOP MANUAL
4DA1 SERIES
Mainly for the truck HFC1042K2(D800)
JAC INTERNATIONAL
2007.10
JAC motors
SHOP MANUAL
Contents
Foreword
Group
Name Page
This shop manual was prepared as Code
reference to properly carry out servicing
and maintenance on JAC vehicles. 0000 General
All the maintenance data in this manual is 1000 Engine

based on the model HFC1042K2
( D800/D801). And it also can be as 1600 Clutch
reference for the other models listed in the
1700 Gearbox
Chapter “General”. Their main common
configurations are as follows: 2200 Driveshaft
HFC4DA1(HFC4DA1-1) engine; JAC
MSB-5M transmission, hydraulic brake 2400 Rear axle
and JAC new model cabin.

2901 Front suspension
All information in this manual is the latest
2911 Rear suspension
data and status of the vehicle at the time
of publishing for your reference. However, 3000 Front axle
due to technological advance or product
updating etc., all contents in this manual 3400 Steering gear
are subject to modification. We reserve
3500 Brake
the right of modification of this manual
without prior notice. 3700 Electric system
Please inform Customer Service
Department of JAC International if there is 5000 Cabin
any mistake, and you will be highly
appreciated.
Tel 0086-0551-2296344
Fax 0086-0551-2296454
Email [email protected]
General
General
Specifications
Vehicle Model
VIN
The mechanic performance table of bolts in China
Specifications
Main specifications of the trucks equipped with 4DA1 engine
The common configurations HFC4DA1 engine, displacement: 2771cc; Max Power (HP/rpm): 77/3600; Max Torque (N.m/rpm) : 174/2100-2300;
JAC MSB-5M transmission, hydraulic brake, JAC new model cabin, no power assist of clutch.
Serious Number Overall Size Wheelbase Gross Vehicle Max Speed Seating Air Power Exhaust
Model Cabin Final gear ratio Tyre Pre-heater
for produce mm) L*W*H) mm Weight kg km/h Capacity Conditioner Steering Braking
Single/King
HFC1040K/KR1 D803/D804 D803-6.142 6.50-16 5745*1866*2213 3000 4930 90 2 ×
Cab
7.00R16
HFC1035KD D836 Single 5.375 4850*1730*2240 2490 3900 110 2 ×
Rear single
D810 Single D800-6.142 7.00R16 5980*1880*2200 3360 5740

HFC1042K 100 2
B826/B827 6.50R16/6.50-16 5980*1998*2200 3308 5215 95 3

HFC1045K2 Single/King B1DAB0-6.142
Single/King
HFC1020K/KR1 D870/D871 D870-6.142 6.50-16 5400*1868*2200 2800 3630 90 2 ×
Cab
Remark: :Standard Equipment :Optional Under develop ×:Not Available

Main specifications of the trucks equipped with 4DA1-1 engine
The common configurations HFC4DA1-1 engine, displacement: 2771cc; Max Power (HP/rpm): 92/3600; Max Torque (N.m/rpm) : 202/2100-2300;
JAC MSB-5M transmission, hydraulic brake, JAC new model cabin, no power assist of clutch.
Serious
Overall Size mm) Wheelbase Gross Vehicle Max Speed Seating Air Power Exhaust
Model Number for Cabin Final gear ratio Tyre Pre-heater
L*W*H) mm Weight kg km/h Capacity Conditioner Steering Braking
produce
7.00R16
HFC1035KD D817 Single 5.375 4850*1730*2240 2490 3900 110 2 ×
Rear single
7.00R16
HFC1042K2RD D819 Double 5.375 4875*1715*2215 2490 3900 110 2+3 0
Rear single
Single/King
HFC1040K/KR1 D830/D831 D803-6.142 6.50-16 5745*1866*2213 3000 4930 90 2
Cab
Single/King
HFC1045K2/R1 B802/803 6.50R16/6.50-16 5980*1998*2220 3308 5735 95 3
Cab B1DAB0-5.571
Single/King
HFC1045K2 B832 6.50R16/6.50-16 5980*1998*2220 3308 5735 95 3
Cab B1DAB0-5.571
Single/King
D800/D801 D800-6.142 7.00R16 5995*1900*2250 3360 5740
HFC1040K2 Cab 100 2
HFC1042KR D802 double D800-6.142 7.00R16 5995×1900×2250 3360 4490 100 2+3
7.00R16
HFC1035KD D874 Single 5.375 4850*1730*2240 2490 3900 110 2
Rear single
Remark: :Standard Equipment :Optional Under develop ×:Not Available

General
Vehicle Model
Company Vehicle Type Main Code from

Product
Code Name Code Specifications company
Serial No.
Code
Company Code Name HFC-----represents JAC motor

Vehicle Type Code 1---Cargo truck 2---Off-road vehicle 3---Dumper
4---Tractor 5---Special purpose vehicle 6---Passenger car
7---Sedan 9---Semitrailer
Main Specifications Code 25---represents the maximum gross weight is 25 tons.
Product serial No. 1---Product development serial No. 1st change 2nd development
Code from company K---Diesel R1---King cabin
For example HFC3251KR1 represents JAC vehicle with king cab, 25 tons maximum gross weight,
the first change.
General
VIN----Vehicle Identification Number

VIN comprises of 17 digits. They separately represent:
O
V N LJ11KDFA440002521
kW
kg kg
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
L J 1 1 K D B C X 8 X X X X X X X
Sequence Number
Vehicle Description
Symbol
Assembly Plant
World Manufacturer Identification

Year
Check Code
General
The mechanic performance table of bolts in China
Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9
Tensile strength limit b max(MPa) 600 800 900 1040 1220
Yield limit s max(MPa) 480 640 720 940 1100
Corresponding to Hyundai standards 4T 6T 7T 8T 10T

The number before the radix point represents one percent of the nominal tensile strength;
The number after the radix point represents ten times of the ratio of the nominal yield limit and
nominal tensile strength.
Section
Engine
HFC4DA1(4DA1-1)
Introduction
We prepare this manual to help technicians get to know and understand 4DA1
Series engine so that they are able to master quick maintenance and service.
The manual gives you instructions on assembly and disassembly of parts and
systems of 4DA1 Series engine, general maintenance standards, special tools
as well as common fault diagnosis and troubleshooting.
Our products are subject to continuous innovation. If any information in this
manual is not applicable for the innovative products, the discrepancies will be
modified in a second edition.
No part or parts of this manual may be reproduced or illegally used in any form
or by any means without written consent of Jianghuai Automobile.
1
Table of Contents
1. Maintenance.......................................................................................................................................... 5
1.1 Diagnosis and troubleshooting ..................................................................................................... 5
1.1.1 Start problems..................................................................................................................... 5
1.1.2 Unstable idle speed ............................................................................................................ 7
1.1.3 Insufficient power................................................................................................................ 8
1.1.4 High fuel consumption ........................................................................................................ 9
1.1.5 High oil consumption ........................................................................................................ 10
1.1.6 Engine overheating........................................................................................................... 10
1.1.7 White smoke coming out of engine exhaust .................................................................... 10
1.1.8 Black smoke coming out of engine exhaust......................................................................11
1.1.9 Low oil pressure.................................................................................................................11
1.1.10 Abnormal engine noise ....................................................................................................11
1.1.11 Engine cooling problem .................................................................................................. 12
1.2 Data and specifications............................................................................................................... 20
1.2.1 Data and specifications............................................................................................................ 20
1.2.2 Engine cooling .................................................................................................................. 21
1.2.3 Starting system ................................................................................................................. 21
1.2.4 Charging system............................................................................................................... 22
1.3 Maintenance standards............................................................................................................... 22
1.3.1 Engine mechanical system............................................................................................... 22
1.3.2 General terms for diesel performance.............................................................................. 24
1.4 Maintenance work ....................................................................................................................... 26
1.4.1 Air filter .............................................................................................................................. 26
1.4.2 Lubricant system............................................................................................................... 27
1.4.3 Fuel system ...................................................................................................................... 28
1.4.4 Cooling system ................................................................................................................. 30
1.4.5 Drive belt adjustment........................................................................................................ 32
1.4.6 Engine control (governed speed, valve clearance, injection timing, compression pressure)
................................................................................................................................................... 33
1.5 Tightening torque ........................................................................................................................ 39
1.5.1 Torque for cylinder head, cylinder head cover and rocker shaft support ....................... 39
1.5.2 Torque for crankshaft, bearing cap, connecting rod bearing cap, crankshaft damper pulley,
flywheel and oil pan ................................................................................................................. 41
1.5.3 Torque for timing pulley chamber, timing pulley, timing gear and camshaft race ............ 42
1.5.4 Engine fuel system ........................................................................................................... 42
1.5.5 Torque for cooling system and lubricant system .............................................................. 43
1.5.6 Torque for intake manifold, exhaust manifold and exhaust pipe ...................................... 44
1.5.7 Engine electrical system................................................................................................... 45
1.5.8 Torque for engine mounting bracket................................................................................. 46
1.6 Special tools ................................................................................................................................ 47
2. Engine mechanical system ............................................................................................................... 49
2
2.1 Cylinder head .............................................................................................................................. 49
2.2 Valve spring, valve guide oil seal, valve guide and push rod ..................................................... 56
2.3 Camshaft and tappet................................................................................................................... 64
2.4. Rocker arm assembly ................................................................................................................ 72
2.5 Oil pump ...................................................................................................................................... 75
2.6. Crankshaft .................................................................................................................................. 80
2.7. Piston and connecting rod ......................................................................................................... 95
2.8 Cylinder block............................................................................................................................ 106
3.4 DA1 Series Engine ......................................................................................................................... 118
3.1 General.......................................................................................................................................118
3.2 Right support of engine..............................................................................................................119
3.3 Left support of engine .......................................................................................................................... 121
3.4 Air-intake manifold..................................................................................................................... 123
3.5 Exhaust manifold....................................................................................................................... 125
3.6 Oil cooler ................................................................................................................................... 127
3.8 Cylinder head cover .................................................................................................................. 130
3.9 Rocker shaft assembly.............................................................................................................. 131
3.10 Valve stem oil seal and valve spring ...................................................................................... 134
3.11 Timing gear.......................................................................................................................................... 138
3.12 Cylinder head assembly and gasket....................................................................................... 146
3.13 Oil pan ..................................................................................................................................... 157
3.14 Oil pump assembly ................................................................................................................. 160
3.15 Piston, Piston ring and connecting rod ................................................................................... 164
3.16 Camshaft and tappet............................................................................................................... 177
3.17 Crankshaft front oil seal .......................................................................................................... 197
3.18 Crankshaft rear oil seal ........................................................................................................... 200
3.19 Crankshaft and main bearing.................................................................................................. 207
4 Engine cooling system ..................................................................................................................... 229
4.1 General...................................................................................................................................... 229
4.2 Water pump............................................................................................................................... 232
4.2.1 On-vehicle repair ............................................................................................................ 232
4.2.2 Single-piece repair.......................................................................................................... 236
4.3 Thermostat ................................................................................................................................ 239
4.4. Radiator.................................................................................................................................... 241
4.5 Drive belt adjustment ................................................................................................................ 244
5 Fuel system........................................................................................................................................ 246
5.1 General...................................................................................................................................... 246
5.2 Fuel filter assembly ................................................................................................................... 250
5.3 Fuel injector............................................................................................................................... 253
5.4 Injection pump assembly .......................................................................................................... 258
5.5 Fuel system related parameters ............................................................................................... 266
5.6 Fuel tank.................................................................................................................................... 267
5.7 Fuel lever gauge ....................................................................................................................... 269
6 Starting system To mention in a reference .............................................................................. 270
6.1 General...................................................................................................................................... 270
3
6.2 Starting circuit............................................................................................................................ 271
6.3 Starter motor ............................................................................................................................. 272
7 Intake/exhaust system ...................................................................................................................... 281
7.1 General...................................................................................................................................... 281
7.1 Air filter ...................................................................................................................................... 282
7.2 Exhaust pipe and charger assembly......................................................................................... 284
4
1. Maintenance
1.1 Diagnosis and troubleshooting
1.1.1 Start problems

