Eight Key Checks in Diesel Engine Repair

1."Three Leaks" Prevention

To prevent and resolve oil, water, and air leaks, follow the "Five-Character Principle": Strictness, Cleanliness, Smearing, Grinding, Tightening.

Strictness: Adhere to operating procedures during disassembly/assembly. For example, tighten bolts sequentially and incrementally to avoid deformation.

2.Cylinder Pressure Check

Ensure adequate compression by verifying:

Piston-cylinder clearance, piston ring end/side gaps

Valve-seat and injector tip tightness

Proper cylinder head gasket thickness

3.Combustion Chamber Volume Check

Avoid altered compression ratios caused by:

Reversed piston installation

Incorrect gasket thickness

Worn/bent crankshaft-linkage components

Misaligned swirl chamber inserts

Excessive valve recession

4.Timing Check

Fuel Injection Timing: Adjust via shims between the injection pump and gear cover (0.1mm shim = 6.3mm flywheel arc for S195/X195 models).

Valve Timing: Correct timing gear alignment errors first, then adjust valve clearance (0.1mm clearance = 3° crankshaft rotation = 11.1mm flywheel arc). Cold clearance must be ≥0.2mm to prevent post-heating leakage.

5."Three Filters" Check

Air Filter: Prevent dust-induced wear of pistons, cylinders, and valves.

Fuel/Oil Filters: Block contaminants to avoid premature wear of precision components (e.g., fuel injectors, crankshaft bearings).

6.Diesel Atomization Check

Inspect fuel system precision parts (plunger, delivery valve, injector needle) to ensure proper atomization, preventing hard starting, incomplete combustion, and power loss.

7.Oil Passages and Small Holes Check

Key Oil Passages (align during installation):

Main bearing oil holes (align with cylinder block/neck holes)

Rocker arm bushing oil holes

Connecting rod bushing oil holes

Starter shaft bushing oil holes

Critical Small Holes (keep unobstructed):

Fuel tank vent (prevents pressure buildup/vacuum)

Crankcase breather (avoids oil leakage and degradation)

Fuel pump drain hole (prevents oil dilution)

Water pump drain hole (prevents bearing damage)

8.Break-In Check

Cold Break-In: Run the engine without injectors using external power; check oil pressure/temperatures, then drain and clean oil.

Hot Break-In: First run no-load, then under specified load. Monitor for abnormal noises, smoke, or leaks, addressing issues immediately.

Guangxi Dingbo Power Equipment Manufacturing Co.,Ltd was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. The company has a registered capital of 218.88 million yuan. The company covers an area of 86,000 square meters and a building area of 55,000 square meters. There are more than 660 employees, including 456 professional technicians and 106 senior technicians. It has 46 sales and service outlets nationwide. The main products are diesel engines, generator sets, and diesel generators, providing users with a one-stop service of design, supply, debugging and maintenance at any time. Dingbo has always insisted on using first-class talents, building first-class enterprises, manufacturing first-class products, creating first-class services, and making every effort to build a first-class domestic enterprise. If any question please feel free to visit our website https://www.dieselgeneratortech.com/ or send email to [email protected].