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CHAPTER 2 ENGINE
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Daidong DK651&751&801&901Engine Manual

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Page 1: Daidong DK651&751&801&901Engine Manual

CHAPTER 2

ENGINE

Page 2: Daidong DK651&751&801&901Engine Manual
Page 3: Daidong DK651&751&801&901Engine Manual

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ENGINE SYSTEM

1. SYSTEMS OPERATION SECTION

(1) Water TemperatureRegulator Housing

(2) Valve MechanismCover

(3) Fuel Transfer Pumpand Fuel Filter

(4) Engine Oil Cooler

(5) Fan Drive

(6) Water Pump

(7) Crankshaft Pulley

(8) Oil Pan

(9) Engine Oil Filter

(10) Engine Oil Filler Cap

(11) Exhaust Manifold

(12) Turbocharger

1.1 ENGINE MODEL VIEWS

C34W201A

(13) Alternator

(14) Flywheel Housing

(15) Flywheel

(16) Starter Motor

1103

1104

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CHAPTER 2 DK651/751/801/901

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1.2 FUEL SYSTEM

The Delphi DP210 fuel injection pump is installed onthe 1104 engine and the 1103 engine.

The Bosch EPVE fuel injection pump is installed onthe 1104 engine only.

The fuel transfer pump draws fuel from the fuel tankand through the water separator. When the fuel goesthrough the water separator, any water in the fuel willgo to the bottom of the bowl. The fuel transfer pumpsends the fuel at a low pressure to the fuel filter. Fromthe fuel filter, the fuel goes through the supply line tothe fuel injection pump.

The fuel injection pump sends fuel through the highpressure fuel line to each of the fuel injectors. The fuelinjector sprays the fuel into the cylinder. Fuel that is notinjected flows through the fuel return line to the top ofthe fuel filter, back to the fuel tank.

The engine must not be started until the fuel injectionpump is full of fuel that is free of air. The fuel injectionpump requires fuel for lubrication. The precision partsof the pump are easily damaged without lubrication.

The fuel system must be primed when any of the fol-lowing conditions occur:

• The fuel filter is changed.

• The fuel line is removed.

• The fuel injection pump is removed.

A. FUEL SYSTEM COMPONENTS

a. Fuel Injection Pump1. General Operation

The fuel injection pump is a pressurized system that istotally enclosed. The pump sends the correct amountof fuel under high pressure at the correct time throughthe fuel injectors to the individual cylinders. The fuelinjection pump regulates the amount of fuel that is de-livered to the fuel injectors.

This action controls the engine rpm by the governorsetting or the position of the throttle control.

The fuel lines to the fuel injectors are equal lengths.

This ensures even pressure and correct injection tim-ing at each fuel injector.

During operation, extra fuel is used as coolant andlubricant for moving parts of the pump. The extra fuel iscirculated through the pump housing. The extra fuel isthen returned to the fuel tank.

The Delphi DP210 fuel injection pump must be ser-viced by an authorized Delphi technician. For repairinformation, contact your Perkins dealer or contact yourPerkins distributor.

High idle and low idle of the fuel injection pump arefactory set. Idle adjustments can not be made to thefuel pump. The fuel injection pump has a boost controland an engine stop solenoid. The Delphi DP210 fuelinjection pump has a feature that vents air from thepump.

The fuel injection pump has a cold starting aid. Thecold starting aid advances the timing of the pump whenthe engine is cold. The cold starting aid is electricallyoperated.

b. Cold Start Advance UnitThe cold start advance unit holds the timing of the fuelinjection pump in an advance position when the en-gine is cold.

The coolant switch for the cold start advance unit is onthe rear of the timing case on the left side of the engine.

When the engine is cold, the sender unit is energizedin order to advance the fuel injection pump timing forthe cold start operation. When the correct temperatureis achieved the sender unit is de-energized and thefuel injection pump timing is returned to the normaloperating position.

If the switch fails in the closed position, the engine willrun with advanced fuel injection timing. The engine willhave higher cylinder pressure and engine damage mayresult.

If the switch fails in the open position the engine willrun with the fuel injection timing in the normal operat-ing position. The engine will be more difficult to start.When the engine is cold the engine might emit whitesmoke.

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ENGINE SYSTEM

1.3 AIR INLET AND EXHAUST SYSTEM

C34W202A

(1) Exhaust Manifold

(2) Intake Manifold

(3) Engine Cylinders

(4) Air Intake

(5) Turbocharger Compressor Wheel

(6) Turbocharger Turbine Wheel

(7) Exhaust Outlet

Engines which are naturally aspirated pull outside airthrough an air cleaner directly into the inlet manifold(2). The air flows from the intake manifold to the en-gine cylinders (3). The fuel is mixed with the air in theengine cylinders. After the fuel combustion occurs inthe engine cylinder, the exhaust gases flow directly tothe outside air through the exhaust manifold (1).

Turbocharged engines pull outside air through an aircleaner into the air intake (4) of the turbocharger.

The suction is caused by the turbocharger compres-sor wheel (5). Then, the turbocharger compressorwheel compresses the air. The air flows through theintake manifold (2) which directs an even distributionof the air to each engine cylinder (3). Air is pulled intothe engine cylinder (3) during the intake stroke of thepiston. Then, the air is mixed with fuel from the fuelinjectors.

Each piston makes four strokes:

1. Intake

2. Compression

3. Power

4. Exhaust

The sequence of the strokes by all of pistons in all ofthe engine cylinders provide constant air flow to theinlet system during the engine operation.

The exhaust stroke and the timing of the valve mecha-nism pushes combustion gases out of the open ex-haust valve through the exhaust manifold (1). The ex-haust gases flow through the blades of the turbo-charger turbine wheel (6) which causes the turbinewheel and the compressor wheel to turn.

Then, the exhaust gases flow through the exhaust out-let (7) of the turbocharger to the outside.

The air inlet system is also equipped with a crankcaseventilation system. The intake strokes of the pistonspull in atmospheric air to the crankcase.

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A. TURBOCHARGER

NOTE:

The turbocharger is not serviceable.

A turbocharger increases the temperature and the den-sity of the air that is sent to the engine cylinder.

This condition causes a lower temperature of ignitionto develop earlier in the compression stroke.

The compression stroke is also timed in a more accu-rate way with the fuel injection. Surplus air

lowers the temperature of combustion. This surplusair also provides internal cooling.

A turbocharger improves the following aspects of en-gine performance:

• Power output is increased.

• Fuel efficiency is increased.

• Engine torque is increased.

• Durability of the engine is increased.

• Emissions of the engine are increased.

A turbocharger is installed between the exhaust andintake manifolds. The turbocharger is driven by exhaustgases which flow through the exhaust inlet (11). Theenergy of the exhaust gas turns the turbine wheel (8).Then, the exhaust gas flows out of the turbine housing(7) through the exhaust outlet (9).

The turbine wheel and the compressor wheel (3) areinstalled on the same shaft. Therefore, the turbinewheel and the compressor wheel rotate at the samerpm. The compressor wheel is enclosed by the com-pressor housing (2). The compressor wheel com-presses the intake air (1). The intake air flows into theengine cylinders through the inlet valves of the cylinders.

The oil from the main gallery of the cylinder block flowsthrough the oil inlet port (5) in order to lubricate theturbocharger bearings (4) and (6). The pressurized oilpasses through the bearing housing of theturbocharger. The oil is returned through the oil outletport (10) to the oil pan.

Some turbochargers have a wastegate. The wastegateis controlled by the boost pressure.

This allows some of the exhaust to bypass the turbo-charger at higher engine speeds. The wastegate is atype of valve that automatically opens at a preset levelof boost pressure in order to allow exhaust gas to flowaround the turbine. The wastegate allows the designof the turbocharger to be more effective at lower en-gine speeds.

The wastegate is controlled by a diaphragm. One sideof this diaphragm is open to the atmosphere.

The other side of this diaphragm is open to the mani-fold pressure.

(1) Air Intake (7) Turbine Housing

(2) Compressor Housing (8) Turbine Wheel

(3) Compressor Wheel (9) Exhaust Outlet

(4) Bearing (10) Oil Outlet Port

(5) Oil Inlet Port (11) Exhaust Inlet

(6) Bearing

C34W203A

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ENGINE SYSTEM

1.4 LABRICATION SYSTEM

C34W204A

(1) Rocker Shaft

(2) Camshaft

(3) Modine Oil Cooler

(4) Oil Gallery

(5) Crankshaft

(6) Connecting Rod BearingJournals

(7) Oil Filter Head

(8) Oil Filter

(9) Pipe

(10) Oil Pump

(11) Oil Pump Gear

(12) Idler Gear

(13) Crankshaft Gear

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CHAPTER 2 DK651/751/801/901

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Pressure for the lubrication system is supplied by theoil pump (10). The crankshaft gear (13) drives a loweridler gear (12). The lower idler gear drives the oil pumpgear (11). The pump has an inner rotor and an outerrotor. The axis of rotation of the rotors are off-centerrelative to each other. There is an interference fit be-tween the inner rotor and the drive shaft.

The inner rotor has five lobes which mesh with the sixlobes of the outer rotor. When the pump rotates, thedistance increases between the lobes of the outer ro-tor and the lobes of the inner rotor in order to createsuction. When the distance decreases between thelobes, pressure is created.

Lubricating oil from the oil pan flows through a strainerand a pipe (9) to the suction side of the engine oilpump. The lubricating oil flows from the outlet side ofthe pump through a passage to the oil filter head (7).The oil then flows from the filter head through a pas-sage to a plate type oil cooler for the 1104 engine, or amodine oil cooler (3) for the 1103 engine. The integraloil cooler is located on the left side of the cylinder block.The modine oil cooler is located on the left side of thecylinder block.

From the oil cooler, the oil returns through a passageto the oil filter head. The oil then flows from the filterhead to the bypass valve and from the bypass valve tothe oil filter (8).

The oil flows from the oil filter through a passage thatis drilled across the cylinder block to the oil gallery (4).The oil gallery is drilled through the total length of theleft side of the cylinder block. If the oil filter is on theright side of the engine, the oil flows through a pas-sage that is drilled across the cylinder block to the pres-sure gallery.

Lubricating oil from the oil gallery flows through highpressure passages to the main bearings of the crank-shaft (5). Then, the oil flows through the passages inthe crankshaft to the connecting rod bearing journals(6). The pistons and the cylinder bores are lubricatedby the splash of oil and the oil mist.

Lubricating oil from the main bearings flows throughpassages in the cylinder block to the journals of thecamshaft. Then, the oil flows from the second journalof the camshaft (2) at a reduced pressure to the cylin-der head. The oil then flows through the center of therocker shaft (1) to the rocker arm levers. The valvestems, the valve springs and the valve lifters are lubri-cated by the splash and the oil mist.

The hub of the idler gear is lubricated by oil from the oilgallery. The timing gears are lubricated by the splashfrom the oil.

Turbochargers are lubricated by oil from a connectionon the side of the cylinder block. An external line fromthe cylinder block supplies oil to the turbocharger. Theoil then flows through a line to the oil pan.

Engines have piston cooling jets that are supplied withoil from the oil gallery. The piston cooling jets spraylubricating oil on the underside of the pistons in orderto cool the pistons.

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ENGINE SYSTEM

1.5 COOLING SYSTEM

C34W205A

1103 1104

The coolant flows from the bottom of the radiator to thecentrifugal water pump. The water pump assists in theflow of the coolant through the system. The water pumpis installed on the front of the timing case. The waterpump is gear-driven by the fuel injection pump gear.

The water pump forces the coolant through a passagein the front of the timing case to the water jacket in thetop left side of the cylinder block. The coolant contin-ues to the rear of the cylinder block and some of thecoolant passes into the oil cooler for the 1104 or intothe modine oil cooler for the 1103. The oil cooler islocated on the left side of the cylinder block with noexternal lines. The modine oil cooler is located on theleft side of the cylinder block.

The coolant flows around the element of the oil coolerto the rear of the cylinder block. The coolant then passesfrom the rear of the cylinder block and into the rear ofthe cylinder head.

The coolant flows forward through the cylinder headand into the water temperature regulator housing.

If the water temperature regulator is closed, the cool-ant goes directly through a bypass to the inlet side ofthe water pump. If the water temperature regulator isopen, the bypass is closed and the coolant flows to thetop of the radiator.

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CHAPTER 2 DK651/751/801/901

2-10

Item

Bore

Stroke

Displacement

Cylinder arrangement

Type of combustion

Compression ratio

Number of cylinders

Valves per cylinder

Valve lash

Firing order

When the crankshaft is viewed from the front of theengine, the crankshaft rotates in the following direction

When the camshaft is viewed from the front of theengine, the camshaft rotates in the following direction

2. SPECIFICATIONS

2.1 ENGINE DESIGN

(A) Inlet Valve

C34W206A

(B) Exhaust Valve

Three Cylinder Engine Four Cylinder Engine

Four cylinder engine

105 mm (4.133 in.)

127 mm (5.000 in.)

4.4 L (269 in3)

In-line

Direct injection

19.3:1

18.2:1

4

2

0.20 mm (0.008 in.)

0.45 mm (0.018 in.)

1, 3, 4, 2

Clockwise

Clockwise

Three cylinder engine

105 mm (4.133 in.)

127 mm (5.000 in.)

3.3 L (201 in3)

In-line

Direct injection

19.3:1

18.25:1

3

2

0.20 mm (0.008 in.)

0.45 mm (0.018 in.)

1, 2, 3

Clockwise

Clockwise

Naturally aspirated engines

Turbocharged engines

Inlet valve

Exhaust valve

The front of the engine is opposite the flywheel end.

The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the frontcylinder.

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ENGINE SYSTEM

2.2 FUEL INJECTION LINES

(1) Nut

C34W207A

30 N·m

3 kgf·m

22 lbf·ft

Tighten the union nutsfor the fuel injector tothe following torque (1)

Item Tightening torque

NOTE:

Tighten the union nuts at the fuel injection pump tothe following torque. 30 N·m (3.0 kgf·m, 22 lbf·ft)

2.3 FUEL INJECTION PUMP

a. DELPHI

NOTE:

Before the fuel injection pump is removed from the enginethe fuel injection pump shaft must be locked. Positionthe engine to TC compression stroke of number one cyl-inder before tightening the locking screw. The lockingscrew will prevent the shaft from rotating. If the fuel injec-tion pump was removed prior to correctly timing the en-gine and locking the shaft, the fuel injection pump willneed to be timed by trained personnel.

NOTE:

The solenoid on the fuel injection pump is a service-able item. The fuel injection pump is a nonserviceableitem.

Locking the Shaft

(1) O-ring (3) Washer

(2) Locking Screw

C34W208A

17 N·m

1.7 kgf·m

12.5 lbf·ft

Loosen locking screw (2)and move the washer (3)to the locked position.Tighten the bolt to thefollowing torque

Item Tightening torque

12 N·m

1.2 kgf·m

8.9 lbf·ft

Loosen locking screw (2)and install the washer (3)to the unlocked position.Tighten the bolt to thefollowing torque

Item Tightening torque

Unlocking the Shaft

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(4) Tighten the Bolt

(5) Tighten the Nut and Bolt

C34W209A

44 N·m

4.5 kgf·m

32.5 lbf·ft

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the mountingbolt to the followingtorque. (4)

Tighten the mountingbolt and the nut to thefollowing torque. (5)

Item Tightening torque

NOTE:

The support bracket must be installed after the cool-ant pump is installed. In order to stop the distortion ofthe timing case, finger tighten the bolt (4) and thentighten the nut and bolt (5). Tighten the bolt (4).

25 N·m

2.5 kgf·m

18.4 lbf·ft

Tighten the bolts thathold the fuel pump tothe front housing to thefollowing torque

Item Tightening torque

b. BOSCH

NOTE:

Before the fuel injection pump is removed from theengine the fuel injection pump shaft must be locked.Position the engine to TC compression stroke of num-ber one cylinder before tightening the locking screw.The locking screw will prevent the shaft from rotating.If the fuel injection pump was removed prior to prop-erly timing the engine and locking the shaft, the fuelinjection pump wil l need to be t imed by trainedpersonnel.

NOTE:

The solenoid on the fuel injection pump is a service-able item. The fuel injection pump is a nonserviceableitem.

Locking the Shaft

(1) O-ring (3) Washer

(2) Locking Screw

C34W2Q1A

31 N·m

3.1 kgf·m

22.9 lbf·ft

Remove spacer (3)before locking screw (2)is tightened to thefollowing torque.

Item Tightening torque

12 N·m

1.2 kgf·m

8.9 lbf·ft

Loosen the bolt andplace spacer (3) behindlocking screw (2).Tighten the bolt to thefollowing torque

Item Tightening torque

Unlocking the Shaft

1.55 mm (0.0610 in.)The lift of the ER fuelinjection pump plunger

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ENGINE SYSTEM

2.4 FUEL INJECTORS

(1) Bolt

C34W210A

35 N·m

3.6 kgf·m

25.8 lbf·ft

Tighten the bolt in theclamp for the fuel injectorto the following torque. (1)

Item Tightening torque

The fuel injector nozzle should be tested at the pres-sure in Table 1.

Leakage in 10 seconds 0 drops

Injection Pressure

29.4 + 0.8 MPa (4264 + 116 psi)

29.4 + 0.8 MPa (4264 + 116 psi)

29.4 + 0.8 MPa (4264 + 116 psi)

Color

Yellow

Blue

Red

Service Setting for the Fuel Injection Nozzle

(4) Bolt

C34W2Q2A

29 N·m

3 kgf·m

21.4 lbf·ft

Tighten the plug for thefuel injection pumpplunger to the followingtorque (4)

Item Tightening torque

(5) Bolt (6) Bolt

C34W2Q3A

44 N·m

4.5 kgf·m

32.5 lbf·ft

22 N·m

2.2 kgf·m

16.2 lbf·ft

25 N·m

2.5 kgf·m

18.4 lbf·ft

Tighten the bolt to thefollowing torque (5)

Tighten the nut and thebolt to the followingtorque (6)

Tighten the bolts thathold the fuel pump tothe front housing to thefollowing torque.

Item Tightening torque

NOTE:

The support bracket must be installed after the cool-ant pump is installed. In order to stop the distortion ofthe timing case, finger tighten the bolt (5) and thentighten the nut and the bolt (6). Tighten the bolt (5).

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CHAPTER 2 DK651/751/801/901

2-14

2.5 FUEL TRANSFER PUMP

(1) Retaining Bolts (5) Fuel Filter Element

(2) Clip (6) O-ring

(3) Spacer (7) Fuel Filter Bowl

(4) Fuel Transfer Pump

C34W211A

12 or 24 volt electricmotor

Fuel transfer pump

Item Type

NOTE:

Tighten the fuel filter bowl by hand. Rotate the bowl 1/8of a turn more by hand.

2.6 LIFTER GROUP

(1) Diameter of the Lifter Body

C34W212A

18.99 ~ 19.01 mm(0.7475 ~ 0.7485 in.)

0.04 ~ 0.09 mm(0.0015 ~ 0.0037 in.)

Diameter of the lifterbody (1)

Clearance of the lifter inthe cylinder block bore

Item Factory spec.

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ENGINE SYSTEM

Clearancebetween therocker armbushing andthe rocker shaft

Maximumpermissibleclearancebetween therocker armbushing andthe rocker shaft

2.7 ROCKER SHAFT

NOTE:

The rocker shaft assembly for the 3 cylinder engineand the rocker shaft assembly for the 4 cylinder en-gine use the same components. The exception is thelength of the rocker shaft.

NOTE:

In order to install the rocker shaft assembly, the tool27610227 Spacing Toolis required.

(1) Snap Ring

(2) Washer

(3) Rocker Arm

(4) Rocker Arm Bore

(5) Spring

(6) Tighten the screws evenly. Begin in the centerand work toward the outside. Tighten thescrews to the following torque

(7) Rocker Shaft

(8) In order to install the rocker shaft assembly,ensure that the machined square is to the topof the rocker shaft.

(9) Locknut

C34W213A

25.01 ~ 25.05 mm(0.9847 ~ 0.9862 in.)

0.03 ~ 0.09 mm(0.0010 ~ 0.0035 in.)

0.17 mm(0.007 in.)

Item Factory spec.

NOTE:

Install the longest screw at the front of the rocker shaftassembly.

Rockerarmbushing

Rocker arm bore

Diameter of the rocker armbore for the bushing

35 N·m

3.5 kgf·m

25.8 lbf·ft

Tighten the screws evenly.Begin in the center andwork toward the outside.Tighten the screws to thefollowing torque.

Item Tightening torque

24.96 ~ 24.99 mm(0.9827 ~ 0.9839 in.)

Diameter of the rockershaft

Item Factory spec.

27 N·m

2.7 kgf·m

19.9 lbf·ft

Torque for the locknut

Item Tightening torque

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CHAPTER 2 DK651/751/801/901

2-16

9.0 N·m

0.9 kgf·m

6.6 lbf·ft

Tighten the bolts for thevalve mechanism coverin the sequence that isshown to the followingtorque

Item Tightening torque

2.8 VALVE MECHANISM COVER

A. FOUR CYLINDER ENGINE

B. THREE CYLINDER ENGINE

9.0 N·m

0.9 kgf·m

6.6 lbf·ft

Tighten the bolts for thevalve mechanism coverin the sequence that isshown to the followingtorque

Item Tightening torque

C34W214A

C34W215A

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ENGINE SYSTEM

2.9 CYLINDER HEAD VALVES

A. VALVE SPRING

C34W216A

(1) Valve Spring

(2) Valve Spring Recess

(3) The Finished Valve Guides

(4) Exhaust Valve

(5) Inlet Valve

(6) Exhaust Valve Face Angle from the Vertical Axis

(7) Diameter of the Exhaust Valve Head

(8) Diameter of the Head of the Inlet Valve

(9) Angle of the Inlet Valve Face from the Vertical Axis

The installedlength of thevalve springs

The load forthe installedvalve springs

The installedlength of thevalve springs

The load forthe installedvalve spring

33.5 mm(1.318 in.)

254 N57.1 lb

34.5 mm(1.358 in.)

229 N51.5 lb

Item Factory spec.

Naturallyaspiratedengines

Turbo-chargedengines

B. THE FINISHED VALVE GUIDES

9.000 ~ 9.022 mm(0.3543 ~ 0.3552 in.)

13.034 ~ 13.047 mm(0.5131 ~ 0.5137 in.)

13.034 ~ 13.047 mm(0.5131 ~ 0.5137 in.)

0.007 ~ 0.047 mm(0.0003 ~ 0.0019 in.)

51.00 ~ 51.50 mm2.018 ~ 2.027 in.)

12.35 ~ 12.65 mm(0.486 ~ 0.498 in.)

Inside diameter of valveguide

Outside diameter of theexhaust valve guide

Outside diameter of theinlet valve guide

Interference fit of valveguide in cylinder head

Length of Valve guide

Projection of the valveguide above the valvespring recess (2)

Item Factory spec.

NOTE:

When new valve guides are installed, new valves andnew valve seat inserts must be installed.

The valve guides and the valve seat inserts are sup-plied as partially finished parts. The unfinished valveguides and unfinished valve seat inserts are installedin the cylinder head. The guides and inserts are thencut and reamed in one operation with special tooling.This procedure ensures the concentricity of the valveseat to the valve guide in order to create a seal that istight. Refer to the Disassembly and Assembly Manualfor removal and installation procedures.

C. EXHAUST VALVE

8.938 ~ 8.960 mm(0.3519 ~ 0.3528 in.)

Diameter of the exhaustvalve stem

Item Factory spec.

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CHAPTER 2 DK651/751/801/901

2-18

0.040 ~ 0.840 mm(0.0016 ~ 0.033 in.)

128.92 ~ 129.37 mm(5.075 ~ 5.093 in.)

Clearance of valve invalve guide

Overall length of theexhaust valve

Item Factory spec.

The face of the exhaust valve is recessed below thecylinder head by the following amount.

Allowable limit

1.06 mm(0.042 in.)

2.06 mm(0.0811 in.)

0.53 ~ 0.81 mm(0.021 ~ 0.032 in.)

1.53 ~ 1.81 mm(0.060 ~ 0.071 in.)

Naturallyaspiratedengines

Turbochargedengines

Item Factory spec.

D. INLET VALVE

8.953 ~ 8.975 mm(0.3525 ~ 0.3533 in.)

0.025 ~ 0.069 mm(0.001 ~ 0.0027 in.)

Diameter of the inletvalve stem

Clearance of valve invalve guide

Item Factory spec.

128.92 ~ 129.37 mm(5.075 ~ 5.093 in.)

Overall length of theinlet valve

Item Factory spec.

The face of the inlet valve is recessed below the cylin-der head by the following amount.

Allowable limit

1.09 mm(0.043 in.)

2.09 mm(0.0823 in.)

0.58 ~ 0.84 mm(0.023 ~ 0.033 in.)

1.58 ~ 1.84 mm(0.062 ~ 0.072 in.)

Naturallyaspiratedengines

Turbochargedengines

Item Factory spec.

E. EXHAUST VALVE FACE ANGLE FROM THEVERTICAL AXIS

Valve face angle

Valve seat angle

Item

30°

30°

Specified

41.51 ~ 41.75 mm(1.634 ~ 1.643 in.)

46.20 ~ 46.45 mm(1.818 ~ 1.828 in.)

Diameter of the exhaustvalve head

Diameter of the head ofthe inlet valve

Item Factory spec.

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ENGINE SYSTEM

30°

30°

Valve face angle

Valve seat angle

Angle of the Inlet Valve Face from the Vertical Axis

Item Specified

0.20 mm(0.008 in.)

0.45 mm(0.018 in.)

Inlet valves

Exhaust valves

Item Factory spec.

The Valve Lash is the Following Value when the En-gine is Cold:

C34W217A

Machine the Recess in the Head for Valve SeatInserts to the Following Dimensions.

(A)

(B)

Maximumradius (C)

(A)

(B)

Maximumradius (C)

(A)

(B)

Maximumradius (C)

(A)

(B)

Maximumradius (C)

9.910 ~ 10.040 mm(0.3901 ~ 0.3952 in.)

47.820 ~ 47.845 mm(1.8826 ~ 1.8836 in.)

0.38 mm(0.015 in.)

9.910 ~ 10.040 mm(0.3901 ~ 0.3952 in.)

42.420 ~ 42.445 mm(1.6701 ~ 1.6711 in.)

0.38 mm(0.015 in.)

10.910 ~ 11.040 mm(0.4295 ~ 0.4346 in.)

47.820 ~ 47.845 mm(1.8826 ~ 1.8836 in.)

0.38 mm(0.015 in.)

10.910 ~ 11.040 mm(0.4295 ~ 0.4346 in.)

42.420 ~ 42.445 mm(1.6700 ~ 1.6710 in.)

0.38 mm(0.015 in.)

Item Factory spec.

Recess forinlet valve seatfor naturallyaspiratedengines

Recess forexhaust valveseat fornaturallyaspiratedengines

Recess forinlet valve seatfor turbo-chargedengines

Recess forexhaust valveseat forturbochargedengines

(10) Machine the recess in the head for valve seatinserts to the following dimensions.

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CHAPTER 2 DK651/751/801/901

2-20

The head bolts require an additional torque turnprocedure. The numbers (1, 3, 4) are three long cylin-der head bolts. All the other bolts are short bolts. Thetightening sequence is shown in the Illustrations.

C34W220A

Place the angle gauge onthe top of each bolt head.Tighten the short bolts tothe additional amount.

Place the angle gauge onthe top of each bolt head.Tighten the long bolts forthe additional amount.

Item

225°

270°

Specified

117.95 ~ 118.05 mm(4.643 ~ 4.647 in.)

117.20 mm(4.614 in.)

Thickness of thecylinder head

Minimum thickness ofcylinder head

Item Factory spec.

NOTE:

The maximum distortion of the cylinder head is givenin table 3.

The cylinder head bolts are two different lengths.

The following information provides the proper torquefor the cylinder head bolts.

Lubricate the threads and the underside of the headbolts with clean engine oil.

2.10 CYLINDER HEAD

Part Description

Angle gauge

Part Number

21825607

Required Tools

Qty

1

C34W218A

C34W219A

50 N·m

5.1 kgf·m

36.9 lbf·ft

100 N·m

10.2 kgf·m

73.8 lbf·ft

Tighten the bolts in thesequence that is shownin Illustrations to thefollowing torque.

Tighten the bolts againto the following torque.

Item Tightening torque

Four Cylinder

Three Cylinder

The maximum distortion of the cylinder head is givenin table 3.

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ENGINE SYSTEM

Four Cylinder

C34W221A

C34W222A

Three Cylinder

0.03 mm (0.0018 in.)

0.05 mm (0.0019 in.)

0.05 mm (0.0019 in.)

Width (A)

Length (B)

Diagonal Line (C)

DimensionMaximum Permissible

Distortion

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C34W223A

2.11 TURBOCHARGER

(1) Actuator Rod

(2) Actuator

(3) Turbocharger

(4) Tighten the Nuts to the Following Torque

(5) Tighten the Bolt to the Following Torque

(6) Tighten the Bolt to the Following Torque

47 N·m

4.8 kgf·m

34.7 lbf·ft

9 N·m

0.9 kgf·m

6.6 lbf·ft

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the nuts to thefollowing torque (4)

Tighten the bolt to thefollowing torque (5)

Tighten the bolt to thefollowing torque (6)

Item Tightening torque

205 kPa(29.7 psi)

1 mm(0.0394 in.)

The maximum testpressure for the waste gate

The movement for therod actuator

Item Factory spec.

A. FOUR CYLINDER

100 ± 5 kPa(14.5040 ± 0.7252 psi)

110 ± 5 kPa(15.9544 ± 0.7252 psi)

128 ± 5 kPa(18.5651 ± 0.7252 psi)

100 ± 5 kPa(14.5040 ± 0.7252 psi)

128 ± 5 kPa(18.5651 ± 0.7252 psi)

128 ± 5 kPa(18.5651 ± 0.7252 psi)

136 ± 5 kPa(19.7254 ± 0.7252 psi)

136 ± 5 kPa(19.7254 ± 0.7252 psi)

136 ± 5 kPa(19.7254 ± 0.7252 psi)

100 ± 5 kPa(14.5040 ± 0.7252 psi)

128 ± 5 kPa(18.5651 ± 0.7252 psi)

2674A200

2674A201

2674A202

2674A209

2674A211

2674A215

2674A223

2674A224

2674A225

2674A226

2674A227

The part number for theturbocharger

The pressure for thewaste gate

B. THREE CYLINDER

100 ± 3 kPa(14.5040 ± 0.4351 psi)

2674A405

The part number for theturbocharger

The pressure for thewaste gate

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ENGINE SYSTEM

C34W224A

2.12 EXHAUST MANIFOLD

A. FOUR CYLINDER

NOTE:

The exhaust manifold must be aligned to the cylinderhead. Refer to the Disassembly and Assembly manual.

33 N·m

3.3 kgf·m

24.3 lbf·ft

Tighten the exhaustmanifold bolts.

Item Tightening torque

C34W225A

B. THREE CYLINDER

NOTE:

The exhaust manifold must be aligned to the cylinderhead. Refer to the Disassembly and Assembly manual.

33 N·m

3.3 kgf·m

24.3 lbf·ft

Tighten the exhaustmanifold bolts.

Item Tightening torque

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CHAPTER 2 DK651/751/801/901

2-24

C34W226A

2.13 CAMSHAFT

(1) End Play of a New Camshaft

0.10 ~ 0.55 mm(0.004 ~ 0.022 in.)

0.60 mm(0.023 in.)

End play of a newcamshaft (1)

Maximum permissibleend play of a worncamshaft

Item Factory spec.

C34W227A

(2) Bolt

(3) Camshaft Thrust Washer

(4) The diameters of the camshaft journals aregiven in the following tables.

95 N·m

9.6 kgf·m

70.1 lbf·ft

Tighten the bolt to thefollowing torque.

Item Tightening torque

5.49 ~ 5.54 mm(0.216 ~ 0.218 in.)

5.54 ~ 5.64 mm(0.218 ~ 0.222 in.)

-0.154 ~ -0.003 mm(-0.0006 ~ -0.0001 in.)

Thickness of the thrustwasher

Depth of the recess inthe cylinder block forthe thrust washer

Tolerance of the thrustwasher in cylinderblock front face

Item Factory spec.

Standard Diameter

50.71 ~ 50.74 mm(1.9965 ~ 1.9975 in.)

50.46 ~ 50.48 mm(1.9865 ~ 1.9875 in.)

49.95 ~ 49.98 mm(1.9665 ~ 1.9675 in.)

Camshaft Journals

1

2

3

1104 Diameters of Camshaft Journals

Standard Diameter

50.71 ~ 50.74 mm(1.9965 ~ 1.9975 in.)

50.46 ~ 50.48 mm(1.9865 ~ 1.9875 in.)

50.46 ~ 50.48 mm(1.9865 ~ 1.9875 in.)

49.95 ~ 49.98 mm(1.9665 ~ 1.9675 in.)

Camshaft Journals

1

2

3

4

1103 Diameters of Camshaft Journals

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C34-WOO May. 2005 2-25

ENGINE SYSTEM

0.05 mm(0.0021 in.)

Maximum wear on thecamshaft journals

Item Factory spec.

C34W228A

(5) Camshaft Lobe Lift

(6) Camshaft Lobe Height

(7) Base Circle

Inlet lobe

Exhaust lobe

Inlet lobe

Exhaust lobe

7.382 ~ 7.482 mm(0.2906 ~ 0.2946 in.)

7.404 ~ 7.504 mm(0.2914 ~ 0.2954 in.)

7.031 ~ 7.130 mm(0.2768 ~ 0.2807 in.)

7.963 ~ 8.063 mm(0.3135 ~ 0.3174 in.)

Item Factory spec.

Naturallyaspirated

Turbo-charged

To determine the lobe lift, use the procedure thatfollows:

1. Measure the camshaft lobe height (6).

2. Measure the base circle (7).

3. Subtract the base circle that is found in Step 2 fromthe camshaft lobe height that is found in Step 1.The difference is the actual camshaft lobe lift.

0.05 mm(0.021 in.)

Maximum permissibleclearance between theactual lobe lift and thespecified lobe lift of anew camshaft

Item Factory spec.

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CHAPTER 2 DK651/751/801/901

2-26

C34W230A

2.14 CAMSHAFT BEARINGS

(1) Camshaft Bearing

50.790 ~ 50.850 mm(1.9996 ~ 2.0020 in.)

The diameter for theinstalled camshaftbearing

Item Factory spec.

C34W229A

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ENGINE SYSTEM

2.15 ENGINE OIL FILTER

A. SPIN-ON OIL FILTER

NOTE:

Lubricate the top of the seal with clean engine oil be-fore installation.

(1) Seal

80 ~ 120 kPa(11.6 ~ 17.4 psi)

Pressure to openengine oil filter bypassvalve

Type Full flow

C34W231A

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CHAPTER 2 DK651/751/801/901

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2.16 ENGINE OIL PUMP

A. FOUR CYLINDER ENGINES WITH BAL-ANCER GROUP

(1) Clearance of the Outer Rotor to the Body

C34W233A

Inner rotor

Outer rotor

6

7

TypeGear-driven differen-

tial rotor

Numberof lobes

0.130 ~ 0.24 mm(0.0050 ~ 0.0094 in.)

Clearance of the outerrotor to the body

Item Factory spec.

(2) Clearance of Inner Rotor to Outer Rotor

C34W234A

0.050 ~ 0.200 mm(0.0020 ~ 0.0079 in.)

Clearance of inner rotorto outer rotor

Item Factory spec.

(3) End Play of Rotor Assembly

C34W235A

Inner rotor

Outer rotor

0.04 ~ 0.11 mm(0.0016 ~ 0.0043 in.)

0.04 ~ 0.00 mm(0.0016 ~ 0.0043 in.)

Item Tightening torque

End playof rotorassembly

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ENGINE SYSTEM

(4) Torque for Cover Bolts for Oil Pump

C34W236A

(5) Idler Gear Bolt

(6) Nut

C34W237A

26 N·m

2.6 kgf·m

19.2 lbf·ft

Torque for cover boltsfor oil pump

Item Tightening torque

NOTE:

Replace the idler gear bolt (5) and the nut for the oilpump gear (6).

NOTE:

Set the engine to the TC position. Refer to Testingand Adjusting , “Finding Top Center Position for No. 1Piston”. Install the balancer. Refer to the Disassem-bly and Assembly manual. Install the gear for the oilpump and tighten the nut (6).

26 N·m

2.6 kgf·m

19.2 lb·ft

95 N·m

9.6 kgf·m

70.1 lb·ft

54 N·m

5.5 kgf·m

39.8 lbf·ft

Tighten the idler gearbolt to the followingtorque (5)

Tighten the nut to thefollowing torque (6)

Tighten the bolts thathold the balancer to thecylinder block to thefollowing torque

Item Tightening torque

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CHAPTER 2 DK651/751/801/901

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B. THREE CYLINDER ENGINES WITHOUTBALANCER GROUP

(1) Clearance of the Outer Rotor to the Body

C34W238A

Inner rotor

Outer rotor

5

6

TypeGear-driven differen-

tial rotor

Numberof lobes

0.152 ~ 0.330 mm(0.0059 ~ 0.0129 in.)

Clearance of the outerrotor to the body

Item Factory spec.

(2) Clearance of Inner Rotor to Outer Rotor

C34W239A

0.040 ~ 0.127 mm(0.0015 ~ 0.0050 in.)

Clearance of inner rotorto outer rotor

Item Factory spec.

(3) End Play of Rotor Assembly

C34W240A

Inner rotor

Outer rotor

0.038 ~ 0.089 mm(0.0014 ~ 0.0035 in.)

0.025 ~ 0.076 mm(0.0010 ~ 0.0029 in.)

Item Tightening torque

End playof rotorassembly(3)

26 N·m

2.6 kgf·m

19.2 lbf·ft

Tighten the bolts thathold the front cover ofthe oil pump assemblyto the following torque

Item Tightening torque

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ENGINE SYSTEM

2.17 ENGINE OIL PRESSURE

C34W241A

300 kPa(43.5 psi)

The minimum oilpressure at the maxi-mum engine speed andat normal operatingtemperature is thefollowing value

Type Full flow

2.18 ENGINE OIL BYPASS VALVE

A. INSTALLED IN THE OIL PUMP

C34W242A

(1) Tighten the Plug for the Relief Valve to theFollowing Torque

(2) Plunger

Diameter ofthe plunger

Clearance ofplunger in bore

19.186 ~ 19.211 mm(0.7554 ~ 0.7563 in.)

0.039 ~ 0.114 mm(0.0015 ~ 0.0045 in.)

Item Tightening torque

Plunger (2)

35 N·m

3.5 kgf·m

25.8 lb·ft

Tighten the plug for therelief valve to thefollowing torque

Item Tightening torque

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CHAPTER 2 DK651/751/801/901

2-32

C34W243A

B. INSTALLED IN THE BALANCER

C34W244A

(1) Tighten the Plug for the Relief Valve to theFollowing Torque

(2) Plunger

Diameter ofthe plunger

Clearance ofthe plunger inthe bore

14.46 ~ 14.48 mm(0.5692 ~ 0.5700 in.)

0.04 ~ 0.08 mm(0.0015 ~ 0.0031 in.)

Item Factory spec.

Plunger (2)

35 N·m

3.5 kgf·m

25.8 lb·ft

Tighten the plug for therelief valve to thefollowing torque

Item Tightening torque

Page 33: Daidong DK651&751&801&901Engine Manual

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ENGINE SYSTEM

2.19 ENGINE OIL PAN

A. FRONT SEALANT

NOTE:

Apply a sealant bead of 3.5 mm (0.1378 in.) that isshown in illustration 44.

C34W246A

(1) Apply 1861108 Powerpart silicone rubber sealantto the cylinder block and to the timing case.

(2) Apply 1861108 Powerpart silicone rubber sealantto the bridge. The sealant must not protrude morethan 5 mm (0.1969 in.) above the bridge.

B. REAR SEALANT

NOTE:

Install the rear oil seal before sealant is applied to thebridge.

NOTE:

The oil pan must be installed within 10 minutes of ap-plying the sealant.

C34W245A

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CHAPTER 2 DK651/751/801/901

2-34

(5) Apply 1861108 Powerpart silicone rubbersealant to the bridge. The sealant must notprotrude more than 5 mm (0.1969 in.) abovethe bridge.

(6) Bolt

(7) Drain Plug

C. THE CAST IRON OIL PAN

NOTE:

The rear face of the cast iron oil pan (5) must bealigned to the rear face of the cylinder block.

0.1 mm(0.0039 in.)

The maximum allowedvalue of the rear facemisalignment (5)

Item Factory spec.

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the front fourbolts. Refer to illustration46. Tighten the remain-ing bolts and the nutsthat fasten the engine oilpan to the cylinder blockto the following torque (6)

Item Tightening torque

C34W248A

NOTE:

The sealant is applied to new bolts. In order to reusethe bolts, apply 21820117 Powerpart threadlock andnutlock to the first three threads of the used bolts.

NOTE:

The engine may be equipped with an oil drain plug.

34 ± 5 N·m

3.4 ± 0.5 kgf·m

25.1 ± 3.7 lbf·ft

Tighten the drain plug forthe engine oil pan to thefollowing torque (7)

Item Tightening torque

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ENGINE SYSTEM

2.20 CRANKCASE BREATHER

C34W250A

(1) Plastic Cover (4) Diaphragm

(2) Cover Plate (5) Cap

(3) Bolts (6) Spring

1.3 N·m

0.13 kgf·m

0.96 lbf·ft

1.8 N·m

0.18 kgf·m

1.3 lbf·ft

Tighten the bolts for thecover plate with a plasticvalve mechanism coverto the following torque (3)

Tighten the bolts for thecover plate with a metalvalve mechanism coverto the following torque (3)

Item Tightening torque

C34W251A

(7) O-ring

(8) Tighten the bolts that secure the breather pipeto the cylinder head to the following torque

9 N·m

0.9 kgf·m

6.6 lbf·ft

Tighten the bolts thatsecure the breather pipeto the cylinder head tothe following torque (8)

Item Tightening torque

NOTE:

Apply 21820221 Powerpart red rubber grease to theO-ring before installing the breather pipe in the valvemechanism cover.

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2.21 WATER TEMPERATURE REGULA-TOR AND HOUSING

C34W252A

(1) O-ring

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the bolts (notshown) that fasten thehousing to the followingtorque

Item Tightening torque

NOTE:

Apply 21820221 Powerpart red rubber grease to theO-ring (1) in order to install the thermostat housing.

C34W253A

79°C ~ 84°C(174°F ~ 151°F)

93°C(199°F)

10 mm(0.3937 in.)

Opening temperature

Full opening tempera-ture

Minimum stroke at fullopen temperature

Item Factory spec.

A. WATER TEMPERATURE REGULATOR

2.22 WATER PUMP

NOTE:

Apply 21820117 Powerpart threadlock nutlock to thefirst three threads of the bolts before installation.

