6M33 Repair Manual Feb 2019 v3

6M33 Repair Manual February 2019
Repair Manual
6M33 Series Industrial Diesel Engine
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Foreword
This series diesel engine features the advantages of excellent technical indicators (compact structure,
reliable operations, and high power performance, economy, and emission), rapid start, simple
operations, convenient maintenances, and especially advanced emission indicator that meet the
international advanced emission standards.
This manual is intended as a guide for staff responsible for maintaining and repairing the 6M33 engine.
We recommend that you read this manual to familiarise yourself with the product and the precautions
that need to be taken before working on it.
Before commencing any work, you should take note of the necessary safety precautions and equip
yourself of the associated personal protective equipment (PPE).
The manual contains specific instructions regarding the repair methods that must be used.
It specifies the dimensions and tolerances that must be strictly observed during maintenance/repair of
the constituent assembles and sub-assemblies.
Thorough familiarisation with and use of this manual it will enable technicians to perform this work
under the best conditions.
The contents of this manual remain subject to future changes, which will be reported to you as and
when they come into force. Please access http://www.baudouin.com to obtain the latest product
information.
Recommendations and opinions on further product improvement from you are welcome.
February 2019
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Special Notice
⚫ Before any operation, the operator of the diesel engine must carefully read this repair manual
and strictly abide by the operation and maintenance practices specified in this manual.
⚫ The diesel engine has been tested strictly in accordance with the testing specification of our
company before delivery. It is prohibited to adjust the ECU data or increase the power of the
diesel engine without permission. Note that failure to observe this requirement shall
invalidate the warranty provided by Weichai Power;
⚫ The rotor of the turbocharger generally rotates at high speeds when the engine is in operation.
It is strictly prohibited to have any moving objects (eg hands, tools, cotton yarns) near the inlet
of the turbocharger, otherwise serious injury or damage could occur. The rotor can only be
removed by turbocharger maintenance specialists or by the service stations authorised by
Weichai Power.
⚫ The number of uses for important bolts is limited and must not exceed the specified re-use
times.
⚫ The oil and fuel added to the diesel engine must be of the grades specified in the operation and
maintenance manual. Additionally, dedicated clean filters must be used. Before adding, allow
the fuel to settle for 72 hours. Before driving the vehicle, check that the coolant and oil levels
meet the requirements;
⚫ It’s prohibited to run the diesel engine without the air filter, in order to prevent the supply of
non-filtered air into the cylinders.
⚫ Before using a new engine, 50 hours commissioning shall be carried out;
⚫ After the cold start of the diesel engine, slowly increase the engine speed, instead of running at
high speed suddenly or long-term idling. After running under a heavy load, run the engine at
low speed for 5~10 minutes before stopping, instead of stopping the engine suddenly (except
special cases);
⚫ After the engine has stopped, and the temperature of the working environment is below 0℃, a
coolant with an antifreeze additive must be used. You must fully drain the coolant from the
water tank and engine if no antifreeze is used to prevent freezing and damaging the engine;
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⚫ The checking and repair for all parts of the electrical system must be undertaken by a
professional electrical technician;
⚫ The checking and repair for all parts of electronic control system must be undertaken by the
professionals of our service station;
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Contents
Chapter 1 General Information ................................................................. 8
1.1 Exterior View of Diesel Engine ....................................................................... 8
1.2 Model Meaning of the Diesel Engine .............................................................. 9
1.3 Basic Parameters of the Diesel Engine ........................................................... 9
1.4 Lifting the Diesel Engine ............................................................................... 10
Chapter 2 Maintenance Guide of Diesel Engine ..................................... 11
2.1 Sealant Application ........................................................................................ 11
2.1 Maintenance Items……………....................................................................11
Chapter 3 Disassembly and Assembly of the Diesel Engine .................. 15
3.1 Overview.......................................................................................................... 15
3.1.1 Danger signs ...................................................................................................................... 15
3.1.2 Safety symbols ................................................................................................................... 16
3.1.3 Special tools ....................................................................................................................... 17
3.1.4 Precautions for health protection .................................................................................... 17
3.1.5 Environmental precaution ............................................................................................... 18
3.1.6 Precautions for disassembly and assembly of the diesel engine.................................... 18
3.2 Cylinder Head Group .................................................................................... 19

3.2.1 Cylinder Head Group Disassembly and Assembly Overview ....................................... 19
3.2.2 Disassembly, Inspection, Maintenance and Assembly of Engine Lifting Plates .......... 20
3.2.3 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head Cover ......... 21
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3.2.4 Disassembly, Inspection, Maintenance and Assembly of Lubricating Oil Pipe .......... 23
3.2.5 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head .................... 24
3.3 Engine Block Group ....................................................................................... 30

3.3.1 Disassembly, Inspection, Maintenance and Assembly of Engine Block ....................... 30
3.3.2 Disassembly, Inspection, Maintenance and Assembly of Flywheel Cover ................... 33
3.3.3 Disassembly, Inspection, Maintenance and Assembly of Front End Cover ................ 36
3.4 Crank and Connecting Rod Mechanism ...................................................... 37

3.4.1 Disassembly, Inspection, Maintenance and Assembly of Crank and Connecting Rod
Mechanism .................................................................................................................................. 37
3.5 Valve Mechanism…………………………………………………………….48

3.5.1 Disassembly, Inspection, Maintenance and Assembly of Valve Train…………………48
3.5.2 Disassembly, Inspection, Maintenance and Assembly of Camshaft……………………49
3.5.3 Disassembly, Inspection, Maintenance and Assembly of the Rocker Arm and Rocker
Arm Shaft……………………………………………………………………………………….51
3.5.4 Disassembly, Inspection, Maintenance and Assembly of Tappet and Push Rod……..53
3.5.5 Disassembly, Inspection, Maintenance and Assembly of Valve………………………..54
3.5.6 Disassembly. Inspection, Maintenance and Assembly of Gear Train………………….56
3.6 Intake and Exhaust System………………………………………………….59

3.6.1 Removal and Installation of the Intake and Exhaust System ....................................... 59
3.6.2 Disassembly, Inspection, Maintenance and Assembly of Intake Manifold .................. 60
3.6.3 Disassembly, Inspection, Maintenance and Assembly of Exhaust Manifold ............... 61
3.6.4 Disassembly, Inspection, Maintenance and Assembly of Turbocharger System ......... 63
3.6.5 Disassembly, Inspection, Maintenance and Assembly of Air Filter System ................ 66
3.7 Fuel system ...................................................................................................... 68

3.7.1 Removal and Installation of Fuel System ....................................................................... 68
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3.7.2 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump .......... 70
3.7.3 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel Pipe .... 73
3.7.4 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector ....................... 74
3.8 Cooling System ............................................................................................... 75

3.8.1 Overview of cooling system .............................................................................................. 75
3.8.2 Disassembly, Inspection, Maintenance and Assembly of Thermostat .......................... 76
3.8.3 Disassembly, Inspection, Maintenance and Assembly of Water Pump ........................ 77
3.8.4 Disassembly, Inspection, Maintenance and Assembly of Outlet Water Pipe ............... 79
3.8.5 Disassembly, Inspection, Maintenance and Assembly of Oil-gas Separator ............... 81
3.8.6 Disassembly, Inspection, Maintenance and Assembly of Fan ....................................... 82
3.9 Lubrication System ........................................................................................ 84

3.9.1 Overview of lubrication system ....................................................................................... 84
3.9.2 Disassembly, Inspection, Maintenance and Assembly of Oil Pump Assembly ............ 85
3.9.3 Disassembly, Inspection, Maintenance and Assembly of Centrifugal Oil Filter ......... 87
3.9.4 Disassembly, Inspection, Maintenance and Assembly of Oil Cooler and Oil Filter ... 88
3.9.5 Disassembly, Inspection, Maintenance and Assembly of Oil Pan ................................. 90
3.9.6 Use and Replacement of Oil ............................................................................................. 91
3.10 Start-up system ............................................................................................. 92

3.10.1 Overview of start-up system .......................................................................................... 92
3.10.2 Disassembly, Inspection, Maintenance and Assembly of Starter Motor .................... 93
Appendix A Recommended Torques for Standard Bolts .................................. 95
Appendix B Recommended Torques for Hollow Bolts ..................................... 96
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Chapter 1 General Information
1.1 Exterior View of Diesel Engine
Figure 1-1 Exterior View of 6M33 Series Diesel Engine
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1.2 Model Meaning of the Diesel Engine
6 M 33 X XXX EX XX
Variant code
Emission level
Power code
Type code
Displacement/Cylinders
Motor diesel
Number of cylinders
Figure 1.2 Identification Plate
1.3 Basic Parameters of the Diesel Engine
Table 1-1 Main Parameters of the 6M33 Series Diesel Engine
Intake method Turbocharged and intercooled

Bore/stroke (mm) 150/185
Displacement (L) 19.6
Compression ratio 15:1
Firing order 1-5-3-6-2-4
Fuel system Mechanical pump
Intake valve: 0.3±0.03
Cold valve clearance (mm)
Exhaust valve: 0.4±0.03
Intake valve open before TDC: (34±5)°
Valve timing Intake valve close after BDC: (40±5)°
（valve clearance: intake, 0.3; exhaust, 0.4） Exhaust valve open before BDC: (61±5)°
Exhaust valve close after TDC: (27±5)°
Thermostat open temperature (℃) 77
Starting method Electric
Lubricating method Pressure lubrication
Oil capacity (L) 60.5
Cooling method Water cooling, forced circulation
Oil pressure (kPa) 450～650
Crankshaft rotation direction (view from free end) Clockwise
Length 1820
Overall dimensions
Width 1036
(mm)
Height 1406
Weight (kg) 2090

1.4 Lifting the Diesel Engine
During the lifting process, ensure you maintain a level to the centre line of the engine crankshaft.
It is prohibited to lift the engine in a tilted or one-sided position. Lifting the engine up and down
should be done slowly. (See Figure 1-3).
Figure 1-3 Diesel Engine Lifting
NOTE
Do not start the diesel engine before it’s correctly installed and connected at the final
position. When the diesel engine is running in an enclosed environment, keep well
ventilated to ensure that the exhaust gas is drained to the open air
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Chapter 2 Maintenance Guide of Diesel Engine
2.1 Sealant Application
Table 2-1 Sealant Application of Diesel Engine

Brand Main use Application locations Remarks
Flywheel housing bolt
Camshaft thrust bearing bolt
Camshaft gear bolt
Rocker shaft bracket nut
It’s applied onto Intake manifold bolt
the threads to Intercooler bracket bolt
prevent loosening Injection pump intermediate
Loctite 242
due to vibration, gear bolt
with moderate Injection pump gear bolt
As an option,
strength Injection pump camshaft nut
DriLoc204 can
Injection pump flange bolt
be used for pre-
Oil pump bolt
coating of the
Fuel filter seat bolt
thread
Suction filter bolt
Water drain valve bolt
Turbocharger oil inlet bolt
Slide valve screw plug of oil
Applied onto outer filter seat
Loctite567
threads for sealing Screw plugs in fuel, oil and
cooling water pipelines (do not
coat for plug with copper
washer)
Sealing between
Loctite 277 Bowl plug
core and hole
Joint faces of engine body and
oil pan
Joint faces of rear end gear
Loctite Coated on the
chamber and engine body
510/silicon bright metal
Joint faces of rear end gear
sealant surface for sealing
chamber and flywheel housing
Joint faces of front-end cover
and engine body
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2.2 Maintenance items
In addition to the daily maintenance, complete the following actions:
⚫ Replace diesel engine oil (as shown in Figure 2-1)
Unscrew the oil drain plug from the bottom of the oil pan to fully drain the engine oil and then
tighten the oil drain plug. Open the oil filler cap and add oil. At the same time, observe the
marking on the oil dipstick, until the required oil level is reached, and then install the oil filler
cap.
Oil filler port

