Introduction...............................................................................................

01
Preparations ............................................................................................. 02
Repair Specification.................................................................................. 03
Fault Diagnosis and Troubleshooting ....................................................... 04
Usage and Maintenance of Engine........................................................... 05
Whole Engine Set..................................................................................... 06
Disassembly of Engine ............................................................................. 07
Assembly of Engine.................................................................................. 08
Mechanical System .................................................................................. 09
Fuel System.............................................................................................. 10
Lubrication System ................................................................................... 11
Cooling System ........................................................................................ 12
Air Intake and Exhaust Systems............................................................... 13
Electrical System ...................................................................................... 14
Introduction
01
How to Use This Manual ..............................................01-1
General .................................................................01-1
Preparations..........................................................01-1 02
Repair Procedures ................................................01-1
Repair Specification ..............................................01-3 03
Tip and Caution................................................. …01-3
International System of Units (SI) ........................01-3 04
Vehicle Identification Mark ...........................................01-4
Engine System Identification.................................01-4 05
Engine Views ...............................................................01-5
View 1. ..................................................................01-5
06
View 2. ..................................................................01-7
View 3. ..................................................................01-9
General Safety Rules .................................................01-11 07
Important Safety Rules .......................................01-11
General Repair Instructions .......................................01-13 08
General ...............................................................01-13
General Cleaning Instructions ....................................01-14 09
Definition of Cleaning ..........................................01-14
Sanding Abrasive Disc and Paper ......................01-15 10
Gasket Surface ...................................................01-16
Solvent and Acid Cleaning ..................................01-16
Steam Cleaning ..................................................01-17
Fuel System ........................................................01-17
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 Introduction - How to Use This Manual 01-1

How to Use This Manual

General
1. This Manual provides the general repair instructions for gasoline engines in the Yuling product 01
series, and your repair quality and efficiency will be improved according to the instructions of this
Manual.
02
Tip:
This Manual is one of the repair manuals for Yuling product series, and only provides the repair
instructions for gasoline engines employed in Yuling product series. 03
2. The common repair operation of gasoline engines falls into the following 3 main procedures:
y Diagnosis; 04
y Removal and installation, replacement, installation and inspection, and debugging;
y Final inspection. 05
3. This Manual mainly describes the first procedure “Diagnosis” (Refer to Chapter 04 Fault Diagnosis
and Troubleshooting), the second procedure “Removal and Installation, Replacement, Installation 06
and Inspection, and Debugging”, and the third procedure “Final Inspection”.
4. For the following basic operations, this Manual only provides a detailed description to the repair of
key parts; however, in all practical repair operations, those operations are necessary. 07
y Clean parts removed, if necessary;
y Visual inspection. 08

09
Preparations
This Manual lists special tools, recommended tools, equipment and auxiliary materials necessary
10
for repair service in Chapter 02 “Preparations”, and describes their respective purposes.

Repair Procedures
1. Part drawings, which are inserted as required, provide a detailed description to the systems to which
the repaired parts belong.
2. Part drawings are exploded drawings that clearly describe the assembly relationship of parts.
 01-2 Introduction - How to Use This Manual

Assembly Relationship of Parts

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1 First Piston Ring 7 Connecting Rod Bush

2 Third Piston Ring 8 Connecting Rod Body

3 Oil Ring Part 9 Connecting Rod Bearing Shell

4 Piston 10 Connecting Rod Cap

5 Piston Pin 11 Connecting Rod Bolt

6 Piston Pin Retainer Ring

List of Part Names

3. Where the installation procedures are just opposite to the removal procedures, this Manual only
provides a description to key parts.
4. This Manual employs illustrations for the key parts and operations in the procedures, provides a
detailed description to them, and lists operation methods, standard values and cautions.
 Introduction - How to Use This Manual 01-3

5. This Manual has the illustrations the same with the similar models of engines. Under this condition,
the information provided may be inconsistent with the practical condition. However, the repair
methods are the same, and inconsistent points if any will give an additional description.
6. The procedures are described in the following order:
y Operation steps give “What to Do” and “Where to Do”. 01
y Operation step titles give “What to Do”.
y Operation steps give How to “Finish the Task”, and the help information for operation such as 02
“Tip” and “Caution” is also provided.
Example:
03
What to Do
Finish the Task 04
Illustration 2. Install Crankshaft
What to Do and Where to Do (a) Install the upper shells of the main bearing shells to 05
the corresponding positions.
Tip: 06
Install the upper shells of the main bearing shells to the
corresponding positions carefully in order. Make sure that
07
the back of each bearing shell is clean, the upper shell of
each main bearing shell is in the center of the shell
groove, and the upper end faces are flush. Apply an 08
appropriate amount of oil or equivalent on the inner side of
the arched surface of each bearing shell after installation. 09

10
Help Information

Repair Specification
The specifications are listed in boldface letter in this Manual, and it is unnecessary for you to refer to
them while stopping the work on hand. Chapter 03 in this Manual also introduces the repair
specification for your quick searching.

Tip and Caution

Tip It provides an additional description, which is helpful to improve the work efficiency of repair.

Caution As represented in bold, it indicates possible damages to parts and equipment or injuries to persons.

International System of Units (SI)

The unit in this Manual is based on the international system of units (SI)
Example:
Torque: 30N•m
 01-4 Introduction - Vehicle Identification Mark

Vehicle Identification Mark

Engine System Identification
01
1. Engine Identification
02 (a) The engine plate is installed on the cylinder head
cover of the engine.
Tip:
03
A refers to the engine plate.

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05

06
2. Fuel Injection Pump Identification
07 (a) Install the fuel injection pump plate on the outer side
wall of the fuel injection body of the engine.
08 Tip:
B refers to the fuel injection pump plate.
09

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3. Oil Pump Identification

(a) Install the oil pump plate on the side wall of the oil
pump body.
Tip:
C refers to the oil pump plate.
 Introduction - Engine Views 01-5

Engine Views
View 1
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 01-6 Introduction - Engine Views

1 Oil Filler 10 Flywheel Housing

2 Diesel Filter 11 Drain Cock

3 Fan 12 Engine Body

01
4 Belt 13 High-pressure Fuel Pipe

02 5 Crankshaft Pulley 14 Hanger

6 Fuel Injection Pump 15 Intake Manifold

03
7 Oil Pan 16 Cylinder Head and Cover
04 8 Drain Plug 17 Fuel Return Pipe

9 Oil Filter 18 Thermostat

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 Introduction - Engine Views 01-7

View 2

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 01-8 Introduction - Engine Views

1 Breather 11 Engine Support

2 Exhaust Manifold 12 Gear Chamber

01 3 Fan 13 Fuel Injection Pump

4 Generator 14 Diesel Filter

02
5 Belt 15 Oil Filler
03 6 Engine Support 16 Intake Manifold

7 Drain Cock 17 Fuel Pipe

04
8 Crankshaft Pulley 18 Cylinder Head and Cover
05 9 Oil Pan 19 Thermostat

10 Oil Filter
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 Introduction - Engine Views 01-9

View 3

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 01-10 Introduction - Engine Views

1 Hanger 9 Dipstick

2 Body 10 Generator
01 3 Flywheel Housing 11 Fan

4 Starter 12 Diesel Filler

02
5 Oil Pan 13 Thermostat
03 6 Drain Cock 14 Breather

7 Crankshaft Pulley 15 Cylinder Head and Cover

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8 Belt 16 Exhaust Manifold
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 Introduction - General Safety Rules 01-11

General Safety Rules

Important Safety Rules
01
Caution:
Incorrect procedures, carelessness or neglect of warnings may result in burns, cuts, physical
02
mutilation, suffocation or other personal injuries, even death.
Tip:
Prior to any repair, it is necessary to carefully read and understand all safety measures and cautions. 03
The following contents include general safety measures which must be followed in order to ensure
personal safety. Furthermore, special safety measures will be included in the practical steps. 04
1. The working area shall be dry, bright and well-ventilated, free from sundries, scattered tools, parts,
fire or other dangerous goods. Pay attention to possible dangers. 05
2. Always wear goggles and protective shoes when working.
3. Rotating parts may result in cuts, physical mutilation, or even death by rotation. 06
4. Never wear loose or broken clothes. Take off all jewels.
5. Before repair, batteries shall be disconnected (disconnect the negative cable first), and all
capacitors shall be allowed to discharge. In order to prevent the accidental start of the starter, the 07
starter shall be disconnected as well.
6. When the engine is rotated manually, only correct engine start methods can be employed. Never 08
pull or pry fans to rotate the crankshaft. Otherwise this behavior will cause serious personal injuries,
property loss or early damage to fan blades. 09
7. If the engine has run for a period of time and coolant is hot, allow the engine to be cooled before
slowly loosening the filler cap to release the pressure of the cooling system. 10
8. Before any repair, hold the workpiece by an appropriate supporting block or bracket all the time.
When there is only a jack or hoisting equipment to support the workpiece, never do any work.
9. Before removing or disconnecting any pipelines, joints or relevant parts, make sure that air, oil, fuel
or the pressure of the cooling system is drained or released. When disconnecting any devices in the
pressure system, pay attention to possible pressure. Never check pressure leakage by hand.
High-pressure or fuel may cause personal injuries.
10. In order to reduce the possibility of mutilation or frozen injury, wear protective clothing, and
disconnect the liquid refrigerant (freon) pipeline only in a well-ventilated working area. In order to
protect the environment, appropriate equipment must be employed for the emptying and filling of the
liquid refrigerant system, and this device shall be capable of preventing refrigerant gas
(fluorocarbon) from going into the air.
11. For parts with a weight of above 23kg, in order to reduce the possibility of personal injuries, hoist
them by hoisting equipment or with the help of others. Make sure that all equipment, such as chains,
hooks or hangers are in good condition and have enough bearing capacity. Confirm that hooks are
in correct hoisting positions. Support the work with crossbars all the time, if necessary. Hooks are
unable to bear lateral load.
12. Anti-corrosive agent (a component in SCA and oil) contains alkali. Never allow it to go into eyes,
avoid long-term repeated skin contact with it, and never eat it. In case of skin contact, wash the skin
with soap and water immediately. In case that it comes into eyes, wash eyes with enough water for
at least 15min immediately, and seek medical advice immediately. Place it in such a place that
children are unable to reach.
13. As both naphtha and MEK are inflammable, special attention must be paid to them. Use of naphtha
and MEK must be subject to the instructions for use from the manufacturer to ensure safety. Place
them in such a place that children are unable to reach.
14. In order to reduce the possibility of burns, pay attention to not touching hot parts, hot liquid in the
pipelines and pipes, and the engine room.
15. Use tools in good condition all the time. Before any repair work, make sure that you know how to
use those tools. Only use parts provided by Foton Automobile.
 01-12 Introduction - General Safety Rules

16. When replacing fasteners, use fasteners with the same part No. (or equivalent) all the time. If
replacement is needed, never use fasteners with inferior quality.
17. When normal work can not be done due to drinking or taking medicine, never do any repair work.
18. It has been proved that used oil is carcinogenic and has reproductive toxicity. Avoid inhaling oil
01 steam, wrongly eating and touching used oil for a long time.
19. Liquefied petroleum gas (LPG), as heavier than air, gathers on the flooring, oil trap or low areas.
02 20. Natural gas (NG), as lighter than air, gathers below the engine hood and sunroof.
21. In order to reduce the possibility of mutilation or frozen injury, wear protective clothing, and
disconnect the NG or LPG pipeline only in a well-ventilated area.
03
22. Coolant is toxic. If it is disused, its disposal shall be subject to the local environmental protection
regulations.
04 23. Catalyst contains urea. Never allow it to go into eyes. In case of contact, wash eyes with enough
water for at least 15min immediately. Avoid long-term repeated skin contact with it. In case of skin
05 contact, wash the skin with soap and water immediately. Never eat it. If inhaling catalyst, seek
medical advice immediately.
06 24. As catalyst contains vanadium pentoxide, wear gloves and goggles all the time when dealing with it.
Never allow it to go into eyes. In case of contact, wash eyes with enough water for at least 15min
07 immediately. Avoid long-term repeated skin contact with it. In case of skin contact, wash the skin
with soap and water immediately.
25. Catalyst matrix contains vanadium pentoxide. If it is replaced, its disposal shall be subject to the
08 local environmental protection regulations.

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 Introduction - General Repair Instructions 01-13

General Repair Instructions

General
01
1. Follow all safety rules referred to in this step.
(a) Use cleaning solvents and other materials recommended by the engine manufacturer for engine
02
repair. The government shall confirm that some solvents or used oil is toxic and carcinogenic. Avoid
inhaling excessively, eating or touching those materials. Follow relevant safety regulations all the
time when using tools and equipment. 03
2. Provide a clean environment, and follow the cleaning procedures specified by the step.
(a) The engine and its parts must be kept clean for any repair. Engine or part contamination will result in 04
early wear.
3. Replace all parts or assemblies damaged or worn seriously beyond the technical 05
specification.
4. Use new genuine service parts and assemblies provided by Foton Automobile. 06
(a) Written assembly skills are provided to be applicable to parts and assemblies as many as possible.
When it is necessary to replace parts or assemblies, parts provided or recommended by Foton
Automobile must be employed in the replacement steps. 07
5. Follow the specified disassembly and assembly steps to reduce the possibility of damage to
parts. 08

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 01-14 Introduction - General Cleaning Instructions

General Cleaning Instructions

Definition of Cleaning
01
1. Debris on parts, which is possible to contaminate any engine systems, must be cleared away. This
02 does not mean that parts must be smooth and new.
2. It is unnecessary to sand the gasket surface to the factory-machined mark by abrasive paper, and
this is usually harmful to the sealing effect. It is important to keep the tolerance of surface roughness
03
and flatness to form a good sealing surface. Gaskets are used to make up the uneven position on
the specific surface.
04 3. If gaskets with molded edge are used, it is usually unnecessary to sand the gasket surface by
abrasive paper. Gaskets with molded edge are bonding sealing material around the edge of metal
05 sheet, and the metal-to-metal connection is formed for the metal part to achieve stability. It is better
to clear away any small amount of sealing material bonded on parts by a blunt scraper, and it is
06 unnecessary to spend time in polishing the whole surface by a automatic grinding machine or
abrasive wheel.
4. For gaskets without molded edge, nearly all of them use some material containing release agent for
07
preventing bonding. However, this does not mean that gaskets are not difficult to remove as they
have been installed for a long time and overheated or some sealant has been used to disable
08 release agent. Our purpose is that the removal of only gaskets will not cause any damage to the
matching surfaces of parts and the engine will not be contaminated (never allow tiny particles to fall
09 into the positions where they are difficult to clear away.)
5. It is unnecessary to clean the piston crown until black stains are cleared away. What needs
10 removing is carbon deposit in the top ring and ring groove.
6. It is not recommended to sand or grind the carbon ring on the top of the cylinder liner by abrasive
paper until clean metal is exposed. Otherwise, that may damage the cylinder liner, and damage any
fault evidences on the reverse indicating arrow (such as dedusting mark) of the top ring. The carbon
ring must be removed to remove the piston more easily. The rated speed shall exceed power tools
used, and high-quality medium-hard steel wire wheel can reach that speed and cause smaller
damage. After the piston is removed, broken steel wires must be looked for carefully. Steel wires
are easy to see and can be attracted by a magnet.
7. Oil on the parts removed from the engine will absorb dust in air and dirt. If possible, keep the used
oil on the part until this part is ready for cleaning, inspection and installation, and then clean that part
and clear away any dust and dirt on it. If clean a part and place it outside, clean it once more before
installation. Make sure that clean oil is used to lubricate parts before installation. It is unnecessary to
fully oil them, but do apply oil between moving parts (or before dragging the engine, conduct good
pre-filling process for the lubrication system).
8. Usually, it is unnecessary to clear away the paint on the part surface by shot blast. Parts may be
re-painted, so what to do is to clear away any peeling paint.
 Introduction - General Cleaning Instructions 01-15

Sanding Abrasive Disc and Paper

1. The key point of sanding lies in “grinding”, and all engine parts will be worn down. In other words,
they are all locked together or mutually slide. Friction material and dust particles will weaken those
01
two functions
Caution:
The oil passage and the wear points of parts must be free from any friction material. The friction 02
material in the oil passage will result in bearing and bushing faults, and further cause damages
to the main parts as time passes, especially for main bearings and connecting rod bearings. 03
2. It is not recommended to sand any parts of any assembled engine or components by abrasive cloth
or abrasive paper, including but not limited to clearing away carbon deposit zone from the cylinder 04
liner, or cleaning cylinder surfaces or countersunk holes.
3. When grinding products are used to clean engine parts, especially partially assembled engine, 05
attention must be paid. There are many forms and sizes of friction cleaning products, including fine
aluminum oxide particles, emery, sand or other similar hard materials. Those fine particles are
harder than most of parts in the engine. As they are hard, when pressed on the soft materials, they 06
will damage those materials and also go into the materials. During use of those grinding products,
the friction cleaning products will fall from the grinding products. If the friction cleaning products are 07
used on the power equipment, the fine particles will thrown around the engine. If the fine particles
fall between two moving parts, it may cause damages to the moving parts. 08
4. If the diameter of fine particles is smaller the static gap (engine shutdown) between moving parts
but greater than the moving gap (engine start), the relative movement of the moving parts will cause 09
damages to parts. When the engine runs with oil pressure, fine particles with a diameter smaller
than the bearing clearance may pass through the two parts without any damages to parts, and then
10
held by the oil filter. However, fine particles with a diameter greater than the bearing clearance will
wear off the material on some part and may go into the part. Once going into one part, they will wear
the other part until the two parts separate without contact. If the damage has an obvious effect on oil
film, the two parts will directly come into contact, which will cause early wear or faults due to
shortage of effective lubrication.
5. Friction particles may fly in the course of cleaning, it is very important to prevent those fine particles
from going into the engine, whenever possible, for the oil filler and oil passage hole, especially for
those holes located at the downstream part of the oil filter. Plug those holes rather than trying to
blow away friction particles and debris with compressed air, because the compressed air will further
blow debris into the oil passage.
6. All original gasket material must be cleared away from the gasket surface of parts. However, it is
unnecessary to clean and polish the gasket surface until sanding off the machined mark. Excessive
sanding or polishing by abrasive paper may damage the gasket surface. Many novel gaskets are
with molded edge (steel base sheet with gasket bonded on it) Clear away a very small amount of
sealing material bonded on parts by a scraper or putty knife. It usually wastes time to clean the
gasket surface of a gasket with molded edge by abrasive disc or paper.
Caution:
Excessive sanding or grinding on the carbon rings on the top of the cylinder liner by abrasive
paper may damage the cylinder liner, and have it disabled. The surface layer may be damaged,
and friction particles may be pressed into the cylinder liner material, which may cause the early
wear of the cylinder or the fault of the piston ring.
7. Seal or plug all openings connected to the inside of any parts by adhesive tapes or plugs before
using abrasive disc or steel wire brush. If a power tool with abrasive disc must be employed due to
time, seal the oil passage with adhesive tape or use a plug, and clean a maximum part of the
surface by the power tool; however, clean the part of surface around the oil filler by hand to avoid
contaminating the oil passage. Then remove the adhesive tape or plug, and never use the tool to
carefully clean other areas. Never blow debris from the oil passage of the assembled engine by
compressed air. It may have an exactly opposite effect to further blow debris into the oil passage. If
both end of the oil passage are opened, the compressed air can be employed to blow the debris
away, but it is rare for an assembled engine.
 01-16 Introduction - General Cleaning Instructions

Gasket Surface
1. The purpose of cleaning the gasket surface is to clear away any gasket material, but not to re-polish
01 the gasket surface of parts.
2. Liquid gasket remover of any specific brands is not recommended. If liquid gasket remover is
employed, check the instructions for use to make sure that the material to be cleaned will not be
02
damaged.
3. Pneumatic gasket scrapers can save time but attention must be paid to not damaging the surface.
03 The angulation part must be opposite to the gasket surface to prevent the blade from cutting into the
surface. Techniques and attentions are needed to use the pneumatic gasket scraper on the parts
04 made of soft material, so as to avoid damages.
4. Never scrape or brush the whole gasket surface, if possible.
05
Solvent and Acid Cleaning
06
1. Some solvents or acid cleaners can be employed to clean disassembled engine parts (except the
07 piston) The experience has shown that the best cleaning effect can be achieved provided that the
cleaners are heated to 90°~95°C. However, kerosene emulsion cleaners have a different technical
08 specification for temperature, see the following. The cleaning tank, capable of continuously mixing
and filtering cleaning solution, can reach the best cleaning effect. Commins does not recommend
09 special cleaner, and it is ok to use the cleaner according to the manual from the cleaner
manufacturer. Before placing parts into the cleaning tank, clear away all gasket materials, O-rings,
sludge deposit and carbon deposit from parts by a steel wire brush or scraper. Pay attention to not
10 damaging any gasket surface. Clean parts with steam before placing them into the cleaning tank, if
possible.
Caution:
The cleaning by solvents and acid or alkaline substances shall be subject to the methods
recommended by the manufacturer. Goggles and protective clothing shall be worn to avoid
personal injuries.
2. The experience has shown that it is best to use kerosene emulsion cleaners to clean the piston.
Those cleaners shall not be heated above 77°C. They will start to discompose above 82°C, and the
cleaning effect will weaken. Never use the solutions mainly composed of hydrochloric ether and
cresol, phenol and/or creosote. When clearing away the deposit in the ring groove, their effect is not
obvious, and the cost of correct disposal is high.
(a) The solutions with a pH above 9.5 or so make aluminum blacken, so high alkaline solutions shall not
be used.
(b) Chemical substances with a pH above 7.0 are deemed as acid substances, while chemical
substances with a pH below 7.0 are deemed as alkaline substances.
(c) The greater the pH deviation from the neutral 7.0, the stronger the alkalinity or acidity is.
3. Before placing parts into the cleaning tank, clear away all gasket materials, O-rings, sludge deposit
and carbon deposit from parts by a steel wire brush or scraper, and pay attention to not damaging
any gasket surface. Clean parts with high-temperature and high-pressure water or steam before
placing them into the cleaning tank, if possible. Removal of the thickest dirt will make the cleaner
more effective before placing in the cleaning tank, and the cleaner will last for a longer time.
4. Wash all parts with hot water after cleaning. Completely dry parts with compressed air. Blow away
water in all bolt holes and oil passages.
5. If parts are not used immediately, apply an appropriate amount of antirust, and clear away the
antirust before assembling or installing parts to the engine.
 Introduction - General Cleaning Instructions 01-17

Steam Cleaning
1. Steam cleaning can clear away all forms of dirt, and the dirt will pollute the cleaning tank. It is a good
method to clean the oil passage and coolant passage.
01
Caution:
When using the steam cleaner, wear goggles or protective mask and protective clothing.
Otherwise, hot steam may cause serious personal injuries. 02
The steam cleaning is inapplicable to the following parts:
(a) Electrical parts; 03
(b) Wire harness;
(c) Fuel injector; 04
(d) Fuel pump;
(e) Belts and hoses; 05
(f) Bearings (balls or rolling cones);
06
Fuel System
07
1. Before repairing any parts of the fuel system, in order to avoid contaminating those parts prior to
their removal, clean the surrounding area of pipe joints, mounting parts and parts to be removed. If 08
the surrounding area is not cleaned, dirt may go into the fuel system or the fuel system may be
contaminated.
09
2. Generally, some oil passages of the fuel injector are very narrow and tiny, and easy to jam by
contaminants. Some fuel injection systems are capable of working at very high pressure.
High-pressure fuel enables single dirt and rust particles to become very abrasive contaminants, 10
which will damage the high-pressure pumping parts and fuel injector.
3. Where there is no steam cleaner, electrical contact cleaner is available. When cleaning the dirt and
debris on the joints of fuel system, use the electrical contact cleaner rather than compressed air.
Diesel on the exposed parts of the fuel system will absorb air contaminants.
4. Select lint-free towels for the operation of the fuel system.
5. Once the fuel system is opened, cover or plug the fuel pipes, joints and ports. Only if the fuel pipes
or other parts is loose or removed from the engine, rust, dirt and paint may go into the fuel system.
In many instances, a good method is to loosen the pipes or pipe joints to allow rust and paint to fall
down, and then clear away those fallen materials.
6. When removing the fuel pipes or pipe joints from a new or newly-painted engine, make sure to clear
away fallen paint segments/debris, which are formed at the time when the wrench touches painted
pipe bolts or pipe joints, or when rapidly-disconnected joints are removed.
7. Tools for the fault judgment and troubleshooting of the fuel system need regular cleaning to avoid
contamination. As the same with the parts of the fuel system, tools will absorb air contaminants
when their surface is covered with oil or fuel.
8. Please remember the following points for the tools for the fuel system:
(a) Keep them as clean as possible.
(b) Clean and dry them before placing in the toolbox.
(c) Keep them in the closed container, if possible.
(d) Make sure they are clean before use.
 - 01-18
Memo - Introduction - General Cleaning Instructions

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Preparations
01
Gasoline Engine...........................................................02-1
Preparations..........................................................02-1
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 02-2 Preparations - General Cleaning Instructions

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 Preparations - Gasoline Engine 02-1

Gasoline Engine
Preparations
Special Tools 01

02
Oil filter wrench To remove oil filter
03

Valve spring compressor To remove and install valve spring 04

05
Valve guide removal and
To remove and install valve guide
installation punch
06

Intake/exhaust valve seat 07

To install intake/exhaust valve seat ring
ring installation punch
08
Valve oil seal removal
To remove valve guide oil seal
pliers 09

Valve oil seal installation 10

To install valve guide oil seal
punch

Valve grinding rod and To grind valve and valve leather cuff
leather cuff (manual) (manual)

To measure the inner diameter of the

Cylinder barrel dial gauge
cylinder

To remove the advancer of high-pressure

Advancer extractor
fuel pump

Camshaft timing gear

To remove camshaft timing gear
extractor
 02-2 Preparations - Gasoline Engine

Puller To remove crankshaft pulley

01
Valve seat ring reamer
To repair valve seat ring
components
02

03 Piston ring remover To remove or install piston ring

04
Piston pin punch To remove piston pin
05

06 Cylinder remover To remove or install cylinder

07
Camshaft bearing shell
To remove camshaft bearing shell
08 remover

09 Tachometer To measure engine’s rotational speed

10
Cylinder pressure gauge
To measure cylinder pressure
components

Oil seal remover To remove oil seal

Oil seal installer To install oil seal

 Preparations - Gasoline Engine 02-3

Recommended Tools

Adjustable or watch-hand
To fasten or remove bolt
torque wrench 01

Quick wrench or long-short 02

To fasten or remove bolt
connecting rod
03
Screwdriver To remove pipe clamp
04

05
Vernier caliper To measure the inner and outer diameter
06
90-degree angle
To measure right-angle 07
measurement

08
Thermometer To test thermostat
09

Regulatory To measure clearance 10

To measure the flatness of cylinder or

Precision ruler
cylinder head

Dial indicator To measure shaft runout or clearance

Magnetic stand To support instruction class (dial indicator)

To measure the diameter and roundness of

Screw micrometer
cylinder

Horizontal jack To lift heavy objects

 02-4 Preparations - Gasoline Engine

Scraper To clean residual gasket

01
Combination pliers To remove cotter pin
02

03
Copper rod To remove or install a gear
04

05
Jack To jack the front axle
06

07
Pry bar and jack pry bar
08

09 Hammer

10

Insurance iron bench To withstand the car frame

Large adjustable wrench To use together with the puller

Oil basin and cleaning brush To clean components

Wire brush To clean stains

Tip punch

Oil seal installer To install an oil seal

 Preparations - Gasoline Engine 02-5

Circlip clamp To remove axis circlip

01

Rubber Hammer 02

03

04

05

06

07

08

09

10
 02-6 Preparations - Gasoline Engine

Equipment

Lifting jack To disassemble transmission or engine in the vehicle groove

01
Horizontal jack To disassemble transmission or engine in the vehicle groove
02
Crankshaft grinding machine To grind crankshaft journal
03
Valve grinding machine To grind valve working surface
04
Air compressor To clean engine parts
05
Fuel injection pump test bench To test the efficacy of the fuel injection pump
06

07 Auxiliaries

08
Engine lubricating oil To lubricate engine frication parts
09
Valve grinding paste To grind valve and valve seat ring
10
Prussian blue To check the tightness between valve and valve seat ring

Thin fuse wire To check the bearing radial clearance

Repair Specification
01
Basic Data ..................................................................03-1
LL380B ...................................................................03-1
02
LL480QB .................................................................03-3
QC480Q (DI) ...........................................................03-5
Repair Data ................................................................03-7 03
LL380B ...................................................................03-7
LL480QB ...............................................................03-11 04
QC480Q (DI) .........................................................03-15
Torque Requirements ...............................................03-17 05
LL380B .................................................................03-17
LL480QB ...............................................................03-18 06
QC480Q (DI) .........................................................03-19
07

08

09

10
 03-2 Repair Specification - Gasoline Engine

01

02

03

04

05

06

07

08

09

10
 Repair Specification - Basic Data 03-1

Basic Data
LL380B
Inline three-cylinder, four-stroke, water-cooled, direct injection 01
Type
combustion chamber
Quantity of Cylinders 3 02

Diameter of Cylinder 80mm 03

Piston Stroke 90mm 04

Compression Ratio 18:1 05

Total Piston Displacement 1.357L 06

Firing Order 1-3-2
07
Min. Idling Speed ≤850r/min
08
Min. Specific Fuel Consumption ≤245g/kw.h
09
Oil Consumption ≤2.72 g/kw.h
10
Steady State Speed Governing
≤10%
Rate
Rotation Direction of Crankshaft
Counterclockwise
(facing power output end)
Starting Method Electric start

Lubrication Method Pressure and splash

Cooling Method Forced circulation water cooling

Temperature of Cooling Water 80~90℃

Temperature of Oil ≤95℃

Temperature of Exhaust Pipe ≤600℃

Net Weight 180kg

Dimensions (L × W × H) 569mm×525mm×640mm

Fuel Injection Pump

Model I pump, IW pump, BQ pump

Type Plunger type

Governor —

Diameter of Plunger Φ8
 03-2 Repair Specification - Basic Data

Fuel Supply Pump Single-acting piston type

Fuel injector;
01
Type —
02 Injector Nozzle Matching Parts
ZCK154S425
and Model
03 Oil Pump

04 Type Gear or rotor type

05 Flow Rate ≥22L/min

06 Working Speed —

07 Working Pressure —

08 Water Pump

Type Centrifugal
09
Working Speed —
10
Flow Rate ≥68L/min

Starter

Model QD1315A or QD138C

Type DC series motor

Voltage 12V

Power 2.5kw

Generator

Type Silicon rectification compound generator

Model JF11 or JFWB13A1

Power 350W

Voltage 14V

Diesel Filter

Type and Model C0506C

Oil Filter

Type and Model J0810H

 Repair Specification - Basic Data 03-3

LL480QB
Inline four-cylinder, four-stroke, water-cooled, direct injection
Type
combustion chamber 01
Quantity of Cylinders 4
02
Diameter of Cylinder 80mm
03
Piston Stroke 90mm
04
Compression Ratio 18:1
05
Total Piston Displacement 1.809L
06
Firing Order 1-3-4-2

Min. Idling Speed ≤850r/min 07

Min. Specific Fuel Consumption ≤247g/kw.h 08

Oil Consumption ≤2.72 g/kw.h 09

Steady State Speed Governing
≤10% 10
Rate
Rotation Direction of Crankshaft
Counterclockwise
(facing power output end)
Starting Method Electric start

Lubrication Method Pressure and splash

Cooling Method Forced circulation water cooling

Temperature of Cooling Water 80~90℃

Temperature of Oil ≤95℃

Temperature of Exhaust Pipe ≤600℃

Net Weight 195kg

Dimensions (L × W × H) 675.5mm×494mm×608mm

Fuel Injection Pump

Model IW pump or BQ pump

Type Plunger type

Governor —

Diameter of Plunger Φ8

Fuel Supply Pump Single-acting piston type

 03-4 Repair Specification - Basic Data

Fuel injector;

Type —
01 Injector Nozzle Matching Parts
ZCK154S425
and Model
02
Oil Pump
03 Type Gear or rotor type

04 Flow Rate ≥22L/min

05 Working Speed —

06 Working Pressure —

07 Water Pump

08 Type Centrifugal

Working Speed —
09
Flow Rate ≥68L/min
10
Starter

Model QD1315A or QD138C

Type DC series motor

Voltage 12V

Power 3.0kw

Generator

Type Silicon rectification compound generator

Model JF11 or JFWB13A1

Power 350W/500W

Voltage 14V

Diesel Filter

Type and Model Single-stage paper element/C0506C

Oil Filter

Type and Model Single-stage paper element/J0810H

 Repair Specification - Basic Data 03-5

LL480Q (DI)
Inline four-cylinder, four-stroke, water-cooled, direct injection
Type
combustion chamber 01
Quantity of Cylinders 4
02
Diameter of Cylinder 80mm
03
Piston Stroke 90mm
04
Compression Ratio 18:1
05
Total Piston Displacement 1.809L
06
Firing Order 1-3-4-2

Min. Idling Speed ≤850r/min 07

Min. Specific Fuel Consumption ≤253g/kw.h 08

Oil Consumption ≤2.72 g/kw.h 09

Steady State Speed Governing
5~10% 10
Rate
Rotation Direction of Crankshaft
Counterclockwise
(facing power output end)
Starting Method Electric start

Lubrication Method Pressure and splash

Cooling Method Forced circulation water cooling

Temperature of Cooling Water 80~90℃

Temperature of Oil ≤95℃

Temperature of Exhaust Pipe ≤600℃

Net Weight 195kg

Dimensions (L × W × H) 676mm×509mm×631.5mm

Fuel Injection Pump

Model BH4Q75R8

Type Plunger type

Governor TQB mechanical whole type

Diameter of Plunger Φ7.5

Fuel Supply Pump Single-acting piston type

 03-6 Repair Specification - Basic Data

Fuel injector;

Type PF68SD
01 Injector Nozzle Matching Parts
ZCK154S425
and Model
02
Oil Pump
03 Type Rotor type

04 Flow Rate 21L/min

05 Working Speed 1500 r/min

06 Working Pressure 400kpa

07 Water Pump

08 Type Centrifugal, volute, single-suction

Working Speed 3000 r/min

09
Flow Rate 80L/min
10
Starter

Model QD138C

Type DC series motor

Voltage 12V

Power 2.5kw

Generator

Type Silicon rectification compound generator

Model JFWB13

Power 350W/500W

Voltage 14V

Diesel Filter

Type and Model Single-stage paper element/C0506C

Oil Filter

Type and Model Single-stage paper element/J0810H

 Repair Specification - Repair Data 03-7

Repair Data
LL380B
Valve Timing 01

Intake Valve Opening (Before TDC) 14.5℃ 02

Intake Valve Closing (After BDC) 37.5℃ 03

Exhaust Valve Opening (Before BDC) 56℃ 04

Exhaust Valve Opening (Before TDC) 12℃ 05

Crankshaft
06
Standard Size of Crankshaft Main Bearing Journal and
Main Bearing Shell Hole Hole
07
Clearance between
Nominal Value 0.08-0.138
Crankshaft Main Bearing 08
Journal and Main Bearing
Limit Value 0.25
Shell Hole
09
Nominal Size of Crankshaft Axial Clearance
10
Nominal Value 0.075-0.24
Axial Clearance of Crankshaft
Limit Value 0.50
Standard Size of Crankshaft Connecting Rod Journal and
Connecting Rod Shell Hole Shaft Hole
Clearance between
Nominal Value 0.04-0.101
Crankshaft Connecting Rod
Journal and Connecting Rod
Limit Value 0.20
Shell Hole
Nominal Size of Clearance between Connecting Rod Big
End Faces
Clearance between Nominal Value 0.10-0.30
Connecting Rod Big End
Faces Limit Value -

Piston
Nominal Size of Piston Pin and Connecting Rod Small
End Bushing Hole Hole

Clearance between Piston Pin Nominal Value 0.025-0.044

and Connecting Rod Small
End Bushing Hole Limit Value 0.10

Nominal Size of Piston Pin and Piston Pin Boss Hole Hole
 03-8 Repair Specification - Repair Data

Nominal Value -0.0045-0.0105

Clearance between Piston Pin
and Piston Pin Boss Hole
Limit Value -
01
Nominal Size of Piston Skirt and Cylinder Linder Skirt
02 Nominal Value 0.10-0.155
Clearance between Piston
03 Skirt and Cylinder Linder
Limit Value 0.40

04 Nominal Value 0.30-0.45

Gap Clearance of Piston Ring
Top Compression Ring
05 Limit Value 2.2
Gap Clearance of Piston Ring
06 Nominal Value 0.25-0.45
Second Compression Ring,
and Gap Clearance of Piston
Limit Value 2.2
07 Ring Oil Ring
Nominal Size of Top Piston Ring and Piston Ring Groove Ring Groove
08
Clearance between Top Nominal Value 0.095-0.128
09 Piston Ring and Piston Ring
Groove Limit Value 0.25
10
Nominal Size of Second Piston Ring and Piston Ring
Groove Ring Groove

Clearance between Second Nominal Value 0.04-0.072

Piston Ring and Piston Ring
Groove Limit Value 0.18

Nominal Size of Oil Ring and Piston Ring Groove Ring Groove

Nominal Value 0.03-0.067

Clearance between Oil Ring
and Piston Ring Groove
Limit Value 0.18

Cam

Nominal Size of Camshaft Journal and Camshaft Hole Shaft Hole

Nominal Value 0.10-0.15

Clearance between Camshaft
Journal and Camshaft Hole
Limit Value 0.20

Nominal Size of Camshaft Axial Clearance

 Repair Specification - Repair Data 03-9

Nominal Value 0.07-0.245

Axial Clearance of Camshaft
Limit Value 0.60
01
Valve Lifter

Nominal Size of Valve Lifter and Lifter Hole 02

Nominal Value 0.016-0.045 03

Clearance between Valve
Lifter and Lifter Hole
Limit Value 0.25 04

Rocker Arm 05
Nominal Size of Rocker Arm Shaft and Valve Rocker Arm
Hole 06

Clearance between Rocker Nominal Value 0.016-0.052

07
Arm Shaft and Valve Rocker
Arm Hole Limit Value 0.20
08
Valve
09
Nominal Size of Intake Valve and Valve Guide Shaft Hole
10
Nominal Value 0.025-0.069
Clearance between Intake
Valve and Valve Guide
Limit Value 0.15

Nominal Size of Exhaust Valve and Valve Guide Shaft Hole

Nominal Value 0.025-0.069
Clearance between Exhaust
Valve and Valve Guide Limit Value 0.15 mm

Intake Valve 0.20~0.30 mm

Valve Clearance
Exhaust Valve 0.25~0.35 mm

Intake Valve 0.7~0.9 mm

Valve Sinkage
Exhaust Valve 0.7~0.9 mm

Gear

Nominal Size of Idle Gear Journal and Bushing Hole Shaft Hole
 03-10 Repair Specification - Repair Data

Nominal Value 0.025-0.075

Clearance between Idle Gear
Journal and Bushing Hole
Limit Value 0.20
01
Nominal Size of Idle Gear End Clearance
02 Nominal Value 0.19-0.276
End Clearance of Idle Gear
03 Limit Value -

04 Nominal Value 0.11-0.18

Gear Backlash
05 Limit Value 0.30

06

07

08

09

10
 Repair Specification - Repair Data 03-11

LL480QB

Valve Timing
01
Intake Valve Opening (Before TDC) 14.5℃
02
Intake Valve Closing (After BDC) 37.5℃
03
Exhaust Valve Opening (Before BDC) 56℃
04
Exhaust Valve Opening (Before TDC) 12℃
05
Crankshaft
Standard Size of Crankshaft Main Bearing Journal and 06
Main Bearing Shell Hole Hole
Clearance between 07
Nominal Value 0.08-0.138
Crankshaft Main Bearing
Journal and Main Bearing
Shell Hole
Limit Value 0.25 08

Nominal Size of Crankshaft Axial Clearance 09

Nominal Value 0.075-0.24 10

Axial Clearance of Crankshaft
Limit Value 0.50
Standard Size of Crankshaft Connecting Rod Journal and
Connecting Rod Shell Hole Shaft Hole
Clearance between
Nominal Value 0.04-0.101
Crankshaft Connecting Rod
Journal and Connecting Rod
Limit Value 0.20
Shell Hole
Nominal Size of Clearance between Connecting Rod Big
End Faces
Clearance between Nominal Value 0.10-0.30
Connecting Rod Big End
Faces Limit Value -

Piston
Nominal Size of Piston Pin and Connecting Rod Small
End Bushing Hole Hole

Clearance between Piston Pin Nominal Value 0.025-0.044

and Connecting Rod Small
End Bushing Hole Limit Value 0.10

Nominal Size of Piston Pin and Piston Pin Boss Hole Hole
 03-12 Repair Specification - Repair Data

Nominal Value -0.0045-0.0105

Clearance between Piston Pin
and Piston Pin Boss Hole
Limit Value -
01
Nominal Size of Piston Skirt and Cylinder Linder Skirt
02 Nominal Value 0.10-0.155
Clearance between Piston
03 Skirt and Cylinder Linder
Limit Value 0.40

04 Nominal Value 0.30-0.45

Gap Clearance of Piston Ring
Top Compression Ring
05 Limit Value 2.2
Gap Clearance of Piston Ring
06 Nominal Value 0.25-0.45
Second Compression Ring,
and Gap Clearance of Piston
Limit Value 2.2
07 Ring Oil Ring
Nominal Size of Top Piston Ring and Piston Ring Groove Ring Groove
08
Clearance between Top Nominal Value 0.095-0.128
09 Piston Ring and Piston Ring
Groove Limit Value 0.25
10
Nominal Size of Second Piston Ring and Piston Ring
Groove Ring Groove

Clearance between Second Nominal Value 0.04-0.072

Piston Ring and Piston Ring
Groove Limit Value 0.18

Nominal Size of Oil Ring and Piston Ring Groove Ring Groove

Nominal Value 0.03-0.067

Clearance between Oil Ring
and Piston Ring Groove
Limit Value 0.18

Cam

Nominal Size of Camshaft Journal and Camshaft Hole Shaft Hole

Nominal Value 0.10-0.15

Clearance between Camshaft
Journal and Camshaft Hole
Limit Value 0.20

Nominal Size of Camshaft Axial Clearance

 Repair Specification - Repair Data 03-13

Nominal Value 0.07-0.245

Axial Clearance of Camshaft
Limit Value 0.60
01
Valve Lifter

Nominal Size of Valve Lifter and Lifter Hole 02

Nominal Value 0.016-0.045 03

Clearance between Valve
Lifter and Lifter Hole
Limit Value 0.25 04

Rocker Arm 05
Nominal Size of Rocker Arm Shaft and Valve Rocker Arm
Hole 06

Clearance between Rocker Nominal Value 0.016-0.052

07
Arm Shaft and Valve Rocker
Arm Hole Limit Value 0.20
08
Valve
09
Nominal Size of Intake Valve and Valve Guide Shaft Hole
10
Nominal Value 0.025-0.069
Clearance between Intake
Valve and Valve Guide
Limit Value 0.15

Nominal Size of Exhaust Valve and Valve Guide Shaft Hole

Nominal Value 0.025-0.069
Clearance between Exhaust
Valve and Valve Guide Limit Value 0.15 mm

Intake Valve 0.20~0.30 mm

Valve Clearance
Exhaust Valve 0.25~0.35 mm

Intake Valve 0.7~0.9 mm

Valve Sinkage
Exhaust Valve 0.7~0.9 mm

Gear

Nominal Size of Idle Gear Journal and Bushing Hole Shaft Hole
 03-14 Repair Specification - Repair Data

Nominal Value 0.025-0.075

Clearance between Idle Gear
Journal and Bushing Hole
Limit Value 0.20
01
Nominal Size of Idle Gear End Clearance
02 Nominal Value 0.19-0.276
End Clearance of Idle Gear
03 Limit Value -

