10 na assembly - flypartsguy 4.2018

Assembly & Disassembly Manual
Gas Engine
Model: WP10GNA
WEICHAI AMERICA CORP.
Document Courtesy of Fly Parts Guy Co.
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Weichai America Corp.
1
Purpose
This manual is intended to inform customers on how to assemble and disassemble the Weichai
America 10 Liters naturally aspirated engine. This document will be provided to customer so they can
incorporate this information into their manuals and service documents.
Maintenance Providers
Maintenance and repair services may be performed by you or any qualified engine service provider that
you choose. However, your engine warranty does not cover damage or failure caused by improper
maintenance or repairs.
Owner’s Manual & Maintenance Records Storage & Use
Store this Owner’s Manual and Maintenance Records in a safe, visible place by your engine. The
maintenance log must be updated whenever your engine is serviced. If repairs are being done under
warranty be sure to follow proper warranty procedures. (see Weichai America Corp Warranty
Procedure Manual)
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Table of Contents
1 Disassembly & Assembly of Engine.....................................................................................5
1.1 Safety Precautions............................................................................................................5
1.2 Environmental Protection Measures .................................................................................5
1.3 Notes for Disassembly and Assembly of Engine...............................................................5
2 Engine Block Group.............................................................................................................6
2.1 Engine Block Group Disassembly and Assembly ..............................................................6
2.3 Gear Housing Group Disassembly and Assembly ...........................................................11
2.4 Front End Cover Plate Disassembly and Assembly.........................................................13
2.5 Piston Cooling Nozzle Disassembly and Assembly. ........................................................14
2.6 Thrust Plate Disassembly and Assembly.........................................................................15
2.7 Front and Rear Oil Seal Disassembly and Assembly.......................................................16
2.8 Flywheel Housing Disassembly and Assembly................................................................18
2.9 Cylinder Head Disassembly and Assembly.....................................................................19
2.10 Cylinder Head Cover Disassembly and Assembly .........................................................27
2.11 Lifting Ring Disassembly and Assembly ........................................................................29
2.12 CCV Breather System Disassembly and Assembly .......................................................30
3 Crank Connecting Rod Mechanism....................................................................................32
3.1 Crank-connecting Rod Mechanism Disassembly and Assembly......................................32
3.2 Crankshaft System Disassembly and Assembly..............................................................33
3.3 Main Bearing Disassembly and Assembly.......................................................................36
3.4 Flywheel Combination Group Disassembly and Assembly ..............................................38
3.5 Piston & Connecting Rod Combination Group Disassembly and Assembly.....................39
3.6 Damper and Crankshaft Pulley Disassembly and Assembly............................................43
4 valve mechanism combination group.................................................................................45
4.1 Valve Mechanism Disassembly and Assembly................................................................45
4.2 Camshaft Disassembly and Assembly.............................................................................46
4.3 Intermediate Gear Disassembly and Assembly ...............................................................48
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4.4 Tappet and Push rod Disassembly and Assembly...........................................................50
4.5 Valve Disassembly and Assembly...................................................................................52
4.6 Rocker Arm Disassembly and Assembly .........................................................................54
5 Air Intake and Exhaust System ..........................................................................................58
5.1 Air Filter Combination Group Disassembly and Assembly ...............................................58
5.2 Air Intake Manifold Combination Group Disassembly and Assembly ...............................59
5.3 Exhaust Tail Pipe Disassembly and Assembly ................................................................60
5.4 Exhaust Pipe Disassembly and Assembly.......................................................................61
6 Ignition System ..................................................................................................................63
6.1 Ignition System Disassembly and Assembly....................................................................63
6.2 Ignition System Disassembly and Assembly....................................................................63
6.3 ECU Combination Group Disassembly and Assembly.....................................................64
6.4 Signal Generator Disassembly and Assembly .................................................................65
7 Fuel System.......................................................................................................................67
7.1 Fuel System Disassembly and Assembly ........................................................................67
8 Cooling System..................................................................................................................70
8.1 Cooling System Disassembly and Assembly ...................................................................70
8.2 Water Pump Inlet Pipe Disassembly and Assembly ........................................................71
8.3 Water Pump Disassembly and Assembly ........................................................................72
8.4 Thermostat Disassembly and Assembly..........................................................................74
8.5 Fan and Hub Disassembly and Assembly .......................................................................75
8.6 Coolant Outlet Pipe Disassembly and Assembly .............................................................76
9 Lubrication System ............................................................................................................78
9.1 Lubrication System Disassembly and Assembly..............................................................78
9.2 Oil Pan Disassembly and Assembly ................................................................................79
9.3 Oil Strainer Disassembly and Assembly ..........................................................................80
9.4 Oil Pump Intermediate Gear Disassembly and Assembly................................................82
9.5 Oil Pump Disassembly and Assembly .............................................................................83
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9.6 Main Oil Pressure Control Valve Disassembly and Assembly Procedure ........................84
9.7 Oil Filter Disassembly and Assembly...............................................................................86
9.8 Engine Oil Cooler Cover Combination Group Disassembly and Assembly ......................87
9.9 Oil Cooler Combination Group Disassembly and Assembly.............................................88
9.10 engine oil cooler bypass valve Disassembly and Assembly...........................................89
10 Starting System ....................................................................................................91
10.1 Starting System Disassembly and Assembly.................................................................91
11 Accessory System ................................................................................................92
11.1 Accessory System Disassembly and Assembly.............................................................92
11.2 Alternator Disassembly and Assembly...........................................................................93
1. Appendix A: General fastening torque .............................................................................100
2. Appendix B Tolerance Clearance for Main Parts of Gas Engine ......................................101
3. Appendix C: The Evaluation Criteria for Main Friction Wear of Gas Engine .....................103
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1 Disassembly & Assembly of Engine
1.1 Safety Precautions
Please strictly comply with instructions in this manual to safely and properly disassemble and
assemble the engine.
1.2 Environmental Protection Measures
Please comply with relevant laws and regulations on environmental protection when handling oil
and hydrocarbon waste. For further instructions please contact your local officials.
1.3 Notes for Disassembly and Assembly of Engine
Failure in complying with safety regulations and basic safety practices causes the majority of
engine-related accidents. Proper training is required for all engine operators and maintenance
personnel. Any violation of instructions in this manual may result in serious injury or death.
Note: Before proceeding with any maintenance or repair operation, place a sign clearly
stating “Maintenance In Progress, Do Not Use” on the engine starter switch.
Take the following precautions before using a lockout tool and beginning maintenance or repair:
• Ensure the maintenance site and surrounding area are clean and suitable for safe operation.
