M33维修手册 Repair Manual

GDMB33V1801
Repair Manual for

M33 Series Powerkit Engine
xxxxxxxxxx
Repair manual-M33
Introduction
This manual is intended as a guide for staff responsible for maintaining and repairing engines
in the M33 range.
We recommend that you read this manual to familiarize yourself with the product and the
precautions that need to be taken before working on it.
Before commencing any work, you should take note of the necessary safety precautions and
avail yourself of the associated personal protective equipment (PPE).
The manual contains specific instructions regarding the repair methods that must be used.
It specifies the dimensions and tolerances that must be strictly observed during maintenance
and repair of the constituent assembles and sub-assemblies.
Thorough familiarization with and use of this manual will enable technicians to perform this
work under the best conditions.
The contents of this manual remain subject to future changes, which will be reported to you as
and when they come into force.
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Contents
R 00 Instruction…………………………………………………………………………………………7
R 00.10 General safety instructions .................................................................................. 7
R 00.20 Marks and symbols ............................................................................................ 19
R 00.30 Engine ID plate .................................................................................................. 20
R 00.40 Technical data .................................................................................................... 21
R 00.50 Clearances and wear limits ................................................................................ 27
R 00.60 Specific tools ...................................................................................................... 29
R 00.70 Troubleshooting ................................................................................................. 33
R 00.80 Ordering of Spare Parts ..................................................................................... 45
R 01 Cylinder head group……………………………………………………………………………47
R 01.10 Rocker arm cover ............................................................................................... 49
R 01.20 Cylinder head ..................................................................................................... 50
R 01.30 Rocker system ................................................................................................... 60
R 02 Engine block group……………………………………………………………………………..62
R 02.10 Liner ................................................................................................................... 64
R 02.20 Piston cooling jet ................................................................................................ 66
R 02.30 Breather set........................................................................................................ 67
R 02.40 Oil filling pipe group ........................................................................................... 68
R 02.50 Flywheel housing ............................................................................................... 69
R 02.60 Front cover group ............................................................................................... 72
R 03 Crankshaft piston and connecting rod………………………………………………………..73
R 03.10 Crankshaft (6M33) ............................................................................................. 76
R 03.20 Crankshaft (12M33) ........................................................................................... 81
R 03. 30 Piston and connecting rod ................................................................................ 85
R 04 Valve mechanism………………………………………………………………………………89
R 04.10 Camshaft ............................................................................................................ 91
R 04.20 Timing gear (6M33) ............................................................................................ 93
R 04.30 Timing gear (12M33) .......................................................................................... 96
R 04.40 Tappet and push rod .......................................................................................... 98
R 05 Intake and exhaust system…………………………………………………………………..101
R 05.10 Air filter ............................................................................................................. 103
R 05.20 Turbocharger.................................................................................................... 104
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R 05.30 Intake manifold ................................................................................................. 116
R 05.40 Exhaust manifold ............................................................................................. 117
R 06 Fuel oil system………………………………………………………………………………...119
R 06.10 Water separator and fuel filter.......................................................................... 121
R 06.20 Drive shaft of injection pump............................................................................ 122
R 06.30 Injection pump .................................................................................................. 124
R 06.40 Injection pump (6M33) ..................................................................................... 126
R 06.50 Fuel delivery pump ........................................................................................... 128
R 06.60 Electric speed controller ................................................................................... 129
R 06.70 Injection pipe .................................................................................................... 133
R 06.80 Injector ............................................................................................................. 134
R 07 Cooling system………………………………………………………………………………..137
R 07.10 Water pump...................................................................................................... 139
R 07.20 Fan ................................................................................................................... 140
R 07.30 Water outlet pipe .............................................................................................. 141
R 07.40 Thermostat ....................................................................................................... 142
R 08 Lubrication system……………………………………………………………………………143
R 08.10 Oil sump ........................................................................................................... 145
R 08.20 Oil pump group ................................................................................................ 147
R 08.30 Oil filter group ................................................................................................... 148
R 08.40 Oil cooler group (6M33) ................................................................................... 149
R 08.50 Oil cooler group (12M33) ................................................................................. 151
R 08.60 Safety and control valves ................................................................................. 153
R 08.70 Safety and control valves ................................................................................. 155
R 09 Startup system………………………………………………………………………………...157
R 09.10 Starter .............................................................................................................. 159
R 09.20 Alternator.......................................................................................................... 160
Appendix……………………………………………………………………………………………..163
Appendix A: Recommended Torques for Hollow Bolts ................................................. 163
Appendix B: Recommended Torques for Standard Bolts.............................................. 164
Appendix C: Data for Tightening Torque ....................................................................... 165
Appendix D: Data for Special Tightening Torque .......................................................... 166
Appendix E:Table of Auxiliary Materials ........................................................................ 167
Appendix F: Table for Sealant Application of Diesel Engine ......................................... 168

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Appendix G: Fit Clearances for Main Parts of Diesel Engine ........................................ 170
Appendix H: Table of planned maintenance programme .............................................. 172
Appendix I: Conversion Table ....................................................................................... 177
Index………………………………………………………………………………………………….180
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R 00 Instruction
R 00.10 General safety instructions
FOLLOW THE SAFETY

INSTRUCTIONS
CAUTION!
You must advise your superiors immediately of any serious
and imminent danger to health or life and avert such dangers
should protection systems malfunction.
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Repair manual-M33
General safety instructions
SAFETY WARNING
Failure to comply with the preventive measures and safety instructions included in this manual
and with warnings indicated on the engine could lead to injury or even death.
This manual must therefore be kept on board the boat and must be easily accessible, ready to
be consulted at any time.
Moreover, this manual must stay with the equipment if it is sold. The subsequent owner of the
equipment will also need the information that it contains.
R 00.11 Symbols used

 Introduction
As you read this manual, take note of the warnings indicating the precautions to be taken to
avoid unsafe practices and conditions.
In this manual, the following symbols are used to highlight specific information.
Clearly, these safety instructions alone do not suffice to prevent the danger they refer to.
The only way to avoid accidents is to comply strictly with the specific instructions that apply to
each operation and to use your common sense.
 Indications of danger
This warning sign is recognized worldwide. In this guide, it is
used to emphasize the importance of the information that
follows. Make sure that you understand the consequences of
a dangerous situation and the ways in which to avoid the
danger. Failure to adhere to warnings can result in material
damage, injury or even death.
We often see an indication of danger as a general warning. In
this Manual, there are different types of warning depending
on the possible consequences of the danger (minor injury,
serious injury and death).
This type of warning indicates a potentially dangerous
situation which, if not avoided, may result in serious injury or
even death, or considerable material damage.
This type of warning indicates a potentially dangerous
situation which, may result in minor injury or material damage.
It may also warn against dangerous practices.
Note:
This kind of note provides information on how to proceed cor-
rectly with the Operation and Maintenance of the S.I. Moteurs
Baudouin product. While simply reading this document can
not eliminate all the potential risks, proper understanding of
the information that it contains will facilitate correct use.
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The warnings in this guide cannot possibly cover all the situations that you might be confronted
with. Use your common sense!
If you decide to use a procedure, a method, a tool or a part not specifically recommended,
make sure that this will not present any danger for you, other people or for the equipment.
 Key to symbols
Safety symbols
Symbol Definition
Wear hand protection
Wear ear protection
Wear eye protection
Wear head protection
Wear foot protection
Wear a protective mask
Wear overalls
Avoid naked flames
Do not smoke
Do not use a mobile phone
Keep an extinguisher close by
Danger: battery acid
Danger: live cables, electrical risks
Highly flammable products
Keep away from hanging loads
Risk of thermal burns
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Symbol Definition
Risk of mechanical drive
Lifting is forbidden
Risk of steam burns
Water drain valve
A number of potential unforeseen risks may occur during the use of the engine.
It is therefore impossible to issue a warning for every potentially hazardous situation. If you
use a procedure which is not specifically recommended, make sure that it is safe and will not
cause material damage.
Key to tools used

Symbol Definition
2.5mm hexagonal wrench
5mm hexagonal wrench
8mm socket
Flat screwdriver
Special tool
10mm flat hexagonal wrench
Anyone using a method or tool not recommended by S.I. Moteurs Baudouin must first be sure
that they are not putting themselves or any other person at risk, and that the method of use,
maintenance or repair will not lead to damage or compromise safety.
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Repair manual-M33
Operation symbols
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Symbol Definition
Disassembly
Reassembly
Align the mark
Inspection
Measurement
Adjustment
Cleaning
Tighten to specified torque
Use special tools of manufatur’s
Lubricate with oil
Lubricate with grease
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Repair manual-M33
R 00.12 Health precautions

The list of “Health Precautions” below is designed to reduce the risk of contamination.
Preventive list for health protection

1 Avoid prolonged and repeated contact with used engine oil.
2 Wear protective clothing, including waterproof gloves, if applicable.
3 Do not put oily rags in pockets.
4 Avoid contaminating clothing with oil, in particular underwear.

Wash overalls regularly. Throw away un-washable clothing and shoes impregnated
5
with oil.
6 Emergency treatment must be immediately sought in the event of cuts and injuries.
Always apply protective cream before working; this will make it easier to remove
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mineral oil from the skin.
Wash with soap and hot water or, alternatively, use hand detergent and a nail brush to
8 make sure that all oil is removed. Products containing lanolin can help replace the
skin's natural oils that may have been removed.
9 Do not use petrol, kerosene, fuel, thinners or solvents to clean the skin.
10 If skin problems occur, immediately consult a doctor.
11 If possible, degrease components before handling them.

When there are risks for the eyes, use safety glasses or a face shield. An eye rinsing
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solution must be kept close at hand.
Do not spill oil or other fluids on the ground when repairing the engine. In the event of
13 an accidental spillage of hydrocarbon or other fluid, take all the necessary measures
to section off the area, clean up and protect people and the environment.
The handling, storage and recycling of hydrocarbons, ethylene, glycol and oil must
14 comply with the safety and environmental standards applicable in the country where
these operations take place.
151. Risk of injury due to high injection pump pressure.
R 00.13 Environmental precautions

There are laws regarding environmental protection and the disposal of waste and
hydrocarbons. To make sure that you are complying with environmental protection laws,
consult your local authorities who will advise you.
Asbestos
Products and spare parts supplied by S.I. Moteurs Baudouin do not contain asbestos.
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R 00.14 General precautions for operations

 Introduction
Most accidents related to the use, maintenance and repair of the engine are due to failure to
comply with the safety regulations and basic precautions. They could therefore be avoided by
acknowledging the risks that you face and by taking the corresponding preventive measures.
To operate, maintain and repair this S.I. Moteurs Baudouin equipment, you need to have the
appropriate training, skills and tooling.
Failure to comply with the instructions set out in this manual may result in serious or even fatal
accidents. S.I. Moteurs Baudouin can not foresee every possible risk. As such, the rules and
instructions set out in this Manual are not exhaustive.
 Before any operation involving a S.I. Moteurs Baudouin product

 Before carrying out any maintenance or repair work, fix a “Do not use” sign or a similar sign
to the starter switches.
 Actuate the starter battery isolating switch.
 Turn off the circuit breaker located on the engine connection box if applicable.
 Turn the engine room cabinet starter switch to OFF (optional feature).
 For engines fitted with a pneumatic starter system, isolate the tanks and drain the pipes
between the tanks and the starter.
 For engines fitted with an automatic starter control device, lock the starting order on the
control box.
 Remove and isolate the bridge consolekey.
 Before using the barring tool, always takethe necessary safety precautions.
 Do not allow any unauthorised person near the engine.
 Make sure that the repair premises and surrounding area are suitable to carry out the work
safely.
 Always make sure that the repair workshop or the area around the engineis clean and tidy.
 Remove any rings, chains and watches before starting work. Wear suitable and close
fitting work wear.
 Lock the emergency buttons.
 Check that the expiry date of the protection equipment (glasses, gloves, shoes,masks,
overalls, helmet,etc.) is not exceeded before starting work.
 Do not use faulty or unsuitable tools.
 Stop the engine during maintenance or repair work.
 Lifting
 Use lifting devices to handle and move heavy parts (over 20kg). Check the condition of the
lifting hooks and chains.
 Before using the handling equipment, make sure that this equipment has been checked
and certified as compliant by a certification body. The engine lifting rings must not touch
the side parts of the engine during lifting.
 Never work under an engine, gearbox or genset that has been left hanging in a lifting
device or hoist.
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Repair manual-M33
 Always use suitable, resistant supports,which are in good condition to handle engines,
gearboxes or gensets.
A lifting ring’s resistance is reduced when the angle between the slings or the chains and the
engine fall below 90°.
Use a lifting device as illustrated below. Avoid any contact between the slings and the engine
parts. Use the fastening links and slings or properly calibrated chains.
 Start-up
 Never use any product to facilitate start-up (risk of explosion).
 Never start an engine, engage a gear reducer or touch a propeller pitch control without
having checked before hand that this operation can be carried out in complete safety for
the people or the equipment.
 When starting the engine, use ear protection to prevent hearing loss.
 Only start or stop the engine using the switches designed for this in the engine room
control box, the bridge console,control boxes, etc.
 Only start or stop the engine using the switches designed for this in the engine room
control box, the bridge console, control boxes, etc.
 When the engine starts, the power loss must never be below 18 VDC.
 Seals
 When the temperature exceeds 300°C, the viton engine seals will produce corrosivehy dro
fluoric acid. Always use protective gear when touching seals subject to high temperatures.
 Always use rubber thick gloves and safety glasses during decontamination operations.
 Clean the seals and the contaminated surfaces using a 10% calciumhy droxide solution or
another cleaning product.
 Keep any parts which have been removed insealed plastic bags and store them in
adedicated area.
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 Starter battery
 Disconnect the batteries before any operation involving the electrical circuit.
 As the battery gas is explosive, keep it away from naked flames and any source of sparks.
 Do not smoke near the fuel system and batteries.
 Never check battery charge by short circuiting it.
 Do not charge a frozen battery. Heat it up to 16°C before hand.
 Sulphuric acid contained in batteries is toxic and corrosive; it can burn clothing and skin, or
even cause blindness in case of contact with the eyes.
 To prevent accidents:
- Fill the batteries in well-ventilated premises.
- Wear suitable gloves and glasses.
- Do not inhale the fumes.
 In the event of contact with a part of the body:
- Rinse the affected part with plenty of water.
- Apply bicarbonate of soda or lime to neutralise the acid.
- Rinse the eyes for 10 to 15 minutes.
- See a doctor as soon as possible.
 In the event of ingestion:
- See a doctor as soon as possible.
 Do not smoke in areas where batteries are charged.
 The batteries give off flammable fumes which can explode.
 If the batteries are in a closed area,make sure there is sufficient ventilation.
 Make sure the batteries are clean and that covers are fitted.
 The battery cables must be fitted with acircuit breaker to isolate the circuit if there is a
problem. Electric wiring must be kept in good condition, properly positioned and soundly
attached.
 Injection devices
 When checking the injectors, make sure that the high pressure jet does not touch the skin.
 Use a fume extraction device.
 If the fuel comes into contact with the skin, it can cause injury. Consult a doctor
immediately.
 Fuel, oil and coolant contain harmful products.
 Avoid all contact with the skin and eyes. Do not ingest.
 The use of gloves and safety glasses is highly advisable.
 Cleaning the engine

 Comply with the safety instructions related to the machine used.
 Protect all orifices. Do not clean an engine that is running or that has just been stopped.
 Use the safety equipment required for operating such machines.
 Servicing
 Certain servicing operations can only be carried out using special tools. Mechanics that
are not equipped for major repairs are therefore strongly advised to contact their S.I.
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Repair manual-M33
Moteurs Baudouin Distributor.

 Welding
 Unplug all engine wiring harnesses before doing welding operations (ECU, engine
cabinets, control boxes…).
 Be sure to comply with all leg is lations before doing welding operations.
 Do not use open fires.
 For all electrical or autogenous welding, usea welding permit to make the area safe.
 Make sure that the work will not affect the on-board electrical and electronic equipment.
 Make sure that the automatic fire exting uishing system is in hibited before any welding or
grinding work.
 Make sure that the premises where the welding will be done are suitably ventilated.
 Do not weld and do not use a torch on pipes or hoses containing flammable liquids.
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R 00.15 Preventing fires and burns

 Preventing fires and explosions
 Do not remove inspection doors from the engine block or reduction gear after an
emergency stop. Wait at least 5 minutes to avoid any risk of explosion.
 Oil or fuel projections or leaks onto hot surfaces can cause fires.
 Make sure that the pipes and hoses are not worn or damaged.
 Hoses must be positioned, supported and firmly fastened.
 Tighten all fittings to the recommended torque.
 Regularly clean the engine surface to remove greasy deposits which maybe flammable.
 Do not smoke while filling the fuel tank or while in the filling area.
 Mobile phones (and in particular their batteries) may give off sparks which could cause an
explosion in certain high riskareas. All mobile phones should be switched off when filling
the fuel tank or while in the filling area.
 Store all fuels and lubricants in sealed containers, which should be clearly labelled and
stored in a safe place.
 Soiled cloths and other flammable materials must not be stored in the engine room.
 Do not smoke in areas where batteries are charged.
 The batteries give off flammable fumes which can explode.
 If the batteries are in a closed area, make sure that sufficient ventilation is provided.
 Make sure the batteries are clean and that covers are fitted.
 The battery cables must be fitted with acircuit breaker to isolate the circuit if there is a
problem. Electrical wiring must be kept in good condition, properly positioned and soundly
attached.
 All wires should be of the recommended size.
 Wires and cables must be protected by a fuse or a calibrated circuit breaker.
 Do not short-circuit fuses and/or circuit breakers.
 Do not weld and do not use a torch on pipes or hoses containing flammable liquids.
 Before welding or flame cutting, carefully clean the inside and outside of hoses or pipes
using a non-flammable solvent.
 Do not expose the engine to flames.
 Make sure that adequate, nonexpired extinguishers are available and that you know how
to use them.
 Preventing burns
 Do not touch the hot parts of an engine that is running or that has just been stopped.
 Do not touch the engine when it is running.
 Let the engine cool down before carrying out any maintenance operation.
 Release the pressure in the greasing, fuel and cooling systems before disconnecting or
removing hoses or associated parts.
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Repair manual-M33
 At operating temperature, the coolant is hot and pressurised. When the pressure is
released sharply, this burning-hot liquid maybe transformed into fumes.
 Any contact with this burning-hot liquid or fumes may cause serious burns.
 Let the components in the coolant system cool down before draining the system.
 Only check the coolant level when the engine has been stopped.
 Slowly unscrew the filler plug to release the pressure.
 Hot oil can cause injury. Avoid contact with the skin.
 Sulphuric acid contained in batteries is toxic and corrosive. It can burn clothing and skin, or
even cause blindness in case of contact with the eyes.
R 00.16 Electrical risks

Isolation checks must be carried out regularly
The engine’s electrical circuit must be isolated from the engine and boat earth.
Isolation problems can cause short-circuits or stray current.
Stray current can damage bushings or crankshaft seating and may also cause radio frequency
disturbance.
The engine earth must be properly connected to the boat earth, the other elements to be
conected to the earth are:
- The flexible hoses of the coolant circuits.
- The flexible hoses of the fuel systems.
- The electrical systems of control and electronic injection.
Earthing errors can cause corrosion in the pipes and engine or propulsion unit components.
R 00.17 Risks about gensets

A genset new or not must not be installed if the insulation is below 1 Mohm for the stator and
100,000 for the other coils.
The operations of maintenance and repair must be followed to avoid accident risks and
maintain the genset in a satisfying state.
All operations (connections and checks) on the genset ends have to be done when the genset
is stopped.
The start and the use of the genset is possible if the installation complies with the rules and
requirements of the maker manual (see the installation and maintenance manual supplied with
the genset).
Genset is with one or two bearings.
While the coupling is done, the alignment of the holes of the disks is mostly done by the
rotation of the thermal engine.
Ensure the timing of the rotor of the genset before all coupling or uncoupling operation.
Never use the fan of the genset to initiate rotation of the genset and the engine.
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R 00.20 Marks and symbols

Picto. Definition
Clamping
Clearance – Dimension be measured (mm)
Axial displacement - Vertical
Radial displacement - Horizontal
Repair size
Wear limit
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R 00.30 Engine ID plate

 ID plate sample
 Description
Model:
xM33 D XXX EX XX
Variant code
Emission level
Power code
Application code
Product series code
Order No:
DH XXX X XXXX
Sequence No.
Product usage
The diesel engine series
Shop Code
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R 00.40 Technical data
6M33/12M33
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R 00.41 Technical data of 6M33 diesel engine

 Designation of Cylinders
Aberration:
ERC-Engine Reference Cylinder
PRC-Pump Reference Cylinder
 Cylinder No. 1 is on the flywheel side.
 Single cylinder heads with 4 valves per cylinder.
 Engine firing order : 1-5-3-6-2-4
 Injection order of injection pump : 6-2-4-1-5-3
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 Performance parameter
SN Item Unit 6M33

