Maintenance Manual of WP10 Four-Valve Mechanical Pump Industrial Diesel Engine

Maintenance manual of 6M16 four-valve mechanical pump industrial diesel engine
Maintenance Manual of WP10 Four-valve

Mechanical Pump Industrial Diesel Engine
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Foreword
This diesel engine is featured by a compact structure, reliable use, good technical indicators
like power performance and economical efficiency, rapid start, simple operation, and easy
maintenance.
The contents of this service manual are the safety precautions, maintenance methods, and
instructions about inspection, adjustment and troubleshooting of WP10 four-valve mechanical pump
industrial diesel engine. We have expended every effort to make the contents of this service manual
systematic, simple and practical. Judging the malfunction cause of diesel engine is a really precise
work. Before the cause is basically identified, do not remove the diesel engine casually, or it will
not only eliminate the malfunction, but also lead to more serious malfunction due to improper
assembly after removal. The servicing of critical components particularly the turbocharger shall be
performed by experienced personnel using dedicated instruments. Persons who are inexperienced or
have no such instruments may not remove or adjust them.
Following the continuous increasing and improvement of this series of diesel engine variants,
all changes will be made without further notice. Please access http: //www.weichai.com to obtain
the latest product information. Recommendations and opinions on further product improvement
from you are welcome.
October, 2016
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Special Notice
 Before the operations, the operator of the diesel engine must carefully read this service manual
and strictly abide by the operation and maintenance practices specified in this manual.
 The diesel engine has tested strictly in accordance with the testing specification of our company
at the time of delivery. It’s prohibited to adjust the oil pump or increase the power of the diesel
engine without permission. Otherwise, all our three-guarantee warranty commitments will be
voided. Please pay attention to that.
 The turbocharger rotor is a high-speed rotating part. When the machine runs, no moveable
items (like hand, tool, and cotton yarn) are allowed to approach the inlet of turbocharger, so as to
avoid causing damages to personnel or machine; the rotor assembly shall not be removed except for
that it is done by professional maintenance personnel or professional maintenance stations licensed
by Weichai;
 The various bolts like main bearing bolt and connecting rod bolt of diesel engine all have strict
torque requirements and use number limits, so the user shall not loosen and remove the bolts; please
refer to the bolt tightening torques and tightening methods given in chapter IV and Appendix, and
the bolts shall not be used repeatedly beyond the limited use number.
 The oil and fuel added to the diesel engine must be of the designations specified in this service
manual. Dedicated clean filters must be used for the addition. Before addition, the fuel shall settle
for 72 hours. Before starting the engine, check that the coolant and oil levels meet the requirements.
 It’s prohibited to run the diesel engine without the air filter, in order to prevent the supply of
unfiltered air into the cylinders.
 When the user uses a new machine, 50-hour trial running is needed to the machine. After the
run-in period, it is required to replace the engine oil and engine oil filter element.
 After the cold start of the diesel engine, slowly increase the engine speed, instead of running at
high speed suddenly or run it at idle speed for a ling time (not more than 3min). After the running
under heavy load, run the engine at low speed for 5~10min before stopping the engine, instead of
stop the engine suddenly (except special cases);
 After the engine is stopped, if the temperature of working environment is probably below 0°C
and the coolant without antifreeze additive is used, fully drain the coolant from the water tank and
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diesel engine.
 The diesel engine is oil sealed at the time of delivery to prevent rusting. The oil sealing period
for diesel engine is generally one year. At the expiration of one year, check and take necessary
supplemental measures.
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Table of Contents
Chapter I General Information................................................................................................................................... 9
1.1 Exterior View of Diesel Engine ................................................................................................................ 9
1.2 Model Meaning of Diesel Engine ........................................................................................................... 10
1.3 Main Technical Specification of Diesel Engine...................................................................................... 10
1.4 Use Instructions of a New Diesel Engine ............................................................................................... 12
1.5 Hoisting of Diesel Engine....................................................................................................................... 13
1.6 Unsealing of Diesel Engine .................................................................................................................... 13
1.7 Pre-start Preparations.............................................................................................................................. 14
1.8 Start of Diesel Engine ............................................................................................................................. 14
1.9 Running of Diesel Engine....................................................................................................................... 15
Chapter II Maintenance Guide................................................................................................................................. 17
2.1 Fuel Oil, Lubricating Oil, Coolant, Urea Solution, and Auxiliary Materials .......................................... 17
2.1.1 Fuel .......................................................................................................................................... 17
2.1.2 Diesel Engine Lubricating Oil ................................................................................................. 17
2.1.3 Engine Coolant ........................................................................................................................ 19
2.1.4 Auxiliary Materials .................................................................................................................. 19
2.2 Routine Maintenance .............................................................................................................................. 21
2.2.1 Details of Routine Maintenance............................................................................................... 21
2.2.2 Details of Routine Service ....................................................................................................... 21
2.2.3 Contents of Maintenance at Each Level .................................................................................. 24
2.3 Maintenance for Long-term Storage ....................................................................................................... 28
2.3.1 Clean the Diesel Engine........................................................................................................... 28
2.3.2 Protection for Long-term Storage ............................................................................................ 29
2.3.3 Oil Seal .................................................................................................................................... 29
Chapter III Faults and Solutions .............................................................................................................................. 30
3.1 Diagnostic and Adjustment Method ....................................................................................................... 30
3.2 Common Fault and Troubleshooting ...................................................................................................... 30
3.2.1 Diesel Engine cannot be started ............................................................................................... 30
3.2.2 Stop of Engine Shortly after Start ............................................................................................ 31
3.2.3 Low Power ............................................................................................................................... 31
3.2.4 Excessive Fuel Consumption ................................................................................................... 32
3.2.5 Black Exhaust Gas ................................................................................................................... 33
3.2.6 White or Blue Exhaust Gas ...................................................................................................... 33
3.2.7 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger............................. 34
3.2.8 Unstable Speed ........................................................................................................................ 34
3.2.9 Engine Oil Pressure Too Low .................................................................................................. 34
3.2.10 High Coolant Temperature ....................................................................................................... 35
3.2.11 Excessive Wear of Parts ........................................................................................................... 35
3.2.12 Excessive Noise ....................................................................................................................... 36
3.2.13 Working Failure of Starter Motor ............................................................................................ 36
3.2.14 Weak Starter Motor .................................................................................................................. 37
3.2.15 Working Failure of Alternator .................................................................................................. 37
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3.2.16 Inadequate Charging Current of Alternator.............................................................................. 37

3.2.17 Instable Charging Current ........................................................................................................ 38
3.2.18 Excessive Charging Current of Alternator ............................................................................... 38
3.2.19 Abnormal Sound of Generator ................................................................................................. 38
Chapter IV Disassembly and Assembly of Engine ......................................................................................... 39
4.1 Overview ................................................................................................................................................ 39
4.1.1 Danger Sign ............................................................................................................................. 39
4.1.2 Safety Sign ............................................................................................................................... 40
4.1.3 Used Tools ............................................................................................................................... 41
4.1.4 Precautions for Health Protection ............................................................................................ 41
4.1.5 Environmental Protection Measures ........................................................................................ 42
4.1.6 Precautions on Removal and Installation of Engine ................................................................ 42
4.2 Engine Block Group ............................................................................................................................... 43
4.2.1 Disassembly and Assembly of Engine Block Group ............................................................... 43
4.2.2 Disassembly and Assembly of Cylinder Block Preassembly ................................................... 45
4.2.3 Disassembly and Assembly of Piston Cooling Nozzle ............................................................ 46
4.2.4 Disassembly and Assembly of Thrust Halfring ....................................................................... 47
4.2.5 Disassembly and Assembly of Gear Chamber Combination Group ........................................ 48
4.2.6 Disassembly and Assembly of Front End Housing Combination Group ................................. 50
4.2.7 Disassembly and Assembly of Flywheel Cover Combination Group ...................................... 51
4.2.8 Removal and Installation of Oil Seal ....................................................................................... 52
4.2.9 Removal and Installation of Cylinder Header Combination Group......................................... 53
4.2.10 Disassembly and Assembly of Cylinder Head Cover Combination Group ............................. 60
4.2.11 Disassembly and Assembly of Oil-gas Separator Combination Group ................................... 62
4.3 Disassembly and Assembly of Crank Connecting Rod Mechanism ....................................................... 64
4.3.1 Disassembly and Assembly of Crankshaft System .................................................................. 64
4.3.2 Disassembly and Assembly of Piston Connecting Rod Combination Group .......................... 66
4.3.3 Disassembly and Assembly of Crankshaft Bearing Shell ........................................................ 70
4.3.4 Disassembly and Assembly of Flywheel Combination Group ................................................ 71
4.3.5 Removal and Installation of Flywheel Ring Gear .................................................................... 73
4.3.6 Disassembly and Assembly of Vibration Damper and Crankshaft Pulley ............................... 73
4.4 Disassembly and Assembly of Valve Mechanism Combination Group.................................................. 74
4.4.1 Disassembly and Assembly of Valve Mechanism Combination Group ................................... 74
4.4.2 Disassembly and Assembly of Camshaft ................................................................................. 75
4.4.3 Disassembly and Assembly of Rocker Arm............................................................................. 77
4.4.4 Disassembly and Assembly of Tappet and Pushrod ................................................................. 79
4.4.5 Disassembly and Assembly of Valve ....................................................................................... 81
4.5 Intake and Exhaust System ..................................................................................................................... 83
4.5.1 Disassembly and Assembly of Intake and Exhaust System ..................................................... 83
4.5.2 Disassembly and Assembly of Turbocharger Combination Group .......................................... 84
4.5.3 Disassembly and Assembly of Intake Pipe Combination Group ............................................. 87
4.5.4 Disassembly and Assembly of Exhaust Pipe Combination Group .......................................... 88
4.6 Fuel System ............................................................................................................................................ 90
4.6.1 Fuel Oil System Diagram ........................................................................................................ 90
4.6.2 Disassembly and Assembly of Fuel System ............................................................................ 90
4.6.3 Disassembly and Assembly of Fuel Injection Pump Combination Group ............................... 91
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4.6.4 Disassembly and Assembly of High-pressure Oil Pipe Combination Group........................... 93

4.6.5 Disassembly and Assembly of Fuel Injector Combination Group ........................................... 94
4.7 Cooling System ...................................................................................................................................... 95
4.7.1 Cooling System Diagram ......................................................................................................... 95
4.7.2 Disassembly and Assembly of Cooling System ....................................................................... 95
4.7.3 Disassembly and Assembly of Fan and Hub Combination Group ........................................... 96
4.7.4 Disassembly and assembly of water pump inlet pipe combination group ............................... 97
4.7.5 Disassembly and assembly of water pump combination group ............................................... 99
4.7.6 Disassembly and Assembly of Thermostat Combination Group ........................................... 100
4.7.7 Disassembly and Assembly of Water Outlet Pipe Combination Group ................................. 101
4.8 Lubrication System ............................................................................................................................... 102
4.8.1 Lubrication System Diagram ................................................................................................. 102
4.8.2 Disassembly and Assembly of Lubrication System ............................................................... 103
4.8.3 Disassembly and Assembly of Oil Pan Combination Group ................................................. 104
4.8.4 Disassembly and Assembly of Engine Oil Pump Combination Group .................................. 105
4.8.5 Disassembly and Assembly of Engine Oil Pump Intermediate Gear ..................................... 106
4.8.6 Disassembly and Assembly of Suction Filter Combination Group........................................ 107
4.8.7 Disassembly and Assembly of Main Oil Passage Pressure Control Valve............................. 108
4.8.8 Disassembly and Assembly of Engine Oil Filter Combination Group .................................. 109
4.8.9 Disassembly and Assembly of Engine Oil Cooler Cover Combination Group ..................... 110
4.8.10 Disassembly and Assembly of Engine Oil Cooler Cover Combination Group ..................... 111
4.8.11 Disassembly and Assembly of Engine Oil Cooler Bypass Valve........................................... 112
4.9 Starting System ..................................................................................................................................... 113
4.9.1 Disassembly and Assembly of Starting System ..................................................................... 113
4.10 Vehicles Accessories System ................................................................................................................ 114
4.10.1 Disassembly and Assembly of Vehicles Accessories System ................................................ 114
4.10.2 Disassembly and Assembly of Generator Combination Group ............................................. 114
Appendix A General Bolt Fastening Torque of Diesel Engine .............................................................................. 120
Appendix B Fit Clearances for Main Parts of Diesel Engine ................................................................................ 124
Appendix C Wear Evaluation References for Main Friction Pairs in Diesel Engine............................................. 125
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Chapter I General Information
1.1 Exterior View of Diesel Engine
Figure1-1 Diesel Engine View 1
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1.2 Model Meaning of Diesel Engine
In which, use code: D indicates that the engine is a stationary engine used for power
generation; power code: the stationary engine for power generation adopts standby power kilowatt.
1.3 Main Technical Specification of Diesel Engine
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Table1-1 Main Technical Parameter Table
Item Technical parameter
Type Four-stroke, water-cooling, in-line, and direct-injection

Intake type Turbochargerd and intercooled
Bore/Stroke (mm) 126×130
Number of cylinders 6
Displacement (L) 9.726
Compression ratio 17:1
Firing order 1-5-3-6-2-4
Fuel system Mechanical pump
Intake valve clearance (cold state) (mm) 0.4
Exhaust valve clearance (cold state) (mm) 0.6

Opening of intake valve: (22±5)° before top dead center.
Closing of intake valve: (25±5)° after bottom dead center.
Valve timing
Opening of intake valve: (60±5)° before bottom dead center.
Closing of exhaust valve: (22±5)° after top dead center.
Startup method Electric startup
Lubrication method Pressurized lubrication
Cooling method Water-cooling
Rated point 350~580
Engine oil pressure (KPa)
Idling point 130~280
Allowed vertical inclination (°) Front/Rear 10/10
Exhaust pipe
Allowed transversal inclination
side/intake 45/15
(°)
pipe side
Diesel inlet temperature (°C) 38±3
Exhaust temperature (°C) ≤550

Air intake temperature after intercooling (°C) 50±5
Lubricating oil pan capacity (L) 30
Crankshaft rotating direction (seeing from fan

Clockwise
end)
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Table1-2 Main Performance Parameters of WP 10 Stationary Industrial Power Diesel Engine for Four-valve
Mechanical Pumps
Item Unit Model
Engine Model — 6M16
Displacement L 9.726
Valve number of per cylinder — 4
Emission level — Non-road stage II
Rated power kW 320~360 (reserve power)
Rated speed r/min 1500～1800
Average effective pressure kPa 2345~2385
Mean piston speed m/s 6.5~7.8
Idling speed r/min 650
Piston air leakage L/min ≤140
Smoke intensity under rated conditions FSN ≤2.0
Exhaust smoke at the maximum torque point FSN ≤2.5
Without auxiliary starter -5 (Limit is -10)

Minimum temperature of cold starting (°C)
With auxiliary starter -25 (Limit is -30)
Engine Weight kg 875
Engine Dimensions
mm 1493×822×1206
(L×W×H)
Exhaust temperature C ≤550
Exhaust backpressure kPa ≤11
Air intake temperature after intercooling C 50～55
Intake pressure kPa ≤7.5
1.4 Use Instructions of a New Diesel Engine

 In the run-in period of a new diesel engine, it is required to limit the load of diesel engine,
and its load shall not exceed 75% of the calibrated load.
 The first oil draining period is 50 hours.
 Conduct daily maintenance and service according to the provisions given in the use
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instructions.
1.5 Hoisting of Diesel Engine

During the hoisting, maintain level the centerline of engine crankshaft. It’s prohibited to hoist
in tilted or unidirectional manner. Hoist up and down slowly (See Figure 1-4).
True False
Figure1-4 Diesel Engine Hoisting
1.6 Unsealing of Diesel Engine

After the diesel engine is unpacked, the user shall firstly count the diesel engine and its
accessories, check the exterior of diesel engine for presence of damage and the connectors for
presence of looseness, and then fulfill the following works:
 Wipe the anti-rusting layer and anti corrosive agent on the exposed parts;
 Drain the sealing oil from the inside of fuel filter and the parts of fuel system (It’s allowed
to start the engine without draining the sealing oil from the fuel system. However, it’s permitted to
run the engine under loaded condition only when the sealing oil in the fuel system is used up and
the diesel is supplied to the engine). Note: The oil sealing period for diesel engine is one year. At
the expiration of one year, conduct checking and take necessary supplemental measures.
 Rotate the flywheel and spray solvent into the intake pipe, till the sealing oil in the cylinder
is completely removed.
 Spray solvent to the intake and exhaust orifices of the turbocharger, till the sealing oil is
completely removed.
 According to the agreement concluded between the manufacturer and the user, the oil pan
shall be filled with specified engine oil by the user if it is empty when the engine is delivered out of
factory. If the oil pan is filled with engine oil containing running-in accelerant when the engine is
delivered out of factory, the user should change engine oil after the vehicle has travelled 2,000km
(or run 50h, whichever comes earlier).
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 In accordance with the agreement concluded between Weichai Power and the user, if
required by the user, the diesel engine shall be filled with the specified coolant. Be sure to check the
coolant performance after unpacking the diesel engine. The coolant that has an anti-freezing
capacity of -30ºC or -35ºC, PH value of 7-8 (neutral) and total hardness of 5-15ºd [9-15ºf (hardness)]
can be used. If the coolant fails to meet these requirements, drain it out of the diesel engine and add
the coolant that contains anti-freeze.
1.7 Pre-start Preparations

 Check the coolant level
Check the coolant level through the glass hole on the expansion tank. When the liquid filling
hole cover with pressure relief valve and exhaust button is opened, if the engine is in hot state, it is
required to open the cover through exhaust button. If the diesel engine remains hot, do not add a
great deal of coolant to cause damage to the parts. If there is no coolant under special cases, it’s
allowed to slowly add cold water in moderate temperature. Add the coolant through the filler port,
till the coolant overflows. Start the engine. While the engine is running (1,000 r/min), continue to
add the coolant, till the coolant level is stable, and finally install the filler port cap.
 Check the fuel level
With the engine installed on the unit, turn on the power supply switch, and check fuel level
from the fuel gauge or check the fuel tank.
 Check the engine oil level
The engine oil level shall be between upper and lower markings of the oil dipstick. If necessary,
add engine oil through the engine oil filler port.
 Check all accessories of diesel engine for reliable connections and solve any abnormal
phenomenon. Check the starter system for normal wiring and check and ensure that the battery is
sufficiently charged. Bleed air from the fuel system.
1.8 Start of Diesel Engine

 If starting conditions are met, turn the key switch to start the engine. If the engine fails to
start within 5 to 10 seconds, wait for 1 minute then repeat the starting process. If the engine can’t be
started by three consecutive attempts, stop the attempt and find out and solve the malfunction before
retry. After the start of engine, observe the readings of all instruments. The engine oil pressure
gauge shall indicate the pressure immediately. Do not have the cold engine running at high speeds.
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Have it running at idle speeds at first for a not very long time.
 The auxiliary starter shall be used to start the diesel engine under cold temperature. By
running the electric heating flange via relay, the engine can start successfully under -30ºC
environment.
1.9 Running of Diesel Engine

 After the diesel engine is started, it shall firstly run for (2-3) minutes at idling speed; the
engine oil pressure shall be higher than 100kPa; when the cooling water temperature is not higher
than 60°C, it is forbidden to run the engine suddenly at a high speed, for this will affect the abrasion
resistance and reliability of engine. Apply load and increase the speed gradually. Avoid the sudden
loading and unloading whenever possible.
 In the run-in period, the diesel engine is better to run under a moderate load.
 Normally the diesel engine can continuously run with rated output and rated speed. After
the unloading, idle the diesel engine for (1~2)min before stop.
 Parameters and checking locations to be observed at all times during operations are as
below:
The main line pressure of lubricating oil: 350 kPa ~580 kPa; engine oil pressure at idling point:
no smaller than 130kPa
Engine oil temperature at the main oil line: 85°C~105°C
Outlet temperature of coolant: 77°C ~93°C
Exhaust temperature after turbine: ≤550°C
Air intake temperature after intercooling: 50°C ~55°C under declared working conditions
Check the exhaust fume color, to estimate the performances of the injectors and the load of the
engine. If the color of exhaust gas is serious black or white, stop and check the engine.
Notice to check the diesel engine for presence of water, air, and fuel leakages. If any, stop the
engine for troubleshooting.
 Precautions for running under cold environments;
A Fuel: Choose diesel of different trademarks depending on the environmental temperature in
winter.
B Lubricating oil: Choose lubricating oil of different viscosities depending on the seasons.
C Coolant: Add antifreeze additive into the cooling system and choose the coolant of
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different trademarks and ratio depending on the ambient temperature.