• Remove any rings, necklaces, watches, or other jewelry and wear appropriate close-fit work
clothes before entering the maintenance site.
• Wear relevant protective devices (goggles, gloves, shoes, masks, work clothes, helmet, etc.)
that are in good condition prior to entering the maintenance site.
• Do not use any defective, worn, broken, or inappropriate tools.
NOTICE: THE ENGINE MUST BE COMPLETELY SHUT DOWN PRIOR TO
MAINTENANCE.
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2 Engine Block Group
2.1 Engine Block Group Disassembly and Assembly
2.1.1 Engine block group disassembly diagram
1、26-Bolts, Cylinder head, 2-Combination washer, 3、8-Screw plug, 4-Bowl plug, 5-Rear seal, 6-Sealing washer, 7-
Screw plug, 8-Screw plug, 9-Relief valve spring, 10-Safety valve, 11-Cylinder liner, 12- Hex socket-head cap screw, 13-
Nozzle, 14-Sealing washer, 15-Hollow bolt, 16-Bolt, 17-Safety valve, Main oil passage, 18- Self-lock washer, 19、21-
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Thrust plate, 20-Sealing washer, 22-Main bearing, 23-Cylinder block, 24-Pin, 25-Flexible pin, 26-Auxiliary bolt, cylinder
head
Figure 2- 1 Engine body group disassembly diagram
2.1.2 Preparation before disassembly
● Tools: Socket spanner, copper hammer
● Preparation before disassembly: Remove the gearbox and clutch, and remove the flywheel,
flywheel cover, gear chamber, and oil pan
2.1.3 Engine block group disassembly procedure
1) Remove the screw plug of main oil passage;
2) Remove the cylinder liners;
3) Remove the auxiliary bolt of cylinder head;
4) Remove the bolts on the peripheral of crankcase;
5) Remove the main bearing bolt;
6) Remove the seal ring.
2.1.4 Engine block group assembly procedure
Reverse the disassembly procedure to assemble engine block group.
2.1.5 Engine block group inspection and maintenance
Key point 1:
Tightening torque （22～29）N·m 8.8
Tightening torque （29～35）N·m 10.9
Key point 2:
Main bearing bolts shall be screwed up symmetrically according to the order given in Figure 2-2. 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.
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Ⅰ
Ⅱ
Ⅲ
Ⅳ
Ⅴ
Ⅵ
Ⅶ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Figure 2-2 Tightening sequence of Main bearing bolts
Tightening torque 265±25N.m
Key point 3:
The auxiliary bolts of cylinder head shall be tightened according to the order given in 2-3, and they can be
used for 2 times repeatedly at most.
Ⅵ Ⅴ Ⅳ Ⅲ Ⅱ Ⅰ
16
17
18
10
11
12
3
4
5
2
1
6
9
8
7
15
14
13
21
20
19
Figure 4-3 Tightening Sequence for Cylinder Head Auxiliary Bolts
Key point 4:
Before installation, check the cylinder liners carefully 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.
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2.2 Cylinder Block Pre-Assembly Disassembly and Assembly
2.2.1 Disassembly diagram
1、4、5、12、13-Bowl plug；2-Rivet；3-Cylinder block；6-Crank case；
7、8-Main bearing bolt；9- Parallel pin with internal threads；10、11-Camshaft bushing
Figure 2-4 Cylinder Block Pre-Assembly Disassembly Diagram
● Preparation before disassembly: Remove the gearbox and clutch, and remove the flywheel,
flywheel cover, gear chamber, and oil pan
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2.2.3 Cylinder block pre-assembly disassembly procedure
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.
2.2.4 Cylinder block pre-assembly assembly procedure
Reverse the Disassembly procedure to assemble Cylinder block pre-assembly.
2.2.5 Cylinder block pre-assembly inspection and maintenance
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.
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2.3 Gear Housing Group Disassembly and Assembly
1-O-ring；2-O-ring；3-Pin；4-Bolt；5-Washer；6-Screw plug；
7-Bolt；8-Bolt；9-Gear housing
Figure 2-5 Gear housing group disassembly diagram
● Tools: Socket spanner
● Preparation before disassembly: Remove the accessories in the front end of gas engine
2.3.3 Gear housing group disassembly procedure
1) Remove the gear housing fixing bolts;
2) Remove the plug and combination washers;
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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 housing;
6) Remove the seal ring.
2.3.4 Gear housing group assembly procedure
Reverse the disassembly procedure to assemble gear housing group.
2.3.5 Gear housing group inspection and maintenance
1）Diagonally tighten the gear housing fixing bolts in the sequence shown in Figure 2-6.
Tightening torque （44～58）N.m
Figure 2-6 Tightening sequence of Gear housing group
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 housing 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.
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4) Install the intermediate gear shaft to the intermediate gear; then put them in the gear housing.
Apply sealant to the back of gear housing, and then press the seal rings in place.
2.4 Front End Cover Plate Disassembly and Assembly
1-Gesket；2-Front end cover plate；3- Hexagon head flanged bolt
Figure 2-7 Front end cover plate disassembly diagram
● Preparation before disassembly: Remove the accessories in the front end of diesel engine
2.4.3 Front end cover plate disassembly procedure
1) Remove the front-end cover fastening bolt;
2) Remove the front-end cover;
3) Remove the front-end cover gasket.
2.4.4 Front end cover plate assembly procedure
Reverse the Disassembly procedure to assemble the front-end cover plate.
2.4.5 Front end cover plate inspection and maintenance
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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.
2.5 Piston Cooling Nozzle Disassembly and Assembly.
1-Hollow bolt；2-Sealing washer；3-Nozzle Assembly；4-Pin
Figure 2- 8 Piston cooling nozzle disassembly diagram
● Preparation before disassembly: Remove the crankcase, crankshaft, and other parts.
2.5.3 Piston cooling nozzle disassembly procedure
1) Remove the Hollow bolt;
2) Remove the nozzle assembly.
3) Remove the flexible parallel pin
2.5.4 Piston cooling nozzle assembly
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Reverse the disassembly procedure to assemble the piston cooling nozzle.
2.5.5 Piston cooling nozzle inspection and maintenance
Key point 1:
Tightening torque of hollow bolt
Tightening torque （24～30）N·m
Key point 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.
2.6 Thrust Plate Disassembly and Assembly
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1-Lower thrust plate；2-Upper thrust plate
Figure 2-9 Thrust plate disassembly diagram
2.6.3 Thrust plate disassembly procedure
1) Remove the crankcase;
2) Remove the crankshaft;
3) Remove the thrust plate.