1 Intake mode — Inter-cooling
2 Cylinders — 12
3 Bore/Stroke mm 150/185
4 Displacement L 19.6
5 Compression ratio — 15:1
Downstream oil pressure
6 MPa 0.40~0.65
of oil filter
Oil temperature after
7 ℃ 85~105
cooling
Thermostat opening
8 ℃ 77
temperature
Exhaust temperature after
9 ℃ ≤500
turbine
Opening of
°CA Intake valve opened, (34±5)°CA before TDC
intake valve
Closing of
°CA Intake valve closed, (40±5)°CA after BDC
Valve intake valve
10
timing Opening of
°CA Exhaust valve opened, (61±5)°CA before BDC
exhaust valve
Closing of
°CA Exhaust valve closed, (27±5)°CA after TDC
exhaust valve
11 Firing order — 1-5-3-6-2-4
12 Rotation direction — Counter-clockwise (facing towards flywheel)
13 Starting method — Electric starter motor
14 Lubrication method — Forced lubrication
15 Cooling method — Water cooling forced circulation
Intake/exhaust valve gap Intake:0.3±0.03
16 mm
(cold state) Exhaust:0.6±0.03
Smoke number at rated
17 FSN ≤1.5
working condition
18 Oil capacity L 60.5
19 Length mm 1820
Overall
20 Width mm 1036
dimensions
21 Height mm 1406
22 Net weight kg 2090
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R 00.42 Technical data of 12M33 diesel engine

 Designation of Cylinders
Aberration:
ERC-Engine Reference Cylinder
PRC-Pump Reference Cylinder
 Cylinder No. 1 is on the flywheel side.
 Single cylinder heads with 4 valves per cylinder.
 Engine firing order : 1-8-5-10-3-7-6-11-2-9-4-12
 Injection order of injection pump : 12-9-4-5-8-11-2-3-10-7-6-1
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 Performance parameter
SN Item Unit 12M33

1 Intake mode — Inter-cooling
2 Cylinders — 12
3 Bore/Stroke mm 150/185
4 Displacement L 39.2
5 Compression ratio — 15:1
Downstream oil pressure
6 MPa 0.40~0.65
of oil filter
Oil temperature after
7 ℃ 85~105
cooling
Thermostat opening
8 ℃ 77
temperature
Exhaust temperature after
9 ℃ ≤500
turbine
Opening of
°CA Intake valve opened, (34±5)°CA before TDC
intake valve
Closing of
°CA Intake valve closed, (40±5)°CA after BDC
Valve intake valve
10
timing Opening of
°CA Exhaust valve opened, (61±5)°CA before BDC
exhaust valve
Closing of
°CA Exhaust valve closed, (27±5)°CA after TDC
exhaust valve
11 Firing order — A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
12 Rotation direction — Counter-clockwise (facing towards flywheel)
13 Starting method — Electric starter motor
14 Lubrication method — Forced lubrication
15 Cooling method — Water cooling forced circulation
Intake/exhaust valve gap Intake:0.3±0.03
16 mm
(cold state) Exhaust:0.6±0.03
Smoke number at rated
17 FSN ≤1.5
working condition
18 Oil capacity L 146
19 Length mm 2524
Overall
20 Width mm 1312
dimensions
21 Height mm 1731
22 Net weight kg 3390
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R 00.50 Clearances and wear limits
R 00.51 Diagram form of clearances and wear limits of 6M33

S/N Items Theoretical value (mm)
1 Main bearing clearance 0.102～0.182
2 Connecting rod bearing clearance 0.08-0.15
3 Crankshaft axial clearance 0.15～0.35
4 Connecting rod axial clearance 0.17～0.48
Clearance between connecting rod small end bush and
5 0.031～0.081
piston pin
Piston ring gap working clearance at cold state
First ring yizheng：0.45～0.6
6 The triple ring group
Second ring yizheng：0.75～1.0
piston ring
Oil control ring 0.45～0.7
BinHai Piston: 0.015~0.03
7 Clearance between piston pin and pin seat
Jiangbin Piston:0.015~0.029
8 Clearance between intake valve stem and valve guide 0.035～0.065
9 Clearance between exhaust valve stem and valve guide 0.055～0.085
10 Intake valve sinkage from cylinder head bottom plane 0.60～1.10
11 Exhaust valve sinkage from cylinder head bottom plane 1.20～1.70
Upper plane of cylinder liner support shoulder above the
12 engine body upper plane (integral cylinder gasket, at 0.07～0.13
compacted state)
13 Camshaft axial clearance 0.15～0.35
14 Camshaft bearing clearance 0.055～0.128
15 Camshaft bearing clearance (thrust bearing) 0.055～0.128
16 Clearance between tappet and hole 0.025～0.066
Clearance between the outer diameter of cylinder liner and 0.014～0.079
the cylinder hole of engine body (upper part)
17
the cylinder hole of engine body (lower part)
20 Intake/exhaust valve gap (cold state) 0.3±0.03/0.6±0.03
21 Rocker arm axial clearance 0.4～0.6
22 Clearance between crankshaft gear and camshaft gear 0.11-0.285
27
Repair manual-M33
R 00.52 Diagram form of clearances and wear limits of 12M33

S/N Items Theoretical value (mm)
5 0.031～0.081
piston pin
piston ring
0.015~0.03 (BoHai Piston)
0.015~0.029 (Jiangbin Piston)
compacted state)
17
Note: if you have any question about the table, please see the graphic above.
28
Repair manual-M33
R 00.60 Specific tools
Complete tool kit for 15188071Y R 01.20

injector sleeve
Injector sleeve
extractor 15189630S R 01.20
Injector sleeve
lower gripper 15189540V R 01.20
Injector sleeve
upper gripper 15189590Z R 01.20
Tap 32 X 150 for

sleeve extraction 15189620G R 01.20
Valve guide
extractor 15189010T R 01.20
Valve guide installer 15189600K R 01.20
29
Repair manual-M33
Intake valve insert

installer 15189600E R 01.20
Exhaust valve insert

installer 15189720Q R 01.20
Cylinder head
hydraulic test plate 15180860K R 01.20
Valve remover 1001773592 R 01.20
Protractor 15599500D R 01.20
30 socket 2692210050 R 01.20
Liner remover 1000336131 R 02.10
Liner Installer R 02.10
30
Repair manual-M33
Oil sump adjusting

shims 15180910P R 08.10
Collar for centering

the crankshaft rear 15180850Z R 02.60
seal
Flywheel guide rods 2692210018 R 02.50
Collar for centering To be created in

crankshaft rear seal accordance with R 02.60
the prod. model
Wall spreader for

crankshaft bearing 3392210018 R 03.10
Piston handle 15180840N R 03.20
Piston ring pliers R 03.20
Piston Guide
Cylinder 1001797241 R 03.20
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Repair manual-M33
Camshaft fitting
guide 1001798443 R 04.10
Tappet Tool 3392210044 R 04.30
Camshaft bearing
fitting/removal tool 1002321364 R 04.10
Injection pump start

of delivery timing 15058340L R 06.30
Magnetic index for 15180510E R 06.30

setting the timing,
Two-stage pump to
calibrate the 12470440B R 06.70
injectors
32
Repair manual-M33
R 00.70 Troubleshooting
 Start failure of diesel engine
Cause Troubleshooting Related
If the starter motor fails, firstly exclude

Working failure of starter motor R 09.10
the malfunctions of electric circuits.
Low air temperature Take the auxiliary starter measure. N/A
Bleed the air, check sealing

Air content in fuel system performance of connectors, and repair R 06
accordingly.
Blockage of fuel delivery pump inet

Check and remove dirt and check fuel
filter screen or fuel lines (such as R 06.50
cleanliness.
hoses)
Check plunger and fuel outlet valve

Malfunction of fuel injection pump R 06.40
and repair or replace damaged parts.
Damage or leakage of valve or fuel

Check and adjust R 06
supply pipes
Damage and leakage of high pressure

Repair and replace R 06.70
fuel pipes
Malfunction of fuel injector Check atomization state of fuel injector. R 06.80
Check sealing performance of valves

Insufficient compression pressure of
and cylinder gasket, check wear of N/A
cylinder
piston rings, and repair or replace.
33
Repair manual-M33
 Stop of engine shortly after start
Check the sealing performance of fuel

pipes and connectors, check and
Air content in fuel system R 06
ensure the tightening of bleeder screw,
and bleed the remained air.
Disassemble the filter body, remove

Blockage of fuel filter internal contaminant and water, and R 06.10
when necessary replace filter element.
Poor fuel quality and high water

Clean filter and replace fuel N/A
content
Check piston and valve of fuel delivery

Working failure of fuel delivery pump R 06.50
pump, clean, and repair
Low regulated idling speed Re-adjust N/A
34
Repair manual-M33
 Low power
Check air filter and intake pipe and

Intake blockage (blockage of air filter) R 05.10
clean or replace filter element.
Check valve timing, check exhaust

Over-high exhaust back pressure R 04.50
pipeline for blockage, adjust and repair.
Insufficient pressure of turbocharger Check and solve leaks at pipeline

R 05.20
system conections.
Abnormal working of turbocharger Replace assembly. R 05.20
Blockage of air compressor or turbine

Clean or replace R 05
runner by dirt
Failure of floating bearing Replace N/A
Carbon deposit and oil sludge at back

Clean N/A
gap of turbine and compressor
Damage and air leakage of inter-cooler Replace or repair N/A
Check sealing performance of fuel

pipes and connectors, check the
contamination degree of filter, repair
Leakage or blockage of fuel pipe line R 06.70
the fuel pipeline or dredge the
blockage dirt, and replace filter
element.
Clean fuel tank, filtration parts and fuel

Poor fuel quality N/A
pipes, and replace fuel.
Excessive wear of fuel injection pump R 06.30

Repair or replace
or speed regulator R 06.40
Damaged diaphragm of fuel injection R 06.30

Replace or repair
pump smoking limiter R 06.40
Damage and air leakage of smoking

Replace N/A
limiter air pipe
Check fuel injection pressure and

Poor atomization of fuel injector nozzle carbon deposit of fuel injector nozzle R 06.80
and adjust and repair.
35
Repair manual-M33
Incorrect valve or fuel supply timing Check and adjust R 04.50
Under-low high-speed adjustment of Check speed regulation characteristic

N/A
speed regulator and adjust accordingly
Check oil dipstick and drain excessive

Over-high oil level of oil sump R 08.10
engine oil
Check compression pressure during

Air leakage of cylinder gasket warm-up and replace damaged R 01.20
cylinder gasket
Wear and breakage of piston rings and Replace worn parts or overhaul the
R 03.30
excessive gap of bearing shells engine
Wear or scuffing of cylinder sleeve or

Repair or replace R 03
piston
36
Repair manual-M33
 Excessive fuel consumption
Check the air filter and intake pipeline

Blockage of intake pipe R 05.30
and clean accordingly
Check exhaust pipeline and clean

Over-high exhaust backpressure R 05.40
accordingly
Poor fuel quality Replace with specified fuel N/A
Blockage of fuel pipeline Check and repair. R 06.70
Leakage of fuel pipeline Check and repair. R 06.70
Poor atomization of fuel injector Check and adjust or repair R 06.80
Adjust valve clearance and fuel supply

Incorrect valve or fuel supply timing R 04.50
advance angle as per specification
Air leakage of cylinder gasket Check compression pressure R 01.20
Excessive gap of bearing shells. The R 03.10

Check and overhaul
overhaul is required for the engine. R 03.20
Replace cylinder sleeve, piston, and

Expanding of piston R 03.30
piston rings.

R 05.20
system conections.
Abnormal working of turbocharger Check and replace R 05.20
37
Repair manual-M33
 Black exhaust gas
Blockage of intake pipe or excessive

Clean R 05.30
exhaust backpressure
Poor fuel quality Clean and replace N/A
Incorrect valve or fuel supply timing Adjust as per specification R 04.50
Poor atomization of fuel injector nozzle Check, repair, or replace R 06.80
Excessive fuel volume of fuel injection

Check and adjust R 06.40
pump

R 05.30
system conections.
Abnormal working of turbocharger Check and replace assembly R 05.30
Incorrect application point of smoking

Re-adjust N/A
limiter
38
Repair manual-M33
 White or blue exhaust gas
Poor fuel quality and high water

Replace fuel N/A
content
Check working temperature of

Under-low coolant temperature thermostat and replace when N/A
necessary.
Wear of turbocharger seal rings Check and replace R 05.20
Wear of turbocharger thrust bearing Check and replace R 05.20
Blockage of turbocharger oil return

Clean or repair R 05.20
pipe
Poor atomization of fuel injector nozzle Check and repair. R 06.80
Incorrect valve or fuel supply timing Check and adjust R 04.50
Check piston rings, cylinder sleeve,

Low compression pressure, incomplete
and cylinder gasket and repair R 03
combustion, and piston expanding
accordingly
Improper run-in of piston rings and

Continue the run-in R 03
cylinder sleeves
Non-staggered openings of piston rings Adjust and reassemble R 03.30
Failure of piston oil rings Replace R 03.30
Large fit clearance between piston and

Repair and replace R 03.30
cylinder sleeve
 Deposit of engine oil at air inlet port and air inlet pipe of turbocharger
Turbocharger sealing failure Repair or replace turbocharger R 05.20
Failure of fuel-air separator Replace R 06.10
Over-high oil sump level and Check and drain engine oil as appropriate to
N/A
excessively added engine oil meet the required level
39
Repair manual-M33
 Unstable speed
Poor fuel quality, with water or paraffin

Replace fuel N/A
content
Check sealing performance of fuel

Air ingress of fuel suction pipe R 06.70
pipes and connectors and bleed air
Abnormal working of speed regulator

(mechanical pump) counterweight and Check and adjust N/A
speed regulation spring
Non-uniform fuel supply Check and adjust N/A
Unstable atomization of fuel injector

Check and repair. R 06.80
nozzle
Check and clean air compressor

Vibration of turbocharger runner, dredge blockage, and remove R 05.20
carbon deposit from exhaust passage
Damage of turbocharger bearing Replace R 05.20
40
Repair manual-M33
 Engine oil pressure too low
Add oil to the specified level of oil

Under-low oil sump level or oil shortage N/A
dipstick.
Replace with specified engine oil and

Inappropriate engine oil trademark N/A
choose an appropriate oil trademark
Over-high water temperature of cooling

Check the cooling system for normal
system and over-high engine oil N/A
working.
temperature
Excessive resistance of engine oil filter Replace with new filter element R 06.10
Blockage of oil cooler Check and clean R 08.40
Check strainer, engine oil pipeline, and Check and clean air compressor
connector gaskets for presence of runner, dredge blockage, and remove N/A
blockage and cracking carbon deposit from exhaust passage
Check oil pipes and connectors and

Leakage of oil pump inlet pipe N/A
repair or replace
Malfunction of main oilway pressure

Check valve and clean and repair N/A
regulator valve
Blockage of main oil-way Check and clean N/A
Excessive gap of bearing shells or

Check and replace R 03.10
damage of bearing shell
Excessive wear of parts. The overhaul Check the working condition of engine
N/A
is required. and overhaul
Leakage of diesel into engine oil Check for presence of diesel odor and
measure and ensure that the flashing
N/A
point of engine oil is no less than that of
new oil
41
Repair manual-M33
 High coolant temperature
Under-low level in water tank Check for water leaks and add water N/A
Blockage of water tank radiator fins Clean water tank radiator fins N/A
Loose water pump belt Adjust tension as per specification R 07.10
Damage of water pump gasket and

Check and repair or replace R 07.10
wear of water pump impellor
Damage of water pipe and ingress of Check water pipes, connectors, and
R 07.30
air gaskets and replace damaged parts
Thermostat malfunction Replace R 07.40
Blockage of water tank Check water tank and clean or repair N/A
Check oil level and oil leaks, repair,
and add oil
 Excessive wear of parts
Disqualified or damaged air filter Check and replace with qualified filter
R 06.10
element element.
Check intake pipe, gasket, and

Short-circuit of intake system. conecting pipe sleeve and repair or R 05.30
replace
Failure for timely replacement of oil

Replace as per specification R 08.30
filter element
Check oil level and oil leaks, repair,

and add oil
Inappropriate oil trademark Replace with specified oil N/A
Use of disqualified engine oil Use qualified oil trademark N/A
Blockage of oil-way Clean oil-way R 08
Breakage or wear of piston ring Replace damaged parts R 03.30
Wear or scuffing of cylinder sleeve or Disassemble and check piston and

R 03.30
piston cylinder sleeve and repair or replace
Non-coaxiality between crankshaft and

Check mounting bracket and repair R 03.10
driven shaft
Excessive wear of parts. The overhaul Check current mileage and determine
N/A
is required. overhaul.
42
Repair manual-M33
 Excessive noise
Poor fuel quality Replace fuel N/A
Check thermostat and replace when

Under-low coolant temperature N/A
necessary.
Incorrect valve or fuel supply timing Check, repair, and adjust R 04.50
Poor atomization of fuel injector nozzle Check, repair, and adjust R 06.80
Excessive fuel volume of fuel injection

Check and adjust R 0.40
pump
Check for damage, check state of

Wear of shock absorber conecting bolts, and replace damaged N/A
parts
Air leakage or improper adjustment of Disassemble and check valves and

N/A
valve adjust
Excessive gear backlash or broken

Check and replace damaged parts N/A
teeth
Wear or scuffing of cylinder sleeve or

Check and repair or replace R 03.30
piston
Bending or breakage of push rod and

Replace R 03.30
breakage of rocker arm
Breakage or wear of piston ring Check and replace damaged parts R 03.30
 Working failure of starter motor
Burnt fuse Replace fuse N/A
Poor contact of connecting wires Clean circuits and tighten wiring posts N/A
Insufficiently charged battery Check and charge or replace battery N/A
Check and repair motor or replace

Short-circuit of starter motor R 09.10
assembly
Clean electric brush surfaces or

Poor contact of electric brush R 09.20
replace electric brush
43
Repair manual-M33
 Weak starter motor
Insufficiently charged battery Charge or replace battery. N/A
Wear of bearing bushing Replace assembly R 09.10
Clean electric brush surfaces or

Poor contact of electric brush R 09.20
replace electric brush
Remove oil dirt and polish with sand

Dirty or burnt commutator N/A
paper or replace assembly
Loose weld of wire ends Re-weld R 09.10
Poor contact of switch Check and repair switch N/A
Adjust working moment of clutch or

Slip of friction clutch N/A
replace assembly
44
Repair manual-M33
R 00.80 Ordering of Spare Parts

Spare parts can be ordered from the S.I. Moteurs Baudouin
When spare parts are ordered or inquired, the following data must be indicated, in order to
ensure correct identification of the required parts:
• Name of customer
• Name of plant /vessel
• Engine Model
• Engine Order NO.
• Engine Serial NO.
• Designation of the Teile. Number
• Teile. Number
• Quantity
Note:
• Components from different engine builders cannot be considered as interchangeable.
• A wide number of spare parts can be orders as spare part kits.
• Selected components may be available in both original and upgraded version.
These data are necessary to ensure supply of the correct spare parts for a particular engine,
even though the spare part illustrations contained in spare parts catalogue may not always be
in complete accordance with the individual components of a specific engine.
45
Repair manual-M33
Information given by customer:
Name of customer Contact information Name of Plant/Vessel
Information found on the nameplate of the engine(s):
Example: (see ID plate)

Engine model Engine Order NO. Engine Serial NO. Engine builder
Information found on each plate at the spare parts catalogue:
Pos. Teile. Number Designation
Pos.
Teile. Number
Designation
46
Repair manual-M33
R 01 Cylinder head group
6M33
47
Repair manual-M33
12M33
48
Repair manual-M33
R 01.10 Rocker arm cover
R 01.11 Pre-assembly Preparation

 Equipment condition
Internal hexagonal wrench
 Preliminary operations
 Shut off all start modes.
 Drain the cooling circuit.
R 01.12 Remove
 Remove the injection pipe set and injector.
 Remove the rocker arm cover and its gasket.
Figure R01-1001
R 01.13 Check
 Check for oil leakage around the rocker arm cover
before disassembling, inspect the related parts if
there is oil leakage.
 Check the rocker arm cover has no crack and
other damage.
Figure R01-1002
R 01.14 Fitting the rocker arm cover

 Install the O-ring seal between the injector holder
and the rocker cover and apply oil to the O-ring.
 Fit the rocker arm cover with gasket.
Note:
The rocker cover gasket must be fitted without adding
any product.
The rocker cover gasket can be used only once.
Figure R01-1003
49
Repair manual-M33
R 01.20 Cylinder head

Sleeve wrench, torque wrench, threadlocker, oil,
micrometer, feeler, screwdriver
 For safety reasons, shut off all start modes.
 Remove the rocker arm cover.
 Remove the rocker set.
 Remove the push rod.
 Remove the injector.
 Remove the turbocharger.
 Remove the water outlet pipe.
 Remove the air intake pipe and gas exhaust pipe.
 Remove the lubrication feed pipe.
Figure R01-2001
R 01.22 Removal of cylinder head
 Removal of an isolated cylinder head
 Loosen the M20 screws in order A-B-C-D.
Loosen the M16 screws in order 1-2-3-4.
Figure R01-2002
 Removal of a full bank of cylinder heads

 Loosen the M20 screws in order A-B-C……N.
Remove the M20 screws, the washers and the
clips.
 Loosen the M16 screws in order 1-2-3……24. Figure R01-2003
Remove the M16 screws.