04 Nominal Value 0.11-0.18

Gear Backlash
05 Limit Value 0.30

06

07

08

09

10
 Repair Specification - Repair Data 03-15

QC480Q (DI)

Vale Timing
01
Intake Valve Opening (Before TDC) 14.5℃
02
Intake Valve Closing (After BDC) 37.5℃
03
Exhaust Valve Opening (Before BDC) 56℃
04
Exhaust Valve Opening (Before TDC) 12℃
05
Crankshaft
Clearance between 06
Nominal Value 0.070-0.139
Crankshaft Main Bearing
Journal and Main Bearing 07
Limit Value 0.25
Shell Hole
Nominal Value 0.075-0.265 08
Axial Clearance of Crankshaft
Limit Value - 09
Clearance between
Nominal Value 0.040-0.089 10
Crankshaft Connecting Rod
Journal and Connecting Rod
Limit Value 0.20
Shell Hole
Piston

Clearance between Piston Pin Nominal Value 0.025-0.046

and Connecting Rod Small
End Bushing Hole Limit Value 0.10

Nominal Value 0.106-0.160

Clearance between Piston
Skirt and Cylinder Linder
Limit Value 0.40

Nominal Value 0.250-0.450

Gap Clearance of Top Piston
Ring
Limit Value 2.20

Nominal Value 0.250-0.450

Gap Clearance of Second
Piston Ring and Oil Ring
Limit Value 2.20

Clearance between Top Nominal Value 0.060-0.092

Piston Ring and Piston Ring
Groove Limit Value 0.20

Clearance between Second Nominal Value 0.040-0.072

Piston Ring and Piston Ring
Groove Limit Value 0.18
 03-16 Repair Specification - Repair Data

Nominal Value 0.03-0.067

Clearance between Oil Ring
and Piston Ring Groove
Limit Value 0.18
01
Cam
02 Nominal Value 0.050-0.100
Clearance between Camshaft
03 Journal and Bushing Hole
Limit Value 0.18

04 Nominal Value 0.050-0.220

Axial Clearance of Camshaft
05 Limit Value -

06 Rocker Arm

Nominal Value 0.016-0.061

07 Clearance between Rocker
Arm Shaft and Rocker Arm
Limit Value 0.20
08
Valve
09
Nominal Value 0.025-0.069
Clearance between Intake
10
Valve and Valve Guide
Limit Value 0.15

Nominal Value 0.040-0.077

Clearance between Exhaust
Valve and Valve Guide Limit Value 0.15 mm

Intake Valve 0.20~0.25mm

Valve Clearance
Exhaust Valve 0.25~0.30 mm

Gear

Nominal Value 0.025-0.075

Clearance between Idle Gear
Journal and Bushing Hole
Limit Value 0.18
 Repair Specification - Torque Requirements 03-17

Torque Requirements
LL380B
01
Fasteners N•m
02
Bolt, Cylinder Head 135-150
03

Bolt, Main Bearing Cover 115-130 04

Connecting Bolt 55-65 05

Flywheel Bolt 50-60 06

07

08

09

10
 03-18 Repair Specification - Torque Requirements

LL480QB

Fasteners N•m
01
Bolt, Cylinder Head 135-150
02

03 Bolt, Main Bearing Cover 115-130

04 Connecting Bolt 55-65

05 Flywheel Bolt 50-60

06

07

08

09

10
 Repair Specification - Torque Requirements 03-19

QC480 (DI)

Fasteners N•m
01
Bolt, Cylinder Head 150-170
02

Bolt, Main Bearing Cover 120-130 03

Connecting Bolt 50-60 04

Flywheel Bolt 60-70 05

06

07

08

09

10
 - 03-20
Memo - Repair Specification - Torque Requirements

01

02

03

04

05

06

07

08

09

10
 Fault Diagnosis and Troubleshooting
01
Steps and Skills............................................................04-1
General.....................................................................04-1
Engine Unable to Start .................................................04-2 02
Fault Analysis ...........................................................04-2
Diagnosis and Troubleshooting ................................04-3 03
Engine Power Shortage ...............................................04-5
Fault Analysis ...........................................................04-5 04
Diagnosis and Troubleshooting ................................04-6
Sudden Engine Flameout.............................................04-9 05
Fault Analysis ...........................................................04-9
Diagnosis and Troubleshooting ..............................04-10
06
Abnormal Engine Noise .............................................04-12
Fault Analysis .........................................................04-12
Diagnosis and Troubleshooting ..............................04-13 07
Abnormal Engine Oil Pressure ...................................04-16
Fault Analysis .........................................................04-16 08
Diagnosis and Troubleshooting ..............................04-17
Engine Overheating or Undercooling .........................04-19 09
Fault Analysis .........................................................04-19
Diagnosis and Troubleshooting ..............................04-20 10
Abnormal Color of Engine Exhaust Gas.....................04-22
Fault Analysis .........................................................04-22
Diagnosis and Troubleshooting ..............................04-23
Engine Fuel Injection Pump Faults.............................04-25
Fault Analysis .........................................................04-25
Diagnosis and Troubleshooting ..............................04-27
Starter Faults..............................................................04-31
Fault Analysis .........................................................04-31
Diagnosis and Troubleshooting ..............................04-32
Generator Faults ........................................................04-35
Fault Analysis .........................................................04-35
Diagnosis and Troubleshooting ..............................04-36
0
 04-2 Fault Diagnosis and Troubleshooting - Torque Requirements

01

02

03

04

05

06

07

08

09

10
 Fault Diagnosis and Troubleshooting - Steps and Skills 04-1

Steps and Skills

General
This manual provides solutions to the common problems of engines equipped for Yuling products, and 01
analyzes and troubleshoots for the common problems of engines.
Tip
02
Engine faults are more complicated, and there are many causes for a certain fault. Never remove parts
blindly when any fault occurs. The overall condition of the complete vehicle shall be known firstly,
possible causes shall be analyzed according to specific phenomena, and the faults shall be inspected 03
and excluded one by one in a simple to difficult manner.
04
Please comply with the following basic steps for fault diagnosis and troubleshooting:
1. Collect all the actual conditions about the fault phenomena. 05
2. Analyze the fault thoroughly.
3. Correlate the symptoms with basic engine system and components. 06
4. Consider whether recent maintenance and service measures are related with the fault phenomena.
5. Reinspect carefully before any removal.
6. Judge fault types and choose the problem which can is the easiest to solve according to the fault 07
diagnosis table at first.
7. Determine the causes for fault and perform the repair. 08
8. Operate the engine after maintenance and make sure the causes for fault are completely
troubleshot. 09

10
 04-2 Fault Diagnosis and Troubleshooting - Steps and Skills

Engine Unable to Start

Fault Analysis
Tip:
01 Generally, the fault of engine unable to start is mainly caused by the problems of fuel system, electric
equipment system, compression pressure in cylinders, engine oil, angle of advance for fuel supply,
02 environmental temperature, etc.

03 Possible causes for engine unable to start:

1. Problems of Fuel System
04 (a). No fuel in fuel tank or discharge switch closed
(b). Air existing in fuel system.
(c). Fuel pipe or diesel filter blocked.
05 (d). Poor atomization of fuel injection.
(e). Rod not returned to the position of maximum oil supply.
06 2. Problems of Electric Equipment System
(a). Bad contact of circuit.
07 (b). Low voltage of battery.
3. Reduced starting rotating speed due to overhigh viscosity of engine oil.
08 4. Lower environmental temperature.
5. Low compression pressure in cylinders.
(a). Wear of cylinder liner, piston and piston ring.
09
(b). Untight fit between valve and valve seat.
(c). Lack of valve clearance.
10 (d). Valve stem clamped in guide pipe.
(e). Gas leakage from cylinder head gasket.
(f). Gas leakage from the hole of fuel injector seat.
(g). Incorrect distribution timing.

Tip:
In case of engine unable to start, it shall be considered at first that whether it is resulted from
misoperation or lack of maintenance.
 Fault Diagnosis and Troubleshooting - Steps and Skills 04-3

Diagnosis and Troubleshooting

Tip:
The possible causes for engine unable to start shall be inspected one by one according to the following
steps. The time for diagnosis can be efficiently saved according to the order from simplicity to
01
complication. The specific steps for impossible causes shall be omitted for analysis, and the following
diagnostic steps can only be used for references.
02
Step Diagnosis Contents Measures
03
Yes Fill hot water or adopt preheating start.
Inspect whether the environmental 04
1
temperature is too low.
No Go to Step 2.
05
Yes Go to Step 3.
Inspect whether the start circuit is in 06
2
good contact.
No Tighten circuit coupling screws.
07

Yes Go to Step 4. 08
Inspect whether the voltage of
3
battery is normal. Charge the battery according to the technical
No 09
requirements.

Inspect whether there is diesel in Yes Fill diesel or switch on the switch. 10
4 the fuel tank or whether the
discharge switch is not open. No Go to Step 5.

Yes Go to Step 6.
Inspect whether fuel rod returns to
5 Apply drawing force on the speed regulation
the position of maximum oil supply.
No lever to return the rod to the position of
maximum oil supply.
Clean the fuel pipe and clean or replace the
Yes
Inspect whether the fuel pipe or diesel filter to solve the problem of blockage.
6
diesel filter is blocked.
No Go to Step 7.
Eliminate air with a manual pump. Inspect
Yes whether the connecting pipes have gas
Inspect whether air exists in the fuel leakage and solve the problem.
7
system.
No Go to Step 8.

Clean the fuel nozzle, adjust the pressure of

Yes
Inspect whether there is poor fuel injection or replace the fuel injector.
8
atomization of fuel injection.
No Go to Step 9.

Inspect whether the angle of Yes Readjust the angle of advance for fuel supply.
9 advance for fuel supply is
satisfactory. No Go to Step 10.

Rotate the crankshaft with a lever for several

Inspect whether the viscosity of Yes
circles or add preheated engine oil.
10 engine oil is overhigh and leads to
the low starting rotating speed. No Go to Step 11.
 04-4 Fault Diagnosis and Troubleshooting - Steps and Skills

Step Diagnosis Contents Measures

Yes Adjust the valve clearance as required.

01 Inspect whether the valve clearance
11
is unavailable or too small.
No Go to Step 12.
02
Yes Clean with kerosene or diesel carefully.
03 Inspect whether the valve stem
12
clamped in guide pipe
No Go to Step 13.
04
Grind the valve and replace damaged valve
05 Yes
Inspect whether the fit between spring.
13
valve and valve seat is not tight.
06 No Go to Step 14.
Inspect whether the nut is tightened and
07 Yes whether the fuel injector gasket is intact.
Inspect whether there is gas
14 leakage from the hole of fuel injector Replace damaged components.
08 seat.
No Go to Step 15
09 Tighten according to the tightening torque of
Inspect whether the cylinder head Yes bolt for cylinder head. Replace the cylinder
10 15 gasket has the phenomenon of gas head gasket.
leakage or back flow.
No Go to Step 16.

Yes Adjust the timing according to the timing mark.

Inspect whether the distribution
16
timing is incorrect.
No Go to Step 17.

Replace the cylinder liner, piston and piston

Yes
ring. Eliminate causes resulting in wear.
Inspect whether the cylinder liner,
17 Inspect carefully according to the above steps
piston and piston ring are worn.
No to find out the fault parts and troubleshoot it
duly.
 Fault Diagnosis and Troubleshooting - Engine Power Shortage 04-5

Engine Power Shortage

Fault Analysis
Tip: 01
Engine power shortage refers to the engine can not meet the design requirement, and the vehicle
carrying heavy load or climbing an abrupt slop will have the phenomena of “lack of strength”, poor color
02
of engine exhaust gas, etc. The fault of engine power shortage is mainly caused by the problems of fuel
system, intake system, exhaust system, cooling system, insufficient compression pressure in cylinders,
abnormal temperature of engine oil, incorrect angle of advance for fuel supply, lower environmental 03
temperature, etc.
04
Possible causes for engine power shortage:
1. Problem of intake system; it is generally manifested by that during urgent acceleration, the rotating 05
speed of engine can not increase to the corresponding rotating speed along with its accelerator
pedal, and blue smoke accompanied by sharp flavor due to the incomplete burning of diesel 06
exhausts from the exhaust pipe.
(a). Blocked air filter element due to too much dust.
(b). Damaged intake pipe of air filter. 07
(c). Untight sealed air intake pipe.
2. Problem of exhaust system; it is generally manifested by abnormal noise of exhaust pipe muffler 08
and abnormal dense smoke exhausted from the exhaust port during acceleration.
(a). Blockage due to damaged exhaust pipe or muffler. 09
(b). Too small turn radius or too many elbows of exhaust line.
3. Problem of fuel system; it is generally manifested by that power or rotating speed still can not be 10
increased and the engine has the symptom of flameout trend after stepping on the accelerator.
(a). No fuel or lower fuel level in fuel tank.
(b). Air existing in fuel system.
(c). Fuel pipe or diesel filter blocked.
(d). Poor atomization of fuel injection.
(e). Accelerator lever of fuel injection pump improperly adjusted.
4. Abnormal temperature of engine oil; it is generally manifested by that the oil warning light is
flickering or normally on. Overhigh or lower temperature of engine oil will lead to degeneration of
engine oil and result in poor lubrication. It is resulted from problems of environmental temperature,
engine cooling system or internal machine of engine, etc.
(a). Filling quantity of engine oil unable to reach the standard.
(b). Engine oil brand nonconforming with environment temperature.
(c). Overhigh engine temperature of engine oil due to abnormal cooling system.
(d). Lower environmental temperature.
5. Low compression pressure in cylinders; it is generally manifested by engine power shortage,
performance reduction, gas leakage, black smoke, abnormal beat, etc.
(a). Wear of cylinder liner, piston and piston ring.
(b). Untight fit between valve and valve seat.
(c). Lack of valve clearance.
(d). Valve stem clamped in guide pipe.
(e). Gas leakage from cylinder head gasket.
(f). Gas leakage from the hole of fuel injector seat.
(g). Incorrect distribution timing.
Tip:
Engine power shortage is usually accompanied by difficult start. They have close correlation with each
other and can be analyzed as reference for each other. It shall be firstly considered whether it is caused
by the lack of maintenance.
 04-6 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

Diagnosis and Troubleshooting

Tip:
The possible causes for the power descending of engine shall be inspected one by one according to the
01 following steps. The time for diagnosis can be efficiently saved according to the order from simplicity to
complication. The specific steps for impossible causes shall be omitted for analysis, and the following
02 diagnostic steps can only be used for references.
Step Diagnosis Contents Measures
03

Yes Clean or replace the air filter element.

04 Inspect whether the air filter element
1
is blocked because it is too dirty.
05 No Go to Step 2.

Replace the broken line. Clear the dust and

06 Yes
foreign matters in the unbroken lines.
Inspect whether the intake pipe of
2
air filter is damaged.
07 No Go to Step 3.

08 Yes Go to Step 4.
Inspect whether the air intake pipe
3
09 is well sealed. Fasten the pipeline joint clamps according to
No
the technical requirements.
10
Inspect whether the fixing bolts at Yes Go to Step 5.
4 the exhaust pipe joint are firmly
fastened. Tighten the loosened bolts to the specified
No
torque
Remove and clean the exhaust line and
Yes
Inspect whether the exhaust pipe or muffler. Replace the muffler if necessary.
5
muffler is blocked.
No Go to Step 6.

Inspect whether there is insufficient Install the exhaust line in accordance with
Yes
displacement or too small turn factory design to ensure unobstructed exhaust.
6
radius or too many elbows of due to
modification of exhaust line. No Go to Step 7.

Yes Go to Step 8.
Inspect whether there is enough fuel
7
in the fuel tank. Fill fuel conforming with local temperature
No
conditions.
Unscrew the fuel return valve on the fuel
injection pump or the discharge bolt on the
diesel filter, and exhaust air by pumping fuel
Yes
Inspect whether air exists in the fuel with the fuel delivery pump. Make sure that not
8 any air exist in the fuel line and fasten the
system.
discharge bolt.
No Go to Step 9.

Clear the fuel delivery line. Replace the fuel

Yes
Inspect whether the fuel pipe or filter if necessary.
9
diesel filter is blocked.
No Go to Step 10.
 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting 04-7

Step Diagnosis Contents Measures

Adjust the accelerator lever to the maximum
Yes quantity of fuel supply as required. Check the
Inspect whether there is poor oil injection pump if necessary. 01
10
atomization of fuel injection.
No Go to Step 11 02

Inspect whether the accelerator Yes Adjust the valve clearance as required. 03
11 lever of fuel injection pump is
improperly adjusted. No Go to Step 12. 04

Yes Go to Step 13. 05

Inspect whether the engine oil
12 Fill engine oil if it is too little. Discharge 06
reaches the standard.
No excessive engine oil if it is too much, and find
out the causes for excessive engine oil. 07
Change to use engine oil conforming with local
Inspect whether the engine oil brand Yes
temperature conditions. 08
13 is nonconforming with environment
temperature. No Go to Step 14.
09
Fill coolant to the standard level. Find out and
Inspect whether the engine Yes troubleshoot the causes for the high 10
temperature is too high due to the temperature of engine.
14
fault of the engine coolant level and
cooling system. No Go to Step 15.
Change to use engine oil conforming with local
Inspect whether there is any temperature conditions. Add a proper heat
Yes
overhigh viscosity of engine oil and preservation component in front of the heat
15 radiator.
poor lubrication due to lower
environmental temperature.
No Go to Step 16.

Yes Clean with kerosene or diesel carefully.

Inspect whether the valve stem
16
clamped in guide pipe.
No Go to Step 17.

Grind the valve and replace damaged valve

Yes
Inspect whether the fit between spring.
17
valve and valve seat is untight
No Go to Step 18.
Inspect whether the nut is tightened and
Inspect whether there is gas Yes whether the fuel injector gasket is intact.
18 leakage from the hole of fuel injector Replace damaged components.
seat.
No Go to Step 19.
Tighten according to the tightening torque of
Inspect whether the cylinder head Yes bolt for cylinder head. Replace the cylinder
19 gasket has the phenomenon of gas head gasket.
leakage or back flow.
No Go to Step 20.
 04-8 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

Step Diagnosis Contents Measures

Yes Adjust the timing according to the timing mark.

01 Inspect whether the distribution
20
timing is incorrect.
No Go to Step 21.
02
Replace the cylinder liner, piston and piston
Yes
03 ring. Eliminate causes resulting in wear.
Inspect whether the cylinder liner,
21 Inspect carefully according to the above steps
piston and piston ring are worn.
04 No to find out the fault parts and troubleshoot it
duly.
05

06

07

08

09

10
 Fault Diagnosis and Troubleshooting - Sudden Engine Flameout 04-9

Sudden Engine Flameout

Fault Analysis
Tip: 01
Sudden engine flameout refers to engine flames out suddenly in normal operation but can not operate
normally again. Sudden engine flameout has two conditions: one is that the engine can be restarted after
02
sudden flameout but can not operate to work normally, which indicates the fault of fuel supply system;
the other is that engine can not be restarted after sudden flameout and can not be driven to rotate by the
starter, which indicates the component faults resulted from the poor lubrication inside the engine. 03

Possible causes for sudden engine flameout: 04

1. Problem of fuel supply system; it is generally manifested by that while stepping on the accelerator
for restart after sudden flameout, the engine has the symptom to be started and a little blue smoke 05
exhausted from the exhaust pipe, but it stops rotating as soon as releasing the ignition switch.
(a). Fuel exhausted in the fuel tank. 06
(b). Air existing in fuel system.
(c). Fuel filter or fuel pipe blocked.
(d). Water contained in diesel. 07
2. Component fault inside engine; engine can not be restarted to rotate along with the starter or rotate
quite slow after sudden flameout. 08
(a). Quite low or small engine oil pressure.
(b). Fault of oil pump 09
(c). Piston clamped in cylinder liner.
(d). Small end or journal of connecting rod seized by crankshaft. 10
(e). Main crankshaft bearing shell seized.

Tip:
When sudden engine flameout occurs, it shall be judged at first whether the engine can rotate by rotating
the starting jaw with a tool. If it can rotate normally, it indicates fault of fuel system; otherwise, it indicates
seizing phenomenon of components inside engine, and the engine shall be disassembled for inspection.
Never try to drive the engine to rotate by the starter so as to avoid unnecessary loss.
 04-10 Fault Diagnosis and Troubleshooting - Sudden Engine Flameout

Diagnosis and Troubleshooting

Tip:
The possible causes for sudden engine flameout shall be inspected one by one according to the
following steps. The time for diagnosis can be efficiently saved according to the order from simplicity to
01
complication. The specific steps for impossible causes shall be omitted for analysis, and the following
diagnostic steps can only be used for references.
02
Step Diagnosis Contents Measures
03
Yes Fill fuel and eliminate air from the fuel pipe.
04 Inspect whether fuel in the fuel tank
1
is exhausted.
No Go to Step 2.
05
Find out and troubleshoot the causes for air
Yes
06 Inspect whether air exists in the fuel intake. Eliminate air from the fuel pipe.
2
system.
No Go to Step 3.
07
Clean the fuel pipe. Replace the fuel filter if
08 Yes
Inspect whether the fuel filter or fuel necessary.
3
pipe is blocked.
09 No Go to Step 4.
Discharge fuel from the fuel tank. Fill new fuel
10 Yes or use the discharged fuel treated by
4 Inspect whether fuel contains water. precipitation.
No Go to Step 5.
Inspect whether the engine is Fill engine oil to standard scale. Rotate the
slightly damaged due to the poor Yes starting jaw with a tool and start the engine
lubrication of components resulted once it rotates smoothly.
5 from lack of engine oil. (the starting
jaw can be rotated by using a tool
No Go to Step 6.
but having damping but damping
force can be felt).
Replace or maintain the oil pump. Maintain the
Yes
Remove the oil pan to inspect worn components.
6
whether the oil pump has any fault.
No Go to Step 7.

Replace damaged piston and cylinder liner.

Yes
Inspect whether the piston is Find out and troubleshoot the causes.
7
clamped in the cylinder liner.
No Go to Step 8.
 Fault Diagnosis and Troubleshooting - Sudden Engine Flameout 04-11

Step Diagnosis Contents Measures

Replace damaged components. Find out and

Inspect whether the small end or Yes
troubleshoot the causes.
8 journal of connecting rod is clamped 01
with crankshaft. No Go to Step 9.
02
Replace the main bearing shell. Replace or
Yes
Inspect whether the main crankshaft the crankshaft. 03
9 bearing shell is clamped with Inspect carefully according to the above steps
crankshaft. No to find out the fault parts and troubleshoot it 04
duly.
05

06

07

08

09

10
 04-12 Fault Diagnosis and Troubleshooting - Abnormal Engine Noise

Abnormal Engine Noise

Fault Analysis
01 Tip:
Abnormal engine noise refers to obvious sound of beat or crash can be heard inside or on the engine
during normal operation, and the magnitude and frequency of the noise will be increased along with the
02
elevated rotating speed of engine. The noise is hard to disappear without remedial measures. At first, it
shall be distinguished whether the abnormal noise is crash resulted from abnormal breakout or beat
03 caused by the abnormal movement of components. The noise source shall be identified according to the
characteristics of noise and the position of noise source in combination with construction principle.
04
Possible causes for abnormal engine noise:
05 1. Abnormal noise of valve mechanism; it is generally manifested by that there is obvious abnormal
noise at the upper part of running automobiles, the magnitude and frequency of the noise will be
06 increased along with the elevated rotating speed of engine, and the noise is hard to disappear
without remedial measures.
(a). Quite low viscosity of engine oil.
07 (b). Engine oil unavailable in valve lifter.
(c). Oversize valve clearance.
08 (d). Rocker arm or rocker arm shaft worn.
(e). Valve clamped, valve seat deflected or too many carbon deposits.
09 2. Abnormal noise due to untimely or too late fuel supply; untimely fuel supply generally manifests as
slivery noise of metal beat from the inside of cylinders during urgent acceleration; too late fuel
10 supply generally manifests as deep and unclear noise of beat from the inside of cylinders during
urgent acceleration and continuous dense smoke accompanied during exhaust.
(a). Untimely fuel supply.
(b). Too late fuel supply.
(c). Fuel injector clamped.
3. Abnormal noise of piston and piston ring; it is generally manifested by that there is “ta-ta” sound
from the upper part of cylinder body and cylinder head, the magnitude and frequency of the noise
will be increased along with the elevated rotating speed of engine, and the noise may be
accompanied by blue smoke in the exhaust gas and power descending of engine.
(a). Piston ring worn seriously.
(b). Piston worn seriously.
(c). Cylinder barrel worn seriously.
(d). Oversize clearance between cylinder barrel and piston.
4. Loose fit between piston pin and liner for the small end of connecting rod; the abnormal noise due to
loose fit between piston pin and liner for the small end of connecting rod is generally manifested by
the slight and hoarse noise during the operation of engine, and the noise is especially clear during
idling operation.
(a). Liner for the small end of connecting rod worn.
(b). Piston pin worn.
5. Collision between valve and piston; the abnormal noise due to collision between valve and piston is
generally manifested by the heavy, uniform and rhythmical beat noise at the upper part of cylinder
body and on the cylinder cover.
(a). Incorrect distribution timing
(b). Undersize valve clearance.
6. Wear and oversize clearance of drive gear; the abnormal noise due to wear and oversize clearance
of drive gear is generally manifested by the abnormal noise from the gear chamber, and crash noise
can be heard at the moment of sudden reduction of speed.
7. The wear of connecting rod bearing shell and main bearing shell leads to the oversize fit clearance,
the crash noise can be heard at the crankcase during operation, and the crash noise becomes more
violent when the rotating speed is increased.
Tip:
Never continue to work in case of abnormal noise and fault noise of engine. The vehicle shall be shut
down for inspection and diagnosis as soon as abnormal noise is heard, and the causes and position of
fault shall be judged and eliminated immediately so as to avoid unnecessary loss.
 Fault Diagnosis and Troubleshooting - Abnormal Engine Noise 04-13

Diagnosis and Troubleshooting

Tip:
The possible causes for the abnormal engine noise shall be inspected one by one according to the
following steps. The time for diagnosis can be efficiently saved according to the order from simplicity to
01
complication. The specific steps for impossible causes shall be omitted for analysis, and the following
diagnostic steps can only be used for references.
02
Step Diagnosis Contents Measures
03
Change to use lubricating conforming to the
climatic conditions. Inspect and replace the
Yes 04
Inspect whether the viscosity of damaged components due to quite low
1 viscosity of engine oil.
engine oil is too low.
05
No Go to Step 2.
06
Add engine lubricant. Replace damaged valve
Inspect whether the valve lifter is Yes
lifter
2 seriously worn due to lack of engine 07
oil. No Go to Step 3.
08
Heavy rumble heard at intake or Yes Adjust all the valve clearance as specified.
3 exhaust port indicates the oversize 09
valve clearance. No Go to Step 4.
10
Replace the damaged components. Readjust
Yes
Inspect whether the rocker arm or the valve.
4
rocker arm shaft is worn.
No Go to Step 5.
Clear the clamped valve, replace the valve seat
Inspect whether valve is clamped, Yes and grind valve. Find out and troubleshoot the
5 valve seat is deflected or carbon causes for excessive carbon deposits.
deposits are too many.
No Go to Step 6.
Adjust the static angle of advance for fuel
supply. Inspect the fuel injection conditions of
Yes
Inspect whether the fuel supply is the fuel injector. Maintain or replace it if
6 necessary.
untimely.
No Go to Step 7.
Adjust the static angle of advance for fuel
supply. Inspect the fuel injection conditions of
Yes
Inspect whether the fuel supply is the fuel injector. Maintain or replace it if
7 necessary.
too late.
No Go to Step 8.

Yes Maintain or replace the damaged fuel injector.

Inspect whether individual fuel
8
injector is clamped.
No Go to Step 9.

Replace the piston ring. Replace the piston as

Yes
Inspect whether the piston ring is well if necessary.
9
seriously worn.
No Go to Step 10.
 04-14 Fault Diagnosis and Troubleshooting - Abnormal Engine Noise

0Step Diagnosis Contents Measures

Replace the damaged piston or cylinder liner.

01 Yes
Find out and troubleshoot the causes.
Inspect whether the piston is
10
seriously worn.
02 No Go to Step 11.

03 Replace the damaged cylinder barrel. Replace

Yes
Inspect whether the cylinder barrel the piston as well if necessary.
11
04 is seriously worn.
No Go to Step 12.

05 Replace the damaged component. Replace the

Inspect whether the crash noise is Yes
complete set if necessary.
12 resulted from the oversize clearance
06
between cylinder barrel and piston. No Go to Step 13.
07 Replace the piston ring. Replace the piston as
Yes
Inspect whether the piston ring is well if necessary.
08 13
seriously worn.
No Go to Step 14.
09
Replace the piston and cylinder liner. Find out
Yes
Inspect whether the piston is and troubleshoot the causes.
10 14
seriously worn.
No Go to Step 15.
Replace the liner for the small end of
Yes connecting rod. Replace the piston pin or
Inspect whether the liner for the connecting rod if necessary.
15
small end of connecting rod is worn.
No Go to Step 16.

Replace the piston pin. Replace the liner for the

Yes
Inspect whether the piston pin is small end of connecting rod if necessary.
16
worn.
No Go to Step 17.

Yes Go to Step 18.

Inspect whether the distribution
17
timing is correct.
No Adjust the timing gear.

Yes Adjust the valve clearance as specified.

Inspect whether the valve clearance
18
is undersize or closed.
No Go to Step 19.
 Fault Diagnosis and Troubleshooting - Abnormal Engine Noise 04-15

Step Diagnosis Contents Measures

Inspect the gear teeth clearance. Replace the

Yes
Inspect whether the wear of drive gear according to the condition of wear.
19 01
gear results in oversize clearance.
No Go to Step 20.
02
Remove and inspect the bearing shell, and
Inspect whether the wear of Yes replace it if necessary. Keep the specified fit 03
connecting rod bearing shell and clearance.
20
main bearing shell results in Inspect carefully according to the above steps
04
oversize clearance. No to find out the fault parts and troubleshoot it
duly.
04 05

06

07

08

09

10
 04-16 Fault Diagnosis and Troubleshooting - Abnormal Engine Oil Pressure

Abnormal Engine Oil Pressure

Fault Analysis
01 Tip:
Both overhigh and quite low engine oil pressure belongs to abnormal engine oil pressure, and quite low
engine oil pressure is more common. In case of quite low pressure, the oil pressure warning unit will
02
flash to indicate low oil pressure or no engine oil. There are various causes for oil pressure fault. Drivers
or maintainers shall treat it seriously to inspect the causes for the fault carefully and troubleshoot the
03 fault.

04 Possible causes for abnormal oil pressure:

1. Oil pressure sensor or oil gauge damaged.
05 2. Quite low engine oil level.
3. Quite low viscosity of engine oil.
06 (a). Engine oil brand nonconforming to local climatic conditions.
(b). Overhigh engine temperature.
(c). Cylinder head gasket damaged; coolant mixed into engine oil.
07 (d). Water blocking ring of cylinder barrel damaged; coolant mixed into engine oil.
(e). Cylinder head or cylinder body cracked; coolant mixed into engine oil.
08 4. Oil filter blocked.
5. Oversize clearance between main bearing shell and connecting rod bearing shell.
09 6. Oil pump faults
(a). Inner and outer rotors of oil pump seriously worn or having oil leakage.
10 (b). Oil feed pipe of oil pump blocked.
(c). Fault of oil pump pressure regulating valve or lubricant pipe broken.
(d). Oil filtering gasket direction reversed.

Tip:
Never continue to operate in case of abnormal engine oil pressure. As soon as the abnormal engine oil
pressure is discovered, it is necessary to shut down the vehicle emergently and flame out the engine to
inspect and eliminate the causes and position of fault immediately so as to avoid unnecessary loss.
 Fault Diagnosis and Troubleshooting - Abnormal Engine Oil Pressure 04-17

Diagnosis and Troubleshooting

Tip:
The possible causes for abnormal engine oil pressure shall be inspected one by one according to the
following steps. The time for diagnosis can be efficiently saved according to the order from simplicity to
01
complication. The specific steps for impossible causes shall be omitted for analysis, and the following
diagnostic steps can only be used for references.
02
Step Diagnosis Contents Measures
Replace oil pressure sensor or oil 03
Yes
Inspect whether the oil pressure sensor or gauge.
1 04
oil gauge is damaged.
No Go to Step 2.
Add a suitable amount of engine oil. Find 05
Yes out and troubleshoot the causes for the
Inspect whether the engine oil level is too
2 quite low oil level. 06
low.
No Go to Step 3.
07
Change to use the engine oil conforming
Judge whether the overhigh or quite low Yes
to local temperature conditions. 08
3 engine temperature is resulted from the
influence of environmental temperature. No Go to Step 4.
09
Inspect whether the cylinder head gasket is Replace the cylinder head gasket.
Yes
damaged. Inspect whether the damaged Replace engine oil. 10
4
cylinder head gasket leads coolant to mix
into engine oil. No Go to Step 5.
Inspect whether the water blocking ring of Replace the water blocking ring of
Yes
cylinder barrel is damaged. Inspect whether cylinder barrel. Replace engine oil.
5
the damaged water blocking ring of cylinder
barrel leads coolant to mix into engine oil. No Go to Step 6.
Inspect whether cylinder head or cylinder Replace the damaged components.
Yes
body cracks. Inspect whether the cracked Replace engine oil.
6
cylinder head or cylinder body leads coolant
to mix into engine oil. No Go to Step 7.
Replace the oil filter. Replace engine oil
Yes
if necessary.
7 Inspect whether oil filter is blocked.
No Go to Step 8.
Replace the main bearing shell or
connecting rod bearing shell. Replace or
Inspect whether the clearance between Yes
maintain the connecting rod or
8 main bearing shell and connecting rod
crankshaft if necessary.
bearing shell is oversize.
No Go to Step 9.

Yes Reinstall or replace it.

Inspect whether the direction of oil filtering
9
gasket is reversed
No Go to Step 10.

Yes Replace or maintain the oil pump.

10 Inspect whether the oil pump has any fault.
No Go to Step 11.
 04-18 Fault Diagnosis and Troubleshooting - Abnormal Engine Oil Pressure

Step Diagnosis Contents Measures

Inspect whether the inner and outer Yes Replace or maintain the oil pump.
01 11 rotors of oil pump is seriously worn
or has oil leakage. No Go to Step 12.
02
Dredge the oil feed pipe of oil pump. Replace
Yes
03 Inspect whether the oil feed pipe of the filter screen of the oil feed pipe.
12
oil pump is blocked.
No Go to Step 13.
04
Replace or maintain the damaged
05 Yes
Inspect whether oil pump pressure components.
13 regulating valve has any fault or Inspect carefully according to the above steps
06 whether lubricant pipe is broken. No to find out the fault parts and troubleshoot it
duly.
07

08

09

10
 Fault Diagnosis and Troubleshooting - Engine Overheating or Undercooling 04-19

Engine Overheating or Undercooling

Fault Analysis
Tip: 01
Engine overheating or undercooling will affect the integral performance of the engine. Engine
overheating normally happens and shows as that the water temperature gauge pointer points to red 02
dangerous calibration, the radiator is easy to boil, and the radiator runs steam when opening the shield.
Driving or maintenance personnel should seriously treat the problems, carefully inspect faults reasons
and eliminate faults. 03

Possible reasons to cause engine overheating or undercooling faults: 04

1. Cooling System Overheating
(a). Lack of water in the water tank. 05
(b). Impurity blockage of external heat sink of the water tank.
(c). Blockage or bad circulation due to excess scale in the water tank. 06
(d). Small fan and water pump discharge capacity due to too loosened fan and water pump belt.
(e). Improper water tank and fan distance.
07
(f). Deformation and blockage of the inlet/outlet hose.
(g). Closed thermostat valve.
(h). Water pump faults. 08
(i). Incorrect oil supply timing.
2. Engine undercooling 09
(a). Opened thermostat valve.
(b). Failed water temperature gauge. 10
3. Later fuel injection or fuel dripping of fuel injector.
(a). Incorrect distribution phase.
(b). Overload operation of engine for a long time

Caution：
y If the engine overheats, do not immediately stopping engine operation or suddenly add
coolant to avoid personal injury or part damage, reduce the throttle, operate under no load,
or spray a small quantity of water on the water tank surface, and misfire for inspection after
coolant temperature in the cooling system lowers.
y When the engine is still hot, do not take down the water tank cover so as to avoiding
scalding, and be careful when filling the coolant.
y If the overheating reason of the engine can not be found or eliminated, immediately contact
repair stations or repair factories, or cause other parts to damage.
 04-20 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

Diagnosis and Troubleshooting

Tip:
Inspect the reasons of engine overheating or undercooling one by one according to the following steps,
01 and effectively save diagnosis time in the sequence from the simple reason to the complex reason, and
directly pass the specific steps of reasons which obvious can not happen. The diagnosis only serves as
02 the reference.
Step Diagnosis Content Measure
03
Eliminate the coolant loss reason, and fill in
Yes
04 Inspect whether the engine is lack of coolant
1
coolant
05 No Go to step 2

Clean the impurities with a brush, and clean

06 Inspect whether the water tank heat sink Yes
dust in the heat sink by compressed air
2 is blocked because of overmuch dust or
07 impurities No Go to step 3
Add aqueous alkaline solution (750 g of
08
washing soda is added into 10 L of water) into
the water tank, and discharge after operating
09 Yes
the engine for 4-8 hours, and clean the
Inspect whether overmuch scale exists in
3 waterway with clean water in a circulating
a waterway
10 mode
No Go to step 4

Adjust belt stretching degree, and replace the

Yes
Inspect whether the fan or the water pump belt if necessary.
4
belt is too loosened or is broken
No Go to step 5

Adjust the distance between the water tank

Yes
Inspect whether distance between the and the fan
5
water tank and the fan is improper or not
No Go to step 6

Yes Replace the deformed rubber hose

Inspect whether the inlet/outlet hose
6
(rubber hose) deforms or not
No Go to step 7

Yes Replace the thermostat

Inspect whether the thermostat valve can
7
normally work or not
No Go to step 8

Yes Replace or repair

Inspect whether the water pump has
8
faults or not
No Go to step 9

Yes Go to step 10
Inspect whether fuel supply timing is
9
correct or not
No Adjust the fuel supply timing to be correct
 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting 04-21

Step Diagnosis Content Measure

Inspect coolant temperature, and replace the

Yes
Inspect whether the water temperature water temperature gauge and a sensor
10 01
gauge fails or not
No Go to step 12
02
Adjust fuel supply timing, inspect the fuel
Yes
Inspect whether the fuel injector injects injector, and replace if necessary 03
12
fuel or the fuel injector drips fuel
No Go to step 13
04

Yes Go to step 14 05
Inspect whether distribution phase is
13
correct
No Re-adjust the distribution phase 06

Inspect whether high temperature is

Yes Properly lower load operation 07
14 caused because of overload operation of Carefully inspect according to the above
the engine for a long time No steps, find fault reasons, and eliminate in 08
time.
09

10
 04-22 Fault Diagnosis and Troubleshooting - Abnormal Color of Engine Exhaust Gas

Abnormal Color of Engine Exhaust Gas

Fault Analysis
01 Tip:
It is a simple and effective method to observe engine exhaust gas color and judge whether the engine
fails. At the normal operation temperature, the exhaust gas color of the diesel engine should be colorless
02
or light grey (so-called “colorless” can not be totally colorless like the gasoline engine, but accompanies
with light gray in colorless), and the color is normal exhaust gas. The exhaust gas color of the diesel
03 engine may be stronger under idling, anxious acceleration and high-speed high load, and abnormal
exhaust gas color is commonly as follows: blue smoke, white smoke and black smoke. Abnormal
04 exhaust gas color can be well known if paying more attention to normal exhaust gas color at other times.

05 Reasons for abnormal exhaust gas color of engine:

1. Blue smoke is generated during engine exhaust gas (oil enters a cylinder).
06 (a). Piston ring and cylinder sleeve abrasion, piston ring bonding or piston ring contra-aperture.
(b). Abrasion of guide hole near an exhaust valve.
(c). Extra high fuel surface in an oil pan.
07 2. White smoke is generated during engine exhaust gas (diesel can not completely burn during diesel
engine overheating or low load).
08 (a). Excess fuel supply of the fuel injector.
(b). Bad fuel atomization, and low fuel injecting pressure.
09 (c). Later fuel supply.
(d). Low cylinder compressed pressure.
10 (e). Water in diesel.
3. Black smoke is generated during engine exhaust gas (combustion is not complete).
(a). Overload operation of the diesel engine.
(b). Bad fuel atomization, or fuel dripping.
(c). Late fuel supply time.
(d). Blockage of air filter.
(e). Excess fuel injecting amount.

Tip:
When the engine exhaust gas color is abnormal, firstly consider whether improper operation or lack of
maintenance causes the phenomenon.
 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting 04-23

Diagnosis and Troubleshooting

Tip:
Inspect the reasons of engine overheating or undercooling one by one according to the following steps,
and effectively save diagnosis time in the sequence from the simple reason to the complex reason, and 01
directly pass the specific steps of reasons which obvious can not happen. The diagnosis only serves as
the reference. 02

1. Fault Diagnosis of Blue Smoke in Exhaust Gas 03

Step Diagnosis Content Measure
04
Inspect whether the blue smoke is Carefully inspect, and replace the abraded
generated for exhaust gas because of Yes
parts when necessary. 05
1 piston and cylinder sleeve abrasion,
piston ring binding or insufficient elasticity No Go to step 2 06
or piston ring contra-aperture
Replace the abraded parts and the grinding
Yes
valve 07
Inspect whether the inlet/outlet valve
2
guide is abraded
No Go to step 3 08

Yes Discharge excess oil 09

Inspect whether the fuel surface in the oil
3
pan is too high Carefully inspect according to the above 10
No
steps, find fault reasons and eliminate in time.