Oil filter
Drain plug
Figure 2-1 Oil filler port, drain plug and oil filter
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⚫ Replace engine oil filter or filter element
Replace the engine oil filter using the following steps:
A. Disassemble the used oil filter;
B. Fill the new filter completely with clean engine oil;
C. Before installing new engine oil filter, apply engine oil onto the rubber gasket;
D. After the rubber gasket comes into contact with the base, tighten for 3/4~1 turn to seal;
E. Start the diesel engine and check for oil leakage.
⚫ Check and adjust the intake and exhaust valve clearances
A. Under the cold status of the diesel engine, turn the engine crankshaft (along the rotation
direction of the flywheel) to the compression top dead centre of the 1st and 6thcylinders. In
such case, the notch on the flywheel is aligned with the pointer on the flywheel housing.
B. Disassemble the valve rocker cover from the cylinder head and judge whether the 1st or 6th
cylinder is at compression stroke (there is a gap between intake/exhaust valve and rocker
for the cylinder under the compression stroke).
Figure 2-2 Adjustment of valve clearance
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C. Using the feeler gauge, check the clearance between the valve bridge top plane and valve
rocker arm (figure 2-3). If the clearance is too large or too small, adjust the adjustment bolt
on the rocker to meet the above-mentioned clearance requirement.
Adjustment
bolt
Clearance of intake valve and exhaust valve are all of 0.3mm

Figure 2-3 Valve clearance
D. After the checking of the 1st cylinder or 6th cylinder, turn the engine crankshaft for 360º to
make the 6th or 1st cylinder to working stroke and then check and adjust the remaining
valves.
Table 2-2 Adjustable Valves of Cylinders in the Compression Stroke
1st 2nd 3rd 4th 5th 6th

cylinder cylinder cylinder cylinder cylinder cylinder
1st cylinder Intake and Intake Exhaust Intake Exhaust Non-
compression exhaust valve valve valve valve adjustable
stroke valves
6th cylinder Non- Exhaust Intake Exhaust Intake Intake and
compression adjustable valve valve valve valve exhaust
stroke valves
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Chapter 3 Disassembly and Assembly of the Diesel Engine
3.1 Overview
During dismantling and assembling of the diesel engine, please follow operating instructions in
this manual strictly and pay attention to operation steps containing danger and safety marks, to
ensure personal safety and avoid accidents.
If the diesel engine is dismantled in reverse installation procedure, only one item is selected for
instruction in this repair manual unless otherwise specified herein.

The tightening torque of special bolts will be specified in relevant installation procedures, and
unless otherwise specified herein, please refer to Chapter V, Tightening Torque of Standard Bolts.
3.1.1 Danger signs
These signs are world recognised “safety warning signs” for industrial purposes, which
stresses the following information. Please make sure that you know what potential risks are
and how to ward off such risks. The violation of such warning information can lead to property
loss, personal injury or even death.
The common danger signs are usually used to indicate general warnings. In this manual, the
warning information are classified as per the levels of hazard effect (minor injury-related,
severe injury-related, and death related).
This warning sign indicates a potential hazard which can lead to great
property loss, serious injury or even death, if the occurrence cannot be
avoided.
This warning sign indicates a potential hazard which can lead to

slight injury or property loss, if the occurrence cannot be avoided.
It can also be used as a hazardous operation warning.
The cautions in this manual can indicate how to properly operate

and safely use the engine manufactured by the company. However,
the potential hazards cannot be removed by reading the manual. The
considerations will not be beneficial to the correct use unless the
implications are properly understood.

The warning information in this manual cannot cover all possible conditions! To apply an
application or method beyond those recommended in this manual, make sure that the operation
will never cause any danger to you, to others or to the equipment.
3.1.2 Safety symbols
Symbol Definition
Wear hand protection
Wear ear protection
Wear eye protection
Wear head protection
Wear foot protection
Wear a protective mask
Wear overalls
Avoid naked flames
Do not smoke
Do not use a mobile phone
Danger: battery acid
Danger: live cables, electrical risks
Highly flammable products
Keep away from hanging loads
Keep an extinguisher close by
Risk of thermal burns
Risk of mechanical drive
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During use of the diesel engine, many potential dangers may occur without any signs. Hence,
this manual cannot give warning instructions for all kinds of potential dangers. If the
procedures taken by you are not recommended ones, please ensure the same procedures are
safe to operate and do not result in any damage to property.
3.1.3 Special tools
To use a method or tool beyond those recommended in this manual, the user shall always
ensure their personal safety, avoid danger of life to the user or to others, meanwhile, make sure
that the use, maintenance or repair method will not result in damage risk or safety hazard.
3.1.4 Precautions for health protection
The list of “Health Protection Precautions” below is designed to reduce the risk of contamination.
Preventive list for health protection

1 Avoid prolonged and repeated contact with used engine oil.
2 Wear protective clothing, including waterproof gloves, if applicable.
3 Do not put oily rags in pockets.
4 Avoid contaminating clothing with oil, in particular underwear.
Wash overalls regularly. Throw away un-washable clothing and shoes impregnated
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with oil.
6 Emergency treatment must be immediately sought in the event of cuts and injuries.
Always apply protective cream before working; this will make it easier to remove
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mineral oil from the skin.
Wash with soap and hot water or, alternatively, use hand detergent and a nailbrush to
8 make sure that all oil is removed. Products containing lanolin can help replace the
skin's natural oils that may have been removed.
9 DO NOT use petrol, kerosene, fuel, thinners or solvents to clean the skin.
10 If skin problems occur, immediately consult a doctor.
11 If possible, degrease components before handling them.
When there are risks for the eyes, use safety glasses or a face shield. An eye-rinsing
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solution must be kept close at hand.
Do not spill oil or other fluids on the ground when repairing the engine. In the event
13 of an accidental spillage of hydrocarbon or other fluid, take all the necessary
measures to section off the area, clean up and protect people and the environment.
The handling, storage and recycling of hydrocarbons, ethylene, glycol and oil must
14 comply with the safety and environmental standards applicable in the country where
these operations take place.
151. Risk of injury due to high injection pump pressure
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3.1.5 Environmental precaution
There are laws regarding environmental protection and the disposal of waste of hydrocarbons.
To ensure compliance with environmental protection laws, consult your local authorities who
will advise you.
Asbestos
The products and spare parts supplied by S. I. Moteurs Baudouin do not contain asbestos.
3.1.6 Precautions for disassembly and assembly of the diesel engine
1) Most accidents in connection with use, maintenance and service of diesel engines are resulted
from failure to observe safety rules and basic precautions. So, you should know risks you face
and take corresponding preventive measures to avoid occurrence of accidents. To conduct
operation, maintenance and service of the diesel engine, you should be trained, and have relevant
skills and use appropriate tools.
2) Failure to follow relevant instructions given in this manual may result in serious accidents,
even endangering the operator's life. S. I. Moteurs Baudouin. cannot foresee all potential risks.
Similarly, guidelines and instructions specified in this manual are not exhaustive.
3) Before proceeding with maintenance or repairing, a signboard containing "Do Not Use" or a
similar sign should be placed on the starter switch.
4) Before use of the barring rod, necessary preventive measures should be taken.
5) Ensure that the maintenance site and surrounding environment are suitable for safe operation.
6) Ensure the maintenance workshop or area around the diesel engine is clean and neat.
7) Before working, please take off all jewellery. Please wear a suitable working uniform.
8) Before working, please check whether corresponding protective equipment (goggles, gloves,
shoes, masks, working uniform, helmet, etc.) are within effective life and that any safety
equipment is in accordance with local safety regulations
9) Do not use faulty or unsuitable tools.
10) Stop the diesel engine during maintenance or service.
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3.2 Cylinder Head Group

3.2.1 Cylinder Head Group Disassembly and Assembly Overview
1) Exploded view
The cylinder head is located on the upper portion of the cylinder block and combined with the
piston head to form the combustion chamber. The parts connected with the cylinder head include
air filter, intake manifold, exhaust manifold, water outlet pipe, fuel injector, cylinder head cover,
cylinder head gasket, and some parts of the valve mechanism, as shown in the Figure 3-1.
Cylinder head cover
Fuel injector
Rocker arm High pressure
Thermostat oil pipe
Water outlet pipe
Exhaust manifold Intake manifold
Cylinder head
lubricating oil pipe
Oil-gas Air filter
separator
Figure 3-1 Connected parts of cylinder head
2) Disassembly
a) The disassembling steps are indicated in turn:
b) Disassemble the air filter. Refer to the disassembling instruction of intake and exhaust
system for details.
c) Disassemble the fuel return pipe of fuel injector and the high-pressure fuel pipe. Refer
to the disassembling instruction of fuel system for details.
d) Disassemble the thermostat and water outlet pipe.
e) Disassemble the exhaust manifold. Refer to the disassembling instruction of intake and
exhaust system for details.
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f) Disassemble the intake manifold. Refer to the disassembling instruction of intake and
exhaust system for details.
g) Disassemble the front and rear lifting plates.
h) Disassemble the cylinder head cover and the gasket.
i) Dismantle the fuel injector, see the dismantling instructions of fuel system for details;
j) Disassemble the rocker arm assembly and push rod. Refer to disassembling instruction
of valve mechanism for details.
k) Disassemble the lubricating oil pipe of cylinder head.
l) Disassemble the cylinder head assembly and the cylinder head gasket.
m) Disassemble the inner and outer springs of valve, upper and lower seats of intake and
exhaust valve springs, valve cotters, and valves. Refer to disassembling instruction of
valve mechanism for details.
n) Disassemble the valve stem sealing sleeve;
3) Assembly
The assembly procedure is in reverse order of disassembly procedure.
3.2.2 Disassembly, Inspection, Maintenance and Assembly of Engine Lifting Plates
1) Exploded view
Engine
hanger plate
Hexagon
bolt
Figure 3-2 Exploded View of Engine Hanger Plate
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Disassembly
a) Disassemble the parts fixed on the hanger plate, loosen the hexagon bolts fixing the
engine hanger plate in turn, and take out the hanger plate, as shown in Figure 4-2:
2) Inspection and Maintenance
a) Before installation the hanger plates, distinguish the front hanger plate from the rear
one. The front hanger plate shall be installed at the front side of the engine (the fan side).
The rear hanger plate shall be installed in the rear side of the engine (the flywheel side);
b) Check the front and rear hanger plates for cracking and other failure and check the
hexagon head bolts for presence of failure. Replace with new parts if necessary.
3) Assembly
a) Tighten the M12 hex bolts that attach the hanger plates to the end plates.
3.2.3 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head Cover
1) Exploded view
Hexagon socket
Cylinder head
cylindrical head screw
cover
Rubber O-ring
Cylinder head
cover gasket
Figure 3-3 Exploded View of Cylinder Head Cover
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2) Disassembly
a) Loosen the cylinder head cover bolts in turn and vertically take out the cylinder head
cover and cylinder head cover gasket, as shown in the Figure 3-3.
a) Check the cylinder head cover for presence of cracking and other damage. If any, replace
with new cylinder head cover;
4) Assembly
a) The cylinder head cover gaskets can be used only once. Replace with new ones in case
of repair. Before installing cylinder head cover gasket, check and ensure that new
cylinder head cover gasket is free of any damage;
b) Wipe clean the top face of cylinder head and assemble cylinder head gaskets correctly;
c) Apply oil to the rubber O-ring, install O-ring into groove of cylinder head cover, wipe
clean the cylinder head cover, and assemble the cylinder head covers onto the cylinder
head in correct sequence;
d) Install and tighten the cylinder head cover bolts.
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3.2.4 Disassembly, Inspection, Maintenance and Assembly of Lubricating Oil Pipe
1) Exploded view
Flanged bolt
Hose clamp
Cylinder head
Hollow bolt lubricating oil pipe
Sealing gasket
Cylinder head
lubricating oil inlet pipe
Hollow bolt
Combination
sealing washer
Figure 3-4 Exploded View of Cylinder Head Lubricating Oil Pipes
2) Disassembly
a) Loosen the hollow bolts fixed on the cylinder block and cylinder head and take out the
lubricating oil pipes of cylinder head, as shown in Figure 3-4:
a) Check the oil pipes for presence of oil permeation and leakage. Upon detection of oil
permeation or leakage, judge the failure state and replace with new lubricating oil pipes
or sealing gaskets.
4) Assembly
a) Fix the cylinder head lubricating oil pipe assembly onto the cylinder head and cylinder
block by using hollow bolts with sealing gasket.
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3.2.5 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head
1) Exploded view
Auxiliary bolt,
cylinder head
Main bolt,
cylinder head Washer
Clamping
block
Cylinder head
Valve stem
sealing sleeve
Cylinder head
gasket
Figure 3-5 Exploded View of Cylinder Head
2) Disassembly
As shown in Figure 3-5:
a) Loosen nuts of cylinder head auxiliary bolts and take out clamping blocks;
b) Loosen the cylinder head cover main bolts;
c) Before disassembling the cylinder head, ensure that the fuel injectors are disassembled,
otherwise the fuel injector nozzle will be easily damaged during the placement of
cylinder head;
d) Disassemble the cylinder head and place the disassembled cylinder head on a paper
board to avoid wearing upper surface of combustion chamber and other sealing surfaces.
If the more than one cylinder head is disassembled, mark the cylinder heads with
cylinder numbers for problem analysis;
e) Disassemble the cylinder head gasket and mark the cylinder numbers on the cylinder
head gaskets for problem analysis;
f) Check and replace the cylinder head auxiliary bolts if necessary;
g) Dismantle the intake and exhaust valves by referring to Instructions for Dismantling of
Valve Mechanism;
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h) Disassemble the valve stem sealing sleeve by using the special tooling or use pliers to
clamp the outer wall of valve stem sealing sleeve and rotate upward to lift out the valve
stem sealing sleeve.
a) Cylinder head
◆ Before dismantling of the cylinder head, first inspect whether there is water leakage,
oil leakage, gas leakage and other abnormal phenomena to accurately locate position where
the problem occurs, and accurately analyse the problem.
◆ Clean the cylinder head, and clean the surface of the combustion chamber, valve
seat, intake and exhaust valves, intake and exhaust ports, and remove the carbon deposit
and mucilage, as well as inspect surface conditions.
b) Appearance inspection
◆ Inspect discoloration and crack of the cylinder head carefully, and in case of crack,
carry out penetrant inspection.
c) Valve sinkage
◆ The valve sinkage is the vertical distance from the bottom surface of the valve to
the bottom surface of the cylinder head, and the difference between the valve sinkage
measurement value and the required value can reflect the wear of the valve and valve seat.
It is possible to use depth micrometer to measure the valve sinkage as shown below.
Figure 3-6 Depth Micrometer
◆ For the required valve sinkage value, refer to the Table 4-3, and if the valve sinkage
exceeds the permissible range, it is required to replace the cylinder head with a new one
to ensure reliability of the engine. If the valve sinkage does not exceed the permissible
value, dismantle the valve for inspection and then inspect the sealing surface of the valve
seat ring. Check whether there is apparent wear and abnormal damage to the valve and
the sealing surface of the valve seat ring.