 Remove the cylinder heads.
Figure R01-2004
Weight of cylinder head: 25.9 kg.
50
Repair manual-M33
R 01.23 Disassembly of cylinder head

 Visual inspection of cylinder head
 Clean the cylinder head and use a descaler bath
to clean the ducts.
 Check the general condition of the cylinder head
and intermediate clamping plate supports, check
that it does not have any dents on the ceiling of
the cylinder head and that the anchoring groove is
not damaged. In case of minor impacts, Figure R01-2005
rectification is possible If not, discard the cylinder

head.
 Stripping the cylinder head

 Pull the valves from their seats using the valve
removal tool ref. 1001773592.
 Remove the half-keys, springs, cups and valves.
Mark the equipment.
Figure R01-2006
R 01.24 Leak test of cylinder head block
 Equip the cylinder head with the test tool ref. 1518
0860K.
 Connect an air inlet onto the water outlet of the
cylinder head. Immerse the cylinder head in a tank
of water and increase pressure up to 5 bar.
 Check that there are no leaks in the intake ducts,
exhaust ducts, injector sleeve, oil passages,
cylinder head ceiling, valve seat housings; discard
the cylinder head if necessary. Figure R01-2007
R 01.25 Recess dimension of valves

 Check the condition of the contact surfaces of the
valves that does not present any defects; replace
the valves if necessary.
 Check the valve recess with depth micrometer.
Figure R01-2008
Note:
51
Repair manual-M33
The recess dimension is the vertical distance from the

bottom surface of the valve to the bottom surface of
the cylinder head, and the difference between the
recess dimension measurement value and the
required valve sinkage value can reflect degree of
wear of the valve and valve seat. If the dimension
recorded is within tolerance, rectification of the seat is
possible. If the dimension recorded is out of tolerance
or close to the permissible limit, the seat must be
replaced.
R 01.26 Replacement of seats

 Use the worn valves, having beforehand reduced
the head to 41.5 mm for the intake valves and
37.5 mm for the exhaust valves.
 Weld the valves onto the seats with 4 weld points.
Remove the seats by moderately striking with a
hammer on the opposite end of the valve.
 Clean, visually inspect and dimensionally check
the seat housings with inside micrometer.
 Cool the new seats in liquid nitrogen.
Note:
You can place the seats in a freezer at -30°C for 12
hours if you do not have access to liquid nitrogen.
 It may then be necessary to let the cylinder head Figure R01-2009
cool evenly (about 50 °C) for the seats to be fitted.

 Fit the intake seats using tool ref. 15189600E.
 Fit the exhaust seats using tool ref. 15189720Q.
Note:
Make sure the seats fit securely at the bottom of the
housing once the temperature is equivalent to that of
the cylinder head.
52
Repair manual-M33
R 01.27 Rectification of seats
Rectification of the seats is not always necessary. If

the recess dimension without machining is within
tolerance and the leak test is also within tolerance, this
operation is not required.
 Use a drill or a grinder at 88°for the exhaust seats.
Use a drill at 118°for the intake valves.
 Rectify the seats so as to remain within the
minimum tolerance of the recess dimension.
R 01.28 Check and replacement of guides

Note: Before rectifying the seats, visually and
dimensionally check the condition of the valve guides.
Replace the guides if necessary.
 Check the valve guide

 Measure the inner diameter of valve guide with in Figure R01-2010
side micrometer in three places: the places 13.5

cm from each edge of the catheter and the center
of the valve guide.
 Measure the installation height of the valve guide
with depth micrometer.
 Measure the outer diameter of the sealing part of
valve guide with outside micrometer.
 Replace the valve guide
 Remove the guides using tool ref. 15189010T.
 Fit the guides using tool ref. 15189600K.
Note:
The valve guide should be fitted in proper position.
R 01.29 Replacement of injector sleeve

 Tap the top of the sleeve using a M32X150 thread
tap ref. 15189620G.
Note:
If the sleeve turns during the tapping operation, you
can make a slight crimp at the top of the sleeve using
tool ref. 15189590Z. Figure R01-2011
53
Repair manual-M33
 Remove the sleeve using tool ref. 15189630S.

 Remove the O-ring of the upper sleeve seal from
the cylinder head.
Carefully clean the sleeve housing, taking care to

remove any copper residues in the grooves of the
lower crimp. The O-ring can be used for once.
 Check the injector sleeve

 Measure the inner diameter of the injector sleeve
with inside micrometer. Make sure the joint face is
clean and smooth.
 Fitting the injector sleeve

 Insert a lightly greased O-ring into the upper
housing of the cylinder head.
 Insert the sleeve, making sure it is securely in
contact with the shoulder of the cylinder head
bore.
Figure R01-2012
 Fit a bridge guide to fix the tool

 Crimp the bottom of the sleeve using tool ref. 1518
9540V.
The ball must fully traverse the lower bore. For this
reason, it is imperative that the operation is performed
with the cylinder head removed.
 Test the cylinder head for leaks

Note:
If the sleeve leaks at the top of the sleeve, you can
make a slight expansion at the top part of the sleeve.
Use tool ref. 15189590Z.
Note：
When you change any part of the cylinder block, it’s
necessary to test the cylinder head for leaks again.
Figure R01-2013
R 01.210 Check the intake/exhaust valve
 Check the intake/exhaust valve for swear and
damage. Clean the soot deposition and sintering.
54
Repair manual-M33
 Measure the outer diameter of the valve. Measure

the thickness of the valve.
Note:
If the valve occurs wear, serious sintering, soot
deposition and other defects replace the valve.
If the outer diameter of the valve spindle has been
worn to minimum value or the thickness of the valve
have been worn to minimum value.
Figure R01-2014
R 01.211 Check the valve springs
 Measure the free height of valve springs with
micrometer, the heigh of intake valve spring is
51.2 mm, the heigh of outer valve spring is
53.0mm.
 Measure the height of intake valve springs with
load 144 N·m and 290 N·m, the height are 38.5
mm and 26.0 mm.
 Measure the height of intake valve springs with
load 220 N·m and 481 N·m, the height are 42.5 Figure R01-2015
mm and 30.0 mm.
R 01.212 Fit the cylinder head unit

 Fit the cylinder head unit with tool ref.
1001773592.
Apply molybdenum disulfide grease on the intake
and exhaust valve stem uniformly.
 Install the intake/exhaust valve to the cylinder
head, and make sure that the intake/exhaust Figure R01-2016
valve can slide in the guide pipe without being

blocked.
 Install the valve stem sealing sleeve to valve
guide.
- All valve stem sealing can only be used for
once.
- Check the valve stem sealing sleeve and spring
for defects.
- Apply lubricating oil to the lip edge of valve stem
sealing sleeve. Figure R01-2017
- Mount the valve stem sealing sleeve by using

special tool and rubber hammer.
 Apply thread locking adhesive to the exhaust
valve spring lower seat uniformly, and install the
55
Repair manual-M33
 lower seat onto the cylinder head in place, and

check if the lower seat is properly seated; when
necessary, remove it for repair or replace with
new one, and forced knocking is prohibited.
 Install the intake valve spring lower seat, place
the valve stem protective sleeve onto the intake
and exhaust valve guide, and then install the
valve stem seal sleeve.
Note:
Check if the spring inside the valve stem seal sleeve is
intact before installation.
 Install the valve spring.
 Install the valve spring upper seat, press the
valve spring and install the valve collet.
 Use a rubber hammer to tap valve collet into the
intake and exhaust valve seat after installation. If
the valve collet or valve spring upper seat is not
properly seated, find out the causes for
troubleshooting.
R 01.213 Check the valves for leaks

 Clean the parts. Figure R01-2018
Fit the valves free and dry.

 Position the sealing plate on the intake duct.
Check the vacuum value (-0.8 to -1 bar).
 Position the sealing plate on the exhaust duct.
Check the vacuum value (-0.8 to -1 bar).
Note:
If the values recorded are out of tolerance, run in
slightly or perform seat rectification again.
R 01.214 Fit the cylinder head group

 Definition of thickness of cylinder head Figure R01-2019
gasket
 Clamp the sleeve onto the engine block at two
points180°from each other. At 4 points 90°from
each other, use an appropriate depth gauge to
measure the dimension X (from the edge of the
sleeve to the cylinder block). Note the average
dimension for calculating the thickness of the
cylinder head gasket.
Figure R01-2020
56
Repair manual-M33
 Measure the dimension Y with micrometer.

(thickness of gasket)
 The thickness of the cylinder head gasket is
calculated according to the following formula:
Z = X + Y + 0.08
Note:
Chose the most appropriate gasket thickness from the
thicknesses available.
 Fitting the cylinder head
 Preparation and placement of fastenings
- Apply a film of clean engine oil to the thread, Figure R01-2021
centering and base of the head of each M16

screw.
Tighten all the M16 screws by hand until they
touch the cylinder head.
- Apply a film of clean engine oil to the concave
washers. Put the washers on the screws.
- Put the M20 screws, equipped with concave
washers, on the clamping plates.
- Apply a film of clean engine oil to the thread and
base of the head of each M20 screw. Tighten all
the M20 screws by hand until they are 1 mm away
from touching the clamping plate.
- Centre the clamping plates using the rocker
covers as positioner.
- Tighten the M20 screws until all parts are in
contact.
Note: Figure R01-2022
The M16 and M20 screws must be replace after three

removals (three punch marks).
 Procedure for tightening the cylinder heads
- Put the cylinder head gaskets defined earlier in
their respective places.
- Fit the cylinder head spacer plates.
- Fit the fastenings (see preparation).
Weight of cylinder head: 25.9 kg Figure R01-2023
 Tightening an isolated cylinder head

- Pre-tighten the M16 screws in order 1-2-3-4 to a
torque of 80 N·m.
- Pre-tighten the M20 screws in order A-B-C-D to
a torque of 80 N·m.
57
Repair manual-M33
Note:
Before the angular tightening phase, mark each screw
in relation to a fixed point on the cylinder head in order
to verify that the final tightening of all the fastenings is
carried out correctly.
- Tighten the M16 screws to an angle of 60°.
Tighten the M20 screws to an angle of 60°. Figure R01-2024
Tighten the M16 screws to an angle of 60°.

Note: After this sequence, final tightening of the M16
screws is complete.
Tighten the M16 screws to an angle of 45°. Figure R01-2025
Note:
After this sequence, final tightening of the M20 screws
is complete.
 Full bank of cylinder heads
- Tighten the M16 screws in order 1-2-3-4 …24 to
a torque of 80 N·m. Tighten the M20 screws in
order A-B-C-D…N to a torque of 80 N·m.
Note:
is complete.
Note:
is complete.
Note:
There is no retightening of the cylinder head screws to
be performed after operation.
58
Repair manual-M33
Figure R01-2024*
Figure R01-2025*
59
Repair manual-M33
R 01.30 Rocker system
R 01.31 Preliminaries
Sleeve wrench, threadlocker, oil
 Remove the injection pipes set(s).
 Remove the leak-off return hoses(s) of the
injectors.
 Remove the rocker covers.
 Remove the injector holder(s).
 Position the cylinder to be checked/set at TDC
compression stroke.
R 01.32 Fit valve bridge seat and valve

bridge
 Apply Loctite 242 to the thread of the hexagon bolts.
Install valve bridge seat. Apply appropriate oil and
install the valve bridge. Fit the valve bridge, the
clearance of the valve bridge is 0.02mm.
 Clean rocker arm shaft, rocker arm bracket, intake
Figure R01-3001
and exhaust rocker arm and sleeve. Assemble the
sleeve, intake/exhaust rocker arm, rocker arm
bracket onto rocker arm shaft. The axial clearance
of the rocker arm sleeve is 0.4~0.6 mm.
 Apply appropriate Loctite 242 to the thread of the
hexagon bolts. Install the rocker arm set on to
cylinder head.
R 01.33 Adjustment of the rocker arm Figure R01-3002
 Check the axial clearance of the rockers with feeler

gauge. Adjust if necessary by loosening the fixing
screws on the rocker system.
 Adjust the clearance by inserting a shim. Hold the
assembly steady and moderately tighten the fixing
screws. Check the play and perform final tightening
to torque of fixing screws.
Note:
Adjustment value for clearances at intake rockers: 0.30
Figure R01-3003
mm with feeler gauge; exhaust rockers: 0.60 mm with
feeler gauge.
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Repair manual-M33
R 01.34 Adjustment of bridges

 Loosen the nuts A2 and E2.
 Press and hold CA and CE.
 Using a screwdriver, turn adjustment screws VA
and VE to obtain simultaneous contact of A1 and
E1 between the valve bridge and the valve stems.
 Tighten the nuts A2 and E2 while holding screws
VA and VE with a screwdriver. Figure R01-3004
R 01.35 Adjust the clearance of the rocker

 Loosen the nuts D1.
Loosen the ball screws R1.
 Insert a 0.30 mm shim between the valve bridge
head and the intake rocker.
Turn the ball screw R1 using a screwdriver until the
shim slides slightly tight. Tighten nut D1 while
holding ball screw R1.
 Check and readjust play if necessary. Figure R01-3005
 Perform the same procedure for the exhaust

rocker.
Use engine oil to lubricate the joint surfaces and
joint areas of the rocker system.
61
Repair manual-M33
R 02 Engine block group
6M33
62
Repair manual-M33
12M33
63
Repair manual-M33
R 02.10 Liner
R 02.11 Preliminary operations

Oil, duster cloth
 Remove the cylinder head.
 Remove the entire mobile coupling.
Note:
Remove the carboned cord at the top of the liner
before removal.
Note:
Remove either the inspection door, the oil filter
support, or the breather opposite for access to con rod
screws.
Take care not to damage the piston jet when removing

the mobile coupling.
R 02.12 Check the liner

 Liner in place, check at four points the working
area of the rings at the upper, middle and lower
working parts. Figure R02-1001
 Check there are no areas where the burnishing is

partly or no longer visible.
 Only the disappearance of a fine even burnishing
on the surface is allowed within the wear tolerance
limit. Replace the liner if it does not meet the
criteria specified.
Note:
Use of a tool such as “FLEX-HONE” to perform
rehoning is completely prohibited. Figure R02-1002
R 02.13 Removal of the liner

 Drain the cooling circuit and oil.
 Use cloths to protect the crankshaft tang and the
bottom of the block to minimize any pollution with
oil compartment.
 Using extraction tool ref. 1000336131, remove the
liner. Figure R02-1003
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Repair manual-M33
Take care not to damage the piston jet when installing

the mobile coupling to the cylinder block.
 Clean the inside of the oil sump. Remove the
protection cloths.
 Check the bore in the cylinder block. Check the
contact area of the liner in the block.
R 02.14 Check
 Use Prussian blue to check the contact area of the
new liner (without O-rings) in the block.
 If the contact is not satisfactory, the contact area
will need to be ground using grinding compound.
Note:
The area of contact of the liner in the cylinder block
must be complete and perfectly smooth without any
marks or scratches. Figure R02-1004
 Clean all the parts.
R 02.15 Fitting the liner

 Equip the liner with new seals coated with tallow
or black soap.
Note:
The O-rings can be used only once.
 Carefully clean the liner housing. Visually inspect
and dimensionally check the bores.
Coat the bore contact areas with tallow or black
soap. Slide the liner into its housing. Figure R02-1005
 Manually, center the liner and apply vertical

pressure to initiate nesting. Finish nesting of liner
using the tool 2692110000.
Note:
The liner has no pre-defined orientation.
 Basically, you just put the liner back in the same
position it was in before. For a new liner, the
supplier mark should always be at 12 o’clock.
 Remove the tool, taking care not to bump or
scratch the liner bore. Figure R02-1006
Note:
Measure the bulge (0.05mm-0.10mm).
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Repair manual-M33
R 02.20 Piston cooling jet

Inner hexagon wrench, oil, threadlocker
 Remove the oil sump and oil pump group.
 Remove the crankshaft.
 Remove the connecting rod and piston.
R 02.22 Assembly of piston cooling jet

 Check the jet has no cracks or brazing faults
between the jet and the body. Use compressed air
or a flexible metal rod to check that the internal
channel of the nozzle is not partially clogged and
is perfectly clean.
 Apply a light film of “Loctite 242” onto the thread of
the hollow screw. Present the piston jet assembly Figure R02-2001
and screw the hollow fixing screw until contact,

taking care to guide the positioning pin into its
blockside housing.
 Tighten the hollow screw to 35 N·m.
Note:
For version of cylinder block without positioning hole,
remove the pin on the jet body.
Figure R02-2002
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Repair manual-M33
R 02.30 Breather set

Inner hexagon wrench, open end wrench
No
R 02.32 Removal of breather set

 Remove all the inner hexagon bolt of the breather.
 Remove the breather set and the breather gasket.
R 02.33 Check the breather set

 Check the breather set has no cracks or brazing
faults between the breather and the body. Make
sure the breather is not partially clogged and is
perfectly clean.
 Check the breather set has no air and oil leakage.
 Check the hose has no aging, cracks and other
damage.
 Check the breather set for air leakage with
compressed air (max.0.5kpa), if there is air Figure R02-3001
leakage change a new one.
R 02.34 Fit the breather set

 Fit a new breather gasket.
 Fit the breather set.
Note:
The breather gasket can be used only once.
R 02.35 Assembly of breather set

 Apply a light film of “Loctite 242” onto the thread of
the double end studs. Tighten it into the breather
set body.
 Fit the U seal ring onto the oil baffle plate.
 Fit the filter element, plate, heel block, oil baffle
plate in turn, tighten them with a nut.
 Fit the rubber hose onto the breather set, tighten
it with a clamp. Figure R02-3002
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Repair manual-M33
R 02.40 Oil filling pipe group

Inner hexagon wrench, open end wrench
No
R 02.42 Removal of oil filling pipe group

 Remove all the inner hexagon bolt of the oil filling
pipe group.
 Remove the oil filling pipe group and the gasket.
R 02.43 Check the oil filling pipe group

 Check the oil filling pipe has no cracks or brazing
faults between the oil filling pipe and the body.
Make sure the oil filling pipe is not partially
clogged and is perfectly clean. Figure R02-4001
 Check the oil filling pipe has no oil leakage.

 Check the hose has no aging, cracks and other
damage.
R 02.44 Assembly
 Fit a new oil filling pipe gasket.
 Fit the oil filling pipe group.
Note:
The oil filling pipe gasket can be used only once.
Figure R02-4002
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Repair manual-M33
R 02.50 Flywheel housing

Sleeve wrench, torque wrench, oil, threadlocker
 Uncouple the engine from the various parts driven
by the engine flywheel.
 Remove the starter.
 Remove the fuel pump.
R 02.52 Removal of engine flywheel

 Remove two diametrically opposed screws from
the engine flywheel. Fit the guides 2692210018
instead.
 Remove all the flywheel fixing screws.
 Fit suitable handling equipment for removing the
flywheel. If the flywheel is difficult to remove, use
an appropriate tool to facilitate dismantling by Figure R02-5001
levering at the starter hatch.

 Remove the flywheel.
Weight of flywheel: 109.80 kg
R 02.53 Removal of flywheel housing

 Removal of flywheel housing
 Check for completeness of parts against the table
of parts. Check the statuses of rear end plate,
flywheel cover, and cylinder block and ensure that
all junction surfaces are free of burrs, oil dirt, and
knocking damages.
 Unscrew fastening bolts of flywheel.
 Take out flywheel cover and remove the rear oil Figure R02-5002
seal.
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Repair manual-M33
R 02.54 Fitting of flywheel housing

 Clean and degrease the mating faces of the timing
gear chamber and flywheel housing.
 Apply silicone sealant to the mating face of the
timing gear chamber.
 Knock the pin into the engine body and mount the
flywheel housing onto the timing gear chamber.
 To fix the flywheel housing to the timing gear
chamber, tighten these bolts in the sequence as Figure R02-5005
shown with Loctite 242 sealant coated at the

threads.
 Tighten these bolts in the sequence as shown to
the torque of 180±10 N·m.
 Apply a proper amount of lubricating oil to the
mating faces of the front oil seal and the
crankshaft timing gear.
 Apply lubricating oil to the rear oil seal, press in
into flywheel housing by using special tooling. Figure R02-5006
Note:
The flywheel cover bolts can be used for two times.
R 02.55 Fitting the flywheel

 Fitting the flywheel
 Fit the guide pins. 2692210018. Using suitable
handling equipment, fit the flywheel.
Note:
Align the crankshaft locating pin and the pin hole of
the flywheel.
 Apply a film of oil to the threads and under the
head of the flywheel fixing screws.
 Fit the screws and bring the flywheel into contact
with the crankshaft.
 Remove the guide pins.
 Tighten the bolts in three steps :
-Tighten to the torque of 80 N·m. Figure R02-5007
-Tighten to the torque of 180±10 N·m.

