JAC HFC1042K2 Service Manual
SHOP MANUAL
4DA1 SERIES
Mainly for the truck HFC1042K2(D800)
JAC INTERNATIONAL
2007.10
JAC motors
4DA1 SERIES
SHOP MANUAL
Foreword
This shop manual was prepared as
reference to properly carry out servicing
and maintenance on JAC vehicles.
Contents
Group
Code
0000 General
Name Page
All the maintenance data in this manual is
based on the model HFC1042K2
( D800/D801). And it also can be as
reference for the other models listed in the
Chapter “General”. Their main common
configurations are as follows:
HFC4DA1(HFC4DA1-1) engine; JAC
MSB-5M transmission, hydraulic brake
and JAC new model cabin.
All information in this manual is the latest
data and status of the vehicle at the time
of publishing for your reference. However,
due to technological advance or product
updating etc., all contents in this manual
are subject to modification. We reserve
the right of modification of this manual
without prior notice.
Please inform Customer Service
Department of JAC International if there is
any mistake, and you will be highly
appreciated.
Tel：0086-0551-2296344
Fax：0086-0551-2296454
Email：hwfw@jac.com.cn
1000 Engine
1600 Clutch
1700 Gearbox
2200 Driveshaft
2400 Rear axle
2901 Front suspension
2911 Rear suspension
3000 Front axle
3400 Steering gear
3500 Brake
3700 Electric system
5000 Cabin
General
General
Specifications
Vehicle Model
VIN
The mechanic performance table of bolts in China
Specifications
Model
Serious Number
Cabin
Final gear ratio
Tyre
L*W*H)
Gross Vehicle
Capacity
Conditioner
teering
heater
Braking
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.
型号
for produce
结构区别号
驾驶室
后桥速比
轮胎
Overall Size
（mm) （
整车尺寸
Wheelbase
（ mm ）
轴距
Weight （ kg ）
最大质量
Max Speed
（ km/h ）
最大时速
Seating
额定成员数
Air
空调
Power
S
动转
Pre-
预热
Exhaust
排气制动
HFC1040K/KR1 D803/D804
HFC1035KD D836 Single 5.375
HFC1042K
HFC1045K2
HFC1020K/KR1 D870/D871
Remark:√:Standard Equipment 〇:Optional ●Under develop ×:Not Available
D810 Single D800-6.142 7.00R16 5980*1880*2200 3360 5740
B826/B827
Single/King
Cab
Single/King B1DAB0-6.142
Single/King
Cab
D803-6.142 6.50-16 5745*1866*2213 3000 4930 90 2
D870-6.142 6.50-16 5400*1868*2200 2800 3630 90 2
7.00R16
Rear single
6.50R16/6.50-16 5980*1998*2200 3308 5215 95 3
4850*1730*2240 2490 3900 110 2
100 2
〇 〇 √
〇 〇
〇 √ √ √
√ √ √ √
〇 √ √
×
√
×
×
Main specifications of the trucks equipped with 4DA1-1 engine
Model
Number for
Cabin
Final gear ratio
Tyre
mm)
Gross Vehicle
Capacity
Conditioner
Steering
heater
Braking
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
型号
HFC1035KD D817 Single 5.375
HFC1042K2RD D819 Double 5.375
HFC1040K/KR1 D830/D831
HFC1045K2/R1 B802/803
HFC1045K2 B832
HFC1040K2
HFC1042KR
HFC1035KD D874 Single 5.375
Remark:√:Standard Equipment 〇:Optional ●Under develop ×:Not Available
produce
结构区别号
D800/D801
D802 double D800-6.142 7.00R16 5995×1900×2250 3360 4490
驾驶室
Single/King
Cab
Single/King
Cab
Single/King
Cab
Single/King
Cab
后桥速比
D803-6.142 6.50-16 5745*1866*2213 3000 4930 90 2
B1DAB0-5.571
B1DAB0-5.571
D800-6.142 7.00R16 5995*1900*2250 3360 5740
轮胎
7.00R16
Rear single
7.00R16
Rear single
6.50R16/6.50-16 5980*1998*2220 3308 5735 95 3
6.50R16/6.50-16 5980*1998*2220 3308 5735 95 3
7.00R16
Rear single
Overall Size（
（L*W*H) 整
车尺寸
4850*1730*2240 2490 3900 110 2
4875*1715*2215 2490 3900 110 2+3
4850*1730*2240 2490 3900 110 2
