Engine JAC HFC4DA1-2C. Service manual — part 4

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

15

No. Name Standard

Size

(mm)

Fitting

nature

Assembly

Clearance for

New Engine

(mm)

Wear Limit

(mm)

Grouping of cylinder sleeve
inside diameter (after
pressed-in)

Group A

93.021～93.032

Group B

93.032～93.043

Group C

93.043～93.054

Group D

93.054～93.065

24

Opening of piston ring

1

st

compression ring

0.2～0.4

1.5

2

nd

compression ring

0.65～0.85

1.5

Oil control ring

0.25～0.50

1.5

25

End clearance of piston ring

1

st

compression ring

0.078～0.139

0.15

2

nd

compression ring

0.045～0.09

0.15

Oil control ring

0.03～0.07

0.15

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

16

Section VII Specification of Main Attachments and Accessories

Lubrication

system

Engine oil pump type

Externally engaged gear pump

Flow rate of engine oil pump

≥ 23L/m (at 1,000r/m and 0.4MPa)
≥ 23L/m (at 1,800r/m and 0.44MPa)

Open pressure of engine oil pump

relief valve

0.7±0.08MPa

Engine oil filter type

Filter element type

Cooling

system

Water pump type

Centrifugal type

Flow rate and head of water pump

(water temperature at 80±5ºC)

Head ≥6.5m (at 3,000r/m) at 100L/min flow rate;

Head ≥12m (at 4,000r/m) at 120L/min flow rate;

Thermostat type

Pellet thermostat

Temperature of thermostat

Initial open: 82ºC; full open: 95ºC

Fan type

Independent electric fan

Electric

system

Preheating plug type

Ceramic type

Voltage of preheating plug

12V

Starter specification

12V，2.8kW

Alternator specification

14V，90A

Battery voltage

12V

Intake system

Turbocharger

Radial flow variable section turbocharger

The top speed of turbocharger is ≤220,000r/m, with

turbocharger ratio at ≤2.2.

EGR

Type of EGR valve

Position feedback type

Voltage of EGR valve position

sensor

5V

Electronically

controlled

common rail

fuel system

Fuel

filter

type

Spin-on type, with fuel-water separator, manual fuel

delivery pump, and diesel heater

High pressure fuel pump

BOSCH CP1H, radial three-plunger pump, with fuel

delivery fuel pump and solenoid valve control

Fuel injector

BOSCH CRI2.2, solenoid valve control

High pressure common rail

Maximum rail pressure: 160MPa

Electronic control unit (ECU)

BOSCH EDC17, with working voltage at 12V

Crankshaft speed sensor

Working clearance: 0.5～1.2mm

Camshaft position sensor

Working clearance: 0.5～1.5

Air flowmeter

HFM6, with working voltage at 12V and flow measurement

range at 40~840kg/h.

Water temperature sensor

NTC type

Rail pressure sensor

Voltage output: 0.5~4.5V

Accelerator pedal position sensor

Voltage: 5V

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

17

Chapter II Maintenance for Main Structures of Engine

Section I Disassembly of Engine Assembly

I. Special Notices:

a) Before overhauling the engine, make sure to firstly disconnect the negative cable of the battery, or it will damage
the harness and other electric units;

b) Unless otherwise specified, rotate the ignition switch to LOCK position;

c) Whenever the air cleaner is disassembled, make sure to plug the intake port, in order to prevent the ingress of
foreign material, which may enter into cylinder and cause serious damage.

II. Disassembly Procedure

z Turn the ignition switch to LOCK position and disconnect the negative cable of the battery.

z Open the oil drainage bolt of the oil sump and fully drain and collect the oil.

z Fully drain the coolant.

z Disassemble the water inlet and outlet hoses of the engine.

z Disassemble the electronic control harness for engine ECU, engine, and complete vehicle.

z Disassemble the power supply wires for alternator, starter, and oil pressure and water temperature sensors.

z Remove the connecting hose between intake connecting pipe and air cleaner.

z Loosen the connecting pipe of inter-cooler.

z Shut off the fuel pipeline and unplug the fuel pipe and return pipe.

z Disconnect the power supply of the radiator fan and when necessary loosen the radiator bracket and take out the

whole radiator.

z Loosen the clutch connecting pipe.

z Disassemble relevant connecting pipes of air conditioner and power steering pump.

z Disconnect the exhaust manifold and exhaust muffler pipe.

z Loosen the connecting mechanism between transmission and the complete vehicle.

z Loosen the fixing bolts between engine and transmission suspension bracket.

z Steadily lower the engine with elevator.

z Loosen the connecting bolts between engine and transmission and separate the transmission from the engine.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

18

III. Illustration for Disassembly of Engine

1. Disassemble the flywheel.

a. Block the flywheel with flywheel clamp, loosen the
fixing bolts between damping pulley and flywheel, and
disassemble the flywheel assembly.

2. Disassemble the belt, air conditioner
compressor, and alternator and water
pump pulleys.

a.

Use an open-end wrench to remove the fixing nuts of
engine fan and remove the cooling fan of the engine.

b.

Loosen the alternator adjustment bolts and fixing bolts,
remove the fan clutch pulley and alternator belt, and
check the side face and toothed face of the belt for
normal state.

c.

Remove the oil and vacuum pump oil return pipe
connectors.

d.

Loosen the alternator fixing bolts and adjustment bolts
and disassemble the alternator belt. Check the
alternator belt for presence of aging, cracking, and
abnormal wear. If yes, replace the belt. Arrange the
parts disassembled orderly on the part shelf, remove
the alternator, use hand to rotate the alternator pulley,
and check the inside for presence of noise, stagnation,
and unbalance. Check the alternator for presence of
ablation and check the shaft for presence of abnormal
wear noise.

e.

Disassemble the water pump pulley.