D Start: The auxiliary starter can be adopted if necessary in winter. After the start of the diesel
engine, wait for the oil pressure and water temperature to turn normal before running at high speed
under loaded condition.
E Charged battery: Before the approach of the cold season, make sure to check the level and
viscosity of electrolyte and unit voltage of the battery. If the diesel engine is not to be used for a
long time and is under extremely low temperature, disassemble the battery and store in a warm
indoor place.
F Stop: To stop the engine under cold weathers, unload the engine, idle the engine for
1min~2min, and wait for all the temperature to cool down before stop. Please be noted that it’s
disallowed to drain the coolant containing antifreeze additive after the stop of the engine. If the
coolant contains no antifreeze additive, make sure to open the water drainage valves or water plugs
on the engine block, oil cooler cover, radiator, and water inlet pipe to fully drain the coolant, in
order to prevent the frozen cracking of the engine.
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Chapter II Maintenance Guide
2.1 Fuel Oil, Lubricating Oil, Coolant, Urea Solution, and Auxiliary Materials
2.1.1 Fuel
Summer: 0# diesel fuel (GB252)
Winter: generally -10# light diesel fuel shall be used (GB252); however, -20# diesel fuel shall
be used if ambient temperature is lower than -15ºC. -35# diesel fuel shall be used if ambient
temperature is lower than -30ºC.
The fuel used must conform to the requirements in section D.1 of Appendix D to national
standard GB20891-2007.
2.1.2 Diesel Engine Lubricating Oil
For WP10 non-road Stage-II industrial diesel engine, CF-4 grade engine oil shall be used. For
details, refer to Table 2-1.
Table2-1 Selection Specification of Weichai Special Engine Oil
Variety Product category Packing specification

10W/30
Diesel engine oil CF-4 15W-40 4L, 18L, 170kg
20W-50
Choose the viscosity of Weichai special engine oil based on the temperature, with reference to
Table 2-2.
Table2-2 Relationship Table between Viscosity and Environmental Temperature
SAE viscosity grade Applicable environmental temperature (ºC)
0W-20 -35-20
5W-30 -30-30
10W-30 -25-30
15W-40 -20-40
20W-50 -15-45
Note:
1) Before starting the diesel engine, ensure to check the engine oil level within oil pan.
2) Do not check the oil level while the diesel engine is running.
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3) Never mix special engine oil of Weichai Power with engine oils of other manufacturers.
For the added volumes of engine oil and numbers of filters of WP10 Series. See Table 2-3.
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Table2-3 Added Volumes of Engine Oil and Numbers of Filters of WP10 Series
Number of filters
Diesel engine
Model Added volume of engine oil (L)
Diesel filter
Engine oil filter
Coarse filter Fine filter
WP10 30 2 1 1
1) Remark:
2) The added volumes listed in the table are only for reference. Actual added volumes shall be decided with
the oil dipstick.
3) If the vehicle is equipped a fuel system protector or fuel filter with moisture separator as developed by
Weichai Power, they shall also be replaced when the fuel filter is replaced.
2.1.3 Engine Coolant

The freezing point specification of Weichai special coolant includes -25ºC, -35ºC, and -40ºC.
Please choose Weichai special coolant of different freezing points based on the local environmental
temperature in such manner that the freezing point is less than local air temperature by
approximately 10ºC, with reference to Table 2-4.
Table2-4 Weichai Special Heavy-Duty Engine Coolant
Variety Product category Packing specification
HEC-Ⅱ-25
Heavy-duty engine coolant HEC-Ⅱ-35 4kg, 10kg
HEC-Ⅱ-40
Note:
1) Make sure to periodically check the coolant and, to prevent the corrosion and
damage, timely replace depending on actual situation.
2) It’s prohibited to use water or low quality coolant as the engine coolant.
2.1.4 Auxiliary Materials
Table2-5 Auxiliary Materials
SN. Name Color Purpose and location

Molykote Pulver Applied on flat and smooth metal surfaces to prevent seize
1 Black
(fine molybdenum powder) For example, applied onto outer surfaces of cylinder liners
Molykote Pulver Lubrication before the lubricating oil pressure builds up.
2 Dark grey
(fine molybdenum powder) For example, applied onto the intake valve stem
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Table2-6 Reference Table for Sealant Application of Diesel Engine
Mark Main use List of locations for application of sealant Supplement

Screw bolt of housing for timing gear
Camshaft thrust halfring bolt
Camshaft timing gear bolt
Intermediate idler bolt
It’s applied onto the threads
Oil filter base bolt
Loctite to prevent being vibrated to
Oil cooler bolt
242 looseness, with moderate Alternatively, the
Air compressor shaft end thread
strength. thread pre-application
Rear screw plug of main oil line
sealant DriLoc204
Screw plug of safety valve
can be pre-applied.
Main oil passage pressure control valve thread
Suction filter bolt
Applied onto outer threads
Loctite for locking, sealing,
Auxiliary bolt, cylinder head
262 preventing vibration from
causing looseness
Bowl plug of auxiliary oil line
Bowl plug of main oil line
Bowl plug of cylinder water cavity
Bowl plug of camshaft bore
Bowl plug of cylinder head
Loctite For sealing between Copper bush of cylinder head
277 element and bore Bowl plug of intake pipe
Oil-gas separator ventilation elbow connected
to cylinder part
Bottom of exhaust valve spring seat
Pipe joint component connected to water pipe
joint part
Interface between cylinder block and crankcase
It’s applied onto shining Front and rear end faces of engine body
Loctite
metal surfaces for sealing Junction surface between air compressor and
510
purpose. housing for timing gear
Interface between oil filter base and crankcase
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2.2 Routine Maintenance

2.2.1 Details of Routine Maintenance
 Check the coolant level, engine oil level and fuel oil level; and check whether the
lubricating grease at the place needing lubrication grease is sufficient;
 Check for presence of oil, water and air leakage.
 Check whether the jointing and fastening of external connections and accessories are good;
 Check whether the fan and belt are too tight or too loosened;
 Oil pressure of diesel engine
 Water temperature of diesel engine
 Check whether the exhaust temperature, color, sound and vibration of diesel engine are
normal, and whether the rotating speed of engine is stable;
2.2.2 Details of Routine Service
 Check the coolant level and temperature.
Observe the coolant level through glass sight hole. If the coolant is insufficient, open the filler
port cap and add coolant. Figure 2-1 and Figure 2-2 respectively show the safety sign for filler cap
of coolant and the diagram of expansion tank.
Note: While opening the filler port cap, make sure to push down the air bleeding button,
in order to prevent the coolant from causing personal injuries under hot state of engine.
Figure2-1 Check the Coolant Level and Temperature
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Expansion tank
Figure2-2 Expansion Tank
 Check the oil level.

It’s prohibited to start the diesel engine when the oil level is below lower marking of oil
dipstick or is above upper marking of oil dipstick.
After the diesel engine is stopped, wait for at least 5min and then check the oil level, in order
to enable the engine oil to flow into the oil pan sufficiently.
The oil amount difference between lower marking and upper marking of oil dipstick is 3L.
Figure 2-3 gives the engine oil dipstick use instructions.
Figure2-3 Engine Oil Dipstick Indication Instructions
 Check the fuel level

Check the fuel level indication from the instrument panel. Add fuel if necessary.
 Check for presence of water, air, oil, and fuel leakage
Check the diesel engine surface for signs of water, air, oil, and fuel leakage.
 Check the level of urea solution
The level shall be kept between 30% and 80% of the gross capacity of urea box.
 Check the fan
Visually check the blades of fan for presence of damage and check connecting bolts for secure
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fastening. See Figure 2-4.
Figure2-4 Check the Fan Blades.
 Check the belt

The belt is tensioned by belt tensioner. Check the tension of belt by pushing the belt with hand.
See Figure 2-5.
Figure2-5 Check the Belt.
 Check whether the exhaust color is normal, as shown in Figure 2-6.
Figure2-6 Check the Color of Exhaust Gas
The normal color of exhaust gas is light grey. Upon detection of change in color, check and
solve the cause.
 Check whether the sound is normal
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 Check whether the rotating speed and vibration are normal

2.2.3 Contents of Maintenance at Each Level
Except for daily maintenance, the following contents shall be added:
 Replace engine oil
Before replacing old engine oil, remove the drain plug at the bottom of oil pan, and drain the
old engine oil. Then tighten the drain plug.
Open the filler cap, and add fresh engine oil until the oil level meets the requirement. Then
tighten the filler cap.
Note: Waste oil must be put in the specified container at the specified place.
 Replace engine oil filter or element.
① Remove the used engine oil filter;
② Fill the new filter completely with clean engine oil;
③ Before installing new engine oil filter, apply engine oil onto the rubber gasket.
④ After the rubber gasket comes into contact with the base, tighten for 3/4~1 turn to seal;
⑤ Start the diesel engine and check for presence of oil leakage.
 Check and adjust the clearances of intake and exhaust valves.
① 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 sight glass cover plate;
② Remove the valve rocker cover from the cylinder head and judge whether the 1st or 6th
cylinder is at compression stroke (there is a gap between exhaust valve and rocker for the cylinder
under the compression stroke);
③ Using the feeler gauges, check the clearance between valve bridge top and valve rocker
arm. For the WP10 diesel engine with two valves per cylinder, the intake and exhaust valve
clearances shall be 0.4mm and 0.6mm, respectively. If the clearance is too large or too small, adjust
the adjustment bolt on the rocker to meet the above-mentioned clearance requirement;
④ After the checking of 1st cylinder or 6th cylinder, turn the engine for 360º to adjust the 6th
or 1st cylinder to power stroke and then check and adjust the remaining valves.
Table2-7 Valve Clearance Adjustment Order
1st cylinder 2nd 3rd 4th 5th 6th cylinder
24
cylinder cylinder cylinder cylinder
1st cylinder Intake and exhaust Intake Exhaust Intake Exhaust Non-adjustable
compression stroke valves valve valve valve valve
6th cylinder Non-adjustable Exhaust Intake Exhaust Intake Intake and exhaust
compression stroke valve valve valve valve valves
 Replace fuel filter element.
① Remove the used fuel filter element. If the water collector installed on the coarse filter can
be reused, please take out the water collector;
② Lubrication sealing port;
③ Screw the filter by hand, till the seal comes into contact with the port;
④ Continue to screw the filter by hand, till the filter is securely installed (for approximately
3/4 turn);
⑤ Bleed the air, till there is no presence of air bubble;
⑥ Conduct the leakage test.
Note: After replacement of the spin-on fuel coarse filter, bleed the new spin-on fuel
coarse filter. After re-installation of the fuel delivery pipe, bleed the spin-on fuel coarse filter.
Procedures are shown in Figure 2-7.
① Shut off the engine.
② Remove the bleeding screw.
③ Operate the manual pump until only fuel comes out of the bleeding screw.
④ Install the bleeding screw.
Figure2-7 Coarse Filter Bleeding
Discharge the water from water collector:

Note: Water must be drained from the water collector when the water collector is full or
25
the spin-on coarse filter is replaced with a new one.

Procedures for water collector draining is shown in Figure 2-8:
① Open the drain plug (2) at the bottom of water collector (1);
② Refit the drain plug.
Figure2-8 Draining Water from the Water Collector
Procedures for water collector replacement are shown in Figure 2-9:

① Stop the engine;
② Drain water from the water collector;
③ If possible, manually remove the screw (1) from the water collector. If the water collector
is too tightly connected to be removed manually, use the removal tool that is provided along with
the new water collector;
④ Apply several drops of lubricating oil to the seal ring (2) of the new water collector;
⑤ Manually tighten the screw. Then using the tool, tighten it in place;
⑥ If the water collector is installed to a new spin-on filter, check the water collector for
damage before installation;
⑦ Using the torque wrench, tighten the water collector to the torque of 20N·m.
26
Figure2-9 Replacing Water Collector
 Check the intake system
Check the intake hose for presence of aging or cracking and check the clip for presence of
looseness. When necessary, tighten or replace parts to ensure air-tightness of intake system.
 Check the air filter element. Figure 2-10 gives the diagram of air filter.
Figure2-10 Air Filter
The maximum intake resistance of diesel engine is 7.5kPa. Check the maximum intake
resistance only when the diesel engine is running at rated speed under full load. When the intake
resistance reaches the maximum permissible limit, clean or replace the filter element as per the
manufacturer’s instructions.
Note: It’s absolutely prohibited to run the engine without the air filter, otherwise the
ingress of dusts and impurities into the diesel engine will lead to earlier wear of engine.
Disassemble the filter element from the air filter and flap lightly the end face to fall off the
dust or blow backward (from inside to outside) by compressed air. Figure 2-11 gives the diagram of
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air filter element.
Figure2-11 Air Filter Element

Note: Do not blow through the filter paper, or clean the filter paper by water or oil, or
clap or knock the filter element forcibly.
 Check the filter element of urea pump
During the maintenance every time, it is required to remove the filter element of urea pump,
and then install it after cleaning it with clear water. Do not pat or beat the filter element strongly.
Note: When the urea nozzle is replaced or dismantled every time, it is required to check the
state of urea nozzle, and the urea nozzle shall be replaced if it is damaged or deformed.
 Clean the urea box and the filter element of urea box
During the maintenance, it is required to check the cleanliness of urea box and filter element,
and clean them when necessary.
2.3 Maintenance for Long-term Storage

2.3.1 Clean the Diesel Engine
 After the engine warm-up, drain the engine oil, clean engine oil filter, and add anti-rusting
oil;
 Drain the fuel and add anti-rust oil mixture;
 Drain the coolant and add coolant with anti-rust agent;
 Start the engine and idle for 15min～25min;
 Fully drain the engine oil, fuel and coolant;
 Take protection measures for other portions;
28
2.3.2 Protection for Long-term Storage

Plug with caps or wrap with plastic film for all oil, gas, and water inlets and outlets and seal
up the entire diesel engine with weather anti-rusting film.
Note: If the transport is required, the external package shall be supplemented.
2.3.3 Oil Seal
Generally the period of validity of oil sealing is one year for the diesel engine in storage. If the
storage period exceeds one year, oil sealing processes shall be performed again as follows:
 The oil sealing processes shall be performed in a clean environment. Before doing so,
remove rust, oil stain, and dust from the engine and parts.
 Depending upon actual requirements, oil sealing processes may be dipping in, spraying,
daubing, and filling with oil.
 Oil sealed locations: Inlet and outlet of turbocharger, inlet of air compressor, and intake
pipe mouth.
29
Chapter III Faults and Solutions
3.1 Diagnostic and Adjustment Method

The common diagnosis methods for malfunctions of diesel engine are generally as below:
 Observation method: Judge the malfunction situation by observing the malfunction
symptom, such as exhaust smoke of diesel engine. See Figure 3-1.
 Listening diagnosis method: Judge the characteristic and extent of the malfunction portion
by listening as per the abnormal sound of diesel engine. See Figure 3-2.
Figure3-1 Observation Method Figure3-2 Listening Diagnosis Method

 Comparison method: For some assemblies or parts, the replacement method is adopted to
determine the presence of malfunction.
Note:
(1) Judging the malfunction cause of diesel engine is a really precise work. Before the cause is
basically identified, do not disassemble the diesel engine casually, or it will not only eliminate the
malfunction, but also lead to more serious malfunction due to improper assembly after removal.
(2) Inspection and maintenance on critical components such as high-pressure fuel pump and
turbocharger shall be performed by experienced personnel using special instruments. If having no
such experience or instruments, the customer shall not remove or adjust these components.
3.2 Common Fault and Troubleshooting

3.2.1 Diesel Engine cannot be started
Cause Troubleshooting
Bleed the air, check sealing performance of connectors,

1. Air content in fuel system
and repair
2. Malfunction of fuel injection pump Check plunger and fuel outlet valve and repair or replace
30
damaged parts.
3. Malfunction of fuel injector Check the injectors for poor atomization.
4. Damage or leakage of valve or fuel supply pipes Check and adjust
5. Damage and leakage of high pressure fuel pipes Repair and replace
Check sealing performance of valves and cylinder gasket,
6. Insufficient compression pressure of cylinder check wear of piston rings, and repair or replace
damaged parts.
7. Air temperature too low Add startup aid equipment measures
3.2.2 Stop of Engine Shortly after Start

Remove the filter body, remove internal contaminant and

1. Blockage of fuel filter.
water, and when necessary replace element.
Check the sealing performance of fuel pipes and
2. Air content in fuel system. connectors, check and ensure the tightening of bleeder
screw, and bleed the remained air.
3. Poor fuel quality and high water content Clean the filter and replace fuel
4. Low regulated idling speed Re-adjust
3.2.3 Low Power

Check air filter and intake pipe and clean or replace

1. Intake blockage (blockage of air filter)
filter element
Check valve timing, check exhaust pipeline for blockage,

2. Over-high exhaust backpressure
and adjust and repair
3. Insufficient pressure of turbocharger system Check and solve leaks at pipeline connections
4. Abnormal working of turbocharger Replace assembly
4.1 Blockage of air compressor or turbine runner by

Clean or replace
dirt
4.2 Failure of floating bearing Replace
4.3 Carbon deposit and oil sludge at back gap of Clean
31
turbine and compressor
Check the tightness of oil pipe and joint, filter pollution
5. Leakage or blockage of fuel pipe and fuel oil pipe repair or clear the fouling, replace the
filter element.
Clean fuel tank, filtration parts and fuel pipes, and replace
6. Poor fuel quality
fuel
7. The fuel injection pump is excessively worn Repair or replace
Check the injection pressure, injection nozzle carbon

8. Poor atomization of fuel injection nozzle
deposit; conduct adjustment or repair
9. Incorrect valve or fuel supply timing Check and adjust
10. Over-high oil level of oil pan Check oil dipstick and drain excessive engine oil
Check compression pressure during warm-up and replace

11. Air leakage of cylinder gasket
damaged cylinder gasket
12. Wear and breakage of piston rings and excessive

Replace worn parts or overhaul the engine
gap of bearing shells
13. Wear or scuffing of cylinder liner or piston Replace worn parts or overhaul the engine
3.2.4 Excessive Fuel Consumption

