Contents

Instructions for use of the diesel engine

• Outline drawing of the diesel engine
• Diesel engine model meaning
• Basic parameters of the diesel engine
• Unsealing of the diesel engine
• Hoisting of the diesel engine
• Preparations before startup
• Engine startup
• Running of the diesel engine

Diesel engine maintenance guide

• Fuel, lubricating oil, coolant, urea solution and auxiliary materials
• Fuel
• Lubricating oil
• Diesel engine coolant
• Urea solution
• Auxiliary material
• Routine maintenance
• Maintenance items
• Maintenance for long-term storage of diesel engine
• Clean the diesel engine
• Protection during storage
• Oil sealing

Common failures and troubleshooting

• Diagnostic method
• Common failure causes and troubleshooting
• Diesel engine cannot be started up
• The engine is difficult to start up
• Insufficient engine power
• The engine always runs at 1000r/min
• Engine idling speed unstable
• After treatment system failure diagnosis and troubleshooting
• Failure analysis of after treatment system component
• Fault diagnosis of after treatment system and troubleshooting

Diesel engine disassembly and assembly

• Overview
• Danger signs
• Safety signs
• Tools used
• Health protection considerations
• Environmental protection measures
• Considerations for engine disassembly and assembly
• Engine block group
• Disassembly and assembly of engine block group
• Disassembly and assembly of cylinder block preassembly
• Disassembly and assembly of piston cooling nozzle
• Disassembly and assembly of thrust plates
• Disassembly and assembly of front and rear oil seals
• Disassembly and assembly of front end cover
• Disassembly and assembly of flywheel casing
• Disassembly and assembly of oil pan
• Disassembly and assembly of cylinder head
• Disassembly and assembly of cylinder head cover
• Disassembly and assembly of engine lifting eye
• Disassembly and assembly of oil-gas separator
• Disassembly and assembly of oil dipstick
• Disassembly and assembly of oil filling pipe
• Disassembly and assembly of air bleeder
• Crankshaft connecting rod system
• Disassembly and assembly of crankshaft connecting rod system
• Disassembly and assembly of crankshaft flywheel group
• Disassembly and assembly of piston and connecting rod mechanism
• Disassembly and assembly of connecting rod bearing
• Disassembly and assembly of vibration damper and crank pulley
• Valve train
• Disassembly and assembly of valve train
• Disassembly and assembly of camshaft
• Disassembly and assembly of rocker arm and rockshaft
• Disassembly and assembly of tappet and push rod
• Disassembly and assembly of valve
• Disassembly and assembly of intermediate gear
• Intake and exhaust system
• Disassembly and assembly of intake and exhaust system
• Disassembly and assembly of intake manifold
• Disassembly and assembly of exhaust manifold
• Disassembly and assembly of turbocharger
• Fuel system
• Disassembly and assembly of fuel system
• Disassembly and assembly of common rail pipe
• Disassembly and assembly of ECU
• Disassembly and assembly of fuel injection pump
• Disassembly and assembly high pressure fuel pipe
• Disassembly and assembly of fuel injector
• Disassembly and assembly of fuel filter
• Disassembly and assembly of low pressure fuel pipe
• Disassembly and assembly of harness
• Cooling system
• Overview of cooling system
• Disassembly and assembly of water pump
• Disassembly and assembly of thermostat
• Disassembly and assembly of fan
• Disassembly and assembly of belt and tensioner
• Lubricating system
• Overview of lubricating system
• Disassembly and assembly of oil pump
• Disassembly and assembly of oil filter and oil filter seat
• Disassembly and assembly of oil cooler cover
• Disassembly and assembly of oil cooler
• Disassembly and assembly of oil pump strainer
• Starting system
• Disassembly and assembly of starting system
• Disassembly and assembly of starter
• Accessories system of the vehicle
• Disassembly and assembly of accessories system of vehicle
• Disassembly and assembly of alternator
• Disassembly and assembly of air-conditioner compressor
• Disassembly and assembly of air compressor
• Disassembly and assembly of hydraulic pump

Tightening of main bolts of the engineя

• Main bearing bolts
• Cylinder head bolts
• Connecting rod bolts
• Flywheel bolts
• Tightening torques and methods of other bolts and nuts

Appendix

• Diagnostic trouble code table
• Fitting clearances for diesel engine main parts
• Evaluation benchmark for wear of main friction pairs of the diesel engine