C34W254A

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the nine boltsthat secure the waterpump to the fronthousing in the numericalsequence that is shownto the following torque

Item Tightening torque

NOTE:

Refer to the Disassembly and Assembly manual inorder to service the water pump.

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ENGINE SYSTEM

2.23 CYLINDER BLOCK

A. FOUR CYLINDER

C34W255A

(1) Cylinder Block

(2) Cylinder Bore

(3) Camshaft Bearings for the Four CylinderEngine

(4) Main Bearings for the Four Cylinder Engine

(5) Main Bearing Cap Bolts for the Four CylinderEngine

105.000 ~ 105.025 mm(4.1338 ~ 4.1348 in.)

Cylinder bore (2)

Item Factory spec.

105.5 ~ 105.525 mm(4.1535 ~ 4.1545 in.)

106.000 ~ 106.025 mm(4.1732 ~ 4.1742 in.)

0 ~ 0.15 mm(0 ~ 0.0059 in.)

The first oversize borediameter

The second oversizebore diameter

The maximum permis-sible wear for thecylinder bore

Item Factory spec.

55.563 ~ 55.593 mm(2.1875 ~ 2.1887 in.)

50.546 ~ 50.597 mm(1.9900 ~ 1.9920 in.)

50.038 ~ 50.089 mm(1.9700 ~ 1.9720 in.)

80.416 ~ 80.442 mm(3.1660 ~ 3.1670 in.)

Diameter of the bore inthe cylinder block forthe number 1 camshaftbearing (3)

Diameter of the bore inthe cylinder block forthe number 2 camshaftjournal (3)

Diameter of the bore inthe cylinder block forthe number 3 camshaftjournal (3)

Bore in the cylinderblock for the mainbearings (4)

Item Factory spec.

Use the following procedure in order to install the mainbearing cap bolts:

1. Apply clean engine oil to the threads of the mainbearing cap bolts.

2. Put the main bearing caps in the correct positionthat is indicated by a number on the top of the mainbearing cap. Install the main bearing caps with thelocating tabs in correct alignment with the recess inthe cylinder block.

3. Evenly tighten the main bearing cap bolts.

245 N·m

24.9 kgf·m

180.7 lbf·ft

Torque for the mainbearing cap bolts

Item Tightening torque

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CHAPTER 2 DK651/751/801/901

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C34W256A

(6) Allen Head Bolts

(7) Silicon Adhesive Into Groove

Use the following procedure in order to install the mainbearing cap bolts:

1. Apply clean engine oil to the threads of the mainbearing cap bolts.

2. Put the main bearing caps in the correct positionthat is indicated by a number on the top of the mainbearing cap. Install the main bearing caps with thelocating tabs in correct alignment with the recess inthe cylinder block.

3. Evenly tighten the main bearing cap bolts.

245 N·m

24.9 kgf·m

180.7 lbf·ft

Torque for the mainbearing cap bolts

Item Tightening torque

Use the following procedure in order to install the Allenhead bolts for the bridge.

NOTE:

Install the rear seal before sealant is applied.

1. Use a straight edge in order to ensure that the bridgeis aligned with the rear face of the cylinder block.

16 N·m

1.6 kgf·m

11.8 lbf·ft

Torque for the Allenhead bolts

Item Tightening torque

2. Tighten the Allen head bolts (6) for the bridge.

3. When the bridge is installed on the cylinder block,apply 21826038 POWERPART Silicon Adhesive intogroove (7) at each end of the bridge. Apply the seal-ant into the groove until the sealant is forced throughthe bottom end of the groove in the bridge.

441.173 ~ 441.274 mm(17.3689 ~ 17.3729 in.)

Total height of thecylinder block betweenthe top and the bottomfaces

Item Factory spec.

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ENGINE SYSTEM

C34W257A

(8) Cylinder Block

(9) Cylinder Bore

(10) Camshaft Bearings for the Four CylinderEngine

(11) Main Bearings for the Three Cylinder Engine

(12) Main Bearing Cap Bolts for the Four Cylinderand Three Cylinder Engines

B. THREE CYLINDER

105.000 ~ 105.025 mm(4.1338 ~ 4.1348 in.)

Cylinder bore (9)

Item Factory spec.

105.5 ~ 105.525 mm(4.1535 ~ 4.1545 in.)

106.000 ~ 106.025 mm(4.1732 ~ 4.1742 in.)

0 ~ 0.15 mm(0 ~ 0.0059 in.)

The first oversize borediameter

The second oversizebore diameter

The maximum permis-sible wear for thecylinder bore

Item Factory spec.

55.563 ~ 55.593 mm(2.1875 ~ 2.1887 in.)

50.546 ~ 50.597 mm(1.9900 ~ 1.9920 in.)

50.546 ~ 50.597 mm(1.9900 ~ 1.9920 in.)

50.038 ~ 50.089 mm(1.9700 ~ 1.9720 in.)

Diameter of the bore inthe cylinder block forthe number 1 camshaftbearing (10)

Diameter of the bore inthe cylinder block forthe number 2 camshaftjournal (10)

Diameter of the bore inthe cylinder block forthe number 3 camshaftjournal (10)

Diameter of the bore inthe cylinder block forthe number 4 camshaftjournal (10)

Item Factory spec.

80.416 ~ 80.442 mm(3.1660 ~ 3.1670 in.)

Bore in the cylinderblock for the mainbearings (11)

Item Factory spec.

245 N·m

24.9 kgf·m

180.7 lbf·ft

Torque for the mainbearing cap bolts

Item Tightening torque

Use the following procedure in order to install the mainbearing cap bolts:

1. Apply clean engine oil to the threads of the mainbearing cap bolts.

2. Put the main bearing caps in the correct positionthat is indicated by a number on the top of the mainbearing cap. Install the main bearing caps with thelocating tabs in correct alignment with the recess inthe cylinder block.

3. Evenly tighten the main bearing cap bolts.

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CHAPTER 2 DK651/751/801/901

2-40

Use the following procedure in order to install the Allenhead bolts for the bridge.

NOTE:

Install the rear seal before sealant is applied.

1. Use a straight edge in order to ensure that the bridgeis aligned with the rear face of the cylinder block.

2. Tighten the Allen head bolts (13) for the bridge.

C34W258A

(13) Allen Head Bolts

(14) Silicon Adhesive Into Groove

16 N·m

1.6 kgf·m

11.8 lbf·ft

Torque for the Allenhead bolts

Item Tightening torque

3. When the bridge is installed on the cylinder block,apply 21826038 POWERPART Silicon Adhesive intogroove (14) at each end of the bridge. Apply the seal-ant into the groove until the sealant is forced throughthe bottom end of the groove in the bridge.

441.173 ~ 441.274 mm(17.3689 ~ 17.3729 in.)

Total height of thecylinder block betweenthe top and the bottomfaces

Item Factory spec.

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C34-WOO May. 2005 2-41

ENGINE SYSTEM

2.24 CRANKSHAFT

C34W259A

(1) Crankshaft for the Four Cylinder Engine

(2) Thrust Washers

(3) Crankshaft Gear

0.51 mm(0.0201 in.)

The maximum end playof the crankshaft

Item Factory spec.

2.26 ~ 2.31 mm(0.089 ~ 0.091 in.)

2.45 ~ 2.50 mm(0.097 ~ 0.098 in.)

Standard thickness (2)

Oversize thickness (2)

Item Factory spec.

NOTE:

The timing mark is toward the outside of the crank-shaft when the gear is installed on the crankshaft.

NOTE:

All new turbocharged engines and turbochargedaftercooled engines have crankshafts that arenitrocarburised. The crankshaft can also be nitridedfor 20 hours, if the nitrocarburised process is notavailable. After a crankshaft has been machined, thecrankshaft must be rehardened.

Inspect the crankshaft for cracks before machiningand after machining. Naturally aspirated engines haveinduction hardened crankshafts.

180°C(356°F)

Maximum permissibletemperature of the gearfor installation on thecrankshaft

Item Factory spec.

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CHAPTER 2 DK651/751/801/901

2-42

C34W260A

NOTE:

Refer to illustration 59 in order to use table 8.

0.25 mm (0.010 in.)

75.909 ~ 75.930 mm(2.9885 ~ 2.9894 in.)

63.220 ~ 63.240 mm(2.4890 ~ 2.4898 in.)

39.47 mm (1.5539 in.) maximum

37.44 mm (1.4740 in.) maximum

44.68 mm (1.7591 in.) maximum

40.55 mm (1.5965 in.) maximum

Do not machine this diameter.

3.68 ~ 3.96 mm(0.1449 ~ 0.1559 in.)

Number

1

2

3

4

5

6

7

8

The Undersize Diameter of the Crankshaft Journals

0.76 mm (0.030 in.)

75.399 ~ 75.420 mm(2.9685 ~ 2.9693 in.)

62.708 ~ 62.728 mm(2.4688 ~ 2.4696 in.)

N/A

N/A

N/A

N/A

N/A

N/A

0.51 mm (0.020 in.)

75.649 ~ 75.670 mm(2.9783 ~ 2.9791 in.)

62.960 ~ 62.982 mm(2.4787 ~ 2.4796 in.)

N/A

N/A

N/A

N/A

N/A

N/A

Refer to table 9 for the maximum run out of the crank-shaft journals.

0.10 mm(0.0039 in.)

The maximum differencein value between onecrankshaft journal and thenext crankshaft journal

Item Factory spec.

Mounting

0.08 mm (0.0031 in.)

0.15 mm (0.0059 in.)

0.08 mm (0.0031 in.)

Mounting

(1)

(2)

(3)

(4)

(5)

Journal Excessive run out

Refer to the Specifications Module, “Connecting RodBearing Journal” topic for more information on the con-necting rod bearing journals and connecting rod bearings.

Refer to the Specifications Module, “Main Bearing Jour-nal” topic for information on the main bearing journalsand for information on the main bearings.

A. FOUR CYLINDER

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ENGINE SYSTEM

C34W261A

B. THREE CYLINDER

0.25 mm (0.010 in.)

75.926 ~ 75.905 mm(2.9892 ~ 2.9884 in.)

63.236 ~ 63.216 mm(2.4896 ~ 2.4888 in.)

39.74 mm (1.5646 in.) maximum

44.68 mm (1.7591 in.) maximum

40.551 mm (1.5965 in.) maximum

133.17 mm (5.2429 in.)Do not machine this diameter.

3.68 ~ 3.96 mm(0.1449 ~ 0.1559 in.)

Number

1

2

3

4

5

6

7

The Undersize Diameter of the Crankshaft Journals

0.76 mm (0.030 in.)

75.418 ~ 75.397 mm(2.9692 ~ 2.9684 in.)

62.728 ~ 62.708 mm(2.4696 ~ 2.4688 in.)

N/A

N/A

N/A

N/A

N/A

0.51 mm (0.020 in.)

75.672 ~ 75.651 mm(2.9792 ~ 2.9784 in.)

62.982 ~ 62.962 mm(2.4796 ~ 2.4788 in.)

N/A

N/A

N/A

N/A

N/A

Refer to table 11 for the maximum run out of the crank-shaft journals.

0.10 mm(0.0039 in.)

The maximum differencein value between onecrankshaft journal and thenext crankshaft journal

Item Factory spec.

Mounting Dia

0.051 mm (0.0020 in.)

0.051 mm (0.0020 in.)

Mounting Dia

(1)

(2)

(3)

(4)

Journal Excessive run out

Refer to the Specifications Module, “Connecting RodBearing Journal” topic for more information on the con-necting rod bearing journals and connecting rodbearings.

Refer to the Specifications Module, “Main Bearing Jour-nal” topic for information on the main bearing journalsand for information on the main bearings.

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CHAPTER 2 DK651/751/801/901

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2.25 CRANKSHAFT SEALS

C34W262A

(1) Crankshaft (3) Crankshaft Seal

(2) Plastic Sleeve (4) Alignment Tool

Remove the alignment tool.

C34W263A

(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in thesequence that is shown in Illustration 62 tothe following torque

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten bolts 1, 2, 3, 4,5, 6, 7, and 10 in thesequence that is shownin Illustration 62 to thefollowing torque (5)

Item Tightening torque

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten bolts 8 and 9 inthe sequence that isshown in Illustration 62to the following torque

Item Tightening torque

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ENGINE SYSTEM

2.26 CONNECTING ROD BEARINGJOURNAL

Refer to the Specifications Module, “Crankshaft” topicfor information on the undersize crankshaft journals.

2.27 MAIN BEARING JOURNAL

Refer to the Specifications module, “Crankshaft” topicfor information on the undersize main bearing journals,and information on the width of main bearing journals.

63.47 ~ 63.49 mm(2.4988 ~ 2.4996 in.)

0.04 mm(0.0016 in.)

40.35 ~ 40.42 mm(1.589 ~ 1.591 in.)

3.68 ~ 3.96 mm(0.145 ~ 0.156 in.)

Ra 0.4 microns(16 µ in.)

The original size of theconnecting rod bearingjournal

Maximum permissiblewear of the connectingrod bearing journals

Width of the connectingrod bearing journals

Radius of the fillet ofthe connecting rodbearing journals

Surface finish ofconnecting rod bearingjournals and radii

Item Factory spec.

76.159 ~ 76.180 mm(2.9984 ~ 2.9992 in.)

0.040 mm(0.0016 in.)

3.68 ~ 3.69 mm(0.1448 ~ 0.1452 in.)

0.4 microns(16 µ in.)

The original size of themain bearing journal

Maximum permissiblewear of the mainbearing journals

Radius of the fillet ofthe main bearingjournals

Surface finish ofbearing journals, crankpins and radii

Item Factory spec.

A. THE SHELL FOR THE MAIN BEARINGSThe shells for the main bearings are available forremachined journals which have the following under-size dimensions.

0.25 mm(0.010 in.)

0.51 mm(0.020 in.)

0.75 mm(0.030 in.)

2.083 ~ 2.089 mm(0.0820 ~ 0.0823 in.)

31.62 ~ 31.88 mm(1.244 ~ 1.255 in.)

0.057 ~ 0.117 mm(0.0022 ~ 0.0046 in.)

Undersize bearing shell

Undersize bearing shell

Undersize bearing shell

Thickness at center ofthe shells

Width of the mainbearing shells

Clearance between thebearing shell and themain bearing journals

Item Factory spec.

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2.28 CONNECTING ROD

C34W264A

(1) Tighten the Torx Screws for the ConnectingRod to the Following Torque

(2) The Bearing shell for the connecting rod

C34W265A

18 N·m

1.8 kgf·m

13.2 lbf·ft

Tighten the torx screwsfor the connecting rod tothe following torque (1)

Item Tightening torque

The mating surfaces of the connecting rod are pro-duced by hydraulically fracturing the forged connect-ing rod.

Tighten the torx screws for the connecting rod for anadditional 120 degrees. The torx screws for the con-necting rod (1) must be replaced after this procedure.

NOTE:

Always tighten the connecting rod cap to the connect-ing rod, when the assembly is out of the engine. Tightenthe assembly to the following torque 20 N·m (2.0 kgf·m,14.7 lbf·ft).

NOTE:

The bearing shell for the connecting rod must be alignedequally from both ends of the connecting rod. Refer to(A) in figure 64. Refer to the Disassembly and assem-bly manual for information on the alignment tool.

70 N·m

7.1 kgf·m

51.6 lbf·ft

Tighten the torx screwsfor the connecting rodagain to the followingtorque

Item Tightening torque

31.62 ~ 31.88 mm(1.245 ~ 1.255 in.)

31.55 ~ 31.88 mm(1.2405 ~ 1.255 in.)

1.835 ~ 1.842 mm(0.0723 ~ 0.0725 in.)

1.835 ~ 1.842 mm(0.0722 ~ 0.0725 in.)

0.030 ~ 0.081 mm(0.0012 ~ 0.0032 in.)

Bearing Width for theconnecting rod

Bearing Width for theconnecting rod cap

Thickness of connectingrod bearing at the center

Thickness of connect-ing rod bearing for thecap at the center

Bearing clearance

0.25 mm (0.010 in.)

0.51 mm (0.020 in.)

0.76 mm (0.030 in.)

Undersized Connecting Rod Bearing

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ENGINE SYSTEM

C34W266A

(3) Diameter of the Parent Bore for the Piston Pin

(4) Distance Between the Parent Bores

(5) Diameter for the Parent Bore for the Connect-ing Rod Bearing

43.01 ~ 43.04 mm(1.693 ~ 1.694 in.)

219.05 ~ 219.10 mm(8.624 ~ 8.626 in.)

67.21 ~ 67.22 mm(2.6460 ~ 2.6465 in.)

Diameter of the parentbore for the piston pin

Distance between theparent bores

Diameter for the parentbore for the connectingrod bearing

Item Factory spec.

C34W267A

Connecting rods are color coded. The color code is areference for the length (Y) of the connecting rod. Referto table 14 for the different lengths of connecting rods.

Length (Y)

165.728 ~ 165.761 mm(6.5247 ~ 6.5260 in.)

165.682 ~ 165.715 mm(6.5229 ~ 6.5242 in.)

165.637 ~ 165.670 mm(6.5211 ~ 6.5224 in.)

165.591 ~ 165.624 mm(6.5193 ~ 6.5206 in.)

165.545 ~ 165.578 mm(6.5175 ~ 6.5188 in.)

165.499 ~ 165.532 mm(6.5157 ~ 6.4961 in.)

Grade Letter

F

G

H

J

K

L

Length Grades for Connecting Rods

Color Code

Red

Orange

White

Green

Purple

Blue

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CHAPTER 2 DK651/751/801/901

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2.29 PISTON AND RINGS

C34W268A

(1) Top Compression Ring

(2) Intermediate Compression Ring

(3) Oil Control Ring

The shape ofthe top com-pression ring

Width of the topcompression ring

Clearancebetween the topcompressionring and thepiston groove

Ring gap

The shape ofthe top com-pression ring

Width of the topcompression ring

Ring gap

Rectangular with abarrel face

2.475 ~ 2.49 mm(0.097 ~ 0.098 in.)

0.09 ~ .15 mm(0.0035 ~ 0.0059 in.)

0.30 ~ 0.55 mm(0.0118 ~ 0.0216 in.)

Keystone with abarrel face

Tapered

0.30 ~ 0.55 mm(0.0118 ~ 0.0216 in.)

Item Factory spec.

Naturallyaspirated(1)

Turbo-charged(1)

NOTE:

When you install a new top compression ring, makesure that the word “TOP” is facing the top of the piston.New top piston rings have a red identification markwhich must be on the left of the ring end gap when thetop piston ring is installed on an upright piston.

Internal step in thebottom edge with a

tapered face

2.47 ~ 2.49 mm(0.097 ~ 0.098 in.)

0.05 ~ 0.09 mm(0.002 ~ 0.003 in.)

0.70 ~ 0.95 mm(0.0275 ~ 0.0374 in.)

The shape of theintermediate compres-sion ring

Width of intermediatecompression ring

Clearance between theintermediate compres-sion ring and the pistongroove

Ring gap

Item Factory spec.

NOTE:

When you install a new intermediate compression ring,make sure that the word “TOP” is facing the top of thepiston. New intermediate rings have a green identifi-cation mark which must be on the left of the ring endgap when the top piston ring is installed on an uprightpiston.

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ENGINE SYSTEM

80 degrees

70 degrees

0.21 ~ 0.35 mm(0.008 ~ 0.014 in.)

2.58 ~ 2.60 mm(0.1016 ~ 0.1024 in.)

Tapered

2.54 ~ 2.56 mm(0.1000 ~ 0.1008 in.)

3.52 ~ 3.54 mm(0.1386 ~ 0.1394 in.)

39.694 ~ 39.700 mm(1.5628 ~ 1.5630 in.)

39.703 ~ 39.709 mm(1.5631 ~ 1.5633 in.)

The combustion bowl re-entrant angle for theturbocharged engine

The combustion bowl re-entrant angle for thenaturally aspirated engine

Piston height abovecylinder block

Width of top groove inpiston for the naturallyaspirated engine

Width of top groove in pistonfor the turbocharged engine

Width of second groove inpiston

Width of third groove inpiston

two-piece coil that isspring loaded

3.47 ~ 3.49 mm(0.1366 ~ 0.1374 in.)

0.03 ~ 0.07 mm(0.0011 ~ 0.0027 in.)

0.30 ~ 0.55 mm(0.0118 ~ 0.0216 in.)

Shape of oil control ring

Width of oil control ring

Clearance between theoil control ring and thegroove in the piston

Ring gap

Item Factory spec.

NOTE:

A pin is used in order to hold both ends of the springof the oil control ring in position. The ends of the springof the oil control ring must be installed opposite theend gap of the oil control ring.

NOTE:

Ensure that the ring end gaps of the piston rings arespaced 120 degrees from each other.

A. PISTON

NOTE:

An arrow which is marked on the piston crown mustbe toward the front of the engine.

Diameter of anew piston pin

Diameter of thebore for thepiston pin

Item Factory spec.

Pistonpin

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2.30 PISTON COOLING JET

NOTE:

The three cylinder naturally aspirated engine may haveinstalled piston cooling jets as an option.

C34W269A

(1) Installed Piston Cooling Jets

9 N·m

0.9 kgf·m

6.6 lbf·ft

The spring loaded valvemust move freely.Tighten the bolt to thefollowing torque.

Item Tightening torque

A. PISTON COOLING JET ALIGNMENTUse the following procedure in order to check the align-ment of the piston cooling jet.

1. Insert rod (3) into the end of the piston cooling jet(2). Rod (3) has a diameter of 1.70 mm (0.067 in.).Rod (3) must protrude out of the top of the cylinderblock.

2. Dimension (A) is 55.25 mm (2.1752 in.) and dimen-sion (B) is 14 mm (0.5512 in.). Dimension (A) anddimension (B) are tangent to the cylinder bore (4).

3. The position of the rod (3) must be within dimen-sion (C). Dimension (C) is 14 mm (0.5512 in.).

C34W270A

(2) Piston Cooling Jet

(3) Rod

(4) Cylinder Block

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ENGINE SYSTEM

2.31 FRONT HOUSING AND COVERS

C34W271A

22 N·m

2.2 kgf·m

16.2 lbf·ft

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the bolts thatfasten the front cover tothe front housing to thefollowing torque. (1)

Tighten the bolts thatfasten the water pumpto the front housing tothe following torque. (2)

Item Tightening torque

C34W272A

(1) Tighten the Bolts that Fasten the Front Coverto the Front Housing to the Following Torque.

(2) Tighten the Bolts that Fasten the Water Pumpto the Front Housing to the Following Torque.

+ 0.05 ~ minus 0.05 mm(+ 0.0020 ~

minus 0.0020 in.)

The front housing mustbe aligned to thecylinder block face.

Item Factory spec.

NOTE:

Refer to Specifications, “Water Pump” for the correctbolt tightening sequence for the water pump.

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95 N·m

9.7 kgf·m

70.1 lbf·ft

34.93 ~ 34.95 mm(1.3750 ~ 1.3760 in.)

34.90 ~ 34.92 mm(1.3741 ~ 1.3747 in.)

0.003 ~ 0.048 mm(0.0001 ~ 0.0019 in.)

68

44 N·m

4.5 kgf·m

32.5 lbf·ft

57.14 ~ 57.18 mm(2.2495 ~ 2.2512 in.)

72.35 ~ 72.36 mm(2.8484 ~ 2.8488 in.)

30.14 ~ 30.16 mm(1.186 ~ 1.187 in.)

50.78 ~ 50.80 mm(1.999 ~ 2.000 in.)

50.70 ~ 50.74 mm(1.9961 ~ 1.9976 in.)

49.975 ~ 49.988 mm(1.9675 ~ 1.9680 in.)

Tighten the bolt for thecamshaft gear to thefollowing torque (2)

Bore diameter of thecamshaft gear (2)

Outside diameter of thecamshaft hub (2)

Clearance between thecamshaft gear and thecamshaft hub (2)

Number of teeth (2)

Tighten the bolts for theidler gear to thefollowing torque (3)

Bore diameter of theidler gear (3)

Bore diameter of theidler gear with rollerbearings (3)

Width of idler gear andsplit bearing assembly (3)

Inside diameter of idlergear bearings withflanges (3)

Outside diameter ofidler gear hub (3)

Outside diameter ofidler gear hub withroller bearings (3)

2.32 GEAR GROUP (FRONT)

C34W273A

(1) Fuel Injection Pump Drive Gear

(2) Camshaft Gear

(3) Idler Gear and Hub

The 1104 mechanical engines use two types of fuelinjection pumps. The fuel injection pump can be eithera Delphi 210 fuel injection pump or a Bosch EPVE fuelinjection pump.

NOTE:

Refer to the Specifications Module, “Fuel injectionpump” for the locking torque for the fuel injection pumpshaft.

24 N·m

2.4 kgf·m

17.7 lbf·ft

90 N·m

9.1 kgf·m

66.4 lbf·ft

68

Tighten the nut to thefollowing torque (1)

Release the lock on thefuel injection pumpshaft. Torque the nut tothe following torque (1)

Number of teeth (1)

Item Tightening torque

Item Tightening torque

0.04 ~ 0.10 mm(0.0016 ~ 0.0039 in.)

0.10 ~ 0.20 mm(0.004 ~ 0.008 in.)

0.10 ~ 0.75 mm(0.0039 ~ 0.0295 in.)

0.38 mm(0.015 in.)

73

Clearance of idler gearbearing on hub (3)

Idler gear end play (3)

Idler gear end play withroller bearings (3)

Maximum permissibleend play (3)

Number of teeth (3)

Item Tightening torque

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ENGINE SYSTEM

C34W274A

(4) Crankshaft Gear

(5) Oil Pump Idler Gear

(6) Oil Pump Gear

47.625 ~ 47.650 mm(1.8750 ~ 1.8760 in.)

47.625 ~ 47.645 mm(1.8750 ~ 1.8758 in.)

0.020 ~ +0.020 mm(0.0008 ~ +0.0008 in.)

34

16.012 ~ 16.038 mm(0.6304 ~ 0.6314 in.)

15.966 ~ 15.984 mm(0.6286 ~ 0.6293 in.)

0.028 ~ 0.072 mm(0.0011 ~ 0.0028 in.)

0.050 ~ 0.275 mm(0.0019 ~ 0.0108 in.)

17

Bore diameter ofcrankshaft gear (4)

Outside diameter ofcrankshaft hub (4)

Clearance of gear oncrankshaft (4)

Number of teeth (4)

Inside diameter of oilpump idler gear bearing(5)

Outside diameter of oilpump idler gear shaft (5)

Clearance of oil pumpidler gear bearing onshaft (5)

End play of the oilpump idler gear (5)

The number of teeth onthe oil pump gear (6)

Item Factory spec.

Backlash betweenthe idler gear (5)and the oil pumpdrive gear (6)

Backlash betweenthe oil pump idlergear (5) and thecrankshaft gear (4)

Backlash betweenthe idler gear (3)and the crankshaftgear (4)

Backlash be-tween the cam-shaft gear (2) andthe idler gear (3)

Backlash betweenthe fuel injectionpump gear (1) andthe idler gear (3)

Backlash betweenthe water pump gear(not shown) and thefuel injection pumpgear (1)

Backlash betweenthe power take-offdrive (if equipped)and the idler gear (3)

0.046 ~ 0.106 mm(0.0018 ~ 0.0041 in.)

0.095 ~ 0.160 mm(0.0037 ~ 0.0063 in.)

0.064 ~ 0.124 mm(0.0025 ~ 0.0049 in.)

0.052 ~ 0.107 mm(0.0020 ~ 0.0042 in.)

0.054 ~ 0.109 mm(0.0021 ~ 0.0043 in.)

0.073 ~ 0.133 mm(0.0028 ~ 0.0052 in.)

0.112 ~ 0.172 mm(0.0044 ~ 0.0068 in.)

Item Factory spec.

Back-lashvalues

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CHAPTER 2 DK651/751/801/901

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A. ENGINES THAT HAVE A BALANCER

C34W275A

(7) Idler Gear for the Oil Pump that has a Bal-ancer

(8) Gear for the Oil Pump that has a Balancer

44

37.197 ~ 37.212 mm(1.4644 ~ 1.4650 in.)

37.152 ~ 37.162 mm(1.4627 ~ 1.4631 in.)

0.12 ~ 0.27 mm(0.0047 ~ 0.0106 in.)

17

0.097 ~ 0.17 mm(0.0038 ~ 0.0067 in.)

The number of teeth onthe gear (7)

The bore diameter ofthe idler gear (7)

The hub diameter forthe idler gear (7)

The end play for theidler gear (7)

The number of teeth onthe gear (8)

Backlash between theoil pump gear (8) andthe idler gear (7)

Item Factory spec.

2.33 FLYWHEEL

C34W276A

(1) Flywheel Ring Gear

(2) Flywheel

(3) Bolt

250°C(480°F)

Heat the flywheel ringgear to the followingtemperature (1)

Item Factory spec.

NOTE:

Do not use an oxyacetylene torch to heat the flywheelring gear.

105 N·m

10.7 kgf·m

77.4 lbf·ft

Tighten the flywheelbolts to the followingtorque (3)

Item Tightening torque

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ENGINE SYSTEM

2.34 FLYWHEEL HOUSING

C34W277A

(1) Bolt

A. FOUR CYLINDERTighten the bolts for the cast iron flywheel housing tothe following torque:

63 N·m

6.4 kgf·m

46.5 lbf·ft

115 N·m

11.7 kgf·m

84.8 lbf·ft

M10 “10.9”

M12 “10.9”

Item Tightening torque

B. THREE CYLINDERThe three cylinder engine is equipped with a back plate.

2.35 CRANKSHAFT PULLEY

C34W278A

(1) Tighten the Three Bolts for the CrankshaftPulley to the Following Torque

(2) Thrust Block

(3) Crankshaft Pulley

NOTE:

Lubricate the threads of the bolts with clean engine oilbefore installation.

115 N·m

11.7 kgf·m

84.8 lbf·ft

Tighten the three boltsfor the crankshaft pulleyto the following torque (1)

Item Tightening torque

NOTE:

Recheck the torque of the bolts (1) twice.

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2.36 FAN DRIVE

C34W279A

(1) Tighten the Bolts for the Fan to the FollowingTorque

22 N·m

2.2 kgf·m

16.2 lbf·ft

22 N·m

2.2 kgf·m

16.2 lbf·ft

Tighten the bolts for thefan to the followingtorque (1)

Tighten the bolts thatsecure the fan drive pulleyto the hub to the followingtorque (not shown)

Item Tightening torque

A. FAN DRIVE HOUSING

44 N·m

4.5 kgf·m

32.5 lbf·ft

61.986 ~ 62.005 mm(2.4404 ~ 2.4411 in.)

61.987 ~ 62.000 mm(2.4404 ~ 2.4409 in.)

0.014 ~ minus 0.018 mm(0.0006 ~ minus 0.0007 in.)

25.002 ~ 25.011 mm(0.9843 ~ 0.9847 in.)

0.20 mm(0.0079 in.)

Tighten the bolts thatsecure the fan drivehousing to the cylinderhead to the followingtorque (not shown)

Bearing bore for thehousing

Outer bearing diameter

Interference fit for thebearing

The outer diameter ofthe shaft

Maximum permissibleend play of the shaft

Item Factory spec.

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ENGINE SYSTEM

2.37 ENGINE LIFTING BRACKET

All engines are equipped with two engine l i f t ingbrackets.

44 N·m

4.5 kgf·m

32.5 lbf·ft

Tighten the two bolts oneach engine lifting bracketto the following torque

Item Tightening torque

2.38 GLOW PLUGS

C34W283A

(1) Tighten the Negative Terminal Nut to theFollowing Torque

(2) Nut (3) Glow Plug

18 N·m

1.8 kgf·m

13.3 lbf·ft

2 N·m

0.2 kgf·m

17.7 lbf·ft

Tighten the glow plugs(3) in the cylinder headto the following torque (1)

Tighten the nuts (2) forthe bus bar (1) that isinstalled on top of theglow plugs to thefollowing torque

Item Tightening torque

Voltage 12 or 24 volts

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C34W2S1A

A. DRAINING TRANSMISSION FLUID1. Place an empty container under the transmission.

2. Remove the drain plug (1) and drain the oi lcompletely.

3. After draining, reinstall the drain plug (1).

(Filling)1. Fill with the new fluid up to the upper line of the

gauge (2).

2. After running the engine for a few minutes, stop itand check the oil level again; add oil to prescribedlevel.

C34W2S0A60 (15.85 U.S.gal.)Oil capacity

(1) Drain Plug (3) Oil Filler Hole

(2) Gauge

(A) Oil Level is Acceptable Within this Range

3. SEPARATE THE ENGINE

• Use only Daedong genuine fluid.

• Refet to “Lubricant List” in page 1-10.

• Do not mix the oil with other products.

IMPORTANT

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ENGINE SYSTEM

C. BONNET1. Open the bonnet and disconnect the battery nega-

tive cable.

2. Remove the both side covers (LH, RH) (2).

3. Remove the bonnet wiring harness (3).

4. Unscrew the bolts and remove the bonnet support1 (4) and 2 (5).

5. Unscrew the nuts and remove the bonnet.

NOTE:

• When disconnecting the battery cables, disconnectthe negative (-) cable first, when connecting, (+)cable first.

C34W2S3A

C34W2S2A

B. DRAINING COOLANT

1. Stop the engine and let cool down.

2. Open the bonnect and remove the radiator draincock and radiator cap (2) to drain the coolant.

3. After all coolant is drained, close the drain plug.

9.1 (2.4 U.S.gal.)

18.5 (4.8 U.S.gal.)

Coolantcapacity

DK651

DK751/801/901

(Fiiling)• Fill coolant fully into the radiator, and fill it up the

point between “Full” and “Low” mark on the coolantrecovery tank.

(1) Drain Plug (2) Radiator Cap

(1) Bonnet (4) Bonnet Support 1

(2) Side Sover (LH, RH) (5) Bonnet Support 2

(3) Bonnet Wiring Harness

• Never remove the radiator cap when the engineis hot.

• Relieve any excess pressure before removing thecap completely.

WARNING

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CHAPTER 2 DK651/751/801/901

2-60

D. REMOVING MUFFLER PIPE1. Remove the nut (1) and washer from the muffler

support.

2. Unscrew the bolts from the muffler (2) and removethe muffler pipe (3).

3. Unscrew the bolts and remove the heat shield (4).

4. Remove the snap pin, plain washer, head pin andbonnet support cylinder (5).

5. Unscrew the nuts and bolts and remove the muffler(2).

C34W2S4A

C34W2S5A

DK651

DK751/801/901

(1) Nut (4) Heat Shield

(2) Muffler (5) Bonnet Support Cylinder

(3) Muffler Pipe

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ENGINE SYSTEM

F. REMOVING EXTERNAL COMPONENTS

a. Right Side1. Unclamp the hose band and remove the fuel hose

(1) and fuel feed hose (2).

2. Unclamp the hose band and remove the heater hose(3). (DK751/801/901)

3. Remove the bonnet wiring harness assembly (4).(Alternator, pressure sensor)

4. Remove the oil cooler pipe (5). (DK751/801/901)

5. Remove the sprit pin, plain washer and nut to re-move the front differential rod (6).

6. Remove the air conditioner hose (7). (DK651)

(1) Fuel Hose (5) Oil Cooler Pipe

(2) Fuel Feed Hose (6) Front Differential Rod

(3) Heater Hose (7) A/C Hose

(4) Harness Assembly

C34W2S6A

C34W2S7A

DK651E. REMOVING BONNET SUPPORT1. Unscrew the bolts and separate the right shield

plate (1) from the shield plate (5).

2. Unscrew the bolts and separate the guide plate (3)from the left shield plate (2).

3. Remove the air bleeder hose (4) from the fuel tank.

4. Unscrew the bolts and remove the fuse box (6) fromthe shield plate.

5. Unscrew the bolts and separate the left shield plate(2) from the bonnet support (5).

6. Unscrew the bolts and remove the bonnet support (5).

(1) Shield Plate (RH) (4) Air Bleeder Hose

(2) Shield Plate (LH) (5) Bonnet Support

(3) Guide Plate (6) Fuse Box

DK651

DK751/801/901

C34W2S8A

DK751/801/901

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CHAPTER 2 DK651/751/801/901

2-62

b. Left Side1. Disconnect the fuel feed hose (1).

2. Disconnect the bonnet wiring harness (2).

3. Disconnect the accelerator pedal cable (3).

4. Remove the air conditioner hose (4).

5. Unclamp the hose band and remove the sustionpipe (5) from the sustion pipe (5).

Unscrew the bolt and remove the sustion pipe.

6. Disconnect the hydraulic pipe L4 (6) and the powersteering pipe 3 (7).

7. Disconnect the power steering hoses (8) (LH, RH).

8. Unclamp the hose band and remove the heaterhoses (9) (A, B). (DK651)

9. Remove the oil cooler pipes (10) (A, D). (DK651)

Tightening torque

24.5 N·m

2.5 kgf·m

18.1 lbf·ft

34.3 N·m

3.5 kgf·m

25.3 lbf·ft

24.5 ~ 34.3 N·m

2.5 ~ 3.5 kgf·m

18.1 ~ 25.3 lbf·ft

Item

Steeringhose

A/C hose

L, R

P, T

Installing the Oil Cooler PipeRegardless of nut sizes of the bite-type connectingpipe, to properly fasten the nut, rotate the nut to thefollowing degrees after the point of drastic increase oftorque from tightening the nut on the connecting pipe.

- Min. tightening angle: 1/6 turns

- Max. tightening angle: 1/3 turns

Tightening torque

9.8 N·m

1.0 kgf·m

7.2 lbf·ft

Item

Hose band

C34W2S9A

DK651

DK751/801/901

(1) Fuel Feed Hose (6) Hydraulic Pipe (L4)

(2) Bonnet Wiring Harness (7) Steering Pipe 3

(3) Accelerator Cable (8) Steering Hose

(4) A/C Hose (9) Heater Hose

(5) Sustion Pipe (10) Oil Cooler Pipe

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ENGINE SYSTEM

G. REMOVING PROPELLER SHAFT1. Remove the bolts and slide the propeller shaft

covers.

2. Pull out the spring pin and remove the propeller shaftwith covers at a time while pushing the coupler.

(When reassembling)• Apply grease to the splines of the propeller shaft

and coupling.

C34W2T0A

H. SEPARATING ENGINE AND CLUTCHHOUSING

1. Install the hydraulic jack under the engine andclutch housing (If some front weights are installed,remove them first).

2. For safety, place the chocks at the front axlebracket and front axle support.

3. Remove the bolts and nuts to separate the clutchhousing from the engine.

(When reassembling)• Completely clean the mating surface of engine and

clutch. Apply the liquid gasket (Threebond 1208Dor equivalent) on the surface.

• Apply the heat-resistant grease to the splines ofthe PTO shaft.

C34W2T1A

Tightening torque

77.4 ~ 90.2 N·m

7.9 ~ 9.2 kgf·m

57.1 ~ 66.5 lbf·ft

Item

Bolt and nut M12(7T)

(1) Bolt

(2) Propeller Shaft Cover 1

(3) Propeller Shaft Cover 2

(4) Packing

(5) O-ring

(6) O-ring

(7) Coupling

(8) Spring Pin

(9) Front Wheel Driving Shaft 3

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CHAPTER 2 DK651/751/801/901

2-64

I. REMOVING AIR CLEANER AND RADIATOR1. Disconnect the negative (-) battery cable (1) from

the front axle frame.

2. Disconnect the positive (+) battery cable (2) fromthe battery.

3. Remove the battery (3).

4. Separate the bonnet wiring harness and the posi-tive (+) battery cable.

5. Unscrew the bolts and remove the bonnet support-ing bracket (4).

6. Remove the radiator hose (5).

7. Unscrew the bolts and remove the tensioning belt(6) and the compressor (7) from the engine.

8. Unscrew the mounting bolts and remove the radia-tor and air cleaner (8) as an assembly.

C34W2T2A

C34W2T3A

(When reassembling)• Check the O-ring for damage.

• Adjust the tension of compressor belt. (Refer to page1-30.)

C34W2T4A

(1) Battery Cable (-)

(2) Battery Cable (+)

(3) Battery

(4) Bonnet Supporting Bracket

(5) Radiator Hose

(6) Tensioning Belt

(7) Compressor

(8) Air Cleaner

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ENGINE SYSTEM

J. REMOVING ENGINE1. Support the engine with a rope.

2. Unscrew the bots and nuts from the front axle frameand engine. Carefully remove the engine.

C34W2T5A

Tightening torque

26.5 ~ 31.0 N·m

2.7 ~ 3.1 kgf·m

19.5 ~ 22.9 lbf·ft

32.0 ~ 37.0 N·m

3.2 ~ 3.7 kgf·m

23.6 ~ 27.3 lbf·ft

20.0 ~ 23.0 N·m

2.0 ~ 2.3 kgf·m

14.8 ~ 17 lbf·ft

Item

Bolt (M16, 9T)

Bolt (M16, 11T)

Nut (M16, 6T)

K. REMOVING CLUTCH1. Remove the clutch from the flywheel (3).

(When reassembling)Take care assembly direction and shorter spline boss(A) should be located toward flywheel (3) when as-sembling clutch disc (5). Take care to treat clutch disc(5) and clean each fiction surface of flywheel (3) andclutch pressure plate. After installation, make sure thatthe height between flywheel (3) surface and releasebearing is within the specified value.

• When attaching clutch cover (4) and clutch discwith flywheel (5), you should set the clutch discon the right position. And then, tight boltequally to the diagonal.

Installation Height (B) 63 ± 0.7 mm

(2.48 ± 0.028 in.)

C34W2T6A

• When removing the clutch, do not fully unscrewa bolt at a time. It may casue serious damage tothe clutch system. Evenly unscrew the bolts withscissors pattern in several steps.

• Be careful no to drop the pressure plate andclutch disc.

CAUTION

(1) Clutch Assembly (4) Clutch Cover

(2) Bolt (5) Clutch Disc

(3) Flywheel (A) Spline Boss

NOTE:• Do not allow grease and oil on the clutch disc facing.

C34W2T7A

Tightening torque

23.5 ~ 27.5 N·m

2.4 ~ 2.8 kgf·m

17.3 ~ 20.3 lbf·ft

Item

Clutchmountingscrews

M8 (7T)

IMPORTANT

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE1. Clean the external surfaces of the fuel priming pump

(4). Position the fuel priming pump (4) and installthe setscrews (1) and new rubber washers.

2. Remove the dust covers from the fuel priming pump.Remove the plugs from the tube assemblies. Connectthe tube assembly (5). Connect the tube assembly (6).

3. Connect the fuel return line to the connector (3).

4. Connect the harness assembly to the connector (2).

5. Remove the air from the fuel system. Refer to the Opera-tions and Maintenance Manual, “Fuel System - Prime”.

4. DISASSEMBLY AND ASSEMBLY

4.1 FUEL PRIMING PUMP

A. REMOVAL PROCEDURE

Start By:a. Remove the assembly of the filter case and the fuel

filter element. Refer to this Disassembly and Assem-bly Manual, “Fuel Filter Base – Remove and Install”.