1. The starter motor fails to work.
Check Causes Remedies
The battery terminal post is loose. Clean and/or tighten the loose terminal
There is bad connection caused by post(s)
oxidation or corrosion.
Battery
The battery is uncharged or in Charge the battery or replace the old
shortage of charge. battery with a new one
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
Fuse The fuse is short circuited. Replace the fuse with a new one
Starter switch The starter switch or relay has failed. Replace the starter switch or relay
The solenoid switch has failed. Repair or replace the solenoid switch
Starter motor
The starter motor has failed. Repair or replace the starter motor
2. The starter motor works well, but the engine fails to run.
The battery terminal post is loose. Clean and/or tighten the loose battery
There is bad connection caused by terminal post(s)
oxidation or corrosion.
Battery
The battery is uncharged or in Charge the battery or replace the old
shortage of charge. battery with a new one
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
The pinion is broken. Replace the broken pinion
The solenoid switch has failed. Repair or replace the solenoid switch
Starter motor
The brush is worn or the brush spring Replace the brush and/or the brush
is too soft. spring
The piston or crankshaft bearing is Repair or replace the damaged part(s)
Engine
jammed or damaged.
3. The engine rotates but it cannot be ignited to start.

Brake mechanism The fuel cut-off solenoid valve is Replace the fuel cut-off solenoid
of engine broken.
The fuel fails to flow into the injection pump.
Fuel The fuel tank is empty. Fill in the fuel tank
Fuel pipe system The fuel pipe is clogged or broken. Repair or replace the fuel pipe
The fuel tube joint is loose. Retighten the fuel tube joint
Fuel filter The fuel filter overflow valve cannot be Repair or replace the fuel filter
closed. overflow valve
5
A fuel filter component is clogged. Replace the fuel filter component or
the filter element
Fuel system There is air in the fuel system. Release the air from the fuel system
Fuel feed pump The fuel feed pump is broken. Repair or replace the fuel feed pump
The fuel flows into the injection pump.
The fuel in service is incorrect. Use the correct fuel
Fuel
There is water in the fuel system. Replace the fuel
Fuel system There is air in the injection pump. Release the air from the fuel system
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel injector is Adjust or replace the fuel injector
Fuel injector
too low.
Atomizing is bad.
The damage of fuel injector results in Replace the delivery valve
fuel dripping after injection.
Something is wrong with the control Repair or replace the control rack of
rack of injection pump. injection pump
The injection pump plunger is worn or Repair or replace the injection pump
Injection pump
jammed. plunger assembly
The drive shaft of injection pump is Replace the drive shaft
jammed or damaged.
The governor spring of injection pump Replace the governor spring of
is jammed. injection pump
4. Quick start system

Preparation work
1. Disconnect the connector of temperature switch
2. Verify whether the glow plug is power on
a) Confirm the start switch is at OFF position
b) Use voltmeter to connect cylinder wall with any glow plug
c) Switch the start switch to the ON position
If the glow plug is power on, the voltmeter indicates 12 V. If the pointer of voltmeter doesn’t
move, it means the glow plug is power off.
3. Trouble shooting
The glow plug is power on.
The indicator lamp of glow The indicator lamp is broken. Replace the indicator lamp
plug is off.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow The quick start timer is broken. Replace the quick start timer
plug is on for 0.3 s.
6
The indicator lamp of glow After the engine is started, switch Replace the quick start timer
plug is on for 3.5 s. the start switch from ST (start) to
ON. If the relay of glow plug keeps
closed for less than 14 s, it
indicates something is wrong with
the quick start timer.
Switch the start switch from OFF Replace the quick start timer
to ON. If the relay of glow plug
keeps closed for less than 14 s, it
indicates something is wrong with
the quick start timer.
Temperature switch The temperature switch is broken. Replace the temperature switch
Connectivity of glow plug The connectivity of glow plug is Replace the glow plug
bad.
The glow plug is power off.
The indicator lamp of glow The fuse of indicator lamp blows Replace the broken fuse
plug is off. out.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow The glow plug relay is broken. Replace the glow plug relay
plug is on for 3.5 s. When the start switch is switched
from OFF to ON, the glow plug
relay is not switched on.
The quick start timer is broken. Replace the quick start timer
A line fault occurs in the circuit of Repair or replace corresponding
glow plug relay. line(s)
The fuse blows out or there is a Replace the fuse or
line fault. corresponding line(s)
When the start switch is switched
from OFF to ON, the glow plug
relay is switched on.
1.1.2 Unstable idle speed

Idle speed system The idle speed is not proper. Adjust the idle speed
High idle speed control The high idle speed control device Repair or replace the high idle
device is broken. speed control device.
Throttle control system The adjustment of throttle control Adjust the throttle control system
system is not proper.
Leakage or blockage occurs in the Repair or replace the fuel system
fuel system.
Fuel system There is air in the fuel system. Release the air from the fuel
system
There is water in the fuel system. Replace the fuel
7
A fuel filter component is clogged. Replace the fuel filter component
Fuel filter
or the filter element.
The fuel feed pump is broken. Repair or replace the fuel feed
Fuel feed pump
pump.
The opening pressure of fuel Adjust or replace the fuel injector
Fuel injector
injector is too low.
Atomizing is bad.
The damage of delivery valve
results in fuel dripping after Replace the delivery valve
injection.
Injection timing is not proper. Adjust injection timing
The injection volume is too low. Increase injection volume
The idle speed spring is broken. Replace the idle speed spring
Injection pump
The shifter is broken Repair or replace the shifter
The regulator valve is not at Adjust or replace the regulator
proper position. valve
The plunger spring is broken Replace the plunger spring
The plunger is worn. Replace the plunger assembly
The cam is worn. Replace the worn cam
Valve clearance The valve clearance is not proper. Adjust the valve clearance
The gasket of cylinder head is
worn.
Compression pressure Replace relevant parts
The cylinder liner is worn.
The piston ring is sticky.
1.1.3 Insufficient power

An air filter component is Clean or replace the filter
Air filter
clogged. component
Fuel There is water in the fuel. Replace the fuel
Replace the fuel filter component
Fuel filter A fuel filter component is clogged.
or the filter element
Repair or replace the fuel feed
Fuel feed pump The fuel feed pump is broken.
pump
The opening pressure of fuel
Fuel injector
injector is too low. Adjust or replace the fuel injector
Atomizing is bad.
The high pressure fuel pipe is Replace the high pressure fuel
High pressure fuel pipe
damaged or blocked. pipe
Repair or replace the regulator
Injection pump The regulator valve is damaged.
valve
8
The delivery valve is damaged. Replace the delivery valve
The timer is broken. Repair or replace the timer
The cam is worn. Replace the worn cam
The control lever doesn’t work
Adjust or replace the control lever
well.
Adjust injection timing
The injection timing is not correct. Repair or replace the injection
pump timer
The governing spring is too soft. Replace the governing spring
The plunger is worn. Replace the plunger assembly
worn.
The valve spring is too soft or
Valve spring Replace the valve spring
broken.
Exhaust system The exhaust pipe is clogged. Clean the exhaust pipe
Seal of full-load adjusting The seal of adjusting screw is Properly adjust the seal of
screw opened or improperly adjusted. adjusting screw and seal again
1.1.4 High fuel consumption

Repair or replace corresponding
Fuel system There is a fuel leak.
parts of fuel system
Clean or replace the air filter
Air filter An air filter component is clogged.
component
The idle speed is not adjusted
Idle speed Adjust the idle speed
properly.
The opening pressure of fuel
Fuel injector injector is too low. Adjust or replace the fuel injector
Atomizing is bad.
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
The damage of delivery valve
Injection pump results in fuel dripping after Replace the delivery valve
injection.
worn.
The valve spring is too soft or
Valve spring Replace the valve spring
broken.
9
1.1.5 High oil consumption
The oil type is not correct. Replace the engine oil
Engine oil
The oil volume is too high. Adjust the oil level
The oil leaks from the oil seal
Oil seal and gasket Replace the oil seal and/or gasket
and/or gasket.
Air vent The air vent is blocked. Clean the air vent
Intake valve and exhaust The valve stem and valve guide Replace intake valve, exhaust
valve are worn. valve and valve guide
1.1.6 Engine overheating

Cooling water The cooling water is insufficient. Supply enough cooling water
Fan clutch The oil leaks from the fan clutch. Replace the fan clutch
Fan belt Loose or damaged fan belt results Replace the fan belt
in slipping.
Radiator The radiator cap is damaged or Replace the radiator cap or clean
the radiator core is blocked. the radiator core
Water pump The water pump is broken. Repair or replace the water pump
Cylinder head and cylinder Damaged cylinder head results in Replace the sealed cap
block leakage of cooling water.
Sealed cap
Thermostat The thermostat is broken. Replace the thermostat
Cooling system The cooling system is clogged by Remove foreign matters from the
foreign matters. cooling system
1.1.7 White smoke coming out of engine exhaust

Cooling water The cooling water is insufficient. Supply enough cooling water
Fuel There is water in the fuel system. Replace the fuel
Fuel injection timing Fuel injection timing is delayed. Adjust the fuel injection timing
worn.
Intake valve and exhaust The valve oil seal is worn.
Replace valve oil seal, valve and
valve The valve stem and valve guide
valve guide
Valve oil seal are worn.
10
1.1.8 Black smoke coming out of engine exhaust
Air filter An air filter component is clogged. Clean or replace the air filter
component
Fuel injector The opening pressure of fuel Adjust or replace the fuel injector
injector is too low.
Atomizing is bad.
Injection pump The damage of delivery valve Replace the delivery valve
results in fuel dripping after
injection.
The injection volume is too high. Reduce injection volume
1.1.9 Low oil pressure

Engine oil The oil viscosity is not correct. Replace the engine oil
The oil volume is too low. Increase the oil volume
Oil pressure gauge or The oil pressure gauge or Repair or replace the oil pressure
assembly assembly is broken. gauge or assembly
Oil pressure indicator light The indicator light is broken. Replace the indicator light
Oil filter An oil filter component is clogged. Replace the oil filter component or
the filter element
Safety valve and bypass The safety valve is jammed and/or Replace the safety valve and/or
valve the bypass valve spring is too soft. bypass valve spring
Oil pump The oil pump strainer is blocked. Clean the oil pump strainer
A component in the oil pump is Replace relevant parts in the oil
worn. pump.
Rocker shaft The rocker shaft bearing is worn. Replace the rocker shaft bearing
Camshaft The camshaft and its bearing are Replace the camshaft and its
worn. bearing
Crankshaft and bearing The crankshaft and its bearing are Replace the crankshaft and/or its
worn. bearing
1.1.10 Abnormal engine noise