Wheelbase
（ mm ）
轴距
Weight （ kg ）
最大质量
Max Speed
（ km/h ）
最大时速
100 2
100 2+3
Seating
额定成员数
Air
空调
〇 〇
〇 〇
〇 〇 √ √
〇 〇 √ √
〇 √ √ 〇
〇 〇 √ √
〇 〇 √ √
〇 √ √ √
Power
动转
Pre-
预热
Exhaust
排气制动
×
0
√
〇
Vehicle Model
General
Company
Code Name
Company Code Name：HFC-----represents JAC motor
Vehicle Type Code：1---Cargo truck 2---Off-road vehicle 3---Dumper
Main Specifications Code：25---represents the maximum gross weight is 25 tons.
Product serial No.： 1---Product development serial No.（1stchange，2nddevelopment）
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.
Vehicle Type
Code
4---Tractor 5---Special purpose vehicle 6---Passenger car
7---Sedan 9---Semitrailer
Main
Specifications
Code
Product
Serial No.
Code from
company
General
VIN----Vehicle Identification Number
VIN comprises of 17 digits. They separately represent:
黑色
中国安徽江淮汽车股份有限公司 制造
VⅠN
36.5
品 牌 ： 江 淮
73
发动机型号
L J 1 1 K D F A 4 4 0 0 0 2 5 2 1
型 号
额定功率
O32-
R2
kW
总 质 量 整 备 质 量
出 厂 编 号 出 厂 日 期
kg
kg
年 月
119
125
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
World Manufacturer Identification
Assembly Plant
Year
Check Code
General
b
s
The mechanic performance table of bolts in China
Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9
Tensile strength limit
Yield limit
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.
max(MPa)
max(MPa)
600 800 900 1040 1220
480 640 720 940 1100
Section Ⅰ
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.
There is bad connection caused by
Battery
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
Starter motor
2. The starter motor works well, but the engine fails to run.
Battery
Starter motor
Engine
oxidation or corrosion.
The battery is uncharged or in
shortage of charge.
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
The solenoid switch has failed. Repair or replace the solenoid switch
The starter motor has failed. Repair or replace the starter motor
The battery terminal post is loose.
There is bad connection caused by
oxidation or corrosion.
The battery is uncharged or in
shortage of charge.
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
The brush is worn or the brush spring
is too soft.
The piston or crankshaft bearing is
jammed or damaged.
Clean and/or tighten the loose terminal
post(s)
Charge the battery or replace the old
battery with a new one
Clean and/or tighten the loose battery
terminal post(s)
Charge the battery or replace the old
battery with a new one
Replace the brush and/or the brush
spring
Repair or replace the damaged part(s)
3. The engine rotates but it cannot be ignited to start.
Check Causes Remedies
Brake mechanism
of engine
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.
Fuel filter The fuel filter overflow valve cannot be
The fuel cut-off solenoid valve is
broken.
The fuel tube joint is loose.
closed.
Replace the fuel cut-off solenoid
Repair or replace the fuel pipe
Retighten the fuel tube joint
Repair or replace the fuel filter
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.
Fuel
Fuel system There is air in the injection pump. Release the air from the fuel system
Fuel injector
Injection pump
The fuel in service is incorrect. Use the correct fuel
There is water in the fuel system. Replace the fuel
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel injector is
too low.
Atomizing is bad.