NOTE:

Put identification marks on all fuel hose assembliesand on all tube assemblies for installation purposes.After being disconnected, plug all fuel hose assem-blies and plug all tube assemblies. This helps preventfluid loss, and this helps to keep contaminants fromentering the system.

C34W284A

• Keep all parts clean from contaminants.

• Contaminants may cause rapid wear and short-ened component life.

CAUTION

• Care must be taken to ensure that fluids are con-tained during performance of inspection,maintenance, testing, adjusting and repair of theproduct. Be prepared to collect the fluid with suit-able containers before opening any compartmentor disassembling any component containing fluids.

• Dispose of all fluids according to local regulationsand mandates.

CAUTION

1. Disconnect the tube assembly (5). Disconnect thetube assembly (6). Install dust covers onto the con-nectors for the fuel priming pump.

2. Disconnect the fuel return line from the connector(3). Install a dust cover to the connector (3).

3. Disconnect the harness assembly from the con-nector (2).

4. Support the fuel priming pump. Remove the threesetscrews (1) and discard the rubber washers.Remove the fuel priming pump (4).

(1) Three Setscrews (4) Fuel Priming Pump

(2) Connector (5) Tube Assembly

(3) Connector (6) Tube Assembly

NOTE:

The removal procedure is identical for four cylinderand three cylinder engines. The illustration shows thefour cylinder engine.

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ENGINE SYSTEM

4.2 FUEL FILTER BASE

A. REMOVAL PROCEDURE

NOTE:

There is an option for the three cylinder engine. Thefuel filter and the fuel priming pump can be installedonto the application rather than onto the engine. If thisis the case, refer to the appropriate OEM informationas well to this text.

NOTE:

The removal procedure is identical for the four cylin-der and the three cylinder engines. The illustrationsshow the four cylinder engine.

1. Place a suitable container below the filter in orderto collect the spilled fuel. Thoroughly clean the out-side surfaces of the fuel filter. Open the drain (1) inorder to drain the fuel from the filter.

2. Use a suitable strap wrench to loosen the filter case(2). Remove the filter case (2) from the filter head (5).

3. Push down against the spring pressure that is ap-plied to the filter element (4). Rotate the filter ele-ment (4) counterclockwise in order to release thefilter element from the filter case (2).

4. Discard the filter element (4) and the O-ring (3).

C34W285A

(1) Drain (4) Filter Element

(2) Filter Case (5) Filter Head

(3) O-ring

C34W286A

B. INSTALLATION PROCEDURE1. Thoroughly clean the inside of the filter case (2) and

thoroughly clean the lower face of the filter head (5).

2. Inspect the thread of a new filter element (4) in or-der to ensure that the thread is not damaged.

Inspect the thread of the adapter in the filter head(5) in order to ensure that the thread is not damaged.

3. Inspect the condition of the spring and ensure that thespring is correctly located within the filter case (2).

4. Install the new filter element (4) into the filter case(2). Push the filter element against the spring pres-sure and rotate the filter element in a clockwise di-rection in order to secure the filter element withinthe filter case (2).

5. Lightly lubricate a new O-ring (3) with clean fuel oil.Install the new O-ring (3) into the recess within thefilter case (2).

6. Close the drain (1).

7. Remove the air from the fuel system. Refer to theOperations and Maintenance Manual, “Fuel System- Prime”. Remove the suitable container and dis-pose of the fuel that has drained as waste.

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE1. Inspect the fuel injection lines (1) for wear and for

damage. Replace any fuel injection line (1) that isworn or any fuel injection line that is damaged.

2. Loosely install the clamps for the fuel injection lines (1).

3. Remove the dust caps from the fuel injection pump(3) and from the fuel injectors (2). Remove the dustcaps from the fuel injection lines (1).

4. Loosely connect the nuts at both ends of the fuelinjection lines (1).

5. Ensure that each fuel injection line (1) does not con-tact any other fuel injection line or any other enginecomponent. Tighten the fasteners for the clamps forthe fuel injection lines (1). Check that the fuel injec-tion lines (1) are still clear of other components.

6. Tighten the fuel injection lines (1) at the fuel injec-tors (2) to a torque of 30 N·m (3.0 kgf·m, 22.1 lbf·ft).

7. Tighten the fuel injection lines (1) at the fuel injec-tion pump (3) to 30 N·m (3.0 kgf·m, 22.1 lbf·ft).

8. Remove the air from the fuel system. Refer to theOperations and Maintenance Manual, “Fuel System- Prime”.

End By:a. Install the cover for the fuel injectors. Refer to this

Disassembly and Assembly Manual, “Fuel InjectorCover - Remove and Install”.

4.3 FUEL INJECTION LINES

A. REMOVAL PROCEDURE

Start By:a. Remove the cover for the fuel injectors. Refer to this

Disassembly and Assembly Manual, “Fuel InjectorCover - Remove and Install”.

1. Disconnect the fuel injection lines (1) at the fuelinjectors (2).

2. Disconnect the fuel injection lines (1) at the fuelinjection pump (3).

3. If it is necessary remove the clamps for the fuelinjection lines or loosen the clamps for the fuel in-jection lines. Remove the fuel injection lines (1).

4. Install dust caps onto the ports of the fuel injectorsand onto the ports of the fuel injection pump. Installdust caps onto both ends of the fuel injection lines.

(1) Fuel Injection Lines

(2) Fuel Injectors

(3) Fuel Injection Pump

C34W287A

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ENGINE SYSTEM

(1) Cover (2) Setscrews

C34W288A

4.4 FUEL INJECTOR COVER

A. REMOVAL PROCEDURE1. Thoroughly clean all of the outer surfaces of the

cover (1) for the fuel injectors.

2. Remove the setscrews (2) from the cover (1).

3. Remove the cover (1).

B. INSTALLATION PROCEDURE1. Thoroughly clean all of the inner surfaces of the

cover (1) for the fuel injectors.

2. Install the cover (1).

3. Install the setscrews (2) for the cover (1). Tightenthe setscrews (2) to a torque of 9 N·m (0.9 kgf·m,6.6 lbf·ft).

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CHAPTER 2 DK651/751/801/901

4.5 FUEL INJECTION PUMP / DELPHIDP210

A. REMOVAL PROCEDURE

Start By:a. Remove the fuel injection lines. Refer to this Dis-

assembly and Assembly Manual, “Fuel InjectionLines - Remove”.

b. Remove the crankshaft pulley. Refer to this Disas-sembly and Assembly Manual, “Crankshaft Pulley -Remove and Install”.

c. Remove the front cover. Refer to this Disassemblyand Assembly Manual, “Front Cover – Remove andInstall”.

1. Ensure that the No. 1 cylinder is at top dead centeron the compression stroke. Refer to the Testing andAdjusting Manual, “Finding Top Center Position forNo. 1 Piston”.

2. Loosen the locking screw (5). Rotate the spacer(6) in order to allow the locking screw (5) to tightenagainst the shaft of the fuel injection pump. Rotatethe fuel injection pump gear in a counterclockwisedirection in order to remove the backlash. Tightenthe locking screw (5) to a torque of 17 N·m (1.7kgf·m, 12.5 lbf·ft).

NOTE:

The locking screw (5) must be tightened in order toprevent the shaft of the fuel injection pump fromrotating. The shaft of the fuel injection pump must notbe rotated after the fuel injection pump has been re-moved from the engine.

NOTE:

Put identification marks on all fuel hose assembliesand on all tube assemblies for installation purposes.After being disconnected, plug all fuel hose assem-blies and plug all tube assemblies with suitable plas-tic plugs. Also install dust caps on all of the connec-tors on the fuel injection pump. This helps prevent fluidloss, and this helps to keep contaminants from enter-ing the system.

3. Disconnect the fuel return line (1). Disconnect thetube assembly (4) from the fuel injection pump.

4. Disconnect the fuel line (3).

5. Disconnect the harness assembly (2) from the tim-ing advance solenoid (7).

C34W289A

(1) Fuel Return Line

(2) Harness Assembly

(3) Fuel Line

(4) Tube Assembly

(5) Locking Screw

(6) Spacer

(7) Timing Advance Solenoid

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ENGINE SYSTEM

6. Remove the nut (8) and the washer from the shaftof the fuel injection pump.

7. Use a suitable puller in order to remove the fuelinjection pump gear (9).

NOTE:

Do not pry the fuel injection pump gear (9) from theshaft of the fuel injection pump.

C34W290A

(10) O-ring (13) Setscrew

(11) Bracke (14) Nut

(12) Bolt (15) Setscrew

C34W291A

8. Remove the nut (14). Remove the bolt (12).

9. If necessary, remove the setscrew (15) and thebracket (11) from the cylinder block.

10. Remove the setscrews (13) in order to remove thefuel injection pump.

11. Remove the fuel injection pump from the fronthousing. Remove the O-ring (10) and discard theO-ring from the fuel injection pump.

(8) Nut

(9) Fuel Injection Pump Gear

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CHAPTER 2 DK651/751/801/901

C34W291A

(10) O-ring (13) Setscrews

(11) Bracket (14) Nut

(12) Bolt (15) Setscrew

B. INSTALLATION PROCEDURE

NOTE:

The shaft of the fuel injection pump must remain lockeduntil the timing gear (9) has been installed and tight-ened onto the shaft of the fuel injection pump. Thelocking screw (5) must remain locked until you areinstructed to loosen the locking screw. The fuel injec-tion pump must be returned to your Perkins Dealer ifthe shaft of the fuel injection pump was rotatedaccidentally.

1. Ensure that the No. 1 cylinder is at top dead cen-ter on the compression stroke. Refer to the Testingand Adjusting Manual, “Fuel Injection Timing -Check”.

NOTE:

Do not lubricate the new O-ring (10). The O-ring shouldbe installed dry.

2. Install the new O-ring (10) onto the fuel injection pump.Position the fuel injection pump onto the front housing.Install the setscrews (13). Tighten the setscrews (13)to a torque of 25 N·m (2.5 kgf·m, 18.4 lbf·ft).

3. Install the setscrew (15) and the bracket (11) ontothe cylinder block if the bracket was previouslyremoved. Ensure that the bracket (11) supports thefuel injection pump without applying any other exter-nal force on the fuel injection pump. Tighten the set-screw (15) to a torque of 44 N·m (4.5 kgf·m, 32.5 lbf·ft).

4. Install the bolt (12) and the nut (14).

NOTE:

Ensure that the mating surfaces of the fuel injectionpump gear and the shaft of the fuel injection pump areclean. Lubricate the threads of the shaft for the fuelinjection pump. The nut (8) must turn freely until con-tact is made with the fuel injection pump gear.

5. Position the fuel injection pump gear (9) onto theshaft of the fuel injection pump. Install the washerand the nut (8). Rotate the fuel injection pump gear(9) in a counterclockwise direction in order to re-move the backlash. Tighten the nut (8) to a torque of24 N·m (2.4 kgf·m, 17.7 lbf·ft).

C34W290A

(8) Nut

(9) Fuel Injection Pump Gear

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ENGINE SYSTEM

C34W289A

(1) Fuel Return Line

(2) Harness Assembly

(3) Fuel Line

(4) Tube Assembly

(5) Locking Screw

(6) Spacer

(7) Timing Advance Solenoid

6. Connect the harness assembly to the timing ad-vance solenoid (7).

7. Connect the harness assembly (2).

8. Remove all of the dust caps from the connectorson the fuel injection pump. Remove all of the plugsfrom the fuel hose assemblies and from the tubeassemblies.

9. Connect the fuel line (3), the fuel return line (1),and the tube assembly (4) to the fuel injectionpump.

10. Loosen the locking screw (5). Move the spacer(6) in order to prevent the locking screw (5) fromtightening against the shaft of the fuel injectionpump. Tighten the locking screw (5) to a torque of12 N·m (1.2 kgf·m, 8.9 Ibf.ft).

NOTE:

The spacer (6) must be correctly positioned and lock-ing screw (5) must be tightened in order to prevent thelocking screw from contacting the shaft of the fuelinjection pump.

C34W290A

(8) Nut

(9) Fuel Injection Pump Gear

11. Tighten the nut (8) to a torque of 88 N·m (8.9kgf·m, 64.9 lbf·ft).

End By:a. Install the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover – Remove andInstall”.

b. Install the crankshaft pulley. Refer to this Disas-sembly and Assembly Manual, “Crankshaft Pulley -Remove and Install”.

c. Install the fuel injection lines. Refer to this Disas-sembly and Assembly Manual, “Fuel Injection Lines- Install”.

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CHAPTER 2 DK651/751/801/901

4.6 FUEL INJECTION PUMP / BOSCHEPVE

A. REMOVAL PROCEDURE

Start By:a. Remove the fuel injection lines. Refer to this Dis-

assembly and Assembly Manual, “Fuel InjectionLines - Remove and Install”.

b. Remove the crankshaft pulley. Refer to this Disas-sembly and Assembly Manual, “Crankshaft Pulley- Remove and Install”.

c. Remove the front cover. Refer to this Disassemblyand Assembly Manual, “Front Cover - Remove andInstall”.

NOTE:

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Ensure that the No. 1 cylinder is at top dead cen-ter on the compression stroke. Refer to the Testingand Adjusting Manual, “Finding Top Center Posi-tion for No. 1 Piston”.

NOTE:

Put identification marks on all fuel hose assembliesand on all tube assemblies for installation purposes.After being disconnected, plug all fuel hose assem-blies and plug all tube assemblies with suitable plas-tic plugs. Also install dust caps on all of the connec-tors on the fuel injection pump. This helps prevent fluidloss, and this helps to keep contaminants from enter-ing the system.

2. Disconnect the tube assembly (1) from the fuel in-jection pump. Disconnect the tube assembly (2)from the fuel injection pump.

3. Disconnect the wiring harness assembly from the coldstart advance unit (3). Disconnect the wiring harnessassembly from the engine shutoff solenoid (4).

C34W2Q4A

(1) Tube Assembly

(2) Tube Assembly

(3) Cold Start Advance Unit

(4) Engine Shutoff Solenoid

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ENGINE SYSTEM

C34W2Q5A

(5) Spacer (6) Locking Screw

4. Loosen the locking screw (6). Move the spacer(5) in order to allow the locking screw (6) to tightenagainst the shaft of the fuel injection pump. Ro-tate the fuel injection pump gear in a counterclock-wise direction in order to remove the backlash.Tighten the locking screw (6) to a torque of 31N·m (3.1 kgf·m, 22.9 lbf·ft).

NOTE:

The locking screw (6) must be tightened in order toprevent the shaft of the fuel injection pump fromrotating. The shaft of the fuel injection pump must notbe rotated after the fuel injection pump has been re-moved from the engine.

C34W2Q6A

(7) Nut

(8) Fuel Injection Pump Gear

5. Remove the nut (7) and the washer from the shaftof the fuel injection pump.

6. Use a suitable puller in order to remove the fuelinjection pump gear (8).

NOTE:

Do not pry the fuel injection pump gear from the shaftof the fuel injection pump.

C34W2Q7A

(9) O-ring (12) Setscrews

(10) Bracket (13) Nut

(11) Bolt

7. Remove the nut (13). Remove the bolt (11).

8. If necessary, remove the setscrew and the bracket(10) from the cylinder block.

9. Remove the setscrews (12) in order to remove thefuel injection pump.

10. Remove the fuel injection pump from the fronthousing. Remove the O-ring (9) from the fuel in-jection pump and discard the O-ring.

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

NOTE:

The shaft of the fuel injection pump must remain lockeduntil the timing gear (8) has been installed and tight-ened onto the shaft of the fuel injection pump. Thelocking screw (6) must remain locked until you areinstructed to loosen the locking screw. The BoschEPVE fuel injection pump can be timed to the engineby a technician. Refer to the Testing and AdjustingManual, “Fuel Injection Pump Timing - Check and FuelInjection Pump Timing - Adjust” if the shaft of the fuelinjection pump was rotated accidentally.

NOTE:

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Ensure that the No. 1 cylinder is at top dead cen-ter on the compression stroke. Refer to the Testingand Adjusting Manual, “Fuel Injection Timing -Check”.

2. Lightly lubricate a new O-ring (9) with Perkins 1766-501 Silicone Fluid MS200/1000. Install the new O-ring (9) onto the fuel injection pump.

Position the fuel injection pump on the front housing.Install the setscrews (12). Tighten the setscrews toa torque of 25 N·m (2.5 kgf·m, 18.4 lbf·ft).

3. Install the setscrew and the bracket (10) onto thecylinder block if the bracket was previously removed.Ensure that the bracket (10) supports the fuel in-jection pump without applying any other externalforce on the fuel injection pump. Tighten the set-screw to a torque of 44 N·m (4.5 kgf·m, 32.5 lbf·ft).

4. Install the bolt (11) and the nut (13).

NOTE:

Ensure that the mating surfaces of the fuel injectionpump gear (8) and the shaft of the fuel injection pumpare clean. Lubricate the threads of the shaft for thefuel injection pump. The nut (7) must turn freely untilcontact is made with the fuel injection pump gear (8).

5. Position the fuel injection pump gear (8) onto theshaft of the fuel injection pump. Install the washerand the nut (7). Rotate the fuel injection pump gear(8) in a counterclockwise direction in order to re-move the backlash. Tighten the nut (7) to a torqueof 24 N·m (2.4 kgf·m, 17.7 lbf·ft).

C34W2Q8A

(9) O-ring (12) Setscrews

(10) Bracket (13) Nut

(11) Bolt

C34W2Q9A

(7) Nut

(8) Fuel Injection Pump Gear

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ENGINE SYSTEM

C34W2R0A

(1) Tube AssemblyUnit

(2) Tube Assembly

(3) Cold Start Advance

(4) Shutoff Solenoid

6. Connect the wiring harness assembly to the en-gine shutoff solenoid (4).

7. Connect the wiring harness assembly to the coldstart advance unit (3).

8. Remove all of the dust caps from the connectorson the fuel injection pump. Remove all of the plugsfrom the fuel hose assemblies and from the tubeassemblies.

9. Connect the tube assembly (2) to the fuel injec-tion pump. Connect the tube assembly (1) to thefuel injection pump.

C34W2R1A

(5) Spacer (6) Locking Screw

10. Loosen the locking screw (6). Move spacer (5) inorder to prevent the locking screw (6) from tight-ening against the shaft of the fuel injection pump.Tighten the locking screw (6) to a torque of 12N·m (1.2 kgf·m, 8.9 Ibf.ft).

NOTE:

The spacer (5) must be installed and the locking screw(6) must be tightened in order to prevent the lockingscrew from contacting the shaft of the fuel injectionpump.

C34W2R2A

(7) Nut

(8) Fuel Injection Pump Gear

11. Tighten the nut (7) to a torque of 88 N·m (8.9 kgf·m,64.9 Ibf.ft).

End By:a. Install the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover - Remove andInstall”.

b. Install the crankshaft pulley. Refer to this Disas-sembly and Assembly Manual, “Crankshaft Pulley- Remove and Install”.

c. Install the fuel injection lines. Refer to this Disas-sembly and Assembly Manual, “Fuel Injection Lines- Install”.

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE1. Lubricate the seat washer (6) with clean engine oil.

Install a new seat washer (6) in the cylinder head.

NOTE:

If the original seat washer (6) is reused, the projectionof the fuel injector (1) will be incorrect.

2. Install a new O-ring seal (5) on fuel injector (1).Install the fuel injector (1) in the cylinder head.

NOTE:

Alignment Pin (7) must be located opposite clamp (4).

3. Position clamp (4) on the fuel injector (1). Installsetscrew (3). Tighten the setscrew to a torque of27 N·m (2.7 kgf·m, 19.9 lbf·ft).

4. Install hose (2) to the fuel injector (1).

End By:a. Install the fuel injection lines. Refer to this Disas-

sembly and Assembly, “Fuel Injection Lines - Install”.

b. Install the cover for the fuel injectors. Refer to thisDisassembly and Assembly Manual, “Fuel InjectorCover - Remove and Install”.

C34W292A

(1) Fuel Injector (4) Clamp

(2) Fuel Hose (5) O-ring Seal

(3) Setscrew (6) Seat Washer

4.7 FUEL INJECTOR

A. REMOVAL PROCEDURE

Start By:a. Remove the cover for the fuel injectors. Refer to

this Disassembly and Assembly Manual, “Fuel In-jector Cover - Remove and Install”.

b. Remove the fuel injection lines. Refer to this Dis-assembly and Assembly, “Fuel Injection Lines -Remove”.

1. Disconnect the tube assemblies from the fuel filterbase for the fuel inlet and the fuel outlet.

2. Remove the fuel hose (2) from the fuel injector (1).

3. Remove the setscrew (3). Remove the clamp (4)from the fuel injector (1).

4. Remove the fuel injector (1) from the cylinder head.Remove the O-ring seal (5) from the fuel injector (1)and discard the O-ring.

5. Remove the seat washer (6) from the cylinder headand discard the seat washer.

NOTE:

If the original seat washer is not removed, the projec-tion of the fuel injector will be incorrect when a newseat washer is installed.

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ENGINE SYSTEM

C34W293A

(1) Turbocharger (3) Setscrew

(2) Nuts (16) Wastegate

4.8 TURBOCHARGER

A. REMOVAL PROCEDURE1. Thoroughly clean the outer surfaces of the turbo-

charger (1).

2. Loosen the hose clamps and remove the air inlethose at the turbocharger compressor housing.

NOTE:

Exhaust elbows are only an option for the four cylinderengines.

3. Remove the exhaust pipe from the turbochargeroutlet or remove the exhaust pipe from the ex-haust elbow. Refer to the OEM provided informa-tion for the correct procedure in order to removethe exhaust pipe.

4. If an exhaust elbow is installed, remove the ex-haust elbow. Refer to this Disassembly and As-sembly Manual, “Exhaust Elbow – Remove andInstall”.

5. Remove the nuts (2) and remove the exhaustadapter (3) from the turbocharger (1).

6. Place a suitable container below the turbocharger(1) in order to collect any spillage of oil.

7. Remove the banjo bolts (5). Remove the oil sup-ply tube assembly (6) and the washers (7) fromthe turbocharger (1). Discard the washers (7).If necessary, remove the oil supply tube assem-bly (6) from the cylinder block and discard thewashers.

8. Remove the setscrews (8). Remove the oil draintube assembly (9) from the turbocharger (1).Remove the joint (10) and discard the joint.If necessary, remove the setscrews (11) and re-move the oil drain tube assembly (9) from the cyl-inder block. Discard the joint.

9. If necessary, remove the studs (12) from the tur-bocharger housing.

NOTE:

Do not use the actuator rod of the wastegate (16) tolift the turbocharger (1).

10. Remove the nuts (13). Remove the turbocharger(1). Remove the gasket (14). Discard the gasket(14). If necessary, remove the studs (15) from theexhaust manifold.

11. Install suitable plastic plugs into the oil supplyand into the oil drain ports of the turbocharger (1).Install suitable plastic covers to the inlet and tothe outlet of the turbocharger (1). Install suitableplastic plugs to the oil supply tube assembly (6)and to the oil drain tube assembly (9). Install suit-able plastic covers to the manifold ports.

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CHAPTER 2 DK651/751/801/901

C. INSTALLATION PROCEDURE

NOTE:

The installation procedure is identical for the threecylinder and the four cylinder engines.

1. Remove all of the plastic plugs from all of the portsof the turbocharger (1). Clean the mating surfacesof the exhaust manifold and the turbocharger.Clean the mating surfaces of the turbocharger tothe oil supply tube assembly (6) and the turbo-charger to the oil drain tube assembly (9).

2. Ensure that all of the turbocharger inlet and outletports are clean and free from restrictions. The tur-bocharger shaft must rotate freely.

3. If the studs (15) were previously removed, installthe studs into the exhaust manifold. Install a newgasket (14) over the studs (15).

NOTE:

Do not use any sealant on the gasket (14).

NOTE:

Do not use the actuator rod of the wastegate (16) tolift the turbocharger (1).

4. Position the turbocharger (1) onto the exhaustmanifold.

5. Install the nuts (13). Tighten the nuts (13) to atorque of 47 N·m (4.8 kgf·m, 34.7 lbf·ft).

6. Lubricate the bearing housing of the turbocharger(1) with clean engine oil.

7. Inspect all of the oil hose assemblies (6 and 9).

If necessary, replace the hose assemblies (6 and 9).

NOTE:

The top flange of the oil drain tube assembly (9) issecured to the turbocharger (1) with 6 mm (0.24 in.)setscrews (8). The bottom flange of the oil draintube assembly (9) is secured to the cylinder blockwith 8 mm (0.32 in.)setscrews (11).

8. Position a new joint (10) and the oil drain tubeassembly (9) onto the bottom of the turbocharger(1). Install the 6 mm (0.24 in.)setscrews (8).Tighten the 6 mm (0.24 in.)setscrews (8) to atorque of 9 N·m (0.9 kgf·m, 6.6 lbf·ft).

9. Position a new joint and the oil drain tube assem-bly (9) onto the cylinder block. Tighten the 8 mm(0.32 in.)setscrews (11) to a torque of 22 N·m(2.2 kgf·m, 16.2 lbf·ft).

10. Position the new washers (7) and the oil supplytube assembly (6) onto the turbocharger (1). In-stall the banjo bolt (5). Tighten the banjo bolt (5)to a torque of 22 N·m (2.2 kgf·m, 16.2 lbf·ft).

C34W294A

(1) Turbocharger

(5) Banjo Bolts

(6) Oil Supply Tube Assembly

(7) Washers

(8) Setscrews

(9) Oil Drain Tube Assembly

(10) Turbocharger (14) Nuts

(11) Nuts (15) Setscrew

(12) Setscrew (16) Wastegate

(13) Turbocharger

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ENGINE SYSTEM

15. Tighten the three nuts finger tight in the sequence(17), (18), and (19). Tighten the nuts (17), (18),and (19) in the same sequence to a torque of 25N·m (2.5 kgf·m, 18.4 lbf·ft).

16. Ensure that there is no restriction in the inlet hose.Position the air inlet hose on the turbocharger com-pressor housing. Install the hose clamps. Tightenthe hose clamps to a torque of 5 N·m (0.5 kgf·m,3.6 lbf·ft).

NOTE:

The air inlet hose has a reflective heat shield that par-tially covers the hose. The reflective heat shield mustbe installed toward the engine. The reflective heat shieldmust be kept clean and free from dust, oil or paint.

NOTE:

Apply a solution of water and 5% soap to the inlet of theturbocharger in order to install a new air inlet hose. Donot use oil or grease in order to install the air inlet hose.

17. Position the exhaust pipe onto the exhaust elbowor onto the turbocharger outlet (3). Refer to theOEM information for the correct procedure in or-der to install the exhaust pipe.

C34W295A

(17) Nut

(18) Nut

(19) Nut

NOTE:

Ensure that the oil supply tube assembly (6) does notcome into contact with any other component when theassembly is installed onto the engine.

11. Install the new washers and the oil supply tubeassembly (6) to the cylinder block. Tighten thebanjo bolt to a torque of 22 N·m (2.2 kgf·m, 16.2lbf·ft).

12. If the studs (12) were previously removed, installthe studs into the turbocharger housing.

13. Position the exhaust adapter (3) onto the studs(12). Install the nuts (2). Do not tighten the nuts(2) at this time.

NOTE:

Exhaust elbows are only an option for the four cylinderengines.

14. If equipped, install the exhaust elbow onto the ex-haust adapter (3). Refer to this Disassembly andAssembly Manual, “Exhaust Elbow – Remove andInstall”.

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CHAPTER 2 DK651/751/801/901

4.9 EXHAUST MANIFOLD

A. REMOVAL PROCEDURE FOR THE THREECYLINDER ENGINE

Start By:a. Remove the turbocharger, if equipped. Refer to this

Disassembly and Assembly Manual, “Turbocharger- Remove”.

C34W296A

(1) Setscrews (2) Exhaust Manifold

1. Remove the setscrews (1) in the reverse numericalorder to the Illustration 34. This will help to preventany distortion of the exhaust manifold (2).

2. Remove the exhaust manifold gasket from the cyl-inder head and remove the exhaust manifold (2).Discard the exhaust manifold gasket.

B. INSTALLATION PROCEDURE FOR THETHREE CYLINDER ENGINE

NOTE:

The improper installation of the exhaust manifold (2)can result in a cracked exhaust manifold. The set-screws (1) for the exhaust manifold must be tightenedin the correct sequence and tightened to the correcttorque.

1. Loosely install two suitable studs into the holes (5and 6) as guides.

NOTE:

Do not use any sealant on the exhaust manifold gasket.

2. Position the new exhaust manifold gasket onto thestuds in the cylinder head. Position the exhaustmanifold (2) onto the studs. Install the setscrews(1) finger tight in order to secure the exhaust mani-fold to the cylinder head.

3. Remove the two studs and install the remainingsetscrews (1). Ensure that the setscrews (1) aretightened in the sequence that is shown in Illustra-tion 35. Tighten the setscrews evenly to a torque of33 N·m (3.3 kgf·m, 24.3 lbf·ft).

End By:a. Install the turbocharger, if equipped. Refer to this

Disassembly and Assembly Manual, “Turbocharger- Install”.

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ENGINE SYSTEM

C34W297A

(1) Setscrews (2) Exhaust Manifold

C. REMOVAL PROCEDURE FOR THE FOURCYLINDER ENGINE

Start By:a. Remove the turbocharger, if equipped. Refer to this

Disassembly and Assembly Manual, “Turbocharger- Remove”.

1. Remove the setscrews (1) in the reverse numericalorder to the Illustration 36. This will help to preventany distortion of the exhaust manifold (2).

2. Remove the exhaust manifold gasket from the cyl-inder head and remove the exhaust manifold (2).Discard the exhaust manifold gasket.

D. INSTALLATION PROCEDURE FOR THEFOUR CYLINDER ENGINE

NOTE:

The improper installation of the exhaust manifold (2)can result in a cracked exhaust manifold. The set-screws (1) for the exhaust manifold must be tightenedin the correct sequence and tightened to the correcttorque.

1. Loosely install two suitable studs into the holes (5and 8) as guides.

NOTE:

Do not use any sealant on the exhaust manifoldgasket.

2. Position the new exhaust manifold gasket onto thestuds in the cylinder head. Position the exhaustmanifold (2) onto the studs. Install the setscrews(1) finger tight in order to secure the exhaust mani-fold to the cylinder head.

3. Remove the two studs and install the remainingsetscrews (1). Ensure that the setscrews (1) aretightened in the sequence that is shown in Illustra-tion 37. Tighten the setscrews evenly to a torque of33 N·m (3.3 kgf·m, 24.3 lbf·ft).

End By:a. Install the turbocharger, if equipped. Refer to this

Disassembly and Assembly Manual, “Turbocharger- Install”.

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CHAPTER 2 DK651/751/801/901

4.10 EXHAUST ELBOW (OPTION FORFOUR CYLINDER ENGINES ONLY)

A. REMOVAL PROCEDURE

Start By:a. Remove the exhaust pipe. Refer to the OEM infor-

mation for the correct procedure in order to removethe exhaust pipe.

C34W298A

(1) Setscrews (4) Bracket

(2) Exhaust Elbow (5) Exhaust Adapter

(3) Setscrews

1. Remove the setscrews (1) from the exhaust elbow(2). Remove the setscrews (3) and remove thebracket (4) from the cylinder block. Remove the ex-haust elbow (2) from the exhaust adapter (5).

B. INSTALLATION PROCEDURE1. Thoroughly clean the exhaust elbow (2) and the ex-

haust adapter (5).

2. Install the exhaust elbow (2) onto the exhaust adapter(5). Position the bracket (4) onto the cylinder blockand install the setscrews (3). Tighten the setscrews(3) finger tight. Align the exhaust elbow with thebracket (4). Install the setscrews (1) in order to se-cure the exhaust elbow (2) to the bracket (4). Tightenthe setscrews (3) and tighten the setscrews (1) to atorque of 44 N·m (4.4 kgf·m, 32.4 lbf·ft).

End By:a. Install the exhaust pipe. Refer to the OEM informa-

tion for the correct procedure in order to install theexhaust pipe.

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ENGINE SYSTEM

NOTE:

The following procedure should be adopted in order toremove the valve springs when the cylinder head isstill installed onto the cylinder block. Refer to this Dis-assembly and Assembly Manual, “Inlet and ExhaustValves - Remove and Install” for the correct procedurethat should be used to remove the valve springs froma cylinder head that has been removed from the cylin-der block.

NOTE:

Ensure that the appropriate piston is at top dead cen-ter before the valve spring is removed.Failure to ensure that the piston is at top dead centermay allow the valve to drop into the cylinder block.

1. Use the following procedure in order to find the topdead center position for the appropriate piston.

• Personal injury can result from being struck byparts propelled by a released spring force.

• Make sure to wear all necessary protectiveequipment.

• Follow the recommended procedure and use allrecommended tooling to release the spring force.

WARNING

Part Description

Valve Spring Compressor

Setscrew Adapter

Part Number

21825666

27610235

Qty

1

1

Required Tools

Start By:a. Remove the rocker shaft assembly. Refer to this

Disassembly and Assembly Manual, “Rocker Shaftand Pushrod - Remove”.

• Keep all parts clean from contaminants.

• Contaminants may cause rapid wear and short-ened component life.

CAUTION

4.11 INLET AND EXHAUST VALVESPRINGS

A. REMOVAL PROCEDURE

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CHAPTER 2 DK651/751/801/901

a. Install 21825666 Valve Spring Compressor (1) andthe appropriate 27610235 Setscrew Adapter (2) inposition on the cylinder head in order to compressthe appropriate valve spring (5).

• Ensure that the valve spring is compressedsquarely or damage to the valve stem may occur.

CAUTION

• Do not turn the crankshaft while the valvesprings are removed.

CAUTION

b. Compress the valve spring (5) sufficiently in orderto open the valve only. Do not compress the valvespring sufficiently so that the valve keepers (3) couldbe removed from the recess in the valve stem.

c. Turn the crankshaft until the piston touches the valve.

d. Continue to turn the crankshaft until the valve stemis at the highest point. The piston is now at top deadcenter. Release the applied pressure of the valvespring compressor (1) at the top center position.

C34W299A

(1) Valve Spring Compressor

(2) Setscrew Adapter

(3) Valve Keepers

(4) Valve Spring Retainer

(5) Valve Spring

2. Use the valve spring compressor (1) in order to com-press the valve spring (5). Remove the valve keep-ers (3).

3. Carefully release the pressure on the valve springcompressor (1). Remove the valve spring retainer(4) and the valve spring (5).

NOTE:

If you are replacing all of the valve springs, the proce-dure can be done on two cylinders at the same time.The procedure can be done on cylinder 1 and cylinder4, and on cylinder 2 and cylinder 3. Remember thatthe crankshaft must not be turned while the valvesprings are removed. Ensure that all of the valvesprings are installed before changing from one pair ofcylinders to the other pair of cylinders.

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ENGINE SYSTEM

1. Place the new valve spring (5) into position.

2. Install the valve spring retainer (4).

• Ensure that the valve spring is compressedsquarely or damage to the valve stem may occur.

CAUTION

3. Install the valve spring compressor (1) in positionon the cylinder head in order to compress the ap-propriate valve spring (5). Compress the valvespring (5).

4. Install the valve keepers (3).

• Do not turn the crankshaft while the valvesprings are removed.

CAUTIONC34W299A

(1) Valve Spring Compressor

(2) Setscrew Adapter

(3) Valve Keepers

(4) Valve Spring Retainer

(5) Valve Spring

5. Carefully release the pressure on the valve springcompressor (1). Remove the valve spring compres-sor (1). Ensure that all of the valves are secured inplace by a valve spring and valve keepers. Rotatethe crankshaft through about 45 degrees in order toclear the piston from the valve. Lightly strike the topof the valve with a soft hammer in order to ensurethat the valve keepers (3) are properly installed.

NOTE:

If you are replacing all of the valve springs the proce-dure can be done on two cylinders at the same time.The procedure can be done on cylinder 1 and cylinder4, and on cylinder 2 and cylinder 3.

End By:a. Install the rocker shaft assembly. Refer to this Dis-

assembly and Assembly, “Rocker Shaft andPushrod - Install”.

B. INSTALLATION PROCEDURE

Part Description

Valve Spring Compressor

Setscrew

Part Number

21825666

27610235

Qty

1

1

Required Tools

• Improper assembly of parts that are springloaded can cause bodily injury.

• To prevent possible injury, follow the estab-lished assembly procedure and wear protectiveequipment.

WARNING

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CHAPTER 2 DK651/751/801/901

• Personal injury can result from being struck byparts propelled by a released spring force.

• Make sure to wear all necessary protectiveequipment.

• Follow the recommended procedure and use allrecommended tooling to release the spring force.

WARNING

3. Install 21825666 Valve Spring Compressor (1) andthe appropriate 27610235 Setscrew Adapter (2) inposition on the cylinder head in order to compressthe appropriate valve spring (5).

C34W2A1A

4.12 INLET AND EXHAUST VALVES

A. REMOVAL PROCEDURE

Part Description

Valve Depth Gauge

Valve Spring Compressor

Setscrew Adapter

Part Number

21825496

21825666

27610235

Qty

1

1

1

Required Tools

Start By:a. Remove the cylinder head assembly. Refer to this

Disassembly and Assembly Manual, “Cylinder Head- Remove”.

NOTE:

Ensure that the machined face of the cylinder head iskept on a clean, soft surface in order to prevent dam-age to the machined surface.

1. Use a dial indicator to check the depth of the valvesbelow the face of the cylinder head before the valvesprings are removed. Refer to the illustration 42and refer to Specifications, “Cylinder Head Valves”for the correct dimensions.

NOTE:

The head of the inlet valve has a larger diameter thanthe head of the exhaust valve.

2. Place a numerical index mark on the heads of theinlet valves and on the exhaust valves so that eachvalve can be installed in the correct sequence dur-ing installation.

C34W2A0A

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ENGINE SYSTEM

• Ensure that the valve spring is compressedsquarely or damage to the valve stem may occur.

CAUTION

C34W2A2A

(1) Valve Spring Compressor

(2) Setscrew Adapter

(3) Valve Keepers (6) Valve Stem Seal

(4) Valve Spring Retainer (7) Inlet Valve

(5) Valve Spring (8) Exhaust Valve

4. Compress the valve spring (5).

5. Remove the valve keepers (3).

6. Carefully release the pressure on the valve springcompressor (1). Remove the valve spring compres-sor (1) and the setscrew adapter (2) from the cyl-inder head.

7. Remove the valve spring retainer (4).

8. Remove the valve spring (5).

9. Remove the valve stem seal (6). Discard the valvestem seal (6).

10. Remove the appropriate valve (7 or 8).

11. Repeat Step 3 to Step 10 for each inlet valve (7)and for each exhaust valve (8).

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CHAPTER 2 DK651/751/801/901

1. Carefully clean the bottom face of the cylinder head.Ensure that there is no debris in the inlet and ex-haust ports. Also ensure that there is no debris inthe coolant passages and in lubrication passages.Inspect the cylinder head. Refer to the Testing andAdjusting Manual, “Cylinder Head Inspect” for fur-ther information.

2. Inspect all of the valve seats for wear and fordamage. Refer to the Specifications Manual, “Cyl-inder Head Valves” for further information. Also re-fer to this Disassembly and Assembly Manual, “In-let and Exhaust Valve Seat Inserts - Remove andInstall” and refer to Testing and Adjusting Manual,“Valve Depth - Inspect ” for further information. Re-place any worn parts.

3. Inspect all of the valve guides for wear and fordamage. Refer to the Specifications Manual, “Cyl-inder Head Valves” for further information. Also re-fer to this Disassembly and Assembly Manual, “In-let and Exhaust Valve Guides - Remove and Install”and refer to Testing and Adjusting Manual, “ValveGuide - Inspect” for further information. Replace anyworn parts.

4. Inspect the valves if the valves are not replacementparts. Refer to the Specifications Manual, “CylinderHead Valves” for further information.

5. Lubricate the stems of all of the inlet valves (7) andlubricate the stems of all of the exhaust valves (8)with clean engine oil. Install the inlet valves (7) andthe exhaust valves (8) in the appropriate positions.

6. Carefully turn over the cylinder head and ensurethat all of the valves remain in place. Place the ma-chined surface of the cylinder head onto a clean,soft surface. Note: The valve guides must be cleanand dry before installing the valve stem seals (6).

NOTE:

The valve guides must be clean and dry before install-ing the valve stem seals (6).

Part Description

Valve Spring Compressor

Setscrew Adapter

Valve Depth Gauge

Part Number

21825666

27610235

21825496

Qty

1

1

1

Required Tools

B. INSTALLATION PROCEDURE

11. Install 21825666 Valve Spring Compressor (1) andthe appropriate 27610235 Setscrew Adapter (2) inposition on the cylinder head in order to compressthe appropriate valve spring (5).

12. Install the valve keepers (3).

13. Carefully release the pressure on the valve springcompressor (1). Remove the valve spring compres-sor (1) and the setscrew adapter (2) from the cyl-inder head. Gently strike the top of the appropri-ate valves with a soft hammer in order to ensurethat the valve keepers (3) are properly installed.

14. Repeat Step 11 to Step 13 for all of the valves (7and 8).

15. Turn over the cylinder head. Use a dial indicatorto check the depth of the new valves below theface of the cylinder head. Refer to Illustration 42and refer to the Specifications Manual, “CylinderHead Valves” for more information on the inletvalves and the exhaust valves. If the depth of thenew valves is below the correct depth, the valveseat inserts must be replaced. Refer to this Dis-assembly and Assembly Manual, “Inlet and Ex-haust Valve Seat Inserts - Remove and Install”.

End By:a. Install the cylinder head assembly. Refer to this

Disassembly and Assembly Manual, “CylinderHead - Install”.

• Personal injury can result from being struck byparts propelled by a released spring force.

• Make sure to wear all necessary protectiveequipment.

• Follow the recommended procedure and use allrecommended tooling to release the spring force.

WARNING

• Ensure that the valve spring is compressedsquarely or damage to the valve stem may occur.

CAUTION

7. Install a new valve stem seal (6) onto each of thevalve guides.

8. Inspect the valve springs (5) for wear and for thecorrect installed length. Refer to the SpecificationsManual, “Cylinder Head Valves” for further infor-mation on the correct installed length of the valvesprings (5). Replace any worn parts.

9. Install the valve springs (5) onto the cylinder head.

10. Install the valve spring retainers (4).

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ENGINE SYSTEM

4.13 INLET AND EXHAUST VALVEGUIDES

A. REMOVAL PROCEDURE

Part Description

Valve Guide Remover/Replacer

Valve Guide Adapter

Part Number

21825478

21825479

Qty

1

1

Required Tools

Start By:a. Remove the cylinder head. Refer to this Disassem-

bly and Assembly Manual, “Cyl inder Head -Remove”.

b. Remove the inlet valves and the exhaust valves.Refer to this Disassembly and Assembly Manual,“Inlet and Exhaust Valves - Remove and Install”.

