226B

Key Points about Assembling or

Disassembling 226B Diesel Engines

Training Material


Contents
1
Assemble Injection Nozzle, Camshaft and cylinder Liner

2
Pre-assemble & Assemble Crankshaft

3
Pre-assemble & Assemble Connecting Rod and Piston

4
Assemble Gear Housing

5
Assemble Flywheel Housing and Flywheel


Contents
6
Assemble High Pressure Fuel Pump

7
Torque Requirements about Tightening Main Bolts of Diesel Engines

8 mm
Fitting Clearance of Main Parts of Diesel Engines (Unit: mm)

1
Assemble Injection Nozzle, Camshaft and Cylinder Liner
Assemble cooling injection nozzle
1.
O CD15W/40 O

Smear O-seal ring with CD15W/40 oil.

Inspect whether O-seal ring worn out or not
2

Insert injection nozzle set into the

injection nozzle bore.
Inspect and make sure the injection nozzle
bore is clean and no burr.
3

Use bolt with spring washer and pressure

plate to tightly press injection nozzle set, and
the pressure plate is pressing the concave
plane of the injection nozzle face.

1
Assemble Injection Nozzle, Camshaft and cylinder Liner
Assemble Cylinder Liner

Put seal ring in the engine body and

cylinder liner, then press cylinder liner into
engine body.

0.05mm-0.10mm
Note: Put cylinder liners in liner bores and
measure the bulge (0.05mm-0.10mm).

1
Assemble Injection Nozzle, Camshaft and cylinder Liner
Assemble camshaft
1

Clean camshaft bore, and smear camshaft

bore and tappet hole with clean and
appropriate oil
2
Assemble tappet.

Note: Tappet can be rotated freely with equal

retarding in the bore.
3
Rub camshaft and bottom bore clean, and
nylon rod used lead assembling the
camshaft.

1
Assemble Injection Nozzle, Camshaft and cylinder Liner

Note: Push the camshaft into the bore with equal force. Dont
damage camshaft surface and engine body bore. The
camshaft end with thread is at the gear case side.
4 35+10 N.m
Assemble thrust plate of camshaft and tighten bolt. Tightening
torque 35+10 N.m
2
Note: Rotate the camshaft two rounds after assembling to make
sure no hand resistance.

2
Pre-assemble & Assemble Crankshaft
Pre-assemble crankshaft
1

Check crankshaft and make sure clean

machining surface, no scratch, no slip mark
and no rust.
2

Heat crankshaft gear, then insert gear pin

into crankshaft pin bore and assemble the
gear into its bottom. Use bass rod to hit the
gear to its bottom position if necessary
when the gear is still hot.

Block stem is
tightening, and
no bulge.

2
Pre-assemble & Assemble Crankshaft
3

a
bcdef
Wedge rivet into fuel passage of crankshaft
as Figure shows. Make sure the rivet
doesnt tilt, and it should not be loosing
when press it by hand. The rivet position: a,
b, c, d, e, f.

2
Pre-assemble & Assemble Crankshaft
Assemble Crankshaft
1

Demount main bearing cap. Note: Main bearing caps

demounted should be in order to facilitate assembling.
2

Assemble top and bottom shell and smear oil. Note: check the
top and bottom shell and make sure they are clean, no scratch
, no slip mark.
3

Hang the crankshaft, and put it in the engine body. Make sure
no scratching in the process. Push the top thrust flake along
the thrust bearing bore.

Note; The face with groove is close to crankshaft.

10

2
Pre-assemble & Assemble Crankshaft
4

Smear every main bearing journal with lubricating oil, then

assemble main bearing cap with thrust flake.
Note
1
The face of thrust flake with concave groove is close to
crankshaft.
2
The face of bearing cap with words faces flywheel hosing.

11

2
Pre-assemble & Assemble Crankshaft
5

Put the angle plate in proper position. Draw out bolt and smear
the thread and support part with oil, and then insert the bolt again.
After tighten bolt of bearing cap with automatically tightening
machine, knock the big end or small end of crankshaft with nylon
hammer to combine thrust flake with connecting face.
Note 1 70Nm 89~92
Tighten by hand: pre-tighten torque of 70Nm, then turn 89~92
2 4-5-3-6-2-7-1
Tightening sequence of 6 cylinders: 4-5-3-6-2-7-1
3 2
After assembling, rotate crankshaft for 2 rounds to feel rotating
freely with no retarding.

12

3
Pre-assemble & Assemble Connecting Rod and Piston
: Assemble piston- connecting
rod, and piston pin
a)
Coat piston pin with lubricating oil.
b)

60
Put the small end in the middle of piston pin bore, then insert
piston pin. The shell mouth of big end of connecting rod should
face the direction showed as Figure. (If its difficult to put piston
pin in due to low ambient temp., heat piston to 60 with oil or
water)
c)
Put in snap ring.