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Table 3-1 Required Valve Sinkage Values

Required Valve Sinkage Values
(mm)
Intake 0.6~1.1
Exhaust 1.2~1.7
d) Clearance between valve stem and valve guide
◆ The inside diameter of the valve guide is the contact surface between the valve
guide and the valve, and if the clearance between valve stem and valve guide exceeds the
permissible value due to wear, it will result in influence on guiding effect of the valve,
reducing reliability of the diesel engine operation. The inside diameter of the valve guide
can be measured by use of an inside micrometer, as shown in Figure 3-1. Using an outside
diameter micrometer, measure the outside diameter of the valve guide. The permissible
range is (0.04~0.07)mm for the clearance between intake valve stem and valve guide pipe
and is (0.06~0.09)mm for the clearance between exhaust valve stem and valve guide pipe.
If out of the permissible range, replace the components to ensure the working reliability
of the diesel engine.
Figure 3-7 Inside micrometer
e) Cylinder head gasket
◆ In case of gas leakage, water leakage, oil leakage and other problems at the cylinder
head gasket, it is required to inspect the cylinder head gasket and replace it wherever
necessary.
◆ Inspect whether there is visible damage to the cylinder head gasket and analyse the
cause. The cylinder head gasket should be replaced with a new one after being dismantled.
f) Valve stem sealing sleeve
◆ Before disassembling, observe the rubber lip of valve stem sealing sleeve for presence of
damage. Once being disassembled, replace with new valve stem sealing sleeve.
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Cylinder head bolt
◆ The cylinder head main bolt can be reused for at most three times.
4) Assembly
a) Install the cylinder head gasket;
Top
Figure 3-8 Cylinder head gasket
◆ The cylinder head gasket can be used once only, and in case that it is returned for
repairing, it must be replaced with a new one;
◆ Wipe clean the top plane of cylinder block and place the cylinder head gasket as per
the corresponding pin holes;
◆ Inspect whether the cylinder head gasket is assembled properly.
b) Attach the cylinder head gasket and then install the cylinder head to the cylinder block;
◆ Wipe clean the cylinder head carefully and ensure that there is no dust, debris, sand
and other contaminants, and then further wipe clean the bottom surface of the cylinder
head;
◆ Inspect whether there are foreign bodies in the cylinder, and the top surface of
cylinder head gasket is clean;
◆ Use the guide rods to screw them into the cylinder head bolt holes;
◆ The cylinder head gasket shall be free of distortion, deformation, and damage.
c) Install the cylinder head main bolts loosely. Apply an appropriate amount of lubricating
oil to the threads and support faces of cylinder head main bolts.
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d) Add the clamping blocks and circular washers, loosely install the cylinder head
secondary bolts, and assemble end plates on two ends of cylinder block;
e) Apply an appropriate amount of lubricating oil to the threads and support faces of
cylinder head secondary bolts;
f) Tighten the cylinder head main and secondary bolts in five rounds:
Angular tightening of the M33 Cylinder Head
Torque tightening Vis / M16 80Nm

Screw
Vis / M20 80Nm
Screw
1st Angular tightening Vis / M16 60°
Screw
Vis / M20 60°
Screw
2nd Angular tightening Vis / M16 60°
Screw
Vis / M20 60°
Screw
3rd Angular tightening Vis / M16 0°
Screw
Vis / M20 60°
Screw
4th Angular tightening Vis / M16 0°
Screw
M20 30°
Table 3- 2 Angular Tightening
Figure 3-9 Tightening sequence for cylinder head main bolts
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Figure 3-10 Tightening sequence for cylinder head auxiliary bolts
g) Assemble the sealing bush of the valve stem on the valve guide;
Figure 3-11 Valve stem sealing sleeve

◆ The valve stem sealing sleeve can be only used once. Make sure to replace with
new one in case of repair;
◆ Check the valve stem sealing sleeve for presence of defect and check valve stem
sealing sleeve spring for intactness;
◆ Install valve stem sealing sleeve on valve guide;
◆ Apply lubricating oil to the lip of valve stem sealing sleeve;
◆ Install the valve stem sealing sleeve.
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3.3 Engine Block Group

3.3.1 Disassembly, Inspection, Maintenance and Assembly of Engine Block
1) Exploded view
Figure 3-12 Exploded View of Engine Block
Figure 3-13 Exploded View of Engine Block
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2) Detailed list of parts
The names and quantities of the parts of engine block are shown in Table 3-3:
Table 3-3 Detailed list of parts of the engine block
Position Designation Quantity
1 Engine Block 1
2 Cylinder Liner 6
3 O-ring 12
4 O-ring 6
5 O-ring 6
6 Main Bearing Cap 6
7 Thrust Bearing Cap 1
8 Main Bearing Bolt 14
9 Camshaft bush 1
10 Camshaft bush 6
11 Bowl Plug 5
12 Parallel Pin 1
13 φ10 Pulling Rivet 5
14 Piston Nozzle Set 6
15 Parallel Pin 16
16 Bowl Plug 4
17 Handhole Cover 1
18 Gasket 1
19 Oil Filling Tube 1
20 Hexagon Head Bolt 2
21 Plain Washer 1
22 Rivet 1
23 Oil Filling Plug 1
24 Lower thrust plate 1
25 Upper thrust plate 1
26 Handle Cover Gasket 3
28 Handhole Cover 1
29 Handle Cover Gasket 1
30 Handhole Cover 2
31 Main Bearing Upper Shell 7
32 Main Bearing Lower Shell 7
33 Sensor Seat 1
34 O-ring 1
35 Hexagon Screw Plug 1
36 Screw Plug 1
Hexagon Socket Head Cap
37 4
Screw
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3) Disassembly
The disassembly of the engine block group is in the reverse order of assembly.
a) Check the machined surfaces of the engine block for burrs, oil stain, and collision-
caused damage. If any, remove them using an oilstone, abrasive paper or towel. If
required, replace the damaged parts.
b) Check the oil passages, water passages, and cavities in the engine block for metal chips,
burrs, and flashes. If any, remove them using an air blower gun or brush.
c) Try installing the tappet. Check the roughness and chamfer of the tappet hole. Check the
tappet hole for burrs and flashes.
d) Check the chamfer of the cylinder liner hole for collision-caused damage.
e) No impression may be found in any seal surface.
5) Assembly
a) Apply evenly Loctite 277 threadlocker to the mating face of the cup plug. Install the cup
plug to the right side, front end, and rear end of the cylinder block. Remove the surplus
threadlocker from the cup plug;
b) Using the expander, expand the corresponding locations in the cylinder block, then put
gently the thrust main bearing cap and other main bearing caps in place. A dowel pin is
used for positioning the thrust bearing cap. Before installing the thrust bearing cap,
install the thrust plate.
c) Apply a proper amount of lubricating oil to the threads and support surfaces of the
fourteen M24 main bearing bolts. First pre-tighten these bolts. Then tighten them in the
sequence (A~N). Two tightening methods may be used.
◆ Manual tightening
1st round: Pre-tighten the main bearing bolts in the sequence to the torque of
(180±10) Nm;
2nd round: Tighten these bolts by 60º in the sequence;
3rd round: Tighten these bolts by 60º in the sequence.
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Front
end
Figure 3-14 Schematic Diagram of Engine Block
d) Tap the parallel pin into the pin hole in the engine block. Align the pin hole in the piston
cooling nozzle with the parallel pin. Tighten the hollow bolt to the torque of 45 Nm.
6) Torque specification
The bolts except for those important ones shall be tightened according to the general
tightening specification.
3.3.2 Disassembly, Inspection, Maintenance and Assembly of Flywheel Cover
1) Exploded view
Figure 3-15 Exploded View of Flywheel Cover
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The names and quantities of the parts of flywheel cover are shown in Table 3-4:
Table 3-4 Detailed list of parts of the flywheel housing
1 Flywheel Housing 1
2 Timing Gear chamber 1
3 Cover Plate 1
4 Cover Plate 1
7 Rear Oil Seal 1
Flywheel Housing Coupling
8 1
Ring
13 Hexagon Flange Bolt 4
17 Washer 1
18 Hexagon Screw Plug 1
19 Parallel Pin 4
21 Indicator 1
22 2
Screw
23 Handhole Cover Plate 1
24 2
Screw
25 Gasket 1
3) Disassembly
The removal of the flywheel cover is in the reverse order of installation.
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a) Check for completeness of parts against the table of parts.
b) Check the statuses of flywheel housing, engine block, and timing gear chamber and
ensure that all junction surfaces are free of burrs, oil dirt, and impact damages.
5) Assembly
a) Clean and degrease the mating faces of the timing gear chamber and flywheel housing.
Apply silicone sealant to the mating face of the timing gear chamber.
Strike the parallel pin into the engine body and mount the flywheel housing onto the
timing gear chamber by using the overhead crane. Apply Loctite 242 threadlocker to the
threads of the eight M12×120 bolts and the six M12×85 bolts. To fix the flywheel housing
to the timing gear chamber, tighten these bolts in the sequence as shown in Figure 4-16
to the torque of (120±10)Nm (for flanged hex bolts) or (105±10) Nm (for hex bolts). After
the proper tightening, add the paint sealing for the bolts.
Figure 3-16 Sequence for Tightening the Flywheel Housing Bolts
b) Apply a proper amount of lubricating oil to the mating faces of the front oil seal and the
crankshaft timing gear. Using the special tool, press the oil seal onto the crankshaft
timing gear. The axial distance from the oil seal to the inner face of the flywheel housing
shall be 3mm.
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3.3.3 Disassembly, Inspection, Maintenance and Assembly of Front End Cover
1) Exploded view
Figure 3-17 Exploded View of Front End Cover
The names and quantities of the parts of front end cover are shown in Table 3-5:
Table 3-5 Detailed list of parts of the front end cover
1 Front cap 1
4 Parallel pin 2
3 Front oil seal 1
2 Hexagon head bolt 14
3) Disassembly
The removal of the front end cover is in the reverse order of installation.
a) Check that the mating faces of the cylinder block and the oil pan are clean without grease
or impact damage.
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5) Assembly
a) Strike the dowel pin into the mating face of the engine block;
b) Apply evenly silicone sealant onto the front end cover;
c) Mount the front end cover onto the engine body by using overhead crane. Apply a
little Loctite 242 threadlocker to the threads of the bolt. Tighten the bolts.
3.4 Crank and Connecting Rod Mechanism