1. Install the 21825479 Valve Guide Adapter (1) intothe 21825478 Valve Guide Remover/Replacer (2).

2. Place the spacer (3) into the appropriate valve seat.

3. Pass the adapter (1) through the valve guide (4)and install the valve guide remover/replacer (2) ontothe spacer (3).

4. Install the attachment (5) in order to secure theadapter (1) to the valve guide (4).

5. Hold the top handle (6) and turn the bottom handle(7) counterclockwise in order to push the valve guide(4) from the cylinder head.

6. Repeat Step 2 to Step 5 in order to extract eachappropriate valve guide (4).

7. Discard all of the valve guides (4) that were removedfrom the cylinder head.

NOTE:

When new valve guides are installed, new valves andnew valve seat inserts must be installed.

8. Remove the valve seat inserts. Refer to this Disas-sembly and Assembly Manual, “Inlet and ExhaustValve Seat Inserts - Remove and Install”.

C34W2A3A

(1) Valve Guide Adaptor

(2) Valve Guide Remover/Replacer

(3) Spacer

(4) Valve Guide

(5) Valve Spring

(6) Top Handle

(7) Bottom Handle

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

Part Description

Valve Guide Remover/Replacer

Valve Guide Adapter

Part Number

21825478

27610234

Qty

1

1

Required Tools

1. Clean the parent bores in the cylinder head for allof the appropriate valve guides (4).

2. Install the 27610234 Valve Guide Adaptor (8) intothe 21825478 Valve Guide Remover/Replacer (2).

3. Install the spacer (3) into the appropriate valve seat.

4. Lubricate the outer surface of a new valve guide (4)with clean engine lubricating oil. Pass the adapter(8) through the parent bore for the valve guide (4)and position the valve guide remover/replacer (2)onto the spacer (3).

5. Install the adapter (10) beneath the valve guide (4).Install the attachment (5) in order to secure theadapter (10) to the valve guide (4).

NOTE:

The valve guide (4) should protrude above the cylinderhead. Ensure that the protrusion (9) is within limits.

6. Hold the top handle (6) and turn the bottom handle(7) clockwise in order to pull the valve guide (4) intothe cylinder head. Continue to pull the valve guide(4) into the cylinder head until the correct amountof protrusion (9) is reached. The valve guides shouldprotrude 12.35 ~ 12.65 mm (0.4862 ~ 0.4980 in.)above the valve spring recess.

7. Repeat the Step 3 to Step 6 in order to install eachappropriate valve guide.

NOTE:

The parent bores of the valve guides must be reamedto the correct size after the valve guides have beeninstalled into the cylinder head. Also, the valve insertsmust be inserted and the seat faces must be cut tothe correct angle. The same tool is used to finish bothcomponents.

8. Instal l the valve seat inserts and f inish bothcomponents. Refer to this Disassembly and As-sembly Manual, “Inlet and Exhaust Valve Seat In-serts - Remove and Install”.

End By:a. Install the inlet valves and the exhaust valves. Re-

fer to this Disassembly and Assembly Manual, “In-let and Exhaust Valves - Remove and Install”.

C34W2A4A

(2) Valve Guide Remover/Replacer

(3) Spacer

(4) Valve Guide

(5) Valve Spring

(6) Top Handle

(7) Bottom Handle

(8) Valve Guide Adaptor

(9) Protrusion

(10) Adapter

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ENGINE SYSTEM

4.14 INLET AND EXHAUST VALVESEAT INSERTS

A. REMOVAL PROCEDURE

Start By:a. Remove the inlet valves and the exhaust valves.

Refer to this Disassembly and Assembly Manual,“Inlet and Exhaust Valves - Remove and Install”.

NOTE:

When new valve seat inserts are installed, new valvesand new valve guides must be installed.

1. Remove the appropriate valve guides. Install par-tially finished valve guides. Refer to this Disassem-bly and Assembly Manual, “Inlet and Exhaust ValveGuides - Remove and Install”.

NOTE:

The inserts for the inlet valves are a larger diameterthan the exhaust valve inserts.

2. Use the partially finished bore of the valve guide asa pilot bore in order to remove the valve insert bymachining. Also use the partially finished bore ofthe valve guide as a pilot bore in order to machine arecess for a new valve seat. Refer to the Specifica-tions Manual, “Cylinder Head Valves” for the requireddimensions of the recess for the valve seat. Re-move all debris from the cylinder head ports andpassages.

3. Repeat the Step 2 for all of the appropriate valveseats.

Part Description

Valve Guide/Valve SeatReamer/Cutter

Part Number

27610030

Qty

1

Required Tools

B. INSTALLATION PROCEDURE

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CHAPTER 2 DK651/751/801/901

NOTE:

If the cylinder head has been previously ground thenthe bottom face of valve seat must be ground in orderto ensure that the valve seat will be installed correctlyinto the cylinder head.

A 30 degree chamfer must be machined to the outeredge of the valve seat after the back face of the valveinsert has been ground to the correct dimensions.The 30 degree chamfer must be within the toleranceof 0.91 ~ 1.3 mm (0.036 ~ 0.051 in.). Also, the cham-fer must be inclined to the vertical face of the valveinsert.

NOTE:

Do not use a hammer in order to install the valve in-sert into the machined recess in the cylinder head.

NOTE:

Do not apply any lubricant before the new valve seatinsert is installed into the cylinder head.

1. Use a suitable tool to install the valve seat insertinto the machined recess in the cylinder head.

2. If necessary, a suitable tool can be manufactured.Refer to the illustration 49. Also refer to the table 8and refer to the table 9 for suitable dimensions.

C34W2A5A

Dimension

1.5 mm (0.06 in.)

20 mm (0.80 in.)

6.8 ~ 7.1 mm (0.268 ~ 0.279 in.)

100 mm (3.94 in.)

38.1 ~ 38.3 mm (1.500 ~ 1.508 in.)

46.25 ~ 46.5 mm (1.82 ~ 1.83 in.)

Maximum radius 1.4 mm (0.055 in.)

Maximum radius 1.5 mm (0.06 in.)

1.5 mm (0.06 in.)

8.77 ~ 8.80 mm (0.345 ~ 0.346 in.)

Callout

1

2

3

4

5

6

7

8

9

10

Tool for the Inlet Valve Seat Inserts

Dimension

1.5 mm (0.06 in.)

20 mm (0.80 in.)

7.2 ~ 7.5 mm (0.283 ~ 0.295 in.)

100 mm (3.94 in.)

34.38 ~ 34.58 mm (1.353 ~ 1.361 in.)

41.75 ~ 42.00 mm (1.643 ~ 1.653 in.)

Maximum radius 1.4 mm (0.055 in.)

Maximum radius 1.5 mm (0.06 in.)

1.5 mm (0.06 in.)

8.77 ~ 8.80 mm (0.345 ~ 0.346 in.)

Callout

1

2

3

4

5

6

7

8

9

10

Tool for the Exhaust Valve Seat Inserts

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ENGINE SYSTEM

NOTE:

Ensure that the 27610030 Valve Guide/Valve SeatReamer/Cutter is assembled correctly with the correctangle of cutter (3) for the valve seat toward the cylin-der head.

NOTE:

Ensure that the cutter (3) for the valve seat is not al-lowed to contact the valve seat insert until the valveguide has been reamed to the correct size.

6. Set the diameter of the cutter (3) to the correct sizefor the valve seat to be cut. Refer to the Specifica-tions Manual, “Cylinder Head Valves” for the correctdiameter. Position the reamer (2) of the tool (1) intothe appropriate valve guide. Carefully turn thehandle in a clockwise direction and gradually movethe reamer (2) into the valve guide until the valveguide is reamed to the finished size.

7. Continue to turn the handle in a clockwise directionin order to cut the valve seat insert. Remove theminimum amount of material in order to ensure agood valve seat. Keep the valve seat as narrow aspossible.

8. Remove the tool (1). Clean the debris from the valveguide and the valve seat.

9. Repeat Step 6 to Step 8 in order to cut all of theappropriate valve seats.

End By:a. Install the inlet valves and the exhaust valves. Refer

to this Disassembly and Assembly Manual, “Inletand Exhaust Valves - Remove and Install”.

C34W2A6A

(1) Tool

(2) Reamer

(3) Correct Angle of Cutter

3. Put the appropriate valve seat insert in position. In-stal l the special tool that was manufacturedpreviously, through the valve seat insert and usethe pilot bore of the valve guide in order to centerthe tool and the insert into the recess. Lightly tapthe valve seat insert in order to start the installation.Press the valve seat insert into the recess with asuitable press. Ensure that the bottom of the valveseat insert is against the bottom of the recess.

4. Repeat Step 3 for the remaining valve seat inserts.

5. After installing the valve guides and valve seatinserts, the valve guides must be reamed and thevalve seat inserts must be cut to the finisheddiameter. The valve guides and valve seat insertsare cut and reamed in one operation. This proce-dure ensures the concentricity of the valve seat tothe valve guide in order to create a good seal. Referto the Specifications Manual, “Cylinder Head Valves”for the finished diameter of the valve guides andvalve seat inserts.

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CHAPTER 2 DK651/751/801/901

4.15 ENGINE OIL FILTER BASE

A. REMOVAL PROCEDURE FOR A SPIN-ONOIL FILTER

NOTE:

This procedure is for the removal of an oil filter with anoil filter element that has an integral housing.

NOTE:

The oil filter can be installed vertically or the oil filtercan be installed horizontally.

1. Remove all dirt, oil, and grease from the engineoil filter assembly and from the drain plug of theengine oil pan. Place a suitable container beneaththe drain plug of the engine oil pan.

2. Operate the engine until the engine is warm. Stopthe engine.

3. Remove the oil drain plug and the O-ring from theengine oil pan. Drain the engine oil into the con-tainer for storage or disposal.

C34W2B0A

(11) Oil Filter Element

(12) Oil Filter Base (15) Adapter

(13) Setscrews (16) Plug

(14) Joint (17) Plug

4. Place a suitable container beneath the oil filterelement (11).

5. Use a suitable strap wrench in order to removethe oil filter element (11). Discard the oil filter ele-ment (11) in a suitable manner.

NOTE:

Step 1 to Step 5 is the procedure for removing the oilfilter element (11). Step 6 to Step 9 is the additionalprocedure for removing the oil filter base (12).

6. Remove the setscrews (13).

7. Remove the engine oil filter base (12) from thecylinder block. Remove the joint (14) and discardthe joint.

8. If necessary, remove the adapter (15) from the oilfilter base (12).

9. If necessary, remove the plug (16) and the O-ring.

10. If necessary, remove the plug (17) and the O-ring.

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ENGINE SYSTEM

B. INSTALLATION PROCEDURE FOR A SPIN-ON OIL FILTER

NOTE:Step 1 to Step 6 is the procedure for installing the oilfilter base if the oil filter base was previously removed.Step 7 to Step 10 is the procedure for installing the oilfilter element.

1. Clean the oil passages within the oil filter base(12). Clean the mating surfaces of the cylinderblock and the engine oil filter base (12).

2. Inspect the adapter (15) if the adapter was removedfrom the oil filter base (12). Install the adapter (15)into the oil filter base (12). Tighten the adapter (15).Refer to the Torque Specifications Manual, “Stan-dard Torque for O-ring Face Seal Fittings and 37Degree Flared Fittings” for the correct torque.

3. Inspect the O-ring for the plug (17) if the plug wasremoved from the oil filter base (12). If necessary,replace the O-ring. Install the O-ring and the plug(17) into the oil filter base (12). Tighten the plug(17) to a torque of 12 N·m (1.2 kgf·m, 8.8 lbf·ft).

4. Inspect the O-ring for the plug (16) if the plug wasremoved from the oil filter base (12). If necessary,replace the O-ring. Install the O-ring and the plug(16) into the oil filter base (12). Tighten the plug(16) to a torque of 12 N·m (1.2 kgf·m, 8.8 lbf·ft).

NOTE:• New setscrews (13) have sealant on the first 13

mm (0.5 in.) of the threads. In order to reuse theold setscrews (13), clean the old sealant from thesetscrews and apply 21820117 POWERPARTThreadlock and Nutlock to the setscrews.

• Do not lubricate the new joint (14).

5. Install the setscrews (13) into the oil filter base (12).Install a new joint (14) onto the setscrews (13). In-stall the setscrews (13) into the cylinder block.

6. Evenly tighten the setscrews (13). Refer to theTorque Specifications Manual, “Standard Torquefor Metric Fasteners” for further information.

7. Clean the mating surface of the oil filter base (12)to the oil filter element (11).

8. Lubricate the top of the O-ring (18) with clean en-gine lubricating oil. Spin the new oil filter element(11) onto the adapter (15). Tighten the oil filter el-ement (11) by hand. Do not use a strap wrench totighten the oil filter element (11).

9. Inspect the O-ring for the drain plug for the engineoil pan. If necessary, replace the O-ring. Install theO-ring onto the drain plug for the engine oil panand install the drain plug into the engine oil pan.Tighten the drain plug to the correct torque. Referto this Disassembly and Assembly Manual, “En-gine Oil Pan – Remove and Install” for the correcttorque. Remove the suitable containers beneath theengine oil pan and beneath the oil filter housing.

10. Fill the engine oil to the correct level that is indi-cated on the engine oil level gauge. Refer to theOperation and Maintenance Manual, “Refill Capaci-ties” for the lubrication system capacity of the engine.

C34W2B1A

(18) O-ring

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CHAPTER 2 DK651/751/801/901

4.16 ENGINE OIL COOLER

A. REMOVAL PROCEDURE FOR THREECYLINDER ENGINE

1. Drain the coolant from the engine into a suitablecontainer. Drain the engine oil from the engine intoa suitable container. Refer to the Operation andMaintenance Manual for the procedure on drainingthe engine coolant and the engine oil.

2. Remove the hose clamp and the hose from the cool-ant inlet (1). Remove the hose clamp and the hosefrom the coolant outlet (2).

3. Remove the adapter (3) from the oil cooler body(4).

4. Remove the O-rings (5), (6), and (7). Discard theO-rings (5), (6), and (7).

5. If necessary, remove the setscrews (8) in order toremove the oil cooler base (9) from the cylinderblock. Remove the joint from the cylinder block.Discard the joint.

C34W2B2A

C34W2B3A

(1) Coolant Inlet (6) O-ring

(2) Coolant Outlet (7) O-ring

(3) Adapter (8) Setscrews

(4) Oil Cooler Body (9) Oil Cooler Base

(5) O-ring

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ENGINE SYSTEM

B. REMOVAL PROCEDURE FOR FOUR CYL-INDER ENGINE

1. Drain the coolant from the engine into a suitablecontainer. Drain the engine oil from the engine intoa suitable container. Refer to the Operation andMaintenance Manual for the procedure on drainingthe engine coolant and the engine oil.

NOTE:

Do not remove the setscrews (7) at this time.

2. Remove the setscrews (6). Remove the setscrews(4).

3. Remove the housing (3) from the cylinder block.

4. Remove the setscrews (7). Remove the engine oilcooler (2) and the seals (5) from the housing (3).Discard the seals (5).

5. Remove the joint (1) from the cylinder block. Dis-card the joint (1).

C34W2B4A

(1) Joint (5) Seals

(2) Engine Oil Cooler (6) Setscrews

(3) Housing (7) Setscrews

(4) Setscrews

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CHAPTER 2 DK651/751/801/901

C. INSTALLATION PROCEDURE FOR THETHREE CYLINDER ENGINE

1. Clean the mating surfaces of the oil cooler base (9)and the oil cooler body (4). If the oil cooler base (9)was removed, clean the mating surfaces of the oilcooler base and the cylinder block.

NOTE:

Do not use sealant on the new joint between the cylin-der block and the oil cooler base (9).

2. If the oil cooler base (9) was removed from thecylinder block, install setscrews into setscrewholes (1) and (6) in the oil cooler base. Install anew joint onto the two setscrews and secure theoil cooler base (9) to the cylinder block. Installthe remainder of the setscrews (8). Tighten thesetscrews (8) in the sequence 1, 2, 3, 4, 5, and 6to a torque of 22 N·m (2.2 kgf·m, 16.2 lb·ft). Referto the illustration 64.

3. Install new O-rings (7) and (8) onto the oil coolerbody (4). Position the oil cooler body (4) onto theoil cooler base (9).

4. Install a new O-ring (7) onto the adapter (3). Installthe adapter (3) through the oil cooler body (4) andinto the oil cooler base (9). Tighten the adapter (3)to a torque of 57 N·m (5.8 kgf·m, 42 lbf·ft).

5. Install the appropriate hose to the coolant outlet(2). Tighten the hose clamp to a torque of 3.5 N·m(0.35 kgf·m, 2.5 lbf·ft).

6. Install the appropriate hose to the coolant inlet (1).Tighten the hose clamp to a torque of 3.5 N·m (0.35 kgf·m, 2.5 lbf·ft).

7. Fill the cooling system with coolant. Fill the lubri-cation system with engine oil. Refer to the Opera-tion and Maintenance Manual, “Refill Capacities”for the cooling system capacity and for the lubrica-tion system capacity of the engine.

C34W2B5A

C34W2B3A

(3) Adapter (6) Seals

(4) Oil Cooler Body (7) Setscrews

(5) Housing

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ENGINE SYSTEM

D. INSTALLATION PROCEDURE FOR THEFOUR CYLINDER ENGINE

1. Clean the mating surfaces of the housing (3) andthe cylinder block.

2. Position the engine oil cooler (2) and the new seals (5)in the housing (3). Install the setscrews (7) in order tosecure the engine oil cooler (2) to the housing (3).

NOTE:

Do not use sealant on the joint (1).

3. Position the housing (3) and the new joint (1) ontothe cylinder block. Install the setscrews (4) and thesetscrews (6) in order to secure the housing (3) tothe cylinder block.

4. Tighten all of the setscrews (4, 6 and 7) to the cor-rect torque. Refer to the Torque specificationsManual, “Standard Torques for Metric Fasteners”for further information.

NOTE:

Refer to the Operation and Maintenance Manual, “Re-fill Capacities” for the cooling system capacity and forthe lubrication system capacity of the engine.

5. Fill the cooling system with coolant. Fill the lubri-cation system with engine oil.

C34W2B4A

(1) New Joint (5) New Seals

(2) Engine Oil Cooler (6) Setscrews

(3) Housing (7) Setscrews

(4) Setscrews

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CHAPTER 2 DK651/751/801/901

4.17 ENGINE OIL RELIEF VALVE(ENGINE OIL PUMP)

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

• Personal injury can result from being struck byparts propelled by a released spring force.

• Make sure to wear all necessary protectiveequipment.

• Follow the recommended procedure and use allrecommended tooling to release the spring force.

WARNING

1. Remove the plug (2). Remove the spring (3) andthe plunger (4) from the engine oil pump (1).

• Improper assembly of parts that are springloaded can cause bodily injury.

• To prevent possible injury, follow the estab-lished assembly procedure and wear protectiveequipment.

WARNING

B. INSTALLATION PROCEDURE1. Clean the spring (3) and the plunger (4) of the en-

gine oil relief valve. Check the spring (3) and theplunger (4) for wear or for other damage. The plunger(4) must slide easily within the bore of the oil reliefvalve within the engine oil pump (1). Lubricate thespring (3) and the plunger (4) with clean engine oil.

C34W2B6A

(1) Engine Oil Pump (3) Spring

(2) Plug (4) Plunger

2. Install the plunger (4) and the spring (3) in the en-gine oil pump (1).

3. Install the plug (2). Tighten the plug (2) to a torqueof 22 N·m (2.2 kgf·m, 16.2 lbf·ft).

End By:a. Install the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

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ENGINE SYSTEM

4.18 ENGINE OIL RELIEF VALVE(BALANCER UNIT FOR THE 1104ENGINES ONLY)

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

1. Remove the plug (2). Remove the spring (3) andthe plunger (4) from the balancer unit (1).

B. INSTALLATION PROCEDURE1. Clean the spring (3) and the plunger (4) of the en-

gine oil relief valve. Check the spring (3) and theplunger (4) for wear or for other damage. The plunger(4) must slide easily within the bore of the oil reliefvalve within the balancer unit (1). Lubricate the spring(3) and the plunger (4) with clean engine oil.

• Personal injury can result from being struck byparts propelled by a released spring force.

• Make sure to wear all necessary protectiveequipment.

• Follow the recommended procedure and use allrecommended tooling to release the springforce.

WARNING

C34W2B7A

(1) Balancer Unit (3) Spring

(2) Plug (4) Plunger

• Improper assembly of parts that are springloaded can cause bodily injury.

• To prevent possible injury, follow the estab-lished assembly procedure and wear protectiveequipment.

WARNING

2. Install the plunger (4) and the spring (3) into thebalancer unit (1).

3. Install the plug (2). Tighten the plug (2) to a torqueof 22 N·m (2.2 kgf·m, 16.2 lbf·ft).

End By:a. Install the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

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C34-WOO May. 20052-104

CHAPTER 2 DK651/751/801/901

4.19 ENGINE OIL PUMP (ENGINESWITHOUT A BALANCER)

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

NOTE:

This procedure is for the removal of the engine oil pumpon engines that are not equipped with a balancer. Re-fer to this Disassembly and Assembly Manual, “Bal-ancer Group - Remove” for information on the removalof the engine oil pump on engines that are equippedwith a balancer.

1. Remove the setscrews (1) and the suction pipe (2).

2. Remove the setscrews (3). Remove the assemblyof the engine oil pump (4) from the cylinder block.

3. If necessary, remove the pressure relief valve (5)from the assembly of the engine oil pump (4). Referto this Disassembly and Assembly Manual, “En-gine Oil Relief Vave - Remove and Install”.

4. Remove the setscrews (6). Remove the engine oil pump(7) from the assembly of the engine oil pump (4).

5. If necessary, remove the setscrews and remove thefront cover assembly from the engine oil pump (7)in order to inspect the components within the en-gine oil pump.

C34W2B8A

(1) Setscrews (3) Setscrews

(2) Suction Pipe (4) Engine Oil Pump

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ENGINE SYSTEM

B. INSTALLATION PROCEDURE

1. Clean all of the internal components of the oil pumpif the front cover of the oil pump was previously re-moved in order to inspect the internal components.Check the internal components for wear and for otherdamage. Check the clearance between the outerrotor of the oil pump and the oil pump body. Checkthe clearance between the outer rotor and the innerrotor. Check the end play movement of the rotor.Refer to the Systems Operation/Testing and Ad-justing Manual, “Engine Oil Pump - Inspect”. Re-place the engine oil pump if any of the componentsare worn or damaged.

2. Lubricate the inner rotor and the outer rotor of theengine oil pump with clean engine lubricating oil.Install the front cover of the engine oil pump ontothe body of the oil pump. Install the setscrews andtighten the setscrews in order to secure the frontcover to the body.

3. Fill engine oil pump (6) with clean engine oil.

4. Install the engine oil pump (6) into the assembly ofthe engine oil pump (4). Install the setscrews (7).Tighten the setscrews to a torque of 9 N·m (0.9kgf·m, 6.6 lbf·ft).

5. Ensure that the dowel pin (8) and the hollow dowel(9) are correctly located in the cylinder block. In-stall the assembly of the engine oil pump (4) ontothe dowels (8 and 9).

6. Install the setscrews (3). Tighten the setscrews toa torque of 44 N·m (4.4 kgf·m, 32.4 lbf·ft).

7. Check the backlash between the idler gear (10) ofthe oil pump and the crankshaft gear. Refer to theSpecifications Manual, “Gear Group - Front” for fur-ther information.

8. If the pressure relief valve (5) was removed, installthe pressure relief valve. Refer to this Disassemblyand Assembly Manual, “Engine Oil Relief Valve -Remove and Install” for further information.

9. Position the suction pipe (2) and install the set-screws (1).

End By:a. Install the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

If any of the parts on the engine oil pump are wornor damaged, the entire pump must be replaced.

CAUTION

C34W2B9A

(3) Setscrews (8) Dowel Pin

(4) Engine Oil Pump (9) Hollow Dowel

(6) Engine Oil Pump (10) Idler Gear

(7) Setscrews

C34W2B8A

(1) Setscrews

(2) Suction Pipe

(3) Setscrews

(4) Engine Oil Pump

(5) Pressure Relief Valve

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CHAPTER 2 DK651/751/801/901

4.20 WATER PUMP

A. REMOVAL PROCEDURE

Start By:a. Remove the fan. Refer to this Disassembly and As-

sembly Manual, “Fan - Remove and Install”.

1. Drain the coolant from the cooling system into asuitable container for storage or disposal.

2. Loosen the clamps and remove the hose from thewater pump inlet.

3. Remove the setscrews (3) that fasten the waterpump (4) to the front housing (1).

4. If necessary, gently tap the water pump (4) with asoft hammer in order to loosen the water pump.

5. Remove the water pump (4). Remove the joint (2)from the front housing (1) and the water pump (4).Discard the joint (2).

C34W2C0A

(1) Front Housing (3) Setscrews

(2) Joint (4) Eater Pump

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ENGINE SYSTEM

B. INSTALLATION PROCEDURE1. Inspect the drive gear for the water pump (4) for

wear or other damage. If necessary, replace thedrive gear.

2. Clean the joint faces of the water pump (4) andthe front housing (1).

3. Install two guide studs (5) into the front housing(1).

NOTE:

Do not use sealant on the new joint (2) for the waterpump (4).

4. Install the new joint (2) onto the front housing (1).

5. Install the water pump (4) onto the front housing(1).

NOTE:

New setscrews have sealant to the first 13 mm (0.5in.) of the threads. In order to reuse the old setscrews,clean the old sealant from the setscrews and apply21820117 POWERPART Threadlock and Nutlock tothe setscrews (3).

6. Install the setscrews (3) that fasten the waterpump (4) to the front housing (1). Do not tightenthe setscrews (3) at this time.

7. Remove the guide studs (5) and install the remain-ing setscrews (3).

NOTE:

Tighten the setscrews (3) evenly in order to pull thewater pump (4) into the front housing (1).

8. Tighten the setscrews (3) in the sequence that isshown in the illustration 83 to a torque of 22 N·m(2.2 kgf·m, 16.2 lbf·ft).

9. Install the hose to the water pump inlet. Tightenthe hose clamps.

10. Fill the cooling system with coolant. Refer to theOperation and Maintenance Manual, “Refill Capaci-ties” for the cooling system capacity.

End By:a. Install the fan. Refer to this Disassembly and As-

sembly Manual, “Fan - Remove and Install”.

C34W2C5A

(1) Front Housing

(2) New Joint

(5) Guide Studs

C34W2C6A

(3) Setscrews

(4) Water Pump

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CHAPTER 2 DK651/751/801/901

C. DISASSEMBLY PROCEDURE

Start By:a. Remove the water pump. Refer to this Disassem-

bly and Assembly Manual, “Water Pump - Removeand Install”.

1. Remove the setscrews (1) from the cover (2) of thewater pump (3). Remove the joint between the cover(2) and the water pump (3). Discard the joint.

NOTE:

All of the other setscrews are removed during the re-moval of the water pump.

C34W2C1A

(1) Setscrews (3) Water Pump

(2) Cover

C34W2C2A

(4) Impeller (5) Suitable Puller

2. Drill twelve 6.35 mm (0.25 in.) holes between theexisting holes in the impeller (4). Break pieces fromthe impeller (4) in order to install a suitable puller(5) with two legs onto the impeller. Remove the im-peller (4) with the suitable puller (5).

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ENGINE SYSTEM

NOTE:

It will be necessary to break the coolant seal (6) in orderto remove the coolant seal from the water pump (3).

3. Drill three 3.175 mm (0.125 in.) holes that areequally spaced into the coolant seal (6). The holesshould be drilled into the face of the coolant seal(6) that would have faced the impeller (4). Insertthree 25.4 mm (1.00 in.) long self-tapping screwsinto the drilled holes. Insert a suitable lever into thecoolant inlet of the water pump (3). Use the suit-able lever under the self-tapping screws in order toevenly pull the coolant seal (6) off the shaft (7). Ifnecessary, remove the center sleeve of the coolantseal from the shaft with a suitable extractor.

4. Remove the outer circlip (8) and discard the outercirclip. Remove the inner circlip (9) and discard theinner circlip.

5. Support the machined face (10) of the housing ofthe water pump (3) on a suitable support. Press onthe shaft (7) until the gear (11) and the bearing (12)are free from the shaft. Discard the shaft (7) andthe bearing (12). Remove the gear (11) through theside of the housing of the water pump (3).

6. Support the machined face (13) of the housing of thewater pump (3) on a suitable support. Insert a suit-able mandrel on the oil seal (14) and press the oilseal out of the housing of the water pump (3). The oilseal (14) can be removed through the side of the hous-ing of the water pump (3) after the seal has been re-leased from the housing. Discard the oil seal (14).

7. Use a suitable mandrel to press the needle bearing(15) out of the housing of the water pump (3). Dis-card the needle bearing (15).

D. ASSEMBLY PROCEDURE1. Thoroughly clean the inside of the housing of the

water pump (3). Ensure that the bores for the bear-ings (12 and 15) and the coolant seal (6) are cleanand free from corrosion.

2. Inspect the gear (11) for wear and/or damage. Ifnecessary, replace the gear (11).

3. Support the machined face (13) of the housing ofthe water pump (3). Use a suitable mandrel and asuitable press to press a new oil seal (14) into thehousing of the water pump (3). Stop pressing theoil seal (14) into the housing when the lower face ofthe oil seal is level with the lower face of the re-cess for the oil seal.

4. Install the gear (11) through the side of the housingfor the water pump (3). Use a suitable adapter topress the shaft (7) through the oil seal (14) and intothe gear (11). Continue to press the shaft (7) intothe gear (11) until there is a gap of 1.5 mm (0.060in.) between the gear and the top of the housing forthe gear within the housing of the water pump (3).

5. Use a suitable adapter in order to press the bearing(12) against the shoulder of the recess for the bearing.

C34W2C3A

(4) Impeller (11) Gear

(6) Coolant Seal (12) Bearing

(7) Shaft (13) Machined Face

(8) Outer Circlip (14) Oil Seal

(9) Inner Circlip (15) Needle Bearing

(10) Machined Face

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CHAPTER 2 DK651/751/801/901

C34W2C4A

6. Install a new circlip (8) into the recess with thehousing for the water pump (3). Install a new circlip(9) into the recess in the shaft (7). Ensure thatboth circlips (8 and 9) are installed correctly.

7. Support the machined face (10) of the housing ofthe water pump (3) on a suitable support. Press theneedle bearing (15) into the housing for the bearing.Continue to press the needle bearing (15) into thehousing until the needle bearing is either level withthe top face of the housing or the needle bearing isno more than a maximum of 0.5 mm (0.020 in.) be-low the top face of the housing.

8. Support the machined face (13) of the housing ofthe water pump (3) on a suitable support.

NOTE:

Avoid hand contact with the coolant seal (6). The cool-ant seal (6) must not be contaminated by oil or grease.The coolant seal (6) must only be touched and/or heldat the edge of the outer flange.

NOTE:

Do not lubricate the coolant seal (6).

9. Manufacture a suitable tool in order to press thenew coolant seal (6) into position. The tool shouldbe made to the dimensions shown in the illustra-tion 81 and the table 10.

Dimensions

A

B

C

D

54.0 mm (2.126 in.)

6.0 mm (0.236 in.)

10.0 mm (0.394 in.)

48.0 mm (1.890 in.)

E

F

G-

44.0 mm (1.732 in.)

18.0 mm (0.709 in.)

54.0 mm (2.126 in.)-

10. Install the new coolant seal (6) onto the shaft (7)with the largest diameter of the coolant seal towardthe bearing (12). Push the coolant seal (6) onto theshaft (7) until the coolant seal is in contact with thecounterbore for the coolant seal. Ensure that thecoolant seal (6) is square with the counterbore. Usea suitable adapter in order to press the coolant seal(6) into the counterbore until the outer flange of thecoolant seal is in contact with the body of the waterpump (3). Maintain the pressure on the coolant seal(10) for about 10 seconds in order to ensure that thecoolant seal remains in position.

11. Press the impeller (4) onto the shaft (7) until thetop of the impeller is level with the top of the shaft.

12. Install a new joint for the cover (2) to the body ofthe water pump (3). Install the cover (2) to thewater pump (3).

13. Install the setscrews (1). Torque the setscrews(1) to a torque of 22 N·m (2.2 kgf·m, 16.2 lbf·ft).

End By:a. Install the water pump. Refer to this Disassembly and

Assembly Manual, “Water Pump - Remove and Install”.

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ENGINE SYSTEM

C34W2C8A

C34W2C9A

(1) Front Housing (5) Guide Studs

(3) New Joint (6) Guide Studs

(4) Guide Studs

4. Install the 27610226 Thermostat Tool (5) into thewater temperature regulator housing (1). Press onthe tool (5) in order to squeeze the retainers (4).Rotate the tool (5) in order to release the water tem-perature regulator (3) from the tabs (6) of the watertemperature regulator housing (1). Remove the tool(5) from the water temperature regulator housing(1). Remove the water temperature regulator (3) fromthe water temperature regulator housing (1).

5. Refer to the Systems Operation/Testing and Ad-justing Manual, “Water Temperature Regulator -Test” for the correct procedure on testing the watertemperature regulator. If necessary, replace thewater temperature regulator (3).

4.21 WATER TEMPERATURE REGULA-TOR

A. REMOVAL PROCEDURE

Required Tools

Part Number

27610226

Part Description

Thermostat Tool

Qty

1

1. Drain the coolant from the cooling system to a levelbelow the water temperature regulator into a suit-able container for storage or disposal.

2. Loosen the hose clamps from the upper radiatorhose and remove the upper radiator hose from thewater temperature regulator housing (1).

3. Remove the setscrews (2) that hold water tempera-ture regulator housing (1) in position on the cylin-der head. Remove the water temperature regulatorhousing (1). Remove the O-ring from the water tem-perature regulator housing (1). Discard the O-ring.

C34W2C7A

(1) Water Temperature Regulator Housing

(2) Setscrews

(3) Water Temperature Regulator

(4) Retainers

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

1. Clean the water temperature regulator housing (1).Ensure that the tabs (6) for the retainers (4) areclean. Ensure that the seat for the O-ring (7) isclean.

2. The water temperature regulator (3) has two vents(8) that are opened and closed by a valve pin. Thesetwo vents (8) bleed hot water and/or air through thewater temperature regulator (3) when the water tem-perature regulator is in the closed position. Ensurethat the valve pins (8) can move freely in the vents.

3. Lubricate the new O-r ing (7) with 21820221POWERPART Red Rubber Grease. Install the O-ring (7) into the appropriate groove in the water tem-perature regulator housing (1).

4. Position the water temperature regulator (3) in thewater temperature regulator housing (1). Install the27610226 Thermostat Tool (5) in order to squeezethe retainers (4). Rotate the tool (5) in order to se-cure the water temperature regulator (3) into thewater temperature regulator housing (1).

NOTE:

The retainers (4) must be inserted behind the tabs ofthe water temperature regulator housing (1) in order tosecure the water temperature regulator (3) during en-gine operation.

5. Ensure that the retainers (4) are correctly installedwithin the tabs (6). Position the water temperatureregulator housing (1) onto the cylinder head.

6. Install the setscrews (2) that fasten the water tem-perature regulator housing (1) to the cylinder head.Tighten the setscrews (2) to the correct torque. Re-fer to the Torque Specifications Manual, “StandardTorques for Metric Fasteners” for further information.

7. Install the upper radiator hose and tighten the hoseclamps. Refer to the Torque Specifications Manualfor the correct torque.

8. Fill the cooling system to the proper level. Refer tothe Operation and Maintenance Manual, “Refill Ca-pacities” for further information.

C34W2D0A

(7) O-ring

C34W2D1A

(8) Valve Pins

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ENGINE SYSTEM

4.22 FLYWHEEL

A. REMOVAL PROCEDURE

1. Remove the two setscrews (1).

2. Install two suitable studs (2) as guides.

NOTE:

The flywheel (3) is heavy. Use suitable lifting equip-ment to support the flywheel (3) before the remainderof the setscrews (1) are removed.

3. Remove the remaining setscrews (1) that secureflywheel (3) to the crankshaft.

C34W2D2A

(1) Setscrews

C34W2D3A

(2) Suitable Stud (3) Flywheel

4. Check the condition of the ring gear (4). Removethe ring gear (4) if the ring gear is worn or damaged.

NOTE:

Identify the orientation of the ring gear on the flywheeland the position of the chamfer on the teeth for thecorrect positioning when the new ring gear is installed.

5. Place the flywheel (3) and the ring gear (4) on a suit-able support. Use a hammer and a chisel in order toremove the ring gear (4) from the flywheel (3).

C34W2D4A

(3) Flywheel (4) Ring Gear

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

Always wear protective gloves when handling partsthat have been heated.

CAUTION

1. Thoroughly clean the flywheel housing. Inspect thecrankshaft rear seal for leaks. If there are any oilleaks refer to this Disassembly and AssemblyManual, “Crankshaft Rear Seal - Remove”.

NOTE:

If the ring gear (4) has been removed from the fly-wheel (3), identify the orientation of the new ring gearin order to install the ring gear correctly onto theflywheel.

NOTE:

Do not use a torch to heat the ring gear (4).

2. Heat the ring gear (4) to 250°C (480°F) in an ovenin order to install the ring gear onto the flywheel(3). Ensure that the orientation of the ring gear (4)is correct and quickly install the ring gear onto theflywheel (3).

3. Clean the flywheel (3) and the ring gear (4) whenthe ring gear has cooled.

4. Ensure that the guide studs (2) are still installed inthe crankshaft.

NOTE:

The flywheel (3) is heavy. Use suitable lifting equip-ment to support the flywheel until the setscrews (1)have been installed.

5. Install the flywheel (3) onto the two guide studs (2).

6. Install most of the setscrews (1) finger tight. Re-move the guide studs (2). Install the remainder ofthe setscrews (1).

7. Tighten the setscrews (1) to a torque of 105 N·m(10.7 kgf·m, 77.4 lbf·ft).

8. Check the alignment of the flywheel (3) with thecrankshaft. Refer to the Testing and AdjustingManual, “Flywheel - Inspect”.

C34W2D5A

(3) Flywheel (4) Ring Gear

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ENGINE SYSTEM

4.23 CRANKSHAFT REAR SEAL

A. REMOVAL PROCEDURE

Start By:a. Remove the flywheel. Refer to this Disassembly and

Assembly Manual, “Flywheel - Remove”.

NOTE:

The assembly of the crankshaft rear seal (2) isnonserviceable. If the assembly of the crankshaft rearseal (2) is removed, the assembly must be replaced.

1. Remove the setscrews (1) from the assembly ofthe crankshaft rear seal (2).

2. Remove the assembly of the crankshaft rear seal(2) from the cylinder block. Discard the assemblyof the crankshaft rear seal (2).

C34W2D6A

(1) Setscrews

(2) Crankshaft Rear Seal

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

NOTE:

The crankshaft rear seal and the housing for the crank-shaft rear seal are manufactured as a one-pieceassembly. The assembly of the crankshaft rear sealuses ten setscrews in order to fasten the assembly tothe cylinder block.

NOTE:

The assembly of the crankshaft rear seal is lubricatedduring manufacture. Do not lubricate the seal or thecrankshaft flange before installation.

NOTE:

Inspect the crankshaft rear seal and replace the as-sembly if there is the slightest sign of damage to theseal.

NOTE:

The following procedure assumes that the crankshaftrear seal is a replacement assembly.

1. Ensure that the crankshaft flange (1) is clean, dryand free from rough metal edges. Ensure that theface of the cylinder block and the bridge in thecrankcase are clean and dry.

2. Remove the packaging from the new assembly ofthe crankshaft rear seal (3). Ensure that the plas-tic sleeve (2) is squarely installed within the seal ofthe assembly of the crankshaft rear seal (3). Theplastic sleeve (2) is included in order to protect thelip of the seal as the lip is pushed over the crank-shaft flange (1).

C34W2D7A

(1) Crankshaft Flange

(2) Plastic Sleeve

(3) Crankshaft Rear Seal

(4) Alignment Tool

(5) Setscrews

3. Place the assembly of the crankshaft rear seal (3)over the crankshaft flange (1) and engage the plas-tic sleeve (2) onto the crankshaft flange.

4. Ensure that the plastic sleeve (2) is engaged ontothe crankshaft flange (1). Push the assembly of thecrankshaft rear seal (3) evenly and push the as-sembly smoothly onto the crankshaft flange (1) un-til the assembly is against the cylinder block. Dur-ing this process, the plastic sleeve (2) will be forcedout of the assembly of the crankshaft rear seal (3).Discard the plastic sleeve (2).

5. Rotate the assembly of the crankshaft rear seal (3)in order to align the setscrew holes in the assem-bly with the setscrew holes in the rear face of thecylinder block.

6. By using the ten setscrews (5), loosely secure theassembly of the crankshaft rear seal (3) to the cyl-inder block.

C34W2D8A

(1) Crankshaft Flange

(2) Plastic Sleeve

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ENGINE SYSTEM

C34W2D9A

NOTE:

The alignment tool (4) is not currently available fromPerkins. Refer to the illustration 103 for the requireddimensions in order to manufacture an alignment tool(4) locally.

7. Install the alignment tool (4) onto the crankshaftflange (1) and over the assembly of the crankshaftrear seal (3) in order to align the assembly with thecrankshaft flange.

8. Tighten the setscrews (5) in the sequence 1, 2, 3,4, 5, 6, 7, and 10 to a torque of 22 N·m (2.2 kgf·m,16.2 lbf·ft). Refer to the illustration 104.

9. Remove the alignment tool (4). Tighten the set-screws 8 and 9 to a torque of 22 N·m (2.2 kgf·m,16.2 lbf·ft). Refer to the illustration 104.

End By:a. Install the flywheel housing. Refer to this Disas-

sembly and Assembly Manual, “Flywheel Housing- Remove and Install”.

b. Install the flywheel. Refer to this Disassembly andAssembly Manual, “Flywheel - Install”.

C34W263A

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CHAPTER 2 DK651/751/801/901

4.24 CRANKSHAFT WEAR SLEEVE(REAR)

A. REMOVAL PROCEDURE

Start By:a. Remove the crankshaft rear seal. Refer to this Dis-

assembly and Assembly Manual, “Crankshaft RearSeal - Remove”.

1. Install a deep score mark along the length of thewear sleeve.

2. Insert a suitable tool between the crankshaft flangeand the wear sleeve next to the score mark. Thewear sleeve should break along the score mark.Remove the wear sleeve. Discard the wear sleeve.

