Engine JAC HFC4DA1-2C. Service manual — part 5

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

19

3. Disassemble the exhaust system.

a. Disassemble the fixing bolts of turbocharger lubricating

oil pipe and disassemble the fixing clamp of return
hose.

b. Remove the exhaust pipe shield.

c. Remove the EGR cooler.

d. Remove the exhaust pipe and turbocharger assembly.

e. Remove the fixing bolts and nuts of exhaust pipe,

remove the exhaust manifold and turbocharger
subassembly, and remove the exhaust manifold gasket.

f. Check:

A) Whether the rotor of turbocharger rotates flexibly.

B) Whether the air compressor wheel is damaged,
observed from the inlet of air compressor.

C) Whether the air compressor interferences with the
housing, observed from the inlet of air compressor.

4. Disassemble the relevant accessories
of fuel system.

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

20

a.

Loosen the conical nut at fuel injector end and the
conical nut on fuel injection pump side (one is to
reversely tighten the fuel inlet of fuel injector and one is
to loosen the nut of high pressure fuel pipe); Loosen the
conical nut on fuel injection pump side (Two wrenches
are used mainly for disassembly, of which one is to
reversely tighten the fuel outlet of fuel injection pump
and one is to loosen the nut of high pressure fuel pipe,
in order to prevent the fuel outlet of the fuel injection
pump from follow-up rotation). Remove the high
pressure fuel pipe and install the high pressure fuel pipe
protective sleeve;

b.

Remove the fuel injector return hose.

c.

Remove the fixing bolts of fuel injector pressure plate,
remove the fuel injector body along with its support,
and install the fuel injector protective sleeve.

4. Disassemble the fuel-gas separator
subassembly

a.

Remove the crankshaft breathe hose and fuel-gas
separator return hose.

b.

Disassemble the fixing bolts of fuel-gas separator.

c.

Remove the fuel-gas separator.

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

21

d.

Remove the fixing bolts of fuel-gas separator housing

and take out the fuel-gas separator filter element. Clean
the fuel-gas separator housing, check the state of filter
element, and when necessary replace the filter element.

e.

Disassemble the fixing bolts of fuel-gas separator
bracket and remove the fuel-gas separator bracket.

4. Disassemble the intake manifold and
other peripheral accessories.

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

22

a.

Disassemble the fixing bolts of power steering pump
and remove the power steering pump.

b.

Check the power steering pump for presence of oil
leakage and check the belt pulley of power steering
pump for presence of wear;

c.

Remove the EGR valve.

d.

Remove the fixing bolts of air intake pipe bracket.

e.

Remove the air intake pipe bracket and fuel-gas
separator bracket.