2.6.4 Thrust plate assembly procedure
1) Install the crankshaft.
2) Install the upper thrust plate (no lug).
3) Install the lower thrust plate.
2.6.5 Thrust plate inspection and maintenance
Thrust plate must be used in pairs. Install the crankshaft to the engine body. Install the upper
thrust plate (no lug). Apply grease to the lower thrust plate; then press slightly it to the crankcase. The
lower thrust plate is installed along with the crankcase. Thrust plate shall be installed with their
lubricating oil grooves facing out.
2.7 Front and Rear Oil Seal Disassembly and Assembly
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1-Rear oil seal；2-Front oil seal
Figure 2-10 Front and rear oil seal disassembly diagram
2.7.3 Front and rear oil seal disassembly procedure
1) Remove the gear chamber;
2) Remove the front oil seal;
3) Remove the crankcase;
4) Remove the rear oil seal.
2.7.4 Front and rear oil seal assembly procedure
Reverse the disassembly procedure to assemble the front and rear oil seal.
2.7.5 Front and rear oil seal inspection and maintenance
1) Before installation, remove dirt (if any) from the mounting hole and oil seal. Press the oil seal
in place steadily by a special tool. Before installation, apply lubricating oil to both the special tool
and the oil seal.
2) The oil seal cannot be reused after disassembling.
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2.8 Flywheel Housing Disassembly and Assembly
1-Flywheel housing；2-Flywheel housing bolt；3-Flywheel；4-Starter；5-Stud bolt；6-Nut
Figure 2-11 Flywheel housing disassembly diagram
● Preparation before disassembly: Remove the gearbox and clutch, and remove the flywheel
2.8.3 Flywheel housing disassembly procedure
1) Unscrew the nuts fastening the starter, and take the starter down;
2) Open the bolts fixing the flywheel housing;
3) Remove the flywheel housing
2.8.4 Flywheel housing assembly procedure
1) Apply the sealant around the oil chamber.
2) Install the flywheel housing on the engine body.
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3) Tighten the bolts fixing the flywheel housing.
4) Install the starter on the flywheel housing, and screw the nuts fixing the starter.
2.8.5 Flywheel housing inspection and maintenance
1) The flywheel housing 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 housing bolts can
be used for two times. Tightening torque: (110~140) Nm.
Figure 2-12 Tightening sequence of Flywheel housing bolt
2) Apply uniformly sealant to junction plane between cylinder block and flywheel housing and
guard flywheel housing against knocking damage during hoisting.
2.9 Cylinder Head Disassembly and Assembly
2.9.1 Cylinder head disassembly diagram
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Figure 2-13 Cylinder head disassembly diagram
2.9.2 Cylinder head disassembly procedure
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 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;
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3) Loosen the main bolts of cylinder head. Remove the main bolts and put them at a proper
location.
4) Remove ignition coil bushing. Loose pressing plate bolts and remove ignition coil, take O-ring
out.
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.
2.9.3 Cylinder head assembly procedure
1) Install the auxiliary bolts, and the auxiliary bolt has 3 types.
a) 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.
b) Apply anaerobic thread sealant 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.
c) Clean the threaded holes in the cylinder block.
d) Tighten the bolts to the torque of (76~102) Nm.
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2) Install cylinder head gasket
Figure 2-14 Cylinder head gasket
a) The cylinder head gasket can be used once only, it must be replaced with a new one if being
removed.
b) Wipe 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.
c) Check 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
a) The valve stem seal can be only used once. Make sure to replace with new one in the event of repair.
b) Check the valve stem seal for presence of defect and check valve stem seal spring for intactness.
c) Install valve stem seal on valve guide pipe.
d) Apply lubricating oil to the lips of valve stem seal.
e) Use valve stem seal assembling tool and rubber hammer to install the valve stem seal.
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Figure 2-15 Installation of valve stem seal
4) Install the cylinder head
a) 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.
b) 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.
c) Before the bolts of cylinder head are tightened, the cylinder head is located with the locating pins.
d) install cylinder head assembly.
5) Install the clamping blocks
a) Wipe clean the clamping blocks.
b) 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.
c) The clamping block shall be installed so that its groove is in the same direction as the gap between the
cylinder heads.
d) Manually tighten the nuts of the auxiliary bolts of cylinder head.
6) Install the cylinder head bolt
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a) Main bolts of cylinder head could be reused 3 times.
b) 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.
c) Using a torque wrench, tighten the main bolts and nuts of auxiliary bolts of cylinder head to the
torque of (30~50) Nm.
d) Tap the clamping blocks so that they descend in place.
e) 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.
f) Using a torque wrench, tighten the main bolts in the specified sequence to the torque of 200Nm. Then
make marks on the bolts.
g) Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence by 90º. Then
make marks on the nuts.
h) Using a torque wrench, tighten the main bolts in the specified sequence by 90º. Then make marks on
the bolts.
i) Using a torque wrench, tighten the nuts of auxiliary bolts in the specified sequence by another 90º to
the torque of (120~160) Nm.
j) Using a torque wrench, tighten the main bolts in the specified sequence by another 90º to the torque
of (240~340) Nm.
k) The cylinder head bolts shall be tightened according to the order given in Figure 2-16, in which, those
numbering 1-21 are auxiliary bolts of cylinder head, while those numbering 22-45 are main bolts of
cylinder head.
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Figure 2-16 Tightening Sequence for Cylinder Head Bolts
7) Install ignition coil bushing
Apply sealant to O-ring and install the O-ring in the groove of sealing ring in cylinder head,
install ignition coil bushing and fixing it by pressing plate, install bolts and tighten.
2.9.4 Cylinder head inspection and maintenance
a) 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.
b) Check appearance of cylinder head. Check discoloration and crack of the cylinder head carefully, and
in case of crack, carry out penetrant inspection.
c) 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.
d) 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.
On the side of fan
On the side of
flywheel
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Figure 2-17 Depth Micrometer
e) For the required valve sinks, refer to Table as following. 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.
Required value of valve sinking (mm)
Intake valve -0.2~0.2
Exhaust valve -0.2~0.2
Valve sinking value
f) 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.
g) 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.
h) 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
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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 2-19. 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.
Figure 2-18 Inside micrometer gauge
i) 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.
j) Before removing the valve stem seal, check the spring for failure. Anyway, replace the valve stem
seal with a new one.
2.10 Cylinder Head Cover Disassembly and Assembly
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Figure 2-19 Cylinder head cover disassembly diagram
2.10.2 Cylinder head cover disassembly procedure
1) Loosen the bolts of cylinder head cover, remove bolts and washers.
