Main installing requirements of Diesel engine

It is very important for users to learn about the installation steps of diesel engine, especially for those who want to use generator or already bought a genset.

1. Installation of the crankshaft

During crankshaft installation, the main bearing bolts should be tightened from thrust gear(the third gear) to both ends in order, and in three steps:

① tighten to 60－80 N.m

② tighten to 160－180 N.m

③ tighten to 220－260 N.m

During every time, the crankshaft should be rotated to check the mobility. It should be able to rotate freely after the final tightening.The axial clearance should be between 0.1 and 0.27 mm.

2. Installations of the piston and the connecting rod

When installing the piston rings, put the surfaces marked upward( the second positive twist ring inner fillet upward). During positioning the piston-connecting rod assembly into the cylinder bore, stagger the joints in turn. And put the arrow marked on the top surface of piston towards the front end of the engine. Remember spreading some clean oil before tightening connecting-rod bolts. The tightening torque should be between 160-200N.m, and completed in three steps:

① tighten to 50－70 N.m

② tighten to 100－120 N.m

③ tighten to 160－200 N.m

3. Installation of the camshaft

Position the camshaft into the cylinder body with caution to make sure not scratch the surfaces of the journals, cams, and liners. And then install the cir clip, cam thrust plate, cam gear, and cam retainer, Finally,tighten fastening bolt with more than 300N.m tightening torque. The camshaft should be able to rotate freely, and its axial clearance is between 0.1-0.2mm.

4. Installation of the valves and valve guides

The valve guides should be pressed in at normal state with 20±0.3mm distances between their top surfaces and the surfaces of the cylinder head spring seats. Both the valve face angles of intake and exhaust valves are 45º. the valves and valve seat inserts should be grind in pair, and checked through kerosene. It must be guaranteed that kerosene do not leak within three minutes. The valve recession heights of the valves should be between 1±0.2mm.

5. Installation of the injectors

Before mounting the cylinder head, the injectors should be installed in the cylinder head first. The nozzles should protrude 3.4±0.1mm from the bottom surface of the cylinder head, which can be ensured by adjusting the width of the injector washer. And then remove the injectors to prepare for following installation. As long as adjusted, the injectors and washers can not be exchanged during installation.

6. Installation of the cylinder head

During cylinder head installation, the cylinder head bolts should be tightened to a tightening torque of between 210-250 N.m, do not finish that in once time and following the sequence shown in the following figure by three steps:

① tighten to 60－80 N.m

② tighten to 120－140 N.m

③ tighten to 210－250 N.m

7. Installation of the gear train

The crankshaft timing gear, injection pump gear, and camshaft gear should all be accordance with the timing requirement, so there are timing marks, which should be aligned during installing the gears, on them and timing idle gear. Oil the tooth surface after installing. The range of the gear meshing clearance is between 0.07-0.25mm.

It’s a shame to throw them away they still have life left in them. All that’s left is the can of dirty off-road diesel that will be poured into the fuel tank with a funnel that was laying on the floor covered with oil dry. She’s ready to fire! Hopefully you understand the shop humor - but sometimes this is not far from the truth. Here is a list of critical installation points. Remember that this is a list of basics and intended to be used as a guide.

    Check for freight damages and get setup in a clean area with the engine specifications supplied by your remanufacturer.

    Check to ensure that the engine’s application is correct prior to bolting on accessories. Bolt patterns on the block and crankshaft flange, crank shaft snout, PTO setup, oil galley and freeze plugs, oil pan configuration, etc.

    Clean both manifolds and check for cracks and warpage when applicable. Do not overtorque. Do not glass bead!

    Clean and flush the fuel filer housing and lines. Dirty fuel/components can instantly clog the fuel injectors and cause black smoke on startup.

    Check fuel lines from tank to pump for cracks or crimps.

    Check transfer or lift pump for proper pressure if not supplied by your remanufacturer.

    Replace all air, fuel, oil and crankcase filters.

    Clean the air filter housing and hoses. Check for cracks and for proper sealing of the air filter.

    Flush or replace the oil cooler if applicable. Ideally you should replace the oil cooler because it is difficult to be sure that all oil

    contaminates are removed.

    Recore or replace the radiator and test.

    Replace the oil pressure sending unit.

    Adjust the clutch to the proper free pedal before starting.

    Check the crankshaft end play before and after installing the transmission.

    • It is up to the technician to prevent thrust bearing failures. Excessive main bearing thrust wear can be caused by the following:

    - Clutch not adjusted properly

    - Pilot shaft or torque converter interference with the crankshaft

    - Blockage and/or restriction of the transmission oil cooler

    Replace the belts, hoses and motor mounts.

    Service and inspect the starter, alternator, etc.

    Install and properly torque flywheel bolts. Over torquing can distort the crankshaft flange on one piece rear main seal designs. Do not use an impact.

    Upon startup NEVER use engine starting fluid. Check oil pressure and coolant flow in the radiator. If oil pressure is not found in ten seconds of startup stop the engine and inspect the oiling system.

    Prior to starting the engine - follow the procedures outlined in the engine’s service manual to prime the fuel system. Operating the injection pump dry can cause pump failure.

    Bleed all of the air out of the fuel system by cracking the injector lines.

    Run the engine at throttle and at no load until it reaches operating temperature.

    Verify that no leaks are present and that the cooling system is working properly.

    Runaround and load test the unit.

    After the engine has heat cycled check the valve lash and re-torque the cylinder head bolts if practical.

    Finish assembly of the truck and it’s ready to ship

Caution

1. every component should be cleaned before being installed, especially the oil passages, no dirt is permitted in them.