2. Fault Diagnosis of White Smoke in Exhaust Gas

Step Diagnosis Content Measure

Adjust the fuel supply amount of the fuel

Yes
Inspect whether the fuel injection pump injection pump
1
supplies too much fuel
No Go to step 2

Inspect whether the fuel injector Yes Go to step 3

2 atomization and pressure are normal or
not Inspect and adjust fuel injector pressure, and
No
replace the fuel injector if necessary

Yes Adjust fuel supply advance angle

Inspect whether the fuel pump supplies
3
fuel too later or not
No Go to step 4
Inspect the cylinder sleeve, the piston, the
Yes piston ring and the grinding valve, and replace
Inspect whether cylinder compressed the abraded parts when necessary
4
pressure is too low
No Go to step 5

Replace diesel, and replace the fuel filter

Yes
element
5 Inspect whether water exists in diesel
Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 04-24 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

3. Fault Diagnosis of Black Smoke in Exhaust Gas

Step Diagnosis Content Measure

01 Yes Lighten load

Inspect whether the diesel engine works
1
under the overload condition
02 No Go to step 2

03 Inspect and adjust fuel injector pressure, and

Yes
Inspect whether the fuel injector has bad replace the fuel injector if necessary
2
04 atomization or drips fuel
No Go to step 3

05
Yes Adjust fuel supply advance angle
Inspect whether the fuel pump supplies
3
06 fuel too later or not
No Go to step 4
07 Clean the air filter and the inlet tube, and
Yes
Inspect whether the air filter is blocked or replace the air filter core if necessary
08 4
not
No Go to step 5
09
Adjust fuel supply amount, and inspect the
Yes
Inspect whether fuel injection amount is fuel injection pump if necessary
10 5
excess Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 Fault Diagnosis and Troubleshooting - Engine Fuel Injection Pump Faults 04-25

Engine Fuel Injection Pump Faults

Fault Analysis
Tip: 01
The fuel injection pump is the main part for supplying engine fuel, so that the problems of the fuel pump
will directly affect normal operation of the engine. The following aspects cause engine faults by the
02
engine fuel injection pump: the engine can not start, has unstable idling and has the phenomenon of
engine “galloping”, engine detonation and the like. Drivers should serious treat the problems. The fuel
injection pump belongs to the precise part which can not be removed and adjusted by laypeople. 03

Reasons causing fuel injection pump faults: 04

1. The fuel injection pump does not supply oil.
(a). Fuel injection valve abrasion or dirty objects. 05
(b). Deformation or breaking of fuel injection valve spring or plunger spring
(c). Disconnection of regulation spring. 06
(d). Clamping of regulation arm with shift fork.
(e). Clamping of fuel delivery pump mandril.
2. The fuel injection pump continuously causes “galloping” (engine rotation speed can not lower or can 07
not be controlled by the accelerator pedal).
(a). Clamping of fuel amount shift fork. 08
(b). Separation of regulation arm.
(c). Burndown of speed controller because of bad lubrication. 09
(d). Insufficient linkage formation.
(e). Loosened flyball parts. 10
(f). Separation of linkage spring.
3. Speed regulation rate is over high.
(a). Overlarge deformation, abrasion and rigidness of speed regulation torsion spring.
(b). Premature action of corrector.
4. Fuel supply amount is unstable.
(a). Water or air contained in fuel.
(b). fuel delivery pump damage.
(c). Plunger spring breakage.
5. Runner wagon.
(a).Large inner frictional resistance of the speed controller.
(b). Overlarge axial gap of the camshaft.
(c). overlarge deformation, abrasion and rigidness of speed regulation torsion spring.
(d). Loosened flyball parts.
(e). Too much lubricating oil.
6. Rated fuel amount is insufficient.
(a). Abrasion of plunger mate parts or a delivery valve.
(b). Improper corrector adjustment.
(c). Incorrect high-speed stop.
7. Each cylinder fuel supply amount is suddenly uneven.
(a). Loosened regulation arm.
(b). Breakage of plunger spring.
(c). Dirty objects on the delivery valve or a fuel spray nozzle.
 04-26 Fault Diagnosis and Troubleshooting - Engine Fuel Injection Pump Faults

8. Low speed is unstable.

(a). Improper regulation of idling adjusting screws.
(b). Uneven low-speed fuel amount.
Tip:
01 y If the engine overheats, do not immediately stopping engine operation or suddenly add coolant to
avoid personal injury or part damage, reduce the throttle, operate under no load, or spray a small
02 quantity of water on the water tank surface, and misfire for inspection after coolant temperature in
the cooling system lowers.
y When the engine is still hot, do not take down the water tank cover so as to avoiding scalding, and
03 be careful when filling the coolant.
y If the overheating reason of the engine can not be found or eliminated, immediately contact repair
04 stations or repair factories, or cause other parts to damage.

05

06

07

08

09

10
 Fault Diagnosis and Troubleshooting - Engine Fuel Injection Pump Faults 04-27

Diagnosis and Troubleshooting

Tip:
Inspect the reasons of engine overheating or undercooling one by one according to the following steps,
and effectively save diagnosis time in the sequence from the simple reason to the complex reason, and
01
directly pass the specific steps of reasons which obvious can not happen. The diagnosis only serves as
the reference.
02
1. Fuel Injection Pump Fails in Pumping Oil
03
Step Diagnosis Content Measure
04
Yes Replace the delivery valve or clean
Inspect whether delivery valve is abraded
1
or provided with dirty objects or not 05
No Go to step 2
06
Inspect whether the delivery valve spring Yes Replace the damaged parts
2 or the plunger spring is deformed for 07
broken or not No Go to step 3
08
Yes replace and press the regulation arm
Inspect whether the regulation spring is 09
3
separated or not
No Go to step 4 10

Yes Replace or repair

Inspect whether the regulation arm and
4
the shift fork are clamped or not
No Go to step 5

Yes Replace or repair

Inspect whether fuel delivery pump is
5
clamped or not Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 04-28 Fault Diagnosis and Troubleshooting - Engine Fuel Injection Pump Faults

2. The Fuel Injection Pump Continuously Causes “Galloping”

Step Diagnosis Content Measure

01 Yes Replace or repair

Inspect whether the regulation arm and
1
the shift fork are clamped or not
02 No Go to step 2

03 Yes Replace and press the regulation arm

Inspect whether the regulation arm is
2
04 separated
No Go to step 3

05
Inspect whether the speed controller shaft Yes Replace or repair
3 sleeve is burnt out because of bad
06
lubrication or not No Go to step 4
07
Yes Adjust the travel of the linkage
Inspect whether the travel of the linkage is
08 4
too small or not
No Go to step 5
09
Yes Fasten the loosened parts
10 Inspect whether the flyball parts are
5
loosened or not
No Go to step 6

Yes Replace the deformed rubber hose

Inspect whether the linkage circlip is
6
separated or not Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time

3. Overhigh Speed Regulation Rate

Step Diagnosis Content Measure

Inspect whether the speed regulation Yes Replace the speed regulation torsion spring
1 torsion spring is deformed and abraded or
has overhigh stiffness No Go to step 2

Yes Re-adjust the correct

Inspect whether the oil pump corrector
2
acts too early Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 Fault Diagnosis and Troubleshooting - Engine Fuel Injection Pump Faults 04-29

4. Fuel Supply Amount is Unstable

Step Diagnosis Content Measure

Yes Remove air or moisture 01

Inspect whether the fuel tank contains air
1
or moisture
No Go to step 2 02

Yes Replace or repair the fuel delivery pump 03

Inspect whether the fuel delivery pump is
2
damaged or not 04
No Go to step 3

Replace the plunger spring, and inspect the 05

Yes
Inspect whether the plunger spring is fuel injection pump
3
broken or is fatigue Carefully inspect according to the above 06
No
steps, find fault reasons, and eliminate in time
07
5. Runner Wagon
08
Step Diagnosis Content Measure
09
Inspect whether the inner part of the Yes Repair and eliminate faults
1 speed regulator has large frictional 10
resistance or not No Go to step 2

Yes Re-adjust the gap

Inspect whether the axial gap of the
2
camshaft is overlarge or not
No Go to step 3

Inspect whether the speed regulation Yes Replace the speed regulation torsion spring
3 torsion spring is deformed and abraded or
has overhigh stiffness or not No Go to step 4

Fasten the loosened part to the specified

Yes
Inspect whether the flyball parts are standard
4
loosened
No Go to step 5

Fill the lubricating oil according to the

Yes
Inspect whether lubricating oil amount is standard
5
overhigh. Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 04-30 Fault Diagnosis and Troubleshooting - Engine Fuel Injection Pump Faults

6. Fuel Supply Amount is Unstable

Step Diagnosis Content Measure

Replace the plunger mate parts or the

01 Yes
delivery valve
Inspect whether the plunger mate parts or
1
the delivery valve is abraded or not
02 No Go to step 2

03 Yes Re-adjust the corrector

Inspect whether the corrector is
2
04 improperly adjusted or not
No Go to step 3

05
Yes Re-adjust the high-speed stop screw
Inspect whether high-speed stop screw is
3
06 improperly adjusted or not Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
07
7. Fuel Supply Amount is Unstable
08
Step Diagnosis Content Measure
09
Yes Update, replace and press
Inspect whether the regulation arm is
10 1
loosened or not
No Go to step 2

Replace the broken plunger spring, and

Yes
Inspect whether the plunger spring is inspect the fuel injection pump
2
broken or not
No Go to step 3

Inspect whether the delivery valve is Yes Replace the delivery valve or clean
3 abraded or is provided with dirty objects or
not Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time

8. Fuel Supply Amount is Unstable

Step Diagnosis Content Measure

Yes Re-adjust the idling fixing bolt

Inspect whether the position of the idling
1
fixing bolt is improperly adjusted
No Go to step 2

Inspect the fuel injection pump, and adjust the

Inspect whether the fuel injection pump Yes
low-speed fuel supply amount
2 supply wrong low-speed fuel supply
amount Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 Fault Diagnosis and Troubleshooting - Starter Faults 04-31

Starter Faults
Fault Analysis
Tip: 01
The function of the starter is characterized in converting electric energy in a storage battery into
mechanical energy to generate electromagnetism torsion to drive the engine to operate to the specified
02
rotation speed, so that the engine starts and operates. The starter also comprises the following faults:
when the ignition switch rotates to the starting position, the starter does not operate and is in starting
incapability, and the starter idles; when started, the driving gear and the flywheel gear ring have the 03
phenomena, such as abnormal sound and the like when meshing.
04
1. Rotate the ignition switch to the starting position to cause the starter to stop.
(a). Bad line contact 05
(b). Severe storage battery power lack or internal open circuit
(c). Fuse fusing 06
(d). Starter self short circuit
(e). Starter bearing or bush abrasion
2. Starter is powerless 07
(a). Insufficient storage battery charging
(b). Starter lead short circuit 08
(c). Corroded storage battery terminal or loosened wiring card
(d). Short circuit of starter magnetic field winding or armature winding intervals 09
(e). Tight starter assembly or friction phenomenon
(f). Overlarge starter resistance 10
3. Starter idles
(a). One-way clutch damage
(b). Whether the electromagnetic switch of the starter is damaged
4. Driving gear and flywheel gear ring have abnormal sound
(a). Severe abrasion of driving gear and flywheel gear ring
(b). Damage of the electromagnetic switch of the starter

Tip:
The time for the starter to operate once does not exceed 15 seconds, and time interval of twice starting
should exceed 2 minutes so as to prevent the starter from damaging the internal parts because of
overheating. When the starter can not be started three times continuously, the engine, the fuel system,
the electromagnetic switch, the starter, the storage battery and the terminal are inspected, and the
starter are restarted after eliminating faults. The ignition switch is released while the starter begins to
work, the starter gear self meshing position retracts, and the starters stops working.
 04-32 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

Diagnosis and Troubleshooting

Tip:
Inspect the reasons of engine overheating or undercooling one by one according to the following steps,
01 and effectively save diagnosis time in the sequence from the simple reason to the complex reason, and
directly pass the specific steps of reasons which obvious can not happen. The diagnosis only serves as
02 the reference.

03 1. The Starter Does Not Operate

Step Diagnosis Content Measure
04
Firmly splice the connection line connector,
Yes
05 Inspect whether the connection line has and replace the connector if necessary
1
bad contact or not
No Go to step 2
06
Charge the storage battery, and replace the
07 Inspect whether the storage battery has Yes
storage battery if necessary
2 severe power leak or internal open circuit
08 or not No Go to step 3

09 Yes Replace the fuse

3 Inspect whether the fuse is fused or not
10 No Go to step 4

Yes Repair or replace the starter

Inspect whether the internal line of
4
starter is in short circuit or not
No Go to step 5

Yes Repair or replace the starter

Inspect whether the starting bearing or
5
the bush is severely abraded Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting 04-33

2. The Starter is Powerfulness

Step Diagnosis Content Measure

Yes Charge the storage battery 01

Inspect whether the storage battery is
1
sufficiently charged or not
No Go to step 2 02

Firmly splice the lead connector, and replace 03

Yes
Inspect whether the starter lead connector the connector if necessary
2
is in bad contact or short circuit 04
No Go to step 3

Clear the fixing bolt of the fastening wiring 05

Inspect whether the storage battery Yes
clamp of corrosive
3 terminal is corroded or the wiring card is
06
loosened No Go to step 4
07
Inspect whether the starter magnetic field Yes Repair or replace the starter
4 winding or armature winding intervals are 08
in short circuit No Go to step 5
09
Repair the starter, and replace the abraded
Yes
Inspect whether the starter is assembly parts if necessary
5 10
too tightly or is abraded
No Go to step 6

Eliminate the reason causing engine

Yes
Inspect whether resistance of the engine resistance
6
is overlarge Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 04-34 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

3. The Starter Idles

Step Diagnosis Content Measure

01 Yes Replace the one-way clutch

1 Inspect whether the one-way clutch slides
02 No Go to step 2

03 Replace the electromagnetic switch of the

Yes
Inspect whether the electromagnetic starter
2
04 switch of the starter is damaged or not Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
05
4. The Driving gear and flywheel gear ring have abnormal sound
06 Step Diagnosis Content Measure

07
Yes Replace the abraded part
Inspect whether the driving gear or the
1
08 flywheel gear ring is severely abraded
No Go to step 2
09 Replace the electromagnetic switch of the
Yes
Inspect whether the electromagnetic starter
10 2
switch of the starter is damaged or not Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 Fault Diagnosis and Troubleshooting - Generator Faults 04-35

Generator Faults
Fault Analysis
Tip: 01
Laidong 4L18 series diesel engine adopts the generator with a vacuum pump.
02
1. The generator totally does not generate electricity or insufficiently charges.
(a). Bad or wrong contact in the line
(b). Short circuit or open circuit of a stator or rotor coil 03
(c). Damaged rectifier tube, short circuit or open circuit
(d). Bad electric brush contact, oil dirt on a slip ring and over loose generator belt 04
2. Unstable charging circuit
(a). Short circuit or open circuit of the rotor coil and the stator coil 05
(b). Bad electric brush contact, small electric brush spring pressure, and bad line contact
3. The generator has abnormal sound 06
(a). Bearing damage when the generator is improperly installed
(b). Rectifier tube short circuit, and nail coil short circuit
07

08

09

10
 04-36 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

Diagnosis and Troubleshooting

Tip:
Inspect the reasons of engine overheating or undercooling one by one according to the following steps,
01 and effectively save diagnosis time in the sequence from the simple reason to the complex reason, and
directly pass the specific steps of reasons which obvious can not happen. The diagnosis only serves as
02 the reference.

03 1. The generator incompletely generates electricity or insufficiently charges

Step Diagnosis Content Measure
04
Yes Inspect and repair
05 Inspect whether line is in bad contact or is
1
connected in a wrong way
No Go to step 2
06

07 Yes Maintain or replace

Inspect whether the stator and rotor coil is
2
in short circuit or open circuit
08 No Go to step 3

09 Inspect whether the rectified tube is Yes Integrally repair or replace

3 damaged and forms short circuit or open
10 circuit No Go to step 4

Repair or clean, and adjust the tightness of

Inspect whether electric brush is in bad Yes
the belt
4 contact, the slip ring has oil dirt and the
generator belt is too loose Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time

2. Charging current is unstable

Step Diagnosis Content Measure

Inspect whether the rotor coil and the Yes Repair or replace
1 stator coil will generate short circuit or
open circuit No Go to step 2

Inspect whether the electric brush is in Yes Repair or replace

2 bad contact, the electric brush pressure is
too small, and the line is in bad contact Carefully inspect according to the above
No
steps, find fault reasons, and eliminate in time
 Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting 04-37

3. Charging current is unstable

Step Diagnosis Content Measure

Inspect whether the generator is Yes Repair or replace 01

1 improperly installed and the bearing is
damaged No Go to step 2 02

Yes Repair or replace 03

Inspect whether the rectified tube and the
2
stator coil are in short circuit Carefully inspect according to the above 04
No
steps, find fault reasons, and eliminate in time
05

06

07

08

09

10
 -04-38
Memo - Fault Diagnosis and Troubleshooting - Diagnosis and Troubleshooting

01

02

03

04

05

06

07

08

09

10
Usage and Maintenance of Engine（Diesel
Engine） 01

02
Cautions .......................................................................05-1
General Cautions......................................................05-1 03
Cautions for Operation and Shutdown......................05-1
Cautions for Engine ..................................................05-1 04
Cautions for Vacuum Pump......................................05-2
Cautions for Starter ..................................................05-2 05
Usage...........................................................................05-3
Fuel, Oil and Cooling Water......................................05-3
Preparation before Start ...........................................05-3 06
Start of Diesel Engine...............................................05-4
Operation of Diesel Engine.......................................05-4 07
Shutdown of Diesel Engine.......................................05-4
Maintenance.................................................................05-5 08
Routine Maintenance................................................05-5
Maintenance after Operation of 100 Hours...............05-5 09
Maintenance after Operation of 500 Hours...............05-6
Storage .....................................................................05-7
10
Running-in ................................................................05-8
Basic Maintenance.....................................................05-10
Judgment during Overhaul .....................................05-10
Judgment of Cylinder Gasket Quality .....................05-10
Adjustment of Valve Clearance ..............................05-11
Adjustment of Fuel Supply Advance Angle.............05-12
Adjustment of Fuel Injector .....................................05-13
Adjustment of Oil Pressure .....................................05-14
Adjustment of Fuel Injection Pump .........................05-14
Adjustment of Fan Pulley........................................05-14
Exhaust of Fuel System..........................................05-14
 04-2 Usage and Maintenance of Engine （Diesel Engine） - Diagnosis and Troubleshooting

01

02

03

04

05

06

07

08

09

10
 Usage and Maintenance of Engine （Diesel Engine） - Cautions 05-1

Cautions
General Cautions
01
1. The adjustment and maintenance during use shall be conducted in accordance with maintenance
methods and requirements described in the Manual. 02
2. High speed and full load operation of a new or overhauled engine is prohibited, and it can start the
operation with normal load after 45 hours’ running-in gradually from low speed and zero load to high
speed and full load. 03
3. Fuel used for diesel engine must be clean, and shall be subject to a week of precipitation or filtered
with a piece of silk cloth. 04
4. Keep normal temperature (80 ℃ -90 ℃), and the normal oil pressure should be 200-400 kPa.
5. In the process of operation, if abnormity is found, shutdown and check immediately. 05

Cautions for Operation and Shutdown 06

1. Increase or decrease for the load and speed of diesel engine and vehicle speed should be gradually 07
carried out evenly. Except special circumstances, don not change load and speed suddenly.
2. During the diesel engine operation and the vehicle operation, please always pay attention whether 08
meter readings are normal and the running status of the engine (running sound, color of exhaust
smoker), if they are out of the normal state, please take immediate measures or stop running. 09
3. Normally, maintain the engine working temperature in 358K (85 ℃) around, oil pressure in the
range the 196 ~ 490 kPa, it is strictly prohibited for vehicles using "acceleration - Shutdown - neutral 10
slide –gear shifting with a clutch and drag ignition" the method of operation .
• Because the diesel engine suddenly stalled under high temperature, oil pump, water pump all
are to stop working, it is unable to make oil and coolant take away parts heat in the engine.
• in case of drag ignition with the clutch and the speed of 40 km / hour, suddenly start the engine
at actual speed of 1300r/min, which is a great impact and very harmful to the engine.
4. Gradually decrease load and speed before diesel engine shutdowns, after shutdown, make idle
running for 3-5 minutes before halting. The aim is to make diesel engines evenly and gradually cool
down to prevent damage to some parts caused by overheating of the engine, which is very
important.

Cautions for Engine

1. The center of the generator pulley shall be aligned with that of the drive pulley, and the belt shall not
too tight or loose, which will have an influence on the reliability and service lift of the generator.
2. The generator must work in parallel with the battery and match with the regulator of proper model,
and the wire connection shall be firm and reliable.
3. The negative pole of the generator shall be grounded, and also the negative pole of battery shall be
grounded, otherwise the generator and regulator will be damaged by burning.
4. The multimeter will be used for checking whether the generator generates power, and the test
method of generating power to the ground is not allowed for inspection.
5. Usually clear away dust and oil dirt from the generator, and keep wire connection in good condition.
6. The maintenance shall be available for the generator for every 1,000 hours of operation, check
whether brushes are worn, clean bearings and fill an appropriate amount of lubricating oil; the filling
amount of lubricating oil shall be 2/3 of the bearing housing, and double sealed bearings are
maintenance-free.
7. In generator's running process, never disconnect or connect each connecting wire to avoid short
circuit and burning the silicon rectifier.
8. When the silicon rectifier is connected with the stator coil, never use a megohmmeter or 200v AC to
check the insulation of the generator; otherwise, diodes will be damaged by breakdown.
 05-2 Usage and Maintenance of Engine （Diesel Engine） - Cautions

Cautions for Vacuum Pump

1. Connect pressure oil with fuel inlet neck, connect vacuum pumps with exhaust adapters, connect oil
01 return connectors with the body, each connection must be sealed.
2. Check whether the pump body and pump seat have cracks or not, whether Pumps core, generator
02 shaft spline and the internal working face have abrasion or scratch or not. If damage is found,
please replace them in time.
3. The width of the blade must be ≥ 3mm, to ensure the pumping performance, if damage is found,
03 please replace the blade in time.
4. If oil leakage is found, please find the place where it leaks first, then repair or replace.
04 5. When using, please ensure cleanliness and proper viscosity of lubricant, work is strictly prohibited
without the lubricant, otherwise it will seriously damage the vacuum pump.
05
Cautions for Stator
06
1. Check the gasoline engine before use, and start the starter after confirming that the gasoline engine
07 can work normally.
2. When connecting starter line, cross-sectional area of copper wire connected to the battery should
08 be not less than 25 mm2, and cross-sectional area of wire connected to switch should be not less
than 4 mm2, the wire should be as short as possible, before startup, please check whether circuit
09 connection to the starter is correct, contact is close, and the battery charge is sufficient.
3. After all is ready, press the electromagnetic switch, starter gear is meshing with flywheel ring gear of
the engine, then start rotation, under normal circumstances, start successfully once, if unsuccessful
10
start once needs start for the second time, do it only after armature and gear are completely static,
otherwise the starter and ring gear of diesel engine will have severe impact and damage.
Note:
In cold weather, please warm-up the diesel engine firstly before starting and using the
starter.
4. Start time the starter should not exceed 15 seconds each time, the time interval between two starts
should be more than 2 minutes to prevent the starter from overheating.
5. When the diesel engine can not start normally for consecutive three times, check diesel engines,
electromagnetic switches, starter, battery and connection circuit, start after troubleshooting.
6. As soon as diesel engine starts to work, immediately release the switch button, otherwise the starter
gear will come back from the meshing position and stop working, so as to prevent the belt of starter
from reversing and damaging.
7. Regularly check whether fasteners of starter are connected firmly, contact for lead wire is close. And
clear up contamination, coat with a little Vaseline to prevent rusty corrosion.
8. Usually check whether the insulation of wires is damaged.
9. Regularly remove dust band, check whether the surface of the commutator is clean and smooth,
brushes is clamped and stagnated in the box, spring pressure is normal. And clear the dust. If brush
is found excessive wear, singeing on the surface of commutator and other faults, immediately
remove and repair them.
10. The starter shall be overhauled yearly, and the overhaul period can be appropriately shortened or
extended according to its condition.
 Usage and Maintenance of Engine （Diesel Engine） - Usage 05-3

Usage
Fuel, Oil and Cooling Water
1. Fuel 01
Users select diesel oil on the basis of the ambient temperature in the region, in the general area of
China, No. 0 light diesel oil is recommend in summer, No.-10 light diesel oil is recommend in winter, 02
No.-35,-20 light diesel oil is recommended in cold areas.
2. Oil
On the basis of atmosphere temperature in the region, please respectively select oil with viscosity 03
level of 5W/50 (used for range -30 ℃ - +40 ℃), 10W/30 (used for range -25 - +40 ℃ ), or with the
performance level of CD, CE or higher level of oil. Great Wall, Tongyi or Kunlun lubricating oil is 04
recommended. Remove the filler cap on the cylinder head cover and then fill the gasoline engine
with oil. Remove the drain plug from the oil pan to drain oil. 05
3. Cooling Water
Rain water or clean river water is applicable. The tap water from wells is inapplicable. In the cold 06
winter, antifreeze is available for the cooling system to prevent freezing. The antifreeze most
commonly used is 50% of glycol (DEG) and 50% of water (volume ratio), or 43% of alcohol, 15% of 07
glycerol and 42% of water (weight ratio). When the ambient temperature is lower than 0℃ and the
gasoline engine is hard to start, heat the cooling water to above 80℃ and fill the water tank of the 08
gasoline engine.
09
Preparation before Start
10
1. Check whether all connections for diesel engine are firm, and operation for control handle (such as
throttle, shutdown handle, etc.) are flexible.
2. Rotate crankshaft for several rotations, check whether all moving parts are flexible, there is any stop
phenomenon.
3. Check oil level in oil pan and oil pump is at upper limit position falling in range that dipstick defines.
4. Check whether water tank has been filled with the cooling water, each connector to water pipe ls
leaking water.
5. Check whether fuel tank has been filled with diesel oil, fuel oil line is smooth, each tubing joint is
sealed, or there are any leakage.
6. Check whether connection for the accessories of diesel engine is reliable (fuel injection pump,
diesel oil filter, oil filter, water pump, fans, generators and bracket, fan belt, starter, water, etc.)
7. Check whether connection of electrical system is correct, secure, reliable. Battery voltage should be
sufficient, cathode for silicon rectifier generator should be grounded, pay attention that cathode for
battery should be earthed.
 05-4 Usage and Maintenance of Engine （Diesel Engine） - Usage

Start of Diesel Engine

1. Put the governor handle at the moderate speed position.
01 2. Release bleeder screw of diesel filter, continuously press hand fuel pump to discharge air in the fuel
system.
02 • If it is a new diesel engine or the engine was not used for a long time, when there exists more
serious air in the fuel system, release bleeder screw of diesel filter, continuously press hand
fuel pump to discharge air in the fuel system.
03 • If the diesel engine is frequently used, it is necessary depending on the circumstances.
3. Make "start" switch at start position, the starter consecutively work no more than 15 seconds. If the
04 first start is unsuccessful, start again after stopping for 2 minutes, if it could not start in the third time,
please check the cause of the malfunction, start it after troubleshooting.
05 4. After diesel engine starts, immediately adjust the throttle, make the engine idle run, pay special
attention that oil pressure should be 49 kPa (0.5 kg / sq cm) or more, and then gradually increase
06 the speed, warm up with zero load.

07 Operation of Diesel Engine

08 1. When the cooling water temperature reach above 50 ℃, it can work with a load, but when using the
rated power, water temperature should reach more than 80 ℃.
09 2. The load of diesel engine or speed increase or decrease should be conducted gradually and
steadily, usually, do not allow a sudden increase or sudden decreased load.
10 3. During diesel engine operation, please always pay attention whether reading on instrument meter is
normal, please note that color of exhaust smoke, running sound, stop to check when abnormality is
detected.

Shutdown of Diesel Engine

1. Before shutdown of diesel engine, please gradually reduce the load and reduce speed to idle, don’t
operate shutdown handle to shutdown the diesel engine until water temperature drops to below 70
℃ before the handle is to stop the engine stop control
2. After shutdown of diesel engine, turn the ignition switch to the median.
3. When temperature below 5 ℃ in winter, after shutdown and water temperature falls to below 60 ℃,
turn on the discharge switch on the engine body and water tank, let go of cooling water to prevent it
from freezing, if antifreeze fluid is used, needn’t drain water.
 Usage and Maintenance of Engine （Diesel Engine） - Maintenance 05-5

Maintenance
Routine Maintenance
Tip: 01
In order to extend engine life, in the course of use, please carry out maintenance work according to the
following procedures. 02
1. Check oil level in oil pan which is falls within two tick marks of dipstick. If diesel engine is new or is
not used for a long time, please add oil to the upper tick mark, then run at low speed for 5-10 03
minutes before shutdown, after that, use a dipstick to measure the height of oil level.
2. Check volume of tank water. 04
3. Check oil level of fuel injection pump and governor, and add to the defined position in case of
insufficient oil. 05
4. Check and eliminate oil leakage, water leakage and air leakage for diesel engine.
5. Check the fastening status for diesel engine accessories. 06
6. Check fastening status for bearing connection to diesel engine.
7. Keep diesel engine clean, remove oil stain, dust, pay particular attention to dry and clean of
07
electrical equipment.
8. Make new diesel engine run-in under light load for 45 hours, timely change the oil (including fuel
injection pump, governor oil) and clean oil filter cartridge. 08
9. Eliminate difference and other abnormality.
09
Maintenance after 100 Hours of Operation 10
1. Change oil in the oil pan.
2. Clean or replace the oil filter cartridge.
3. Clean or replace diesel filter elements (or replace after running for total 200 hours).
4. Check tightened condition for the cylinder head bolts.
5. Check whether valve clearance meets the requirement, adjust it when necessary.
6. Check tension for fan belt, adjust it when necessary.
7. Remove dust in air intake pipe and air filter.
8. After running for total accumulated 200 hours, check oil injection pressure and oil injection status,
clean and adjust it when necessary.
9. Check battery voltage. The proportion of the electrolyte should be 1.28-1.29 (atmospheric
temperature 15 ℃), generally not less than 1.27, and check whether liquid level of electrolyte is
higher 10-15 mm than polar plate, otherwise add distilled water.
10. Change the cooling water depending on water turbidity. Remove the thermostat, refit water pipe,
start diesel engine and change speed from time to time so as to make flow rate of cooling water
fluctuate and wash sediments in the cooling system, and then open water drain cock of water tank
and engine body to drain water, continuously fill clean water into water tank, then Start diesel engine
under idle operation to make water flow, timely check water quality after opening water drain cock,
until water is clean, turn off water drain cock and shutdown, refit thermostat.
11. Due to maintenance and demolition of parts and components in the re-assembly, ensure that the
installation location is correct, and reliable.
 05-6 Usage and Maintenance of Engine （Diesel Engine） - Maintenance

Maintenance after Operation of 500 Hours

Tip:
Besides work items accordance with "Maintenance after operation every 100 hours’ work items, add
01 following work
1. Check fuel injection pressure for fuel injector and observe atomization quality, pay attention to
02 cleaning and adjusting.
2. Check fuel injection advance angle, adjust if necessary.
3. Remove the cylinder head, remove carbon deposit, and check the valve sealing status and grind it
03 in case of non-conforming to the requirement.
4. Check the fastening status for connecting rod bolts, main bearing bolts and flywheel bolts.
04 5. Re-screw the cylinder head bolts in a certain order, adjust valve clearance in accordance with the
provisions. (Refer to Chapter 08, Engine Assembly)
05 6. Clean or replace air filter cartridge (based on how much dust under work environment, maintenance
work can be advanced after operation of every 100 hours “or" or less time).
06 7. Change oil in fuel injection pump and the governor.
8. Clean the cooling system, cleaning fluid is made from 150 grams of caustic soda (NaOH) plus a
mixture of 1 liter of water. Before cleaning, discharge water in the water cooling system first, and
07
then filled with cleaning fluid, 8-12 hours later, run diesel engine, shutdown after the water
temperature reaches its operating temperature, immediately release cleaning fluid, so as to avoid to
08 deposit water scale floating in the cleaning fluid, Finally clean the cooling system with clean water.
9. Check the thermostat work status.
09 10. Check electrical equipment parts for starter, check whether fastener connection is firm, lead wire
contact is tightened. Replace it in case of burn marks.
10 11. Generally check all engine parts, and make necessary repairs and adjustments
Tip:
In addition to these regular maintenance in the above, user can conduct a more detailed maintenance
depending on situations.
 Usage and Maintenance of Engine （Diesel Engine） - Maintenance 05-7

Storage
1. If diesel engine is ready to stop using for long period of time, after shutdown, fill clean oil, cooling
water and fuel timely when diesel engine is hot, clean oil pan and oil filter element. 01
2. Conduct appropriate technical maintenance.
3. Remove the inlet and outlet pipes, fill 50 grams clean dehydrated oil to gas line and each cylinder
02
(oil is heated to 100-120 ℃ until the air bubbles completely disappears), and turn the crank, make
oil evenly attach onto the surface of oil valve, cylinder head, cylinder liner, piston, piston rings and
other parts. 03
4. Wiped oil stain, water stains and dust off the surface of diesel engine, parts which are not painted
should be coated with anti-rust oil (dehydrated oil and butter, after dissolved, evenly mix them), 04
rubber and plastic products should not be oiled.
5. Block air filter intake port and silencer port, or wrap it with plastic cloth to prevent debris or 05
contamination entering.
6. Diesel engine should be placed at the well-ventilated, dry, clean site, it is prohibited close to the pile 06
of chemicals.
Tip:
07
It can be stored for three months by the above oil sealing cocooning, but re-conduct oil sealing in case of
expiration.
08

09

10
 05-8 Usage and Maintenance of Engine （Diesel Engine） - Maintenance

Running-in
Tip:
Before normally using new diesel engine, running-in is necessary make good motion and avoid
01 abnormal wear and damage. The facts proves that diesel engine lifespan, work economy and reliability
to a large extent depends on good or bad running in the initial period, please strictly follow the running-in
maintenance provisions.
02
1. Running-in Specification:
03 (a) Running-in period:
The running-in period is about 60 hours, it can conduct together with the vehicle, running-in mileage
04 is 1,500 ~ 2,000 km.
(b) Refer to the following table for the load and speed requirements during running-in:
05 Mileage (km) Maximum load Maximum speed

06
0 ~ 2000 zero load -
07
200 ~ 800 50% of rated load 70% of rated speed
08
800 ~ 1500 70% of the rated load 75% of rated speed
09
1500 ~ 2000 75% of the rated load Not exceed the maximum speed
10
 Usage and Maintenance of Engine （Diesel Engine） - Maintenance 05-9

2. Maintenance Contents and Standards for Running-in

No. Contents Standards

Select depending on environmental

1 Replace lubricant brand for oil pan 01
temperature
Clean oil pan, replace paper type oil filter Use parts and components produced by 02
2
element official sub-supplier

3 Clean up filter element

Use parts and components produced by 03
official sub-supplier
Use parts and components produced by 04
4 Replace paper type diesel oil filter element
official sub-supplier
55 ~ 65N • m (LL380 \ LL480) / 05
5 Check bolt torque of connecting rod
50 ~ 60N • m (QC480)
115 ~ 130N • m (LL380 \ LL480) 06
6 Check bolts torque of the main bearing
120 ~ 130N • m (QC480)
07
135 ~ 150N • m (LL380 \ LL480)
7 Check bolt torque of cylinder head
150 ~ 170N • m (QC480)
08
Cold car, intake valve 0.2 ~ 0.25mm /
8 Check and adjust valve clearance
Exhaust valve 0.25 ~ 0.3mm
09
Check and tighten water pump shaft nut, fill
9 40 ~ 45N • m torque, calcium soap grease
lubrication grease 10
Single vertical belt is applied with force 39N,
10 Check tension of the fan belt
the deflection is10 ~ 15mm

11 Check fuel supply advance angle By provisions of product "Operation Manual".

12 Fastening exposed bolts, nuts According to requirement.

13 Check the atomization condition of fuel injector opening pressure is about 20 ± 0.5Mpa

Clean oil intake filter screen of fuel transfer

14 No dirt, no damage
pump
 05-10 Usage and Maintenance of Engine （Diesel Engine） - Basic Maintenance

Basic Maintenance
Judgment during Overhaul
01
1. Growth Rate of 0il Consumption
02 When setting a new car, Oil consumption ratio (running mileages or hours per liter) is 100%, it
needs overhaul when the ratio drops to 50%.
2. Growth Rate for Fuel Consumption
03
When setting a new car, Oil consumption ratio (running mileages or hours per liter) is 100%, it
needs overhaul when the ratio drops to 60%.
04 3. There Is Internal Abnormal Noise
There are various reasons for abnormal noise, if it is indeed caused by diesel engines overheated
05 or overworn, or due to improper operation, maintenance, repair, it needs overhaul early.

06 Judgment of Cylinder Gasket Quality

07 Tip:
The cylinder gasket is placed at the junction between the bottom of cylinder head and the top of the
08 cylinder body, under the high-strength cylinder head bolts, it forms gas sealing chamber, the combustion
gas pushes the piston to do work without leakage, while also it functions sealing effect for circulating
09 coolant and pressure oil passing by the cylinder head lubricating rocker body. So the requirements for
tightness and heat resistance on the cylinder head is higher, the machine applies composite panel
10 cylinder gasket, cylinder hole is bound by steel plate, steel wire guard ring is available in the inner, water
hole, oil hole all are bound by copper sheet or by special treatment, with good sealing and high service
life.
1. Check whether there is cracks on the cylinder gasket, water hole and oil hole are connecting in
series, if so, replace cylinder gasket.
2. When replacing it with a new gasket, measure the gap of the piston top (between the bottom and
the cylinder head), and its value must falls within the range of 0.9 ~ 1.1mm.
 Usage and Maintenance of Engine （Diesel Engine） - Basic Maintenance 05-11

Adjustment of Valve Clearance

Tip:
When overhauling the diesel engine or maintaining it with technology, please check the clearance of 01
adjusting valve.

1. Disassemble cylinder head cover, check and tighten the valve rocker bearing nut. 02
2. Rotate the crankshaft to the first piston position for dead center of work, at this time, the mark on the
observation window of the flywheel is precisely aligning with "O" tick mark of the flywheel, or "O" on 03
the pulley of the crankshaft is just aligning with the pointer on the cover of gear chamber.
3. Use feeler gauge to respectively insert into the first cylinder, exhaust valve and rocker, check and 04
adjust the intake and exhaust valve clearance, maintain the cold gap of 0.20 to 0.25 and 0.25 ~ 0.30
mm. After that, respectively rotate crankshaft with half rotation (ie 180 °) of the 4-cylinder diesel 05
engine on the basis of cylinder work order of 1-3-4-2, adjust the valve clearance of each cylinder.
And respectively rotate crankshaft to 240 °) of the 3-cylinder diesel engine on the basis of cylinder
06
work order of 1-3-2, adjust the valve clearance of each cylinder.
07

08

09

10
 05-12 Usage and Maintenance of Engine （Diesel Engine） - Basic Maintenance

Adjustment of Fuel Supply Advance Angle

Tip:
01 In order to obtain the most economical fuel consumption ratio and excellent running performance, fuel
supply advance angle must be adjusted appropriately.
02
1. Exhaust air in the fuel system, repeatedly turning the crankshaft so as to make fuel injection pump
full of fuel.
03 2. Remove the first-cylinder high-pressure oil pipe, rotate the crankshaft clockwise slowly and pay
close attention to oil level in the hole of oil pipeline connector, the moment the oil surface fluctuates,
04 immediately stop turning the crankshaft.
3. Check TDC (top dead center) mark at observation window of flywheel housing and aligns tick mark
05 on the flywheel (or scale mark on crankshaft pulley) to see whether it meets the best angles of the
above requirements.
06 4. If the fuel supply advance angle is too large or too small, remove the front cover of the gear
chamber, adjust by releasing 3 timing gear bolts in strap hole of the fuel injection pump. If the
advance angle is too large, counterclockwise turn an angle of fastening bolts in the strap hole on the
07
gear. If advance angle is too small, turn an angle in the opposite direction.
Tip:
08 If adjustment position in the strap hole is not enough, adjust by releasing 3 nuts on the triangular flange
plate of fuel injection pump, view backward from the front side, injection pump is turning clockwise, fuel
09 supply advance angle decreases, if counterclockwise rotating, fuel supply advance angle increases.

10
 Usage and Maintenance of Engine （Diesel Engine） - Basic Maintenance 05-13

Adjustment of Fuel Injector

Tip:
Test and adjustment on the fuel Injector is carried out on the injector tester, the purpose is to adjust fuel
injection pressure, observe atomization quality and troubleshooting. 01
When the fuel injection pressure of injector is too high or too low, fuel injection is not normal, and parts
are damaged, diesel engine will emerge dark smoke during operation, the power and speed decreases,
exhaust temperature increases or other cylinder Knocking etc faults. Adjust the faulty injector by cutting 02
out cylinder in turn, gradually release connection nuts between fuel injector and high-pressure fuel
injection pipe and stop fuel injection, in the meantime, observe color of exhaust smoke, if there is any 03
fault in fuel injector, stop fuel injection, exhaust gas will stop smoking, the engine speed changes little or
no change at all, move the flywheel and listen to fuel injection sound of each cylinder, in case of the loss 04
of crisp sound, the fuel injector in this cylinder may be faulty.
05
1. Install fuel injector to test stand installed in the injector
2. Use hand pump till the press meter shows 180 × 10 Pa, continuously press hands pumps slowly,
06
the pressure meter shows rising to 200 × 10 Pa fuel injection, observe fuel injection hole of nozzle
hole is free of drops of oil or leakage. After test several times, there is still oil dripping, remove the
matching parts of oil nozzle, do cleaning, inspection or grinding, and then test again. 07
3. Adjust fuel injection pressure, remove pressure regulating nuts of fuel injector, loosen or tighten the
regulating screw to make fuel injection pressure falling within 200 × 10 Pa, and then tighten the 08
pressure regulating nut, and retest it.
4. Observe mist spray quality, with the fuel injection rate of approximately once per second, do 09
mist-spray test, fuel mist should be fine and even, the oil flying foam can not be seen by the naked
eye, it is forbidden that the local density is uneven and fuel injection is at the single side, there 10
should be clear crisp sound of fuel cut-off.
Tip:
Generally, abnormal fuel injection maybe be the cause that needle valve of nozzle is not moving flexibly
or ineffectively, oil dripping at injection hole is caused by the damaged sealing surface, fuel filling occurs
ramification is caused by nozzle head with carbon deposition and thermal deformation.
 05-14 Usage and Maintenance of Engine （Diesel Engine） - Basic Maintenance

Adjustment of Oil Pressure

1. Loosen the lock nut.
01 2. Twist the pressure regulating screw with a wrench, so as to make oil pressure falls within the range
of 200 to 400 kPa (allow slightly higher for cold car)
02 3. After adjustment, and tighten the nut.

03 Adjustment of Fuel Injection Pumps

Tip:
04 Fuel injection pump has been adjusted and checked before leaving factory, if re-adjustment is necessary,
conduct it on the special fuel injection pump test stand with standard injectors and standard length of a
05 high-pressure oil pipe on the basis of relative instructions of fuel injection pump.

