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SINOTRUK HOWO D10 Engine Port-to-Direct Injection Conversion Kit D10-34-40
Core Modification Kit Components
1. Mechanical High-Pressure Fuel Pump Assembly
Uses the P8500 or PS8500 mechanical fuel pump (compatible with the WD615 engine; equipped with a mechanical governor and a fuel-cutoff cylinder).
2. Drive and Mounting Support System
Fuel pump drive gear: Matches the gear ratio of the D10 engine's front gear housing.
Connecting flange and coupling: Connects the gear to the fuel pump's main shaft.
Fuel pump mounting bracket and fixing bolts: Securely mounts the mechanical pump to the engine block.
3. High- and Low-Pressure Fuel Circuit System
Low-pressure fuel transfer pump and fuel line kit: Draws diesel from the fuel tank to the main fuel pump.
High-pressure fuel line assembly (6 lines): High-pressure steel lines connecting the mechanical pump to the six cylinders; bend angles and lengths are custom-fitted for the specific vehicle.
4. Fuel Injector Assembly (6 units)
The original electronically controlled common-rail injectors must be removed and replaced with fully mechanical injector assemblies.
Note: The injector mounting holes in the D10 cylinder head differ from those of the traditional WD615; the kit typically includes specialized injector adapter sleeves (copper or steel) or custom-sized mechanical injectors.
5. Throttle Control System (Mechanical Throttle Cable Assembly)
Since the original electronic throttle pedal is rendered obsolete, a long throttle cable must be installed to connect the cab's throttle pedal directly to the governor control lever on the engine's fuel pump (some kits include a modified pneumatic engine-stop valve).
Key Technical Aspects of the Conversion
1. Timing Alignment (Fuel Injection Advance Angle): This is critical to the success of the conversion. You must strictly adhere to WD615 series standards: align Cylinder 1 to Top Dead Center (TDC) and precisely adjust the mechanical pump's fuel injection advance angle. Incorrect alignment can lead to severe engine knocking, white exhaust smoke, or a complete failure to start.
2. Pneumatic Engine Shutdown Modification: While electronic fuel injection (EFI) vehicles shut down by cutting power to the ECU, the conversion to a mechanical pump requires connecting an air line to the pump's pneumatic fuel-cutoff cylinder. Activating the pneumatic switch (or key-linked valve) in the cab supplies air to drive the pushrod, thereby cutting off the fuel supply and stopping the engine.
3. Instrument Cluster Handling: Removing the original common-rail system's ECU and vehicle sensors typically causes the "Check Engine" light to remain illuminated and may render the tachometer and coolant temperature gauge inoperative. Since conversion kits usually do not include instrument cluster modifications, separate wiring is required to connect traditional coolant temperature and tachometer sensors (with the tachometer signal sourced from the alternator's "W" terminal).
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