13

3
Pre-assemble & Assemble Connecting Rod and Piston
Assemble piston rings
a)

Use dedicated tool to assemble them. If assemble them by hand, simple

tool made by yourself should be used to avoid scratching excircle surface
of the piston.
b) Top

Distinguish barrel-face ring and taper-face ring when assemble the two
compression rings. Please remember that the side
with Top faces up.
c)
When assemble the oil ring, should pay attention to the situation of the
helical spring in the groove to avoid loosening.
d)
After assembling the three rings, drip lubricating oil into ring grooves and
the rings. Turn each ring to make sure free turning with no retarding.
14

3
Pre-assemble & Assemble Connecting Rod and Piston
: Assemble piston- connecting rod
a)

Put the shell in the connecting rod body and connecting rod cap,
and coat a little oil, then clean the bolt bore in the connecting rod
body.
b)
Wipe clean the inner wall of cylinder liner and the crankshaftconnecting rod journal, and coat enough lubricating oil.
c)
Turn the engine to a proper position where the connecting rod cap
could be easily mounted with crankshaft-connecting rod journal.

15

3
Pre-assemble & Assemble Connecting Rod and Piston
d)

120 30

Put the piston-connecting rod in the cylinder liner with dedicated tool.
Pay attention to that the open-end of the shell should face oil filter, and
make sure the right position of each ring. Make sure that the angle of
every two open-ends of rings should be 120and the open-end
should deviate more than 30from axial line of piston pin. A piece of
iron sheet could be used to make a barrel-shape bail clipped by a
pliers to slowly push piston in if there were not dedicated tool.
e)

When assemble the connecting rod cap, the two sides of connecting
rod body and cap with the same number should be at the same
side, and coat the sawtooth-face with lubricating oil.
16

3
Pre-assemble & Assemble Connecting Rod and Piston
f)
30Nm 60

Should coat thread with oil before tighten bolts of the connecting rod.
Alternately tighten the two bolts with the torque of 30Nm for the first time,
and then turn 60for the second time. If the bolt can not meet torque
requirement, must change them. Forbidden to tighten them based on feeling, or
use old bolts.
g)
The crankshaft should be rotated freely with no retarding. Shake the
connecting rod to feel axial clearance and radial clearance

( )

Note: Bolts of connecting rod is the most important component for diesel engine, therefore,
its assembling can greatly influence the quality of diesel engine. The bolts with bad
quality probably can result in failure of three major components (crankshaft, cylinder
body and piston-connecting rod) or even wbore engine failure. Its better to use dedicate
fittings.
17

4
Assemble Gear Housing
1 0.2mm
Assemble oil pump: Gear clearance of 0.2mm is controlled by
clearance guage, then tighten bolt and nut.
2 0

0

Assemble gears: Adjust oil pump gear with torque wrench to

make 0 the most closed from camshaft. Turn the camshaft
by hand to make the head groove face cylinder head. Mark 0
on oil pump gear, driving oil pump gear, camshaft gear and
crankshaft timing gear, then put in the driving oil pump gear.

0 0

oil pump gear

0meshing

Groove faces cylinder hea

Note: 0 position on the oil pump gear

should be meshing with that on the driving oil
pump gear.
18

4
Assemble Gear Housing
1 0
0 0
Rotate crankshaft to make 0 on the timing gear the
most closed from camshaft.
Note: 0 point on the camshaft should be meshing
with that on the crankshaft timing gear.
2

Adjust the retaining plate to make the asymmetry bores

align, then pre-tighten bolts of camshaft gear, then pretighten bolts connecting camshaft gear with camshaft.
3
M10*1.25 80N.m+5N.m II
55N.m+5N.m
Tighten bolts connecting camshaft gear with camshaft
with torque wrench, then seal them with lacquer sealer.
Tightening torque of M10*1.25: 80N.m+5N.m.
Driving injection pump gear with Euro II structure is also
tighten here, and the torque is 55N.m+5N.m

0
0 0 point on the
camshaft should be meshing with that on the
crankshaft timing gear.

