Dongfeng DFA1101GZ5AD6J-907. Manual — part 17

General Adjustment

9—3

Note:
Open the cap of radiator while the engine is

hot, be sure to turn the radiator cap slowly to low
pressure position to reduce the inner pressure
to avoid the hurt by the hot water injection.

Check the Opening Temperature

of the Thermostat

Check the thermostat working

condition in hot water while perform the
48,000km maintenance.

The opening temperature of the

thermostat is 76 ℃ and 86 ℃

The full opening stroke of the

thermostat: not less than 6mm
(3~5min, in boiling water).

Note:
The thermostat is necessary for engine to

keep normal working, so it can not be removed
arbitrarily.

Adjustment of Fan Belt

The tightness of fan belt should be

checked frequently. The checking
method is like this, press the belt at a
force of 29~39N to see whether
deflection is in the range of 10~15mm
(Note: Both belts should meet the
requirement). Over tighten will damage
the bearing of water pump and the
bearing of generator, over loosen will
cause the belt slipping, low cooling
efficiency and engine over heating.

Chang the relative position of

adjusting arm to the generator to adjust
the tightness of fan belt.

General Adjustment

9—4

Pump Fuel Manually and Bleed

Air Out of Fuel Supply System

1.Bleed screw
2.Handle screw cap
3.Drain plug

Loosen the bleed screw (1) on the

injection pump and the screw located
above the diesel filter, and screw out
the handle screw cap (2) of fuel supply
pump, take out the handle up and down
till the there is no bubble in the flowing
fuel out from the screw, then tighten the
screw and the handle screw cap.

Water-leak Hole of the Water

Pump

The water-leak hole under water

pump body is used to leak the water
from the water seal, so keep the hole
not being blocked is very important,
thus the water will not be remained
inside the water pump cavity to

damage the bearing lubrication.

If the water leaks a lot from the

hole while parking, dismantle the water
pump for repairing.

Air Valve Clearance Adjustment

1.Camshaft gear
2.Timing of pin
3.Gear case cover

Check and adjust the air valve

clearance every 12,000km, and the
normal clearance is(under cold

condition):

Inlet valve: 0.25mm
Exhaust valve: 0.50mm
No matter the clearance is too

large or too small are harmful to the
engine. If you find the noise of the air
valve is too loud during using, you must
adjust it in time.The air valve clearance

General Adjustment

9—5

adjustment should be done under the
cold engine.
Adjusting method:

1.Remove the air valve cover.

2.Press the timing pin of the engine(on
the timing gear chamber close to fuel
injecting pump), and use a wrench to
turn the engine slowly until the timing
pin is inserted into the timing hole of the
camshaft gear and the 1st cylinder is in
the compressed top dead center.

3.During this time, you must adjust the
following air valve clearance(counted
from the front to the end): valve 1(inlet),
2 (exhaust), 3 (inlet), 6 (exhaust).

4.After the adjustment, make marks on
the pulley and the timing gear chamber,
then turn the engine to align the marks.

5.Then adjust the following air valve
clearance: 4 (exhaust), 5 (inlet), 7

(inlet), 8 (exhaust).

Note:
When you have found the top dead center

of the 1st cylinder, you must first drop out the
timing pin then you can adjust the air valve
clearance.

Adjustement of Clutch

The clutch is controlled by

hydraulic mechanism, the adjustment
method for the total travel and free
travel of the pedal is as below:

1.Adjust the clearance between the
push rod and the piston of master

General Adjustment

9—6

cylinder to 0.2~0.7mm. When made the
adjustment, loosen the lock nut and
turn the push rod towards the piston,
when the push rod touch the piston,
withdraw the push rod by 1/7~1/2 pitch,
then tighten the lock nut.

2.Adjust the free travel of slave cylinder
push rod to 3~5mm and tighten the lock
nut.

3.After the above adjustments has
finished, the travel of master cylinder
push rod and slave cylinder push rod
should be 20~24mm, and 17~20mm,
the free travel of clutch pedal should be
30~40mm.

Air Release of Clutch

The existence of air in clutch

hydraulic system may lead to abnormal
work for clutch control system,
therefore it is necessary to release air.
The method is like this:

1.Fill up the clutch oil reservoir with
composite brake liquid, and make the
air pressure of the air tank reached to
650kPa.

2.First remove the dust cap of clutch
slave cylinder, and loosen its bleeding
bolt, then engage a matchable hose to
bleeding bolt at one end and put the
other end into a bottle filled with brake
fluid, and then trample the clutch pedal
repeatedly until some air bubbles come
out.