1. Engine slap
Verify the engine is completely warmed up before troubleshooting.
Fuel The fuel is not correct. Replace the fuel
Fuel injection timing Fuel injection timing is not proper. Adjust the fuel injection timing
Fuel injector The opening pressure of fuel Adjust or replace the fuel injector
injector or atomizing is not proper.
11
Compression pressure The gasket of cylinder head is Replace the gasket of cylinder
worn. head or piston ring
The piston ring is broken.
2. Air leak noise
Exhaust pipe The connection of exhaust pipe is Tighten the connection of exhaust
loose. pipe
The exhaust pipe is broken. Replace the exhaust pipe
Fuel injector and/or glow The fuel injector and/or glow plug Replace the gasket
plug are loose. Tighten the fuel injector and/or
glow plug
Exhaust manifold The connection to exhaust Tighten the connection to exhaust
manifold is loose. manifold
Cylinder head gasket The cylinder head gasket is worn. Replace the cylinder head gasket
3. Continuous noise
Fan belt The fan belt is loose. Adjust the tightness of fan belt
again.
Cooling fan The cooling fan is loose. Retighten the cooling fan
Water pump bearing The water pump bearing is worn Replace the water pump bearing
or damaged.
Alternator or vacuum pump The alternator or vacuum pump is Repair or replace the alternator or
broken. vacuum pump
4. Clapping noise
Rocker arm The rocker arm is broken. Replace the rocker arm
Flywheel The flywheel bolt is loose. Retighten the flywheel bolt
Crankshaft and thrust The crankshaft and/or thrust Replace the crankshaft and/or
bearing bearing is worn or damaged. thrust bearing
Crankshaft and connecting The crankshaft and/or connecting Replace the crankshaft and/or
rod bearing rod bearing is worn or damaged. connecting rod bearing
Connecting rod bushing and The connecting rod bushing and Replace the connecting rod
piston pin piston pin are worn or damaged. bushing and/or piston pin
Piston and cylinder liner The piston and cylinder liner is Replace the piston and cylinder
worn or damaged. liner
1.1.11 Engine cooling problem

Engine overheating The coolant level is too low. Fill in the coolant
The thermostatic control is Replace the thermostatic control
broken.
The thermostat is broken. Replace the thermostat
12
Something is wrong with the Repair or replace the cooling
cooling element. element
The radiator is blocked. Clean or replace the radiator
The radiator cap is damaged. Replace the radiator cap
The oil level is too low or the oil is Fill in or replace the oil
disqualified.
The cylinder head gasket is worn. Replace the cylinder head gasket
The exhaust system is blocked. Clean the exhaust system or
replace the damaged parts
The fan belt is loose. Adjust the fan belt
The fuel injection volume is too Adjust the fuel injection
high.
The injection timing is not correct. Adjust the injection timing
Engine overcooling The thermostat is broken. Replace the thermostat
Long engine preheating The thermostat is broken. Replace the thermostat
time The thermostatic control is Replace the thermostatic control
broken.
Check the battery and make the following diagnosises.
13
The starter doesn’t run.
Check the battery
Charging is invalid or the life of

battery is expired. The battery is normal.
Check the battery
Check the terminal post
Connection is interrupted. The terminal post is OK.
Clean the battery terminal post and reconnect it. Check the starter or the starter switch
Faulty
Repair or replace
Turn on the headlamp and starter switch
The headlamp is off or dim. The headlamp is bright.
a) The starter circuit has open circuit.

a) The battery has insufficient charge.
b) The starter coil has open circuit.
b) The starter coil is short-circuited.
c) The starter switch is faulty.
c) A starter part is faulty.
14
The engagement between the pinion and tooth
flank is not good.
When the starter switch is switched to ST (start)

position, check whether there is voltage at the
terminal post "S" of solenoid switch.
Yes No
Or
In this case, check whether the voltage at 3BW
connector of solenoid switch on the starter relay is
normal
The pinion and gear The sliding resistance
ring are worn badly. of starter is too high.
Normal Abnormal
Repair or replace the Repair or replace the
starter, and replace starter
the gear ring.
There is an open circuit Check there is voltage at
between the starter switch 3BW connector of starter
and the solenoid switch, or switch on the starter relay
the connection between them
is faulty.
Repair
Yes No
The connection of starter There is an open circuit

switch is faulty. between the starter
switch and the battery, or
the connection between
them is faulty.
Replace the starter

switch
Repair
15
The starter switch is switched to ST (start) position, but
the solenoid switch doesn't work.
When the starter switch is switched to ST (start)

position, check whether there is voltage at the terminal
post "S" of solenoid switch.
Yes No
Check the grounding cable Check whether the instrument

indicator light is normal
Good Bad Normal Abnormal
Repair
Verify the circuit between the There is an open circuit
starter switch and the between the battery and
terminal post "S" of solenoid the starter switch, or the
Or connection is faulty.
switch.
The sliding The solenoid switch or

part of pinion coil has an open circuit
doesn’t move. or is burned out. Repair
Check the starter The starter switch

relay connection is faulty.
Repair or replace the starter. Check the clutch Replace the starter
and starter switch switch
16
The pinion engages with the gear ring well, but
the engine doesn't run.
Check the grounded cable
Good Bad
Repair or replace the

grounding cable
A fault occurs between The solenoid starter The exciting coil has The armature coil The clutch of
the brush and rectifier. switch is burned out. an open circuit or is has an open circuit or pinion slips.
damaged. is damaged.
Repair or replace the starter
17
The starter switch is switched from ST to ON,
but the starter doesn't stop.
Disconnect the wiring of starter switch and verify the operation of starter switch
Connector No.
Terminal Post No.

The position of
starter switch Terminal Post No.
key
OFF
Locked
Accessory
ON
ON
Start
Besides the wiring mentioned above, other circuits should be opening.
Yes No
The solenoid switch contact is Replace the solenoid switch

melted and hard to move.
Otherwise, the return spring is
broken or damaged.
Replace the starter switch
18
4DA1 Series oil filter and oil cooler
with bypass-type filter
Battery
Indicator
light
Oil pressure switch
Vertical cylinder oil gallery
Regulator
Oil filter and cooler
valve
Idler gear
shaft Camshaft Vacuum
bearing pump
Bypass Full-flow Safety Oil
filter oil filter valve nozzle
Crankshaft Rocker
bearing shaft
Oil Safety Oil pipe
cooler valve
Rocker
Piston arm
Connecting
Oil pump Timing rod bearing
Relief
valve gear
Oil
strainer
Oil pan
Opening pressure of relief valve at oil filter: 430-470kPa
Opening pressure of safety valve at oil filter: 960-100kPa
The lubrication system for 4DA1 Series engine is full-flow type.

The lubricant flows from the oil pump to the vertical cylinder oil gallery through oil cooler
and oil filter pump (the replaceable oil filter is equipped on the oil filter).And then, the
lubricant is delivered from the vertical cylinder oil gallery to the main parts of engine.
19
1.2 Data and specifications
1.2.1 Data and specifications

Engine model
4DA1 4DA1-1
Item
Turbocharged
Natural admission (NA)
Engine type Inter-cooling (TCI)
Four strokes, high mounted valve, water cooling
Combustion chamber type type direct injection
Dry type, thin-wall chrome-plated steel cylinder
Cylinder liner type
liner
Cylinder number - cylinder bore stroke mm 4—93×102
Number of piston ring 2 gas rings, 1 oil ring
Total piston displacement L 2.771
Compression ratio 18.2 17.5
Design compression pressure kPa 3040
Engine weight (net) kg 230 240
Fuel injection sequence 1—3—4—2
16 to the top dead 12 to the top dead
Fuel injection timing
center (before) center (before)
Above -5 Above -14 Above -29
Ambient temperature Above 4
Required fuel type
Light diesel fuel type 0# -10 # -20 # -35 #
Idle speed r/min 750 50
Valve clearance Intake valve mm 0.30 0.40
(cold) Exhaust valve mm 0.30 0.40
Valve clearance Intake valve mm 0.30
(hot) Exhaust valve mm 0.30
Open (before top dead center) 24.5
Intake valve Close (after bottom top dead
55.5
center)
Open (before bottom top dead
54
Exhaust valve center)
Close (after top dead center) 26
Lubricant system
Lubrication method Pressure feed lubrication and spray lubrication
Required oil (class AP1) CF-4 15W-40
Oil pump type External gearing
Oil filter type Full-flow type, paper element, replaceable
Oil volume (including oil filter) L 6
Oil cooler type Water cooling
20
Engine model
4DA1 4DA1-1
Item
Fuel system
Injection pump type VE dispensing pump
Speed governor type Mechanical, all-speed
Injector type Small pressure cell, cellular type
Injector opening pressure MPa 19.0-20.0 18.6-19.6
Main fuel filter type Paper cartridge and water separator
Air filter type Dry-type paper filter element
Alternator output V-A 14-60
Starter motor output V-kW 12-2.8
1.2.2 Engine cooling

Coolant pump Centrifugal impeller
Pulley drive ratio 1.12
Thermostat type Wax-type thermostat, dual valves
Valve opening temperature 82
Valve full opening temperature 95
Coolant total volume L 10
1.2.3 Starting system

Type S14-204A
Rating
Voltage V 12
Output kW 2.8
Time s 30
Number of pinion 9
Rotation direction (view from the pinion end) Clockwise
Weight (approximate) kg 5.4
No load characteristics
Voltage/current V/A 11/160 or less
Revolution speed r/min 4100 or above
Load characteristics
Torque N m 8.5
Revolution speed r/min 1750 or above
Brake characteristics
Torque N m 31
21
1.2.4 Charging system
Type JFB161
Rated voltage V 14
Rated output A 60
Regulation voltage V 14.4-15
Rated revolution speed r/min 5000
Rotation direction (view from the pulley end) Clockwise
Polarity Negative earth
Operate mode Continuous rating
Regulator type IC regulator
Pulley effective diameter mm 80
Weight (with pump) kg 6.1
1.3 Maintenance standards
1.3.1 Engine mechanical system

Standard dimension Ex-work
Wear
configuration
No. Designation Fitting way limit
4DA1 4DA1-1 Clearance
(mm)
(mm)
Contact width of valve and
retainer
1.
Intake valve 1.7 2.2
Exhaust valve 2 2.5
Valve sinkage
2. Intake valve 0.65 1.28
Exhaust valve 0.65 1.20
3. Valve retainer bore angle 15 45 75
4. Flank clearance 0.10-0.17 0.30
5. Axial runout clearance of idler A 0.07 0.20
0.010
Tappet outer diameter 13 0.028
6. Gapping 0.01~0.046 0.10
0.018
Tappet bore 13 0
7. Push rod radial runout 0.3

8. Rocker shaft deflection 0.3
0
Rocker shaft outer diameter 19 0.02
9. Gapping 0.01~0.05 0.20

0.03
Rocker bore 19 0.01
22
0.039
Intake valve stem diameter 8 0.054
10. Gapping 0.039~0.071 0.20

0.017
Valve guide bore 80
0.064
Exhaust valve stem diameter 8 0.079
11. Gapping 0.064~0.096 0.25

0.017
Valve guide bore 80
Free height of valve spring 48
12.
Squareness of valve spring 1.4
0.025
Idler A bearing outer diameter 45 0.055
13. Gapping 0.025~0.080 0.20