19

5
Assemble Flywheel Housing and Flywheel
Assemble flywheel housing
1 .
Clean the connecting face between flywheel housing and
engine body, then smear sealant, then assemble the
flywheel housing.
2

Retaining pin bores is aligned with engine body bores, then

special punch is used hit the retaining pin to its bottom. Coat
bolt thread and supporting face with lubricating oil, then put
in bolts.
3 1-2-3-4-5-6
M12 140N.m+5N.m M10
80N.m+5N.m
Tighten bolts: the torque for M12 bolts is 140N.m+5N.m, the
torque for M10 bolts is 80N.m+5N.m. Tightening sequence is
showed as Figure: 1-2-3-4-5-6

20

5
Assemble Flywheel Housing and Flywheel
Assemble flywheel
1

Assemble gear rim of flywheel in the proper position,

and make sure no scratching. Hit retaining pin in the
bore.
2
The gear rim face downward, and pin bores should be
aimed at, then mount the flywheel.
3 : 285+10 N.m
Put in bolts and tighten them with torque of
285+10 N.m

21

6
Assemble High Pressure Fuel Pump
1

When assemble fuel pump gear, firstly clean the connecting section
between fuel pump and frond end cover with alcohol, then blow it dry
to coat sealant. Turn the engine to the TDC of 1st cylinder.
2 ,
.

Remove gear shaft nut, gasket and key jacket, then mount the fuel
pump gear aiming at the half round key, and pre-screw the nuts. Using
a tool to assemble the fuel pump gear, then tighten the nut with torque
wrench.

Note: Check whether the half round key is in place or not.

M18*1.5 100+10 N.
Note: Tightening torque of M18*1.5 nut is 100+10 N.
M14*1.5 85+15 N.m
Note: Tightening torque of M14*1.5 nut is: 85+15 N.m

22

7
Torque Requirements about Tightening Main Bolts of Diesel Engines
bolts name
( )

specification

tightening

M141.5

torque Nm
25 30

M101.25-10.9

55 60

M24

250+50

M4

1.50.25

M16

25 35

M18

27 32

M141.5

25 35

Locking nut of high pressure fuel

pipe (injector side)

Fixing bolts of injector

Retaining nut of common rail pump

gear

Wire pole of injector

Each low pressure tie-in of fuel

pump

( )
Locking nut of high pressure fuel
pipe (rail side)

( )
Locking nut of high pressure fuel
pipe (fuel pump side)

23

7
Torque Requirements about Tightening Main Bolts of Diesel Engines
bolts name
retaining bolts of
intake& exhaust pipe
flywheel bolt

Crankshaft hub retaining bolts

Vibration damper retaining bolts

Camshaft gear retaining bolts

Gear retaining bolts connecting camshaft and

fuel pump

Intermedial gear retaining bolts

II
Fuel pump gear retaining bolts (Euro II)
nuts on the fuel pump shaft
nuts on the fuel pump shaft

Hexogen bolts and two-head bolts of flywheel

specification
M10

45 50

inspection valve
Nm
45 60

M16-10.9
M16-10.9
M16-12.9
M10-10.9

285 295

285 340

240 250

240 280

65 70

65 80

M101.25-12.9

85 90

85 110

M8-12.9

55 60

55 70

M10

65 70

65 80

M10-10.9

65 70

65 80

M141.5
M181.5
M12-12.9
M10-12.9

85 100
100 110
140 145
80 85

85 110
100 120
140 170
80 95

control
value Nm

24

7
Torque Requirements about Tightening Main Bolts of Diesel Engines
oil pan retaining bolt
socket cap
bolt supporting oil pan
retaining bolt
used by double-level balance mechanism
oil pump retaining bolt

Two-head stud with locking nut

rocker-arm support bolt
adjusting nut of rocker arm
cylinder head cover
retaining bolt
high pressure fuel pipe
locking nut
injector retaining nut
II injector
retaining bolt (Euro II engine)
hub belt pulley
retaining bolt

M8-8.8

20 25

20 35

M8-10.9

30 35

30 45

M8-8.8

20 25

20 35

M8-12.9

30 40

30 50

M8-8.8

20 25

20 35

M10-8.8

40 45

40 55

M91

20 25

20 35

M8-8.8

10 15

10 25

M141.5

20 25

20 35

M8-8.8

10 15

10 25

M101.25-10.9
M8-8.8
M10-10.9

55 60
45 50
65 70

55 70
45 60
65 80

M12-8.8

85 90

85 100

25

8 mm
Fitting Clearance of Main Parts of Diesel Engines (Unit: mm)
No.
1
2
3
4
5
6
7
10
11
12

Item

Theoretical value

main bearing clearance

0.08 0.11

bearing clearance of connecting rod

0.07 0.10

axial clearance of crankshaft

0.04 0.25

axial clearance of connecting rod

plane
clearance between small
end bush of connecting rod and piston pin
clearance between piston pin seat
and piston pin
clearance between valve rod and
valve guide
plane value of air valve
below the cylinder head
plane valve of cylinder liner
above engine body

0.30 0.50
0.03 0.08
0.003 0.015
0.03 0.06
1.0 1.45
0.05 0.10

axial clearance of camshaft

0.10 0.29

13

bearing clearance of camshaft

14

clearance between valve tappet

and tappet bore

0.04 0.08
0.006 0.035

26