2) Vertically pull up the cylinder head cover and cylinder head cover gasket.
3) Loosen and remove cover plate bolts, remove O-ring and cover plate.
2.10.3 Cylinder head cover assembly procedure
1) Put O-ring into the groove, install cover, install and tighten bolts.
2) Before installing cylinder head cover gaskets, check and ensure that new cylinder head cover
gaskets are free of manufacturing and operation defects and damages;
3) Wipe the top surface of cylinder head and install cylinder head gaskets in turn;
4) Clean the cylinder head cover, and accurately install it onto the cylinder head cover in turn.
5) Install and tighten the cylinder head cover bolts, tighten torque: （10～15）N·m
2.10.4 Cylinder head cover inspection and maintenance
Key point 1: The cylinder head cover gaskets can be used only once. Replace with new ones in the
event of repair.
Key point 2:
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.
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2.11 Lifting Ring Disassembly and Assembly
Figure 2-20 Lifting ring disassembly diagram
2.11.2 Lifting ring disassembly procedure
Loose bolts and take engine lifting ring/ oil and gas separator down in proper order.
2.11.3 Lifting ring assembly procedure
Check the lifting ring and bolts for crack and defect, check the thread for failure, if any, replace it
with a new one.
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2.12 CCV Breather System Disassembly and Assembly
2.12.1 CCV breather disassembly diagram
Figure 2-21 CCV breather disassembly diagram
2.12.2 CCV breather disassembly procedure
1) Loose the clamp fixed air outlet pipe, loose the clamp fixed pipe connector and air outlet pipe,
remove air outlet pipe
2) Loose the clamp fixed oil return pipe, remove oil return pipe.
3) Loose bolt, remove pipe connector which connected with oil return pipe.
4) Loose the clamp fixed air intake hose and air intake pipe assembly.
5) Loose bolts, remove air intake pipe assembly.
6) Loose bolts, remove CCV breather assembly.
7) Loose bolts, remove CCV breather bracket.
8) Loose bolts, remove bolts, seal washer, breather and O-ring.
2.12.3 CCV breather assembly procedure
1) Install CCV breather
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2) Install CCV breather air intake pipe, oil return pipe, air outlet pipe, oil inlet pipe and
2.12.4 CCV breather inspection and maintenance
Inspection:
1) Inspect every component’s appearance; check parts for damage and crack, check hoses for
ageing and leakage, if any, replace it with a new one.
2) Check all connectors for leakage.
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3 Crank Connecting Rod Mechanism
3.1 Crank-connecting Rod Mechanism Disassembly and Assembly
3.1.1 Crank-connecting rod mechanism disassembly diagram
Figure 3-1 Crank-connecting rod mechanism disassembly diagram
3.1.2 Crank-connecting rod mechanism disassembly procedure
1) Preparation before disassembly: Check axial backlash of the connecting rod and tightening
torque of the connecting rod bolt; 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;
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.
Remove other piston assemblies and connecting rod assemblies with the same method.
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Respectively number the piston, connecting rod bolt, and connecting rod cover, and place them
in order;
2) Remove bolts of crankshaft pulley, take pulley and damper down.
3) Remove flywheel bolts, take flywheel down.
3.1.3 Crank-connecting rod mechanism assembly procedure.
Reverse the disassembly procedure to assemble Crank-connecting rod mechanism.
3.2 Crankshaft System Disassembly and Assembly
3.2.1 Crankshaft system disassembly diagram
Figure 3- 2 Crankshaft system disassembly diagram
3.2.2 Crankshaft system disassembly procedure
1) Enable the engine crankcase upward, remove the main bearing bolts, and put them on the
ground in sequence.
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2) Remove the crankshaft and flywheel, front and rear thrust plates, and flywheel end bearing.
Take out the oil seal. Unscrew the bolts of front pulley. Remove the pulley, and vibration
damper. 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.
3.2.3 Crankshaft system assembly procedure
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.
a) 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.
b) 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 plates and press it into the cylinder block. The oil groove of the
upper thrust plates should be outward (toward the crankshaft).
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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 plates 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.
Figure 3- 3 Tightening Sequence of Main Bearing Bolt
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.
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3.2.4 Crankshaft system inspection and maintenance
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.
3.3 Main Bearing Disassembly and Assembly
3.3.1 Main bearing disassembly diagram
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1-Crank block；2-crankcase；3-Main bearing bolt；4-Crankshaft；5-Upper main bearing；6-Lower main bearing
Figure 3-4 Main bearing 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 crankshaft pulleys and
flywheel combination groups, remove the crankcase, reversely fix the cylinder body on the
rotating support, and lift the crankshaft out.
3.3.3 Main bearing Disassembly procedure
1) Pull the lower main bearing out by hand from one side, mark it and make sure it is one-to-one
correspondence between the bearing and the seat on crankcase.
2) Remove crankshaft
3) Pull the upper main bearing out by hand from one side, mark it and make sure it is one-to-one
correspondence between the bearing and the bearing seat on engine body.
3.3.4 Main bearing assembly procedure
1) Wash and wipe the bearing and bearing seat cleanly.
2) Install the upper main bearing on bearing seat according to the mark orderly.
3) Install the lower main bearing on bearing seat according to the mark orderly.
4) Install crankshaft and crankcase.
3.3.5 Main bearing inspection and maintenance
Key point1: Inspection
Check the main bearing shell wearing conditions; and check the alloy layer for scratching,
peeling, and sliding phenomena;
Key point 2: Assembly
Pay attention to distinguish lower bearing and upper bearing. It is upper bearing if having oil
groove. Apply lubricating oil to main bearing when assembling.
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3.4 Flywheel Combination Group Disassembly and Assembly
3.4.1 Flywheel Combination Group Disassembly Diagram
Figure 3-5 Flywheel combination group disassembly diagram
3.4.2 Flywheel combination group Disassembly procedure
Reverse the assembly procedure to disassemble flywheel combination group.
3.4.3 Flywheel combination group Assembly procedure
1) Fix the flywheel gear ring to the flywheel by 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;
a) Apply lubricating oil to the threads and pressure-bearing surface of the flywheel bolts.
b) Flywheel bolt M14×1.5 (9 pieces).
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Fasten with hands; 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 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.