06 Adjustment of Fan Pulley

07 1. Apply force of 39N to the single belt middle position between two pulleys, the disturbing degree is 10
~ 15mm.
08 Tip:
Adjustment in case of non-conforming to the requirements, the adjustment steps refers to the following.
(a) Release regulating screws on the engine support.
09
(b) Use stress application pipe to pry out the generator to outside the engine, and then lock screw on
the generator support, till up to standard.
10

Exhaust of Fuel System

Tip:
Total exhaust need to be done when there is air from oil tank to fuel transfer pump pipeline or replacing
diesel oil filter.
Exhaust steps:
1. Rotate out the handle of hand pump, press up and down to supply fuel to the fuel system.
2. Release bolts on the small fuel pump return pipe of the fuel filter and exhaust bolts on the fuel
injection pump and continuously use manual fuel pump to supply fuel until the fuel flows out but no
bubbles occurs.
3. Tighten bolts and screws while tightening the handle of manual fuel pump.
Complete Engine Set
01
Removal and Installation of Complete Engine Set .......06-1
Cautions ...................................................................06-1
Removal Steps .........................................................06-2 02
Installation Steps ......................................................06-4
Instructions for Key Points ........................................06-6 03
Storage of Complete Engine Set..................................06-8
04

05

06

07

08

09

10
 05-2 Complete Engine Set - Basic Maintenance

01

02

03

04

05

06

07

08

09

10
 Complete Engine Set - Removal and Installation and Complete Engine Set 06-1

Removal and Installation and Complete Engine Set

Cautions 01

1 Park the vehicle on a vehicle groove or vehicle repair stand. 02

2 Set the parking brake lever in the parking position.
3 Fix the wheels with trigs or wedges which shall be arranged against the front and rear sides 03
of types; it is preferable to fix both side wheels.
4 Stall the engine while operating under the chassis; switch off the ignition switch (in the OFF 04
position).
5 Arrange a marker indicating “No Starting” in the position of the steering wheel or on the
driver’s seat while operating under or behind the vehicle. 05
6 Keep away from a fire while removing the Complete Engine Set.
7 Disconnecting any part connected with the engine; arrange the disconnected parts in the 06
positions having no influence on removal; fix the parts on the frame with cables and mark
them. 07

08

09

10
 06-2 Complete Engine Set - Removal and Installation and Complete Engine Set

Removal Steps
1. Disconnect positive and negative leads of the battery.
01 Tip:
In order to avoid the danger of electric spark caused by accidental grounding of the wrench while
removal, the negative and positive leads of the battery shall be removed in order.
02
2. Discharge engine coolant.
3. Discharge engine lubricating oil.
03 Tip:
The discharge of engine lubricating oil shall depend on whether the engine needs maintaining or not.
04 4. Remove the driver’s and the co-driver’s seats.
5. Remove the transmission control mechanism and the service brake control mechanism.
05 6. Remove the supporting plate of the service brake control mechanism.
7. Lift the rear mat and remove the rear inspection cover of the engine.
06 8. Remove the cargo box.
Tip:
Removing the cargo box is convenient for removal and installation of the complete engine set.
07 9. Disconnect all the cooling lines connected with the engine; remove the cooling lines when
necessary.
08 Tip:
It is recommended to remove the inlet and outlet hoses of the engine as much as possible so as to avoid
09 damage.
10. Remove the cooling fan of the engine.
10 Tip:
The removal of cooling fan is to avoid damage to the engine by collision during removal of engine.
11 Disconnect the fuel feed pipe and the fuel return pipe connected with the engine.
Tip: The removed fuel lines must be sealed and fixed in the frame crossbeam groove.
12. Disconnect the accelerator cable and the flameout cable with the engine.
13. Remove fixing clamps for the intake hose of the engine; remove the intake hose and seal t he
intake manifold joint.
14. Remove the lead of the oil pressure warning unit.
15. Disconnect the grounding wire connected with the engine, and the leads connected with the
generator and starter.
16. Remove the vacuum pipe of the engine, and seal it so as to avoid dirt or impurities from
entering.
17. Disconnect the exhaust pipe from the exhaust manifold.
Tip
To facilitate the removal and installation of the complete engine set, remove the exhaust pipe and the
muffler as possible.
18. Remove the clutch master cylinder and the support from the flywheel housing.
Tip:
It is unnecessary to remove the oil pump of the clutch slave cylinder, and fix the slave cylinder assembly
in the crossbeam groove of the frame after removal.
19. Remove the control cable and the parking brake cable on the transmission.
Tip:
The disconnected cable on the transmission shall be fixed in the crossbeam groove of the frame.
20. Disconnect the lead of the reverse switch with the reversing lamp switch.
21. Disconnect the drive shaft with the transmission.
22. Place the jack under the engine, select a suitable position to slightly support the engine, and
install the safety rope.
Tip:
y While removing the engine by the jack, the engine must be fixed with the safety rope on the jack so
as to prevent the engine from inclining and falling during movment and descending.
 Complete Engine Set - Removal and Installation and Complete Engine Set 06-3

y The factor of the load capacity of the bracket shall be considered sometimes. While removing the
engine assembly, the transmission can also be removed before removing the engine so as to
reduce the load of the bracket.
y When necessary, the bottoms of the transmission and the engine can be supported by two brackets.
y Make sure that all the leads and lines around the engine are disconnected. 01
23. Remove engine suspension fixing bolts connected with the frame.
24. Remove suspension fixing bolts at the rear end of the transmission. 02
25. Jack the engine a little steadily; move the engine slowly to a suitable angle after the front
engine suspension leaves the suspension bracket. 03

26. Lower both brackets slowly. 04

27. Push the vehicle backwards or forwards so as to expose the engine in the vehicle groove;
release the safety ropes on the bracket; hoist the engine from the floor groove by hangers; 05
and place the engine on the removing stand slowly.
06

07

08

09

10
 06-4 Complete Engine Set - Removal and Installation and Complete Engine Set

Installation Steps
1. Place two brackets in the vehicle groove; place the engine with transmission assembly
01 steadily on the brackets in the vehicle groove by hangers; fasten the engine on the brackets
by the safety ropes on the brackets.
Tip:
02 Because the engine with transmission assembly is quite heavy, two or more persons shall be preferred
for installation in order to avoid accidents.
03 2. While pushing the vehicle into the vehicle groove, the engine shall correspond to the
mounting position on the frame.
04 3. Jack both brackets slowly at the same time; approach the engine suspension to the
suspension brackets on the crossbeam; align the fixing bolt holes.
05 4. Install and fasten the fixing bolts for front engine suspension.
5. Install the rear engine support on the frame cross member by the brackets; install and fasten
the fixing bolts.
06
Tip:
After making sure that both the front and rear fixing bolts for the engine suspensions are firmly installed,
07 the engine brackets shall be slowly lowered and then moved away for convenience of installing the
engine connecting pieces.
08 6. Install the drive shaft and fixing bolts; fasten the fixing bolts.
7. Firmly plug the reverse switch lead into the transmission reverse switch lead connector.
09 8. Install the transmission control cable and parking brake cable on the transmission.
9. Install the clutch slave cylinder with support assembly to the flywheel housing and fix, and
10 install the clutch reset spring.
10. Install the exhaust pipe and muffler; install the joint gasket for connecting the exhaust pipe
with the exhaust manifold and fixing bolts and tighten.
11. Install the vacuum tube on the vacuum pump joint at the tail of the engine and tighten.
12. Install the engine grounding lead on the flywheel housing and fasten.
13. Install the generator and starter leads on the corresponding terminals or in the connectors.
Tip:
Make sure that all the leads are firmly plugged without grounding.
14. Plug the lead of the oil pressure warning unit on the connector of the alarm.
15. Install the intake component and the intake hose of the engine on the intake manifold of the
engine; fasten the clamp.
Tip:
The intake pipe of the engine must be well sealed. The intake quality of the engine will directly affect its
service life.
16. Install the engine accelerator cable and flameout cable; make suitable adjustment.
Tip:
After installation, the accelerator cable must be debugged to avoid the over-large opening of the
accelerator while starting the engine.
17. Install the fuel feed pipe on the fuel inlet of the fuel supply pump and install the clamp; install
fuel return pipe fixing bolts and tighten.
19. Install the cooling fan on the water pump pulley; screw up the fan fixing bolts and tighten.
20. Install the engine cooling line and tighten hose clamps; install the heater line, and fasten
clamps.
21. Fill the engine coolant to the standard level.
22. Fill an amount of engine lubricating oil. Ensure that lubricating oil is enough by observing
the dipstick.
23. Observe the connecting pieces around the engine so as to ensure firm and reliable
installation. Perform the engine test after making sure that the transmission is in the neutral
position.
24. Connect the battery leads.
 Complete Engine Set - Removal and Installation and Complete Engine Set 06-5

Tip:
When installing the battery leads, install the positive terminal, and fix the bolt with sealing and insulation
treatment; then install the negative terminal, and fix the boil with sealing and insulation treatment.
25. Switch on the ignition switch, observe the display of instruments and make sure there are no
problems, and then start the engine. 01
Tip:
After the engine runs, observe the oil pressure gauge and water temperature gauge and make sure that 02
they are normal, enter the vehicle groove and observe whether there are water leakages, oil leakages
and air leakages around the engine, and shut down the engine for troubleshooting if any. Install other
accessories in order after making sure that the engine runs normally. 03
26. Install the cargo box.
27. Install the rear inspection cover of the engine, and then level the rear mat. 04
28. Install the supporting plate for the service brake control mechanism.
29. Install the transmission control mechanism and service brake control mechanism. 05
30. Install the driver’s and co-driver’s seats.
06

07

08

09

10
 06-6 Complete Engine Set - Removal and Installation and Complete Engine Set

Instructions for Key Points

1. Instructions for Disconnecting and Connecting
01 Battery Grounding Wire
Instructions:
While removing the engine, the negative pole of the
02
battery shall be disconnected so as to ensure that the
engine is removed under power failure. On completion of
03 all the works, the negative pole shall be connected after
checking again carefully.
04

05
2. Instructions for Removing and Installing Oil Pipes
06 Instructions:
While removing oil pipes, the disconnected end shall be
07 capped with the oil pipe cap. Because fuel is inflammable,
cigarettes, open fire, indicating lamps, electric arc
08 equipment and switches shall be away from the working
area which shall be provided with ventilating equipment so
as to reduce the possibility of serious personal injury or
09
even death.
10

3. Instructions for Removing and Installing Hoses,

Pipes and Retaining Components and Parts
Instructions:
The engine has too many pipelines and wire terminals to
distinguish easily. For convenience of correct installation,
the positions of all the hoses, pipes, connecting rods and
electrical terminals shall be marked by sticking labels
during removal and tied up on one side of the frame so as
to prevent blocking the operation. During installation they
shall be installed to the correct positions according to the
indications on the labels.

4. Instructions for Protecting Engine

Instructions:
Tiny foreign matters existing in the engine will cause
engine failure to run, even major damages to the engine.
Therefore, it is necessary to cover all openings after
disconnecting the pipes connected with the engine to
prevent dirt and debris from falling into the engine.
Complete Engine Set - Removal and Installation and Complete Engine Set 06-7

5. Instructions for Removal and Installation

Methods of Engine
Instructions:
The complete engine set needs to be removed from the
lower end of the crossbeam by using a bracket, and 01
installed from the lower end of the crossbeam as well.
02

03

04

05

06

07

08

09

10
 06-8 Complete Engine Set - Storage of Complete Engine Set

Storage of Complete Engine Set

Instructions:
y After storage for 24 months, the cooling system of the engine must be discharged, and the
01 engine must be washed with suitable solvent or hot and mild mineral oil. The washing steps
shall be repeated before reuse.
02 y Never remove the radiator pressure cap from a hot engine. The pressure cap can not be
removed until the temperature of coolant is reduced to 50℃ and below. Otherwise, the
03 high-temperature coolant or steam will eject to result in personal injury.
y Coolant is toxic. Children and pets must be kept away from coolant. Coolant shall be
04 disposed in accordance with local applicable regulations for environmental protection if it is
not used any more.
1. Methods for Long-Term Storage of Engine
05
(a). Operate the engine at high idling until the coolant temperature reaches 71℃.
(b). Stall the engine.
06 (c). Discharge the engine oil.
(d). Install the drain plug.
07 (e). Apply preservative oil or equivalent so provide anti-rust protection for the long-term storage of
engine.
08 (f). Disconnect the fuel pipes for connecting fuel return pipes of the engine filter and the fuel injector.
(g). Apply preservative oil or equivalent.
09 (h). Fill one container with gasoline and fill another container with preservative oil. Arrange both fuel
pipes in the container filled with gasoline.
(i). Start the engine to operate for 25 minutes so as to distribute the preservative oil.
10
(j). Change the fuel supply pipe into the container filled with preservative oil when the engine operates
steadily.
(k). Operate the engine until the preservative oil flows out of the fuel return pipe of the fuel injector.
(l). “Stall” the engine.
(m). Connect the fuel pipe to the fuel return pipes of the fuel filter and the fuel injector.
(n). Drain the preservative oil from the oil sump of the engine oil plate and the Oil Filter.
(o). Evacuate engine coolant. Cover all the openings of the cooling system with plastic bowl-shaped
plug and adhesive tape.
(p). Remove the intake manifold and the exhaust manifold.
(q). Inject the preservative oil into the intake port and the exhaust port on the cylinder cover and the
manifolds.
(r). Remove the cover of the rocker arm chamber.
(s). Spray the preservative oil on the rocker arms, valve stems, valve springs, valve guide and tappets.
Apply preservative oil on the flywheels, flywheel housing and all other unpainted machined
surfaces.
(t). Install the cover of the rocker arm chamber, the intake manifold and the exhausted manifold.
(u). All the openings of parts and all the engine openings shall be covered with plastic bowl-shaped plug
and adhesive tape after removing the exhaust pipes so s to prevent dust and moisture from entering
into the engine.
Tip:
A label for warning shall be arranged on the engine, and the contents are as follows:
• Do not operate the engine.
• Do not drag the crank shaft.
• Engine has been treated with protection measures.
• Coolant has been drained.
• Date of treatment.
 Complete Engine Set - Storage of Complete Engine Set 06-9

2. Cleaning of Engine after Long-Term Storage

(a). Washing the fuel system with cleaning gasoline until all the preservative oil is cleared.
(b). Remove the screw plug in the main oil gallery. Apply hot and mild mineral oil.
(c). Clear the preservative oil in the engine by washing.
(d). Drag the engine crankshaft for 3~4 circles in the process of washing. 01
(e). Fill the oil sump of the engine oil plate, the Oil Filter and the fuel filter.
(f). Fill coolant into the cooling system. 02
(g). Prefill engine oil into the lubrication system.
(h). Adjust the gap between the fuel injector and the valve.
(i). Screwing in the mounting bolts of the exhaust manifold. 03

04

05

06

07

08

09

10
 - 06-10
Memo - Complete Engine Set - Storage of Complete Engine Set

01

02

03

04

05

06

07

08

09

10
Disassembly of Engine
Disassembly Instructions .............................................07-1 01
Instructions ...............................................................07-1
Starter and Generator ..................................................07-2
Removal ...................................................................07-2 02
Dipstick and Breather...................................................07-4
Removal ...................................................................07-4 03
Oil Filler........................................................................07-5
Removal ...................................................................07-5 04
Fuel Pipe and Fuel Injector ..........................................07-6
Removal ...................................................................07-6 05
Fan and Water Pump .................................................07-10
Removal .................................................................07-10
06
Cylinder Head Cover and Rocker Arm .......................07-12
Removal .................................................................07-12
Cylinder Head ............................................................07-15 07
Removal .................................................................07-15
Intake and Exhaust Manifold and Hanger ..................07-16 08
Removal .................................................................07-16
Valve and Flywheel ....................................................07-18 09
Removal .................................................................07-18
Fuel Injection Pump ...................................................07-20 10
Removal .................................................................07-20
Crankshaft Pulley and Timing Gear Chamber Cover .07-23
Removal .................................................................07-23
Camshaft Timing Gear and Timing Idle Gear.............07-25
Removal .................................................................07-25
Water Drain Cock and Oil Filter ................................07-27
Removal .................................................................07-27
Oil Pressure Warning Unit and Support .....................07-29
Removal .................................................................07-29
Oil Pan and Flywheel Housing ...................................07-31
Removal .................................................................07-31
Camshaft and Oil Pump .............................................07-33
Removal .................................................................07-33
Timing Gear Chamber and Piston Assembly .............07-35
Removal .................................................................07-35
Crankshaft and Lifter..................................................07-39
Removal .................................................................07-39
 06-2 Disassembly of Engine - Storage of Complete Engine Set

01

02

03

04

05

06

07

08

09

10
 Disassembly of Engine - Disassembly Instructions 07-1

Disassembly Instructions
Instructions
01

02

03

04

05

06

07

08

09

10

1. This Chapter provides the overall process of disassembling a full set of gasoline engine in the
manners of from top to bottom as well as from outside to inside. The disassembly is introduced layer
by layer by combining pictures with texts.
2. LL480 Diesel Engine configured for Yuling Series products is taken as an example for removal. This
Chapter can be used as a reference for the removal of LL380 and QC480.
3. The engine assembly shall be arranged on the disassembly stand or on the clean and flat ground
before disassembling engine. Necessary removal tools and professional container or environment
for arranging parts shall be prepared.
4. The environment for disassembly shall be far away from the places having safety problems as much
as possible, such as fire, children, etc.
 07-2 Disassembly of Engine - Starter and Generator

Starter and Generator

Removal
01 1. Remove the starter.
(a) Remove the two fixing bolts on the starter with a
02 wrench.

03

04

05

06 (b) Remove the starter assembly.

07

08

09

10

2. Remove the generator.

(a) Remove the hollow bolts on the generator backend
connecting the vacuum tube and engine body.
Caution：
Prevent the hollow bolt from contaminating.

(b) Remove another hollow bolt.

Caution：
Prevent the hollow bolt from contaminating.
Disassembly of Engine - Starter and Generator 07-3

(c) Separate the intake and output oil pipes of generator

vacuum pump from the engine body.

01

02

03

04
(d) Remove the connection of generator upper support.
Tip： 05
While removing the generator upper support, loosen the
adjusting bolts on the support firstly, then untie the
generator belt, and remove generator upper support 06
finally. It is easy to move in such a way.
07

08

09
(e) Push the generator upwards. Loosen the generator
belt. 10

(f) Remove the fixing bolts at the lower end of the

generator support.
Tip：
It could directly remove the connecting bolts between the
generator and generator bottom support. Remove them
according to actual needs.

(g) Remove the generator assembly.

 07-4 Disassembly of Engine - Dipstick and Breather

Dipstick and Breather

Removal
01
1. Remove the dipstick.
02 (a) Unscrew the connection bolt of the dipstick and
engine body.
03

04

05

06
(b) Pull out the dipstick assembly.
07

08

09

10

2. Remove the breather assembly.

(a) Remove the fixing bolt of breather assembly.

(b) Remove the breather assembly.

 Disassembly of Engine - Oil Filter 07-5

Oil Filter
Removal
01
1. Remove Oil Filter.
(a) Remove the fixing bolts of the oil filter and support.
02
Tip：
Directly remove the oil filter assembly and never remove
the support according to the needs. 03

04

05

06
(b) Remove the oil filter assembly.
07

08

09

10
 07-6 Disassembly of Engine - Fuel Pipe and Fuel Injector

Fuel Pipe and Fuel Injector

Removal
01 Caution：
Fuel is flammable. When the fuel system is working, make sure cigarettes, open flame, light, arc
02 equipment and switches are away from the work area, and the ventilation equipment is also
equipped in the work area, so as to reduce the possibility of the serious personal injury or death.
03
1. Remove the fuel pipe between the oil pump and
fuel filter.
04 (a) Remove the hollow bolts connecting the fuel feed
hose with fuel filter.
05 y Remove the washer.
Caution：
06 Prevent the hollow bolt and oil pipe connector from
contaminating.
07

08
(b) Remove the hollow bolts of the fuel feed hose and oil
09 pump.
y Remove the washer.
10 Caution：
Prevent the hollow bolt and oil pipe connector from
contaminating.

(c) Remove the fuel pipe between the oil pump and fuel
filter.

2. Remove the fuel pipe between the fuel filter and

fuel injection pump.
(a) Remove the hollow bolts on the both ends of oil outlet
pipe of fuel filter.
y Remove the washer.
Caution：
Prevent the hollow bolt and oil pipe connector from
contaminating.
 Disassembly of Engine - Fuel Pipe and Fuel Injector 07-7

(b) Remove the hose between the fuel filter and fuel
injection pump.

01

02

03

04
3. Remove the hose between fuel injection pump and engine body.
(a) Same as the above method to remove the lubricating oil hose between the fuel injection pump and 05
the engine body.
06
4. Remove the fuel return pipe.
(a) Remove the four fixing hollow bolts of the fuel return
pipe. 07
y Remove the washer.
Caution： 08
Prevent the hollow bolt and oil pipe connector from
contaminating. 09

10

(b). Remove the fuel return pipe.

Tip：
After removing the fuel return pipe，the hollow bolt and the
gasket shall be installed on the fuel injector.

5. Remove the high-pressure fuel pipe.

(a) Unscrew the nuts at the junction of the high-pressure
fuel pipe and fuel injector. Untie the connection
between the high-pressure fuel pipe and fuel injector.
Caution：
After the connection is untied, immediately cover the
connectors of the pipe and fuel injector.
 07-8 Disassembly of Engine - Fuel Pipe and Fuel Injector

(b) Unscrew the nuts at the junction of the high-pressure

fuel pipe and fuel injector. Untie the connection of the
high-pressure fuel pipe and fuel injector..
Caution：
01 After the connection is untied, immediately cover the
connectors of the pipe and fuel injector.
02

03

04
(c) Remove the high-pressure fuel assembly.
05

06

07

08

09
6. Remove the fuel filter.
10 (a) Remove the fixing bolt of fuel filter.

(b) Remove the fuel filter.

Tip：
Place the fuel filter in the clean container, so as to avoid
causing pollutions.

7. Remove the fuel injector.

(a) Remove the fixing nut of the fuel injector.
Disassembly of Engine - Fuel Pipe and Fuel Injector 07-9

(b) Pry the fuel injector with the crowbar.

Tip：
Remove the fuel injectors one by one, mark them or
arrange them in a sequential order carefully. If the fuel
injector is not validated，the fuel injector must be installed 01
on the original location.
Caution： 02
There is one copper gasket under each fuel injector,
which could be come out with the fuel injector 03
together when removing. Remove and protect them
carefully. 04

05

06

07

08

09

10
 07-10 Disassembly of Engine - Fan and Water Pump

Fan and Water Pump

01 Removal
02 1. Remove the fan.
(a) Remove the four fixing bolts on the fan.
03

04

05

06

07 (b) Remove the fan.

08

09

10

2. Remove the fan pulley.

(a) Directly remove the fan pulley.

3. Remove the distributed water pipe of water pump.

(a) Loosen the two-wire hoop at the both ends of the
distributed water pipe of water pump.
Disassembly of Engine - Fan and Water Pump 07-11

(b) Relieve off the distributed water pipe of water pump

and remove the distributed water pipe.

01

02

03

04
4. Remove the thermostat housing assembly.
(a) Remove the fixing bolt connecting the thermostat
05
housing with the cylinder head.
06

07

08

09
(b) Remove the thermostat housing assembly.
Tip： 10
The thermostat housing and cylinder head are often
connected tightly. It is more convenient to take them out
by beating with the rubber hammer. Never beat with the
hammer.

5. Remove the water pump assembly.

(a) Remove the fixing bolt of the water pump assembly.

(b) Remove the water pump assembly.

Tip：
The water pump assembly and engine body are often
connected tightly. It is more convenient to take them out
by beating with the rubber hammer. Never beat with the
hammer.
 07-12 Disassembly of Engine - Cylinder Head Cover and Rocker Arm

Cylinder Head Cover and Rocker Arm

Removal
01
1. Remove the cylinder head cover.
02 (a) Unscrew the filter cap.
Tip：
Turn over the filter cap and place the inside upwards.
03

04

05

06
(b) Remove the four cap nuts fixing the cylinder head
07 cover.

08

09

10

(c) Remove the cylinder head cover.

Tip：
After removing the cylinder head cover，the cylinder head
cover shall be turned over to be placed. Never let the
gasket surface of the cylinder head cover face downward.

2. Remove the rocker arm assembly.

(a) Remove the four fixing nuts on the rocker arm
assembly.
Disassembly of Engine - Cylinder Head Cover and Rocker Arm 07-13

(b) Remove the four fixing bolts on the rocker arm

assembly.

01

02

03

04
(c) Remove the rocker arm assembly.
05

06

07

08

09
3. Disassemble the rocker arm assembly.
(a) Disassemble the circlip at the end of the rocker arm 10
assembly with the circlip pliers.

(b) Disassemble the first valve rocker arm assembly.

Tip：
More easily remove the valve rocker arm assembly with
rotation.

(c) Remove the first rocker arm support.

Tip：
More easily remove the rocker arm support with rotation
from side to side.
 07-14 Disassembly of Engine - Cylinder Head Cover and Rocker Arm

(b) Disassemble the second valve rocker arm assembly.

Tip：
More easily remove the valve rocker arm assembly with
rotation.
01

02

03

04
(e) Remove the locating screw on the rocker arm.
05

06

07

08

09
(f) Draw out the rock arm shaft.
10 Tip：
More easily remove the rocker arm shaft with rotation
from side to side.
Caution：
After drawing out the rocker arm shaft, the rock arm
support, the rock arm spring and the valve rocker arm
assembly shall be spread out. Arrange them in
sequential order carefully.
 Disassembly of Engine - Cylinder Head 07-15

Cylinder Head
Removal
Caution： 01
Due to the cylinder head is heavy, make sure to lift the component or assembly with one
assistant or the suitable lifting equipment, so as to avoid causing serious personal injury. 02
1. Remove the tappet.
(a) Directly remove the tappet. 03
Tip：
The tappet shall be installed on the original poison, so all 04
tappets shall be marked and placed neatly after taking
out. 05

06

07

2. Remove the cylinder head assembly. 08

(a) Remove the ten bolts fixing on the cylinder head.
Tip： 09
Suggest unscrewing the ten bolts one by one with the way
of crossing symmetry and then remove each bolt. 10

(b) Bring the cylinder head into with the sling. Lift the
exhaust manifold assembly away from the engine
body.
Tip：
To repair the cylinder head, disassemble the cylinder
head according to the specific requirements. Otherwise,
never disassemble the cylinder head.

(c) Remove the cylinder head gasket.

 07-16 Disassembly of Engine - Intake and Exhaust Manifold and Hanger

Intake and Exhaust Manifold and Hanger

Removal
01
1. Remove the intake and exhaust manifold
02 assembly.
(a) Remove the fixing bolt of the intake and exhaust
manifold assembly.
03
Tip：
The intake manifold is also available to directly and
04 separately disassemble from the engine ， but it is
inconvenient. When implementing the overhaul, suggest
05 using the overall disassembly method in this Chapter.

06
(b) Remove the intake manifold assembly.
07 y Remove the intake manifold gasket.
Tip：
08 The intake manifold gasket in this machine is paperboard
gasket. After removing the intake manifold, the
09 paperboard gasket shall be cleaned out and can not be
used again.
10 Caution：
Sealing materials and other materials shall not be
entered into the intake manifold mouth.

2. Remove the exhaust manifold.

(a) Remove the fixing nut of the exhaust manifold.
Tip：
The exhaust manifold can be separately and easily
removed from the engine. Removal steps for reference
only.

(b) Remove the exhaust manifold.

y Remove the exhaust manifold gasket.
Tip：
When removing, shock the exhaust manifold to be loose
with the rubber hammer and them remove it.
Caution：
Sealing materials and other materials shall not be
entered into the intake manifold mouth.
Disassembly of Engine - Intake and Exhaust Manifold and Hanger 07-17

3. Remove the front and back hangers.

(a) Remove the fixing bolt of the front hanger,
y Remove the front hanger.

01

02

03

04
(b) Remove the fixing bolt of the back hanger,
y Remove the back hanger. 05

06

07

08

09

10
 07-18 Disassembly of Engine - Valve and Flywheel

Valve and Flywheel

Removal
01
1. Remove the valve.
02 (a) Press downward the valve spring with the
professional tool of disassembling the valve.
Tip：
03
y Slightly tap the valve spring support with the rubber
hammer and make the valve lock clamp be loose.
04 y Don’t force excessively, as long as the valve lock
clamp can be exposed.
05

06
(b) Remove the valve lock clamp.
07 Tip：
The best thing is two persons to co-operate to complete it.
08

09

10

(c) Loosen the valve spring and take out the internal &
external springs of the valve and the valve spring
upper support.

(d) Tap out the valve oil seal.

Tip：
After removing, the old valve oil seal must be replaced
with the new one.

(e) Turn over the cylinder head and take out the valve. Remove other valves in the same way.
Disassembly of Engine - Valve and Flywheel 07-19

2. Remove the flywheel.

(a) Remove the bolt fixing the flywheel.
Tip：
When removing it, lock the flywheel at the point of
installing the engine with the object, so as to avoid the 01
flywheel rotating and convenient to remove it.
02

03

04
(b) Remove the flywheel gasket.
05

06

07

08

09
(c) Remove the flywheel.
Tip： 10
Due to the flywheel has a certain weight, be careful to
remove it.
 07-20 Disassembly of Engine - Fuel Injection Pump

Fuel Injection Pump

Removal
01 Caution：
Fuel is flammable. When the fuel system is working, make sure cigarettes, open flame, light, arc
02 equipment and switches are away from the work area, and the ventilation equipment is also
equipped in the work area, so as to reduce the possibility of the serious personal injury or death.
03
1. Remove the front cover of timing gear chamber.
(a) Remove the fixing bolt of the front cover of timing
04 gear chamber.

05

06

07

08
(b) Slightly tap the edge of the front cover of the timing
09 gear chamber with the mallet, copper rod or
equivalent properties and make it loose.
10

(c) Remove the front cover of the timing gear chamber.

y Remove the gasket of the timing gear chamber
cover.

2. Preparations before removing the timing advance

assembly.
(a) Rotate the crankshaft pulley and make the timing
advance gear align with the scale of timing idle gear.
Tip：
The purpose is to ensure to restore the original state when
installing. It is also available to directly make a new mark
on the gear.
Disassembly of Engine - Fuel Injection Pump 07-21

3. Remove the timing advance assembly.

(a) Remove the fixing bolt of timing advance.

01

02

03

04
(b) Screw up the male bolt of timing advance.
05

06

07

08

09
(c) Tighten the male bolt inward and top out the timing
advance assembly. 10

(d) Remove the timing advance assembly.

4. Remove the fuel injection pump.

(a) Remove the three fixing nuts of the fuel injection
pump.
 07-22 Disassembly of Engine - Fuel Injection Pump

(b) Take out the fuel injection pump.

Tip：
Due to the fuel injection pump is heavy, be careful to take
out it.
01

02

03

04
(c) Remove the fuel injection pump gasket.
05

06

07

08

09

10
 Disassembly of Engine - Crankshaft Pulley and Timing Gear Chamber Cover 07-23

Crankshaft Pulley and Timing Gear Chamber Cover

Removal
01
1. Remove the crankshaft pulley.
(a) Remove the fixing bolt of the crankshaft pulley.
02

03

04

05

06
(b) Remove the crankshaft pulley.
07

08

09

10

2. Remove the timing gear chamber cover.

(a) Remove the fixing bolt of the timing gear chamber
cover.
Tip:
The lengths of the fixing bolt of timing gear chamber cover
are different. Loosen all the bolts firstly and don’t remove
immediately. Then Remove them and write down their
installation positions, being convenient for the installation.

(b) Remove the timing gear chamber covers.

Tip：
If the timing gear chamber cover is too tight, it is available
to tap and loosen it with the rubber hammer and then
remove it.
 07-24 Disassembly of Engine - Crankshaft Pulley and Timing Gear Chamber Cover

(c) Remove the gasket of the timing gear chamber cover.

Tip：
The gasket of the timing gear chamber cover is
paperboard gasket. When removing, it can be directly
01 removed away and the debris shall be cleaned up.

02

03

04

05

06

07

08

09

10
 Disassembly of Engine - Camshaft Timing Gear and Timing Idle Gear 07-25

Camshaft Timing Gear and Timing Idle Gear

Removal
01
1. Remove the camshaft timing gear.
(a) Remove the fixing bolt of camshaft timing gear.
02
Tip：
At this time, the camshaft assembly can not be removed.
After removing the oil pan and oil pump, it is available to 03
remove the camshaft. It is only available to separately
remove the camshaft timing gear. When removing the 04
camshaft, the fixing bolt of the camshaft thrust plate is
removed, It also can remove with the camshaft together 05
and then break down.
06
(b) Install two bolts with the appropriate length on the
reserved hole of camshaft timing gear. 07

08

09

10

(c) Tighten the bolts and push out the camshaft timing
gear.
Tip：
When tightening the bolts, it is necessary to pre-tighten
backwards and forwards one by one to make two bolts
stressed evenly at the same time.

(d) Remove the camshaft timing gear.

 07-26 Disassembly of Engine - Camshaft Timing Gear and Timing Idle Gear

2. Remove the timing idle gear.

(a) Remove the two fixing bolts of the timing idle gear.

01

02

03

04
(b) Remove the idle gear plate.
05

06

07

08

09
(c) Remove the timing idle gear assembly.
10

(d) Break down the timing idle gear assembly.

Tip：
Directly separate the timing idle gear assembly.
 Disassembly of Engine - Water Drain Cock and Oil Filter 07-27

Water Drain Cock and Oil Filter

Removal
01
1. Remove the water drain cock.
(a) Remove the cotter pin of the water drain cock rod.
02

03

04

05

06
(b) Remove the water drain cock rod.
07

08

09

10

(c) Directly remove the water drain cock assembly with a

wrench.
y Remove the water drain cock.

2. Break down the water drain cock.

(a) Remove the bottom cotter pin of water drain cock and
break down the water drain cock.
 07-28 Disassembly of Engine - Water Drain Cock and Oil Filter

3. Remove the oil filter.

(a) Remove the fixing bolt of the oil filter assembly.

01

02

03

04
(b) Shock the oil filter assembly to be loose. Remove the
05 oil filter assembly.

06

07

08

09
(c) Remove the oil filter gasket.
10
 Disassembly of Engine - Oil Pressure Warning Unit and Support 07-29

Oil Pressure Warning Unit and Support

Removal
01
1. Remove the oil pressure warning unit.
(a) Remove the oil pressure warning unit and oil
02
pressure warning unit connector with a wrench.
03

04

05

06
2. Remove the right engine support.
(a) Remove the fixing bolts of the right engine support. 07

08

09

10

(b) Remove the right engine support.

3. Remove the left engine support.

(a) Remove the fixing bolts of the left engine support.
 07-30 Disassembly of Engine - Oil Pressure Warning Unit and Support

(b) Remove the left engine support.

01

02

03

04

05

06

07

08

09

10
 Disassembly of Engine - Oil Pan and Flywheel Housing 07-31

Oil Pan and Flywheel Housing

Removal
01
1. Remove the oil pan.
(a) Turn over the body and remove the fixing bolt & nut of
02
the oil pan.
03

04

05

06
(b) Shock the oil pan to be loose with the rubber hammer
and pry the oil pan. 07
Tip:
Pry it loose from all directions. Pay attention not to force 08
excessively and avoid causing the oil pan distortion.
09

10

(c) Remove the oil pan.

2. Remove the flywheel housing.

(a) Remove the fixing bolts of flywheel housing.
Tip:
The lengths of the flywheel housing bolts are different.
Loosen all the bolts firstly and don’t remove immediately.
After loosening all bolts, remove them one by one and
write down their installation positions, being convenient
for the installation.
 07-32 Disassembly of Engine - Oil Pan and Flywheel Housing

(b) Remove the flywheel housing.

y Remove the flywheel housing gasket.
Tip:
Due to the flywheel has a certain weight, be careful to
01 remove it. The best thing is two persons to co-operate to
complete it.
02

03

04

05

06

07

08

09

10
 Disassembly of Engine - Oil Pump and Camshaft 07-33

Oil Pump and Camshaft

Removal
01
1. Remove the oil pump.
(a) Remove the fixing bolt of oil pump outlet pipe.
02

03

04

05

06
(b) Remove the fixing nut of oil pump assembly.
07

08

09

10

(c) Pry the nut tip of oil pump assembly with crowbar
Tip:
The oil pump is installed on the body with a certain
gradient，so it is difficult to directly remove. It is necessary
to pry it with crowbar as shown in the figure.

(d) Remove the oil pump assembly.

Tip:
Slowly remove to avoid bumping.
 07-34 Disassembly of Engine - Oil Pump and Camshaft

2. Remove the camshaft.

(a) Remove the fixing bolts of camshaft thrust plate
（two）.

01

02

03

04
(b) Remove the camshaft.
05 Tip:
Be careful when removing the camshaft. Slowly remove
06 and avoid bumping between the camshaft and body.
Caution：
When removing the camshaft, the body camshaft
07
surface must be facing up. Let the lifter fall into the
lifter hole freely, it can remove camshaft smoothly.
08

09

10
 Disassembly of Engine - Timing Gear Chamber, Piston Assembly 07-35

Timing Gear Chamber, Piston Assembly

Removal
01
1. Remove Timing Gear Chamber
(a). Remove the fixing bolts for the timing gear chamber.
02

03

04

05

06
(b). Remove the timing gear chamber.
y Remove the bush for the timing gear chamber. 07
Tip:
Take the timing gear chamber out in parallel so as to 08
avoid contacting the crankshaft gear and damaging it.
09

10

2. Remove Piston Assembly

(a). Rotate the crankshaft until the pistons of the first and
fourth cylinders to the lowest point, 1.4., the piston
connecting rod vertically exposed.

(b). Loosen bolts for piston connecting rods of the first

and fourth cylinders.
Tip:
Loosen the bolts in pairs, but never take them out.
 07-36 Disassembly of Engine - Timing Gear Chamber, Piston Assembly

(c). Remove the connecting rod cap.

Tip:
Grasp the connecting rod bolts by both hands, rock the
connecting rod cap, or loosen it with a rubber hammer,
01 and then take the connecting rod cap out.
Caution:
02 y When removing the connecting rod cap, never
damage the surface with split end face of the
03 connecting rod or connecting rod cap. If the
surface with split end face is damaged, the
connecting rod and the connecting rod cap must
04 be changed, because it is good for lowering the
possibility of engine damage. Wrong assembly
05 will damage the connecting rod.
y Never put the connecting rod cap on the surface
06 with split end face, or it will damage the surface
with split end face.
07
(d). Take out the connecting rod bearing shell.
Caution:
08
Never damage the connecting rod bearing shell.
09

10

(e). Mark on the smooth surface of the positioning tongue

for the connecting rod bearing shell.

(f). Install the connecting rod bearing shell to the

corresponding connecting rod cap and protect it.
Disassembly of Engine - Timing Gear Chamber, Piston Assembly 07-37

(g). Clear the carbon deposit in the piston cylinder.

Caution:
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer. Goggles and 01
protective clothing shall be worn to avoid
personal injuries. 02
y Some solvents are inflammable and toxic. Before
use, carefully read the manual of the
03
manufacturer.

04
(h). Push out the piston assembly.
Tip: 05
The piston assembly shall be pushed out with a
substance made of wood or rubber. Never use those
06
made of metal to avoid damaging the end surfaces of the
connecting rod.
07

08

09
(i). Take out the piston assembly from the other side.
10

(j). Take down the connecting rod bearing shell and mark
it.

(k). Put the whole set of piston assembly parts together

and mark them.
Tip:
If these parts will be used continuously, the piston and the
connecting rod assembly must be mounted in the same
cylinder jacket for mounting, and the ground mating faces
must be ensured to be in correct fit.
 07-38 Disassembly of Engine - Timing Gear Chamber, Piston Assembly

(i). Rotate the crankshaft to expose the connecting rod

caps of cylinders 2 and 3.

01

02

03

04
(m). Remove the piston assemblies of the cylinders 2
05 and 3.
Tip:
06 If the piston assembly will not used at once, the
connecting rod and the piston assembly shall be put in the
container to avoid damage.
07

08

09

10
 Disassembly of Engine - Crankshaft and Lifter 07-39

Crankshaft and Lifter

Removal
01
1. Removal of Crankshaft Assembly
(a). Unscrew the bolts for the main bearing cover one by
02
one.
Tip:
The bolts shall be unscrewed one by one in a cross 03
manner. But never remove them.
04

05

06
(b). Remove the main bearing cover. Arrange them in
order. 07
Tip:
y Grasp the bolts for main bearing cover by both 08
hands, rock the main bearing cover, or loosen it with
a rubber hammer, and then take the main bearing 09
cover out.
y Each main bearing cover shall have a label for
assistance of memory. 10

(c). Remove the lower shell of the main bearing shell.

Tip:
Never forget to remove the thrust plates of the crankshaft.
Remember to record the installation positions and the
front and back faces to avoid mistake while installation.

(d). Mark each main bearing shell on its movable lug.

 07-40 Disassembly of Engine - Crankshaft and Lifter

(e). Install the bearing shells to the bearing shell covers

and put them in order.

01

02

03

04
(f). Take out the crankshaft assembly.
05 Tip:
The heavier component or assembly shall be lifted under
06 the assista
nce of others or by using suitable lifting equipment so as
to avoid serious personal injury.
07

08

09
(g). Take out the upper shells of the main bearing shell.
10 Tip:
The upper shells shall be taken out one by one and
marked with the cylinder number on the movable lugs.
Never forget to remove the thrust plates of the crankshaft.
Remember to record the mounting positions and the front
and back faces.

2. Removal of Lifter
(a). Attract the lifter out of the installation position with a
magnet, and put it in order.
Assembly of Engine
Assembly Instructions ..................................................08-1 01
Instructions ...............................................................08-1
Lifter and Crankshaft....................................................08-2
Installation ................................................................08-2 02
Timing Gear Chamber and Piston Assembly ...............08-5
Installation ................................................................08-5 03
Oil Pump and Camshaft ...............................................08-7
Installation ................................................................08-7 04
Flywheel Housing and Oil Pan ...................................08-13
Installation ..............................................................08-13 05
Support and Oil Pressure Warning Unit .....................08-15
Installation ..............................................................08-15
06
Oil Filter and Water Drain Cock..................................08-17
Installation ..............................................................08-17
Timing Idle Gear and Camshaft Timing Gear.............08-19 07
Installation ..............................................................08-19
Timing Gear Chamber Cover and Crankshaft Pulley .08-22 08
Installation ..............................................................08-22
Fuel Injection Pump ...................................................08-24 09
Installation ..............................................................08-24
Flywheel and Valve ....................................................08-26 10
Installation ..............................................................08-26
Hanger and Intake and Exhaust Manifold ..................08-28
Installation ..............................................................08-28
Cylinder Head ............................................................08-30
Installation ..............................................................08-30
Rocker Arm and Cylinder Head Cover .......................08-32
Installation ..............................................................08-32
Water Pump and Fan .................................................08-35
Installation ..............................................................08-35
Fuel Injector and Fuel Pipe ........................................08-38
Installation ..............................................................08-38
Oil Filler......................................................................08-42
Installation ..............................................................08-42
Breather and Dipstick.................................................08-43
Installation ..............................................................08-43
Generator and Starter ................................................08-44
Installation ..............................................................08-44
 07-2 Assembly of Engine - Crankshaft and Lifter

01

02

03

04

05

06

07

08

09

10
 Assembly of Engine - Assembly Instructions 08-1

Assembly Instructions
Instructions
01

02

03

04

05

06

07

08

09

10

1. This Chapter provides a whole process for assembling a complete set of diesel engine from top to
bottom as well as from inside to outside. The diesel engine is assembled layer by layer, as
introduced by both pictures and text.
2. The diesel engine assembled in this Chapter is the LL480 diesel engine of Yuling product series.
The assembly of LL380 and QC480 diesel engines is consistent with that of this diesel engine, and
this Chapter can be used for reference.
3. The diesel engine shall be assembled in such a safe place that is far away from fire, children, etc. as
much as possible.
4. The original components shall be assembled in the original positions before disassembly, without
neglecting any parts.
5. In the process of assembly, replace all paper gaskets which shall be out of service.
6. Make sure all parts to be assembled are good and free from contamination in the process of
assembly. Make sure each part is installed in position and fixed.
 08-2 Assembly of Engine - Lifter and Crankshaft

Lifter and Crankshaft

Installation
01
1. Install Lifter
02 (a). Place the crankcase side of the cylinder upwards and
stably.
Tip:
03
Make sure there are no impurities in the crankshaft.

04

05

06
(b). Place 8 lifters into the lifter mounting holes in order.
07 Tip:
Apply oil or equivalent on lifters and in lifter mounting
08 holes.

09

10

2. Install Crankshaft
(a). Install the upper shells of the main bearing shells to
the corresponding positions.
Tip:
Install the upper shells of the main bearing shells to the
corresponding positions carefully in order. Make sure that
the back of each bearing shell is clean, the upper shell of
each main bearing shell is in the center of the shell
groove, and the upper end faces are flush. Apply an
appropriate amount of oil or equivalent on the inner side of
the arched surface of each bearing shell after installation.

Caution:
Make sure that the locating lugs of the bearing shells
are aligned with the locating grooves on the cylinder
saddle of the main bearing shells during installation.
Assembly of Engine - Lifter and Crankshaft 08-3

(b). Install the crankshaft assembly to the corresponding

position.
Caution:
y As this component is heavy, in order to avoid
serious personal injuries, this component or 01
assembly shall be lifted with the help of others or
by suitable hoisting equipment.
y The crankshaft shall be installed carefully to 02
avoid damaging the main bearing, especially the
thrust/main bearing journal. The service life of the 03
engine will be shortened once the crankshaft is
damaged. 04

(c). Apply oil on the lower shell of each main bearing 05

shell, and install it to the main bearing cover.
Tip:
Slide the lower shell of the main bearing shell into the 06
main bearing cover from one side, and flatten the end
face. 07

08

09

Caution: 10
Make sure that the locating lugs of the bearing shells
are aligned with the locating grooves on the main
bearing cover during installation.

(d). Install the crankshaft thrust washer and bearing shell

at the rear main bearing cover side to the rear main
bearing cover.
Caution:
y Make sure that the locating lugs of the bearing
shells are aligned with the locating grooves on
the main bearing cover during installation.
y Make sure that the side of the crankshaft thrust
washer with a groove is outward during
installation.

(e). Install the main bearing covers in order.

Tip:
y When installing the rear main bearing cover, note that
the crankshaft thrust washers may fall off.
y Install the main bearing covers to the original
positions according to their marks without any
mistake.
 08-4 Assembly of Engine - Lifter and Crankshaft

(f). Place the main bearing cover bolts into mounting

holes in order, and screw them up slightly with hands.
Tip:
Drop an appropriate amount of oil on the threads of the
01 main bearing cover bolts.