1. Blockage of intake pipe Check and clean air filter and intake pipe
2. Over-high exhaust backpressure Check and clean exhaust pipe and brake valve.
3. Poor fuel quality Replace with specified fuel
4. Blockage of fuel pipe Check and repair
5. Leakage of fuel pipe Check and repair
6. Poor atomization of fuel injector Check and adjust or repair
Adjust valve clearance and fuel supply advance angle as

7. Incorrect valve or fuel supply timing
per specification
8. Air leakage of cylinder gasket Check the compressed pressure
9. Excessive gap of bearing shells. The overhaul is

Check and overhaul
required for the engine.
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10. Piston cylinder expanding Replace the cylinder sleeve, piston, and piston ring
11. Insufficient pressure of turbocharger system Check and solve leaks at pipeline connections.
12. Abnormal working of turbocharger Check and replace
3.2.5 Black Exhaust Gas

1. Blockage of intake pipe or excessive exhaust

Clean
backpressure
2. Poor fuel quality Clean and replace
3. Incorrect valve or fuel supply timing Adjust as per specification
4. Poor atomization of fuel injection nozzle Check, repair or replace
5. Excessive fuel volume of fuel injection pump Check and adjust
6. Insufficient pressure of turbocharger system Check and solve leaks at pipeline connections.
7. Abnormal working of turbocharger Check and replace assembly
3.2.6 White or Blue Exhaust Gas

1. Poor fuel quality and high water content Replace fuel
Check working temperature of thermostat and replace

2. Under-low coolant temperature
when necessary.
3. Incorrect valve or fuel supply timing Check and adjust
4. Poor atomization of fuel injection nozzle Check and repair
5. Low compression pressure, incomplete Check piston rings, cylinder liner, and cylinder gasket
combustion, and piston expanding and repair accordingly
6. Improper run-in of piston rings and cylinder

Continue the run-in
liners
7. Non-staggered openings of piston rings Adjust and reassemble
8. Failure of piston oil rings Replace
9. Large fit clearance between piston and cylinder

Repair and replace
liner
10. Wear of turbocharger seal rings Check and replace
33
11. Wear of turbocharger thrust bearing Check and replace
12. Blockage of turbocharger oil return pipe Clean or repair
3.2.7 Deposit of Engine Oil at Air Inlet Port and Air Inlet Pipe of Turbocharger
1. Turbocharger sealing failure Repair or replace turbocharger
2. Failure of oil-gas separator Replace
3. Over-high oil pan level and excessively added Check whether proper engine oil is discharged to meet
engine oil the stipulations
3.2.8 Unstable Speed

1. Poor fuel quality, with water or paraffin content Replace fuel
Check sealing performance of fuel pipes and connectors

2. Air ingress of fuel suction pipe
and bleed air
3. Non-uniform fuel supply Check and adjust
4. Instability of fuel injection nozzle Check and repair
Check and clean air compressor runner, dredge blockage,

5. Spray vibration of turbocharger
and remove carbon deposit from exhaust passage
6. Damage of turbocharger bearing Replace
3.2.9 Engine Oil Pressure Too Low

1. Under-low oil pan level or oil shortage Check oil level and oil leaks, repair, and add oil
2. Malfunction of main oil-way pressure regulator

Check valve and clean and repair
valve
3. Check coarse filter, engine oil pipeline, and Check and clean air compressor runner, dredge blockage,
connector gaskets for presence of blockage and and remove carbon deposit from exhaust passage
cracking
Replace with specified engine oil and choose an

4. Inappropriate engine oil trademark
appropriate oil trademark
5. Leakage of oil pump inlet pipe Check the oil pipes and connectors and repair or replace
34
6. Over-high water temperature of cooling system

Check the cooling system for normal working, and correct
and over-high engine oil temperature
7. Excessive resistance of engine oil filter Replace with new filter element
8. Blockage of oil cooler Check and clean
9. Blockage of main oil-way Check and clean
10. Excessive gap of bearing shells or damage of

Check and replace
bearing shell
Check number of operating hours of engine and overhaul

11. Excessive wear of parts. The overhaul is required.
engine.
3.2.10 High Coolant Temperature

1. Under-low level in water tank Check water leaks and add water
2. Blockage of water tank Check water tank and clean or repair
3. Loose water pump belt Adjust tension as per specification
4. Damage of water pump gasket and wear of water

Check and repair or replace
pump impellor
5. Thermostat malfunction Replace
Check water pipes, connectors, and gaskets and replace

6. Damage of water pipe and ingress of air
damaged parts
3.2.11 Excessive Wear of Parts

1. Disqualified or damaged air filter element Check and replace with qualified filter element
2. Short-circuit of intake system. Check intake pipe, gasket, and connecting pipe sleeve and
repair or replace
4. Blockage of oil-way Clean oil-way
5. Inappropriate oil trademark Replace with specified oil
6. Breakage or wear of piston ring Replace damaged parts
35
Remove and check piston and cylinder liner and repair or

7. Wear or scuffing of cylinder liner or piston
replace
8. Failure for timely replacement of engine oil filter

Replace as per specification
element
9. Excessive wear of parts. The overhaul is required. Check current mileage and determine overhaul
10. Crankshaft misalignment with driven member Check mounting bracket and repair
11. Use of disqualified engine oil Use qualified oil trademark
3.2.12 Excessive Noise

1. Poor fuel quality Replace fuel
2. Under-low coolant temperature Check thermostat and replace when necessary
3. Incorrect valve or fuel supply timing Check, repair, and adjust
4. Poor atomization of fuel injection nozzle Check, repair, and adjust
5. Excessive fuel volume of fuel injection pump Check and adjust
Check for damage, check state of connecting bolts, and

6. Wear of shock absorber
replace damaged parts
7. Air leakage or improper adjustment of valve Remove and check valves and adjust
8. Excessive gear backlash or broken teeth Check and replace damaged parts
9. Wear or scuffing of cylinder liner or piston Check and repair or replace
10. 1 Bending or breakage of push rod Replace
11. Breakage or wear of piston ring Check or replace damaged parts
3.2.13 Working Failure of Starter Motor

1. Insufficiently charged battery Check and charge or replace battery
2. Poor contact of connecting wires Clean circuits and tighten wiring posts
3. Burnt fuse Replace fuse
4. Poor contact of electric brush Clean electric brush surfaces or replace electric brush
5. Short-circuit of starter motor Check and repair motor or replace assembly
36
3.2.14 Weak Starter Motor

1. Insufficiently charged battery Charge or replace battery
2. Wear of bearing bushing Replace assembly
3. Poor contact of electric brush Clean electric brush surfaces or replace electric brush
Remove oil dirt and polish with sand paper or replace

4. Dirty or burnt commutator
assembly
5. Loose weld of wire ends Re-weld
6. Poor contact of switch Check and repair switch
7. Slip of friction clutch Adjust working moment of clutch or replace assembly
3.2.15 Working Failure of Alternator

Check alternator and ampere meter for loose connection.

1. Open circuit, short circuit, or loosen connection
Reconnect conductor if necessary.
2. Open circuit, short circuit, or earthing of rotor

Repair or replace assembly
coil or stator coil.
3. Rectifier damaged Replace assembly
4. Terminal paper insulation damaged, or

Repair
conductor disconnected
5. Regulator voltage setting too low Repair
6. Regulator contact fusion Repair or replace assembly
3.2.16 Inadequate Charging Current of Alternator

1. Open circuit, short circuit, or loosen connection Repair
2. Open circuit, short circuit, or earthing of rotor

Repair or replace assembly
coil or stator coil.
3. Loose alternator pulley Check and adjust belt tension
4. Rectifier of alternator damaged; battery loose Repair
37
connection
5. Regulator voltage setting too low Adjust
6. Regulator coil or resistor disconnected Repair or replace
7. Insufficient battery electrolyte, or old battery Add electrolyte, or replace battery
3.2.17 Instable Charging Current

1. Open or short circuit is to occur for stator coil or

Repair or replace
rotor coil
2. Poor contact of electric brush Repair
3. Terminal comes loose or poor contact Repair
4. Damage of voltage regulator Repair
5. Improper voltage regulation Check and adjust
3.2.18 Excessive Charging Current of Alternator

1. Internal short circuit of battery Repair or replace
2. Regulator voltage too high Repair and adjust
3. Regulator insecure earthing Repair
4. Regulator contact failed, voltage coil

Repair or replace
disconnected, or resistor disconnected
3.2.19 Abnormal Sound of Generator

1. Improper alternator installation Repair
2. Damaged bearing Replace bearing
3. Rotor comes in contact with stator Repair or replace
4. Short circuit of rectifier Replace
5. Short circuit of stator coil Repair or replace
38
Chapter IV Disassembly and Assembly of Engine

4.1 Overview
During disassembly and assembly of diesel engine, please follow operating instructions in this
manual strictly and pay attention to operation steps containing danger and safety marks, so as to
ensure personal safety and avoid accidents.
As disassembly of the diesel engine is in the reverse order of assembly, only one item will be
explained herein unless otherwise stipulated.
The tightening torque of special bolts will be given in the related installation procedures. If
without special explanations, please refer to the standard bolt tightening torque given in Appendix.
4.1.1 Danger Sign
This sign is a worldwide recognized warning sign. In the
manual, this sign is used to stress the importance of the following
information. Please make sure that you know what potential risks
are and how to ward off such risks. In case of any behaviors in
violation of the warning information, it may result in damage to
property, personal injury and even death.
Some common danger signs are usually used for ordinary
warnings. Warning information in this manual is classified into
different types (slight injury, serious injury and death) according to
severity of possible consequences.
Warming This warning sign indicates a potential danger, which, if not

warded off, may lead to severe injury, death or major property loss.
This warning sign indicates a potential danger, which, if not
Notice warded off, may lead to slight injury or property loss. It is also used
to warn against dangerous operations.
The instructions herein are provided to explain how to correctly operate and install the diesel
engine of our company. Simply reading through this document will not prevent risks from
happening. But only through adequate understanding can these instructions will be correctly
39
applied.
The warning information provided herein may not cover all possible situations! If you decide
to use a procedure or a method that is recommended, please make sure that such operation will not
bring harm to yourself, any other person or the equipment.
4.1.2 Safety Sign
During use of the diesel engine, many potential dangers occur without any signs. Hence, this
manual cannot give warning instructions for all kinds of potential danger. If the procedures taken
by you are not recommended ones, please ensure the same procedures are safe to operate and do
not result in any damage to property.
Sign Description
40
4.1.3 Used Tools

Should any method or tool used is not recommended in this manual, the user must first ensure
personal safety, and avoid jeopardizing the life of the user or other personnel, as well as guarantee
that the use, maintenance or repairing method will not cause damage risks or jeopardize personal
safety.
Picto Definition
hexagonal wrench
hexagonal wrench
socket
Flat screw driver
Special tool
flat hexagonal wrench
4.1.4 Precautions for Health Protection

The following “Precautions for health protection” are to reduce pollution risks.
a) Avoid the long-term repeated touch of used engine oil.
b) If possible, please wear the protective clothing and water-proof gloves.
c) Never place any oil-immersed rag into your pocket.
d) Guard your clothing, especially the underwear, against the oil contamination.
e) Wash your working clothing frequently. Throw away oil-immersed clothing and shoes that
can’t be cleaned.
f) In event of cuts or injuries, please immediately take the emergency treatment.
g) Make sure to apply to apply the protective paste before operations, which will make the
removal of oil easier if your skin is contaminated by mineral oil.
h) Use soap and hot water or use liquid soap and fingernail brush to wash hands, in order to
completely remove oil dirt. If the naturally secreted grease on your skin is removed during the
hand-washing, a product with wool fat content can replace this naturally secreted grease to help
moisturize the skin.
41
i) Do not clean the skin by gasoline, kerosene, fuel, thinner, or solvent.

j) Upon detection of skin irritation, please immediately seek for medical treatment.
k) If possible, deoil the parts before the handling of parts.
l) Please use goggles or face mask whenever your eyes are endangered. Make sure to prepare
the eye flushing fluid at all accessible places.
m) During the repair of diesel engine, never splash oil or other liquid onto the ground. In
event of accidental leakage of hydrocarbon or other liquid, take all necessary measures to
quarantine this area to keep clean the environment and guard personnel against injuries.
n) The handling, storage, and recovery of hydrocarbon, ethylene, glycol, and petroleum must
abide by the safety and environmental standards of the country in which the operations are fulfilled.
4.1.5 Environmental Protection Measures
Please observe relevant environmental protection laws and regulations with respect to disposal
of waste oil and hydrocarbons. For details, consult local officials.
4.1.6 Precautions on Removal and Installation of Engine
Most accidents in connection with use, maintenance and service of diesel engine are resulted
from failure to observe safety rules and basic precautions. So, you should know the risks you face
and take corresponding preventive measures to avoid occurrence of accidents. Operation,
maintenance, and repair of the diesel engine shall be performed by personnel who have received
required trainings and have proper skills using proper tools.
Failure to follow relevant instructions given in this manual may result in serious accidents,
even endangering the operator's life. Weichai Power Co., Ltd. cannot foresee all potential risks.
Similarly, guidelines and instructions specified in this manual are not exhaustive.
Before proceeding with maintenance or repairing, a signboard containing “Don’t Use” or a
similar sign should be placed on the starter switch.
Before use of the barring rod, necessary preventive measures should be taken.
 Ensure that the maintenance site and surrounding environment are suitable for safe
operation.
 Ensure the maintenance workshop or area around the diesel engine is clean and neat.
 Before work, remove ring, necklace and watch. And wear well-fitted working clothes.
 Before working, please check whether corresponding protection equipment (goggles,
42
gloves, shoes, masks, working uniform, helmet, etc.) are within effective life.
 Do not use faulty or unsuitable tools.
 Stop the diesel engine during maintenance or service.
4.2 Engine Block Group

4.2.1 Disassembly and Assembly of Engine Block Group
a Exploded view of engine block group
1,26- bolt, 2- Combination 3,8- Hexagon screw 4- Cup plug 5- Rear oil seal
cylinder head washer plug;
6- Sealing washer 7- Screw plug 8- Hexagon screw 9- Relief valve 10- Safety valve
plug; spring
11- Cylinder liner 12- Hex socket-head 13- Nozzle 14- Sealing 15- Hollow bolt
cap screw assembly washer
16- Hexagon bolt 17- Main oil passage 18- Self-lock 19,21- Thrust 20- Seal ring
pressure control washer halfring
valve assembly
22- Main bearing 23- Cylinder block 24- Parallel pin 25- Flexible 26- Auxiliary
shell parallel pin bolt, cylinder
subassembly head
Figure4-1 Exploded View of Engine Body Group
b Preparation before disassembly
43
● Tools: Socket spanner, copper hammer

● Preparation before disassembly: Remove the gearbox and clutch, and remove the flywheel,
flywheel cover, gear chamber, and oil pan
c Disassembly
1) Remove the screw plug of main oil passage;
2) Remove the cylinder liners;
3) Remove the auxiliary bolt, cylinder head;
4) Remove the bolts on the peripheral of crankcase;
5) Remove the main bearing bolt;
6) Remove the seal ring.
d Installation
Installation sequence is in the reverse order of removal.
e Key points of maintenance
1)
Tightening torque （22～29）N·m 8.8 Level

Tightening torque （29～35）N·m 10.9 Level
2) Main bearing bolts shall be screwed up symmetrically according to the order given in Figure
4-2. Before assembly, brush clean lubricating oil at the bearing surface of crankcase and the thread
part of main bearing bolt. The main bearing bolt can be used for 6 times repeatedly, and the
extended bolt length is smaller than 172mm.
Figure4-2 Tightening Sequence of Main Bearing Bolts
Tightening torque （265±25）Nm

3) The auxiliary bolts of cylinder head shall be tightened according to the order given in 4-3, and
they can be used for 2 times repeatedly at most.
44
Figure4-3 Tightening Sequence for Cylinder Head Auxiliary Bolts
4) Before installation, check carefully the cylinder liners for cracks. Clean the cylinder liners.
Apply molybdenum power to the outer surface of cylinder liner. Using the special tool, press the
cylinder liner into cylinder bore. Before doing so, apply molybdenum powder to the outer surface
of cylinder liner.
4.2.2 Disassembly and Assembly of Cylinder Block Preassembly
a Exploded View of Cylinder Block Preassembly
1,4,5,12,13- Cup plug 2- Self-plugging rivet 3- Cylinder block 6- Crankcase

7,8 Main bearing bolt 9- Parallel pin with internal threads 10,11- Camshaft bushing
Figure4-4 Exploded View of Cylinder Block Preassembly

45
● Preparation before disassembly: Remove the gearbox and clutch, and remove the flywheel,
flywheel cover, gear chamber, and oil pan
c Disassembly
1) Remove the camshaft bushing;
2) Remove the main bearing bolts and crankcase fixing bolts.
3) Remove the crankcase.
4) Remove the parallel pin with internal threads.
d Installation
1) Using a special tool, remove the camshaft bushing. While doing so, be careful not to cause
damage to other bushings.
2) Before installing the camshaft bushing, check the inner surface of camshaft bushing for
scratches. If any, replace it. Align the lubricating oil hole in the camshaft bushing with that for
camshaft in the engine body.
3) Before installation, clean and apply sealant to the upper plane of the crankcase.
4) If a bowl plug needs replacement, before assembly, it is required to clean the hole bottom and
the bowl plug surface, and then evenly paint sealant on the contact face between the bowl plug and
the engine body. The bowl plug shall be pressed via tooling, and the pressing depth shall be
controlled according to (0~1) mm below chamfer, and moreover, the bowl plug end face height
after the bowl plug is pressed shall be not greater than 0.5mm.
4.2.3 Disassembly and Assembly of Piston Cooling Nozzle
a Exploded View of Piston Cooling Nozzle
46
1- Hollow bolt 2- Sealing washer 3- Nozzle assembly 4- Parallel pin

Figure4-5 Exploded View for Piston Cooling Nozzle

● Tools: Socket spanner
● Preparation before disassembly: Remove the crankcase, crankshaft, and other parts.
c Disassembly
1) Remove the Hollow bolt;
2) Remove the nozzle assembly.
3) Remove the flexible parallel pin
d Installation
1) Hollow bolt tightening torque
Tightening torque (24～30)Nm
2) Check the locating pin for damage. Replace the damaged locating pin. Aligning the locating
pin with the pin hole in the engine body, tap the nozzle body using a copper hammer, until the
locating pin fully enters the hole.
4.2.4 Disassembly and Assembly of Thrust Halfring
a Disassembly diagram
47
1- Lower thrust halfring 2- Upper thrust halfring

Figure4-6 Thrust Plate Disassembly Diagram

c Disassembly
1) Remove the crankcase;
2) Remove the crankshaft;
3) Remove the thrust halfring
d Installation
1) Install the crankshaft.
2) Install the upper thrust halfring (no lug).
3) Install the lower thrust halfring.
Thrust halfrings must be used in pairs. Install the crankshaft to the engine body. Install the upper
thrust halfring (no lug). Apply grease to the lower thrust halfring; then press slightly it to the
crankcase. The lower thrust halfring is installed along with the crankcase. Thrust halfrings shall be
installed with their lubricating oil grooves facing out.
4.2.5 Disassembly and Assembly of Gear Chamber Combination Group
48
1- Seal ring 2- Seal ring 3- Parallel pin 4- Hexagon 5- Combination

flange bolt washer
6- Hexagon head 7- Hexagon 8- Hexagon head 9- Timing gear
screw plug flange bolt screw plug chamber
Figure4-7 Gear Chamber Disassembly Diagram