0.025
Idler A bearing inner diameter 45 0
Cylinder liner bore 0.060
93 0.021
14. Overtopping height of the
cylinder liner to the body 0~0.08
Axial runout clearance of 0.05~0.114 0.20
15. camshaft Gapping
Cam height of camshaft 42.02 0.05 0.38
0.025
Inner diameter of camshaft 0
50
16. bearing bush Gapping 0.025~0.080 0.12
0.025
Camshaft journal diameter 50 0.055
Camshaft bearing bush

17. 0.02 0.10
deflection
0 0 0.002~0.015
Piston pin 31 0.005 34 0.005
18. Gapping 0.03

0.010 0.010
Piston pin hole 31 0.002 34 0.002
Connecting rod big end 0

33 0.04
thickness
19. Gapping 0.175~0.290 0.35
Crankshaft connecting rod 0.250
33 0 .175
journal bore
Intake/exhaust valve cold
20. Gapping 0.3~0.4
clearance
0.068
Main shaft diameter 70 0.086
21. Main bearing halfshell (after Gapping 0.031~0.066 0.11

0.003
assembly) 70 0.033
0 0
Piston pin outer diameter 31 0.006 34 0.006
22. Connecting rod bushing inner Gapping 0.008~0.026 0.05

0.020 0.020
diameter 31 0.008 34 0.008
23
Crankshaft connecting rod 0.070
53 0.085
journal
23. Gapping 0.029~0.069 0.10
Connecting rod bearing 0.016
53 0.041
halfshell hole (after assembly)
Piston outer diameter
grouping
Group A 92.957~92.970
Group B 92.970~92.983
Group C 92.983~92.996 Grouping
24. 0.051~0.077
Cylinder liner grouping (after Gapping
pressing in)
Group A 93.021~93.034
Group B 93.034~93.047
Group C 93.047~93.060
Piston ring end gap 1.5
First gas ring 0.2~0.4 0.2~0.4
Second gas ring 0.2~0.4 0.6~0.85
Oil ring 0.1~0.3 0.35~0.65
25.
Piston ring end gap
First ring 0.09~0.125 0.078~0.139 0.15
Second ring 0.05~0.075 0.045~0.09 0.15
Oil ring 0.03~0.07 0.03~0.07 0.15
Vertical height of injector to
0.36 0.53
26. cylinder head lower 3.94 0 .23 mm 2.41 0.31 mm
undersurface
1.3.2 General terms for diesel performance

Net power
The correction value for effective power outputted by the engine with all on-board parts
Total power
The correction value for effective power outputted by the engine with essential parts for operation
Rated power
The total output power given by the manufacturer at the specified rated speed according to the
specific engine application, as indicated on the nameplates of engine HFC4DA1 and 4DA1-1
Maximum power
The maximum total power outputted by the engine at full-load working condition, which is generally
greater than or equal to the rated power
Load
The ratio between the actual engine output power and the possible maximum power at the same
speed, which is expressed by percentage
Maximum no load governed speed
The speed which the engine reaches when the accelerator reaches its limit and the engine runs
under no load working condition
To avoid diesel overspeed, the speed indicates the maximum speed control given by the injection
24
pump governor. The maximum no load governed speed of HFC4DA1 and 4DA1-1 is 4000 4200
rpm.
Maximum rated speed
The maximum speed that the governor allows at full load.
The maximum rated speed of HFC4DA1 and 4DA1-1 is 3600 rpm.
Minimum rated speed
1. The allowable minimum speed at the following three maximum speed of engine: 45% of
maximum rated speed, 1000rpm and the speed provided by the idling governor, whichever is
greaterThe minimum rated speed of HFC4DA1 and 4DA1-1 is 1620 rpm.
2. The minimum speed specified by the manufacturer
Full load filter paper type smoke
Under full load (i.e. external characteristics) working condition, the blackening of filter paper in a
specific area (working diameter: 32 mm) by the smoke in a specified length of air column taken
from the engine exhaust pipe
To measure the speed range from the minimum to the maximum rated speed, arrange proper
testing points including full load working conditions at the maximum power speed and maximum
torque speed.
Free accelerating working condition
When the engine runs at idle speed, the condition that pedaling the accelerator pedal rapidly but
gently to make the injection pump provide maximum fuel
Keep this condition before the engine reaches the allowable maximum speed given by the
governor. Once it reaches the maximum speed, release the accelerator pedal to make engine
returns to idling.
Free accelerating filter paper type smoke
Under free accelerating working condition, the blackening of filter paper in a specific area (working
diameter: 32 mm) by the smoke in a specified length of air column taken from the engine exhaust
pipe
Speed characteristics
The characteristics of main performance index (torque, power, oil consumption, exhaust
temperature and smoke, etc.) changes depending on the speed when the engine fuel governing
mechanism keeps the same
External characteristic
The speed characteristic when the engine fuel governing mechanism is fully opened
It is also called full load speed characteristic.
Load characteristic
The characteristic of performance index changes depending on load when the engine keeps
running at the same speed
25
1.4 Maintenance work
Only qualified personnel should be allowed to

perform general maintenance work.
Type marking
Engine Serial Number
The engine serial number is stamped at the left
side of the rear end of cylinder block.
1.4.1 Air filter

Dry-type paper filter element
Depending on the type of filter element, the
method for cleaning a filter element is different.
Dust accumulated at the filter element

Turn the filter element by hand and blow the
compressed air into the filter element in order to
blow off the dust.
Pressure of compressed air (392-490 kPa)
Caution:
Protect the filter element from colliding by
other objects in cleaning. Otherwise, the filter
element may be damaged.
Carbon and dust accumulated at the filter

element
1. Prepare the cleaning liquid for air filter
(DonaldmnDl400) originally provided by JAC,
and dilute it with water.
2. Immerse the filter element in the cleaning

liquid for 20 minutes.
26
3. Take the filter element out of the cleaning
liquid and flush it with running water.
The water pressure should be less than 274 kPa.
4. Dry the filter element at a place with good

ventilation.
Use a fan for quick drying.
Note:
Never use the compressed air or open fire for
quick drying.
It may result in damage of filter element.
Generally, it will take two to three days to
completely dry a filter element. In this case, a
standby should be prepared for temporary
use.
1.4.2 Lubricant system

Main oil filter (paper filter element)
Replace procedure
1. Loosen the oil drain plug to drain out the oil.
2. Several minutes later, retighten the oil drain

plug.
3. Unscrew the used filter counter-clockwise

with a filter wrench.
4. Clean the fitting surface of oil cooler to

ensure suitable fitting with the new oil filter.
5. Apply a thin layer of oil to the O-ring.
6. Screw in the new oil filter until the filter O-ring

makes perfect contact with the sealing
surface.
7. Further screw in the filter by 1+1/4 turn with a

filter wrench.
Filter wrench: 1010300FA-9101
27
8. Check the oil level. If necessary, fill in some
oil until the oil level reaches the specified
level. The filling oil volume is approximate
0.7 L.
9. Start the engine and verify there is no oil leak

from the main oil filter.
1.4.3 Fuel system

Fuel filter
Replace procedure
1. Unscrew the used filter counter-clockwise
with a filter wrench.
2. Clean the fitting surface of the filter upper

cover to ensure suitable fitting with the new
fuel filter.
3. Screw in the fuel filter until it makes perfect

contact with the sealing surface.
4. Further screw in the filter by N 2/3 turn with a

filter wrench.
28
5. Loosen the bleeder plug on the overflow
valve of injection pump.
6. Operate the priming pump until the fuel flows
out of the fuel filter.
7. Retighten the bleeder plug.
8. Repeatedly operate the priming pump and
verify there is no fuel leak.
Note:
It is strongly recommended that you should
use a fuel filter provided by JAC or an original
one.
Procedure of water drain from the fuel filter

If water content in the water separator exceeds
the specified value, the indicator light will light up.
Discharge water and other impurities from the
water separator according to the following steps.
1. Park the vehicle at a safe place.
2. Open the engine hood and put a container
(approximate 0.2 L) at the end of ethylene
hose under the water drain plug of water
separator.
3. Unscrew the water drain plug
counter-clockwise (about five turns) and
operate the priming pump about ten times
until approximate 0.1 L water drains out.
4. Once the water drains is finished, screw in
the water drain plug clockwise and manually
operate the priming pump several times.
5. Verify there is no fuel leak from the water
drain plug after the engine starts.
Also, verify the indicator light of fuel filter is
off.
If frequent water drain from a water separator
is required, you may ask for a fuel tank for
water drain from a local JAC distributor.
29
Bleeding
1. Loosen the bleeding screw on the overflow
valve of injection pump.
2. Operate the priming pump until the fuel with
foam flows out of the bleeding screw.
3. Tighten the bleeding screw.
4. Repeatedly operate the priming pump and
verify there is no fuel leak.
1.4.4 Cooling system

Coolant level
Check the coolant level. If necessary, fill in the
radiator reservoir.
If the coolant level falls under “MIN”, carefully
check whether there is a leakage in the cooling
system. And then, fill in the coolant until it reaches
“MAX”.
Reservoir
Note:
Never make a reservoir overflow.
The radiator filler cap should be opened only if it
Long life coolant is very necessary.
Freezing point ( C)
Coolant level check can only be performed when

the engine is cold.
For mixing ratio between the cooling water and
anti-freezer, please refer to the left figure.
Mixing ratio (%)
Cooling System Check

Place an American tester for radiator filler on the
radiator.
Apply test pressure on the cooling system and
check the leakage.
The test pressure shall not exceed the specified
pressure.
Test pressure: 196kPa
30
Radiator filler cap check
The radiator filler cap is designed to keep the
pressure at 105 kPa in the coiling system. Use
radiator filler cap tester to check the cap.If the
radiator filler cap doesn’t keep at the specified
pressure in testing, it shall be replaced by a new
one.
The pressure of radiator filler cap
Pressure valve 88-118 kPa
Negative pressure valve (reference value) 1.0 -3.9 kPa
Thermostat test
1. Completely immerse the thermostat in the
water.
2. Heat up the water.
Continuously stir the water to avoid directly
heating the thermostat.
3. Check the initial opening temperature of
thermostat.
The initial opening temperature of thermostat:
82
4. Check the full opening temperature of
thermostat.
The full opening temperature of thermostat:
95
The valve lift at full opening: 8mm
31
1.4.5 Drive belt adjustment
Check whether the drive belt is worn or damaged.
If necessary, replace it with a new one. Check the
belt tension. If necessary, make proper
adjustment.
Check the belt tension.
Press the central section of belt by a force of
Air conditioning compressor
drive belt and power steering 100N and check deflection of each belt.
pump drive belt
Standard deflection
mm
Alternator and fan pulley
drive belts
Air conditioning 8-10
compressor drive belt
Alternator and fan
pulley drive belts Power steering pump
drive belt
Alternator drive belt

Mount the alternator drive belt and adjust the
belt tension.
Mount fixing bolts and tighten them to the
specified torque.
Alternator
Fixing bolt torque 37.5
Adjusting plate fixing bolt torque 25
Air conditioning compressor pulley

drive belt and power steering pump
drive belt
Move the oil pump to adjust the oil pump drive
belt tension
Tighten the bolt to the specified torque.
Adjuster locking bolt torque 37 N m
32
1.4.6 Engine control
(governed speed, valve
clearance, injection timing,
compression pressure)
Idle speed check
1. Handle the parking brake and brake driving
wheels.
2. Place the transmission at neutral position.
3. Start the engine and warm it up.
4. Remove the engine control cable from the
control lever.
5. Mount the tachometer on the engine.
6. Check the engine idle speed.
If the engine idle speed exceeds the
specified range, you must make adjustment.
Engine idle speed:750 50 r min
Adjust the idle speed

