47

0.050.38mm
19
While installing, the proper gear side clearance shall be ensured and the radial
clearance of the camshaft middle gear hall be 0.050.38mm
refer to fig. 19
While installing the timing gear, the crankshaft timing gear shall be marked at the 11
oclock position and the camshaft timing gear shall be marked at the 9 oclock position first,
and then align the two marks on the camshaft transmission gear with the above
mentioned two marks, at last, install the fuel injection pump gear after the cover of the
KING LONG
CHINAS BUS & COACH LEADER

48
timing gear chamber and the crankshaft damper being installed. Pay attention that the fuel
injection pump can only be installed after the timing of it and the engine are properly
adjusted first.
The outer transmission mechanism is of belt transmission, refer to fig. 13. The belt
wheel on the crankshaft damper drives the air compressor and water pump ( the fan and
the water pump is co-axial) by V belt, and the generator is driven by tension wheel through
belt. 4050N 58mm
20
The belt shall not be too loose or too tight. If the belt is too loose, the transmission
efficiency shall be reduced and the rotation speed of the water pump and fan will not be sufficient,
which will affect the cooling effect; if the belt is too tight, it will affect the life-span
of the components such as belt and the bearing. The tension of the belt is ensured by
adjusting the tension wheel, and the usual belt tension shall be within 5~8mm while
tensioning force is 4050N. Refer to fig. 20
20
Fig 20 diagram of belt tightness check

2.4
Crankshaft connecting rod system

KING LONG
CHINAS BUS & COACH LEADER

49
21
The crankshaft connecting rod system is the major working system of the engine. Its
effects are to convert the straight reciprocating movement to the rotation of the crankshaft
and convert the force applied on the piston by the combusted air to the crankshaft torque
to output the power. The crankshaft connecting rod system includes the piston connecting
rod system and the crankshaft flywheel system. Refer to fig.21 for the parts of piston
connecting rod system.
The pistons are divided into A group and B group according to the max diameter of
the skirt. Install them according to group when assembling.
22
23
24
The direction of the piston ring shall be paid attention during installation, refer to fig.
22. And the piston ring opening shall also be installed with regulated direction, refer to fig.
23. The piston is cooled by oil spryed by the cooling nozzle and it can be effectively kept in
cooling status instead of over-heat, refer to fig. 24. The cooling nozzle is not allowed to be
demounted and not

YC4G210-20
YC4G
Special note: YC4G210-20 engine and YC4G 2-valve diesel engine adopt different
fuel cooling injection hook of the pistons. Therefore, it is forbidden to replace it at
will. Please go toYuchai service station to replace with special techniques.
KING LONG
CHINAS BUS & COACH LEADER

50
24

Fig 24 The oil cooling nozzle of the piston

The mark on the rod shall be toward the front during installation. Put the small end
into the middle of the piston pin seat and insert the piston pin into the pin hole, knocking
with soft metal lightly, and make sure that the inserted piston and connecting rod are
swiveled freely and there is no block. While replacing the piston ring, the radial and
opening clearance shall be checked.

2005
YC4G
Especially note that: from 2005, YC4G diesel engines (including 2-valve and
4-valve) started to adopt steel cylinder sleeve and new piston design. The piston
group is different from the cast iron sleeve and old matching chromeplate piston
KING LONG
CHINAS BUS & COACH LEADER

51
ring group. It is forbidden to use chromeplate piston ring on steel sleeve and new
designed piston to avoid scuffing of cylinder bore. Do not replace piston rings by
yourself and please go to a service point of Yuchai to have it replaced.

175Nm
Tightening torque of the connecting rod bolts is 175Nm. After the bolts are tightened,
ensure that the crankshaft can freely rotate and check if axial clearance at head end of the
connecting rod is satisfactory.
5
3

25
There are 5 pieces of the main bearing shell, among which the third one is a flanged
one which acts also as a thrust washer. Please install it as specified, otherwise you will get
a wrong axial clearance, Refer to fig 25
The installing method of crankshaft thrust bushing is as follows:
Pry crankshaft and let it move towards the thrust shoe
z
Maintain the thrust on crankshaft and then pry main bearing cap on thrust shaft
hole back
z
215Nm

KING LONG
CHINAS BUS & COACH LEADER
50
1234567890ABCDEFGHIJKLMNabcdefghijklmn!@#$%^&&*

97
to decrease wear between the cylinder and piston, piston set itself, and valve
components. The structure is shown in Figure 66.
YC4G
1000

The rated air filtering mass of YC4G diesel engine shall be at least 1000 m3/h
The filter element will get dirty after a period of time in operation, and its air intake
resistance will increase; when the said resistance reaches a certain level, the engine will
exhaust with smoke which is resulted from insufficient air supply and under power.
Operation and maintenance of the air filter:
It is absolutely forbidden to run the engine without air filter or with a faulty air filter.
The clog situation of the air filter can be judge by means of observation of the air
resistance indicator installed on the intake pipe after the air filter; when the said indicator
turns from green under normal working conditions to red, it means the air intake
resistance has exceeded the limit value, and now it is requested to check, clean or replace
the air filter. Periodically inspect, clean or replace the air filter, if there is no air resistance
indicator, according to the dust content in the air:
1.
25005000km