3.4.1 Disassembly, Inspection, Maintenance and Assembly of Crank and Connecting Rod
Mechanism
1) Exploded view
1. Engine block
2. Crankshaft assembly
3. Main bearing shell
4. Main bearing cap
5. Main bearing bolt
6. Piston and
connecting rod
7. Crankshaft timing
gear
8. Parallel pin
9. Flywheel housing
10. Flywheel assembly
11. Flywheel bolt
12. Oil pump gear
13. Front end cover
14. Vibration damper
bolt
15. Vibration damper
16. Pulley
17. Pulley bolt
Figure 3-18 Exploded View of Crank and Connecting Rod Mechanism
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18. Trapezoidal-barrel-face piston

ring
19. Twist-taper-face piston ring
20. Coil spring-loaded oil ring
21. Piston
22. Circlip
23. Piston pin
24. Connecting rod shank
25. Connecting rod upper bearing
shell
26. Connecting rod lower bearing
shell
27. Connecting rod cap
28. Connecting rod bolt
29. Parallel pin
Figure 3-19 Exploded View of Piston and Connecting Rod
2) Preparation before removal
◆ Tools: Torque wrench, overhead crane, guide stud, and long nose pliers.
◆ Preparations before disassembling:
a) Remove the belt before removing the pulley (16) and the vibration damper (15);
b) Remove the flywheel housing (9), front end cover (13), main bearing cap (4), and
the piston and connecting rod (6) before removing the crankshaft assembly (2).
3) Disassembly
a) Using the torque wrench, remove the pulley bolts (17). Remove the pulley assembly.
Remove the vibration damper bolts (14), then the vibration damper (15).
b) Align the automatic tightening machine with the flywheel bolts (11). Start the automatic
tightening machine to tighten the flywheel bolts (11). Screw the guide stud into the
threaded hole at the rear end of the crankshaft assembly (2). Screw two M12 bolts into
two holes in the flywheel bolt circle, with the two holes just opposite to each other at
both ends of the diameter of flywheel bolt circle. Draw the flywheel assembly out of the
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flywheel housing (9). Attach the slings of the overhead crane to the two M12 bolts.
Using the overhead crane, remove the flywheel. Remove the guide stud.
c) After removal of the flywheel housing (9), remove the crankshaft timing gear (7).
Remove the parallel pin (8).
d) Using the torque wrench, remove the connecting rod bolts (28) from the observation
hole in the engine block. Remove the connecting rod caps (27). Draw the piston group
(18, 19, 20, 21, 22, and 23) together with the connecting rod shank (24) out of the
cylinder liner. Remove the upper and lower bearing shells (25, and 26) of the connecting
rod.
e) Using the long nose pliers, remove the internal circlip (22) from the piston (21). Remove
the piston pin (23) and the connecting rod shank (24). Using the piston ring spreader,
remove the trapezoidal-barrel-face piston ring (18), twist-taper-face piston ring (19), and
coil-spring-loaded piston ring (20);
f) Turn the engine block upside down. Remove the main bearing cap (4) and main bearing
lower shell (3). Using the overhead crane, lift and move the crankshaft assembly (2).
Remove the main bearing upper shell (3).
a) Apply lubricating oil to the flanged faces of the flywheel bolt. Tighten the flywheel bolts
in the sequence as shown in Figure 4-20:
◆ Manual tightening:
Tighten the bolts in three rounds: 1st round, to the torque of 80Nm; 2nd round, to the
torque of 300Nm, and 3rd round, to the torque of (600±50)Nm.
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Figure 3-20 Flywheel Bolts Tightening Sequence
b) Apply lubricating oil to the heads of the crankshaft pulley bolts. Tighten the bolts in a
diagonal sequence in two rounds: 1st round, to the torque of 80Nm, and 2nd round, to
the torque of (300±20)Nm.
c) Apply lubricating oil to the heads of the vibration damper bolts. Tighten the bolts in a
diagonal sequence in two rounds: 1st round, to the torque of 80Nm, and 2nd round, to
the torque of (140±10)Nm.
d) Apply lubricating oil to the threads and support surfaces of the connecting rod bolts:
◆ Manual tightening:
Tighten the bolts in three rounds: 1st round, to the torque of 70Nm; 2nd round, to the
torque of 200Nm, and 3rd round, to the torque of (350±30) Nm.
Finally, apply paint to the bolts. These bolts can be reused for at most three times.
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5) Assembly
a) Heat the oil pump gear (12). Place it onto the front end journal of the crankshaft
assembly (2). Place the parallel pin into the pin hole at the rear end of the crankshaft.
Turn the engine body upside down. Clean the main bearing holes. Place the main bearing
shells (3) in these holes. Apply a proper amount of lubricating oil to the main bearing
shells. Using the overhead crane, move the crankshaft assembly (2) into the main
bearing holes in the engine block (1). Install the main bearing caps (4) according to the
requirements;
Figure 3 - 21 Piston gears side
Loosen the bearing cap screws in reverse alphabetical order from N to A. ( Fig. 3-21)
Remove all fastenings.
Remove the bearing caps.
Remove and number the half-shells of the cap.
NOTE
Bearing Caps are dismantled using the wall spreader ref: 13599730Q
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Figure 3-23 Bearing Caps
Use a comparator mounted on a magnetic base to ensure stressing does not exceed 0.15
mm (Fig 3-23).
Remove the crankshaft.
CAUTION
Weight of crankshaft: 240kg
NOTE
Position the crankshaft so the end counterweights are facing up.

Remove and number the bearing half-shells
Clean all the parts
Figure 3-24 Engine Block
Checking the Engine Block
Put the caps on without shells. Tighten the caps to the recommended normal torque.
Use a 2-point gauge (Fig 3-24) to check the internal diameter of the bearing (diameter
and distortion).
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Figure 3-25 Crankshaft Crank Pins Fig 3.26

Checking the Crankshaft
CAUTION
Weight of crankshaft: 240kg
Check the tangs of the crank pins and bearing for scratches, punctures or excessive wear.
NOTE
Tiny scratches (that cannot be detected by a fingernail) are permissible
Check the conditions of the tap threads of the engine flywheel fixing screws.
Check the condition of the flywheel locating pin.
Check the condition of the front and rear lip seal contact surfaces.
Dimensionally check the crankshaft (crank pins, journals, width of stop flange).
(Fig 3-25) (Fig 3-26).
Disassembly of the crankshaft, rectification and magnetic search for cracks.
Figure 3-27 Measuring the Crankshaft
Check the bounce of the crankshaft. (Fig 3-27). Put the crankshaft on the two V’s,
measure the bounce. Position the horizontal comparator to exclude the natural sag of
the crankshaft.
Carry out MAGNAFLUX inspection of crankshaft (detection of cracks and crevices).
This operation must be carried out by a specialised body.
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CAUTION
If any cracks have been detected, it is IMPERATIVE that the crankshaft be replaced.
Protect the crankshaft against corrosion and dust with a light film of oil and cover in case of
short-term storage.
Bearing shells and stop flanges
Figure 3-28 Bearing Shells Figure 3-29 Stop Flanges
Clean the shells using a degreaser. The shells must be replaced if they show signs of cavitation,
knocks, metal peeling, deep scratches beyond the coating layer, pronounced wear (yellow metal
appearing in areas).
Check the thickness of the shells individually or assembled (Fig 3-27). Replace the shells if out
of tolerance.
NOTE
If the shell is being re-used, it must be put back in its original place. You cannot
replace just one half-shell; it is imperative that you replace the full set of half-shell.
Check the thickness of the stop flanges at the wear points (Fig 3-28). Replace the stop flanges
if out of tolerance.
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Fitting the crankshaft
Figure 3-29 Half-Shells

Fit the half-shells on the engine block side. (Fig 3-29) Fit the half-shells on the cap’ side.
(Fig 3-29)
Apply a film of engine oil all over the half-shell.
Figure 3-30 Crankshaft Fixing

Fit the crankshaft, taking care to make sure the end counterweights face down. (Fig 3-30)
Figure 3-31 Bearing Caps

Fit the bearing caps, respecting mounting direction and numbering. (Punch marks facing each
other and same number Fig 3-31). Fit the rear bearing cap, along with its stop flanges which
have been oiled beforehand.
NOTE
If the bearing caps are difficult to slot in, use
tool 13599730Q combined with a comparator
to ensure correct distance from the engine
block. (Fig 3-32)
Figure 3-32 Fitting Bearing Caps
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Figure 3-33 Fixing of screws to Bearing Caps
Fix the fixing screws of the caps, oiled beforehand on the threads and mating surfaces.
(Fig 3-33). Bring all the screws into contact with the bearing caps
Figure 3-34 Crankshaft Rotation

Check free rotation of the crankshaft and passage of counterweights
Check the axial play of the crankshaft by applying moderate pressure to the front/rear using
the appropriate tool (Fig 3-34)
b) Using the piston ring spreader, install the trapezoidal-barrel-face piston ring (18), twist-
taper-face piston ring (19), and coil-spring-loaded piston ring (20) to the pistons (21).
Place the connecting rod shank into the inner chamber of the piston. Insert the piston
pin (23) through the piston pin hole and connecting rod bushing, and fix the piston pin
by using circlips (22);
c) Push the already-assembled piston group (18, 19, 20, 21, 22, and 23) together with the
connecting rod shank (24) into the cylinder liner. Using the torque wrench or tightening
machine, tighten the connecting rod bolts (28) according to the requirements;
d) Clean the crankshaft timing gear (7) and install it onto the rear end of the crankshaft
with aligning the parallel pin (8);
e) After installation of the flywheel housing (9), screw the guide stud into the threaded
hole at the rear end of the crankshaft. Using the overhead crane, align the pin hole in the
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flywheel with the parallel pin (8), hoist the flywheel and push the flywheel onto the
crankshaft assembly (2) with the help of the guide stud. Remove the guide stud, and
tighten the flywheel bolts (11) by using the tightening machine;
f) After installation of the front end cover, tighten the vibration damper bolts (14), for
fixing the vibration damper (15) to the crankshaft pulley (16); and tighten the crankshaft
pulley bolts (17), for fixing the crankshaft pulley (16) to the crankshaft assembly (2).
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3.5 Valve Mechanism

3.5.1 Disassembly, Inspection, Maintenance and Assembly of Valve Train
Exploded view
Intake rocker arm assembly

Sleeve Exhaust rocker arm assembly
Rocker arm shaft
Hexagon bolt Hexagon bolt
Rocker arm support
Valve bridge subassembly
Rocker arm support
Valve bridge base
Upper retainer for the valve spring Valve collet
Outer valve spring
Inner valve spring
Cylinder head Lower retainer for the valve spring
Exhaust valve Intermediate gear shaft

Pushrod Intermediate gear subassembly
Tappet
Camshaft assembly Spacer
Hexagon bolt Hexagon bolt
Engine block Hexagon bolt

Hexagon
bolt Intermediate gear subassembly
Camshaft timing gear
Thrust plate
Figure 3- 35 Exploded View of Valve Train
1) Disassembly
a) Remove the rocker arm shaft support, rocker arm, and rocker arm shaft.
b) Remove the intake and exhaust valves.
c) Remove the tappet and push rod.
d) Remove the gear train.
e) Remove the camshaft.
2) Assembly
a) Install the camshaft.
b) Install the gear train.
c) Install the tappet and push rod.
d) Install the intake and exhaust valves.
e) Install the rocker arm support, rocker arm, and rocker arm shaft.
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3.5.2 Disassembly, Inspection, Maintenance and Assembly of Camshaft
1)Exploded view
Camshaft assembly
Hexagon bolt
Hexagon bolt
Camshaft timing gear
Thrust plate
Figure 3-36 Exploded View of Camshaft