● Preparation before disassembly: Remove the accessories in the front end of diesel engine
c Disassembly
1) Remove the gear chamber fixing bolts;
2) Remove the plug and combination washers;
3) Remove the intermediate gear shaft;
4) Remove the intermediate gear shaft and intermediate gear shaft bolt of the engine oil pump ;
5) Remove the gear chamber;
6) Remove the seal ring.
d Installation
1) Diagonally tighten the gear chamber fixing bolts in the sequence shown in Figure 4-5.
Tightening torque （44～58）N·m
49
Figure4-8 Tightening Sequence of Gear Chamber Bolts
2) Before installing the seal ring, check it for scratches and other defects. If any, replace it with a
new one. Before installing the seal ring, apply lubricating oil to it, and then press it fully in the
groove, avoiding damage caused by the groove.
3) Remove first the gear chamber fixing bolts, then the intermediate gear shaft of the gear
chamber, and the intermediate gear shaft of the engine oil pump. These individual components
must be placed in a clean environment.
4) Install the intermediate gear shaft to the intermediate gear; then put them in the gear chamber.
Apply sealant to the back of gear chamber, and then press the seal rings in place.
4.2.6 Disassembly and Assembly of Front End Housing Combination Group
1- Gasket 2- Front end cover 3- Hexagon head flanged bolt

Figure4-9 Front End Housing Combination Group Disassembly Diagram
50

● Preparation before disassembly: Remove the accessories in the front end of diesel engine
c Disassembly
1) Remove the front end cover fastening bolt;
2) Remove the front end cover;
3) Remove the front end cover gasket.
d Installation
1) The removed front end cover shall be put in a clean place. Before assembling the front end
cover, check its inner side for dirt. Remove it if any.
2) Check the seal gasket for damage. Replace the damaged seal ring with a new one. Press the
seal gasket completely in the groove of front end cover.
4.2.7 Disassembly and Assembly of Flywheel Cover Combination Group
1- Flywheel cover 2- Flywheel cover bolt 3- Flywheel 4- Starter 5- Stud bolt 6- Nut
Figure4-10 Flywheel Cover Combination Group Disassembly Diagram

● Preparation before disassembly: Remove the gearbox and clutch, and remove the flywheel
51
c Disassembly
1) Unscrew the nuts fastening the starter, and take the starter down;
2) Open the bolts fixing the flywheel cover;
3) Remove the flywheel cover
d Installation
1) Apply the sealant around the oil chamber.
2) Install the flywheel cover on the engine body.
3) Tighten the bolts fixing the flywheel cover.
4) Install the starter on the flywheel cover, and screw the nuts fixing the starter.
1) The flywheel cover bolts shall be tightened symmetrically according to the order given in the
figure below. Before assembly, paint oil on the bolt flange face. The flywheel cover bolts can be
used for two repeated times. Tightening torque: (110~140) Nm.
Figure4-11 Tightening Sequence of Flywheel Cover Bolts
2) Apply uniformly sealant to junction plane between cylinder block and flywheel cover and
guard flywheel cover against knocking damage during hoisting.
4.2.8 Removal and Installation of Oil Seal
52
1- Rear oil seal 2- Front oil seal

Figure4-12 Front and Rear Oil Seals Disassembly Diagram

c Disassembly
1) Remove the gear chamber;
2) Remove the front oil seal;
3) Remove the crankcase;
4) Remove the rear oil seal.
d Installation
1) Before installation, remove dirt (if any) from the mounting hole and oil seal. Using a special
tool, press steadily the oil seal in place. Before installation, apply lubricating oil to both the special
tool and the oil seal.
2) Using a special tool, remove the camshaft bushing. While doing so, be careful not to cause
damage to other bushings.
4.2.9 Removal and Installation of Cylinder Header Combination Group
53
1- Cylinder cover 2- Cylinder head 3- Lifting ring 4- Cylinder head 5- Auxiliary bolt,
main bolt nut clamping block sub-assembly cylinder head 1
6- Cylinder head 7- Auxiliary bolt, 8- Cylinder 9- Auxiliary bolt,
10- Clamping block
gasket cylinder head 2 combination group cylinder head 3
11- Cylinder head 12- Intake valve 13- Exhaust valve
clamping block stem seal stem seal
Figure4-13 Cylinder Header Combination Group Disassembly Diagram

● Tools: Socket spanner or pneumatic wrench, torque spanner, and open-end wrench;
● Preparation before disassembly: It is required to dismantle the cylinder head cover, intake pipe,
exhaust pipe, water drain pipe, high-pressure oil pipe, high-pressure connector, and oil-gas
separator, and other parts which may be fixed on the cylinder head or interfere with the cylinder
head removing.
c Disassembly
1) Loosen and remove the fixing screws of lifting rings.
2) Unscrew the auxiliary bolts and nuts of cylinder head, and take down the clamping block; the
clamping block has three kinds of structures: the first type is a cylindrical clamping block
assembled between the two cylinder heads and it is installed on an auxiliary bolt; the second type is
a clamping block respectively assembled on the two ends of engine and only installed on a cylinder
head, and they are installed on two auxiliary bolts, and ring connection blocks can be installed; the
54
third type is a clamping block respectively assembled on two ends of engine and only installed on a
cylinder head, and they are installed on one auxiliary bolt;
3) Loosen the main bolts of cylinder head. Remove the main bolts and put them at a proper
location.
4) Remove the fuel injectors. Since the fuel injector heads normally project beyond the cylinder
head underside, make sure that the fuel injectors have been removed before removing the cylinder
head. Otherwise, damage is probably caused to the fuel injector heads when the cylinder head
removed is put at a location.
5) Remove the cylinder head and place the removed cylinder head on a paper board, in order to
prevent wearing the top surface of combustion chamber and other sealing surfaces. If the removal
of multiple cylinder heads is required, mark the cylinder heads with cylinder numbers to ease the
problem analysis.
6) Remove the cylinder head gasket. If the removal of multiple cylinder head gaskets is required,
mark the cylinder numbers on the cylinder head gaskets to ease the problem analysis.
7) If the replacement or checking is required for the cylinder head auxiliary bolts, remove the
cylinder head auxiliary bolts.
8) Remove the rocker arm support, intake and exhaust valves, and other valve mechanisms;
9) If the Valve stem seal shall be checked or replaced, remove it using a special tool. The valve
stem seal may also be removed using a pair of pliers. Clamp the outer surface of the valve stem seal
using the pliers. Rotate the pliers up and down, to take out the valve stem seal. The removed seal
may not be reused.
d Installation
1) Install the auxiliary bolts, and the auxiliary bolt has 3 types.
① Auxiliary bolts of cylinder head may be reused once. If the cylinder head is installed for the
third time, these bolts must be replaced with new ones.
② Apply anaerobic thread locker 262 to the screw-in ends (with shorter threaded section length)
of auxiliary bolts of cylinder head in the first row on the side of the engine oil cooler cover
assembly. Apply pre-applied adhesive to the other auxiliary bolts.
③ Clean the threaded holes in the cylinder block.
④ Tighten the bolts to the torque of (76~102)Nm.
55
2) Install cylinder head gasket
Figure4-14 Cylinder Head Gasket
①The cylinder head gasket can be used once only, and in case that it is returned for repairing, it must
be replaced with a new one.
②Wipe clean the inner wall of the cylinder liner and apply some clean lubricating oil; wipe clean the
top plane of cylinder block and place the cylinder head gasket as per the corresponding pin holes.
④Check that the holes of the cylinder head gasket align with the corresponding holes in the cylinder
block, to ensure correct installation.
3) Install the valve stem seal
Spring Spring
(a) (b)
Figure4-15 Valve Stem Seal
① The valve stem seal can be only used once. Make sure to replace with new one in event of
repair.
② It is required to note that the valve rod seal cartridges are different in the installation of intake
valve and exhaust valve. The valve rod seal cartridge used for intake valve installation is of
monolithic type, as shown in Figure 4-15 (a); and the valve rod seal cartridge used for exhaust
valve installation is of integral type, as shown in Figure 4-15 (b);
③ Check the valve stem seal for presence of defect and check valve stem seal spring for
intactness.
④ Install valve stem seal on valve guide pipe.
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⑤ Apply lubricating oil to the lips of valve stem seal.

⑥ Use valve stem seal assembling tool and rubber hammer to install the valve stem seal.
Guide rod sealing safety rod
Valve stem seal
Valve Guide
Cylinder head
Figure4-16 Installation of Valve Stem Seal
4) Install the cylinder head

① Wipe clean the cylinder head carefully and ensure that there is not dust, debris, sand and other
contaminants, and then further wipe clean the bottom surface of the cylinder head.
② Check the air ducts and coolant passages in the cylinder head for foreign matters. Check the
cylinders, cylinder head gasket, and cylinder head underside for foreign matters.
③ Before the bolts of cylinder head are tightened, the cylinder head is located with the locating
pins.
④ Cylinder head assembly.
5) Install the clamping blocks
① Wipe clean the clamping blocks.
② Apply clean lubricating oil to the working faces of the clamping blocks. Install the clamping
blocks to the cylinder head according to the removal location. Do not apply too much lubricating
oil; otherwise lubricating oil may overflow into the gap between the cylinder heads.
③ The clamping block shall be installed so that its groove is in the same direction as the gap
between the cylinder heads.
④ Manually tighten the nuts of the auxiliary bolts of cylinder head.
6) Install the cylinder head bolt
① Main bolts of cylinder head may be reused twice.
57
② Align the cylinder head with the cylinder block. Apply a proper amount of clean lubricating oil
to the threads and pressure-bearing surfaces of shoulders of the main bolts of cylinder head, and the
shouldered nuts. Install the main bolts to the cylinder head. Install the nuts to the auxiliary bolts of
cylinder head, and clamping blocks.
③ Using a torque wrench, tighten the main bolts and nuts of auxiliary bolts of cylinder head to the
torque of (30~50) Nm.
④ Tap the clamping blocks so that they descend in place.
⑤ Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence to the
torque of 100Nm. Then make marks on the nuts.
⑥ Using a torque wrench, tighten the main bolts in the specified sequence to the torque of 200Nm.
Then make marks on the bolts.
⑦ Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence by 90º.
Then make marks on the nuts.
⑧ Using a torque wrench, tighten the main bolts in the specified sequence by 90º. Then make
marks on the bolts.
⑨ Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence by another
90º to the torque of (120~160) Nm.
⑩ Using a torque wrench, tighten the main bolts in the specified sequence by another 90º to the
torque of (240~340) Nm.
⑪ The cylinder head bolts shall be tightened according to the order given in Figure 4-17, in which,
those numbering 1-21 are auxiliary bolts of cylinder head, while those numbering 22-45 are main
bolts of cylinder head.
On the side of fan On the side of

flywheel
Figure4-17 Tightening Sequence for Cylinder Head Bolts
58

1) Before removing the cylinder head, check the interface between cylinder head and engine body
for signs of water, air, oil, and fuel leakage, and other abnormal signs. In the case of leakage,
replace the cylinder head gasket with a new one. Check whether the leakage occurs. Refer to this
section for the removal and installation of cylinder head gasket.
2) Check appearance of cylinder head. Check discoloration and crack of the cylinder head
carefully, and in case of crack, carry out penetrant inspection.
3) Before removal, check the lubricating oil inlet pipe for cracks, excessive wear, corrosion, and
sign of leakage. If any cracks, replace the pipe. In the case of serious corrosion that could affect
reliability, analyze the cause and replace the pipe. In the event of oil leakage in the hollow bolt part,
the hollow bolt shall be replaced, and the sealing washer shall be tightened; then it is required to
check whether there is oil leakage or not.
4) Before removing the valve gear, measure the valve sink, which is the vertical distance between
valve underside and cylinder head underside. The difference between measured and required valve
sinks reflects indirectly the degrees of wear of valve and valve seat. It is possible to use depth
micrometer to measure the valve sink as shown in Figure 4-18.
Figure4-18 Depth Micrometer
For the required valve sinks, refer to Table 4-1. If measured valve sink is outside the specified
range, check the degrees of wear of the valve and valve seat. To check the degree of wear of the
valve seat, a new valve may be used to measure the valve sink. If the valve sink is still outside the
specified range, the cylinder head shall be replaced to ensure the reliability of diesel engine
operation. If the valve sink does not exceed the permissible value, remove the valve for checking
and then check the sealing surface of the valve seat ring. Check whether there is apparent wear and
abnormal damage to the valve and the sealing surface of the valve seat ring.
4.6.1 Required Valve of Valve sink
59
Required valve of valve sink (mm)
Intake -0.2~0.2
Exhaust -0.2~0.2
5) With the valve gear removed, check the intake and exhaust ducts in the cylinder head for sign
of water leakage. If any, clean the cylinder head. Using the paint impression method, identify the
cause for leakage. If necessary, replace the cylinder head with a new one.
6) Clean the cylinder head, and clean the surfaces of the combustion chamber, valve seat, intake
and exhaust valves, intake and exhaust ports, and remove the carbon deposit and varnish, as well as
inspect surface conditions.
7) Check inside diameter of valve guide. The inside diameter of the valve guide is the contact
surface between the valve guide and the valve, and if the inside diameter of the valve guide exceeds
the permissible value due to wear, it will result in influence on guiding effect of the valve, reducing
reliability of the diesel engine operation. The inside diameter of the valve guide can be measured by
use of an inside micrometer, as shown in Figure 4-19. Specified range for inside diameter of valve
guide is（8.5~8.59）mm. If measured value is outside the specified range, the cylinder head shall be
replaced to ensure the reliability of diesel engine operation.
Figure4-19 Inside Micrometer
8) Removing cylinder head gasket, and check whether there is visible damage to the cylinder head
gasket and analyze the cause. Regardless of problems at the cylinder head gasket, it should be
replaced with a new one after being removed.
9) Before removing the valve stem seal, check the spring for failure. Anyway, replace the valve
stem seal with a new one.
4.2.10 Disassembly and Assembly of Cylinder Head Cover Combination Group
60
1- Supporting 2- Flexible 3- Cylinder head 4- Cylinder head 5- Cylinder head

block corrugated gasket cover bolt cover cover gasket
Figure4-20 Cylinder Head Cover Combination Group Disassembly Diagram

● Tools: Socket wrench or pneumatic wrench.
● Preparation before removal: Fix the engine. Remove the parts above the cylinder head cover.
c Removal
1) Using a wrench, loosen the bolts of cylinder head cover, and the supporting block.
2) Vertically pull up the cylinder head cover and cylinder head cover gasket.
3) Put the cylinder head cover and cylinder head cover gasket at an appropriate location for
inspection.
d Installation
1) The cylinder head cover gaskets can be used only once. Replace with new ones in event of
repair. Before installing cylinder head cover gaskets, check and ensure that new cylinder head cover
gaskets are free of manufacturing and operation defects and damages;
2) Wipe clean the top face of cylinder head and assemble cylinder head gaskets correctly in turn;
3) Clean the cylinder head cover, and accurately install it onto the cylinder head cover in turn.
4) Install the cylinder head cover bolts, and then tighten them. The supporting blocks and stands
to be installed in the corresponding positions shall be installed according to Figure 4-20, and then
the bolts shall be tightened.
5) As for a split-type cylinder head cover, install the cylinder head cover in the lower layer
according to 1), 2) and 3), then install the locating sleeve and middle cylinder head cover gaskets,
61
clean the cylinder head cover in the upper layer, and correctly install on the lower-layer cylinder
head cover, finally install and tighten the cylinder head cover bolts.
1) Observe the cylinder head cover for presence of cracking and serious wear. Upon detection of
cracking, replace with new cylinder head cover.
2) In the case of oil leakage from the cylinder head cover gasket, check for cylinder head gasket
failure, and excessive wear of the upper plane of cylinder head and the underside of cylinder head
cover. Replace the cylinder head cover gasket with a new one, and then check whether oil leakage
still occurs.
4.2.11 Disassembly and Assembly of Oil-gas Separator Combination Group
1- Gas inlet pipe 2- Flange 3- Flange (welded 4- Hexagon socket 5- Flexible

joint of oil-gas gasket with oil-gas screw corrugated
separator separator) washer
6- Hexagon nut; 7- Oil-gas 8- Hexagon flange 9- Hexagon flange bolt 10- Oil-gas
separator support nut separator
11- Clamp 1 12- Oil-gas 13- Pipe clamp 14- Oil-gas-separator 15- Pipe clamp
separator outlet assembly 1 return fuel pipe assembly 2
pipe
16- Return oil pipe 17- Clamp 2
Figure4-21 Oil-gas Separator Combination Group Disassembly Diagram

● Tools: Socket wrench or pneumatic wrench, open-end wrench;
62
● Preparation before disassembly: Remove the parts blocking the oil-gas separator.
c Removal
1) Remove the two bolts used for fixing the gas inlet pipe joint of oil-gas separator to the cylinder
block.
2) Remove the bolts used for fixing the oil-gas separator on the cylinder head ring clamping
block.
3) Remove the oil-gas separator and the clamps fixed with exhaust pipe and oil return pipe of
oil-gas separator, and remove each hose joint;
4) Remove the bolts used for fixing the gas outlet pipe clamps and return oil pipe clamps of
oil-gas separator. Remove the gas outlet pipe. Remove the clamps for the return oil hose and return
oil pipe. Remove the return oil hose.
5) If the return oil pipe that extends into the oil pan shall be removed for inspection, loosen the
return oil pipe then take it out.
6) If other parts need removal, the oil-gas separator assembly may be removed.
d Installation
1) Install the oil-gas separator shell body, and tighten two fixing bolts on the cylinder body
coupling;
2) Install the bolt used for fixing the oil-gas separator to the front lifting plate.
3) If the connecting pipe at the end of return oil pipe of oil-gas separator is removed, insert the
connecting pipe into the crankcase correctly. Tighten the sleeve.
4) Install the clamps and clamps for the gas outlet pipe and return oil pipe of the oil-gas separator,
and those for the return oil pipe of the oil pan.
1) Check the parts for damage including cracks. Check the hose for failure such as hardening and
brittleness. If any, replace the faulty part.
2) Feed air to the gas inlet pipe of the oil-gas separator to check for obstruction. In the case of
obstruction, feed pressurized air to the nipples of oil-gas separator to remove foreign matters such
as oil sludge. If obstruction is still there, replace the oil-gas separator with a new one.
3) Make sure that each hose and each connector are in correct positions according to Figure 4-21,
and the hoses shall not be bent.
63
4.3 Disassembly and Assembly of Crank Connecting Rod Mechanism

4.3.1 Disassembly and Assembly of Crankshaft System
1- Main 2- Crankcase 3- Connecting 4- Crankshaft assembly 5- Main

bearing bolt rod cap bearing shell
6- Torsional 7- Crankshaft 8- Pulley bolt 9- Piston connecting rod 10- Engine
damper pulley combination group block
11- Flywheel 12- Flywheel 13- Flywheel ring
bolt gear
Figure4-22 Crankshaft System Disassembly Diagram

