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Dongfeng Chaoyang Diesel engine Co CYQD 32 Series CYQD32 Service Manual
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Dongfeng Chaoyang Diesel engine Co CYQD 32 Series CYQD32 Service Manual

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Serve with whole heart
Satisfaction accompanies the whole way
Maintenance manual
Model CYQD32 Series Diesel Engine
Dongfeng Chaoyang Diesel engine Co. LTD.
1

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Summary of Contents for Dongfeng Chaoyang Diesel engine Co CYQD 32 Series CYQD32

  • Page 1 Serve with whole heart Satisfaction accompanies the whole way Maintenance manual Model CYQD32 Series Diesel Engine Dongfeng Chaoyang Diesel engine Co. LTD.
  • Page 2 Foreword CYQD 32 series diesel engine is a product with international advanced level. The technology was introduced from Nissan Diesel Engine Automobile Individual Plant by our Company. It can equip with 1-2 tons light-duty truck, light-duty bus, pick-up, jeep, army vehicle, cross-country vehicle and business vehicle and ect.
  • Page 3 according to the customer’s requirement, the configuration will continue to perfect. So some contents may be unconformity future productions, and please customers notice and take care of the new manual publishing.

  • Page 4: Table Of Contents

    Catalogue I. Summary 1. The main data and brief specification of diesel engine 2 . The main performance and outline dimension of diesel Engine 3. Indication symbol and meaning II. Outer part disassembly and assemble III. Inner part disassembly and assemble IV.
  • Page 5 3. Inlet preheating system 4. EGR system（CYQD32EGR） 5. Turbocharger charger （CYQD32T、CYQD32Ti）...
  • Page 9 II. Outside parts disassembly and assembly (1)
  • Page 11 1.In principle, assembly order countered with disassembly order, in other words, first disassembly last assembly, last disassembly first assembly. 2. Note: 1) Seal gasket and plug When installing, gear chamber cover, oil sump, high pressure fuel injection pump gear cover must be painted sealing glue, the other parts don’t need to be painted sealing glue.
  • Page 12 stipulated digital order and required torque. 4) Oil cooler To tighten screw bolt according to the stipulated digital order and required torque. Note: Different length screw bolts don’t make wrong. 5) Oil sump To tighten screw bolt according to the stipulated direction and required torque.

  • Page 13: Inner Part Disassembly And Assemble

    III. Inner parts disassembly and assembly (cylinder -block ) Seal gasket，seal ring Tightening torque [big] N.m Tighten torque matrix [small] N.m To paint oil for lubrication To use seal glue which recommended.
  • Page 14 III. Inner parts disassembly and assembly (cylinder –head) Seal gasket，seal ring Tightening torque [big] N.m Tighten torque matrix [small] N.m To paint oil for lubrication...
  • Page 15 1.In principle, assembly order countered with disassembly order, in other words, first disassembly last assembly, last disassembly first assembly. 2.When assembly, every moving plane of union must add just the right amount grease (oil). 1) The main bearing bush To make the main bearing bush locating lip insert in the main bearing cover locating groove.
  • Page 16 4) The main bearing bolt To tighten to required torque by twice according to stipulated digital order. Torque (N.m) 167-177 5) Piston connecting –rod group Piston ring opening lies to the position recommended. The mark on the piston top faced to the front (or the inlet valve notch deviation the front end.) When install piston, to make...
  • Page 17 7) Camshaft thrust plate and gear To tighten thrust plate bolt by the hole of camshaft gear. After painted oil, to assembly camshaft gear compress bolt. Torque (N.m) 57—66 8）Timing mark install timing gear according to the timing mark symbol. Idler press plate chamfer faced to outside.
  • Page 18 12) Start paw To use oil paint on the thread, then tighten start paw to the stipulated torque with 6102.29.01 start paw wrench and 6102.29.02 wrench lever. Torque (N.m) 373—402 13) Cylinder block gasket To make cylinder block gasket cylinder hole turned edge side faced to the cylinder block link surface.

  • Page 19: Diesel Engine Maintenance, Checking And Adjusting

    IV. Diesel engine maintenance, checking and adjusting 1. Valve clearance To adjust valve clearance with QD290.CN 101 valve clearance gauge according to the following methods: rotate crankshaft according to diesel engine rotation direction, make T.D.C. calibration mark crankshaft be justification with timing calibration mark...
  • Page 20 2. Fuel filter Exhaust ponding Regularly release lever lower plug of fuel filter and exhaust ponding in filter. Clean or replace filter element To disconnecting the filter case, and take out filter element, clean or replace fuel filter element (dismounting fuel filter resolution and reassembly), if...
  • Page 21 4. Air filter To clear out dust deposit. To take off ash pan and clean dust deposit. Regularly carry out according to the practice. To clean filter element When the filter element was stained with dust, we must clean it. First, rotate filter element, in the same time, blow it from inner with compress air.
  • Page 22 5. Fan (water pump) belt and air compressor belt To add 39 N strength to the belt (single one ), the deflection is 10-15mm.