1) Disassembly
a) Turn the camshaft, and inspect whether the camshaft and timing gear are flexible,
without blockage;
b) Use a dial indicator to inspect the camshaft for axial float;
c) Check the backlash between the camshaft timing gear tooth and the mating gear
tooth;
d) On the working bench for installation and dismantling of the engine, turn the
crankshaft to enable the camshaft timing gear to be at the top dead centre of the
1st cylinder. Inspect whether the hexagon bolts of the camshaft are loosened.
Dismantle the hexagon bolts of the timing gear and camshaft timing gear;
e) Dismantle the hexagon bolts of the thrust plate for the camshaft, dismantle the
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thrust plate, and lightly remove the camshaft. It is required to protect the camshaft
bearing shell from being impacted.
a) Inspect whether the cam surface in contact with the tappet is worn or not, and
whether the main bearing journal is seized or worn;
b) Inspect whether the hexagon bolts fixing the timing gear is bent or deformed, and
tooth broken of the camshaft timing gear occurs or the tooth surface is worn
seriously.
3) Assembly
a) After dismantling, inspect the camshaft and timing gear. If wear occurs or a big
deviation in other parameters is produced, it is required to repair them, or have
them replaced with a new camshaft and/ or timing gear;
b) Clean the camshaft bore, inspect the camshaft bushing for damages due to
impacting. Repaired part is not allowed to use. Apply an appropriate amount of
lubricating oil into the camshaft bushing by an oiler, without any oil flow or drip;
c) Install the camshaft, wipe clean the camshaft, check the camshaft for collision
damage, connect the camshaft and camshaft guide sleeve together, and apply an
appropriate amount of lubricating oil. Insert carefully the camshaft and the
camshaft guide through the camshaft bushing. Be sure not to cause damage to the
camshaft bushing;
d) Place the camshaft thrust plate at the rear end of the engine. The grade 10.9 M8×20
hex bolts shall be used to fix the thrust plate. Apply Loctite 242 threadlocker to
the heads of the bolts. Tighten the bolts to the torque of 32Nm;
e) Note that the axial clearance between the thrust plate and camshaft shall be
uniform. Check that the camshaft can rotate smoothly without sticking.
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3.5.3 Disassembly, Inspection, Maintenance and Assembly of Rocker Arm and

Rocker Arm Shaft
1) Exploded view
Exhaust rocker Intake rocker
arm assembly arm assembly Socket head cap screw
Socket head cap screw Rocker arm
shaft
subassembly
Sleeve
Rocker arm
support
Rocker arm
support
Valve bridge
Valve bridge subassembly
subassembly
Cylinder
Valve bridge base head
Figure 3-37 Exploded View of Rocker Arm and Rocker arm Shaft
2) Disassembly
a) Turn the crankshaft, and observe whether the rocker arm is rotated flexibly;
b) Measure clearance of individual valves, and inspect change in clearance of the
valves;
c) If the rocker arm rotates inflexible, or the valve clearance varies greatly, loosen
the socket head cap screw, and carefully remove the rocker arm support, rocker
arm, and the sleeve. Make marks on them to avoid confusion with those of other
valves.
a) Clean the rocker arm, observe appearance of the rocker arm, and determine
whether there are cracks and other defects;
b) Inspect whether the rocker arm hole is worn or abraded, and measure its diameter;
c) Inspect the rocker arm adjusting screw, and determine whether the arc surface of
the other side of the rocker arm is worn;
d) Check the oil passages for blockage;
e) Measure diameters of the rocker arm hole and rocker arm shaft, and then calculate
their fit clearance.
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4) Assembly
a) Inspect whether the parts to be assembled are clean, and free from collision
damages, scratches and rust;
b) Install the valves. See the relative section. Slightly tighten manually the four
M10×35 socket head cap screws, for fixing the valve bridge base to the cylinder
head. Apply a proper amount of lubricating oil to the valve bridge base. Dripping
of lubricating oil shall not be permitted;
c) Clean the intake rocker arm assembly, exhaust rocker arm assembly, rocker arm
support, rocker arm shaft, sleeve, and socket head cap screw. Install rivets at both
ends of the rocker arm shaft. Apply a proper amount of lubricating oil to the
mating face of the rocker arm shaft. Dripping of lubricating oil shall not be
permitted;
d) Insert the rocker arm shaft through the intake rocker arm, sleeve, and exhaust
rocker arm. Then place them on the rocker arm supports. Align the gap of the
rocker arm shaft with the threaded holes in the rocker arm supports. The bosses of
the rocker arm supports shall be placed opposite to each other;
e) Insert the four M10×75 socket head cap screws into the threaded holes in the
rocker arm supports;
f) Apply Loctite 242 threadlocker to the threads of the bolts for the valve bridge
base. Tighten the bolts. Apply lubricating oil to the valve bridges. Install the valve
bridges to the valve bridge base. Check that the valve bridges can move smoothly
in the valve bridge base without sticking. In the case of any sticking, replace the
valve bridges.
g) Check that the valve bridges align with the valves. In the case of any
misalignment, adjust the valve bridge base. Finally, tighten the bolts for the valve
bridge base;
h) Slightly tighten manually the socket head cap screws for fixing the rocker arm
shaft subassembly to the cylinder head;
i) Apply Loctite 242 threadlocker to the threads of the screws for fixing the rocker
arm shaft supports. Tighten the screws to the torque of 54Nm. The axial clearance
of the rocker arm shaft shall be 0.4 to 0.6mm.
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Valve timing of 6M33 series diesel engine:
Intake valve opens: (34±5)º before top dead centre.
Intake valve closed: (40±5)º after bottom dead centre.
Exhaust valve opens: (61±5)º before bottom dead centre.
Exhaust valve closed: (27±5)º after top dead centre.
3.5.4 Disassembly, Inspection, Maintenance and Assembly of Tappet and Push Rod
1) Exploded view
Cylinder head Push rod
Tappet
Engine block
Figure 3-38 Exploded View of Tappet and Push Rod

1) Disassembly
a) After the rocker arm and rocker arm shaft have been dismantled, directly remove
the pushrod and tappet, and put them aside in sequence;
a) Clean the push rod and tappet;
b) Check the oil passages of the tappet and push rod for blockage;
c) Check the push rods for bending and excessive wear;
d) Check the ball end and socket end of the push rod for excessive wear;
e) Check the surface and end face of the tappet for excessive wear;
f) Check the mating socket of the tappet for excessive wear.
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3) Assembly
a) Check the tappet and pushrod and replace them with a new one if necessary.
Before assembling of the tappet, clean it with compressed air, and inspect whether
the oil hole is smooth;
b) Evenly apply some clean lubricating oil onto the engine block tappet hole and the
cylindrical surface of the valve tappet;
c) Lightly put the tappet into the tappet hole that the tappet can be returned freely in
the tappet hole by hand, and the resistance force should be even;
d) Fix the rocker arm shaft support to the cylinder head. Check the push rod for dirt
and welding cracks;
e) Apply some clean lubricating oil onto the pushrod in such a manner that the ball
end has adequate lubricating oil.
f) Assemble the pushrod, and lightly put the pushrod through the cylinder head and
into the tappet socket end.
3.5.5 Disassembly, Inspection, Maintenance and Assembly of Valve
Upper retainer for Valve collet

the valve spring
Inner valve spring Outer valve spring
Lower retainer for

Cylinder head the valve spring
Intake valve Exhaust valve
Figure 3-39 Exploded View of Valve

1) Disassembly
a) Using the valve spring compressor or an overhead valve spring pincer or another
equivalent tool, compress squarely the valve spring. Remove the valve collet.
Remove the upper retainer for the valve spring, and the inner and outer valve
springs;
b) Remove the valve from the cylinder head.
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a) Inspect whether the valve stem and valve stem end surface are worn;
b) Inspect whether the valve cone is worn or damaged;
c) Inspect whether there is carbon deposit at the valve cone and arc surface;
d) If the valve is worn or seriously carbon-deposited or has other bad phenomena, it
is required to change the used valve with a new one.
3) Assembly
a) Apply some molybdenum disulfide paste on the intake and exhaust valve stems
evenly, and assemble the intake and exhaust valves into the cylinder head,
ensuring that the intake and exhaust valves can slide in the guide without
blockage;
b) Install the lower retainer for the valve spring. Check that the valve spring come in
close contact with the lower retainer. If necessary, replace the spring or retainer. It
is not permitted to rudely strike the springs into place;
c) Install the seal sleeve of valve stem, the valve spring, and the upper retainer for
the valve spring;
d) Using the valve collet installer, install the valve collet;
e) After installation of the valve collet, tap the intake and exhaust valves using a
rubber hammer so that the valve collets come in close contact with the upper
retainers for the valve springs. If the valve collet fails to come in to contact with
the upper retainer for the valve spring, identify the cause for troubleshooting.
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3.5.6 Disassembly, Inspection, Maintenance and Assembly of Gear Train