Then perform paint sealing of bolts.
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Repair manual-M33
 Replacement of engine flywheel gear ring

 Heat the gear ring to 200°C. Extract the flywheel
gear ring using a bronze drift and by levering with
two crowbars in opposition.
 Clean the gear ring housing.
 Heat the gear ring to 250°C for 30 minutes. If
using a blow torch, use a sheet-metal plate to
distribute the heat. Check the temperature at 3
points.
 Fit the gear ring, respecting the mounting
direction.
The engagement chamfer must be oriented
towards the engine side.
Figure R02-5008
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Repair manual-M33
R 02.60 Front cover group

Sleeve wrench, open end wrench, oil, threadlocker
 Remove the front accessories.
R 02.62 Replacement of front cover
group
 Removal of front cover
 Remove all the front cover screws.
 Remove the front cover.
 Remove front seal collar
 Check the front cover

 Check the mating faces of the cylinder block and Figure R02-6001
the oil pan for cleanness without burrs, oil stains

or impact damages.
 Fitting the front cover group

 Apply silicone sealant to the joint face of front end
cover.
 Knock the two parallel pins into the pin holes in the
joint face of engine body.
 Mount the front end cover onto the engine body by Figure R02-6002
using overhead crane.

 Apply a little Loctite 242 threadlocker to the
threads of the bolt. Tighten the bolts.
 Apply lubricating oil to the lip of oil seal and press
it into front end cover by using special tools.
Figure R02-6003
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Repair manual-M33
R 03 Crankshaft piston and connecting rod
6M33
73
Repair manual-M33
12M33
74
Repair manual-M33
6M33/12M33
75
Repair manual-M33
R 03.10 Crankshaft (6M33)

Sleeve wrench, open end wrench, torque wrench, oil,
threadlocker, micrometer, duster cloth
 Drain the cooling and lubrication circuit.
 Uncouple the engine from the various parts.
 Completely strip the cylinder block.
- Supercharging
- Intake and exhaust manifolds
- Oil and water heat exchangers
- Cylinder heads
- Mobile couplings
- Front face of engine and timing
- Flywheel and flywheel housing
- Injection pump
- Camshaft
 Turn the engine block.
 Remove the oil sump.
 Remove the oil pump and peripherals.
R 03.12 Remove the crankshaft

Note:
The bearing caps are marked by numbers in
ascending order. The same numbers are stamped on
the lower plane of the cylinder block. The 2 punch
marks must always be facing each other.
 Loosen the bearing cap screws in reverse
alphabetical order from N to A. Remove all
fastenings. Figure R03-1001
 Remove the bearing caps.

 Remove and number the half-shells of the caps.
Note:
Bearing caps are dismantled using the wall spreader
ref. 3392210018.
 Use a comparator mounted on a magnetic base
to ensure stressing does not exceed 0.15 mm.
Remove the crankshaft.
 Remove and number the bearing half-shells.
 Clean all the parts. Figure R03-1002
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Repair manual-M33
R 03.13 Check the engine block

 Put the caps on without shells.
 Tighten the caps to the recommended nominal
torque. Use a 2-point gauge to check the internal
diameter of the bearing。
R 03.14 Check the crankshaft
Weight of crankshaft: 235.86 kg

 Check the tangs of the crank pins and bearing for Figure R03-1003
scratches, punctures or excessive wear.

Note:
Tiny scratches (that can not be detected by fingernail)
are permissible.
 Check the conditions of the tap threads of the
engine flywheel fixing screws.
 Check the condition of the flywheel locating pin.
 Check the condition of the front and rear lip seal
contact surfaces.
Dimensionally check the crankshaft (crank pins,
journals, with of stop flange).
 Check the bounce of the crankshaft.
 Put the crankshaft on the two V-block, measure
the bounce. Position the horizontal comparator to
exclude the natural sag of the crankshaft.
Figure R03-1004
 Disassembly of the crankshaft, rectification

and magnetic search for cracks
 Remove the counterweights
Note:
Each counterweight is marked with respect to its crank
web and the direction of mounting onto the web.
 Carry out magnaflux inspection of crankshaft
(detection of cracks and crevices). This operation
must be carried out by a specialized body.
If any cracks have been detected, it is imperative that

the crankshaft be replaced.
77
Repair manual-M33
st
 Rectification of the crankshaft is possible in 1
nd
and 2 dimension for the crank pins and journals
st
and 1 dimension for stop flange housing.
 Rectification of front and rear lip seal contact
surfaces is possible by machining + chroming +
rectification. See machining dimensions.
 After rectification, carry out dimensional checking
of crankshaft. Check that the fillets are made
without primers.
 Remove the lubrication duct plugs from the
crankshaft.
 Carefully clean the crankshaft using a steam jet,
focusing on the lubrication ducts with a swab and
degreasing agent. Clean it with compressed air.
 Protect the crankshaft against corrosion and dust
with alight film of oil and cover in case of shorterm
storage. Figure R03-1005
 Assembly of the crankshaft

 Apply a drizzle of “Loctite 242” threadlocker to the
threads of the plugs (reference 13605340N).
Fit and tighten the plugs to the bottom of the
thread.
 Refit the counterweights in their respective
places.
All the counterweight screws must be replaced upon

each disassembly or within the context of general
engine overhaul.
 Fit the screws, lubricated beforehand with engine
oil. Pre-tighten the screws to 100 N·m. Tighten
the screws to a torque 450 N·m. Figure R03-1006
 Perform dynamic balancing of the crankshaft with

its counterweights fitted.
 Bearing shells and stop flanges

 Clean the shells using a degreaser. The shells
must be replaced if they show signs of cavitation,
knocks, metal peeling, deep scratches beyond
the coating layer, pronounced wear (yellow metal
appearing in areas). Figure R03-1007
78
Repair manual-M33
 Check the thickness of the shells individually or

assembled. Replace the shells if out of tolerance.
Note:
If a shell is being reused, it must be pub back in its
original place. You cannot replace just one half-shell; it
is imperative that you replace the full set of half-shells.
 Check the thickness of the stop flanges at the
wear points.
 Replace the stop flanges if out of tolerance. Figure R03-1008
Figure R03-1009
R 03.15 Fitting the crankshaft
 Fit the grooved half-shells on the engine block
side. Fit the smooth half-shells on the cap side.
Apply a film of engine oil all over the half-shell.
 Fit the crankshaft, taking care to make sure the
end counterweights face down.
 Fit the bearing caps, respecting mounting
direction and numbering. (Punch marks facing
each other and same number).
 Fit the rear bearing cap, along with its stop
flanges which have been oiled beforehand. Figure R03-1010
Note:
The grooves in the stop flanges must be oriented
towards the faces of the crankshaft.
Note:
If the bearing caps are difficult to slot in, use tool
3392210018 combined with a comparator to ensure
correct distance from engine block.
 Fit the fixings screws of the caps, oiled
beforehand on the threads and mating surfaces. Figure R03-1012
Bring all the screws into contact with the bearing

caps.
 Tighten each screw in alphabetical order (A to N)
to a torque of 180±10 N·m.
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Repair manual-M33
 Tighten each screw in alphabetical order (A to N)

to an angle of 60°.
Tighten each screw in alphabetical order (A to N)
to an angle of 60°.
 Check free rotation of crankshaft and passage of
counterweights.
 Check the axial play of the crankshaft by applying
moderate pressure to the front/rear using an
appropriate tool.
R 03.16 Check after assembling

 After the tightening of main bearing bolts, rotate Figure R03-1013
the crankshaft to check the rotation flexibility and

radial clearance and measure the axial clearance
as per the specification.
 The crankshaft shall rotate flexibly without
obstruction. The crankshaft endplay is 0.15~0.35.
Figure R03-1014
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Repair manual-M33
R 03.20 Crankshaft (12M33)

Sleeve wrench, open end wrench, torque wrench, oil,
threadlocker, micrometer, duster cloth
 Drain the cooling and lubrication circuit.
 Uncouple the engine from the various parts.
(forward or rear power take-off, gearbox, etc.)
 Completely strip the cylinder block.
- Supercharging
- Intake and exhaust manifolds
- Oil and water heat exchangers
- Cylinder heads
- Mobile couplings
- Front face of engine and timing
- Flywheel and flywheel housing
- Injection pump
- Camshaft
 Turn the engine block.
 Remove the oil sump.
 Remove the oil pump and peripherals. Figure R03-1001
R 03.12 Removal of bearing caps

Note:
The bearing caps are marked by numbers in
ascending order starting from the back. The same
numbers are stamped on the machining plane of the
cylinder block oil sump.
 Loosen the crankshaft as follows
 Loosen and remove the side screws in reverse Figure R03-1002
alphabetical order on each side. Loosen the

bearing cap screws in reverse alphabetical order.
 Remove all the screws.
 Bearing caps are dismantling using the wall
spreader ref. 3392210018. And a 3/4’’ ratchet
wrench. Use a comparator mounted on a
magnetic base to ensure stressing does not
exceed 0.25 mm.
Figure R03-1003
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Repair manual-M33
 Position the crankshaft so that the

counterweights do not hamper the bearing
removal operation.
 Position tool ref. 3392210018 between the
beaings to be removed. Put the comparator on.
Apply radial force by turning the screw on tool ref.
3392210018.
 Remove the two opposite caps. Remove and
number the lower half-shells. Perform the same
procedure for the other bearings. Figure R03-1004
 For the rear bearing, recover and number the

stop half-flanges on the cap side.
 Then, remove and number the 2 upper half-
flanges by pivoting them.
R 03.13 Removal of the crankshaft

 Sling the crankshaft and remove it. The end
counter weights vertical and facing up.
 Remove and number the upper half-shells.
Figure R03-1005
R 03.14 Check the crankshaft
If possible, it is recommended that you have a

specialized workshop carry out a “Magna flux”
inspection of the crankshaft to ensure there are no
metallurgical defects. If a defect is detected, it is
IMPERATIVE that the crankshaft be replaced.
 Put the crankshaft on the two vs between the
external bearings and position a comparator in
the center. Figure R03-1006
 Measure the bounce of the crankshaft.

 Check the condition and roughness of the tangs,
fillets and lip seal contact areas. Measure the
diameter of the crank pins, journals and the stop
flange mating surfaces.
 Contact a specialized workshop for any
rectification operations or refilling by chroming for
the lip seal contacts.
Figure R03-1007
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Repair manual-M33
 If a rectification operation is performed, the repair

dimension shells and stop flanges will have to be
used. If the counterweights are removed/refitted,
it is imperative that the fixing screws be replaced.
 Perform dynamic balancing of the crankshaft with
its counterweights fitted.
R 03.15 Fitting the crankshaft

 Fit the grooved upper half-shells (engine block
side). Fit the lower half-shells (cap side).Oil the
half-shells.
 Fit the crankshaft, cleaned beforehand, making
sure the end counterweights are facing up. After
handling, orientate the crankshaft with the end
counterweights facing down.
 Fit the upper stop half-flanges on the crankshaft
(block side), making sure the lubrication grooves
face the area of friction. Figure R03-1008
 Position tool ref. 3392210018 between the wall of

the two rear bearings. Put on a comparator
mounted on a magnetic base. Perform stressing
of the cylinder block (max. 0.25 mm).
 Prepare the rear bearing by positioning the
previously oiled stop half-flanges and grooves
facing the friction faces of the crankshaft.
 Fit the bearing, observing the numbering and
mounting direction (punch marks facing each
other).
 Oil and bring into contact the side and upper Figure R03-1009
screws.
 Perform the same procedure for the other
bearings.
R 03.16 Tightening of bearing cap screws

 Insert each cap screw, oiled beforehand on the
thread and under the head, in alphabetical order
(A to N) and tighten them to a torque of 180±10
N·m.
 Tighten all the side screws, oiled beforehand on
the thread and under the head, on one side of the
V in alphabetical order (A to G) to a torque of 80
N·m. Tighten all the side screws on the other Figure R03-1010
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Repair manual-M33
side of the V in alphabetical order (A to G) to a

torque of 80 N·m.
 Tighten each cap screw in alphabetical order (A
to N) to an angle of 60°.
Tighten each cap screw in alphabetical order (A
to N) to an angle of 60°.
 Tighten all the side screws in alphabetical order
(A to G) to a torque of 270±20 N·m.
 Check free rotation of crankshaft and passage of
counterweights.
 Position a comparator at the end of the Figure R03-1011
crankshaft and check the axial play by applying

moderate axial pressure to the front/rear using an
appropriate tool.
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Repair manual-M33
R 03. 30 Piston and connecting rod

Sleeve wrench, torque wrench, oil, threadlocker,
nipper piper, duster cloth, micrometer
 Remove the cylinder head(s).
 Remove the accessories impeding access to
remove the inspection doors.
 Remove the inspection doors (for V-engine,
remove the inspection door opposite the cylinder
to be removed).
 Remove the oil cooler supports if necessary.
 Remove the breather(s) if necessary.
R 03.32 Removal of mobile coupling

 Remove the carbon deposits from the top of the
cylinder.
 Crank the engine so that the upper fixing screw of
the cap of the con rod to be removed is in line
with the inspection door opening. Loosen and
remove the upper screw.
 Crank the engine so that the lower screw is in line
with the inspection door opening. Loosen and
remove the lower screw. Figure R03-3001
 Remove the con rod cap with the lower half

bearing.
 Crank the engine in the upward direction of the
crankpin so that the piston moves up to TDC
without escaping from the con rod. Using tool ref.
151808 40N, extract the mobile coupling by
manually guiding the con rod and by tilting the
assembly slightly to avoid the piston jet catching
during passage.
 Take care to recover the upper half-bearing.
 Fit the cap, half-bearings and screws previously Figure R03-3002
removed onto the con rod.

Note:
The con rod, cap and piston are stamped with the
number of the corresponding cylinder.
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Repair manual-M33
Note:
Use a punch to mark the head of the con rod screws.
After 3 punch marks or 16,000 operating hours, the
screws must be replaced. The new screws are not
marked when they are first used.
 Remove the circlips and extract the shaft.
 Uncouple the con rod from the piston.
Note:
If you have difficulty extracting the shaft, allow the
piston to cool to make the operation easier.
 Remove the ring set using tool ref. 15180880G.
 Clean all the parts. Soak the piston in a bath of
hot water with added detergent and dispersant
such as washing up liquid or in an ultrasonic bath
to descale it.
Figure R03-3004
R 03.33 Check the piston
 Dimensionally check the piston。
 Check there are no signs of seizure on the
peripherals, cracks on the edges of the
combustion chamber, impact or incrustation on
the big end.
 Perform dimensional checks.
- Ring grooves
- Skirt diameter Figure R03-3005
R 03.34 Check the con rod

 Dimensionally check the con rod。
 Check:
- The condition of the surface of contact between
the cap and the con rod big end.
- The bore of the con rod big end, having
previously tightened the cap screws to 350 N·m.
- The diameter of the small end bushings. Figure R03-3006
- Buckling and twisting.
R 03.35 Check the bearings

 Check the bore of the bearings in situ on the con
rod.
 Check the thickness of the bearings.
Figure R03-3007
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Repair manual-M33
Note:
Bearing dimensions available
- Nominal dimension
- 1st repair size: + 0.5 mm
- 2nd repair size: + 1.0 mm
 Check and replace the bearings in case of deep
scratches, areas of pronounced wear, peeling of
the coating, cracks or erosion.
R 03.36 Prepare the piston

Note: The rings must always be replaced when fitting
a new liner.
st
1 groove: Keystone firing ring Figure R03-3008
The marking TOP must face the top of the piston.

nd
2 groove: Sealing ring.
The marking TOP must face the top of the piston.
rd
3 groove: Scraper ring.
No marking. Does not matter which way up it is fitted.
 Carefully clean the ring grooves.
Check if there is any burr.
 Using tool ref. 15180880G, fit the rings, making
sure the marking faces the top of the piston. Figure R03-3009
Note:
The gaps of the inner spring and external ring of the
scraper are diametrically opposed.
 After fitting the rings, check that they move easily
and do not catch on the grooves.
 Offset the ring gaps by 1/3 in relation to each
other.
Note:
A new piston has to be marked with the corresponding Figure R03-3010
engine cylinder number.
R 03.37 Prepare the con rod

Note: In case of a new con rod, use a punch to mark
the engine cylinder number on the con rod and its cap.
Note: It is imperative that the con rod screws be
replaced after 3 removals.
Note: The small end bushing is not supplied
separately. If a con rod bushing is worn, the complete Figure R03-3011
con rod must be replaced.
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Repair manual-M33
R 03.38 Assembly of con rod/piston

Note: The piston does not have a mounting direction.
In principle, the manufacturer marking on the top of
the piston will be oriented towards the flywheel side.
 Fit the 1st circlip onto one end of the piston shaft.
 Lightly oil the bore openings and insert the shaft
into the first part of the bore.
 Present the con rod and continue to insert the
shaft until it butts up against the circlip on the
opposite bore.
 Fit the second circlip.
Note:
In case of difficulty inserting the shaft, you can heat
the piston in an oven to a temperature of about 60°C.
R 03.39 Fitting the mobile coupling

 Apply a film of engine oil onto the ring set. Check
the ring gaps are offset by 1/3 in relation to each
other.
 Fit the ring compression tool ref. 1001797241,
taking care not to constraining the rings.
 Position the crank pin so that the con rod big end
can pass under it without catching.
 Apply a film of oil to the liner, crank pin, half-
bearings, threads and under the heads of the Figure R03-3012
screws.
Note: To avoid hitting the jet during con rod assembly,
rotate the mobile coupling 35°clockwise ¾of the way
in. Return it to its initial orientation for the rest of the
way.
 Lower the mobile coupling until the con rod big
end and its half-bearing are in place on the crank
pin.
Note: Guide the con rod big end to prevent the crank
pin escaping and blocking during the operation.
 Fit the con rod screws and fully engage the cap
(turn the crankshaft to facilitate fitting of screws).
 Check the radial play of the con rod.
 Tighten the screws to 200 N·m.
Tighten the screws to an angle of 60°.
Tighten the screws to an angle of 45°.
 Check the radial play of the con rod using a feeler
gauge set.
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Repair manual-M33
R 04 Valve mechanism
6M33
89
Repair manual-M33
12M33
90
Repair manual-M33
R 04.10 Camshaft

Sleeve wrench, internal hexagonal wrench, oil,
micrometer
 Remove the rocker system and push rods.
 Remove the injector holders.
 Remove the cylinder heads.
 Remove the tappets.
 Remove the flywheel housing.
R 04.12 Check before assembly

 Rotate the camshaft and check the camshaft for
flexible motion without obstruction.
 Use a dial indicator to inspect whether the
camshaft is subject to axial float.
 Check the backlash between the camshaft timing
gear tooth and the mating gear tooth.
Figure R04-1001
R 04.13 Removal of the camshaft

 Turn the camshaft, and inspect whether the
camshaft and timing gear are flexible, without
blockage.
 Rotate the crankshaft to enable the camshaft
timing gear to be at the top dead center of the 1st
cylinder.
 Remove the thrust plate, and lightly remove the
camshaft.
It is required to protect the camshaft bearing shell from

being impacted. Figure R04-1002
R 04.14 Visually and dimensionally

 Check there are not a lot of deep punctures,
peeling, pitting or wear on the tops of the camshaft
for the gearing and the camshaft.
 Wear, deep scratches, peeling of material for the
bushings and camshaft bearing. Figure R04-1003
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Repair manual-M33
 Check the height of each cam. Check the

dimensions and the contact surfaces of each
tappet.
 Replace in case of uneven or profound wear.
R 04.15 Removal a camshaft bushing

 Remove the mobile couplings.
 Remove the crankshaft after turning the engine
block.
 Remove the camshaft bushing using tool ref.
1002321364.
R 04.16 Fitting a camshaft bushing

 Smear the camshaft bushing with tallow. Figure R04-1004
 Using tool ref. 1002321364, insert bushing until

flush with wall, taking care to align one of its hole
with that of the cylinder block.
R 04.17 Fitting the front bearing and the

camshaft
 Apply a film of oil to the camshaft bushing contact
areas. Apply a film of oil to the camshaft bearings.
Figure R04-1005
 Fit the camshaft, gradually rotating it as you insert
it. Use tool ref. 1001798443.
 Apply a film of oil to the thrust plate. Place the
camshaft thrust plate at the rear end of the engine.
 Apply a film of “Loctite 242” to the bolt of thrust
plate and tighten to a torque of 39 N·m.
 Use a dial indicator to inspect the camshaft for
axial float.
Figure R04-1006
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Repair manual-M33
R 04.20 Timing gear (6M33)

 Remove the flywheel.
 Remove the flywheel housing.
R 04.22 Check before assembly

 Manually rotate the flywheel until the piston of the
1st cylinder reaches top dead center.
 Now, the marked tooth on the crankshaft timing
gear is in the middle of the two marked teeth on
intermidiate big gear.
 The marked tooth on the intermidiate small gear is
in the middle of the two marked teeth on the
camshaft timing gear and fuel pump idler gear. Figure R04-2001
 At the same time, the marked tooth on the

injection pump gear is in the middle of the two
marked teeth on the fuel pump idler gear.
R 04.23 Removal the timing gear

 With the markings facing each other, remove the
intermidiate big gear.
 Remove the crankshaft timing gear. Figure R04-2002
 Remove the pressure plate and fuel injection

pump gear.
 Remove the camshaft timing gear.
 Remove the fuel pump idler gear and its shaft.
 Remove the intermediate small gear, and
intermediate gear shaft.
R 04.24 Replacement of camshaft Figure R04-2003
See R 04.10.
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Repair manual-M33
R 04.25 Fitting the timing gear

 Before the assembly, check that all the parts are
free of manufacturing and functional defects
including damage.
 Install the intermediate gear shaft to the engine
block. Install the intermediate small gear with the
shaft oiled. Tighten the bolts with the spacer to the
torque of 70±5 N·m.
 Manually rotate the gear to check whether it can
rotate smoothly.
 Install the idler gear shaft to the engine block. Fix
the idler gear with the gear shaft oiled. Tighten the
bolts with the spacer to the torque of 95±5 N·m. Figure R04-2004
Note:
At the moment, the marked tooth of the
intermediate small gear lies in the middle of the
two marked teeth of the idler gear.
 Manually rotate the two gears to check whether
they can rotate smoothly.
 Position the camshaft timing gear using the dowel
pin. Fix the camshaft timing gear to the camshaft
using the flanged hex bolts, which shall be Figure R04-2005
tightened to the torque of 65±5 N·m.