3.4.4 Flywheel combination group inspection and maintenance
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;
3.5 Piston & Connecting Rod Combination Group Disassembly and Assembly
3.5.1 Piston & connecting rod combination group disassembly diagram
1-Engine block, 2-Piston and connection rod components, 3-connecting rod component,
4-Crankshaft, 5-Cylinder liner
Figure 3-6 Piston & connecting rod disassembly diagram
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6-Piston, 7-The first ring, 8-The second ring, 9-Oil ring, 10-Piston pin, 11-Piston pin circlip, 12-Connecting rod body, 13-
Connecting rod cover, 14-Connecting rod bolt, 15-Connecting rod upper bearing, 16-Connecting rod lower bearing
Figure 3-7 Piston & connecting rod 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.
3.5.3 Piston & Connecting rod combination group disassembly procedure
1) Rotate the crankshaft till the 1 and 6 pistons arrive at appropriate position, remove connecting
rod bolts, take connecting rod cover and bearing down.
2) Pull pistons & connecting rods out from liners.
3) Remove pin circlip from two sides of piston pin by internal circlip plier, pull the piston pin out
and take connecting rod body down. Number the piston pins and connecting rod body
according to the cylinder number.
4) Remove piston rings and number them.
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5) Remove connecting rod upper bearing and number them.
6) Rotate crankshaft, disassemble the 2,3,4,5 pistons as the same procedure.
3.5.4 Piston & Connecting rod combination group assembly procedure
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 circlip shall face
the inside, and the opening position of circlip is up.
2) Insert the connecting rod small end into the inner cavity of the piston, enable the small end to
align with the piston pin hole, and then mount the piston pin.
3) Install the piston pin circlip on other side. Before assembly, the small end hole of connecting
rod and the piston pin, 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.
4) 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.
5) Wipe the inner wall of the cylinder, crankshaft crank arm and piston connecting rod parts
cleanly, and apply clean lubricating oil at individual kinematic pair positions.
6) 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
below.
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Figure 3-8 Assembly angle of piston rings
7) 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;
8) Rotate the crankshaft and install other piston & connecting rod combination as same as
procedure 1-7.
3.5.5 Piston & connecting rod combination inspection and maintenance
Key point 1: Inspection
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 the outer surfaces of piston rings for excessive wear; Check the upper and lower sides of
piston rings for excessive wear;
3) Check the outer surface of piston pin for excessive wear.
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4) 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;
5) Check the connecting rod bearing shell wearing conditions; and check the alloy layer for
scratching, peeling, and sliding phenomena;
1) Connecting rod bolts: First slightly screw them in. Then symmetrically tighten them to the
torque of 120 Nm. 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.
2) According to different weight, there are 4 groups of pistons marked by G1、G2、G3、G4. It
is required to use pistons with same weight group in the same engine.
3.6 Damper and Crankshaft Pulley Disassembly and Assembly
3.6.1 Damper and crankshaft pulley disassembly diagram
Figure 3-9 Damper and crankshaft pulley disassembly diagram
3.6.2 Damper and crankshaft pulley disassembly procedure
Remove the pulley bolts. Remove the pulley and vibration damper.
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3.6.3 Damper and crankshaft pulley assembly procedure
With the timing gear chamber installed, fix the vibration damper and pulley to the crankshaft flange
using the pulley bolts.
3.6.4 Damper and crankshaft pulley inspection and maintenance
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.
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4 valve mechanism combination group
4.1 Valve Mechanism Disassembly and Assembly
4.1.1 Valve mechanism disassembly diagram
1-Gear chamber 2-Hexagon bolt 3-Camshaft timing gear 4-Hexagon bolt 5-Thrust halfring 6-Camshaft assembly
7-Intake valve 8-Cylinder head 9-Valve tappet 10- Pushrod 11-Lower seat of valve spring
12-Valve spring 13-Upper seat of valve spring 14-Valve collet 15-Valve bridge 16-Pin 17-Rocker arm
component 18-Rocker arm shaft assembly 19-Hexagon bolt 20-Rocker arm bracket 21-Exhaust valve
Figure 4-1 Valve mechanism disassembly diagram
4.1.2 Valve mechanism disassembly procedure
1) Disassemble the rocker arm and rocker arm shaft. For details, see the disassembly procedures.
2) Disassemble the intake and exhaust valves. For details, see the valve disassembly procedures;
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3) Disassemble the tappet and pushrod. For details, see the tappet and pushrod disassembly
procedures;
4) Disassemble the camshaft and camshaft timing gear. For details, see the disassembly
procedures.
5) Disassemble the intermediate gear. For details, see the disassembly procedures.
4.1.3 Valve mechanism assembly procedure
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.
4.2 Camshaft Disassembly and Assembly
4.2.1 Camshaft disassembly diagram
Figure 4-2 Camshaft disassembly diagram
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● 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.
4.2.3 Camshaft disassembly procedure
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.
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 half rings. Remove the thrust half rings. Remove
the camshaft assembly.
4.2.4 Camshaft assembly procedure
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
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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
4.2.5 Camshaft inspection and maintenance
1) Check whether the cam surface in contact with the tappet is worn or not, and whether the main
bearing journal is seized or worn;
2) 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.
3) It is forbidden to reuse if the camshaft mounting hole is damaged.
4) While inserting the camshaft through the camshaft hole, be careful not to cause damage to the
camshaft bushing.
5) Apply sealant on the threaded part of thrust plate bolt, and the tighten it.
4.3 Intermediate Gear Disassembly and Assembly
4.3.1 Intermediate gear disassembly diagram
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Figure 4-3 Intermediate gear disassembly diagram
● Tools: wrench, lubricating oil, towel.
● Preparation before disassembly: Make sure the gears of air compressor, signal generator and
camshaft have already been removed.
4.3.3 Intermediate gear disassembly procedure
1) Remove 4 M10 hexagon bolts and take the washer down.
2) Screw a M8 bolt into the intermediate gear shaft and pull the shaft out, preventing the
intermediate gear falling off in this process, demount the intermediate gear assembly and
intermediate gear shaft together.
4.3.4 Intermediate gear assembly procedure
1) Install the oil pump, crankshaft and oil pump intermediate gear assemblies in sequence;
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2) Install the gear housing. Before installing the gear housing, place the intermediate gear shaft
into the intermediate gear assembly (intermediate gear & bush), keeping the face with "V" on
the intermediate gear outward (i.e. "V" is not to be overlapped by the intermediate gear shaft),
locate the intermediate gear assembly and intermediate gear shaft in the gear housing into
position. During this installation, keep the engine upside down to prevent the intermediate gear
assembly and intermediate gear shaft from falling off. Install the shaft into intermediate shaft
and make sure the thread is outward and the oil hole is inside.
3) Install washer and 4 M10 bolts.
