Engine JAC HFC4DA1-2C. Manual — part 13

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

51

c. Rotate the crankshaft, till the top dead center (TDC)

line of crankshaft damping pulley is aligned with the

timing pointer. In such case, either 1

st

cylinder piston or

4

th

cylinder piston is at top dead center (TDC) of

compression stroke.

d. Check the clearance of push rod for the intake valve

and exhaust valve of 1

st

cylinder. If there is a

clearance between 1

st

cylinder intake valve and valve

push rod, the 1

st

cylinder piston is at top dead center

of compression stroke (1236). If the 1

st

cylinder

intake valve is pressed tightly by exhaust valve push

rod, the 4

th

cylinder piston is at top dead center of

compression stroke (4578).

e. Valve clearance (under cold state): 0.3-0.4 mm

f. Loosen the clearance adjustment screws for the

valves, as shown in the figure.

g. Insert the feeler gauge with appropriate thickness

between rocker arm and valve rod end.

h. Rotate the valve clearance adjustment screw, till a

light resistance is felt on the feeler gauge.

i. Securely tighten the lock nut.

j. Rotate the crankshaft for 360º.

k. Align the TDC marking of crankshaft damping pulley

with the timing pointer.

l. Adjust the clearance for other valves, as shown in the

figure.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

52

9. Install other peripheral accessories.

a. In turn install the fuel injection assembly with sealing

gasket onto the cylinder head.

b. Install the fuel injector fixing pressure plate and

install and tighten the fuel injector pressure plate

bolts to 8±2N.m+40～45°.

c. Install the 1

st

cylinder high pressure fuel pipe

assembly, 2

nd

cylinder high pressure fuel pipe

assembly, fuel injection pump high pressure fuel

pipe, 3

rd

cylinder high pressure fuel pipe assembly,

and 4

th

cylinder high pressure fuel pipe assembly and

tighten the corresponding nuts. Notice: 1. Notice the

installation direction of high pressure fuel pipes; 2.

The tightening torque for nuts at fuel injector end is

27±5N.m; 3. The tightening torque is 20±5N.m for

nuts at high pressure fuel rail end, 27±2N.m for high

pressure fuel pipe nuts at fuel pump end, and

20±2N.m for high pressure nuts at fuel rail end.

d. Use accelerator cable bracket bolts to install the fuel

return three-way valve onto the gear chamber and

tighten to 7.5±2.5N.m.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

53

e. Install the engine oil filter and O-ring subassembly

and tighten the fixing bolts of engine oil filter bracket

to 25±5 N.m.

f. Install the engine right bracket and shock absorber

subassembly and install and pre-tighten the fixing

bolts.

g. Install the water inlet pipe gasket and water pump

inlet pipe weldment subassembly, pre-tighten the

bolt, spring, and plain washer subassembly (of water

pump inlet pipe), and install and tighten the bracket

fixing bolts at the lower end of water pump inlet pipe

weldment.

h. Install the engine left bracket and shock absorber

assembly and tighten the fixing bolts.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

54

i. Check the cylinder head shield O-ring.

j. Install the cylinder head shield and install and tighten

the cylinder head shield bolts to 13±5N.m.

k. Install the exhaust manifold gasket and install the

exhaust manifold and turbocharger subassembly.

l. Install the spring washers and hexagon nuts and

tighten the fixing nuts and fixing bolts as per

specified sequence.