Note:
two marked teeth of the camshaft timing gear.
The pin hole in the camshaft timing gear becomes
horizontal;
 Fix the fuel injection pump gear and pressure
plate to the fuel injection pump using the flanged
hex bolts, which shall be tightened to the torque of Figure R04-2006
128 N·m.
Note:
two teeth of the idler gear.
The marks on the gear, pressure plate and fuel
injection pump hub align with each other.
Figure R04-2007
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Repair manual-M33

 Referring to the dowel pin already installed to the
crankshaft, install the crankshaft timing gear. At
the moment, the pin hole in the crankshaft timing
gear lies at the 12 o’clock position.
 Install the dowel pin to the intermediate small gear
that has already been installed.
 Referring to the dowel pin, fix the intermediate big Figure R04-2008
gear to the intermediate small gear using the

flanged hex bolts, which shall be tightened to the
torque of 30±5 N·m.
Note:
intermediate big gear lies in the middle of the two
marked teeth of the crankshaft timing gear.
Figure R04-2009
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Repair manual-M33
R 04.30 Timing gear (12M33)

 Remove the cooling pump.
 Remove the belts.
 Remove the crankshaft front pulley with vibration
damper.
 Remove the fuel feed pump.
 Remove the timing cover.
 Remove the injection pipes and leak-off returns.
R 04.32 Check the clearances

 Release the camshaft by unscrewing the
adjustment screws for the entire rocker system.
 Release the injection pump drive gear by
uncoupling the injection pump from the drive
shaft.
 Check the condition of the pinions, peeling, pitting,
contact area.
 Measure the backlash at 4 points at 90°to each
pinion as well as the axial play of the camshaft.
Figure R04-3001
R 04.33 Timing setting/verification
 Turn the crankshaft so that the “0” engraved on
the pinion is at 12 o’clock. (the pinion keyway is
also positioned at 12 o’clock).
 The “N” mark on the camshaft wheel must be
facing the “0” on the crankshaft sprocket when at
the same time the “N” on the intermediate pinion
of the camshaft is facing the “0” on the drive shaft
gear of the injection pump.
Figure R04-3002
R 04.34 Removal the timing gear

 With all the timing marks facing each other,
remove the wheel/camshaft intermediate pinion
assembly.
 Remove the injection pump drive shaft gear.
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Repair manual-M33
R 04.35 Replacing the crankshaft

sprocket
 Weld 2 threaded rods onto the sprocket and
extract the sprocket to be heated evenly to 150°
C to facilitate the operation.
 Mount the sprocket, heated beforehand to 150°C.
 The trough of the teeth located in the axis of the
keyway is marked at one point and must be
Figure R04-3003
facing outwards.
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Repair manual-M33
R 04.40 Tappet and push rod

Sleeve wrench, internal hexagonal wrench, oil,
micrometer
 Remove the connecting pipes of cylinder head.
 Remove the cylinder head.
R 04.42 Removal of tappet and push rod

 After the rocker arm and rocker arm shaft have
been dismantled, directly remove the pushrod and
tappet, and put them aside in sequence. Using
tool ref. 2668010057.
R 04.43 Checking the tappet and push

rod
 Clean the push rod and tappet.
 Check the tappet for excessive wear.
 Check the push rod for excessive wear.
Figure R04-4001
 Check the oil passages of the tappet and push rod
for blockage.
R 04.44 Fitting the tappet and push rod

 Before assembling of the tappet, clean it with
compressed air, and inspect whether the oil hole
is smooth. Evenly apply some clean lubricating oil
onto the engine block tappet hole and the
cylindrical surface of the valve tappet.
Figure R04-4002
 Lightly put the tappet into the tappet hole.
 Assemble the pushrod, and lightly put the pushrod
through the cylinder head and into the tappet
socket end. Using tool ref. 2668010057.
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Repair manual-M33
 Adjust the clearance of the rockers

INTKE: 0.30 mm / EXHAUST: 0.60 mm(6M33)
 Under the cold status of diesel engine, turn the
engine (along the rotation direction of engine) to
the compression top dead center of 1st/6th
cylinder. In such case, the notch on the flywheel
is aligned with the pointer on the flywheel cover.
 Disassemble the valve rocker cover from the
cylinder head and judge whether the 6st or 6th
cylinder is at compression stroke (there is a gap Figure R04-4003
between exhaust valve and rocker for the cylinder

under the compression stroke).
 Using the feeler gauges, check the clearance
between Valve Bridge top and valve rocker arm. If
the clearance is too large or too small, adjust the
adjustment bolt on the rocker to meet the above
mentioned clearance requirement.
 let the #1 cylinder's piston come at the
compression top dead center by rotating the
crankshaft, adjust the valve clearances.
 Rotate the engine crankshaft for 360ºto make the Figure R04-4004
#6 cylinder to working stroke, adjust the valve

clearances.
Adjustable Valves of Cylinders in the Compression Stroke

Adjust valve clearancees
Intake valves Exhaust valves
Cyl 1 TDC 1-2-4 1-3-5
Cyl 6 TDC 3-5-6 2-4-6
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Repair manual-M33
 Adjust the clearance of the rockers

INTKE: 0.30 mm / EXHAUST: 0.60 mm(12M33)
 Under the cold status of diesel engine, turn the
engine (along the rotation direction of engine) to
the compression top dead center of 7st/12th
cylinder. In such case, the notch on the flywheel
is aligned with the pointer on the flywheel cover.
 Disassemble the valve rocker cover from the
cylinder head and judge whether the 7st or 12th
cylinder is at compression stroke (there is a gap Figure R04-4005
between exhaust valve and rocker for the cylinder

under the compression stroke).
 Using the feeler gauges, check the clearance
between Valve Bridge top and valve rocker arm. If
the clearance is too large or too small, adjust the
adjustment bolt on the rocker to meet the above
mentioned clearance requirement.
 let the #7 cylinder's piston come at the
compression top dead center by rotating the
crankshaft, adjust the valve clearances.
 Rotate the engine crankshaft for 360ºto make the Figure R04-4006
12th cylinder to working stroke, adjust the valve

clearances.
Adjustable Valves of Cylinders in the Compression Stroke

Adjust valve clearancees
Intake valves Exhaust valves
Cyl 7 TDC 1-3-5-7-8-10 2-3-6-7-9-11
Cyl 12 TDC 2-4-6-9-11-12 1-4-5-8-10-12
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Repair manual-M33
R 05 Intake and exhaust system
6M33
101
Repair manual-M33
12M33
102
Repair manual-M33
R 05.10 Air filter

Open end wrench, duster cloth
 Remove the connecting pipes of air filter.
R 05.12 Check the filter

 The maximum permissible intake resistance of
diesel engine is 7 kPa.
 When the resistance of the intake air reaches the
permissible limit, clean or replace the filter element
as per the manufacturer’s instructions.
 Disassemble the filter element from the air filter
and tap lightly the end face to fall off the dust or
blow backward (from inside out) by compressed
air. Figure R05-1001
Check the maximum intake resistance only when the

diesel engine is running at rated speed under full load.
R 05.13 Fitting the air filter

 Install the air filter bracket to the engine.
 Install the air filter.
Figure R05-1002
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Repair manual-M33
R 05.20 Turbocharger

Open-end wrench, threadlocker, micrometer
 Remove the connecting pipes.
R 05.22 Remove the turbocharger

 Remove the outlet joint pipe from the
turbocharger.
 Remove the exhaust manifold heat shield
assembly.
 Remove the inlet and outlet oil pipes.
R 05.23 Measuring the clearances

 Axial play Figure R05-2001
 Immobilize the compressor bearing.

 Position a comparator parallel to the shaft.
Place the comparator needle in contact with the
hub of the turbine.
 Push the shaft on the turbine side till it butts up
against the bearing ( A ).
 Adjust the dial with the comparator needle to “0”.
 Push the shaft on the compressor side till it butts
up against the bearing ( B ).
 Note the clearance value. Repeat the operation to
validate. Figure R05-2002
Turbocharger axial play

Min.: 0.076 mm / Max.: 0.13 mm
 Radial play
 Immobilize the compressor bearing.
 Position a comparator perpendicular to the shaft.
Place the comparator needle in contact with the
smooth part of the nut on the compressor wheel.
 Hold the turbine and push it down as far as it will
go on the compressor wheel side ( A ).
 Adjust the dial with the comparator needle to “0”.
 Lift the compressor wheel as high as it will go ( B ).
 Note the clearance value. Repeat the operation to
validate. Figure R05-2003
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Repair manual-M33
Turbocharger radial play

Min.: 0.74 mm / Max.: 0.94 mm
R 05.24 Fitting the turbocharger

 Fit the inlet oil pipe of the turbocharger.
 Fit the turbocharger.
Apply some sealant to combining site between inlet

and outlet oil pipes and the engine.
Before installing the turbocharger put some oil into the
turbocharger and rotate the rotor.
Figure R05-2004
R 05.25 Disassembling the turbocharger

The installation angle of turbine seat and the
installation angles of bearing seat and compressor
seat depend on the installation condition of the engine.
Add markings before the start of disassembling.
 Disassemble the compressor seat

 Disassemble the flat hexagon head bolts and
compressor side plate.
 Disassemble the compressor seat.
Note:
Apply liquid sealant to the compressor surface for
installation of bearing seat.
While disassembling the compressor seat, take
cautions to prevent damaging the compressor
impellor. Figure R05-2005
 Disassemble the compressor impellor

 Disassemble the shaft end clamping plate by a
socket wrench (10mm) on the turbine end of
turbine shaft.
Note:
Note the loosening direction, as the shaft end nut is of
left-hand thread.
 Disassemble the compressor impellor.
 Disassemble the turbine seat Figure R05-2006
 Loosen the hexagon nut and turbine end metal

plate.
 Disassemble the turbine seat.
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Repair manual-M33
 Take out the turbine shaft

 Hold the thermal shield lightly by hand and
withdraw the turbine shaft.
Note:
If it’s difficult to withdraw the turbine shaft, lightly knock
the compressor end by a wood hammer.
 Take out the thermal shield.
 Disassemble the sealing plate

 Loosen the T-shaped torque screws by a torque
adjustable screwdriver. While disassembling the Figure R05-2007
sealing plate, notice that the installation surfaces

of sealing plate and bearing seat are applied with
liquid sealant.
 Take out the engine oil slinger from the sealing
plate.
 Disassemble the sliding bearing and thrust

bushing
 Loosen the M3 T-shaped torque screws of thrust
bearings by a torque adjustable screwdriver.
 Knock out the thrust bearing and thrust bushing by
a copper bar.
 Disassemble the floating bearing

 Take out the retainer ring from the bearing seat by
a thrust ring pliers.
 Take out the floating bearing from the bearing
seat.
 Disassemble the seal ring

 Take out the turbine end seal ring from the turbine
shaft. Figure R05-2008
 Take out the compressor end seal ring (small) and

the compressor end seal ring (large) from the
engine oil slinger.
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Repair manual-M33
R 05.26 Clean
Checking before cleaning before cleaning, visually observe every part and check for trace of
seizure, wear, foreign material, and carbon deposit. Check and judge the problem cause by
self, especially at the occurrence of problem.
 Main checking items
Checking point Checking location

 Turbine shaft, turbine end seal ring, and turbine rear end
face.
Adhesion of carbon chipping
 Installation location of thermal shield disc and inside of
bearing chamber.
 Turbine shaft, journal location, and thrust bearing oil
Lubricating oil status (such as
slinger.
wear, seizure, and
 Floating bearing and thrust bearing.
discoloration)
 Bearing chamber and bearing fixing ring inner walls
 Inner walls of turbine chamber.
 Inner walls of turbine chamber and installation location
of thermal shield disc.
 Turbine shaft, turbine end seal ring, and turbine rear end
Oil leakage status cap.
 Inner walls of compression chamber.
 Rear end of compression blade.
 Surface of sealing disc and the sealing insertion
segment
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Repair manual-M33
 Cleaning procedure
Parts Tools and cleanser Procedures

 Boil the turbocharger in a barrel and do
not scrape the carbon chipping by a
sharp blade.
 Immerse it within the detergent, till the
Tools:
carbon chipping and other deposits are
Bucket (500*500);
softened.
Heat source
 Remove the softened deposits by a
Steam or gas
plastic scrape or a hard brush.
Turbine shaft Brush
 Guard the bearing surfaces and seal
ring grooves on the turbine shaft
Cleanser:
against damage.
Standard carbon chipping
 The residual deposits on the turbine
detergent
shaft due to incomplete cleaning will
lead to unbalance of turbine shaft.
 Ensure the thorough clean and do not
use a metal brush.
 Boil the turbocharger in a barrel.
The same as above  Immerse it within the detergent, till the
Turbine chamber carbon chipping and other deposits are
 softened.
Remove the deposits by a plastic
The same as above scrape or a hard brush.
 Immerse within a barrel, till the deposits

Tools:
are softened.
Bucket (500*800);
Blade and chamber  Remove the deposits by a plastic
Brush
scrape or a hard brush and do not use a
Detergent
metal brush.
 Clean other parts by diesel.
Others  Blow the lubricating oil ways by compressed air.
 Take special cautions not to damage or corrode the parts.
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Repair manual-M33
R 05.27 Check
 Compressor seat
 Check the compressor seat for contact trace with
compressor impellor, for surface damage, and for
indentation or cracking at junction surface.
 Upon detection of such problem, replace the
parts.
 Turbine seat
 Check it for the contact trace with turbine rotor and
check it for the falloff, thermal deformation, and
cracking due to surface oxidizing annealing of Figure R05-2009
castings.
 Upon detection of such problem, replace with new
parts.
 Compressor impellor
 Check for contact trace, fragment, corrosion, and
deformation. Upon detection of such problem,
replace with new parts.
 Turbine shaft Figure R05-2010
 Check the turbine rotor for contact trace, fragment,

thermal discoloration, and deformation. Check for
bending of shaft, for thermal discoloration and
abnormal wear at shaft journal, and for surface
damage and wear at seal ring grooves.
 Upon detection of such problem, replace with new
parts.
 Measure the outside diameter of turbine shaft (A) Figure R05-2011
and width of seal ring groove (E).

If out of wear limit, replace with new turbine shaft.
 Measure the wear extent of turbine shaft. If
beyond the 0.011mm, replace with new turbine
shaft.
 Thermal shield
 Check thermal shield for contact trace, thermal
deformation, and wear.
 Upon detection of damage, replace with new
parts.
Figure R05-2012
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Repair manual-M33
 Thrust bearing, engine oil slinger, and thrust

bearing
Check every part for wear, surface damage, and
discolorration. Upon detection of any abovementioned
damage, replace with new parts, even if they are still
within the wear limit.
 Thrust bushing
Measure the distance (K) between the groves of thrust
bushing. If out of wear limit, replace with new parts.
 Engine oil slinger
Measure the widths (G1) and (G2) of seal ring grooves.
If beyond wear limit, replace with new parts.
Wear limit:
RHF5………..G1: 1.31mm, G2: 1.11mm
RHB51………G1: 1.31mm, G2: 1.11mm
RHB31………G1: 1.04mm, G2: 0.84mm Figure R05-2013
 Thrust bearing
Measure the width (J) of thrust bearing. If beyond the
wear limit, replace with new parts.
Wear limit:
RHF5………..3.98mm
RHB51………3.98mm
RHB31………3.58mm
 Floating bearing
 Check the floating bearings for abnormal wear,
discoloration, and surface damage. Upon
detection of such defect, replace with new parts.
 Measure the outside diameter (C) and inside
diameter (D). If either is beyond the wear limit,
replace with new part.
Wear limit:
RHF5…………Outer diameter (D): 12.31mm
Inner diameter (C): 8.04mm
RHB51…….…Outer diameter (D): 12.31mm Figure R05-2014

RHB31…….…Outer diameter (D): 9.93mm
 Bearing seat
 Check the surfaces of bearing seat castings for
oxidizing falloff, deterioration, indentation, and
cracking. Upon detection of such defect, replace
with new parts.
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Repair manual-M33
 Check the retainer ring 16 for breakage and

cracking. Upon detection of such defect, replace
with new parts.
 Check the locations (B) and (F) in the bearing seat,
as shown in the figure below. If the wear exceeds
any limit, replace with new parts.
Wear limit for inside diameter (B) of bearing seat
RHF5………..12.42mm
RHB51………12.42mm
RHB31………10.01mm
Insertion position (F) of seal ring on turbine side
RHF5………..15.05mm
RHB51………15.05mm
RHB31………11.03mm
Figure R05-2015
 Seal plate
 Check the contact trace of seal plate and check it
for surface defect, indentation, and cracking.
Upon detection of such defect, replace with new
parts.
 Check the installation dimensions (H1 and H2) of
seal ring on the compressor side. If beyond wear
limit, replace with new seal ring.
Wear limit
RHF5………..H1: 12.45mm, H2: 10.05mm
RHB51………H1: 12.45mm, H2: 10.05mm
RHB31………H1: 10.04mm, H2: 8.01mm
 Seal ring
New seal ring.
 Check the pressure plate and bolts for
deformation. Upon detection of such defect,
replace with new parts. Replace with new M3
torque screws.
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Repair manual-M33
R 05.28 Assembling
 Before the assembling of turbocharger, prepare
the common tools, special tools, liquid gasket
sealant, and solid sealant.
 During the assembling, replace the following parts:
-One turbine end seal ring
-One compressor end seal ring (large)
-One compressor end seal ring (small)
-Three M3 screws
-Four M3 screws
Assembling:
 Install the floating bearing
 Install the inner retainer ring into bearing seat by
pliers.
 Install the floating bearing to the bearing seat.
 Install the outer retainer ring into bearing seat by
pliers.
The joint of retainer ring shall follow the location

shown in right figure. The round edge of retainer ring
shall face towards the bearing. Before assembling,
add lubricateng oil to the place of floating bearing.
 Install the turbine shaft

 Attach the seal ring onto the turbine shaft.
 Install the thermal shield to the turbine end
bearing seat.
 Apply lubricating oil to the turbine shaft journal
and install from the turbine end of bearing seat.
Note:
Operate carefully to prevent the turbine shaft from
damaging the floating bearing. After the centering of
turbine shaft, the joint of seal ring shall be at the oil
inlet side.
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Repair manual-M33
 Install the thrust bearing

 Attach the thrust bearing onto the turbine shaft.
 Apply lubricating oil to the bearing face of thrust
bearing and install the thrust bearing into the
bearing seat.
 Apply the sealant to the threads of M3 screws and
then fix the thrust bearing to the specified torque
by a torque wrench.
 Tightening torque: 1.3±0.1N·m (13±1kgf·cm).
 Install the seal plate Figure R05-2017
 Attach the seal ring onto the oil slinger.