  • Page 23: Basic Parts Disassemble And Reassemble

    V. Basic parts disassembly and reassembly...
  • Page 25 When disassembly and install, please note following: 1) Valve seal ring After lubricating valve seal ring with clean oil, then install it. And install it with special installing tools. 2) Inlet/ exhaust valve Because the heads of inlet and exhaust valves are different, don’t make wrong.
  • Page 26 3. Piston connecting-rod assembly...
  • Page 27 When disassembly and install, please note following: 1) Connecting-rod When assembly, matching No. on connecting-rod body and cover must be at the same side. Note: The piston top is the same direction with the convex words on connecting-rod body. 2）Check ring To disassembly and reassembly check ring with special tools or clippers.

  • Page 28: Basic Parts Checking And Maintenance

    VI. Basic parts checking and maintenance When checking, if found wear, damage or the other abnormal phenomena, repair and replace according to the practice. 1 Cylinder-head bottom planeness and thickness 2.Inlet and exhaust valve sinkage 3. valve seat ring 1) Replace valve seat ring When valve inferior limit is over limit value, we must replace seat ring.
  • Page 29 3) Air distribution valves and sealing checking When we use new valve and new valve seat ring, we must ensure valve sinkage amount in the standard. clean conjunction between valve and valve seat ring, and paint red lead red on the valve cane, and put the valve on the seat, then gently turn valve, contacting...
  • Page 30 4. Valve and valve guide 1) Valve seal coning angle and head thickness Valve seal coning angle: 90° Valve head thickness Standard Limit 2) Valve lever diameter 3) Valve guide inner diameter 4) Clearance between valve lever and guide...
  • Page 31 5) Replace valve guide To dismantle valve guide with blanking tool and hammer. To make valve guide install in cylinder-head guide hole with blanking tool and hammer. The distance is 16 ±0.20 from the bottom of cylinder-head valve spring to valve guide top. 5、Cylinder-head gasket “d”...
  • Page 32 (2) To choose qualified cylinder gasket According to max. protruding height of piston in four cylinders.
  • Page 33 Spring length perpendicularity 2) Spring force 7. Tappet 1) To check tappet whether it existed any kinds of wear, damage and other abnormal phenomenon. 2) Tappet diameter Standard Limit Φ 25.960— Φ 25.970 Φ 26.93 3) Tappet hole inner diameter Standard Limit Φ...
  • Page 34 8. Push rod conjunction deviation of straightness Generatrix deviation of straightness Φ 0.3 Limit 9. Rocker-arm conjunction 1) To check all disassembly parts, to see if there is any wear, damage other abnormal phenomenon. 2) Rocker-arm shaft diameter 3) Rocker-arm conjunction inner diameter 4) Clearance between rocker-arm and rocker –arm shaft...
  • Page 35 10. Camshaft all parts 1) To check all disassembly parts, to see if there is wear, damage or the other abnormal phenomenon. 2) Camshaft axial clearance Standard Limit 0.08-0.28 There is abnormal phenomenon or side clearance is too big, we should replace gear.
  • Page 36 6) Clearance between camshaft and bush Standard Limit 0.02-0.109 0.15 Note: When camshaft journal is close to the limit value, we must adjust bush hole dimension to ensure the fit clearance don’ t exceed limit value, or we must replace camshaft ahead of time. 7) To replace camshaft bush To replace camshaft bush with special...
  • Page 37 8) Cam height 9) Radial beat of camshaft journal 11. Idler and idler shaft 1) Idler shaft outside diameter Standard Limit Φ41.959-Φ41.975 Φ41.85 12. Final manufacture cylinder hole according to the following dimension producing group. Cylinder hole wear limit value: 0.20 X-Y standard value: ≤...
  • Page 38 The choice of pistons which were assembled by group. 13. Piston, piston pin and piston ring 1) Piston diameter Measure position Diesel engine distance stroke S from measure point to the top 54.8 Diameter dimension group 2) Clearance between piston and cylinder...
  • Page 39 3) Clearance between piston ring and ring groove 4) Clearance of the piston ring opening 5) Clearance between piston pin and pin hole ￠ 33 -0.07 Piston hole inner diameter +0.005 Φ33 005 -0.003 Clearance after assembled by group...
  • Page 40 6) To assemble piston pin When assembling piston pin, heating piston to 60-70 °C, and painted oil to piston pin and connecting-rod small end bush hole, and ensure piston swing smoothly. 14) Con-rod, bearing shell and bushing 1) Clearance between piston pin small end hole of con-rod Standard limit...
  • Page 41 To produce bush according to connecting-rod small end wedge plane, then remove burr. 4)Degree of parallelization about the small and big end hole of con-rod Limit 100:0.075 Free tension connecting—rod shell If the shell is with sufficient free tension, when installing it, the finger should be with certain strength.
  • Page 42 3) The diameter of crankshaft connecting-rod journal Φ56.913-Φ56.926 Standard 4) Clearance Standard Limit Standard Limit 0.035-0.087 0.20 16 、Clearance between the main bearing bush and crankshaft main journal 1) Free tension of the main bearing bush If the shell is with sufficient free tension, when installing it, the finger should be with certain strength.
  • Page 43 4) The diameter of crankshaft main journal Φ 70.907- Standard Φ 70.920 5) Clearance Standard Limit First 0.024-0.044 0.10 0.024-0.056 0.10 6) Axial clearance of crankshaft Standard Limit 0.06~0.25 0.40...
  • Page 44 17. Radial beat of the crankshaft main journal To measure radial beat of the other every journal with V iron supporting 2, 4 main journal. Standard Limit 0.03 18. The crankshaft regrinding and shell thickening 1) Because dimension, shape and position deviation extra,...
  • Page 45 20、Flywheel conjunction 1) Flywheel friction surface wear Allowance wear limit value is 1.5. 2) To replace gear ring To disassemble with brass bar and hammer. Making gear ring heat by gas spray flame or boil heat oil in order to make it swelling, then install it with hammer.