4.3.5 Intermediate gear inspection and maintenance
1) Check the mark on the mounting bolts for bolt looseness before disassembly.
2) Check if the mounting bolt thread is in good condition;
3) Check all gears for tooth metal spalling or breakage, the bolt bearing surface for crushing and
the thread hole or through hole in the gear for deformation;
4) Check if any abnormal wear occurs between the intermediate gear shaft and the intermediate
gear bush. Check if the oil hole is blocked by dirt
4.4 Tappet and Push rod Disassembly and Assembly
4.4.1 Tappet and push rod disassembly diagram
Figure 4-4 Tappet and push rod disassembly diagram
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 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.
4.4.3 Tappet and push rod disassembly procedure
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 cylinder head removal procedures), take
out the tappets and place them in order.
4.4.4 Tappet and push rod assembly procedure
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;
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.
4.4.5 Tappet and push rod inspection and maintenance
Key point 1: Check after removal
a) Clean the push rods and tappets;
b) Check the oil passages of the tappets and push rods for obstruction;
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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.
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.
4.5 Valve Disassembly and Assembly
4.5.1 Valve disassembly diagram
Figure 4-5 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.
4.5.3 Valve disassembly procedure
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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.
4.5.4 Valve assembly procedure
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.
4.5.5 Valve inspection and maintenance
Key point 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;
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c) Check whether the cone surface and arc surface of valve is accumulated with carbon or
worn.
a) Guarantee that the intake valve and exhaust valve to slide in the conduit without blocking;
b) Before assembling, must check whether the internal spring in the sealing bush of the valve
stem is kept intact.
4.6 Rocker Arm Disassembly and Assembly
4.6.1 Rocker arm disassembly diagram
Figure 4-6 Rocker arm disassembly diagram
● Tools: Torque spanner, small wrench, oil can, and lubricating oil
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● 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.
4.6.3 Rocker arm disassembly procedure
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.
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.
4.6.4 Rocker arm assembly procedure
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;
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7) Tighten bolts.
 Inspect and adjust valve lash.
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;
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)°.
4.6.5 Rocker arm inspection and maintenance
1) Clean the rockers and observe the appearances of rockers for presence of defects (such as
cracking).
2) Check whether the rocker arm hole is worn or abraded, and measure its diameter;
3) Check whether the ball pin and rocker arm base are worn.
4) Check the all oil-ways for presence of obstruction.
5) Measure the rocker arm hole diameter and rocker arm shaft diameter, and calculate the fitting
clearance.
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6) 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.
7) 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.
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5 Air Intake and Exhaust System
5.1 Air Filter Combination Group Disassembly and Assembly
5.1.1 Air filter combination group disassembly diagram
Figure 5-1 Air filter combination group disassembly diagram
● Tool: wrench, socket
● Preparation before removal: remove peripheral parts of the air filter.
5.1.3 Air filter combination group disassembly procedure
Reverse the assembly procedure to disassemble air filter.
5.1.4 Air filter combination group assembly procedure
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1）Fix the bracket on the filter body by bolts, tighten bolts by wrench.
2）Fix the filter body and filter bracket combination on the flywheel housing by bolts, flat washers
and spring washers, tighten bolts.
3）Connect hose by clamps and tighten clamps
5.2 Air Intake Manifold Combination Group Disassembly and Assembly
5.2.1 Air intake manifold combination group disassembly diagram
Figure 5-2 Air intake manifold combination group disassembly diagram
Tools: wrench, sleeve
5.2.3 Air intake manifold combination group disassembly procedure
1）Loose bolts and nuts on the supporting seat successively and take supporting seat down.
2）Loose and take down the clamp connected throttle and mixed-air inlet pipe, remove hose and
mixed-air inlet pipe.
3）Loose bolts, remove throttle and gasket.
4）Loose air intake manifold bolts orderly, take air intake manifold/ air intake connected pipe and
gasket down.
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5）Loose bolts, take air intake connected pipe and gasket down.
5.2.4 Air intake manifold assembly procedure
Reverse the disassembly procedure to assemble air intake manifold. The recommended torque of
air intake manifold bolts is 23 N·m.
5.2.5 Air intake manifold inspection and maintenance
1）Check air intake manifold for crack/defect and deformation, if any, replace it with a new one.
2）Check gaskets for defect and deformation, if any, replace it with a new one.
3）Check the temperature and pressure sensor for damage and failure, if any, replace it with a new
one.
5.3 Exhaust Tail Pipe Disassembly and Assembly
Figure 5-3 Exhaust tail pipe disassembly diagram
● Tool: wrench, socket
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● Preparation before removal: remove peripheral parts of the exhaust tail pipe.
5.3.3 Exhaust tail pipe assembly procedure
Reverse the disassembly procedure to assemble exhaust tail pipe.
5.3.4 Exhaust tail pipe disassembly procedure
1）Loose the nut fixed heat shield, remove exhaust pipe heat shield and gasket
2）Loose clamps on both sides of expansion joint, remove the expansion joint.
5.3.5 Exhaust tail pipe inspection and maintenance
1）Do not remove the Oxygen sensor unless cutting off the power, contrary to follow may lead
ECU damage.
2）Check the Oxygen sensor for defect and damage, if any, replace it with a new one.
3）Do not knot or haul the cable when assembly and disassembly.
5.4 Exhaust Pipe Disassembly and Assembly
Figure 5-4 Exhaust pipe disassembly diagram
● Tool: wrench/ sleeve
● Preparation before disassembly: Remove the parts related to exhaust tail pipe.
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5.4.3 Exhaust pipe disassembly procedure
Reverse the assembly procedure to disassemble exhaust pipe.
5.4.4 Exhaust pipe assembly procedure
1）Install the middle exhaust pipe on cylinder heat with a loosened way by bolts through the
sleeve and washer.
2）Install seal rings into the ring slot, the openings of seal ring are not allowed to overlap.
3）Install the front and rear exhaust pipe on cylinder head with a loosened way. Adjust the
position slightly to aline exhaust pipes and tighten bolts symmetrically. The recommended
torque of exhaust pipe bolt is 65~80 N•m. The exhaust pipe bolt only could be use twice.
5.4.5 Exhaust pipe inspection and maintenance
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.
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.
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6 Ignition System
6.1 Ignition System Disassembly and Assembly
6.1.1 Ignition system disassembly procedure
1) Remove ECU
2) Remove ignition coils.
3) Remove spark plugs
4) Remove signal generator
6.1.2 Ignition system assembly procedure
Reverse the disassembly procedure to assemble ignition system.