3. Use a suitable solvent in order to remove any oldsealant from the crankshaft.

B. INSTALLATION PROCEDURE1. Ensure that the crankshaft flange (4) is thoroughly

clean, dry, and free from old sealant prior to the in-stallation of a new crankshaft wear sleeve (2). Re-move any rough edges from the crankshaft flange (4).

2. Use a prybar to move the crankshaft toward thefront of the engine.

3. Apply a small continuous bead (1) of 21820518POWERPART Liquid Gasket to the inner surface5.00 mm (0.197 in.) from the flange end of crank-shaft wear sleeve (2).

4. Position crankshaft wear sleeve (2) on the crank-shaft flange (4). Position the installation tool (3)that is provided with the new crankshaft wear sleeve(2) over the crankshaft wear sleeve. Use a hammerto drive the crankshaft wear sleeve (2) onto thecrankshaft flange (4). The flange of the crankshaftwear sleeve (2) must be within (5) 0.40 ~ 0.60 mm(0.017 ~ 0.024 in.) of the cylinder block (6).

5. Remove the installation tool (3). Measure the dis-tance between the flange of the crankshaft wearsleeve (2) and the cylinder block (6) in two placesthat are 180 degrees from each other. The correctdistance (5) is 0.40 ~ 0.60 mm (0.017 ~ 0.024 in.).

6. After the crankshaft wear sleeve (2) has beeninstalled, remove any rough edges from the crank-shaft flange (4) and the crankshaft wear sleeve (2).

End By:a. Install the crankshaft rear seal. Refer to this Disas-

sembly and Assembly Manual, “Crankshaft RearSeal - Install”.

C34W2E0A

(1) Continuous Bead (4) Crankshaft Flange

(2) Crankshaft Wear Sleeve (5) Correct Distance

(3) Installation Tool (6) Cylinder Block

C34W2E1A

(1) Continuous Bead (4) Crankshaft Flange

(2) Crankshaft Wear Sleeve (5) Correct Distance

(3) Installation Tool (6) Cylinder Block

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ENGINE SYSTEM

4.25 FLYWHEEL HOUSING

A. REMOVAL PROCEDURE

Start By:a. Remove the electric starting motor. Refer to this

Disassembly and Assembly Manual, “Electric Start-ing Motor - Remove and Install”.

b. Remove the flywheel. Refer to this Disassembly andAssembly Manual, “Flywheel - Remove”.

NOTE:

The flywheel housing (2) is heavy. Use suitable liftingequipment to support the flywheel housing (2) whilethe setscrews (1) are being removed and while the fly-wheel housing is being removed.

1. Remove all of the setscrews (1) from the flywheelhousing (2).

2. Remove the flywheel housing (2). If necessary, hitthe flywheel housing with a soft faced hammer inorder to separate the flywheel housing (2) from thedowels (3) in the cylinder block.

C34W2E2A

(1) Setscrews

(2) Fywheel Housing

(3) Dowels

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE1. Clean the rear face of the cylinder block and the

mating surface of the flywheel housing (2).

2. If a felt seal (4) is installed, replace the felt sealInspect the dowels (3) in the cylinder block thatalign the flywheel housing (2). Replace the dowels(3), if necessary.

NOTE:

The flywheel housing (2) is heavy. Use suitable liftingequipment to support the flywheel housing (2) whilethe flywheel housing is being lifted and while the set-screws (1) are being installed.

3. Install the flywheel housing (2) onto the dowels (3)that are in the cylinder block.

4. Install all of the setscrews (1) that attach the fly-wheel housing (2) to the cylinder block.

Tighten the setscrews (1) to the following torque:

44 N·m

4.5 kgf·m

32.4 lbf·ft

63 N·m

6.4 kgf·m

46.4 lbf·ft

75 N·m

7.6 kgf·m

55.3 lbf·ft

115 N·m

11.7 kgf·m

84.8 lbf·ft

M10 “8.8”

Item

M10 “10.9”

Tightening torque

M12 “8.8”

M12 “10.9”

5. Check the alignment of the flywheel housing (2)with the cylinder block. Refer to the Testing andAdjusting Manual, “Flywheel Housing - Inspect”.

End By:a. Install the flywheel. Refer to this Disassembly and

Assembly Manual, “Flywheel - Install”.

b. Install the electric starting motor. Refer to this Dis-assembly and Assembly Manual, “Electric Start-ing Motor - Remove and Install”.

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ENGINE SYSTEM

4.26 CRANKSHAFT PULLEY

A. REMOVAL PROCEDURE

Start By:a. Remove the V-Belts. Refer to this Disassembly and

Assembly Manual, “V-Belts - Remove and Install”.

1. Remove the setscrews (1). Remove the thrust block(2).

2. Remove the pulley (3) from crankshaft (4).

3. Clean the pulley (3) and clean the thrust block (2).Inspect the pulley (3) and the thrust block (2) forwear and for damage. If necessary, replace anydamaged component. Inspect the area on the pul-ley (3) that is normally in contact with the crank-shaft front seal. If there is excessive wear then awear sleeve can be installed. Refer to this Disas-sembly and Assembly Manual, “Crankshaft WearSleeve (Front) - Remove and Crankshaft WearSleeve (Rear) - Install” for further details.

4. Position the pulley (3) onto crankshaft (4).

5. Lubricate the threads and the shoulder of the set-screws (1) with clean engine oil. Position the thrustblock and install the setscrews (1). Tighten the set-screws evenly to a final torque of 115 N·m (11.5kgf·m, 85 lb·ft).

6. Tighten each of the setscrews (1) again to the sametorque in order to ensure that the setscrews arestill at the required torque.

End By:a. Install the V-Belts. Refer to this Disassembly and

Assembly, “V-Belts - Remove and Install”.

C34W2E3A

(1) Setscrews

(2) Thrust Block

(3) Pulley

(4) Crankshaft

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CHAPTER 2 DK651/751/801/901

4.27 CRANKSHAFT FRONT SEAL

A. REMOVAL PROCEDURE

Required Tools

Part Number

27610230

Part Description

Three legged puller

Qty

1

Start By:a. Remove the crankshaft pulley. Refer to this Disas-

sembly and Assembly Manual, “Crankshaft Pulley- Remove and Install”.

b. Thoroughly clean the area around the housing forthe crankshaft front seal.

NOTE:

Do not remove the crankshaft front seal at this time ifthe housing (front) will also be removed. It is easier toremove the crankshaft front seal when the housing(front) has been removed from the engine.

Refer to this Disassembly and Assembly Manual,“Housing (Front) - Remove”.

1. Install the legs of the puller (1) under the crank-shaft front seal (2) and lock the legs into position.

2. Install a suitable adapter (3) between the crank-shaft (4) and the puller (1).

Ensure that the main lip is used in order to removethe crankshaft front seal. Do not damage the edgeof the housing for the crankshaft front seal.

CAUTION

3. Use the puller (1) in order to remove the crankshaftfront seal (2). Discard the crankshaft front seal (2).

C34W2E4A

(1) Puller (3) Suitable Adapter

(2) Crankshaft Front Seal (4) Crankshaft

Part Description

Crankshaft Front Seal Replacer

Fastener Plate

Pressure Plate

Adapter

B. INSTALLATION PROCEDURE

Required Tools

Part Number

21825577

21825580

21825578

27610217

Qty

1

1

1

1

NOTE:

This procedure assumes that the housing (front) isstill on the engine. Do not follow this procedure if thehousing (front) has been removed from the engine.Refer to this Disassembly and Assembly Manual,“Housing (Front) - Install” if the housing (front) hasbeen removed from the engine.

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ENGINE SYSTEM

1. Clean the oil seal housing (8) and inspect the oilseal housing for damage. If necessary, replacethe housing (front). Refer to this Disassembly andAssembly Manual, “Housing (Front) - Remove andHousing (Front) - Install”.

2. Check the face on the pulley that contacts thecrankshaft front seal for wear. If necessary, repairthe crankshaft pulley. Refer to this Disassemblyand Assembly Manual, “Crankshaft Wear Sleeve(Front) - Remove and Crankshaft Wear Sleeve(Front) - Install” for further details.

NOTE:

A sleeve (5) is attached to the new crankshaft frontseal (6). Do not remove the sleeve (5) at this time.Discard the new crankshaft front seal (6) if the sleeve(5) is not installed on the new crankshaft front seal.

3. Install the 21825580 Fastener Plate (7) to the frontof the crankshaft.

4. Install the nut (1) and 21825578 Pressure Plate(2) onto the threaded bar (3).

NOTE:

Do not lubricate the crankshaft front seal (6). Do notlubricate the oil seal housing (8).

5. Align the assembly of the sleeve (5) and the crank-shaft front seal (6) to the front of the oil seal hous-ing (8).

6. Install the 27610217 Adapter (4) onto the sleeve (5).

7. Install the pressure plate (2) onto the adapter (4)and tighten the threaded bar (3) onto the astenerplate (7). Check the alignment of the assemblyand the crankshaft front seal (6) to the oil sealhousing (8).

8. Insert a suitable rod through the hole (9) in thethreaded bar (3) in order to prevent the threadedrod from turning as the nut (1) is tightened. Tightenthe nut (1) in order to push the crankshaft frontseal (6) into the oil seal housing (8). Continue totighten the nut (1) until contact is made with thebottom face of the oil seal housing (8).

9. Remove items (1), (2), (3), and (4).

10. Turn the sleeve (5) counterclockwise and pull thesleeve at the same time in order to remove thesleeve from the oil seal housing (8). Remove theadapter (7).

11. Immediately install the crankshaft pulley. Referto this Disassembly and Assembly Manual,“Crankshaft Pulley - Remove and Install”.

C34W2E5A

(1) Nut (7) Astener Plate

(2) Pressure Plate (8) Oil Seal Housing

(3) Threaded Bar (9) Hole

(4) Adapter

(5) Sleeve

(6) Crankshaft Front Seal

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CHAPTER 2 DK651/751/801/901

4.28 CRANKSHAFTWEAR SLEEVE(FRONT)

A. REMOVAL PROCEDURE

Start By:a. Remove the crankshaft pulley (1). Refer to this Dis-

assembly and Assembly Manual, “Crankshaft Pul-ley - Remove and Install”.

NOTE:

A new crankshaft front seal (3) must be installed whena new crankshaft wear sleeve (front) (2) is installed.

1. Remove the crankshaft front seal (3). Refer to thisDisassembly and Assembly Manual, “CrankshaftFront Seal - Remove”. Discard the crankshaft frontseal (3).

2. If an existing crankshaft wear sleeve (front) (2) isinstalled onto the crankshaft pulley (1), remove thecrankshaft wear sleeve (front). Install a deep scoremark along the length of the crankshaft wear sleeve(front) (2).

3. Insert a suitable tool between the crankshaft pul-ley (1) and the crankshaft wear sleeve (front) (2)next to the score mark. The crankshaft wear sleeve(front) (2) should break along the score mark.

4. Use a suitable solvent in order to remove any oldsealant from the crankshaft pulley (1).

C34W2E6A

B. INSTALLATION PROCEDURE1. Install a new crankshaft front seal (3). Refer to this

Disassembly and Assembly Manual, “CrankshaftFront Seal - Install”.

2. Thoroughly clean the crankshaft pulley (1).

3. Install the crankshaft wear sleeve (front) (2). Referto the installation information in the packaging forthe crankshaft wear sleeve (front) (2).

NOTE:

It is not necessary to remove the flange (4) from thecrankshaft wear sleeve (front) (2) after the crankshaftwear sleeve (front) has been installed onto the crank-shaft pulley (1).

End By:a. Install the crankshaft pulley. Refer to this Disas-

sembly and Assembly Manual, “Crankshaft Pulley- Remove and Install”.

(1) Crankshaft Pulley

(2) Crankshaft Wear Sleeve (Front)

(3) Crankshaft Front Seal

(4) Flange

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ENGINE SYSTEM

4.29 FRONT COVER

A. REMOVAL PROCEDURE

Start By:a. Remove the water pump. Refer to this Disassembly

and Assembly Manual, “Water Pump - Remove andInstall”.

NOTE:

In order to remove the front cover, it is not necessaryto remove the cooling fan, the fan drive, the crank-shaft pulley, or the alternator. Removal of the fan andfan drive will assist the access to the front cover. Forillustration purposes, these components have beenremoved.

1. Remove the setscrews (3), the setscrews (4), andthe setscrew (5) from the front cover (1).

2. Remove the front cover (1) from the front housing.

3. Remove the joint (2) from the front cover (1).

Discard the joint (2).

C34W2E7A

(1) Three Setscrews (4) Fuel Priming Pump

(2) Connector (5) Tube Assembly

(3) Connector

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CHAPTER 2 DK651/751/801/901

C34W2E8A

(6) Appropriate Hole (8) Hole

(7) Dowel (9) Hole

B. INSTALLATION PROCEDURE1. Thoroughly clean all the surfaces of the front cover

(1) and clean the joint face of the housing (front).

2. nstall two guide studs into the appropriate holes(6) within the housing (front). Ensure that the threedowels (7) are located in the front cover (1). Ensurethat the dowels (7) are not worn. If necessary, re-place the dowels (7).

3. Position the joint (2) onto the front cover (1).

NOTE:

The joint is located by the three locating dowels (7) onthe front cover.

4. Position the front cover (1) and the joint (2) on thefront housing. Install setscrews (3) into holes (8).Install setscrew (5) into hole (9). Remove the twoguide studs from the holes (6). Install the remain-der of the setscrews (4). Tighten all of the setscrewsfinger tight.

5. Loosely install the water pump. Refer to this Dis-assembly and Assembly Manual, “Water Pump -Remove and Install”.

6. Tighten all of the setscrews (3, 4, and 5) for the frontcover (1) and tighten all of the setscrews for the waterpump to a torque of 22 N·m (2.2 kgf·m, 16.2 lbf·ft).

End By:a. If necessary, install the fan drive. Refer to this Dis-

assembly and Assembly, “Fan Drive - Remove andInstall”.

b. If necessary, install the fan. Refer to this Disas-sembly and Assembly Manual, “Fan - Remove andInstall”.

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ENGINE SYSTEM

NOTE:

Care must be taken in order to ensure that the fuelinjection pump timing is not lost during the removal ofthe fuel injection pump and/or fuel injection pump gear.Carefully follow the appropriate instructions in order toremove the fuel injection pump and/or fuel injectionpump gear.

NOTE:

If necessary, remove the glow plugs in order to allowthe crankshaft to rotate more freely. Refer to this Dis-assembly and Assembly Manual, “Glow Plugs - Re-move and Install”.

1. Rotate the crankshaft to top dead center. Refer tothe Testing and Adjusting Manual, “Finding TopCenter for No. 1 Piston”. Apply hand pressure tothe fuel injection pump gear (1) in a counterclock-wise direction in order to remove the backlash (2)in the gears. Mark the orientation of each of thegears for installation purposes.

NOTE:

Timing pins are used in order to time the engine at topdead center. The timing pins are a slip fit. Do not useexcessive force to install the timing pins. Do not usethe timing pins to lock the engine during repairs.

2. Insert the 27610211 Crankshaft timing pin (3)through the housing (front) and into the web of thecrankshaft. Insert the 27610212 Camshaft timingpin (4) through the camshaft gear (5) and into thehousing (front).

3. Remove the rocker shaft. Refer to this Disassem-bly and Assembly Manual, “Rocker Shaft andPushrod - Remove”.

NOTE:

The fuel injection pump must be locked before pro-ceeding further.

NOTE:

The three cylinder engine is equipped with the DelphiDP210 fuel injection pump.

C34W2E9A

(1) Fuel Injection Pump Gear

C34W2F0A

(2) Backlash

(3) Crankshaft Timing Pin

(4) Camshaft Timing Pin

(5) Camshaft Gear

4.30 GEAR GROUP (FRONT)

A. REMOVAL PROCEDURE

Start By:a. Remove the front cover. Refer to this Disassembly

and Assembly Manual, “Front Cover – Remove andInstall”.

Part Description

Crankshaft timing pin

Camshaft timing pin

Required Tools

Part Number

27610211

27610212

Qty

1

1

NOTE:

The four cylinder engine can be equipped with eitherthe Delphi DP210 or the Bosch EPVE fuel injectionpump. The two types of fuel injection pump have adifferent procedure for locking the fuel injection pumpshaft.

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CHAPTER 2 DK651/751/801/901

6. Release the nut (10). Install a suitable puller withtwo legs (11) through two holes (12) in the fuel in-jection pump gear (1). Tighten the puller (11) in or-der to release the gear (1) from the fuel injectionpump. Remove the nut (10), the gear (1), and thepuller (11).

7. Remove the camshaft gear (5). Refer to this Disas-sembly and Assembly Manual, “Camshaft Gear -Remove and Install”.

8. Remove the idler gear (13). Refer to this Disas-sembly and Assembly Manual, “Idler Gear - Re-move and Install”.

9. If necessary, remove the crankshaft gear. Refer tothis Disassembly and Assembly Manual, “Crank-shaft Gear - Remove and Install”. C34W2F3A

(1) Fluel Injection Pump Gear (11) Puller

(4) Camshaft Timing Pin (12) Holes

(10) Nut (13) Idler Gear

4. In order to lock the Bosch EPVE fuel injectionpump, loosen the locking screw (6) and removethe washer (7). Tighten the locking screw (6) to atorque of 31 N·m (3.1 kgf·m, 22.8 lbf·ft).

C34W2F1A

(6) Locking Screw (7) Washer

5. In order to lock the Delphi DP210 fuel injection pump,loosen the locking screw (8) and move the washer(9). Ensure that the washer (9) can now turn aboutthe locking screw (8) and tighten the locking screwto a torque of 17 N·m (1.7 kgf·m, 12.5 lbf·ft).

C34W2F2A

(8) Locking Screw (9) Washer

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ENGINE SYSTEM

B. INSTALLATION PROCEDURE

Part Number

27610211

27610212a

Required Tools

Part Description

Crankshaft timing pin

Camshaft timing pin

Qty

1

1

NOTE:

The fuel injection pump shaft must remain locked un-til this procedure instructs you to unlock the fuel in-jection pump shaft.

1. If necessary, install the crankshaft gear. Refer tothis Disassembly and Assembly Manual, “Crank-shaft Gear - Remove and Install”.

2. Thoroughly clean the housing (front).

3. Thoroughly clean all of the components and in-spect all of the components of the front gear group.If necessary, replace any worn components and/or any damaged components of the front geargroup.

4. Ensure that No. 1 piston is still at top dead center.

Refer to the Testing and Adjusting Manual, “Find-ing Top Center for No. 1 Piston”.

5. Install the camshaft gear (1). Refer to this Disas-sembly and Assembly Manual, “Camshaft Gear -Remove and Install”.

6. Install the idler gear (2). Refer to this Disassem-bly and Assembly Manual, “Idler Gear - Removeand Install”.

7. Ensure that the mesh of the idler gear (2) is cor-rect with the camshaft gear (1).

8. Install the fuel injection pump gear (3) onto thefuel tight.

9. Apply hand pressure to the fuel injection pump gearTighten the nut (6) to a torque of 24 N·m (2.4 kgf·m,17.7 lbf·ft).

10. Ensure that all of the timing marks on the gears(1), (2), and (3) are in alignment.

Delphi DP210 fuel injection pump.

NOTE:

The four cylinder engine can be equipped with eitherthe Delph DP210 or the Bosch EPVE fuel injectionpump. The two types of fuel injection pump have adifferent procedure for unlocking the fuel injectionpump shaft.

11. Release the locked fuel injection pump shaft.

In order to unlock the Bosch EPVE fuel injectionpump shaft, loosen the locking screw (7) and in-stall the washer (8). Tighten the locking screw (7)onto the washer (8) to a torque of 12 N·m (1.2kgf·m, 8.8 lbf·ft).

12. In order to unlock the Delphi DP210 fuel injectionpump shaft, loosen the locking screw (9) and movethe washer (10). Tighten the locking screw (9) ontothe washer (10) to a torque of 12 N·m (1.2 kgf·m,8.8 lbf·ft).

13. Tighten the nut (6) to an increased torque of90 N·m (9.1 kgf·m, 66.3 lbf·ft). Refer to illus-tration 124.

14. Remove the timing pins (4) and (5). Refer to illus-tration 123.

15. Check the backlash value for the fuel injectionpump gear (3). Refer to the Specifications Manual,“Gear Group (Front)” for further information.

16. Check the end play of the idler gear (2). Refer tothis Disassembly and Assembly Manual, “IdlerGear - Remove and Install” and refer to the Speci-fications Manual, “Gear Group (Front)” for furtherinformation.

17. Check the backlash value for the idler gear (2).

Refer to this Disassembly and Assembly Manual,“Idler Gear - Remove and Install” and refer to theSpecifications Manual, “Gear Group (Front)” forfurther information.

18. Check the end play of the camshaft gear (1).

Refer to this Disassembly and Assembly Manual,“Camshaft Gear - Remove and Install”.

19. Check the backlash value for the camshaft gear(1). Refer to this Disassembly and AssemblyManual, “Camshaft Gear - Remove and Install” andrefer to the Specifications Manual, “Gear Group(Front)” for further information.

20. Lightly lubricate each gear with clean engine lu-bricating oil.

End By:a. Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Remove and Install”.

b. Install the glow plugs. Refer to this Disassemblyand Assembly Manual, “Glow Plugs - Remove andInstall”.

c. Install the rocker shaft. Refer to this Disassemblyand Assembly Manual, “Rockershaft and Pushrod- Install”.

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CHAPTER 2 DK651/751/801/901

C34W2E4A

C34W2F0A

(1) Fuel Injection Pump Gear

(2) Three Setscrews (4) Fuel Priming Pump

(3) Connector (5) Tube Assembly

4.31 IDLER GEAR

A. REMOVAL PROCEDURE

Part Number

27610212

27610211

Required Tools

Part Name

Camshaft (Timing Pin)

Crankshaft (Timing Pin)

Qty

1

1

Start By:a. Remove the front cover if the front cover has not

previously been removed. Refer to this Disassem-bly and Assembly Manual, “Front Cover - Removeand Install”.

NOTE:

• There are two types of idler gear that may be in-stalled on these engines. The standard idler gearis supported on the hub by two bushes. The heavyduty idler gear is supported on the hub by two rollerbearings.

• If necessary, remove the glow plugs in order to al-low the crankshaft to rotate more freely. Refer tothis Disassembly and Assembly Manual, “GlowPlugs - Remove and Install”.

• The three cylinder engine is equipped with the DelphiDP210 fuel injection pump.

• The four cylinder engine is equipped with either theDelphi DP210 fuel injection pump or the BoschEPVE fuel injection pump. The two fuel injectionpumps have different drive gears. The removal pro-cedure for both drive gears is identical.

C34W2F4A

(4) Fuel Priming Pump

(9) Assembly

(11) Crankshaft Front Seal

1. Ensure that the No. 1 cylinder is at top dead cen-ter on the compression stroke. Refer to the Testingand Adjusting Manual, “Finding Top Center Posi-tion for No. 1 Piston”. Apply hand pressure to thefuel injection pump gear (1) in a counterclockwisedirection in order to remove backlash (2) in thegears. Mark the orientation of each of the gears forinstallation purposes.

NOTE:

Timing pins are used in order to time the engine at topdead center. The timing pins are a slip fit. Do not useexcessive force to install the timing pins. Do not usethe timing pins to lock the engine during repairs.

2. Insert the 27610211 Crankshaft timing pin (3)through the housing (front) and into the web of thecrankshaft if the timing pin has not previously beeninstalled. Insert the 27610212 Camshaft timing pin(4) through the camshaft gear (5) and into the hous-ing (front) if the timing pin was not previouslyinstalled.

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ENGINE SYSTEM

3. Remove the rocker shaft if the rocker shaft was notpreviously removed. Refer to this Disassembly andAssembly Manual, “Rocker Shaft and Pushrod -Remove”.

4. Remove the fuel injection pump gear (1) if the gearhas not previously been removed. Refer to this Dis-assembly and Assembly Manual, “Gear Group(Front) - Remove”.

5. Remove the three setscrews (6) from the idler gear(8). Remove the plate (7) from the idler gear (8).

6. Remove the assembly (9) of the idler gear (8) andthe hub from the recess (10) in the cylinder block.The assembly (9) must be lifted over the housingfor the crankshaft front seal (11) as the assemblyis moved forward.

7. Disassemble the assembly (9) of the idler gear (8)and the hub. In order to disassemble the standardassembly (9), slide the hub (12) out of the idler gear(8). Inspect the bushes (13) in the idler gear (8) forwear and/or damage. If necessary, remove thebushes (13) from each side of the idler gear (8).

C34W2F5A

C34W2F6A

(10) Recess

(6) Setscrews (12) Hub

(7) Plate (13) Bushes

(8) Idler Gear

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CHAPTER 2 DK651/751/801/901

4. Lift the assembly (9) of the idler gear and the hubover the housing for the crankshaft front seal (11)and insert the hub into the recess (10) in the cylin-der block.

NOTE:

Ensure that the oil hole (20) is to the top of the hub (12).

NOTE:

Ensure that the marks (19) on the idler gear assembly(9) align with the marks on the camshaft gear and withthe crankshaft gear. Refer to the illustration 135.

B. INSTALLATION PROCEDURE

Part Number

27610212

27610211

Required Tools

Part Name

Camshaft (Timing Pin)

Crankshaft (Timing Pin)

Qty

1

1

1. Clean all of the components and inspect all of thecomponents that were removed in the previousprocedure. If necessary, replace any worn compo-nent and/or any damaged component.

NOTE:

Timing pins are used in order to time the engine at topdead center. The timing pins are a slip fit. Do not useexcessive force to install the timing pins. Do not usethe timing pins to lock the engine during repairs.

2. Ensure that the No. 1 cylinder is still at top deadcenter on the compression stroke. If necessary,refer to the Testing and Adjusting Manual, “FindingTop Center Position for No. 1 Piston”.

Ensure that the timing pin (3) for the crankshaft isinstalled and that the timing pin (4) for the cam-shaft is installed.

(3) Timing Pin (4) Timing Pin

C34W2F8A

(9) Assembly (19) Marks

C34W2P9A

NOTE:

Ensure that the marks (19) on the idler gear (8) facetoward the front of the engine when the assembly (9)of the idler gear and the hub is being assembled.

3. Assemble the assembly (9) of the idler gear andthe hub. In order to assemble the standardassembly, press new bushes (13) into the idler gear(8) if the bushes were previously removed.

Lubricate the hub (12) with clean engine lubricat-ing oil. Slide the hub (12) into the idler gear (8).

Ensure that the oil hole (20) is to the top of the hub(12) and ensure that the marks (19) are to the frontof the idler gear (8).

NOTE:

The new bearing assembly (16) is supplied with a pro-tective sleeve. Do not remove this protective sleeve.The protective sleeve prevents the rollers from fallingout of the roller bearings.

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ENGINE SYSTEM

C34W2F9A

6. Align the holes in the plate (7) with the holes inthe hub (12). Insert the setscrews (6) through theplate (7) and into the hub (12).

7. Evenly tighten the setscrews (6) to a torque of 44N·m (4.5 kgf·m, 32.4 lbf·ft).

8. Check the end play for the idler gear. Refer to theillustration 141 and refer to the SpecificationsManual, “Gear Group (Front)” for more information.

9. Check the backlash between the idler gear andthe camshaft gear. Refer to the illustration 142and refer to the Specifications Manual, “GearGroup (Front)” for more information.

10. Check the backlash between the idler gear andthe crankshaft gear. Refer to the SpecificationsManual, “Gear Group (Front)” for more information.

NOTE:

The three cylinder engine is equipped with the DelphiDP210 fuel injection pump.

NOTE:

The four cylinder engine can be equipped with eitherthe Delphi DP210 fuel injection pump or the BoschEPVE fuel injection pump. The two fuel injection pumpshave different drive gears.

The installation procedure for both drive gears isidentical.

11. Install the fuel injection pump gear. Refer to thisDisassembly and Assembly Manual, “Gear Group(Front) - Install”.

12. Remove the timing pin for the crankshaft (3) andremove the timing pin for the camshaft (4).

13. Lightly lubricate all of the gears with clean enginelubricating oil.

End By:

a. Install the rocker shaft. Refer to this Disassemblyand Assembly Manual, “Rocker Shaft and Pushrod- Install”.

b. Install the glow plugs if the glow plugs were previ-ously removed. Refer to this Disassembly and As-sembly Manual, “Glow Plugs - remove and Install”.

c. Install the front cover. Refer to this Disassemblyand Assembly Manual, “Front Cover - Remove andInstall”.

C34W2G0A

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CHAPTER 2 DK651/751/801/901

4.32 HOUSING (FRONT)

A. REMOVAL PROCEDURE

Start By:

a. Drain the coolant into a suitable container for stor-age or disposal.

b. Remove the fan drive. Refer to this Disassemblyand Assembly Manual, “Fan Drive - Remove andInstall”.

c. If necessary, remove the alternator. Refer to thisDisassembly and Assembly Manual, “Alternator -Remove”.

d. Remove the fuel injection pump. Refer to the appro-priate fuel injection pump within this Disassembly andAssembly Manual, “Fuel Injection Pump - Remove”.

e. Remove the engine oil pan. Refer to this Disas-sembly and Assembly Manual, “Engine Oil Pan -Remove and Install”.

f. Remove the gear group (front). Refer to this Disas-sembly and Assembly Manual, “Gear Group (Front)- Remove”.

C34W2G1A

1. Remove the setscrews (1). Remove the bypass tube(2) from the cylinder head. Remove the O-rings fromthe bypass tube (2). Discard the O-rings.

2. Remove the setscrews (3) and the setscrews (4)that fasten the front housing (5) to the cylinder block.

3. Remove the front housing (5). Remove the joint (6)from the cylinder block and the front housing (5).

4. Remove the joint (7) from the back side of the fronthousing (5).

(1) Setscrews (2) Bypass Tube

C34W2G3A

(8) Thrust Washer (9) Camshaft

5. Remove the thrust washer (8) from the camshaft(9).

C34W2G2A

(3) Setscrews (6) Joint

(4) Bypass Tube (7) Joint

(5) Front Housing

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ENGINE SYSTEM

C34W2G4A

C34W2G5A

(1) Studs (4) Camshaft

(2) Thrust Washer (5) Joint

(3) Hollow Dowel

1. Thoroughly clean the mating surfaces on the cylin-der block for the front housing. Install two tempo-rary studs (1) into the cylinder block.

Ensure that the thrust washer (2) is aligned withthe hollow dowel (3). Install the thrust washer ontothe camshaft (4). Install a new joint (5) onto thecylinder block.

2. Thoroughly clean the front housing (6). Especiallyclean the mating surfaces of the front housing (6).Inspect the front housing (6) for wear and fordamage. If necessary, replace the front housing (6).

NOTE:

If it is necessary to replace the front housing (6), itmay also be necessary to install blanking plugs whichshould be sealed with a suitable sealant into the fronthousing.

3. Install a new joint (7) to the front housing (6).

C34W2G6A

(6) Front Housing (7) Joint

B. INSTALLATION PROCEDURE

Part Number

27610216

Required Tools

Part Name

Alignment Tool

Qty

1

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CHAPTER 2 DK651/751/801/901

4. Install the 27610216 Alignment Tool (8) into the re-cess within the cylinder block. Install the front hous-ing (6) onto the cylinder block.

5. Install the setscrews (9). Tighten the setscrews (9)finger tight. Except for the two holes with the tempo-rary studs (1), install the setscrews (10).

Tighten the setscrews (10) finger tight. Remove thetwo temporary studs (1). Install the remainder ofthe setscrews (10). Tighten the remaining two set-screws (10) finger tight.

6. Align the front housing (6) to the lower machinedface of the cylinder block (11). Use a suitable straightedge and a feeler gauge to check the tolerance forthe alignment (11). Refer to the SpecificationsManual, “Front Housing and Covers” for furtherinformation.

7. With the alignment within tolerance, tighten the set-screws (9) and the setscrews (10) to a torque of 22N·m (16 lbf·ft). Remove the alignment tool (8).

C34W2G7A

(6) Front Housing (10) Setscrews

(8) Joint (11) Cylinder Block

(9) Setscrews

8. Install new O-rings onto the bypass tube (12).

Apply POWERPART 21820221 Red Rubber Greaseto the O-rings. Install the bypass tube (12) into thecylinder head. Install the setscrews (13).

End By:a. Install the gear group (front). Refer to this Disas-

sembly and Assembly Manual, “Gear Group (Front)- Install”.

b. Install the engine oil pan. Refer to this Disassem-bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

c. Install the fuel injection pump. Refer to the appro-priate fuel injection pump within this Disassemblyand Assembly Manual, “Fuel Injection Pump -Install”.

d. Install the alternator if the alternator was removedpreviously. Refer to this Disassembly and Assem-bly Manual, “Alternator - Install”.

e. Install the fan drive. Refer to this Disassembly andAssembly Manual, “Fan Drive - Remove and Install”.

f. At the appropriate time, fill the cooling system.

C34W2G8A

(12) Bypass Tube (13) Setscrews

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ENGINE SYSTEM

4.33 ACCESSORY DRIVE

A. REMOVAL PROCEDURE1. Remove the setscrews (1) and the front cover (2).

2. Remove the Allen head screws (3) and (4).

Remove the accessory drive assembly from the rearface of the front housing (6).

3. Remove the circlip (5).

4. Place the flange of the front housing (6) onto a suit-able support. Press the assembly of the gear (7)and the bearings (8 and 9) out of the front housing(6). Use a suitable puller in order to remove thebearings (8 and 9) from the gear (7).

5. Remove the O-ring (10) from the front housing (6)and discard the O-ring.

C34W2G9A

(1) Setscrews (6) Front Housing

(2) Front Cover (7) Gear

(3) Screws (8) Bearings

(4) Screws (9) Bearings

(5) Circlip (10) O-ring

B. INSTALLATION PROCEDURE1. Inspect the condition of the teeth and the splines

of the gear (7), the bearings (8 and 9), the circlip(5), and the groove for the circlip in the front hous-ing (6) for wear and for damage.

Replace any worn component or any damagedcomponent.

2. Apply a small continuous bead (11) of 21820603POWERPART Retainer (oil tolerant) to the outersurface of the bearing (9). Place the front flange ofthe front housing (6) onto a suitable support.

Press on the outer race of the bearing (9) until thebearing is against the front face of the recess forthe bearing in the front housing (6). Remove anyexcess sealant.

3. Apply a small continuous bead (12) of 21820603POWERPART Retainer (oil tolerant) to the innersurface of the bearing (9). Place the front face of theinner race of the bearing (9) onto a suitable support.Press the smaller shaft of the gear (7) into the bear-ing (9) until the shoulder of the gear is against thebearing. Remove any excess sealant.

C34W2H0A

(1) Setscrews (8) Bearings

(2) Front Cover (9) Bearings

(3) Screws (10) O-ring

(4) Screws (11) Bead

(5) Circlip (12) Bead

(6) Front Housing (13) Bead

(7) Gear (14) Bead

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CHAPTER 2 DK651/751/801/901

4. Apply a small continuous bead (14) of 21820603POWERPART Retainer (oil tolerant) to the outersurface of the bearing (8). Apply a small continuousbead (13) of 21820603 POWERPART Retainer (oiltolerant) to the inner surface of the bearing (8). En-sure that the front face of the inner race of the bear-ing (9) is still on a suitable support. Press the bear-ing (8) onto the larger shaft of the gear (7) until thebearing (9) is against the shoulder of the gear. Re-move any excess sealant.

5. Install the circlip (5) into the groove in the front hous-ing (6). Ensure that the circlip (5) is correctly posi-tioned in the groove.

6. Refer to the illustration 154 and check the backlashbetween the idler gear and gear (7). The backlashshould be within 0.11 ~ 0.17 mm (0.004 ~ 0.007 in.).

7. Lightly lubricate a new O-ring (10) with 21820221POWERPART Red Rubber Grease and install theO-ring into the recess in the front housing (6). Lightlylubricate the bearing (8), the bearing (9), and thegear (7) with clean engine lubricating oil.

8. By using the Allen head screws (3 and 4), install theassembly of the accessory drive to the rear of thefront housing (6). Refer to the Torque SpecificationsManual, “Standard Torques for Metric Fasteners” forthe correct torques.

9. By using the setscrews (1), install the front cover(2). Refer to this Disassembly and Assembly Manual,“Front Cover - Remove and Install.”.

C34W2H1A

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ENGINE SYSTEM

C34W2H2A

4.34 CRANKCASE BREATHER

A. REMOVAL PROCEDURE FOR THE DIA-PHRAGM VALVE

NOTE:

All naturally aspirated three cylinder and four cylinderengines in the 1100 Series are equipped with a closedbreather system. A closed breather system is optionalfor turbocharged three cylinder and four cylinder en-gines in the 1100 Series.

NOTE:

All of the engines that are equipped with a closedbreather system have a diaphragm valve in the valvemechanism cover.

1. Refer to the appropriate illustration 155 or illustra-tion 156. Loosen the hose clamp (1) and releasethe hose from the connector (2).

2. Remove the fasteners (3) and remove the connec-tor (2) from the cylinder head and from the valvemechanism cover (4). Remove the O-ring (5) fromthe connector (2). Discard the O-ring (5). Removethe joint (6). Discard the joint (6).

3. Remove the plastic cover (7) from the valve mecha-nism cover (4).

(1) Hose Clamp (8) Screws

(2) Connector (9) Plate

(3) Fasteners (10) Diaphragm

(4) Cover (11) Cap

(5) O-ring (12) Spring

(6) Joint (13) Recess

(7) Cover

4. Remove the screws (8). Remove the plate (9).

5. Remove the diaphragm (10) and the cap (11).

Remove the spring (12).

6. If the recess (13) for the assembly of the diaphragmvalve needs to be cleaned, remove the valve mecha-nism cover (4). Refer to this Disassembly and As-sembly Manual, “Valve Mechanism Cover - Removeand Install”. If necessary, thoroughly clean the valvemechanism cover (4) and especially clean the re-cess (13).

• Personal injury can result from parts and/or cov-ers under spring pressure.

• Spring force will be released when covers areremoved.

• Be prepared to hold spring loaded covers as thebolts are loosened.

WARNING

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE FOR THEDIAPHRAGM VALVE

NOTE:

The installation procedure is identical for the three cyl-inder and the four cylinder engines. The illustrationsshow the four cylinder engine.

1. Thoroughly clean all of the previously removedcomponents. Inspect all of the components for wearand for damage. Especially check the condition ofthe hose for the connector (2) and the diaphragm(10) for damage. Replace any component that isworn and/or damaged.

2. If the valve mechanism cover (4) was removed, in-stall the valve mechanism cover. Refer to this Dis-assembly and Assembly Manual, “Valve MechanismCover - Remove and Install”.

• Improper assembly of parts that are spring loadedcan cause bodily injury.

• To prevent possible injury, follow the establishedassembly procedure and wear protectiveequipment.

WARNING

3. Install the spring (12), the cap (11), and the dia-phragm (10) into the recess (13) in the valve mecha-nism cover (4).

4. Ensure that the two domes (14) are uppermost andensure that the hole (15) is toward the connector(2) of the valve mechanism cover (4). Refer to illus-tration 158. Install the plate (9).

Install the screws (8). Tighten the screws (8) to atorque of 1.3 N·m (0.13 kgf·m, 0.9 lbf·ft).

5. Push the plastic cover (7) onto the valve mecha-nism cover (4).

6. Install a new O-ring (5) onto the connector (2).

7. Install a new joint (6) to the connector (2). Install theconnector (2) into the valve mechanism cover (4)and onto the cylinder head.

8. Install the fasteners (3). Tighten the fasteners (3) toa torque of 9 N·m (0.9 kgf·m, 6.6 lbf·ft).

9. Install the hose onto the connector (2). Ensure thatthe hose is clear of all hot surfaces, clear of allcomponents that move, and clear of all componentsthat vibrate when the engine is operating. Tightenthe hose clamp (1) to a torque of 5 N·m (0.5 kgf·m,3.6 lbf·ft).

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ENGINE SYSTEM

4.35 VALVE MECHANISM COVER

A. REMOVAL PROCEDURE

Start By:a. Remove the heat shields, if equipped.

b. Remove the cover for the fuel injectors. Refer to thisDisassembly and Assembly Manual, “Fuel InjectorCover - Remove and Install”.

1. Remove the breather tube (3) from the valve mecha-nism cover (1). Refer to this Disassembly and As-sembly Manual, “Crankcase Breather - Remove andInstall”.

2. Remove the fasteners (2). Remove the valve mecha-nism cover (1). Remove the joint for the valve mecha-nism cover and discard the joint.

C34W2H3A

(1) Cover (3) Breather Tube

(2) Fasteners

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CHAPTER 2 DK651/751/801/901

C34W214A

6. If you are working on a four cylinder engine, tighten thefasteners for the valve mechanism cover in the se-quence that is shown in Illustration 162. Tighten thefasteners to a torque of 9 N·m (0.9 kgf·m, 6.6 lbf·ft).

7. Connect the breather tube (3) to the valve mecha-nism cover (1). Refer to this Disassembly and As-sembly Manual, “Crankcase Breather - Remove andInstall”.

End By:a. Install the cover for the fuel injectors. Refer to this

Disassembly and Assembly Manual, “Fuel InjectorCover - Remove and Install”.

b. If equipped, ensure that the heat shields are cleanand free from dust, oil, and paint. Install the heatshields.

B. INSTALLATION PROCEDURE

NOTE:

The installation procedure is identical for the threecylinder and the four cylinder engines. Only the se-quence for tightening the fasteners for the valve mecha-nism cover is different. Refer to the appropriate illus-tration for further information.

1. Thoroughly clean the valve mechanism cover (1).Ensure that the groove for the joint for the valvemechanism cover (1) is clean and dry.

Ensure that the mating face on the cylinder head isclean and dry.

2. If the valve mechanism cover (1) is equipped withan oil filler cap, check the condition of the O-ring forthe oil filler cap. If necessary, replace the O-ring.

3. Install a new joint to the valve mechanism cover (1)and install the valve mechanism cover onto the cyl-inder head.

4. Check the condition of the fasteners (2). Replace thefasteners (2), if necessary. Install the fasteners (2).

5. If you are working on a four cylinder engine, go toStep 6. If you are working on a three cylinder engine,tighten the fasteners for the valve mechanism coverin the sequence that is shown in Illustration 161.Tighten the fasteners to a torque of 9 N·m (0.9 kgf·m,6.6 lbf·ft). Go to Step 7

C34W215A

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ENGINE SYSTEM

C34W2H4A

(1) Rocker Shaft Assembly

(2) Rocker Arms

(3) Cylinder Head

(4) Pushrods

(6) Assembly Tools

(7) Spring

1. If the rocker shaft will not be disassembled, installthe rocker assembly tools (6) between each pair ofrocker arms (2). The rocker arms (2) must be heldaway from the machined face of the cylinder head(3) during reassembly.

2. Start from the ends of the rocker shaft assembly (1)and work toward the center of the rocker shaft as-sembly in order to remove the torx screws (5). Evenlyloosen the torx screws (5) in order to remove therocker shaft assembly (1).