The damage of fuel injector results in
fuel dripping after injection.
Something is wrong with the control
rack of injection pump.
The injection pump plunger is worn or
jammed.
The drive shaft of injection pump is
jammed or damaged.
The governor spring of injection pump
is jammed.
Adjust or replace the fuel injector
Replace the delivery valve
Repair or replace the control rack of
injection pump
Repair or replace the injection pump
plunger assembly
Replace the drive shaft
Replace the governor spring of
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.
Check Causes Remedies
The indicator lamp of glow
plug is off.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow
plug is on for 0.3 s.
The indicator lamp is broken. Replace the indicator lamp
The quick start timer is broken. Replace the quick start timer
6
After the engine is started, switch
plug is on for 3.5 s.
Temperature switch The temperature switch is broken. Replace the temperature switch
Connectivity of glow plug The connectivity of glow plug is
The glow plug is power off.
The indicator lamp of glow
plug is off.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow
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
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.
bad.
The fuse of indicator lamp blows
out.
The glow plug relay is broken.
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
glow plug relay.
The fuse blows out or there is a
line fault.
When the start switch is switched
from OFF to ON, the glow plug
relay is switched on.
Replace the quick start timerThe indicator lamp of glow
Replace the quick start timer
Replace the glow plug
Replace the broken fuse
Replace the glow plug relay
Repair or replace corresponding
line(s)
Replace the fuse or
corresponding line(s)
1.1.2 Unstable idle speed
Check Causes Remedies
Idle speed system The idle speed is not proper. Adjust the idle speed
High idle speed control
device
Throttle control system The adjustment of throttle control
Fuel system
The high idle speed control device
is broken.
system is not proper.
Leakage or blockage occurs in the
fuel system.
There is air in the fuel system. Release the air from the fuel
There is water in the fuel system. Replace the fuel
Repair or replace the high idle
speed control device.
Adjust the throttle control system
Repair or replace the fuel system
system
7
Fuel filter
Fuel feed pump
Fuel injector
Injection pump
Valve clearance The valve clearance is not proper. Adjust the valve clearance
Compression pressure
A fuel filter component is clogged. Replace the fuel filter component
or the filter element.
The fuel feed pump is broken. Repair or replace the fuel feed
pump.
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel
injector is too low.
Atomizing is bad.
The damage of delivery valve
results in fuel dripping after
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
The shifter is broken Repair or replace the shifter
The regulator valve is not at
proper position.
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
The gasket of cylinder head is
worn.
The cylinder liner is worn.
The piston ring is sticky.
Adjust or replace the fuel injector
Replace the delivery valve
Adjust or replace the regulator
valve
Replace relevant parts
1.1.3 Insufficient power
Check Causes Remedies
Air filter
Fuel There is water in the fuel. Replace the fuel
Fuel filter A fuel filter component is clogged.
Fuel feed pump The fuel feed pump is broken.
Fuel injector
High pressure fuel pipe
Injection pump
An air filter component is
clogged.
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel
injector is too low.
Atomizing is bad.
The high pressure fuel pipe is
damaged or blocked.
The regulator valve is damaged.
Clean or replace the filter
component
Replace the fuel filter component
or the filter element
Repair or replace the fuel feed
pump
Adjust or replace the fuel injector
Replace the high pressure fuel
pipe
Repair or replace the regulator
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
well.
The injection timing is not correct.
The governing spring is too soft. Replace the governing spring
The plunger is worn. Replace the plunger assembly
The gasket of cylinder head is
Compression pressure
Valve clearance The valve clearance is not proper. Adjust the valve clearance
Valve spring
Exhaust system The exhaust pipe is clogged. Clean the exhaust pipe
Seal of full-load adjusting
screw
worn.
The cylinder liner is worn.
The piston ring is sticky.
The valve spring is too soft or
broken.
The seal of adjusting screw is
opened or improperly adjusted.