● Tools: Socket spanner or pneumatic wrench, torque spanner, open-end wrench, internal circlip
pliers, and engine oil, etc.
● Preparation before disassembly: It is required to fix the cylinder body on the rotating support in
advance, and remove the engine cylinder head, oil pan and front-end wheel.
c Removal
1) Enable the engine crankcase upward, remove the main bearing bolts, and put them on the
ground in sequence.
2) Remove the crankshaft and flywheel, front and rear thrust halfrings, and flywheel end bearing.
Take out the oil seal. Unscrew the bolts of front pulley. Remove the pulley, and vibration damper.
64
Put the crankshaft on the bracket (If the crankshaft is put on the bracket too long, the crankshaft
should be put vertically).
3) All parts removed should be put by category as required.
d Installation
1) Wipe clean the bottom hole of cylinder block.
2) Clean the pre-formed hole in cylinder block for the upper bearing shell. Remove foreign
matters from the bearing shell.
① Before the upper bearing shell is pressed in the bottom hole, it is required to strictly check
whether it is collided, and if collided, it cannot be repaired for use.
② After the upper bearing is installed, it shall be aligned to the oil hole and oil groove on the
cylinder body, and the bearing deviating from the oil hole by 1/5-1/4 shall not be assembled; the
upper bearing shall be completely fitting to the bottom hole of cylinder body.
3) Apply appropriate quantity of clean lubricating oil onto the inner surface of the upper bearing
shell.
4) Deoil and wipe clean the lower surface of cylinder block and ensure that the lower surface of
cylinder block is free of oil.
5) Apply a line of sealant to the lower surface of cylinder block and ensure the uniform and
continuous sealant by a sealant roller.
6) Lift the crankshaft, and purge the oil port with compressed air, and wipe clean the main bearing
journal and connecting rod journal with a towel, and then lightly lower them into the cylinder block.
In this process, it is required that the crankshaft be free from collision.
7) Wipe clean the upper thrust halfring and press it into the cylinder block. The oil groove of the
upper thrust halfring should be outward (toward the crankshaft).
8) On the precondition of guaranteeing the level oil seals without distortion or deformation, place
the oil seals levelly into the seal grooves on the lower surface of cylinder block by special tooling.
9) Press the lower main bearing shell and lower thrust halfring into the crankcase (with the oil
groove facing towards crankshaft side) and assemble the crankcase.
10) Apply clean lubricating oil to the bolt-supporting plane of the crankcase and the threads of the
main bearing bolts. Slightly tighten the main bearing bolts. Pre-tighten all the main bearing bolts in
the sequence as shown in Figure IV.
65
Figure4-23 Tightening Sequence of Main Bearing Bolts
11) Tightening the bolts for the first time is performed using a low-torque pneumatic wrench.
Tightening the bolts for the second and third times attains the torque of 80Nm and (250~280)
Nm, respectively. Complete assembling of the crankshaft.
1) Check whether the main journal of crankshaft and the fillet part of connecting rod neck have
cracks; in the combination part of crankshaft and bearing shell, check the dredging pipeline for
cracks and other abnormalities.
2) Check wear of the main bearing journal and connecting rod journal, and whether there are
linear cracks and metal peelings.
3) Check wear condition of the front and rear oil seals;
4) Check whether the main bearing bolts are subject to thread damage and other failures;
5) Check whether the crankshaft flange bolt holes are cracked;
6) Check the wear status of crankshaft journal and check crankshaft for presence of bending and
distortion.
4.3.2 Disassembly and Assembly of Piston Connecting Rod Combination Group
66
1- Piston 2- Piston pin 3- Connecting rod 4- Connecting rod caps

shank
5- Connecting rod bolts 6- Trapezoidal barrel 7- Distorted cone 8- Coil-spring loaded
surface ring surface ring oil ring
9- Piston pin retainer 10- Connecting rod 11- Upper bearing of 12- Lower bearing of
bushing connecting rod connecting rod
Figure4-24 Piston Connecting Rod Combination Group Disassembly Diagram

 Tools: Socket spanner or pneumatic wrench, wooden hammer, and internal circlip pliers
 Preparation before disassembly: Fix the cylinder body and incline it, unscrew the bolts of
connecting rod cap, and take down the cap.
c Removal
1) Preparation before disassembly: Check axial backlash of the connecting rod and tightening
torque of the connecting rod bolt;
2) Put the slant side of the engine against the ground, turn the piston to the bottom dead center,
and remove the connecting rod bolt and connecting rod cap;
3) Turn the piston to the top dead center, and tap out the piston with a wood hammer. Care should
be taken to protect the big end of the connecting rod from being seized in the cylinder block.
4) Remove other piston assemblies and connecting rod assemblies with the same method.
Respectively number the piston, connecting rod bolt, and connecting rod cover, and place them in
order;
5) Use a pair of internal circlip pliers to dismantle the circlips on both sides of the piston carefully,
and push out the piston pin to remove the connecting rod shank. Assign numbers to the piston pin
and connecting rod shank, and put them in numerical sequence;
67
6) Use a pair of piston ring pliers to dismantle the 1st & 2nd gas rings and oil ring respectively,
and mark them.
7) Remove the upper and lower bearing of connecting rod, and number them at the back
respectively, and then place them in order;
d Installation
The connecting rods and pistons of the same machine are respectively in the same mass group; the
connecting rod body and the connecting rod cap shall be matched.
1) Use a pair of internal circlip pliers to install one circlip onto the piston circlip groove, and turn
the circlip to have it inserted completely. The face with edges and corners of retainer ring shall face
the inside, and the opening of retainer ring is in the position 30° derived from the piston center line.
See Figure 4-25.
The opening of retainer ring

is in the position 30° derived
from the piston center line.
Figure4-25 Piston Pin Retainer Ring Assembly Diagram
2) Insert the connecting rod small end into the inner cavity of the piston, and enable the small end
to align with the piston pin hole, and then mount the piston pin, and eventually mount the piston pin
circlip on other side. The small end hole of connecting rod and the piston pin, before assembly,
shall be painted with a proper amount of clean lubricating oil, and the connecting rod’s oblique
incision direction is opposite to the piston cooling oil pipe’s oil inlet hole direction, as shown in
Figure 4-26;
68
The oblique incision of

connecting rod body shall
back on to the piston oil
injection notch.
Figure4-26 Diagram of Piston Connecting Rod Assembly Relations
3) Put the assembled parts of the piston connecting rod aside in sequence of the cylinder numbers,
and use a pair of piston ring pliers to mount the oil ring, 2nd and 1st gas rings into the piston ring
groove in sequence. The “TOP” end of the piston ring should be upward, and the ring should be
turned flexibly in the ring groove.
4) Wipe clean the inner wall of the cylinder, crankshaft crank arm and piston connecting rod parts,
and apply some clean lubricating oil at individual kinematic pair positions.
5) Adjust direction of opening end of rings: the first ring is installed in such a manner that its
opening end is deflected from the centerline of the piston pin by 30°, and the second ring is
installed in such a manner that its opening end is staggered from the opening end of the first ring by
120°, and the oil ring is installed in such a manner that its opening end is staggered from the
opening end of the first ring and the second ring by 120°, respectively, and is at position where the
perpendicular bisector of the piston pin centerline is placed. See Figure 4-27.
1st gas ring 2nd gas ring
Horizontal direction of
piston pin
Oil ring
69
Figure4-27 Piston Ring Gap Arrangement
6) Manually rotate the flywheel until the pistons in the 1st and 6th cylinders reach approximately
their respective bottom dead centers. Install the piston connecting rod parts of the 1st and 6th
cylinders. Slightly tighten the connecting rod bolts. The piston oil injection notch and the piston
cooling injection on the engine body are on the same side; the piston cylinder sub-item number is
same as the cylinder number; the connecting rod cap is matched to the connecting rod body; and
the connecting rod bolts shall be applied with clean lubricating oil before assembly;
7) Connecting rod bolts: First slightly screw them in. Then symmetrically tighten them to the
torque of 120Nm. Finally tighten them by 90°±5° to the torque of 170Nm~250Nm. In the same
manner, install the pistons and connecting rods of the remaining cylinders.
1) Check whether the piston combustion chamber throat and piston pin seat have cracks; check
whether the piston skirt and head have scuffing phenomenon; and check whether the wearing of
piston pin hole is normal;
2) Check whether the piston ring is clamping in the piston ring groove;
3) Check the outer surfaces of piston rings for excessive wear; Check the upper and lower sides of
piston rings for excessive wear;
4) Check the outer surface of piston pin for excessive wear.
5) Check the connecting rod big end pre-formed hole, connecting rod shank, and connecting rod
small end lubricating oil hole for cracks; Check the connecting rod bearing shells for excessive
wear or peeling-off of alloy layer; Check the flanks of connecting rod for excessive wear. Check the
connecting rod shank for bending;
6) Check the connecting rod bearing shell wearing conditions; and check the alloy layer for
scratching, peeling, and sliding phenomena;
4.3.3 Disassembly and Assembly of Crankshaft Bearing Shell
70
1- Crankshaft 2- Upper main bearing shell 3- Lower main bearing shell
Figure4-28 Crankshaft Bearing Shell Assembly and Disassembly Diagram

● Tools: When without special tooling, a marking pen shall be prepared for the purpose of
marking.
● Preparation before disassembly: Remove the front and rear end belt pulleys and flywheel
combination groups, remove the crankcase, reversely fix the cylinder body on the rotating support,
and lift the crankshaft out.
c Removal
Push out the bearing shell from its side by hand, and mark the bearing shell dismantled,
corresponding to saddle bores of the engine block and crankcase.
d Installation
1) First, clean main bearing shell and assembling holes, and wipe them clean.
2) If the bearing shell is not replaced with a new one, mount the upper bearing shell into the
engine block and the lower bearing shell into the crankcase in dismantling sequence. Pay attention
to differentiate the upper and lower bearing shells. The bearing shell with oil groove is the upper
one. If the bearing shell is replaced with a new one, it is directly installed. During installation, pay
attention that the lips should be aligned, and applied with a small amount of oil.
1) Clean the bearing shell, and check wear condition of the bearing shell.
2) Check whether the bearing shell is subject to metal peeling, damage to the locating lip and
transversal cracks.
4.3.4 Disassembly and Assembly of Flywheel Combination Group
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1- Locating pin 2- Flywheel ring gear 3- Flywheel 4- Hexagon bolt

5- Bearing 6- Retainer 7- Flywheel bolt 8- Stud bolt
Figure4-29 Flywheel Combination Group Assembly and Disassembly Diagram

● Tools: Socket spanner, pneumatic wrench
● Preparation before disassembly: Two bolts are needed on the outer ring of flywheel, to
facilitate the removal.
c Removal
Installation is in the reverse order of removal.
d Installation
1) Fix the flywheel gear ring to the flywheel using the bolts.
2) Knock in the parallel pin to the rear end of crankshaft and make sure to knock in the parallel
pin to the end.
3) After inserting the flywheel guide bar in the threaded hole of the crankshaft, mount the
flywheel parts and pre-tighten the flywheel bolts in a diagonal manner;
① Apply lubricating oil to the threads and pressure-bearing surface of the flywheel bolts.
② Flywheel bolt M14×1.5 (9 pieces).
Fasten with hands; after the thread and bearing surfaces are lubricated, the flywheel bolt shall be
20
installed into threaded hole to screw them diagonally, with the tightening torque 60 0 Nm; and then
turn by two 90°±5° angles, and the torque shall reach (230~280)Nm at the same time. Replace the
bolts for which the required torque can’t be met at the specified torsion angle. The bolts can be
re-used for 2 times.
Tighten with auto-wrench; after the thread and bearing surfaces are lubricated, the flywheel bolt
shall be installed into threaded hole to screw them diagonally, with the tightening torque 60Nm;
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and then turn by 160°+5°, and the torque shall reach (230~300)Nm at the same time. Replace the
bolts for which the required torque can’t be met at the specified torsion angle. The bolts can be
re-used for 2 times. The flywheel installation is then completed.
1) Check whether the bolt is subject to thread damage and other failures.
2) Check the flywheel surface for damage;
3) Check whether the flywheel gear ring is damaged;
4) Check whether the flywheel support, flywheel connecting ring, and bushing are damaged.
5) Check whether the contact surface between flywheel and clutch is seriously cracked.
4.3.5 Removal and Installation of Flywheel Ring Gear
Please refer to 4.12.3 for flywheel combination group removal and installation procedures as well
as cautions
4.3.6 Disassembly and Assembly of Vibration Damper and Crankshaft Pulley
1- Crankshaft assembly 2- Vibration damper 3- Crankshaft pulley 4- Hexagon bolt

Figure4-30 Vibration Damper, and Crankshaft Pulley Assembly and Disassembly Diagram

● Tools: Socket spanner, pneumatic wrench
● Preparation before disassembly: Remove the belt and other connecting parts
c Removal
Remove the pulley bolts. Remove the pulley and vibration damper.
d Installation
With the timing gear chamber installed, fix the vibration damper and pulley to the crankshaft flange
using the pulley bolts.
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1) Check the vibration damper for deformation and collision damage.
2) Check whether the pulley is damaged, and bolts are crushed;
3) Check the pulley bolts for damage.
4.4 Disassembly and Assembly of Valve Mechanism Combination Group

4.4.1 Disassembly and Assembly of Valve Mechanism Combination Group
1- Gear 2- Hexagon 3- Camshaft 4- Hexagon 5- Thrust 6- Camshaft 7- Intake

chamber bolt timing gear bolt halfring assembly valve
8- Cylinder 9- Valve 10- Pushrod 11- Lower 12- Valve 13- Upper 14- Valve
head tappet seat of valve spring seat of valve collet
spring spring
15- Valve 16- Pin 17- Rocker 18- Rocker 19- Hexagon 20- Rocker 21- Exhaust
bridge arm arm shaft bolt arm bracket valve
component assembly
Figure4-31 Valve Mechanism Combination Group Disassembly and Assembly
b Removal
Disassemble the rocker arm and rocker arm shaft. For details, see the disassembly procedures.
1) Disassemble the intake and exhaust valves. For details, see the valve disassembly procedures;
2) Disassemble the tappet and pushrod. For details, see the tappet and pushrod disassembly
procedures;
3) Disassemble the camshaft and camshaft timing gear. For details, see the disassembly
procedures.
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4) Disassemble the intermediate gear. For details, see the disassembly procedures.
c Installation
1) Assemble the intermediate gear. For details, see the intermediate gear assembly procedures;
2) Assemble the camshaft and camshaft timing gear. For details, see the camshaft and camshaft
timing gear assembly procedures.
3) Assemble the tappet and pushrod. For details, see the tappet and pushrod assembly procedures;
4) Assemble the intake and exhaust valves. For details, see the intake and exhaust valves
assembly procedures;
5) Assemble the rocker arm and rocker arm shaft. For details, see the assembly procedures.
4.4.2 Disassembly and Assembly of Camshaft
1- Hexagon bolt 2- Camshaft timing gear 3- Hexagon bolt 4- Thrust halfring

5- Camshaft assembly 6- Gear chamber 7- Engine block
Figure4-32 Camshaft Disassembly Diagram

● Tools: Torque spanner, small wrench, oil can, and lubricating oil
● Preparation before disassembly: Fix the engine on the removing stand, and after removal of
rocker arm cover, remove the rocker arm and rocker arm shaft.
c Removal
1) Turn the crankshaft, and check whether the camshaft assembly and timing gear are flexible,
without blockage;
2) Check visually for axial play of the camshaft.
3) Check the timing gear backlash.
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4) On the working bench for installation and removal of the engine, turn the crankshaft to enable
the camshaft timing gear to be at the top dead center of the 1st cylinder. Check whether the
hexagon bolts fixing the crankshaft 5) timing gear are loosened, and remove the hexagon bolts of
crankshaft timing gear, to remove the timing gear;
5) Remove the hexagon bolts for camshaft thrust halfrings. Remove the thrust halfrings. Remove
the camshaft assembly.
d Installation
1) With the camshaft assembly and timing gear removed, check them for excessive wear or
deviation from parameter specifications. If any, repair the camshaft and timing gear, or replace
them with new ones.
2) Using a towel, clean the camshaft holes. Check the hole for collision damage. Using a
lubricator, apply lubrication oil to the camshaft bushings. The camshaft hole with collision damage
(if any) removed is not permitted.
3) Place the crankshaft guide tool and crankshaft lubricating sleeve into the crankshaft hole, clean
the crankshaft and check whether it is knocked or damaged, align the cylinder on the tail of guide
tooling to the cylinder on the head of crankshaft, and then penetrate the crankshaft assembly into
the crankshaft hole; after the installation of crankshaft, take down the crankshaft guide tool and the
crankshaft sliding sleeve. While inserting the camshaft through the camshaft hole, be careful not to
cause damage to the camshaft bushing.
4) Install the crankshaft thrust plate, apply clear lubricating oil on the two sides of crankshaft
thrust plate, turn the crankshaft and it shall be able to rotate flexibly, and apply sealant 242 on the
threaded part of thrust plate bolt, and then tighten it.
5) Polish the rear end face of cylinder body, and clean it after applying oil, the junction surface
shall be smooth and clean, beat the rear end face of crankshaft into the round pin, and then install
the flywheel cover connecting plate, and finally tighten four tightening bolts;
6) Apply special adhesive on the connecting plate, and the glue line shall be continuous and even;
7) Fasten the bolts used for camshaft thrust plate and timing gear on the camshaft.
1) Check
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a) Check whether the cam surface in contact with the tappet is worn or not, and whether the main
bearing journal is seized or worn;
b) Check whether the timing gear fastening hexagon bolts are bent and deformed; and check
whether the camshaft timing gear is broken in tooth or whether the tooth surface is serious worn.
2) Assembly
a) The camshaft hole with collision damage (if any) removed is not permitted.
b) While inserting the camshaft through the camshaft hole, be careful not to cause damage to the
camshaft bushing.
c) Apply sealant242 on the threaded part of thrust plate bolt, and the tighten it.
4.4.3 Disassembly and Assembly of Rocker Arm
1- Cylinder head 2- Valve bridge 3- Parallel pin 4- Rocker arm assembly

5- Rocker arm shaft assembly 6- Hexagon bolt 7- Rocker arm bracket
Figure4-33 Rocker Arm Disassembly Diagram