 Install the oil slinger into sealing plate.
Note: The joint of the seal ring shall be installed as per
the above figure.
 Apply liquid gasket sealant to the installation face
of sealing plate and to the bearing bore of
compressor end. Sealant application thickness:
0.1-0.2 mm.
 Install the sealing plate to the bearing bore.
 Apply the sealant to the threads of screws and fix Figure R05-2018
the sealing plate to the specified torque by a

torque wrench.
 Install the compressor impellor

 Attach the compressor impellor to the turbine
shaft.
 Fix the turbine end of turbine shaft by a 10mm
socket and tighten the shaft end nut.
Note: The shaft end is of left-hand thread. Notice the
disassembling direction during tightening.
 Install the turbine chamber Figure R05-2019
 Align the marking of bearing chamber added

during disassembling with the marking of turbine
chamber and install.
Note:
For replacement of parts, please check the locations
of engine oil inlet and outlet and the location of
exhaust gas inlet before assembling.
 Install the turbine support plate and tighten the M8
12 hexagon head bolts.
 Tightening torque: 285±10N·m (28±1kgf·cm). Figure R05-2020
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Repair manual-M33
 Install the compressor chamber

 Apply liquid gasket sealant to bearing chamber
and compressor end flange.
Note:
Refer to Install the seal plate for the application
locations. Sealant application thickness: 0.1~0.2mm.
 Check the marking on the compressor chamber
and install the compressor chamber onto the
bearing seat. Figure R05-2021
Note:
During replacement of parts, determine the locations
of oil inlet and exhaust port and reinstall the parts.
 Install the compressor support plate and tighten
the M8 hexagon head bolts.
 Tightening torque: 48±5N·m (4.7±0.5kgf·cm).
 Perform the rotor running test

If the running of rotor fails to meet the specification, it
should be caused by an assembling error or the use of
incorrect parts. Ensure to reassemble the parts.
Maintenance criterion of rotor during axial running
RHF5………..0.03~0.06mm
RHB51………0.03~0.06mm
RHB31………0.022~0.053mm
Maintenance criterion of rotor during radial running
RHF5………..0.08~0.13mm
RHB51………0.08~0.13mm
RHB31………0.061~0.093mm
R 05.29 Installation instruction of

turbocharger
Handling after assembling strictly abide by the
following installation instruction while installing the
turbocharger to the engine or during the handling after
reinstalllation. Take special cautions to prevent the
falling of foreign material into turbocharger.
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Repair manual-M33
 Lubrication System
 Before installing the turbocharger to the engine
port, add new engine oil through oil filler port and
rotate the turbine shaft by hand to lubricate the
floating bearings and thrust bearings.
 Flush the oil inlet and return pipes. Check for
cracking, dust, and foreign material.
 Properly connect the oil return pipe to prevent oil
leakage.
 Intake system
Check the intake pipe for presence of oil dirt and dust.
Properly connect the intake pipe and air filter to
prevent air leakage.
 Exhaust system
 Check the exhaust system for presence of foreign
material.
 The bolts and nuts used for the exhaust system
are made of heat-resistant steel. Do not use
common bolts or nuts. Apply the antilubricant
while tightening the bolts or nuts.
 Properly connect the exhaust pipe to prevent the
air leakage from the joint.
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Repair manual-M33
R 05.30 Intake manifold

Socket head wrench, glue, duster cloth
R 05.32 Removal of the intake manifold

 Remove the various accessories that may be
attached to the manifold.
 Remove the fixing screws on the cylinder head
side.
 Remove the intake manifold assembly.
 Remove the manifold sections.
 Remove all the O-rings.
Note:
It is possible to remove a single manifold section. Figure R05-3001
Remove the sleeve retaining strips.

Push the 2 sleeves for the section to be removed right
over to the other side.
Remove the section.
R 05.33 Check the intake manifold

 Check the intake manifold for welding defects. If
necessary, replace it with a new one.
 Check whether the intake manifold gasket is
deformed, damaged or absence, and if any, it is
required to replace.
R 05.34 Fitting the manifold

 Apply a film of neutral grease and fit the O-rings
onto the connecting sleeves and onto the sections
on the cylinder head side. Fit the intake manifold
section by section.
 Fit the connecting sleeves. Fit the connecting
sleeve retaining strips.
 Pre-tighten all fastenings. Check there are no Figure R05-3002
restrictions on the manifold assembly.

 Perform final tightening of all fastenings.
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Repair manual-M33
R 05.40 Exhaust manifold

Socket head wrench, glue, duster cloth
R 05.42 Removal of the exhaust manifold

 Remove the various accessories that may be
attached to the manifold.
 Remove the fixing screws on the cylinder head
side.
 Remove the exhaust manifold assembly.
 Remove the manifold sections.
 Remove all the O-rings.
Figure R05-4001
R 05.43 Check the exhaust manifold

 Inspect whether the exhaust manifold is cracked
or damaged, and the flange is deformed.
 Check the exhaust manifold flange for leakage.
 Check whether the exhaust manifold gasket is
deformed, damaged or absence.
 Check the expansion joint and clamps for soot. If
any, replace them with new ones.
R 05.44 Fitting the manifold

 Apply some sealant to the bolts of the exhaust
manifold.
 Put the exhaust manifold to the cylinder head in
the appropriate position with the gaskets.
 Tighten the bolts from middle to the two sides
symmetry.
Figure R05-4002
The gasket can be only used once.

The exhaust manifold bolts should be applied with
antiseize sealant (molybdenum disulfide), and the bolt
can be reused twice at most.
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Repair manual-M33
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Repair manual-M33
R 06 Fuel oil system
6M33
119
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12M33
120
Repair manual-M33
R 06.10 Water separator and fuel filter

Socket head wrench, oil, duster cloth
R 06.12 Check
 Check the water level in the water collector of fuel
strainer and drain the water once every 100 hours.
 Replace the fuel filter element once every 400
hours.
R 06.13 Fitting the fuel filter

 Disassemble the fuel strainer element and fuel
fine filter element by an appropriate wrench and
clean the filter seats. Figure R06-1001
 Apply engine oil to the new filter element seal

gasket.
 Install the filter element in place by hand in such
manner that the seal ring comes into contact with
the sealing surface of filter seat.
 Tighten the filter element by 3/4~1 turn by an
appropriate wrench.
 Loosen the bleeder plug of fuel strainer and pump
the fuel by the manual pump on the fuel strainer,
till the fuel flows out from the bleeder plug.
 Tighten the bleeder plug. Figure R06-1002
 Loosen the hollow bolt at the fuel outlet of fuel

fine filter, pump the fuel by the manual pump on
the fuel delivery pump, till the fuel flows out from
the loosened hollow bolt, and then tighten the
hollow bolt.
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Repair manual-M33
R 06.20 Drive shaft of injection pump

Sleeve wrench, open end wrench, threadlocker,
micrometer, torque wrench
 Remove the cooling pump.
 Uncouple and remove the injection pump.
R 06.22 Removing the drive shaft

 Remove the fixing screws of the lip seal holder
plate of the drive shaft.
 Remove the fixing screws of Injection pump drive
gear (You have to “turn” the engine to remove all
the screws).
Note:
Before detaching the drive shaft from the gear, take
care to mark the teeth of the intermediate pinions of
the camshaft and drive shaft of the injection pump.
 Remove the injection pump drive shaft from the V Figure R06-2001
side of the engine.
R 06.23 At the workbench

 Mark by marking the angular positioning of the
bearing hub in relation to the “0” of the opposite
adjusting drum. (make a straight edge to be used
in situ)
 Release the clamping element on the bearing
side.
 Remove the bearing holder hub.
 Remove the lip seal with its flange.
 Remove the lip seal and the O-ring. Figure R06-2002
 Remove the bearing.

R 06.24 Assembling the drive shaft

 Heat the bearing to 140°C.
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Repair manual-M33
Use suitable and protective gloves

 Fit the new bearing supported on the sleeve.
 Fit the new lip seal coated with “Loctite 270” on
the external face.
 Fit the flange equipped with the lip seal and the
O-ring and fit the hub equipped with the bearing.
 Position the mark on the hub, drawn earlier upon
removal, in line with the “0” mark on the opposite
adjusting drum. Use the straight edge mentioned
earlier.
 Position the front clamping element while inserting
a 7mm shim between the lip seal holder flange
and the clamping element (the dimension will be
approx. 8.5 mm after full clamping of the clamping
element).
 Proceed to tighten the element, taking care to
tighten the screws in opposition so that the faces
of the ring are parallel.
 Tighten the screws several times using the torque
wrench until they stabilize at the tightening torque
of 12 N·m.
R 06.25 Fitting on engine

 Fit the assembled shaft, taking care to align the
shaft nose pin with the locating hole on the pinion.
 Check that the injection pump drive gear has not
skipped any teeth in relation to the camshaft
wheel. Apply a drizzle of “Loctite 242” to the
screws and tighten to torque 70 N·m.
 Fit the lip seal support.
 Fit the screws and tighten to torque 35 N·m.
 Fit the injection pump and proceed to engine
timing.
During mounting, please respect the axial position of

1.5 mm of the bearing with relation to the lip seal
holder.
 Fit the cooling pump and connection pipes.
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Repair manual-M33
R 06.30 Injection pump

Socket head wrench, open end wrench, glue
 Remove the connecting fuel pipes.
R 06.32 Check before disassembly

 Insert an 8mm pin into the pinning hole of the
flywheel housing.
 Turn the engine CW until the hole in the flywheel
housing is aligned with the hole in the engine
flywheel. Insert the pin into the flywheel.
Note:
Make sure the #12 cylinder's piston is at the Figure R06-3001
compression top dead center.

 At the moment, the groove mark on the drive
plate is aligned with the mark on the fuel pump
housing.
 Remove the 8mm pin from the flywheel.
R 06.32 Remove the fuel pump

 Remove the injection pipes. Remove the injection
pump lubrication pipes. Remove the injection
pump fuel pipes.
 Loosen and remove the screws from the adjusting
drum and pump coupling.
Turn the engine to remove all the screws from the

adjusting drum and coupling.
 Reposition the engine at the TDC compression
stroke of engine reference cylinder no. 12 (ERC)
by inserting the pin into the engine flywheel.
 Remove the injection pump fixing screws.
 Remove the injection pump.
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Repair manual-M33
R 06.33 Fitting the drive plate

 Check the condition of the cones and the contact
of the pump shaft and drive plate. Slight wear is
tolerated. If the contact is less than 80%, replace
the drive plate.
 Install the injection pump drive plate with its key
and tighten to 200 N·m.
R 06.34 Injection pump timing

 Slowly turn the injection pump CW by the front
drive until the groove mark on the drive plate is
aligned with the mark on the fuel pump housing.
 At the moment, the #1cylinder of the fuel pump
wich supplys fuel to the #12cylinder of the engine
supply fuel.
 Position the engine at TDC compression stroke of Figure R06-3003
engine reference cylinder no. 12 (ERC) by

inserting the pin into the engine flywheel.
 Fit the pre-timed injection pump.
Weight of pump: 45.11 kg

 Fit but do not tighten the fixing screws.
 Set the axial play of the drive shaft in the
mid-position.
 Advance the injection pump until the plates are in
contact.
 Tighten the fixing screws to torque.
 Insert but do not tighten the 6 fixing screws. Figure R06-3004
Note:
The plates must be able to rotate freely one over the
other when you turn the engine for timing adjustment.
 Remove the Ø 8mm pin from the engine flywheel.
 Slowly turn the engine ACW beyond the timing
value then CW until the timing value required is
next to the edge of the fixed index. Make sure the
injection pump is still at the start of delivery at
PRC No.1.
 Tighten the 6 screws of the pump coupling plates Figure R06-3005
/drive shaft. Check and repeat the timing

operation if necessary.
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Repair manual-M33
R 06.40 Injection pump (6M33)

Open end wrench, socket head wrench, micrometer,
duster cloth, glue
 Remove the front cover.
R 06.42 Check before disassembly

 At the moment, the groove mark in the fuel
injection pump gear and that in the fuel injection
pump flange shall align with each other. Figure R06-4001
R 06.42 Remove the pump

 Remove the injection pipes.
 Remove the oil feed and return hoses.
 On the flywheel housing, a hole of Ø 8mm
corresponding to the hole on the engine flywheel
determines the TDC (top dead center) of the
#1\#6 cylinder.
 Turn the engine using the driver fixed onto the Figure R06-4002
nose of the crankshaft.

 Introduce the Ø 8mm pin into the hole in the
flywheel housing provided for this purpose. Slowly
turn the engine until the pin holes in the flywheel
housing and the flywheel are aligned. Nake sure
the piston of the 1st cylinder reaches top dead
center.
 Remove the fuel injection pump and the pressure
plate. Figure R06-4003
 Remove the injection pump.

 Remove the locking nut of the fuel injection pump.
Figure R06-4004
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Repair manual-M33
R 06.43 Fitting the fuel injection pump

 Install the fuel injection pump drive gear and
pressure plate.
Note :
Make sure that the mark on the drive gear aligns
with the groove mark in the pressure plate.
 Fit the assembled hub (pay attention to the
keyway), the locking nut shall be tightened to a
torque of 300-340 N·m with the washer.
 Fit the O-ring.
1st cylinder reaches top dead center. Figure R06-4005
 Rotate the fuel injection pump gear so that the

marks in the fuel injection pump drive gear, fuel
injection pump hub, pressure plate and fuel
injection pump flange align with each other.
 Install the fuel injection pump assembly.
 After completion of the final installation, the fuel
supply advance angle shall be 22º(which may be
altered after type approval).
 Tighten the fixing bolts for the auxiliary supports of Figure R06-4006
fuel injection pump in the sequence.
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Repair manual-M33
R 06.50 Fuel delivery pump

Socket head wrench, duster cloth
R 06.52 Remove the delivery pump

 Disassemble three connecting hexagon head
bolts between fuel delivery pump and fuel
injection pump body by a wrench.
 Disassemble the fuel inlet and outlet pipe
conector bolts by a wrench and at the same time
take out the filter screen from the fuel inlet pipe
connector.
 Disassemble the check valve nut and manual
pump by a wrench.
 Disassemble the check valve and check valve
spring by a pair of tweezers.
 Loosen the large screw plug by a wrench and
disassemble the piston spring and piston. Figure R06-4001
 Disassemble the wire retainer ring and take out

the roller body assembly.
R 06.53 Check
 Check the disassembled parts after cleaning.
 Upon detection of defects such as serious wear,
cracking, deformation, and rusting, replace with
new one.
 The piston spring, check valve, O-ring, and
washer are of wearing parts and shall be
replaced.
R 06.54 Fitting the fuel delivery pump

 The assembling procedure of fuel delivery pump
is in reverse to the disassembling procedure.
Note:
The O-ring or oil seal must be applied uniformly with
lubricating grease before assembling.
The tightening torque is 40~45N·m (4~4.5 kg·m) for
the check valve nut and manual pump and is
80~90N·m (8~9kg·m) for large screw plug. Figure R06-4002
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R 06.60 Electric speed controller

R 06.61 The basic electronic
characteristics
Supply voltage: 12V or 24V DC
Supply consumption :< 0.1A (static state)
Speed fluctuation ratio: ≤ ±0.25%
Steady states peed droop: 0~5%
Ambient temp.: -40°C ~ +85°C
Relative humidity:<95%
Figure R06-6001
The speed control unit is installed on the control box or
fixed other peripheral equipment in the engine. It
should be installed in the place of air drying and
temperature suitable. If it be installed in the place of
more water and humidity, the speed control unit
should be mounted vertically.
R 06.62 Connection of speed control unit

 The Electromagnetic Actuator connects to
Terminals 1 and 2 and battery connections to
Terminals 5 and 6. Terminals 1, 2, 5, and 6
should be #16 AWG (1.3 mm sq) or larger. Long
cables require an increased wire size to minimize
voltage drops. The battery positive (+) input,
Figure R06-6002
Terminal 6, should be fused for 15 amps as
illustrated.
 Magnetic speed sensor connects to Terminal 3
and 4 MUST BE TWISTED AND/OR SHIELDED
for their entire length. The speed sensor cable
shield should only be connected to Terminal 4.
The shield should be insulated to insure no other
part of the shield comes in connect with engine
ground, otherwise stray speed signals may be
introduced into the speed control unit to stop the
engine.
 The remote potentiometer connects to Terminal 7
and 9. If it resistance is 5KΩ speed adjusting
range is 2400HZ.
Figure R06-6003
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Repair manual-M33
 Speed droop connects to Terminal 10 and 11.

When the Terminal 10 and 11 is off, speed droop
is 0; When the Terminal 10 and 11 is closed,
speed droop range is 0-5%.
 Rated and idle speed switch connects to Terminal
7 and 12. The switch close for idle, the switch off
for rated speed.
 Terminal 13 receives input signal from load
distribution device, automatic synchronizer device
and other governor system auxiliary device.
R 06.63 Installing and Debugging

 Installing of The Electronic Governor
The C2002 speed control unit is rugged enough to be
placed in a control cabinet or engine mounted
encloseure with other dedicated control equipment. If
water, mist, or condensation may be in contact with
the controler, it should be mounted vertically. This will
allow the fluid to drain away from the speed control
unit.
An overspeed shutdown device, independent of

the governor system, should be provided to
prevent loss of engine control which may cause
personal injury or equipment damage. Do not rely
exclusively on the governor system of electric
actuator to prevent overspeed. A secondary shut
off device, such as a fuel solenoid, should be
used.
 Adjustments before Starting Engine

 Check to insure the GAIN and STABILITY
adjustments, normally this value is set mid
position by factory. Leave factory conditions of
Red State Switch is ,namely

RSW-1,RSW-3=OFF, RSW-2 = ON.
 Rated and idle speed of the speed control unit
had been set by factory. Normally, this value is
near from the user’s engine working rotate speed
value. In practice, after some adjustments,
controller can achieve rated and idle speed, and
the stability would be very well.
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Repair manual-M33
 Adjustment of the Controller after Starting

 Crank the engine with D.C. power applied to the
governor system. Start fuel quantity varies with
environmental temperature of engine start.
Though adjusting start fuel quantity potentiometer;
exhaust smoke from the engine can be adjusted
to the best state.
 The governor system should control the engine at
low idle speed. If the engine is unstable after
starting, turn the GAIN and STABILITY
adjustments counterclockwise until the engine is
stable.
 The governed speed set point is increased by
clockwise rotation of the SPEED adjustment
control. Remote speed adjustment can be
obtained with an optional Speed Trim Control.
 Once the engine is at the operating speed and at
no load, the following governor performance
adjustment scan be made.
 Rotate the GAIN adjustment clockwise until
instability develops.
Gradually move the adjustment counterclockwise
until stability returns. Move the adjustment one
division further counterclockwise to insures table
performance.
 Rotate the STABILITY adjustment clockwise until a b
instability develops. Gradually move the
adjustment counterclockwise until stability returns.
Move the adjustment one division further counter
clock wise to insures table performance.
 Gain and stability adjustments may require minor
changes after engine load is applied. Normally,
Adjustment
adjustments made at no load achieve satisfactory c d
performance. A strip chart recorder can be used Figure R06-6004
to further optimize the adjustments.