1. Loosen the locking nut (s) of idle adjusting
bolt (s) on the injection pump.
2. Use idle adjusting bolt to adjust idle speed to
the specified range.
3. Use the locking nut (s) to lock the idle
adjusting bolt (s).
4. Check the idle speed control cable is
tightened (no looses).
If necessary, eliminate any loose of the
cable.
Accelerator control cable adjustment

1. Loosen clamp bolts for the accelerator
cables.
2. Check whether the control knob is turned to
the idle speed position.
3. Place the accelerator lever at the fully closed
position, and then tighten the control cable in
the arrow direction to eliminate any loose.
33
Valve clearance adjustment
1. Turn the crankshaft until the to the crankshaft

damper reaches the top dead center. When
the line aligns the timing pointer, either the
first cylinder piston or the fourth cylinder
piston locates at the top dead center of
compression stroke.
2. Check whether there is any loose rocker

shaft seat nut.
Before adjust the valve clearance, tighten
any loose rocker shaft support nut.
Torque of rocker shaft support nut 55 N m
3. Check the clearance at the intake valve push

rod and exhaust valve push rod in the first
cylinder.
If there is clearance at the intake valve push
rod and exhaust valve push rod in the first
cylinder, the piston in the first cylinder locates
at the top dead center of compression stroke.
If there is compression force applied on the
intake valve push rod or exhaust valve push
rod in the first cylinder, the piston in the
fourth cylinder locates at the top dead center
of compression stroke.
Adjust the valve clearance in the first or fourth

cylinder when corresponding cylinder piston
locates at the top dead center.
34
Valve clearance (cold) :
0.3-0.4 mm(optimum value: 0.35 mm)
4. Loosen each valve clearance adjusting

screw as shown in the figure.
5. Insert a proper clearance gauge between the
rocker arm and valve stem.
6. Turn the valve clearance adjusting screw
until you feel there is slight resistance on the
clearance gauge.
7. Screw down the locking nut.
8. Turn the crankshaft 360 .
9. Realign the timing marking at the crankshaft
damper pulley to the line of top dead center.
10. Adjust clearance for other valves as shown in
the figure.
35
Adjust injection timing
Step 1 Remove the front screw (at the rear end of

Dial indicator Gauge stand
injection pump) on the injection pump distribution
plunger.
Step 2 Mount special tools for injection advance angle
adjustment: dial indicator and gauge stand.
Step 3 Turn the engine crankshaft clockwise to a position
with approximate 45° to the top dead center of the first
Special tools
cylinder.
Step 4 Turn the engine crankshaft about 8° to left or right,
the pointer of dial indicator shall stand still.
Step 5 Turn the dial indicator to zero the pointer. The
position of dial indicator shall not be changed after zero
adjustment.
Step 6 Turn the crankshaft clockwise to the top dead
Use a tool to turn the
center. For assembly, to determine the top dead center,
crankshaft
use a lever indicator to measure the height difference
between top surface of piston in the first cylinder and
upper surface of body. For commissioning and
inspection, alignment timing marking (position marking of
crankshaft pulley top dead center and timing marking on
the gear case) is allowed to use.
Step 7 Unscrew two tight nuts to the injection pump
flange and the connecting bolt to the injection pump
support. Crankshaft position timing marking
marking
Step 8 Pull the injection pump inward or outward to make
the reading of dial indicator show X mm. Dial indicator
zeroing
Step 9 Screw down two tight nuts to the fuel pump flange
and the connecting bolt to the injection pump support.
Fuel pump running shall be avoided in screwing.
Step 10 Repeat Step 3 to verify zero adjustment.If the
zero adjustment is not proper, return to Step 5.
Step 11 Repeat Step 6 to verify the reading of dial
indicator. If the reading is not correct, return to Step 7.
Step 12 Remove the special tools: dial indicator and
gauge stand.
Step 13 Mount the front screw on the injection pump The crankshaft locates at the
top dead center.
distribution plunger. Injection advance angle adjustment
is over.
Type X Value mm
HFC4DA1 1.60
HFC4DA1-1 1.50
36
The essential torque is given below.
Tightening torque for the tight nuts to the injection pump flange: 25±5Nm;
Tightening torque for the connecting bolt to the injection pump support: 25±5Nm;
Tightening torque for the bolt to the distributive head of injection pump: 35±5Nm;
Tightening torque for the nut to the high pressure fuel pipe: 30 5 Nm
If the special tools like dial indicator and seat stand are not available, it is allowed to use “Overflow”
method to make injection advance angle adjustment.
Note:
A new cooper gasket must be used when you mount a plug at the top of distributor.
37
Compression pressure measurement
1. Start the engine and keep idling until the
coolant temperature reaches 70-80 .
2. Remove the following parts:

All glow plugs (or injectors)(Measuring
at the injector hole or the glow plug hole
is optional depending on different gauge
outfits.)
Fuel cut solenoid connector
Fuse for Quick On Start System(QOS) on
a connector
3. Mount the joint and pressure gauge in the

glow plug hole in the first cylinder (or in the
injector hole).
Compression pressure gauge
(with joint): 1002100FA-9101
Joint: 1002100FA-9102
4. Use the starter motor to run the engine and

record the readings on the pressure gauge.
Compression pressure at 200 r/min
Nominal Limit
3040 2158
5. For other cylinders, repeat Step 3 and 4.

If the measured value is less then the limit
value, refers to the section “Diagnosis and
troubleshooting” in this manual.
38
1.5 Tightening torque
1.5.1 Torque for cylinder head, cylinder head cover and rocker
shaft support (N·m)
Step 1 Step 2 Step 3
39
40
1.5.2 Torque for crankshaft, bearing cap, connecting rod
bearing cap, crankshaft damper pulley, flywheel and oil pan
(N·m)
Step 1 Step 2
41
1.5.3 Torque for timing pulley chamber, timing pulley, timing
gear and camshaft race (N·m)
1.5.4 Engine fuel system (N·m)
42
1.5.5 Torque for cooling system and lubricant system (N·m)
43
1.5.6 Torque for intake manifold, exhaust manifold and exhaust
pipe (N·m)
44
1.5.7 Engine electrical system (N·m)
Cold district is
excluded.
45
1.5.8 Torque for engine mounting bracket (N·m)
Independent
suspension
Left-mounted
Right-mounted
46
1.6 Special tools
Illustration Tool No. Tool Name
1010300FA-9101 Oil filter wrench
1003016FA-9101 Valve oil seal erector
1003102FA-9101 Valve guide replacer
Compression pressure
1002100FA-9101
gauge
1002100FA-9102 Pressure gauge joint
1100300FA-9101 Measuring unit
1002420FA-9101 Front oil seal erector
1002430FA-9101 Rear oil seal erector
Valv spring
1003015FA-9101
compressor
1007017FA-9101 Camshaft gear puller
47
Camshaft bearing
1002107FA-9101
replacer
1002430FA-9102 Rear oil seal remover
1002106FA-9101 Cylinder liner erector
1002106FA-9102 Cylinder liner remover
Piston mounting taper

1004001FA-9102
sleeve
1007011FA-9101 Timing gear puller
Crankshaft timing gear

1007011FA-9102
erector
1002420FA-9101 Front oil seal erector
48
2. Engine mechanical system
2.1 Cylinder head
Disassembly sequence
1. Thermostat chamber assembly
2. Injector body
3. Glow plug and glow plug connector
4. Rocker shaft and rocker
5. Push rod
6. Cylinder head
Reassembly sequence
Reassemble all parts in reverse
sequence.
Note:
In disassembly, you should collect all
parts of valve set and identify each
part so that they will return to their
original positions by assembling.
Before you remove the cylinder head
from the engine and disassemble the
valve mechanism, you should carry
out a compression test and record
the test result.
49
Disassembly
1. Thermostat casing and water outlet
assembly
2. Injector body
1) Unscrew the injector body support nut.
2) Use an injector remover and a sliding

hammer to disassemble the injector and
its support together.
3. Glow plug and glow plug connection

board
5. Push rod
6. Cylinder head
Unscrew the cylinder head bolts in
several times according to the sequence
number given in the figure. Unscrew a
bolt in at least two times.
Note:
If you don’t unscrew the cylinder head bolts in
several times according to the sequence
number, bad effect like warping may incur on
the undersurface of cylinder head.
50
Cleaning
Cylinder head bolt
Cylinder head
Carefully clean up any oil sludge, smoke and
carbon deposit until the natural color of metal is
exposed. Never use an electrical wire brush on
any gasket or sealing surface.
Inspection and repair

If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.
Check whether there is leakage, corrosion or
blow-by gas of cylinder head gasket and
contact surface. If a gasket fails, investigate
the causes:
- Improper assembling
- Loose or warping cylinder head
- Insufficient tightening torque for the
cylinder head bolt
- Warping cylinder block surface
1. Check whether the cylinder head bolt thread
is damaged or drawn out. Also, check
whether the cylinder head is damaged
caused by improper tool usage.
Caution
Any questionable bolt must be replaced by a
new one.
2. Check whether there is any crack on the
cylinder head, particularly the valve edge and
exhaust port.
3. Check whether there is any corrosion at the
cylinder head cover plate, any sand or loose
hole inside the cylinder head.
Caution
Never repair the key surface of cylinder head.
If it is broken, replace it with a new one.
4. There are strict requirements for flatness of
cylinder head undersurface and contact
surface of intake and exhaust manifolds.
Use grinding process to repair these
surfaces. If the surface ”flatness” exceeds
the specified value, you should grind the
surface until the flatness meets the
requirement. If the flatness exceeds the
specified value too much, the part shall be
replaced by a new one.
51
mm
Nominal Limit
Warpage of
cylinder head 0.05 or less 0.20
undersurface
Height of
92 91.55
cylinder head
5. Check the contact surface of water jacket
bowel-like plug.
6. Use a ruler or clearance gauge to measure
the warpage of contact surface between the
exhaust manifold and cylinder head.
If the measurement value is greater than the
nominal value but less than then limit value,
you should regrinding the contact surface
between the exhaust manifold and cylinder
head.
If the measurement value exceeds the
specified limit, the manifold has to be
replaced.
Warpage of exhaust manifold mm

Nominal Limit
0.05 or less 0.20
Reassembly
6. Cylinder head
1) Mount the valve seat
1. Carefully place the attachment
(its outer diameter is slightly less
than that of valve seat) on the valve
seat .
Note
Make sure that the surface contacting
with the valve seat is the smooth side of
attachment.
2. Use a table press to gradually
press the attachment until the valve
seat seats in place.
52
Note
Never apply excess compressive force
on the valve seat when you use a table
press. Otherwise, the valve seat may be
damaged.
Measure upper height of valve guide from the
upper surface of cylinder head.
Upper height of valve guide (H) (reference value)
13 mm
Note
If a valve guide has been disassembled,
you should replace the valve and valve
guide in pairs.
2) Lower spring seat