Adjust or replace the control lever
Adjust injection timing
Repair or replace the injection
pump timer
Replace relevant parts
Replace the valve spring
Properly adjust the seal of
adjusting screw and seal again
1.1.4 High fuel consumption
Check Causes Remedies
Fuel system There is a fuel leak.
Air filter An air filter component is clogged.
Idle speed
Fuel injector
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
Injection pump
Valve clearance The valve clearance is not proper. Adjust the valve clearance
Compression pressure
Valve spring
The idle speed is not adjusted
properly.
The opening pressure of fuel
injector is too low.
Atomizing is bad.
The damage of delivery valve
results in fuel dripping after
injection.
The gasket of cylinder head is
worn.
The cylinder liner is worn.
The piston ring is sticky.
The valve spring is too soft or
broken.
Repair or replace corresponding
parts of fuel system
Clean or replace the air filter
component
Adjust the idle speed
Adjust or replace the fuel injector
Replace the delivery valve
Replace relevant parts
Replace the valve spring
9
1.1.5 High oil consumption
Check Causes Remedies
Engine oil
Oil seal and gasket
Air vent The air vent is blocked. Clean the air vent
Intake valve and exhaust
valve
The oil type is not correct. Replace the engine oil
The oil volume is too high. Adjust the oil level
The oil leaks from the oil seal
and/or gasket.
The valve stem and valve guide
are worn.
Replace the oil seal and/or gasket
Replace intake valve, exhaust
valve and valve guide
1.1.6 Engine overheating
Check Causes Remedies
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
in slipping.
Radiator The radiator cap is damaged or
the radiator core is blocked.
Water pump The water pump is broken. Repair or replace the water pump
Cylinder head and cylinder
block
Sealed cap
Thermostat The thermostat is broken. Replace the thermostat
Cooling system The cooling system is clogged by
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
Damaged cylinder head results in
leakage of cooling water.
foreign matters.
Replace the fan belt
Replace the radiator cap or clean
the radiator core
Replace the sealed cap
Remove foreign matters from the
cooling system
1.1.7 White smoke coming out of engine exhaust
Check Causes Remedies
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
The gasket of cylinder head is
Compression pressure
Intake valve and exhaust
valve
Valve oil seal
worn.
The cylinder liner is worn.
The piston ring is sticky.
The valve oil seal is worn.
The valve stem and valve guide
are worn.
10
Replace relevant parts
Replace valve oil seal, valve and
valve guide
1.1.8 Black smoke coming out of engine exhaust
Check Causes Remedies
Air filter An air filter component is clogged. Clean or replace the air filter
component
Fuel injector The opening pressure of fuel
injector is too low.
Atomizing is bad.
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
The damage of delivery valve
results in fuel dripping after
injection.
The injection volume is too high. Reduce injection volume
Adjust or replace the fuel injector
Replace the delivery valveInjection pump
1.1.9 Low oil pressure
Check Causes Remedies
Engine oil The oil viscosity is not correct.
The oil volume is too low.
Oil pressure gauge or
assembly
Oil pressure indicator light
Oil filter An oil filter component is clogged. Replace the oil filter component or
Safety valve and bypass
valve
Rocker shaft The rocker shaft bearing is worn. Replace the rocker shaft bearing
Camshaft The camshaft and its bearing are
Crankshaft and bearing The crankshaft and its bearing are
The oil pressure gauge or
assembly is broken.
The indicator light is broken.
The safety valve is jammed and/or
the bypass valve spring is too soft.
The oil pump strainer is blocked. Clean the oil pump strainerOil pump
A component in the oil pump is
worn.
worn.
worn.
Replace the engine oil
Increase the oil volume
Repair or replace the oil pressure
gauge or assembly
Replace the indicator light
the filter element
Replace the safety valve and/or
bypass valve spring
Replace relevant parts in the oil
pump.