1. Crankshaft timing gear
2. Camshaft timing gear
3. Hexagon flange bolt
4. Intermediate gear shaft
5. Intermediate small gear
6. Spacer a
8. Idler gear shaft
9. Idler gear
10. Spacer b
12. Fuel injection pump
gear
13. Parallel pin
14. Intermediate big gear
16. Pressure plate
Figure 3-40 Exploded View of Gear System
Figure 3-40a View of Gear train
Figure 3-40b View of Gears
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2) Disassembly
a) Check the mounting marks and ensure that the bolts are installed to their original
locations. Manually rotate the flywheel until the piston of the 1st cylinder reaches top
dead centre. Check if the timing mark is correct.
b) Loosen the flanged hex bolts (15). Remove the intermediate big gear (14).
c) Remove the crankshaft timing gear (1);
d) Loosen the hex bolts (17). Remove the pressure plate (16) and fuel injection pump
gear (12);
e) Loosen the flanged hex bolts (3). Remove the camshaft timing gear (2);
f) Loosen the flanged hex bolts (7). Remove the spacer a (6), fuel injection pump idler
gear (9) and fuel injection pump idler-gear shaft (8);
g) Loosen the flanged hex bolts (11). Remove the spacer b (10), intermediate small gear
(5), and intermediate gear shaft (4).
a) Inspect whether the threads of the mounting bolts are in good condition;
b) Inspect the individual gears for tooth surface spalling or tooth flank breakage, and the
load bearing surface of the bolt is crushed, and the tapped holes or through holes on
the gear are deformed;
c) Check the intermediate gear shaft and intermediate gear bushing for excessive wear.
Check their oil orifices for clogging.
4) Assembly
a) Before the assembly, check that all the parts are free of manufacturing and functional
defects including damage;
b) Install the intermediate gear shaft (4) to the engine block. Install the intermediate
small gear (5). Tighten the flanged hex bolts (7) for the spacer a (6) to the torque of
(70±5)Nm. Manually rotate the gear to check whether it can rotate smoothly;
c) Rotate the intermediate small gear (5) so that one of its two marked teeth moving to
the lower left and the other marked tooth moving to the lower right. Install the idler
gear shaft (8) to the engine block. Fix the idler gear (9), and spacer b (10) to the oil
idler gear shaft (8) using the flanged hex bolts (11), which shall be tightened to the
torque of (95±5)Nm. Note: At present, two marked teeth of the idler gear move to the
upper left and another two marked teeth move to the upper right, and the lower right
marked tooth of the intermediate small gear lies in the middle of the upper left two
teeth of the idler gear. Check whether the two gears rotate smoothly;
d) Rotate the intermediate small gear (5) to the state before installing idler gear. Position
the camshaft timing gear (2) using the dowel pin. Fix the camshaft timing gear to the
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camshaft using the flanged hex bolts (3), which shall be tightened to the torque of
(65±5)Nm. Note: At present, the lower left marked tooth of the intermediate small
gear lies in the middle of the two marked teeth of the camshaft timing gear, and the
pin hole in the camshaft timing gear becomes horizontal;
e) The installation of the fuel injection pump shall be completed. Fix the fuel injection
pump gear (12) and pressure plate (16) to the fuel injection pump using the flanged
hex bolts (17), which shall be tightened to the torque of 128Nm. Note: At the moment,
the lower left marked tooth of the intermediate small gear lies in the middle of the
upper right two teeth of the idler gear, and the marks on the gear, pressure plate and
fuel injection pump hub align with each other. The arrangement of rear gear train
shown in Figure 3-41;
1. Figure 3-41 Arrangement of Rear Gears
f) Manually rotate the flywheel until the piston of the 1st cylinder reaches top dead
centre. Referring to the dowel pin already installed to the crankshaft, install the
crankshaft timing gear (1). At the moment, the pin hole in the crankshaft timing gear
(1) lies at the 12 o’clock position;
g) Install the dowel pin to the intermediate small gear (5) that has already been installed.
Referring to the dowel pin, fix the intermediate big gear (14) to the intermediate small
gear (5) using the flanged hex bolts (15), which shall be tightened to the torque of
(30±5)Nm. Note: At present, the marked tooth of the intermediate big gear lies in the
middle of the two marked teeth of the crankshaft timing gear.
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3.6 Intake and Exhaust System
3.6.1 Removal and Installation of the Intake and Exhaust System
1) Exploded view
Intake manifold Air filter
Exhaust manifold
Turbocharger
Figure 3-42 Exploded View of Intake and Exhaust System
2) Disassembly
a) Loosen the fixing bolts and the hose clamps of the air filter. Remove the air filter and its
hose;
b) Loosen other hose clamps. Remove the outlet joint pipe from the turbocharger
compressor;
c) Loosen the exhaust manifold heat shield fixing bolts. Remove the exhaust manifold heat
shield assembly;
d) Loosen the inlet and outlet oil pipes fixing bolts of the turbocharger. Remove the inlet
and outlet oil pipes and their gaskets;
e) Loosen the exhaust tailpipe fixing bolts and the turbocharger fixing bolts. Remove the
turbocharger;
f) Loosen the exhaust manifold fixing bolts. Remove the exhaust manifold and its gasket.
For details, refer to section 3.6.1 “Disassembly, Inspection, Maintenance and Assembly
of Exhaust Manifold”
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g) Loosen the intake manifold fixing bolts. Remove the intake manifold and its gasket. For
details, refer to section 3.6.2 “Disassembly, Inspection, Maintenance and Assembly of
Intake Manifold”.
3) Assembly
The assembly procedure is in reverse order of the disassembly procedure.
3.6.2 Disassembly, Inspection, Maintenance and Assembly of Intake Manifold
1) Exploded view
Figure 3-43 Exploded View of Intake Pipe
The names and quantities of the parts of intake manifold are shown in Table 3-6:
Table 3-6 Detailed list of parts of the intake manifold
1 Intake Manifold 1
2 Intake Manifold Gasket 6
3 Plain Washer 12
4 Hexagon Head Bolt Full Thread 12
5 Intake Connecting Pipe Gasket 3
6 Intake Cover 1
7 Spring Washer 8
8 Hexagon Socket Head Cap Screw 4
9 Heater 1
10 Intake Connecting Pipe 1
12 Sealing Washer 1
13 Screw Plug 1
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3) Disassembly
a) Loosen the socket head cap screws for the heater. Remove the heater and its intake
connecting pipe;
b) Loosen the socket head cap screws for the intake manifold cover. Remove the intake
cover and its gasket;
c) Loosen the intake manifold bolts in sequence and remove the intake manifold and its
gasket.
a) Check the intake manifold for welding defects. If necessary, replace it with a new one;
b) Check whether the intake manifold gasket is deformed, damaged or absence, and if any,
it is required to replace.
5) Assembly
a) The installation of intake manifold is in the reverse order of removal. The intake
manifold fixing bolts shall be tightened to the torque of 23 Nm.
3.6.3 Disassembly, Inspection, Maintenance and Assembly of Exhaust Manifold
1) Exploded view
Figure 3-44 Exploded View of Exhaust Pipe
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The names and quantities of the parts of exhaust manifold are shown in Table 3-7:
Table 3-7 Detailed list of parts of the exhaust manifold

1 Exhaust Manifold 2
2 Expansion Pipe 2
3 Middle Exhaust Manifold 1
4 Exhaust Manifold 6
5 Clamp 4
6 Sleeve 21
7 Exhaust Manifold Bolt 24
3) Disassembly
a) Loosen the clamps of the expansion joint of exhaust manifold;
b) Loosen the exhaust manifold fixing bolts. Remove the front and rear exhaust manifolds
and their gaskets;
c) Remove the expansion joint and the intermediate exhaust manifold and its gasket.
a) Inspect whether the exhaust manifold is cracked or damaged, and the flange is deformed,
and if any, it is required to replace the exhaust manifold with a new one;
b) Check the exhaust manifold flange for leakage, and replace if necessary;
c) Check whether the exhaust manifold gasket is deformed, damaged or absence, and if
any, it is required to replace;
d) Check the expansion joint and clamps for soot. If any, replace them with new ones.
5) Assembly
The installation of exhaust manifold is in the reverse order of removal, and it should be noted
during installation that:
a) Be sure to securely tighten the clamp for the expansion joint and exhaust manifold;
b) The exhaust manifold bolts should be applied with anti-seize sealant (molybdenum
disulfide) and tightened to a torque of (60±5) Nm, and the bolt can be re-used twice at most.
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3.6.4 Disassembly, Inspection, Maintenance and Assembly of Turbocharger System
1) Exploded view
Figure 3-45 Exploded View of Turbocharger System
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The names and quantities of the parts of turbocharger system are shown in Table 3-8:
Table 3-8 Detailed list of parts of the turbocharger system
1 Turbocharger 1
2 Turbocharger Gasket 1
3 Double End Stud 4
4 All Metal Hexagon Flange Locknut 4
5 Turbocharger Oil Inlet Pipe Gasket 1
6 Turbocharger Oil Inlet Pipe Set 1
8 Connector 1
10 Pipe Joint 1
11 Clamp 3
13 Turbocharger Oil outlet Pipe Gasket 1
16 O-Ring 1
17 Fixed Plate 1
18 Assembled Sealing Washer 1
19 Turbocharger Bracket 1
20 Turbocharger Bracket 1
23 All Metal Hexagon Flange Locknut 2
3) Disassembly
The disassembly procedure is in reverse order of assembly procedure.
a) Inspect operation condition of the rotor
By lightly turning the air compressor impeller with hand, rotation of the impeller by more than
one turn indicates that it is in normal condition. If the impeller stops immediately, it indicates
that the bearing is worn abnormally or collision or jamming between the rotating part and the
stationary part occurs, it is required to analyse the causes and carry out troubleshooting.
b) End play inspection of rotor
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Enable the dial indicator probe to be against the compressor end and push and pull the rotator
shaft axially with hand, and measure and record the difference indicated on the dial indicator, as
shown in Figure 3-46. The end play of rotor should be within 0.088mm~0.118mm, and in case
of exceeding this range, it indicates that the thrust bearing plate or thrust plate and bearing body
are worn, and it is required to analyse causes and eliminate the problem.
Figure 3-46 Diagram for measurement of axial clearance
c) Inspection of radial clearance of the compressor impeller
Press the compressor impeller with hand in radial direction and use a plug gauge to measure
the minimum and maximum clearance between the compressor impeller and compressor
scroll, as shown in Figure 3-47. This value should be within 0.4mm~0.8mm, and in case
of exceeding this range, it is required to inspect the bearing, and eliminate the problem.
NOTE
The measurement should be carried out in cold state of the turbocharger.
Figure 3-47 Diagram for measurement of radial clearance
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3.6.5 Disassembly, Inspection, Maintenance and Assembly of Air Filter System
1) Exploded view
Figure 3-48 Exploded View of Air Filter System
The names and quantities of the parts of air filter system are shown in Table 3-9:
Table 3-9 Detailed list of parts of the air filter system
1 Air Filter Bracket 1

2 Air Filter 1
3 Compressor Intake Pipe 1
4 Connecting Pipe 1
5 Air Connecting Rubber 1
6 Clamp 1
7 Clamp 3
8 Hexagon Head Bolt, Full Thread 1
9 Air Filter Service Alarm Indicator 1
11 Nut 6
13 Pad 2
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3) Disassembly
The Disassembly procedure is in reverse order of assembly procedure.
a) The maximum permissible intake resistance of diesel engine is 7kPa; Check the
maximum intake resistance only when the diesel engine is running at rated speed under
full load. When the intake resistance reaches the permissible limit, clean or replace the
filter element as per the manufacturer’s instructions.
b) Disassemble the filter element from the air filter and tap lightly the end face to fall off
the dust or blow backward (from inside out) by compressed air.
Do not damage the filter paper.

Do not clean the filter paper with water or oil, and
Do not clap or knock the filter element forcibly
5) Assembly
a) Install the air filter bracket to the engine;
b) Install the air filter;
c) Connect the pipe between the intake manifold and air filter. Fix the pipe using clamps.
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3.7 Fuel system

3.7.1 Removal and Installation of Fuel System
1) Overall layout of fuel system
Figure 3-49 Overall layout of fuel system
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2) Exploded view
High-pressure fuel
pipe assembly
Fuel injector
assembly
Fuel injection pump

assembly
Low-pressure fuel
pipe assembly Shutting-down device
assembly
Fuel filter assembly
Figure 3-50 Exploded View of Fuel System
3) Disassembly
a) Remove the low-pressure fuel pipe;
b) Remove the high-pressure fuel pipe;
c) Remove the fuel injector;
d) Remove the fuel filter;
e) Remove the high-pressure fuel pump;
4) Assembly
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3.7.2 Disassembly, Inspection, Maintenance and Assembly of Fuel Injection Pump
1) Exploded view
Fuel injection
pump
Hexagon flange
Hexagon flange bolt Rubber O-ring
bolt
Hollow bolt
Sealing washer
Fuel Plain Hexagon flange
Pressure
injection washer bolt
plate Lubricating oil pipe of
pump hub
fuel injection pump
Fuel Fuel Type 1 hexagon nut

Hexagon injection injection
Fuel injection pump
flange bolt pump Fuel injection
pump flange support pump bracket
bracket
Figure 3-51 Exploded View of Fuel Injection Pump
2) Disassembly
a) Remove the flanged hex bolts for fixing fuel injection pump flange to the gear chamber;
b) Remove the fuel injection pump and gear subassembly from the engine;
c) Remove the locking nut of the fuel injection pump;
d) Remove the flanged hex bolts for fuel injection pump body and fuel injection pump
flange;
e) Remove the fuel injection pump flange.
a) The structure of fuel injection pump is shown in Figure 3-52. Manually rotate the
flywheel until the piston of the 1st cylinder reaches top dead centre. At the moment, the
groove mark in the fuel injection pump gear and that in the fuel injection pump flange
shall align with each other.
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1—Inlet fuel pipe；2—High-pressure fuel outlet；3—Return fuel pipe joint；4—Speed

governor；5—Fuel delivery pump；6—Inlet oil pipe joint
Figure 3-52 Structure of Fuel Injection Pump
4) Assembly
a) Fix the fuel injection pump body, fuel injection pump flange and fuel injection pump hub
using the flanged hex bolts;
b) Install the fuel injection pump drive gear and pressure plate so that the mark on the drive
gear aligns with the groove mark in the pressure plate. The drive gear locking nut
M24×1.5 shall be tightened to the torque of (300~340)Nm;
c) Rotate the fuel injection pump gear so that the marks in the fuel injection pump drive
gear, fuel injection pump hub, pressure plate and fuel injection pump flange align with
each other as shown in Figure 3-53;
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Vertical
direction of
the engine
Mark in the fuel injection

pump flange
Mark in the fuel-
injection-pump gear
Mark in the pressure plate

Mark in the fuel injection
pump hub
Figure 3-53 Marks of Fuel Injection Pump Flange
d) Manually rotate the flywheel until the piston of the 1st cylinder reaches top dead centre.
To prevent the fuel injection pump drive gear from rotating during the installation of
already assembled fuel injection pump assembly, temporarily install two guide studs in
the mounting holes of the gear chamber and fuel injection pump flange. Install the fuel
injection pump assembly. After completion of the final installation, the fuel supply
advance angle shall be 20º (which may be altered after type approval).
e) Sequence for tightening the fixing bolts for the auxiliary supports of fuel injection pump:
Tighten the fixing bolts for the auxiliary supports of fuel injection pump in the sequence
as shown in Figure 3-54.
Flange hex bolt
Figure 3-54 Sequence for Tightening the Fixing Bolts
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3.7.3 Disassembly, Inspection, Maintenance and Assembly of High Pressure Fuel Pipe
1) Exploded view
Pipe clamp assembly
High-pressure fuel pipe subassembly
Figure 3-55 Exploded View of High Pressure Fuel Pipe
2) Disassembly
a) Remove the high-pressure fuel pipe bracket;
b) Remove the high-pressure fuel pipe between the pump and the common rail;
c) Remove the high-pressure fuel pipe between the common rail to fuel injector.
Note: Baudouin special sleeve is required for disassembly.
3) Assembly
Note: The nuts for high-pressure fuel pipe joints (M18×1.5 nut at fuel injection pump
end, and M16×1.5 nut at fuel injector end) shall be tightened to the torque of 40Nm.
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3.7.4 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector
1) Exploded view
Figure 3-56 Exploded View of Fuel Injector
Replacement of the fuel injectors shall be performed by Bosch Authorized Service Station.
3) Disassembly
a) Loosen the hold-down nut of the high-pressure joint;
b) Take out the fuel injector assembly from the cylinder head.
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3.8 Cooling System