3. Remove the rocker shaft assembly (1) from the cyl-inder head (3).

4. Place an identification mark on the pushrods (4) forinstallation. Remove the pushrods (5) from the cyl-inder head (3).

4.36 ROCKER SHAFT AND PUSHROD

A. REMOVAL PROCEDURE

Part Number

27610227

Required Tools

Part Description

Rocker Assembly Tool

Qty

4

Start By:a. Remove the valve mechanism cover. Refer to this

Disassembly and Assembly Manual, “Valve Mecha-nism Cover - Remove and Install”.

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

Part Number

27610227

Required Tools

Part Description

Rocker Assembly Tool

Qty

4

1. Apply clean engine lubricating oil to both ends ofthe pushrods (4). Install the pushrods (4).

NOTE:

Ensure that the pushrods (4) are installed in the origi-nal location and that the pushrods are seated in thevalve lifters correctly.

2. If the rocker shaft assembly was disassembled, in-stall 27610227 Rocker Assembly Tool (6) aroundthe rocker arms (2) in order to slightly compressthe spring (7). The rocker arms (2) must be heldaway from the machined face of the cylinder head(3) during reassembly.

3. Loosen the nut (8) and the adjustment screw (9) oneach rocker arm (2). This will help prevent a bentvalve or a bent pushrod during the installation ofthe rocker shaft.

NOTE:

The rocker shaft of the rocker shaft assembly (1) isnot symmetrical. The rocker shaft has a machined flat(10) at the front end of the shaft.

Ensure that the machined flat (10) is toward the topand toward the front end of the engine.

4. Position the rocker shaft assembly (1) onto the cyl-inder head (3).

5. Install the torx screws (5) in the rocker shaft (3).

NOTE:

The longest torx screw (5) must be installed at thefront of the cylinder head in hole (11).

6. Ensure that the adjustment screws (9) are properlyseated in the ends of pushrods (4).

7. Alternately tighten the torx screws (5). Start fromthe center and work toward the outside. Tighten torxscrews (5) to a torque of 35 N·m (3.5 kgf·m, 26 lbf·ft).

8. Remove the rocker assembly tool (6) from the rockershaft assembly (1).

9. Adjust the inlet valve lash to 0.20 mm (0.008 in.)and adjust the exhaust valve lash to 0.45 mm (0.018in.). Refer to the Testing and Adjusting Manual, “En-gine Valve Lash - Inspect/Adjust” for more informa-tion on adjusting the valve lash.

End By:a. Install the valve mechanism cover. Refer to this Dis-

assembly and Assembly Manual, “Valve MechanismCover - Remove and Install”.

C34W2Q0A

(4) Pushrods (8) Nut

(5) Torx Screws (9) Screw

C34W2H6A

(10) Flat (11) Hole

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ENGINE SYSTEM

C. DISASSEMBLY PROCEDURE

Required Tools

Part Description

Suitable Pliers for External Circlips

Qty

1

Start By:a. Remove the rocker shaft assembly. Refer to this

Disassembly and Assembly Manual, “Rocker Shaftand Pushrod - Remove”.

• Personal injury can result from being struck byparts propelled by a released spring force.

• Make sure to wear all necessary protectiveequipment.

• Follow the recommended procedure and use allrecommended tooling to release the spring force.

WARNING

1. Remove the circlip (1) and remove the washer (2)from both ends of the rocker shaft assembly.

NOTE:

The rocker shaft (6) is not symmetrical as there is amachined flat (7) toward one end of the shaft.

2. Place an identification mark on each of the compo-nents for installation. Ensure that you note thecomponent’s relationship to the machined flat (7).

3. Remove the rocker arm assembly (3) for the inletvalve from the rocker shaft (6). Remove the rockerarm assembly (4) for the exhaust valve from therocker shaft (6).

4. Remove the spring (5) from the rocker shaft (6).

5. Repeat Step 3 and Step 4 in order to completelydisassemble the rocker shaft assembly.

C34W2H5A

(1) Circlip

(2) Washer

(3) Rocker Arm Assembly

(4) Rocker Arm Assembly

(5) Spring

(6) Rocker Shaft

(7) Machined Flat

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CHAPTER 2 DK651/751/801/901

8. Install the remaining washer (2) and the remainingcirclip (1) onto the rocker shaft (6).

End By:

a. Install the rocker shaft assembly. Refer to this Dis-assembly and Assembly Manual, “Rocker Shaft andPushrod - Install”.

• Improper assembly of parts that are springloaded can cause bodily injury.

• To prevent possible injury, follow the estab-lished assembly procedure and wear protectiveequipment.

WARNING

D. ASSEMBLY PROCEDURE

Required Tools

Part Description

Suitable Pliers for External Circlips

Qty

1

1. Clean all of the components and inspect all of thecomponents. Inspect the grooves for the circlips (1)and ensure that all of the oil holes in the rockershaft (6) and in the rocker arms (3 and 4) are notplugged before you begin the assembly procedure.If necessary, replace any worn components and anydamaged components.

2. Check the clearance between the rocker shaft (6)and the bushing of every rocker arm (3 and 4). Re-fer to the Specifications Manual, “Rocker Shaft” orfurther information. If necessary, replace any worncomponents.

3. Lubricate all of the components with clean engineoil before assembly.

NOTE:

Ensure that the machined flat (7) on the rocker shaft(6) is facing upward.

4. Install a circlip (1) onto the end of the rocker shaft(6) that is closest to the machined flat (7).

Install a washer (2) onto the rocker shaft (6).

5. Install the rocker arm assembly (3) for the inlet valveonto the rocker shaft (6). Install the rocker arm assem-bly (4) for the exhaust valve onto the rocker shaft (6).

6. Install the spring (5) onto the rocker shaft (6).

7. Repeat Step 5 and Step 6 in order to assemble therocker shaft assembly.

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ENGINE SYSTEM

4.37 CYLINDER HEAD

A. REMOVAL PROCEDURE

Start By:a. Drain the coolant from the engine into a suitable

container for storage or disposal.

Drain the engine oil from the engine into a suitablecontainer. Refer to the Operation and MaintenanceManual for the procedure on draining the enginecoolant and the engine oil.

b. Remove the hose from the air filter to the integral airinlet. Refer to the OEM information for further details.

c. Remove the fuel priming pump. Refer to this Disas-sembly and Assembly Manual, “Fuel Priming Pump- Remove and Install”.

d. Remove the pipe for the boost control, if equipped.

e. Remove the fuel injectors. Refer to this Disassem-bly and Assembly Manual, “Fuel Injector - Remove”.

f. Remove the exhaust manifold. Refer to this Disas-sembly and Assembly Manual, “Exhaust Manifold -Remove and Install”.

g. Remove the rocker shaft assembly and thepushrods. Refer to this Disassembly and Assem-bly Manual, “Rocker Shaft and Pushrod - Remove”.

h. Remove the glow plugs. Refer to this Disassemblyand Assembly Manual, “Glow Plugs - Remove andInstall”.

1. Disconnect the harness assembly from the coolanttemperature sensor (1).

2. Remove the setscrews (2). Remove the bypass tube(3) from the cylinder head (4). Remove the O-ringsfrom the bypass tube (3).

C34W2H7A

(1) Coolant Temperature Sensor

(2) Setscrews

(3) Bypass Tube

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CHAPTER 2 DK651/751/801/901

3. Refer to the illustration 174 for three cylinder en-gines or illustration 175 for four cylinder engines.Gradually loosen the setscrews (5) in the reversenumerical order. This will help prevent distortion ofthe cylinder head (4).

4. Remove the setscrews (5) from the cylinder head(4).

NOTE:

The cylinder head (4) is heavy. To avoid injury, takecare when the cylinder head (4) is lifted. Also takecare not to damage the machined surfaces of the cyl-inder head (4) during lifting and lowering the cylinderhead.

NOTE:

Do not use a lever to separate the cylinder head (4)from the cylinder block.

C34W2H8A

C34W2H9A

• Place the cylinder head on a surface that will notscratch the face of the cylinder head.

CAUTION

5. Use a suitable lifting device and carefully lift the cyl-inder head (4) off the cylinder block.

6. Remove the cylinder head gasket and discard thecylinder head gasket.

7. Note the location of the dowels in the cylinder blockfor installation purposes.

C34W2I0A

(4) Cylinder Head

(5) Setscrews

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ENGINE SYSTEM

B. INSTALLATION PROCEDURE

Part Number

21825607

Required Tools

Part Description

Angle Gauge

Qty

1

NOTE:

• Thoroughly clean the top of the cylinder block (1)and the bottom of the cylinder head (2). Ensurethat there is no debris in the cylinder bores, thecoolant passages, and the lubricant passages.

• Thoroughly clean the hole in the cylinder head forthe gas that is ventilated from the crankcase.

Ensure that the hole is not restricted by debris and/or oil deposits.

1. Install suitable studs (3) into the cylinder block (1)in the setscrew holes 2 and 3. Refer to the illustra-tion 179 for the three cylinder and refer to the illus-tration 180 for the four cylinder head.

NOTE:

• Do not use any sealant or compound on the cylin-der head gasket (4).

C34W2I1A

(1) Cylinder Block (4) Cylinder Head Gasket

(3) Studs (5) Dowels

C34W2I2A

(2) Cylinder Head (7) Threads

(6) Setscrews

2. Install the cylinder head gasket (4) onto the studs(3) and onto the dowels (5) in the top of the cylinderblock (1).

NOTE:

The cylinder head (2) is heavy. To avoid injury, takecare when the cylinder head (2) is lifted. Also takecare not to damage the machined surfaces of the cyl-inder head (2) during lifting and lowering the cylinderhead.

3. Use a suitable lifting devce to install the cylinderhead (2).

NOTE:

Ensure that the cylinder head (2) is positioned ontothe dowels (5).

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CHAPTER 2 DK651/751/801/901

C34W2H9A

4. Remove the studs (3).

5. Clean the threads of the setscrews (6) for the cylin-der head (2). Inspect the setscrews (6) for the cylin-der head (2).

NOTE:

Do not use the setscrews (6) if there is any visual re-duction in the diameter of the threads (7) that have notbeen engaged with the cylinder block (1). Use astraight edge to check the setscrews (6).

6. Lubricate the threads and the shoulder of the set-screws (6) for the cylinder head (2) with clean en-gine oil before installation.

NOTE:

There are two different lengths of setscrew (6) for thecylinder head (2).

NOTE:

For the three cylinder engine, the short setscrews (6)are installed into the holes that are marked 2, 5, 6, 7,and 8. The long setscrews (6) are installed into theholes that are marked 1, 3, and 4.

NOTE:

For the four cylinder engine, the short setscrews (6) areinstalled into holes that are marked 2, 5, 6, 7, 8, 9, and10. The long setscrews (6) are installed into the holesthat are marked 1, 3, and 4.

7. Install the appropriate setscrews (6) into the cylin-der head (2).

8. Tighten the setscrews (6) for the cylinder head (2)in numerical order to a torque of 50 N·m (5.0 kgf·m,37 lbf·ft). Refer to the illustration 179 for the threecylinder and refer to illustration 180 for the four cyl-inder engine.

9. Tighten the setscrews (6) for the cylinder head (2)again in the appropriate numerical order to a torqueof 100 N·m (10 kgf·m, 74 lbf·ft). Refer to the illus-tration 179 for the three cylinder and the illustra-tion 180 for the four cylinder engine.

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ENGINE SYSTEM

C34W2I5A

(8) Angle Gauge (10) Stop

(9) Wrench (11) Pointer

10. Finally tighten the setscrews (6) for the cylinderhead (2) in the appropriate numerical order by anadditional amount of degrees.

a. Turn the short setscrews (2, 5, 6, 7, and 8) forthe three cylinder or turn the short setscrews(2, 5, 6, 7, 8, 9, and 10) for the four cylinderengine for an additional 225 degrees.

b. Turn the long setscrews (1, 3, and 4) for anadditional 270 degrees.

11. Use 21825607 Angle Gauge in order to achievethe correct final torque.

12. Install the angle gauge (8) onto a suitable ratchetwrench (9). Refer to the appropriate illustration forthe first setscrew (6) of the tightening sequence,illustration 179 for the three cylinder and illustra-tion 180 for the four cylinder engine. Position thestop (10) against a suitable protrusion on the cyl-inder head (2) in order to prevent movement of theangle gauge (8) in a clockwise direction. Align thepointer (11) of the angle gauge (8) with the appro-priate angle on the dial of the angle gauge. Tightenthe appropriate setscrew (6) until the pointer alignswith the zero on the dial of the angle gauge (8).

13. Repeat Step 12 for all of the cylinder head set-screws (6) in the correct tightening sequence.

Refer to illustration 179 for the three cylinder andillustration 180 for the four cylinder engine.

NOTE:

The following alternative method can be used if21825607 Angle Gauge is not available.

NOTE:

For reference, 225 degrees of rotation is equal to 3.75flats on the setscrew and 270 degrees of rotation isequal to 4.5 flats on the setscrew.

14. Place an index mark on the cylinder head (2) inline with a corner of each setscrew (6). Make an-other mark in a counter clockwise direction andat the correct angle for the length of setscrew (6)on the edge of the setscrew.

15. Tighten the setscrews (6) for the cylinder head (2)in numerical order. Refer to the illustration 179 forthe three cylinder and illustration 180 for the fourcylinder engine.

16. Turn the short setscrews (2, 5, 6, 7, and 8) or turnthe short setscrews (2, 5, 6, 7, 8, 9, and 10)through an additional 225 degrees.

C34W2I0A

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CHAPTER 2 DK651/751/801/901

C34W2I6A

(12) Bypass Tube

(13) Setscrews

(14) Coolant Temperature Sensor

17. Apply 21820221 POWERPART Red RubberGrease to the new O-rings before the O-rings areinstalled onto the bypass tube (12). Install the newO-rings onto the bypass tube (12). Install the by-pass tube (12) into the cylinder head (2). Installthe setscrews (13).

18. Connect the harness assembly onto the coolanttemperature sensor (14).

End By:a. Install the glow plugs. Refer to this Disassembly

and Assembly Manual, “Glow Plugs - Remove andInstall”.

b. Install the rocker shaft and the pushrods. Refer tothis Disassembly and Assembly Manual, “RockerShaft and Pushrod - Install”.

c. Install the exhaust manifold. Refer to this Disas-sembly and Assembly Manual, “Exhaust Manifold -Remove and Install”.

d. Install the fuel injectors. Refer to this Disassemblyand Assembly Manual, “Fuel Injector - Install”.

e. Install the pipe for the boost control, if equipped.

f. Install the fuel priming pump. Refer to this Disas-sembly and Assembly Manual, “Fuel Priming Pump- Remove and Install”.

g. Install the hose from the integral air inlet to the airfilter. Refer to the OEM information for further details.

h. Refill the engine with coolant and engine oil.

Refer to the Operation and Maintenance Manual forthe correct procedure, the quantities, the coolantspecification, and the specification for the engine oil.

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ENGINE SYSTEM

4.38 LIFTER GROUP - INSTALL

A. REMOVAL PROCEDURE

Start By:a. Remove the cylinder head if the cylinder head has not

previously been removed. Refer to this Disassemblyand Assembly Manual, “Cylinder Head - Remove”.

b. Remove the engine oil pan if the engine oil pan hasnot previously been removed. Refer to this Disas-sembly and Assembly Manual, “Engine Oil Pan -Remove and Install”.

c. Remove the camshaft. Refer to this Disassembly andAssembly Manual, “Camshaft - Remove and Install”.

1. Use a suitable magnet to remove each cam fol-lower (1).

NOTE:

Place an identification mark on each cam follower forinstallation purposes.

C34W2I7A

(1) Cam Follower

B. INSTALLATION PROCEDURE1. Lubricate each cam follower (1) with clean engine oil.

2. Install each cam follower (1) into the appropriatehousing in the cylinder block.

NOTE:

Ensure that each cam follower (1) is installed in theoriginal location and that each cam follower is seatedcorrectly.

End By:a. Install the camshaft. Refer to this Disassembly and

Assembly Manual, “Camshaft - Remove and Install”.

b. Install the engine oil pan if this is the appropriatetime. Refer to this Disassembly and AssemblyManual, “Engine Oil Pan - Remove and Install”.

c. Install the cylinder head if this is the appropriatetime. Refer to this Disassembly and AssemblyManual, “Install”.

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

NOTE:

Ensure that the camshaft (3) is clean.

Lubricate the camshaft (3) with clean engine oil priorto installation.

• Do not damage the lobes or the bearings whenthe camshaft is removed or installed.

CAUTION

1. Carefully install the camshaft (3) into the cylinderblock.

2. Put the thrust washer (1) in position if this is theappropriate time. Make sure that the thrust washer(1) is aligned with the hollow dowel (2).

End By:a. Install the front housing if this is the appropriate

time. Refer to this Disassembly and AssemblyManual, “Housing (Front) - Install”.

b. Install the cylinder head if this is the appropriatetime. Refer to this Disassembly and AssemblyManual, “Cylinder Head - Install”.

4.39 CAMSHAFT

A. REMOVAL PROCEDURE

Start By:a. Remove the cylinder head if the cylinder head has

not previously been removed. Refer to this Disas-sembly and Assembly Manual, “Cylinder Head -Remove”.

b. Remove the front housing if the front housing hasnot previously been removed. Refer to this Disas-sembly and Assembly, “Housing (Front) - Remove”.

1. Turn the engine upside-down so that the cam fol-lowers are held in a position away from the camshaft.

2. Remove the thrust washer (1) if the thrust washerhas not previously been removed. Make a note ofthe location of the hollow dowel (2) for installationpurposes.

C34W2I8A

(1) Thrust Washer (3) Camshaft

(2) Hollow Dowel

• Do not damage the lobes or the bearings whenthe camshaft is removed or installed.

CAUTION

3. Carefully remove the camshaft (3) from the cylinderblock.

C34W2I9A

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ENGINE SYSTEM

4.40 CAMSHAFT GEAR

A. REMOVAL PROCEDURE

Start By:a. Remove the front cover if the front cover has not

previously been removed. Refer to this Disassem-bly and Assembly Manual, “Front Cover - Removeand Install”.

b. Remove the idler gear if the idler gear has not pre-viously been removed. Refer to this Disassemblyand Assembly Manual, “Idler Gear - Remove andInstall”.

1. Remove the setscrew (1) and the washer from thecamshaft gear (2).

2. Remove the camshaft gear (2) from the camshaft.

NOTE:

Do not lose the key that is located in the camshaft forthe camshaft gear (2).

(1) Setscrew (2) Camshaft Gear

B. INSTALLATION PROCEDURE1. Inspect the camshaft gear (2) and the key in the

camshaft for wear or damage.

2. Ensure that the marked teeth on the camshaft gear(2) are facing toward the front and that the key isinstalled in the camshaft. Install the camshaft gear(2) onto the camshaft. If necessary, tap the cam-shaft gear (2) with a soft hammer in order to seatthe key in the keyway.

3. Install the setscrew (1) and the washer onto thecamshaft gear (2). Tighten the setscrew (1) to atorque of 95 N·m (9.6 kgf·m, 70 lbf·ft).

End By:a. Install the idler gear if ths is the appropriate time.

Refer to this Disassembly and Assembly Manual,“Idler Gear - Remove and Install”.

b. Install the front cover if this is the appropriate time.Refer to this Disassembly and Assembly Manual,“Front Cover - Remove and Install”.

C34W2J0A

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CHAPTER 2 DK651/751/801/901

4.41 CAMSHAFT BEARINGS

A. REMOVAL PROCEDURE

Start By:a. Remove the camshaft. Refer to this Disassembly

and Assembly Manual, “Camshaft - Remove andInstall”.

1. If the camshaft bearing (1) is worn or damaged usea suitable adapter in order to press the bearing outof the cylinder block.

(1) Camshaft Bearing

B. INSTALLATION PROCEDURE1. Ensure that the bearing housing in the cylinder block

is clean. Ensure that the oil hole in the bearing hous-ing is clean and free from debris.

NOTE:

Align the oil hole in camshaft bearing (1) with the oilhole in the cylinder block.

2. Use a suitable adapter in order to press the cam-shaft bearing (1) into the cylinder block.

Continue to press the camshaft bearing (1) into thecylinder block until the bearing is flush with the faceof the recess in the cylinder block.

Ensure that the oil holes are still in alignment.

End By:a. Install the camshaft. Refer to this Disassembly and

Assembly Manual, “Camshaft - Remove and Install”.

C34W2J1A

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ENGINE SYSTEM

4.42 ENGINE OIL PAN

A. REMOVAL PROCEDURE

NOTE:

Ensure that the engine oil pan is fully supported be-fore the oil pan is removed. Particular care must betaken with the cast iron version of the engine oil sumpas this version is heavy.

1. Remove all dirt, oil, and grease from the exteriorsurfaces of the oil pan (5).

2. Operate the engine until the engine is warm.

Stop the engine.

3. If necessary, remove the nut (2), the seal, and thetube assembly from the engine oil pan (5).

4. Remove the oil drain plug (6) and the O-ring.

Drain the engine oil into a suitable container forstorage or disposal.

5. Remove the setscrews (3) and the setscrews (4)from the engine oil pan (5).

6. Remove engine oil pan (5) and remove the joint (1)from the cylinder block. Discard the joint (1).

7. Clean the engine oil pan (5) with a suitable clean-ing fluid. Ensure that all of the cleaning fluid isremoved.

(1) Joint (4) Setscrew

(2) Nut (5) Oil Pan

(3) Setscrew (6) Oil Drain Plug

C34W2J2A

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

NOTE:

If the bridge for the cylinder block and/or the timingcase have just been installed the engine oil pan mustbe installed before the silicon sealant has cured.

NOTE:

Ensure that any old silicon rubber sealant is removedfrom the mating surfaces of the engine oil pan whenthe sump is installed.

1. Clean the flange face of the engine oil pan (5) andthe flange face of the cylinder block.

2. Install four temporary studs (7) as guides. Refer toillustration 193 for the correct location of the tempo-rary studs (7).

NOTE:

When the joint for the engine oil pan is removed, dam-age may occur to the existing sealant in the bridge ofthe cylinder block.

C34W2J3A

(7) Studs

3. If the silicon sealant is damaged, apply a sufficientamount of 21826038 POWERPART Silicone Rub-ber Sealant in order to fill the groove (8).

C34W2J4A

(8) Groove

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ENGINE SYSTEM

4. Also, apply a sufficient amount of new silicon rub-ber sealant if the silicon rubber sealant (9) be-tween the cylinder block and the front cover isdamaged.

5. Carefully position the joint (1) over the temporarystuds (7). Ensure that the engine oil pan is prop-erly supported while the engine oil pan (5) is in-stalled onto the temporary studs (7). The cast ironsump is heavy.

NOTE:

New setscrews have sealant on the first 13 mm (0.5in.) of the threads. In order to reuse the old setscrews,clean the old sealant from the setscrews and apply21820117 POWERPART Threadlock and Nutlock tothe setscrews.

6. Install the setscrews (4) in order to secure theengine oil pan (5) to the cylinder block. Tightenthe setscrews (4) finger tight.

C34W2J5A

(9) Silicon Rubber Sealant

C34W2J6A

(10) Four Setscrews

7. Remove the temporary studs (7) and install the re-maining setscrew (3 and 4). Tighten the four set-screws (10) to a torque of 22 N·m (2.2 kgf·m, 16.2lbf·ft).

8. Tighten remaining setscrews (3) and setscrews(4) to a torque of 22 N·m (2.2 kgf·m, 16.2 lbf·ft).

9. Inspect the O-ring for the drain plug (6). Replacethe O-ring if it is necessary. Install the O-ring sealand drain plug (6). Tighten the drain plug (6) to atorque of 34 N·m (3.4 kgf·m, 25 lbf·ft).

10. If necessary, install the seal and the tube assem-bly in the engine oil pan. Tighten the nut (2) to atorque of 18 N·m (1.8 kgf·m, 13.2 lbf·ft).

11. Fill the engine oil pan to the correct level that isindicated on the engine oil level gauge. Refer tothe Operation and Maintenance Manual, “RefillCapacities” for the lubrication system capacity ofthe engine.

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1. Put the No. 1 cylinder at top dead center on thecompression stroke. Refer to this Testing and Ad-justing Manual, “Fuel Injection Timing - Check”.

2. Install the 27610225 Timing Pin into the balancer.Ensure that the timing pin (1) is fully located into thedrive shaft (2).

NOTE:

The balancer is heavy. Take care when the balanceris lifted and/or when the balancer is lowered. If theengine is not inverted, support the balancer beforeremoving the setscrews (3).

3. Refer to the Note above and remove the setscrews(3). Use a suitable lifting device to remove thebalancer.

NOTE:

The balancer is a nonserviceable item. Use the fol-lowing procedure in order to remove the engine oil pumpfrom the balancer.

4. Remove the setscrew (4) and the shaft (5).

Remove the idler gear (6) and the thrust washer (7).Use a suitable adapter in order to press the bearing(8) from the idler gear (6). Discard the bearing (8).

5. Remove the nut (9). Use a suitable puller in order toremove the gear (10) from the shaft.

6. Remove the setscrews (11). Remove the cover (12).

7. Remove the rotor assembly (13).

8. If necessary, remove the dowel (14) and the hollowdowel (15).

C34W2J7A

(1) Timing Pin (3) Setscrews

(2) Drive Shaft

4.43 BALANCER (4 CYLINDERENGINES ONLY)

A. REMOVAL PROCEDURE

Part Number

27610225

Required Tools

Part Description

Timing Pin (Balancer)

Qty

1

Start By:a. Remove the engine oil pan. Refer to this Disas-

sembly and Assembly Manual, “Engine Oil Pan -Remove and Install”.

b. Remove the engine oil relief valve. Refer to this Disas-sembly and Assembly Manual, “Engine Oil Relief Valve- Remove and Install (Balancer Unit for the Engine)”.

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ENGINE SYSTEM

Part Number

27610225

Required Tools

Part Description

Timing Pin (Balancer)

Qty

1

B. INSTALLATION PROCEDURE1. Clean all of the components and inspect all of the

components that were removed previously.

Replace any component that is worn or damaged.

2. Clean the mating surfaces of the cylinder blockand the balancer.

3. Install the rotor assembly (13). Check the clear-ance between the outer rotor and the body.

Check the clearance between the inner rotor andthe outer rotor. Check the end play for the rotorassembly. Refer to the Specifications Manual, “En-gine Oil Pump” for information.

4. Lubricate the rotor assembly (13) with clean en-gine oil. Install the cover (12). Install the setscrews(11). Tighten the setscrews (11) to a torque of 28N·m (2.8 kgf·m, 20.6 lbf·ft).

5. Ensure that the threads (16) of the shaft are cleanand dry. Position the oil pump gear (10) onto theshaft. Install the nut (9). Tighten the nut (9) to atorque of 95 N·m (9.6 kgf·m, 70 lbf·ft).

6. Install a new bearing (8) into the idler gear (6).

7. Lubricate the bearing (8) with clean engine oil.

Install the shaft (5) into the idler gear (6).

8. Position the idler gear (6) and the thrust washe(7) onto the balancer. Ensure that the threads ofthe setscrew (4) are clean and dry. Apply 21820117POWERPART Threadlock and Nutlock to thethreads of the setscrew (4) and instal l thesetscrew. Tighten the setscrew (4) to a torque of26 N·m (2.6 kgf·m, 19.1 lbf·ft).

9. Check the end play for the idler gear (6). Refer tothe Specifications Manual, “Engine Oil Pump”.

10. Check the backlash between the gear (10) for theengine oil pump and the idler gear (6). Refer tothe Specifications Manual, “Engine Oil Pump”.

11. Ensure that the dowel (14) and the hollow dowel(15) are installed in the balancer.

12. Ensure that the No. 1 piston is at top dead centeron the compression stroke. Refer to the Testingand Adjusting Manual, “Fuel Injection Timing -Check”.

13. Install two temporary studs (17) into the cylinderblock.

14. Install the 27610225 Timing Pin (1) into the shaft(2).

15. Carefully position the balancer onto the tempo-rary studs (17). Ensure that the teeth of the idlergear (6) and the crankshaft gear are aligned.

16. Install two setscrews (3) into the center of thebalancer. Tighten the setscrews (3) to a torque of54 N·m (5.5 kgf·m, 39.8 lbf·ft).

C34W2J8A

(4) Setscrew (11) Setscrews

(5) Shaft (12) Cover

(6) Idler Gear (13) Rotor Assembly

(7) Thrust Washer (14) Dowel

(8) Bearing (15) Hollow Dowel

(9) Nut (16) Thread

(10) Gear (17) Temporary Studs

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CHAPTER 2 DK651/751/801/901

17. Remove the temporary studs (17) and install theremaining setscrews (3). Tighten the remainingsetscrews to a torque of 54 N·m (5.5 kgf·m, 39.8lbf·ft).

18. Remove the timing pin (1). Rotate the crankshaftin order to ensure that the balancer turns freely.

End By:a. Install the engine oil relief valve. Refer to this Dis-

assembly and Assembly Manual, “Engine Oil Re-lief Valve - Remove and Install (Balancer Unit forthe Engine)”.

b. Install the engine oil pan. Refer to this Disassem-bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

C34W2J9A

(17) Studs

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ENGINE SYSTEM

1. Remove the setscrew (1). Remove the piston cool-ing jet assembly (2) from the cylinder block.

NOTE:

The engine crankshaft may be rotated in order to ac-cess all of the piston cooling jet assemblies.

C34W2K0A

(1) Setscrew

(2) Cooling Jet Assembly

4.44 PISTON COOLING JETS

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pan. Refer to this Disas-

sembly and Assembly Manual, “Engine Oil Pan -Remove and Install”.

B. INSTALLATION PROCEDURE1. Clean each piston cooling jet assembly (2).

Inspect each assembly for damage and especiallycheck that the tube of the piston cooling jet assem-bly (2) has not been damaged.

Ensure that the ball moves freely within each valveassembly of the piston cooling jet (2).

Replace any damaged assembly.

2. Install each piston cooling jet assembly (2) into thecylinder block. Install the setscrew (1).

Tighten the setscrew (1) to a torque of 9 N·m (0.9kgf·m, 80 lbf·ft).

NOTE:

Ensure that piston cooling jet assembly (2) is properlylocated on the cylinder block. Refer to the Specifica-tions Manual, “Piston Cooling Jet” for the correct pro-cedure for the alignment of the piston cooling jet.

End By:a. Install the engine oil pan. Refer to this Disassembly

and Assembly Manual, “Engine Oil Pan - Removeand Install”.

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CHAPTER 2 DK651/751/801/901

C34W2K1A

(1) Screws (2) Rod Cap

4.45 PISTONS AND CONNECTING RODS

A. REMOVAL PROCEDURE

Start By:a. Remove the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Remove”.

b. Remove the engine oil pump. Refer to Disassem-bly and Assembly, “Engine Oil Pump - Remove”.

c. Remove the piston cooling jets. Refer to Disassem-bly and Assembly, “Piston Cooling Jets - Removeand Install”.

1. Position the pistons that are being removed at thebottom center position.

2. Remove the carbon buildup from the inner surfaceof the top of the cylinder liner.

3. Ensure that the connecting rod and the cap are cor-rectly marked to the cylinder.

NOTE:

Do not punch the connecting rod or stamp the con-necting rod assembly as this may cause damage.

4. Remove the torx screws (1) from the connecting rod.

5. Remove the connecting rod cap (2) with the bearingshell.

6. Push the piston and the connecting rod through thetop of the cylinder block.

NOTE:

Make a mark under the piston on the pin boss in orderto identify the cylinder. Always mark the front pin bossto aid installation.

7. The bearing shell for the connecting rod and thebearing shell for the connecting rod cap must beplaced with the correct rod and the correct connect-ing rod cap.

8. Always tighten the connecting rod cap to the con-necting rod, when the assembly is out of the engine.Tighten the assembly to the following torque 20 N·m(2.0 kgf·m, 14.7 lbf·ft).

B. INSTALLATION PROCEDURE

Part Number

21825615

Required Tools

Part Description

Piston sleeve(installation tool)

Qty

1

1. Thoroughly clean all of the components.

2. Lubricate the piston and the cylinder bore with cleanengine oil.

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ENGINE SYSTEM

NOTE:

The piston and connecting rod are matched to a spe-cific cylinder. Ensure that the connecting rod and pis-tons are installed in the correct cylinder.

3. Rotate the crankshaft until the connecting rod jour-nal is at the bottom center. Lubricate the connect-ing rod journal with clean engine oil.

4. Ensure that the piston assembly is correctly markedto the cylinder.

5. Lubricate the bearing shells for the connecting rodwith clean engine oil.

6. Lubricate the piston sleeve (1) with clean engine oiland install the piston sleeve.

NOTE:

• The arrow or the “FRONT” mark that is on the topof the piston must be toward the front of the engine.Ensure that the piston rings are 120 degrees awayfrom each other.

• Ensure that the piston sleeve is installed correctlyand that the piston can easily slide from the tooland into the cylinder.

7. Push the piston and the connecting rod assemblyinto the cylinder and onto the connecting rod journal.

C34W2K8A

(1) Sleeve

C34W2K9A

(2) Cap (3) Screws

NOTE:

• New torx screws must be installed.

• Ensure that the etched number on connecting rodbearing cap (2) matches the etched number on con-necting rod.

8. Install the cap (2) with the bearing shell onto theconnecting rod journal and the new torx screws forthe cap.

9. Tighten the new torx screws to 20 N·m (2.0 kgf·m,14.7 lbf·ft). Refer to Testing and Adjusting, “PistonHeight - Inspect” for the correct procedure on check-ing the height of the piston above the cylinder block.

10.Tighten the torx screws (3) to 70 N·m (7.1 kgf·m,51.6 lbf·ft). Again tighten the torx screws by 120degrees.

Refer to the insert in the illustration 214. Check thatthere is no binding after this tightening sequence instep 9 and step 10.

End By:a. Install the piston cooling jets. Refer to Disassem-

bly and Assembly, “Piston Cooling Jets - Removeand Install”.

b. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump - Install”.

c. Install the cylinder head. Refer to Disassembly andAssembly, “Cylinder Head - Install”.

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CHAPTER 2 DK651/751/801/901

C. DISASSEMBLY PROCEDURE

Start By:a. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Piston andConnecting Rods - Remove”.

• Removal of the piston pin bushing must be car-ried out by personnel with the correct training.Also special machinery is required. For more in-formation refer to your authorized Perkins dealeror your Perkins distributor.

CAUTION

1. Use a suitable ring expander in order to remove thethree piston rings (1) and (2), and the oil controlring (3) from the piston (6).

Remove the lower connecting rod bearing from theconnecting rod cap. Remove the upper connectingrod bearing from the connecting rod.

2. Use suitable pliers in order to remove the circlips (8).

3. Remove the piston pin (7) from the piston (6).

NOTE:

If the piston pin cannot be removed by hand, heat thepiston to a temperature of 45 ± 5°C (113 ± 9°F). Donot use a oxyacetylene torch to heat the piston.

C34W2K2A

(1) Piston Rings (5) Rod

(2) Piston Rings (6) Piston

(3) Oil Control Ring (7) Pisiton Pin

(4) Bushing (8) Circlips

4. Remove the bearing shells (9) from the connectingrod (10) and the connecting rod cap (11).

5. Use a suitable press and a suitable adapter in or-der to remove the piston pin bushing (4) from theconnecting rod (5).

C34W2K3A

(9) Bearing Shells (11) Connecting Rod Cap

(10) Connecting Rod

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ENGINE SYSTEM

C34W2K5A

(1) Mark (3) Arrow

(2) Boss Cutout (4) Circlips

C34W2K4A

3. Align the mark (1) on the connecting rod to the bosscutout (2) of the piston. Also check that the arrow (3)that is marked on top of the piston is aligned. Installthe piston pin into the piston and through the con-necting rod

NOTE:

If the piston pin cannot be installed by hand, use hotwater in order to heat the piston to a temperature of45° ± 5°C (113° ± 9°F).

4. Use suitable pliers in order to install the circlips (4)that hold the piston pin in position.

5. Use a suitable ring expander in order to install thepiston rings on the piston with the following steps.

NOTE:

A new piston pin bushing is in a shape of a wedge. Forfurther information on installation of the piston pinbushing, refer to your authorized Perkins dealer or yourPerkins distributor for assistance.

1. Refer to Testing and Adjusting, “Connecting Rod -Inspect” for the correct height grade for the frac-tured split connecting rod.

2. The bearing shells for the connecting rod and theconnecting rod cap must be aligned by a tool be-fore the bearing shells are installed.

Refer to illustration 208. Check the alignment of thebearing shells and remove the alignment tool fromthe assembly. The bearing shell must be an equaldistance from each end. Refer to illustration 209.

NOTE:

The alignment tool is supplied with new bearing shells.

D. ASSEMBLY PROCEDURE

• Keep all parts clean from contaminants.

• Contaminants may cause rapid wear and short-ened component life.

CAUTION

• Installation of the piston pin bushing must be car-ried out by personnel with the correct training.Also special machinery is required.

CAUTION

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CHAPTER 2 DK651/751/801/901

a. Install the spring (6) for the oil control piston ring(7) in the groove (4) that is lowest on the piston.The latch pin (5) must be located inside the endsof the spring. Locate the oil control ring (7) overthe internal spring (6).

NOTE:

Ensure that the latch pin is 180 degrees from the oilcontrol ring gap.

C34W2K6A

(4) Groove (6) Spring

(5) Latch Pin

b. Install the intermediate piston ring (8) with thetapered face into the second groove on the piston.he stamp “TOP” must be toward the top of thepiston.

NOTE:

Intermediate piston rings that are new have a greenmark which must be on the left of the piston ring gapwhen the piston ring is installed.

c. Install the top piston ring (9) with the barrel faceand the molybdenum insert into the top grooveon the piston. The top piston ring has a keystonering. The stamp “TOP” must be toward the top ofthe piston.

NOTE:

Top piston rings that are new have a red mark whichmust be on the left of the ring gap when the ring isinstalled.

d. Position the piston ring gaps at 120 degrees awayfrom each other.

End By:a. Install the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Piston andConnecting Rods - Install”.

C34W2K7A

(7) Oil Control Ring (9) Piston Ring

(8) Piston Ring

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ENGINE SYSTEM

4.46 CONNECTING ROD BEARINGS

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pump. Refer to Disassem-

bly and Assembly, “Engine Oil Pump - Remove”.

NOTE:

Remove one pair of connecting rod caps at a time andinstall one pair at a time. Damage can occur when thefractured split connecting rods are separated.

1. In order to remove the connecting rod caps, rotatethe crankshaft in a clockwise direction until one pairof pistons is at the bottom center position.

NOTE:

Check that the connecting rod and the cap are cor-rectly marked to the cylinder. If the connecting rodassembly requires marking do not punch the connect-ing rod assembly or stamp the connecting rod assem-bly as this may cause damage.

2. Remove the torx screws from the caps and removeboth pair of caps with the bearing shells.

Push both pair of connecting rods into the cylinder.Do not allow the connecting rods to contact the pis-ton cooling jets.

3. Carefully rotate the crankshaft in order to give ac-cess to both pair of connecting rods.

4. Remove the bearing shells from the connecting rodsand the caps.

5. Before continuing with the next pair of connectingrods, install all the new bearing shell into the con-necting rods and caps. Refer to Disassembly andAssembly , “connecting rod bearing - install”.

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CHAPTER 2 DK651/751/801/901

4. Pull the connecting rod onto the crankshaft journaland install the correctly marked cap with the bear-ing shell onto the connecting rod.

NOTE:

Do not allow the connecting rod into contact with thepiston cooling jet.

5. Install new torx screws into the connecting rodassembly. Tighten the torx screws to 20 N·m (2.0kgf·m, 14.7 lbf·ft). Rotate the crankshaft in order tocheck for binding. Again tighten the torx screws to70 N·m (7.1 kgf·m, 51.6 lbf·ft).

Finally rotate the torx screws by 120 degrees.

NOTE:

Rotate the crankshaft in order to recheck that there isno binding.

End By:a. Install the piston cooling jets. Refer to Disassem-

bly and Assembly, “Piston Cooling Jets - Removeand Install”.

b. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump - Install”.

c. Install the cylinder head. Refer to Disassembly andAssembly, “Cylinder Head - Install”.

B. INSTALLATION PROCEDURE1. Carefully rotate the crankshaft in order to give ac-

cess to the connecting rod.

2. Ensure that the components are clean before thecomponents are assembled.

C34W2L0A

NOTE:

The alignment tool is supplied with the new bearingshells.

3. The bearing shell for the connecting rod must bealigned by a tool before the bearing shells areinstalled. Refer to illustration 215. Check the align-ment of the shell and remove the tool from theassembly. The bearing shell must be an equal dis-tance from each end. Refer to illustration 216. Lu-bricate both the bearing shells and lubricate thecrankshaft journal.

C34W2K4A

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ENGINE SYSTEM

NOTE:

The main bearings and the main bearing caps (2) mustbe installed in the same location when the engine isreassembled.

1. Make sure that the main bearing caps (2) aremarked for the location and direction for installation.

2. Remove the setscrews (1) and the main bearingcap (2).

3. Remove the lower bearing shell (3) from the mainbearing cap (2). Keep the respective bearing shell(3) and the main bearing cap (2) together for properinstallation.

C34W2L1A

(1) Setscrews (2) Bearing Caps

4.47 CRANKSHAFT MAIN BEARINGS

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pan. Refer to this Disas-

sembly and Assembly Manual, “Engine Oil Pan -Remove and Install”.

b. Only if the engine is not equipped with a balancer,remove the engine oil pump. Refer to this Disas-sembly and Assembly Manual, “Engine Oil Pump -Remove”.

c. If the engine is equipped with a balancer, removethe balancer. Only remove the engine oil pump if itis necessary. Refer to this Disassembly and As-sembly Manual, “Balancer - Remove”.

d. Remove the flywheel housing in order to removethe rear main bearing with the crankshaft in position.Refer to this Disassembly and Assembly Manual,“Flywheel Housing - Remove and Install”.

e. Remove the crankshaft rear seal in order to removethe rear main bearing with the crankshaft in position.Refer to this Disassembly and Assembly Manual,“Crankshaft Rear Seal - Remove”.

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CHAPTER 2 DK651/751/801/901

4. Push the upper bearing shell (4) from the oppositeside of the bearing tab with a suitable tool. Care-fully rotate the crankshaft while you push on thebearing shell (4). Remove the upper bearing shell(4) from the cylinder block. Keep all of the upperhalves of the bearing shells (4) together in order toensure proper installation.

5. Repeat Step 2 through Step 4 for the remainingmain bearings.

NOTE:

Thrust washers (5) and (6) are installed onto one mainbearing in order to limit crankshaft end play. Thesethrust washers are installed onto the No.3 main bear-ing of the three cylinder and onto the center main bear-ing of the four cylinder engine. The removal procedureis identical for the three cylinder and the four cylinderengines. The appropriate illustrations show the fourcylinder engine.