02

03

04
(g). Screw up the main bearing cover bolts according to a
05 certain order and torque.

06 Model Torque (N·m)

LL380 135~150
LL480 135~150
07
QC480 120~130
08

09
Tip:
10 y The bolts shall not be tightened once but screwed
little by little until reaching the specified torque
gradually.
y The main bearing cover bolts must be tightened in a
certain order (as shown in the left picture).

Tip:
The crankshaft installed shall be rotated for several circles to check whether the rotation is smooth and
flexible.
 Assembly of Engine - Timing Gear Chamber and Camshaft 08-5

Timing Gear Chamber and Camshaft

Installation
01
1. Install Timing Gear Chamber
(a). Install the gear chamber gasket. 02
Tip:
The gear chamber gasket to be installed shall be new,
03
and the incomplete gasket on the engine body shall be
cleared away before installation.
04

05

06
(b). Install the timing gear chamber.
07

08

09

10

(c). Install timing gear chamber fixing bolts and tighten.

Tip:
Never tighten one bolt overly once, and the timing gear
chamber fixing bolts shall be tightened alternately layer by
layer.

2. Install Camshaft Assembly

(a). Apply an appropriate amount of grease or equivalent
on the inner wall of the rear camshaft hole.
 08-6 Assembly of Engine - Timing Gear Chamber and Camshaft

(b). Apply an appropriate amount of grease or equivalent

on the cam and journal of the camshaft.

01

02

03

04
(c). Slowly install the camshaft to the installation position.
05 Caution:
y Before installing the camshaft, make sure that the
06 lifters has been inserted into lifter mounting
holes completely. If the lifters have not been
inserted completely, the camshaft may be
07 damaged during installation.
y When installing the camshaft, it is necessary to
08 place the crankcase side of the engine body
upwards, and allow the lifters to fall into the
09 mounting holes freely, which is convenient for
the installation of the camshaft.
10 y Rotate the camshaft and carefully put it through
the camshaft bushing. When all camshaft
journals pass through the bushing, the camshaft
shall be placed down a little, and the camshaft is
fixed in the bushing. Rotating the camshaft will
separate the camshaft from the bushing, and the
camshaft can be installed again.

(d). Install camshaft thrust plate fixing bolts.

Tip:
Rotate the camshaft, and check whether the camshaft can
rotate freely.
Caution:
Never rotate the camshaft forcibly; otherwise, the
camshaft bushing will be damaged. If the camshaft
fails to rotate freely, it is necessary to analyze the
cause and re-install it.
 Assembly of Engine - Piston Assembly and Oil Pump 08-7

Piston Assembly and Oil Pump

Installation
01
1. Install Piston Assembly
(a) Install the upper shell of the connecting rod bearing 02
shell.
Tip:
03
The cylinder and all parts must be kept clean before
assembly. Clean the connecting rod and bearing shell by
a piece of clean lint-free cloth. 04
Caution:
Make sure that the connecting rod and the back side 05
of the connecting rod bearing are clean, free from any
debris. The back side of the connecting rod bearing 06
shall not be lubricated.
07
Caution:
Make sure that the locating lugs of the bearing shells
are aligned with the locating lugs on the connecting 08
rod during installation.
09

10

(b) Drop clean oil or equivalent on the inner side of the

bearing shell.

(c) Lubricate the piston ring and piston skirt with clean
oil.
 08-8 Assembly of Engine - Piston Assembly and Oil Pump

(d) Rotate and adjust the opening position of the piston

ring according to the left picture.
Tip:
The opening of each piston ring shall not be aligned with
01 the openings of the piston pins or other piston rings. If the
opening position of the piston ring is incorrect, the piston
02 ring can not be sealed correctly.

03

04
(e) Compress the piston ring to the working position by a
05 piston ring compressor.
Tip:
06 It is allowable to make an annular cylinder if there are no
special tools.
07

08

09
(f) Rotate the crankshaft to allow the journal of the
10 connectingp rod to be installed to stay at the bottom
dead center.

(g) Apply a thick layer of oil on the cylinder wall.

(h) Insert the connecting rod into the cylinder hole, until
the piston ring compressor touches the cylinder top.
Assembly of Engine - Piston Assembly and Oil Pump 08-9

Tip:
Align the arrow on the piston top to allow it to point to the
engine front. The big end of the connecting rod and the
notch on the piston skirt shall stay at the exhaust side of
the engine. If not, check whether the piston is installed on 01
the connecting rod correctly.
Caution: 02
Noncompliance with this procedure will cause
serious damage to the engine.
03

04
(i) Support the cylinder with the piston ring compressor,
put the piston through the piston ring compressor and 05
push into the cylinder hole.
Caution:
06
If the piston can not move freely, remove it and check
whether the piston ring is broken or damaged.
07

08

09
(j)Install the lower shell of the connecting rod bearing
shell to the connecting rod bearing shell cover. 10
Caution:
y Make sure that the connecting rod cap and the
back side of the connecting rod bearing are
clean, free from any debris. The back side of the
connecting rod bearing shall not be lubricated.
y If a new bearing is unavailable, the old one must
be installed on the same connecting rod from
which it is removed.

Caution:
Make sure that the locating lugs of the bearing shells
are aligned with the locating grooves on the
connecting rod cap during installation.

(k) Lubricate the inner side of the lower shell of the

connecting rod bearing shell with clean oil.
 08-10 Assembly of Engine - Piston Assembly and Oil Pump

(l) Install each connecting rod cap to the journal

corresponding to its crankshaft.

01

02

03

04
Caution:
05 The No. of the connecting rod must be the same with
that of the connecting rod cap, and must be installed
06 in the correct cylinder. The No. of both the connecting
rod and connecting rod cap must be located at the
same side of the connecting rod to avoid damage to
07 the engine during running.

08

09
(m) Lubricate connecting rod bolts with clean oil or
10 equivalent grease.

(n) Screw up connecting rod bolts, and tighten them

alternately time and again with a torque wrench
according to the angular tightening method.
Tip:
The connecting rods need tightening alternately and
gradually in pair

Model Torque (N·m)

LL380 55~65
LL480 55~65
QC480 50~60
Assembly of Engine - Piston Assembly and Oil Pump 08-11

(o) Measure the clearance between the connecting rod

body and crankshaft.
Tip:
Do not measure the backlash between the connecting rod
cap and crankshaft. 01

Model Nominal Value Limit Value 02

LL380 0.04~0.101mm 0.20 mm
LL480 0.04~0.101mm 0.20 mm 03
QC480 -- --
Tip: 04
If the piston, crankshaft, connecting rod or cylinder is
changed/replaced, it is necessary to measure the
extrusion of the piston from the cylinder combustion front. 05
The steps are as follows:
y Install a dial indicator on the cylinder head, and zero 06
it.
y Move the dial indicator over the piston top to 07
eliminate all sidewise movements.
y Rotate the crankshaft to the top dead center. Rotate 08
the crankshaft clockwise and counterclockwise,
observe the maximum reading of the dial indicator,
09
and record the measurement results. Judge the
result.
10

2. Install Oil Pump Assembly

(a) Apply lubricating oil on the oil pump gears, and place
the oil pump assembly to the installation position.

(b) Install oil pump assembly fixing nuts.

Tip:
Do not screw up too tightly.
 08-12 Assembly of Engine - Piston Assembly and Oil Pump

(c) Install oil pump assembly fixing bolts.

Tip:
Tighten the oil pump assembly fixing nuts and bolts
alternately in order.
01

02

03

04

05

06

07

08

09

10
 Assembly of Engine - Flywheel Housing and Oil Pan 08-13

Flywheel Housing and Oil Pan

Installation
01
1. Install Flywheel Housing
(a) Place the flywheel housing to the installation position. 02
Tip:
Never forget to install the flywheel housing gasket before
03
installation, and pay attention to safety because the
flywheel housing is heavy.
04

05

06
(b) Install flywheel housing fixing bolts and tighten.
Tip: 07
Tighten flywheel housing fixing bolts by hand at first, and
then tighten them alternately layer by layer. 08

09

10

2. Install Oil Pan

(a) Apply appropriate sealant at the engine’s position to
install the oil pan gasket.
y Install a new gasket.

(b) Close the oil pan.

y Screw up all oil pan fixing nuts and bolts by
hand.
Tip:
Do not neglect any one, and clean and check the threads
and sealing surface of the drain plug.
 08-14 Assembly of Engine - Flywheel Housing and Oil Pan

(c) Tighten all oil pan fixing nuts and bolts.

Tip:
Never tighten some bolt or nut overly once.

01

02

03

04
Tip:
05 Tighten all bolts in an order as shown in the left picture.

06

07

08

09

10
 Assembly of Engine - Support and Oil Pressure Warning Unit 08-15

Support and Oil Pressure Warning Unit

Installation
01
1. Install Left Engine Support
(a) Place the left support to the installation position. 02

03

04

05

06
(b) Screw up left support fixing bolts and tighten.
07

08

09

10

2. Install Right Engine Support

(a) Place the right support to the installation position.

(b) Screw up right support fixing bolts and tighten.

 08-16 Assembly of Engine - Support and Oil Pressure Warning Unit

3. Install Oil Pressure Warning Unit

(a) Put on the oil pressure warning unit and oil pressure
warning adaptor as shown in the picture, and tighten.

01

02

03

04

05

06

07

08

09

10
 Assembly of Engine - Oil Filter and Water Drain Cock 08-17

Oil Filter and Water Drain Cock

Installation
01
1. Install Oil Filter
(a) Install the oil filter assembly gasket. 02
Tip:
Apply sealant at the engine’s position to install the oil filter,
03
and change a new gasket.

04

05

06
(b) Place the oil filter assembly assembled to the
installation position, align with the mounting holes, 07
and screw up oil filter fixing bolts by hand.
08

09

10

(c) Tighten the oil filter fixing bolts.

2. Install Water Drain Cock

(a) Assemble the water drain cock..
 08-18 Assembly of Engine - Oil Filter and Water Drain Cock

(b) Place the water drain cock assembly to the

installation position and tighten.

01

02

03

04
(c) Put on the water drain cock rotating rod, and align it
05 with the mounting hole.

06

07

08

09
(d) Install the cotter pin for the water drain cock rotating
10 rod.
 Assembly of Engine - Timing Idle Gear and Camshaft Timing Gear 08-19

Timing Idle Gear and Camshaft Timing Gear

Installation
01
1. Install Timing Idle Gear
(a) Install the timing idle gear shaft on the cylinder. 02
Tip:
It is necessary to install the oil hole in the idle gear shaft
03
upwards, and make sure that the oil hole in the idle gear
shaft is aligned with that in the cylinder.
04

05

06
(b) Rotate the crankshaft to allow the teeth with marks at
the side edge of the crankshaft timing gear to point to 07
the installation of the timing idle gear.
08

09

10

(c) Place the timing idle gear assembly to the installation

place.

Caution:
Make sure that the timing mark on the crankshaft
timing gear is aligned with that on the timing idle
gear, as shown in the left picture.
 08-20 Assembly of Engine - Timing Idle Gear and Camshaft Timing Gear

(d) Install the timing idle gear pressure plate.

01

02

03

04
(e) Install timing idle gear fixing bolts and tighten.
05 Tip:
Rotate the crankshaft after installation and check whether
06 the timing idle gear is installed in position. Check with a
feeler gauge whether the axial clearance of the idle gear
meets the standard.
07 Reference Clearance: 0.07mm
Reference Limit: 0.2mm
08

09
2. Install Camshaft Timing Gear
10 (a) Place the camshaft timing gear to the installation
place.

Caution:
Check and make sure that the timing mark on the
camshaft gear is aligned with that on the timing idle
gear.
Assembly of Engine - Timing Idle Gear and Camshaft Timing Gear 08-21

(b) Install the camshaft timing gear pressure plate.

01

02

03

04
(c) Install camshaft timing gear fixing bolts and tighten.
Tip: 05
Check whether the gear backlash meets the standard
after installation. 06
Reference Gear Backlash: 0.1~0.17mm
Reference Backlash Limit: 0.3mm
07

08

09

10
 08-22 Assembly of Engine - Timing Gear Chamber Cover and Crankshaft Pulley

Timing Gear Chamber Cover and Crankshaft Pulley

Installation
01
1. Install Timing Gear Chamber Cover
02 (a) Install the timing gear cover gasket.
Tip:
Make sure that all dowel pins for the gear chamber are
03
installed.

04

05

06
(b) Place the timing gear cover to the installation
07 position.
Tip:
08 Align the dowel pins, screw timing gear cover fixing bolts
by hand, and note that long and short bolts shall be
09 installed to their original positions.

10

(c) Tighten all bolts alternately and diagonally.

2. Install Crankshaft Pulley

(a) Place the crankshaft pulley to the installation position.
Caution:
Check and make sure that the notch mark on the
crankshaft shall be aligned with the pointer position
on the timing gear chamber cover.
Assembly of Engine - Timing Gear Chamber Cover and Crankshaft Pulley 08-23

(b) Put on the starting claw gasket, screw up the starting

claw and tighten.
Tip:
When screwing up the starting claw, fix the crankshaft to
limit its rotation. For example, jam the timing idle gear with 01
a wrench. Different methods can be adopted flexibly
according to different removal and installation orders. The 02
assembly process of this Manual is only used as an
appropriate reference. 03

04

05

06

07

08

09

10
 08-24 Assembly of Engine - Fuel Injection Pump

Fuel Injection Pump

Installation
01
1. Install Fuel Injection Pump
02 (a) Install the fuel injection pump gasket.

03

04

05

06
(b) Install the fuel injection pump assembly.
07

08

09

10

(c) Screw up three fixing bolts for fuel injection pump and
tighten.

(d) Install the advancer assembly.

Assembly of Engine - Fuel Injection Pump 08-25

(e) Check whether the mark on the advancer is aligned

with that on the timing idle gear; if not, align them.

01

02

03

04
Caution:
Make sure all marks on timing gears are aligned. 05

06

07

08

09
(f) Screw up advancer fixing nuts and tighten.
Tip: 10
Do not neglect washers inside.

(g) Close the gasket of the timing gear chamber front

cover and timing gear chamber front cover.

(h) Install the fixing bolts for timing gear chamber front
cover and tighten.
 08-26 Assembly of Engine - Flywheel and Valve

Flywheel and Valve

Installation
01
1. Install Flywheel
02 (a) Place the flywheel to the installation position.

03

04

05

06
(b) Install the flywheel bolt gasket.
07

08

09

10

(c) Screw up flywheel fixing bolts and tighten.

Model Torque (N·m)

LL380 50~60
LL480 50~60
QC480 60~70

2. Install Valve
(a) Lubricate all valve guide holes and valve stems with
clean oil.
Tip:
Failure to lubricate valve guides and valve stems will
cause the early wear of valve guides.
Assembly of Engine - Flywheel and Valve 08-27

(b) Place valve stems to the installation position.

Tip:
If the valve to be installed is the same with the valve
removed previously, make sure than the valve is installed
at the position where the valve is removed. At the same 01
time, a new oil seal will be used.
02

03

04
(c) Install internal and external valve springs and upper
valve spring seat. 05
Caution:
Once the valve oil seal is removed, it shall be
06
replaced. Refer to Chapter 09 Mechanical System,
Valve for the detailed replacement method.
07

08

09
(d) Compress valve springs with a valve spring
compressor, and expose the installation positions for 10
valve lock clamps.

(e) Install valve lock clamps, and then release the valve
spring to allow the valve lock clamps to clock the
valves. After assembly, strike valve spring seats with
a plastic hammer to make sure the lock clamps are
installed correctly.
Caution:
In order to reduce the possibility of personal injuries,
wear goggles. If the lock clamps are installed
incorrectly, when the valve spring seats are struck
with the plastic hammer, the lock clamps will fly.
 08-28 Assembly of Engine - Hanger and Intake and Exhaust Manifolds

Hanger and Intake and Exhaust Manifolds

Installation
01
1. Install Rear Hanger
02 (a) Place the rear hanger to the installation position,
screw up hanger fixing bolts and tighten.
03

04

05

06
2. Install Front Hanger
07 (a) Place the front hanger to the installation position,
screw up hanger fixing bolts and tighten.
08

09

10

3. Install Intake Manifold

(a) Place four intake manifold gaskets to the installation
position.

(b) Place the intake manifold assembly to the installation

position.
Tip:
The intake manifold may be installed after the cylinder
head is installed. The assembly order in this Manual is
only use for reference.
Assembly of Engine - Hanger and Intake and Exhaust Manifolds 08-29

(c) Screw up intake manifold fixing nuts and tighten.

Tip:
Tighten nuts alternately and diagonally.

01

02

03

04
4. Install Exhaust Manifold
(a) Place four exhaust manifold gaskets to the 05
installation position.
06

07

08

09
(b) Place the exhaust manifold assembly to the
installation position. 10
Tip:
The exhaust manifold may be installed after the cylinder
head is installed. The assembly order in this Manual is
only use for reference.

(c) Screw up exhaust manifold fixing bolts and nuts and

tighten.
Tip:
Tighten bolts and nuts alternately and diagonally.
 08-30 Assembly of Engine - Cylinder Head and Tappet

Cylinder Head and Tappet

Installation
01
1. Install Cylinder Head Assembly
02 (a) Install the cylinder head gasket in position.
Tip:
Make sure that the gasket is aligned with the holes in the
03
cylinder. If the gasket is not aligned correctly, the cylinder
may be damaged.
04

05

06
(b) Carefully hoist the cylinder head assembly on the
07 cylinder and align.
Tip:
08 As this component is heavy, in order to avoid serious
personal injuries, this component or assembly shall be
09 lifted with the help of others or by suitable hoisting
equipment.
10

(c) Screw up cylinder head fixing bolts and tighten.

Tip:
Lubricate the threads and the part below bolt end of
cylinder head fixing bolts with clean oil.

Model Torque (N·m)

LL380 135~150
LL480 135~150
QC480 150~170

Caution:
The cylinder head bolts shall be tightened, little by
little time and again, to specified value in the order
shown in the left picture.
Assembly of Engine - Cylinder Head and Tappet 08-31

2. Install Tappet
(a) Place valve tappets in the mounting holes in a
reverse order for removal one by one.

01

02

03

04
(b) Drop clean oil on the bowl-shaped groove of each
tappet. 05

06

07

08

09

10
 08-32 Assembly of Engine - Rocker Arm and Cylinder Head Cover

Rocker Arm and Cylinder Head Cover

Installation
01
1. Assemble Rocker Arm Assembly
02 (a) Put rocker arms, rocker arm springs, rocker arm shaft
supports through the rock arm shaft in a reverse
order for removal.
03
Tip:
It is necessary to apply clean oil on the rocker arms,
04 rocker arm shaft support holes and rocker arm shaft
surface.
05

06
(b) Align the locating holes of the rear rocker arm shaft
07 supports with the holes of the rocker arm shaft, and
screw up rocker arm shaft locating screw.
08

09

10

(c) Install rocker arm retainer rings with circlip pliers.

Caution:
The retainer rings are elastic and easy to move. Pay
attention during installation, and it is better to wear
goggles.

2. Install Rocker Arm Assembly

(a) Place the rocker arm assembly to the installation
position gently, and align mounting holes.
Assembly of Engine - Rocker Arm and Cylinder Head Cover 08-33

(b) Screw up rocker arm assembly fixing bolts and

tighten.
Tip:
Do not tighten at the moment, and tighten them in order
after installing rocker arm assembly fixing nuts. 01

02

03

04
(c) Screw up rocker arm assembly fixing nuts and
tighten. Then tighten rocker arm assembly bolts and 05
nuts alternately in pair.
06

07

08

09
3. Adjust Valve Clearance
(a) Measure and adjust the valve clearance (refer to 10
Chapter 09 Mechanical System, Valve).

4. Install Cylinder Head Cover

(a) Close the cylinder head cover.
Tip:
If the cylinder head cover gasket needs replacing due to
aging or corrosion, directly install it on the cylinder head
cover.

(b) Screw up cylinder head cover bolts and tighten.

 08-34 Assembly of Engine - Rocker Arm and Cylinder Head Cover

(c) Close the filler cap.

01

02

03

04

05

06

07

08

09

10
 Assembly of Engine - Water Pump and Fan 08-35

Water Pump and Fan

Installation
01
1. Install Water Pump
(a) Install the water pump assembly. 02
Caution:
Never neglect the water pump gasket. Apply a small
03
amount of sealant around the water passage opening
when installing the water pump gasket.
04

05

06
(b) Screw up water pump fixing bolts and tighten.
07

08

09

10

2. Install Thermostat Assembly

(a) Assemble the thermostat assembly according to the
assembly relationship as shown in the left picture.

(b) Place the thermostat assembly to the installation

position, and screw up fixing bolts by hand.
Caution:
Never neglect the thermostat housing gasket.
 08-36 Assembly of Engine - Water Pump and Fan

(c) Tighten thermostat assembly fixing bolts.

01

02

03

04
(d) Install the water pump manifold hose.
05 Tip:
When installing the manifold hose, it is necessary to apply
a little sealant or equivalent on the inner wall of the
06
manifold hose, which is favorable for installation and
sealing.
07

08

09
(e) Tighten the double-steel wire ring.
10

3. Install Water Pump Pulley

(a) Put on the water pump pulley to the installation
position.

(b) Install the water pump belt.

Tip:
Put on the water pump belt before installing the fan, which
is convenient for the installation of subsequent belts.
Assembly of Engine - Water Pump and Fan 08-37

4. Install Fan
(a) Place the fan to the installation position, and align the
mounting holes.

01

02

03

04
(b) Screw up fan fixing bolts by hand and tighten by
wrench. 05
Tip:
Rotate the fan, and check whether the fan is installed in
06
position.
07

08

09

10
 08-38 Assembly of Engine - Fuel Injector and Fuel Pipe

Fuel Injector and Fuel Pipe

Installation
01
1. Install Fuel Injector
02 (a) Install the injector copper gasket on the fuel injector.
Tip:
In order to prevent the copper gasket from falling when
03
installing the fuel injector, apply a little lithium-based
lubricating oil on it during installation.
04

05

06
(b) Place the fuel injector to the installation position.
07 Tip:
The fuel inlet holes of the fuel injector shall face the intake
08 side of the engine.

09

10

(c) Screw up fuel injector fixing nuts and tighten.

Tip:
Tighten the fuel injector fixing nuts alternately time and
again as well as little by little.

2. Install Diesel Filter

(a) Place the diesel filter to the installation position.
Assembly of Engine - Fuel Injector and Fuel Pipe 08-39

(b) Screw up diesel filter fixing bolts and tighten.

01

02

03

04
3. Install High-pressure Fuel Pipe
(a) Place high-pressure fuel pipes assembly to the 05
installation position.
Tip:
06
When installing high-pressure fuel pipes, put them in from
the lower end of the intake manifold. Never remove the
high-pressure fuel pipe joint covers early. 07

08

09
(b) Remove the high-pressure fuel pipe joint covers, and
connect the high-pressure fuel pipes with the fuel 10
injection pump.
Tip:
Never directly tighten too much, and tighten one by one
wholly after the other end is installed.

(c) Connect the joints of the high-pressure fuel pipes and

fuel injector, and tighten with nuts.
Tip:
Tighten high-pressure fuel pipes in pair at the moment.

4. Install Fuel Return Pipe

(a) Remove hollow fixing bolts for fuel return pipe from
the fuel injector, and place the fuel return pipe to the
installation position.
 08-40 Assembly of Engine - Fuel Injector and Fuel Pipe

(b) Screw up hollow fixing bolts for fuel return pipe and
tighten.

01

02

03

04
5. Install Fuel Line
05 (a) Place the fuel pipe from the fuel filter to fuel injection
pump to the installation position.
06

07

08

09
(b) Screw up hollow bolts for fuel pipe joint and tighten.
10

(c) Place the fuel pipe from the fuel supply pump to fuel
filter to the installation position.

(d) Screw up hollow bolts for fuel pipe joint at the fuel
supply pump end and tighten.
Assembly of Engine - Fuel Injector and Fuel Pipe 08-41

(e) Screw up hollow bolts for fuel pipe joint at the diesel
filter end and tighten.

01

02

03

04

05

06

07

08

09

10
 08-42 Assembly of Engine - Oil Filler

Oil Filler
Installation
01
1. Install Oil Filler
02 (a) Place the oil filler assembly to the installation
position.
03

04

05

06
(b) Screw up oil filter fixing bolts and filler support fixing
07 bolts and tighten.

08

09

10
 Assembly of Engine - Breather and Dipstick 08-43

Breather and Dipstick

Installation
01
1. Install Breather Assembly
(a) Place the breather assembly to the installation 02
position.
03

04

05

06
(b) Screw up breather assembly fixing bolts and tighten.
07

08

09

10

2. Install Dipstick Assembly

(a) Insert the dipstick assembly into the dipstick
mounting hole.

(b) Tighten the dipstick.

 08-44 Assembly of Engine - Generator and Starter

Generator and Starter

Installation
01
1. Install Generator
02 (a) Install the generator support, and place the generator
assembly with vacuum pump on it. Screw up
adjusting bolts at the upper end of the generator by
03
hand.

04

05

06
(b) Screw fixing bolts at the lower end of the generator
07 and tighten.

08

09

10

(c) Adjust the position of the generator, and install the

generator belt.

(d) Tighten the adjusting bolts at the upper end of the

generator.
Assembly of Engine - Generator and Starter 08-45

(e) Press down the generator belt by force, and check

whether the belt is installed in position.
Reference Standard:
39N force, with a deflection of about 10~15mm.
01

02

03

04
2. Install Vacuum Line
(a) Fix the inlet and outlet pipes of the vacuum pump by 05
hollow bolts and tighten.
06

07

08

09
3. Install Starter
(a) Place the starter assembly to the installation position. 10

(b) Screw up starter fixing bolts and tighten.

 - 08-46
Memo - Assembly of Engine - Generator and Starter

01

02

03

04

05

06

07

08

09

10
Mechanical System
Cylinder Head ..............................................................09-1 01
Parts Drawing ...........................................................09-1
Overhaul ...................................................................09-3
Rocker Arm Assembly................................................09-22 02
Parts Drawing .........................................................09-22
Overhaul .................................................................09-23 03
Valve ..........................................................................09-32
General...................................................................09-32 04
Adjustment..............................................................09-33
Overhaul .................................................................09-57 05
Camshaft and Tappet.................................................09-53
Parts Drawing .........................................................09-53
06
Overhaul .................................................................09-54
Piston and Connecting Rod Assembly .......................09-67
Parts Drawing.............................................................09-67 07
Overhaul .................................................................09-68
Crankshaft and Flywheel Assembly ...........................09-83 08
Parts Drawing .........................................................09-83
Overhaul .................................................................09-84 09
Engine Body...............................................................09-93
Parts Drawing .........................................................09-93 10
Overhaul .................................................................09-95
 08-2 Mechanical System - Generator and Starter

01

02

03

04

05

06

07

08

09

10
 Mechanical System - Cylinder Head 09-1

Cylinder Head
Part Drawing
01

02

03

04

05

06

07

08

09

10
 09-2 Mechanical System - Cylinder Head

1 Filler Cap 20 Valve Guide

2 Acorn Num M8 21 Oil Gallery Plug φ6
3 Gasket 22 Bowl-shaped Plug φ32
01 4 Rivet 2×6 23 Bolt M8×25
5 General Nameplate 24 Thermostat Housing Gasket
02
6 Cylinder Head Cover 25 Cylinder Head
7 Cylinder Head Cover Gasket 26 Bolt M8×60
03
8 Nut M8 27 Bowl-shaped Plug φ25
04 9 Washer 8 28 Intake Pipe Gasket
10 Bolt M8×30 29 Bolt M8×25
05 11 Exhaust Pipe Gasket 30 Front Hanger
12 Washer 8 31 Exhaust Valve Seat
06
13 Fastening Bolt, Rocker Arm Support 32 Exhaust Valve

07 14 Bolt M8×20 33 Intake Valve Seat

15 Upper Valve Spring Seat 34 Intake Valve
08 16 Valve Lock Clamp 35 Locating Screw, Rocker Arm Shaft
17 Outer Valve Spring 36 Washer 6
09
18 Inner Valve Spring 37 Rocker Arm Assembly
19 Valve Oil Seal
10
 Mechanical System - Overhaul 09-3

Overhaul
Caution:
During removal, the parts of the valve group must be concentrated together and marked with
identification codes so as to return them to their original positions in installation again. Before 01
removing the cylinder head from the engine and disassembling the valve mechanism, the
compression test shall be performed, and the results shall be recorded. 02

1. Perform Initial Inspection for Engine 03

(a) Clean the outside of the engine with steam or a
high-pressure water gun. 04
Caution:
When using the steam cleaner, wear goggles or
protective mask and protective clothing. Otherwise, 05
hot steam may cause serious personal injuries.
06

07

08

09

10

(b) Allow the engine to fun at low idle speed, and check
whether the part between the cylinder head and
engine cylinder leaks oil or coolant.
 09-4 Mechanical System - Overhaul

(c) Listen to whether the part between the cylinder head

and engine cylinder chatters.
Tip:
If the engine chatters when accelerating, it indicates that
01 the combustion chamber leaks.
The method for confirming leakage is: Fill the coolant
02 reservoir with water until the overflow pipe of the coolant
reservoir is immersed, allow the engine to run at high idle
03 speed, open the thermostat and observe whether there
are steam bubbles in the water. This will prove that the
combustion chamber leaks.
04 Caution:
If detecting leakage, remove and check the cylinder
05 head and all relevant parts.

06

07 2. Remove Fuel Injector Assembly

(a) Remove fixing bolts (totally four) for fuel return pipe
08 on the fuel nozzle.
Tip:
09 Make sure that combined sealing washers for fuel pipe
will not miss, which will be used for installation.
10

(b) Take out the fuel return pipe upwards.

(c) Remove connecting nuts (totally four) on the fuel

injector and high-pressure fuel pipe.
Mechanical System - Overhaul 09-5

(d) Remove fixing bolts on the fuel nozzle, and take out
the spring washer and flat washer.

01

02

03

04
(e) Remove the fuel nozzle.
Tip: 05
Pry it with a crowbar.
06

07

08

09
3. Remove Cylinder Head Cover
(a) Remove the filler cap, and rotate it counterclockwise 10
to take down.

(b) Check whether the filler cap crack or is corroded, and

replace if any.
Tip:
Observe whether there is water vapor in the filler cap; if
any, it indicates coolant goes into the cylinder. Carefully
check the cylinder gasket, cylinder head and water
passage are damaged; if any, maintain or replace
damaged parts.

(c) Remove four fixing nuts on the cylinder head cover.

y Take out sealing washers.
 09-6 Mechanical System - Overhaul

(d) Take out the cylinder head cover upwards.

y Take out the cylinder head cover gasket

01

02

03

04
(e) Clean the cylinder head cover by solvent, and acid or
05 alkaline substances.
Caution:
06 y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer.
07 y Goggles and protective clothing shall be worn to
avoid personal injuries.
08 y Some solvents are flammable and toxic; before
use, carefully read the manual of the
09 manufacturer.

10 (f) Dry the cylinder head cover by compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.

(g) Check whether the cylinder head cover cracks, and

replace if any.

(h) Check whether the cylinder head cover ages,

deforms or is corroded, and replace if any.
Mechanical System - Overhaul 09-7

4. Remove Rocker Arm Assembly

(a) Remove rocker arm locking nuts.
y Take out the spring washer and flat washer.
01

02

03

04

(b) Remove rocker arm fixing bolts. 05

y Take out the spring washer and flat washer.
06

07

08

09

(c) Clean bolts with gasoline-based solvent. Clear away 10

deposit on the bolt bar and threads completely by a
steel wire brush, soft steel wire wheel brush or
non-abrasive shot blasting.
Caution:
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
avoid personal injuries.
y Some solvents are flammable and toxic. Before
use, carefully read the manual of the
manufacturer.
y Never clean cylinder head bolts with acid or
alkaline solutions; otherwise, parts will be
damaged.

(d) Check visually whether there are damaged threads or

corroded surface on cylinder head bolts, and replace
if any.
 09-8 Mechanical System - Overhaul

(e) Check whether the threads of fixing bolts are

damaged, and replace if any; in addition, check two
washers below each nut, and replace if there are
cracks or damages.
01

02

03

04
(f) Take out the rocker arm assembly.
05

06

07

08

09
5. Remove Cylinder Head Assembly
10 (a) Take out the tappet.
Tip:
Clean the tappet and mark for installation.

(b) Remove cylinder head fixing bolts.

Caution:
Carefully clear away all sludge, carbon black and
carbon deposit on the cylinder head bolts and
cylinder head, and the motor wire brush is not
suitable for the gasket.

Tip:
Remove cylinder head fixing bolts according to the order
as shown in the left picture.
Caution:
The fixing bolts shall be removed diagonally step by
step, and failure to do so will cause harmful influence
on the lower surface of the cylinder head.
Mechanical System - Overhaul 09-9

(d) Clean bolts with gasoline-based solvent. Clear away

deposit on the bolt bar and threads completely by a
steel wire brush, soft steel wire wheel brush or
non-abrasive shot blasting.
Caution: 01
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage 02
proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
03
avoid personal injuries.
y Some solvents are flammable and toxic. Before
use, carefully read the manual of the 04
manufacturer.
y Never clean cylinder head bolts with acid or 05
alkaline solutions. Otherwise, parts will be
damaged. 06

(e) Check visually whether there are damaged threads or 07

corroded surface on cylinder head bolts, and replace
if any.
08

09

10

(f) Check whether the threads of fixing bolts are

damaged, and replace if any; in addition, check two
washers below each nut, and replace if there are
cracks or damages.

(g) Fix the hanger with rope, and take out the cylinder
head.
Caution:
As the cylinder head assembly is heavy, in order to
avoid serious personal injuries, this assembly must
be lifted by two persons or by suitable hoisting
equipment.
 09-10 Mechanical System - Overhaul

(h) Remove the intake manifold assembly.

Tip:
y Check whether bolts and nuts on the cylinder head
and intake port are damaged, and replace if any.
01 y Check whether the plane of the cylinder head and the
plane of intake manifold fitting surface (which can be
02 trimmed by grinding and cutting method)

03

04
(i) Remove the exhaust manifold assembly.
05 Tip:
y Check whether bolts and nuts on the cylinder head
06 and exhaust port are damaged, and replace if any.
y Check whether the plane of the cylinder head and the
plane of exhaust manifold fitting surface (which can
07 be trimmed by grinding and cutting method)

08

09
6. Remove Valve
10 (a) Compress valve springs with special tools, and
remove valve lock clamps.
Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
injuries, goggles with side guard shall be worn.

(b) Take out valve lock clamps.

Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
injuries, goggles with side guard shall be worn.

(c) Check whether the valve lock clamps crack or are

damaged, and replace if any.
Mechanical System - Overhaul 09-11

(d) Take out the valve spring seat and valve spring.

01

02

03

04
(e) Take out the valve oil seal by a screwdriver or special
tools for removing valve oil seal. 05
Caution:
The valve oil seals are wearing parts, so they shall be
06
replaced once taken once taken out.
07

08

09
(f) Take out valves from the bottom of the cylinder head.
10

7. Clean Cylinder Head Primarily

(a) Clean the sealing surface of the cylinder head and
intake pipe.

(b) Clean the combustion front of the cylinder and

cylinder head.
 09-12 Mechanical System - Overhaul

8. Deeply Clean and Maintain Cylinder Head

(a) Clear away the carbon deposit on the fuel injector
seat by a fuel injector hole brush or equivalent.

01

02

03

04
(b) Clean the valve seat ring with a hairbrush.
05

06

07

08

09
(c) Blow out foreign matters with compressed air.
10 Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.

(d) Place the cylinder head in the container filled with

acid solution to wash away the deposits of the
cylinder head, but do remove the expansion plug
firstly. Clear away the deposits in the coolant
passage.
Mechanical System - Overhaul 09-13

(e) Clean the cylinder head combustion front with a

polishing pad or equivalent and cleaner after
cleaning.
Caution: 01
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage 02
proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
03
avoid personal injuries.
y Some solvents are flammable and toxic. Before
use, carefully read the manual of the 04
manufacturer.
05
(f) Clean the valve seat and valve guide.
Caution: 06
• Wear goggles when clearing away carbon deposit
to avoid injuries. 07
• If the valve seat comes into contact with the steel
wire wheel, the valve seat will be damaged when
the steel wire wheel rotates. For this case, the 08
new valve seat must be cut or a new valve seat
ring must be installed. 09
• An inferior steel wire wheel will leave steel wires
when working, which will cause additional 10
contamination. Use a superior steel wire wheel
installed on the bit or mold polishing machine to
clear away carbon deposit on the valve guide.

(g) If the valve seat ring must be removed, use a steel

wire brush and solvent to clear away deposit in valve
seat ring mounting holes.

(h) Dry the cylinder head surface with compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.
 09-14 Mechanical System - Overhaul

(i) Clean the cylinder head with hot soap water, and
then wash with clean water.

01

02

03

04
(j) Dry the cylinder head by compressed air.
05 Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
06
debris and dirt from causing personal injuries.
07

08

09
9. After cleaning, re-check the cylinder head.
10 (a) Check whether on the cylinder cover are there
cracks, corrosion and discoloration that will affect its
continuous use.
Caution:
Pay close attention to the following areas: fuel
injector hole, combustion front, valve seat and valve
guide.

Tip:
If cracks do not extend to the valve seat, it can be used
continuously.

Tip:
If cracks extend to the valve seat or pass through it,
replace the cylinder head.
Caution:
If the cylinder head is not replaced, the cracks
extending to or passing through the valve seat hole
will cause the falling of the valve seat ring, and further
the damages to the engine.
Mechanical System - Overhaul 09-15

Tip:
If it is still installed, check whether there are cracks or
ablation points on the valve seat. If the valve seat ring is
damaged, replace it according to the working face and
sinkage degree of the valve seat ring. 01

02

03

04
(b) Check screw holes on the rocker arm shaft support
and cylinder head; if the threads are damaged or 05
deform, ream, repair or replace.
06

07

08

09
(c) Measure the diagonal length of the lower surface of
the cylinder head, and judge whether the cylinder 10
head deforms.
Caution:
If the diagonals are unequal, it indicates that the
cylinder head deforms, and replace it; if equal, it
indicates that the cylinder head is good.

(d) Check the oil passage and water passage on the

cylinder head, and clean with a water gun.
Caution:
Clean water passage holes and oil passage holes one
by one.

10. Install Valve Assembly

(a) Lubricate all valve guide holes and the external walls
of valve guides to be installed by oil.
Tip:
The external wall of the valve guide is lubricated for
conveniently installing into the valve guide hole.
 09-16 Mechanical System - Overhaul

(b) Tap the valve guide in from the top of the cylinder
head by special tools.
Caution:
It is necessary to apply oil on the external surface of
01 the valve guide before installation; install the valve
guide and check its height.
02 Reference Height: 13mm

03

04
(c) Lubricate all valve guide holes and valve stems with
05 oil.
Tip:
Failure to lubricate valve guides and valve stems will
06
cause the early wear of valve guides. Before installing the
valve, lubricate the valve stem with oil.
07

08

09
(d) Install the valve
10 Caution:
y If the valve to be installed is the same with the
valve removed previously, make sure than the
valve is installed at the position where the valve
is removed.
y If the cylinder head can not be used immediately,
install the valve stem by assembly lubricant or
equivalent.

(e) Install the valve oil seal to the valve guide by a valve
oil seal installer.

(f) Install the valve spring and valve spring seat.

Mechanical System - Overhaul 09-17

(g) Compress the valve spring by special tools, and

install the valve lock clamp.
Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal 01
injuries, goggles with side guard shall be worn.
02

03

04
(h) Install the valve lock clamp.
Caution: 05
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
06
injuries, goggles with side guard shall be worn.
07

08

09
(i) Slowly take out the special tools to allow the valve
lock clamp to fall into the valve spring seat. 10
Tip:
After installing all valve lock clamps, tap valve seat rings
gently by a rubber hammer to ensure that all valve lock
clamps are installed in position.

11. Assemble Cylinder Head Assembly

(a) Lubricate bolts with clean oil.

(b) Install the intake manifold assembly.

 09-18 Mechanical System - Overhaul

(c) Install the exhaust manifold assembly.

01

02

03

04
(d) Install the cylinder head to the engine body by
05 hoisting equipment.
Caution:
As the cylinder head assembly is heavy, in order to
06
avoid serious personal injuries, this assembly must
be lifted by two persons or by suitable hoisting
07 equipment.

08

09
(e) Screw up cylinder head bolts and tighten.
10

Tip:
The order for installing cylinder head bolts is shown in the
left picture.
Caution:
The fixing bolts shall be installed diagonally step by
step, and failure to do so will cause harmful influence
on the lower surface of the cylinder head.

(f) Install the tappet

Mechanical System - Overhaul 09-19

(g) Drop an appropriate amount of clean oil on the

bowl-shaped groove of each tappet.

01

02

03

04
12. Install Rocker Arm Assembly
(a) Install the rocker arm assembly on the engine. 05

06

07

08

09
(b) Lubricate bolts with clean oil.
10

(c) Install rocker arm fixing bolts.

(d) Install rocker arm locking nuts.

Tip:
After installing the rocker arm assembly, adjust the valve
clearance to avoid damages to valves when rotating the
engine.
 09-20 Mechanical System - Overhaul

13. Install Cylinder Head Cover

(a) Put the cylinder head cover on the cylinder head.
Tip:
The holes of the cylinder head cover must be aligned with
01 stud bolts on the engine, and gaskets and sealing
washers shall be installed.
02

03

04
(b) Install four fixing nuts on the cylinder head cover.
05

06

07

08

09
(c) Install the filler cap, and rotate it clockwise.
10

14. Install Fuel Injector Assembly

(a) Install the fuel injector
Tip:
the fuel pipe joint of the fuel injector shall face the intake
manifold side.

(b) Install fixing bolts on the fuel injector.

Tip:
Pay attention to installing flat washers and spring washers
on the fixing bolts. The fuel injector fixing bolts shall be
tightened symmetrically.
Mechanical System - Overhaul 09-21

(c) Install connecting nuts (totally four) on the fuel

injector and high-pressure fuel pipe.
Tip:
The nuts at the connecting ends of the high-pressure fuel
pipe and fuel injector are only connected without being 01
tightened.
02

03

04
(d) Install the fuel return pipe.
Tip: 05
Note that there are sealing washers at both sides of the
fuel return pipe joint, and install them one by one.
06

07

08

09
(e) Install fixing bolts (totally four) for fuel return pipe on
the fuel injector. 10
Tip:
Discharge the air in the fuel line by a manual fuel pump,
start the engine, shut down it when a little fuel is injected
from the position of nuts at the connecting end of the
high-pressure fuel pipe and fuel injector, and tighten all
high-pressure fuel pipes.
 09-22 Mechanical System - Rocker Arm Assembly

Rocker Arm Assembly

Part Drawing
01

02

03

04

05

06

07

08

09

10

1 Nut M8 9 Washer 6
2 Washer 8 10 Bowl-shaped plug
3 Washer 8 11 Retainer Ring 16
4 Fastening Bolt, Rocker Arm Support 12 Rocker Arm Shaft
5 Nut M8×1 13 Rocker Arm Shaft Support
6 Valve Clearance Adjusting Screw 14 Spring, Rocker Arm Shaft
7 Bolt M8×60 15 Processing Assembly, Valve Rocker Arm
8 Locating Screw, Rocker Arm Shaft 16 Rear Support, Rocker Arm Shaft
 Mechanical System - Rocker Arm Assembly 09-23

Overhaul
Caution:
If excessive wear or damage is detected during inspection, the adjustment, repair or replacement
of parts are necessary. 01
1. Remove Cylinder Head Cover
02
(a) Remove the filler cap, and rotate it counterclockwise
to take out.
03

04

05

06

(c) Remove four fixing nuts on the cylinder head cover. 07

08

09

10

(d) Take out the cylinder head cover and cylinder head
cover gasket upwards.