● Tools: Torque spanner, small wrench, oil can, and lubricating oil
● Preparation before disassembly: Fix the engine on the removing stand, and after removal of
rocker arm cover, remove the rocker arm and rocker arm shaft.
c Removal
1) Turn the crankshaft, and observe whether the rocker arm is turned flexibly.
2) Measure clearance of individual valves, and check change in clearance of the valves.
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3) If the rocker arm cannot rotate flexibly or the valve clearance has a larger change, loosen the
hexagonal head screws and gently take down EVB support, rocker arm shaft assembly, rocker arm
assembly, rocker arm bracket, and mark them correspondingly, to avoid the mixing of rocker arms
of each cylinder.
d Installation
1) Place the rocker arm on the operating desk, screw the adjusting screw on the rocker arm and
unscrew the nut to check;
2) Install round pin into the pin hole on the lower plane of rocker arm shaft, beat the round pin to
the bottom, and the round pin shall be crack-free;
3) Tighten the hexagon bolts to two M5 screw holes on two sides of the rocker arm shaft assembly,
apply 271 sealant on the screws not pre-glued, and the screw heads shall be (0~1)mm concave on
the side of rocker arm shaft;
4) Assemble the rocker arm bracket and the rocker arm shaft assembly, tightly combine the rocker
arm bracket and the rocker arm shaft assembly, apply little lubricating oil on the rocker arm shaft
assembly and then install the rocker arm parts, the rocker arm parts shall be able to flexibly turn;
and finally insert two hexagon bolts on the rocker arm shaft assembly;
5) After installation of valve push rod, as shown in valve push rod assembly process, and then
place valve bridge respectively on the intake valve and the exhaust valve;
6) Install the rocker arm parts and pre-tighten them; align the pin hole on the lower side of rocker
arm bracket to the locating pin on the upper plane of cylinder head; and place the ball pin of rocker
arm into the round hole of valve push rod;
 Check and adjust the clearances of intake and exhaust valves.
1) Manually rotate the flywheel until the piston in the 1st cylinder reaches top dead center, that is,
the scale on the flywheel aligns with that on the flywheel cover.
2) Adjust the intake valve clearance of the 1st, 2nd, and 4th cylinders, which shall be (0.38±0.03）
mm. Adjust the exhaust valve clearance of the 1st, 3rd, and 5th cylinders, which shall be (0.58±0.03)
mm. The adjusting nuts of intake and exhaust valves shall be tightened to the torque of (45±5)
Nm.
3) Install turning gear fixing device on the flywheel cover and fasten the two hexagon nuts on the
outside, and set the turning gear be in the position of top dead center of cylinder 6;
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4) Adjust the clearances of intake valves of cylinders 3, 5 and 6 as well as of exhaust valves of
cylinders 2, 4, and 6. The piston of cylinder 6 is in the top dead center of explosion. The intake
valve clearance shall be (0.38±0.03)mm；the exhaust valve clearance shall be (0.58±0.03)mm；
5) Clod state inspection of cylinder valve timing phase before opening of top dead center of
intake valve (22±5)° and after closing of top dead center of exhaust valve (22±5)°, after the closing
of bottom dead center of intake valve (25±5)°, and before the opening of top dead center of exhaust
valve (60±5)°.
1) Check after disassembly
a) Clean the rockers and observe the appearances of rockers for presence of defects (such as
cracking).
b) Check whether the rocker arm hole is worn or abraded, and measure its diameter;
c) Check whether the ball pin and rocker arm base are worn.
d) Check the all oil-ways for presence of obstruction.
e) Measure the rocker arm hole diameter and rocker arm shaft diameter, and calculate the fitting
clearance.
f) Check whether the rocker arm shaft combination group is worn, and whether the rocker arm
bracket is in good condition and free of crack and wearing.
2) Assembly
Apply little lubricating oil on the rocker arm shaft, and then install the rocker arm component, and
the rocker arm component shall rotate flexibly, and then insert two hexagon bolts on the rocker arm
shaft assembly.
4.4.4 Disassembly and Assembly of Tappet and Pushrod
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1- Engine block 2- Tappet 3- Cylinder head 4- Pushrod
Figure4-34 Tappet and Push Rod Disassembly Diagram

● Tools: Tappet installation tool, and lubricating oil can.
● Preparation before disassembly: After the cylinder head is removed, unscrew the fixing
hexagon bolts of rocker arm shaft assembly, and then remove the push rod; after removal of
cylinder head, remove the tappet.
c Removal
1) After the rocker arm and rocker arm shaft have been dismantled, directly remove the pushrod,
and put it aside in order;
2) After removing the cylinder head (for details, see the removal procedures), take out the tappets
and place them in order.
d Installation
1) Check whether the tappet and pushrod have a problem, and if a problem occurs, replace them
with a new one, respectively. Before installation of the tappet, must purge it with compressed air,
and check whether the oil hole is unobstructed;
2) Apply clean lubricating oil on the outer circle and bottom of valve tappet evenly;
3) Install the tappet in the tappet hole with tappet installation tools, and during the installation
process, both tappet and tappet hole shall not bump with each other.
4) After assembly of cylinder head (please refer to cylinder head assembly procedures), purge the
push rod with compressed air, and check whether the oil hole is unimpeded;
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5) Apply clean lubricating oil to the push rods. Ensure that the push rod ends are sufficiently
lubricated.
6) Install the push rod, with the spherical surface facing down.
1) Check after removal
a) Clean the push rods and tappets;
b) Check the oil passages of the tappets and push rods for obstruction;
c) Check the push rods for bending and excessive wear;
d) Check the ball ends of the push rods for excessive wear;
e) Check the cylindrical surfaces and undersides of the tappets for excessive wear;
f) Check the mating sockets of the tappets for excessive wear.
2) Assembly
a) Apply clean lubricating oil on the outer circle and bottom of valve tappet evenly;
b) Apply clean lubricating oil to the push rods. Ensure that the push rod ends are sufficiently
lubricated.
4.4.5 Disassembly and Assembly of Valve
1- Intake valve 2- Cylinder head 3- Lower seat of valve spring 4- Upper seat of valve spring
5- Valve collet 6- Valve spring 7- Exhaust valve
Figure4-35 Valve Disassembly Diagram

● Tools: Valve spring compressor or valve overhead pliers or other valve spring tools
● Preparation before disassembly: After removal of rocker arm shaft, take down the cylinder
head from the engine body, and then remove the valves.
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c Removal
1) Using the valve spring compressor or an overhead-valve spring pincer or another equivalent
tool, compress squarely the upper seat of valve springs. Remove the valve collets. Remove the
upper retainers for the valve springs, and the valve springs;
2) Remove the intake and exhaust valves from the valve seat.
d Installation
1) If the valve is worn or seriously carbon-deposited or has other bad phenomena, it is required to
change the used valve with a new one.
2) Apply some molybdenum disulfide paste on the intake and exhaust valve stems evenly, and
assemble the intake and exhaust valves into the cylinder head, ensuring that the intake and exhaust
valves slide in the guide, without blockage;
3) Beat the locating pins on the upper plane of cylinder head, three on each cylinder head, and the
locating pins shall be beat to the bottom.
4) Install the lower seat of intake valve spring. Put the protective sleeves in the valve guides.
Install the valve stem seal. Before assembling, must check whether the internal spring in the sealing
bush of the valve stem is kept intact.
5) Install the valve spring;
6) Install the upper retainer for the valve spring. Press the valve spring in place. Install the valve
collet;
7) After installation of the valve collets, tap the intake and exhaust valves using a rubber hammer
so that the valve collets come in close contact with the upper retainers for the valve springs. If the
valve collets fail to come in contact with the upper retainers for the valve springs, identify then
remove the causes.
1) Check after disassembly
a) Check whether the valve stem and valve stem end surface are worn;
b) Check whether the valve cone is worn or damaged;
c) Check whether the cone surface and arc surface of valve is accumulated with carbon or worn.
2) Assembly
a) Guarantee that the intake valve and exhaust valve to slide in the conduit without blocking;
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b) Before assembling, must check whether the internal spring in the sealing bush of the valve
stem is kept intact.
4.5 Intake and Exhaust System

4.5.1 Disassembly and Assembly of Intake and Exhaust System
1- Intake pipe assembly 2- Exhaust pipe 3- Turbocharger 4- Turbocharger lubricating oil pipe
Figure4-36 Air Intake and Exhaust System Disassembly Diagram
b Disassembly
The disassembly sequence is opposite to the assembly sequence.
c Installation
1) According to the intake pipe assembly procedures, assemble the intake pipe and other parts on
the side of air intake;
2) According to the exhaust pipe assembly procedures, assemble the exhaust pipe and other
related parts on the side of air exhaust;
3) According to the turbocharger assembly procedures, install the turbocharger and other parts on
the exhaust pipe;
4) According to the assembly procedures of oil inlet and return pipes of turbocharger, assemble
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the turbocharger oil inlet pipe assembly and oil return pipe assembly, and then fasten the oil pipe
assemblies through clamps.
4.5.2 Disassembly and Assembly of Turbocharger Combination Group
1- Return pipe bolt 2- Self-lock washer 3- Turbocharger oil return 4- Pipe joint
pipe assembly
5- Turbocharger oil return 6- Turbocharger oil inlet 7- Turbocharger oil inlet 8- Self-lock
pipe gasket pipe gasket pipe assembly washer
9- Hex socket-head cap 10- Hexagon screw plug; 11- Sealing washer 12- Pressure
screw sensor joint
Figure4-37 Turbocharger Oil Inlet and Return Pipe Combination Group Disassembly Diagram
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1- Turbocharger 2- Stud 3- Turbocharger 4- 2 fully-metallic 5- Stud 6- 2 fully-metallic

gasket bolt hexagon locknut bolt hexagon locknut
Figure4-38 Turbocharger Combination Group Disassembly Diagram

● Tools: Pneumatic wrench, internal hexagonal wrench, sleeve, copper hammer, lubricating oil,
and brush;
● Preparation before disassembly: Remove other peripherals on the turbocharger.
c Disassembly
The disassembly sequence is opposite to the assembly sequence.
d Installation
1) Screw one end of the turbocharger oil inlet pipe in the screw plug in the rear screw plug of the
main oil passage in the cylinder block. Adjust the position of the oil inlet pipe for easy connection
to the turbocharger.
2) Assemble the turbocharger gasket onto the exhaust pipe flange.
3) Mount the return pipe of the turbocharger and stud bolt onto the turbocharger assembly, and
apply 0# molybdenum disulfide and clean lubricating oil onto the stud bolt. Tighten the return pipe
bolt to a torque within 22Nm -29Nm.
4) Place a turbocharger gasket between the exhaust pipe flange and the turbocharger assembly,
and mount the type 2 fully-metallic hexagon locknut in a loose fit manner, and then tighten it.
5) Inject proper amount of clean lubricating oil into the turbocharger oil inlet, and wipe away the
spilled lubricating oil.
6) Install the turbocharger oil inlet pipe and washer. Slightly tighten the hex socket head cap bolt
and self-lock washer. Tighten the inlet pipe bolt to a torque within 22Nm -29Nm. Rotate the
turbocharger impeller to determine whether it rotates freely without jamming.
7) Install the oil return bent pipe. Apply Loctite 271 thread locker to the outer surface of mating
end of the oil return bent pipe.
8) Assemble the return pipe and pipe clamp of the turbocharger, and tighten them. Note that the
two pipe clamps shall be in the same direction and adjust the position of return oil pipe;
9) All washers may be used once. Replace them with new ones when the turbocharger system is
repaired.
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1) Check the running status of rotor

By lightly turning the air compressor impeller with hand, rotation of the impeller by more than 1
turn indicates that it is in normal condition. If the impeller stops immediately, it indicates that the
bearing is worn abnormally or collision or jamming between the rotating part and the stationary
part occurs, it is required to analyze cause and carry out troubleshooting.
2) Check the run-out of rotor
Enable the dial indicator probe to be against the air compressor end, and push and pull the rotator
shaft, and measure and record difference indicated on the dial indicator, as shown in Figure 4-38.
The rotor displacement should be within 0.088mm~0.118mm, and in case of exceeding this range,
it indicates that the thrust bearing plate or thrust halfring and bearing body are worn, and it is
required to analyze cause and eliminate the problem.
Figure4-39 Axial Clearance Measurement Diagram
3) Check the radial clearance of air compressor impeller

Press the air compressor impeller by hand in axial direction, and use a plug gauge to measure the
minimum and maximum clearance between the air compressor impeller and air compressor scroll,
as shown in Figure 4-39. This value should be within 0.4mm~0.8mm, and in case of exceeding this
range, it is required to check the bearing, and eliminate the problem.
Note: The measurement should be carried out in cold state of the turbocharger.
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Figure4-40 Axial Clearance Measurement Diagram
4) Check whether the connecting pipe between the turbocharger and the engine is loosened or not,
and if any, eliminate the problem.
5) Check whether the turbocharger is subject to air leakage or oil leakage, and if any, it is required
to timely eliminate the problem in time.
6) Check whether the fastening screws of the turbocharger are loosened or not, and if any, it is
required to eliminate the problem in time.
7) Check the air filter, and if the air filter is dusted heavily, it required to clean it in time.
4.5.3 Disassembly and Assembly of Intake Pipe Combination Group
1- Intake pipe 2- Intake pipe gasket 3- Hexagon 4- Hexagon 5- Intake pipe

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assembly flange bolt flange bolt gasket

6- Intake 7- Hexagon flange 8- Gasket 9- Heater 10- Intake
connecting pipe bolt connecting pipe;
11- Flat washer 12- Flexible 13- Hexagon bolt
corrugated gasket
Figure4-41 Intake Pipe Combination Group Disassembly Diagram

● Tools: Pneumatic wrench, sleeve
● Preparation before disassembly: Remove the peripherals on the intake pipe
c Disassembly
1) Loosen the intake pipe bolts in sequence, and remove the intake pipe, intake connecting pipe
and gasket.
2) Loosen the intake throttle valve fastening nuts, and take down the intake throttle valve gaskets.
3) Loosen the fixing nuts of the intake pipe, and remove the intake connecting pipe, intake heater
and heater gasket.
d Installation
The assembly procedures are in the reverse order of the disassembly procedures. The bolts should
be tightened to the torque of 23Nm.
1) Check whether the intake pipe is cracked, deformed or damaged, and if any, it is required to
replace the pipe with a new one.
2) Check whether the intake pipe gasket, heater gasket, and intake throttle valve gasket are
deformed, torn, or missing; replace a new one with defects.
3) Check whether the intake heater is burned out and shorted, and if any, it is required to replace
it.
4.5.4 Disassembly and Assembly of Exhaust Pipe Combination Group
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1- Exhaust pipe gasket 2- Front exhaust 3- Exhaust pipe seal 4- Middle exhaust
manifold ring manifold
5- Rear exhaust 6- Sleeve 7- Exhaust pipe bolts
manifold
Figure4-42 Exhaust Pipe Disassembly Diagram

● Tools: Pneumatic wrench, sleeve
● Preparation before disassembly: Remove the turbocharger, thermal shield and other parts
c Disassembly
1) Loosen the fastening bolts of front and rear exhaust manifolds in order, and then take down the
front and rear exhaust manifolds, sleeves and gaskets.
2) Separate the front and rear exhaust pipes, and take down the front and rear exhaust manifolds
and connecting sealing rings.
3) Loosen the fastening bolts of the middle manifolds in order, and then take down the middle
exhaust manifold, sleeves and gaskets.
d Assembly
The assembly procedures are in the reverse order of the disassembly procedures.
1) Check whether the exhaust pipe is cracked or damaged, and the flange is deformed, and if any,
it is required to replace the use exhaust pipe with a new one.
2) Check whether the exhaust pipe flange is subject to gas leakage, and if any, it is required to
replace the used exhaust pipe gasket with a new one.
3) Check the washer of exhaust pipe for deformation, tear and absence. If necessary, replace it
with a new one.
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4) Check the seal ring for sintering, rust, and carbon deposit. If any, replace it with new one.
5) During the installation of exhaust pipe, it is required to not scratch the exhaust pipe connection
surface.
6) Apply molybdenum disulfide on the exhaust pipe bolts, and the exhaust pipe bolts can be used
for two times repeatedly at most.
7) The bolts and nuts used by exhaust system are made of heat resistant steel, so it is forbidden to
use the ordinary bolts and nuts instead.
4.6 Fuel System

4.6.1 Fuel Oil System Diagram
Coarse filter Fuel delivery pump
Fine filter
Tank Return fuel

Fuel injection pump;
Fuel injector
Combustion chamber
Figure4-43 Fuel Oil System Diagram
4.6.2 Disassembly and Assembly of Fuel System

Figure4-44 Fuel System Disassembly Diagram

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b Removal
1) Remove the low-pressure fuel pipe
2) Remove high-pressure fuel pipe
3) Remove the fuel injector
4) Remove the filter
5) Remove high-pressure fuel pump
c Installation
4.6.3 Disassembly and Assembly of Fuel Injection Pump Combination Group
1- Fuel injection 2- Fuel injection 3- Fuel injection 4- Seal ring 5- Bracket

pump flange pump assembly pump gear
6- Stud bolt 7- Type 2 hexagon 8- Flat washer 9- Self-lock washer 10- Hexagon
nut bolt
11- 1support 12- support 13- Hexagon 14- Hexagon flange 15- Spring
flange bolt bolt washer
16- Type 1 hexagon 17- Air pipe of 18- Hollow bolt 19- Combination
nut smoke limiter sealing washer
Figure4-45 Fuel Injection Pump Combination Group Disassembly Diagram
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● Tools: Socket wrench or open spanner
● Preparation before disassembly: Before disassembly of fuel injection pump, firstly remove the
high-pressure oil pipe, low-pressure oil pipe, lubricating oil pipe, and air pipe of smoke limiter
connected to the fuel injection pump.
c Removal
1) Remove the hexagon nuts used for fixing the fuel injection pump flange to the gear chamber.
2) Remove the fuel injection pump and gear subassembly from the engine;
3) Remove the locking nut of the fuel injection pump;
4) Remove the hexagon bolts used for fixing the fuel injection pump to the flange
5) Remove the fuel injection pump flange
d Installation
1) Manually rotate the flywheel until the piston in the 1stcylinder reaches 21º CA before top dead
center. Slightly fix the fuel injection pump to the flange (the stud bolt is in the middle of the fuel
injection pump kidney-shape slot). Install the fuel injection pump gear and flange, with their scales
aligning with each other. During the installation, check the position of the scale of fuel injection
pump gear (see the figure below, the piston in the 1st cylinder is 21º before the top dead center in
the compression stroke, and the scale deviates by 2.41º from the vertical line), or check the position
of the timing pin.
2) Finally, achieve the specified fuel injection advance angle by adjusting the fuel injection pump
kidney-shape slot.
3) Tighten the hexagon nuts for fixing the fuel injection pump to the gear chamber.
Scale on the
gear
Figure4-46 Fuel Injection Pump Gear Carving Diagram

e Check the fuel supply starting point of the fuel injection pump
1) Manually rotate the flywheel to （30~40）° before the top dead center in the compression stroke
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of the 1st cylinder;

2) Remove the high-pressure fuel pipe from fuel injection pump to the 1st cylinder. Clockwise
rotate the flywheel until the fuel level at the joint of high-pressure fuel pipe to the 1st cylinder
slightly increases. Read the fuel injection advance angle from the flywheel.
f Check the fuel supply starting point of the fuel injection pump
Manually rotate the flywheel (in the normal direction, not the opposite direction) to the
specified fuel advance angle before the top dead center in the compression stroke of the 1st cylinder.
Remove the high-pressure fuel pipe to the 1st cylinder. Set the throttle at the maximum opening.
Bleed air out of the fuel pipe. Manually slowly rotate the flywheel (in the normal direction, not the
opposite direction) until fuel just comes out of the delivery valve of the 1st cylinder. Record the
position of flywheel at the moment. Without operating the pump, tighten the pump fixing bolt.
Observe the fuel injection advance angle. If the angle does not comply with the requirement, adjust
it by loosening the pump fixing bolt, and manually rotating the pump.
4.6.4 Disassembly and Assembly of High-pressure Oil Pipe Combination Group
1- High-pressure oil 2- High-pressure oil 3- High-pressure oil 4- High-pressure oil

pipe of cylinder 1 pipe of cylinder 2 pipe of cylinder 3 pipe of cylinder 4
5- High-pressure oil 6- High-pressure oil 7- Pipe clamp
pipe of cylinder 5 pipe of cylinder 6
Figure4-47 High-pressure Oil Pipe Combination Group Disassembly Diagram

● Tools: Open spanner
● Preparation before disassembly: High-pressure oil pipe may be directly disassembled.
c Removal
1) Remove high-pressure fuel pipe bracket
2) Remove high-pressure fuel pipe
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d Installation
High-pressure oil pipe fixing nut fastening torque: (30~40)Nm at the end of fuel injector,
(30~40)Nm at the side of track and oil pump
4.6.5 Disassembly and Assembly of Fuel Injector Combination Group
1- Fuel 2- High pressure 3- Gland 4- Fuel injector 5- Washer 6- Hexagon

injector connection nut clamping block nut;
Figure4-48 Fuel Injector Combination Group Disassembly Diagram