 After the governor speed setting has been
adjustted, place the optional external selector
switch in the IDLE position. The idle speed set
point is increased by clockwise rotation of the
IDLE adjustment control. When the engine is at
idle speed, the speed control unit applies droop to
the governor system to insure stable operation.
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Repair manual-M33
 Through the above adjustments engine still

unable to stability, it needs to be adjusted Red
State Switch now, figure 3.2 four cases (a:
RSW-1, RSW-3 = ON, RSW-2 =. OFF; b: RSW-1,
RSW-2 = OFF, RSW-3 =. ON; c: RSW-1, RSW-2
= ON, RSW-3 =. OFF; d: RSW-1, RSW-3 = OFF,
RSW-2 = ON). After every adjusting Red State
Switch go on the 5 and 6adjusting procedure
again. If it is still unable to stability, should inspect
engine and fuel pump for service condition. And
then, contact with manufacturer.
 Speed Droop Operation
 Droop is typically used for the paralleling of
engine driven generators.
 Place the optional external selector switch in the
DROOP position, that is connected Terminals 10
and 11. Droop is increased by clockwise rotation
of the DROOP adjustment control. When in droop
operation, the engine speed will decrease as
engine load increases. The percentage of droop
is based on current change from no load to full
load of the actuator.
 After the droop level has been adjusted, the rated
engine speed setting may need to be reset.
Check the engine speed and adjust the speed
setting accordingly.
 Accessory Input
 When the Auxiliary Terminal 13 accepts input
signals from load sharing units, auto
synchronizers and other governor system
accessories are directly connected to this
terminal. It is recommended that this connection
form accessories should be shielded as it is a
sensitive input terminal.
 When an accessory is connected to Terminal 13,
the speed will decrease and the speed
adjustment must be reset.
 Accessory Output
The +10 voltage regulated supply, Terminal 14, can be
utilized to provide power to FORTRUST governor
system accessories. Up to 20 ma of current can be
drawn from this supply. Ground reference is Terminal
7. Caution a short circuit on this terminal can damage
the speed control unit.
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R 06.70 Injection pipe

Open end wrench, duster cloth
No
R 06.72 Check the injection pipe

 Check the injection pipe has no damage with the
joint, if there is any damage, change it.
 Check the injection pipe has no clog.
 Check the pipe has no leakage.
Figure R06-7001
R 06.73 Removal/fitting the injection
pipe
 Remove the injection pipe and return pipe.
 Fit the injection pipes set(s) and tighten the nuts to
a torque of 35 N•m~45 N•m.
Figure R06-7002
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R 06.80 Injector

Open end wrench, oil, torque wrench, duster cloth
 Remove the injection pipe set, the injector leak-off
return and the rocker cover.
 Remove the injector holder using tool ref. 151892
30H.
R 06.82 In a closed workshop (free of

dust)
 Remove the nut.
 Remove the injector.
 Remove the intermediate disc.
 Remove the spring retainer.
 Remove the compression spring.
 Retrieve the adjusting shim(s).
 Descale the parts with a nylon or brass brush and
Figure R06-8001
rinse them with clean test fluid.
 Check that the needle falls back gently under its
own weight onto the seat, tilting at 45° to the
injector body.
R 06.83 Fitting Figure R06-8002
 Fit the shim(s).

 Fit the compression spring.
 Fit the spring retainer.
 Fit the intermediate disc.
 Fit the injector.
 Tighten the screw to the torque 70 N·m.
R 06.84 Adjustment
Make sure the pressurized oil flow does not come in to

contact with your skin because it can cause serious
injury.
 Fix the injector onto the test device ref. 1247044
0B.
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 Connect the high-pressure tube of the injector

(connection: M16X150).
 Turn on the vap our vacuum system.
 With the pressure gauge isolated, carry out a few
quick strokes of the pump to purge the circuits.
R 06.85 Checking the opening pressure

 Close the shut-off valve and press the lever a few
times quickly.
 Open the shut-off valve then increase the
pressure slowly by pressing the lever until the
injector opens.
 Read the pressure indicated on the pressure
gauge; if correction is necessary, correct it with an
appropriate shim.
Maintenance without changing the injector nozzle:
250 0/+8 bar
Maintenance with replacement of injector nozzle:
260 0/+8 bar
R 06.86 Checking the spray pattern of

the injector
 Close the shut-off valve on the pressure gauge
then press the lever quickly (1 to 2 pumps a
second).
 Watch the injector jet; spraying must be fine,
uniform and symmetric. Check that all the holes
are spraying.
 The injector should produce a humming sound
during operation and must spray uniformly without
lateral projection.
R 06.87 Checking the injector seat seal

 Wipe the end of the injector.
 Increase the pressure to a pressure 20 bars lower
than the injector opening pressure.
 Maintain the pressure. If the injector is not sealed,
a drop will form in under 10 seconds.
R 06.88 Checking the leak time

Figure R06-8003
 Press the lever until the injector opens, then hold
the lever in position.
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Repair manual-M33
The drop in pressure must not exceed 1/3 of the

setting of the injector within a period of 10 seconds.
R 06.89 Checking the injector seal of the

injector holder
When pressurized, the assembly must not seep to the
outside except for through the leak-off return.
R 06.810 Fitting the injector holder

 Carefully clean the injector sleeve.
 Check that the old copper seal is not still on the
contact area at the bottom of the sleeve. Clean
and check the condition of the bottom of the
sleeve.
 Fit the injector holder equipped with a new copper
Figure R06-8004
seal (imperative).
 Tighten the injector holder using tool 15189230H
to the torque 120 N·m, having taken care to orient
it towards the leak-off return.
 Fit and tighten the rocker cover screws to 20 N·m.
Note:
Systematically replace the O-ring and the flat rocker
cover gasket.
 Tighten the injection pipe nuts to the torque 25
N·m.
136
Repair manual-M33
R 07 Cooling system
6M33
137
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12M33
138
Repair manual-M33
R 07.10 Water pump

Inner hexagon wrench, torque wrench, micrometer, oil,
glue, duster cloth
 Open the battery switches.
R 07.12 Removing the cooling pump

 Remove the volute fixing screws.
 Remove the volute with flange.
 Remove the fixing screws and the elbow.
 Remove the pump.
Figure R07-1001
Weight of pump 24 kg
R 07.13 Check the cooling pump

Check the bearings of cooling pump for abnormal
noise, blockage, swing, and water leakage.
Figure R07-1002
R 07.14 Fit the cooling pump
 Replace the O-ring of water pump with new one.
 Apply a line of “Loctite 572” onto the suction
flange support.
 Fit the suction flange.
Figure R07-1003
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R 07.20 Fan

Open-end wrench
 Remove the radiator.
R 07.22 Remove the fan

 Unscrew the bolt and nut connecting the fan and
the flange to remove the fan.
 Unscrew the stud and nut connecting the flange
and the fan bracket to remove the intermediate
flange.
 Remove the fan bracket.
Figure R07-2001
R 07.23 Check
 Check the fan
 Check the fan rivets for looseness, check the fan
blades for bending.
 Ensure the normal working of fan.
 Check the V-belt

 Visually observe the poly V-belt for cracking and
scratch and when necessary replace.
Figure R07-2002
R 07.24 Fitting the fan

Tighten fix hexagon head bolts in turn. The required
tightening torque is as below.
Tightening torque
Bolt size Rating
specification
M14 10.9 190N·m
140
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R 07.30 Water outlet pipe

Inner hexagon wrench, glue, duster cloth
 Remove the connecting pipes of the water outlet
pipe.
R 07.32 Removal of the water outlet pipe

 Remove the sensor wire harness on the water
outlet pipe first and then the clips.
 Remove the water outlet pipe bolt in proper
sequence.
 Remove the water outlet pipe and the gasket.
R 07.33 Check the water outlet pipe Figure R07-3001
 Before disassembling, check the water outlet pipe

for water leakage, and check the pipe for cracks,
wear, corrosion and other damages; if there is
any crack, replace the water outlet pipe, and in
the event of corrosion affecting the reliability, find
out the causes and replace the pipe.
 In the event of water leakage at the joint, replace
the joint and tighten it, and then check if water
leakage still exists; if the connecting thread is
damaged, replace the pipe.
 Check the thermostat for working status. If the
water temperature is abnormal high, replace it
and check again.
Figure R07-3002
R 07.34 Fitting the water outlet pipe
 Install the thermostat, O-ring, gasket, cover and
flange on the water outlet pipe and tighten the
bolts.
 Wipe the water outlet pipe mating face and install
it onto cylinder head with tightening bolts.
 Tighten the fastening bolt.
Note:
The intake manifold gasket can be used once only.
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Repair manual-M33
R 07.40 Thermostat
 Checking of thermostat
Immerse the automatic thermostat in a water container.
After heating, measure the water temperature and
observe the temperatures of thermostat for consistency
with the temperatures listed in the table below.
Figure R07-4001
Initial opening Lift height at full opening

temperature (ºC)
−1 ℃
73+2 ≥9.5mm (85℃)
Figure R07-4002
142
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R 08 Lubrication system
6M33
143
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12M33
144
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R 08.10 Oil sump

Socket head wrench, open end wrench, glue
 Uncouple the engine from its peripheral parts.
 Drain the oil and water.
 Remove the oil coolers and their supports.
 Remove the oil centrifuges.
 Remove the distribution door.
 Remove the oil pump.
 Remove the engine/chassis fastenings (if you
need to lift the engine).
Use suitable lifting means

Weight of oil sump:xxkg
R 08.12 Removal of oil sump

 Loosen all fixing screws on the oil sump.
 Take the oil sump off, move it and put it on two
crossbars and remove all fastenings.
Use suitable lifting means.

Weight of engine: xxkg
 Remove the oil pump (6M33).
 Remove the inlet pipe and the strainer.
 Clean all the parts. Check the inlet pipes (for Figure R08-1001
cracks, air intakes). Check/replace the safety

valve.
 Replace all O-rings and gaskets.
 Clean the mating faces of the oil sump and engine
block.
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Repair manual-M33
R 08.13 Fitting the oil sump

 Apply a line of “Loctite JS 545” onto the mating
face. Set up 2 threaded rods opposite each other
for guiding the oil sump.
 Present the oil sump.
 Put all oil sump fixing screws in place and loosely
fit them without tightening them.
 Fit the oil sump adjusting shims in relation to the
front face of the engine block. Tighten all the oil
sump fixing screws to 62 N·m. Figure R08-1002
 Remove the adjusting shims.

 Fit the timing cover.
 Fit all peripheral parts.
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Repair manual-M33
R 08.20 Oil pump group

Inner hexagon wrench, glue, duster cloth
 The oil sump has been removed.
R 08.22 Removal of oil pump

 Remove the Oil Suction Strainer Bracket.
 Remove the oil pump and strainer from the
engine.
 Loosen the screw and take the strainer.
R 08.23 Check the oil pump

 Check whether there is any bump or not.
 Check the oil strainer for damage, especially the
screen.
 Check the oil pipe, ensure there is no foreign
body.
 Rotate the oil pump, it’s flexible and unblocked. Figure R08-2001
R 08.24 Fitting the oil pump

 Clean the joint face of the oil pump and oil inlet
pipe. Put a new O-ring onto the oil pump oil-inlet
pipe.
 Apply a little sealant to the threads of the bolts.
Assemble the oil inlet pipe onto oil pump.
 Clean the joint face of the oil pump and engine
block. Put a new O-ring onto the oil pump.
 Apply a little sealant to the threads of the bolts of Figure R08-2002
the oil pump and assemble the oil pump onto the
engine.
 Assemble the Strainer Bracket onto the engine.
Note:
After the installation of engine oil pump, check the
engine oil pump for smooth rotation. If the rotation of
the engine oil pump is tight, the oil pump will be
probably damaged during running of engine.
Figure R08-2003
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Repair manual-M33
R 08.30 Oil filter group

Socket head wrench, duster cloth, oil
No
R 08.32 Removal of oil filter group

 Loosen the fasten bolts of the oil filter bracket.
 Take the oil filter group.
R 08.33 Replacement of oil filter element

 Clean the oil filter base.
 Apply oil (instead of lubricating grease) to the Figure R08-3001
sealing gasket.
 Tighten the oil filter by hand and rotate by
approximately 3/4 turn.
 Check the oil level and pre-lubricate the engine.
Re-check the oil level and when necessary add
sufficient oil. Ensure that the oil filter is free of oil
leakage.
Note: Replace the filter element on schedule. In
addition, replace the filter element when replacing the
oil. Figure R08-3002
R 08.34 Assembly of the oil filter group

 Clean the joint face of the oil filter gasket.
 Put gaskets onto the right place without damage.
 Apply a little sealant to the thread of the bolts and
the joint face of the oil filter bracket, assemble the
oil filter group onto the engine.
Figure R08-3003
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Repair manual-M33
R 08.40 Oil cooler group (6M33)

Socket head wrench, glue, oil, duster cloth
 Drain the lubrication circuit.
R 08.42 Remove
 Remove the manual oil priming/drain pump and its
connections.
 Remove the connecting elbow.
 Remove the fixing screws on the oil cooler cover.
 Remove the oil cooler assembly, taking care to
disconnect it from the oil filter support.
 Clean the parts with a high-pressure steam jet.
Dry the parts with compressed air at a pressure of
8 bar.
Figure R08-4001
The water and any other cleaning products must be

carefully removed from the inside of the cores
otherwise the engine could be damaged through oil
pollution.
If the engine has sustained damage that was caused

by the formation and penetration of metal particles in
the lubrication circuit, the cooler cores must be
replaced. Figure R08-4002
R 08.43 Testing of the core

 Using compressed air set at a pressure of 5 bar,
test the core immersed in a bath of hot water at
80°C.
In there are any leaks, it is imperative the core be

replaced. Figure R08-4003
 Repair is not possible.
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Repair manual-M33
R 08.44 Fitting the cooler

 Change all the gaskets and O-rings + BS washer.
Put O-ring to the oil inlet and oil outlet of the oil
cooler cover.
 Apply a film of “Loctite 242” on the thread of the
bolt, fit the oil cooler on the oil cooler cover.
Tighten the M 8 fastenings to 35 N·m.
 Fit the cooler assembly on the engine block
without tightening. Put the elbow on. Tighten all
the M8 screws to 35 N·m, taking care to align the Figure R08-4004
parts to avoid any constraint.
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Repair manual-M33
R 08.50 Oil cooler group (12M33)

Socket head wrench, glue, oil, duster cloth
R 08.52 Remove
Note:
Depending on cooler accessibility, removal of the
support/cooler assembly is recommended.
 Remove the oil filters.
 Remove the pipes on the oil cooler.
 Remove the complete oil cooler assembly.
 Clean the sealing junction surface between oil
coolerand engine block.
R 08.53 Removing the core

 Disassemble the oil cooler core with a hexagon
socket wrench from the back of oil cooler
assembly, and clean the flange junction surface of
oil cooler core;
 Clean the parts with a high-pressure steam jet.
Dry the parts with compressed air at a pressure of
8 bar.
R 08.54 Testing of the core Figure R08-4001
 Make a suitable testing tool.

 Pressurize the oil side core to 5 bar.
 Immerse the core in a bath of hot water at 80°C.
 Check there are no air bubbles.
If one or more of the pipes leaks, they can be
repaired by plugging both ends of the pipe. Tap
both ends of the damaged pipe and fit 2 plugs with
“Loctite 270”.
Note:
The number of pipes that may be plugged is limited to
5. Figure R08-4002
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Repair manual-M33
 Replace the core if the number of damaged pipes

is any higher than this.
Note:
It is possible to perform a hydraulic test on the
complete oil cooler assembly.
 Make some flanges to close and send air into the
oil side circuit.
 Leave the water side circuit open.
 Immerse the assembly into a bath of water at
80°C and apply a pressure of 5 bar. Check there Figure R08-4003
are no air bubbles.
R 08.55 Fitting
 Replace the O-ring of oil cooler core;
 Install the new oil cooler core and tighten the
hexagon screws;
 Install the oil cooler and tighten the inner hexagon
screws and hexagon bolts.
Note:
Apply Loctite 242 sealant to the threads before
tightening the bolts. Figure R08-4002
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R 08.60 Safety and control valves

(6M33)

Ring spanner, threadlocker, torque wrench
R 08.62 Removing/Fitting the pressure

limiting valves
 Removal of valves
 Remove the inspection doors for cylinders.
 Through the access hatch, using a ring spanner,
remove the pressure limiting valves. If removal is
not possible by this method, the oil sump will have
to be removed to replace the valves.
 Valve testing
 Check the operation and condition of the
Figure R08-6001
component parts of the valve.
 The opening pressure of the valve is 1030±50kp,
the full opening pressure of the valve is 1487±
50kp.
Note :
It is imperative that the valve be replaced if the
condition and setting criteria are not met.
In case of complete disassembly of the valve,
position the holes on the slide to face those of the
body.
 The pressure limiting valve should be without any
leakage under the pressure of 800kp, only guttate
Figure R08-6002
leakage is allowed under the pressure between
800kp and 1000kp.
 Apply apply a film of “Loctite 242” and tighten the
valves to 70±5 N·m.
R 08.63 Removing/Fitting the pressure

regulating valve
 Remove the control valve.
component parts of the valve. Figure R08-6003
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 Valve testing
 The opening pressure and full opening pressure
are 5.5±0.25 bar and 8.5±0.25 bar respectively.
Note :
It is imperative that the valve be replaced if the
condition and setting criteria are not met.
In case of complete disassembly of the valve,
position the holes on the slide to face those of the
body. Figure R08-6004
 Fit the pressure regulating valve with seal, tighten

it to a torque of 70±5 N·m.
R 08.64 Removing/Fitting Bypass valve

 Remove all the component parts of the bypass
valve.
 Check the operation and condition of the slide
valve and of the bore of filter support body.
 Fit the valve.
 The opening pressure of the valve is 220±20kp.
Figure R08-6005
Figure R08-6006
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R 08.70 Safety and control valves

(12M33)

Ring spanner, threadlocker, torque wrench
R 08.72 Oil pump pressure limiting valve

 Remove the inspection door/front starboard
breather.
 Through the access hatch, using a ring spanner,
remove the 3 safety valves.
 Valve testing
Figure R08-5001
 Start of opening for P°= 1.03±0.05 MPa. Sealed
at lower pressure. It is imperative that the valve be
replaced if the condition and setting criteria are
not met.
 In case of complete disassembly of the valve,
position the holes on the slide valve to face those
of the body.
 After clamping the end plug, lock the assembly
with a weld point.
Figure R08-5002
 Fit the safety valves with new seals and locking
product.
 Apply apply a film of “Loctite 242” and tighten the
valves to 70 N·m.
R 08.73 Removing/Fitting the mail oil

pressure limiting valve
 Remove the oil cooler seat.
 Using a socket and extension, remove the valve.
 Apply apply a film of “Loctite 242” and tighten the Figure R08-5003
valves to 70 N·m.
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Repair manual-M33
 Valve testing
 Start of opening for P°= 0.525±0.025 MPa.
 Replace the valve if the condition and setting
criteria are not met.
Figure R08-5005
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R 09 Startup system
6M33
157
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12M33
158
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R 09.10 Starter

Open end spanner
 Remove the connecting wires.
R 09.12 Removal of the starter

To remove the steering pump, remove the bolts by a
16 mm wrench, take out the nuts and washers, and
lightly knock the housing by a rubber hammer (never
knock by a hard object) to disassemble the starter
motor.
R 09.13 Check the starter

 Check if there are any bumps on the starter.
 Rotate the gear to check for slippage.
 Pull the gear to check if it can be extended
normally.
 Check the status of junction surface between
starter motor and flywheel cover. The junction
surface shall be free of burr, oil mist, and knocking
damage.
 The wires of the starter shall be connected
correctly and securely. Figure R09-1001
R 09.14 Fitting the starter

 Place the starter motor vertical to the installation
hole, pass the starter motor through the studs and
install to the flywheel cover, and ensure the
correct engagement of starter pinion.
 Use three hexagon nuts attached with special
washers to install the starter motor loosely to the
flywheel cover and tighten the nuts.
Apply appropriate grease to the gear of the starter

before installation.
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Repair manual-M33
R 09.20 Alternator

Open end spanner
 Remove the connecting wires.
R 09.22 Secure installation

The alternator shall be installed on the engine or
vehicle correctly, securely, and reliably. The mounting
bolts must match with mounting holes of alternator
and must be tightened. The grooves of the pulley shall
be within same plane with those of drive pulley.
Note:
Recommendation: Immediately tension the belt after
20 km mileage or 20min engine running time for a new Figure R09-2001
vehicle. Periodically check the belt for proper seating

within the grooves. The mounting bracket for the
alternator must ensure the necessary strength and
stiffness requirements.
R 09.23 Appropriate tension of belt

The appropriate belt tension is generally in such
manner that the belt deflection is 10~20mm when a
150N (15kgf) force is applied onto the belt in the
middle point between two pulleys (or that the belt is
free of obvious vibration during loaded running).
Check the belt tension once every 2 months. Figure R09-2002
Warning:
The loose belt will lead to “speed loss” of the alternator
and cause the malfunctions such as insufficient power
generation, battery depletion, stator burn out, and
bearing damage. A new replacement belt must be
retensioned after 5min running.
Recommendation:
Appropriately adjust the adjustment arm to ensure the
appropriate belt tension and tighten all fastening nuts
of motor to specified torque.
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R 09.24 Correct and secure wiring

 Description of alternator wiring terminals. Never
connect the terminals incorrectly, in order to
prevent burning the vehicle harnesses and
damaging the alternator units.
B+: Positive terminal, to battery and other loads
(with battery motor).
B-: Negative output, to circuit (double wire system
motor).
E: Negative grounding terminal.
N: Neutral terminal.
W/AC/R: Phase output terminal.
IG/WL/D+/L: Charging indicator lamp terminals
(sometimes also with excitation function. The 2W
indicator lamp is recommended. The terminals D+
/WL can output ≤1A current.
 For an alternator without battery application, there Figure R09-2003
are special wiring requirements. Please refer to

the operation instruction of alternator without
battery application.
 Before the disassembling/assembling of
alternator and electric welding of vehicle, ensue to
disconnect the wires of battery and alternator.
 Special notice: Disconnect the negative wire
before positive wire for disassembling and
connect positive wire before negative wire for
installation.
R 09.25 Maintenances of alternator