3) Valve stem oil seal
Mount a new oil seal to the valve.
Use a special tool to guide.
Oil seal erector: 1003016FA-9101
4) Valve
Apply oil to the part above the borehole
diameter of valve stem before you install a
valve.
5) Valve spring
Mount the valve spring on the upper
spring seat.
Caution
The section with painting on the
valve spring shall be placed
downwards.
Supply compressed air from glow
plug hole to cylinder until the valve
seats in place.
Install the valve cotter with special
tools.
Valve spring compressor: 1003015FA-9101
53
6) Valve cotter
Use a spring compressor to press the
valve spring to the proper position.
Mount the spring seat and valve cotter.
Use a soft-faced hammer to tap the cotter
head until it seats in place.
5. Push rod

Tighten the rocker shaft fixing bolt.
55 5 N m
3. Glow plug and glow plug connection

board
Tighten the glow plug.
25 5 N m
2. Injector body
1) Install the injector copper gasket and
O-ring onto the injector body .
Make sure tight contact between the
O-ring and injector groove.
2) Apply oil in the cylinder head hole where
the injector body seats.
3) Mount the injector body and injector
pressure plate together to the cylinder
head.
40±5 N m
4) Tighten the injector body nut and gasket
to the specified torque.
40±5 N m
54
2. Fuel injector
Use a wrench or a special tool to tighten
the nut (s) on the fuel injector to the
specified torque as shown in the figure.
Caution
When you mount the return pipe, injector
and injection pipe, use air to blow off dust.
Injector tightening torque 34±5N m
1. Thermostat casing assembly

Tighten the thermostat casing assembly
fixing bolt.
25 ±5 N m
55
2.2 Valve spring, valve guide oil seal, valve guide and push rod
Disassembly sequence
1. Rocker assembly
2. Valve cotter
3. Valve spring
4. Valve
5. Valve guide oil seal
6. Valve guide
Reassemble sequence
sequence.
Disassembly
1. Rocker assembly
2. Valve cotter
Use a special tool to compress the valve spring.
3. Valve spring
4. Valve
6. Valve guide
Valve guide replacer: 1003102FA-9101
56
Valve spring
Caution
Visually check the valve spring. If there is
damage or obvious abnormal abrasion, you
should replace it with a new one.
1. Free height
Measure the free height of valve spring.If the
height is less than the specified limit value,
the spring shall be replaced.
Free height mm
Nominal Limit
48.0 47.10
2. Squareness
Use a steel square to measure the
squareness of valve spring. The
measurement value shall be less than 1.2
mm.
If measurement value exceeds prescribed
limit, the valve spring shall be replaced.
Limit 1.5 mm
3. Spring tension
Use a spring tester to compress the spring to
the installation height. Measure the
compression spring tension.
If the measured tension is lower than the
prescribed limit, the spring shall be replaced.
Tension N
Installation
Nominal Limit
height
38.9mm 296 268
57
Valve guide
Caution
Carefully clean up the carbon deposit at the
valve head to protect the valve seat contact
surface from damaging.
Carefully check whether there is any damage
or abnormal abrasion on the valve stem.
If so, replace the valve and valve guide in
pairs.
1. Valve guide clearance
Use a micrometer to measure the outer
diameter of valve stem.
If the out diameter of valve stem is lower than
the specified limit, replace the valve and
valve guide in pairs.
Mm
Nominal Limit
Valve Intake valve 7.946-7.961 7.880
stem Exhaust valve 7.921-7.936 7.850
diameter
Use a micrometer to measure the inner
diameter of valve guide.
Make a subtraction between the valve guide
inner diameter and the valve stem outer
diameter.
If the subtraction value is lower than the
specified limit, replace the valve and valve
guide in pairs.
Valve guide clearance mm

Nominal Limit
Inlet clearance 0.200 7.880
Exhaust 0.250 7.850
clearance
58
Valve guide replacement
1. Use a special tool to knock the valve guide
out from one side of combustion chamber.
2. Apply oil to the outer surface of valve guide.

Use a special tool to mount a new valve
guide from one side of cylinder head upper
surface and check the valve guide height.
Height 13 mm
Note
If a valve guide has been disassembled, you
should replace the valve and valve guide in
pairs.
Valve thickness
1. Measure the valve thickness.
2. If the meausred value is lower than the
specified limit, replace the valve and valve
guide in pairs.
Valve thickness mm
Nominal Limit
Exhaust value 1.5
59
Valve seat conical surface angle on the
valve
1. Measure the valve seat conical surface
angle.
2. If the measurement value exceeds the limit,
you should replace the valve, valve guide
and valve seat together.
Nominal: 45
Valve sinkage
1. Mount the valve (1) to the cylinder head (2).
2. Use a depth gauge or a ruler and steel
square to measure the valve sinkage from
the bottom surface of cylinder head.
If the measurement value exceeds
prescribed limit, the valve seat shall be
replaced.
Valve sinkage mm
Nominal Limit
4DA1
Exhaust
Series 0.65 1.20
value
Valve contact width

1. Check the roughness and flatness of valve
contact surface. Make sure that the contact
surface is smooth.
2. Measure the valve contact width.
If the measurement value exceeds
prescribed limit, the valve seat shall be
replaced.
Contact width mm
Nominal Limit
Exhaust value 2 2.5
60
Valve seat replacement
Disassemble valve seat
1. Perform arc welding at the inside periphery
of valve seat .
2. Cool down the valve seat for several
minutes.
The contraction will facilitate the disassembly
of valve seat.
3. Use a screwdriver to pry off the valve
seat.
Carefully pry off it. Otherwise, the cylinder
head may be damaged.
4. Carefully clean up carbon deposits and other
foreign matters on the valve seat installation
hole of cylinder head.
Assemble valve seat

1. Carefully place the attachment (its
borehole diameter is slightly less than that of
valve seat) on the valve seat .
Note
Make the smooth side of attachment
contact with the valve seat.
2. Use a table press to gradually press the
attachment until the valve seat seats in
place.
Note
Never apply excess compressive force
on the valve seat when you use a table
press. Otherwise, the valve seat may be
damaged.
Valve seat correction

1. Clean up the carbon deposit on valve seat
surface.
2. Use a milling cutter (blade angle of 15 , 45
and 75 ) to minimize abrasion and rough
areas of valve seat so that the contact width
reaches the nominal value.
You should only eliminate abrasion and
rough areas. Don’t cut off too much.
Carefully avoid cutting off good areas on
valve seat surface.
61
Valve seat angle: 45
Note
You may use an adjustable milling cutter
guide lever. It is not allowed to stir the
milling cutter guide lever in the valve
guide hole.
3. Apply grinding paste on valve seat surface.

4. Insert the valve into the valve guide.
5. Turn the valve for perfect fitting with the valve

seat while tapping it from top or bottom.
6. Check the valve contact width is proper.
7. Check whether the valve seat surface has
completely contacted with the whole valve
periphery.
Bending of push rod

1. Put the push rod on a platform.
2. Roll the push rod along the platform and use
a feeler gauge to measure bending of push
rod. If the measurement value exceeds
prescribed limit, the push rod shall be
replaced.
Push rod bending limit:
0.4 mm or less
3. Visually check whether there is any excess
abrasion or damage at both ends of push
rod.
If so, replace the push rod.
Reassembly
6. Valve guide
Apply oil to the outer surface of valve guide.
Use a special tool to mount a new valve
guide from one side of camshaft.
62

Press in a new oil seal with a special tool.
4. Valve
Apply oil to the outer surface of valve stem.
3. Valve spring
Mount the valve spring on the upper spring
seat. The section with painting on the valve
spring shall be placed downwards (i.e. the
spring with less pitch placed downwards).
2. Valve cotter
Use a spring compressor to press the valve
spring to a proper position.
Use a soft-faced hammer to slightly tap the
cotter head until it seats in place.
1. Rocker assembly
Installation torque:55 5N m
63
2.3 Camshaft and tappet
Assembly sequence
1. Cylinder head assembly
2. Flywheel
3. Cylinder block liftback
4. Oil pan assembly
5. Oil pump assembly
6. Camshaft timing gear
6a. Camshaft timing pulley
7. Camshaft thrust plate
7a. Camshaft pulley central flange
8. Camshaft
9. Tappet
Reassembly sequence
sequence.
Disassembly
2. Flywheel
3. Flywheel baffle
4. Oil pan assembly
Remove camshaft timing gear bolt(s)
from the camshaft.
Note
Fasten the camshaft to avoid turning.
Pull out camshaft timing gear with a
universal puller .Universal puller:
1007017FA-9101
Remove the thrust washer .
64
7. Camshaft thrust washer
8. Camshaft
9. Tappet

1. Measure the camshaft thrust

clearance
Measure the camshaft axial clearance with a
dial gauge.
This shall be done before disassembling the
camshaft gear.
If the camshaft axial clearance exceeds
prescribed limit, the thrust washer shall be
replaced.
Camshaft axial clearance mm
Nominal Limit
0.005-0.114 0.2
2. Camshaft journal outer diameter

diameter of each camshaft journal in
direction and . If the measurement
value exceeds prescribed limit, the camshaft
shall be replaced.
Journal outer diameter mm
Nominal Limit
49.945 49.975 49.60
3. Cam height
Use a micrometer to measure the cam height
a. If the measurement value is lower than the
prescribed value, the cam shall be replaced.
Cam height mm
Nominal Limit
42.02 0.05 41.65
65
4. Camshaft radial runout
Put the camshaft on a V block.
Measure the radial runout with a dial gauge.
If the measurement value exceeds prescribed
limit, the camshaft shall be replaced.
Radial runout mm
Nominal Limit
0.04 or less 0.10
5. Camshaft and camshaft bearing

clearance
Measure the camshaft bearing inner
diameter with a dial gauge.
Camshaft bearing inner diameter mm
Nominal Limit
50.00 50.03 50.08
Camshaft bearing clearance mm

Nominal Limit
0.025 0.080 0.12
If the camshaft bearing inner diameter or the

journal clearance exceeds the prescribed values,
the camshaft bearing shall be replaced.
Camshaft bearing replacement

Camshaft bearing disassembly
1. Remove cylinder block stopper.
2. Disassemble the camshaft bearing
with a camshaft bearing replacer.
Camshaft bearing replacer:
1002107FA-9101
66
Camshaft bearing assembly
1. Align the oil hole on the bearing to the oil
hole on the cylinder block.
2. Mount the camshaft bearing with a camshaft
bearing replacer.
Camshaft bearing replacer: 1002107FA-9101
Tappet
Visually check whether there is any point
corrosion, crack and other abnormities on contact
surface between the camshaft and tappet. If so,
replace the tappet.
See left figure.
Normal contact
Crack
point corrosion
Abnormal contact
Abnormal contact
Note
The tappet has spherical surface.Never use an
oilstone or similar tools to grind the spherical
surface when you repair the tappet.If the
tappet is damaged, you must replace it with a
new one.
Tappet outer diameter

1. Measure the tappet outer diameter with a dial
gauge. If the measurement value exceeds
prescribed limit, the tappet shall be replaced.
Tappet outer diameter mm

Nominal Limit
12.72 12.90 12.70
67
2. Measure the upper tappet installation hole
inner diameter on the cylinder block and
calculate the clearance.
If the clearance exceeds the limit value,
replace the tappet and/or cylinder block.
Clearance between the tappet and tappet hole

mm
Nominal Limit
0.010-0.046 0.10
Reassembly
9. Tappet
1) Apply oil to the tappet and in the upper
tappet installation hole on the cylinder block.
2) Determine the tappet position according to
the identification made in disassembling (if
the tappet is newly used).
Note
The tappet shall be installed before
assembling the camshaft.
8. Camshaft
1) Apply oil to the camshaft and camshaft
bearing.
2) Install the camshaft to the cylinder block.
Be careful not to damage the camshaft bearing.
7. Camshaft thrust washer