6.1.3 Ignition system inspection and maintenance.
Spark plug, ignition coil, signal generator and ECU should be inspected and maintained by
authorized service provider.
6.2 Ignition System Disassembly and Assembly
6.2.1 Ignition system disassembly diagram
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1-Bolt;2-Spring washer;3-Ignition coil;4-Spark plug
Figure 6-1 Ignition system disassembly diagram
6.2.2 Ignition system disassembly procedure
1) Remove bolt fitted ignition coil
2) Pull ignition coil out.
3) Remove spark plug by spark plug socket.
6.2.3 Ignition system assembly procedure
1) Check the clearance between the positive pole and negative pole of spark plug, the correct
value is 0.5mm.
2) Adjust clearance if it is not correct.
3) Install spark plug after inspecting and adjusting clearance, tighten it by spark plug socket.
4) Install ignition coil and tighten fixed bolts.
6.2.4 Spark plug inspection and maintenance
Tool: Spark plug socket
① Clearance: 0.5mm
② Tighten torque of spark plug: (25-28) Nm
6.3 ECU Combination Group Disassembly and Assembly
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1-Supporting bolt; 2-ECU brakcet;3-Hexagon bolt;4- Hexagon bolt;5-ECU;6-Hexagon bolt
Figure 6-2 ECU combination group disassembly diagram
6.3.2 ECU combination group disassembly procedure
1) Remove the ECU from bracket
2) Remove the bracket from engine block.
6.3.3 ECU combination group assembly procedure
Reverse the disassembly procedure to assemble ECU combination group
6.3.4 ECU combination group inspection and maintenance
Check the pin for bend.
6.4 Signal Generator Disassembly and Assembly
1-Hexagon flange bolt；2-Pointer；3-Stud bolt；4-Signal generator gear；5-O-ring；6-Signal generator；7- Hexagon
flange bolt；8-Phase sensor；9-Hexagon nut；10-Fluted disc；11-Spring washer；12- Hexagon nut；13-Gasket； 14-
Cover plate；15- Hexagon flange bolt
Figure 6- 3 Signal generator disassembly diagram
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6.4.2 Signal generator disassembly procedure
1) Remove the connecting bolts of the pump gear and signal generator.
2) Remove the hex nuts between signal generator flange and engine block.
3) Remove the signal generator from the engine.
6.4.3 Signal generator assembly procedure
1) Adjust the crankshaft to TDC: the first cylinder piston should be in its compression stroke.
Tighten the connecting bolts between the pump gear and signal generator.
2) Tighten the hex nuts between signal generator and engine block.
3) Adjust the fluted signal generator disc until its TDC mark points at the center of the speed
sensor and the predetermined ignition angle is reached.
4) Tighten the locknut on the signal generator fluted disc.
5) Tighten the hex nuts on the signal generator cover plate.
6.4.4 Signal generator inspection and maintenance
1) Check for damage to the signal generator shaft threads.
2) Check that the locknuts of the signal generator fluted disc are tightened and that the ignition
angle of the signal generator is correct.
3) Check the O-ring and cover plate for crack and damage, if any, replace it with a new one.
4) Check for damage to the speed sensor, fluted disc, or housing.
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7 Fuel System
7.1 Fuel System Disassembly and Assembly
7.1.1 Disassembly procedure
1. Air intake connected pipe; 2-EPR;3-Gas pipe;4-4Pipe connector;5-Solenoid;6-LPG water inlet pipe;7-Solenoid;8-
LPG water return pipe;9-LPG Evaporator;10-LPG pressure pipe;11-LPG Evaporator bracket;
12-Gas pipe;13-Bracket;14-Mixer bracket;15-Mixer;
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16-Gas hose;17-air intake connecting pipe;18-Washer
19-O-ring;20-O-ring;21-O-ring
Figure 7-1 Fuel system disassembly diagram
7.1.2 Fuel system disassembly procedure
1) Remove (6) LPG water inlet pipe and (8) LPG water return pipe
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2) Remove (10) LPG pressure pipe
3) Remove (12) Gas pipe
4) Remove (9) Evaporator
5) Remove (11) LPG Evaporator bracket
6) Remove (16) Gas hose
7) Remove (14) Mixer bracket
8) Remove (13) Bracket
9) Remove (15) mixer, (2) EPR, (13) connector, (5) solenoid and related hoses or pipes integrally.
10)Remove parts one by one from the integral group removed in step 9.
7.1.3 Fuel system assembly procedure
Reverse the disassembly procedure to assemble fuel system.
7.1.4 Fuel system inspection and maintenance
1) It is required to replace gasket and sealing O-ring with new one after disassembly.
2) Check if all connectors and clamps are in good condition.
3) Check if there is pressure balance pipe connecting on the mixer.
4) Check the NG pressure in intake pipe, the normal value is 2.5kPa
5) Check all connectors for leakage.
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8 Cooling System
8.1 Cooling System Disassembly and Assembly
Cooling system diagram
Figure 8- 1 Cooling system diagram
8.1.1 Cooling system disassembly diagram
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1-Fan and hub；2-Belt；3-Alternator；4-Water inlet pipe；5-Water pump；
6-Thermostat；7-Water outlet pipe
Figure 8-2 Cooling System Disassembly Diagram
8.1.2 Cooling system disassembly procedure
1) Remove fan and hub, see the procedure of fan and hub disassembly for details.
2) Swing the tensioning wheel clockwise, remove 2 belts.
3) Remove alternator from water inlet pipe, see the procedure of alternator disassembly for details.
4) Remove water inlet pipe, see the procedure of water inlet pipe disassembly for details.
5) Remove water pump, see the procedure of water disassembly for details.
6) Remove thermostat, see the procedure of thermostat disassembly for details.
7) Remove water outlet pipe, see the procedure of water outlet pipe disassembly for details.
8.1.3 Cooling system assembly procedure
Reverse the disassembly procedure to assemble cooling system.
8.2 Water Pump Inlet Pipe Disassembly and Assembly
8.2.1 Water pump inlet pipe disassembly diagram
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1-Water pump；2-Gasket；3-Water inlet pipe；4、5-Bolt；6-Pipe connector；
7-Bolt；8- Hexagon head screw plug
Figure 8-3 Water pump inlet pipe 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
8.2.3 Water pump inlet pipe disassembly procedure
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.
8.2.4 Water pump inlet pipe assembly procedure
Reverse the disassembly procedure to assemble water pump inlet pipe.
8.2.5 Water pump inlet pipe inspection and maintenance
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.