 Check the wear and slip status of belt.
 Check wires for broken ends and damage.
 Check all fasteners of alternator and all wiring
post nuts of alternator. Check the terminal nuts of
all electric devices for looseness and retighten all
fasteners to prevent the vibration of alternator
from causing hitching of bracket and alternator or Figure R09-2004
prevent the loose connecting nuts from causing

flow-through of high current and damage of
regulator.
 Periodically check the wear status of alternator
carbon brush and slip ring and when necessary
remove the dusts adhered onto the slip ring by
sand paper.
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 Check the fan blades for damage and when

necessary replace with new fan.
 Maintenance-free for full-sealed heavy-duty
bearings.
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Appendix
Appendix A: Recommended Torques for Hollow Bolts
Specification Head type Recommended tightening torque (N·m)
M8×1 Hexagon head 7±1
17±2
Hexagon head
M10×1 13±2 (Copper bolt and small combination washer)
Flange bolt 20±3
Hexagon head 22±3

M12×1.5
Flange bolt 28±3
Hexagon head 27±3

M14×1.5
Flange bolt 32±3
Hexagon head 30±3

M16×1.5
Flange bolt 36±3
M18×1.5 Hexagon head and flange bolts 60±5
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Appendix B: Recommended Torques for Standard Bolts
Friction
0.125 (zinc plated) 0.14 (polished)
coefficient
Strength grade 6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
Bolt size Recommended torque (N·m)
M4 2.3 2.7 3.8 4.6 2.4 2.9 4.1 4.9
M5 4.7 5.5 8.0 9.5 5.0 6.0 8.5 10
M6 8.0 9.5 13.0 16.0 8.5 10 14.0 17
M8 19 23 32 39 21 25 35 41
M10 39 46 64 77 41 49 69 83
M12 67 80 110 135 72 86 120 145
M14 105 125 180 215 115 135 190 230
M16 165 195 275 330 180 210 295 355
M18 225 270 390 455 245 290 405 485
M20 325 385 540 650 345 410 580 690
M22 435 510 720 870 465 550 780 930
M24 560 660 930 1100 600 710 1000 1200
M27 830 980 1400 1650 890 1050 1500 1800
M30 1100 1350 1850 2250 1200 1450 2000 2400
M8×1 21 25 35 42 23 27 38 45
M10×1.25 41 49 66 82 44 52 73 88
M12×1.25 74 88 125 150 80 95 135 155
M12×1.5 70 83 115 140 76 90 125 150
M14×1.5 115 140 195 235 125 150 210 250
M16×1.5 175 210 295 350 190 225 315 380
M18×1.5 255 305 425 510 275 325 460 550
M20×1.5 360 425 600 720 385 460 640 770
M22×1.5 480 570 800 960 520 610 860 1050
M24×1.5 610 720 1000 1200 650 780 1100 1300
M27×1.5 890 1050 1500 1800 970 1150 1600 1950
M30×1.5 1250 1450 2050 2500 1350 1600 2250 2700
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Appendix C: Data for Tightening Torque
Data for Tightening Torque
Recommended
Tightening of screws and nuts Thread Assembly
tightening torque (N·m)
M14×1.5 Lub. oil

Injector pipe nut 40±3
M16×1.5 Lub. oil
Screw for return pipe of injector M8×1 Lub. oil 8±0.5
Screw for adjust plate of alternator M8 (10.9) Lub. oil 35±3
Screw for fixing bracket rod of alternator M10 (10.9) Lub. oil 50±5
Exhaust manifold bolt M10 (10.9) Loctite 242 65±5
Intake manifold bolt M10 (10.9) Loctite 242 65±5
Engine hanger plate screw M12 (10.9) Lub. oil 110±5
Screw for fixing turbocharger oil out-let pipe M10 (10.9) Loctite 242 38±3
Screw for fixing fuel injection pump bracket

M10 (10.9) Lub. oil 45±3
onto pump
Nut for fixing fuel injection pump bracket
M8 (12.9) Lub. oil 40±3
onto block (double end stud)
Fuel injection pump inter gear screw M10 (10.9) Loctite 242 75±5
Fuel injection pump gearing screw M12 (12.9) Loctite 242 128±5
Injection pump camshaft nut M24×1.5 Loctite 242 320±20
Oil cooler screw M8 (10.9) Loctite 242 35±3
Valve bridge adjusting nut M10（10.9） Loctite 242 45±3
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Appendix D: Data for Special Tightening Torque
Data for Tightening Torque
Tightening of
Thread Assembly Recommended tightening torque (N·m)
screws and nuts
Tighten the screws to a torque of 200 N·m
Connecting Rod Bolt M16×1.5 Loctite 242 Tighten the screws to an angle of 60°
Tighten the screws to an angle of 45°
Tighten the screws to a torque of（180 ±10）N•m
Main Bearing Bolt M24×2 Lub. oil Tighten the screws to an angle of 60°
Tighten the screws to an angle of 60°
Tighten the M16 screws in order 1-2-3-4 …24 to a
M16 torque of 80 N·m ; Tighten the M20 screws in order
(Main Bolt) A-B-C-D…N to a torque of 80 Nm
Cylinder head bolt
Lub. oil Tighten the M16 screws to an angle of 60°±5°;
M20 Tighten the M20 screws to an angle of 60°±5°
(Secondary) Tighten the M20 screws to an angle of 60°±5°;
Tighten the M20 screws to an angle of 60°±5°
Screw for fixing rocker
arm bracket onto M10 (10.9) Lub. oil 65±5
cylinder head
Crankshaft damper
M12 (10.9) Loctite 242 125±5
bolt
Tighten the screws to a torque of 100±10 N•m
Flywheel screw M20×2.0 Lub. oil
Tighten the screws to an angle of 45±5 °
Screw for fixing Tighten the screws to a torque of 15~20N•m
M8 (12.9) Loctite 242
camshaft Thrust Plate Tighten the screws to a torque of39N•m
Camshaft timing gear
M10 (10.9) Loctite 242 70±5
screw
Screw for fixing oil
M10 (10.9) Loctite 242 75±5
pan onto block
Screw for adjusting
M10（10.9） Lub. oil 45±3
rocker arm
Flywheel housing
M14 (10.9) Lub. oil 180±10
screw
Nut for fixing starter
M10 (10.9) Loctite 242 65±5
(double end stud)
Valve bridge screw M10 (12.9) Loctite 242 75±5
Water pump screw M8 (10.9) Loctite 242 35±3
Crankshaft pulley bolt M14 (10.9) Loctite 242 215±10
Front cover screw M10 (10.9) Loctite 242 65±5
Injector holder nut M32×1.5 Lub. oil 120±5
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Appendix E:Table of Auxiliary Materials
SN. Name Color Purpose and location

Applied on flat and smooth metal surfaces
to prevent seize
1 Molykote Pulver Black
For example, applied onto outer surfaces
of cylinder liners
Lubrication before the lubricating oil
pressure builds up.
2 Molykote G-N-U plus Dark grey
For example, applied onto the intake valve
stem
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Appendix F: Table for Sealant Application of Diesel Engine
List of locations for application

Mark Main use Supplement
of sealant
Screw plug
Control valve
Oil cooler bolt
Engine oil cooler
Flywheel cover bolt
Front end cover bolt
It’s applied onto the
Engine oil filter base
threads to prevent
Intermediate idler bolt
Loctite 242 being vibrated to
Camshaft thrust plate bolt Alternatively, the
looseness, with
Camshaft timing gear bolt thread
moderate strength.
Bolt, fuel return pipe fixing device, pre-application
fuel pump sealant DriLoc 204
Air compressor shaft end thread can be preapplied.
Strainer bolt
Bolts of sensor and harness fixing
device
Applied onto outer
threads for locking,
Loctite 262 sealing, preventing Auxiliary bolt, cylinder head
vibration from
causing looseness
Preventing
Loctite 271 Cup plug, oil drain hole N/A
looseness, fixing
For sealing between
Loctite 277 Other cup plugs N/A
element and bore
Sealing cylinder
Loctite 270 Push rod, cylinder head N/A
head top
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List of locations for

Mark Main use Supplement
application of sealant
Interface between cylinder block
and crankcase.
Plates connecting engine body
front end face to front end cover
and connecting engine body rear
end face to flywheel cover.
Interface between engine oil filter
Loctite 518 It’s applied onto
base and crankcase.
(modified shining metal
Interface between water pump N/A
from Loctite surfaces for sealing
rear cover and engine body front
510) purpose.
end face.
Interface between flywheel cover
and its connecting plate.
and engine oil cooler cover.
and engine oil filler pipe.
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Appendix G: Fit Clearances for Main Parts of Diesel Engine
S/N Items (6M33) Theoretical value (mm)

5 0.031～0.081
piston pin
piston ring
BinHai Piston: 0.015~0.03
Jiangbin Piston:0.015~0.029
compacted state)
17
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S/N Items (12M33) Theoretical value (mm)

5 0.031～0.081
piston pin
piston ring
0.015~0.03 (BoHai Piston)
0.015~0.029 (Jiangbin Piston)
compacted state)
17
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Appendix H: Table of planned maintenance programme
 COP Rating
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173
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 PRP Rating
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Appendix I: Conversion Table
Basic Sl Units
Quantity Name Symbol
Length metre m
Mass kilogram kg
Time second s
electric current ampere A
absolute temperature* kelvin K
amount of substance mole mol
luminous intensity candela cd
Supplementary SI Units
Quantity Name Symbol
plane angle radian rad
solid angle steradian sr
Additional SI Units
Quantity Name Symbol Definition
Time minute min 1 min = 60 s
Time hour h 1 h = 60 min
plane angle degree ° 1°= (p/180) rad
Volume litre l 1 l = 1 dm³
Pressure bar bar 1 bar = 105 Pa
Length (m)
1 in (inch) 25.40 mm = 0.0254 m
1 ft (foot) = 12 inches 0.3048 m
1 yd (yard) = 3 ft = 36 inches 0.9144 m
1 statute mile = 1760 yds 1609 m
1 n mile (international nautical mile) 1852 m
Force (1 kg m/ s²= 1 N)
1 kp (kilopound)* 9.807 N
1 poundal** 138.3 /10³N
1 lbf (pound force) 4.448 N
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Energy, Work (1 N·m = 1 J, Wh)

1 cal I.T* 4.187 J*
1 kpm 9.807 J
1 hph (metric) 2.648 x 106 J = 0.7355 kWh
1 ft. lbf 1.356 J
1 hph (UK, US) 2.685 x 106J = 0.7457 kWh
1 BTU (UK, US) 1.055 x 103J = 1.055 KJ
Power (1 kg m²/ s³= 1 N m/s = 1 J/s = 1 W)

1 kpm/s 9.807 W
1 hp (metric) = 75 kpm/s 735.5 W = 0.7355 kW
1 kcalI.T./h 1.163 W
1 ft lbf/s 1.356 W
1 hp (UK, US) = 550 ft.lbf/s 745.7 W
1 BTU/h 0.2931 W
Specific fuel consumption* (g/kWh)

1 g/hph (metric) 1.360 g/kWh
Temperature difference (K)

1 °C (Celsius) 1K
1 °F (Fahrenheit) 5/9 K
Temperature levels (K) (see "Derived SI Units with special Names)

t °C (Celsius) tc + 273.15 = K
t°F (Fahrenheit) 5/9(tf - 32) + 273.15 = K
Celsius from Fahrenheit: tc = 5/9(tf - 32)
Fahrenheit from Celcius: tf = 9/5 x tc + 32
Volume (1 m³= 1000 l)

1 cub. in (cubic inch) 16.39 x 10-6 m³
1 cub. ft (cubic foot) 28.32 x 10-3 m³= 28.32 l
1 gallon* (imperial, UK) 4.546 x 10-3 m³= 4.546 l
1 gallon* (US) 3.785 x 10-3 m³= 3.785 l
1 barrel (US petroleum barrel) = 42 gallon (US) 0.1590 m³
1 bbl (dry barrel, US) 0.1156 m³
1 register ton = 100 cub. ft 2.832 m³
* 1 gallon = 4 quarts = 8 pints
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Mass (kg)
1 lb (pound mass) = 16 ozs (ounces) 0.4536 kg
1 cwt (UK) (hundredweight) = 112 lbs 50.80 kg
1 long ton (UK) = 20 cwt = 2240 lbs 1.016 metric tons = 1016 kg
1 short ton (UK) = 2000 lbs 0.907 metric tons = 907 kg
1 slug* 14.59 kg
* Unit and mass in the ft-lb-s system
Pressure
2 -3
(1 N/m = 1 Pa, 1 bar = 105 Pa, 1 mbar = 10 bar)
2
1 kp/cm = 1 at = 0.9678 atm 98.07 x 103 Pa = 0.9807 bar
1 at = 735.5 mm Hg* = 10 m H2O** (T = 277 K)
750 mm Hg* 105 Pa = 1 bar
1 mm Hg* (T = 273 K) 133.3 Pa = 1.333 mbar
1 mm H2O** (T = 277 K) 10-4 at = 9.807 Pa = 98.07 /10³mbar
1 in Hg* (T = 273 K) 3386 Pa = 33.86 mbar
1 in H2O** (T = 277 K) 249.1 Pa = 2.491 mbar
1 atm (standard atmosphere) 760 mm Hg 1.013 x 105 Pa = 1013 mbar
1 atm = 1.033 at
1 lbf/sq.in (psi) 6895 Pa = 68.95 mbar
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Index
A
Air filter………………………………………………………………………………….……………102
Alternator…………………………………………………………………………………………….160
Appendix……………………………………………..………………………………………………163
B
Breather set.…………………….…………………………………………………………………….66
C
Clearances and wear limits…………………………………………………………………..……...26
Cylinder head group ……………………………………………………………………....…………46
Cylinder head…………………………………………………………………………………..……..49
Crankshaft piston and connecting rod …………………………….……………………...………..72
Crankshaft (6M33) …...……………………………………………………………...……………....75
Crankshaft (12M33)………………………………………………………………...……….............80
Camshaft……………………………………………………………………………………………....90
Cooling system …………………………………………………….……………...………………..137
D
Drive shaft of injection pump (12M33)…………….………………………………………..……. 121
E
Engine ID plate………………………………………………………………………………………..19
Engine block group.…………………………………………………………....…………...………..61
Exhaust manifold……………………………………………………………………………..……..116
Electric speed controller………………………………………………………………………...….129
F
Flywheel housing………………………………………………………………………………….….68
Front cover group……………………………………………………………………………………..71
Fuel oil system………………………………………...………………………………………….....118
Fuel delivery pump……………………………………………………………………………….....128
Fan…………………………………………………………………………………………………....140
G
General safety instructions……………………………………………………………………………6
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I
Instruction ………………………………...………………………………………...……………….…6
Intake and exhaust system ……………………………………………………………...….……..100
Intake manifold ……………………………………………………………………………………...115
Injection pump (12M33)…... ………………………………………………………...………….....123
Injection pump (6M33) …………….…………………...………………………………………..…126
Injection pipe…………………………………………………………………………………..…….133
Injector………………………………………………………………………………………….…….134
L
Liner……………………………………………………………………………………………………63
Lubrication system………………………………….………………………………...…………….143
M
Marks and symbols…………………………………………………………………….…………….18
O
Ordering of Spare Parts……………………………………………………………………………...45
Oil filling pipe group………………………………………………………………………….……….67
Oil sump……………………………………………………………………………………………...145
Oil pump group………………………………………………………………………………………147
Oil filter group…………………………………………………………………………………….….148
Oil cooler group (6M33)………………….……………………………………………………..…..149
Oil cooler group (12M33)……………………….…………………………………………………..151
P
Piston cooling jet…………………………………………………………………………………...…65
Piston and connecting rod.………………………………………………...…………………..…....84
R
Rocker arm cover ………………………………………………………...…………………...……..48
Rocker system ……………………………………………………………………………………..…59
S
Specific tools ………………………………………………………………………………………….28
Safety and control valves (6M33)……………………………………...……………….…………153
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Safety and control valves (12M33)…………….………………………………………………….155
Startup system……………………………………………………..…...……………...…………...157
Starter……………………………………………………………………………………………..….159
T
Technical data…………………………………………………………...……………………………20
Troubleshooting…………………………………………………………………………….………...32
Timing gear (6M33)…………………………………………………………………………..…..…..92
Timing gear (12M33)…………………………………………………………………………………95
Tappet and push rod………………………………………………………...……………….…...….97
Turbocharger…………………………………………………………………………...……………103
Thermostat …………………………………………………………………………...…………..…142
V
Valve mechanism………………………………………………………………………….………....88
W
Water separator and fuel filter ………………………………………………………...………..…120
Water pump ………………………………………………………………………………………....139
Water outlet pipe …………………………………………………………...………………..……..141
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Contact Us
Address: Moteurs Baudouin, Technoparc du Bregadan, 13260 Cassis, France

Website: Baudouin.com
Aftersales Service Center: sav@baudouin.com
©2018 Société International des Moteurs Baudouin

All Rights Reserved
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M33维修手册 Repair Manual

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GDMB33V1801

Repair Manual for

R 00.10 General safety instructions .................................................................................. 7

R 00.20 Marks and symbols ............................................................................................ 19

R 00.30 Engine ID plate .................................................................................................. 20

R 00.40 Technical data .................................................................................................... 21

R 00.50 Clearances and wear limits ................................................................................ 27

R 00.60 Specific tools ...................................................................................................... 29

R 00.70 Troubleshooting ................................................................................................. 33

R 00.80 Ordering of Spare Parts ..................................................................................... 45

R 01 Cylinder head group……………………………………………………………………………47

R 01.10 Rocker arm cover ............................................................................................... 49

R 01.20 Cylinder head ..................................................................................................... 50

R 01.30 Rocker system ................................................................................................... 60

R 02 Engine block group……………………………………………………………………………..62

R 02.10 Liner ................................................................................................................... 64

R 02.20 Piston cooling jet ................................................................................................ 66

R 02.30 Breather set........................................................................................................ 67

R 02.40 Oil filling pipe group ........................................................................................... 68

R 02.50 Flywheel housing ............................................................................................... 69

R 02.60 Front cover group ............................................................................................... 72

R 03 Crankshaft piston and connecting rod………………………………………………………..73

R 03.10 Crankshaft (6M33) ............................................................................................. 76

R 03.20 Crankshaft (12M33) ........................................................................................... 81

R 03. 30 Piston and connecting rod ................................................................................ 85

R 04.10 Camshaft ............................................................................................................ 91

R 04.20 Timing gear (6M33) ............................................................................................ 93

R 04.30 Timing gear (12M33) .......................................................................................... 96

R 04.40 Tappet and push rod .......................................................................................... 98

R 05 Intake and exhaust system…………………………………………………………………..101

R 05.10 Air filter ............................................................................................................. 103

R 05.20 Turbocharger.................................................................................................... 104

R 05.30 Intake manifold ................................................................................................. 116

R 05.40 Exhaust manifold ............................................................................................. 117

R 06 Fuel oil system………………………………………………………………………………...119

R 06.10 Water separator and fuel filter.......................................................................... 121

R 06.20 Drive shaft of injection pump............................................................................ 122

R 06.30 Injection pump .................................................................................................. 124

R 06.40 Injection pump (6M33) ..................................................................................... 126

R 06.50 Fuel delivery pump ........................................................................................... 128

R 06.60 Electric speed controller ................................................................................... 129

R 06.70 Injection pipe .................................................................................................... 133

R 06.80 Injector ............................................................................................................. 134

R 07.10 Water pump...................................................................................................... 139

R 07.20 Fan ................................................................................................................... 140

R 07.30 Water outlet pipe .............................................................................................. 141

R 07.40 Thermostat ....................................................................................................... 142

R 08.10 Oil sump ........................................................................................................... 145

R 08.20 Oil pump group ................................................................................................ 147

R 08.30 Oil filter group ................................................................................................... 148

R 08.40 Oil cooler group (6M33) ................................................................................... 149

R 08.50 Oil cooler group (12M33) ................................................................................. 151

R 08.60 Safety and control valves ................................................................................. 153

R 08.70 Safety and control valves ................................................................................. 155

R 09.10 Starter .............................................................................................................. 159

R 09.20 Alternator.......................................................................................................... 160

Appendix A: Recommended Torques for Hollow Bolts ................................................. 163

Appendix B: Recommended Torques for Standard Bolts.............................................. 164

Appendix C: Data for Tightening Torque ....................................................................... 165

Appendix D: Data for Special Tightening Torque .......................................................... 166

Appendix E:Table of Auxiliary Materials ........................................................................ 167

Appendix F: Table for Sealant Application of Diesel Engine ......................................... 168

Appendix H: Table of planned maintenance programme .............................................. 172

Appendix I: Conversion Table ....................................................................................... 177