Replace the camshaft and its
bearing
Replace the crankshaft and/or its
bearing
1.1.10 Abnormal engine noise
1. Engine slap
Verify the engine is completely warmed up before troubleshooting.
Check Causes Remedies
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
injector or atomizing is not proper.
11
Adjust or replace the fuel injector
Compression pressure The gasket of cylinder head is
worn.
The piston ring is broken.
2. Air leak noise
Exhaust pipe The connection of exhaust pipe is
loose.
The exhaust pipe is broken.
Fuel injector and/or glow
plug
Exhaust manifold The connection to exhaust
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
Cooling fan The cooling fan is loose. Retighten the cooling fan
Water pump bearing The water pump bearing is worn
Alternator or vacuum pump The alternator or vacuum pump is
Valve clearance The valve clearance is not proper. Adjust the valve clearance
4. Clapping noise
Check Causes Remedies
Valve clearance The valve clearance is not proper. Adjust the valve clearance
Rocker arm The rocker arm is broken. Replace the rocker arm
Flywheel The flywheel bolt is loose. Retighten the flywheel bolt
Crankshaft and thrust
bearing
Crankshaft and connecting
rod bearing
Connecting rod bushing and
piston pin
Piston and cylinder liner The piston and cylinder liner is
The fuel injector and/or glow plug
are loose.
manifold is loose.
or damaged.
broken.
The crankshaft and/or thrust
bearing is worn or damaged.
The crankshaft and/or connecting
rod bearing is worn or damaged.
The connecting rod bushing and
piston pin are worn or damaged.
worn or damaged.
Replace the gasket of cylinder
head or piston ring
Tighten the connection of exhaust
pipe
Replace the exhaust pipe
Replace the gasket
Tighten the fuel injector and/or
glow plug
Tighten the connection to exhaust
manifold
again.
Replace the water pump bearing
Repair or replace the alternator or
vacuum pump
Replace the crankshaft and/or
thrust bearing
Replace the crankshaft and/or
connecting rod bearing
Replace the connecting rod
bushing and/or piston pin
Replace the piston and cylinder
liner
1.1.11 Engine cooling problem
Check Causes Remedies
Engine overheating
The coolant level is too low. Fill in the coolant
The thermostatic control is
broken.
The thermostat is broken. Replace the thermostat
Replace the thermostatic control
12
Something is wrong with the
cooling 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
disqualified.
The cylinder head gasket is worn. Replace the cylinder head gasket
The exhaust system is blocked. Clean the exhaust system or
The fan belt is loose. Adjust the fan belt
The fuel injection volume is too
high.
The injection timing is not correct. Adjust the injection timing
Engine overcooling The thermostat is broken. Replace the thermostat
The thermostat is broken. Replace the thermostatLong engine preheating
time
Check the battery and make the following diagnosises.
The thermostatic control is
broken.
Repair or replace the cooling
element
Fill in or replace the oil
replace the damaged parts
Adjust the fuel injection
Replace the thermostatic control
13
The starter doesn’t run.
battery is expired.
Check the battery
Charging is invalid or the life of
Check the battery
Connection is interrupted.
Clean the battery terminal post and reconnect it.
The battery is normal.
Check the terminal post
The terminal post is OK.
Check the starter or the starter switch
Faulty
Turn on the headlamp and starter switch
The headlamp is off or dim.
a) The battery has insufficient charge.
b) The starter coil is short-circuited.
c) A starter part is faulty.
Repair or replace
The headlamp is bright.
a) The starter circuit has open circuit.
b) The starter coil has open circuit.
c) The starter switch is faulty.
14
The engagement between the pinion and tooth
sliding resistance
connector of solenoid switch on the starter relay is
normal
starte
r
the connection between them
is
faulty
.
Abnormal
, or
them is
faulty
.
When the starter switch is switched to ST (start)
position, check whether there is voltage at the
terminal post "S" of solenoid switch.
Yes
The pinion and gear
ring are worn badly.