2. Remove Rocker Arm Assembly

(a) Remove rocker arm locking nuts.
 09-24 Mechanical System - Rocker Arm Assembly

(b) Remove rocker arm fixing bolts.

01

02

03

04
(c) Clean bolts with gasoline-based solvent. Clear away
05 deposit on the bolt bar and threads completely by a
steel wire brush, soft steel wire wheel brush or
non-abrasive shot blasting.
06
Caution:y The cleaning by solvents and acid or
alkaline substances shall be subject to the usage
07 proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
08 avoid personal injuries.
y Some solvents are flammable and toxic. Before
09 use, carefully read the manual of the
manufacturer.
10 y Never clean cylinder head bolts with acid or
alkaline solutions. Otherwise, parts will be
damaged.

(d) Check visually whether there are damaged threads or

corroded surface on cylinder head bolts, and replace
if any.

(e) Check whether the threads of fixing bolts are

damaged, and replace if any; in addition, check two
washers below each nut, and replace if there are
cracks or damages.
Mechanical System - Rocker Arm Assembly 09-25

(f) Take out the rocker arm assembly.

01

02

03

04
3. Disassemble Rocker Arm Assembly
(a) Take down circlips with circlip pliers. 05

06

07

08

09
(b) Remove fixing nuts for valve clearance adjusting
screws on the rocker arm. 10

(d) Rotate valve clearance adjusting screws clockwise

with a screwdriver, and take out below the rocker
arm.

(e) Remove rocker arm shaft locating screws on the rear

rocker arm shaft support, and take out washers.
 09-26 Mechanical System - Rocker Arm Assembly

(f) Take out accessories on the rocker arm shaft.

01

02

03

04
(g) Remove the rocker arm shaft supports and rocker
05 arms, and mark its position when removing each part.
Tip:
During assembly, the shaft supports and rocker arms
06
must be installed in the original positions and directions.
07

08

09
4. Check Rocker Arm Assembly
10 (a) Clean all parts with cleaner/hot water solution in high
concentration.

(b) Clear away deposit on rocker arm supports and

rocker arms by a steel wire brush or soft steel wire
wheel brush.

(c) Rinse parts in clean hot water, and then dry them with
compressed air.
Caution:
y Appropriate goggles and protective masks shall
be worn for using compressed air to prevent
splashed debris and dirt from causing personal
injuries.
y Shaft supports are made of metal powder, so it
seems wet after cleaning and drying.
Mechanical System - Rocker Arm Assembly 09-27

(d) Check whether the fixing nuts for valve clearance

adjusting screws crack or their threads deform, and
replace if any.
01

02

03

04

(e) Check whether the threads of valve clearance 05

adjusting screws deform or their round head are
worn, and replace if any.
06

07

08

09

(f) Check whether there are cracks or excessive wear in 10

the hole.

(g) Check whether the oil holes on the rocker arm are
jammed, and blow them with compressed air if any.
 09-28 Mechanical System - Rocker Arm Assembly

(h) Measure the inside diameter of the rocker arm with a

vernier caliper or dial indicator.

Model Nominal
01 LL380 φ16H7( )
LL480 φ16H7( )
02
QC480 —
03

04
(i) Measure the outside diameter of the rocker arm at the
05 swinging position on the rocker arm shaft by a
micrometer.
06
Model Nominal
07 LL380 φ16f7( )
LL480 φ16f7( )
08 QC480 —

09

10
(j) Place the rocker arm shaft on V-blocks, and measure
the radial runout in the middle by a dial indicator.

Model Reference Limit

LL380 0.2
LL480 0.2
QC480 0.2

Caution:
If the radial runout is slight, correct the radial of the
rocker arm shaft by a bench press. If the runout
exceeds the specified limit, the rocker arm shaft must
be replaced.

5. Install Rocker Arm Assembly

(a) Lubricate the rocker arm shaft with clean oil.
Mechanical System - Rocker Arm Assembly 09-29

(b) Lubricate the inner holes of rocker arms and rocker

arm supports with clean oil.

01

02

03

04
(c) Assemble Rocker Arm
Caution: 05
y All rocker arm parts must be installed in their
original positions and directions
06
y Tighten adjusting screws, and then install locking
nuts.
07

08

09
(d) Assemble the rock arm assembly in order according
to the marks made during removal. 10

(e) Install the rocker arm shaft locating screw and

washer on the rear rocker arm shaft support.

(f) Install the rocker arm assembly on the cylinder head.

 09-30 Mechanical System - Rocker Arm Assembly

(g) Lubricate bolts with clean oil.

01

02

03

04
(h) Install rocker arm fixing bolts.
05

06

07

08

09
(i) Install rocker arm locking nuts.
10 Tip:
After installing the rocker arm assembly, adjust the valve
clearance to avoid damages to valves when rotating the
engine.

6. Install Cylinder Head Cover

(a) Put the cylinder head cover on the engine.
Tip:
The holes of the cylinder head cover must be aligned with
stud bolts on the engine, and the gasket shall be installed.

(b) Install four fixing nuts on the cylinder head cover.

Mechanical System - Rocker Arm Assembly 09-31

(c) Install the filler cap, and rotate it clockwise.

01

02

03

04

05

06

07

08

09

10
 09-32 Mechanical System - Valve

Valve
General
01 1. The valve train has a direct influence on the normal running of the engine. It shall ensure that clean
air can go into the cylinder in the intake stroke, with the air charging volume up to the maximum; the
02 waste gas in the cylinder is exhausted duly in the exhaust stroke to reduce the residual volume of
waste gas as much as possible. In addition, in the compression and expansion strokes, the valves
are required to close tightly.
03
2. The components of the valve train are worn or corroded, or deform in long-term use due to impact
by high-temperature gas, impact load or poor lubrication, so the technical characteristics and mating
04 relationship are damaged to cause faults and part failures.

05

06

07

08

09

10
 Mechanical System - Valve 09-33

Adjustment
Tip:
As the valve clearance has an influence on the technical conditions of the diesel engine, it must be
checked and adjusted according to the maintenance specification or practical use conditions. The intake 01
valve clearance in cold state shall be 0.20~0.30mm, and the exhaust valve clearance in cold state shall
be 0.25~0.35mm. The adjustment methods are as follows:
02
1. Remove Cylinder Head Cover
(a) Remove the filler cap, and rotate it counterclockwise 03
to take down.
04

05

06

07

(c) Remove four fixing nuts on the cylinder head cover. 08

09

10

(d) Take out the cylinder head cover and cylinder head
cover gasket upwards.

2. Rotate the crankshaft until the scale of the

crankshaft damping pulley is aligned with the
timing pointer, and the piston of the first cylinder
or fourth cylinder stays at the dead center of the
compression stroke.
Caution:
The engine stays in cold state.
 09-34 Mechanical System - Valve

3. Judge whether the piston of the first cylinder or

fourth cylinder stays at the dead center of the
compression stroke.
Tip:
01 Shake the intake or exhaust valve rocker arm of the first
or fourth cylinder by hand. Shake the valve rocker arm of
02 the first cylinder, and if there is a clearance, it indicates
that the piston of the first cylinder stays at the top dead
center of the compression stroke. If the valve rocker arm
03
of the first cylinder can not be shaken, shake the valve
rocker arm of the fourth cylinder; if there is a clearance, it
04 indicates that the piston of the fourth cylinder stays at the
top dead center of the compression stroke.
05
4. Adjust Valve Clearance
06 (a) When the piston of the first cylinder stays at the top
dead center of the compression stroke, check the
07 valve clearance with a feeler gauge.

Model Intake Valve Exhaust Valve

08
LL380 0.20-0.30 0.25-0.35
LL480 0.20-0.30 0.25-0.35
09 QC480 0.20～0.25 0.25～0.30

10

(b) When the valve clearance is too small, rotate the

valve clearance adjusting bolt counterclockwise until
the feeler gauge can be inserted with a little
resistance.
Caution:
When adjusting the valve clearance and rotating the
valve clearance adjusting bolt, it is better to use a
screwdriver and wrench to adjust jointly.

(c) When the valve clearance is too great, rotate the

valve clearance adjusting bolt counterclockwise until
the feeler gauge can be inserted with a little
resistance.
Mechanical System - Valve 09-35

(d) When the piston of the first cylinder stays at the top
dead center of the compression stroke, the
adjustment order is the clearance of first, second,
third and sixth valves as shown in the left picture.
01

02

03

04
(e) Rotate the crankshaft by 360°, then align the scale of
the crankshaft damping pulley with the timing pointer, 05
and then adjust the clearance of other valves.
06

07

08

09
(f) When the piston of the fourth cylinder stays at the top
dead center of the compression stroke, check the 10
valve clearance with a feeler gauge.

Model Intake Valve Exhaust Valve

LL380 0.20-0.30 0.25-0.35
LL480 0.20-0.30 0.25-0.35
QC480 0.20～0.25 0.25～0.30

(g) When the valve clearance is too small, rotate the

valve clearance adjusting bolt counterclockwise until
the feeler gauge can be inserted with a little
resistance.
 09-36 Mechanical System - Valve

(h) When the valve clearance is too great, rotate the

valve clearance adjusting bolt counterclockwise until
the feeler gauge can be inserted with a little
resistance.
01

02

03

04
(i) When the piston of the first cylinder stays at the top
05 dead center of the compression stroke, the
adjustment order is the clearance of fourth, fifth,
06 seventh and eighth valves as shown in the left
picture.
Tip:
07 After adjusting the valve clearance, re-check whether the
valve clearance adjusting bolt is fixed in position, re-check
08 the valve clearance with a feeler gauge if necessary to
endure that the valve clearance meets the specified
09 standard.

10 5. Install Cylinder Head Cover

(a) Put the cylinder head cover on the engine.
Tip:
The holes of the cylinder head cover must be aligned with
stud bolts on the engine, and the gasket shall be installed.

(b) Install four fixing nuts on the cylinder head cover.

(c) Install the filler cap, and rotate it clockwise.

 Mechanical System - Valve 09-37

Overhaul
1. Remove Cylinder Head Cover
(a) Remove the filler cap, and rotate it counterclockwise
to take down. 01

02

03

04

(b) Remove four fixing nuts on the cylinder head cover. 05

06

07

08

09

10
(c) Take out the cylinder head cover and cylinder head
cover gasket upwards.

2. Remove Rocker Arm Assembly

(a) Remove rocker arm locking nuts.
 09-38 Mechanical System - Valve

(b) Remove rocker arm fixing bolts.

01

02

03

04
(c) Clean bolts with gasoline-based solvent. Clear away
05 deposit on the bolt bar and threads completely by a
steel wire brush, soft steel wire wheel brush or
non-abrasive shot blasting.
06
Caution:
y The cleaning by solvents and acid or alkaline
07 substances shall be subject to the usage
proposal from the manufacturer.
08 y Goggles and protective clothing shall be worn to
avoid personal injuries.
09 y Some solvents are flammable and toxic. Before
use, carefully read the manual of the
10 manufacturer.
y Never clean cylinder head bolts with acid or
alkaline solutions. Otherwise, parts will be
damaged.

(d) Check visually whether there are damaged threads or

corroded surface on cylinder head bolts, and replace
if any.

(e) Check whether the threads of fixing bolts are

damaged, and replace if any; in addition, check two
washers below each nut, and replace if there are
cracks or damages.
Mechanical System - Valve 09-39

(f) Take out the rocker arm assembly.

01

02

03

04
3. Remove Cylinder Head
(a) Take out tappets. 05
Caution:
Carefully clear away all sludge, carbon black and 06
carbon deposit on the cylinder head bolts and
cylinder head, and the motor wire brush is not
suitable for the gasket. 07

08

09
(b) Remove cylinder head fixing bolts.
10

Tip:
Remove cylinder head fixing bolts according to the order
as shown in the left picture.
Caution:
The fixing bolts shall be removed diagonally step by
step, and failure to do so will cause harmful influence
on the lower surface of the cylinder head.
 09-40 Mechanical System - Valve

(d) Clean bolts with gasoline-based solvent. Clear away

deposit on the bolt bar and threads completely by a
steel wire brush, soft steel wire wheel brush or
non-abrasive shot blasting.
01 Caution:
y The cleaning by solvents and acid or alkaline
02 substances shall be subject to the usage
proposal from the manufacturer.
03 y Goggles and protective clothing shall be worn to
avoid personal injuries.
y Some solvents are flammable and toxic. Before
04 use, carefully read the manual of the
manufacturer.
05 y Never clean cylinder head bolts with acid or
alkaline solutions. Otherwise, parts will be
06 damaged.

07 (e) Check visually whether there are damaged threads or

corroded surface on cylinder head bolts, and replace
if any.
08

09

10

(f) Check whether the threads of fixing bolts are

damaged, and replace if any; in addition, check two
washers below each nut, and replace if there are
cracks or damages.

4. Remove Valve
(a) Compress valve springs with special tools, and
remove valve lock clamps.
Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
injuries, goggles with side guard shall be worn.
Mechanical System - Valve 09-41

(b) Take out valve lock clamps.

Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
injuries, goggles with side guard shall be worn. 01

02

03

04
(c) Remove valve spring seats and valve springs.
05

06

07

08

09
(d) Pry valve oil seals with a screwdriver.
Caution: 10
The valve oil seals are wearing parts, and they shall
be replaced once pried.

(e) Take out valves from the bottom of the cylinder head.

5. Overhaul Valve Parts

(a) Check whether the valve lock clamps crack or are
damaged, and replace if any.
 09-42 Mechanical System - Valve

(b) Measure the verticality of valve spring by a steel

square.
Caution:
01 If the measured value exceeds the specified limit,
replace the valve spring.
02 Model Reference Limit
LL380 1.17mm
03 LL480 1.17mm
QC480 1.17mm
04

05 (c) Compress springs to the installation height by a

spring tester, and measure the tension of the
06 compressed spring.
Caution:
If the measured tension exceeds the specified limit,
07
replace the valve spring.
Reference
08 Reference
Model Installation Nominal
Limit
Height
09 LL380 38.9mm — 257.9N
LL480 38.9mm — 257.9N
10 QC480 38.9mm — 257.9N

(d) Measure the free height of the valve spring by a

vernier caliper.
Caution:
If the measured value exceeds the specified limit,
replace the valve spring.
Model Nominal Reference Limit
LL380 — 47.100mm
LL480 — 47.100mm
QC480 — 47.100mm

(e) Polish the valve stem by a polishing pad and solvent.

Mechanical System - Valve 09-43

(f) Check visually whether the tip of the valve stem is

worn excessively, and replace if any.

01

02

03

04
(g) Check whether the cylinder head and valve stem are
worn excessively, and replace if any. 05

06

07

08

09
(h) Measure the valve thickness by a steel square,
replace the valve and valve guide in pair if the 10
measured value is smaller than the specified limit.
Reference Standard: Reference Limit
Intake Valve —
1.50mm
Exhaust Valve —

(i) Measure the valve-seat contact cone angle, and

replace the valve, valve guide and valve seat in group
if the measured value exceeds the specified limit.
Nominal Value: 30° for intake valve, and 45° for
exhaust valve.

(j) Measure the outside diameter of the valve stem by a

micrometer.
Nominal Value: φ8e8(-0.025/-0.047)
 09-44 Mechanical System - Valve

(k) Measure the radial runout of each valve cone by a

dial indicator and V-clock.
Tip:
This inspection aims to ensure the airtightness between
01 the valve and valve seat.
Limit of Radial Runout of Valve Cone: 0.03mm
02

03

04
(l) Polish the valve in two steps; apply coarse polishing
05 paste on the valve surface at first, then apply fine
polishing paste, and polish according to the general
06 polishing methods each time.
Caution:
After polishing, wipe off the polishing paste on the
07 valve and valve seat, use red lead for contact
inspection, and make sure it comes into contact with
08 the width of the valve seat and the contact color band
is free from gaps; it is necessary to check, and if
09 necessary, adjust the valve clearance after installing
the valve head and valve components.
10
(m) Measure the valve sinkage from the plane of the
cylinder head bottom by a depth gauge or ruler, and
replace the valve seat if the measured value exceeds
the specified limit.
Intake Valve Exhaust Valve
Model
Sinkage Sinkage
LL380 0.7~0.9 mm 0.7~0.9 mm
LL480 0.7~0.9 mm 0.7~0.9 mm
QC480 0.9~1.1 mm 0.9~1.1 mm

(n) Check the coarseness and flatness of the valve

contact surface, and replace the valve set if the
measured value exceeds the specified limit.
Reference Limit of Intake Valve: 2.2mm
Reference Limit of Exhaust Valve: 2.5mm
Mechanical System - Valve 09-45

6. Overhaul Valve Guide

(a) Measure the outside diameter of the valve stem by a
micrometer, and measure the inside diameter of the
valve guide at the same time.
Nominal Value: φ8e8(-0.025/-0.047) 01
Tip:
The valve and valve guide must be replaced in pair. 02
Therefore, when measuring the outside diameter of the
valve stem, it is necessary to measure the inside diameter 03
of the valve guide by a micrometer, and then subtract the
measured inside diameter of the valve guide from the
measured outside diameter of the valve stem. If the value 04
obtained from subtraction exceeds the specified limit, the
valve and valve guide must be replaced in pair. 05
Clearance between Intake Valve and Valve Guide
Model Nominal Reference Limit 06
LL380 0.025~0.069 mm 0.15 mm
LL480 0.025~0.069 mm 0.15 mm 07
QC480 0.025~0.069 mm 0.15 mm
Clearance between Exhaust Valve and Valve Guide 08
Model Nominal Reference Limit
LL380 0.025~0.069 mm 0.15 mm
09
LL480 0.025~0.069 mm 0.15 mm
QC480 0.040~0.077 mm 0.15 mm
10
(b) If the valve guide needs replacing, tap the valve
guide out from the bottom of the cylinder head by
special tools.

7. Install Valve Guide

(a) Lubricate all valve guide holes and the external walls
of valve guides by oil.
Caution:
Failure to lubricate valve guides will cause the early
wear of valve guides.
 09-46 Mechanical System - Valve

(b) Tap the valve guide in from the top of the cylinder
head by special tools.
Tip:
It is necessary to apply oil on the external surface of the
01 valve guide before installation; install the valve guide and
check its height.
02 Reference Height: 13mm

03

04
8. Check Valve Seat
05 (a) Check whether the valve seat is worn, and remove
and replace if any.
The method for removing the valve seat is as follows:
06
Conduct arc welding for the inner side of the valve seat,
allow the valve to get cool, and then pry the valve seat by
07 a screwdriver.
Caution:
08 Pay attention to not damaging the cylinder head
during removal.
09
9. Install Valve Seat
10 (a) Install the valve seat.
Tip:
Use a bench press to exert pressure gradually to the valve
seat and force it in position during installation.
Caution:
The pressure exerted by the bench press shall not be
too great; otherwise, the valve seat will be damaged.

(b) Clear carbon deposit on the surface of the valve seat,

and process with a valve cutter to minimize its
scratches and other coarse areas, which can recover
the contact width to the nominal value.
Caution:
Only scratches and coarse areas are removed, and do
not cut too much.
Mechanical System - Valve 09-47

(c) Measure the valve sinkage from the plane of the

cylinder head bottom by a depth gauge or ruler, and
replace the valve seat if the measured value exceeds
the specified limit.
01
Intake Valve Exhaust Valve
Model
Sinkage Sinkage 02
LL380 0.7~0.9 mm 0.7~0.9 mm
LL480 0.7~0.9 mm 0.7~0.9 mm 03
QC480 0.9~1.1 mm 0.9~1.1 mm
04
10. Grind Valve Seat
(a) Apply a little oil or Prussian blue on the surface of the 05
valve seat.
Tip: 06
For a new or repaired valve, check whether fitting
between it and valve seat is good. 07

08

09

(b) Install the valve with oil or Prussian blue. 10

(c) Rotate 1/4 circle left and right several times.

 09-48 Mechanical System - Valve

(d) Take out the valve.

01

02

03

04
(e) Check the contact face of the valve, which shall be
05 covered evenly and completely with oil or Prussian
blue in a shape of a complete annular band.
06

07

08

09
(f) If the contact annular band fails to meet the
10 requirement and is located at the upper part of the
valve cone, it is necessary to trim the valve seat with
a 30° and 45° cutter.

(g) If the contact annular band fails to meet the

requirement and is located at the lower part of the
valve cone, it is necessary to trim the valve seat with
a 60° and 45° cutter.

(h) Apply grinding paste on the surface of the valve seat.

Mechanical System - Valve 09-49

(i) Grind the valve until it can fit with the valve perfectly.
(j) Completely clean the valve, valve seat and valve
guide after grinding.

01

02

03

04
11. Install Valve
(a) Lubricate all valve guide holes and valve stems with 05
oil.
Tip: 06
Failure to lubricate valve guides and valve stems will
cause the early wear of valve guides.
07

08

09
(b) Install Valve
Tip: 10
If the valve to be installed is the same with the valve
removed previously, make sure than the valve is
installed at the position where the valve is removed. If
the cylinder head can not be used immediately, install
the valve stem by assembly lubricant or equivalent.

(c) Install the valve oil seal to the valve guide by special
tools.

(d) Install the valve spring and valve spring seat.

 09-50 Mechanical System - Valve

(e) Compress the valve spring by special tools, and

install the valve lock clamp.
Caution:
As the valve springs stay in tension state, they will be
01 thrown out if released. In order to avoid personal
injuries, goggles with side guard shall be worn.
02

03

04
(f) Install the valve lock clamp.
05 Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
06
injuries, goggles with side guard shall be worn.
07

08

09
(g) Slowly take out the special tools, and leave the valve
10 lock clamp on the installation position.
Caution:
As the valve springs stay in tension state, they will be
thrown out if released. In order to avoid personal
injuries, goggles with side guard shall be worn.

12. Install Cylinder Cover (Refer to Chapter 08 Assembly of Engine – Cylinder Head and Tappet,
Installation)

13. Install Rocker Arm Assembly

(a) Install the rocker arm assembly on the engine.
 Mechanical System - Valve 09-51

(b) Lubricate bolts with clean oil.

01

02

03

04
(c) Install rocker arm fixing bolts.
05

06

07

08

09
(d) Install rocker arm locking nuts.
10

14. Adjust the valve clearance (Refer to Chapter 09 Mechanical System – Valve, Adjustment).

15. Install Cylinder Head Cover

(a) Put the cylinder head cover on the engine.
Tip:
The holes of the cylinder head cover must be aligned with
stud bolts on the engine, and the gasket shall be installed.
 09-52 Mechanical System - Valve

(b) Install four fixing nuts on the cylinder head cover.

01

02

03

04
(c) Install the filler cap, and rotate it clockwise.
05

06

07

08

09

10
 Mechanical System - Camshaft and Tappet 09-53

Camshaft and Tappet

Part Drawing
01

02

03

04

05

06

07

08

09

10

1 Bolt M12×35 6 Key C8×18

2 Washer 12 7 Tappet

3 Retainer Ring, Camshaft Gear 8 Lifter

4 Camshaft Timing Gear 9 Camshaft

5 Camshaft Thrust Plate

 09-54 Mechanical System - Overhaul

Overhaul
01 1. Remove Cylinder Head Cover
(a). Remove the filler cap, and rotate it counterclockwise
02 to take down.

03

04

05

06
(b). Remove four fixing nuts on the cylinder head cover.
07

08

09

10

(c). Take out the cylinder head cover and cylinder head
cover gasket upwards.

2. Remove Rocker Arm Assembly

(a). Remove rocker arm locking nuts.
Mechanical System - Overhaul 09-55

(b). Remove rocker arm fixing bolts.

01

02

03

04
(c). Take out the rocker arm assembly.
05

06

07

08

09
3. Overhaul Tappet
(a). Take out tappets. 10
Caution:
Carefully clear away all sludge, carbon black and
carbon deposit on the cylinder head bolts and
cylinder head, and the motor wire brush is not
suitable for the gasket.

(b). Clean the tappet with hot soap water.

(c). Dry with compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.
 09-56 Mechanical System - Overhaul

(d). Check whether wear, damage by pulling or other

damages appear at both ends of the tappet.
Check whether there are cracks at the position of the ball
and ball cup for press-connecting ejector sleeve..
01

02

03

04
(e). Visually check whether the tappet bends, and replace
05 directly if it bends obviously.

06

07

08

09
(f). If the tappet does not bends obviously, place it at a
10 horizontal surface to roll, and check its straightness.
Replace it if bending.

4. Remove Cylinder Head

(a). Remove cylinder head fixing bolts.

Tip:
Remove cylinder head fixing bolts according to the order
as shown in the left picture.
Caution:
The fixing bolts shall be removed diagonally step by
step, and failure to do so will cause harmful influence
on the lower surface of the cylinder head.
Mechanical System - Overhaul 09-57

(b). Take out the cylinder head by appropriate hoisting

equipment.
Caution:
As the cylinder head assembly is heavy, in order to
avoid serious personal injuries, this assembly must 01
be lifted by two persons or by suitable hoisting
equipment. 02

03

04
5. Remove Crankshaft Pulley
(a). Take down crankshaft pulley fixing bolts. 05

06

07

08

09
(b). Take out the crankshaft pulley.
10

6. Remove Timing Gear Chamber Cover

(a). Remove timing gear chamber cover fixing bolts.
Tip:
The timing gear chamber cover fixing bolts are different in
length. Loosen all bolts, but do not take out immediately.
Then take out one by one, and mark each one with its
installation position for installation.

(b). Take out the timing gear chamber cover.

Tip:
If the timing gear chamber cover is tightened overly,
loosen it by a rubber hammer first and then take out.
 09-58 Mechanical System - Overhaul

(c). Take out the timing gear chamber cover gasket.

Tip:
The timing gear chamber cover gasket is made of paper.
Directly tear it down during removal, and clear away
01 segments.

02

03

04
7. Remove Camshaft
05 (a). Measure the axial clearance of the camshaft, and
replace the thrust plate if the measured axial
06 clearance of the camshaft exceeds the specified limit.
Limit
Model Nominal Value
Value
07
LL380 0.07~0.245 mm 0.60 mm
LL480 0.07~0.245 mm 0.60 mm
08 QC480 0.050~0.220 mm —
Tip:
09 When removing the camshaft, place the oil pan upwards,
and remove the oil pan and oil pump. As connected with
10 the camshaft drive gear, the oil pump must be removed,
and then the camshaft can be taken out.
(b). Remove thrust plate fixing bolts (two) with a sleeve.

(c). Remove the camshaft assembly with gear.

Tip:
The camshaft can be taken out by continuously rotating
the camshaft during removal.
Caution:
When installing the camshaft, make sure that the
crankcase side of the engine body is placed upward,
and allow the lifter to fall into the lifter hole. In this
way, the camshaft can be installed successfully.
Mechanical System - Overhaul 09-59

8. Disassemble Camshaft Assembly

(a). Screw off the camshaft gear bolt, and remove the
camshaft gear by a puller.
Tip:
Fix the camshaft by a bench vice, and note that the bench 01
vice shall not be tightened overly to avoid damaging the
camshaft. 02

03

04
(b). Take down the key on the camshaft.
05

06

07

08

09
(c). Remove the thrust plate.
10

(a). Clean parts by solvent.

Caution:
The cleaning by solvents and acid or alkaline
substances shall be subject to the usage proposal
from the manufacturer.
Goggles and protective clothing shall be worn to
avoid personal injuries.

(b). Clear away deposits on the camshaft by a steel wire

brush or soft steel wire wheel.
 09-60 Mechanical System - Overhaul

(c). Dry with compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
01 debris and dirt from causing personal injuries.

02

03

04
(d). Check whether the inner hole of the camshaft is
05 blocked, or oil or sludge is accumulated at the inner
side of the camshaft.
06

07

08

09
(e). Place the camshaft on V-blocks, measure its radial
10 runout by a dial indicator, and replace if the
measured value exceeds the specified limit.
Limit
Model Nominal Value
Value
LL380 ≤0.02 mm 0.10mm
LL480 ≤0.02 mm 0.10mm
QC480 ≤0.02 mm 0.10mm

(f). Measure the outside diameter of each camshaft

journal in two vertical directions by a screw
micrometer, and replace if the measured value is
smaller than the specified limit.
Limit
Model Nominal Value
Value
LL380 ≤0.02 mm 0.10mm
LL480 ≤0.02 mm 0.10mm
QC480 ≤0.02 mm 0.10mm
Mechanical System - Overhaul 09-61

(g). Measure the height of each cam by a micrometer,

and replace if measured value exceeds the specified
limit.

01

02

03

04
(h). Visually check whether point corrosion, cracks or
other abnormal defects appears on the camshaft 05
surface, and replace if any.
06

07

08

09
10. Overhaul Camshaft Gear
(a). Clean the camshaft gear by solvent. 10
Caution:
The cleaning by solvents and acid or alkaline
substances shall be subject to the usage proposal
from the manufacturer.
Goggles and protective clothing shall be worn to
avoid personal injuries.

(b). Clear away deposits on the camshaft gear by a steel

wire brush or soft steel wire wheel.

(c). Dry with compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.
 09-62 Mechanical System - Overhaul

(d). Check whether bolts on the camshaft and camshaft

gear crack or are corroded.

01

02

03

04
(e). Check whether the camshaft gear is corroded. Check
05 whether there are cracks or broken teeth on the
camshaft gear. Replace if any.
06

07

08

09
(f). Clear away any corrosion, burrs or protruded metal
10 by a polishing pad. Replace the gear if the corrosion,
burrs or protruded metal on it can not be cleared
away.

11. Overhaul Camshaft Thrust Plate

(a). Measure the thickness of the camshaft thrust plate by
a screw micrometer, and replace if the measured
value exceeds the specified limit.

(b). Check visually whether the camshaft thrust plate is

damaged or crack, and replace if any.
Mechanical System - Overhaul 09-63

12. Overhaul Lifter

(a). Remove the oil pan.
y Turn over the engine body, and remove oil pan
fixing bolts and nuts.
Tip: 01
In the process of removal, the oil pan seal shall be kept in
the oil pan whenever possible. 02

03

04
y Loosen the oil pan by a rubber hammer, and pry
it. 05
Tip:
Pry in all directions. 06

07

08

09
y Take down the oil pan.
10

(b). Take out the lifter by attraction with the help of a

high-performance magnet.

(c). Clean the lifter by solvent.

Caution:
The cleaning by solvents and acid or alkaline
substances shall be subject to the usage proposal
from the manufacturer.
Goggles and protective clothing shall be worn to
avoid personal injuries.
 09-64 Mechanical System - Overhaul

(d). Dry with compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
01 debris and dirt from causing personal injuries.

02

03

04
(e). Check whether there are corrosions, cracks and
05 other damages on the lifter seat, stem and surface.
Tip:
06 y Normal contact (increased).
y Do not use any more for irregular contact.
y Do not use any more for irregular contact.
07

08

09
(f). Check whether there is corrosion in pit on the lifter
10 surface.
Tip:
The following standards definite the allowable range of
corrosion in pit on the lifter surface.
y The single corrosion in pit shall not be greater than
2mm.
y The corrosions in pit are not allowed to extend into a
whole.
y The total diameter of corrosions in pit accumulated
shall not exceed 6mm or 4% of the lifter surface area.
y Corrosions in pit are not allowed to appear at the
edge of the lifter wear surface.

(g). Measure the outside diameter of the lifter by a screw

micrometer.
Nominal Value:
Tip:
At the same time, measure the inside diameter of the lifter
hole by the micrometer, and then subtract the inside
diameter of the lifter hole from the outside diameter of the
lifter. Replace the lifter if the value obtained from
subtraction exceeds the specified value.
Limit
Model Nominal Value
Value
LL380 0.016~0.045 mm 0.25mm
LL480 0.016~0.045 mm 0.25mm
QC480 - -
 Mechanical System - Overhaul 09-65

13. Install Lifter

(a). Apply clean oil on the lifter.

01

02

03

04
(b). Install the lifter.
05

06

07

08

09
14. Install Oil Pan (Refer to Chapter 08 Assembly of Engine – Flywheel Housing and Oil Pan,
Installation) 10

15. Assemble Camshaft

(a). Lubricate the camshaft thrust plate with clean engine
oil.

(b). Install the thrust plate on the camshaft.

 09-66 Mechanical System - Overhaul

(c). Install the key in the camshaft keyway.

01

02

03

04
(d). Screw up the camshaft gear bolt.
05

06

07

08

09
16. Install Camshaft (Refer to Chapter 08 Assembly of Engine – Timing Gear Chamber and
10 Camshaft, Installation)
17. Install Timing Gear Chamber Cover (Refer to Chapter 08 Assembly of Engine – Timing Gear
Chamber Cover and Crankshaft Pulley, Installation)
18. Install Camshaft Pulley (Refer to Chapter 08 Assembly of Engine – Timing Gear Chamber and
Camshaft Pulley, Installation)
19. Install Cylinder Head Assembly (Refer to Chapter 08 Assembly of Engine – Cylinder Head
and Tappet, Installation)
20. Install Rocker Arm Assembly (Refer to Chapter 08 Assembly of Engine – Rocker Arm and
Cylinder Head Cover, Installation)
21. Install Cylinder Head Cover (Refer to Chapter 08 Assembly of Engine – Rocker Arm and
Cylinder Head Cover, Installation)
 Mechanical System - Piston and Connecting Rod Assembly 09-67

Piston and Connecting Rod Assembly

Part Drawing
01

02

03

04

05

06

07

08

09

10

1 Top Piston Ring 7 Connecting Rod Bushing

2 Third Piston Ring 8 Connecting Rod Body
3 Oil Ring 9 Connecting Rod Bearing Shell
4 Piston 10 Connecting Rod Cap
5 Piston Pin 11 Connecting Rod Bolt
6 Retainer Ring, Piston Pin
 09-68 Mechanical System - Piston and Connecting Rod Assembly

Overhaul
1. Remove Cylinder Head Cover (Refer to Chapter 07 Disassembly of Engine – Cylinder Head
Cover and Rocker Arm, Removal)
01
2. Remove Rocker Arm Assembly (Refer to Chapter 07 Disassembly of Engine – Cylinder Head
Cover and Rocker Arm, Removal)
02 3. Remove Cylinder Head (Refer to Chapter 07 Disassembly of Engine – Cylinder Head Cover,
Removal)
03 4. Remove Oil Pan and Flywheel Housing (Refer to Chapter 07 Disassembly of Engine – Oil Pan
and Flywheel, Removal)
04 5. Remove Timing Gear Chamber (Refer to Chapter 07 Disassembly of Engine – Camshaft and
Timing Gear Chamber, Removal)
05
6. Remove Piston Assembly
(a). Rotate the crankshaft, and allow the pistons of the
06 first and fourth cylinders to stay at the lowest point,
namely that the connecting rod caps of the first and
07 fourth cylinders are exposed vertically.

08

09

10
(b). Loosen the connecting rod bolts of the first and fourth
cylinders.
Tip:
Loosen bolts in pair, but not take out.

(c). Take down the connecting rod caps.

Tip:
Hold connecting rod cap bolts with both hands and shake
the connecting rod cap, or loosen the connecting rod cap
by a rubber hammer, and then take out the connecting rod
cap.
Caution:
y When removing the connecting rod cap, never
damage the surface with split end face of the
connecting rod or connecting rod cap. If the
surface with split end face is damaged, the
connecting rod and the connecting rod cap must
be changed, because it is good for lowering the
possibility of engine damage. Wrong assembly
will damage the connecting rod.
y Never put the connecting rod cap on the surface
with split end face. Otherwise, the surface with
split end face will be damaged.
Mechanical System - Piston and Connecting Rod Assembly 09-69

(d). Take out the connecting rod bearing shell.

Caution:
Never damage the connecting rod bearing shell.

01

02

03

04
(e). Mark on the smooth side of the locating lug for the
connecting rod bearing shell. 05

06

07

08

09
(f). Install the connecting rod bearing shell to the
corresponding connecting rod cap and protect it. 10

(g). Clear away the carbon deposit in the piston cylinder.

Caution:
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
avoid personal injuries.
y Some solvents are flammable and toxic. Before
use, carefully read the manual of the
manufacturer.

(h). Push out the piston assembly.

Tip:
The piston assembly shall be pushed out with tools made
of wood or rubber. Never use tools made of metal to avoid
damaging the end faces of the connecting rod.
 09-70 Mechanical System - Piston and Connecting Rod Assembly

(i). Take out the piston assembly from the other side.

01

02

03

04
(j). Take down the connecting rod bearing shell and mark
05 it.

06

07

08

09
(k). Rotate the crankshaft, and expose the connecting rod
10 caps of the second and third cylinders.

(l). Remove the piston assemblies of the second and

third cylinder with the same method.
Tip:
If the piston assembly is not used immediately, mark each
piston and connecting rod assembly with cylinder No. by
labels. Put the connecting rod and piston assembly into a
container to avoid damages.

7. Remove Piston Assembly

(a). Remove three piston rings by a special remover for
piston ring.
Mechanical System - Piston and Connecting Rod Assembly 09-71

(b). Remove retainer rings at both sides of the piston by

circlip pliers.

01

02

03

04
(c). Punch out the piston pin by a punching bar.
05

06

07

08

09
8. Overhaul Bearing
(a). Check whether the bearing is damaged. 10
Tip:
Replace the bearing if the following damages appear.
y Corrosion in pit
y Peeling
y Corrosion
y Damage of latch bolt
y Scratch.

9. Overhaul Connecting Rod

(a). Measure the inside diameter of the connecting rod
small end, and replace the connecting or bushing
and pin if the clearance between the small end hole
and piston pin fails to meet the standard.
Nominal Size of Inside Diameter of Connecting Rod
Small End:
Tip:
Subtract the measured inside diameter of the small end
hole from the outside diameter of the piston pin.
Replace the lifter if the value obtained from subtraction
exceeds the specified value.

Model Nominal Value Limit Value

LL380 0.025~0.044 mm 0.10 mm
LL480 0.025~0.044 mm 0.10 mm
QC480 0.025~0.046 mm 0.10 mm
 09-72 Mechanical System - Piston and Connecting Rod Assembly

(b). Remove the bushing by an appropriate bar and

hammer.
Caution:
A hammer is available for installation; the oil hole of
01 the bushing shall be aligned with that the
connecting rod; after installing a new bushing,
02 polish the bushing hole by a pinhole grinding
machine.
03

04
(c). Clean the connecting rod by solvent.
05 Caution:
The cleaning by solvents and acid or alkaline
06 substances shall be subject to the usage proposal
from the manufacturer.
Goggles and protective clothing shall be worn to
07 avoid personal injuries.

08

09
(d). Clean the contact surface between the connecting
10 rod and connecting rod cap by a nylon brush.
Caution:
The contact surface between the connecting rod and
connecting rod cap is not a machined surface. Pay
attention to the cleaning to avoid damaging parts.

(e). Dry the connecting rod with compressed air.

Caution:
The pressure of compressed air for cleaning shall
not exceed 207kPa.
Goggles and protective clothing shall be worn to
avoid personal injuries.

(f). Check whether there are scorings, cracks, burrs,

scratches or damages on the connecting rod cap.
Caution:
If any part of the connecting rod or connecting rod
cap is worn obviously, replace both as an assembly.
Mechanical System - Piston and Connecting Rod Assembly 09-73

(g). Check whether there are scorings, cracks, burrs,

scratches or damages on the connecting rod cap.

01

02

03

04
(h). Check the contact surface between the connecting
rod and connecting rod cap. 05
Caution:
The contact surface between the connecting rod and 06
connecting rod cap is not a machined surface.
Unless there are scratches or cracks on it, this
surface is deemed to be undamaged. 07

08

09
(i). Check whether the connecting rod piston pin hole is
damaged. 10
Caution:
There is no oil passage on the connecting rod small
end to be aligned with the hole in the bushing. The
hole on the bushing is used only in manufacture.

10. Overhaul Piston Pin

(a). Check visually whether there are cracks, scratches
or other damages on the piston pin, and replace if
any.

(b). Measure the outside diameter of the piston pin at

three different positions in two different directions by
a micrometer.
Nominal Size of Piston Pin:
 09-74 Mechanical System - Piston and Connecting Rod Assembly

(c). Measure the inside diameter of the connecting rod

small end, and replace the connecting or bushing and
pin if the clearance between the small end hole and
piston pin fails to meet the standard.
01 Nominal Size of Inside Diameter of Connecting
Rod Small End:
02 Tip:
Subtract the measured inside diameter of the small end
03 hole from the outside diameter of the piston pin.
Replace the lifter if the value obtained from subtraction
04 exceeds the specified value.
Model Nominal Value Limit Value
05 LL380 0.025~0.044 mm 0.10 mm
LL480 0.025~0.044 mm 0.10 mm
06 QC480 0.025~0.046 mm 0.10 mm

07 11. Overhaul Piston

(a). Immersion of the piston for a whole night can loosen
the carbon deposit. Immerse the piston into the part
08
cleaning fluid.
Caution:
09 y Never clean the piston by shot blasting, because
shots will go into aluminum to damage the piston.
10 y Never clean the piston in acid solution.
Otherwise, the piston will be damaged.

(b). Clean the piston by mixed cleaner/hot water solution

in high concentration.
Caution:
Never use a steel brush, because it will damage the
piston ring groove.

(c). Re-clean the piston in cleaner solution or solvent, and

then rinse with clean hot water.
Caution:
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
avoid personal injuries.
y Never clean the piston and connecting rod in the
container filled with acid solution. Otherwise, the
piston and connecting rod will be damaged.
Mechanical System - Piston and Connecting Rod Assembly 09-75

(d). Dry the piston with compressed air.

Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries. 01

02

03

04
(e). Check whether the piston skirt, pin hole, top and ring
groove are damaged or worn. 05
Check whether the piston pin is damaged or worn.
06

07

08

09
(f). Measure the outside diameter of the piston at the
piston holding position by a screw micrometer. 10
Nominal Size of Piston Holding:
Caution:
The piston holding position is 74mm down from the
piston top.

(g). Insert the piston pin into the piston pin boss hole and
rotate. If the piston rotates flexibly without clearance,
the clearance is normal; if it rotates roughly with
clearance, measure its clearance. If the clearance
measured exceeds the specified limit, replace the
piston and piston pin.
Model Nominal Value Limit Value
LL380 -0.0045~0.0105 mm -
LL480 -0.0045~0.0105 mm -
QC480 - -
 09-76 Mechanical System - Piston and Connecting Rod Assembly

(h). Install the piston ring into he cylinder liner, and

measure its opening clearance by a feeler gauge.
Tip:
Push the piston ring by the piston top to make it vertical to
01 the cylinder wall and go into the smallest position of the
cylinder liner hole.
02

03

04
(i). Measure the clearance between the piston ring
05 groove and piston ring. If the clearance measure
exceeds the specified the limit, replace the piston
06 ring; if the clearance still fails to meet the standard
after a new piston ring is installed, replace the piston.
Caution:
07 The piston ring must be replaced in group.
Clearance between Top Piston Ring and Piston Ring
08 Groove:
Reference
Model Nominal Value
09 Limit
LL380 0.095~0.128 mm 0.25mm
10 LL480 0.095~0.128 mm 0.25mm
QC480 0.060~0.092 mm 0.20mm

Clearance between Second Piston Ring and Piston

Ring Groove:
Reference
Model Nominal Value
Limit
LL380 0.04~0.072 mm 0.18mm
LL480 0.04~0.072 mm 0.18mm
QC480 0.040~0.072 mm 0.18mm

Clearance between Oil Ring and Piston Ring Groove:

Reference
Model Nominal Value
Limit
LL380 0.03~0.067 mm 0.18mm
LL480 0.03~0.067 mm 0.18mm
QC480 0.03~0.067 mm 0.18mm
Mechanical System - Piston and Connecting Rod Assembly 09-77

12. Check Piston Ring

(a). Check the abrasive wear of the piston ring.
Tip:
Black abrasive coating on the right side of the piston ring
decreases rapidly, and sometimes the black abrasive 01
coating disappears, which indicates that the abrasive
wear occurs to the intermediate ring. Usually, this is 02
deemed as complete wear of the ring surface. The rapid
decrease of coating will cause the result that the bottom 03
edge of the intermediate ring is sharpened. Concentrated
vertical scratches on the top ring also indicate the
abrasive wear. The following points may cause abrasive 04
wear:
y Suction of abrasive; 05
y Incomplete cleaning in previous repairs;
y Embedding of particles into the cylinder hole; 06
y Extension of oil drain interval, causing increased soot
content in oil; 07
y Scratching and scoring.
(b). Check the oil ring is blocked.
08
Tip:
The evidence for oil ring blocking is that deposits exist on
the oil ring groove. It can be caused by the following 09
points:
y The working temperature of the engine is low – long 10
at idle speed or faults in the cooling system;
y The oil replacement interval extends;
y Use the engine oil with a wrong grade;
y Use inferior engine oil.
Caution:
The oil return blocking of the oil ring limits the return
flow of oil, the area where the piston ring is located
will be filled with oil, and the oil control is poor.