Mount the thrust washer to the cylinder block and
tighten the thrust washer bolt (s) to specified
torque.
Thrust washer bolt torque : 25 5N m
68
1) Install camshaft timing gear to the camshaft.
The timing gear mark (“Y-Y”) shall face
outwards.
2) Tighten the timing gear bolt to the specified
torque.
Timing gear bolt torque 110 10 N m

Apply some oil on the oil pipe O-ring and
mount it to the cylinder block O-ring groove.
Install the oil pump assembly and oil outlet
pump to the cylinder block. Tighten the fixing
bolt(s) to specified torque.
25 5 N m
Tighten sleeve nut(s) to the following
specified torque:
30 5N m
4. Oil pan assembly

As shown in the figure, apply recommended silica
gel (Loctite 598) or equivalent in alignment on the
arc area of the fifth bearing cap, groove, the arc
area of timing gear casing and oil pan gasket.
Mount the rear lip of seal washer into the

groove of the fifth bearing cap.
Make sure the lip perfectly contacts with the
groove.
Install the oil pan to the cylinder block.
Tighten oil pan bolt(s) to the specified torque.
Oil pan bolt torque 23.5 3.5 N m
69
3. Flywheel baffle
Tighten the flywheel baffle fixing bolts to the
specified torque.
Flywheel baffle bolt torque 85 10N m
2. Flywheel
Apply some oil to fixing bolts.
Screw down the flywheel bolts to the
specified torque in two steps by torque
tightening method.
Tighten them as the sequence number shown in
the figure.
Flywheel bolt torque N m
25 70 120 10

1) Assemble the valve seat
1. Carefully place the attachment (its outer
diameter is less than that of valve seat) on
the valve seat .
Note
Make the smooth side of attachment contact with
the valve seat.
2. Use a table press to gradually press the
attachment until the valve seat seats in
place.
Note
Never apply excess compressive force on the
valve seat when you use a table press. Otherwise,
the valve seat may be damaged.
Measure the upper height of valve guide from the
upper surface of cylinder head.
Upper height of valve guide (H) (reference value):
13 mm
70
Note
If a valve guide has been disassembled,
you should replace the valve and valve
guide in pairs.
2) Lower spring seat
3) Valve stem oil seal
Mount a new oil seal to the valve.
Use a special tool to guide.
4) Valve
5) Valve spring
Mount the valve spring on the upper spring
seat.
Caution
The section with painting on the valve spring
shall be placed downwards.
Supply compressed air from glow plug hole
to cylinder until the valve seats in place.
Install the valve cotter with a special tool.
6) Valve cotter
Use a spring compressor to press the spring
in place.
Use a soft-faced hammer to tap the cotter
head until it seats in place.
71
2.4. Rocker arm assembly
Disassembling sequence:
1.Rocker shaft assembly
2.Rocker shaft elastic retainer
3. Rocker arm
4. Rocker shaft support
5. Rocker arm
6. Rocker shaft spring
7. Rocker shaft
Reassembling sequence:
sequence.
Disassembly
1. Rocker shaft assembly
2. Elastic retainer of rocker shaft
3. Rocker arm
4. Rocker shaft retainer
5. Rocker arm
7. Rocker shaft

If excessive abrasion and damage is found
during checking, adjust, repair and replace
parts in time.
Measure the outer diameter of rocker shaft at
its swinging position with a dial gauge.
Replace the rocker shaft if the diameter
exceeds prescribed limit.
mm.
Nominal Limit
18.98—19.00 18.9
72
Oil film clearance
1. Measure the inner diameter of rocker shaft
hole with a vernier caliper or dial gauge.
Inner diameter of rocker shaft hole mm
Nominal Limit
19.010—19.030 19.100
2. Measure the outer diameter of rocker shaft.If
the measured value exceeds prescribed limit,
replace rocker arm or rocker shaft.
Clearance between rocker arm and rocker
shaft mm
Nominal Limit
0.01—0.05 0.10
3. Check the upper oil hole of rocker arm is

blocked.
Blow clean the oil hole of rocker shaft with
compressed air if necessary.
Rocker arm correction

Check there is abrasion or scratch with the
upper valve stem contact surface.
If there is slight abrasion or scratch of step
shape with the contact surface, polish it with
oil.
The rocker arm has to be replaced if this
abrasion or scratch is serious.
73
Radial runout of rocker shaft
1. Put the rocker shaft on a V block.
2. Measure the radial runout at middle part of
rocker shaft with a dial gauge.
If the radial runout is slight, correct this
runout with a table press.
If the radial runout of rocker shaft exceeds
prescribed limit, the rocker shaft has to be
replaced.
Radial runout of rocker shaft mm
Limit
0.2
Reassembly
7. Rocker shaft
Apply a thin layer of oil to the rocker
shaft.
The rocker shaft should be placed in
such a way that the bigger hole (ø4)
faces the engine forepart.
Install the rocker shaft, rocker shaft
retainer and spring together.
5. Rocker arm
4. Rocker shaft retainer
3. Rocker arm
2. Elastic retainer of rocker shaft
1. Rocker shaft assembly
Install the rocker shaft assembly on the
cylinder head.
Tighten the flywheel baffle fixing bolts to
the specified torque.
74
2.5 Oil pump
Assembling sequence:
1. Flywheel
2. Rear plate of cylinder block
3. Oil pan assembly
5. Oil pipe
6. Strainer
7. Pump cover
8. Driven gear and bush
9. Drive gear
10. Driven shaft
11. Pinion pin
12. Pinion
13. Drive shaft
14. Oil pump body
sequence.
Disassembly
1 Flywheel
2. Flywheel baffle
3 Oil pan assembly
75
4 Oil pump assembly
5. Oil pipe
6. Strainer
7. Pump cover
9. Drive gear
10. Driven shaft
11. Pinion pin
File flat the tip of pinion stop pin.
Knock out the pinion pin with a hammer
and bar.
Remove the pinion.
12. Pinion
13. Drive shaft
14. Oil pump body

Housing and gear
The oil pump assembly must be replaced if one of
the following conditions is found:
The driven gear sleeve is worn or
damaged seriously.
The upper gear teeth is worn or
damaged seriously.
Clearance between upper gear teeth and

inner housing wall
Measure the clearance between upper gear
teeth and inner housing wall with a clearance
gauge.
If the clearance between upper gear teeth
and inner housing wall exceeds prescribed
limit, either the gear or housing has to be
replaced.
Clearance between upper gear teeth and inner
housing wall
mm
Nominal Limit
0.14 0.20
76
Clearance between gear and cover
Measure the clearance between gear
and cover with a clearance gauge.
If the clearance between gear and cover
exceeds prescribed limit, the housing
must be replaced.
Clearance between gear and cover mm
Nominal Limit
0.06 0.15
Clearance between drive shaft and oil

pump body
Use a micrometer to measure the
borehole diameter of drive shaft.
Measure the inner diameter of pump
body with a dial gauge.
If the Clearance between drive shaft and
oil pump body exceeds prescribed limit,
the oil pump assembly has to be
replaced.
Clearance between drive shaft and oil pump
body mm
Nominal Limit
0 04 0 20
Clearance between driven shaft and

bush
diameter of driven shaft.
Measure the inner diameter of bush with
a dial gauge.
If the clearance between driven shaft
and bush exceeds prescribed limit, the
bush must be replaced.
Clearance between driven shaft and bush mm
Nominal Limit
0.05 0.15
Reassembly
14. Oil pump body
13. Drive shaft
12. Pinion
77
11. Pinion pin
Install new drive shaft on the pump body.
Install the pinion on the drive shaft.
Drill a hole with 5mm (0.20in) bore bit
for the pinion and drive shaft to pass
through.
Insert the pinion pin into the hole.
Rivet the pin.
10. Driven shaft
9. Drive gear
7. Pump cover
6. Strainer assembly
Mount the strainer assembly and screw
down its fixing bolts.
20±5 N·m
5. Oil pipe
4 Oil pump assembly
Apply oil containing molybdenum to the
oil pump driven gear and camshaft drive
gear.
Tighten the oil pump fixing bolts to the
specified torque.
20±5 N·m
3 Oil pan assembly

Apply recommended liquid sealant or
equivalents to the fifth bearing cap arch
section, groove and timing gear
chamber arch section shown in the
diagram.
78
Mount the rear lip of seal washer into the
groove of the fifth bearing cap.
Make sure that the lip is perfectly in
contact with the groove.
Install the oil pan on the cylinder block.
Tighten oil pan bolt(s) to the specified
torque.
Oil pan bolt torque: 23.5±3.5 N·m
2. Flywheel baffle
Align the flywheel baffle with the anchor
pin of cylinder block, and tighten
flywheel baffle bolt(s) to the specified
torque: 85±10 N·m
1 Flywheel
Apply some oil to fixing bolt.
Screw down the flywheel bolts to the
tightening method.
Flywheel bolt torque N·m
Step Step Step

25 70 120±10
79
2.6. Crankshaft
Assembling sequence:
1. Cylinder head assembly and
gasket
2. Oil pan
3. Timing gear
3a. Timing belt and pulley
4. Front oil seal
5. Timing pulley chamber
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
10. Rear plate of cylinder block
11. Rear oil seal of crankshaft
12. Main bearing cap
13. Crankshaft
sequence.
Disassembly
1. Cylinder head assembly and gasket
2. Oil pan assembly
3. Timing gear
4. Timing gear chamber
80
7. Piston and connecting rod
8. Flywheel
9. Flywheel baffle
10. Rear oil seal
Push in the oil seal, install the special
tools according to the sequence shown in
the diagram to facilitate removing the oil
seal.
Rear oil seal remover: 1002430FA-9102
Note: Take care not to damage the flywheel
baffle and crankshaft sealing surface
during oil seal removal.
12. Crankshaft

If excessive abrasion or damage is found
during checking, adjust, repair and replace
parts in time.
1. Crankshaft
Thrust clearance
Install dial gauge according to the sequence
shown in the diagram and measure the thrust
clearance of crankshaft.
If the thrust clearance exceeds prescribed
limit, the thrust bearing shall be replaced in
pair.
Thrust clearance mm
Nominal Limit
0.040-0.201 0.30
2. Main bearing clearance