  • Page 46: Accessory Parts Disassembly And Checking, Repairing And

    VII. Accessory parts disassembly and checking, repairing and adjusting 1. Lubrication system...
  • Page 47 2) Piston cooling injection nozzle 1. To push pressure limiting value with plastic pole or copper pole, and ensure moving smoothly. 2. To ensure nozzle unobstructed, if necessary we may clean it with metal wire. When installing nozzle, ensure nozzle justification with the main oil gallery of cylinder-block.
  • Page 48 3) Oil filter Checking and maintenance 1. Oil overflow valve To check overflow valve motion by pushing overflow valve steel ball, to see if it is flexible and if it is fracture. If it damaged, we must replace a new overflow valve. 2.
  • Page 49 (2) When slide valve is smeared by oil, checking if slide valve can move freely in the valve hole. If it can’t move, we must repair and replace it. 4) Oil cooler...
  • Page 50 1. Overflow valve To check overflow valve motion by pushing overflow valve steel ball if it is flexible and if it is fracture. If it is damaged, we must replace new overflow valve.
  • Page 51 2. Equalizer-valve (1) To check equalizer- valve unit if it is wear or damaged. If it is damaged, we should replace new equalizer- valve. (2) When slide valve is smeared by oil, checking if slide valve can move freely in the valve hole. If it can’t move, we must repair and replace it. To check all disassembly parts, to see if it is wear, damaged or other abnormal phenomenon, especially whether cooler core is block or not.

  • Page 52: Injection Pump

    checking adjusting injection pump To check plunger lift: 1. To disassembly high pressure oil pipe and hollow bolt adopter, and install dial gauge. 2. To measure plunger lift: (1) To make crankshaft from the first cylinder piston T. D.C rotate anticlockwise 20°...
  • Page 53 5. Exhaust The highest idling adjusting: Before injection pumps leave being out of the factory, the max speed adjusting bolt is locked by the special tool., usually, don’ t need to adjust. If we must adjust, we may reference following requirements: 1.
  • Page 54 Injection oil amount adjusting data form...
  • Page 55 3．Preheating controlling system Preheating controlling box connection elementary diagram Operation instructions and notes: 1). Please strictly according to the right connecting of the drawing, specially pay attention to right connection of power source positive pole and negative pole, or electric device will not normal working and maybe damage due to it.
  • Page 56 showed electric plug is heated after carrying out, and it will close automatically about after 40 seconds. 4). During engine begin to run, if there is more than one electric plug, overflow valve(KSB valve), preheating relay or circuit happened failure, the preheating plug indicating light will blink quickly(it hinted customers should check circuit or change electric plug and overflow valve ect, by it, but electric controlling device still continue to work.
  • Page 57 Checking and maintenance EGR controlling unit. EGR controlling valve To give EGR vacuum pipe supply vacuum with manual vacuum pump, valve membrane should be raised, or we must replace EGR controlling valve. Air throttle To give air throttle supply vacuum with manual vacuum pump, throttle should be closed, must replace...
  • Page 58 5. Turbocharger (CYQD32T、CYQD32Ti) To check and measure outside of the turbine-super-charger To check and measure the turbine-super-charger, if found abnormal, then disassembly. Note: Adhering oil in compressor pipeline is normal. It is oil which lubricated rotator, if exhaust air without abnormal white smoking, it belongs to the normal every parts outside checking.
  • Page 59 Disassembly 1. Execution unit · To disassembly the rear of execution unit pole from venting valve crank lever. · To disassembly rubber pipe · To disassembly execution unit bracket. 2. Compressor case · To make mark between central body and compressor case. ·...

This manual is also suitable for:

Cyqd32egrCyqd32tCyqd32tiCyqd32 seriesCyqd32
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