8.3 Water Pump Disassembly and Assembly
8.3.1 Water pump disassembly diagram
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1-Water pump pulley；2-Stud bolt；3- Locking hexagon nut；4-Water pump；5- Locking hexagon nut；
6-Gasket；7、8-Stud bolt；9-Seal washer；10- Hexagon head screw plug
Figure 8-4 Water pump disassembly diagram
● 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
8.3.3 Water pump disassembly procedure
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
8.3.4 Water pump assembly procedure
Reverse the disassembly procedure to assemble water pump.
8.3.5 Water pump inspection and maintenance
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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.
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.
8.4 Thermostat Disassembly and Assembly
8.4.1 Thermostat disassembly diagram
1-Water outlet pipe；2-Thermostat；3-Thermostat cap；4-Plug cover；5- Hexagon flange bolt
Figure 8-5 Thermostat 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.
8.4.3 Thermostat disassembly procedure
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1) Remove 4 bolts as No.5 and take the cover down.
2) Remove thermostat
8.4.4 Thermostat assembly procedure
1) Before assembly, firstly check the gasket, bolt, thermostat, and thermostat cover, to guarantee
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.
8.4.5 Thermostat inspection and maintenance
1) Check whether the thermostat cover has damages like crack, and replace the defective one if
any with a good one;
2) Check the thermostat for breakage. If any, replace it with a new one.
8.5 Fan and Hub Disassembly and Assembly
8.5.1 Fan disassembly diagram
1-Fan；2- Hexagon flange bolt；3-Fan connecting plate；4、6- Hexagon locknut；5- Hexagon flange bolt
Figure 8-6 Fan and hub disassembly diagram
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● Tools: Socket spanner or pneumatic wrench, open spanner
8.5.3 Fan disassembly procedure
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.
8.5.4 Fan assembly procedure
Reverse the disassembly procedure to assemble fan.
8.5.5 Fan inspection and maintenance
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.
8.6 Coolant Outlet Pipe Disassembly and Assembly
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1-Water outlet pipe, 2、3-Hexagon flange bolt, 4-Clamp, 5-Coolant hose, 6-Gasket, 7-Pipe connector, 8-Plug
9-Temprature sensor, 10-Plug, 11、14-Hexagon, 12、13、16-Sealign washer, 15-Pipe connector
Figure 8-7 Coolant outlet pipe disassembly diagram
● Tools: Socket spanner or pneumatic wrench, open spanner, rubber hammer
● Preparation before disassembly: Remove thermostat assembly
8.6.3 Coolant outlet pipe disassembly procedure
1) Remove the clamp and hose connected with coolant outlet pipe.
2) Remove the hexagon flange bolts in order, and take down the coolant outlet pipe and gasket;
3) Remove hexagon head plug, bonded washer, water block, seal washer, and other parts;
8.6.4 Coolant outlet pipe assembly procedure
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;
8.6.5 Coolant outlet pipe inspection and maintenance
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.
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9 Lubrication System
9.1 Lubrication System Disassembly and Assembly
9.1.1 Lubrication system disassembly diagram
1-Oil pump；2-Oil pan；3-Oil strainer；4-Main oil pressure limiting valve；5-Dipstick；6-Oil filter；
7-Oil cooler cover；8-Oil cooler；9-Oil cooler pass-by valve；10-Oil filling pipe
Figure 9-1 Lubrication system disassembly diagram
9.1.2 Lubrication system disassembly procedure
1) Remove oil pan, see oil pan disassembly procedure for details.
2) Remove oil strainer, see oil strainer disassembly procedure for details.
3) Remove oil pump intermediate gear, see oil pump intermediate gear disassembly procedure for
details.
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4) Remove oil pump, see oil pump disassembly procedure for details.
5) Remove main oil pressure limiting valve, see main oil pressure limiting valve disassembly
procedure for details.
6) Remove oil filter, see oil filter disassembly procedure for details.
7) Remove oil filter cover, see oil filter cover disassembly procedure for details.
8) Remove oil cooler, see oil cooler disassembly procedure for details.
9) Remove oil cooler bypass valve, see oil cooler bypass valve disassembly procedure for details.
9.1.3 Lubrication system assembly procedure
Reverse the disassembly procedure to assemble lubrication system.
9.2 Oil Pan Disassembly and Assembly
1-Sealing gasket；2- Oil pan supporting block；3-Hexagon；4-Oil pan；5-Washer；6- Magnetic plug
Figure 9- 2 Oil pan disassembly diagram
● Preparation before disassembly: Unscrew the oil drain screw block, to empty the oil
9.2.3 Oil pan disassembly procedure
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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.
9.2.4 Oil pan assembly procedure
Reverse oil pan disassembly procedure to assemble oil pan.
9.2.5 Oil pan inspection and maintenance
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.
Figure 9- 3 Sequence for tightening oil pan bolts
9.3 Oil Strainer Disassembly and Assembly
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1-Gasket；2、8-Washer；3、6-Hexagon bolt；4-Oil strainer；5-Supporting bracket；
7-Spring washer；9-Fixing bracket；10-Hexagon nut；11-Plate；
Figure 9-4 Oil strainer disassembly diagram
● Preparation before disassembly: Remove oil pan
9.3.3 Oil strainer disassembly procedure
1) Remove bolts and nuts fixed bracket 5 and 9, remove flat washer and spring washer.
2) Remove bolts 3, take oil strainer and gasket down.
3) Remove fixing bracket 9 and plate.
4) Remove supporting bracket 5.
9.3.4 Oil strainer assembly procedure
Reverse disassembly procedure to assemble oil strainer.
9.3.5 Oil strainer inspection and maintenance
Check the suction filter and gasket for cracks. If any, replace them with new ones.
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9.4 Oil Pump Intermediate Gear Disassembly and Assembly
1-Hexagon bolt；2-Sealing ring；3-Intermediate gear shaft；4- Intermediate gear
Figure 9- 5 Oil pump intermediate gear disassembly diagram
● Preparation before disassembly: Remove oil pan, oil pump and oil strainer
9.4.3 Oil pump intermediate gear disassembly procedure
1) Loosen and remove the hexagon bolt.
2) Using a special tool, remove the intermediate gear shaft. Then remove the engine oil pump
intermediate gear subassembly.
9.4.4 Oil pump intermediate gear assembly procedure
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.
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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.
9.4.5 Oil pump intermediate gear inspection and maintenance
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.
9.5 Oil Pump Disassembly and Assembly
1-Hexagon bolt；2-Hexagon flange bolt；3-Oil pump；4-Oil pump gasket
Figure 9- 6 Oil pump disassembly diagram
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10 na assembly - flypartsguy 4.2018

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