13. Install Piston Assembly

(a). Install the upper shell of the connecting rod bearing
shell.
Tip:
The cylinder and all parts must be kept clean before
installation. Clean the connecting rod and bearing shell by
a piece of clean lint-free cloth.
Caution:
Make sure that the connecting rod and the back side
of the connecting rod bearing are clean, free from any
debris. The back side of the connecting rod bearing
shall not be lubricated.

Caution:
Make sure that the locating lugs of the bearing shells
are aligned with the locating lug groove on the
connecting rod during installation.
 09-78 Mechanical System - Piston and Connecting Rod Assembly

(b). Drop clean oil or equivalent on the inner side of the

bearing shell.

01

02

03

04
(c). Lubricate the piston ring and piston skirt with clean
05 oil.

06

07

08

09
(d). Rotate and adjust the opening position of the piston
10 ring according to the left picture.
Tip:
The opening of each piston ring shall not be aligned with
the openings of the piston pins or other piston rings. If the
opening position of the piston ring is incorrect, the piston
ring can not be sealed correctly.

(e). Compress the piston ring to the working position by a

piston ring compressor.
Tip:
It is allowable to make an annular cylinder if there are no
special tools.

(f). Rotate the crankshaft to let the journal of the

connecting rod to be installed stay at the bottom dead
center.
Mechanical System - Piston and Connecting Rod Assembly 09-79

(g). Apply a thick layer of oil on the cylinder wall.

01

02

03

04
(h). Insert the connecting rod into the cylinder hole until
the piston skirt goes into the cylinder, and allow the 05
piston ring mounter to touch the lower edge of the
cylinder. 06

07

08

09
Tip:
Align the arrow on the piston top to allow it to point to the 10
engine front. The big end of the connecting rod and the
notch on the piston skirt shall stay at the exhaust side of
the engine. If not, check whether the piston is installed on
the connecting rod correctly.
Caution:
Noncompliance with this procedure will cause
serious damage to the engine.

(i). Use a piston ring compressor against the cylinder,

and tap the piston in the cylinder by a rubber or wood
bar.
Caution:
If the piston can not move freely, remove it and check
whether the piston ring is broken or damaged.

(j). Install the lower shell of the connecting rod bearing

shell to the connecting rod bearing shell cover.
Caution:
y Make sure that the connecting rod cap and the
back side of the connecting rod bearing are
clean, free from any debris. The back side of the
connecting rod bearing shall not be lubricated.
y If a new bearing is unavailable, the old one must
be installed on the same connecting rod from
which it is removed.
 09-80 Mechanical System - Piston and Connecting Rod Assembly

Caution:
Make sure that the locating lugs of the bearing shells
are aligned with the locating lug grooves on the
connecting rod cop during installation.
01

02

03

04
(k). Lubricate the inner side of the lower shell of the
05 connecting rod bearing shell with clean oil.

06

07

08

09
(l). Install each connecting rod cap to the journal
10 corresponding to its crankshaft.

Caution:
The No. of the connecting rod must be the same with
that of the connecting rod cover, and must be
installed in the correct cylinder. The No. of both the
connecting rod and connecting rod cover must be
located at the same side of the connecting rod to
avoid damage to the engine during running.

(m). Lubricate connecting rod bolts with clean oil or

equivalent grease.
Mechanical System - Piston and Connecting Rod Assembly 09-81

(n). Screw up connecting rod bolts and tighten them

alternately time and again by a torque and angular
tightening method.
Tip:
The connecting rods need tightening alternately and 01
gradually in pair
Model Torque (N·M) 02
LL380 55~65
LL480 55~65 03
QC480 50~60
04
(o). Measure the clearance between the connecting rod
body and crankshaft. 05
Tip:
Do not measure the backlash between the connecting rod 06
cover and crankshaft.
Model Nominal Value Limit Value 07
LL380 0.04~0.101mm 0.20 mm
LL480 0.04~0.101mm 0.20 mm 08
QC480 - -
Tip: 09
If the piston, crankshaft, connecting rod or cylinder is
changed/replaced, it is necessary to measure the 10
extrusion of the piston from the cylinder combustion front.
The steps are as follows:
y Install a dial indicator on the cylinder head, and zero
it.
y Move the dial indicator over the piston top to
eliminate all sidewise movements.
y Rotate the crankshaft to the top dead center. Rotate
the crankshaft clockwise and counterclockwise,
observe the maximum reading of the dial indicator,
and record the measurement result. Judge the result.

14. Install Oil Pump Assembly

(a). Apply lubricating oil on the oil pump gears, and place
the oil pump assembly to the installation position.
Tip:
Before installing the oil pump, measure the pressure of
the oil pump, and fill the oil pump with a little lubricating oil
if the pressure is satisfied.
 09-82 Mechanical System - Piston and Connecting Rod Assembly

(b). Install oil pump assembly fixing nuts.

Tip:
Do not screw up too tightly.

01

02

03

04
(c). Install oil pump assembly fixing bolts.
05 Tip:
Tighten oil pump fuel outlet pipe fixing bolts and oil pump
06 assembly fixing bolts alternately one by one.

07

08

09
15. Install Timing Gear Chamber (Refer to Chapter 08 Assembly of Engine – Timing Gear
10 Chamber and Crankshaft, Installation)
16. Install Flywheel Housing and Oil Pan (Refer to Chapter 08 Assembly of Engine – Flywheel
Housing and Oil Pan, Installation)
17. Install Cylinder Head Assembly (Refer to Chapter 08 Assembly of Engine – Cylinder Head
and Tappet, Installation)
18. Install Rocker Arm Assembly (Refer to Chapter 08 Assembly of Engine – Rocker Arm and
Cylinder Head Cover, Installation)
19. Install Cylinder Head Cover (Refer to Chapter 08 Assembly of Engine – Rocker Arm and
Cylinder Head Cover, Installation)
 Mechanical System - Crankshaft and Flywheel Assembly 09-83

Crankshaft and Flywheel Assembly

Part Drawing
01

02

03

04

05

06

07

08

09

10

1 Starting Claw 8 Pin B8×20

2 Gasket, Starting Claw 9 Flywheel Ring Gear
3 Crankshaft Pulley 10 Flywheel
4 Crankshaft Timing Gear 11 Flywheel Bolt Gasket
5 Key C10×65 12 Flywheel Bolt
6 Crankshaft 13 Clutch Driven Disc
7 Deep Groove Ball Bearing 14 Clutch Pressing Disc and Housing Assembly
 09-84 Mechanical System - Overhaul

Overhaul
1. Remove Flywheel
(a). Remove flywheel fixing bolts.
01 Tip:
Jam the flywheel with articles from the starter position
02 during removal to prevent the flywheel from rotating and
facilitate the removal.
03

04

05
(b). Take down the flywheel gasket.
06

07

08

09

10
(c). Take down the flywheel.
Tip:
The flywheel is heavy, pay attention when taking down,
and handle with care to avoid damaging the ring gear.

2. Overhaul Flywheel
(a). Check the flywheel working face visually; repair or
replace if there are grooves formed due to wear or
the ring gear is worn.
 Mechanical System - Overhaul 09-85

(b). Check flywheel teeth, and repair or replace if they are

worn or damaged.

01

02

03

04
3. Remove Cylinder Head Cover (Refer to Chapter 07 Disassembly of Engine – Cylinder Head
Cover and Rocker Arm, Removal) 05
4. Remove Rocker Arm Assembly (Refer to Chapter 07 Disassembly of Engine – Cylinder Head
Cover and Rocker Arm, Removal) 06
5. Remove Cylinder Head (Refer to Chapter 07 Disassembly of Engine – Cylinder Head Cover,
Removal)
6. Remove Oil Pan and Flywheel Housing (Refer to Chapter 07 Disassembly of Engine – Oil Pan 07
and Flywheel, Removal)
7. Remove Timing Gear Chamber (Refer to Chapter 07 Disassembly of Engine – Camshaft and 08
Timing Gear Chamber, Removal)
8. Remove Oil Pump (Refer to Chapter 07 Disassembly of Engine – Oil Pump and Piston 09
Assembly, Removal)
9. Remove Connecting Rod and Piston (Refer to Chapter 07 Disassembly of Engine – Oil Pump 10
and Piston Assembly, Removal)

10. Perform Initial Testing for Crankshaft Axial

Clearance
(a). Measure the axial clearance of the crankshaft by a
dial indicator and magnetic base.
Tip:
The sizes of the thrust bearing and crankshaft journal
determine its axial clearance.
Model Nominal Value Limit Value
LL380 0.075~0.24 mm 0.5 mm
LL480 0.075~0.24 mm 0.5 mm
QC480 0.075~0.265 mm -

11. Remove Main Bearing Shell and Crankshaft

(a). Loosen main bearing cover bolts one by one.
Tip:
Loosen all bolts diagonally one by one, but do not take
them down.
 09-86 Mechanical System - Overhaul

(b). Take down the main bearing covers, and put them in
order.
Tip:
y Hold main bearing cover bolts with both hands and
01 shake the main bearing cover, or loosen the main
bearing cover by a rubber hammer, and then take out
02 the main bearing cover.
y Mark each main bearing cover on the top, which is
03 convenient for installation.

04
(c). Remove the lower shell of each main bearing shell.
05 Tip:
The crankshaft thrust washers are installed at the position
06 of the rear main bearing cover, do not forget to take
down, and record the installation positions as well as
right and back sides to avoid wrong installation.
07

08

09
(d). Mark each main bearing shell on its movable lug.
10

(e). Install bearing shells on bearing shell covers in order.

(f). Take out the crankshaft assembly.

Tip:
As this component is heavy, in order to avoid serious
personal injuries, this component or assembly shall be
lifted with the help of others or by suitable hoisting
equipment. Because this component is a precision part,
handle it with cares, and make sure it is placed on a clean
workbench horizontally or vertically.
Mechanical System - Overhaul 09-87

(g). Take out the upper shell of each main bearing shell.
Tip:
Take out each upper shell in order and mark; do not forget
to take down crankshaft thrust washers and record the
installation positions as well as right and back sides. 01

02

03

04
12. Overhaul Main Bearing Shell and Main Bearing
Cover 05
(a). Clean main bearing covers, etc. by clean steam or
hot soap water. 06
Caution:
When using the steam cleaner, wear goggles or
protective mask and protective clothing. Otherwise, 07
hot steam may cause serious personal injuries.
08

09
(b). Dry all parts with compressed air.
Caution: 10
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.

(c). Check whether there are deep scratches on all main

bearing covers and main bearing bolts or they are
overheated.
Caution:
Replace if the main bearing cover is damaged.

(d). Check whether there are deep scratches on main

bearing shells or they are overheated.
Caution:
Replace if the main bearing shell is damaged.
 09-88 Mechanical System - Overhaul

(e). Check whether there are scorings or burrs on the

bearing shell seating surface.
Tip:
If there are scorings or burrs, use a polishing pad to grind.
01 If the scorings or burrs can not be cleared away by the
polishing pad or equivalent, replace the bearing.
02

03

04
(f). Check the rear main bearing cover, and make sure
05 that the annular locating pins have been installed.

06

07

08

09
13. Overhaul Crankshaft
10 (a). Clean the crankshaft and gear by hot soap water.

(b). Clear away oil holes by a non-metal scrubbing brush.

(c). Dry with compressed air. Make sure that water drops
are blown away from screw holes at both ends of the
crankshaft and from oil passage.
Caution:
Appropriate goggles and protective masks shall be
worn for using compressed air to prevent splashed
debris and dirt from causing personal injuries.
Mechanical System - Overhaul 09-89

(d). Check whether the threads at both ends of the

crankshaft are damaged. Replace the crankshaft if
any.
Caution:
Do not trim the threads of the crankshaft. Otherwise, 01
the engine will be damaged seriously.
02

03

04
(e). Check the middle of the crankshaft web and the ends
of the crankshaft web and connecting rod journal, and 05
replace if there are cracks.
06

07

08

09
(f). Check whether there are scratches; repair if
scratches are light, or replace it scratches are 10
serious.

(g). Perform multi-point measurement on the same cross

section of the crankshaft by an outside micrometer.
Nominal Size of Crankshaft Main Journal:

Tip:
The crankshaft main journal is fit with the main bearing
shell hole. Therefore, when measuring the outside
diameter of the crankshaft main journal, measure the
inside diameter of the main bearing shell hole by the
micrometer, and subtract the measured inside diameter of
the main bearing shell from the measured outside
diameter of the crankshaft main journal. Replace the main
bearing shell if the value obtained from subtraction
exceeds the specified value.
Model Nominal Value Limit Value
LL380 0.08~0.138 mm 0.25 mm
LL480 0.08~0.138 mm 0.25 mm
QC480 0.070~0.139 mm 0.25 mm
 09-90 Mechanical System - Overhaul

(h). Carefully place the crankshaft on the V-blocks, rotate

it slowly and measure its redial runout; replace or
perform cold straightening for the crankshaft if the
radial runout of the crankshaft exceeds the specified
01 limit.
Nominal Value: ≤0.05mm
02 Limit Value: 0.08mm

03

04
(i). For the straightening of crankshaft bending, deform
05 the crankshaft by striking the non-processed face of
the crankshaft surface, force the crankshaft axis to
shift, and thus straighten the crankshaft.
06

07

08

09
14. Install Crankshaft
10 (a). Install the upper shells of the main bearing shells to
the corresponding positions.
Tip:
Install the upper shells of the main bearing shells to the
corresponding positions carefully in order. Make sure that
the back of each bearing shell is clean, the upper shell of
each main bearing shell is in the center of the shell
groove, and the upper end faces are flush. Apply an
appropriate amount of oil or equivalent on the inner side of
the arched surface of each bearing shell after installation.

Caution:
Make sure that the locating lugs of the bearing shells
are aligned with the locating lug grooves on the
cylinder saddle of the main bearing shells during
installation.

(b). Install the crankshaft assembly to the corresponding

position.
Caution:
y As this component is heavy, in order to avoid
serious personal injuries, this component or
assembly shall be lifted with the help of others or
by suitable hoisting equipment.
y The crankshaft shall be installed carefully to
avoid damaging the main bearing, especially the
thrust/main bearing journal. The service life of the
engine will be shortened once the crankshaft is
damaged.
Mechanical System - Overhaul 09-91

(c). Apply oil on the lower shell of each main bearing shell
evenly, and install it to the main bearing cover.
Tip:
Slide the lower shell of the main bearing shell into the
main bearing shell cover from one side, and flatten the 01
end face.
02

03

04
Caution:
Make sure that the locating lugs of the bearing shells 05
are aligned with the locating lug grooves on the main
bearing cover during installation. 06

07

08

09
(d). Install the crankshaft thrust washer and bearing shell
at the side of rear main bearing cover to the rear main 10
bearing cover.
Caution:
y Make sure that the locating lugs of the bearing
shells are aligned with the locating lug grooves
on the main bearing cover during installation.
y Make sure that the side of the crankshaft thrust
washer with a groove is outward during
installation.

(e). Install the main bearing covers in order.

Tip:
y When installing the rear main bearing cover, note that
the crankshaft thrust washers may fall off.
y Install the main bearing covers to the original
positions according to their marks without any
mistake.

(f). Put main bearing cover bolts into the mounting holes
in order and tighten slightly by hand.
Tip:
Drop am appropriate amount of oil on the threads of main
bearing cover bolts.
 09-92 Mechanical System - Overhaul

(g). Tighten the main bearing bolts according to certain

sequence and torque.
Model Torque (N·M)
LL380 135~150
01 LL480 135~150
QC480 120~130
02

03

04
Tip:
05 y The bolts shall not be tightened once but screwed
little by little until reaching the specified torque
06 gradually.
y The main bearing cover bolts must be tightened in a
certain order (as shown in the left picture).
07 Tip:
The crankshaft installed shall be rotated for several circles
08 to check whether the rotation is smooth and flexible.

09
14. Check Crankshaft Axial Clearance
10 (a). Measure the axial clearance of the crankshaft by a
dial indicator and magnetic base.
Tip:
The sizes of the thrust bearing and crankshaft journal
determine its axial clearance.
Model Nominal Value Limit Value
LL380 0.075~0.24 mm 0.5 mm
LL480 0.075~0.24 mm 0.5 mm
QC480 0.075~0.265 mm -

15. Install Piston Assembly (Refer to Chapter 08 Assembly of Engine – Piston Assembly and Oil
Pump, Installation)
16. Install Oil Pump Assembly (Refer to Chapter 08 Assembly of Engine – Piston Assembly and
Oil Pump, Installation)
17. Install Timing Gear Chamber (Refer to Chapter 08 Assembly of Engine – Timing Gear
Chamber and Crankshaft, Installation)
18. Install Flywheel Housing and Oil Pan (Refer to Chapter 08 Assembly of Engine – Flywheel
Housing and Oil Pan, Installation)
19. Install Cylinder Head Assembly (Refer to Chapter 08 Assembly of Engine – Cylinder Head
and Tappet, Installation)
20. Install Rocker Arm Assembly (Refer to Chapter 08 Assembly of Engine – Rocker Arm and
Cylinder Head Cover, Installation)
21. Install Cylinder Head Cover (Refer to Chapter 08 Assembly of Engine – Rocker Arm and
Cylinder Head Cover, Installation)
 Mechanical System - Engine Body 09-93

Engine Body
Part Drawing
01

02

03

04

05

06

07

08

09

10
 09-94 Mechanical System - Engine Body

1 Cylinder Liner 11 Washer 8

2 Cylinder Head Bolt 12 Nut M8
3 Locating Sleeve 13 Bolt M8×16
4 Gasket, Cylinder Head 14 Gasket, Side Plate
5 Water Seal Ring, Cylinder Liner 15 Side Cover (I)
01
6 Pin B10×20 16 Bolt M10×25
7 Bowl-shaped Plug φ10 17 Rear Bushing, Camshaft
02 8 Plug, Main Oil Passage 18 Intermediate Bushing, Camshaft
9 Plug φ55 19 Front Bushing, Camshaft
10 Bolt M8×22
03

04

05

06

07

08

09

10
 Mechanical System - Overhaul 09-95

Overhaul
1. Remove Engine Body (Chapter 07 Disassembly of Engine)
01
2. Remove Cylinder Liner
(a). Remove the cylinder head gasket. 02

03

04

05

06

(b). Install a cylinder liner remover on the cylinder liner, 07

inspect whether the bottom edge of the cylinder liner
is firmly supported by the base on the remover shaft,
and then slowly rotate the hand wheel of removal 08
shaft counterclockwise to pull out the cylinder liner.
09

10

3. Overhaul Engine Body

(a). Clean the engine body in a cleaning tank.
Caution:
y The cleaning by solvents and acid or alkaline
substances shall be subject to the usage
proposal from the manufacturer.
y Goggles and protective clothing shall be worn to
avoid personal injuries.
y Clean by the solution which can not damage the
camshaft bushing.
y The cleaning by the cleaning tank shall be subject
to the operation instruction from the
manufacturer.
y The cleaning by solvents shall be subject to the
operation instruction from the manufacturer.

(b) Completely clean the cylinder with steam and then

dry it with compressed air.
Caution:
y When using the steam cleaner, wear goggles or
protective mask and protective clothing.
y Hot steam may cause serious personal injuries.
 09-96 Mechanical System - Overhaul

Caution:
In order to reduce the possibility of engine damage,
make sure all the debris are cleared from the bolt
holes and oil passages. If the cylinder is not used
01 immediately, one layer of protective oil shall be
applied so as to prevent rusting. The cylinder shall be
02 covered to prevent dirt from adhering to oil.

03

04
(c). After cleaning the cylinder, re-check whether on the
05 cylinder cover are there cracks, corrosion and
discoloration that will affect its continuous use.
06

07

08

09

(d). Check whether there are scorings, scratches or

10
excessive wear for the crankshaft hole. If the damage
degree of the hole exceeds the allowable range, the
cylinder must be replaced, because there are larger
bushings.

(e). Measure the lengths of four sides and the diagonal

lines on the engine body. If the measured value
exceeds the specified limit, the engine body must be
replaced.

(f). Measure the flatness of the engine body surface with

a ruler and a feeler gauge, and repair or replace the
engine body if the measure value exceeds the
specified limit.
Mechanical System - Overhaul 09-97

(g). Check visually whether the cylinder head gasket is

damaged or crack, and replace if any.

01

02

03

04
(h). Measure the diameter of the cylinder liner by an
inside dial indicator at least two different directions. 05
The cylinder liner must be replaced if the measured
value exceeds the specified limit. 06
Nominal Size of Cylinder Liner:
Tip: 07
The cylinder liner hole is fit with the cylinder liner.
Therefore, when measuring the diameter of the cylinder
liner hole, it is necessary to measure the outside diameter 08
of the corresponding cylinder liner by a micrometer, and
then subtract the measured diameter of the cylinder liner 09
hole from the outside diameter of the cylinder liner.
Replace the cylinder liner if the value obtained from 10
subtraction exceeds the specified value.
Reference Limit: 0.2mm
Caution:
The diameter of the cylinder liner hole and the outside
diameter of the cylinder liner, which are measured on
the smooth surface of the upper and lower sections,
are effective.

(i). Visually check whether the cylinder liner cracks or is

corroded, and replace if any.

(j). Take down the cylinder liner water seal ring.

 09-98 Mechanical System - Overhaul

(k). Visually check whether the cylinder liner water seal

ring cracks or is corroded, and replace if any.

01

02

03

04
(l). Clean the oil passage and water passage on the
05 engine body by a water gun after removing all the
accessories from the engine body.
06

07

08

09
4. Install Cylinder Liner
10 (a). Install the cylinder liner water seal ring.
Tip:
After installing the cylinder liner water seal ring, it is
necessary rotate one circle to prevent the water seal ring
from distortion, and apply an appropriate amount of
lubricating oil on the water sealing ring evenly.

(b). Install the cylinder liner with special tools.

Tip:
Completely clean the surfaces of the cylinder liner and
cylinder hole with new kerosene or diesel, and then dry
with compressed air. All the foreign matters must be
cleared away carefully from the cylinder liner and cylinder
hole before installing the cylinder liner.
Fuel System
Fuel System .................................................................10-1 01
General.....................................................................10-1
Part Drawing.............................................................10-2
Fuel Filter .....................................................................10-3 02
Overhaul ...................................................................10-3
Fuel Pipeline ................................................................10-6 03
Overhaul ...................................................................10-6
Fuel Injection Pump ...................................................10-11 04
Adjustment..............................................................10-11
Fuel Injector ...............................................................10-14 05
Part Drawing...........................................................10-14
Test ........................................................................10-16
06
Disassembly and Cleaning .....................................10-17
Overhaul .................................................................10-20
Assembly and Debugging.......................................10-22 07

08

09

10

11

12
 09-2 Fuel System - Overhaul

01

02

03

04

05

06

07

08

09

10

11

12
 Fuel System - Fuel System 10-1

Fuel System
General
Fuel system is a major operation part of diesel engine, and it comprises a fuel pump, a fuel filter, fuel 01
injectors, high pressure oil pipes, etc. The fuel transfer pump sends fuel in the fuel tank to the fuel filter,
and then the fuel enters the fuel injection pump, the fuel generates high pressure in the fuel pump and is
02
injected to the combustion room for combustion in a mist form from the fuel injector via high-pressure
pipelines.
The remaining fuel in the fuel injector and the surplus fuel supplied by the fuel injection pump flow back 03
into the fuel tank through oil return lines. A check valve is equipped at the connecting bolt at oil return
lines of filters and fuel injection pump to prevent fuel and air from returning and entering oil supply 04
system in case that engine fails to work, and ensure that fuel pump provides stable fuel pressure at the
low pressure fuel chamber. 05

06

07

08

09

10

11

12
 10-2 Fuel System - Fuel System

Part Drawing

01

02

03

04

05

06

07

08

09

10

11

12

1 Fuel Filter Parts 7 Fuel Injector Assembly

2 Fuel Pump to Fuel Oil Filter Pipe 8 High-Pressure Pipeline Components
3 Fuel Filter To Fuel Injection Pump Pipe 9 Fuel Injection Pump Assembly
4 Washers 10 10 Hollow Bolts
5 Bolt M10 × 30 5 11 O-Ring
6 Fuel Return Pipe Parts
 Fuel System - Fuel Filter 10-3

Fuel Filter
Overhaul
1. Remove Fuel Filter 01
(a) Remove the hollow bolt at oil inlet of the fuel filter.
• Remove the hollow bolt seals and fuel pipe
02
routing from oil transfer pump to the fuel filter.
• Check whether O-ring is aged, if it is aged,
replace it with a new one. 03

04

05

(b) Remove the hollow bolt at oil outlet of the fuel filter. 06
• Remove O-ring at hollow bolt and oil pipe routing
from fuel filter to fuel injection pump. 07
• Check whether O-ring is aged, if it is aged,
replace with a new one. 08

09

10

11
(c) Remove the fixed bolts of the fuel filter.
• Remove the fuel filter. 12

2. Check Fuel Filter

(a) Clean fuel filter with diesel oil.
• Check whether the outer surface of the fuel filter
has defects and cracks, if so, replace it with a
new fuel filter.
 10-4 Fuel System - Fuel Filter

3. Replace Fuel Filter Elements

(a) Remove center bolt of the oil filter, and remove the oil
filter element.
(b) Check O-ring of the fuel filter and detect whether it is
01 aged or damaged, if so, replace it with a new one
(c) Replace the fuel filter elements.
02

03

04
4. Assemble Fuel Filter
05 (a) Screw the center of the fuel filter by hand, and tighten
it.
06 Note:
When assembling fuel filter, keep contact surfaces
clean between the fuel filter holder and fuel filter
07 elements, and coat with a thin layer of oil to O-ring or
bonded seals.
08

09
(b) Use a wrench to screw the center bolt of fuel filter and
10 tighten it to the standard requirement.
Note:
11 Do not screw the center of the fuel filter bolts too
tight, so as to avoid damaging bolts and screw
12 thread.

5. Install Fuel Filters to Engine

(a) Install fuel filters to the engine, mount connecting
bolts for fuel filters and engine, and screw it to the
standard requirement.

(b) Install oil pipe from fuel filter to fuel injection pump
and mount hollow bolt that is connected to fuel filter.
Tip:
When installing, coat with a thin layer of oil to O-ring at
hollow bolt.
Fuel System - Fuel Filter 10-5

(c) Install oil pipe from oil transfer pump to fuel filter and
mount a hollow bolt that is connected to fuel filter.
Tip:
When installing, coat with a thin layer of oil to O-ring at
hollow bolt. 01

02

03

04

05

06

07

08

09

10

11

12
 10-6 Fuel System - Fuel Line

Fuel Line
Overhaul
01 1. Overhaul Oil Pipe From Oil Transfer Pump To
Fuel Filter.
02 (a) Remove the hollow bolts at both ends of oil transfer
pump to fuel filter.
• Remove oil pipe from oil transfer pump to fuel
03
filter.

04

05

06
(b) Check whether sealing surface on the hollow joint
surface at both ends of oil transfer pump to fuel filter
07 is damaged.
• Check whether the bonded seal gasket is aged
08 or damaged, if so, replace it with a new one.
• Check oil pipes from oil transfer pump to fuel
09 filter are aging, if it is aged, replace them with
new ones.
10

11
(c) Install oil pipe from oil transfer pump to fuel filter,
12 sealing gaskets and hollow bolts, screw hollow bolts
with a wrench to the standard requirement.

2. Overhaul Oil Pipe from Fuel Filter to Fuel

Injection Pump.
(a) Remove the hollow bolts at both ends from fuel filter
to fuel injection pump.
• Remove O-ring and gasket and oil pipe from fuel
filter to fuel injection pump.
Fuel System - Fuel Line 10-7

(b) Check hollow connector at both ends from the fuel

filter to the injection pump.
Whether the surface of the sealing surface is
damaged.
• Check whether the O-ring is aged or damaged, if 01
so, replace it with a new one.
• Check oil pipe from the fuel filter to the fuel 02
injection pump is aged, if it is aged, replace it
with a new oil pipe.
03

04
(c) Mount oil pipe from fuel filter to fuel injection pump,
sealing gaskets and hollow bolts, and use a wrench 05
to tighten hollow bolts to the standard requirement.
06

07

08

09
3. Overhaul Oil Return Pipe.
(a) Remove hollow bolts of fuel injector, and remove the 10
gasket and O-ring.
11

12

(b) Remove hollow bolts of oil return pipe and washer

and gasket.
Tip:
Remove the hollow connector of oil return pipe, screw
hollow bolts of oil return pipe to this location, so as to
avoid mixing with other hollow bolts.

(c) Remove oil return pipe parts

 10-8 Fuel System - Fuel Line

(d) Check whether sealing surface on the surface of

hollow connector of fuel injector is damaged.
• Check whether the combined gasket and o-ring
is aged or damaged, if it is damaged, replace it
01 with a new one.
• Check whether the oil pipe is aged, if it is
02 damaged, replace it with a new one.

03

04
(e) Check whether the surface of hollow connector of oil
05 return pipe is aged
• Check whether the combined gasket and o-ring
06 is aged or damaged, if it is damaged, replace it
with a new one.
• Check whether the oil pipe is aged, if it is
07 damaged, replace it with a new one.

08

09
(f) Put oil return pipe parts to fuel injector.
10

11

12

(g) Install sealing washer of injector, hollow bolts, and

screw hollow bolts with a wrench to the standard
requirement.

(h) Install the sealing washer of injector, hollow bolts,

hollow bolts, and screw hollow bolts with a wrench to
the standard requirement.
Fuel System - Fuel Line 10-9

4. Overhaul High-Pressure Pipeline Parts

(a) Disassemble connecting nuts for high pressure oil
pipe and fuel injector.

01

02

03

04
(b) Remove connecting nuts for high pressure oil pipe
and fuel injector. 05
Tip:
After removing, immediately use sealing cover of oil pipe
connector to seal both oil outlet port of fuel injection pump 06
and oil inlet port of the injector.
07

08

09
(c) Respectively remove the high-pressure oil pipe.
10

11

12

(d) Use clean diesel oil to clean high pressure oil pipe,
check whether it is damaged. If it is damaged,
replace it with a high pressure oil pipe.
• Cleaning oil circuit of the high-pressure oil pipe.

(e) Remove the sealing cover for oil outlet pipe of fuel
injection pump and oil outlet pipe of fuel injector, and
install the high-pressure oil pipe.
 10-10 Fuel System - Fuel Line

(f) Mount the connection nut for high-pressure oil pipe

and fuel injection pump, and screw the nut to the
standard requirement with a wrench.
Note:
01 When installing, ensure the clean interface between
high-pressure fuel pipe and fuel injection pump.
02

03

04
(g) Install the connection nut for high-pressure fuel pipe
05 and injector, screw the nut to the standard
requirement with a wrench
06 Tip:
When installing, ensure the clean interface between
high-pressure fuel pipe and fuel injection pump. Don’t
07 tighten directly high pressure oil pipe of injector side, after
starting the engine, and after injecting fuel at nut
08 connection between high pressure oil pipe and fuel
injector, close the engine, and screw all nuts for high
09 pressure oil pipe of fuel injector to the standard
requirement once.
10

11

12
 Fuel System - Fuel Injection Pump 10-11

Fuel Injection Pump

Adjustment
1. Adjustment of Injection Timing. 01
(a) Discharge air in the fuel system.
(b) Repeatedly turn the crankshaft so as to make fuel
02
injection pump full of fuel.
03

04

05

(c) Remove the first-cylinder high-pressure oil pipeline. 06

07

08

09

10

11
(d) Blow leftover oil away from connector hole of oil valve
seat. 12

(e) Slowly turn the crankshaft.

 10-12 Fuel System - Fuel Injection Pump

(f) Observe the oil level of connector hole, at the

moment the oil level fluctuates, and immediately stop
turning the crankshaft.

01

02

03

04
(g) Check whether the scale on leather driving wheel
05 meets the above requirements of fuel supply advance
angle.
06 Tip:
Fuel supply advance angle: 15 ± 1 ° CA.
When the engine is at the dead center of 4-cylinder
07 compression stroke, 1 cylinder outlet port for
high-pressure fuel pump doesn’t have oil injection, turn
08 the crankshaft 360 °, so when the scale on the pulley and
the is again close to pointer calibration, turn slowly crank,
09 when seeing first cylinder oil outlet port for high-pressure
fuel pump flows out fuel, stop turning the crankshaft,
10 observe the scale on the pulley, whether 15 ± 1 ° is at
pointer position, if it is not up to the standard, adjust fuel
supply advance angle.
11

12 (h) If the advance angle is too large or too small, adjust it

by releasing the three bolts on the connection plate
for high-pressure fuel pump.

(i) If the advance angle is too large, turn the

high-pressure fuel pump counterclockwise to an
appropriate angle.
Fuel System - Fuel Injection Pump 10-13

(j). If the advance angle is too small, turn high-pressure

fuel pump clockwise to an appropriate angle..

01

02

03

04
(k). Tighten the three bolts.
• Recheck the fuel supply advance angle. 05
• Repeat steps h-k, until the scale on pulley meets
fuel supply advance angle defined in above.
06

07

08

09
(l). Mount the first cylinder high-pressure fuel pipe.
10

11

12
 10-14 Fuel System - Fuel Injector

Fuel Injector
Part Drawing
01

02

03

04

05

06

07

08

09

10

11

12
 Fuel System - Fuel Injector 10-15

1 Connector Hollow Bolt of Oil Return Pipe 8 Injector Body

2 Combined Sealing Washer 9 Seal Washer
3 Combined Sealing Washer 10 Fuel Inlet Pipe Joints
4 Lock Nuts 11 needle Valve
5 Pressure Adjusting Screw 12 Needle Valve Body 01
6 Pressure Adjusting Spring 13 Nozzle Fastening Nut
7 Mandrill 14 Seal Washer 02

03

04

05

06

07

08

09

10

11

12
 10-16 Fuel System - Fuel Injector

Test
1. Disassemble Fuel Injector Assembly
(a) Disassemble Injector (Refer to Chapter 07 Disassembly of Engine -- Fuel Line and Fuel
01 Injector, Removal).

2. Fuel Injector Test

02
(a) Install fuel injector to the test stand of the injector,
press the handle of fuel injection detector at a speed
03 of 4 to 6 times/sec, check whether particles flow out,
drop backward, spray abnormally in direction, etc.
04 Maintain the fuel injection pressure below 21.0MPa, if
there isno leak, it means good.
05 Opening pressure was 25 ± 0.5MPa, in case of any
abnormity, repair or replace the injector parts.
06

07

08

09
3. Fuel Injection Status of Injector.
10 (a) See the left picture for fuel injection of the injector.
(b) In case of bad atomization, adjust and repair the
11 injector.

12
 Fuel System - Fuel Injector 10-17

Disassembly and Cleaning

1. Clean Fuel Injector
(a) Put injector into the oil basin and clean the surface of
01
it.
Note:
When operating, please protect the head of needle 02
valve, clean it with a soft brush.
03

04

05
2. Disassemble Injector
(a) Clamp the injector well with table vice padded with 06
sheet copper, make the nozzle upward, remove the
nozzle fastening nut, and then remove the needle 07
valve body.
Note: 08
If the needle valve body is blocked by nozzle because
of carbon deposit and was fastened inside the nut,
please immerse it in clean diesel oil, then take out, 09
and hard-hit and hard pull are prohibited.
10

(b) Clamp the injector with table vice padded with sheet 11
copper, make the nozzle downward, unscrew the lock
nut, and unscrew the fuel inlet pipe connector of the 12
injector.

(c) Use a flat screw driver to unscrew the pressure

regulating screw, and then remove the pressure
regulating spring and mandrill.
 10-18 Fuel System - Fuel Injector

(d) Take the needle valve out of the inner of needle valve
body. If the needle valve was stuck inside of needle
valve body, it is forbidden to pull hard, it should be
soaked in clean kerosene, after a period of time
01 (sometimes a day), use pliers to clamp with pad to
grip and unscrew it.
02 Note:
All removed parts and components should be neatly
03 placed, and the needle valve and needle valve body
should be placed in pairs.
04
3. Cleaning Fuel Injector Parts
05 (a) Use clean diesel oil or kerosene to respectively clean
nozzle fastening nut, the fuel injector body, mandrel,
06 locking nut, adjusting screw and pressure regulating
spring.
(b) Use a copper needle to clean up oil line of the fuel
07 injector body.

08

09
(c) Use a soft brush or a fine copper wire brush to clean
10 external carbon deposit of needle valve body.

11

12

(d) Use a soft brush or a fine copper wire brush to clean

external carbon deposit of needle valve.

(e) Use a copper needle to clean the oil line of valve

needle body.
Fuel System - Fuel Injector 10-19

(f). Use a brass elbow scraper to insert into the pressure

chamber and rotate it to scrape the carbon deposit in
the pressure chamber of needle valve body.
(g). Use clean diesel oil to clean pintle nozzle matching
parts again. 01
Note:
Pintle nozzle matching parts can not be 02
interchangeable, not in disorder.
03

04

05

06

07

08

09

10

11

12
 10-20 Fuel System - Overhaul

Overhaul
1. Check Fuel Injector Body
01 Requirements:
Ensure precision plane matched with pintle nozzle
02 matching parts is clean and smooth, no scratches, and no
injuries for complete threads, plane for pad bearing is
03 even and smooth, replace in case of non-conforming to
the requirement.
04

05

06 2. Check Nozzle Fastening Nut

Requirements:
07 It is clean for Internal and external surfaces, no scratches,
complete thread without injury, the plane for pintle nozzle
matching part seat is clean, no signs of damage, replace
08 in case of non-conforming to the requirement.

09

10

11 3. Check Mandrel,
Requirements:
12 The shaft is upwright, and area that contacts with needle
valve is free of crack, replace it in case of non-conforming
to the requirement.

4. Check Pressure Regulating Spring

Requirements:
Plane for both ends is smooth, without excessive wear,
there are still good elasticity, without nicks on the surface,
and replace it in case of non-conforming to the
requirement.
Fuel System - Overhaul 10-21

5. Check Pressure Regulating Nut and Locking Nut

Requirements:
Thread is free of injuries, internal and external surface is
smooth and no cracks, nut bearing surface of pressure
regulating spring is smooth, without excessive wear, 01
pressure regulating nut with flat groove is good without
injuries, replace it in case of non-conforming to the 02
requirement..
03

04
6. Check Oil Intake Pipe Connector and Washers.
Requirements: 05
Thread for oil inlet pipe is complete free of injuries, the
surface is clean, no signs of damage, each pad surface is
smooth and no injuries, replace it in case of 06
non-conforming to the requirement.
07

08

09
7. Check Pintle Nozzle Matching Parts
Detection method is as below: 10
Pintle nozzle matching parts can be tested for sliding after
cleaning, so as to check whether the matching parts can 11
be used. Detection method is to put needle valve dipped
with clean diesel oil into needle valve body, and then the 12
pintle nozzle matching parts are tilted to 45 °, the needle
valve is drawn 1/3 length out from total length of needle
valve body, then let it go , it can reply on its own weight to
slide down slowly and smoothly, it is free of any obstacles,
sticking etc. replace in case pintle nozzle matching parts
are found with serious defects, if the defect is not so
serious, such as needle valve and the needle valve body
are less smooth, and when sliding test does not meet the
requirement, please use grinding method to repair it.
 10-22 Fuel System - Overhaul

Assembly and Debugging

1. Injector Assembly
(a) The injector body was clamped by the table vice
01 padded with copper pad, install mandrel, adjust the
spring, put regulating screws, use flat screw driver to
screw the adjusting screw, install into connector seal
02
gasket for oil inlet pipe of fuel injector, screw oil inlet
pipe of fuel injector to the standard requirement.
03

04

05
(b) Screw lock nut of fuel injector and tighten slightly.

06

07

08

09

10
(c) Turn the fuel injector upside down and clamp it with
11 table vice padded with sheet copper, install the
needle valve needle into the need valve body, then
12 make oil line of needle valve and that of fuel injector
aligned, install nozzle tightening nut and tighten it to
the standard requirement.

2. Injector Debugging
(a) Install the fuel injector to the injector tester, and use a
flat screw driver to adjust the adjustment screw of the
injector until atomization is good and meets the
requirements.
(b) After adjusting fuel injector well, remove the fuel
injector, then clamp the fuel injector by a table vice
padded with sheet copper to screw the lock nut of the
fuel injector to the standard requirement.
Lubrication System
Lubrication System ........................................................................11-1 01
General.......................................................................................11-1
Part Drawing...............................................................................11-2
Measurement .............................................................................11-5 02
Discharge ...................................................................................11-6
Refilling.......................................................................................11-7 03
Oil Pump ......................................................................................11-10
Overhaul...................................................................................11-10 04
Oil Filter........................................................................................11-14
Replacement ..........................................................................11-14 05
Adjustment of Oil Pressure .....................................................11-15
Oil Pan .........................................................................................11-16
06
Overhaul...................................................................................11-16
Dipstick ........................................................................................11-20
Replacement ..........................................................................11-20 07

08

09

10

11

12
 10-2 Lubrication System - Overhaul

01

02

03

04

05

06

07

08

09

10

11

12

13
 Lubrication System - Lubrication System 11-1

Lubrication System
General:
1. The lubrication system comprises the oil strainer, oil pump, oil filter, dipstick and pipelines. 01
2. The series of diesel engines is based on pressure and splash lubrication. The crankshaft main
bearings, connecting rod bearings, camshaft bushings, rocker arm shaft bushings, etc. depend on
02
pressure lubrication, while the cylinder liners, pistons, piston pins, connecting rod bushings, cams
and lifters, valves and valve guides, etc. depend on splash lubrication with oil mist. In addition, the
rolling bearing at the water pump shaft is lubricated by filling grease regularly. 03
3. Oil stored in oil pan oil is sucked through the oil strainer and then the oil intake pipe into the oil pump,
and is sent to the oil filter after pressurization. The oil after filtration enters the body main oil gallery 04
in three ways:
y One way reaches the connecting rod bearings after passing through main bearings and 05
crankshaft oil holes.
y One way leads to the camshaft bushing, and oil is intermittently fed to the rocker arm shaft 06
through the camshaft journal on the eccentric-strap oil groove;
y One way lead to the timing idle gear bearing.
4. The oil pump is a gear pump with an oblique structure, and the oil filter is of a single-stage paper 07
element type which can be changed regularly. During use, if the element is blocked, open the safety
valve so that oil flows into the main oil gallery, but then it loses the filtration effect. Therefore, 08
regularly clean or replace the element according to the requirements of "Technical Maintenance".
09

10

11

12

13
 11-2 Lubrication System - Lubrication System

Part Drawing

01

02

03

04

05

06

07

08

09

10

11

12

13

14
Lubrication System - Lubrication System 11-3

01

02

03

04

05

06

07

08

09

10

11

12

13
 11-4 Lubrication System - Lubrication System

1 Nut 18 Welded Part, Filter Screen

2 Washer 19 Flat Washers
3 Oil Pump Drive Gear 20 Bolt
4 Oil Pump Bushing 21 Dipstick Components
5 oil Pump Body 22 Welded Part, Dipstick Pipe
01
6 Woodruff Key 23 Gasket
7 Oil Pump Shaft 24 Oil Pan Gasket
02 8 Inner Rotor 25 Oil Pan
9 Pin 26 A Bounded Washer
10 External Rotor 27 Drain Plug
03
11 Oil Pump Gasket 28 Oil Filter Gasket
12 Oil Pump Cover 29 Gasket
04 13 Oil Outlet Pipe Gasket 30 Bolt
14 Oil Outlet Pipe 31 Oil Filter Parts
05 15 Filter Screen Body 32 Gasket
16 Washer 33 Bolt
17 Bolt
06

07

08

09

10

11

12

13

14
 Lubrication System - Lubrication System 11-5

Measurement
Tip:
Measure the oil level in the oil pan to see whether it falls between two scales of the oil gauge. Refill oil to
the upper scale for the diesel engine which is new or has not been used for a long time, stop after
01
running at the low speed for 5-10 minutes, and then use the oil gauge to measure the oil level height.