● Tools: Ordinary open spanner or socket spanner
● Preparation before disassembly: Before disassembly of fuel injector, firstly remove the
high-pressure oil pipe and rocker arm cover.
c Removal
1) Remove the hexagon bolt used for fixing the fuel injector clamping block.
2) Remove the fuel injector clamping block and fixed block.
3) Loosen the gland nuts of high pressure connection
4) Take the fuel injector assembly from the cylinder head.
d Installation
1) The contact surface between the fuel injector and O-shaped seal ring of high pressure
connection, as well as between the high pressure connection thread and nut and the connection shall
be applied with lubricating oil during installation.
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2) The various protective caps can be removed only before their installation.
3) Place the fuel injector into the cylinder head, and then screw up the clamping bolts of fuel
injector with 3Nm moment.
4) Loosen the clamping bolts of fuel injector, to make their axial force to fuel injector be 0 kN.
5) Pre-fasten the high pressure connection (nut) with the moment (15-20) Nm.
6) Fasten the fuel injector clamping bolt with the moment 10Nm +120°.
7) Fasten the high pressure connection (nut) with the moment (50-55) Nm.
8) High pressure connection, O-shaped seal ring, and seal washer can be used only for one time.
After assembly, check the O-shaped seal ring and seal washer for tightness.
BOSCH fuel injector shall be replaced in the special maintenance service station of BOSCH.
Note: Fuel injectors with different part numbers may not be exchanged
4.7 Cooling System

4.7.1 Cooling System Diagram
Expansion tank Fan heater
Water outlet pipe

Radia
tor Fan Thermostat
Inter-c
ooler
Cylinder head
Cylinder block
Water pump Oil cooler

Driving direction
Figure4-49 Cooling System Diagram
4.7.2 Disassembly and Assembly of Cooling System

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1- Fan 2- Ribbed 3- Water pump 4- Water pump 5- Thermostat 6- Water outlet

and hub belt inlet pipe assembly pipe assembly
Figure4-50 Cooling System Disassembly Diagram
b Removal
1) Remove the fan and hub. For details, see the instructions for removal of fan and hub;
2) Swing the tensioning wheel clockwise, remove the belt tensioning force, and dismantle the
poly V-belt;
3) Remove the water pump inlet pipe. For details, see the instructions for removal of fan and hub;
4) Remove the water pump assembly. For details, see the instructions for removal of water pump
assembly;
5) Remove the water outlet pipe assembly. For details, see the instructions for removal of water
outlet pipe assembly;
6) Remove the thermostat. For details, see the instructions for removal of thermostat.
c Installation
4.7.3 Disassembly and Assembly of Fan and Hub Combination Group
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1- Fan 2- Hexagon flange 3- Fan connecting 4,6- Hexagon 5- Hexagon flange

bolt plate locknut bolt
Figure4-51 Fan and Hub Combination Group Disassembly Diagram

● Tools: Socket spanner or pneumatic wrench, open spanner
c Removal
1) Remove the connecting bolts and nuts between fan and fan connecting plate, to remove the fan;
2) Remove the bolts and nuts, to remove the fan connecting plate.
d Installation
1) Before assembly, firstly check the fan, fan connecting plate, bolts and nuts, to guarantee no
defects and damages in manufacture and use;
2) Check whether the fan and fan drive shaft have damages like crack.
4.7.4 Disassembly and assembly of water pump inlet pipe combination group
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1- Water pump 2- Water inlet pipe 3- Water pump inlet 4,5 Hexagon flange bolt
assembly gasket pipe
6- Pipe joint 7- Square head tapered 8- Hexagon flange bolt 9- Hexagon head screw
plug plug
Figure4-52 Water Pump Inlet Pipe Combination Group Disassembly Diagram

● Tools: Socket spanner or pneumatic wrench, copper hammer
● Preparation before disassembly: Remove the front end gear poly V-belt, to dismantle the
generator
c Removal
1) Remove two hexagon flange bolts
2) Remove the hexagon flange bolts, and take down the water pump inlet pipe and gasket;
3) Remove the coupling, square head tapered plug and hexagon head plug.
d Installation
1) Before assembly, check each part, to guarantee no defects and damages in manufacture and
use.
2) Check the pipe joint for blockage, cracks. If any, replace them with new one.
3) Check whether the water inlet pipe gasket is broken or has other damages, and replace the
defective gasket if any.
4) Check the bolts for scratches. If any, replace them with new ones.
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4.7.5 Disassembly and assembly of water pump combination group

1- Water pump 2- Stud 3- Locking hexagon nut 4- Water pump 5- Hexagon flanged
pulley bolt assembly lock nut
6- Water pump 7,8- Stud 9- Combination sealing 10- Hexagon head
gasket bolt washer screw plug
Figure4-53 Water Pump Combination Group Disassembly Group

● Tools: Socket spanner or pneumatic wrench, open spanner, copper hammer
● Preparation before disassembly: Remove the fan, front end gear poly V-belt, and water pump
inlet pipe
c Removal
1) Remove the hexagon flange nuts on the water pump, and take down the water pump assembly
and water pump gasket;
2) Remove the stud bolts
3) Remove the hexagon nuts, and take down the water pump pulley;
4) Remove the stud bolts
d Installation
1) Before assembly, firstly check the nut, bolt, water pump gasket, and water pump, to guarantee
no defects and damages in manufacture and use;
2) Clean the inner cavity of gear chamber that links the water pump.
3) Installation is in the reverse order of removal.
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4) Check whether the water pump gasket is broken or has other damages, replace the defective
one if any with a good one;
5) Check each bolt and nut for threaded scratch and other damages, and replace the defective one
if any with a good one;
6) Check the water pump for cracks. If any, replace it with a new one.
4.7.6 Disassembly and Assembly of Thermostat Combination Group
1- Water outlet 2- Hexagon 3- Thermostat 4- Blanking 5- Pipe 6- Built-in

pipe assembly flange bolt body cap coupling thermostat
component
7- Thermostat 8- Blanking 9- Hexagon 10- Clamp 11- Coolant
cover cap flange bolt connecting hose
Figure4-54 Thermostat Combination Group Disassembly Diagram

● Tools: Socket spanner or pneumatic wrench, open spanner, rubber hammer
● Preparation before disassembly: Remove all water pipeline connecting hoses on the thermostat
assembly.
c Removal
1) Remove the clamp and hose from the thermostat to the water pump inlet;
2) Remove three hexagon flange bolts, to remove the thermostat assembly;
3) Remove the hexagon bolts, and take down the thermostat cover;
4) Take down the thermostat.
d Installation
1) Before assembly, firstly check the gasket, bolt, thermostat, and thermostat cover, to guarantee
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no defects and damages in manufacture and use;

2) Clean the water outlet pipe of water pump. Ensure no ingress of foreign matters in the water
outlet pipe.
3) Installation is in the reverse order of removal.
1) Check whether the thermostat cover has damages like crack, and replace the defective one if
any with a good one;
2) Check whether the gasket is in good condition, and replace the defective one if any with a good
one;
3) Check the thermostat for breakage. If any, replace it with a new one.
4.7.7 Disassembly and Assembly of Water Outlet Pipe Combination Group
1- Water outlet 2,3,4- Hexagon 5- Gasket 6- Water outlet 7- Sealing

pipe flange bolt pipe gasket washer
8- Hexagon head 9- Water block 10- Combination 11- Hexagon head
screw plug sealing washer screw plug
Figure4-55 Water Outlet Pipe Combination Group Disassembly Diagram

● Tools: Socket spanner or pneumatic wrench, open spanner, rubber hammer
● Preparation before disassembly: Remove thermostat assembly
c Removal
1) Remove the hexagon flange bolts in order, and take down the water outlet pipe and gasket;
2) Remove hexagon head plug, bonded washer, water block, seal washer, and other parts;
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d Installation
1) Recommendation is that the gasket should be used only once. Replace it with a new one in the
servicing of intake pipe.
2) Clean the water outlet pipe mating face. Then connect the pipe to the cylinder head and insert
the fixing bolts.
3) Tighten the fixing bolts.
4) Fasten the hexagon head plug, bonded washer, water block, and seal washer in order on the
water outlet pipe;
1) Before removal, check the water outlet pipe for cracks, excessive wear, corrosion, and sign of
leakage. If any cracks, replace the pipe. In the case of serious corrosion that could affect reliability,
analyze the cause and replace the pipe.
2) In the case of water leakage at pipe joint, replace the joint with a new one, and then check for
sign of leakage again. In the case of damaged threads of water outlet pipe, replace the pipe with a
new one.
4.8 Lubrication System

4.8.1 Lubrication System Diagram
4.9.1.9 Lubrication system diagram
Suction Machine Filter Engine

filter pump seat oil filter
Safety
valve
Oil pan Oil

cooler
Connecti Main
ng rod bearing
Turbocha Main
rger oil
passage
Rocker Pushrod Tappet Camshaf
arm t bearing
Fuel
injection
Secondar
Intermed
iate gear y fuel Pressure
relief
Piston Piston
cooling
Secondar
y
Figure 4-58 Lubrication system diagram
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Figure4-56 Lubrication System Diagram
4.8.2 Disassembly and Assembly of Lubrication System

1- Oil pan 2- Suction 3- Oil 4- Engine oil filter 5- Oil

filter pump dipstick
6- Engine oil cooler 7- Oil cooler 8- Oil 9- Main oil passage pressure 10- Oil filler
bypass valve cover cooler control valve pipe
Figure4-57 Lubrication System Disassembly Diagram
b Removal
1) Remove the oil pan. For details, see the instructions for removal of oil pan.
2) Remove the suction filter
3) Remove the crankshaft pulley, vibrator, and hexagonal thread plug on the gear chamber. For
details, see the instructions for removal of crank connecting rod mechanism.
4) Remove the engine oil pump intermediate gear subassembly.
5) Remove the oil pump
6) Remove the main oil passage pressure control valve
7) Remove the engine oil filter
8) Loosen the hollow bolt on the engine oil cooler cover, and the hexagon bolt used for fixing the
oil dipstick subassembly. Remove the engine oil cooler cover.
9) Remove the oil cooler
10) Remove the engine oil cooler bypass valve.
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c Installation
4.8.3 Disassembly and Assembly of Oil Pan Combination Group
1- Sealing 2- Oil pan 3- Hexagon flange 4- Oil 5- Washer 6- Magnetic

gasket supporting block bolt pan plug
Figure4-58 Oil Pan Combination Group Disassembly Diagram

● Preparation before disassembly: Unscrew the oil drain screw block, to empty the oil
c Removal
1) Turn over the diesel engine with the oil pan facing up;
2) Remove the oil pan fixing bolts;
3) Remove the oil pan supporting block;
4) Remove the oil pan and sealing gasket;
5) Remove the magnetic plug and combination washers.
d Installation
1) Before removing the oil pan, drain oil from it. Place the container containing oil beneath the
drain plug of the oil pan, and use a screw plug wrench to loosen the drain plug to empty oil.
2) Fix the bolts in the sequence as shown in Figure 4-58 to the torque of (22~29) Nm.
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Figure4-59 Sequence for Tightening the Oil Pan Fixing Bolts
4.8.4 Disassembly and Assembly of Engine Oil Pump Combination Group

1- Hexagon flange bolt 2- Hexagon flange bolt 3- Oil pump 4- Engine oil pump gasket
Figure4-60 Engine Oil Pump Combination Group Disassembly Diagram
a Preparation before disassembly

● Preparation before disassembly: Remove oil pan and suction filter
b Removal
Loosen the two hexagon head flanged bolts on the engine oil pump. Remove the engine oil pump
and gasket.
c Installation
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1) Before installation, check the engine oil pump and gasket for defects in manufacturing or
application, and damage. They shall be in good conditions.
2) Clean the mating faces of the engine oil pump and crankcase;
3) Install the engine oil gasket;
4) Install the engine oil pump;
5) Install the two hexagon head flanged bolts, and then tighten them.
d Key points of maintenance
1) Check the engine oil pump for cracks. Check whether the inner cavity of the pump is smooth.
If necessary, remove the pump;
2) Check the engine oil pump gasket for leakage. If any, analyze the cause and replace the gasket
with a new one.
4.8.5 Disassembly and Assembly of Engine Oil Pump Intermediate Gear
1- Hexagon 2- Seal 3- Intermediate gear 4- Engine oil intermediate gear

bolt ring shaft subassembly
Figure4-61 Engine Oil pump Intermediate Gear Assembly Disassembly Diagram

● Preparation before disassembly: Remove oil pan , oil pump and suction filter
c Removal
1) Loosen and remove the hexagon bolt.
2) Using a special tool, remove the intermediate gear shaft. Then remove the engine oil pump
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intermediate gear subassembly.

d Installation
1) Before installation, check the engine oil pump intermediate gear subassembly, intermediate
gear shaft, hexagon bolts, and seal ring for defects in manufacturing or application, and damage.
2) Clean the mating faces of crankcase and engine oil pump intermediate gear subassembly, and
the engine oil pump intermediate gear subassembly.
3) Install the seal ring to the intermediate gear.
4) Install the engine oil pump intermediate gear, with its raised side facing inward.
5) Install the intermediate gear shaft
6) Install the hexagon bolts, and then tighten it.
1) Check the engine oil pump intermediate gear and intermediate gear shaft for cracks. If any,
replace them with new ones;
2) Check the seal ring for breakage. If any, replace it with a new one.
4.8.6 Disassembly and Assembly of Suction Filter Combination Group
1- Gasket 2- Flat washer 3- Hexagon bolt 4- Suction filter
Figure4-62 Suction Filter Combination Group Disassembly Diagram

● Preparation before disassembly: Remove oil pan
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c Removal
Loosen the two hexagon bolts of the suction filter. Remove the filter and gasket.
d Installation
1) Before installation, check the suction filter and gasket for defects in manufacturing or
application, and damage. They shall be in good conditions.
2) Clean the junction surface of suction filter and engine oil pump as well as the cavity of suction
filter;
3) Install the gasket and suction filter;
4) Install the hexagon bolts, and then tighten it.
Check the suction filter and gasket for cracks. If any, replace them with new ones.
4.8.7 Disassembly and Assembly of Main Oil Passage Pressure Control Valve
1- Main oil passage pressure control valve
Figure4-63 Main Oil Passage Pressure Control Valve Disassembly Diagram

● Preparation before disassembly: None.
c Removal
Unscrew and take down the main oil passage pressure control valve
d Installation
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1) Before the assembly, check that main oil passage pressure control valve are free of
manufacturing and functional defects including damage.
2) Clean the hole in engine body for the main oil passage pressure control valve, and the pressure
control valve.
3) Apply sealant to the threads of the main oil passage pressure control valve.
4) Install the main oil passage pressure control valve, and then tighten it.
1) Check the main oil passage pressure control valve for failure. If any, replace it with a new one;
2) Check the main oil passage pressure control valve for cracks. If any, replace it with a new one.
4.8.8 Disassembly and Assembly of Engine Oil Filter Combination Group
1- Flexible 2- Hexagon 3- Engine oil 4- Engine oil filter 5- Rotary

corrugated gasket socket-head cap screw filter seat seat washer engine oil filter
Figure4-64 Engine Oil Filter Combination Group Disassembly Diagram

c Removal
Loosen the 4 bolts used for fixing the engine oil filter. Remove the engine oil filter assembly and
engine oil filter holder gasket.
d Installation
1) Before installation, check the engine oil filter holder gasket and engine oil filter assembly for
defects in manufacturing or application, and damage. They shall be in good conditions.
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2) Clean the mating faces of the engine oil filter assembly and engine body.
3) Install the engine oil filter holder gasket and engine oil filter assembly.
4) Install the flexible corrugated gasket and bolt, and then tighten them.
1) Check the engine oil filter assembly for damage. If any, replace it with a new one.
2) Check the engine oil filter holder gasket for damage. If any, replace it with a new one.
4.8.9 Disassembly and Assembly of Engine Oil Cooler Cover Combination Group
1- Engine oil 2- Oil cooler 3- Hexagon 4- Seal 5- Supporting 6- Hexagon

cooler cover cover flange bolt washer block flange bolt
washer
7- Seal washer 8- Hexagonal 9- Water outlet 10- Seal 11- Hollow bolt
screw plug connection washer
Figure4-65 Engine Oil Cooler Cover Combination Group Disassembly Diagram

● Preparation before disassembly: Open the water drain valve, to empty the water
c Removal
Before removal, drain coolant from the engine. Loosen the bolts of engine oil cooler cover. Remove
the engine oil cooler cover and gasket.
d Installation
1) Before installing the engine oil cooler cover gasket, check it and the engine oil cooler cover for
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defects in manufacturing or application, and damage. They shall be in good conditions.