1) Remove the main bearing cap according to
the sequence shown in the diagram.
Place the removed main bearing cap
according to the sequence number of
cylinder.
2) Remove crankshaft. Dismantle main bearing.
3) Clean the upper and lower bearings and
main journal of crankshaft.
4) Check the bearing is damaged or
excessively worn.
If excessive abrasion or damage is found
during checking, the bearing has to be
replaced in pair.
81
5) Install the upper bearing and thrust washer
on their original positions. Carefully install the
crankshaft.
6) Mount the lower bearing to the bearing cap in
its original position.
7) Install plastic cord clearance gauge on the
main journal of crankshaft.
8) Install main bearing cap. Apply oil to the
threads and mating surfaces of bolts. Tighten
the bolt to the specified torque.
170±10 N·m
Note:
The crankshaft is not allowed to rotate.
9) Remove main bearing cap.
10) Measure the width of plastic cord clearance
gauge and determine the oil film clearance.
If the oil film clearance exceeds prescribed
limit, the main bearing and (or) crankshaft
has to be replaced in pair.
11) Remove the plastic cord clearance gauge off
bearing and crankshaft.
Dismantle crankshaft and bearing.
Oil film clearance mm(in)
Nominal Limit
0 031—0 066 0 11
3. Radial runout
1) Carefully put the crankshaft on a V block.
Slowly rotate the crankshaft and measure the
radial runout.If the radial runout of crankshaft
exceeds prescribed limit, the crankshaft has
to be replaced.
Radial runout mm
Nominal Limit
0.05 or less 0 08
82
Measure the diameter of main journal and
crankpin and the uneven abrasion.
If the abrasion of crankshaft exceeds prescribed
limit, the crankshaft has to be replaced.
mm
Nominal Limit
Main journal
69.91—69.932 69.910
diameter
Crankpin
52.91—52.930 52.900
diameter
Uneven
0.05 or less 0.08
abrasion limit
Crankshaft inspection
Check the main journal of crankshaft and
crankpin surface are damaged or excessively
worn.
Check there is excessive abrasion or
damage on the mating surface of oil seal.
Check the oil hole is blocked.
The tested part has to be kept in Inspection on soft nitrogen treatment of

balance to prevent testing fluid
flowing.
No testing fluid is crankshaft
necessary around
the oil hole. 1. Thoroughly clean the crankshaft with a
Sliding surface of
crankpin or main
kind of organics. There must be no oil
journal stains on the tested surface.
About 10mm 2. Prepare some solution containing 5
—10 ammonium cupric chloride
(dissolved in distilled water).
3. Apply the solution on the tested surface
with an injector.
Keep the tested surface in full level state
to prevent solution flowing.
Note:
The solution is not allowed to wash the oil
hole and area around.
Test
1. Wait for 30—40 seconds.
If the color does not change after 30—40
seconds, the crankshaft can be used.
If the color changes (the tested surface
becomes copper color), the crankshaft has to
be replaced.
83
2. Clean the crankshaft surface with steam
immediately after test is completed.
Note:
There is high corrosiveness with
ammonium cupric chloride solution.
Therefore, it is absolutely necessary to
clean the crankshaft surface immediately
after test is completed.
Crankshaft bearing selection
When assembling new crankshaft bearing or
replacing old bearing, see the selection table
below.
When selecting and installing new crankshaft
bearing, pay attention to the diameter size
mark of the upper journal hole and crankshaft
main journal 2.
Note:
Although there are oil grooves and holes
(cylinder block side) with all the upper
bearings of main journal and there are not oil
grooves and holes (bearing cap side) with all
the lower bearings, still pay attention to
identify them during assembly.
84
Main bearing hole diameter Crankshaft main journal
Main bearing Oil film
(mm) diameter (mm)
size mark clearance
Size mark Bore diameter Size mark Outer diameter
0.010
1 69.926-69.932 Black 2 0.006 0.036-0.062
1 73.988-74.000
2 69.920-69.926 0.014 0.034-0.060
Blue 2 0.010
3 69.914-69.920 0.040-0.066
1 69.926-69.932 0.006 0.031-0.057
Green 2 0.002
2 69.920-69.926 0.037-0.063
2 73.975-73.987
0.010
3 69.914-69.920 Black 2 0.006 0.035-0.061
Reassembly
13. Crankshaft
Install the main bearing on the cylinder
block and main bearing cap.
Make sure that their positions are
correct.
Apply fresh oil to the upper and lower
main bearing surfaces.
Carefully install the crankshaft.
Apply oil to the thrust washer.
Install the thrust washer on the third
main journal. Its oil groove must face the
crankshaft.
85
other equivalents to the fifth crankshaft
bearing cap as shown in the drawing.
Install arc gasket on the fifth bearing
cap. Put the arc gasket into the bearing
cap groove with fingers.

other equivalents to the fifth crankshaft
bearing cap as shown in the drawing.

other equivalents to points and of
the fifth crankshaft bearing cap cylinder
block mating surface as shown in the
drawing.
Note:
Ensure that there in no oil stain on the
mating surface of bearing cap before
coating liquid sealant.
Make sure the liquid sealant do not block
cylinder thread hole and bearing.
Install the bearing cap, and make sure

the arrow mark on its top points at
engine forepart.
Apply oil to crankshaft bearing cap bolts.
Tighten the crankshaft bearing cap bolts
step by step in several times according
to the sequence shown in the drawing
until specified torque is reached.
Nm
Step Step Step (final
(sealing (sealing torque)
torque) torque)
20 110 170
86
Note:
Manually rotate the crankshaft to check
whether it is flexible.
11. Rear oil seal of crankshaft

Install the oil seal on the cylinder block with
an oil seal erector.
Rear oil seal erector: 1002430FA-9101
Notes:
Clean the rust and chips off the press-in
portion of the oil seal.
Pay attention to the press-in direction of
the oil seal.
1) Connect the adaptors of special tools to
the rear end of the crankshaft with two
bolts.
2) Install the oil seal to the periphery of the
adaptors.
3) Insert the socket into the adaptor and
screw down the bolt (M12XL75L=70) until
the adaptor tip is in contact with the
socket.
4) Remove the adaptor and socket.
5) Check the oil seal installation depth and
flatness after it is installed.
Depth standard: 12.5±0.3mm
10. Flywheel baffle
Align the baffle with the upper anchor pin of
cylinder block.
Tighten the flywheel baffle bolts to the
specified torque: 85±10N·m
9. Flywheel
1) Thoroughly clean out the oil stains on the
crankshaft thread(s).
2) Install the flywheel on the crankshaft, and
then mount the washer(s).
3) Apply oil to flywheel bolt thread(s).
4) Align the flywheel with the anchor pin of
crankshaft.
5) Screw down the flywheel bolts to the
tightening method. Tightening sequence
is shown in the diagram.
Flywheel bolt torque N·m
Step Step Step (final
(sealing (sealing torque)
torque) torque)
25 70 120±10
87
8. Piston and connecting rod assembly
Apply oil to cylinder hole, connecting rod
bearing, crankpin, piston ring and piston.
Check the position of piston ring
opening is correct.
Encase piston/connecting rod assembly

into each cylinder with a piston ring
compressor.
The front mark must face the engine
forepart.
The number on cap should be in pair
with the one on connecting rod. Align the
printing mark on connecting rod with the
one on cap.
Apply oil to the threads and mating
surfaces of nuts.
Screw down the connecting rod cap nuts
in two steps by torque tightening method
according to the following descriptions.
N·m
First step Second step
(pretightening) (tightening)
20 85±5
Check the crankshaft rotates freely after the
connecting rod nuts are tightened.

Tighten bolt(s) and injection nozzle
plug(pressure limiting valve) to the
specified torque.
Bolt: 20±5 N·m
Injection nozzle plug
(pressure limiting valve): 30±5 N·m
88
1) Prepare some solution containing 80
oil and 20 supramoly.
2) Apply a thin layer of the above solution
to the teeth of oil pump pinion.
3) Install the oil pump and tighten bolt(s) to
the specified torque.
25±5 N·m
Note:
Take care not to damage O-ring when
screwing down oil pipe bolt(s).
4) Tighten sleeve nut(s) to the specified
torque:
30±5 N·m
5. Timing pulley chamber

1) Install timing pulley chamber on the
cylinder block.
2) Use bolt(s) to tighten both timing pulley

chamber and timing pulley chamber
gasket(s) to the specified torque.
25±5 N·m
3) Cut off the gasket tip on the mating

surface (as shown in the diagram).
4. Front oil seal of crankshaft

Install the front oil seal of crankshaft on the
gear chamber cover assembly with a front oil
Front oil seal seal erector as shown in the diagram.
of crankshaft Front oil seal erector: 1002420FA-9101
Note:
Take care not the twist the front oil seal.
89
3 Timing gear
11) Crankshaft gear
Install crankshaft gear
Install crankshaft gear with crankshaft
gear erector .Crankshaft gear timing
mark (“K-X”) must face the outside.
10) Camshaft timing gear

Install camshaft timing gear to the
camshaft with timing gear mark (“Y-Y”)
toward outside.
Tighten camshaft timing gear bolt(s) to
the specified torque:
110±10 N·m
9) Idler gear
Apply some oil to the idler gear and its
shaft.
The oil hole in idler gear shaft must face
upward.
Idler gear setting marks “X” and “Y”
should face the engine forepart during
assembly.
Align idler gear setting mark “X” with

setting mark “X-X” of crankshaft timing
gear .
Align idler gear setting mark “Y” with
setting mark “Y-Y” of camshaft timing
gear .
Install thrust ring and bolt(s) on the
cylinder block.
Thrust ring oil hole must be toward
upward, while its chamfer shall face the
outside.
Tighten idler gear bolt(s) to the specified
torque.
25±5 N·m
90

Manual de Reparacion Motor Jac 4da1 Parte 1

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SHOP MANUAL

All the maintenance data in this manual is 1000 Engine

and JAC new model cabin.

Main specifications of the trucks equipped with 4DA1 engine

D810 Single D800-6.142 7.00R16 5980*1880*2200 3360 5740

B826/B827 6.50R16/6.50-16 5980*1998*2200 3308 5215 95 3

Remark: :Standard Equipment :Optional Under develop ×:Not Available

Remark: :Standard Equipment :Optional Under develop ×:Not Available

Company Vehicle Type Main Code from

Company Code Name HFC-----represents JAC motor

VIN----Vehicle Identification Number

World Manufacturer Identification

The mechanic performance table of bolts in China

Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9

Tensile strength limit b max(MPa) 600 800 900 1040 1220

Yield limit s max(MPa) 480 640 720 940 1100

Corresponding to Hyundai standards 4T 6T 7T 8T 10T

systems of 4DA1 Series engine, general maintenance standards, special tools

as well as common fault diagnosis and troubleshooting.

Our products are subject to continuous innovation. If any information in this

modified in a second edition.

or by any means without written consent of Jianghuai Automobile.

1.1.1 Start problems

3. The engine rotates but it cannot be ignited to start.

4. Quick start system

1.1.2 Unstable idle speed

1.1.3 Insufficient power

1.1.4 High fuel consumption

1.1.6 Engine overheating

1.1.7 White smoke coming out of engine exhaust

1.1.9 Low oil pressure

1.1.10 Abnormal engine noise

1.1.11 Engine cooling problem

Check the battery and make the following diagnosises.

Check the battery

Charging is invalid or the life of

Check the battery

Check the terminal post

Connection is interrupted. The terminal post is OK.

Turn on the headlamp and starter switch

The headlamp is off or dim. The headlamp is bright.

a) The starter circuit has open circuit.

When the starter switch is switched to ST (start)

The connection of starter There is an open circuit

Replace the starter

When the starter switch is switched to ST (start)

Check the grounding cable Check whether the instrument

Good Bad Normal Abnormal

The sliding The solenoid switch or

Check the starter The starter switch

Check the grounded cable

Repair or replace the

Repair or replace the starter

Terminal Post No.

Besides the wiring mentioned above, other circuits should be opening.

The solenoid switch contact is Replace the solenoid switch

Replace the starter switch

Oil pressure switch

D810 Single D800-6.142 7.00R16 598018802200 3360 5740

B826/B827 6.50R16/6.50-16 598019982200 3308 5215 95 3