C34W2L2A

(4) Bearing Shells

C34W2L3A

(5) Thrust Washer

6. Remove the lower half of the thrust washer (5) fromeach side of the appropriate main bearing cap.

C34W2L4A

(6) Thrust Washer

7. Remove the upper half of the thrust washer (6) fromeach side of the appropriate main bearing in thecylinder block with a suitable tool. Carefully rotatethe crankshaft while you push on the thrust washer(6). If necessary, move the crankshaft to the front orto the rear of the engine in order to loosen a tightthrust washer (6).

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ENGINE SYSTEM

B. INSTALLATION PROCEDURE

NOTE:

Ensure that the lower bearing shells (3), the upperbearing shells (4), and the appropriate main bearingcaps (2) are kept in sets and in the correct sequencefor installation.

1. Ensure that all of the main bearing caps (2) are cleanand dry. Ensure that both of the hollow dowels (1)are not damaged and that the hollow dowels aresecurely in place within the main bearing cap (2).

2. Gently wipe the lower bearing shells (3) and theupper bearing shells (4) in order to ensure that thebearing shells are clean and dry. Inspect the lowerbearing shells (3) and the upper bearing shells (4).If necessary, replace the bearing shells that areworn or damaged.

NOTE:

Bearing shells must be replaced in pairs. If a pair ofbearing shells need to be replaced, consider replac-ing all of the bearing shells at the same time.

NOTE:

The upper bearing shell for the No. 1 crankshaft jour-nal has a lubricating oil slot. The remaining upper bear-ing shells have an oil hole for lubrication. All new up-per bearing shells will have the slot for lubrication.

3. Gently wipe the main journals of the crankshaft inorder to ensure that the main journals are cleanand dry.

4. Lubricate the bearing surface of the upper bearingshell (4) and lubricate the appropriate main journalwith clean engine oil.

NOTE:

Ensure that the upper bearing shell (4) is installed sothat the bearing tabs fit into the notch in the cylinderblock.

C34W2L5A

(1) Hollow Dowels (3) Bearing Shells

(2) Bearing Caps

• Only the upper half of the main bearing has lubri-cation holes. Make sure the upper half of the mainbearing is installed correctly in the cylinder blockto ensure proper lubrication.

CAUTION

5. Slide the upper bearing shell (4) into position be-tween the appropriate crankshaft journal and thecylinder block.

6. Lubricate the bearing face of the appropriate lowerbearing shell (3) with clean engine oil.

NOTE:

Ensure that the lower bearing shell (3) is installed sothat the bearing tab fits into the notch in the appropri-ate main bearing cap.

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CHAPTER 2 DK651/751/801/901

C34W2L6A

(6) Thrust Washers

7. Install the lower bearing shell (3) into the appro-priate main bearing cap (2). Install the main bear-ing cap (2) into the appropriate position and en-sure that the hollow dowels (1) are located withinthe main bearing cap and within the recesses inthe cylinder block.

8. Repeat Step 4 through Step 7 for the remainingmain bearings.

NOTE:

Thrust washers (5) and (6) are installed onto one mainbearing in order to limit crankshaft end play. Thesethrust washers are installed onto No. 3 main bearingof the three cylinder and onto the center main bearingof the four cylinder engine. The installation procedureis identical for the three cylinder and the four cylinderengines.

The appropriate illustrations show the four cylinderengine.

9. Gently wipe the upper thrust washers (6) and thelower thrust washers (5) in order to ensure thatthe thrust washers are clean and dry. Inspect theupper thrust washers (6) and the lower thrust wash-ers (5). If necessary, replace any damaged thrustwashers.

10. Lightly lubricate the upper thrust washers (6) withclean engine oil. Install the upper thrust washers(6) onto each side of the appropriate main bear-ing in the cylinder block. The grooves on the up-per thrust washers (6) must be located againstthe crankshaft. If necessary, move the crankshaftto the front or to the rear in order to install thethrust washers (6).

11. Lightly lubricate the lower thrust washers (5) withclean engine oil. Install the lower thrust washers(5) onto each side of the appropriate main bearingcap. The grooves on the lower thrust washers (5)must be located against the crankshaft.

12. Lubricate the threads of the setscrews (7) withclean engine oil.

13. Install the setscrews (7). Tighten the setscrews(7) to a torque of 245 N·m (24.9 kgf·m, 180.7 lbf·ft).

14. Rotate the crankshaft in order to ensure that thecrankshaft turns freely.

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ENGINE SYSTEM

C34W2L7A

(5) Thrust Washers (8) Play

15. Check the crankshaft end play. Use a prybar tomove the crankshaft toward the front of the engine.Use a suitable feeler gauge to measure the endplay (8) between rear thrust washer (5) and thecrankshaft. The maximum permissible crankshaftend play is 0.51 mm (0.020 in.).

End By:a. Install the rear bridge. Refer to this Disassembly

and Assembly Manual, “Crankshaft - Install”.

b. Install the crankshaft rear seal. Refer to this Disas-sembly and Assembly Manual, “Crankshaft RearSeal - Install”.

c. Install the flywheel housing. Refer to this Disas-sembly and Assembly Manual, “Flywheel Housing -Remove and Install”.

d. If the engine is equipped with a balancer and theengine oil pump was removed from the balancer,install the engine oil pump. Install the balancer.

Refer to this Disassembly and Assembly Manual,“Balancer - Install”.

e. If the engine is not equipped with a balancer, installthe engine oil pump. Refer to this Disassembly andAssembly Manual, “Engine Oil Pump - Install”.

f. Install the engine oil pan. Refer to this Disassem-bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

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CHAPTER 2 DK651/751/801/901

4.48 CRANKSHAFT

A. REMOVAL PROCEDURE

Start By:a. Remove the engine oil pan. Refer to this Disassem-

bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

b. Only if the engine is not equipped with a balancer,remove the engine oil pump. Refer to this Disassem-bly and Assembly Manual, “Engine Oil Pump -Remove”.

c. If the engine is equipped with a balancer, removethe balancer. Only remove the engine oil pump if itis necessary. Refer to this Disassembly and As-sembly Manual, “Balancer - Remove”.

d. Remove the flywheel housing. Refer to this Disas-sembly and Assembly Manual, “Flywheel Housing- Remove and Install”.

e. Remove the crankshaft rear seal. Refer to this Dis-assembly and Assembly Manual, “Crankshaft RearSeal - Remove”.

f. Remove the front housing. Refer to this Disassemblyand Assembly Manual, “Housing (Front) - Remove”.

1. Remove the Allen head screws (1) from the bridge(2).

2. Remove the bridge (2) from the cylinder block.

NOTE:

Make sure that the main bearing caps (4) and the con-necting rod caps (6) are marked for the location anddirection for installation.

NOTE:

This procedure assumes that the engine has been re-moved from the application and that the engine hasbeen inverted. If the engine is not inverted or if thebottom end of the engine has not been moved throughat least 90 degrees horizontally, remove the connect-ing rods from the cylinder bores. Refer to this Disas-sembly and Assembly Manual, “Pistons and Connect-ing Rods - Remove” for further information. Proceed toStep 6.

3. If the engine has been inverted or if the bottom endof the engine has been moved through at least 90degrees horizontally, remove the setscrews (5) fromthe connecting rods. Discard the setscrews (5).

NOTE:

Do not reuse the setscrews (5). Use new setscrews inorder to secure the connecting rod cap for reassembly.

C34W2L8A

(1) Screws

(2) Bridge

(3) Setscrews

(4) Bearing Caps

(5) Setscrews

(6) Connecting Rod Caps

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ENGINE SYSTEM

4. Remove the connecting rod bearing caps (6) fromthe connecting rods. Remove the bearing shells fromthe connecting rod bearing caps.

Keep the bearing shell for the connecting rod capwith the appropriate connecting rod cap.

5. Push the piston assemblies into the cylinder bores.

NOTE:

This procedure assumes that the engine has been re-moved from the application and that the engine has beeninverted. If the engine has not been inverted, ensurethat the crankshaft is fully supported before removingthe setscrews (3) for the main bearing caps (4).

6. Remove the setscrews (3) from the main bearingcaps (4).

Do not allow the connecting rods to strike the pis-ton cooling jets. Damage or misalignment mayoccur.

CAUTION

C34W2L9A

(4) Bearing Caps (8) Bearing Shells

7. Remove the main bearing caps (4) from the cylin-der block. Remove the bearing shells (8) from themain bearing caps (4). Keep the main bearingshells (8) with the respective main bearing cap (4).

8. Attach lifting straps and a suitable lifting device tothe crankshaft. Lift the crankshaft out of the cylin-der block. Take care to ensure that you do notscratch any of the f in ished surfaces on thecrankshaft.

C34W2M0A

(7) Bearing Shells

9. Remove the upper main bearing shells (7). Keepthe upper main bearing shells with the respectivemain bearing caps (4).

NOTE:

Thrust washers (9) and (10) are installed onto one mainbearing in order to limit crankshaft end play. Thesethrust washers are installed onto the No. 3 main bear-ing of the three cylinder and the center main bearingof the four cylinder engine. The removal procedure isidentical for the three cylinder and the four cylinderengines. The appropriate illustrations show the fourcylinder engine.

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CHAPTER 2 DK651/751/801/901

C34W2M1A

(9) Thrust Washers

10. Remove the upper thrust washers (9) from the ap-propriate main bearing block.

C34W2M2A

(10) Thrust Washers

11. Remove the lower thrust washers (10) from theappropriate main bearing cap.

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ENGINE SYSTEM

NOTE:

Bearing shells must be replaced in pairs. If a pair ofbearing shells need to be replaced, consider replac-ing all of the bearing shells at the same time.

NOTE:

The upper bearing shell for the No. 1 crankshaft jour-nal has a lubricating oil slot. The remaining upper bear-ing shells (1) have an oil hole for lubrication. All newupper bearing shells (1) will have the slot for lubrication.

C34W2M4A

(2) Bearing Caps (6) Hollow Dowels

(3) Bearing Shells (7) Bearing Tabs

3. Install the upper main bearing shells (1). The bear-ing tabs (5) for the upper main bearing shells (1)must be located in the correct position in the cylin-der block (5). Lubricate the upper main bearingshells (1) with clean engine oil.

4. Ensure that all of the main bearing caps (2) areclean and dry. Ensure that both of the hollow dow-els (6) are not damaged and that two hollow dow-els are securely in place within each of the mainbearing caps (2).

NOTE:

This procedure assumes that the engine has been re-moved from the application and that the engine hasbeen inverted. If the engine has not been inverted,ensure that the crankshaft is completely supporteduntil the main bearing caps (2) and setscrews are com-pletely installed.

C34W2M5A

(1) Bearing Shells (5) Cylinder Block

(4) Housing

B. INSTALLATION PROCEDURE

NOTE:

Ensure that the upper bearing shells (1), the appropri-ate main bearing caps (2), and the appropriate lowerbearing shells (3) are kept in sets and in the correctsequence for installation.

1. Ensure that all of the housings (4) in the cylinderblock for the upper bearing shells (1) are clean anddry. Ensure that all of the lubrication passages inthe housings (4) are clean and free from debris.

2. Gently wipe the lower bearing shells (3) and theupper bearing shells (1) in order to ensure that thebearing shells are clean and dry. Inspect the lowerbearing shells (3) and the upper bearing shells (1).If necessary, replace the bearing shells that areworn or damaged.

C34W2M3A

(1) Bearing Shells (4) Housings

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CHAPTER 2 DK651/751/801/901

5. Gently wipe the main journals of the crankshaft inorder to ensure that the main journals are cleanand dry. Attach sui table l i f t ing straps to thecrankshaft.

6. Take care to ensure that you do not scratch any ofthe finished surfaces on the crankshaft and thatyou do not damage the upper main bearing shells(1) or dislodge the upper main bearing shells. Thecrankshaft is heavy. Use suitable lifting equipmentto carefully lift the crankshaft into the upper mainbearing shells (1).

7. Install the appropriate lower main bearing shells (3)into main bearing caps (2) with the bearing tabs (7)in the correct position. Lubricate the lower mainbearing caps (2) with clean engine oil.

NOTE:

Do not install the No. 3 main bearing cap of the threecylinder or the center main bearing cap of the fourcylinder engine at this time.

8. Use the hollow dowels (6) in order to locate theappropriate main bearing caps (2) and install themain bearing caps into the appropriate housing (4)in the cylinder block. Insert the setscrews (8) fin-ger tight.

NOTE:

Thrust washers (9) and (10) are installed onto one mainbearing in order to limit crankshaft end play. Thesethrust washers are installed onto the No. 3 main bear-ing of the three cylinder and the center main bearingof the four cylinder engine. The installation procedureis identical for the three cylinder and the four cylinderengines. The appropriate illustrations show the fourcylinder engine.

9. Clean the upper half of the thrust washers (9) andlubricate the upper half of thrust washers.

Place the upper half of the thrust washers (9) intoboth side recesses in the cylinder block next tothe housing for the appropriate main bearing shell.The grooves on the thrust washer (9) must be lo-cated against the crankshaft.

C34W2M6A

(2) Bearing Caps (8) Setscrews

C34W2M1A

(9) Thrust Washer

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ENGINE SYSTEM

15. Install the connecting rod caps (11). Install newsetscrews (12) into the connecting rods. Tightenthe setscrews (12) evenly to an initial torque of 18N·m (1.8 kgf·m, 13 lb·ft).

NOTE:

Do not reuse the old setscrews (12) in order to securethe connecting rod caps (11).

NOTE:

Ensure that the etched number on the connecting rodbearing cap matches the etched number on the con-necting rod. Ensure that the etched numbers are onthe same side.

16. The setscrews must be tightened again to a highertorque. Tighten the setscrews (12) to a torque of70 N·m (7.1 kgf·m, 51.6 lbf·ft).

17. Finally tighten the setscrews (12) for an additional120 degrees. Refer to the insert in the Illustration239 in order to achieve the correct final torque.

18. Rotate the crankshaft in order to ensure that thereis no binding.

C34W2M7A

(11) Rod Caps (12) Setscrews

C34W2M2A

(10) Thrust Washer

10. Clean the lower half of the thrust washers (10)and lubricate the lower half of thrust washers. Placethe lower half of the thrust washers (10) on bothsides of the appropriate main bearing cap. Thegrooves on the thrust washers (10) must be lo-cated against the crankshaft.

11. Install the No. 3 main bearing cap onto the crank-shaft of the three cylinder or the center main bear-ing cap onto the crankshaft of the four cylinderengine. Install the remaining setscrews (8).

12. Tighten all of the setscrews (8) to a torque of245 N·m (24.9 kgf·m, 180.7 lbf·ft).

13. If the piston assemblies were removed previously,install the piston assemblies. Refer to this Disas-sembly and Assembly Manual, “Pistons and Con-necting Rods - Install”. Go to Step 18.

14. If the piston assemblies are still inside the cylin-der bores, ensure that the upper bearing shellsfor the connecting rods are centered in the con-necting rods. Ensure that the lower bearing shellsfor the connecting rods are centered in the con-necting rod caps (11). Lubricate the faces of thebearing shell with clean engine oil.

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CHAPTER 2 DK651/751/801/901

C34W2N0A

(15) Play

20. Check the crankshaft end play. Use a prybar tomove the crankshaft toward the front of the engine.Use a feeler gauge to measure the end play (15)between the rear thrust washer and the crankshaft.Refer to the Specifications Manual, “Crankshaft”for the further information.

End By:a. Install the front housing. Refer to this Disassembly

and Assembly Manual, “Housing (Front) - Install”.

b. Install the crankshaft rear seal. Refer to this Disas-sembly and Assembly Manual, “Crankshaft RearSeal - Install”.

c. Install the flywheel housing. Refer to this Disas-sembly and Assembly Manual, “Flywheel Housng -Remove and Install”.

d. If the engine is equipped with a balancer, installthe balancer. Refer to this Disassembly and As-sembly Manual, “Balancer - Install”.

e. If the engine is not equipped with a balancer, in-stall the engine oil pump. Refer to this Disassem-bly and Assembly Manual, “Engine Oil Pump -Install”.

f. Install the engine oil pan. Refer to this Disassem-bly and Assembly Manual, “Engine Oil Pan - Re-move and Install”.

C34W2M8A

(13) Bridge (14) Screws

C34W2M9A

19. Clean the bridge (13) and the face of the cylinderblock. Apply a thin bead of 21826038POWERPART Silicone Adhesive onto the cornersof the seat for the bridge. Also apply POWERPARTSilicone Adhesive around the thread holes in theseat for the bridge. Use the following steps whenyou apply POWERPART Silicone Adhesive to thecylinder block and the bridge.

a. Apply a 3.0 mm (0.12 in.) bead of thePOWERPART Silicone Adhesive along the cor-ner of the top recess in the cylinder block.

NOTE:

The maximum protrusion for the bridge (13) from theoutside of the cylinder block is 0.075 mm (0.0029 in.).

b. Install the bridge (13). Use a straight edge toline up the bridge with the face of the cylinderblock. Tighten the socket head screws (14) toa torque of 16 N·m (1.6 kgf·m, 11.8 lbf·ft). Tightenthe socket head screws (14) evenly.

c. When the bridge (13) is positioned and thesocket head screws (14) have been tightened,inject POWERPART Silicone Adhesive into thegroove that is at each end of the bridge. Thegroove must be completely filled.

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ENGINE SYSTEM

4.49 CRANKSHAFT GEAR

A. REMOVAL PROCEDURE

NOTE:

The crankshaft gear (1) may be a slip fit on the crankshaft(3). If the crankshaft (3) is installed in the engine, use asuitable tool to ensure that the crankshaft gear (1) is not aslip fit before the crankshaft is removed from the engine.

1. If the crankshaft gear (1) is a slip fit on the crank-shaft (3), use a suitable tool to remove the crank-shaft gear and proceed to Step 4.

2. If the crankshaft gear (1) is not a slip fit on thecrankshaft (3), remove the crankshaft from theengine. Refer to this Disassembly and AssemblyManual, “Crankshaft - Remove”.

3. Use suitable tooling to remove the crankshaft gear(1) from the crankshaft (3).

4. Remove the key (2) from the crankshaft (3).

B. INSTALLATION PROCEDURE1. Thoroughly clean the journal on the crankshaft (3) for

the crankshaft gear (1) and the keyway slot for the key(2). Inspect the journal for the crankshaft gear (1), thekeyway slot, and the key for wear and/or damage. Ifnecessary, replace any damaged component.

2. Install the key (2) into the keyway slot in the crank-shaft (3).

NOTE:

The crankshaft gear (1) may be a slip fit on the crank-shaft (3).

3. Check if the crankshaft gear (1) is a slip fit on thecrankshaft (3). If the crankshaft gear (1) is a slip fiton the crankshaft (3), proceed to Step 5.

NOTE:

Ensure that heat is applied to the crankshaft gear (1)only. Do not apply heat directly onto the crankshaft (3).

NOTE:

Ensure that suitable clothing is worn in order to handlethe heated crankshaft gear.

4. If the crankshaft gear is not a sl ip f i t on thecrankshaft, heat the crankshaft gear in an oven to200°C (392°F).

5. Ensure that the shoulder on the crankshaft gear (1)is installed toward the front of the crankshaft (3).Install the crankshaft gear (1) onto the crankshaft(3) and the key (2).

End By:a. If the crankshaft was removed from the engine, in-

stall the crankshaft (3) at an appropriate time.

Refer to this Disassembly and Assembly Manual,“Crankshaft - Install”.

C34W2N1A

(1) Crankshaft Gear

(2) Key

(3) Crankshaft

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CHAPTER 2 DK651/751/801/901

4.50 BEARING CLEARANCE

A. MEASUREMENT PROCEDURE

Required Tools

Description

Plastic Gauge (Green)0.025 ~ 0.076 mm(0.001 ~ 0.003 in.)

Plastic Gauge (Red)0.051 ~ 0.152 mm(0.002 ~ 0.006 in.)

Plastic Gauge (Blue)0.102 ~ 0.229 mm(0.004 ~ 0.009 in.)

Plastic Gauge (Yellow)0.230 ~ 0.510 mm(0.009 ~ 0.020 in.)

Qty

1

1

1

1

NOTE:

Perkins does not recommend the checking of the ac-tual clearances of the bearing shells particularly onsmall engines. This is because of the possibility ofobtaining inaccurate results and the possibility of dam-aging the bearing shell or the journal surfaces. EachPerkins bearing shell is quality checked by Perkinsfor specific wall thickness.

NOTE:

The measurements should be within specifications andthe correct bearing shells should be used. No furtherchecks are necessary if the main journals and thebearing shells were measured during disassembly ofthe engine. No further checks are necessary if thecrank pins of the crankshaft and the bearing shellswere checked during the disassembly of the connect-ing rods.

However, Plastic Gauge is an acceptable method ifthe technician still wants to measure the clearance ofthe bearing shell. Plastic Gauge is less accurate onjournals with small diameters if clearances are lessthan 0.10 mm (0.004 in.).

• Lead wire, shim stock or a dial bore gauge candamage the bearing surfaces.

CAUTION

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ENGINE SYSTEM

The technician must be very careful to use PlasticGauge correct ly. The fol lowing points must beremembered:

• Ensure that the backs of the bearing shells and thebores of the bearing shells are clean and dry.

• If the bearing shells have locking tabs ensure thatthe locking tabs are properly seated in the tabgrooves.

• The crankshaft must be free of oil at the contactpoints of the Plastic Gauge.

C34W2N2A

(1) Plastic Gauge

1. Put a piece of the Plastic Gauge (1) on the crownof the bearing shell that is in the cap.

NOTE:

Do not allow the Plastic Gauge (1) to extend over theedge of the bearing shell.

2. Use the correct torque-turn specifications in orderto install the bearing cap. Do not use an impactwrench. Be careful not to dislodge the bearing shellwhen the cap is installed.

NOTE:

Do not turn the crankshaft when the Plastic Gauge (1)is installed.

3. Carefully remove the bearing cap, but do not re-move the Plastic Gauge (1). Measure the width ofthe Plastic Gauge (1) while the Plastic Gauge is inthe bearing cap or on the crankshaft journal.

Refer to the Illustration 245.

4. Remove all of the Plastic Gauge (1) before you in-stall the bearing cap.

NOTE:

When Plastic Gauge is used, the readings can some-times be unclear. For example, all parts of the PlasticGauge are not the same width. Measure the major widthin order to ensure that the parts are within the specifi-cation range. Refer to the Specifications Manual, “Con-necting Rod Bearing Journal” and refer to the Specifi-cations Manual, “Main Bearing Journal” for the correctclearances.

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CHAPTER 2 DK651/751/801/901

B. INSTALLATION PROCEDURE

1. Clean the threads of the glow plugs.

2. Install the glow plugs (5) into the cylinder head.

Tighten the glow plugs to a torque of 18 N·m (1.8kgf·m, 13.2 lbf·ft).

3. Position the bus bar (3) onto the glow plugs.

Tighten the nuts (4) on the glow plugs. Tighten thenuts to a torque of 2 N·m (0.2 kgf·m, 1.4 lbf·ft).

4. Connect the harness assembly (6).

5. Position the cover (2) onto the cylinder head.

Install the setscrews (1). Tighten the setscrews toa torque of 9 N·m (0.9 kgf·m, 6.6 lbf·ft).

6. Turn the disconnect switch to the ON position.

4.51 GLOW PLUGS

A. REMOVAL PROCEDURE

C34W2N3A

(1) Setscrews (2) Cover

2. Remove the setscrews (1). Remove the cover (2)from the cylinder head.

C34W2N4A

(3) Bus Bar (4) Nuts

(5) Glow Plugs (6) Harness Assembly

3. Disconnect the harness assembly (6).

4. Loosen the nuts (4) that secure the bus bar (3) tothe glow plugs (5).

5. Remove the bus bar from the glow plugs.

6. Remove the glow plugs from the cylinder head.

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ENGINE SYSTEM

4.52 V-BELTS

A. REMOVAL PROCEDURE1. Loosen the setscrew (1), and the tension adjust-

ment setscrew (2). Slide the alternator toward theengine.

2. Maneuver the V-belts around the fan and removethe V-belts.

NOTE:

Never replace only one V-belt. Always replace the V-belts as a set.

C34W2N5A

(1) Setscrews

(2) Tension Adjustment Setscrews

B. INSTALLATION PROCEDURE1. Install the V-belts behind the fan and onto the cor-

rect pulleys.

2. Adjust the tension on the V-belts by moving thealternator away from the engine. Tighten the ten-sion adjustment setscrew (2) after the correct belttension is made. Refer to Specifications, “Belt Ten-sion Chart” for the correct tension of the V-belts.Tighten the tension adjustment setscrew (2) to atorque of 78 N·m (7.9 kgf·m, 57.5 lb·ft).

3. Tighten the setscrew (1) to a torque of 22 N·m(2.2 kgf·m, 16.2 lbf·ft).

4. Tighten the nut (1) to a torque of 22 N·m (2.2 kgf·m,16.2 lbf·ft).

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CHAPTER 2 DK651/751/801/901

4.54 FAN DRIVE

A. REMOVAL PROCEDURE

Start By:a. Remove the fan. Refer to this Disassembly and As-

sembly Manual, “Fan - Remove and Install”.

1. Remove the setscrews (1) from the fan drive (2).

2. Remove the fan drive (2).

B. INSTALLATION PROCEDURE1. Install the fan drive (2).

2. Install the setscrews (1). Tighten the setscrews toa torque of 44 N·m (4.4 kgf·m, 32.4 lbf·ft).

End By:a. Install the fan. Refer to this Disassembly and As-

sembly Manual, “Fan - Remove and Install”.

C34W2N6A

(1) Setscrews (2) Fan Drive

4.53 FAN

A. REMOVAL PROCEDURE

Start By:a. Remove the V-Belts. Refer to this Disassembly and

Assembly Manual, “V-Belts - Remove and Install”.

1. Remove the setscrews (1).

2. Remove the fan.

3. If equipped, remove the extension for the fan.

4. Remove the fan pulley.

C34W279A

(1) Setscrews

B. INSTALLATION PROCEDURE1. Inspect the condition of the fan pulley. Replace the

fan pulley, if necessary.

2. Install the fan pulley.

3. If the engine is equipped with an extension for thefan, install the extension.

4. Inspect the condition of the fan and replace the fan,if necessary.

5. Install the fan.

6. Install the setscrews (1). Tighten the setscrews (1)to a torque of 12 N·m (1.2 kgf·m, 8.8 lbf·ft).

End By:a. Install the V-Belts. Refer to this Disassembly and

Assembly Manual, “V-Belts - Remove and Install”.

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ENGINE SYSTEM

5. TESTING AND ADJUSTING SECTION

5.1 FUEL SYSTEM

A. FUEL SYSTEM - INSPECTA problem with the components that send fuel to theengine can cause low fuel pressure. This can decreaseengine performance.

1. Check the fuel level in the fuel tank. Ensure that thevent in the fuel cap is not filled with dirt.

2. Check all fuel lines for fuel leakage. The fuel linesmust be free from restrictions and faulty bends.

Verify that the fuel return line is not collapsed.

3. Inspect the fuel filter for excess contamination. Ifnecessary, install a new fuel filter. Determine thesource of the contamination. Make the necessaryrepairs.

4. Service the primary fuel filter (if equipped).

5. Remove any air that may be in the fuel system.

Refer to Testing and Adjusting, “Fuel System - Prime”.

B. AIR IN FUEL - TESTThis procedure checks for air in the fuel system.

This procedure also assists in finding the source ofthe air.

1. Examine the fuel system for leaks. Ensure that thefuel line fittings are properly tightened. Check thefuel level in the fuel tank. Air can enter the fuel sys-tem on the suction side between the fuel transferpump and the fuel tank.

2. Install a suitable fuel flow tube with a visual sightgauge in the fuel return line. When possible, installthe sight gauge in a straight section of the fuel linethat is at least 304.8 mm (12 in.) long. Do not in-stall the sight gauge near the following devices thatcreate turbulence:

• Elbows

• Relief valves

• Check valves

Observe the fuel flow during engine cranking.

Look for air bubbles in the fuel. If there is no fuelthat is present in the sight gauge, prime the fuelsystem. Refer to Testing and Adjusting, “Fuel Sys-tem - Prime” for more information. If the enginestarts, check for air in the fuel at varying enginespeeds. When possible, operate the engine underthe conditions which have been suspect.

• Work carefully around an engine that is running.

• Engine parts that are hot, or parts that aremoving, can cause personal injury.

WARNING

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CHAPTER 2 DK651/751/801/901

C34W2O0A

(1) A steady stream of small bubbles with a diam-eter of approximately 1.60 mm (0.063 in.) is anacceptable amount of air in the fuel.

(2) Bubbles with a diameter of approximately 6.35 mm(0.250 in.) are also acceptable if there is two sec-onds to three seconds intervals between bubbles.

(3) Excessive air bubbles in the fuel are not acceptable.

3. If excessive air is seen in the sight gauge in the fuelreturn line, install a second sight gauge at the inletto the fuel transfer pump. If a second sight gauge isnot available, move the sight gauge from the fuelreturn line and install the sight gauge at the inlet tothe fuel transfer pump.

Observe the fuel flow during engine cranking.

Look for air bubbles in the fuel. If the engine starts,check for air in the fuel at varying engine speeds.

If excessive air is not seen at the inlet to the fueltransfer pump, the air is entering the system afterthe fuel transfer pump. Refer to the Testing andAdjusting, “Fuel System - Prime”.

If excessive air is seen at the inlet to the fuel trans-fer pump, air is entering through the suction side ofthe fuel system.

• To avoid personal injury, always wear eye andface protection when using pressurized air.

WARNING

• To avoid damage, do not use more than 55 kPa(8 psi) to pressurize the fuel tank.

CAUTION

4. Pressurize the fuel tank to 35 kPa (3.05 kgf/cm2, 5psi). Do not use more than 55 kPa (0.56 kgf/cm2, 8psi) in order to avoid damage to the fuel tank. Checkfor leaks in the fuel lines between the fuel tank andthe fuel transfer pump. Repair any leaks that arefound.

Check the fuel pressure in order to ensure that thefuel transfer pump is operating properly. For infor-mation about checking the fuel pressure, see Test-ing and Adjusting, “Fuel System Pressure - Test”.

5. If the source of the air is not found, disconnect thesupply line from the fuel tank and connect an exter-nal fuel supply to the inlet of the fuel transfer pump.If this corrects the problem, repair the fuel tank orthe stand pipe in the fuel tank.

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ENGINE SYSTEM

C. FINDING TOP CENTER POSITION FORNO. 1 PISTON

Part Number

27610211

27610212

Required Tools

Part Description

Crankshaft timing

Camshaft timing

Qty

Pin 1

Pin 1

1. Remove the valve mechanism cover, the glow plugs,and the cover for the front housing.

NOTE:

The crankshaft timing pin can be inserted with thecrankshaft pulley still on the engine.

2. Rotate the crankshaft in the normal direction of theengine until the inlet valve of the No. 4 cylinder hasjust opened and the exhaust valve of the No. 4 cylin-der has not completely closed.

3. Carefully rotate the crankshaft in the normal direc-tion of the engine in order to align the hole in thecrankshaft with the hole in the cylinder block andthe timing case. Insert the 27610211 CrankshaftTiming Pin fully into the hole in the crankshaft web.

4. Insert the 27610212 Camshaft Timing Pin throughthe hole in the camshaft gear and into the body ofthe timing case. The engine is set at the top centerposition for No. 1 piston.

NOTE:

The camshaft gear can rotate a small amount whenthe pin is installed.

5. Remove the timing pins from the camshaft gear andthe crankshaft web.

C34W2O1A

(1) Hole for Crankshaft Pin

(2) Hole for Camshaft Pin

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CHAPTER 2 DK651/751/801/901

D. FUEL INJECTION PUMP TIMING - CHECK

a. DELPHI DP210 Series Fuel Injection Pump

NOTE:

The Delphi DP210 Series fuel injection pump timingcannot be checked. If you suspect that the fuel injec-tion pump timing is incorrect, contact your Perkinsdealer or your Perkins distributor for further information.

The Delphi DP210 Series fuel injection pump must beserviced by an authorized Delphi technician. For repairinformation, contact your Perkins dealer or your Perkinsdistributor. The internal adjustment for the pump tim-ing is tamper proof. High idle and low idle are factoryset. Idle adjustments can not be made to the fuel pump.

b. Bosch EPVE Fuel Injection Pump

NOTE:

The Bosch EPVE fuel injection pump is only installedon the 1104C-44 engine. (DK751)

1. Set the number one piston at the top center pistonon the compression stroke. Refer to Testing andAdjusting, “Finding Top Center Position for the No.1 Pistion” for the procedure.

2. Remove the high pressure fuel lines from the fuelinjection pump.

3. Remove the plug (1) and the washer from the rearof the fuel injection pump and install 27610248 fuelinjection pump timing adapter (2).

Install a suitable dial indicator (3) into 27610248fuel injection pump timing adapter. Set the dial in-dicator to approximately 3 mm (0.1181 in.).

4. Rotate the crankshaft counterclockwise until thedial indicator (3) indicates that the plunger of thefuel injection pump is at the bottom of the stroke.

Set the dial indicator (3) to zero.

5. Rotate the crankshaft clockwise, until the crank-shaft timing pin can be pushed into the hole in thecrankshaft web.

6. With the engine set at the Top Center Position forthe No. 1 piston, check the reading on the dial indi-cator (3). Refer to Specifications, “Fuel InjectionPump” for the correct reading for the plunger.

Part Number

27610248

Required Tools

Part Description

Bosch EPVE fuel injectionpump timing adapter

Qty

Pin 1

C34W2R3A

(1) Plug

C34W2R4A

(2) Bosch EPVE Fuel Injection Pump TimingAdapter

(3) Dial Indicator

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ENGINE SYSTEM

7. If the fuel injection pump timing is correct removethe dial indicator (3). Remove 27610248 fuel injec-tion pump timing adapter from the fuel injectionpump. Install a new washer to the plug and installthe plug in the back of the fuel injection pump. Re-fer to Specifications, “Fuel Injection Pump” for thecorrect torque.

8. Install the high pressure fuel lines on the fuel injec-tion pump. Eliminate all air from the fuel system.Refer to Testing and Adjusting, “Fuel System -Prime”.

9. If the fuel injection pump timing is incorrect, referto Testing and Adjusting, “Fuel Injection Pump Tim-ing - Adjust”.

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CHAPTER 2 DK651/751/801/901

E. FUEL INJECTION PUMP TIMING - ADJUST

a. DELPHI DP210 Series Fuel Injection PumpThe Delphi DP210 Series fuel injection pump must beserviced by an authorized Delphi technician. For repairinformation, contact your Perkins dealer or your Perkinsdistributor. The internal adjustment for the pump tim-ing is tamper proof. High idle and low idle of the fuelinjection pump are factory set. Idle adjustments cannot be made to the fuel pump.

b. Bosch EPVE Fuel Injection Pump

NOTE:

The Bosch EPVE fuel injection pump is only installedon the 1104C-44 engine. (DK751)

Part Number

27610248

Required Tools

Part Description

Bosch EPVE fuel injectionpump timing adapter

Qty

Pin 1

(1) Plug

NOTE:

• This procedure must only be carried out by a per-son with the correct training.

• Do not rotate the fuel injection pump if the fuel in-jection pump shaft is locked.

1. Set the number one piston at the top center on thecompression stroke. Refer to Testing and Adjusting,“Finding Top Center Position for the No. 1 Pistion”for the procedure.

2. Remove the rocker shaft. Refer to Disassembly andAssembly, “Rocker Shaft and Pushrods”.

3. Remove the high pressure fuel lines from the fuelinjection pump.

C34W2R5A

(2) Bosch EPVE Fuel Injection Timing Adapter

(3) Dial Indicator

C34W2R6A

4. Remove the plug (1) and the washer from the rearof the fuel injection pump and install 27610248 fuelinjection pump timing adapter (2).

Install a suitable dial indicator (3) into 27610248fuel injection pump timing adapter. Set the dial in-dicator to approximately 3 mm (0.1181 in.).

5. Ensure that the timing pins have been removed fromthe engine.

6. Rotate the crankshaft counterclockwise when thecrankshaft is viewed from the front of the engine.Carefully rotate the crankshaft until the dial indica-tor (3) indicates that the plunger of the fuel injec-tion pump is at the bottom. Set the dial indicator(3) to zero.

7. Rotate the crankshaft clockwise, until the requiredl i f t on the plunger is achieved. Refer toSpecifications, “Fuel Injection Pump” for the cor-rect reading.

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ENGINE SYSTEM

(7) Outlet

C34W2R9A

NOTE:

• A key should not be installed in the keyway (6).

• If the fuel injection pump is on the correct stroke,the keyway (6) is toward the outlet (7).

12. Set the number one piston at the top center pistonon the compression stroke. Refer to Testing andAdjusting, “Finding Top Center Position for the No.1 Pistion” for the procedure.

13. Install the fuel injection pump gear. Refer to Dis-assembly and Assembly, “Fuel Injection pump -Install”.

14. Install the front cover. Refer to Disassembly andAssembly, “Front Cover - Remove and Install”.

15. Install the water pump. Refer to Disassembly andAssembly, “Water Pump - Remove and Install”.

16. Install a new washer to the plug and install theplug in the back of the fuel injection pump. Referto Specifications, “Fuel Injection Pump” for thecorrect torque.

17. Install the rocker shaft. Refer to Disassembly andAssembly, “Rocker Shaft and Pushrods”.

18. Install the high pressure fuel lines on the fuel in-jection pump. Eliminate all air from the fuelsystem. Refer to Testing and Adjusting, “Fuel Sys-tem - Prime”.

(4) Washer (5) Locking Screw

C34W2R7A

8. Lock the fuel injection pump shaft.

In order to lock the shaft of the Bosch EPVE fuelinjection pump, loosen the locking screw (5) andremove the washer (4). Tighten the locking screwto 31 N·m (3.1 kgf·m, 23 lbf·ft). Ensure that theneedle of the dial indicator has not moved.

9. Remove the water pump. Refer to Disassemblyand Assembly, “Water Pump - Remove and Install”.

10. Remove the front cover. Refer to Disassembly andAssembly, “Front Cover - Remove and Install”.

11. Remove the fuel injection pump gear. Refer to Dis-assembly and Assembly, “Fuel Injection pump -Remove”.

(6) Keyway

C34W2R8A

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CHAPTER 2 DK651/751/801/901

G. FUEL SYSTEM - PRIMEIf air enters the fuel system, the air must be purgedbefore the engine can be started. Air can enter the fuelsystem when the following events occur:

• The fuel tank is empty or the tank has been partiallydrained during normal operation.

• The low pressure fuel lines are disconnected.

• A leak exists in the low pressure fuel system dur-ing engine operation.

• The fuel filter or the fuel pump is replaced.

• The high pressure fuel lines are disconnected.

a. DELPHI DP210The Delphi fuel pump will eliminate the air from thefuel system automatically. Position the starting switchto the RUN position for three minutes. Air in the fueland the fuel lines will be purged from the system.

b. Bosch EVPEThe Bosch EPVE fuel pump will not eliminate air auto-matically from the fuel system. the following proce-dure must be used.

• Remove the valve mechanism cover.

• Turn the start switch to the RUN position for threeminutes. Then return the start switch to the OFFposition.

• Loosen the high pressure lines at the fuel injectors.

• Operate the starting motor until fuel free from aircomes from the connections.

• Tighten the connections for the fuel injectors.

Refer to Specifications, “Fuel injection Lines”.

• Operate the engine and check for leaks.

• Fit the valve mechanism cover.

F. FUEL QUALITY - TESTUse the following procedure to test for problems re-garding fuel quality:

1. Determine if water and/or contaminants are presentin the fuel. Check the water separator (if equipped).If a water separator is not present, proceed to Step2. Drain the water separator, if necessary. A fullfuel tank minimizes the potential for overnightcondensation.

NOTE:

A water separator can appear to be full of fuel whenthe water separator is actually full of water.

2. Determine if contaminants are present in the fuel.Remove a sample of fuel from the bottom of the fueltank. Visual ly inspect the fuel sample forcontaminants. The color of the fuel is not neces-sarily an indication of fuel quality. However, fuel thatis black, brown, and/or similar to sludge can be anindicat ion of the growth of bacter ia or oi lcontamination. In cold temperatures, cloudy fuelindicates that the fuel may not be suitable for theoperating conditions. Refer to Operation and Main-tenance Manual, “Fuel Recommendations” for moreinformation.

3. If fuel quality is still suspected as a possible causeof problems regarding engine performance, discon-nect the fuel inlet line, and temporarily operate theengine from a separate source of fuel that is knownto be good. This will determine if the problem iscaused by fuel quality. If fuel quality is determinedto be the problem, drain the fuel system and re-place the fuel filters. Engine performance can beaffected by the following characteristics:

• Cetane number of the fuel

• Air in the fuel

• Other fuel characteristics

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ENGINE SYSTEM

Idle

Rated speed

Idle

Rated speed

Item Tightening torque

BoschEPVE

DelphiDP210

H. FUEL SYSTEM PRESSURE - TESTThe pressure test measures the output pressure of thefuel transfer pump. Low fuel pressure and starting dif-ficulty may be indications of problems with the fuelpriming pump.

a. Check the Function of the Fuel Transfer Pump1. Make a note of the location of the fuel lines from

the fuel transfer pump. Remove the two lines fromthe outlets (A) and (B).

2. Connect two lengths of 5/16 in. rubber hose to out-lets (A) and (B). Place the hoses into a suitablecontainer that is capable of holding 3 L (3.17 qt) offuel.

3. Energize the fuel transfer pump until a constant flowof fuel is running from the outlet for the supply forthe fuel injection pump.

NOTE:

The flow from the outlet for the return for the fuel tankwill have a slower flow rate.

4. Measure the combined flow of both outlets with astopwatch. Fuel flow should be a minimum of 2 L/min(0.53 US gpm).

5. If the combined flow is less than 2 L/min (0.53 USgpm), repair the pump or replace the pump.

6. Reconnect the outlet lines in the correct positions.

7. Start the engine and check for any leakage of fuelor air from the fuel lines.

b. Check the Function of the Pressure Regulator1. Remove the fuel line from the outlet for the supply

for the fuel injection pump (B).

2. Install a pipe with a tap for a pressure gauge. Con-nect a 0 ~ 80 kPa (0 ~ 0.81 kgf/cm2, 0 ~ 11.6 psi)pressure gauge.

3. Start the engine and run the engine at idle for twominutes in order to remove any trapped air.

4. Record the pressure reading at idle and at ratedspeed. The pressure reading should be the follow-ing values:

C34W2O2A

(A) Fuel Outlet (B) Fuel Outlet

(1) Fuel Transfer Pump

(2) Fuel Filter

31 kPa(0.31 kgf/cm2, 4.49 psi)

31 kPa(0.31 kgf/cm2, 4.49 psi)

27.5 kPa(0.28 kgf/cm2, 3.98 psi)

28 kPa(0.29 kgf/cm2, 4.06 psi)

NOTE:

Maximum pressure for the fuel injection pump is 80kPa (0.81 kgf/cm2, 11.6 psi).