1. Check Oil Level 02

(a) Take out the dipstick.
03

04

05

06

07
(b) Check the oil level, which shall be neither higher than
the upper limit position, nor below the lower limit 08
position.
09

10

11

12

13
 11-6 Lubrication System - Lubrication System

Discharge
1. Unscrew Drain Plug with Wrench.
Note:
01 Before discharging oil, run the engine until the
coolant temperature reaches about 60 °C, so as to
ensure complete release of all the engine oil and
02
suspended dirt.

03

04

05

06

07

08 2. Discharge Oil in Oil Pan

Note:
When discharging oil, prevent skin from contacting
09 hot oil to avoid scald.

10

11

12

13

14
 Lubrication System - Lubrication System 11-7

Filling
1. Check Drain Plug
(a) Unscrew oil screw bolts, check discharge oil bolt and
a bounded washer, and replace it in case of damage.
01

02

03

04

(b) Clean and check oil discharge screw thread and the 05
sealing surface, if the thread is damaged, tapping or
reaming repair can be employed. 06

07

08

09

10
(c) Before installing the drain plug, clean it with clean
lubricating oil. 11

12

13

(d) Mount A-type bounded washer and drain plug, coat it

if necessary. Wipe suitable sealant.
Tip:
When changing oil, oil filter element must be replaced.
 11-8 Lubrication System - Lubrication System

2. Unscrew Oil Filler Caps

(a) Unscrew dish nut.
(b) Remove the oil filler caps.

01

02

03

04

05

06

07 3. Select oil
Tip:
08 Oil must be above CD grade diesel oil, and select to use oil based on work ambient temperature for
diesel engines.
09 Implement according to the following table:
Oil Brand Appropriate Ambient Temperature
10
30# Below 5 degrees to 30 degrees
11 40# Above 5 degrees

12 10W Below 20 degrees to below 5 degrees

5W/30 Above 25 degrees
13
15W/40 Above 10 degrees
14 Notes:
(a) Select appropriate grade of oil and diesel fuel brand upon ambient temperature, and oil must
be changed regularly according to regulations.
(b) Never to use different brands of oil, so as to avoid adverse chemical and physical reactions
resulting oil deterioration and faults.

4. Fill Oil
Tip:
If oil capacity in the oil pan is unknown, fill the minimum
oil capacity into oil pan. Then refill for several times,
each time add a certain amount of oil until the oil level
reaches the high oil level mark at the dipstick.
Record total refilling amount, so as to know oil capacity
when oil change next time.
Note:
When filling oil to the oil pan, use oil filling pipe
aside the engine rather than oil filling pipe at the top
of rocker chamber.
 Lubrication System - Lubrication System 11-9

5. Screw on Engine Oil Filler Caps

(a) Install engine oil filler caps.
(b) Tighten the dish nut.

01

02

03

04

05

06

6. After-checking 07
(a) To make the engine idle running, check whether there is oil leakage from the drain plug. If replacing
the oil filter seal, check whether there is leakage from the seal. 08
Tip:
After starting the engine for 15 seconds, the instrument meter must display oil pressure, if it failed to 09
display oil pressure within 15 seconds, immediately stop the engine to avoid damage.
10

11

12

13
 11-10 Lubrication System - Oil Pump

Oil Pump
Overhaul
01 1. Disassemble Oil Pump Assembly (Refer to Chapter 07 Disassembly of Engine - Oil Pump and
Piston Assembly, Removal)
02
2. Oil Pump Test
(a) Immerse oil pump into oil basin, clockwise rotate
03
pump shaft until the oil flows out of the oil hole. Then
block oil hole with the thumb, continuously rotate
04 bump shaft, if the shaft rotational resistance
increases, it is normal.
05 Also oil pressure meter can be used to measure
pressure of oil pump to check whether pressure
06 meets standard values.
Tip:
Standard value of the oil pump pressure: 200 ~ 400kPa.
07

08

09

10 3. Disassemble Oil Pump

(a) Use pliers to pull the filter clamp at filter screen body
11 upright, and remove the filter brazing parts.

12

13

14

(b) Remove the fixed bolt at filter screen body, and take
off filter screen body, oil pump cover, oil pump gasket
and oil pump outer rotor.
Lubrication System - Oil Pump 11-11

(c) Disassemble the pipeline parts and connection bolts

of oil pump.
• Remove pipe parts and the oil outlet pipe flange
gasket.
01

02

03

04
(d) Use table vice padded with sheet copper to grip oil
pump drive gear, use a wrench to remove nuts on the 05
oil pump shaft.
• Remove the gasket.
06
• Dismantle oil pump shaft by knocking oil pump
shaft head with a copper rod.
• Remove woodruff Key. 07

08

09
(e) Use a punch to make pin out of the oil pump shaft
and the inner rotor. 10

11

12

13

4. Oil Pump Overhaul

(a) Use a feeler to check clearance between outer rotor
and the oil pump.
Reference value: 0.10 ~ 0.16mm
Reference limits: 0.20mm
Tip:
If the clearance is beyond limit value, must replace with
new parts.

(b) Use a feeler to check top surface teeth space for the
inner and outer rotors.
Reference value: 0.04 ~ 0.12mm
Reference limits: 0.18mm
Tip:
If the clearance is beyond limit value, must replace with
new parts.
 11-12 Lubrication System - Oil Pump

(c) Use a ruler and feeler to check axial clearance of

external and outer rotor.
Reference value: 0.03 ~ 0.09mm
Reference limit: 0.15mm
01 Tip:
If the clearance is beyond limit value, replace them with
02 new parts.

03

04
(d) Measure clearance between oil pump and oil pump
05 body.
Reference value: 0.03 ~ 0.07mm
06 Reference limits: 0.10mm
Tip:
Respectively measure the outside diameter of the oil
07 pump shaft and the corresponding aperture, calculate
their difference, i.e. clearance between oil pump and oil
08 pump body.

09
5. Assemble Oil Pump
10 (a) Use a punch to make pin out of the oil pump shaft
and inner rotor.
11

12

13

14

(b) Mount the assembled oil pump shaft into the oil pump
body, and use the table vice padded with sheet
copper to grip oil pump drive gear, as well as use a
wrench to tighten nuts on the oil pump shaft.

(c) Mount connecting bolts of oil outlet pipe and oil pump
body.
Tip:
Remember to mount flange gasket for oil outlet pipe.
 Lubrication System - Oil Pump 11-13

(d) Close outer rotor of the oil pump, oil pump gasket,
filter screen body and oil pump cover, fit and tighten
the fixed bolts.

01

02

03
.
04
(e) Mount filter screen brazing parts, use pliers to make
clamp at filter screen body curved, and lock the filter 05
screen body.
06

07

08

09
6. Reset Oil Pump
(a) After assembling oil pump, immerse oil pump into oil 10
basin, clockwise rotate pump shaft until the oil flows
out from the oil hole. Then block oil hole with the 11
thumb, continuously rotate bump shaft, if the shaft
rotational resistance increases, it is normal. 12
Also oil pressure meter can be used to measure
pressure of oil pump to check whether pressure 13
meets standard values.
Tip:
Standard value of the oil pump pressure: 200 ~ 400kPa.

7. Install Oil Pump Assembly (Refer to Chapter 08 Assembly of Engine -- Piston Assembly and
Oil Pump, Installation)
 11-14 Lubrication System - Oil Filter

Oil Filter
Replacement
01
1. Replace oil filter element.
02 (a) Remove center bolt of the oil filter, take the oil filter
element, replace it with new oil filter element.
• Check 0-ring of oil filter, replace in case of aging
03
and damage.
Tip:
04 When replacing of oil filter, replace oil as well. Generally,
replacement cycle of oil filter element is the same as that
05 of oil, replacement can’t only for oil but not for oil filter
element, so as to avoid engine failure caused by dirty
06 filter element.

07
(b) Screw center bolt on the oil filter by hand, and use the
wrench to tighten it
08 Note:
When assembling oil filter, keen contact surface clean
09 between oil filter holder and oil filter element, and
refill in the amount of oil into the oil filter while
10 smearing thin layer of oil at 0-ring.

11

12
(c) Use a wrench to tighten the center bolt of a fuel filter
13 up to the standard requirement.

14
 Lubrication System - Oil Filter 11-15

Oil Pressure Adjustment

1. Oil pressure adjustment
(a) Release lock nut oil for oil pressure adjusting screw
pressure at the oil filter.
01

02

03

04

(b) Use a flat screw driver to adjust the fuel pressure 05

regulator screw, so that oil pressure falls within the
range of 200 ~ 400kPa (allow a bit higher value for 06
cold car).
07

08

09

10
(c) After adjustment, lock nut with the wrench.
11

12

13
 11-16 Lubrication System - Oil Pan

Oil Pan
Overhaul
01 Tip:
Before disassembling oil pan, ensure that oil in oil pan has been completely discharged.
02 1. Disassemble Oil Pan
(a) Upturn the body and remove fixed bolts and nuts in
the oil pan.
03
Tip:
During disassembly, the oil pan seals should be
04 maintained within the oil pan possibly.

05

06

07 (b) Use a rubber hammer to loosen the oil pan, and

unclench the oil pan with a scraper.
08 Tip:
Unclench oil pan loose from the oil pan and cylinder
09 block joint surface in all directions, so as to avoid
deformation or damage of the oil pan.
10

11

12
(c) Remove the oil pan.
13

14

2. Clean and Inspect Oil Pan

(a) Scrape all remaining gasket materials of the oil pan
and cylinder block. Clean the oil pan by steam
cleaning, and use compressed air to dry it.
Note:
• When using a steam cleaner, please wear
goggles or protective mask, and wear
protective clothing and avoid serious injury
caused by hot steam.
• When using compressed air, please wear
suitable goggles and protective masks to avoid
personal injury caused by flying debris and dirt.
• Do not use sharp objects to clean sealant at
gasket of oil pan or gasket surface to avoid
seals damage. bodily
Lubrication System - Oil Pan 11-17

(b) Check whether the oil pan can still be used yet.
Tip:
Oil pan is made of thin steel plate by stamping, for storing
oil and providing heat for the oil, the oil pan must have no
hollow units or crack phenomenon. 01
When maintaining and installing the oil pan, replace the oil
pan gasket. 02

03

04
Tip:
Generally, in case that crack is not big, it is easy and 05
reliable to repair without replacing it.
Repair methods are as follows:
06
If the small crack or small section happens to oil pan
during the way of car driving, oil will leak from the mid and
small cracks during car driving, please find a pop can, cut 07
a strip slightly larger than a small crack, use abrasive
paper to clean the small crack,, coat it with 496 Loctite 08
glue, as well as clean pop can with fine abrasive paper,
and paste it to the glue place. To make it security and firm, 09
it is best to discharge oil and remove the oil pan, and then
glue pop cans from the inside article, after gluing, install 10
oil pan, fill moderate oil, start the engine, and observe
whether the oil is leaked.
11

(c) Un-tighten oil bolts, check drain plug and the 12

bounded washer, and check whether it is damaged.
13

(d) Clean and check drain plug thread and the sealing
surface, if the thread is damaged, tapping or reaming
may be employed.
 11-18 Lubrication System - Oil Pan

(e) Before installing the drain plug, lubricate it with clean

oil.

01

02

03

04
(f) Mount the bounded sealing washer and the drain
05 plug.

06

07

08

09
2. Install New Oil Pan Gasket
10 (a) Coat with suitable sealant at the sealing position on
oil pan gasket.
11 • Install the new gasket.

12

13

14

(b) Close the oil pan.

• Screw the fixed all bolts and nuts in the oil pan
by hand.
Tip:
Remember to install, clean and check the drain plug
threads and sealing surfaces.

(c) Tighten all fixed bolts and nuts for the oil pan.
Tip:
Do not overtighten a bolt or nut once.
Lubrication System - Oil Pan 11-19

Tip:
Follow orders shown on the left picture to tighten all bolts.

01

02

03

04

05

06

07

08

09

10

11

12

13
 11-20 Lubrication System - Oil Gauge or Dipstick

Oil Gauge or Dipstick

Overhaul
01
1. Clean Up Around The Oil Gauge Pipe
02 (a) Use compressed air to dry the dust around oil gauge.
Tip:
Oil system needs to be clean, clean up the dust around
03
the oil gauge pipe to prevent debris and other debris from
entering the oil system.
04

05

06
2. Disassemble Oil Gauge
07 (a) Use a wrench to unscrew the connecting nut between
oil gauge pipe and oil body.
08

09

10

11

12 (b) Pull out the oil gauge assembly.

13

14

3. Install Oil Gauge Assembly

(a) Insert oil gauge assembly into mounting holes of oil
gauge.
Lubrication System - Oil Gauge or Dipstick 11-21

(b) Tighten the fixed nuts of oil gauge.

01

02

03

04

05

06

07

08

09

10

11

12

13
 - 11-22
Memo - Lubrication System - Oil Gauge or Dipstick

01

02

03

04

05

06

07

08

09

10

11

12

13

14
Cooling System
Cooling System ............................................................12-1 01
General.....................................................................12-1
Part Drawing.............................................................12-2
Thermostat ...................................................................12-4 02
General.....................................................................12-4
Overhaul ...................................................................12-5 03
Water Pump .................................................................12-8
Overhaul ...................................................................12-8 04
Pulley and Fan ...........................................................12-12
Overhaul .................................................................12-12 05
Drive Belt ...................................................................12-15
Overhaul .................................................................12-15
06

07

08

09

10

11

12

13
 11-2 Cooling System - Oil Gauge or Dipstick

01

02

03

04

05

06

07

08

09

10

11

12

13
 Cooling System - Cooling System 12-1

Cooling System
General
1. Cooling system is used for keep the engine in suitable temperature range under all the operating 01
conditions. The cooling system shall prevent the engine from overheating and undercooling. The
cooling system shall ensure the engine after cold start to warm up quickly so as to reach normal
02
working temperature as soon as possible.
2. Cooling system of a forced circulation water-cooled type is composed of a heat radiator, a water
pump, a fun, a Thermostat, a wind scooper, etc. 03
3. Water pump shaft adopts shaft bearing as the support, and graphite ceramic water seal is used. The
water pump is driven by crankshaft pulley and water pump belt. 04
While in use, when the water seal is damaged and the drain hole under the water pump body drips
seriously, the water seal shall be replaced and it is not allowed to block the drain hole during water 05
leakage, otherwise water will enter the bearing and result in the wear of bearing soon. The bearing
shall be replaced in case of abnormal noise during operation. 06
4. The tensioning of fan belt shall be regularly inspected and adjusted as required by “technical
maintenance”. The water pump belt shall be adjusted by the methods of pressing the belt between
the water pump pulley and generator pulley manually and the pressed distance of 10~15mm is 07
preferable.
08

09

10

11

12

13

14
 12-2 Cooling System - Cooling System

Part Drawing

01

02

03

04

05

06

07

08

09

10

11

12

13
 Cooling System - Cooling System 12-3

1 Bolt M6×22 14 Washer 8

2 Washer 6 15 Bolt M8 × 30
3 Washer 6 16 Bolt M8 × 20
4 Thermostat Cover 17 Water Pump Bearing
5 Thermostat 18 Water Seal 01
6 Thermostat Cover Gaskets 19 Pump Casing
7 Screw Plug 20 Water Pump Gasket 02
8 Thermostat Housing 21 Water Pump Impeller
9 Minor Cycles Nipple 22 Pump Rear Cover
10 Dual Steel-Wire Hoops 26 23 Water Pump Pulley 03
11 Pump Water Hose 24 Tape A-1050
12 Three-way Nipple 25 Fans Parts 04
13 Screw Plug
05

06

07

08

09

10

11

12

13

14
 12-4 Cooling System - Thermostat

Thermostat
General
01 1. Thermostat controls the engine coolant temperature of. When the coolant temperature is lower than
working temperature, the engine coolant flows back to the water pump inlet through bypass. As
02 soon as the engine coolant temperature reaches the operating range, the thermostat is started and
the bypass is closed so as to force the engine coolant to flow into heat radiator or heat exchanger.
2. The incorrect specification or fault of thermostat may result in the overheating or undercooling of
03
engine operation.
3. Never operate the engine under the condition of without any thermostat. Without Thermostat, the
04 path with the minimum resistance for coolant is to flow into the water pump inlet through the bypass,
and engine overheating will be caused as a result.
05

06

07

08

09

10

11

12

13
 Cooling System - Overhaul 12-5

Overhaul
1. Remove Thermostat
(a) Remove the fixing bolts for thermostat with a wrench. 01
· Take out flat washer.
· Take out hexagon bolt. 02
· Take out spring washer.
03

04

05

(b) Remove the thermostat cover. 06

07

08

09

10

(c) Pull out the thermostat. 11

12

13

14

2. Cleaning and Inspection for Continuous Use

(a) Inspect whether the outside of thermostat is
damaged.
Inspect whether there is any crack, embedded debris,
loss of one-way valve ball, damage of base and other
damage.
· Replace the thermostat in case of any damage.
 12-6 Cooling System - Overhaul

(b) Inspect whether any gasket adheres to the contact

surface between Thermostat housing and thermostat
cover.
· Any gasket shall be removed with a shovel.
01

02

03

04
(c) Clean the installing surface of thermostat housing.
05

06

07

08

09
(d) Inspect whether there is any crack or other damage
10 on the installing surface of thermostat housing.
· Replace the thermostat housing in case of crack
11 or other damages.

12

13

3. Measure
(a) If it is doubted that the thermostat has any fault,
measure the starting temperature of the thermostat,
and put the thermostat and a thermometer with the
measuring range of 100°C in a container filled with
water.
Caution:
Never make the thermostat or thermometer get
contact with the container.

(b) Heat water and inspect thermostat according to the

following steps.
· Heat water in the container to 90℃ or above by
observing the thermometer to start the
thermostat automatically.
· If the thermometer is not started even though
water in the container is heated to 90 ℃ or
above, it indicates damage or incorrect model of
thermostat, and it shall be replaced.
Caution:
Nominal working temperature is marked on the
thermostat.
Cooling System - Overhaul 12-7

4. Install Thermostat
(a) Apply sealant on the installing surface of thermostat
housing.

01

02

03

04
(b) Install new sealing gasket.
05

06

07

08

09
(c) Install the thermostat.
10

11

12

13

14

(d) Close the thermostat cover.

Tip:
It is necessary to apply sealant on the installing surface of
thermostat cover.

(e) Install and fasten fixing bolts for the thermostat cover.
 12-8 Cooling System - Water Pump

Water Pump
Overhaul
01
1. Primary Inspection
02 (a) Use steam or high pressure water jets to clean the
exterior of engine water pump.
Note:
03
When using steam cleaners, wear goggles or
protective mask, and wear protective clothing. Hot
04 steam may cause serious personal injury.
(b) Running the engine at low idle, check whether the
05 water pump is leaking.

06

07

08

09
2. Disassemble Pump Assembly
(a) Disassemble four fixed bolts on the fan.
10 Note:
Do not screw with too much force, so as to avoid
11 damaging the fan.

12

13

(b) Slowly remove the fan.

Note:
When removing the fan, be careful of pulley dropping.

(c) Remove the fan pulley and fan belt.

Cooling System - Water Pump 12-9

(d) Release the fixed hoop of water hose.

01

02

03

04
(e) Rotate the hoops position of water hose to loosen the
water hose, pull out both end joints of hose, and then 05
remove the water hose.
06

07

08

09
(f) Disassemble the water pump and four fixed nuts of
cylinder block. 10
• Remove the nut, spring washer and flat washer
11

12

13

14

(g) Remove the water pump assembly.

3. Disassemble Water Pump Assembly

(a) To remove the fixed bolts of rear cover for water
pump, so as to make the rear cover and water pump
assembly separated, it is convenient to check
whether water pump impeller is damaged.
 12-10 Cooling System - Water Pump

4. Clean, Continuously Use and Inspect

(a) Overhaul and check whether the pump impeller is
decayed.
• If it is decayed, replace it.
01

02

03

04
5. Assemble Pump Assembly
05 (a) Mount water pump assembly and rear cover of water
pump.
06 (b) Install water pump assembly and the rear cover of
water pump to connect and tighten bolts.
07

08

09

6. Install Water Pump Assembly

10
(a) Fit the pump assembly to assemble parts, then mount
and tighten the blots..
11

12

13

(b) Mount water pump hose.

Tip:
When installing water hose, the inner wall of water hose
should be coated with little sealant or something
equivalent, in this way, it is convenient for installing and
good sealing.

(c) Fasten dual wire hoop.

Cooling System - Water Pump 12-11

(d) Mount water pump pulley to the installation position.

01

02

03

04
(e) Mount water pump belt.
Tip: 05
Mount water pump belt before assembling the fan, to
facilitate the incoming installation of the belt.
06

07

08

09
(f) Put the fan to the installation position and align the
mounting holes. 10

11

12

13

14

(g) Tighten the fixed bolts on the fan by hands, and

tighten it with a wrench.
Tip:
By rotating fan, check whether installation is in place.
 12-12 Cooling System - Pulley and Fan

Pulley and Fan

Overhaul
01
1. Disassemble Fan and Pulley
02 (b) Disassemble four fixed bolts on the fan.
Note:
Do not screw with too much force, so as to avoid
03
damaging the fan.

04

05

06
(b) Slowly remove the fan.
07 Note:
When removing the fan, be careful of pulley dropping.
08

09

10

11

12 (c) Disassemble fan pulley and fan belt.

13

2. Clean Pulley
(a) Use solvent to clean pulley.
Note:
When using solvents, acid or alkaline cleaning
materials, follow use recommendations by the
manufacturer. Wear goggles and wear protective
clothing to avoid personal injury.
Cooling System - Pulley and Fan 12-13

(b) Check whether the fan belt pulley is crackled nearby

bolt holes and contact surface to the drive belt is
damaged.
• If pulley is found damaged, check the fan belt as
well. 01

02

03

04
3. Check Fan
(a) Check whether the cooling fan has defects or cracks 05
and other damage.
• If there are cracks or defects, etc, replace the
06
cooling fan.

07

08

09
4. Install Fan and Pulley
(a) Mount water pump pulley to round flange, align four 10
bolt holes.
11

12

13

14

(b) Mount the fan belt.

(c) Put the fan in the right place, to align bolt holes on the
pulley.
 12-14 Cooling System - Pulley and Fan

(d) Mount the fixed bolts, and tighten the fixed blot with
symmetry.

01

02

03

04

05

06

07

08

09

10

11

12

13
 Cooling System - Pulley and Fan 12-15

Transmission Belt
Overhaul
1. Disassemble Fan and Pulley 01
(a) Disassemble the four fixed bolts on the fan.
Note: 02
Do not screw with too much force, so as to avoid
damaging the fan. 03

04

05

06
(b) Slowly to remove the fan.
Note:
07
When removing the fan, be careful of pulley dropping.
08

09

10

11
(c) Disassemble the fan pulley and fan belt.
12

13

14

2. Check Belt
(a) Carefully check each parts of belt, in case of following
injury, replace with new pulley.
• The back rubber is aged, reflective and
non-elastic, there is no mark scratching by nail.
 12-16 Cooling System - Pulley and Fan

• Back rubber has cracks.

01

02

03

04
• The teeth bottom has cracks.
05

06

07

08

09
(b) Check the drive belt tension.
10 Reference standard:
Force is 39N, deflection is about 10 ~ 15mm
11

12

13

• If the tension is too large, adjust tension by the

generator.

3. Install Drive Belt

(a) Install the fan belt.
Cooling System - Pulley and Fan 12-17

(b) Put the fan in the right place, to align bolt hole on the
pulley.

01

02

03

04
(c) Mount the fixed bolts, and tighten the fixed bolts with
symmetry.
05

06

07

08

09

10

11

12

13

14
 - 12-18
Memo - Cooling System - Pulley and Fan

01

02

03

04

05

06

07

08

09

10

11

12

13
Air Intake/Exhaust System
Air Intake System .........................................................13-1 01
General.....................................................................13-1
Part Drawing.............................................................13-2
Intake Manifold.............................................................13-4 02
Overhaul ...................................................................13-4
Exhaust System ...........................................................13-8 03
General.....................................................................13-8
Part Drawing.............................................................13-9 04
Exhaust Manifold........................................................13-11
Overhaul .................................................................13-11 05

06

07

08

09

10

11

12

13

14
 12-2 Air Intake/Exhaust System - Pulley and Fan

01

02

03

04

05

06

07

08

09

10

11

12

13

14
 Air Intake/Exhaust System - Air Intake System 13-1

Air Intake System

General
1. The air intake system mainly includes a high-level intake pipe assembly, an air filter, an intake 01
manifold and relevant hoses, and it provides pure air for cylinders.
2. The intake manifold distributes clean air to the intake channel of the cylinders. A preheating plug as
02
an auxiliary starting device is installed on the intake pipe and used for elevate the temperature of
combustion chamber during the cold start of the engine.
3. The four-cylinder engine and the three-cylinder engine are similar in structure, and now the 03
four-cylinder engine is taken as an example for introduction.
04

05

06

07

08

09

10

11

12

13

14
 13-2 Air Intake/Exhaust System - Air Intake System

Part Drawing

01

02

03

04

05

06

07

08

09

10

11

12

13

14

1 Intake Pipe 7 Spring Washer

2 Intake Manifold Gasket 8 Flat Washer
3 Intake Pipe Joints 9 Intake End Plate
4 Spring Washer 10 Intake Manifold Gasket
5 Bolt 11 Preheating Plug
6 Bolt
 Air Intake/Exhaust System - Air Intake System 13-3

01

02

03

04

05

06

07

08

09

10

11

12

13

14

1 Bolt 6 Intake Pipe

2 Spring Washer 7 Intake Pipe Joints
3 Flat Washers 8 Bolt
4 Intake End Plate 9 Preheating Plug Assembly
5 Intake Manifold Gasket
 13-4 Air Intake/Exhaust System - Air Intake System

Intake Manifold
Overhaul
01 1. Disassemble Intake Manifold Assembly (Refer to Chapter 07 Disassembly of Engine -- Intake
and Exhaust Manifold and Hanger, Removal)
02
2. Disassemble Intake Manifold
03 (a) Please use a wrench to remove connecting bolts
between intake manifold and intake pipe joints, so as
04 to take off the intake pipe joints.

05

06

07
(b) Please use a wrench to remove the connecting bolts
08 between the intake pipe and intake end plate, so as
to take off the intake end plate.
09 Tip:
If inner intake pipe needs to be cleaned up, please
10 remove the intake end plate first.

11

12

13 (c) Disassemble the preheating plug.

14

3. Clean and check all parts and components

(a) Please use a scraper and a piece of clean cloth to
clean the cylinder head and intake manifold sealing
surface.
Note:
Sealing materials, other dirt and debris are forbidden
to enter the air intake port.
Air Intake/Exhaust System - Air Intake System 13-5

Tip:
When cleaning the sealing surface with a scraper, it is
preferable to use duster cloth to plug the air intake port.

01

02

03

04
(b) Please use a scraper to clean the intake manifold
sealing surface between the intake pipe joint and 05
intake pipe.
06

07

08

09
(c) Use a piece of clean duster cloth to clean the sealing
surface of intake pipe and the inner of intake pipe 10
joint.
11

12

13

14

(d) Check if the intake pipe joints are free of cracks, and
the sealing surface must be free of serious flaws or
defects.

(e) Use a scraper to clean the sealing surface of intake

pipe.
 13-6 Air Intake/Exhaust System - Air Intake System

(f) Use a piece of clean cloth to clean the sealing

surface and end surface of the intake end plate.

01

02

03

04
(g) Check if the intake pipe end plate is free of cracks,
05 the picture shows the sealing surface has a serious
defect and the deformed end plate, or the
replacement of intake end plate.
06

07

08

09
(h) Use a scraper and a clean duster cloth to clean all
10 sealing surfaces of intake pipe.

11

12

13

14

(i) Use high-pressure air to blow the dirt and debris

away from the intake pipe.

(j) Use a high-precision board ruler and a feeler gauge

(or at the plane efficacy platform) to measure the
plane of intake manifold and cylinder head joint
surface, and check all the planes’ flatness. If
unevenness or roughness is beyond the
technological range, the intake pipe should be
machined or replaced.
 Air Intake/Exhaust System - Air Intake System 13-7

(k) Connect one terminal of the preheating unit to the

anode of power to see if there is preheating effect.
• If there is not preheating effect, please replace it
with a new preheating unit.
01

02

03

04
3. Install Intake Manifold
(a) Preheat plug when installing. 05
Note:
If disassembling the heater plug with the seal, replace
06
with new seal.

07

08

09
(b) When installing an intake end plate, use a wrench to
screw connecting bolts to a standard measure. 10
Note:
When installing the intake end plate, replace it with a 11
new gasket of intake end plate.
12

13

14

(c) Install the intake pipe joint.

Note:
When installing the intake pipe joint, replace it with a
new gasket of intake end plate.

4. Install Air Intake Manifold Assembly (Refer to Chapter 08 Assembly of Engine -– Hanger and
Intake and Exhaust Manifold, Installation)
 13-8 Air Intake/Exhaust System - Exhaust System

Exhaust System
General
01 1. Exhaust system comprises an exhaust manifold, a muffler, an exhaust pipe welding assembly and
other related lifting lug supports, to reduce exhaust noise and exhaust energy.
02 2. LL380B three-cylinder series diesel engine and 4L18 four-cylinder engine series are similar in
structure, and are maintained with the same way, now the four-cylinder engine is taken as an
example for introduction.
03

04

05

06

07

08

09

10

11

12

13

14
 Air Intake/Exhaust System - Exhaust System 13-9

Part Drawing

01

02

03

04

05

06

07

08

09

10

11

12

13

14

1 Exhaust Pipe 4 Stud Bolt

2 Exhaust Manifold Gasket 5 Nut
3 Spring Washer
 13-10 Air Intake/Exhaust System - Exhaust System

01

02

03

04

05

06

07

08

09

10

11

12

13

14

1 Nut 4 Stud Bolts

2 Spring Washer 5 Exhaust Pipe
3 Exhaust Manifold Gasket
 Air Intake/Exhaust System - Exhaust System 13-11

Exhaust Manifold
Overhaul
1. Disassemble Exhaust Manifold Assembly (Refer to Chapter 07 Disassembly of Engine -- 01
Intake and Exhaust Manifold and Hanger, Removal)
02
2. Clean and Check Exhaust Manifold
(a) Use a scraper and a piece of clean cloth to clean the 03
joint sealing surface between the cylinder head and
exhaust pipe.
04
Note:
Sealing materials and other dirt and debris is
forbidden to be discharged into the exhaust port. 05

06

07
(b) Use a scraper and a clean cloth to clean the joint
sealing surface among the exhaust pipe and the 08
muffler and exhaust pipe welding assembly.
09

10

11

12

(c) Use a scraper and clean cloth to clean the joint 13

sealing surface between exhaust pipe and the
cylinder head.
14

(d) Use a piece of crocus cloth to clean up carbon

deposit at the sealing surface on the exhaust pipe.
 13-12 Air Intake/Exhaust System - Exhaust System

(e) Use steam to clean the exhaust pipe.

Note:
When using steam to clean exhaust pipe, wear
goggles or protective mask and wear protective
01 clothing to avoid personal injury.

02

03

04
(f) Use compressed air to dry exhaust pipe.
05

06

07

08

09
(g) Check whether sealing surface on the intake manifold
10 has cracks and other damage, in case of serious
damage, replace the exhaust pipe.
11

12

13

14

(h) Check whether the stud bolts at the exhaust pipe

have rust corrosion and thread is damaged, if so,
replace the stud bolts.

(i) Check whether sealing surface on the exhaust

manifold has cracks and other damage, in case of
serious damage, replace the exhaust pipe.
 Air Intake/Exhaust System - Exhaust System 13-13

(j) Use high-precision board ruler and feeler gauge to

check the flatness of assembly side for exhaust pipe,
if unevenness or roughness is beyond the
technological range, the intake pipe should be
machined or replaced. 01

02

03

04
3. Install Air Exhaust Manifold Assembly (Refer to Chapter 08 Engine Assembly – Hanger and
Intake and Exhaust Manifolds, Installation) 05

06

07

08

09

10

11

12

13

14
 - 13-14
Memo - Air Intake/Exhaust System - Exhaust System

01

02

03

04

05

06

07

08

09

10

11

12

13

14
Electrical System
Generator .....................................................................14-1 01
General.....................................................................14-1
Part Drawing.............................................................14-2
Generator Test .........................................................14-3 02
Removal and Installation of Generator .....................14-5
Starter ..........................................................................14-9 03
General.....................................................................14-9
Part Drawing...........................................................14-10 04
Starter Test.............................................................14-11
Removal and Installation of Starter.........................14-14 05

06

07

08

09

10

11

12

13

14
 13-2 Electrical System - Exhaust System

01

02

03

04

05

06

07

08

09

10

11

12

13

14
 Electrical System - Generator 14-1

Generator
General
Generator is the main power supply for automobile electric equipment. During the normal operation of 01
automobile, the generator not only supplies power for the electrical equipment except starter, but also
charges the battery. 02
Attentions shall be paid to the following issues in the process of usage and maintenance of AC
generator:
1. The earth of battery and the polarity of AC generator must be consistent and shall be negative earth, 03
otherwise the battery will discharge greatly through the silicon rectifier diode of generator and burn
out the diode as a result. 04
2. Never judge whether the generator generates or not by the method of transiently grounding
(earthing) the output terminal of the generator (trying to ignite). 05
3. Never remove battery and other main electric equipment during the operation of generator at high
speed so as to avoid the occurrence of transient over-voltage which will damage diode, regulator or 06
other electric equipment.
4. The connecting wire between generator and battery shall be inspected frequently to ensure the firm
07
and reliable connection.
5. The tensioning degree of the generator pulley shall be inspected frequently to ensure it meets the
requirements while leaving factory. Over-loose belt will result in the undercharge of battery, while 08
over-tight belt will easily damage the belt and generator bearing.
6. The generator which operates abnormally shall be duly inspected so as to find out the faults and 09
troubleshoot.
7. The generator shall be maintained regularly. Generally, the wearing elements of the generator, such 10
as electric brush, rectifying elements, regulator, bearing, etc., shall be subject to an inspection and
necessary tests after 75 hours of operation or 30,000km of traveling for automobile. 11

12

13

14
 14-2 Electrical System - Generator

Part Drawing

01

02

03

04

05

06

07

08

09

10

11

12

13

14

1 Generator 3 Spring Washer

2 Nut 4 Bolt
 Electrical System - Generator 14-3

Generator Test
1. Test of Generator Output DC Voltage
(a) Start the engine and operate it in the idling state.
(b) Measure the voltage at both terminals of the battery
01
with a digital multimeter. The voltage readings shall
be within the range of 13~15V (depending on the
setting value of the regulator). When the rotating 02
speed of the generator is increased, the output DC
voltage of the generator shall generally remain 03
unchanged.
04

05

06

07
2. AC Component Test of Generator Output Voltage
08
Connect the AC voltage position of the digital multimeter with the positive and negative terminals of the
battery in parallel to measure the output AC voltage of generator (the normal value shall be no more than
0.4V). 09
The specific steps are as follows:
(a) Start the engine and operate it at the rotating speed of 2000rpm; 10
(b) Switch on the headlights and apply certain load to the generator;
11
(c) Connect the digital multimeter with the positive and
negative terminals of the battery in parallel and read 12
the AC voltage value. If the voltage ≤0.4V, it indicates
the rectifier of generator operates normally. If the
voltage > 0.5V, it indicates that the rectifier of the 13
generator has certain faults.
14

3. Voltage Drop Test of Charging System

The voltage drop test is mainly used for judging whether the connecting wire between the generator and
the battery is well connected. The specific steps are as follows:
(a) Start the engine and operate it at the rotating speed of 2000rpm[
(b) Switch on the headlights and apply certain load to the generator;
(c) Measure the voltage drop between the output terminal of the generator and the positive terminal of
the battery with the DC voltage position of the digital multimeter. The normal voltage value shall be
no more than 0.4V. The voltage value higher than 0.4V indicates the higher resistance at the
connecting point of the conducting wire.
Tip:
The picture below is only a schematic diagram.
 14-4 Electrical System - Generator

01

02

03

04

05

06

07

08

09
(d) Measure the voltage drop between the housing of the generator and the negative terminal of the
10 battery with the DC voltage position of the digital multimeter. The normal voltage value shall be no
more than 0.3V. The voltage value higher than 0.3V indicates the loose connection of the
11 conducting wire and the higher resistance at the connecting point.
Tip:
12 The picture below is only a schematic diagram.

13

14
 Electrical System - Generator 14-5

Removal and Installation of Generator

1. Shutdown Vehicle Stably and Switch Off Ignition Switch

2. Disconnect Battery Pole Lead 01

(a) Break the dustproof rubber belt of the battery pole
lead.
(b) Unscrew the fixing bolt for the battery pole lead. 02
(c) Rock leftwards and rightwards to take out the battery
pole lead. 03
Caution:
While removing pole leads, the negative pole of power 04
must be removed prior to removing other pole lead.
05

06
(d) Pull out the positive pole lead of the battery.
07

08

09

10

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3. Remove Generator
(a) Cut through the vacuum connecting pipe of generator. 12
(b) Disconnect the connecting leads on terminal of the generator.
13
(c). Remove the oil inlet pipe on the generator.
14

(d). Remove the oil outlet pipe on the generator.

 14-6 Electrical System - Generator

(e) Separate the oil inlet and outlet pipes of the generator
from the generator body.

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(f) Disconnect the connection of the generator upper
05 support.
Tip:
06 While removing the generator upper support, loosen the
adjusting bolts on the support firstly, then untie the
07 generator belt, and remove generator upper support
finally. It is easy to move in such a way.
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10 (g) Push the generator upwards. Loosen the generator

belt.
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(h) Remove the connecting bolt between the generator

and the lower support of the generator.

(i) Pull out the connecting bolt between the generator

and the lower support of the generator, and remove
the generator.
Electrical System - Generator 14-7

(a) Place the repaired generator on the lower support of

the engine for installing the generator, loosen the
connecting bolts, align the bolt hole of the generator
to the lower support hole of the generator, and install
the connecting bolt. 01

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04
(b) Install the spring washer and nut of the connecting
bolt between the generator and the lower support of 05
the generator, and screw up the nut to the standard
level with a wrench. 06

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(c) Push the generator upwards. Install the generator 10

belt.
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(d). Install the connecting bolts for upper support of

generator.
Tip:
When installing the connecting bolts for upper support of
generator, install the washers for connecting bolts first,
screw the connecting bolts with hands, tighten them
slightly, then press the generator, adjust the tension
degree of the generator belt to the standard level, and
finally screw the connecting bolts for upper support of the
generator to the standard level with a wrench.
 14-8 Electrical System - Generator

(e). Install the oil inlet and outlet pipes of the generator,
and screw the hollow bolts with hands.
Caution:
When installing the oil inlet and outlet pipes, check
01 the combined seal rings first, and replace it if it is
damaged.
02

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04
(f) Screw the hollow bolt to the standard level with a
05 wrench.

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10 (g) Connect the vacuum connecting pipe of the

generator.
(h) Connect the connecting leads on the terminal of the
11 generator.

12 5. Connect Battery Pole Lead

(a) Connect the positive lead of battery.
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14

(b) Sheathe the battery pole lead on the pole.

(c) Screw up the fixing bolt for battery pole lead.
(d) Cover the battery bracing dust cover.
 Electrical System - Starter 14-9

Starter
General
Starter refers to the process of converting an engine from the idle state to the operating state. The start 01
of engine must be realized with the help of external force, and starter is a device for converting an engine
from the idle state to the operating state.
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 14-10 Electrical System - Starter

Part Drawing

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1 Starter
 Electrical System - Starter 14-11

Starter Test
1. Voltage Drop Test of Starting System
The voltage drop test is mainly used for inspecting the connecting conditions of the conducting wires of
the starter main circuit. The voltage shall be measured with the DC voltage position of a digital
01
multimeter according to the following picture. The voltage value measured in each position shall be no
more than 0.2V. The measured voltage of ＞0.2V in a certain position indicates that the connecting wire
here has certain problem. 02

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2. Starter Test 13
The quality of performance and technical conditions of starter shall be judged by the no-load test, brake
test, the performance test of electromagnetic switch, etc. 14
(a) No-Load Test
· Switch on the circuit to observe whether the starter operates normally. Connect the ampere
meter with the circuit in series and read the current value. The current value shall be no more
than 90A.
Caution:
The idling period of starter shall be no more than 1 minute.
 14-12 Electrical System - Starter

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(b) Brake (Lock-Rotor) Test
10
The brake test shall be performed on a starter test bed. The fault of starter internal circuit shall be further
inspected by measuring the torque and consumed current while braking. Furthermore, the slippage of
11 meshing gears can also be inspected. Only the starter passing the no-load test can be used in the brake
test. The test methods are as follows:
12
· Clamp the starter to be tested on the braking
13 clamp of a universal test bed, and clamp the
three teeth on the pinion gear with the clamping
14 block on the brake linkage.

· Connect the connecting wires of the test bed and

the starter.

Starter
 Electrical System - Starter 14-13

· Press down the button SB on the universal test

bed (must press down firmly without lifting the finger)
to brake the starter. Read the readings of voltage and
current on the dials of the voltmeter and ampere
meter respectively, and read the torque value on the 01
spring scales. Compared the measured values of
voltage, current and torque with the standard value, 02
and judge whether the starter has any fault or not by
analysis. 03
Caution:
The connecting period of circuit shall be no more
than 5s. If another test is required, it is necessary to 04
perform the test after 1~2 minutes of rest for the
battery so as to avoid shortening the service life of 05
the battery.
06
3. Performance Test of Electromagnetic Switch
(a) Remove the connecting wire between terminal M and the electromotor as shown in the picture. 07
(b) Connect the negative pole of battery with the starter housing and connect the positive pole with
terminal S as shown in the picture. At the moment, the armature does not move due to the small
08
electromagnetic force although the coil is kept electrified.
(c) Connect the negative pole with terminal M. A snap for pick-up can be heard inside the
electromagnetic switch, and the driving gear is pushed out. 09
(d) Move the negative pole away from terminal M, and keep the electromagnetic switch picked-up. The
resistance between the two contactors of the electromagnetic switch shall be “0”. 10

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 14-14 Electrical System - Starter

Removal and Installation of Starter

1. Disconnect Battery Pole Lead
(a) Break the dustproof rubber belt of the battery pole
01 lead.
(b) Unscrew the fixing bolt for the battery pole lead.
(c) Rock leftwards and rightwards to take out the battery
02
pole lead.
Caution:
03 While removing pole leads, the negative pole of power
must be removed prior to removing other pole lead.
04

05 (d) Pull out the positive pole lead of the battery.

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10
2. Disconnect Al Connecting Leads on the Terminal of Starter.
11
3. Remove Starter Assembly
(a) Remove the two fixing bolts of the starter assembly.
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(b) Remove the starter assembly.

 Electrical System - Starter 14-15

4. Install Starter Assembly

(a) Put a good starter in the mounting position of starter.

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(b) Install two fixing bolts for the starter.
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5. Connect All Connecting Leads on Terminal of Starter. 10

6. Connect Battery Pole Lead 11

(a) Connect positive pole lead of battery.
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(b) Sheathe the battery pole lead on the pole.

(c) Screw up the fixing bolt for battery pole lead.
(d) Cover the battery bracing dust cover.
 -14-16
Memo - Electrical System - Starter

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