3.8.1 Overview of cooling system
The 6M33 series diesel engine only adopts the circulation of heat carrying fluid within a closed
loop.
The long and short circulations of the cooling system are controlled by the thermostat:
◆ When the temperature of coolant is low, the thermostat closes so that the coolant returns to
water pump via bypass pipeline for cooling circulation, without flowing through the
radiator (Short circulation of coolant).
◆ When the temperature of coolant is high, the thermostat opens so that the coolant
completely flows through the radiator and then flows into water pump for cooling
circulation (Long circulation of coolant).
Thermostat
Outlet pipe
circulation
Cylinder head
Short
Fan
Cylinder block
Water pump Oil cooler

Water tank
Engine
Figure 3-57 Schematic diagram of cooling system
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3.8.2 Disassembly, Inspection, Maintenance and Assembly of Thermostat
1) Exploded view
Gasket
Thermostat
Thermostat body
Thermostat cover
Figure 3-58 Exploded View of Thermostat assembly
Immerse the automatic thermostat in a water container, as shown in Figure 3-59. After heating,
measure the water temperature and observe the temperatures of thermostat for consistency with the
temperatures listed in the table below.
Thermometer
Initial opening Lift height at full

temperature opening (ºC)
(ºC)
𝟕𝟑 ± 𝟐℃ ≥9.5mm(85℃)
Thermostat
Figure 3-59 Schematic Diagram for Measuring Thermostat Opening Temperature
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3.8.3 Disassembly, Inspection, Maintenance and Assembly of Water Pump
The water pump is located at the front end of the diesel engine and is driven by a V-ribbed belt.
The V-ribbed belt automatic tensioner is fixed on the cylinder block through brackets to keep a
sufficient tension of V-ribbed belt.
1) Exploded view
Figure 3-60 Exploded View of Water Pump
The names and quantities of the parts of water pump are shown in Table 3-10.
Table 3-10 Detailed list of parts of the water pump

Tightening
SN. Name Quantity Specifications
torque
1 Water pump bracket 1
2 Water pump assembly 1
3 Hexagon flange bolt 3 M12 80Nm
4 Pipe joint 1
5 Rubber O-ring 1
6 Standard spring washer 8
7 Hexagon bolt 4 M10 46Nm
8 Stud 2 M10 46Nm
9 Type 1 hexagon nut 2 M10 46Nm
Hexagon socket cylindrical
11 2 M8 25Nm
head screw
12 Rubber O-ring 1
13 Rubber O-ring 1
14 Drain valve subassembly 1
Hexagon socket cylindrical
15
head screw
2 M10 46Nm
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3) Disassembly
a) Remove the fan;
b) Remove the V-ribbed belt.
c) Disassemble the water pump.
a) Check the rotation of water pump bearing, abnormal sound, and failed seal.
b) The belt before assembly shall not be twisted or turned inside out.
5) Assembly
a) Check that the ring seals are not damaged. Replace the damaged ring seal with new one
if necessary;
b) Install the bracket to the water pump;
c) Install the O-ring. Fix the pipe joint to the water pump jacket;
d) Using bolts, fix the water pump bracket and water pump to the engine block;
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3.8.4 Disassembly, Inspection, Maintenance and Assembly of Outlet Water Pipe
For the 6M33 series diesel engine, the outlet water pipe of water pump is located at the engine
side and fixed to the cylinder head.
1) Exploded view
Figure 3-61 Exploded View of Outlet Water Pipe
The names and quantities of the parts of outlet water pipes are shown in Table 3-11:
Table 3-11 List of Parts of Outlet Water Pipe

Tightening
torque
1 Connecting water pipe 1
2 Rubber O-ring 3
3 Water outlet pipe 2
6 Spring washer 4
7 Flange 2
8 Gasket 2
9 Connecting pipe 1
10 Plug screw 1
11 Rubber O-ring 6
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3) Disassembly
Remove the flanged bolts from the outlet water pipe. Remove the outlet water pipe.
a) Check the joints between the outlet water pipes and the joint between the outlet water
pipe and the cylinder head for leakage;
b) Check that the O-ring is not damaged. Replace the damaged O-ring with new one if
necessary.
5) Assembly
The assembly procedures are in the reverse order of disassembly procedures.
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3.8.5 Disassembly, Inspection, Maintenance and Assembly of Oil-gas Separator
Seen from the front end, the oil-gas separator is located at the front right end of the engine block.
As a result of separation, the gas enters the atmosphere via the outlet pipe, and the oil returns to
the oil pan.
1) Exploded view
Figure 3-62 Exploded View of Oil-gas Separator
The names and quantities of the parts of oil-gas separator are shown in Table 3-12:
Figure 3-12 Detailed list of parts of the oil-gas separator

Tightening
torque
2 Breather 1
3 Hose clamp 3
4 Oil-gas separator inlet pipe 1
5 Oil-gas separator 1
6 Flat gasket 4
8 Hose clamp 2
9 Pipe clip 1
10 Pipe clip assembly 1
Oil-gas-separator oil return
11 pipe assembly
1
12 Oil-gas separator outlet pipe 1
13 Single-pipe clip assembly 1
14 Gasket 1
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3) Disassembly
Loosen the six bolts used for fixing the breather and the four bolts used for fixing the oil-gas
separator, remove the oil-gas separator.
Check the seal of the oil-gas separator subassembly, replace it if necessary.
5) Assembly
The assembly procedures are in the reverse order of disassembly procedures.
3.8.6 Disassembly, Inspection, Maintenance and Assembly of Fan
For the 6M33 series diesel engine, a V-ribbed belt is used for driving the fan and a ventilation fan
is used according to the demand of diesel engine for power generation.
1) Exploded view
Figure 3-63 Exploded View of Fan
The names and quantities of the parts of fan are shown in Table 3-13:
Table 3-13 Detailed list of parts of the fan

Tightening
torque
1 Fan bracket 1
4 Fan 1
5 Spacer block 1
3) Disassembly
Unscrew six hexagon head bolts and take out spacer block, fan, and spring washer in turn.
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a) Check the fan rivets for looseness, check the fan blades for bending, and ensure the
normal working of fan.
b) Visually observe the V-ribbed belt for cracking and scratch and replace it if necessary.
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3.9 Lubrication System

3.9.1 Overview of lubrication system
The schematic diagram of the lubrication system of 6M33 series diesel engine is shown in Figure
4-50. The lubrication system is a pressurized lubrication system. The gear oil pump is located at
the bottommost place of the engine. The oil pump is driven by the gear on the front of crankshaft.
All lubricating points and accessories requiring lubrication are connected by the pipeline or
conduit in the pressurized lubrication system. The splash lubrication mode is adopted to lubricate
the timing gear. The lubricating oil is splashed to the pistons for continuous cooling.
Cylinder head Rocker arm

lubricating oil shaft and
Connecting Turboc Main Camshaft pipe rocker arm
rod harger bearing bushing
shell Cylinder
head and
Lubricating oil engine body
Piston pipe of fuel
injection pump
Main oil passage
Piston
cooling
nozzle Bypass valve
Oil cooler Oil filter Engine oil

pump
Centrifugal Strainer
Pressure
regulator of oil filter
cooler
Oil pan
Figure 3-64 Diagram of lubrication system
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3.9.2 Disassembly, Inspection, Maintenance and Assembly of Oil Pump Assembly
1) Exploded view
Figure 3-65 Exploded View of Engine Oil Pump
The names and quantities of the parts of oil pump are shown in Table 3-14:
Table 3-14 List of engine oil pump parts

1 Engine oil pump body 2 Bushing
3 Bushing 4 Parallel pin
5 Shaft and gear assembly 6 Shaft and gear
assembly
7 Hexagon bolt 8 Drive gear
9 Pressure-limiting valve of oil pump
a) During installation, the backlash of engine oil pump with the crankshaft gear is (0.2~0.25)
mm.
b) While installing the fastening bolts of engine oil pump, apply Loctite 242 to the threads
of the bolts to prevent vibration looseness.
NOTE
After the installation of the engine oil pump, check the engine oil pump for smooth rotation. If
the rotation of the engine oil pump is tight, the oil pump will probably be damages during the
running of the engine
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4) Adjustment of oil pressure
a) Pressure-limiting valve
Two pressure-limiting valves are provided for oil pump. If oil pressure exceeds the
opening pressure of the pressure-limiting valve, i.e. 12bar, the pressure-limiting valve
opens to reduce the pressure in the lubrication system thus ensure the safety of elements
in the system. If oil pressure is below the opening pressure, the pressure-limiting valve
closes.
Figure 3-66 Schematic Diagram of Pressure-limiting Valve
b) Pressure regulating valve
The pressure regulating valve is integrated with the oil cooler. It is used to regulate the
pressure in the main oil passage. Its opening pressure and full opening pressure are
(5.5±0.25) bar and (8.5±0.25) bar respectively. The outlet of the pressure regulating
valve is connected to the oil pan. If the pressure in the main oil passage exceeds the
opening pressure, the pressure regulating valve opens to drain oil thus maintains the
pressure in the main oil passage within the set range.
Figure 3-67 Schematic Diagram of Pressure Regulating valve
c) Bypass valve
The bypass valve is also integrated with the oil cooler. If the pressure drop across the
oil cooler is greater than the opening pressure of the bypass valve, i.e. 2bar, then the
bypass valve opens. In this case, the oil from the bypass valve directly enters the main
oil passage, bypassing the oil cooler.
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Figure 3-68 Schematic Diagram of the Bypass Valve
3.9.3 Disassembly, Inspection, Maintenance and Assembly of Centrifugal Oil Filter
The 6M33 series diesel engine is equipped with a centrifugal oil filter. The inlet oil passage of
centrifugal oil filter and the main oil passage of lubrication system are connected in parallel. The
centrifugal oil filter is installed on the right side of the oil pan.
1) Exploded view
Figure 3-69 Exploded View of Centrifugal Filter
2) Replacement of the centrifugal filter element
a) Loosen the top nut 5;
b) Take out the intermediate filter cup 1;
NOTE
If the nut 4 on the filter cup is loosened, please take out this nut and tighten it to the fixing
seat during reassembling.
c) Disassemble the filter element 2 and sealing gasket 3;
d) Clean the filter cup and fixing seat;
e) Install new filter element and use the sealing gasket 3 attached in new filter element;
f) Reinstall the filter cup, tighten to 20Nm, and ensure that the filter cup is free of distortion.
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3.9.4 Disassembly, Inspection, Maintenance and Assembly of Oil Cooler and Oil Filter
1) Exploded view
Figure 3-70 Exploded View of Oil Cooler
The names and quantities of the parts of oil cooler are shown in Table 3-15:
Table 3-15 List of oil pump parts