Repair or replace the
starter, and replace
the gear ring.
Or
The
of starter is too high.
Repair or replace the
No
In this case, check whether the voltage at 3BW
Normal
There is an open circuit
between the starter switch
and the solenoid switch, or
Repair
Yes No
Check there is voltage at
3BW connector of starter
switch on the starter relay
The connection of starter
switch is faulty.
Replace the starter
switch
There is an open circuit
between the starter
switch and the battery
the connection between
Repair
15
The starter switch is switched to ST (start) position, but
the solenoid swi
tch doesn't work.
Verify the circuit between the
terminal post "S" of solenoid
The solenoid switch or
coil has an open circuit
indicator light is normal
When the starter switch is switched to ST (start)
position, check whether there is voltage at the terminal
Yes No
post "S" of solenoid switch.
Check the grounding cable
Good Bad
Repair
Or
The sliding
part of pinion
doesn’t move.
Repair or replace the starter.
or is burned out.
Check whether the instrument
Normal Abnormal
There is an open circuit
starter switch and the
switch.
Check the starter
relay
Check the clutch
and starter switch
The starter switch
connection is faulty.
Replace the starter
switch
between the battery and
the starter switch, or the
connection is faulty.
Repair
16
The pinion engages with the gear ring well, but
the engine doesn't run.
has an open circuit or
The exciting coil has
n open circuit or is
damaged.
The clutch of
Check the grounded cable
Good
A fault occurs between
the brush and rectifier.
Repair or replace the starter
The solenoid starter
switch is burned out.
Bad
Repair or replace the
grounding cable
a
The armature coil
pinion slips.
is damaged.
17
The starter switch
is switched from ST to ON,
Terminal Post No.
Terminal Post No.
The position of
ON
Access
ory
but the starter doesn't stop.
Disconnect the wiring of starter switch and verify the operation of starter switch
Connector No.
starter switch
OFF
Locked
ON
Start
Besides the wiring mentioned above, other circuits should be opening.
Yes
The solenoid switch contact is
melted and hard to move.
Otherwise, the return spring is
broken or damaged.
Replace the starter switch
No
Replace the solenoid switch
18
4DA1 Series oil filter and oil cooler
Indicator
light
R
egulator
pump
shaft
arm
C
rankshaft
Connecting
valve
strainer
with bypass-type filter
Battery
Oil pressure switch
Vertical cylinder oil gallery
Bypass
filter
Oil filter and cooler
Full-flow
oil filter
Oil
cooler
Oil pump
Oil
Safety
valve
Safety
Relief
valve
valve
Oil
nozzle
Piston
Oil pan
Idler gear
shaft
Oil pipe
Timing
gear
Camshaft
bearing
Rocker
bearing
Rocker
rod bearing
① Opening pressure of relief valve at oil filter: 430-470kPa
Vacuum
② 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
Item
Natural admission (NA)
Four strokes, high mounted valve, water cooling
Combustion chamber type
Cylinder liner type
Cylinder number - cylinder bore stroke mm
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
Fuel injection timing
Required fuel type
Idle speed r/min
Valve clearance
(cold)
(hot)
Intake valve
Exhaust valve
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
Ambient temperature
Light diesel fuel type 0 # -10 # -20 # -35 #
Intake valve mm
Exhaust valve mm
Intake valve mm 0.30Valve clearance
Exhaust valve mm 0.30
Open (before top dead center)
Close (after bottom top dead
center)
Open (before bottom top dead
center)
Close (after top dead center)
Dry type, thin-wall chrome-plated steel cylinder
16 to the top dead
Above 4 ℃
4DA1 4DA1-1
Inter-cooling (TCI)Engine type
ω type direct injection
liner
4— 93×102
12 to the top dead
center (before)
Above -5℃Above -14℃Above -29
750±50
0.30～0.40
0.30～0.40
24.5
55.5
54
26
center (before)
Turbocharged
℃
20
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