5. Reconnect the fuel line. Run the engine at idle fortwo minutes in order to remove any trapped air.

Check for the following issues if the pressures are out-side of the above specifications.

• All electrical connections are installed correctly.

• There are no leaks in the fuel lines or connections.

• The O-ring on the fuel filter housing (2) does notleak.

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CHAPTER 2 DK651/751/801/901

A. AIR INLET AND EXHAUST SYSTEM - IN-SPECT

A general visual inspection should be made to the airinlet and exhaust system. Make sure that there are nosigns of leaks in the system.

There will be a reduction in the performance of theengine if there is a restriction in the air inlet system orthe exhaust system.

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.

WARNING

Making contact with a running engine can causeburns from hot parts and can cause injury from ro-tating parts.

When working on an engine that is running, avoidcontact with hot parts and rotating parts.

WARNING

1. Inspect the engine air cleaner inlet and ducting inorder to ensure that the passageway is not blockedor collapsed.

2. Inspect the engine air cleaner element. Replace adirty element with a clean element.

3. Check for dirt tracks on the clean side of the engineair cleaner element. If dirt tracks are observed, con-taminants are flowing past the element.

5.2. AIR INLET AND EXHAUST SYSTEM

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ENGINE SYSTEM

B. WASTEGATE - TEST

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.

WARNING

• Keep all parts clean from contaminants.

• Contaminants may cause rapid wear and short-ened component life.

CAUTION

NOTE:

The turbocharger is a nonserviceable item.

The pressure for the wastegate can be checked, butnot adjusted.

1. Use a suitable magnetic base dial indicator (1).

Align the dial gauge to the actuator rod (2).

2. Remove the air hose to the actuator (3). Install anair line that can be adjusted in order to give thecorrect pressure.

NOTE:

Do not exceed 205 kPa (2.09 kgf/cm2, 29.7 psi) inorder to check the actuator. Refer to the Specification,“Turbocharger” topic for information on the correct pres-sure setting for your actuator.

3. Carefully apply the air pressure until the air pres-sure has moved the rod 1 mm (0.0394 in.).

Check that the air pressure is correct for yourturbocharger.

4. For more information on installing a new turbocharger,contact your Perkins dealer or your Perkinsdistributor.

C34W2O3A

(1) Magnetic Base Dial Indicator

(2) Actuator Rod

(3) Actuator

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CHAPTER 2 DK651/751/801/901

C. COMPRESSION - TESTThe cylinder compression test should only be usedin order to compare the cylinders of an engine. If oneor more cylinders vary by more than 350 kPa (3.5kgf/cm2, 51 psi), the cylinder and related componentsmay need to be repaired.

A compression test should not be the only methodwhich is used to determine the condition of an

engine. Other tests should also be conducted in orderto determine if the adjustment or the replacement ofcomponents is required.

Before the performance of the compression test, makesure that the following conditions exist:

• The battery is in good condition.

• The battery is fully charged.

• The starting motor operates correctly.

• The valve lash is set correctly.

• All fuel injectors are removed.

• The fuel supply is disconnected.

1. Install a gauge for measuring the cylinder compres-sion in the hole for a fuel injector.

2. Operate the starting motor in order to turn theengine. Record the maximum pressure which isindicated on the compression gauge.

3. Repeat Steps 1 and 2 for all cylinders.

D. ENGINE VALVE LASH - INSPECT/ADJUST

• To prevent possible injury, do not use the starterto turn the flywheel.

• Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring valve clearance.

WARNING

Refer to Systems Operation, “Engine Design” for thelocation of the cylinder valves.

If the valve lash requires adjustment several times in ashort period of time, excessive wear exists in a differ-ent part of the engine. Find the problem and make nec-essary repairs in order to prevent more damage to theengine.

Not enough valve lash can be the cause of rapid wearof the camshaft and valve lifters. Not enough valve lashcan indicate that the seats for the valves are worn.

Valves become worn due to the following causes:

• Fuel injectors that operate incorrectly

• Excessive dirt and oil are present on the filters forthe inlet air.

• Incorrect fuel settings on the fuel injection pump.

• The load capacity of the engine is frequentlyexceeded.

Too much valve lash can cause broken valve stems,springs, and spring retainers. Too much valve lash canbe an indication of the following problems:

• Worn camshaft and valve lifters

• Worn rocker arms

• Bent pushrods

• Broken socket on the upper end of a pushrod

• Loose adjustment screw for the valve lash

If the camshaft and the valve lifters show rapid wear,look for fuel in the lubrication oil or dirty lubrication oilas a possible cause.

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ENGINE SYSTEM

a. Inspect Valve LashAn adjustment is NOT NECESSARY if the measurementof the valve lash is in the acceptable range. Inspect thevalve lash while the engine is stopped. The tempera-ture of the engine does not change the valve lash setting.

Engine valve lash for the 1104 engine

Inlet valves1104

0.20 mm(0.008 in.)

1,2

3,4

Exhaust valves1104

0.45 mm(0.018 in.)

1,3

2,4

Valve lash(Stopped engine)

TC compressionstroke

TC exhauststroke (1)

Firing order

If the measurement is not within the acceptableclearance, adjustment is necessary. Refer to “ValveLash Adjustment”.

b. Valve Lash Adjustment for the 1104 Engine

NOTE:

The No. 1 cylinder is at the front of the engine.

1,3,4,2 (2)

(1) 360° from TC compression stroke

(2) The No. 1 cylinder is at the front of the engine.

Engine valve lash for the 1103 engine

Inlet Valves

0.20 mm(0.008 in.)

1, 3, 5

Exhaust Valves

0.45 mm(0.018 in.)

2, 4, 6

Valves

Valve lash

Valves

Firing order 1, 2, 3

C34W2O4A

(1) Adjustment Screw (2) Feeler Gauge

• Accidental engine starting can cause injury ordeath to personnel.

• To prevent accidental engine starting, turn the igni-tion switch to the OFF position, place a do not oper-ate tag at the ignition switch location and discon-nect and tape the electrical connection to the stopsolenoid that is located on the fuel injection pump.

WARNING

Remove the valve mechanism cover and perform thefollowing procedure in order to adjust the valve lash:

1. Put the No. 1 piston at the top center position on thecompression stroke. Refer to Testing and Adjusting,“Finding Top Center Position for No.1 Piston”.

Inlet valves

0.20 mm(0.008 in.)

1,2

Exhaust valves

0.45 mm(0.018 in.)

1,3

TC compres-sion stroke

Valve lash

Cylinders

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CHAPTER 2 DK651/751/801/901

2. Adjust the valves according to Table 5.

a. Lightly tap the rocker arm at the top of the ad-justment screw with a soft mallet. This will en-sure that the lifter seats against the camshaft.

b. Loosen the adjustment locknut.

c. Place the correct feeler gauge between the rockerarm and the valve stem. Then, turn the adjust-ment screw in a clockwise direction.

Slide the feeler gauge between the rocker armand the valve stem. Continue turning the adjust-ment screw until a slight drag is felt on the feelergauge. Remove the feeler gauge.

d. Tighten the adjustment locknut to a torque of27 N·m (2.7 kgf·m, 19.9 lbf·ft). Do not allow theadjustment screw to turn while you are tighten-ing the adjustment locknut. Recheck the valvelash after tightening the adjustment locknut.

3. Rotate the engine by 360 degrees. The engine willbe on TC compression stroke for cylinder 4.

Inlet valves

0.20 mm(0.008 in.)

3,4

Exhaust valve

0.45 mm(0.018 in.)

2,4

TC exhauststroke(3)

Valve lash

Cylinders

(3) Position for No. 1 cylinder

4. Adjust the valves according to Table 7.

a. Lightly tap the rocker arm at the top of the ad-justment screw with a soft mallet. This will en-sure that the lifter seats against the camshaft.

b. Loosen the adjustment locknut.

c. Place the correct feeler gauge between the rockerarm and the valve stem. Then, turn the adjust-ment screw in a clockwise direction.

Slide the feeler gauge between the rocker armand the valve stem. Continue turning the adjust-ment screw until a slight drag is felt on the feelergauge. Remove the feeler gauge.

d. Tighten the adjustment locknut to a torque of27 N·m (2.75 kgf·m, 19.9 lbf·ft). Do not allowthe adjustment screw to turn while you are tight-ening the adjustment locknut. Recheck thevalve lash af ter t ightening the adjustmentlocknut.

Install the valve mechanism cover. Refer to Disassem-bly and Assembly, “Valve Mechanism Cover - Removeand Install”.

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ENGINE SYSTEM

c. Valve Lash Adjustment for the 1103 Engine

NOTE:

The No. 1 cylinder is at the front of the engine.

Remove the valve mechanism cover and perform thefollowing procedure in order to adjust the valve lash:

1. Put the No. 1 piston at the top center position on thecompression stroke. Refer to Testing and Adjusting,“Finding Top Center Position for No.1 Piston”.

C34W2O4A

(1) Adjustment Screw (2) Feeler Gauge

Inlet valves

0.20 mm(0.008 in.)

1, 3, 5

Exhaust valves

0.45 mm(0.018 in.)

2, 4, 6

Valves

Valve lash

Valves

2. Rotate the crankshaft until the inlet valve for thecylinder 1 has just opened and the exhaust valvefor the cylinder 1 is not completely closed. Thenadjust the number 3 valve and the number 6 valve.

a. Adjust the valves according to Table 8.

b. Lightly tap the rocker arm at the top of the ad-justment screw with a soft mallet. This will en-sure that the lifter seats against the camshaft.

c. Loosen the adjustment locknut.

d. Place the correct feeler gauge between the rockerarm and the valve stem. Then, turn the adjust-ment screw in a clockwise direction. Slide thefeeler gauge between the rocker arm and the valvestem. Continue turning the adjustment screw untila slight drag is felt on the feeler gauge. Removethe feeler gauge.

e. Tighten the adjustment locknut to a torque of27 N·m (2.7 kgf·m, 19.9 lbf·ft). Do not allowthe adjustment screw to turn while you are tight-ening the adjustment locknut. Recheck the valvelash after tightening the adjustment locknut.

3. Rotate the engine by 360 degrees. Then adjust thenumber 1 valve and the number 5 valve. Then ad-just the number 2 valve and the number 4 valve.

a. Adjust the valves according to Table 8.

b. Lightly tap the rocker arm at the top of the adjust-ment screw with a soft mallet. This will ensurethat the lifter seats against the camshaft.

c. Loosen the adjustment locknut.

d. Place the correct feeler gauge between the rockerarm and the valve stem. Then, turn the adjust-ment screw in a clockwise direction. Slide thefeeler gauge between the rocker arm and the valvestem. Continue turning the adjustment screw untila slight drag is felt on the feeler gauge. Removethe feeler gauge.

e. Tighten the adjustment locknut to a torque of27 N·m (2.7 kgf·m, 19.9 lbf·ft). Do not allowthe adjustment screw to turn while you are tight-ening the adjustment locknut. Recheck the valvelash after tightening the adjustment locknut.

Install the valve mechanism cover. Refer to Disassem-bly and Assembly, “Valve Mechanism Cover - Removeand Install”.

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CHAPTER 2 DK651/751/801/901

E. VALVE DEPTH - INSPECT

Part Description

Dial gauge

Dial gauge holder

Part Number

21825617

21825496

Qty

1

1

Required Tools

1. Use the dial gauge (1) with the dial gauge holder(2) to check the depths of the inlet valves and theexhaust valves below the face of the cylinder head.Use the cylinder head face (3) to zero the dial gauge(1).

2. Position the dial gauge holder (2) and the dial gauge(1) in order to measure the valve depth.

Measure the depth of the inlet valve and the exhaustvalve before the valve springs are removed.

Refer to Specifications, “Cylinder Head Valves” forthe minimum, the maximum, and the service wearlimits for the valve depth below the cylinder headface.

If the valve depth below the cylinder head face ex-ceeds the service limit, use a new valve to checkthe valve depth. If the valve depth still exceeds theservice limit, renew the cylinder head or renew thevalve seat inserts (if equipped). If the valve depth iswithin the service limit with a new valve, renew thevalves.

3. Inspect the valves for cracks and other damage.

Check the valve stems for wear. Check that the valvesprings are the correct length under the test force.Refer to Specifications, “Cylinder Head Valves” forthe dimensions and tolerances of the valves andthe valve springs.

C34W2O5A

(1) Dial Gauge

(2) Dial Gauge Holder

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ENGINE SYSTEM

F. VALVE GUIDE - INSPECT

Perform this inspection in order to determine if a valveguide should be replaced.

1. Place a new valve in the valve guide.

2. Place a suitable dial indicator with the magneticbase on the face of the cylinder head.

3. Lift the edge of the valve head to a distance of 15.0 mm(0.60 in.).

4. Move the valve in a radial direction away from thedial indicator. Make sure that the valve moves awayfrom the dial indicator as far as possible.

Position the contact point of the dial indicator on theedge of the valve head. Set the position of the needleof the dial indicator to zero.

5. Move the valve in a radial direction toward the dialindicator as far as possible. Note the distance ofmovement which is indicated on the dial indicator.If the distance is greater than the maximum clear-ance of the valve in the valve guide, replace the valveguide.

When new valve guides are installed, new valvesand new valve seat inserts must be installed.

Valve guides and valve seat inserts are supplied asan unfinished part. The unfinished valve guides andunfinished valve seat inserts are installed in thecylinder head. Then, the valve guides and valve in-serts are cut and reamed in one operation with spe-cial tooling.

Refer to Specifications, “Cylinder Head Valves” forthe maximum clearance of the valve in the valveguide.

C34W2O6A

(1) Valve Guide

(2) Radial Movement of the Valve in the ValveGuide

(3) Valve Stem

(4) Dial Indicator

(5) Valve Head

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CHAPTER 2 DK651/751/801/901

5.3. LUBRICATION SYSTEM

A. ENGINE OIL PRESSURE - TEST

a. Low Oil PressureThe following conditions will cause low oil pressure.

• The oil level is low in the crankcase.

• A restriction exists on the oil suction screen.

• Connections in the oil lines are leaking.

• The connecting rod or the main bearings are worn.

• The rotors in the oil pump are worn.

• The oil pressure relief valve is operating incorrectly.

A worn oil pressure relief valve can allow oil to leakthrough the valve which lowers the oil pressure.

Refer to the Specifications Module, “Engine Oil ReliefValve” for the correct operating pressure and otherinformation.

When the engine runs at the normal temperature foroperation and at high idle, the oil pressure must be aminimum of 280 kPa (2.85 kgf/cm2, 40.6 psi). A lowerpressure is normal at low idle.

A suitable pressure gauge can be used in order to testthe pressure of the lubrication system.

b. High Oil PressureHigh oil pressure can be caused by the followingconditions.

• The spring for the oil pressure relief valve is installedincorrectly.

• The plunger for the oil pressure relief valve becomesjammed in the closed position.

• Excessive sludge exists in the oil which makes theviscosity of the oil too high.

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B. ENGINE OIL PUMP - INSPECTIf any part of the oil pump is worn enough in order toaffect the performance of the oil pump, the oil pumpmust be replaced.

Perform the following procedures in order to inspectthe oil pump for clearances and torques.

Refer to the Specifications Module, “Engine Oil Pump”.

1. Remove the oil pump from the engine. Refer to theDisassembly and Assembly, “Engine Oil Pump -Remove”. Remove the cover of the oil pump.

2. Remove the outer rotor. Clean all of the parts.

Look for cracks in the metal or other damage.

3. Install the outer rotor. Measure the clearance of theouter rotor to the body (1).

C34W2O7A

(1) Measure the Clearance of the Outer Rotor tothe Body.

4. Measure the clearance of the inner rotor to the outerrotor (2).

C34W2O8A

(2) Measure the Clearance of the Inner Rotor tothe Outer Rotor.

5. Measure the end play of the rotor with a straightedge and a feeler gauge (3).

6. Clean the top face of the oil pump and the bottomface of the cover. Install the cover on the oil pump.Install the oil pump on the engine.

Refer to Disassembly and Assembly, “Engine OilPump - Install”.

C34W235A

(3) Feeler Gauge

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CHAPTER 2 DK651/751/801/901

C. EXCESSIVE BEARING WEAR - INSPECTWhen some components of the engine show bearingwear in a short time, the cause can be a restriction inan oil passage.

An engine oil pressure indicator may show that thereis enough oil pressure, but a component is worn dueto a lack of lubrication. In such a case, look at the pas-sage for the oil supply to the component. A restrictionin an oil supply passage will not allow enough lubrica-tion to reach a component. This will result in early wear.

D. EXCESSIVE ENGINE OIL CONSUMPTION- INSPECT

a. Engine Oil Leaks on the Outside of the EngineCheck for leakage at the seals at each end of thecrankshaft. Look for leakage at the gasket for the en-gine oil pan and all lubrication system connections.Look for any engine oil that may be leaking from thecrankcase breather. This can be caused by combus-tion gas leakage around the pistons. A dirty crankcasebreather will cause high pressure in the crankcase. Adirty crankcase breather will cause the gaskets andthe seals to leak.

b. Engine Oil Leaks into the Combustion Area of theCylinders

Engine oil that is leaking into the combustion area ofthe cylinders can be the cause of blue smoke.

There are several possible ways for engine oil to leakinto the combustion area of the cylinders:

• Leaks between worn valve guides and valve stems

• Worn components or damaged components(pistons, piston rings, or dirty return holes for theengine oil)

• Incorrect installation of the compression ring and/or the intermediate ring

• Leaks past the seal rings in the turbocharger shaft

• Overfilling of the crankcase

• Wrong dipstick or guide tube

• Sustained operation at light loads

Excessive consumption of engine oil can also result ifengine oil with the wrong viscosity is used. Engine oilwith a thin viscosity can be caused by fuel leakage intothe crankcase or by increased engine temperature.

E. INCREASED ENGINE OIL TEMPERATURE- INSPECT

Look for a restriction in the oil passages of the oil cooler(if equipped). The oil temperature may be higher thannormal when the engine is operating. In such a case,the oil cooler may have a restriction.

A restriction in the oil cooler will not cause low oil pres-sure in the engine.

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ENGINE SYSTEM

5.4. COOLING SYSTEM

A. COOLING SYSTEM - CHECK (OVERHEATING)Above normal coolant temperatures can be caused bymany conditions. Use the following procedure to deter-mine the cause of above normal coolant temperatures:

1. Check the coolant level in the cooling system. Ifthe coolant level is too low, air will get into the cool-ing system. Air in the cooling system will cause areduction in coolant flow and bubbles in the coolant.Air bubbles will keep the coolant away from theengine parts, which will prevent the transfer of heatto the coolant. Low coolant level is caused by leaksor incorrectly filling the expansion tank.

2. Check the mixture of antifreeze and water. The mix-ture should be 50 percent water and 50 percent21825166 POWERPART antifreeze.

3. Check for air in the cooling system. Air can enter thecooling system in different ways. The most com-mon causes of air in the cooling system are notfilling the cooling system correctly and combustiongas leakage into the cooling system.

Combustion gas can get into the system throughinside cracks, a damaged cylinder head, or a dam-aged cylinder head gasket. Air in the cooling sys-tem causes a reduction in coolant flow and bubblesin the coolant. Air bubbles keep the coolant awayfrom the engine parts, which prevents the transferof heat to the coolant.

4. Check the sending unit. In some conditions, thetemperature sensor in the engine sends signals toa sending unit. The sending unit converts these sig-nals to an electrical impulse which is used by amounted gauge. If the sending unit malfunctions,the gauge can show an incorrect reading. Also ifthe electric wire breaks or if the electric wire shortsout, the gauge can show an incorrect reading.

5. Check the radiator for a restriction to coolant flow.

Check the radiator for debris, dirt, or deposits onthe inside of the core. Debris, dirt, or deposits willrestrict the flow of coolant through the radiator.

6. Check the filler cap. A pressure drop in the coolingsystem can cause the boiling point to be lower.This can cause the cooling system to boil.

Refer to Testing and Adjusting, “Cooling System -Test”.

7. Check the cooling system hoses and clamps.

Damaged hoses with leaks can normally be seen.Hoses that have no visual leaks can soften duringoperation. The soft areas of the hose can becomekinked or crushed during operation.

These areas of the hose can cause a restrictionin the coolant flow. Hoses become soft and/or getcracks after a period of time. The inside of a hosecan deteriorate, and the loose particles of the hosecan cause a restriction of the coolant flow.

8. Check for a restriction in the air inlet system.

A restriction of the air that is coming into the en-gine can cause high cylinder temperatures.

High cylinder temperatures require higher than nor-mal temperatures in the cooling system.

9. Check for a restriction in the exhaust system.

A restriction of the air that is coming out of theengine can cause high cylinder temperatures.

a. Make a visual inspection of the exhaust system.

b. Check for damage to exhaust piping. Checkfor damage to the exhaust elbow. If no dam-age is found, check the exhaust system for arestriction.

10. Check the water temperature regulator. A watertemperature regulator that does not open, or awater temperature regulator that only opens partof the way can cause overheating. Refer to Test-ing and Adjusting, “Water Temperature Regulator- Test”.

11. Check the water pump. A water pump with a dam-aged impeller does not pump enough coolant forcorrect engine cooling. Remove the water pumpand check for damage to the impeller.

12. Consider high outside temperatures. When out-side temperatures are too high for the rating ofthe cooling system, there is not enough of a tem-perature difference between the outside air andcoolant temperatures. The maximum temperatureof the ambient air that enters the engine shouldnot exceed 50°C (120°F).

13. When a load that is applied to the engine is toolarge, the engine rpm does not increase with anincrease of fuel. This lower engine rpm causes areduction in coolant flow through the system.

This combination of less air and less coolant flowduring high input of fuel will cause above normalheating.

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CHAPTER 2 DK651/751/801/901

B. COOLING SYSTEM - INSPECTThis engine has a pressure type cooling system. A pres-sure type cooling system gives two advantages:

• The pressure type cooling system can operatesafely at a higher temperature than the boiling pointof water at a range of atmospheric pressures.

• The pressure type cooling system prevents cavita-tion in the water pump.

Cavitation is the sudden generation of low pressurebubbles in liquids by mechanical forces. The genera-tion of an air or steam pocket is much more difficult ina pressure type cooling system.

Regular inspections of the cooling system should bemade in order to identify problems before damage canoccur. Visually inspect the cooling system before testsare made with the test equipment.

a. Visual Inspection of the Cooling System1. Check the coolant level in the cooling system.

2. Look for leaks in the system.

3. Inspect the radiator for bent fins and other restric-tion to the flow of air through the radiator.

4. Inspect the drive belt for the fan.

5. Inspect the blades of the fan for damage.

6. Look for air or combustion gas in the cooling system.

7. Inspect the radiator cap for damage. The sealingsurface must be clean.

8. Look for large amounts of dirt in the radiator core.

Look for large amounts of dirt on the engine.

9. Shrouds that are loose or missing cause poor airflow for cooling.

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ENGINE SYSTEM

C. COOLING SYSTEM - TESTRemember that temperature and pressure worktogether. When a diagnosis is made of a cooling sys-tem problem, temperature and pressure must bechecked. The cooling system pressure will have aneffect on the cooling system temperature. For anexample, refer to Illustration 34. This will show the ef-fect of pressure on the boiling point (steam) of water.This will also show the effect of height above sea level.

• Personal injury can result from hot coolant,steam and alkali.

• At operating temperature, engine coolant is hotand under pressure. The radiator and all lines toheaters or the engine contain hot coolant or steam.Any contact can cause severe burns.

• Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

WARNING

The coolant level must be to the correct level in orderto check the coolant system. The engine must be coldand the engine must not be running.

After the engine is cool, loosen the pressure cap inorder to relieve the pressure out of the cooling system.Then remove the pressure cap.

The level of the coolant should not be more than 13mm (0.5 in.) from the bottom of the filler pipe.

If the cooling system is equipped with a sight glass,the coolant should be to the correct level in the sightglass.

a. Making the Correct Antifreeze MixturesDo not add pure 21825166 POWERPART antifreeze tothe cooling system in order to adjust the concentrationof antifreeze. The pure antifreeze increases the con-centration of antifreeze in the cooling system. The in-creased concentration increases the concentration ofdissolved solids and undissolved chemical inhibitorsin the cooling system.

The antifreeze mixture must consist of equal quanti-ties of antifreeze and clean soft water. The corrosioninhibitor in the antifreeze will be diluted if a concentra-tion of less than 50% of antifreeze is used.

Concentrations of more than 50% of antifreeze mayhave the adverse effect on the performance of thecoolant.

C34W2O9A

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CHAPTER 2 DK651/751/801/901

b. Checking the Filler CapOne cause for a pressure loss in the cooling systemcan be a faulty seal on the radiator pressure cap.

C34W2P0A

(1) Sealing Surface Between the Pressure Capand the Radiator

• Personal injury can result from hot coolant,steam and alkali.

• At operating temperature, engine coolant is hotand under pressure. The radiator and all lines toheaters or the engine contain hot coolant or steam.Any contact can cause severe burns.

• Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

WARNING

To check for the amount of pressure that opens thefiller cap, use the following procedure:

1. After the engine cools, carefully loosen the fillercap. Slowly release the pressure from the coolingsystem. Then, remove the filler cap.

2. Inspect the pressure cap carefully. Look for dam-age to the seal. Look for damage to the surface thatseals. Remove any debris on the cap, the seal, orthe sealing surface.

Carefully inspect the filler cap. Look for any dam-age to the seals and to the sealing surface.

Inspect the following components for any foreignsubstances:

• Filler cap

• Seal

• Surface for seal

Remove any deposits that are found on these items,and remove any material that is found on theseitems.

3. Install the pressure cap onto a suitable pressuriz-ing Pump.

4. Observe the exact pressure that opens the filler cap.

5. Compare the pressure to the pressure rating thatis found on the top of the filler cap.

6. If the filler cap is damaged, replace the filler cap

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ENGINE SYSTEM

c. Testing the Radiator and Cooling System forLeaks

Use the following procedure to test the radiator andthe cooling system for leaks.

• Personal injury can result from hot coolant,steam and alkali.

• At operating temperature, engine coolant is hotand under pressure. The radiator and all lines toheaters or the engine contain hot coolant or steam.Any contact can cause severe burns.

• Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.

WARNING

1. When the engine has cooled, loosen the filler capto the first stop. Allow the pressure to release fromthe cooling system. Then remove the filler cap.

2. Make sure that the coolant covers the top of theradiator core.

3. Put a suitable pressurizing Pump onto the radiator.

4. Use the pressurizing pump to increase the pres-sure to an amount of 20 kPa (0.2 kgf/cm2, 2.9 psi)more than the operating pressure of the filler cap.

5. Check the radiator for leakage on the outside.

6. Check all connections and hoses of the cooling sys-tem for leaks.

The radiator and the cooling system do not haveleakage if all of the following conditions exist:

• You do NOT observe any leakage after fiveminutes.

• The dial indicator remains constant beyond fiveminutes.

The inside of the cooling system has leakageonly if the following conditions exist:

• The reading on the gauge goes down.

• You do NOT observe any outside leakage.

Make any repairs, as required.

D. ENGINE OIL COOLER - INSPECT

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components to con-tact the skin.

WARNING

a. Engine Oil Cooler for the 1104 EnginePerform the following procedure in order to inspect theengine oil cooler (if equipped):

1. Place a container under the oil cooler in order tocollect any engine oil or coolant that drains from theoil cooler.

2. Refer to Disassembly and Assembly, “Engine OilCooler - Remove” for removal of the engine oilcooler.

3. Thoroughly clean the flange face of the cover plateand the cylinder block.

• Personal injury can result from air pressure.

• Personal injury can result without following properprocedure. When using pressure air, wear a pro-tective face shield and protective clothing.

• Maximum air pressure at the nozzle must be lessthan 205 kPa (2.09 kgf/cm2, 29.7 psi) for clean-ing purposes.

WARNING

4. Inspect the cooling plates for cracks and dents.

Replace the cooling plates if cracks or dents exist.

If necessary, clean the outside and clean the insideof the cooling plates. Use a solvent that is not cor-rosive on copper. Ensure that no restrictions for theflow of lubricating oil exist in the cooling plates.

Dry the cooling plate with low pressure air.

Flush the inside of the cooling plate with clean lu-bricating oil.

5. Refer to Disassembly and Assembly, “Engine OilCooler - Install” for installation of the engine oil cooler.

6. Ensure that the cooling system and the oil systemof the engine are filled to the correct level.

Operate the engine. Check for oil or coolant leakage.

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CHAPTER 2 DK651/751/801/901

b. Modine Oil Cooler for the 1103 EnginePerform the following procedure in order to inspect themodine oil cooler (if equipped):

1. Place a container under the modine oil cooler inorder to collect any engine oil or coolant that drainsfrom the modine oil cooler.

2. Refer to Disassembly and Assembly, “Engine OilCooler - Remove” for removal of the engine oil cooler.

3. Thoroughly clean the outside of the cooler plateswith a suitable cleaning fluid.

4. Thoroughly clean the inside of the cooler plates withclean water.

Dry the cooling plate with low pressure air.

Flush the inside of the cooling plate with clean lu-bricating oil.

5. Install the modine oil cooler. Refer to Disassemblyand Assembly, “Engine Oil Cooler - Install”.

6. Ensure that the cooling system and the oil systemof the engine are filled to the correct level.

Operate the engine. Check for oil or coolant leakage.

• Personal injury can result from air pressure.

• Personal injury can result without following properprocedure. When using pressure air, wear a pro-tective face shield and protective clothing.

• Maximum air pressure at the nozzle must be lessthan 205 kPa (2.09 kgf/cm2, 230 psi) for clean-ing purposes.

WARNING

E. WATER TEMPERATURE REGULATOR - TEST

NOTE:

Do not remove the water temperature regulator fromthe water temperature regulator housing in order toperform the test.

1. Remove the water temperature regulator housingwhich contains the water temperature regulator fromthe engine. Refer to Disassembly and Assembly,“Water Temperature Regulator - Remove and Install”.

2. Heat water in a pan until the temperature of thewater is equal to the fully open temperature of thewater temperature regulator. Refer to Specifications,“Water Temperature Regulator” for the fully opentemperature of the water temperature regulator. Stirthe water in the pan.

This will distribute the temperature throughout thepan.

3. Hang the water temperature regulator housing inthe pan of water. The water temperature regulatorhousing must be below the surface of the water.

The water temperature regulator housing must beaway from the sides and the bottom of the pan.

4. Keep the water at the correct temperature for tenminutes.

5. After ten minutes, remove the water temperatureregulator housing. Immediately measure the open-ing of the water temperature regulator.

Refer to Specifications, “Water Temperature Regu-lator” for the minimum opening distance of the wa-ter temperature regulator at the ful ly opentemperature.

If the distance is less than the amount listed in themanual, replace the water temperature regulator.

Refer to Disassembly and Assembly, “Water Tempera-ture Regulator - Remove and Install”.

Install the water temperature regulator. Refer to Dis-assembly and Assembly, “Water Temperature Regula-tor - Remove and Install”.

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ENGINE SYSTEM

5.5 BASIC ENGINE

A. PISTON RING GROOVE - INSPECT

a. Inspect the Piston and the Piston Rings1. Check the piston for wear and other damage.

2. Check that the piston rings are free to move in thegrooves and that the rings are not broken.

b. Inspect the Clearance of the Piston Ring1. Remove the piston rings and clean the grooves and

the piston rings.

2. Fit new piston rings (2) in the piston grooves (3).

3. Check the clearance for the piston ring by placing asuitable feeler gauge (1) between the piston groove(3) and the top of piston ring (2).

Refer to Specifications, “Piston and Rings” for thedimensions.

NOTE:

Some pistons have a tapered top groove and the pis-ton ring is wedged. The clearance for the top pistonring cannot be checked by the above method whenthis occurs.

C34W2P1A

(1) Feeler Gauge (3) Piston Grooves

(2) Piston Ring

c. Inspect the Piston Ring end Gap1. Clean all carbon from the top of the cylinder bores.

2. Place each piston ring (1) in the cylinder bore justbelow the cylinder ring ridge (2).

3. Use a suitable feeler gauge (3) to measure the pis-ton ring end gap. Refer to Specifications, “Pistonand Rings” for the dimensions.

NOTE:

The coil spring must be removed from the oil controlring before the gap of the oil control ring is measured.

C34W2P2A

(1) Piston Ring (3) Feeler Gauge

(2) Cylinder Ring Ridge

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CHAPTER 2 DK651/751/801/901

B. CONNECTING ROD - INSPECTThis procedure determines the following characteris-tics of the connecting rod:

• The distortion of the connecting rod

• The parallel alignment of the bores of the connect-ing rod

1. Use the appropriate tools in order to measure thedistances for the connecting rod (2).

• Appropriate gauges for measuring distance

• Measuring pins (1)

NOTE:

The connecting rod bearings should be removed be-fore taking the measurements.

2. Measure the connecting rod for distortion and par-allel alignment between the bores.

The measurements must be taken at distance (K).Distance (K) has a value of 127 mm (5.0 in.) fromboth sides of the connecting rod.

Measure length (L).

The total difference in measurements of length (L)from each side should not vary more than ± 0.25mm (± 0.010 in.).

If the piston pin bearing is not removed, the limitsare reduced to ± 0.06 mm (± 0.0025 in.).

3. Inspect the piston pin bearing and the piston pin forwear and other damage.

4. Measure the clearance of the piston pin in the pis-ton pin bearing. Refer to Specifications, “Connect-ing Rod” for clearance dimensions.

C34W2P3A

(1) Measuring Pins

(2) Connecting Rod

(L) Measure the distance between the center ofthe bore for the piston pin bearing and thecenter of the connecting rod bearing bore.

(K) Measure the distance 127 mm (5.0 in.) fromthe connecting rod.

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ENGINE SYSTEM

C. CONNECTING ROD BEARINGS - INSPECTCheck the connecting rod bearings and the connect-ing rod bearing journal for wear or other damage.

Connecting rod bearings are available with a smallerinside diameter than the original size bearings. Thesebearings are for crankshafts that have been ground.

D. MAIN BEARINGS - INSPECTCheck the main bearings for wear or other damage.

Replace both halves of the bearings and check thecondition of the other bearings if a main bearing is wornor damaged.

Main bearings are available with a smaller inside di-ameter than the original size bearings. These bear-ings are for main bearing journals that have beenground.

E. CYLINDER BLOCK - INSPECT1. Clean all of the coolant passages and the oil

passages.

2. Check the cylinder block for cracks and damage.

3. The top deck of the cylinder block must not bemachined. This will affect the piston height abovethe cylinder block.

4. Check the camshaft bearing for wear. If a new bear-ing is needed, use a suitable adapter to press thebearing out of the bore. Ensure that the oil hole inthe new bearing faces the front of the block. The oilhole in the bearing must be aligned with the oil holein the cylinder block.

The bearing must be aligned with the face of therecess. Refer to Disassembly and Assembly, “Cam-shaft Bearings - Remove and Install”.

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CHAPTER 2 DK651/751/801/901

F. CYLINDER HEAD - INSPECT1. Remove the cylinder head from the engine.

2. Remove the water temperature regulator housing.

3. Inspect the cylinder head for signs of gas or cool-ant leakage.

4. Remove the valve springs and valves.

5. Clean the bottom face of the cyl inder headthoroughly. Clean the coolant passages and thelubricating oil passages. Make sure that the con-tact surfaces of the cylinder head and the cylinderblock are clean, smooth and flat.

6. Inspect the bottom face of the cylinder head forpitting, corrosion, and cracks. Inspect the areaaround the valve seat inserts and the holes for thefuel injectors carefully.

7. Test the cylinder head for leaks at a pressure of 200kPa (2.03 kgf/cm2, 29 psi).

8. Measure the cylinder head for flatness. Measurethe flatness of the cylinder head with a straight edgeand with a feeler gauge.

• Measure the cylinder head from one side to theopposite side (A).

• Measure the cylinder head from one end to theopposite end (B).

• Measure the cylinder head from one corner tothe opposite corner (C).

Refer to Specifications, “Cylinder Head” for the re-quirements of flatness.

C34W2P4A

(A) Side to Side (C) Diagonal

(B) End to End

a. Remachining the Cylinder HeadThe bottom face of cylinder head can be resurfaced ifany of the following conditions exist:

• The bottom face of the cylinder head is not flat withinthe specifications.

• The bottom face of the cylinder head is damagedby pitting, corrosion, or wear.

NOTE:

The thickness of the cylinder head must not be lessthan 117.20 mm (4.614 in.) after the cylinder head hasbeen machined.

If the bottom face of the cylinder head has beenremachined, the recesses in the cylinder head for thevalve seat inserts must be machined. The valve seatinserts must be ground on the side which is insertedinto the cylinder head. Grinding this surface will en-sure that no protrusion exists above the bottom faceof the cylinder head. Refer to Specifications, “CylinderHead Valves” for the correct dimensions.

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ENGINE SYSTEM

G. PISTON HEIGHT - INSPECT

Part Description

Dial gauge

Dial gauge holder

Part Number

21825617

21825496

Qty

1

1

Required Tools

If the height of the piston above the cylinder block is notwithin the tolerance that is given in the SpecificationsModule, “Piston and Rings”, the bearing for the pistonpin must be checked. Refer to Testing and Adjusting,“Connecting Rod - Inspect”.

If any of the following components are replaced orremachined, the piston height above the cylinder blockmust be measured:

• Crankshaft

• Cylinder head

• Connecting rod

• Bearing for the piston pin

The correct piston height must be maintained in orderto ensure that the engine conforms to the standardsfor emissions.

NOTE:

The top of the piston should not be machined.

If the original piston is installed, be sure that the origi-nal piston is assembled to the correct connecting rodand installed in the original cylinder.

Six grades of length of connecting rods determine thepiston height above the cylinder block. The grade oflength of a connecting rod is identified by a letter or acolor. The letter or the color is marked on the side ofthe connecting rod. Refer to Testing and Adjusting,“Connecting Rod - Inspect” and Specifications, “Con-necting Rod” for additional information.

1. Use the dial gauge (1) and the dial gauge holder (2)in order to measure the piston height above the cyl-inder block. Use the cylinder block face to zero thedial gauge (1).

2. Rotate the crankshaft until the piston is at the ap-proximate top center.

3. Position the dial gauge holder (2) and the dial gauge(1) in order to measure the piston height above thecylinder block. Slowly rotate the crankshaft in orderto determine when the piston is at the highestposition. Record this dimension.

Compare this dimension with the dimensions thatare given in Specifications, “Piston and Rings”.

C34W2P5A

(1) Dial Gauge

(2) Dial Gauge Holder

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CHAPTER 2 DK651/751/801/901

H. FLYWHEEL - INSPECT

a. Alignment of the Flywheel Face1. Install the dial indicator. Refer to Illustration 41.

2. Set the pointer of the dial indicator to 0 mm (0 in.).

3. Turn the flywheel. Read the dial indicator for every90 degrees.

NOTE:

During the check, keep the crankshaft pressed to-ward the front of the engine in order to remove any endclearance.

4. Calculate the difference between the lowest mea-surement and the highest measurement of the fourlocations. This difference must not be greater than0.03 mm (0.001 in.) for every 25 mm (1.0 in.) of theradius of the flywheel.

The radius of the flywheel is measured from the axisof the crankshaft to the contact point of the dial indicator.

C34W2P6A

b. Flywheel Runout1. Install the dial indicator. Refer to Illustration 42.

2. Set the pointer of the dial indicator to 0 mm (0 in.).

3. Turn the flywheel. Read the dial indicator for every90 degrees.

4. Calculate the difference between the lowest mea-surement and the highest measurement of the fourlocations. This difference must not be greater than0.30 mm (0.012 in.).

C34W2P7A

c. Gear Group - InspectRemove the front timing cover and inspect the gears.The timing marks on the gears indicate the front sideof the gears. Inspect the gears for broken teeth or wornteeth.

C34W2P8A

(1) Fuel Pump Drive Gear (3) Idler Gear

(2) Camshaft Drive Gear

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ENGINE SYSTEM

623W2J1A

623W2H8A

623W2H9A

623W2J0A

623W2J2A

623W2H7A

623W2H6A

6. LIST OF SPECIAL TOOLS

Number IllustrationDescription

PD.1D

PD.1D-1A Adaptor for use with PD.1D.

Part number 21825552

PD.1D-12 Adaptor for use with PD.1D and PD.1D-1A

Part number 21825937

PD.41DD Gauge for piston height, valve depth and cylinderliner flange; for use with PD.208.

Part number 21825496

PD.67-3 Gear adaptor for use with MS.67B.

Part number 21825513

PD.145D Replacer tool for crankshaft rear seal.

Part number 21825540

PD.155C Basic puller for fuel pump gear.

And water pump hub.

Part number 21825565

Remover/replace for valve guides (main tool).

Part number 21825478

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CHAPTER 2 DK651/751/801/901

623W2J9A

623W2J8A

623W2J7A

623W2J6A

623W2J5A

623W2J3A

623W2J4A

Number IllustrationDescription

PD.155B-5 Adaptors for use with PD.155C.

Part number 21825568

PD.162B Centralising tool for timing case cover.

Part number 21825571

PD.170 Replacer tool for seal of timing case cover (maintool).

Part number 21825577

PD.170-1 Pressure plate for use with PD.170.

Part number 21825578

PD.170-4 Adaptor for use with PD.170.

Part number 21825582

PD.208

PD.6118B Valve spring compressor.

Part number 21825666

Dial gauge for use with PD.41D.

Part number 21825617

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ENGINE SYSTEM

623W2K6A

623W2K5A

623W2K4A

623W2K3A

623W2K2A

623W2K1A

623W2K0A

Number IllustrationDescription

PD.6118B-10 Stud adaptor for use with PD.6118B.

Part number 21825934

MS.67B Universal timing gauge.

Part number 21825619

MS.76B Handle set for valve seat cutters

(also included in MS.73).

Part number 21825619

MS.76-150-7 Adjustable pilot for valve seat cutters

(also included in MS.73).

Part number 21825550

MS.76-285 Cutter for exhaust valve seats.

Part number 21825633

MS.76-692

(MS.1531) Angle gauge to tighten cylinder head setscrews.

Part number 21825607

Cutter for inlet valve seats.

Part number 21825977

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CHAPTER 2 DK651/751/801/901

623W2K8A

623W2K7A

623W2L0A

623W2K9A

Number IllustrationDescription

PD.241 Locking pin for crankshaft.

Part number 21836001

No.8 Piston ring compressor.

Part number 21825491

PD.246 Timing pin for Lucas and Stanadyne fuel injectionpumps.

Part number (1)

PD.2576 Liner fitting adaptor.

Part number 27610024

(1) Refer to your nearest Perkins Distributor