2) Clean the mating faces of the engine oil cooler cover and engine body. Install the engine oil
cooler cover gasket.
3) Install the bolts of the engine oil cooler cover, and then tighten it.
1) Observe the oil cooler cover for presence of cracking and other damage. Upon detection of
cracking, replace with new oil cooler cover;
2) Check the engine oil cooler cover gasket for sign of leakage. If any, identify the cause and
replace the gasket with a new one.
4.8.10 Disassembly and Assembly of Engine Oil Cooler Cover Combination Group
1- O-ring 2- Oil cooler 3- Washer 4- Hexagon socket-head cap screw
Figure4-66 Engine Oil Cooler Cover Combination Group Disassembly Diagram

● Preparation before disassembly: Dismantle the engine oil cooler cover, and prepare an oil
receiving tray
c Removal
Loosen the 4 bolts of the engine oil cooler. Remove the engine oil cooler and seal ring.
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d Installation
1) Before installation, check the engine oil cooler for defects in manufacturing or application, and
damage. They shall be in good conditions.
2) Clean the mating faces of the engine oil cooler and engine body.
3) Install the seal ring and engine oil coolers.
4) Install the flexible corrugated gasket and bolt, and then tighten it.
Check the engine oil cooler for cracks. If any, replace it with a new one.
4.8.11 Disassembly and Assembly of Engine Oil Cooler Bypass Valve
1- Hexagon screw plug; 2- Combination washer 3- Spring 4- Valve core
Figure4-67 Engine Oil Cooler Bypass Valve Disassembly Diagram

c Removal
Loosen and remove the hexagon head screw plug. Remove the combination washer, relief valve
spring, and relief valve.
d Installation
1) Before installation, check the relief valve, relief valve spring, combination washer, and
hexagon head screw plug for defects in manufacturing or application, and damage. They shall be in
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good conditions.
2) Clean the engine oil cooler bypass valve and the hole in engine body for the engine oil cooler
bypass valve.
3) Install the relief valve, relief valve spring, and combination washer.
4) Install the hexagon head screw plug, and then tighten it.
1) Check the relief valve spring for lack of flexibility. If any, replace the spring with a new one;
2) Check the relief valve, hexagon head screw plug, and combination washer for cracks. If any,
replace them with new ones.
4.9 Starting System
4.9.1 Disassembly and Assembly of Starting System
1- Flywheel cover 2- Stud bolt 3- Hexagon flange nut 4- Starter
Figure4-68 Start-up System Disassembly Diagram

● Tools: Ordinary open spanner or socket spanner
● Preparation before disassembly: Disconnect the connection wires between starter and storage
battery and starting switch
c Removal
1) Remove three hexagon flange nuts with spanner;
2) Firmly hold starter with two hands, and take it down along the direction parallel to the axis of
starter.
d Installation
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1) Firmly hold the starter with two hands, and install it into the installation hole on the flywheel
cover along the direction parallel to the axis of starter, and make the relay of starter face upwards;
2) Install three hexagon flange nuts, and lock them with spanner;
1) During the maintenance, each terminal and harness shall be protected, and it is forbidden to
impact or pull the terminal or harness;
2) During the installation, check whether each insulating cover, sleeve, and pad is in good
conditions, and replace the injured or damaged one if any. The 30 end of starter shall be not
short-circuited with the shell.
4.10 Vehicles Accessories System
4.10.1 Disassembly and Assembly of Vehicles Accessories System
1- Fan and hub 2- Ribbed belt 3- Alternator
Figure4-69 Engine Accessories System Dismantle Diagram
b Removal
1) Swing the tensioning wheel clockwise, remove the belt tensioning force, and dismantle the
belt;
2) Remove the generator. For details, see the instructions for removal of generator;
c Installation
4.10.2 Disassembly and Assembly of Generator Combination Group
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1- Water pump inlet pipe (also 2- Alternator 3- Hexagon 4- Hexagon 5- Clamping

serving as the generator support) bolt flange bolt block
Figure4-70 Generator Combination Group Disassembly Diagram

● Tools: Ordinary open spanner or socket spanner.
● Preparation before disassembly: Disconnect the connection wires between generator, storage
battery and vehicle, and remove the fan.
c Removal
1) Remove the poly V-belt, hexagon bolts and hexagon flange bolts, and take down the clamping
clock;
2) Slightly lift the generator, and remove it from the generator support.
d Installation
1) Place the generator on the generator support, install the generator on the generator support with
hexagon bolts, clamping block, and hexagon flange bolts in a loosened way, and then screw up the
hexagon flange bolts and hexagon bolts with spanner in order;
2) Install 8PK poly V-belt
During installation, check all insulation gaskets and sleeves for intactness and ensure to replace any
damaged one. The positive terminal of alternator can’t be short circuited with the housing,
otherwise it’s prohibited to install the alternator onto the vehicle to prevent causing serious vehicle
accidents.
1) Generator fault judgment
During the maintenance, firstly test on the vehicle, to judge whether there s generator fault. Tool:
Test lamp. The test method is as shown in Figure 4-68.
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Turn on the power switch of the vehicle and connect the test lamp to the terminal
B+ and E (negative) of the alternator.
No It indicates that there is no voltage at terminal B+

Is test lamp ON? of alternator and the wire to the positive pole of
battery is malfunctioned.
Yes
Connect the wire from terminal E
to terminal D+ of alternator
No
Is test lamp ON? It indicates that the internal electric circuit at
terminal D+ of alternator is malfunctioned.
Yes
Start the engine
Yes
Is test lamp ON? Alternator malfunction
No
Alternator is not
malfunctioned
Figure4-71 Flowchart for Judgment of Alternator Malfunction
2) Malfunction diagnosis and troubleshooting of charging system

a) Charging failure
Malfunction 1: Charging failure
Vehicle symptom Fault Detection Solution
① If the alternator indicator lamp terminal voltage
is really low, it indicates low power of excitation line
indicator lamp or loose connection in circuit. Adjust
the indicator lamp power or check the circuit
connectors and connection points.
② If the alternator indicator lamp terminal voltage
a Check whether the
is zero, it indicate the presence of short-circuit to
voltage to ground of the
ground at the excitation circuit alternator terminal. In
alternator exciting terminal is
(1) The charging such case, check the circuit.
within 1~3V.
indicator lamp fails to ③ If the alternator indicator lamp terminal voltage
turn off while the engine is the battery voltage, it indicates the presence of
is running. malfunction in vehicle excitation circuit and that the
alternator regulator and excitation tube may be
damaged. In such case, make sure to correct the
excitation circuit and then repair the alternator.
b Check whether the ① If the B+ voltage to ground is zero, check
voltage to ground of the whether both the positive and negative wires between
alternator output terminal B+ alternator and battery are under continuity status.
equals to battery voltage of ② If the B+ voltage to ground is significantly
approximately 24V. below the battery voltage, check the connecting
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points of positive and negative wires between

alternator and battery for presence of looseness or
check the battery for damage.
Recommended measurement method: Jumper
connect one 2W indicator lamp between alternator
output terminal B+ and excitation terminal D+/L and
observe the working status of indicator lamp.
Solution:
① The lighting intensity of indicator lamp is
normal, the indicator lamp turns off after the engine
is started, and the alternator output voltage is
27~28.5V. The vehicle excitation circuit is
malfunctioned and needs checking and repair.
② The lighting intensity of indicator lamp is
normal, the indicator lamp turns on constantly after
the engine is started, and the alternator output voltage
is 27~28.5V. The alternator regulator is
malfunctioned and needs to be replaced.
③ The lighting intensity of indicator lamp is
normal, the indicator lamp turns on constantly after
the engine is started, and the alternator output voltage
is the battery voltage. The alternator regulator,
rectifier bridge, stator, or internal connection may be
malfunctioned and need repair or replacement.
a Check charging ① Check alternator indicator lamp for presence of
(2) The charging
indicator lamp voltage to ground. If not, replace indicator lamp or
indicator lamp fails to
b Check the excitation check circuit
turn on after turn-on of
circuit for presence of ② If yes, it indicates that the alternator regulator or
key switch
open-circuit rotor is malfunctioned. Repair or replace alternator.
(3) The charging
a Low power of indicator
indicator lamp fails to
lamp or loose parallel ① Use recommended 2~6W lamp bulb or repair
turn off during idling of
excitation resistor circuit
engine and turns off
b Low idling speed of ② Adjust idling speed of the engine
during high-speed
engine
running of engine
b) Low charging voltage

Malfunction 2: Low charging voltage
The measurement of alternator terminal B+
The battery is frequently
Understand whether the voltage shall be at 27.8~28.4V. If the
charged insufficiently, with
alternator output power is voltage is normal, it indicates that the
low charging voltage, and its
reasonably matched with the voltmeter or voltmeter sampling point is
voltage drops significantly
electric devices of vehicle. malfunctioned and needs to be repaired or
when being loaded.
replaced.
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① It’s recommended that the no-load

idling speed of alternator is higher than
1600RPM
a Check voltmeter for damage ② When the alternator is working under
b Check the alternator speed high power load condition (for instance, the
air conditioner is switched on), the
alternator speed shall be ≥2000rpm or the
voltage shall be approximately 27V.
① Check the quality of belts for alternator
and relevant pulley systems and replace any
burnt, ruptured, distorted belt or the belt
c Check the drive belt quality with tooth breakage or the belt dropping to
and tension for alternator and the bottom of groove.
related gear system. ② Re-tension the alternator and relevant
pulley systems.
★Note: For the systems with double drive
belt, replace both belts in event of
replacement.
d Check alternator pulley Tighten if loosened
① If the voltage difference is higher than
1V (high voltage drop due to thin wires)
under heavy-load condition, replace the
wires.
e Check wires for reasonable 35A within S ≥6mm2 70A within S
2
use and measure voltages at ≥12mm
alternator and battery terminals 100A within S ≥20mm2 150A within S
≥25mm 2
② If the wire or connector has clear

temperature rise under heavy-load working
condition, replace the wire or connector.
① Grind the wire lugs with oxidized
surfaces and the housing surface for
f Check for presence of high installation of grounding bolt and reinstall
temperature due to looseness, ② Retighten any loose nut and wire lug
oxidation, or loose connection at and re-insert the connectors
The battery is frequently the joint between wire and bolt of ★Note: Run the reinstalled or re-tightened
charged insufficiently, with charging system portions for 3~5min when the alternator is
low charging voltage, and its under heavy-load and then check for the
voltage drops significantly presence of high temperature
when being loaded If there is high difference between phase
g Check the phase output
terminal (W/R/AC) output voltage and
voltage of alternator (This
normal output, the alternator rectifier bridge
voltage shall be approximately
or stator is malfunction and the checking
one half of B+ output voltage.)
and replacement shall be considered.
h Check the battery for normal The charging current shall drop to
118
charging approximately 10A after 10min charging. If

the charging current is at 30~90A constantly,
the battery is damaged and needs repair or
replacement.
c) High charging voltage

Malfunction 3: High charging voltage
Vehicle
Fault Detection Solution
symptom
The measurement of alternator B+ terminal
voltage generally shall be at 27~28.4V. If the
a Check voltmeter for damage voltage is normal, it indicates that the calibration
error of voltmeter is high and the voltmeter needs
to be repaired or replaced.
b Check the wires and connections of the
charging system, check the connection bolts ① In event of poor contact or loose connection,
for presence of looseness, loose connection, retighten or re-insert the connectors.
and high temperature, and check for presence ② In event of short-circuit, re-connect the
of short-circuit between wires and alternator wires.
housing.
① Observe during the charging of battery
The whether the charging current varies greatly within
voltmeter a short period (from 50A to below 10A). If not,
indicates the replacement of battery as soon as possible
high voltage c Check battery for normal working status shall be considered.
② Observe the battery surfaces for cleanliness
and dryness and check whether the wiring
terminals and clamps are in good fit. Replace as
soon as possible in event of any damage.
If there is high difference between phase terminal
d Check the phase output voltage of (W/R/AC) output voltage and normal output and
alternator (This voltage shall be the voltage drop is high when the alternator is
approximately one half of B+ output loaded, the alternator rectifier bridge or stator is
voltage.) malfunctioned and the checking and replacement
shall be considered.
e The malfunction symptom is not solved Replace alternator regulator, rotor, or whole
after above checking. alternator.
d) Unstable charging voltage

Malfunction 4: Unstable charging voltage
The voltmeter indicates the charging during Tension belts for
a Loose belt or belt run-out for
normal running of engine, but the pointer alternator and related
alternator or related pulley systems.
fluctuates and the reading can’t be read (or pulley systems.
the charging indicator lamp turns off b Looseness or poor contact at Check and tighten
119
occasionally). connections of charging circuit connections of charging

circuit
c Contamination of collector ring,
Remove contaminants
excessive wear of electric brush, or
or replace electric brush
softening or breakage of electric brush
or electric brush spring
spring
d Damage of regulator Replace the regulator.
e) Alternator noise
Malfunction 5: Alternator noise
a The bracket of alternator is deformed Increase the support rigidity, and adjust
or is too close to other external housings. the installation state
b Looseness or slip of alternator belt Replace engine belt.
c Loose alternator pulley Tighten pulley.
There is an abnormal d Oil shortage or damage of alternator
Replace alternator bearing
noise during running of bearings
alternator. The stator coil is short circuited.
e Low noise within alternator
Replace it.
This is the noise generated by the
f Speed-dependent squealing within
vibration of stator . If necessary, replace
alternator
stator subassembly.
Appendix A General Bolt Fastening Torque of Diesel Engine
Appendix A.1 Recommended Torque for Standard Hexagon Bolts, Hexagon Nuts, Hexagon Socket
Head Screws
Friction coefficient 0.125 (phosphorization, oxidization) 0.14 (galvanization)

Strength grade 6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
Bolt specification Recommended torque, Nm
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
120
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
121
Appendix A.2 Recommended Torque for Standard Hexagon Flange Bolts and Hexagon Flange Nuts
Friction coefficient 0.125 (phosphorization, oxidization) 0.14 (galvanization)
Strength grade 6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
Bolt specification Recommended torque, Nm
M5 5.4 6.3 9.1 10.8 5.7 6.9 9.7 11.4
M6 9.0 10.7 14.6 18.0 9.6 11.2 15.7 19.1
M8 21.0 25.4 35.3 43.0 23.2 27.6 38.7 45.3
M10 42.9 50.6 70.4 84.7 45.2 54.0 76.0 91.4
M12 78.5 93.7 128.8 158.1 84.5 100.9 140.8 170.2
M14 117.0 139.3 200.5 239.5 128.3 150.6 212.0 256.6
M16 184.4 217.9 307.3 368.8 201.4 235.0 330.1 397.2
M18 254.3 305.1 440.7 514.2 277.3 328.3 458.4 549.0
M20 370.6 439.0 615.7 741.1 394.0 468.2 662.3 788.0
Appendix A.3 Hollow Hexagonal Head Bolt Torque
Type Bolt specification Bolt material Torque setting (Nm)
M10×1 Copper bolt 13±2
M10×1 21±3
Hollow hexagonal head bolt torque M14×1.5 27±3

Steel bolt
M16×1.5 40±5
M6×1 6±1
M10 20±3
M12 28±3
Hollow flange bolt
M14 32±3
M16 36±3
122
Appendix A.4 Bolt Torque Tolerance Table

Torque range, Nm Torque tolerance, Nm
≤3 ±0.1
3~10 ±0.5
10~25 ±2
25~50 ±3
50~150 ±5
150~300 ±10
300~500 ±30
500~1000 ±50
＞1000 ±100
Note: When there are no special tolerance requirements, this table shall prevail.
Appendix A.5 Clamp Torque Recommendation

Tightening
Constraint Tightening
Clamp type tolerance, Remark
condition torque, Nm
Nm
Clamping range
2 ±0.2 Stainless steel, worm
≤16mm
Q675 drive, gear belt without
16mm＜clamping
3 ±0.3 hole
range ≤160mm
Gear belt width
Q676 6 ±0.5 Stainless steel, worm
14mm
drive, tooth belt with
Gear belt width
Q676B 2.6 ±0.3 hole
8.5mm
Nut M5 3 ±0.3
Nut M6 4.8 ±0.5
Q677 Power, nut drive
Nut M8 14.5 ±1.5
Nut M10 36 ±3
Other powerful Nut M6 8.5 ±1
T-shaped or V-shaped Independent design
clamps Nut M8 11.5 ±1.5
Note: When the fastening torque is stipulated in the drawings, the drawings shall prevail; and this
form shall be followed when there is no fastening torque given in the drawings.
123
Appendix B Fit Clearances for Main Parts of Diesel Engine
SN. Item Theoretical value

(mm)
1 Main bearing clearance 0.095～0.171
2 Connecting rod bearing clearance 0.059～0.135
3 Crankshaft endplay 0.102～0.305
4 Axial clearance of connecting rod plane 0.15～0.35
5 Clearance between connecting rod small end and piston pin 0.04～0.061
6 Clearance between piston pin boss 0.005～0.018

Working clearance of piston ring opening in cold state
1st ring 0.35～0.55
7
2nd ring 0.4～0.6
Oil ring 0.2～0.4
End clearance of piston ring in cold state
1st ring
8
2nd ring 0.08～0.115
Oil ring 0.04～0.075
9 Clearance between intake valve stem and valve guide 0.023～0.052
10 Clearance between exhaust valve stem and valve guide 0.045～0.072
11 Valve bottom concave in the cylinder end plane exhaust/intake ±0.2/±0.2
12 Protrusion of cylinder liner top above engine body top 0.05～0.10
13 Camshaft axial clearance 0.1～0.4
14 Camshaft bearing clearance 0.04～0.12
15 Clearance between tappet and tappet hole 0.025～0.089

Interference or clearance between cylinder liner outside diameter and cylinder liner -0.02～0.023
16
hole in engine body
17 Clearance between intake rocker arm and rocker arm shaft 0.015～0.057
18 Clearance between exhaust rocker arm and rocker arm shaft 0.022～0.082
19 Backlash between mating teeth of timing gear and intermediate gear 0.015～0.33
20 Valve clearance intake/exhaust (cold state) 0.40/0.60
124
Appendix C Wear Evaluation References for Main Friction Pairs in Diesel
Engine
(Reference value)
Wear limit Clearance limit Service life of part
mm mm h
Closed gap of the 1st piston ring 1.70 -
Height of the 1st piston ring 0.10 -
Closed gap of the 2nd piston ring 1.50 -
Height of the 2nd piston ring 0.10 -
Closed gap of oil ring 1.50 -
Height of oil ring 0.15 -
Outside diameter of piston skirt 0.25
0.60
Inside diameter of cylinder liner 0.50
Outside diameter of piston pin 0.04
Inside diameter of piston pin hole 0.08 0.10
Inside diameter of bushing at connecting rod small end 0.08
Outside diameter of main journal of camshaft 0.06
0.10
Inside diameter of camshaft bushing 0.06
Height of cam nose relative to basic circle 2.00 -
Outside diameter of basic circle of cam 0.05 -
Outside diameter of crankshaft journal for connecting rod 0.12
0.15
Inside diameter of connecting rod bearing 0.10
Outside diameter of crankshaft main journal 0.08
0.15
Inside diameter of main bearing 0.10
Thickness of thrust bearing 0.40 -
Intake valve sink 0.04*d(1)
Intake valve seat 0.75
Intake valve seat 0.75
Exhaust valve sink 0.04*d(1)
Exhaust valve seat 0.85
Exhaust valve seat 0.85
Inside diameter of intake valve guide 0.06
0.1
Outside diameter of intake valve stem 0.06
Inside diameter of exhaust valve guide 0.06
0.1
Outside diameter of exhaust valve stem 0.06
Inside diameter of bushing of rocker arm shaft 0.10
0.12
Outside diameter of rocker arm shaft 0.05
(1): d is the neck diameter of intake valve or exhaust valve.
125

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Maintenance manual of 6M16 four-valve mechanical pump industrial diesel engine

Maintenance Manual of WP10 Four-valve

have no such instruments may not remove or adjust them.

from you are welcome.

voided. Please pay attention to that.

that it is done by professional maintenance personnel or professional maintenance stations licensed

unfiltered air into the cylinders.

stop the engine suddenly (except special cases);

3.2.16 Inadequate Charging Current of Alternator.............................................................................. 37

4.6.4 Disassembly and Assembly of High-pressure Oil Pipe Combination Group........................... 93

Chapter I General Information

1.1 Exterior View of Diesel Engine

Figure1-1 Diesel Engine View 1

Figure1-2 Diesel Engine View 2

Figure1-3 Diesel Engine View 3

1.2 Model Meaning of Diesel Engine

1.3 Main Technical Specification of Diesel Engine

Table1-1 Main Technical Parameter Table

Item Technical parameter

Type Four-stroke, water-cooling, in-line, and direct-injection

Exhaust valve clearance (cold state) (mm) 0.6

Exhaust temperature (°C) ≤550

Lubricating oil pan capacity (L) 30

Crankshaft rotating direction (seeing from fan

Item Unit Model

Engine Model — 6M16

Valve number of per cylinder — 4

Emission level — Non-road stage II

Rated power kW 320~360 (reserve power)

Rated speed r/min 1500～1800

Average effective pressure kPa 2345~2385

Mean piston speed m/s 6.5~7.8

Idling speed r/min 650

Piston air leakage L/min ≤140

Smoke intensity under rated conditions FSN ≤2.0

Exhaust smoke at the maximum torque point FSN ≤2.5

Without auxiliary starter -5 (Limit is -10)

Engine Weight kg 875

Exhaust temperature C ≤550

Exhaust backpressure kPa ≤11

Air intake temperature after intercooling C 50～55

Intake pressure kPa ≤7.5

1.4 Use Instructions of a New Diesel Engine

1.5 Hoisting of Diesel Engine

Figure1-4 Diesel Engine Hoisting

1.6 Unsealing of Diesel Engine

1.7 Pre-start Preparations

1.8 Start of Diesel Engine

1.9 Running of Diesel Engine

different trademarks and ratio depending on the ambient temperature.

Chapter II Maintenance Guide

Variety Product category Packing specification

SAE viscosity grade Applicable environmental temperature (ºC)

2.1.3 Engine Coolant

SN. Name Color Purpose and location

Table2-6 Reference Table for Sealant Application of Diesel Engine

Mark Main use List of locations for application of sealant Supplement