Every 2500~5000km
for the highway vehicle working under a special working
conditions with a high dust content in the air, for example a mining vehicle.
2.
100200h
Every 100~200 hours (it can be properly prolonged if the dust content is lower)
for an engine which is not used on vehicle (for example the generating set).
3.
Once the air filter is clogged, stop the engine to clean or replace the element with
a new one; and press and reset the rubber plug at the end of air resistance
indicator.
KING LONG
CHINAS BUS & COACH LEADER

98
Notes

Changing of such component should rigidly follow instructions and the

same model of air filter supplied to OEMs of Yuchai shall be used. Air leakage and
short circuit should be avoided during installation, otherwise power may lose and

early wearing can be expected. Only correct operation and maintenance can
guarantee and prolong the lifetime of the diesel engine.
215
Air intake pipe assembly
67
The air intake pipe assembly is used to provide fresh, clean, supercharged (intercooler)
air to working cylinders. It is consisted of air intake pipe, air intake pipe gasket, air intake
connecting pipe, air intake connecting pipe gasket, installing bolt and gasket. See Fig. 67
for the structure.
YC4G
The air intake pipe of YC4G engine is integral structure at left side of the cylinder head.
The inner line of air intake pipe should be unblocked to reduce the air intake resistance.
67
Fig. 67
Air Intake Pipe Assy and Installation

Flame preheating not assembled

KING LONG
CHINAS BUS & COACH LEADER

99
35Nm
The air intake pipe is made of casting aluminum with shim integrated. The material of the
shim is not asbestos fiber artificial rubber. For replacement, the cylinder head and intake
pipe should be cleaned out and the tightening torque of the bolt of the intake pipe is
35Nm.
Tighten the air intake pipe from the middle to both sides in two times according the
tightening order requirement.
Make sure that there is no air leak in air intake pipe. Check and ensure the fastening
bolt torque when maintenance.
YC4G
The air intake pipe type of YC4G engine may differ from others with different models.
Contact Yuchai service network for details.
216
Exhaust pipe assembly
68
The exhaust pipe assembly is used to ensure the combustion gas of the engine
exhausting to the outside. See Fig 68 for the structure.

68 YC4G

Fig. 68
Exhaust Pipe Assay of YC4E Diesel Engine
4
85Nm
Exhaust pipe is made of heat-resistant casting iron with 4 pieces of bushes, and the
one at the flange of the charger is of steel alloy which is not replaceable with common
materials. The tightening torque of the exhaust pipe is 85Nm.
The exhaust pipe cover could reduce the engine surface temperature. The engine
should be cooled down when maintenance to avoid burnt.
KING LONG
CHINAS BUS & COACH LEADER

100
Tighten the exhaust pipe bolt from the middle to both sides in two times according the
tightening order requirement

Make sure that there is no air leak in exhaust pipe. Check and ensure the fastening
bolt torque when maintenance
Operation and maintenance of the diesel engine

Operation of engine
1.
Before starting
Check the oil surface of lubricant in oil pan; making sure lubricant is enough, if it is not
enough, lubricant should be added to the regulated position of scale plate.
Check the cooling fluid in radiator to make sure cooling smoothly (Yuchai series
supercharger must adopt anti-freeze cooling fluid).
Check and drain the air in fuel pipeline and water in diesel filter.
Check fuel tank and add fuel if it is not enough.
Check electrical system (credibility and fastness of all connections and switch connections;
the capacity of battery electrolyte, add it if necessary).
Check the strap, the tightness should be suitable; if too loose, water pump and fan will
work abnormally by strap skidding, the cooling effect will be very bad and water
temperature in engine will be very high; if tool tight, the load of sprat axle is too high and
cut service life of sprat.
Check vehicle batholiths and control devices; avoid vehicle runs in danger.
2
Starting

KING LONG
CHINAS BUS & COACH LEADER

101
Start the engine (In cold winter, diesel engine should be started after heating for a
while) after completing preparation and ensuring all requirements are satisfied. When
starting engine, continuous starting time should be limited in 10 seconds; the time gap for
restart should be at least one minute; if it can not be continuously started for three times,
driver should check the cause and eliminate faults and restart engine. After starting, driver
should check:
0.1Mpa
Oil pressure: The pressure should not be lower than 0.1Mpa in ideal speed; if it is too low,
bad lubricating of engine will cause secondary worn of action.
Good working situation of water pump; make sure cooling fluid has entered the internal
cycle of engine water jacket; no three leakages and abnormal sound.
Working situation of all vehicle instruments: If there is fault, driver must stop the vehicle
and check and solve the problem, driver can also call somebody to repair the vehicle if
necessary.
3
Running

510
After the diesel engine starts in cold condition, it shall start 5-10 minutes after operating
from idling speed to low-medium speed with no load; when the engine starts at wram
condition, the engine shall start after establishing fuel pressure to guarantee good
lubricating effect of the engine.
60
It is forbidden to operate the engine at high speed with heavy load in a sudden; the
rotation speed of the diesel engine shall be increased gradually with the water
temperature of over 60 and the engine could work normally after the engine is librated
and heated.
The exhaust brake can be only used as auxiliary brake. Generally, the exhaust brake
valve shall not be used or used rarely, frequent use could damage the engine seriously,
such as run-out of the valve clip, valve loose or crack, supercharger damaged.

KING LONG
CHINAS BUS & COACH LEADER