1 Oil cooler assembly 2 Oil filter
Socket head screw
3 Washer 4
plug
Standard spring
5 Plain washer 6
washer
Hexagon socket
Fully-threaded hex
7 8 cylindrical head
bolt
screw
9 Hexagon bolt 10 Hexagon bolt
Oil cooler cover Oil cooler cover
11 12
gasket gasket
Drain valve
13
assembly
The oil cooler is combined with the oil filter. Leaving the oil filter, the oil enters the oil cooler
for cooling.
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Replacement of the oil cooler core

a) Using an M8 socket head wrench, loosen the M8 socket head screws of the oil cooler
cover. Using a general wrench, loosen the hex bolts of the oil cooler. Remove the oil
cooler cover. (Drain the coolant from engine before disassembling);
b) Clean the sealing junction surface between oil cooler cover and cylinder block and
replace the oil cooler cover gasket with new one;
c) Disassemble the oil cooler core with a M8 hexagon wrench and clean the flange junction
surface of oil cooler core;
d) Replace the O-ring of oil cooler core;
e) Install new oil cooler core and tighten the M8 hexagon socket head screws;
f) Put the oil cooler cover in original place. Tighten the socket head screws and hex bolts.
3) Inspection and maintenance essentials of oil cooler
a) Apply Loctite sealant 242 to the threads before tightening the bolts;
b) All oil filters adopt full-flow one-time filter element. In the case of oil filter clogging, the
safety device located at the filter element will operate to prevent oil flow interruption.
Oil flow interruption can cause damage to the bearing shells. Replace the filter element
on schedule. In addition, replace the filter element when replacing the oil.
4) Replacement of oil filter element
a) Clean the oil filter base;
b) Apply oil (instead of lubricating grease) to the sealing gasket;
c) Tighten the oil filter by hand and rotate by approximately 3/4 turn;
Figure 3-71 Installation diagram of engine oil filter
d) Check the oil level and pre-lubricate the engine. Re-check the oil level and when
necessary add sufficient oil. Ensure that the oil filter is free of oil leakage.
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Inspection and maintenance of oil filter

a) Before disassembling the oil filter, remove the dirt from its surrounding area;
b) Loosen the filter element with oil filter wrench during replacement.
3.9.5 Disassembly, Inspection, Maintenance and Assembly of Oil Pan
1) Exploded view
Figure 3-72 Exploded View of Oil Pan
The names and quantities of the parts of oil pan are shown in Table 3-16:
Table 3-16 Detailed list of parts of the oil pan

1 Oil pan 2 Gasket
Hexagon socket
3 Cover plate 4
cylindrical head screw
Magnetic screw plug
5 6 Screw plug
assembly
Square-head screw
7 8 Plain washer
plug
Hexagon socket Hexagon socket
9 10
cylindrical head screw cylindrical head screw
Socket head screw
11 Plain washer 12
plug
Oil dipstick
13 Pipe joint 14
assembly
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3) Disassembly
a) Prior to dismantling of the oil pan, drain the oil fully. Place a container under the oil
drainage plug of the oil pan, and use a screw plug wrench to loosen the drainage plug to
drain the oil;
b) Disassemble the oil dipstick assembly. Do not damage the oil dipstick during
disassembling;
c) Disassemble the bolts connecting the oil pan and cylinder block with a wrench and then
separate the cylinder block from oil pan by using overhead traveling crane (Notice to
remove the silicone sealant at all times during separation and do not hoist the cylinder
block too high);
d) After the separation of oil pan, check the levelness and check for damage.
Check that the mating faces of the cylinder block and the oil pan are clean without grease or
collision-caused damage.
5) Assembly
a) Apply evenly silicone sealant to the mating face of the oil pan.
b) Using the overhead crane, move the engine block onto the oil pan;
c) Apply Loctite 242 threadlocker to the threads of all the socket head cap screw bolts.
Tighten the bolts and remove the surplus silicone sealant from these bolts;
d) Place washers onto the hex screw plug and pipe joint. Fix them to the oil pan.
3.9.6 Use and Replacement of Oil
1) Oil type
Use CF15W/40 or higher grade of oil as specified by GB11122.
2) Oil tank capacity
For the 6M33 series diesel engine, the standard oil tank has a capacity of approximately 60.5L.
3) Replacement of oil
a) Stop the engine, use the manual pump for the replacement of oil;
b) Place the three-way connector to the "Drain" place shown in figure below;
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Drain
Pre-lubrication
Figure 3-73 Diagram of manual oil pump
c) To collect used oil, connect a pipe to the outlet pipe of the manual oil pump;
d) Repeatedly operate the handle of the manual oil pump until all used oil drains out of the
engine;
e) Place the three-way connector to the "Pre-lubrication" place shown in figure;
f) Add fresh oil via the filler port into the oil pan.
NOTE
Add clean oil into diesel engine oil tank, till the oil level reaches the upper marking of oil
Dipstick. Start and idle the engine and check the oil filter and drainage plug for oil leakage.
Stop the engine, wait for approximately 5min for the oil to return from upper parts into oil
pan, and check the oil level once again. When necessary, add new oil till the oil level
reaches the upper marking of oil dipstick.
3.10 Start-up system

3.10.1 Overview of start-up system
1) Overview of starter motor
The starter motor is one of the core parts of vehicle starter system and is functioned to convert
the electric energy of battery to electromagnetic torque and, via the gear and ring gear mechanism,
drive the rotation of engine to start the engine. The starter motor is mainly composed of DC motor,
one-way clutch, starter pinion (or reduction gear train), electromagnetic switch, and starter relay.
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Control relay Battery terminal Solenoid
Switch terminal Motor
Circuit diagram
Figure 3-74 The circuit diagram of starter motor
3.10.2 Disassembly, Inspection, Maintenance and Assembly of Starter Motor
1) Exploded view
Stud
Starter motor
Spring washer
Type 1 hexagon nut
Figure 3-75 Exploded View of Starter
2) Disassembly
a) Remove the hex nuts and their spring washers;
b) Hold securely the starter motor and take it out along the gear rotation axis.
The wires of the starter shall be connected correctly and securely.
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4) Assembly
a) Install the starter motor;
b) Put the spring washers in place. Tighten the hex nuts.
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Appendix A Recommended Torques for Standard Bolts
Recommended Torques for Standard Bolts

Friction
0.125 (zinc plated) 0.14 (polished)
coefficient
Strength
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
grade
Bolt size Recommended torque, Nm
M4 2.3 2.7 3.8 4.6 2.4 2.9 4.1 4.9
M5 4.7 5.5 8.0 9.5 5.0 6.0 8.5 10
M6 8.0 9.5 13.0 16.0 8.5 10 14.0 17
M8 19 23 32 39 21 25 35 41
M10 39 46 64 77 41 49 69 83
M12 67 80 110 135 72 86 120 145
M14 105 125 180 215 115 135 190 230
M16 165 195 275 330 180 210 295 355
M18 225 270 390 455 245 290 405 485
M20 325 385 540 650 345 410 580 690
M22 435 510 720 870 465 550 780 930
M24 560 660 930 1100 600 710 1000 1200
M27 830 980 1400 1650 890 1050 1500 1800
M30 1100 1350 1850 2250 1200 1450 2000 2400
M8×1 21 25 35 42 23 27 38 45
M10×1.25 41 49 66 82 44 52 73 88
M12×1.25 74 88 125 150 80 95 135 155
M12×1.5 70 83 115 140 76 90 125 150
M14×1.5 115 140 195 235 125 150 210 250
M16×1.5 175 210 295 350 190 225 315 380
M18×1.5 255 305 425 510 275 325 460 550
M20×1.5 360 425 600 720 385 460 640 770
M22×1.5 480 570 800 960 520 610 860 1050
M24×1.5 610 720 1000 1200 650 780 1100 1300
M27×1.5 890 1050 1500 1800 970 1150 1600 1950
M30×1.5 1250 1450 2050 2500 1350 1600 2250 2700
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Appendix B Recommended Torques for Hollow Bolts
Recommended Torques for Hollow Bolts

Recommended tighten torque
Specification Head style
(Nm)
M8×1 Hexagon head 7±1
17±2
Hexagon head 13±2 (Copper bolt and small
M10×1
combination washer)
Flange bolt 20±3
Hexagon head 22±3
M12×1.5
Flange bolt 28±3
Hexagon head 27±3
M14×1.5
Flange bolt 32±3
Hexagon head 30±3
M16×1.5
Flange bolt 36±3
Hexagon head and
M18×1.5 60±5
flange bolts
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6M33 Repair Manual Feb 2019 v3

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6M33 Repair Manual February 2019

6M33 Series Industrial Diesel Engine

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invalidate the warranty provided by Weichai Power;

removed by turbocharger maintenance specialists or by the service stations authorised by

meet the requirements;

non-filtered air into the cylinders.

⚫ Before using a new engine, 50 hours commissioning shall be carried out;

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professional electrical technician;

professionals of our service station;

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Chapter 1 General Information ................................................................. 8

1.1 Exterior View of Diesel Engine ....................................................................... 8

1.2 Model Meaning of the Diesel Engine .............................................................. 9

1.3 Basic Parameters of the Diesel Engine ........................................................... 9

1.4 Lifting the Diesel Engine ............................................................................... 10

Chapter 2 Maintenance Guide of Diesel Engine ..................................... 11

2.1 Sealant Application ........................................................................................ 11

2.1 Maintenance Items……………....................................................................11

Chapter 3 Disassembly and Assembly of the Diesel Engine .................. 15

3.1.2 Safety symbols ................................................................................................................... 16

3.1.3 Special tools ....................................................................................................................... 17

3.1.4 Precautions for health protection .................................................................................... 17

3.1.5 Environmental precaution ............................................................................................... 18

3.1.6 Precautions for disassembly and assembly of the diesel engine.................................... 18

3.2 Cylinder Head Group .................................................................................... 19

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3.2.5 Disassembly, Inspection, Maintenance and Assembly of Cylinder Head .................... 24

3.3 Engine Block Group ....................................................................................... 30

3.3.2 Disassembly, Inspection, Maintenance and Assembly of Flywheel Cover ................... 33

3.4 Crank and Connecting Rod Mechanism ...................................................... 37

3.5 Valve Mechanism…………………………………………………………….48

3.5.2 Disassembly, Inspection, Maintenance and Assembly of Camshaft……………………49

3.5.5 Disassembly, Inspection, Maintenance and Assembly of Valve………………………..54

3.5.6 Disassembly. Inspection, Maintenance and Assembly of Gear Train………………….56

3.6 Intake and Exhaust System………………………………………………….59

3.6.2 Disassembly, Inspection, Maintenance and Assembly of Intake Manifold .................. 60

3.6.3 Disassembly, Inspection, Maintenance and Assembly of Exhaust Manifold ............... 61

3.6.4 Disassembly, Inspection, Maintenance and Assembly of Turbocharger System ......... 63

3.7 Fuel system ...................................................................................................... 68

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3.7.4 Disassembly, Inspection, Maintenance and Assembly of Fuel Injector ....................... 74

3.8 Cooling System ............................................................................................... 75

3.8.2 Disassembly, Inspection, Maintenance and Assembly of Thermostat .......................... 76

3.8.3 Disassembly, Inspection, Maintenance and Assembly of Water Pump ........................ 77

3.8.5 Disassembly, Inspection, Maintenance and Assembly of Oil-gas Separator ............... 81

3.8.6 Disassembly, Inspection, Maintenance and Assembly of Fan ....................................... 82

3.9 Lubrication System ........................................................................................ 84

3.9.5 Disassembly, Inspection, Maintenance and Assembly of Oil Pan ................................. 90

3.9.6 Use and Replacement of Oil ............................................................................................. 91

3.10 Start-up system ............................................................................................. 92

3.10.2 Disassembly, Inspection, Maintenance and Assembly of Starter Motor .................... 93

Appendix A Recommended Torques for Standard Bolts .................................. 95

Appendix B Recommended Torques for Hollow Bolts ..................................... 96

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Chapter 1 General Information

1.1 Exterior View of Diesel Engine

Figure 1-1 Exterior View of 6M33 Series Diesel Engine